Considerations for Preparation
of
Operation and Maintenance Manuals
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Water Program Operations
Washington, D.C. 20460
EPA-430/9-74-001
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CONSIDERATIONS FOR PREPARATION OF
OPERATION AND MAINTENANCE MANUALS
by
R. L. GREEN, PE
G. L. PAGE, JR., PE
W. M. JOHNSON, PE, CP
OPERATION AND MAINTENANCE PROGRAMS
OFFICE OF WATER PROGRAMS OPERATIONS
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D. C.
UNDER CONTRACT #68-01-0341
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.0.20402 - Price $2.85
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EPA Review Notice
This report has been reviewed by the Environmental
Protection Agency and approved for publication.
Approval does not signify that the contents necessarily
reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or
commercial products constitute endorsement or recommenda^
tion for use.
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ABSTRACT
This document provides considerations for the preparation of complete
and adequate municipal wastewater treatment plant operation and main-
tenance (0 & M) manuals. Proper utilization of these considerations
will assist in complying with the eligibility requirements of the
Construction Grant Program of the U. S. Environmental Protection
Agency (EPA), as stated in 40 CFR, Part 35, Section 35.935-12 (or
any amendments thereto).
Preliminary steps in this work included a revision of the existing
guide for an operation and maintenance manual in the Appendix of the
"Federal Guidelines For Design, Operation and Maintenance of Waste
Water Treatment Facilities", 1970 (to be totally revised in 1973).
Existing manuals now being used in municipal wastewater treatment
plants were surveyed and persons experienced in plant operation and
manual preparation were consulted for advice.
This manual includes a separate section covering each of the chapters
recommended for an operation and maintenance manual of a treatment
facility. Detailed discussions on the type of information to be
included in the operation and maintenance manual are found in each
section. A suggested manual outline has been prepared for treatment
plants and a second outline has been prepared for pumping stations
and pipelines.
The guidelines presented are not intended to be a rigid format; each
manual must be modified to the individual situation. However, the
availability of a national format should speed manual preparation and
review procedures.
This report was submitted in fulfillment of Contract 68-01-0341 under
the sponsorship of the Office of Water Programs Operations, Environ-
mental Protection Agency.
iii
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CONTENTS
SECTION PAGE
I CONCLUSIONS 1
II RECOMMENDATIONS 3
III INTRODUCTION 5
IV WRITING SKILLS REQUIRED IN 0 & M MANUAL PREPARATION 9
V 0 & M MANUAL ADAPTABILITY TO PLANT ENLARGEMENT
AND/OR UPGRADING 11
VI SUGGESTED GUIDE AND CHECKLIST FOR AN OPERATION
AND MAINTENANCE MANUAL FOR MUNICIPAL WASTEWATER
TREATMENT FACILITIES 13
SUGGESTED GUIDE AND CHECKLIST FOR AN OPERATION
AND MAINTENANCE MANUAL FOR MUNICIPAL WASTEWATER
PUMPING STATIONS AND/OR PIPELINES 13
********************************************
OPERATION AND MAINTENANCE MANUAL CHAPTERS
VII 0 & M MANUAL CHAPTER I
INTRODUCTION 39
Manual User Guide 40
Operation and Managerial Responsibility 40
Type of Treatment and Treatment Requirements/
Effluent Limitations 42
Description of Plant Type and Flow Pattern 43
VIII 0 & M MANUAL CHAPTER II
PERMITS AND STANDARDS 47
Discharge Permit and Permit Requirements 48
Reporting Procedures For Spills of Raw or
Inadequately Treated Wastewater 49
Water Quality Standards 51
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CONTENTS
(Continued)
SECTION PAGE
IX 0 & M MANUAL CHAPTER III
DESCRIPTION, OPERATION AND CONTROL OF WASTEWATER
TREATMENT FACILITIES 53
GENERAL 62
Unit/Process Description 62
Relationship to Adjacent Units 62
Classification and Control 63
Major Components 64
Common Operating Problems 64
Laboratory Controls 65
Start-up 66
SPECIFIC PLANT OPERATION 67
Normal Operation 67
Alternate Operation 67
Emergency Operations and Failsafe Features 68
X 0 & M MANUAL CHAPTER IV
DESCRIPTION, OPERATION AND CONTROL OF SLUDGE HANDLING
FACILITIES 69
GENERAL 75
Unit/Process Description 75
Relationship to Adjacent Units 75
Classification and Control 76
Major Components 77
Common Operating Problems 77
Laboratory Controls 78
Start-up 78
SPECIFIC PLANT OPERATION 80
Normal Operation 80
Alternate Operation 80
Emergency Operations and Failsafe Features 81
XI 0 & M MANUAL CHAPTER V
PERSONNEL 83
Manpower Requirements/Staff 84
Qualifications 86
Certification 89
vi
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CONTENTS
(Continued)
SECTION PAGE
XII 0 & M MANUAL CHAPTER VI
LABORATORY TESTING 91
Purpose 93
Sampling Program 93
Operator/Laboratory References 96
Interpretation of Laboratory Tests 96
Sample Laboratory Worksheets 99
XIII 0 & M MANUAL CHAPTER VII
RECORDS 103
Daily Operating Log 105
Laboratory Records 107
Monthly Report to State Agencies 107
Annual Report 107
Maintenance Records 112
Operating Costs and Record Keeping 112
Personnel Records 113
Emergency Conditions Record 113
XIV 0 & M MANUAL CHAPTER VIII
MAINTENANCE 115
General 116
Equipment Record System 117
Planning and Scheduling 126
Storeroom and Inventory System 129
Maintenance Personnel 132
Costs and Budgets for Maintenance Operations 133
Miscellaneous Maintenance Records 134
Housekeeping 134
Special Tools and Equipment 135
Lubrication 136
Major Equipment Information 138
Warranty Provisions 139
Contract Maintenance 140
vn
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CONTENTS
(Continued)
SECTION PAGE
XV 0 & M MANUAL CHAPTER IX
EMERGENCY OPERATING AND RESPONSE PROGRAM 141
Objectives 146
Vulnerability Analysis 147
Methods to Reduce System Vulnerability 148
Mutual Aid Agreements 153
Emergency Equipment Inventory 156
Preserving Treatment System Records 156
Industrial Waste Inventory/Monitoring System 156
Coordinating Instructions for Local Police
and Fire Departments 161
Responsibilities of Treatment System Personnel 162
Emergency Response Center 164
Auxiliary Personnel Requirements 164
XVI 0 & M MANUAL CHAPTER X
SAFETY 169
General 171
Sewers 171
Electrical Hazards 171
Mechanical Equipment Hazards 172
Explosion and Fire Hazards 172
Bacterial Infection (Health Hazards) 172
Chlorine Hazards 172
Oxygen Deficiency and Noxious Gases 173
Laboratory Hazards 173
Safety Equipment 173
Process Chemical Handling 174
Safety References 174
XVII 0 & M MANUAL CHAPTER XI
UTILITIES 177
General 178
Electrical 178
Telephone 179
Natural Gas 179
Water 179
Fuel Oil 180
viii
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CONTENTS
(Continued)
SECTION PAGE
XVIII 0 & M MANUAL CHAPTER XII
ELECTRICAL SYSTEM 183
General 184
Power Source 184
Power Distribution System 185
Control and Monitoring System 186
Alternate Power Source 186
XIX 0 & M MANUAL APPENDICES 187
Schematics 188
Valve Indices 188
Sample Forms 189
Chemicals Used In Plant 190
Chemicals Used In Laboratory 190
Emergency Operating and Response Program 190
Detailed Design Criteria 190
Equipment Suppliers 191
Manufacturers' Manuals 191
Sources for Service and Parts 191
As-BuiIt Drawings 192
Approved Shop Drawings 192
Dimension Prints 192
Construction Photos 192
Warranties and Bonds 193
Copies of State Reporting Forms 193
Copies of Federal Inspection Forms 193
Infiltration Controls 193
Industrial Waste Controls 193
Piping Color Codes 194
Painting 194
References 194
**-*.*********************************
XX 0 & M MANUAL: PREPARATION COST GUIDELINES 213
XXI ACKNOWLEDGEMENTS 223
XXII REFERENCES 225
XXIII APPENDICES 237
ASSOCIATED EPA PROGRAMS 238
ix
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FIGURES
NO. PAGE:
1 BASIC FLOW DIAGRAM 44
2 SAMPLE WALL POSTER 50
3 SAMPLE LABORATORY TESTING PROGRAM 95
4 SAMPLE SOLIDS DETERMINATION WORKSHEET 100
5 SAMPLE BOD DETERMINATION WORKSHEET 101
6 SAMPLE OPERATOR'S WORKSHEET - ANAEROBIC DIGESTER 106
7 SAMPLE DAILY OPERATING LOG 108
8 SAMPLE ANNUAL REPORT FORMAT 111
9 SAMPLE EQUIPMENT RECORD CARD 121
10 PRINCIPLE OF EDGE-PUNCHED CARD RECORD SYSTEM
FOR MAINTENANCE PROGRAMS 122
11 SAMPLE CARD FOR THE WEEKLY FREQUENCY GROUP 124
12 SAMPLE WORK ORDER 130
13 SAMPLE WORK ORDER 131
14 VULNERABILITY ANALYSIS WORKSHEET 149
15 SAMPLE MUTUAL AID AGREEMENT FORMAT 154
16 SAMPLE MUTUAL AID AGREEMENTS/CONTRACTS SHEET 155
17 SAMPLE INVENTORY WORKSHEET 157
18 SAMPLE EMERGENCY INVENTORY SHEET 159
19 SAMPLE INDUSTRIAL WASTE INVENTORY 160
20 SAMPLE EMERGENCY RESPONSE CARD 163
21 SAMPLE ACCIDENT REPORT FORM 176
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TABLES
NO. PAGE
1 MINIMUM OPERATING PERSONNEL 86
2 COMPLEXITY FACTORS 219
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SECTION I
CONCLUSIONS
1. The 0 & M Manuals currently being developed for municipal wastewater
treatment systems vary greatly with respect to content and prepara-
tion cost. A major reason for this wide variance is that existing
manuals have been prepared without the benefit of comprehensive
guidance that could be followed regardless of the size and type
treatment system. The guidance contained in this manual should be
flexible enough to be applicable to any municipal wastewater treat-
ment system.
2. The purpose of an 0 & M Manual is to give treatment system personnel
the proper understanding, techniques and references necessary to
efficiently operate their facilities. Many existing manuals contain
a few exceptional sections with the remainder of the manual being
inadequate. Some manuals have taken the form of engineering reports
and are totally inadequate as an 0 & M document. A few very good
manuals have been produced as a result of conscientious and compre-
hensive effort on the part of experienced operating personnel-and
sanitary engineers.
3. A problem area common to most existing 0 & M Manuals is the language
style in which they are written. Generally these manuals are writ-
ten by engineers, critiqued by engineers and approved by engineers.
If these manuals are to benefit treatment system operation, they
must be aimed at those individuals operating the facilities and not
design engineers.
4. A large percentage of current municipal treatment plant construction
involves the enlarging and/or upgrading of existing facilities. Many
facilities that are being modified either do not have 0 & M Manuals
or have manuals which are inadequate.
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5. Persons involved in 0 & M Manual preparation require timely and
accurate information from suppliers of wastewater treatment equip-
ment for incorporation in 0 & M Manuals. The information should
be tailored for the specific equipment item supplied.
6. Consulting engineers generally provide 0 & M Manuals for their
clients on a cost of preparation plus a given percentage of these
costs for profit basis. In general, consultants attempt to address
all topics listed in the Suggested Guide For An 0 & M Manual found
in the Appendix of "Federal Guidelines, Design, Operation and Main-
tenance of Waste Water Treatment Facilities," 1970, but not neces-
sarily in the suggested format. The needs and desires of each
client play a large part in the detail of the manual.
7. Some existing 0 & M Manuals do not possess the necessary flexibil-
ity to remain viable tools to operating personnel. The manuals are
not designed to be modified and, therefore, cannot keep pace with
changing treatment system operating and maintenance needs. A manual
with too rigid an approach can be obsolete as a result of the
changes and modifications that accompany the start-up of treatment
facilities.
8. The first 0 & M Manual produced by an organization generally reflects
the learning process accompanying this effort; as a result, prepara-
tion costs often are higher than anticipated. As more manuals are
produced, cost reductions are realized through the use of standard-
ized manual sections and increased preparation efficiency.
9. Treatment facilities that were not provided with a formal 0 & M
Manual when placed into operation generally accumulate sufficient
equipment manufacturer's data to create a makeshift manual. Although
this collection of data is better than having no manual, it is not
an adequate substitute for a comprehensive 0 & M Manual.
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SECTION II
RECOMMENDATIONS
Although every municipal treatment system's 0 & M Manual must be tailor-
ed to that system's special needs, persons developing manuals should
be familiar with the guidance contained in this report. Following this
guidance will help ensure consideration of all pertinent 0 & M topics
during the development of the manual.
Individuals responsible for 0 & M Manual development should obtain input
from persons experienced in treatment system operations. This input,
combined with the design engineer's expertise, is essential to any good
manual. If possible, operations input should be obtained from persons
with experience in the same processes as those described in the manual.
Persons responsible for 0 & M Manual preparation and review should encour-
age organizations such as the Water Pollution Control Federation and the
American Society of Civil Engineers to provide opportunities for persons
involved in 0 & M Manual preparation to receive up-to-date training in
this area. Improvements in treatment process operating techniques and
maintenance procedures are being made continuously. It is important
that these new improvements be quickly and efficiently incorporated in
all new manuals. Persons responsible for 0 & M Manual preparation should
strive for maximum flexibility in their manuals.
Persons involved in the preparation of the 0 & M Manual should take the
necessary action to insure they obtain timely and accurate operations
and maintenance information on all equipment items. These actions might
simply be enforcement of existing requirements or adding sections to
project specifications calling for submittal of preliminary 0 & M infor-
mation prior to paying for equipment.
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SECTION III
INTRODUCTION
Scope and Purpose
The primary function of municipal wastewater treatment facilities is to
collect and treat municipal wastewaters so as to attain an interim
national "... goal of water quality which provides for the protection
and propagation of fish, shellfish, and wildlife, and provides for recre-
ation in and on the water." The Federal Water Pollution Control Act
Amendments of 1972 stipulate that this is to be accomplished by publicly
owned treatment works in a consistent and reliable manner so as to meet
effluent limitations based upon secondary treatment or any more strin-
gent applicable limitation, by July 1, 1977, and so as to employ the
best practicable waste treatment technology by July 1, 1983. The spec-
ific conditions and limitations will be identified in a permit issued
to each point source discharge under the "National Pollutant Discharge
Elimination System" as established by the Act.
Since the discharge of pollutants in excess of the effluent limitations
of discharge permits is prohibited by the Act, it is essential that
municipal wastewater plants, from the day of initial operation, effec-
tively treat wastewater in compliance with those limitations. This
manual has been prepared to assist in the accomplishment of this objec-
ti ve.
This manual provides considerations for the preparation of a municipal
wastewater treatment facility's operation and maintenance manual.
This volume provides a format for the organization of an operation and
maintenance manual, describes the type information to be included in
these manuals, and provides checklists and examples to assist persons
preparing 0 & M Manuals.
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Project Phases
The development of these 0 & M Manual preparation considerations began
with concurrence between EPA personnel and Wiley & Wilson, Inc. repre-
sentatives in the following areas:
1. Tentative revisions to the existing Suggested Guide
for an 0 & M Manual in the "Federal Guidelines,
Design, Operation and Maintenance of Waste Water
Treatment Facilities", 1970.
2. New requirements for 0 & M Manuals.
3. Integration of subject areas of other EPA reference
manuals now in preparation.
4. Coordination with associated EPA programs.
A survey of existing 0 & M Manuals was made. A questionnaire was pre-
pared, approved by the Office of Management and Budget, and mailed to
over 200 municipal treatment facilities across the country. Field trips
were made to selected facilities to evaluate the completeness of their
manuals.
Telephone and field conferences were held with persons experienced in
the operation and maintenance of treatment systems to discuss 0 & M
Manual preparation. A survey of other operation and maintenance liter-
ature was made. Certain subject areas of other EPA manuals now in prep-
aration and several associated EPA programs were reviewed for inclusion
in this report.
The results of the survey of existing 0 & M Manuals, the responses to
the questionnaire, the field trips, the conferences, the reviews of
associated EPA programs and the input from Wiley & Wilson's sanitary
engineering conceptual design team are included in this manual.
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Manual Format
Users of this manual first should become familiar with its Table of
Contents. A principal section addresses each of the chapters recommended
for operation and maintenance manuals. A supplementary table of contents
page has been provided at the beginning of each section to help in locat-
ing desired information. Further, the information contained in each
section has been condensed into the comprehensive outline form in the
section entitled Suggested Guide and Checklist for an Operation and
Maintenance Manual for Municipal Wastewater Treatment Facilities. A
similar outline has been provided for pumping station and pipeline
manuals.
The References section of this manual contains a tabulation which relates
existing reference materials to each recommended manual chapter.
Persons preparing 0 & M Manuals should be cautioned not to simply dupli
cate pages out of this considerations manual. Information in a facility's
0 & M Manual should be tailored to the specific needs of that facility.
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SECTION IV
WRITING SKILLS REQUIRED IN 0 & M MANUAL PREPARATION
The primary purpose of an 0 & M Manual is to help ensure the performance
record of a treatment system remains high. The manual thus serves as a
tool for the operating and maintenance personnel of the plant. The key
to a manual's ultimate success is the language used and the writing style,
There are two basic problems to be considered in the preparation of such
manuals: First, since most 0 & M Manuals are prepared by consulting
engineering firms, these firms must make certain they obtain information
from persons actually experienced in plant operation and maintenance.
The problem is to translate the design engineer's concepts into a lan-
guage form acceptable to operating personnel. Second, the comprehension
of the users of the manual must be considered. Because of the technical
nature of the wastewater treatment field, a certain level of competence
by persons using the manual must be required. Factors determining the
competence of manual users might include past performance, operator
certification, and available training programs. Individuals preparing
an 0 & M Manual must not overestimate nor underestimate this competence
level in their writing.
Some municipal treatment systems are capable of producing their own
0 & M Manuals. The same writing considerations are demanded as when
design engineers prepare the manuals.
These "Considerations for Preparation of Operation and Maintenance Man-
uals" are written in a style similar to that recommended for 0 & M Man-
uals. A further suggested example of writing style for 0 & M Manuals
is found in New York's "Manual of Instruction for Sewage Treatment Plant
Operators."
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SECTION V
0 & M MANUAL ADAPTABILITY TO PLANT ENLARGEMENT
AND/OR UPGRADING
A large part of current municipal wastewater treatment plant construction
involves plant enlargement and/or upgrading. In this regard, many munici-
palities either do not have 0 & M Manuals or their existing manuals are
inadequate. Because important emphasis is currently being placed on plant
enlargement and/or upgrading, the problems related to adapting 0 & M Man-
uals to these situations need to be discussed.
Plant Enlargement
Treatment facilities are often enlarged by adding units identical to
existing treatment units. In such cases, consideration should be given
to maintaining the existing 0 & M Manual. Appendices and addenda can
be added to describe the pertinent features of the enlargement. It is
imperative that input from persons experienced in the operation of the
existing facility be obtained. The existing manual should be thoroughly
reviewed and updated as required.
Plant Upgrading
The upgrading of existing municipal treatment systems is common. This
situation presents to the operator a totally new concept in treatment
philosophy. It is accompanied by more complex process operations and
maintenance requirements. This type of upgrading usually requires the
development of a new 0 & M Manual , although certain sections of the
existing manual may find application in the new manual. Input from
persons experienced in the new process operations should be obtained.
Plant Enlargement and Upgrading
One of the most common situations involves enlarging the capacity of a
system to meet, new loadings together with an upgrading of treatment
facilities to protect receiving waters. A new 0 & M Manual is usually
11
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required in this situation. Input must be obtained from persons with
operational experience. The existing manual should be reviewed thor-
oughly to determine what sections can be included in the new manual.
Any design provisions for plant enlargement or upgrading should be
thoroughly discussed in the 0 & M Manual. Such provisions might include
metering capabilities for future plant flows, flexibility in splitter
boxes and excess capacity in plant piping. Some facilities are designed
to be expanded by adding more treatment components. The 0 & M Manual
for the original facility can be tailored to receive inserts describing
component expansion. This technique will eliminate the need for a com-
pletely new manual after plant enlargement. However, at the time these
inserts are added, the existing manual should be thoroughly reviewed.
Such a review will help to keep the manual current with respect to
operational experiences and maintenance techniques.
In some cases, existing treatment units are modified for use in new pro-
cesses. This situation will require a new process description, operation
and control section as a minimum addition to an existing manual. Usually
this type of modification requires preparing a new manual.
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SECTION VI
SUGGESTED GUIDE AND CHECKLIST FOR AN OPERATION AND MAINTENANCE MANUAL
FOR MUNICIPAL WASTEWATER TREATMENT FACILITIES
and
SUGGESTED GUIDE AND CHECKLIST FOR AN OPERATION AND MAINTENANCE MANUAL
FOR MUNICIPAL WASTEWATER PUMPING STATIONS AND/OR PIPELINES
The formats presented in this section are intended to be a flexible guide
for the preparation of an 0 & M Manual for a wastewater treatment system
and can be modified to fit the particular system at hand. It is antici-
pated that these formats can be used in most cases. If manual prepara-
tion follows these formats, the review process will be greatly accelerated
Each of the twelve (12) chapters and the appendices in the suggested guide
and checklist for wastewater treatment facilities is addressed in a sep-
arate section of this manual. In each section, detailed descriptions of
the type information required in that respective chapter of the 0 & M
Manual are given.
It should be remembered that the 0 & M Manual will provide assistance in
developing standard operating procedures for each system. The adequacy
of these procedures plays a major role in determining how well the system
will operate. The 0 & M Manual should provide the necessary information
to insure these standard operating procedures can be readily developed.
Once an acceptable set of procedures has been established, the 0 & M
Manual becomes a reference book for the entire treatment system. The
information contained in the manual will provide answers to many of the
questions that arise frequently in the operation of a wastewater treat-
ment system.
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SUGGESTED GUIDE AND CHECKLIST FOR AN
OPERATION AND MAINTENANCE MANUAL FOR
MUNICIPAL WASTEWATER TREATMENT FACILITIES
TABLE OF CONTENTS
CHAPTER I. INTRODUCTION
SUGGESTED GUIDE AND CHECKLIST FOR AN
OPERATION AND MAINTENANCE MANUAL FOR
MUNICIPAL WASTEWATER PUMPING STATIONS
AND/OR PIPELINES
TABLE OF CONTENTS
CHAPTER I. INTRODUCTION
Mdnual User Guide
Table of Contents
A. Operation and managerial responsi-
bility
1. Operator responsibility
a. General - outline responsi-
bilities
(1) Know proper operational
procedures
(2) Keep accurate records
(3) Properly manage
operating funds
(4) Keep supervisors
informed
(5) Keep informed of
current 0 & M
practices
b. List short courses and operator
schools available
c. Provide suggested list of
journals/periodicals related
to municipal wastewater
treatment
?. Treatment system management respon-
sibility - outline responsibilities
a. Maintain efficient plant
operation and maintenance
b. Maintain adequate records
c. Establish staff requirements,
prepare job descriptions and
assign personnel
d. Provide good working con-
ditions
e. Establish operator training
program
f. Provide incentives for
employees
Manual User Guide
Table of Contents
A. Operation and managerial responsi-
bility
1. Operator responsibility
a. General - outline responsi-
bilities
(1) Know proper operational
procedures
(2) Keep accurate records
(3) Properly manage
operating funds
(4) Keep supervisors
informed
(5) Keep informed of
current 0 & M
practices
b. List short courses and operator
schools available
c. Provide suggested list of
journals/periodicals related
to municipal wastewater
treatment
2. Treatment system management respon-
sibility - outline responsibilities
a. Maintain efficient plant
operation and maintenance
b. Maintain adequate records
c. Establish staff requirements,
prepare job descriptions and
assign personnel
d. Provide good working con-
ditions
e. Establish operator training
program
f. Provide incentives for
employees
14
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g. Maintain good public
relations
h. Prepare budgets and reports
i. Plan for future facility
needs
j. Develop standard operating
procedures
B. Type of treatment and treatment
requirements/effluent limitations
1. Type treatment - Describe major
process
a. Primary
b. Secondary - trickling filter
c. Secondary - activated sludge
d. Other
2. Treatment requirements/effluent
limitations state whether
monthly or yearly averages are
used
a. Biochemical oxygen demand (BOD)
b. Suspended solids concentration
c. pH
d. Other
C. Description of plant type and flow
pattern
1. Plant type - Briefly describe
individual units
a. Pretreatment
b. Primary treatment
c. Secondary treatment
d. Disinfection
e. Sludge handling
2. Flow Pattern
a. Include a basic flow diagram
b. Bypasses and alternate flow
paths can generally be omitted
from this introductory diagram
g. Maintain good public
relations
h. Prepare budgets and reports
i. Plan for future facility
needs
j. Develop standard operating
procedures
B. Description of pumping stations and/
or pipeline type
1. Pumping station type - Describe
station type
a. Municipal wastewater
b. Storm water runoff
c. Industrial wastes
d. Combined municipal & storm
water
e. Sludge
f. Treated municipal wastewater
2. Pumping station classification
Discuss how station is classified
a. Capacity (gpm, mgd)
b. Energy source (Primary and
Stand-by)
(1) Electric
(2) Diesel
(3) Steam
(4) Other
c. Construction method
3. Discuss pumping station chlori-
nation facilities
4. Pipeline types and sizes Describe
pipeline
a. Asbestos-cement
b. Brick masonry
c. Clay
d. Concrete
15
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CHAPTER II. PERMITS AND STANDARDS
Table of Contents
A. Discharge permit and permit require-
ments
1. Give permit number
2. Give renewal date if applicable
3. List permit requirements
4. Include permit application guide-
lines
5. Copy of Federal/State laws or
agency regulations dealing with
municipal wastewater discharge
permits should be included
B. Reporting procedure for spills of raw
or inadequately treated wastewater
1. Include copies of Federal/State
laws and/or agency regulations
requiring reporting of bypass/
spill condition
a. Discuss owner's responsibilities
b. Discuss penalties
2. Outline reporting procedure to
include telephone numbers and
sample report format
e. Iron and Steel
(1) Cast iron
(2) Ductile iron
(3) Fabricated steel
5. Describe type of joint used
6. Discuss pipeline appurtenances
and special structures
a. Manholes
b. Check valves and relief
overflows
c. Siphons
d. Flap gates
e. Metering stations
f. Air relief valves
g. Other
CHAPTER II. PERMITS AND STANDARDS
Table of Contents
A. Permit and permit requirements
1. Give permit number
2. Give renewal date if applicable
3. List permit requirements
4. Include permit application guide-
lines
5. Include copy of Federal/State
laws or agency regulations dealing
with pumping station permits
B. Reporting procedure for spills of raw
or inadequately treated wastewater
1. Include copies of Federal/State
laws and/or agency regulations
requiring reporting of bypass/
spill condition
a. Discuss owner's responsibilities
b. Discuss penalties
2. Outline reporting procedure to
include telephone numbers and
sample report format
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C. Water Quality Standards
1. Provide copy of State's Quality
Standards for receiving stream
for treatment plant's effluent
2. Provide copy of State's stream
classification system
C. Water Quality Standards for adjacent
water courses
1. Provide copy of State's Quality
Standards for any water courses
adjacent to pumping stations or
pipelines, where there is a
potential for a spill of raw
wastewater
2. Provide copy of State's stream
classification system
CHAPTER III. DESCRIPTION, OPERATION AND
CONTROL OF WASTEWATER TREAT-
MENT FACILITIES
Table of Contents
A. General Each major wastewater treat-
ment unit/process should be discussed
separately with respect to the follow-
ing considerations:
1. Description
a. Provide a brief general descrip-
tion with each major treatment
unit/process discussed
(1) Pretreatment
(2) Primary sedimentation
(3) Biological processes
(4) Secondary sedimentation
(5) Disinfection
(6) Other
b. The description should physically
trace the wastewater through
the unit/process and comment on
design efficiency
2. Relationship to adjacent units
a. Give type and function of any
or all preceding units/processes
as they relate to unit/process
being considered
b. Give type and function of any
or all following units/processes
as they relate to unit/process
being considered
CHAPTER III. DESCRIPTION, OPERATION AND
CONTROL OF PUMPING STATIONS
AND/OR PIPELINES
Table of Contents
A. General
1. Pumping station description
Provide a brief general descrip-
tion of the pumping station
a. Typical
b. Package
c. Pneumatic-ejector
d. Other
2. Pipeline description Provide a
brief general description of the
pipeline
a. Gravity
b. Force Main
3. Pumping station major components
List major components
a. Pumps
b. Suction and discharge piping
c. Wet well
d. Automatic Controls
e. Other
4. Pipeline major components List
major components
a. Pipe
b. Manholes
17
-------
3. Classification and Control
a. Classification - Briefly
describe relation to similar
units/processes
(1) Standard/conventional
(2) Modified
(3) Other
b. Control - give methods of con-
trolling unit/process
(1) Flow to Plant
(2) Recirculation Pumps
(3) Air Supply
(4) Sludge Return/Wasting
Rates
(5) Other (Physical and process
controls)
4. Major components
a. List all components within the
unit/process
b. List all major mechanical equip-
ment items within the unit/
process
c. Other
5. Common operating problems
a. State problems that might occur
in unit/process
b. List probable causes
c. Discuss control/prevention
techniques
6. Laboratory Controls
a. List tests and give expected
ranges for test results
b. Give relation between test
results and treatment unit/
process operation
7. Start-up - give start-up techniques
Specific Plant Operation
1. Normal Operation
c. Siphons
d. Metering stations
e. Other
5. Pumping Station and/or Pipelines -
Common Operating/Maintenance
Problems
a. State problems
b. List probable causes
c. Give control/prevention
techniques
6. Pumping Stations and/or Pipelines
Start-up - give start-up techniques
B. Specific Pumping Station and/or
Pipeline Operation
1. Normal Operation
a. Discuss the normal operation of
each type pumping station and/
or pipeline
(1) Pump settings
(2) Valve positions
(3) Flow meter settings
(4) Chlorination system
(5) Other
2. Alternate Operation
a. List alternative modes of
operation
b. Provide discussion and schematics
to illustrate alternate operation
3. Emergency Operations and Failsafe
Features
a. Discuss emergency operating
procedures for potential
emergency conditions
b. List failsafe features
c. Describe operation of failsafe
features
18
-------
a. Discuss the normal operation of
each unit/process. This dis-
cussion should include the
following information as it
may apply to the particular
unit/process
(1) Valve positions
(2) Sluice gate settings
(3) Weir elevations
(4) Sludge rake speeds
(5) Pump settings
(6) Recirculation rates
(7) MLSS concentrations
(8) Other
Alternate Operation
a. List alternate modes of operation
b. Provide discussion and schematics
to illustrate alternate operations
Emergency Operations and Failsafe
Features
a. Discuss emergency operating
procedures for potential
emergency conditions
b. List failsafe features
c. Describe operation of failsafe
features
CHAPTER IV. DESCRIPTION, OPERATION AND
CONTROL OF SLUDGE HANDLING
FACILITIES
Table of Contents
A. General - each major sludge handling
unit/process should be discussed
separately with respect to the
following considerations:
1. Description
a. Provide a brief general descrip-
tion with each major unit/
process discussed
(1) Concentration/thickening
19
-------
(2) Digestion
(3) Conditioning
(4) Dewatering/drying
(5) Incineration
(6) Wet oxidation
(7) Disposal
(8) Other
b. The description should phys-
ically trace the sludge through
the unit/process and comment
on how the character of the
sludge is altered
2. Relationship to adjacent units
a. Describe type and function of
any or all preceding units/
processes as they relate to
unit/process being considered
b. Describe type and function of
any or all following units/
processes as they relate to
process being considered
3. Classification and control
a. Classification Describe relation
to similar units/processes
(1) Standard/conventional
(2) Modified
(3) Other
b. Control - Give methods of con-
trolling unit/process
(1) Recirculation Pumps
(2) Aerobic Digestion Air Supply
(3) Conditioning Chemicals
(4) Temperature
(5) Other
4. Major components
a. List all components within the
unit/process
20
-------
b. List all major mechanical equip-
ment items within the unit/
process
c. Other
5. Common operating problems
a. State problems that might occur
in unit/process
b. List probable causes
c. Discuss control/prevention
techniques
6. Laboratory controls
a. List tests and give expected
ranges for test results
b. Give relation between test
results and treatment process
operation
7. Start-up give start-up techniques
Specific Plant Operation
1. Normal operation
a. Discuss the normal operation of
each unit/process. This dis-
cussion should include the follow-
ing information as it may apply
to the particular unit/process
(1) Valve positions
(2) Heat requirements
(3) Sludge blanket depths
(4) Sludge pumping schedule
(5) Sludge collector/stirring
speeds
(6) Vacuum filter hours of
operation
(7) Other
2. Alternate Operation
a. List alternate modes of operation
b. Provide discussion and schematics
to illustrate alternate operations
3. Emergency operations and failsafe
features
21
-------
a. Discuss emergency operating
procedures for potential
emergency conditions
b. List failsafe features
c. Describe operation of failsafe
features
CHAPTER V. PERSONNEL
Table of Contents
A. Manpower Requirements/Staff List
personnel required
1. Supervisors
2. Administrative
3. Operational
4. Maintenance
B. Qualifications
1. For each job title give:
a. Training
b. Experience
c. Skills required
d. License/certificate required
C. Certification Program
1. Include copy of State Certifi-
cation Board's Rules and
Regulations
2. Discuss pertinent aspects of
operator certification as they
apply to the facility at hand
CHAPTER IV. PERSONNEL
Table of Contents
A. Manpower Requirements/Staff List
personnel required
1. Supervisors
2. Administrative
3. Operational
4. Maintenance
B. Qualifications
1. For each job title give:
a. Training
b. Experience
c. Skills required
d. License/certificate require
C. Certification Program
1. Include copy of State Certifi-
cation Board's Rules and
Regulations
2. Discuss pertinent aspects of
operator certification as they
apply to the facility at hand
CHAPTER VI. LABORATORY TESTING
Table of Contents
A. Purpose discuss purpose of laboratory
testing
1. Essential to treatment process
control
2. Provides an operating record for
treatment system
3. Aids in problem analysis and
prevention
22
-------
B. Sampling
1. Give grab sample definition
2. Give composite sample definition
3. Outline a sampling program for
the treatment system
C. Laboratory References List pertinent
references
1. WPCF MOP No. 18, Simplified
Laboratory Procedures for
Wastewater Examination
2. Standard Methods for the
Examination of Water and
Sewage
3. Other
D. Interpretation of Laboratory Tests
give brief definition and sanitary
engineering application for all tests
1. pH
2. Dissolved oxygen (DO)
3. Biochemical oxygen demand (BOD)
4. Settleable and suspended solids
discuss importance of solids
balance
5. Chlorine residual
6. Other
E. Sample Laboratory Worksheets give
instructions for completing sample
forms
1. Solids determinations
2. BOD determinations
3. Other
CHAPTER VII. RECORDS
Table of Contents
A. Process Operations/Daily Operating
Log provide sample form and
discuss features
1. Weather conditions
2. Facility .influent flow
CHAPTER V. RECORDS
Table of Contents
A. Process Operations/Daily Operating
Log Provide sample form and
discuss features
1. Routine operational duties
2. Power consumption
23
-------
3. Recirculation rate
4. Grit removed
5. Sludge handling data
6. Status of secondary treatment process B.
7. Operators on duty
8. Complaints received
9. Plant visitors
10. Power consumption
11. Chemicals used
12. Unusual conditions (operational
and maintenance)
13. Routine operational duties
b. Laboratory Comprehensive discussion
of laboratory records should be included
under laboratory controls chapter of
the manual
C. Monthly Report to State Agencies
1. Provide sample form
2. Give instructions for completing
form
3. Outline techniques for maximum
utilization of State forms to
eliminate using any supplemental
forms
4. Tell when and where to submit
completed forms
D. Annual Report
1. Designate individual responsible
for preparing report
2. State whether calendar or fiscal
year summary
3. Give sample report format
a. Annual summary of operating
data
b. Annual summary of management
data
4. Provide coordinating instructions
with financial arm of parent
Governmental body
3. Unusual conditions
4. Chemicals used
5. Other
Monthly Report to State Agencies
1. Provide sample form
2. Give instructions for completing
form
3. Outline techniques for maximum
utilization of State forms to
eliminate using any supplemental
forms
4. Tell when and where to submit
completed form
C. Annual Report
1. Designate individual responsible
for preparing report
2. State whether calendar or fiscal
year summary
3. Give sample report format
a. Annual summary of operating
data
b. Annual summary of management
data
4. Provide coordinating instructions
with financial arm of parent
Governmental body
D. Maintenance - Comprehensive discussion
of maintenance records should be
included under maintenance chapter
of the manual
E. Operating Costs and Record Keeping
list and discuss each major cost group
and record keeping procedures for each
1. Labor
a. Operation
b. Administration
c. Maintenance
2. Utilities
a. Electricity
24
-------
E. Maintenance - Comprehensive discussion
of maintenance records should be
included under maintenance chapter
of the manual
F. Operating Costs and Record Keeping
list and discuss each major cost group
and record keeping procedure for each
1. Labor
a. Operation
b. Administration
c. Maintenance
2. Utilities
a. Electricity
b. Fuel oil
c. Potable water
d. Telephone
e. Other
3. Chemicals (Process only)
a. Lime
b. Alum
c. Chlorine
d. Other
4. Supplies
a. Laboratory chemicals
b. Cleaning materials
c. Maintenance materials
d. Other expendable items
G. Personnel Records
H. Emergency Conditions Record
a. Bypass report
b. Deteriorated effluent record
c. Other
b. Fuel oil
c. Potable water
d. Telephone
e. Other
3. Chemicals
a. Chlorine
b. Lime
c. Other
4. Supplies
a. Cleaning materials
b. Maintenance materials
c. Other expendables
F. Personnel Records
G. Emergency Conditions Record
a. Bypass report
b. Other
25
-------
CHAPTER VIi!. MAINTENANCE
Table of Contents
A. General
1. State purpose of maintenance
system
2. Outline scope of recommended
maintenance system
3. List basic features
a. Equipment record system
b. Planning and scheduling
c. Storeroom and inventory system
d. Maintenance personnel
e. Cost and budgets for maintenance
operations
B. Equipment Record System
1. Describe equipment numbering
system
2. Outline equipment catalog
3. Discuss the type information
and equipment data which should
be maintained
4. Provide instructions on preparing
and filing information in the
record system
5. Describe data retrieval system
6. Provide completed equipment name-
plate data cards for each item
of equipment
7. Other
C. Planning and Scheduling
1. Provide guidelines for preventive
maintenance and corrective main-
tenance tasks
2. Describe schedule chart board
3. Outline work order system
a. Provide sample forms
b. Describe work order log
4. Discuss contract maintenance work
CHAPTER VI. MAINTENANCE
Table of Contents
A. General
1. State purpose of maintenance
system
2. Outline scope of recommended
maintenance system
3. List basic features
a. Equipment record system
b. Planning and scheduling
c. Storeroom and inventory system
d. Maintenance personnel
e. Costs and budgets for maintenance
operations
B, Equipment Record System
1. Describe equipment numbering
system
2. Outline equipment catalog
3. Discuss the type information
and equipment data which should
be maintained
4. Provide instructions on preparing
and filing information in the
record system
5. Describe data card retrieval system
6. Provide completed equipment name-
plate data cards for each item
of equipment
7. Other
C. Planning and Scheduling
1. Provide guidelines for preventive
maintenance and corrective main-
tenance tasks
2. Describe schedule chart board
3. Outline work order system
a. Provide sample forms
b. Describe work order log
4. Discuss contract maintenance work
26
-------
5. Other
D. Storeroom and Inventory System
1. Recommend spare parts/components
to be maintained
2. Outline stockroom inventory
procedures
a. Numbering system for all items
b. Sample withdrawal slip
c. Maximum/minimum quantities to
be maintained
d. Record system
3. Discuss purchase orders
4. Other
E. Maintenance Personnel
1. Outline maintenance staff
2. Review maintenance staff capabil-
ities and limitations
F. Cost and Budgets for Maintenance
Operations
1. Discuss importance of separation
of maintenance costs
a. Preventive maintenance
b. Corrective maintenance
c. Major repairs or alterations
2. Suggest a cost accounting system
for storeroom stock, special pur-
chase items and man-hours
3. Other
G. Miscellaneous Maintenance Records
1. Provide sample preventive/
corrective maintenance log
2. Give breakdown report format
3. Other
H. Housekeeping discuss housekeeping
activities
1. Yard work
2. Painting
5. Other
D. Storeroom and Inventory System
1. Recommend spare parts/components
to be maintained
2. Outline stockroom inventory
procedures
a. Numbering system for all items
b. Sample withdrawal slip
c. Maximum/minimum quantities to
be maintained
d. Record system
3. Discuss purchase orders
4. Other
E. Maintenance Personnel
1. Outline maintenance staff
2. Review maintenance staff capabil-
ities and limitations
F. Cost and Budgets for Maintenance
Operations
1. Discuss importance of separation
of maintenance costs
a. Preventive maintenance
b. Corrective maintenance
c. Major repairs or alterations
2. Suggest a cost accounting system
for storeroom stock, special pur-
chase items and man-hours
3. Other
G. Miscellaneous Maintenance Records
1. Provide sample preventive/
corrective maintenance log
2. Give breakdown report format
3. Other
H. Housekeeping discuss housekeeping
activities
1. Yard work
2. Painting
27
-------
3. General cleaning
4. Other
I. Special Tools and Equipment
1. Outline tool room procedures
a. Tool inventory
b. Tool check control system
2. Discuss use of tool boards
a. Special/frequently used tools
b. Location of boards
3. Give maintenance skills required
for all special tools
J. Lubrication
1. Give lubrication specifications
2. Provide interchangeable lubri-
cants chart
3. Discuss use of color coded
lubrication tags for all
equipment
4. Give sample consumption/
inventory records
5. Outline sample lubrication route
K. Major Equipment Information
1. List all major equipment items
a. Comminutors
b. Grit chambers
c. Sedimentation tanks
d. Aerators
e. Pumps
f. Digesters
g. Drying beds
h. Lagoons
i. Other
2. Outline basic maintenance con-
siderations for all major electri-
cal and mechanical equipment
items
3. General cleaning
4. Other
I. Special Tools and Equipment
1. Outline tool room procedures
a. Tool inventory
b. Tool check control system
2. Discuss use of tool boards
a. Special/frequently used tools
b. Location of boards
3. Give maintenance skills required
for all special tools
J. Lubrication
1. Give lubrication specifications
2. Provide interchangeable lubri-
cants chart
3. Discuss use of color coded
lubrication tags for all
equipment
4. Give sample consumption/
inventory records
5. Outline sample lubrication route
K. Major Equipment Information
1. List all major equipment items
2. Outline basic maintenance consid-
erations for all major electrical
and mechanical equipment items
3. Outline procedure for ordering
parts/components or new items
L. Warranty Provisions
1. List all guaranteed equipment
2. Give guarantee period for each
piece of equipment
3. Discuss pertinent features of
each guarantee
M. Contract Maintenance
1. Provide list of suggested
contract jobs
28
-------
3. Outline procedure for ordering
parts/components or new items
L. Warranty Provisions
1. List all guaranteed equipment
2. Give guarantee period for each
piece of equipment
3. Discuss pertinent features of
each guarantee
M. Contract Maintenance
1. Provide list of suggested
contract jobs
2. Provide list of suggested
contractors
2. Provide list of suggested
contractors
CHAPTER IX. EMERGENCY OPERATING AND
RESPONSE PROGRAM
Table of Contents
A. Give results of vulnerability
analysis of system
B. List methods to reduce system
vulnerability
C. List mutual aid agreements
D. Include emergency equipment
inventory
E. Give method of preserving treat-
ment system records
F. Include industrial waste inventory/
monitoring system
G. Give coordinating instructions for
local police and fire departments
H. Define responsibilities of treat-
ment system personnel
I. Designate an emergency response
center
J. List auxiliary personnel require-
ments
K. Provide a mechanism for ensuring
plan is updated periodically
CHAPTER X. SAFETY
Table of Contents
A. General
CHAPTER VII. EMERGENCY OPERATING AND
RESPONSE PROGRAM
Table of Contents
A. Give results of vulnerability
analysis of system.
B. List methods to reduce system
vulnerability
C. List mutual aid agreements
D. Include emergency equipment
inventory
E. Give method of preserving treat-
ment system records
F. Include industrial waste inventory/
monitoring system
G. Give coordinating instructions for
local police and fire departments
H. Define responsibilities of treat-
ment system personnel
I. Designate an emergency response
center
J. List auxiliary personnel require-
ments
K. Provide a mechanism for ensuring
plan is updated periodically
CHAPTER VIII. SAFETY
Table of Contents
A. General
29
-------
1. Management's responsibility -
discuss responsibilities
a. Conmunicate safety infor-
mation to employees
b. Eliminate hazardous working
conditions
c. Motivate employees to be
safety minded
d. Other
2. Emergency telephone numbers -
provide a list of all numbers
a. Hospital
b. Fire station
c. Ambulance Service
d. Chlorine supplier
e. Other
B. Sewers - discuss safety aspects of
sewer maintenance
1. Work site protection
2. Gas testing equipment
3. Nonsparking tools
4. Other
C. Electrical Hazards
1. Discuss grounding of electric
tools
2. Outline first aid for electric
shock victim
3. Designate authorized personnel
to perform electrical repairs
4. Other
D. Mechanical Equipment Hazards
1. Discuss equipment guards
2. Discuss noise level consid-
erations
3. Designate authorized personnel
to perform mechanical repairs
4. Other
1. Management's responsibility -
discuss responsibilities
a. Communicate safety infor-
mation to employees
b. Eliminate hazardous working
conditions
c. Motivate employees to be
safety minded
d. Other
2. Emergency telephone numbers -
provide a list of all numbers
a. Hospital
b. Fire station
c. Ambulance service
d. Chlorine supplier
e. Other
B. Sewers - discuss safety aspects of
sewer maintenance
1. Work site protection
2. Gas testing equipment
3. Nonsparking tools
4. Other
C. Electrical Hazards
1. Discuss grounding of electric
tools
2. Outline first aid for electric
shock victim
3. Designate authorized personnel
to perform electrical repairs
4. Other
D. Mechanical Equipment Hazards
1. Discuss equipment guards
2. Discuss noise level consid-
erations
3. Designate authorized personnel
to perform mechanical repairs
4. Other
30
-------
E. Explosion and Fire Hazards
E. Explosion and Fire Hazards
1. Discuss storage of flammable
materials
2. Give type and location of fire
extinguishers
3. Discuss use of flammable vapor
detectors
4. Outline hazards associated
with digester gases
5. Other
F. Bacterial Infection (Health
Hazards)
1. State policy on tetanus
shots
2. Outline personal hygiene
considerations
3. State policy on care of
cuts and other injuries
4. Other
G. Chlorine Hazards
1. Discuss cylinder handling
2. Outline procedure for testing
for and responding to leaks
3. Describe self-contained breath-
ing apparatus use
4. Other
H. Oxygen Deficiency and Noxious Gases
1. Outline noxious gas testing
procedures
2. Discuss ventilating equipment
3. Provide tabulation of common
gases encountered in wastewater
treatment systems
4. Other
I. Laboratory Hazards
1. Discuss volatile materials
handling
2. Describe protective clothing
and devices
1. Discuss storage of flammable
materials
2. Give type and location of fire
extinguishers
3. Discuss use of flammable vapor
detectors
4. Other
F. Bacterial Infection (Health
Hazards)
1. State policy on tetanus
shots
2. Outline personal hygiene
considerations
3. State policy on care of
cuts and other injuries
4. Other
G. Chlorine Hazards
1. Discuss cylinder handling
2. Outline procedure for testing
for and responding to leaks
3. Describe self-contained breathing
apparatus use
4. Other
J. Oxygen Deficiency and Noxious Gases
1. Outline noxious gas testing
procedures
2. Discuss ventilating equipment
3. Provide tabulation of common
gases encountered in wastewater
treatment systems
4. Other
I. Safety Equipment list safety
equipment required
1. First aid kits
2. Fire extinguishers
3. Gas masks/air packs
4. Protective clothing and hard
hats
31
-------
3. Discuss proper ventilation
4. Other
J. Safety Equipment list safety
equipment required
1. First aid kits
2. Fire extinguishers
3. Gas masks/air packs
4. Protective clothing and hard
hats
5. Safety harnesses
6. Other
K. Process Chemical Handling - discuss
procedures for all chemicals used
1. Alum
2. Lime
3. Ferric Chloride
4. Ferrous Sulfate
L. References list pertinent safety
references
1. WPCF MOP #1 Safety in
Wastewater Works
2. WPCF MOP #18 Operation of Waste-
water Treatment
Plants
3. Chlorine Institute, Chlorine
Manual
4. EPA Manual Safety in the Design
Operation and
Maintenance of Waste-
water Treatment Works,
Contract No. 68-01-0324
5. Other
5. Safety Harnesses
6. Other
J. Process Chemical Handling discuss
procedures for all chemicals used
K. References list pertinent safety
references
1. WPCF MOP
Safety in
Wastewater Works
2. WPCF MOP #7 Sewer Maintenance
3. Chlorine Institute, Chlorine
Manual
4. EPA Manual Safety in the Design,
Operation and
Maintenance of Waste-
water Treatment Works,
Contract No. 68-01-0324
5. Other
CHAPTER XI. UTILITIES
Table of Contents
A. General
1. Give name of utility company
2. List contact men'within
utility company
CHAPTER IX. UTILITIES
Table of Contents
A. General
1. Give name of utility company
2. List contact men within
utility company
32
-------
.-i. Routine contact
b. emergency contact
3. Discuss reliability of service
4. Give any cost information
avai Table
B. Electrical
1. Give voltage of service adjacent
to facility
2. Give reduced voltage entering
facility
3. Discuss stand-by power from
a second source
C. Telephone
1. Outline telephone communications
system within treatment system
2. Discuss any alarm systems that
utilize telephone wires
D. Natural Gas
1. Give cubic feet of gas per hour
2. Give normal operating pressure
3. Give size of gas line
E. Water
1. Give size of water line
2. Give normal operating pressure
3. Discuss any backflow preventer
prevention systems present
F. Fuel Oil
1. List capacities of storage tanks
2. Outline program to insure
adequate supplies of fuel oil
are always on hand
3. List potential suppliers
a. Routine contact
b. Emergency contact
3. Discuss reliability of service
4. Give any cost information
avai1 able
B. Electrical
1. Give voltage of service adjacent
to facility
2. Give reduced voltage entering
facility
3. Discuss stand-by power from
a second source
C. Telephone
1. Outline telephone communications
system within treatment system
2. Discuss any alarm systems that
utilize telephone wires
D. Natural Gas
1. Give cubic feet of gas per hour
2. Give normal operating pressure
3. Give size of gas line
E. Water
1. Give size of waterline
2. Give normal operating pressure
3. Discuss any backflow preventer
prevention systems present
F. Fuel Oil
1. List capacities of storage tanks
2. Outline program to insure
adequate supplies of fuel oil
are always on hand
3. List potential suppliers
CHAPTER XII. ELECTRICAL SYSTEM
Describe the Electrical System
Table of Contents
A. General
1. Schematic diagrams
CHAPTER X. ELECTRICAL SYSTEM
Describe the Electrical System
Table of Contents
A. General
1. Schematic diagrams
33
-------
2. Tables
3. Manufacturer's literature
4. Shop drawings
5. Designer's notes
B. Power Source
1. Give name of electrical utility
company
2. Give characteristics of primary
distribution line
3. Describe main transformer and
state ownership
4. Discuss protective devices
5. Give maximum available short-
circuit current at point(s) of
service from utility company
C. Power Distribution System
1. Describe service entrance
equipment
2. Describe motor control centers
and control panels
3. Provide tabulations indicating
power wiring from and loads fed
by major electrical components
D. Control and Monitoring System
1. Provide tabulations of type
controls present and process
equipment involved
2. Provide schematic diagrams
E. Alternate Power Source
1. Describe power source
2. Describe any duplicate equipment
in the power distribution system
2. Tables
3. Manufacturer's literature
4. Shop drawings
5. Designer's notes
B. Power Source
1. Give name of electrical utility
company
2. Give characteristics of primary
distribution line
3. Describe main transformer and
state ownership
4. Discuss protective devices
5. Give maximum available short-
circuit current at point(s) of
service from utility company
C, Power Distribution System
1. Describe service entrance
equipment
2. Describe motor control centers
and control panels
3. Provide tabulations indicating
power wiring from and loads fed
by major electrical components
D. Control and Monitoring System
1. Provide tabulations of type
controls present and process
equipment involved
2. Provide schematic diagrams
E. Alternate Power Source
1. Describe power source
2. Describe any duplicate equipment
in the power distribution system
APPENDICES
Table of Contents
A. Schematics provide as required
1. Basic flow diagrams
2. Process flow sheets
APPENDICES
Table of Contents
A. Schematics provide as required
1. Basic flow diagrams
2. Bypass piping diagrams
34
-------
3. Bypass piping diagrams
4. Hydraulic profile
5. Other
B. Valve Indices describe all major
valves
1. Function
2. Type/size
3. Location
4. Identification
C. Sample Forms provide as required
1. Daily Operating Log
2. Equipment Data Cards
3. Maintenance Work Order
4. Purchase Order
5. Accident Report Form
6. State Reports
7. Other
D. Chemicals Used in Plant
1. List all chemicals
2. Give safety precautions and
outline storage considerations
in Safety Chapter of Manual
3. List suppliers
4. Provide reorder schedule
E. Chemicals Used in Laboratory
1. Give common name
2. Give chemical formula
3. List suppliers
F. Emergency Operating and Response
Program provide as required
1. Schematic diagrams
2. Sample forms
G. Detailed Design Criteria tabulate
criteria
3. Hydraulic profile
4. Other
B. Valve Indices desc^be all major
valves
1. Function
2. Type/Size
3. Location
4. Identification
C. Sample Forms provide as required
1. Daily Operating Log
2. Equipment Data Cards
3. Maintenance Work Order
4. Purchase Order
5. Accident Report Form
6. State Reports
7. Other
D. Chemicals Used in System
1. List al1 chemicals
2. Give safety precautions and
outline storage considerations
in Safety Chapter of Manual
3. List suppliers
4. Provide reorder schedule
E. Emergency Operating and Response
Program provide as required
1. Schematic diagrams
2. Sample forms
F. Detailed Design Criteria tabulate
criteria
1. Population served
2. Wastewater volume
3. Line size and capacities
4. Pump sizes and capacities
5. Pumping characteristics
35
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1. °opulation served
2. Wastewater volume/strength
a. Present/future
b. Domestic
c. Industrial
3. Quantities of screenings, grit
and sludge removed per million
gallons of wastewater treated
4. Unit sizes and capacities
5. Hydraulic and organic loadings
6. Detention times
7. Pumping characteristics
8. Sludge treatment and disposal
data
H. Equipment Suppliers
1. Give name
2. List equipment furnished
3. Give reference to where detail
information on representatives
can be found in manual
I. Manufacturers' Manuals
1. May be bound separately
2. Manuals should give adequate
operating and maintenance
instructions
3. Manuals should be indexed/
cross-referenced
J. Sources for Service and Parts
1. List service organizations for
all equipment
2. List local repair services
a. Meter repair
b. Motor rewinding
c. Other
3. List local parts sources
a. Plumbing wholesalers
6. Other
G. Equipment Suppliers
1. Give name
2. List equipment furnished
3. Give reference to where detail
information on representatives
can be found in manual
H. Manufacturers' Manuals
1. May be bound separately
2. Manuals should give adequate
operating and maintenance
instructions
3. Manuals should be indexed/
cross-referenced
I. Sources for Service and Parts
1. List service organizations for
all equipment
2. List local repair services
a. Meter repair
b. Motor rewinding
c. Other
3. List local parts sources
a. Plumbing wholesalers
b. Electrical wholesalers
c. Mill supply houses
d. Other
J. As-BuiIt Drawings
1. Ensure drawings are complete
and accurate
2. Cross-reference with shop
drawings
K. Approved Shop Drawings
1. Index adequately
2. Cross-reference with engineering
drawings and construction
specifications
L. Dimension Prints
36
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b. Electrical wholesalers
c. Mill Supply Houses
d. Other
K. As-Built Drawings
1. Ensure drawings are complete
and accurate
2. Cross-reference with shop
drawings
L. Approved Shop Drawings
1. Index adequately
2. Cross-reference with engineering
drawings and construction speci-
fications
M. Dimension Prints
1. Provide when necessary to show
units relation to other units,
adjacent walIs, etc.
2. Use to tie shop drawings to
engineering drawings
N. Construction Photos
1. Label and date all photos
2. Outline photo indexing system
0. Warranties and Bonds
1. Provide copies
2. Index properly
P. Copies of State Reporting Forms
provide as required
1. Monthly Operating Report
2. Bypass Report
3. Chlorine Failure Report
4. Other
Q. Copies of Federal Inspection Forms -
provide as required
1. EPA Form 7500-5 (4-72)
2. Other
1. Provide when necessary to show
units relation to other units,
adjacent walls, etc.
2. Use to tie shop drawings to
engineering drawings
M. Construction Photos
1. Label and date all photos
2. Outline photo indexing system
N. Warranties and Bonds
1. Provide copies
2. Index properly
0. Copies of State Reporting Forms
provide as required
1. Monthly Operating Report
2. Bypass Report
3. Chlorine Failure Report
4. Other
P. Copies of Federal Inspection Forms
provide as required
Q. Infiltration Controls
1. Provide copy of existing ordinance
2. Provide model ordinance if none
exists
R. Industrial Waste Controls
1. Provide copy of existing ordinance
2. Provide model ordinance if none
exists
S. Piping Color Codes
1. List color for each piping system
2. State if directional flow arrows
and/or labeling required
T. Painting
1. Give type coating required for
each unit
2. Give painting frequency schedule
37
-------
R. Infiltration Controls
1. Provide copy of existing ordinance
2. Provide model ordinance if none
exists
S. Industrial Waste Controls
1. Provide copy of existing ordinance
2. Provide model ordinance if none
exists
T. Piping Color Codes
1. List color for each piping system
2. State if directional flow arrows
and/or labeling required
U. Painting
1. Give type coating required for
each unit
2. Give painting frequency schedule
3. Provide a copy of Water Pollution
Control Federation, MOP-17, Taints
and Protective Coatings", (1969)
V. References to be maintained at treatment
facility
1. MOP #1
2. MOP #11
3. Suggested references for detailed
study of process utilized
4. Other
3. Provide a copy of Water Pollution
Control Federation, MOP-17, "Paints
and Protective Coatings", (1969)
38
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SECTION VII
0 & M MANUAL CHAPTER I: INTRODUCTION*
PAGE
MANUAL TABLE OF CONTENTS „ 40
MANUAL USER GUIDE 40
OPERATION AND MANAGERIAL RESPONSIBILITY ..... 40
Operator Responsibility . 41
Treatment System Management Responsibility ....... 41
TYPE OF TREATMENT AND TREATMENT REQUIREMENTS/EFFLUENT
LIMITATIONS 42
Type Treatment 42
Treatment Requirements/Effluent Limitations 42
DESCRIPTION OF PLANT TYPE AND FLOW PATTERN ............ 43
Plant Type 43
Flow Pattern 43
*The format suggested for the table of contents page for the Introduction
Chapter of an 0 & M Manual is similar, except for the manual table of
contents discussion, to the format given for this section of the
Considerations Manual.
39
-------
MANUAL TABLE OF CONTENTS
A clear and complete table of contents is essential in any reference
book or manual. A municipal wastewater treatment facility's operation
and maintenance manual should contain a table of contents to assist
manual users to locate information efficiently. The table of contents
format should have all 0 & M Manual chapters listed and should give
sufficient subsections in each chapter to permit easy identification
of topics addressed in the manual.
MANUAL USER GUIDE
An operation and maintenance manual is a treatment system's primary
reference book. Because the manual will be used by plant personnel
as a reference book, it is essential that desired information be found
quickly. The manual's table of contents page should be supplemented
by a user guide to help personnel become familiar with the manual 's
format. The user guide should explain the manual's organization and
its intended use.
OPERATION AND MANAGERIAL RESPONSIBILITY
To insure efficient and economical municipal wastewater treatment system
operation, the responsibilities of both the operational personnel and
the system's management must be clearly defined. The problems confront-
ing each group must be fully understood by both parties. The operation
and managerial responsibility section of the facility's 0 & M Manual
can be used to outline the scope of responsibility for each party-
In any employer-employee relationship, there should be a mutual under-
standing of the objectives and requirements of the work to be performed.
40
-------
The following is a suggested list of the
operational personnel's responsibilities:
1. Know proper operational procedures.
2. Operate the treatment system
effectively.
3. Keep continuously informed of the
best operating and maintenance
practices.
4. Participate in short courses and
schools when available.
5. Subscribe to and regularly read
several of the periodicals related
to municipal wastewater treatment.
6. Maintain accurate and neat system
operational and maintenance records.
7. Use sound judgment in the expenditure
of operating funds.
8. Keep management advised of potential
major problems in operation and
maintenance of the system.
9. Assist supervisors in preparing an
adequate budget.
10. Be aware of safety hazards connected
with wastewater treatment.
11. Be prepared to discuss plant operation
with plant visitors.
12. Know expected efficiencies of all
unit operations and processes in
the treatment system and how to
moni tor these units.
The following is a suggested list of
management's responsibilities:
1. Maintain efficient plant operation
and maintenance.
2. Maintain adequate treatment system
operational and management records.
3. Establish staff requirements, prepare
job descriptions, develop organizational
charts and assign personnel
4. Provide operational personnel with
sufficient funds to properly operate
and maintain the treatment facility.
5. Ensure operational personnel are paid
a salary commensurate with their
level of responsibility.
6. Provide good working conditions, safety
equipment and proper tools for the
operational personnel.
7. Establish a harmonious relationship
with operational personnel.
8. Provide operational personnel with job
security and career ladder.
9. Establish operator training program.
10. Provide incentives for employees.
11. Motivate personnel to achieve maximum
efficiency of operation.
12. Make employees aware of importance of
proper plant performance.
13. Make periodic inspections of the treat-
ment system to discuss mutual problems
with the operational personnel and to
observe operational practices.
14. Create an atmosphere that will make
operational personnel feel that they
can bring special problems to manage-
ment's attention.
15. Maintain good public relations.
16. Prepare budgets and reports.
17. Plan for future facility needs.
41
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TYPE OF TREATMENT AND TREATMENT REQUIREMENTS/EFFLUENT LIMITATIONS
In this section of the 0 & M Manual the type of treatment should be
stated in general terms (primary, secondary-trickling filter, secondary-
activated sludge, other). The removal efficiencies and/or discharge
concentrations of significant parameters that the facility has been
designed to produce should be given. These parameters could include:
1. Biochemical Oxygen Demand (BOD).
2. Suspended Solids Concentration
3. pH
4. Other
The design flow, concentrations of significant parameters in the influent,
peak hydraulic flow, discharge permit/certificate requirements as they
apply to treatment efficiencies or effluent standards (yearly average
or monthly average) should be included.
Example:
The City "A" sewage treatment plant is an activated sludge
type secondary treatment plant. It is designed for 85%
removal of raw BOD and suspended solids at a concentration
of 200 mg/1 respectively in the influent, and at a daily
average flow of 5 MGD (18,925 cu m/day). Peak hydraulic
capacity of the plant is 12.5 MGD (47,313 cu m/day) with
any single unit out of service.
The plant design is intended to satisfy the discharge
certificate which requires a monthly average of the daily
average effluent BODs and suspended solids not to exceed a
concentration of 30 mg/1 respectively.
42
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DESCRIPTION OF PLANT TYPE AND FLOW PATTERN
The description of the plant type should be of an introductory nature.
Detailed descriptions of unit operations and processes are found in the
description, operation and control sections of the manual. Detailed
design criteria should be tabulated in the manual's appendix. This
introductory description should be presented in a clear and logical
manner. A suggested format for this section would be to categorize the
treatment system:
Collection system
Pretreatment
Primary treatment
. Secondary treatment
. Advanced treatment
. Disinfection
Sludge handling
All units within each category should be described briefly. This intro-
ductory description of plant type should be limited to one or two pages
in the 0 & M Manual.
A flow pattern should be provided in this section and should complement
the plant description given previously. The flow pattern is of an
introductory nature and is not intended to illustrate all possible
alternate flow paths in the system. Detailed flow diagrams and hydraulic
profile should be provided in the engineering drawings of the facility.
Figure No. 1 is a sample flow pattern of the type suggested for this
section of the manual.
43
-------
RIVER
EFFLUENT
SCREENS AND
GRIT CHAMBER
INFLUENT
CHLORINE
CONTACT TANK
NO. 1
PRIMARY
SEDIMENTATION
TANK NO. 1
PRIMARY
SEDIMENTATION
TANK NO. 2
- CHLORINE
CONTACT TANK
NO. 2
SECONDARY
SEDIMENTATION
TANK NO. 2
-ACTIVATED SLUDGE
RETURN LINE
1
t
AERATION TANK
NO. 1
AERATION TANK
NO. 2
I
fe,
PRIMARY
DIGESTER
-WASTE
ACTIVATED
SLUDGE
LINE
I
SLUDGE
I
DRYING
i. t
BEOS
L Jf
FIGURE NO. 1 BASIC FLOW DIAGRAM
-------
A well presented plant description and flow pattern will help generate
interest in total plant operation among persons using the manual. If
the information is presented in a clear and logical manner, the section
can also be used as a guide when explaining the treatment system to
plant visitors.
45
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SECTION VIII
0 & M MANUAL CHAPTER II: PERMITS AND STANDARDS*
PAGE
DISCHARGE PERMIT AND PERMIT REQUIREMENTS . . 48
REPORTING PROCEDURES FOR SPILLS OF RAW OR INADEQUATELY
TREATED WASTEWATER 4y
WATER QUALITY STANDARDS ............ 51
* The format suggested for the table of contents page for the Permits
and Standards Chapter of an 0 & M Manual is identical to the format
given for this section of the Considerations Manual.
47
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DISCHARGE PERMIT NUMBER AND PERMIT REQUIREMENTS
Sometimes persons in responsible positions within a treatment system
are not aware that their facility is operating under a Federal and/or
State Discharge Permit. The facility's 0 & M Manual is a convenient
and practical location to maintain a copy of this permit. A discussion
of the permit requirements should be included. If operating personnel
are aware of permit requirements it can reduce the chances of permit
violations occurring as a result of an operator not realizing the
consequences of his actions.
The 0 & M Manual should give the number of the Federal and/or State
Discharge Permit for the particular treatment system. The permit
requirement should be listed. These requirements include but are not
limited to the following:
1. The manner, nature, volume and frequency of the
discharge permitted.
2. Procedures for and frequency of any industrial
waste monitoring. ,:
3. Proper operation and maintenance of the system by
qualified personnel.
4. Any additional condition or restrictions specified
by the Regulatory Agencies and/or Permitting
Authori ty.
5. Time period for which permit is valid (expiration
date).
A copy of the permit and Federal/State laws or agency regulations deal-
ing with municipal wastewater discharge permits should be included in
48
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the manual's appendix or bound separately and properly referenced in
this section.
REPORTING PROCEDURES FOR SPILLS OF RAW OR INADEQUATELY TREATED WASTEWATER
The importance of having treatment system personnel at all levels informed
of the reporting procedures for spills of raw or inadequately treated
wastewater cannot be overemphasized. Prompt reporting ensures spill
clean-up and monitoring assistance can be dispatched to help minimize
health hazards and environmental damage. Penalties for being negligent
in reporting these conditions are also generally severe and the damage
done to public relations can be disastrous to any treatment system.
Included in this section of the 0 & M Manual should be a discussion of
the Federal/State laws and/or agency regulations requiring reporting of
a bypass/spill condition. The owner's responsibilities and liabilities
should be clearly outlined and penalties for violations should be dis-
cussed.
Reporting requirements and procedures should be outlined. Telephone
numbers for immediate reporting should be listed. Sample reporting forms
should be provided and instructions for completing them given. Responsi
bilities for this reporting should be clearly established for all treat-
ment system personnel.
Persons preparing this portion of an 0 & M Manual should be aware that
Federal Guidelines on reporting procedures are subject to revision. All
information included in this section should be based on current laws and
regulations.
A sample wall poster to assist operational personnel in reporting any
emergency is shown in Figure No. 2 (similar to poster used by the State
of Wisconsin).
49
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IN CASE OF SPILLS OF RAW OR
INADEQUATELY TREATED MUNICIPAL
WASTEWATER IN THE STATE.
CALL THE STATE WATER POLLUTION
CONTROL AGENCY;
NUMBER
AND GIVE AS MUCH AS POSSIBLE OF
THE FOLLOWING INFORMATION;
NAME OF FACILITY
TIME/DATE SPILL STARTED
SPILL VOLUME AND STRENGTH
PROVISIONS FOR CHLORINATION
CONDITIONS SURROUNDING SPILL
ABATEMENT ACTIONS
ASSISTANCE REQUIRED
STREAM SAMPLING PLAN
THE STATE WATER POLLUTION
CONTROL AGENCY WILL ACCEPT
COLLECT CALLS IF YOU INFORM
OPERATOR THAT YOU WISH TO
REPORT A SPILL. THE STATE WATER
POLLUTION CONTROL AGENCY
MAINTAINS 24 HOUR SERVICE.
FIGURE NO. 2 SAMPLE WALL POSTER
(SIMILAR TO POSTER USED BY STATE OF WISCONSIN)
50
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WATER QUALITY STANDARDS
Treatment system personnel are often not aware that a classification
exists for the body of water receiving their facility's treated effluent.
An awareness of the intended use of the receiving stream will help these
personnel realize the importance of maintaining a high performance level
at their facility. Being able to relate their receiving stream's class-
ification to the State's overall classification system will help these
personnel appreciate their role in enhancing the quality of the State's
waters.
Copies of the water quality standards for the receiving stream should be
provided in this section of the 0 & M Manual and properly referenced to
an appended or separately bound copy of the State's Stream Classification
System.
Proper forms and guidelines for permit applications and copies of water
quality standards are generally available from one or more of the follow-
ing sources :
1. State Water Pollution Control Agency
2. State Health Department
3. State Department of Water Resources
4. Environmental Protection Agency Regional Office
51
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SECTION IX
0 & M MANUAL CHAPTER III: DESCRIPTION, OPERATION AND CONTROL
OF WASTEWATER TREATMENT FACILITIES
PAGE
DISCUSSION 54
GENERAL 62
UNIT/PROCESS DESCRIPTION ... 62
RELATIONSHIP TO ADJACENT UNITS ... 62
CLASSIFICATION AND CONTROL . 63
MAJOR COMPONENTS ..... .64
COMMON OPERATING PROBLEMS ...... . . 64
LABORATORY CONTROLS 65
START-UP . 66
SPECIFIC PLANT OPERATION ...... 67
NORMAL OPERATION 67
ALTERNATE OPERATION 67
EMERGENCY OPERATIONS AMD FAILSAFE FEATURES 68
53
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DISCUSSION
The Description, Operation and Control Chapter of an 0 & M Manual riust
be considered a key element in any good manual. It is here that operat-
ing personnel find detailed descriptions of the unit operations and pro-
cesses within their systems. Guidance on operating and controlling the
treatment plant is outlined in this chapter. This chapter will be con-
sulted when an emergency condition exists. New personnel will study this
chapter to learn about the treatment system. Decisions made during plant
start-up or when down units are returned to service will be based on the
information presented in this chapter. The flexibility designed into
the treatment system is outlined here and could prove invaluable in
correcting problems arising within the system. It is essential that
persons preparing 0 & M Manuals recognize the importance of this chapter.
The purpose of this chapter is to assist the reader in understanding the
construction drawings, the purpose and functions of the treatment plant,
and to state the engineer's concept of operation and control of the waste-
water treatment processes.
The writer should present a detailed description of the operation, con-
trol, and relationship to other plant units of each wastewater treatment
process and component, in the order of wastewater flow through the plant,
i.e., plant influent system, pretreatment area (screens, grit facilities,
comminutors), wastewater flow meter, raw wastewater pumps, primary treat-
ment process (splitter box, primary clarifiers), secondary treatment
process (mixing box, trickling filters, recirculation pumps, final
clarifiers) (mixing box, aeration tanks, aerators, return activated
sludge pumps, final clarifiers), disinfection system (mixing box, contact
tanks, disinfection equipment), outfall sewer, effluent water system
(pumps, froth control water, cooling water, wash water, chlorine injector
water), and City water system (potable water, service water). Included
should be photographs and/or schematic diagrams to supplement the verbal
descriptions of routine, alternate and emergency operation. The writer
54
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should Include in his process discussions applicable manual, automatic,
physical, chemical, analytical, biological, and laboratory control
measures. Discussions concerning applicable safety features, failsafe
features, operating problems, causes, and suggested cures, and start-up
guidance should also be included.
Suitable references for further study by plant operators should be pro-
vided with appropriate consideration given to the complexity of the
treatment units/processes and the expertise of the plant personnel.
SAMPLE FORMAT: Table of Contents - 0 & M Manual Chapter III: Description
Operation and Control of Wastewater Treatment Facilities
DESCRIPTION, OPERATION AND CONTROL OF
WASTEWATER TREATMENT FACILITIES
PAGE
PLANT INFLUENT SYSTEM
PRETREATMENT FACILITIES
RAW WASTEWATER METERING
RAW WASTEWATER PUMPING .
PRIMARY TREATMENT PROCESS
SECONDARY TREATMENT PROCESS
ADVANCED WASTEWATER TREATMENT PROCESS
DISINFECTION SYSTEM
PLANT EFFLUENT SYSTEM
IICIPAL WATER SYSTEM
The sample format given above is for this chapter's table of contents
page in an 0 & M Manual. Several treatment units may be grouped under
a single major heading. For example, under Pretreatrnent Facilities, the
following units should be discussed:
Pretreatment Facilities
1. Grit Collecting
55
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2. Pre-aeration
3. Screening
4. Comminution
Format for Individual Treatment Units and Processes
The sample format given below can be applied to any wastewater treatment
unit cr process. It can also be applied to any sludge handling unit or
process. The format is intended for use with individual treatment units
and processes and not for an entire treatment facility.
This format is intended to be flexible. The person preparing this chap-
ter of the 0 & M Manual should use this sample format as a guide to help
ensure all units and processes are adequately described, their operation
is discussed and methods for controlling them are outlined.
UNIT OPERATION OR UNIT PROCESS NAME
PAGE
GENERAL
UNIT/PROCESS DESCRIPTION
RELATIONSHIP TO ADJACENT UNITS
CLASSIFICATION AND CONTROL
MAJOR COMPONENTS
COMMON OPERATING PROBLEMS
LABORATORY CONTROLS
START-UP .....
SPECIFIC PLANT OPERATION
NORMAL OPERATION
ALTERNATE OPERATION .....
EMERGENCY OPERATIONS AND FAILSAFE FEATURES
56
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Certain components within the wastewater treatment system do not lend
themselves to description using the above format. Such treatment related
components as prechlorination provided in the plant influent system,
raw wastewater metering and pumping, foam control water in the plant
effluent system and the municipal water system are in this category.
Persons preparing an 0 & M Manual should give these treatment related
components the same attention that is required for treatment units and
processes such as primary sedimentation, activated sludge, disinfection
and others.
Examples - Introduction
The following examples are included for illustrative purposes to serve
as a guide for the preparation of secondary treatment process sections
and as a format guide for the preparation of other wastewater treatment
process sections. It should be noted that the examples are divided into
two major divisions: a general division containing information generally
applicable to all similar treatment processes, and a specific division
containing operating information pertinent to the specific plant in
question. Although it was outside of the scope of the Considerations
Manual to prepare "canned""inserts , the utilization of this format will
allow the editing and insertion of "canned" general divisions or at
least the reuse in future manuals of general divisions already prepared.
EXAMPLE
TRICKLING FILTER
General
A. Process Description
1. Basic principles
biological slime
2. Operational features
a. Media bed
ACTIVATED SLUDGE
General
A. Process Description
1. Basic Principles
biological floe
2. Operational features
a. Mixed liquor suspended
solids (MLSS)
57
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EXAMPLE
TRICKLING FILTER (Continued)
b. Final settling
c. Recirculation
3. Design Efficiency
B. Relationship to adjacent units
1. Primary treatment
2. Disinfection
C. Classification and control
1. Classification - high rate
2. Control - recirculation rate
D. Major Components
1. Trickling filters
a. Distributor
b. Media
c. Underdrain system
d. Vents
2. Final clarifiers
a. Influent structure
and baffle
b. Scum baffle, skimmer
and trough
ACTIVATED SLUDGE (Continued)
b. Oxygen supply
c. Final settling
d. Sludge recirculation
3. Design efficiency
B. Relationship to adjacent units
1. Primary treatment
2. Disinfection
3. Sludge thickening
C. Classification and control
1. Classification conventional
2. Control
a. Oxygen supply
b. Mixed liquor suspended
solids (MLSS)
(1) Return sludge rate
(2) Sludge wasting
c. Hydraulic control
D. Major Components
1. Aeration tanks
2. Aeration equipment
3. Final clarifiers
a. Influent structure and
baffle
b. Scum baffle, skimmer,
and trough
c. Sludge removal and
recirculation
d. Effluent weir
4. Return sludge pumps
58
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EXAMPLE
TRICKLING FILTER (Continued)
c. Sludge removal and
recirculation
d. Effluent weir
3. Recirculation Pumps
a. Pumps
b. Pump vaults
c. Piping
E. Common Operating Problems
1. Ponding
2. Odors
3. Psychoda flies
4. Icing of filter surfaces
5. Nozzle clogging
6. Clogged vent pipes
7. Clogged underdrain
8. Recirculation pumps
a. Will not start
b. Reduced rate of discharge
c. High power requirements
d. Excess noise
e. Intermittent feed
f. Other
9. Final clarifiers
a. Floating sludge
b. Weirs fouling
c. Broken sludge collection
mechanism
d. Larva
ACTIVATED SLUDGE (Continued)
a. Pumps
b. Piping
5. Waste sludge pumps and sludge
thickening (see Chapter on
Sludge Handling Facilities)
6. Metering
E. Common Operating Problems
1. Sludge bulking
2. Rising sludge
3. Frothing
4. Shock loads
5. Diffuser clogging
6. Surface aerator motor
a. FaiIs to start
b. FaiIs to operate at
rated speed
c. Runs hot
d. Excess vibration and/or
noi se
7. Recirculation pumps
a . Wi11 not start
b. Reduced rate of discharge
c. High power requirements
d. Excess noise
e. Other
8. Final clarifiers
a. Floating sludge
b. Weirs fouling
59
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EXAMPLE
TRICKLING FILTER (Continued)
F. Laboratory Controls
1. Biochemical oxygen demand (BOD)
2. Suspended solids
3. Total solids
4. Dissolved oxygen
5. pH
6. Ammonia, nitrate, nitrite
and total organic nitrogen
G. Start-up
1. Equipment adjustments
2. Start-up procedures
3. Controlling start-up
II. Specific Plant Operation
A. Normal Operation
1. General - schematics
2. Trickling filters
3. Final clarifiers
4. Sludge removal and recir-
culation
5. Recirculation pump station
B. Alternate Operation
1. General description of
alternate modes of operation
ACTIVATED SLUDGE (Continued)
c. Broken sludge collection
mechanism
d. Solids carryover
F. Laboratory Controls
1. Suspended solids
2. Dissolved oxygen
3. Volatile suspended solids
4. Settleable solids
5. Turbidity
6. Biochemical oxygen demand (BOD)
7. Chemical oxygen demand (COD)
8. Microscopic examination
G. Start-up
1. Equipment adjustments
2. Start-up procedures
3. Controlling start-up
II. Specific Plant Operation
A. Normal Operation
1. General schematics
2. Aeration tanks
3. Final clarifiers
4. Return sludge pumps
5. Sludge wasting (MLSS)
B. Alternate Operation
1. General description of
alternate modes of operation
60
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EXAMPLE
TRICKLING FILTER (Continued)
ACTIVATED SLUDGE (Continued)
2. Table of valve and gate
positions for alternate
operating conditions
3. References to construction
drawings, shop drawings and
construction specifications
2. Table of valve and gate
positions for alternate
operating conditions.
3. References to construction
drawings, shop drawings and
construction specifications
C. Emergency Operations and
Failsafe Features
1. Warning devices
2. Standby power
3. Hydraulic design
4. Sludge collector mechanism
overload alarm
5. Other
C. Emergency Operations and
Failsafe Features
1. Warning devices
2. Standby power
3, Hydraulic design
4. Sludge collector mechanism
overload alarm
5. Surface aerator thermal
overload device.
6. Other
61
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WASTEWATER TREATMENT
GENERAL
UNIT/PROCESS DESCRIPTION
If persons using an 0 & M Manual are to understand the overall objectives
of a treatment plant, they must be provided with descriptions of the
major wastewater treatment units and processes in the plant. The descrip-
tions should be brief with appropriate references to more detailed dis-
cussions of the unit or process. The description should physically trace
the wastewater flow through the treatment unit or process and contain
information on design efficiency.
References for persons preparing 0 & M Manuals:
EPA Manual Entitled: Procedures for Evaluating Performance of
Wastewater Treatment Plants*, Contract No. 68-01-0107,
Appendices C through G.
Operation of Wastewater Treatment Plants*, a Field Study Training
Program, Sacramento State College, for EPA Technical Training
Grant No. 5TT1-WP-16-03, Chapters 4 through 10.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants. Chapters
3 through 17.
*NOTE: Both of these references list other sources of additional infor-
mation.
RELATIONSHIP TO ADJACENT UNITS
Very few major treatment units or processes operate independently in a
municipal wastewater plant. Each unit or process is usually preceded
by or followed by units that contribute significantly to overall treatment
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objectives. Persons using an 0 •& M Manual should be made aware of the
role played by units adjacent to the unit or process under consideration.
The discussion of the relationships of these adjacent units should in-
clude their type and function as they relate to the unit or process being
considered. It is also important that a discussion be provided on the
point of introduction, the source, nature and effects of extraneous flows
(Supernatant, centrate, filtrate, scrubber waste, etc.)
References for persons preparing 0 & M Manuals:
WPCF MOP NO. 8, Sewage Treatment Plant Design, Chapters 3
through 16.
Manual of Wastewater Operations, Texas Water Utilities
Association, Chapters 7, 9, 11 through 16, and 21.
CLASSIFICATION AND CONTROL
Classification - Knowing the relationship between the unit or process
under consideration and other similar units or processes
will enable persons using an 0 & M Manual to compare
their treatment systems with other similar systems.
The relationship description should be brief with
appropriate references cited for detailed information
on unit or process modifications.
Control - If proper wastewater treatment is to be achieved,
operating personnel should understand the methods
available for controlling units and processes. The
0 & M Manual should list and discuss the control
techniques available for each major treatment unit
and process.
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References for persons preparing 0 & M Manuals:
Metcalf and Eddy, Inc., "Wastewater Engineering, Collection , Treaty
ment and Disposal", 1972, Chapters 8 through 14.
WPCF MOP No. 11, Operation of jjastewater Treatment Plants, Chapters
3 through 6, and 13 through 17.
MAJOR COMPONENTS
Most wastewater treatment units contain several major mechanical equip-
ment items. Most wastewater treatment processes also contain several
major components. The 0 & M Manual should list these components for
each major treatment unit/process in the facility. These listings will
provide manual users with a better understanding of how several components
combine to achieve the desired results in a treatment unit or process.
References for persons preparing an 0 & M Manual:
Manual of Instruction for Sewaae Treatment Plant Operators, New
York State Department of Health, Chapters 4 through 8.
Steel, E. W. , "Hater Supply and Sewerage", 1960, Chapters 22
through 27.
COMMON OPERATING PROBLEMS
One of the principal uses for an 0 & M Manual will be as a reference
book to help solve any operating problems that arise. Each major treat-
ment unit/process within the facility should be analyzed and potential
operating problems defined. Potential problems that are peculiar to
the facility under consideration should be discussed in the 0 & M Manual.
General problems that are adequately described in other sources should
be listed and properly referenced.
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References* for persons preparing an 0 & M Manual:
EPA Manual entitled, Procedures For Evaluating Performance of
Hastewater Treatment Plants, Contract No. 68-01-0107, Section IV.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants, Chapters
3, 5, 6, 14, 15 and 17.
Ontario Water Resources Commission, Basic Gas Chlorination Manual
*NOTE: Suppliers of wastewater treatment equipment often provide trouble
shooting guides with their equipment. These guides can provide
valuable information on recognizing and responding to operating
problems.
LABORATORY CONTROLS
Operating personnel must understand the relationship between laboratory
test results and the proper operation of treatment units and processes.
This portion of an 0 & M Manual should list the laboratory tests that
furnish information to evaluate and control the performance of the unit/
process under consideration. Expected ranges for the results of these
tests should also be given.
References for persons preparing an 0 8 M Manual:
EPA Manual entitled, Estimating Laboratory Needs For Municipal
Wastewater Treatment Facilities , Contract No. 68-01-0328
Standard Methods For The Examination of Hater and Sewage, 13th
Edition, 1971
WPCF Publication No. 18, Simplified Laboratory Procedures For
Wastewater Examination
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Sawyer, Chemistry For Sanitary Engineers
McKinney, Microbiology For Sanitary Engineers
START-UP
The start-up of a modern municipal wastewater treatment plant is a
complex and demanding task. This portion of the 0 & M Manual should
provide operating personnel with the guidance necessary to inspect
and adjust all equipment prior to start-up. The manual should out-
line the steps for placing the treatment unit or process in operation.
Information should also be provided on the special monitoring and con-
trolling of the unit/process until treatment objectives are met.
References* for persons preparing an 0 & M Manual :
EPA Manual entitled, Start-up of Municipal Wastewater Treatment
Facilities, Contract No. 68-01-0341.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants, Chapters
15 and 17.
* NOTE: Suppliers of wastewater treatment equipment often provide pro-
cedures for placing their equipment into operation.
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WASTEWATER TREATMENT
SPECIFIC PLANT OPERATION
NORMAL OPERATION
It is essential that the treatment plant designer relay to the operating
personnel how he intends for the treatment units/processes to operate.
This portion of the manual should discuss the normal operation of each
wastewater treatment unit and process. Information presented in this
section should describe valve and .gate positions, wastewater loadings on
units, pump settings, speeds of rotating mechanical equipment, and pro-
cess control variables where applicable. Schematics in the 0 & M Manual
or proper referencing to engineering drawings should be used with this
discussion on normal operation.
References* for persons preparing an 0 & M Manual:
WPCF MOP No. 11, Operation of Wastewater Treatment Plants, Chapters
3 through 6 and 14 through 17.
Manual of Wastewater Operations, Texas Water Utilities Association,
Chapters 7, 9, 11 through 16 and 21.
*NOTE: The operating instructions furnished by wastewater treatment
equipment suppliers describe the normal operation of their
equipment and units.
ALTERNATE OPERATION
The information on the flexibility of treatment units and processes is
as important to operating personnel as the guidance on normal operation.
This information on alternate modes of operation will help operating
personnel respond to problems arising in their treatment systems. This
portion of the manual should list and discuss alternate operating
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conditions for units/processes. Any information in engineering drawings,
equipment shop drawings and construction specifications that helps illus-
trate alternate modes of operation should be referenced in this section.
NOTE: The treatment plant designer should ensure that all the alternate
modes of operation for his treatment units/processes are adequately
described in the 0 & M Manual.
EMERGENCY OPERATIONS AND FAILSAFE FEATURES
Although the 0 & M Manual should contain an Emergency Operating and Re-
sponse Program Chapter, the information in that chapter deals primarily
with total facility readiness. Treatment plant operating personnel
should also be made aware of procedures to follow when isolated equipment
items or treatment units require emergency operations. In connection
with these emergency operations, information on failsafe features such
as no bypass, peak flow capacities, standby power and overload alarms
should be made available to operating personnel. This section of the
0 & M Manual should list and discuss the emergency operating procedures
and failsafe features for each wastewater treatment unit and process.
References* for persons preparing an 0 & M Manual:
EPA Manual entitled, Emergency Operating Procedures For
Municipal Wastewater Facilities, Contract No. 68-01-0341.
EPA Manual entitled, Procedures For Evaluating Performance
of Wastewater Treatment Plants, Contract No. 68-01-0107,
Section IV.
*NOTE: The treatment plant designer should ensure that all failsafe
features in his treatment units/processes are adequately
described in the 0 & M Manual.
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SECTION X
0 & M MANUAL CHAPTER IV: DESCRIPTION, OPERATION AND CONTROL OF
SLUDGE HANDLING FACILITIES
PAGE
DISCUSSION 70
GENERAL 75
UNIT/PROCESS DESCRIPTION 75
RELATIONSHIP TO ADJACENT UNITS 75
CLASSIFICATION AND CONTROL 76
MAJOR COMPONENTS ...... .... 77
COMMON OPERATING PROBLEMS 77
LABORATORY CONTROLS ..... 78
START-UP . 78
SPECIFIC PLANT OPERATION ...... 80
NORMAL OPERATION .......... . . 80
ALTERNATE OPERATION . 80
EMERGENCY OPERATIONS AND FAILSAFE FEATURES ....... 81
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DISCUSSION
In the field of municipal wastewater treatment, the facilities for
handling sludge are becoming quite sophisticated. Some existing 0 & M
Manuals devote over half of their contents to the treatment system's
sludge handling facilities. Because of its importance and because the
processes involved can be readily separated from the treatment of the
liquid fraction of the raw wastewater, a separate chapter of the 0 & M
Manual should address the sludge handling facilities. The preparation
of this chapter should be given the same care as the wastewater treat-
ment facilities chapter. Operating personnel will consult this sludge
handling section for the same purposes as those outlined under the waste
water treatment chapter.
The purpose of this chapter is to assist the reader in understanding the
purpose, functions, operation and control of the sludge handling facili-
ties.
The writer should give a detailed description of the operation, control,
and relationship to other plant units of each sludge handling component
and unit, i.e., sludge thickeners, pumping stations, digesters, drying
beds, conditioning, gas control and use, incineration, dewatering,
ultimate disposal, and other items. Include photographs and/or sche-
matic diagrams to supplement the verbal descriptions of routine, alter-
nate and emergency operation. Included should be applicable manual,
automatic, physical, chemical, analytical, biological, and laboratory
control measures. The applicable safety and failsafe features should
be discussed including any encountered operating problem, causes, and
suggested cures. Start-up guidance also should be included.
Suitable references for further study by plant operators should be pro-
vided with appropriate consideration given to the complexity of the
treatment units/processes and the expertise of the plant personnel.
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SAMPLE FORMAT: Table of Contents - 0 & M Manual Chapter IV: Description,
Operation and Control of Sludge Handling Facilities
PAGE
SLUDGE PUMPING
CONCENTRATION
DIGESTION
CONDITIONING
DEWATERING/DRYING
INCINERATION/HEAT TREATMENT OR WET OXIDATION
ULTIMATE DISPOSAL
The sample format given above is for this chapter's table of contents
page in an 0 & M Manual. The format is intended to be flexible and few
treatment systems will have units in all the headings listed.
Format for Individual Unit Operations and Processes
The sample format for individual treatment units and processes presented
in Section IX, Description, Operation and Control of Wastewater Treatment
Facilities can be used for all sludge handling units and processes.
Example - Introduction
The purpose of this example is similar to that outlined under the intro-
duction for the trickling filter and activated sludge process examples
in Section IX, Description, Operation and Control of Wastewater Treatment
Facilities. This example can serve as a guide in the preparation of this
chapter of an 0 & M Manual.
NOTE: Certain components used in sludge handling do not lend themselves
to description using the format mentioned above. Such sludge
handling related components as sludge pumping and ultimate sludge
disposal techniques are in this category. Persons preparing an
0 & M Manual should give these sludge handling components the
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same attention that is required for major sludge handling units
and processes such as thickeners, digestion, and vacuum filters
EXAMPLE
GRAVITY SLUDGE THICKEIO
I. General
A. Unit Description
1. Basic principles
a. Hydraulic surface loading
b. Solids loading
2. Operational features
a. Circular tank
b. Sludge collection and transfer mechanism
3. Design efficiency
B. Relationship to Adjacent Units
1. Aeration tanks
2, Clarifiers
3. Digesters
C. Classification and Control
1. Classification - Activated sludge thickener
2. Control
a. Sludge volume ratio (SVR)
b. Sludge density
D. Major components
1. Thickener tank
2. Sludge collection mechanism
3. Sludge pumps
4. Dilution water pumps
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EXAMPLE
GRAVITY SLUDGE THICKENER
(Continued)
E. Common Operating Problems
1. Floating sludge
2. Broken sludge collection mechanism
3. Sludge pumps
a. Pump will not start
b. Reduced rate of discharge
c. High power requirements
d. Excess noise
e. Other
4. Odors
F. Laboratory Controls
1. Solids loading
2. Dissolved oxygen
3. Hydraulic loading
G. Start-up
1. Equipment inspection
2. Start-up procedures
3. Controlling start-up
II. Specific Plant Operation
A. Normal Operation
1. General Schematics
2. Sludge collection and transfer mechanism
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EXAMPLE
GRAVITY SLUDGE THICKENER
(Continued)
B. Alternate Operation
1. General description of alternate operation modes
2. Table of valve and gate positions for alternate
operating conditions
3. References to construction drawings, equipment
shop drawings and construction specifications
C. Emergency Operations and Failsafe Features
1. Warning devices
2. Standby power
3. Hydraulic design
4. Sludge collector mechanism overload alarm
5. Pump capacities
6. Piping configuration
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SLUDGE HANDLING
GENERAL
UNIT/PROCESS DESCRIPTION
As municipal wastewater sludge handling facilities become more sophis-
ticated, it is essential that 0 & M Manual users be provided with adequate
descriptions of the major sludge handling units and processes in the plant,
The descriptions should be brief, physically trace the sludge through the
unit or process, and contain information on design performance.
References* for persons preparing 0 & M Manuals:
FWPCA, A Study of Sludge Handling and Disposal, Grant No.
PH-86-66-32, Publication WP-20-4, May 1968.
WPCF MOP No. 20, Sludge Dewatering, 1969.
Operation of Wastewater Treatment Plants**, a Field Study
Training Program, Sacramento State College, for EPA Technical
Training, Grant No. 5TT1-WP-16-03, Chapter 8.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants,
Chapters 7 through 12.
*NOTE: Manufacturers of sludge handling equipment such as vacuum filters,
centrifuges, and incinerators generally provide acceptable descrip-
tions for their units.
**NOTE: This reference lists other sources of additional information.
RELATIONSHIP TO ADJACENT UNITS
Most sludge handling units and processes are usually preceded by and/or
followed by units that contribute significantly to the plant's overall
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sludge handling objectives. For a complete understanding of any given
sludge handling unit/process, 0 & M Manual users should understand the
function of units adjacent to the unit/process under consideration. The
discussion of the relationships of these adjacent units should include
their type and function.
References for persons preparing 0 & M Manuals:
Metcalf & Eddy, Inc. "Wastewater Engineering Collection Treatment
and Disposal", 1972, Chapters 8, 11 and 13.
EPA Manual entitled, Procedures For Evaluating Performance of
Wastewater Treatment Plants*, Contract No. 68-01-0107, Appendix F.
*NOTE: This reference lists other sources of additional information.
CLASSIFICATION AND CONTROL
Classification - 0 & M Manual users should benefit from a comparison
between the sludge handling unit/process under con-
sideration and other similar facilities. This
comparison should be brief and references for
additional information on these related units/
processes should be listed.
Control - The satisfactory performance of most sludge handling
units/processes is dependent upon proper operator
control. The control techniques available for each
major sludge handling unit and process should be
listed and each technique discussed in the 0 & M
Manual.
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References for persons preparing 0 & M Manuals:
FWPCA, A Study of Sludge Handling and Disposal, Grant No.
PH-86-66-32, Publication WP-20-4, May 1968.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants,
Chapters 7 through 12.
MAJOR COMPONENTS
Most municipal sludge handling processes consist of several major com-
ponents. Even individual sludge handling units usually have several
major mechanical equipment items. 0 & M Manual users should be made
aware of the major components that comprise the sludge handling unit/
process under consideration. The 0 & M Manual should list these com-
ponents for each major sludge handling unit/process in the plant.
References for persons preparing an 0 & M Manual.
Manual of Wastewater Operations, Texas Water Utilities
Association, Chapters 17 through 20.
WPCF MOP No. 8, Sewage Treatment Plant Design, Chapters 13
through 15.
COMMON OPERATING PROBLEMS
After standard operating procedures have been developed and the plant
has started-up, the 0 & M Manual's primary function is that of a tool
to help solve operating problems. Potential operating problems for
each major sludge handling unit/process should be defined. Problems
peculiar to the plant's sludge handling facilities should be discussed
in the 0 & M Manual, General problems, adequately discussed in other
sources, should be listed and properly referenced.
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References* for persons preparing an 0 & M Manual:
EPA Manual entitled, Procedures For Evaluating Performance of
Wastewater Treatment Plants, Contract No. 68-01-0107, Section IV.
*NOTE: Suppliers of wastewater treatment equipment often provide trouble
shooting guides with their equipment. These guides can provide
valuable information on recognizing and responding to operating
problems.
LABORATORY CONTROLS
Laboratory test results provide information essential to evaluating and
controlling sludge handling units/processes. This portion of the 0 & M
Manual should list all required laboratory tests and give expected
ranges for the results of these tests.
References for persons preparing an 0 & M Manual:
Standard Methods For The Examination of Water and Sewage,
13th Edition, 1971.
WPCF Publication No. 18, Simplified Laboratory Procedures
For Wastewater Examination
Weber, "Physicochemical Processes For Water Quality Control",
Chapter 12.
START-UP
Starting-up the sophisticated sludge handling facilities in a modern
municipal treatment plant is a complex task. Operating personnel
should be provided with information on inspecting and adjusting mechan-
ical equipment prior to start-up. The personnel should be given
instructions on placing units/processes into operation and controlling
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them until the sludge handling objectives are met. This portion of an
0 & M Manual should describe the start-up information for the unit/
process under consideration.
References* for persons preparing an 0 & M Manual.
EPA Manual entitled, Start-up of Municipal Wastewater Treatment
Facilities, Contract No. 68-01-0341
WPCF MOP No. 16, Anaerobic Sludge Digestion, Chapter 6
*NOTE: Suppliers of wastewater treatment equipment often provide pro-
cedures for placing their equipment into operation.
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SLUDGE HANDLING
SPECIFIC PLANT OPERATION
NORMAL OPERATION
An important function of any 0 & M Manual is to provide operating
personnel with an understanding of the normal operation of each major
sludge handling unit and process. This section of an 0 & M Manual
should describe valve positions, heat requirements, sludge blanket
depths, sludge pumping schedules, and other pertinent sludge handling
facts. Schematics in the 0 & M Manual or proper referencing to engi-
neering drawings should be used with this discussion on normal operation
References* for persons preparing an 0 & M Manual:
FWPCA, A Study of Sludge Handling and Disposal, Grant No.
PH-86-66-32, Publication WP-20-4, May 1968.
WPCF MOP No. 11, Operation of Wastewater Treatment Plants,
Chapters 7 through 12.
WPCF MOP No. 20, Sludge Dewatering, 1969
WPCF MOP No. 16, Anaerobic Sludge Digestion, 1968.
*NOTE: The operating instructions furnished by suppliers of sludge hand-
ling equipment and units describe the normal operation of these
iterns.
ALTERNATE OPERATION
The flexibility designed into sludge handling units/processes can best
be described by listing alternate modes of operation for each unit and
process under consideration. Any information in engineering drawings,
equipment shop drawings, and construction specifications that helps
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illustrate alternate modes of operation should be referenced in this
section of an 0 & M Manual.
NOTE: The treatment plant designer should ensure that all the alternate
modes of operation for his treatment units/processes are ade-
quately described in the 0 & M Manual.
EMERGENCY OPERATIONS AND FAILSAFE FEATURES
Having procedures established for operating sludge handling facilities
during emergency conditions can minimize damages to equipment and pro-
cesses. These procedures can also reduce the chances for injury to
operating personnel. This portion of an 0 & M Manual should list and
discuss the emergency operating procedures and failsafe features for
each sludge handling unit and process. Failsafe features associated
with sludge handling facilities include standby power, overload alarms,
explosive gas alarms, etc.
References* for persons preparing an 0 & M Manual:
EPA Manual entitled, Emergency Operating Procedures for Municipal
Wastewater Facilities, Contract No. 68-01-0341.
EPA Manual entitled, Procedures for Evaluating Performance of
Wastewater Treatment Plants, Contract No. 68-01-0107, Section IV.
*NOTE: The treatment plant designer should ensure that all failsafe
features in his treatment units/processes are adequately
described in the 0 & M Manual.
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SECTION XI
0 & M MANUAL CHAPTER V: PERSONNEL*
PAGE
GENERAL ....................... 84
MANPOWER REQUIREMENTS/STAFF ... .......... 84
QUALIFICATIONS ......................... 86
CERTIFICATION ..... ................ 89
* The format suggested for the table of contents page for the Personnel
Chapter of an 0 & M Manual is similar, except for the general dis-
cussion, to the format given for this section of the Considerations
Manual.
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GENERAL
Regardless of the care which goes into the design and construction of a
treatment facility, without qualified personnel in adequate numbers to
operate the processes, the full capabilities of the facility cannot be
realized. A well thought-out staff requirement will assist the treat-
ment system's management as they seek funds for staffing their facility.
The manpower requirements recommended should be compatible with existing
Federal and State guidelines.
Up-to-date training for operators and maintenance personnel should be
stressed as being of critical importance in the proper functioning of
the wastewater treatment facility. The purpose is to protect the huge
investment in plant equipment from damage or deterioration, and to
improve the quality of the effluent.
The purpose of this section of the 0 & M Manual is to give the manpower
requirements for the treatment system. The qualifications of personnel
to include training, experience and demonstrated skills are given in
this section. Plant operator certification programs should be discussed
and job descriptions for all personnel should be given.
MANPOWER REQUIREMENTS - STAFF
The preparation of this section of a facility's 0 & M Manual should be
closely coordinated with the owners of the treatment system. The need
for information on manpower requirements will vary with a facility's
ability to determine their own plant staff and training needs.
The Environmental Protection Agency has developed three manuals entitled
"Estimating Staffing For Municipal Wastewater Treatment Facilities",
Contract No. 68-01-0328, "Estimating Costs and Manpower Requirements for
Conventional Wastewater Treatment Facilities", Contract No. 14-12-462,
and "Estimating Laboratory Needs For Municipal Wastewater Treatment
Facilities", Contract No. 68-01-0328, to provide assistance in estimating
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facility personnel requirements. The Environmental Protection Agency
also is establishing manpower planning and training capabilities in
regional, state and local water pollution control agencies to assist
in this area. Other ongoing EPA programs include maintaining and
disseminating manpower planning criteria in the form of occupation
definitions and staffing guides.
To adequately prepare manpower recommendations, a task analysis of each
job within the treatment system should be made. This analysis will
provide details on the skills and qualifications required for each
position.
There are specialized methods and techniques and professionals available
for the determination of manpower and training requirements. Persons
responsible for 0 & M Manual preparation should consider using personnel
with specialized skills in manpower factors to determine personnel and
training needs.
The manpower requirements or staff should be given as a total number with
individual areas such as supervision, administration, operation and main-
tenance broken down.
If minimum staffing requirements have been established by a state regu-
latory agency for various size treatment facilities the applicable
requirement should be cited. Table No, 1 gives a typical breakdown of
plant capacity versus minimum operating personnel.
l-lhere certain positions in the treatment system require certification
by state law, these should be indicated in this section and discussed
in the certification section.
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STATE Of !I LINO IS
ENVIRO"S'r?:TAl PROTECTION AGENCY
VPC 'IfCll'llCAL POLIC1 c.Q-;-4
REVI SCO JULY, 1971
TABLE NO. 1
MINIMUM OPERATING PERSONNEL
PLANi CAPACITY
0.1 Mil LI ON GAL/DAY
(LESS THAI!)
0.1 MILLION GAL/DAY
0.25 MILLION GAL/DAY
0.5 MILLION GAL/DAY
1.0 MILLION GAL/DAY
[i,0 MILLION GAL/DAY
10.0 MILLION GAL/DAY
OPERATOR
MINIMUM OF 2 HOURS OPERATION
TIME DAILY
1/2 FULL TIME 5 DAYS PER V.'ELK
2 MRS, SAT., SUN, 1 HOLIDAYS
1 FULL TIME - 5 DAYS PER WEEK
2 HRS. SAT., SUN. (.. HOLIDAYS
1 rUM. TIME OPERATOR
\/?. TIME ASSISTANT (l Ul.L
TIME TOR ACTIVATED SLUDGE
PLANT)
2 FULL TIME OPERATORS
1 ASSISTANT
1 SUPERINTENDENT
4 OPERATORS
1 MAIIiTl NANCE MAN
1 ASSISTANT
1 S;':>SRIN'IENDENT
1 Cnft'lST
1 MAINTENANCE MAN
In some municipal wastewater treatment operations, the character of each
of the three daily shifts is quite different. An example would be the
reduction of the maintenance forces during the 4:00 PM to 8:00 AM shifts
Another example could be a vacuum filter operation that is run inter-
mittently and where manpower requirements drop off when the filter is
idle. The personnel chapter of an 0 & M Manual should discuss the
particular shift staffing requirements for the facility at hand.
QUALIFICATIONS
The qualifications for all types of personnel should be listed. Person-
nel types include superintendent, operators, maintenance men, chemists
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and assistants for all levels. Job descriptions for all personnel should
be given. This description might include the following for an operator:
Follow shift standard procedures, keep daily operating records, check
all meters and recorders for proper operation and check and adjust chlo-
rinators for proper operation, chlorine used, and chlorine residual.
The following is a list of the types of personnel commonly employed for
operation and maintenance of conventional wastewater treatment systems:
Occupation Description*
1. Superintendent
2. Assistant Superintendent
3. Clerk-Typist
4. Operations Supervisor
5. Shift Foreman
6. Operator II
7. Operator I
8. Automotive Equipment Operator
9. Maintenance Supervisor
10. Mechanical Maintenance Foreman
11. Maintenance Mechanic II
12. Maintenance Mechanic I
13. Electrician II
14. Electrician I
15. Maintenance Helper
16. Laborer
17. Painter
18. Storekeeper
19. Custodian
20. Chemist
21. Laboratory Technician
*Report for EPA, "Estimating Costs and Manpower Requirements for Con-
ventional Wastewater Treatment Facilities", Contract No. 14-12-462.
The following outline for presenting an occupation description is taken
from a report prepared for EPA entitled, "Estimating Costs and Manpower
Requirements for Conventional Wastewater Treatment Facilities", Contract
No. 14-12-462.
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Title: (Give title of position)
Job Description
Qualifications Profile
1. Formal education
2. General requirements
3. General educational development
a. Reasoning
b. Mathematical
c. Language
4. Special vocational preparation
5. Aptitudes - Relative to general working conditions
a. Intelligence
b. Verbal
c. Numerical
d. Form perception
e. Spatial
f. Clerical perception
g. Motor coordination
h. Finger dexterity
i. Manual dexterity
j. Eye-hand-foot coordination
k. Color discrimination
6. Interests
7. Temperament
8. Physical demands
9. Working conditions
Complete and accurate job descriptions are sometimes difficult to prepare.
The effort required to develop these job descriptions should not be under-
estimated. Good job descriptions should include but are not limited to the
following:
-------
1. List items or processes that individual must operate.
2. State if monitoring of gages or meters is required.
3. Discuss interpreting of any meter or gage readings for process
control actions.
4. List any logs or records to be maintained.
5. Outline any maintenance duties required.
6. State any other title that individual might carry.
7. Discuss decision making requirements.
8. State responsibilities and authority given to individual in job
being described.
9. List any report or budget functions that must be performed.
10. Discuss any supervisory or inspection functions.
Any training requirements for treatment system personnel should be out-
lined in this section.
Any state and federal training programs available at or near the treat-
ment plant should be listed in this section.
CERTIFICATION
The pertinent details of any existing State Certification Program should
be discussed with emphasis on how they apply to the treatment system at
hand. This discussion should include a copy of the rules and regulations
of the State Certification Board. This copy may be appended or bound
separately if properly referenced in this section of the manual.
NOTE:
A Model State Act for mandatory certification of operators of water
treatment plants, water distribution systems, and wastewater facilities
has been adopted by the Council of State Governments and can be found
in the Journal Water Pollution Control Federation Vol. 44, p. 1884
(October 1972). This Model State Act will be of interest to individuals
not familiar with operator certification.
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SECTION XII
0 & M MANUAL CHAPTER VI: LABORATORY TESTING*
PAGE
DISCUSSION 92
PURPOSE 93
SAMPLING PROGRAM 93
OPERATOR/LABORATORY REFERENCES 96
INTERPRETATION OF LABORATORY TESTS 96
SAMPLE LABORATORY WORKSHEETS 99
* The format suggested for the table of contents page for the Laboratory
Testing Chapter of an 0 & M Manual is similar, except for the Dis-
cussion portion, to the format given for this section of the Consid-
erations Manual.
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DISCUSSION
The treatment system laboratory testing program provides the basis for
process control and produces a record of how the treatment facilities
are operating. This information keeps the operating personnel informed
of plant efficiencies and helps in predicting problems that are develop-
ing in the system. Because laboratory test results are a record of plant
performance, they are often evaluated by governing and/or regulatory
bodies. For these reasons, it is essential a treatment system's labora-
tory testing program produce complete and accurate results.
This chapter of an 0 & M Manual should be used to emphasize the neces-
sity and importance of laboratory tests in municipal wastewater treatment.
The sampling procedures and frequency for the various laboratory tests
should be described. The tests to be performed should be listed and a
brief description of their nature and purpose given. The detailed dis-
cussion of how each type test can be used in controlling and/or monitor-
ing a specific treatment process should be given in the "Description,
Operation and Control" chapters of the manual.
The definitions of grab and composite sampling should be given. A sug-
gested schedule for performing the various laboratory tests should be
outlined. A list of reference materials for use in the laboratory should
be given. All references considered essential for proper laboratory
operation should be provided as a part of the total 0 & M Manual package.
Samples of the laboratory worksheets recommended for use in the lab
should be included.
Any information related to required effluent and receiving stream monitor-
ing should be included under the Permits and Standards chapter of the
manual. Water Quality Standard information should also be included under
the Permits and Standards Chapter.
92
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The EPA Construction Grants Program requires that the grantee ensure,
for each grant assisted plant, provisions for adequate laboratory test-
ing in accordance with Section 35.935-12 of the 40 CFR, Part 35.
To provide detailed information on laboratory equipment and staffing,
EPA has developed a manual entitled, "Estimating Laboratory Needs For
Municipal Wastewater Treatment Facilities", Contract No. 68-01-0328.
In mid-1973 EPA also will publish in the Federal Register, Guidelines
establishing test procedures for the analysis of pollutants as required
by Section 304(g) of the FWPCA Amendments of 1972.
PURPOSE
This section of the 0 & M Manual's Laboratory Testing Chapter must relay
to treatment facility personnel the importance of complete and accurate
laboratory records. It shu'ild explain the role of the laboratory in
treatment process control , in providing an operating record for the
treatment system, and in analyzing problems within a treatment unit/
process.
SAMPLING PROGRAM
The value of results from wastewater laboratory testing is dependent
upon the sample being representative of the source from which it was
taken. There are two types of samples taken for wastewater laboratory
analyses. Their definitions follow:
Composite Sample A combination of individual samples taken
at selected time intervals, for some specified period, to
minimize the effect of the variability of the individual
sample. Samples may be of equal volume or proportional to
flow at time of sampling.
Grab Sample - A single sample taken at neither set time nor
flow.
93
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The following is a list of general guidelines for sampling municipal
wastewater:
1. Samples should be taken at locations where the wastewater
is as completely mixed as possible (Specific locations
should be given for system at hand).
2. Particles greater than one-quarter inch in diameter should
be excluded when sampling.
3. Any floating materials, growths, etc., which may have
collected at a sampling location should not be included
when sampling.
4. If samples are to be kept for an hour or more prior to
testing, they should be immersed in ice water to retard
bacterial action.
5. Proper sampling equipment should be provided and safety
precautions should be exercised during all sampling.
6. Consideration should be given to the relationship between
the plant's daily flow variation and detention time
through the units so that influent and effluent samples
relate to the same waste.
Figure No. 3 is a sample format for a Laboratory Sampling Program.
This portion of the manual should contain a discussion of potential
cross-connection hazards and suggestions for periodic testing for
bacteria in the plant's potable water system.
94
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FIGURE NO. 3 SAMPLE LABORATORY TESTING PROGRAM
t-O
en
RAW
SEWAGE
PRIMARY
EFFLUENT
SECONDARY
EFFLUENT
CHLORINE
CONTACT TANK
MIXED
LIQUOR
PLANT
EFFLUENT
UJ
_J
CD
o;
co
a:
o
Q
Q
co
co
CO
-JO
< —
t— _J
oo
H-CO
W
crco
o—
— CO
Q
UJ
Ouj
COO
co>-
— X
QO
CO
-JO
-------
The EPA Manual entitled, "Procedures for Evaluating Performance of Waste-
Water Treatment Plants", Contract No. 68-01-0107 contains a minimum pro-
cess testing guide. Additional information on sampling programs can be
found in the EPA Manual entitled "Estimating Laboratory Needs for Munic-
ipal Facilities", Contract No. 68-01-0328.
OPERATOR/LABORATORY REFERENCES*
1. "Standard Methods for Examination of Water arid Sewage."
2. EPA publication "Methods for Chemical Analysis of Water
and Waste" (GPD Stock No. 5501-0067).
3. WPCF Publication No. 18, "Simplified Laboratory Procedures
for Wastewater Examination."
4. WPCF Manual of Practice No. 11, "Operation of Wastewater
Treatment Plants."
5. "Manual of Wastewater Operations", Texas Water Utilities
Association.
6. "Manual of Instruction for Sewage Treatment Plant Operators",
New York State Department of Health.
7. "Chemistry for Sanitary Engineers", Sawyer, McGraw-Hill.
*NOTE: All essential references should be provided as part of the total
0 X M Manual package.
INTERPRETATION OF LABORATORY TESTS
The detailed discussion of how each test can be used in controlling and/
or monitoring a specific treatment process should be given in the
"Description, Operation and Control" chapters of the 0 & M Manual.
96
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The detailed procedures for performing each test do not have to be
included in the 0 & M Manual, but should be properly referenced to one
or more of the laboratory reference documents provided.
In this section each laboratory test should be defined and its general
applications to municipal wastewater treatment discussed. This dis-
cussion should be tailored according to the laboratory staff capabilities
of the facility under consideration.
The following are examples of the type information to be provided for
various tests under this section.
pH is a term used to express the intensity of the acid or
alkaline condition of a solution. The pH scale is usually
represented as ranging from 0 to 14, with pH 7 representing
absolute neutrality. Acid conditions increase as pH values
decrease, and alkaline conditions increase as the pH values
increase.
Dissolved Oxygen (DO)
Dissolved Oxygen represents the amount of oxygen in solution
(dissolved) in a liquid. The solubility of oxygen in fresh
waters ranges from 14.6 mg/1 at 0° C to about 7 mg/1 at 35 C.
The solubility of oxygen is at a minimum when temperatures are
high. In wastewater testing, dissolved oxygen measurements
are used to monitor aerobic conditions in receiving streams
and in controlling aerobic treatment processes.
Biochemical Oxygen Demand (BOD)
The BOD test is used to determine the oxygen required to stabi
lize biologically the organic matter present in the wastewater.
It is the principal test to determine the strength, in terms of
97
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oxygen required, of municipal wastewater. It is widely used
to evaluate the efficiency of various treatment processes and
to estimate the effects of pollution on receiving streams. BOD
test results are usually reported in milligrams per liter (mg/1)
of oxygen consumed at the end of a five day test period. These
results are referred to as the 5-day BOD (BODg) and should not
be confused with the ultimate BOD (BODy) of the sample.
Settleable Solids
The term "settleable solids" is applied to solids in suspension^
that will settle, under quiescent conditions, because of the
influence of gravity. This test is an indication of the volume
of solids removed by sedimentation and test results are meas-
ured and reported in terms of milliliters per liter of settle-
able solids.
Suspended Solids
The undissolved substances in wastewater are usually referred
to as suspended solids. It is a major parameter in evaluating
wastewater strength and in determining the efficiency of treat-
ment processes. It is also used to estimate effects of pollution
on receiving streams. It is used with activated sludge mixed
liquor testing in determining the sludge density index. This
index is an important part of activated sludge process control.
Suspended solids test results are reported in terms of milli-
grams per liter.
Chlorine Residual
Chlorine residual is the chlorine remaining in wastewater at
the end of a specified contact period and test results are
reported in terms of milligrams per liter. It is used to
determine if desired chlorination objectives are being met.
98
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Volatile Acid
Volatile acids are formed during the anaerobic degradation of
carbohydrates, proteins, and fats. The test is valuable in
the routine control of anaerobic digestion units. The volatile
acid content of digesting sludges usually is in the range of
50 to 250 mg/1 , expressed as acetic acid.
Chemical Oxygen Demand (COD)
The COD test is based on the fact that practically all organic
compounds can be oxidized by the action of strong oxidizing
agents under acid conditions. During the test, organic matter
is converted to carbon dioxide and water regardless of the
biological assimilability of the substances. As a result,
COD values can be much greater than BOD values if large amounts
of biologically resistant organic matter are present. The
test is widely used in the ooeration of industrial treatment
facilities because of the speed with which results can be
obtained. It is also used to estimate the effects of pol-
lution and receiving streams. COD test results are reported
in terms of milligrams of oxygen per liter of sample.
SAMPLE LABORATORY WORKSHEETS
Samples of the laboratory worksheets recommended for use in the lab
should be included. Figure No. 4 is a sample worksheet for solids
determinations and Figure No. 5 is a sample worksheet for BOD deter-
minations. A detailed discussion of the laboratory records recommended
for use by the treatment system should also be included in this portion
of the chapter.
99
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SAMPLE BENCH SHEET FOP SOLIDS DETERMINATION*
Dai TV Renort Sheet Date
Citv State
19
Suspended Solids
Container number
Volume filtered (ml)
Weiaht of container plus solids (q)
Weiaht of container (n)
Difference in mn (A)
1,000 (B)
ml volume filtered
(A) x (B)
Sludge Solids
Dish No.
Sample volume (ml )
Weiaht of dish plus solids (q)
Weiaht of dish (n)
(C) Difference in q
Weinht of dish plus dried solids (g)
Weight of dish (q)
(D) Difference in q
Percent sol ids -~ x 100
Volatile Solids
Dish No.
Dish (q) + dry sol ids
Dish + Ash (n)
(E) Loss Wt. (g)
Percent Volatile
Solids = =r x 100
Row
50
24.3760
24.3620
14.0
20
280
Primary
Effluent
100
Raw
9
25
25.7420
20.0000
5.742
20.2871
20.0000
.2871
5.0%
Raw
9
20.2R71
20.2762
0.2009
0.2009 x lf)0
Mixed
Liquor
Paner &
100
0.3500
.0500
300.0
10
3,000
Final
Effluent
100
0 igested
Digested
= 70%
FIGURE NO, 4 SANPLE: SOLIDS DETERMINATION WORKSHEET
*Courtesy of Water Pollution Control Federation, Manual of Practice
No. 18, p. 57
100
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SAMPLE BENCH SHEET FOR POO HETER'MNATION'
City
Dailv Penort Sheet
State .
Date
19
BOD Sample
Bottle no.
ml samnle in bottle
Percent dilution
Dilution factor
Before incubation :
Buret read, after (ml)
Buret read, before (ml)
(A) Difference, ml of "thio"
After 5 days, 20UC:
Buret read, after (ml)
Buret read, before (ml)
(B) Difference, ml of "thio"
(C) DO depletion, A-B (ml)
Dilution factor
BOD (ma/1)
If sample was seeded with 1 ml seed:
(C) Depletion (nil)
Correction, seed (ml)
(D) Corrected difference (ml)
Dilution factor
Corrected BOD (mq/1)
(D x dilution factor)
Raw
61 62 63
369
1 2 3
100 50 33.3
7.8 15.7 23.4
0 7.8 15.7
7.8 7.9 7.7
5.8 9.6
0 5.8
5.8 3.8
2.0 4.1
100 50
200 205
2.0 4.1
0.3 0.3
1.7 3.8
100 50
170 190
Primary
Effluent
64 65 66
6 9 12
2 3 4
50 33.3 25
Final
Effluent
Blank
Wafer
70
0
1
8.2
0
8.2
15.6
7.6
8.0
0.2
Seed Settled
Sewage
73
6
2
50
8.0
0
8.0
13.0
7.0
6.0
2.0
Correction for
1 ml seed =
M= 33
6 '•"
FIGURE NO, 5 BOD DETERMINATION WORKSHEET
* Courtesy of Water Pollution Control Federation, Manual of Practice, No. 18, D.58.
-------
SECTION XIII
0 & M MANUAL CHAPTER VII: RECORDS*
PAGE
DISCUSSION 104
DAILY OPERATING LOG 105
LABORATORY RECORDS 107
MONTHLY REPORT TO STATE AGENCIES 107
ANNUAL REPORT 107
MAINTENANCE RECORDS 112
OPERATING COSTS AND RECORD KEEPING 112
PERSONNEL RECORDS 113
EMERGENCY CONDITIONS RECORDS 113
* The format suggested for the table of contents paqe for the Records
Chapter of an 0 & M Manual is similar, except for the Discussion por-
tion, to the format given for this section of the Considerations Manual
103
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DISCUSSION
An important factor in any efficient wastewater treatment system is the
maintenance of accurate operational and financial records. Without a
record of past operational performance, it is impossible to identify
trends in any process. Operating cost records are essential if mean-
ingful budgets are to be prepared. Accurate records permit plant
operating personnel and management to maintain control of their facility
This chapter of the 0 & M Manual should list only those records neces-
sary for efficient operation of the treatment system.
The objective of this chapter of the 0 & M Manual is to describe the
records and reports that should be maintained. The importance of keep-
ing neat and accurate records should be stressed in this chapter of the
manual.
The principal types of records discussed in this chapter include:
. Monthly operating report to State Water Pollution Control
Agency
. Daily Log, by shift, of process operations
Operating cost records
. Annual report to governmental body responsible for
treatment system
Other records such as laboratory, maintenance and safety should be list-
ed in this chapter. Detailed descriptions of these records should be
provided in the chapters of the 0 & M Manual dealing with these topics.
Miscellaneous records that can be discussed include by-pass reports,
chlorine failure reports and average monthly operating records.
104
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DAILY OPERATING LOG
Operator's worksheets should be maintained. These sheets are temporary
until data is transferred to the daily operating log or they may be kept
if they apply to a remote location. Information contained on these work'
sheets might include the following:
1. Facility influent flow (MGD).
2. Recirculation rate,
3. Grit removed.
4. Screenings removed.
5. Sludge handling data (Sludge pumping, etc.).
6. Status of secondary treatment process.
7. Visual assessment of influent, effluent and receiving
stream quality.
Figure No. 6 is a sample worksheet for an anaerobic digester.
A daily operating log should be maintained. This log should be bound in
notebooks to prevent the destruction or alteration of these important
records. Information on this daily log should include the following:
1. Routine operational duties.
2. Unusual conditions (operational and maintenance).
3. Accidents to personnel.
4. Complaints (odor, etc.).
5. Power consumption.
6. Plant visitors.
Figure No. 7 is a sample daily operating log. The daily log utilizes
two pages per day in the facility's log book. Page one is always the
left hand page and contains the record of the first and second shifts.
Page two, the right hanc page, contains a record of the third shift's
activities and the summary of the day's operation. The summary forms a
basic data source for each day's entry on the monthly operating report.
105
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D IGESTER NO.
DATE:
OPERATOR:
TIME
24:00
01 :00
02:00
03:00
04:00
05:00
06:00
07 :.00
08:00
09:00
10:00
1 1 :00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21 :00
22:00
23:00
TOTALS
GAS
METER
•
-------
LABORATORY RECORDS*
A daily laboratory worksheet should be maintained. Information on this
laboratory worksheet should include the following:
1. A summary of all lab tests run.
2. A format for calculating BOD.
3. Weather conditions (temperature, precipitation, etc.)
4. Chemicals used.
* The Laboratory Testing Chapter of the 0 & M Manual should contain a
detailed discussion of the laboratory records recommended for use by
the treatment system.
MONTHLY REPORT TO STATE AGENCIES
The records section of the 0 & M Manual should explain how the State's
monthly report applies to the specific treatment system at hand. Maximum
usage of this State form will prevent using supplemental forms, thus
eliminating unnecessary paper work. Sample forms should be provided
either in this section or in the manual's appendix.
ANNUAL REPORT
The persons preparing the 0 & M Manual should discuss annual reports in
this section of the manual. Information on who is to prepare the report
should be given.
Generally the treatment plant superintendent will be responsible for pre-
paring an annual report. Tell whether the report is prepared at the end
of the calendar or the fiscal year.
The annual report is generally divided into two parts, a Management Data
Section and an Operating Data Section. Figure No. 8 lists most of the
information required in the Operating Data Section of an annual report.
107
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PLANT
Fl NAL
INITIAL
TOTAL
NFLUENT FLOW METER
GAS PRODUCED
Fl NAL
INITIAL
TOTAL
HOUR
D. 0.
DESCRI PT ION
SCREENINGS
GR T
SCUM
USED
CL2 RES.
QUANT 1 TY
CHECKLIST
AIR COMP. SPRAY PUMPS
BLOWERS GAS COMP.
GAS LINES HEAT EXCH.
RETURN SLUDGE
SLUDGE PUMPED
CHLORINE USED
FINAL
INITIAL
TOTA^
BLOWER NO. 1
Fl NAL
INITIAL
TOTAL
BLOWER NO. 2
FINAL
INITIAL
TOTAL
A i R TEMP
SEWAGE TL
WEATHER •
°F
MP. °F
WASTE SLUDGE
HEAT EXCHANGER
TEMPERATURE
1 N OUT
"F °F
A IR SUPPLI ED
DIGESTER
TEMPERATURE
SVI
MLSS
REMARKS : 1ST SHI FT
OPERATOR :
2A1L:
PLANT 1 NFLUENT FLOW METER
Fl NAL
"INITIAL
TOTAL
GAS PRODUCED
Fl NAL
IN 1 T 1 AL
TOTAL
HOUR
0. 0.
DESCR °TION
USED
CL? RES.
RETURN SLUDGE
SLUDGE PUMPED
CHLORINE USED
FINAL
INITIAL
TOTAL
! BLOWER NO. !
QUA NT 1 TY
SCREENINGS |
GR T
SCUM
CHECKLI ST
A IR COMP.
BLOWERS
GAS LIMES
SPRAY PUMPS
GAS COMP.
HEAT EXCH.
Fl NAL
INITIAL
TOTAL
BLOWER NO. 2
FINAL
INITIAL
TOTAL
AIR TEMP °F
SEWAGE TEMP, °F
WEATHER
WASTE SLUDGE 1 AIR SUPPLIED
,
HEAT EXCHAMGER I DIGESTER
TEMPERATURE 1 TEMPERATURE
IN OUT
T °F -
1
SVI
MLSS
REMARKS . ?NO SHI FT
OPERATOR :
P*TC:
FIGURE NO. 7
SAMPLE DAILY OPERATING LOG
108
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PLANT INFLUENT FLOW METER
Fl NAL
INITIAL
TOTAL
GAS PRODUCED
F 1 NAL
INITIAL
TOTAL
HOUR
D. 0.
DESCRIPTION
SCREENINGS
GR T
SCUM
USED
CL? RES.
QUANT 1 TY
CHECKL1 oT
AIR COMP . 1 SPRAY PUMPS
BLOWERS I GAS COMP.
GAS LINES 1 HEAT EXCH .
RETURN SLUDGE
SLUDGE PUMPED
CHLORINE UScD
FINAL
INITIAL
TOTAL
BLOWER NO. 1
Fl NAL
INITIAL
iTOTAL
BLOWER NO. 2
Fl NAL
INITIAL
TOTAL
A 1 R TEMP
SEWAGE TE
WEATHER :
"F
MP. CF
WAS It bLUDGE
HEAT EXCHANGER
TEMPERATURE
IN OUT
°F °F
A IR SUPPLIED
DIGESTER
TEMPERATURE
SVI
MLSS
REMARKS . 3RD SHI FT
OPERATOR :
^AILj
INFLUENT FLOW (MG )
SCREENINGS (CU. FT.)
GRIT (CU. FT.)
SCUM (CU. FT.)
GAS PRODUCED (CU . FT. )
GAS USED (CU. FT . i
CHLORINE USED (LBS^
LABORATORY SUMMARY
PH RAW SEWAGE
PH FINAL EFFLUENT
PH DIGESTER
SUSP. SOLIDS RAW SEWAGE
SUSP. SOLIDS PRIMARY EFF.
SUSP. SOLIDS FINAL EFF.
SUSP. SOLIDS % RED.
AVG. CHLORINE RESIDUAL
AVG. FINAL EFF. D. 0.
BOD RAW SEWAGE
BOD FINAL EFFLUENT
BOD SUPERNATANT
ALKALINITY PRIMARY SUPER.
VOLATILE ACIDS PRIMARY SUPER.
TOTALS
1 RETURN SLUDGE (MG)
WASTE SLUDGE (MG)
RAW SLUDGE PUMPED (MG)
BLOWER NO. 1 (HR.)
'{ BLOWER MO. 2 (HR . )
1 i IR SUPPLIED (CU. FT. )
_^
1 j PROCESS DATA
1, % RETURN SLUDGE
' CU. FT. AIR/GAL.
j REMARKS: SUMMARY OF SHIFT LOGS
1
i
i
|
RAINFALL INCHES
!
| COMPLAINTS: PLANT VISITORS.
il
FIGURE NO. 7 CONTINUED
SAMPLE DAILY OPERATING LOG
109
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In addition to the items shown in Figure No. 8, the annual report should
include the following information:
Management Data :*
1. Total historical capital cost.
2. Total historical capital cost depreciated.
3. Replacement cost.
4. Replacement cost depreciated.
* The debt service should be included in the management data portion
of the annual report and should list the outstanding debt schedule.
Operating Data*
The unit operating costs per million gallons for the year should
be given using the following costs:
1. All cost exclusive of debt service.
2. All cost including debt service.
^Provide a graph showing at least 10 years of record (if available)
1. Average daily flow for each month.
2. Average daily flow for year.
3. Project curve for next 5 years.
4. Total unit cost for the year.
110
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ANNUAL REPORT
OPERATING DATA
CONNECTED POPULATION
EQUIVALENT POPULATION
FLOW (MGD)
pH
INFLUENT
EFFLUENT
SCREENINGS (CU. FT. PER DAY )
BOD (rng/1)
INFLUENT
EFFLUENT
REDUCTION
SUSPENDED SOLIDS (mg/1)
INFLUENT
EFFLUENT
REDUCTION
CHLORINE
TOTAL USED (LB.'
RESIDUAL (mg/1)
RAW SLUDGE
AMOUNT (GAL/DAY)
TOTAL SOLIDS (%)
VOLATILE SOLIDS I
DIGESTED SLUDGE
VOLUME WITHDRAWN (GAL/DAY)
MOISTURE (%} .
VOLATILE SOLIDS (%) . . .
GAS PRODUCTION
CU. FT. PER DAY
METHANE (%) . .
MANAGEMENT DATA
OPERATING EXPENSE ($)
SALARIES (OPERATING PERSONNEL)
SALARIES (PREVENTIVE MAINTENANCE)
SALARIES (CORRECTIVE MAINTENANCE)
SALARIES (CLERICAL STAFF) ....
SALARIES (ADMINISTRATIVE STAFF) .
CHEMICALS ...
LABORATORY
TREATMENT
VEHICLE OPERATION
MISCELLANEOUS
TOTAL EXPENSES ($) .
BUDGET OR REVENUE ($)
FIGURE NOo 8 SAMPLE: ANNUAL REPORT
III
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MAINTENANCE RECORDS*
Physical plant records should be available for reference at the plant
and should include:
1. Plant 0 & M Manual
2. As-built engineering drawings
3. Copy of construction specifications
4. Equipment suppliers' manuals
5. Piping and wiring diagrams
6, Data cards on all equipment
7. Facility hydraulic profile
8. Inventory of industrial waste contributors
9. Construction photographs
* A comprehensive discussion of maintenance records for major equipment
items should be provided in the Maintenance Chapter of the Manual .
OPERATING COSTS AND RECORD KEEPING
The major categories of operating costs are labor, utilities, chemicals
and supplies, iabor should be broken down into operation, administration
and maintenance. Utilities include electricity, fuel oil, telephone, gas
and potable water. Chemicals should be limited to those used in the
treatment processes. Supplies include lab chemicals, cleaning materials,
maintenance supplies and other expendable items. This section of the
manual should provide a suggested operating cost breakdown for the treat-
ment system.
Costs should include information on unit costs, total costs and amounts/
quantities used. Any cost accounting system should be compatible with
the parent governmental body accounting system.
The Water Pollution Control Federation Manual of Practice No. 10, "Uni-
form System of Accounts for Wastewater Utilities" gives the following
breakdown for operating expenses:
112
-------
Collection system expenses
Wastewater pumping expense
Wastewater treatment expense
Users' accounting and collecting expenses
Administration and general expense
An important operating cost is that of insurance for the wastewater
treatment system. A record system for monitoring this cost should be
recommended.
PERSONNEL RECORDS
Records that reflect such things as training individuals have received
and employee turnover rate are valuable to treatment system management.
A personnel records procedure should be recommended in this section of
the manual.
EMERGENCY CONDITIONS RECORD
A record of emergency conditions affecting the treatment system should
be maintained. A system for maintaining these records should be recom-
mended in this section of the manual. These emergency condition records
might include bypass reports and records of deteriorated effluent con-
ditions.
113
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SECTION XIV
0 & M MANUAL CHAPTER VIII: MAINTENANCE*
PAGE
GENERAL 116
Purpose of Maintenance System 116
Scope of Recommended Maintenance System . 116
Basic Features of the Maintenance Management System . . 116
EQUIPMENT RECORD SYSTEM ..... 117
PLANNING AND SCHEDULING 126
STOREROOM AND INVENTORY SYSTEM ..... 129
MAINTENANCE PERSONNEL ... 132
COSTS AND BUDGETS FOR MAINTENANCE OPERATIONS .133
MISCELLANEOUS MAINTENANCE RECORDS 134
HOUSEKEEPING 134
SPECIAL TOOLS AND EQUIPMENT 135
LUBRICATION 136
MAJOR EQUIPMENT INFORMATION 138
WARRANTY PROVISIONS 139
CONTRACT MAINTENANCE 140
* The format suggested for the table of contents page for the Maintenance
Chapter of an 0 & M Manual is identical to the format given for this
section of the Considerations Manual.
115
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GENERAL
Purpose
This portion of the manual's maintenance chapter should discuss the
importance of maintenance to overall treatment plant performance. The
treatment plant must be recognized as a highly specialized and complex
manufacturing facility producing an acceptable effluent. It is the
plant management's responsibility to produce this effluent at the low-
est unit cost and at the highest quality possible. A key to fulfilling
this responsibility is a sound maintenance management program. If the
person preparing an 0 & M Manual relates the importance of maintenance
to operating personnel, it can be an important factor in moving a treat-
ment system toward a sound maintenance program. For additional assis-
tance on maintenance management systems, preparers of 0 & M Manuals
should consult the EPA manual entitled "Maintenance Management Systems
for Municipal Wastewater Facilities", Contract No. 68-01-0341.
Scope
The scope of the maintenance management system being recommended should
be discussed in this portion of the manual. The reasoning behind the
selection of the system should be included. Any input obtained from
operating personnel on maintenance topics should be mentioned. The
flexibility and limitations of the maintenance system should be dis-
cussed. This portion of the manual should inform the operating person-
nel of their maintenance system's overall capabilities.
Basic Features of the Maintenance Management System*
This section of the manual should outline the basic features of a com-
plete maintenance management system. The following is a list of the
* The EPA Manual entitled "Maintenance Management Systems for Municipal
Wastewater Facilities", Contract No. 68-01-0341 contains detailed dis-
cussions on each of these features.
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basic features which should be included in this section and should
be applicable to all plants regardless of treatment type or size:
Equipment Record System
. Planning and Scheduling
Storeroom and Inventory System
. Maintenance Personnel
. Cost and Budgets for Maintenance Operations
EQUIPMENT RECORD SYSTEM
The persons preparing the Maintenance chapter of an 0 & M Manual should
recommend an equipment record system for the facility. The facility
owner should be involved in selecting the system to be recommended. The
equipment record system should contain information on each item of equip-
ment. This system may be only one card on each item of equipment, a
number of cards for each item or for larger plants, a combination of
information cards and data maintained on a computer.
Equipment Numbering System
The first step in establishing an equipment record system is to select
an equipment numbering system that best satisfies the needs of the par-
ticular treatment facility. Each item of equipment in the plant requir-
ing maintenance should be assigned a number for easy identification and
to help ensure that all equipment receives proper attention. One ap-
proach is to start numbering the equipment beginning with the point where
the wastewater enters the plant and continue to number each item of
equipment as the wastewater continues through the plant, followed by
suitable coverage of process side streams.
A second approach is to number all equipment in a specified area or
building with a range of numbers such as 100-120 and the equipment in
another area 200-230. This system of block numbering for a specified
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area aids in locating equipment, permits adding equipment, and setting
up a numbering system for the equipment card file.
A third approach is to divide the facility into nine stages and assign-
ing 1000 numbers to each, the stages may be further broken down to 100
series numbers to identify specific items and to allow for future addi-
tional units.
Equipment Catalog
After each item of equipment has been assigned a number, a catalog should
be prepared that lists equipment descriptions, locations and equipment
numbers. The catalog will provide a convenient reference for locating
equipment and identifying equipment numbers.
Card File Systems
Various card files are available such as single equipment cards, a three
card system, edge-punched cards and card files which are set upright or
are located in a horizontal position and have an edge exposed on which
color tabs are placed. These color coding tabs mark the month and week
in which preventive maintenance work is to be performed. These card
systems are readily available through most office supply agencies and
the systems can be adapted to plants based on their individual needs.
The person recommending the equipment record system should ensure the
system contains the following information:
Description of equipment and equipment number with
location in plant.
. Supplier with address, representative, phone number,
date of purchase with cost.
Size, model, type and serial number.
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Electrical and/or mechanical data.
Inventory of spare parts on hand.
. Preventive maintenance (PM) itens to be accomplished with
their frequency. Space to note when PM was performed, by
whom and pertinent comments. Data on man-hours, cost, and
material or supplies consumed.
. Information on corrective maintenance work should be
maintained in a manner similar to that outlined above
for preventive maintenance.
A system to compile this information for use in determining
costs and for future use in budget development.
The following information describes some of the card systems available
for maintaining equipment records:
Single Card System for Preventive Maintenance
This system uses ordinary ruled 5" x 8" cards or 8%" x 11" cards. This
system is adequate for small plants where a single supervisor is respon-
sible for maintenance and record keeping is a duty he must perform by
himself. Each item of equipment should have a single card either filed
by equipment number or filed alphabetically. The equipment card face
should contain the following information:
. Name and location of equipment or structure
. Name of manufacturer, supplier, or builder
. Cost and installation date
. Type, style, model
. Capacity, size, rating
. Serial .and code numbers
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Nature and frequency of maintenance
Proper lubricants, coatings
The backs of the cards are used to record the date the work is performed,
the type of work, and the initials of the person performing the tasks.
Corrective maintenance tasks may also be noted on the back of the card
to provide a complete record of all maintenance work performed on the
item of equipment. Figure No. 9 shows the face and back of a sample
card from a single card system.
Edge-punched Card System for Preventive Maintenance
Edge-punched cards offer advantages for all but the smallest installa-
tions. The edge-punched card type of record systems are available with
either a hand-sorted punched card filing system or electromagnetic filing
system. The cards have rows of holes prepunched along each edge. The
face and back of the card are used for a written record of the desired
data. Each hole or combination of holes along the edge is assigned a
specific meaning.
To designate, for example, a semiannual service, the paper between the
edge of the card and the hole marked "semiannual" is removed, thus form-
ing a notch. To select this card from a pack of cards, and all others
calling for a semiannual service, the pack is aligned in a vertical
position with the desired hole in the upper edge. As indicated in
Figure No. 10 a needle similar to an ice pick is then passed through
the hole. Upon fanning out the pack and lifting it with the needle, all
cards notched in the selected position drop from the pack, while those
not notched remain suspended from the needle.
Anywhere from one to five cards can be prepared for any one item of
equipment, depending on the frequencies of maintenance work required.
More effort is required to place data on extra cards, but it is felt
the ease with which personnel can identify work assigned on a particular
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JA:I.
1234
FEU.
1234
IIAR.
1234
APR.
1234
HAY
1234
Preventive Maintenance Program
JUNE
1234
JULY
1 Z 3 4
AUG.
1234
SEPT.
1234
OCT.
1234
NOV. DEC.
1234 1234
Equipment Record Dumber
EQUIPMENT DESCRIPTION
Name
Serial No.
Vendor
Vendor Address
Vendor Rep.
Initial Cost
Phone
Date
ELECTRICAL OR MECHANICAL DATA
Size
Model
Type
WORK TO BE DONE
FREQUENCY
TIME
DATE
WORK DOME
SIGNED
DATE
IIORK DONE
SIGNED
DATE
WORK DONE
SIGNED
FIGURE NO. 9 SAMPLE EQUIPMENT RECORD CARD
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Courtesy of Journal Water Pollution
Control Federation, Vol. 26, p. 1399
(Nov. 1954)
O O O
oooo\ooo
O O O
SEMI ANNUAL
FIGURE 10. PRINCIPLE OF EDGE-PUNCHED CARD RECORD SYSTEM FOR
MAINTENANCE PROGRAMS.
122
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day more than compensates for this initial work. Figure No. 11 is a
typical card for the weekly frequency group.
Three Card System
The three card system may be used by large or small facilities. Several
types of three card systems are currently available. The following is
an outline of the basic information which may be maintained on each of
the three cards:
A. The first card has equipment number, description, nameplate
data, vendor name, cost information, location, mechanical
and/or electrical data on the front of the card. A spare
parts list and space for additional information is on the
reverse side of the card.
B. The second card contains equipment item, number, preventive
maintenance tasks and their frequencies. The card should
have a metal tab or some other method to identify when
a maintenance task is to be performed.
C. The third card contains item, department, preventive
maintenance work performed, with labor hours, labor cost,
materials, and total cost. The remaining side contains
corrective maintenance work performed with man-hours and
cost data as outlined for preventive maintenance. The
date is also entered to identify when the work was per-
formed.
Computerized PM and Lubrication Program
Some facilities may find it economical to computerize their maintenance
programs. The following description outlines the capabilities and basic
features of such a computer system. The goal of this system is to
establish a closed-loop maintenance system that would permit one
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FIGURE NO. 11 SAMPLE CARD FOR THE WEEKLY FREQUENCY GROUP
Courtesy of Journal Water Pollution
Control Federation, Vol. 26, p. 1399
(Nov. 1954)
-------
reporting plan to furnish a total documented control readout of
scheduling, cost, equipment history, and manpower requirements.
The system is based on total plant rather than area approach. The
first step in developing the system is to establish PM requirements
on each piece of equipment. This is done considering the following
equipment parameters:
Number of hours operated
Severity of use
. Condition and age
A program coordinator must be responsible for programming each piece
of equipment into the system. He must also perform the following
tasks :
Ensure computer input cards are properly printed
Field check the system
. Monitor printouts
Coordinate with key maintenance personnel
The PM time estimates and cost information are input to the computer
to determine budget expenditures in relation to services performed.
This system provides the following functions:
Schedules work
. Verifies completion of PM function
. Prints out maintenance costs in labor and parts
. Stores current information on materials and spare parts
. Maintains information on work order backlog
. Stores information on available resources (craftsmen,
mobile equipment, etc.)
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Work order cards are prepared in advance by data processing and distrib-
uted to the maintenance section. Upon completion of the work, the work
order is returned to be recorded. The work order cards are reviewed and
sent to data processing where data is placed into the computerized
equipment maintenance record.
Nameplate Data
In addition to recommending the equipment record system, the persons
preparing the manual should provide the nameplate data for all major
items of equipment. This data should be placed on the appropriate card
from the equipment record system. The nameplate data should include
but not be limited to the following information:
1. Equipment Name
2. Vendor
3. Model Number
4. Serial Number
5. Make or Type
6. Pertinent Mechanical/Electrical Data
PLANNING AND SCHEDULING
Wastewater treatment facilities do not observe holidays and vacation
shutdowns. The facilities do experience variations in flows and main-
tenance work loads. Under these conditions, it is imperative that main-
tenance be planned and scheduled so that there is no idle time or peak
work load period. Maintenance scheduling will vary with the size and
complexity of the facility and with the type of personnel available.
However, proper management will provide a maintenance plan no matter what
the facility size.
Maintenance planning and scheduling involves time, personnel, equipment,
schedules, costs, work orders and priorities. This section of the 0 & M
Manual should make recommendations on planning and scheduling maintenance
126
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tasks. This section should also outline the use of chart boards and
work orders to aid in planning and scheduling.
In planning and scheduling preventive maintenance work, the size and
capabilities of the maintenance staff will affect the amount of main-
tenance work which can be accomplished. Corrective maintenance functions
should be considered when setting up the preventive maintenance program.
Corrective maintenance requirements can be estimated from past experience
and maintenance history records. Maintenance labor standards will aid
in determining the time required to accomplish specific maintenance tasks
Provisions should be made in planning and scheduling to allow time in
the maintenance schedule to perform corrective maintenance. The extent
to which the corrective maintenance can be planned for will aid in
determining the actual time which will be available to perform preventive
maintenance tasks.
A schedule chart with priorities of subjects, personnel and time is a
convenient aid to reduce impulse searches for work for idle personnel.
The schedule chart may be divided into daily, weekly, monthly, quarterly,
semiannually, and yearly sections so that the entire range of main-
tenance functions can be observed. Color tabs and labels can be coded
to account for all personnel and their duties at a specific point in
time. The removal of the tag from the schedule chart board indicates
the work is underway or has been completed. The chart board provides a
graphic indication of progress and manpower usage. The chart board also
provides a graphic indication of tasks that are running behind. Chart
boards are available from most office supply companies. The size, method
of use, and detail of the schedule chart board depends upon the facility
management.
Indoor and outdoor maintenance should be scheduled to take advantage of
open or inclement weather, low load or flow periods and other variable
conditions beyond the control of the operating staff.
127
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All maintenance work should be scheduled just as the operating routine
has to be scheduled. Preventive maintenance should not be a haphazard
procedure to be done if time permits.
Some type of maintenance must be scheduled for the once a year oppor-
tunity when the plant load normally is at its lowest. This may be the
time to drain, check, repair, and paint the clarifier and certain under
water items of equipment.
There are seasonal items to be scheduled such as:
1. Clearing sludge from drying beds
2. Lawn and landscaping work
3. Snow removal
4. Exterior painting
There are items which may occur annually or others with as much as 4 or
5 year intervals. The items include:
1. Painting
2. Roofing
3. Paving and road repairs
4. Fencing
5. Insulating
6. Electrical system upgrading
7. Plumbing revisions
The manufacturer's maintenance manual is generally the best guide for
preventive maintenance instructions for any item of equipment. Most
equipment is mass produced on a competitive basis and the cost of its
maintenance should be consistent with its value, life expectancy and
replacement costs. Equipment should be rated as to its critical posi-
tion in the plant operating system and its maintenance priority.
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Unnecessary or too frequent preventive maintenance can be as wasteful
as improper maintenance procedures. The preoarer of the 0 & M Manual
should assist treatment system management to determine the optimum
preventive maintenance schedule and replacement proqram.
The plant maintenance personnel should be cautioned to continuously
monitor the plant operations to determine other maintenance work to be
accomplished. When emergencies and breakdowns occur, these tasks must
be reviewed and work initiated to return the plant to its full capacity
and efficiency.
Owners should be guided to arrangements with contractors and repair
services to aid the facility maintenance personnel in performing var-
ious maintenance tasks and emergency repairs. These tasks may include
electrical and mechanical problems or malfunctions in the chloririation
system. Other general maintenance tasks as snow removal, ground work,
painting, or other minor functions can be contracted out. A suggested
list of contractors and contract jobs should be provided in the Contract
Maintenance portion of the Manual's Maintenance Chapter.
A work order system should be established to initiate all corrective
maintenance tasks. The work order system will aid in identifying work
to be accomplished, procedure priority, and information on any special
aspects of the job. A log of the work orders will provide a record of
when the work order was initiated and completed. The work orders should
be numbered to provide a means of maintaining accountability. The fol-
lowing two figures are examples of work orders. Figure No. 12 outlines
the possible format for a small plant. Figure No. 13 provides a format
for the information which would be required by a large facility.
STOREROOM AND INVENTORY SYSTEM
This section should outline the importance of having a storeroom and in-
ventory system with recommendations on establishing such a system for
the particular plant.
129
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WORK ORDER
WORK ORDER NO.
WORK TO BE PERFORMED:
MATERIALS REQUIRED:
WORK PERFORMED BY:
1.
2.
3.
4.
WORK COMPLETED:
SIGNED:
DATE:
DATE;
HOURS
HOURS
HOURS
HOURS
COMMENTS:
FIGURE NO. 12 SAMPLE WORK ORDER
130
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Date.
Work Order No.
Location
Requested By:
(Phone)
Priority:
Equipment Name
No.
Inspect r~J Replace I I Service
Repair II Overhaul II Paint
Work Description
Work Performed/Comments
Job Estimate
Labor $.
Material $
Maintenance Superintendent
Work Record
Personnel Assigned
Total
Work Completed By
WnrV ArrpntpH Rv
Manhour s
Date
Work Done
D
Parts & Materials
ate
FIGURE NO. 13
SAMPLE : WORK ORDER
131
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A central storeroom for spare parts, equipment, and supplies should be
maintained. A review of the equipment and the manufacturer's recommen-
dations will aid in determining what spare parts and miscellaneous
supplies should be maintained. The spare parts and components should
be listed in a central catalog and assigned a number. A minimum and
maximum quantity to be stocked should be established. A card system
to record information on quantity, item number, description, when last
purchased, cost, date, vendor, and other information is helpful. A
system for arranging items in the storeroom should be established to
aid in locating items. When items are taken from this stock, the date
and use should be noted on the card file. For items which may be long
lead items, a reorder point should be established to aid in resupply.
A central storeroom may be used with other municipal divisions with
spare parts for the wastewater plant, filtration plant, and streets
divisions. A storeroom clerk could maintain accountability of the parts,
keep records, initiate information for purchase orders, and handle a
stores withdrawal system to maintain information on parts obtained by
each division. A store ticket or withdrawal slip should be completed
when any item is used. The ticket will be a record showing when the
item was used and for what purpose. This information can be transferred
to the card for the item to aid in determining when reorder is reauired.
This system will provide an inventory of items currently in stock.
A purchase order system should be established. The system should pro-
vide a record of the date an item was ordered and when received, quan-
tity, unit cost, total cost, supplier and item destination (stock, pre-
ventive maintenance or corrective maintenance). Standing purchase orders
can be used effectively for spreading out delivery of large quantities
of supplies.
MAINTENANCE PERSONNEL
It should be noted in this section that only properly trained personnel
can be expected to perform satisfactory inspections, repairs and
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preventive maintenance tasks. Properly trained personnel should possess
a thorough knowledge of the functions and operations of their equipment
and the procedures for servicing it. A good maintenance management pro-
gram must consider the limitations of plant operators and maintenance
personnel. The program must also consider obtaining outside consultants
or factory representatives to perform certain required maintenance
functions.
This section should make reference to the Personnel chapter of the man-
ual which provides job titles, job descriptions, and qualifications for
maintenance personnel. Any general information regarding maintenance
personnel or particular information on possible sources of maintenance
help should be included in this section.
COSTS AND BUDGETS FOR MAINTENANCE OPERATIONS
This section should provide guidelines for the determination of main-
tenance cost and the development of maintenance budgets.
Plant information on maintenance cost and the development of a main-
tenance budget are very important for their incorporation into the
plant's total operation and maintenance budget. Before an accurate
estimate of maintenance cost can be made or a sound maintenance budget
can be prepared, it is necessary to divide the maintenance operations
into service categories such as preventive maintenance, corrective main-
tenance, and major repairs or alterations. With the maintenance oper-
ations defined, the information in the equipment record system on work
performed, work contracted out, items used from storeroom stock and
purchased, and a breakdown of man-hours provide information on maintenance
cost. Using these costs and making allowances for equipment replacement,
expansion, and information on maintenance history for the plant, the
maintenance budget can be developed.
The needed information on contract maintenance and cost of items on pur-
chase orders may require the plant to set up a filing system to retain
133
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this information. The information could be maintained by log books
with file folders to maintain purchase orders, receipts, and other
important papers.
For plants in which most personnel are performing certain maintenance
duties, the man-hours for each employee should be broken into each
half hour of the work shift with charge numbers established to sepa-
rate operations and maintenance work. For the maintenance work, indiv-
idual charge numbers should be established to cover each phase of main-
tenance work such as preventive maintenance, corrective maintenance,
and special charge numbers to handle major repairs and alterations.
The 0 & M Manual preparer should recommend that the facility's personnel
work in conjunction with the municipal bookkeeping department to main-
tain the information on cost and man-hours.
MISCELLANEOUS MAINTENANCE RECORDS
In conjunction with the maintenance records previously discussed, logs
are often kept of preventive and corrective maintenance work accomplished
with description, man-hours, cost, date, and maintenance personnel who
accomplished work. This is especially helpful at unattended pumping
stations and other remote facilities.
History records should be maintained with maintenance cards for the pre-
vious years and breakdown reports for all major problems encountered.
These records will aid in budget planning, scheduling, manpower, operat-
ing expenses, and other needed information as required. Such records
will assist in determining the time at which it is more economical to
replace an item of equipment instead of repairing it.
HOUSEKEEPING
This section of the 0 & M Manual should recommend housekeeping activities
to be performed within the treatment system.
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Housekeeping of buildings and grounds should receive the same attention
as the operating equipment. A clean and neat appearance with unneces-
sary odors eliminated will promote public support for the facility. Rou-
tine housekeeping can be incorporated into shift standard operating pro-
cedures.
Process equipment should be cleaned and painted as required for appear-
ance and to minimize odor sources. The doors, windows, floors, walls,
and other areas should be kept clean and in good repair. Outside main-
tenance work such as mowing, snow removal, painting, cleaning gutters
and drains should be scheduled as required.
SPECIAL TOOLS AND EQUIPMENT
This section of an 0 & M Manual should provide recommendations on tool
room procedures, the use of tool boards, and maintenance skills required
for all special tools.
A review of the work to be performed by the maintenance personnel will
aid in developing a list of the tools and equipment required for the
facility- The tools and equipment should be maintained in good working
order and available when required. Where some items may be required
in more than one location, this should be taken into account.
It is suggested that maintenance tools and supplies should not be placed
any more than 100 to 200 feet from the point or points of use. Tool
boards with specialized or frequently used tools should be located with
appropriate equipment where required.
Facilities large enough to warrant a central tool room should maintain
a complete tool inventory. Tools should be issued under a tool check
control system. All tools should be regularly checked for their con-
dition in terms of personnel safety and equipment protection.
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LUBRICATION
The Lubrication section of an 0 & M Manual should appropriately reference
each equipment manufacturer's lubrication specification. An interchang-
able lubricants chart should be provided in this section. This section
should contain information on the use of color coded lubrication tags
for all equipment. Sample forms for recording quantities of lubricants
consumed and in stock should be included. A sample lubrication route
should be outlined to assist maintenance supervisors in developing lub-
rication routes for the facility.
The following comments are provided to assist persons preparing the
lubrication portion of the 0 & M Manual.
Those responsible for preventive maintenance should also be responsible
for lubrication. Their duties should include the following:
1. Conduct lubrication studies.
2. Prepare lubrication specifications.
3. Establish schedules.
4. Train lubricators.
5. Standardize application methods.
6. Maintain consumption and inventory records.
7. Establish proper handling and storage.
8. Investigate new lubricants; evaluate and revise specifi-
cations as necessary.
9. Standardize lubricants whenever possible to eliminate
stocks of identical material under various trade names.
The most important step in establishing a lubrication system involves
the gathering of basic lubrication data. Lubrication specifications can
be developed from manufacturers' lubrication recommendations, ASLE and
ASTM Standards. Lubrication routes should be established and every item
of equipment given a route number. Lubrication points, types and fre-
quencies should be defined for each item of equipment. All data pertinent
136
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to lubrication of selected equipment should be assembled into a lubri-
cation guidebook. Equipment can be color coded with decals to indicate
point of service, frequency of application, and type lubricant. Speci-
fying the highest grade lubricant required for more than one application
and specifying a single mid-range viscosity oil to replace several with-
in a certain viscosity range are two methods for consolidation of lubri-
cants. Many plants have successfully computerized their lubrication
programs.
Each manufacturer of equipment will very likely specify some one or
more trade name lubricants by the producers number or by an SAE number
(Society of Automotive Engineers) or some other designation. This may
result in numerous trade named lubricants being designated for the
treatment facility equipment. A standard designation has been prepared
for all comparable and interchangeable lubricants and indicated on an
extensive tabular chart by Plant Engineering Magazine (August 22, 1968)
whereby each type lubricant is assigned a "PE" number. The use of this
designation in buying lubricants will very likely reduce the variety and
inventory of products required at the treatment works.
The lubrication frequency is determined by many factors but a lubri-
cation schedule must be established and followed to insure proper oper-
ation of the facility- The equipment card for each piece of equipment
requiring lubrication should list the lubricant to be used and frequency
advisable for efficient operation. For convenience and simplification
of the lubrication process, a color coded tag or decal label can be
used to identify the part, frequency and type of lubricant required for
moving part in question. A suggested color code for various categories
is :
Color & Type Frequency
Blue - Gear Lube Daily
White Spindle Oil Weekly
137
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Color & Type (Cont.) Frequency (Cont.)
Green Way Oil Monthly
Red - Hydraulic Oil Semi-Annually
Brown - Grease Annually
The tag should also indicate the appropriate lubricant.
The plant size will determine the man-hours required for the lubrication
routine. The same lubricator should perform the service each time if
possible in order to narrow the range or responsibility for lubrication
activities. A fixed hour or day should be established for the routine
when possible and a record filed on completion of the routine. A master
card may be used to facilitate routing and recording operations. In
large operations a computer printout for the various frequencies and
lubricants may be of assistance in reducing time requirements. Machine
number and data may be key punched for the preventive maintenance super-
visor and completed route records filed with him.
Oil change schedules and operations must also be maintained and recorded
with the maintenance supervisor. Oil must be sampled to determine when
changes are required. Where large quantities of oil are required and oil
changes are necessary, the facility may justify the use of oil centri-
fuges, filters or other clean process to permit the reuse of the purified
or reconditioned oil.
Air conditioning equipment, heat exchangers and related services require
coolants and antifreeze liquids for operations under wide ranges of temp-
erature and service conditions. These liquids and their concentration
must be checked and records made of routine procedures in a manner similar
to those for lubrication oils.
MAJOR EQUIPMENT INFORMATION
The Maintenance chapter of the manual should have a portion which lists
each major item of electrical and mechanical equipment. The basic
138
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maintenance considerations for each item of equipment are usually found
in the manufacturer's catalog. The person preparing the 0 & M Manual
should determine if the manufacturer's catalog contains an adequate
maintenance section that is presented in a usable form. If the catalog
information is adequate, it should be properly referenced in this section
of the 0 & M Manual. In referencing these catalogs a numerical system
patterned after the equipment numbering system can be used.
If the manufacturer's maintenance information is not considered adequate,
the person developing the 0 & M Manual should prepare detailed maintenance
guidelines for the item of equipment. These maintenance guidelines can
be included in this section of the manual or may be bound separately.
This section should also outline the procedure for ordering parts/compo-
nents or new items of equipment. This information should be provided for
each major item of equipment.
WARRANTY PROVISIONS
Most facilities are constructed to include a one-year guarantee period.
During this period, the contractor has the responsibility to repair,
correct, or replace any equipment or material that fails to perform in
accordance with the terms and provisions of the contract. This section
should include a caution that alteration of supplied equipment by facil-
ity personnel, without the knowledge and consent of the contractor and
manufacturer, may result in refusal of these parties to accept responsi-
bility for any subsequent problems. Equipment which is not regularly
in service during the guarantee period must be maintained and should be
operated periodically to prevent problems which might arise due to the
equipment not being operated. The fact that a guarantee is in effect
should not be cause to allow improper maintenance or operation of equip-
ment and thus reduce its useful life.
139
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The 0 & M Manual should provide a listing of all equipment guaranteed
and pertinent features of each guarantee. Copies of the warranties
should be included in the Manual's Appendix.
CONTRACT MAINTENANCE
Due to plant size, complexity of equipment and/or maintenance personnel
qualifications, the facility may find it feasible to contract some main-
tenance work. Many equipment manufacturers will provide maintenance
service for their equipment on a contract basis. However, contracting
routine inspections, lubrication, and minor parts replacement can become
very costly. Plant personnel should develop their maintenance capabil-
ities in order to perform all but the most complex tasks. The manual
should have a suggested list of contractors and contract jobs for the
particular facility based upon its capabilities.
To provide additional information on maintenance systems, EPA has devel-
oped a manual entitled "A Planned Maintenance Management Program",
Project No. 11010GWI.
140
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SECTION XV
0 & M MANUAL CHAPTER IX: EMERGENCY OPERATING AND RESPONSE PROGRAM*
PAGE
DISCUSSION ...... 142
General Considerations . 142
OBJECTIVES 146
VULNERABILITY ANALYSIS ....... 147
METHODS TO REDUCE SYSTEM VULNERABILITY ..... 148
MUTUAL AID AGREEMENTS ........ 153
EMERGENCY EQUIPMENT INVENTORY . . 156
PRESERVING TREATMENT SYSTEM RECORDS ...... 156
INDUSTRIAL WASTE INVENTORY/MONITORING SYSTEM ..... 156
COORDINATING INSTRUCTIONS FOR LOCAL POLICE AND FIRE DEPARTMENTS. 161
RESPONSIBILITIES OF TREATMENT SYSTEM PERSONNEL ......... 162
EMERGENCY RESPONSE CENTER .... ..... 164
AUXILIARY PERSONNEL REQUIREMENTS ...... 164
CHECKLIST - EMERGENCY OPERATING AND RESPONSE PLAN CHAPTER OF
AN 0 & M MANUAL 166
* The format suggested for the table of contents page for the Emergency
Operating and Response Program Chapter of an 0 & M Manual is similar,
except for the Discussion and Checklist portion, to the format given
for this section of the Considerations Manual.
141
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DISCUSSION
Emergency conditions can be imposed on a treatment system by natural
disasters, strikes, civil disorders and equipment failures. Emergency
planning is essential to insure continued effective operation during
emergencies. The care and detail used in preparing this chapter of
an 0 & M Manual will directly affect the adequacy of the treatment
system's emergency operating and response program.
This section of the 0 & M Manual gives the treatment system's emergency
response plan for insuring the effective continued operation of the
wastewater treatment system under emergency conditions imposed by
catastrophe, failure of process or equipment or unavoidable shutdown
of components. (NOTE: The Emergency Operating and Response Plan
chapter may be bound separately.)
The EPA Construction Grants Program requires that the grantee provide,
for each grant assisted plant, an emergency operating and response
program in accordance with Section 35.935-12 of 40 CFR, Part 35.
The Environmental Protection Agency has developed two manuals entitled,
"Emergency Operating Procedures for Municipal Wastewater Treatment
Facilities", and "Emergency Response Programs for Municipal Wastewater
Treatment Facilities, State-Local Aspects", both under Contract No.
68-01-0341 to assist in the preparation of local emergency plans.
Another EPA report entitled, "Design Criteria for Mechanical, Electric
and Fluid System and Component Reliability", under Contract No. 68-01-0001
also contains information related to emergency planning.
Included in this manual are a list of general emergency planning consid-
erations and a checklist for preparing an emergency operating plan.
General Considerations
The persons preparing an 0 & M Manual are responsible for developing the
basic emergency response program guidelines for the treatment system.
142
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This program will be outlined in the Emergency Operating and Response
Program chapter of the facility's operation and maintenance manual. The
following are general considerations for preparing this portion of an
operation and maintenance manual :
1. Recommend a sewer ordinance for the protection of the
collection system, treatment facility, receiving waters,
and the public.
2. Recommend a system for maintaining adequate engineering
drawings of the wastewater treatment system.
3. Provide facilities for chlorination during emergencies
affecting the system.
4. Outline procedure for notifying Federal/State Regulatory
Agencies of discharges of raw or inadequately treated
wastes.
5. Suggest a program to eliminate storm flows and illegal
connections to the sanitary sewers.
6. Recommend staffing of the system with sufficient numbers
of trained personnel.
7. Suggest an inspection program for remote pumping stations.
8. Provide an alarm system for all remote pumping stations
and at critical manholes for flood flows and gas.
9. Provide recommendations on accepting discharges from
septic tank trucks.
143
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10. Outline State monthly reporting requirements for pump
station failures.
11. Ensure adequate laboratory facilities and personnel
are provided to detect and monitor emergencies affecting
effluent characteristics.
12. List required emergency equipment for response to emer-
gencies involving chlorine gas.
13. Recommend a system for recording on-the-job injuries
with emphasis on prevention measures.
14. List all safety equipment required (safety harness,
devices to measure flammability of an atmosphere, and
devices to measure oxygen in an atmosphere).
15. Set up a first aid training program for facility person-
nel and recommend type and number of industrial first
aid kits to be maintained.
16. Recommend a procedure to insure all personnel receive
tetanus toxoid inoculations and typhoid vaccine inocu-
lations on a regular basis.
17. Outline a drill schedule for proper use of emergency
breathing equipment.
18. Give preventive maintenance schedule for all emergency
alarm systems.
19. Develop a list of industrial process chemicals that
might enter the treatment system.
144
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20. Recommend a list of downstream and upstream water users
be prepared. (Water intakes, recreation areas, shellfish
beds, and other waste discharges.)
21. Discuss problems that will exist upon failure or shutdown
of major treatment system components with respect to
effluent quality, effect on receiving stream and potentia'
health hazard.
22. Outline corrective maintenance procedures to be employed
to eliminate or minimize by-passing of treatment units.
23. Recommend coordination between the treatment system
emergency response program and local civil defense
activities.
24. State the potential for various natural disasters in
the area where the treatment system is located.
25. Suggest mutual aid agreement alternatives and recommend
a standard mutual aid agreement form.
26. Prepare an emergency equipment inventory for the treat-
ment system.
27, Suggest the treatment system prepare a list of key
personnel at local utility companies and request the
local telephone company to give treatment system calls
priority during a disaster.
28. Outline auxiliary personnel requirements.
29. Recommend a system for receipt of emergency reports
on a 24 hour a day, 7 days a week basis.
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30. Develop an emergency response program organization
chart.
31. Provide guidelines for an emergency response center
(location, facilities, and staffing).
32. Prepare treatment process flow diagrams for use in
emergencies.
33. Prepare diagrams showing how emergency reports are
received and relayed to appropriate personnel.
34. Provide owner with sample vulnerability worksheets
so he may continually upgrade his emergency response
program.
OBJECTIVES
The Emergency Operating and Response Program's objectives should be listed
in this section. The objectives of an Emergency Operating and Response
Program include:
1. Eliminate or minimize adverse effects from emergency
situations affecting the treatment system.
2. Develop procedures for properly responding to
emergencies.
3. Provide instruction for system personnel to ensure
they understand their responsibilities during
emergency situations.
4. Provide inventories of available emergency equipment and
outline existing mutual aid agreements and contracts with
outside organizations for specialized assistance.
146
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VULNERABILITY ANALYSIS
The persons preparing an 0 & M Manual should perform a study to determine
the potential for natural disaster, strikes and civil disorder in the
area where the municipal wastewater treatment system is located. The
following natural disasters should be investigated:
1. River floods
2. Tornadoes and windstorms
3. Hurricanes and storm surges, lightning
4. Forest and grass fires
5. Earthquakes
6. Landslides
7. Tsunami , (Tidal wave)
8. Volcanoes
9. Frosts, freezes and sleet storms
10. Droughts and low stream flows in receiving stream
This study will result in a priority list to use in performing the var-
ious system vulnerability analyses. For example, in areas that have a
history of frequent hurricanes, the treatment system should be prepared
to continue operation under the emergency conditions imposed on that
system by a hurricane.
A vulnerability analysis of the system is an estimation of the degree
to which the system is adversely affected, in relation to the function
it must perform by an emergency condition.
The following steps should be followed in making a vulnerability analysis
1. List components of treatment system.
2. Select emergency condition to be investigated.
147
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3. Estimate effects of emergency condition on each component
of system, use vulnerability worksheet.
4. Estimate treatment system's ability to perform its intended
function during the emergency.
5. If system fails to perform, identify key system components
responsible for the failure.
A vulnerability analysis worksheet is shown in Figure No. 14.
The results of the system vulnerability analysis should be discussed in
this section of the manual. These results will include a list of the
most vulnerable components of the treatment system.
METHODS TO REDUCE SYSTEM VULNERABILITY
A discussion of methods to reduce a treatment system's vulnerability
should be provided. The Emergency Operating and Response Program chapter
of the Manual should indicate priorities for repair of the system and
alternate provisions in case of light or severe damage. The following
methods can be employed to reduce the system's vulnerability:
1. An optimum preventive maintenance and testing program.
2. Duplication and separation of vital works.
3. Minimizing dependence on power and pumping.
4. Provision for more than one power source and/or trans-
mission line.
5. Flexibility in operation of treatment works.
6. Maintenance of adequate chemical supplies.
148
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VULNERABILITY ANALYSIS WORKSHEET
TREATMENT SYSTEM:
ASSUMED EMERGENCY:
DESCRIPTION OF EMERGENCY:
SYSTEM
COMPONENT
EFFECTS OF EMERGENCY
TYPE AND EXTENT
PREVENTION
RECOMMENDATIONS
Collection Lines
Pumping Stations
FIGURE NO. 14. VULNERABILITY ANALYSIS WORKSHEET
.149
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VULNERABILITY ANALYSIS WORKSHEET
SYSTEM
COMPONENT
EFFECTS OF EMERGENCY
TYPE AND EXTENT
PREVENTION
RECOMMENDATIONS
PRETREATMENT
CLARIFICATION
SECONDARY UNITS
FIGURE NO.14 (CONTINUED)
150
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VULNERABILITY ANALYSIS WORKSHEET
SYSTEM
COMPONENT
EFFECTS OF EMERGENCY
TYPE & EXTENT
PREVENTION
RECOMMENDATIONS
SLUDGE HANDLING
ADVANCED TREATMENT
POWER SUPPLY
FIGURE NO. 14 (CONTINUED'
151
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VULNERABILITY ANALYSIS WORKSHEET
SYSTEM
COMPONENT
EFFECTS OF EMERGENCY
[YPE AND EXTENT
PREVENTION
RECOMMENDATIONS
COMMUNICATIONS
PERSONNEL
DATE:
ANALYST:
FIGURE NO. 14 (CONTINUED)
152
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7. Provision of dual power sources, on-site storage of fuel
and auxiliary power units, remote and/or automated con-
trols, and ready conversion of automatic controls to
manual operation.
8. Provision of portable pumps with fuel-operated units.
9. Provision at major pumping stations of more than one
incoming and discharge pipeline.
10. Training of regular and auxiliary personnel in emergency
operations and procedures. Training should be a combi-
nation of classroom instruction and on-the-job training.
11. Conducting emergency operations exercises periodically.
12. Provide proper tools in adequate supply and in the
proper location. A tool and work room or shop is a
necessity and should be in proportion to the plant
size.
MUTUAL AID AGREEMENTS
A list of mutual aid agreement alternatives should be given. The
following is a partial list of organizations to be considered:
1. Other community divisions
2. Consulting engineers for the facility
3. Industrial firms
4. Construction companies
5. Electric, gas and telephone utilities
6. Fire and police departments
7. Civil defense organization
8. Health department
Figure No. 15 is a sample mutual aid agreement form.
153
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SAMPLE
MUTUAL-AID AGREEMENT*
EMERGENCY SITUATIONS COULD ARISE IN A MUNICIPALITY'S WASTEWATER
TREATMENT SYSTEM THAT WOULD REQUIRE ASSISTANCE FROM AN ADJOINING
MUNICIPALITY TO RESTORE NORMAL OPERATION.
IF AN EMERGENCY SITUATION ARISES IN _ OR
THE OFFICIALS IN BOTH MUNICIPALITIES AGREE
(CUT)
TO SUPPORT EACH OTHER DURING THE EMERGENCY.
EACH CITY HAS A CONTINGENCY PLAN FOR RESPONSE TO EMERGENCIES AFFECTING
ITS WASTEWATER TREATMENT SYSTEM. THE ^_^ AGREES TO
(City"]
SUPPORT IN THE FOLLOWING AREAS:
(City) (Fire-fighting,
Rescue Crews, Communications, Portable Chlorination, Operational/
Maintenance, Personnel, etc.)
TO
THE EXTENT POSSIBLE UPON REQUEST INITIATED BY:
Name Name
Title Title
City City
PERSONNEL RESPONDING TO THE REQUESTS FOR ASSISTANCE UNDER THIS AGREEMENT
WILL REMAIN UNDER THE CONTROL OF THE CITY PROVIDING THEM.
Signed Signed
Name Name
Title Title
City City
*Similar to format suggested by Planning Section, Virginia Office of Civil
Defense.
FIGURE NO. 15 SAMPLE MUTUAL-AID AGREEMENT FORMAT
154
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SAMPLE MUTUAL AID AGREEMENTS/CONTRACTS SHEET
NAME
Public Works Department
City Water Department
DESCRIPTION OF ASSISTANCE
Department of Parks maintains 1,000 feet of
6 inch quick coupling aluminum pipe that is
available to assist treatment system during
emergencies.
Water Department maintains 2 portable chlorinat-
ors which can be used for emergencies within
the wastewater treatment system.
COORDINATION INFORMATION
To obtain pipe contact Dept. of
Parks (Phone) during normal
working hours or call city
switchboard (Phone) after normal
working hours.
Contact Water Department Supt.
(Phone) or operator on duty at
main filter plant (Phone).
ABC Construction Company 4 tractor mounted back-hoes are available
on a 24-hour basis.
ACME Welding Co.
Machine shop facilities and a portable
welding machine are available on a 24-hour
basis.
Contact company main office
(Phone) or after hours call
John Doe, Equipment foreman (Phone)
Call: (Phone) Office
(Phone) Home
(Phone) Home
FIGURE NO. 16. SAMPLE MUTUAL AID AGREEMENTS/CONTRACTS SHEET
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EMERGENCY EQUIPMENT INVENTORY
An inventory should be made of equipment, materials and chemicals that
are available within the treatment system. A sample wastewater treat-
ment system emergency inventory worksheet is shown in Figure No. 17.
Using this inventory and the results of the system vulnerability analysis
any additional emergency equipment/supplies required may be purchased
and stockpiled and/or arrangements made to obtain these items through
mutual aid agreements or outside contracts. A sample emergency inventory
sheet is shown in Figure No. 18. Similar sheets should be prepared for
the treatment system at hand and included in this section of the manual.
PRESERVING TREATMENT SYSTEM RECORDS
A program should be recommended for the protection of essential records,
maps and inventories. It is especially important that maintenance crews
and service vehicles be provided with maps and current records showing
location and condition of collection lines. Full size copies of maps
and other detail sheets should be made each year and kept in a vault
that is not subject to flooding. Copies of the layouts of important
pumping installations can also be kept here. These items are available
for immediate use and can be reproduced as required. These records are
readable and do not have to be processed by any further mechanical steps.
INDUSTRIAL WASTE INVENTORY/MONITORING SYSTEM
An inventory should be made of all industrial contributors to the munic-
ipal treatment system. Each industry should be located on a collection
system map and a list of the potential hazardous spill materials present
prepared.
The names and phone numbers of key personnel with each industry should
also be listed. Consideration should be given to installing industrial
waste monitoring equipment in the sewer network at critical locations.
A sample industrial waste inventory form is shown in Figure No. 19.
Similar information for all industrial contributors should be provided
in this section of the manual.
156
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SYSTEM:
WASTEWATER TREATMENT SYSTEM
EMERGENCY INVENTORY
PREPARED BY:
DATE:
(Signature'
DUPLICATE EQUIPMENT IN STOCK
DESCRIPTION
MAKE
SIZE
TYPE
VOLTAGE
HP
CAPACITY
NO.
PARTS & COMPONENTS IN STOCK
DESCRIPTION
SIZE
— i
NO.
APPLICATION IN SYSTEM
FIGURE NO. 17 SAMPLE INVENTORY WORKSHEET
157
* Us
-------
EMERGENCY EQUIPMENT & REPAIR TOOLS
DESCRIPTION
NO.
APPLICATION IN SYSTEM
PIPE
SIZE
TYPE
LENGTH
AVERAGE
CHEMICAL
STOCK
TYPE
FORM
QUANTITY
COMMUNICATIONS EQUIPMENT
DESCRIPTION
LOCATION
MAPS AND FACILITY LAYOUT DETAILS
FIGURE NO. 17 (CONTINUED)
OFF ICIAL AUTHORIZING
INVENTORY
158
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EMERGENCY INVENTORY
LOCATION
PUMPS
PIPE
CHLORINATORS
EQUIPMENT
GENERATORS HFAVY EQUIPMENT COMMUNICATIONS
MISC.
CHEMICALS
PERSONNEL
(NAME OF
MUNICIPALITY;
SANITARY DIST.
OR INDUSTRY)
NAME
NAME
NAME
NAME
TWO PORTABLE
GASOLINE-
POWFREO
6" PUMPS
600' OF 4"
LIGHTWEIGHT
QUICK-COUPLING
ALUMINUM PIPE
ONE MOBILE
CHLORINATOR,
300 LBS.
PER 24-HR.
CAPACITY
TWO-40 KW,
110/P08 VOLT
GASOLINE DRIVEN
ELECTRIC GEN-
ERATOR SETS
TWO DUMP
TRUCKS 5 CU. YD
CAPACITY
ONE 35 -TON
CAPACITY MOBILE
CRAMF
ONE, AIR
COMPRESSOR,
125 CFM,
100 PSI
ONE,
PORTABLE
ARC WELDING
MACHINE
FIFTY 100 LB.
BAGS OF LIME
TWO
EXPERIENCED
LABORATORY
TECHNICIANS
ONE
EXPERIENCED
INSTRUMENT
TECHNICIAN
en
FIGURE NO. 18 SAMPLE EMERGENCY INVENTORY SHEET
-------
INDUSTRIAL WASTE INVENTORY*
Name & Location
Industries should be
in alphabetical order.
Location should in-
clude manhole where
industrial waste
enters municipal
system.
Industrial Waste Description/
Pretreatment Provided
List waste by common name, chemical
nomenclature, and trade name if
applicable. Also list any other
hazardous materials on hand that
can potentially enter municipal
treatment system and give neutra-
lizing agents if applicable.
Describe pretreatment system.
Key Personnel
Give names, titles
and phone numbers
of all key personnel,
At least one number
should be designated
as a 24 hour a day
number.
Acme Mfg. Co.
Industrial waste
is discharged into
manhole at inter-
section of Main
St. and Church St.
SAMPLE
Waste is acidic, pH below 4.0 due
to presence of sulfuric acid,
HLSCL. There exists.potential
for a spill of concentrated sul-
feric acid which can be neutral-
ized with strong basic materials
such as lime. No pretreatment
is provided.
John Doe
Plant Manager
(Phone)
Bill Smith
Maintenance
(Phone)
Supt.
inventory should be cross-referenced using
Industrial Waste Description.
Plant Security
Office
(Phone)**
**24-hour number
common names of chemicals/materials found under
FIGURE
19 SAMPLE: INDUSTRIAL WASTE INVENTORY
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COORDINATING INSTRUCTIONS FOR LOCAL POLICE AND FIRE DEPARTMENTS
The treatment system's Emergency Operating and Response Program should be
coordinated with the local police and fire departments. These coordinat-
ing instructions should be outlined in this section of the manual. Con-
sideration should be given to the items in the following checklists:
Police Department Checklist:
1. Critique existing treatment system security measures.
2. Make routine checks of treatment facility and pumping
stations.
3. Notify treatment plant in the event of a street spill
of hazardous materials.
4. Be prepared to assist during emergencies within the
treatment system.
Fire Department Checklist:
1. Routinely check fire fighting equipment within the
facility and inspect facility for potential fire
hazards.
2. Provide first aid instruction to treatment system person-
nel .
3. Coordinate with treatment system personnel on safety pre-
cautions to be used with chlorine gas.
161
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RESPONSIBILITIES OF TREATMENT SYSTEM PERSONNEL
The municipal wastewater treatment system director should have overall
responsibility for the emergency program. The wastewater treatment
superintendent and the collection system superintendent are responsible
for implementing the emergency program within their respective areas
and they report directly to the treatment system director. If the treat-
ment system is organized so that a single individual is in charge of the
treatment facilities and the collection system, then this facility super-
intendent has overall responsibility for the emergency program.
The wastewater treatment system management should be familiar with the
Disaster Relief Act of 1970 (Public Law 91-606). Management should be
familiar with the Office of Emergency Preparedness Circular 4000.5C,
Manual for Applications, Federal Disaster Assistance Program. If manage-
ment is familiar with the procedures described in these documents, it
will ensure that Federal assistance is received in a prompt and efficient
manner.
Treatment system personnel should be given identification cards with
their picture attached. These cards will permit them to gain access
to areas that may be restricted during an emergency.
All regular and auxiliary wastewater treatment system personnel should
be issued an emergency response card.
Each individual should familiarize himself with the data contained on
his card. This information outlines what tasks and responsibilities he
has in given emergency situations.
Figure No. 20 is a sample Emergency Response Card.
Persons preparing the 0 & M Manual should outline the responsibilities
of the system's personnel and outline procedures for preparing emergency
response cards.
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SAMPLE
EMERGENCY RESPONSE CARD*
( NAME OF CITY ) WASTEWATER TREATMENT SYSTEM
EMERGENCY RESPONSE CARD
NAME:
NORMAL DUTY
EMERGENCY
SITUATION:
John
(FIRST)
ASSIGNMENT:
J.
(MIDDLE)
Mechanics Helper
EMERGENCY
ASSIGNMENT:
Jones
(LAST)
Pump Station Report to Maintenance Shop
Power Failure and stand by to serve on
emergency crew for portable
pumps (Give Name of Crew Chief)
Mechanical Equipment Report to Maintenance Foreman
Failure (Give Name) in treatment plant
main control building for
assignment.
Chlorine Gas Leak Assist senior mechanic to
correct problem. Pick up gas
masks and chlorine cylinder
repair kit located in main
control building.
Natural Disaster or Try to contact Emergency
Civil Disorder Response Center to determine
if conditions require you to
report to maintenance shop.
If you are told to report for
duty, your supervisor is
(Give Name).
*Similar to cards in Virginia's "NATURAL DISASTER ASSISTANCE RELIEF PLAN"
FIGURE NO. 20 SAMPLE EMERGENCY RESPONSE CARD
163
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EMERGENCY RESPONSE CENTER
A study should be made to determine the location, facilities, and staff-
ing of the treatment system's Emergency Response Center and alternate
center.
In most cases, the Emergency Response Center will be located in the main
building of the treatment facility. The senior operator on duty should
be responsible for the center and all individuals who perform this func-
tion must be adequately trained and thoroughly familiar with the Emer-
gency Operating and Response Program.
A main control panel at the emergency response center should contain the
pumping station high water/power failure alarms and the high water alarms
for critical manhole locations. Upon receipt of an alarm, the operator
on duty should dispatch the on-call maintenance crew to the scene of the
alarm. A current telephone call list should be maintained at the emer-
gency center as well as collection system maps and treatment facility
piping and wiring diagrams.
When emergency condition notices are received by telephone at the emer-
gency response center, the operator on duty should have a procedure to
ensure all pertinent information surrounding the emergency is accurately
recorded.
In this section of the manual the location, layout and operating pro-
cedures for the emergency response center should be given.
AUXILIARY PERSONNEL REQUIREMENTS
Based on the results of the system vulnerability analysis, the person
preparing the manual should make recommendations on auxiliary personnel
needs.
Conditions can occur for which the treatment system is not adequately
staffed or when staff members are not able to reach their assigned
164
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emergency positions. Auxiliary personnel obtained from other departments
within the local government or through mutual aid agreements should be
trained as back-ups for the regular staff. Procedures for alerting these
auxiliary personnel should be clearly outlined and provisions for rehears
als to keep these personnel up to date on emergency operating procedures.
Process diagrams should be developed to show how units may be by-passed
during emergencies and/or help pinpoint problem areas when emergencies
arise. These diagrams would show all units within the facility, valve
arrangements and settings for achieving specific conditions and splitter
box locations with their capabilities shown.
A procedure should be established for the treatment system owner to
critique responses to emergency situations. The areas that should be
critiqued include:
1. Performance of automatic alarm system.
2. Performance of emergency standby equipment.
3. Response time reasonable.
4. Personnel training adequate.
5. Mutual aid agreements and/or contracted assistance adequate.
6. Emergency equipment/supplies adequate.
7. Treatment process flexibility.
8. Adequacy of emergency procedures.
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CHECKLIST*
EMERGENCY OPERATING AND RESPONSE PLAN
CHAPTER OF 0 & M MANUAL
Perform a study to determine the potential for natural disaster in the
area where the municipal wastewater treatment system is located. This
study should result in an estimate of the severities and frequencies of
occurrence for each natural disaster investigated. From the severity/
frequency estimate a priority list can be established for use in perform-
ing the various system vulnerability analyses.
Perform a vulnerability analysis of the treatment system. Compare the
analyses results and identify the key-most vulnerable components of the
system. List these key components and indicate priorities for repair.
Suggest techniques to reduce vulnerability of key components.
Inventory the emergency equipment, materials, and chemicals available
within the treatment system. This inventory should be printed in the
emergency response plan chapter of the 0 & M Manual. Suggest any addi-
tional equipment/supplies that should be purchased and maintained.
Based on the disaster study, vulnerability analyses, and emergency inven-
tory, prepare a list of potential mutual aid agreements. This portion
of the plan could contain a sample mutual aid agreement form.
Develop a program for the protection of essential records, maps and
inventories. A list of the documents to be protected should be prepared,
Prepare an inventory of all industrial contributors to the municipal
treatment system. Locate each industrial discharge on a map of the
* This checklist is provided to assist persons preparing the Emergency
Operating and Response Program Chapter of an 0 & M Manual.
166
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collection system. Suggest monitoring equipment in collection lines if
necessary. List potential hazardous materials and neutralizing chemi-
cals. Prepare a list of key personnel at each industry. Suggest mecha-
nism for industries to report accidental spills to treatment plant.
Establish a program for local fire and police departments to periodically
review treatment system for adequacy of fire prevention methods and
security measures. These agencies should also be made aware of any
potential chlorine gas emergencies.
Prepare emergency response cards for all treatment system personnel.
These cards outline each individual's emergency condition duties. Sample
cards should be included in the 0 & M Manual.
Designate the area that is to serve as the emergency response center.
List the equipment and staffing requirements for this center.
An important area to be covered in the emergency response plan chapter
of the manual is the procedure to be followed when reporting damages to
the treatment system's insurance company.
Develop the requirements for auxiliary personnel to assist when conditions
exceed capability of existing staff or staff members are unable to reach
their assigned emergency positions.
Prepare treatment process diagrams to show how units may be bypassed dur-
ing emergencies and to assist in locating problem areas during emergencies
Develop a program to allow the treatment system owner to critique the
emergency response actions of his personnel.
Prepare an emergency condition matrix. This matrix should list likely
emergency conditions and give response plan actions and prevention recom-
mendations for that particular system.
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Establish a program for training personnel in emergency operating
procedures.
Prepare a list of local contractors and repair services. This list
can be used in selecting firms from which to request assistance during
emergencies.
Coordinate with local utility companies. Determine the probability
of power failures that would affect the treatment system. List key
personnel at utility companies to be contacted during emergencies.
Describe the failsafe alarm system that is installed at the treatment
plant and at remote pumping station.
Establish a plan to insure chlorination can be provided to any poten-
tial spill of raw or inadequately treated municipal wastewater.
Set up a program for placing emergency standby equipment into service
periodically.
Coordinate with local water utility and establish priorities for repair-
ing lines and facilities after a disaster.
During a major emergency the water treatment plant and distribution
system may suffer major damage resulting in very little flow of waste-
water reaching the treatment facility. For this reason, careful coordi-
nation with the local water supply system is necessary as it may well be
that the waterworks restoration has priority over the wastewater treatment
plant.
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SECTION XVI
0 & M MANUAL CHAPTER X: SAFETY*
PAGE
DISCUSSION . .......... 170
GENERAL ............... ......... 171
SEWERS „ 171
ELECTRICAL HAZARDS ..... .171
MECHANICAL EQUIPMENT HAZARDS ..... 172
EXPLOSION AND FIRE HAZARDS ...... 172
BACTERIA INFECTION (HEALTH HAZARDS) .... 172
CHLORINE HAZARDS ...... 172
OXYGEN DEFICIENCY AND NOXIOUS GASES . 173
LABORATORY HAZARDS . 173
SAFETY EQUIPMENT ..... ........... 173
PROCESS CHEMICAL HANDLING 174
SAFETY REFERENCES ......... 174
* The format suggested for the table of contents page for the Safety
Chapter of an 0 & M Manual is similar, except for the Discussion
portion, to the format given for this section of the Considerations
Manual.
169
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DISCUSSION
The safety hazards associated with municipal wastewater treatment systems
are many and varied. They run from the dangers of chlorine handling to
the potential for contracting waterborne diseases. Treatment personnel
should be made aware of all these hazards. They should be protected from
these hazards to the greatest extent possible and should receive proper
first aid training in the event an accident does occur. A treatment sys-
tem with a poor safety record will generally be providing marginal waste-
water treatment as well. This chapter of an 0 & M Manual can play an
important part in launching a treatment system into a sound safety pro-
gram.
The primary purpose of this chapter of an 0 & M Manual is to help prevent
personal injury to the treatment system staff. To fulfill this stated
purpose the safety portion of the manual should inform personnel of
potential hazards, preventive measures, and emergency procedures. Empha-
sis should be placed on the specific hazards within the treatment system
under consideration.
The treatment system management must assume full responsibility for the
safety program within their system. For a discussion of management's
responsibility for safety, the EPA has a Technical Bulletin under develop-
ment entitled "Safety in the Operation and Maintenance of Wastewater
Treatment Works", Contract No. 68-01-0324.
The overall dangers of accident are much the same whether in sewers,
pumping stations or treatment facilities. These hazards may be classi-
fied into the following broad categories:
Physical injuries
Bacterial infections
. Gas (explosive or noxious vapors) and oxygen deficiency
Radiological hazards
170
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The telephone numbers of several local physicians, the nearest hospital,
police and fire departments, ambulance services and rescue squad should
be posted at each phone in the treatment system. The telephone number of
the chlorine equipment manufacturer and local supplier should be readily
available in the event of a chlorine emergency.
GENERAL
An important aspect of plant safety is the prompt reporting of personnel
injuries to the treatment system's insurance company. Details on report-
ing accidents should be outlined and any other pertinent insurance infor-
mation discussed in this section of the manual.
The sections suggested for an 0 & M Manual's Safety Chapter are listed
below with references to assist manual preparers.
SEWERS
References for persons preparing an 0 & M Manual:
WPCF MOP No. 1, Safety in Wastewater Works, Chapter 2.
WPCF MOP No. 7, Sewer Maintenance. Chapter 9.
ELECTRICAL HAZARDS
References for persons preparing an 0 & M Manual:
EPA Technical Bulletin entitled, Safety jn The Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 4.5.
Operation of Wastewater Treatment Plants, A Field Study Train-
ing Program, Environmental Protection Agency, Technical Train-
ing Grant No. 5TT1-WP-16-03, Chapter 12.17.
171
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MECHANICAL EQUIPMENT HAZARDS
References for persons preparing an 0 & M Manual:
EPA technical Bulletin entitled, Safety in The Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 4.17.
Operation of Wastewater Treatment Plants, A Field Study Train-
ing Program, Environmental Protection Agency, Technical Train-
ing Grant No. 5TT1-WP-16-03, Chapter 12.21.
EXPLOSION AND FIRE HAZARDS
References for persons preparing an 0 & M Manual :
WPCF MOP No. 1, Safety in Wastewater Works, Chapter 4.
EPA Technical Bulletin entitled Safety in The Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 4.6 through 4.10.
BACTERIAL INFECTION (HEALTH HAZARDS)
References for persons preparing an 0 & M Manual:
EPA Technical Bulletin entitled Safety in The Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 4.14.
Manual of Instruction For Sewage Treatment Plant Operators,
New York State Health Department, Chapter 14.
:HLORINE HAZARDS
Deferences for persons preparing an 0 & M Manual :
Chlorine Manual , Chlorine Institute, Sections 1, 3, 6 and 7.
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AWWA, Hater Quality and Treatment, 3rd Edition, Chapter 5.
Basic Gas Chlorination Manual, Ontario Water Resources
Commission.
OXYGEN DEFICIENCY AND NOXIOUS GASES
References for persons preparing an 0 & M Manual:
WPCF MOP No. 1, Safety in Wastewater Works, Chapter 4.
Operation of Wastewater Treatment Plants, a Field Study
Training Program, Environmental Protection Agency, Technical
Training Grant No. 5TT1-WP-16-03, Sections 12.12 and 12.13.
LABORATORY HAZARDS
References for persons preparing an 0 & M Manual :
WPCF Publication No. 18, Simplified Laboratory Procedures
For Wastewater Examination, Section 1.7.
WPCF MOP Mo. 1, Safety in Wastewater Works, Chapter 8.
SAFETY EQUIPMENT
References for persons preparing an 0 & M Manual:
EPA Technical Bulletin entitled Safety in the Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 2.15.
WPCF MOP No. 1, Safety in Wastewater Works, Chapter 5.
173
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PROCESS CHEMICAL HANDLING
References for persons preparing an 0 & M Manual :
AWWA, Water Quality and Treatment, 3rd Edition, Chapter 17.
EPA Technical Bulletin entitled Safety in The Operation and
Maintenance of Wastewater Treatment Works, Contract No.
68-01-0324, Section 4.4.
SAFETY REFERENCES
This section of the 0 & M Manual should contain a list of safety refer-
ences of interest to operating personnel.
EPA Technical Bulletin*
Safety in the Operation and Maintenance of Wastewater
Treatment Works, Contract No. 68-01-0324
*NOTE: This bulletin is in preparation at this time.
Water Pollution Control Federation
MOP No. 1 Safety in Wastewater Works
MOP No. 4 Chlorination of Wastewater and Industrial
Wastes
MOP No. 7 Sewer Maintenance
MOP No. 11 Operation of Wastewater Treatment Plants
MOP No. 18 Simplified Laboratory Procedures for
Wastewater Examination
174
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State of New York, Health Education Service
Manual of Instruction for Sewage Treatment Plant
Operators
Texas Water Utilities Association
Manual of Wastewater Operations
Ontario Water Resources Commission
Basic Gas Chlorination Manual
Chlorine Institute
Chlorine Manual
American Water Works Association
Water Quality & Treatment, 3rd Edition
Figure No. 21 is a sample accident report form of the type that could be
used at a municipal wastewater facility. A copy of the accident report
form recommended for the treatment system should be included in the 0 & M
Manual unless the treatment system's insurance company has a standard
accident report form. If a standard form exists it should be properly
referenced in the 0 & M Manual.
-------
ACCIDENT REPORT FORM
DATE
INSURED
PERSON
(NAME) (JOB TITLE)
DATE OF INJURY PM
(DAY) (MONTH) (TIME)
PLACE ACCIDENT OCCURRED,
DESCRIPTION OF ACCIDENT^
CORRECTIVE ACTION TAKEN
INSURANCE COMPANY
TIME LOST
PERSON MAKING REPORT_ _____
(NAME)
REMARKS, DIAGRAM, RECOMMENDATIONS, ETC. :
FIGURE NO. 21 SAMPLE ACCIDENT REPORT FORM
176
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SECTION XVII
0 & M MANUAL CHAPTER XI: UTILITIES*
PAGE
GENERAL ..... 178
ELECTRICAL 178
TELEPHONE 179
NATURAL GAS 179
WATER 179
FUEL OIL f 180
* NOTE: This section's table of contents format can be used for the
table of contents page for the Utilities Chapter of an 0 & M
Manual.
177
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GENERAL
The utilities serving a municipal wastewater treatment facility play a
major role in the proper operation of the facility. Frequent or pro-
longed interruptions of service can have significant effects, even on
systems that have some form of standby or alternate service. This
section of an 0 & M Manual should be prepared emphasizing that all treat-
ment system personnel have an interest in the reliability of the util-
ities they use. The sizes and capacities of the lines serving the facil-
ity are also of interest. The identification of contact men within each
utility company is essential for proper response to routine and emergency
operations.
ELECTRICAL
This section of the 0 & M Manual should give the name of the electrical
utility company supplying power to the treatment system. The voltage
of the electrical service adjacent to the facility should be given as
well as the reduced voltage entering the plant. If standby power is
provided from a second line, this system should be completely described.
The standby power capacity furnished may have been substantially less
than that of normal power requirements if the local water utilities
reliability is directly affected by power outages. Reductions in avail-
able water will directly affect wastewater volumes. If this condition
exists, it should be described here.
A detailed description of the power source should be included in the
Electrical System Chapter of the 0 & M Manual.
A brief statement on the reliability of electrical service should be
made. This statement should be based on studies of past performance and
discussions with utility personnel. The discussion should include clearly
defined break points in responsibility for service facilities between the
utility company and the wastewater facility.
178
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Coordination with the electrical utility company is essential during
power failures and other electrical problems. Key personnel within the
utility company should be designated as contact men and provisions made
for reaching them during emergencies. Advanced arrangements should
include suitable priority for restoration of normal service following
areawide power loss.
TELEPHONE
The telephone communications system within the treatment system should
be discussed. Many alarm systems used in wastewater treatment operations
utilize telephone lines. These alarm systems should be described and
a statement made as to "failsafe" capabilities. Contact men within the
telephone company should be designated for routine and emergency oper-
ations. Arrangements with the telephone company should ensure priority
to wastewater facility calls during emergencies that limit telephone
service.
NATURAL GAS
The natural gas utility company serving the treatment facility should
be named and a description of the service given. Contact men within the
company should be designated and a statement of reliability made. The
cubic feet per hour and the normal operating pressure should be given
for the gas lines servicing the facility.
WATER
The name of the water utility providing water to the treatment system
should be given. The size waterline serving the facility and its oper-
ating pressure should be given. If a pressure-reducing valve is used,
its function and location should be mentioned. If any nonpotable water-
lines are connected to the potable system using backflow preventer
valves, they should be discussed. Additional information on cross-
connection prevention should be outlined. On site fire service water
supply should also be discussed.
179
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Contact men within the water utility company should be designated and
provisions made for reaching them during emergencies. A statement of
reliability of water supply should be included.
FUEL OIL
If facilities or processes require fuel oil for heating purposes, the
sources for this fuel should be listed. A schedule or method of ensur-
ing adequate fuel supplies are on hand should be outlined. Capacities
of fuel oil storage facilities at the treatment plant should be given.
The following is a sample of the Electrical portion of the Utilities
Chapter of a typical 0 & M Manual:
SAMPLE
Electrical
Electrical power is provided to the main wastewater treatment plant by
the ABC Power Company. A 12,500 volt line is adjacent to the facility
and a transformer reduces the voltage to 480 volts for use at the plant.
A standby source of power comes to the plant on a second line and origi-
nates on the East side of the city. Power company records show that
only once in the past ten years has power been off from both sources at
the same time. The power reliability records indicate excellent reli-
ability can be expected. Maximum power outage in the past ten years
has been 5% hours. The break point for responsibility for electric ser-
vice facilities between the power company and the wastewater plant owner
is the main service disconnect.
The following individuals have been designated as contact men within the
power company to respond to electrical emergencies at the treatment
plant:
180
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Name
Title
Business Phone Home Phone
John Oones Foreman
Bill Smith Foreman
24 Hour Emergency Repair
Owner's Contractor
D. R, Brown Electrical
Contractor
124-3333
124-3333
(124-3330)
123-4567
123-8910
124-4444
123-2121
NOTE: Many wastewater treatment plants have overlapping utilities. For
example, the fuel used for heating the plant's control building
may be either fuel oil, sludge gas or natural gas. In these cases
the 0 & M Manual Utilities Chapter should describe the alternate
or overlapping utilities.
181
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SECTION XVIII
0 & M MANUAL CHAPTER XII: ELECTRICAL SYSTEM*
PAGE
DISCUSSION 184
GENERAL 184
POWER SOURCE 184
POWER DISTRIBUTION SYSTEM 185
CONTROL AND MONITORING SYSTEM 186
ALTERNATE POWER SOURCE 186
* The format suggested for the table of contents page for the Electrical
System Chapter of an 0 & M Manual is similar, except for the Discussion
portion, to the format given for this section of the Considerations
Manual.
183
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DISCUSSION
In today's modern treatment plants, the electrical system has become the
most important single factor affecting all processes. Practically all
operations involve some type of electric motor to power a pump, sludge
collector mechanism or aeration equipment. A facility's electrical sys-
tem must be adequately described in this chapter of an 0 & M Manual if
operating personnel are to successfully use the flexibility designed into
their electrical systems.
The purpose of this chapter of the 0 & M Manual is to provide sufficiently
detailed information on the treatment system's electrical system to insure
efficient plant operation. The importance of a complete and accurate
electrical system chapter cannot be overemphasized.
GENERAL
Description of the electrical system should be accomplished by a combina-
tion of schematic diagrams, tables, manufacturer's descriptive literature,
and manufacturer's and contractor's detailed shop drawings. These docu-
ments can be filed and properly indexed with the indexing system described
in the 0 & M Manual. Also included should be notes by the Engineer indi-
cating pertinent information.
POWER SOURCE
The following information should be included in a description of the
power source:
1. Name of electric utility company.
2. Characteristics (voltage, overhead or underground, etc.)
of primary distribution line serving the plant.
3. Description of the main transformer(s) (ownership,
voltage, phase, connection, capacity, type, impedance,
taps, etc.) as well as the physical location.
184
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4. Types, ratings, and settings of protective devices.
5. Value of the maximum available short-circuit current
at point(s) of service from the electric utility
company.
A properly noted one-line schematic diagram would be the best way to pre-
sent most of the above information. Manufacturer's literature and shop
drawings should supplement this diagram.
POWER DISTRIBUTION SYSTEM
As in the case of the power source, the power distribution system also
would best be described by a properly noted one-line schematic diagram.
This diagram or any written description should contain the following
information:
1. Service entrance equipment description (location, type
of equipment, load capacity, short-circuit interrupting
capacity, calculated short-circuit duty, voltage rating,
etc.).
2. All motor control centers, distribution switchgear assem-
blies, panelboards, or other major components of the
electrical system should be described similar to (1.)
above.
3. Also included should be tabulations of schedules of the
components of the equipment in (1.) and (2.) above which
indicate the power wiring from and the loads fed by
such components.
Manufacturer's literature and shop drawings should be provided for each
major component of equipment. Contractor's shop drawings should also be
provided.
185
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CONTROL AND MONITORING SYSTEM
Process monitoring and control instrumentation should be described by
appropriate schedules and tabulation indicating the type of controls
and monitors, and the process equipment involved. Where involved
sequences are present, schematic diagrams should be prepared.
Manufacturer's literature on specific components of control and monitor-
ing equipment should be provided.
ALTERNATE POWER SOURCE
The alternate power source should be described in the same detail as
the primary power source previously discussed. If the alternate power
system includes any duplicate power distribution equipment, this equip-
ment should be described in the same detail as the power distribution
system previously discussed.
186
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SECTION XIX
0 & M MANUAL: APPENDICES *
PAGE
SCHEMATICS 188
VALVE INDICES 188
SAMPLE FORMS 189
CHEMICALS USED IN PLANT 190
CHEMICALS USED IN LABORATORY 190
EMERGENCY OPERATING AND RESPONSE PROGRAM . . . . 190
DETAILED DESIGN CRITERIA 190
EQUIPMENT SUPPLIERS 191
MANUFACTURERS' MANUALS (MAY BE BOUND SEPARATELY) 191
SOURCES FOR SERVICE AND PARTS 191
AS-BUILT DRAWINGS 192
APPROVED SHOP DRAWINGS :•• 192
DIMENSION PRINTS 192
CONSTRUCTION PHOTOS 192
WARRANTIES AND BONDS .193
COPIES OF STATE REPORTING FORMS 193
COPIES OF FEDERAL INSPECTION FORMS . 193
INFILTRATION CONTROLS (ORDINANCES) 193
INDUSTRIAL WASTE CONTROLS (ORDINANCES) 193
PIPING COLOR CODES 194
PAINTING .194
REFERENCES TO BE MAINTAINED AT TREATMENT FACILITY 194
* NOTE: The format for this section's table of contents is identical
to the format suggested for the Appendix of an 0 & M Manual.
187
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This section of an 0 & M Manual is used for including any additional or
supplemental material not suitably included in the text of the manual.
Certain appendix items may be too bulky or cumbersome to be bound in the
manual itself. These items should be bound separately or folded and
placed in plastic pouches in the Appendix of the Manual. Fold-out pages
can be used effectively in some places.
Several of the appendix subject areas are interdependent and the depth
of content of any one is substantially dependent on the content of the
others. The subject areas involved are: Schematics, Valve Indices,
As-Built Drawings, Approved Shop Drawings, Dimension Prints and Color
Coding. The overriding guidelines to the detail that should be provided
under each subject is that the total blend of these subjects, together
with proper coordinating narration, quickly and clearly conveys to the
operational staff necessary information on operational modes and related
controls. Key valves and gates must be suitably identifiable both on
the drawings and schematics and in place.
Schematics
Basic flow diagrams, process flow sheets, bypass piping diagrams and
hydraulic profiles are very useful in explaining and illustrating treat-
ment plant operation. Generally these schematics are a part of the
engineering drawings. They can be included in the manual text to illus-
trate a specific point. However, there will be cases where schematics
are more logically placed in the manual's appendix. The individuals
preparing an 0 & M Manual for a specific treatment system can best decide
what schematics should be included in the appendix and in what form they
should appear. A separate section of the manual's appendix has been
designated for as-built drawings. Approved shop drawings and dimension
prints each have a separate section in the appendix.
Valve Indices
Having a complete list of the treatment system's primary valves will
help ensure efficient and continuous facility operation. Valve indices
188
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are systems for identifying or locating valves and can be one, or a
combination, of the following:
(a) A complete tabulation of principal valves, each separately
numbered and identified as to type, location and function,
with each to be suitably field tagged with a noncorrosive
tag.
(b) A coding system for each type of valve (plug, gate, throt-
tling, etc.) together with a prefix or suffix identifying
its liquid content or process function (raw sludge, return
sludge, etc.) and each valve coded on the construction
drawings.
(c) A series of sketches for principal valves or clusters of
valves and adjacent piping that are buried. The sketch
permits immediate location by giving three lateral
measurements to nearby permanent aboveground objects
and usually includes a tabulation of key characteristics,
e.g., size, make, type, year, direction, and turns to
open, depth to top of stem, valve box size and marking,
process control, etc.
Sample Forms
The operation and maintenance of any municipal wastewater treatment
system involves the use of many forms such as daily operating logs,
State monthly operating reports, equipment data cards, maintenance
work orders and purchase orders for supplies and equipment. A sample
of all forms to be used at the treatment facility should be included
either in the manual text or appendix. Instructions for completing
each form should be given.
189
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Chemicals Used in Plant
Any chemicals used in the treatment process should be listed. Safety
precautions to be used when handling these chemicals should be outlined
in the Safety Chapter of the 0 & M Manual. Storage considerations should
be discussed. Chemical suppliers should be listed and an ordering sched-
ule should be given to insure adequate quantities are on hand at all
times. Capacities of dry chemical storage areas and liquid storage
tanks at the facility should be described. Chemicals common to munici-
pal wastewater treatment include lime, alum, ferric chloride, ferrous
and ferric sulfate, chlorine, sulfuric acid, sulfur dioxide and polymers.
Chemicals Used in Laboratory
A discussion of laboratory chemicals should be included in the Laboratory
Testing Chapter of the 0 & M Manual. This section of the Appendix should
list the lab chemicals by common name, chemical name and give the chemical
formula. If any chemicals used in the lab are to be purchased in bulk
quantities, they should be so designated. Suppliers' names and suggested
quantities to be ordered should be given. The construction specifications
usually contain similar information on lab chemicals and should be refer-
enced to supplement the information in this section.
Emergency Operating and Response Program
The Emergency Operating and Response Program Chapter of the 0 & M Manual
should give a detailed description of the treatment system's plan for
responding to emergencies. This section of the Appendix should be used
for any supplementary material such as schematic diagrams and sample
forms.
Detailed Design Criteria
This section of the Appendix should give the design criteria for all unit
operations and processes in the treatment system. Typical criteria in-
cludes approach velocity and allowable head loss for bar screens; esti-
mate of cubic feet of screenings to be removed per million gallons of
190
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wastewater treated; comminutor capacities; grit chamber size and flow
through velocity; estimate of cubic feet of grit to be removed per
million gallons of wastewater treated; surface loading rates, detention
time, weir loadings and unit dimensions should be given for sedimentation
tanks; detention time and desired residual for chlorine contact tanks;
food-to-microorganism ratio or mean cell residence time, air require-
ments, and tank dimensions for the activated sludge process; trickling
filter dimensions, hydraulic loading, and recirculation capacities, load-
ings to sludge thickeners; digestion capacities, heat requirements, and
chemicals required; both wastewater and sludge pumping criteria should
be given; vacuum filter yield; sludge drying bed capacities; incinera-
tion heat requirements, and so forth.
Equipment Suppliers
The equipment supplied to a new municipal wastewater treatment plant is
generally not precisely known until the contractors have submitted their
bids for the construction of the facility. However, the individuals pre-
paring this section of an 0 & M Manual 's Appendix can develop a relatively
complete list of suppliers and up-date this portion of the manual after
the actual equipment suppliers have been confirmed. The list of suppliers
should include their name, equipment furnished and local representative.
Manufacturers' Manuals
The operating and maintenance manual furnished with each piece of equip-
ment should be kept as an appendix to the treatment system's 0 & M Manual,
and may be bound separately. These manuals will be valuable when per-
forming maintenance on equipment and when ordering parts, components or
new items. The indexing system used with the Manufacturers' Manuals
should be outlined. The system could be numerical and patterned after
the equipment numbering system.
Sources for Service and Parts
Local repair services and supply houses should be canvassed. A list of
potential sources for the types of repairs and equipment parts required
191
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by the treatment facility should be made. Such a list might include a
meter repair service and plumbing supply wholesaler.
As-Bui It Drawings
It is essential that the personnel responsible for operating and main-
taining a municipal wastewater treatment facility be furnished with a
complete and accurate set of as-built engineering drawings. These as-
built drawings should be furnished sufficiently in advance of start-up
to permit proper training of operating and maintenance personnel. These
drawings help during repair work, modifications and/or plant enlarge-
ments. Proper indexing is essential to use these drawings and an index-
ing system should be given in the manual.
Approved Shop Drawings
Just as a complete and accurate set of as-built drawings is important,
so are the approved shop drawings. These shop drawings give the detailed
description of specialty items within the facility and of built-in or
concealed items. They show such things as clarifier sludge removal mecha^
nisms and anaerobic digester mixing mechanisms. Proper indexing is
essential to use these drawings and an indexing system should be given
in the manual.
Dimension Prints
Dimension prints give the actual relationship between installed equip-
ment and adjacent walls and openings. These prints are especially help-
ful to evaluate modifications or equipment replacements, and permit
important preliminary actions to be undertaken without shutdown.
Construction Photos
Photographs should be taken throughout the construction phase of the pro-
ject. Special attention should be given to underground or other con-
cealed piping and diversion structures. These photos can be valuable
during emergencies and in everyday plant operational difficulties. All
192
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pictures should be labeled and dated. A system for indexing and filing
the photos should be outlined.
Warranties and Bonds
All equipment within a treatment system should be under warranty for at
least one year. Copies of these warranties together with roof bonds
should be placed in the 0 & M Manual's Appendix. A performance bond
guarantees the Contractor can fulfill his contractual obligation to
the Owner of the system and usually remains in effect during the warranty
period of one year. A copy of this bond should also be included in the
Manual's Appendix.
Copies of State Reporting Forms
Pertinent State forms not found in other sections of the Manual should
be placed in the Appendix. Instructions for completing these forms
should also be included. Typical State forms include monthly operating
report, bypass report, chlorine failure report, and others applicable to
the permit program.
Copies of Federal Inspection Forms
A copy of EPA Form 7500-5 (.4-72), Report on Operation and Maintenance of
Wastewater Treatment Plant, should be included in the 0 & M Manual 's
Appendix. This will assist operational personnel in familiarizing them-
selves with the federal inspection criteria.
Infiltration Controls
If there is an existing infiltration ordinance, a copy should be included
in the 0 & M Manual's Appendix. If no ordinance exists, a suggested
model ordinance could be included in this section.
Ind u s tr i a 1 Waste Con tro1s
If there is an existing industrial waste ordinance, a copy should be
included in the 0 & M Manual's Appendix. If no ordinance exists, a
193
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suggested model ordinance could be included in this section. (See
Water Pollution Control Federation, MOP #3, p. 24, 1968.)
Piping Color Codes
The various piping systems should be color coded for safety purposes and
to insure efficient operation. The coding system selected for use in
the treatment system should be outlined in this section of the Appendix.
This should be the standard color code for treatment works.
For additional information in piping color codes, refer to the Water
Pollution Control Federation, MOP #17, "Paints & Protective Coatings",
(1969) and EPA Technical Bulletin entitled (in preparation at this time)
"Safety in The Design of Wastewater Treatment Works", Contract No.
68-01-0324.
Painting
Keeping units and equipment painted with proper protective coatings is
an important preventive maintenance function. This section of the
Appendix should describe the various type of coatings to be used through-
out the facility and give a suggested painting schedule. The manufac-
turer's trade name, and number and color should be specified. Comparable
coatings by other manufacturers may sometimes be obtained when this infor-
mation is known and the original material is not available.
For additional information on painting, refer to the Journal Water Pol-
lution Control Federation, MOP #17, "Paints and Protective Coatings",
(1969).
References
Reference books, manuals and publications can be valuable tools to treat-
ment system personnel. They may provide detailed laboratory test pro-
cedures or give hints on the proper operation of a biological process.
The Appendix of the 0 & M Manual should provide a list of essential
194
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references recommended for immediate procurement and a second list
giving references that may be obtained at a later date.
Several examples of certain Appendix items suggested for an 0 & M Manual
have been included in the balance of this section. These examples are
not intended to be rigid formats for their respective appendix items but
only samples of the type information to be included in an 0 & M Manual.
The examples include:
Appendix Item Page
Detailed Design Criteria 196
Construction Photos 200
Federal Inspection Forms 201
Painting 207
References 209
195
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DETAILED DESIGN CRITERIA
Detailed design criteria should be included on the plant as a whole and
for each individual unit. Design criteria should be stated for the
initial conditions as well as for the design conditions, and any special
considerations such as existing and future industrial waste flows should
be included.
Example: Detailed Design Criteria:
Design,
initial Year
1972 1,99.0...
Population 4,000 10,000
Quantity and Quality of Wastes
Per capita contributions
Sewered:
Average daily flow, gal./capita/day 100 100
5-day BOD, Ib/capita/day 0.17 0.20
Suspended solids, Ib/capita/day 0.20 0.22
Industrial waste characteristics, mg/1,
average
5-day BOD 200 300
Suspended solids 240 350
Domestic flows, tngd, average 0.40 1.00
Industrial flows, mgd, average 0.30 1.00
Total flows (domestic plus industrial), mgd
Average 0.70 2.00
Sustained peak 1.05 3.10
Instantaneous peak 1.40 4.00
Minimum 0.30 0.50
BOD loadings, Ib/day, average
Domestic , 680 2,000
Industrial 510 2,500
Total 1,190 44500
196
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Suspended solids
Domestic
Industrial
Total
loadings, Ib/day average
Parshall Flume
No. of Units
Throat width, in.
Aerated Grit Chamber
No. of Units
Width, ft.
Length, ft.
Average water depth, ft.
Detention at average flow, minutes
Detention at instantaneous peak flow,
minutes
No. of blowers
Unit blower capacity, cfm
Air cfm/lf. maximum
Method of cleaning
Comminutor and Bypass Screen
Comminutor:
No. of Units
Unit size , in .
Unit capacity, mgd
Screen:
No. of Units
Width of channel, ft.
Capacity, mgd
Method of cleaning
Primary Settling Tanks
No. of tanks
Diameter, ft.
Sidewall water depth, ft.
Unit volume, ga.
Detention at average flow, hr.
Overflow rate at average flow,
gal./sq. ft./ day
Weir rate at average flow, gal./If/day
Initial
1972
800
600
1,400
1
6
1
10.0
23.0
7.0
22.9
11.5
2
150
6.5
Design,
Year
1990
2,200
2,921
5,121
1
18
1
10.0
23.0
7.0
8.0
4.0
2
150
6.5
clamshell bucket and hoist
1
25
7.9
1
3.4
7.9
1
25
7.9
1
3.4
7.9
manual raking
2
45
8.5
101,000
6.9
220
2,490
2
45
8.5
101,000
2.42
630
7,100
197
-------
Design,
Initial Year
1972 1990
Aeration Tanks
No. of tanks 4 4
Average water depth, ft. 15 15
Overall tank dimensions:
Length, ft. 54 54
Width, ft. 30 30
Unit volume, cf 24,300 24,300
Total volume, cf 97,200 97,200
No. of tanks in service 2 4
Detention time, hr:
At average flow 12.4 8.7
At sustained peak flow 8.3 5.6
BOD to aeration tanks, Ib/day 910 2,930
Tank loading, Ib BOD/1,000 cf 18.8 30.2
MLSS concentration, mg/1 4,000 2,000
Total MLSS in aeration tanks, Ib 12,100 12,100
F/M ratio, Ib BOD/lb MLSS 0.075 0.24
Aeration Equipment
Oxygen requirement, Ib/lb BOD applied 1.8 1.0
Total oxygen required, Ib/day:
Average 1,640 2,930
Peak (150% of average) 2,460 4,400
Aerator capacity, Ib oxygen/hp/day 44.7 44.7
(Corrected for temperature, dissolved
oxygen level, and K factor)
Total horsepower required
Average 37 65
Peak (150% of average) 55 98
No. of aerators 8 8
Uni t horsepower 15 15
Total horsepower 120 120
Total corrected oxygenation capacity
installed:
Lb/day 5,360 5,360
Lb/Lb BOD applied, peak 3.93 1.22
198
-------
Initial
1972
Design,
Year
1990
Final Settling Tanks
Type of sludge removal
No. of tanks
Diameter, ft.
Sidewall water depth, ft.
Unit volume, gal.
Detention at average flow, hr.
Overflow rate at average flow, gal./
sq. ft./day
Weir rate at average flow, gal/If./dz;v
Chlorination System
Chlorine Feed:
Dosage, average mg/1
Average chlorine demand, Ib/day
Maximum chlorine demand, Ib/day
Chlorinators:
No.
Unit capacity, Ib./day, maximum
Chlorine contact tanks:
No.
Unit capacity, cf
Detention at instantaneous peak
flow, minutes
Sludge Dewatering Facilities
Dewatering units
No. of filters
Unit filtration area, sq. ft.
Total filtration area, sq. ft.
Solids to filters, Ib./wk.
Average
Maximum week
Filtration rate, Ib/sq.ft./hr.
Total filtration capacity, Ib./hr.
Estimated operating period with
all units in service, hr./wk.
Average
Maximum week
uction type
40
11.0
104,000
3.56
558
5,560
40
11.0
104,000
2.50
797
7,960
8
46
92
2
1,000
2
2,800
8
133
266
2
1,000
2
2,800
42.8
15.2
rotary vacuum filter
with continuous media wash
2 2
200 200
400 400
9,850
14,750
2
800
12
19
35 ,000
52,500
4
1,600
23
35
One unit operating.
199
-------
SAMPLE CONSTRUCTION PHOTO FORM
PHOTO NO. PM FILE NO.
CONSTRUCTION PHOTO
PHOTO DESCRIPTION:
PHOTO SHORT TITLE
DATE TAKEN:
REMARKS:
TIME TAKEN:
LOCATION OF NEGATIVE:
200
-------
ENVIRONMENTAL PROTECTION AGENCY
REPORT ON OPERATION AND MAINTENANCE
OF WASTEWATER TREATMENT PLANT
DATE OF INSPECTION
Form Approved
OMB No. 758-R0035
A. GENERAL INFORMATION
1. PLANT
(a.) NAME
2. TYPE OF PLANT
(b.) OWNER
(c.) LOCATION
3. PROJ ECT NO.
4. AVG. DESIGN FLOW (m£d)
5. DESIGN POPULATION
EQUIVALENT
COLLECTION SYSTEM
COMBINED
SEPARATE
7. DATE PRESENT PLANT BEGAN OPERATING
8. STATE PERMIT NO.
9. IN THE SPACE PROVIDED BELOW, FURNISH A SIMPLIFIED FLOW DIAGRAM OR A WRITTEN DESCRIPTION OF THE PLANT UNITS IN
FLOW SEQUENCE.
10. IDENTIFY RECEIVING WATERS
11. IDENTIFY PERTINENT STREAM STANDARDS AND,- OR USES OF THE RECEIVING WATERS
12. GIVE THE EFFLUENT STANDARDS AND/OR REQUIREMENTS FOR STATE OPERATING PERMIT
B. CURRENT PLANT LOADING
1. ANNUAL AVG DAILY FLOW RATE (mgd)
2. PEAK FLOW RATE (mgd)
DRY WEATHER WET WEATHER
3. POPULATION SERVED
4. ANNUAL AVG BOD5 OF RAW SEWAGE (mg/1)
5. ANNUAL AVG SUSPENDED SOLID OF RAW SEWAGE (mg/1)
6. PRINCIPAL TYPES OF INDUSTRIAL WASTE DISCHARGED TO
MUNICIPAL SYSTEM
7. POPULATION EQUIVALENT (BOD) OF INDUSTRIAL WASTES
B. POPULATION EQUIVALENT (SS) OF INDUSTRIAL WASTES
9. VOLUME OF INDUSTRIAL WASTES
10. INFILTRATION PROBLEMS
EPA Form 7500-5 (4-72) REPLACES FORM FWPCA-12 WHICH IS OBSOLETE.
GPO • 1972-722-096
201
-------
C. PLANT PERFORMANCE
1
LABORATORY AN A L Y SI S ( Total plant)
MONTHLY ITEMS
(b.)
SELiLC
F ROM
1 1 A V 1 M '
r DATA
^ONTH
S M A X 1 -
|
MON TH
SEL EC
FROM
H A V I N
MUM A V
MON TH
YEAR
r DATA
MONTH
G MINI-
G FLOW
YEAR
MONTHLY
AVERAGE FLOW
(date)
DAY OFMIN FLOW
(dale)
MO N TH L Y
AVERAGE FLOW
DAY OF MAX FLOW
DAY OF MIN FLOW
(MO 0)
(a.) REPORTING PERIOD
FROM (Munth, day, venr)
SETTLEABLE SOLIDS
(ml/I)
(f.)
EN T
E N T
SUSPEN DED SOLIDS
(mg/l)
(d.)
EN T
MOV L
TO (Munth, day, year)
BOD5 (mg/1)
V
?,. LABORATORY AN A L YSIS (Effluent Only)
(a.)
SELECT DATA
F ROM MON TH
HAVING MA XI-
1
MON TH YEAR
SELECT DATA
F ROM MON T H
HAVING MINI-
MUM AVG FLOW
1
MONTH YEAR
MONTHLY
AVERAGE FLOW
frlalf,}
DAY OF MIN FLOW
(dale)
MO NTHL Y
AVERAGE FLOW
DAY OF MAX FLOW
DAY OF MIN FLOW
FLOW
(WGD)
(f.) ARE EFFLUENT STANDARDS ESTABLISHED'
r ~; Y as L" } N o
(b.)
DO
fmjJ/0
(c.)
CHLORINE
RESIDUAL(mg/0
(d.)
CO LI FORM (Per 100 ml)
TOTAL
(g.) ARE EFFLUENT STANDARDS BEING ME!
n YES rn NO
FECAL
?
(O
OTHER
(h.) ARE MONTHLY OPERATING RECORDS FILED WITH STATE
AGENCY? Q YES fJD NO
EPA Form 7500-5 (4-72) PAGE 2
-------
3. DOES PLANT HAVE ALTERNATE ELECTRIC COWER SOURCE'
_1 DUAL FEED [ GENERATOR | NONE
4. ADEQUATE ALARM SYSTEM FOR POWER OR EQUIPMENT
FAILURES? | I Y ES [' j NO
EQUIPMENT PROGRAM
(a.) ROUTINE MAINTENANCE SCHEDULES
RECORDS OF M Al N T EN AN C E.REP AIRS 6 REPLCMT
(c.) SPARE PARTS INVENTOR*,
AD E QU ATE
INADEQUATE
6. IS PLANT EFFLUENT
BEING CHLORINATED?
7. DOES SEWAGE BY-PASS
PLANTINWETWEATHER
8. DOES SEWAGE BY-PASS
PLANT IN DRY
WEATHER'
] YES
j NO
9. AGENCIES NOTIFIED OF EACH BYPASS
10. BYPASS FREQUENCY
(. lion thly)
1 1. AVG DURATION OF
BYPASS ,'Wrs)
12. REASON FOR BYPASSING
13. CAN BYPASS SEWAGE BE
CHLORINATED' |~ I Y ES
14. DO SEWER OVERFLOWS OCCUR
UPSTREAM OF PLANT'
15. ANY ODOR COMPLAINTS BEYOND PLANT PROPERTY' (It yes, explain)
16. OBSERVED APPEARANCE OF EFFLUENT, RECEIVING STREAM OR DRAINAGE WAY
17. IS A CONSULTING ENGINEER RETAINED OR AVAILABLE FOR CONSULTATION ON OPERATING AND MAINTENANCE PROBLEMS'
I i YES [ NO (It res, check one of C/ie toltuwing) \ ] CONTINUING BASES | | REQUEST BASES
18. DO OPERATORS AND OTHER PERSONNEL ROUTINELY ATTEND SHORT
COURSES, SCHOOL OR OTHER TRAINING' [^] Y E S L7 1 N °
(a.) If yes, cite course sponsor, and date of last course.
(b.) If no, are there any courses available in this area3
(c.) Is there an established procedure for training new operators3
19. IS LAB TESTING ADEQUATE FOR THE CONTROL
REQUIRED FOR THIS SIZE AND TYPE OF PLANT
AND USES OF RECEIVING WATERS'
Q YES [ j NO (II No, evp/a/n.J
20. EXPLAIN MAIN DIFFICULTY EXPERIENCED WITH INDUSTRIAL WASTES
21. PERMANENT RECORD FILE
(a.) PLANT OPERATION AND MAINTENANCE MANUAL' | ]YES[ ]NO (b.) AS BU I L T PL AN S AN D SP ECI Fl C ATI ON S ' [",YES[_]NO
(c.) MANU FACTURERS OPERATION ft MAINTENANCE SPECIFICATIONS' Q Y ES Q] NO (d.) FLOW CH A RTS' (3YES fjNO
22. ESTIMATED WEEKLY MAN-HOURS FOR LAB WORK INCLUDING MAINTENANCE OF RECORDS AND PREPARATION OF REPORTS
23. ANNUAL BUDGET FOR MAINTAINING AND OPERATING PLANT
SALARIES Ji WAGES ELECTRICITY CHEMICALS MAINTENANCE STAFFING & TRAINING OTHER
24. STABlLl ZATION PONDS
\3.) WEEDS CUT AND VEGETATION GROWTH IN PONDS REMOVED'
(b.) BANKS AND Dl K ES M A I N T Al N E D' ('Krosion, dr.)
[" | Y ES LZ] N0
(c.) ANY REPORTS OF GROUND WATER CONTAMINATION FROM POND7 (II yus, Hlvo details) [_l Y ES _J NO
REPORTED'
Y ES . ! NO
(L-.) ADEQUATE DEPTH CONTROL'
1 Y E S I ~" I N O
(f.) EFFLUENT RELEASE IS
[~~] CONTINUOUS [""[INTERMITTENT
SE ASON AL
EPA Form 7500-5 (4-72) PAGE 3
203
-------
D. LABORATORY CONTROL
CODING INSTRUCTION
Enter test codes opposite appropriate items. If any of the below tests are used to monitor industrial wastes, place an "X" in
addition to the test code.
1 7 or more per week 3 - 1, 2 or 3 per week 5 ' 2 or 3 per month 7 - Quarterly 9 - Annually
2 - 4, 5 or 6 per week 4 - as required 6-1 per month 8 - Semi-Annually
ITEM
(a.)
1. BO D
2. SUSPENDED SOLIDS
3. SETTL E ABU E SO LI DS
4. SUSPENDED VOLATILE
5. DISSOL V ED O X Y G EN
6, TOT AL SOLI DS
7. VOL ATI L E SO LI DS
8. pH
9. TEMPERATURE
10. COLIFORM DENSITY
11. RESIDUAL CHLORINE
12. VOLATILE ACIDS
13. M B STABILITY
14. ALKALINITY
15.
16.
17.
18.
1 9,
RAW
(b.)
PRIMARY
EFFLUENT
(c.)
MIXED
LIQUOR
(d.)
FINAL
(e.)
(f.) SLUDGE
RAW
SUPER-
NATANT
DIGESTER
(g->
RECEIVING
STREAM
(h.)
COMMENTS
E. PLANT PERSONNEL INVENTORY
PERSONNEL CLASSIFICATION
(a.)
1 MANAGEMENT/SUPERVISOR
2. OPERATOR
3. LABORATORY
4, MAINTENANCE
5. OTHER PLANT WORKERS
6. OTHER OFFICE'CLERICAL
7. TOTAL
EMPLOYMENT
(b.)
AC TU AL
MAN-HOURS
P ER WEEK
N UMB ER
NUMB ER
BUDGETED
NO. RE-
CO MM ENDED
(c.) CERTIFICATION
VO LUN T A R Y
MANDATORY
NO. RECOM-
MENDED OR
R EQUl RED
BY STATE
ACTUAL
NO.
CERTIFI ED
TRAINING REQUIRED
NEXT 12 MONTHS
(d.)
NEW
HIRES
UPGRADE
(Promotion
Of skill /rti-
peovement
EPA Form 7500-5 (4-72) PAGE 4
* CPO: 1 972-722-093
204
-------
F. GUIDE • VISUAL OBSERVATION - UNIT PROCESS
RATING CODES: S - Satisfactory; U r Unsatisfactory; M ~ Marginal; IN - In Operation; OUT - Out of Operation
_i
<
o:
z
UJ
o
PRELIMINARY
PRIMARY
SLUDGE DISPOSAL
OTHER
SECONDARY-TERTIARY 1
(List items as required)
CHLORINE
CONDITION OR APPEARANCE
GRO UN DS
BU 1 L Dl N GS
POTABLE WATER SUPPLY PROT
SAFETY FEATURES
B Y P ASSES
STORM WATER OVERFLOWS
MAINTENANCE OF COLLECTION SYSTEMS
PUMP STATION
VEN TIL ATION
BAR SCREEN
DISPOSAL OF SCREENINGS
COMMINUTOR
G Rl T C H AM B ER
DISPOSAL OF GRIT
SETTLING T AN K S
SCUM REMOVAL
SLUDGE REMOVAL
EFFLU EN T
DIGESTERS
TEMPERATURE ANDpH
GAS PRODUCTION
HEATING EQUIPMENT
SLUDGE PUMP S
DRY! N G BEDS
V A CUUM FILTER
INCINERATION
DISPOSAL OF SLUDGE
RECO RDS
LAB CON T RO L S
EFFLU EN T
C H LO RIN A TO PS
CON TACT TIME
CONTACT TANK
RATING
COMMENTS
-------
G. NOTATIONS BY EVALUATOR
I. ARE THERE ANY PENDING ACTIONS (Enforce,
UPGRADING OF TREATMENT BY THIS PLANT
•, change i
'"j NO (If
'cr'er Qualil
exp/.iio)
• St.:.ilaril*, el t.J THAT WOULD REQUIRE
2. IS ANY FOLLOW-UP ACTION REQUIRED TO: (I) CORRECT DEFICIENCIES IN THE PLANT OR ITS OPERATION, (2) RESOLVE
INDUSTRIAL WASTE PROBLEMS, (3) STAFF DEFICIENCI ES OR TRAINING NEEDS' ^) Y ES ONO (H yes. describe)
IS PURPOSE OF INSPECTION TO DETERMINE I F N EW CONSTRUCTION COMPLIES
WITH FEDERAL REQUIREMENTS FOR THE PROVISION OF AN OPERABLE
FACILITY? [JYES Q NO
GENERAL RATING
ACCEP TABLE
CON Dl TION t
UNACCEPTABLE
EVALUATION PERFORMED BY
TITLE
ORGANIZATION
INFORMATION FURNISHED BY
ORGANIZATION
EPA Form 7500-5 (4-72) PAGE 6
GPO: 1972- 722-091
206
-------
PAINTING
The required frequency of painting depends on several factors, the most
important being (1) severity of environment, and (2) the quality of
paint system applied and adequacy of surface preparation and application
Generally speaking, concrete and metal surfaces that are submerged or
otherwise located in severe environmental areas that have properly
applied quality coatings, should not need repainting more often than
annually. This frequency may increase in coastal areas or other areas
exposed to high concentrations of salts. Properly protected equipment
and surfaces in protected areas should not need repainting more often
than every three years. Spot painting should be performed as needed.
The following is a list of suggested painting systems for various
exposure conditions:
Painting
Exposure Condition
Paint Type
1. Steel exposed to weather,
high himidity, and in-
dustrial atmosphere.
Primer:
1. Iron oxide and/or red lead -
zinc chromate - alkyd varnish
2. Coal tar derivative (no top
coats)
Top Coats:
Alkyd
2. Steel continuously immersed
or wetted
Primer:
1. Iron oxide and/or red lead
zinc chromate - phenolic
primer.
207
-------
Exposure Condition
Paint Type
2. Coal tar derivative
Top Coats:
1. Phenolic.
2. Coal Tar Enamel
3. Surfaces subject to
abrasion.
4. Galvanized iron
Neoprene
Short-oil alkyd
Phenolic
Vinyl
Primer:
Zinc-dust-zinc oxide
5. Concrete
Top Coats:
Conventional
Cement-water paints (above water)
Resin-emulsion paints (above water)
Chlorinated-rubber paints (below water)
Coal Tar Products (below water)
208
-------
REFERENCES TO BE MAINTAINED
AT TREATMENT FACILITY
INITIAL MINIMUM REFERENCES
Water Pollution Control Federation Publications
MOP #1 Safety in Wastewater Works
MOP #11 Operation of Wastewater Treatment Plants
MOP #18 Simplified Lab Procedures For Wastewater Examination
Other References
Standard Method For The Examination of Water & Wastewater
WPCF, APHA & AWWA
Glossary of Terms, WPCF, APHA, ASCE & AWWA
Manual of Wastewater Operations, Texas Water Utilities Asso-
ciation and/or Manual of Instruction For Sewage Treatment
Plant Operators , New York State Department of Health.
Operation of Wastewater Treatment Plants, EPA Grant No.
5TT1-WP-16-03, Prepared by Sacramento State College, Dept.
of Civil Engineering.
Chlorine Manual , Chlorine Institute
RECOMMENDED SUPPLEMENTARY REFERENCES
Depending on the size and complexity of the treatment facility, any or
all of the following references should be provided. These references
would be in addition to the list given above:
209
-------
Hater Pollution Control Federation Publications
MOP #2 Sludge Utilization
MOP #5 Aeration in Mastewater Treatment
MOP #7 Sewer Maintenance
MOP #10 Uniform System of Accounts for Wastewater Utilities
MOP #16 Anaerobic Sludge Digestion
MOP #17 Paints & Protective Coatings
MOP #20 Sludge Dewatering
Public Relations Handbook
Text Books
Sawyer, C. H. and McCarty, P. L., Chemistry for Sanitary
Engineers , McGraw-Hill, 1967.
Metcalf & Eddy, Inc., Mastewater Engineering: Collection,
Treatment and Disposal, McGraw-Hill, 1972.
EPA Manuals
Procedural Manual for Evaluating The Performance of Wastewater
Treatment Plants, Contract No. 68-01-0107.
Middle Management Concepts for Municipal Wastewater Operations,
Contract No. 68-01-0341.
Start-up of Municipal Wastewater Treatment Plants, Contract
No. 68-01-0341.
Emergency Operating Procedures for Municipal Wastewater
Facilities, Contract No. 68-01-0341.
210
-------
EPA Manuals (Continued)
Methods for Chemical Analysis of Water and Waste,
GPO Stock No. 5501-0067.
211
-------
SECTION XX
0 & M MANUAL PREPARATION COST GUIDELINES
The 0 & M Manuals currently being produced vary widely in their prepara-
tion costs. Not only do these costs vary with the size and complexity of
each facility, but there are also wide variations among similar facilities
The primary reason for these cost variations is the detail of each manual.
The man-hour estimates contained in this section are not based on a statis-
tical study. Input on manual preparation costs was obtained from consult-
ing engineers involved in this work. These estimates are broken down by
the recommended chapters to be included in an 0 & M Manual. The man-hour
requirements used in these guidelines are not intended to represent
national or regional averages and are based on information gathered dur-
ing this manual's preparation.
Base Plant - To illustrate a typical cost breakdown, an ideal plant was
selected as a base from which estimations of 0 & M Manual preparation
costs for facilities of various types and sizes could be made. The
following is a description of the base plant selected:
Plant Type: Conventional Activated Sludge
Plant Size: 10 MGD
Sludge Handling Facilities: Anaerobic Digestion
Vacuum Filtration
Landfilling
213
-------
BASE PLANT
0 & M MANUAL COST GUIDELINES
Manual Chapter Title
Man-hours
Title
I. Introduction
&
II. Permits and Standards
III. Description, Operation
and Control of Waste-
water Treatment
Facilities
IV. Description, Operation
and Control of Sludge
Handling Facilities
V. Personnel
VI. Laboratory Testing
VII. Records
VIII. Maintenance
IX. Emergency Operating and
Response Program
Safety
XI. Utilities
40
20
5
80
40
10
80
40
10
20
5
5
20
10
5
20
10
5
80
40
10
40
20
5
40
10
5
20
5
5
Project Engineer
Technician
Typist
Project Engineer
Technician
Typist
Project Engineer
Technician
Typist
Project Engineer
Technician
Typist
Project Engineer
Technician
Typist
Project Engineer
Techni cian
Typist
Project Engineer
Technician
Typist
Project Engineer
Techni cian
Typist
Project Engineer
Technician
Typist
Project Engineer
Technician
Typist
214
-------
Electrical System
XIII. Appendix
MISCELLANEOUS
Project Management
Manual Review
Checking/Proofing
Manual
Printing/Binding
80
40
10
40
20
5
60
20
20
20
Project Engineer
Technician^
Typist
Project Engineer
Technician
Typist
Project Manager
Director
Project Manager
Project Manager
215
-------
The hourly rates to be used with the man-hours given in these guidelines
will have to be adjusted to reflect existing salaries. Salaries vary with
geographic location and various other factors. The following references
can be used to assist in making realistic manual preparation cost esti-
mates:
JOB DESCRIPTION
REFERENCE
REMARKS
Professional
Engineers
Engineering
Technicians
Income and Salary Survey
National Society of
Professional Engineers
(NSPE)
Salaries of Engineering
Technicians, Engineering
Manpower Commission,
Engineers Joint Council
(EJC)
Biennial report on the
findings of a national
salary survey conducted
by NSPE. Respondents
to survey are all mem-
bers of NSPE.
Biennial Report on the
findings of a national
survey conducted by EJC,
Typist
State Employment Commis-
sion, Wage Rates For
Selected Occupations
State Employment Commis-
sions usually publish
yearly compilation of
salary surveys.
Complexity Factors
In order to estimate the 0 & M Manual preparation cost for a particular
size and type facility, this cost must be related to the "Base Plant"
described previously. An attempt has been made to relate this base
plant cost figure to other size and type plants through the use of
"complexity factors" displayed in Table No. 2. Complexity factors
have been developed for three basic wastewater treatment plant types:
216
-------
primary*, trickling filter and activated sludge. Under each of these
plant types, the sludge handling has been broken down to three major
methods:
1. Digestion
Drying Beds/Lagoons
2. Digestion
Vacuum Filtration
3. Vacuum Filtration
Incineration
* NOTE: Although no primary plants will be constructed in the future,
there can be plant expansions that will only affect the primary
treatment facilities and sludge handling facilities.
The complexity factors are related to the following plant sizes: 1 MGD,
10 MGD, 50 MGD and 100 MGD.
The estimate of manual preparation cost is made by multiplying the "Base
Plant" cost figure times the complexity factor for the particular size and
type plant under consideration.
EXAMPLE:
Plant Type: Activated Sludge
Plant Size: 1 MGD
Sludge Handling: Anaerobic Digestion
Drying Beds
From Table No. 2C, the complexity factor is 0.39
Assume Base Plant Manual cost is estimated at $16,330.00
0 & M Manual Preparation Cost = (Base Plant Cost) x (Complexity Factor)
= $16,330.00 x 0.39
= $6,400.00
217
-------
It should be remembered that the total cost figures arrived at using
these guidelines do not represent national averages and the cost figures
should be thought of as being within a range of preparation cost for a
particular manual.
218,
-------
COMPLEXITY FACTORS
PRIMARY PLANTS
WASTEWATER TREATMENT
1 MGD
10 MGD
50 MGD
100 MGf
Primary
Wastewater Treatment
Raw wastewater pumping
Pretreatment Primary
Sedimentation Chlorination
Sludge Handling
Primary sludge pumping
Sludge digestion
Sludge drying beds
or
Sludge lagoons
Primary sludge pumping
Sludge digestion
Sludge holding tanks
Vacuum filtration
Primary sludge pumping
Sludge holding tanks
Vacuum filtration
Incineration
0.35
0.41
0.45
0.79
0.!
0.93
1.78
2.94
1.88
3.13
1.98
3.25
TABLE NO. 2A
-------
COMPLEXITY FACTORS TRICKLING FILTER
WASTEWATER TREATMENT
Trickling Filter
Wastewater Treatment
Raw wastewater pumping
Pretreatment Primary
Sedimentation Trickling
FiIters
Final sedimentation
Recirculation pumping
Ch1 orination
Sludge Handling
Primary sludge pumping
Sludge digestion
Sludge Drying beds
or
Sludge lagoons
Primary sludge pumping
Sludge digestion
Sludge holding tanks
Vacuum filtration
Primary sludge pumping
Sludge holding tanks
Vacuum filtration
Incineration
1 MGD
0.36
0.43
10 MGD
50 MGD
100 MGD
0.83
1.86
3.07
0.93
1.96
3.27
0.47 0.98
TABLE NO. 2B
2.06
3.40
-------
WASTEWATER TREATMENT
Activated
Wastewater Treatment
Raw wastewater pumping
Pretreatment Primary
sedimentation
Aeration
Final sedimentation
Recirculation pumping
Chiorination
Sludge Handling
Primary sludge pumping
Sludge digestion
Sludge drying beds
or
Sludge lagoons
Primary sludge pumping
Sludge digestion
Sludge holding tanks
Vacuum filtration
Primary Sludge pumping
Sludge holding tanks
Vacuum fiItration
Incineration
COMPLEXITY FACTORS ACTIVATED SLUDGE
1 MGD 10 MGD 50 MGD 100 MGD
0.39
0.46
0.89
1.0*
0.50 1.05
TABLE NO. 2C
2.0
3.31
2.11
3.52
2.22 3.66
*BASE PLANT
-------
SECTION XXI
ACKNOWLEDGEMENTS
The data received through personal communications with wastewater treat-
ment plant superintendents, consulting engineers and operation and main-
tenance staff personnel with the EPA is gratefully acknowledged.
The support of the project by the Office of Water Programs Operations,
U.S. Environmental Protection Agency, and the help provided by Mr. Royal
C. Thayer, the Project Officer, is acknowledged with appreciation.
223
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SECTION XXII
REFERENCES
1. Federal Guidelines, Design Operation and Maintenance of Waste Hater
Treatment Facilities , Sept. 1970.
2. Comptroller General of the United States, Report to the Congress,
Need for Improved Operation and Maintenance of Municipal Haste
Treatment Plants, Date Sept. 1, 1970.
3. Michel, R. L. , Pelmotor, A. L. ; Palange, R. C.; "Operation and
Maintenance of Municipal Waste Treatment Facilities", J. WPCF,
Vol. 41, No. 3, p. 335, (March 1969).
4. Recommended Standards for Sewage Works, Great Lakes - Upper
Mississippi River Board of State Sanitary Engineers, Health
Education Service, Albany, New York.
5. Sewage Manual , Division of Sanitary Engineering, Pennsylvania
Department of Health, 1971.
6. Michel, R. L., "Costs and Manpower for Municipal Waste Water Treat-
ment Plant Operation and Maintenance, 1965-1968", J. WPCF, Vol. 42,
No. 11, P. 1183 (Nov. 1970).
7. Garber, W. F. , "Treatment Plant Equipment and Facilities Maintenance",
j. WPCF, Vol. 42, No. 10, p. 1740 (Oct. 1970).
8. FWPCA Sewage Treatment Plant Operation and Maintenance Questionnaire.
9. Report for EPA, "Estimating Costs and Manpower Requirements for Con-
ventional Wastewater Treatment Facilities", Contract No. 14-12-462.
225
-------
10. "Recommendations for Minimum Personnel Laboratory Control and Record
for Municipal Waste Treatment Works", Presented at 38th Annual Meet-
ing, Conference of State Sanitary Engineers (June 1963).
11. Nelson, M. K., "Operation and Maintenance - A Responsibility of the
Design Engineer", J. WPCF, Vol. 36, No. 11, p. 1415 (Feb. 1967).
12. WPCF Publication No. 18, "Simplified Laboratory Procedures for Waste-
water Examination", 1969.
13. Standard Methods for the Examination of Water and Wastewater, 13th
Edition, 1971.
14. WPCF Manual of Practice No. 8, "Sewage Treatment Plant Design", 1967.
15. WPCF Manual of Practice No. 11, "Operation of Wastewater Treatment
PI a, os", 1966.
16. WPCF Manual of Practice No. 1, "Safety in Wastewater Works", 1967.
17. WPCF Manual of Practice No. 9, "Design and Construction of Sanitary
and Storm Sewers", 1969.
18. WPCF Manual of Practice No. 7, "Sewer Maintenance", 1966.
19. Operations Manual for 7.5 MGD Water Reclamation Plant, South Tahoe
P.U.D., Sept. 1967.
20. Operations and Maintenance Manual, Sewage Treatment Plant, Culpeper,
Virginia
21. Operations Manual for the 1.0 MGD Water Pollution Control Facility,
Greater Manassas Sanitary District, Manassas, Virginia, July, 1968.
226
-------
22. WPCF Manual of Practice No. 3, "Regulation of Sewer Use", 1968.
23. "Glossary - Water and Wastewater Engineering", ASCE, New York,
New York (1969)
24. "Manual of Instruction for Sewage Treatment Plant Operators", New
York State Department of Health, Health Education Service, Albany,
New York.
25. WPCF Manual of Practice No. 16, "Anaerobic Sludge Digestion", 1968.
26. Campbell, E. H. , "City Control of Industrial Wastes in Municipal
Sewers", Sewage and Industrial Wastes, Vol. 30, No. 4, p. 562
(April 1958).
27. Rown, P. 0.; Jenkins, K. L. ; and Howells, D. H.; "Estimating Sewage
Treatment Plant Operation and Maintenance Costs", Journal WPCF,
Vol. 33 Mo. 25 p. Ill (Feb. 1961).
28. Bustard, W. B., "Electrical Maintenance in Sewage Treatment Plants",
Journal WPCF, Vol. 32, No. 1, p. 99 (Jan. 1960).
29. Mick, K. L. , "Paints and Painting", Journal WPCF, Vol. 32, No. 1,
p. 104 (Jan. 1960).
30. Meier, E. B. , "Plant Maintenance and the Consulting Engineer",
Journal WPCF, Vol. 32, No. 6, p. 658 (June 1960).
31. Rapp, W. F., Jr., "Sewage Lagoon Maintenance", Journal WPCF, Vol. 32
No. 6, p. 660 (June I960),
32. Scott, D, P., "Digestion Tank Maintenance", Journal WPCF, Vol. 32,
No. 6, p. 668 (June 1960).
227
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33. Leaver, R. E. , "Primary Clarifier Operating Guide", Sewage and
Industrial Hastes, Vol. 30, No. 10, p. 1303 (Oct. 1958).
34. Bowers, M., "Tips on Sludge Drying Bed Care", Sewage and Industrial
Wastes, Vol. 29, No. 7, p. 835 (July 1957).
35. Shafer, S. W. , "Initial Digester Start-Up at Alexandria, Virginia",
Sewage and Industrial Wastes, Vol. 29, No. 10, p. 1190 (Oct. 1957).
36. Ehrenfest, P., "Sewage Pump Bearings and Packing", Sewage and Indus-
trial Hastes, Vol. 29, No. 10, p. 1199 (Oct. 1957).
37. "Proper Pump Maintenance", Sewage and Industrial Hastes, Vol. 29,
No. 10, p. 1203 (Oct. 1957).
38. Krapp, L. , "Pump Bearing Maintenance", Sewage and Industrial Hastes,
Vol. 29, No. 11, p. 1313 (Nov. 1957).
39. "Parts Inventory Control", Sewage and Industrial Hastes, Vol. 29,
No. 1, p. 102 (Jan. 1957).
40. Pfreimer, H. A., "Preventive Maintenance of Air Force Sewage Works",
Sewage and Industrial Hastes, Vol. 29, No. 3, p. 309 (March 1957).
41. Evans, L. M., "Centrifugal Pump Noise Control", Sewage and Industrial
Wastes, Vol. 28, No. 12, p. 1507 (Dec. 1956).
42. "New Products for Spring Painting", Sewage and Industrial Wastes,
Vol. 28, No. 5, p. 704 (May 1956).
43. "Piping Color Codes", Sewage and Industrial Wastes, Vol. 28, No. 6,
p. 813 (June 1956).
228
-------
44. Campbell, M. S., "Sewage Pumping", Sewage and Industrial Wastes,
Vol. 28, No. 8, p. 1042 (Aug. 1956).
45. "How To Pack A Stuffing Box", Sewage and Industrial Wastes, Vol. 28,
No. 8, p. 1060 (Aug. 1956).
46. Quartly, E. V., "The Responsibility of the Administrator and the
Operator," Sewage and Industrial Wastes, Vol. 27, No. 9, p. 1080
(Sept. 1955).
47. "Trouble Chart for Centrifugal Pumps", Sewage and Industrial Wastes,
Vol. 27, No. 7, p. 867 (July 1955).
48. Had ley, N. L. and Potthoff, E. 0., "Electric Power Reliability in
the Sewage Plant", Sewage and Industrial Wastes, Vol. 27, No. 4,
p. 393 (April 1955).
49. Strudgeon, G., "Operation and Maintenance of Sewage Pumps", Sewage
and Industrial Wastes, Vol. 27, No. 4, p. 506 (April 1955).
50. Garno, R. A., "Cleaning Digesters at Niles, Michigan", Journal WPCF,
Vol. 33, No. 9, p. 996 (Sept. 1961).
51. Pierce, D. M., "The Primary Sedimentation Tank - Control Center of
the Treatment Plant", Journal WPCF, Vol. 32, No. 9, p. 1015 (Sept.
1960).
52. Chanin, G., "Low-Cost Lab and Simple Records", Sewage and Industrial
Wastes, Vol. 31, No. 1, p. 97 (Jan. 1959).
53. Olewiler, G. M. , "Sewer Maintenance - Panel Discussion, Records and
Permits", Sewage and Industrial Wastes, Vol. 31, No. 3, p. 307
(March 1959).
229
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54. Beatty, E. J., "Economical Practices in Sewage Treatment Plant
Operation", Sewage and Industrial Wastes, Vol. 31, No. 6, p. 753
(June 1959).
55. Short, F. , "Small Plant Safety Hazards", Sewage and Industrial Wastes,
Vol. 30, No. 1, p. 93 (Jan. 1958).
56. Goodman, S. H., "Sewer Maintenance in Santa Clara County, California",
Sewage and Industrial Wastes, Vol. 30, No. 1, p. 101 (Jan 1958).
57. Newell, W. A., "An Operator Views Plant Operation and Design",
Sewage and Industrial Wastes, Vol. 30, No. 8, p. 1057 (Aug. 1958).
58. Thayer, R. C., "Mechanical Maintenance Program", Sewage and Indus-
trial Wastes. Vol. 30, No. 9, p. 1194 (Sept. 1958).
59. Kronewitter, R. A., "Maintenance of Collector and Conveyor Equipment",
Journal WPCF, Vol. 35, No. 1, p. 123 (Jan. 1963).
60. Ross, E. E., "Safety Aspects of Sewer Maintenance", Journal WPCF,
Vol. 35, No. 4, p. 469 (April 1963).
61. Goff, J. D. , "Records and Reports for Wastewater Treatment Plants",
Journal WPCF, Vol. 35, No. 8, p. 1017 (Aug. 1963).
62. Wirts, J. J., "Sludge Pump Maintenance", Journal WPCF, Vol. 35,
No. 10, p. 1290 (Oct. 1963).
63. McDaniel , S. L. , "Severe Operating Conditions and Their Effect on
Lubricants", Journal WPCF, Vol. 35, No. 11, p. 1474 (Nov. 1963).
64. Betz, J. M.; Garber, W. F.; and Thwaytes, G. W. ; "Collector Chain
Maintenance at Hyperion", Journal WPCF, Vol. 35, No. 11, p. 1486
(Nov. 1963).
230
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65. Hemphill, H, B. , "Lubrication of Equipment", Journal WPCF, Vol. 34
No. 2, p. 145 (Feb. 1962).
66. Thayer, R. C. , "Pump Operation and Maintenance", Journal WPCF.
Vol. 34, No. 6, p. 616 (June 1962).
67. Bernhardt, C. J., "Public Relations Value of Annual Operating
Reports", Journal WPCF. Vol. 34, No. 9, p. 901 (Sept. 1962).
68. Thwaytes, G. W., "Settling Tank Maintenance at Hyperion", Journal
WPCF, Vol. 34, No. 12, p. 1235 (Dec. 1962).
69. Quirl, N. , "Trickling Filters: Operation and Maintenance", WPCF
Highlights, Vol. 9, No. 8, p. D-6 (August 1972).
70. AWWA, Water Quality & Treatment, 3rd Edition, A Handbook of Public
Water Supplies.
71. Operations and Maintenance Manual, Westerly Wastewater Treatment
Plant, Marlborough, Massachusetts, August, 1971.
72. Operation and Maintenance Manual, Sewage Treatment Facility, Ester,
Missouri , 1972.
73. Operation and Maintenance Guide, Wastewater Treatment Facilities,
Huntsville, Missouri, 1972.
74. Operation and Maintenance Manual, Waste Treatment Facility, Winnebago,
Illinois, 1971.
75. "Requirements and Suggested Guide For an Operation and Maintenance
Manual For Waste Treatment Facilities", EPA Region X, 1971.
231
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76. Operation and Maintenance Manual, Advanced Waste Treatment Facility,
Coll insvilie, Illinois, 1972.
77. Operation and Maintenance Manual, Sewage Treatment Plant, Gillett,
Wisconsin, 1971.
78. Operation and Maintenance Manual, Shoal Creek Wastewater Treatment
Plant, Joplin, Missouri, 1972.
79. Operation and Maintenance Manual, Wastewater Treatment Plant,
Staplehurst, Nebraska, 1970.
80. Operation and Maintenance Manual, Water Pollution Control Facilities,
Cresco, Iowa, 1972.
The attached tabulation gives references for each of the chapters recom-
mended for an 0 & M Manual.
232
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EPA MANUALS
Considerations For
Preparation of
Operation and
Maintenance Manuals
Procedural Manual
For Evaluating The
Performance of
Wastewater Treatment
Plants
Estimating Laboratory
Needs for Municipal
Wastewater
Treatment Facilities
Estimating Costs and
Manpower Requirements
for Conventional
Wastewater Treatment
Plants
Estimating Staffing
for Municipal
Wastewater Facilities
Maintenance Management
Systems for Municipal
Wastewater Facilities
Emergency Operating
Procedures For
Municipal Wastewater
Treatment Facilities
A Planned Maintenance
Management Program
Emergency Response
Program For Municipal
Wastewater Treatment
Facilities State and
Local Aspects
Safety In The Design,
Operation and
Mantenance of
Wastewater
Treatment Works
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ES
UT
ECTRICAL
MISCELLANEOUS REFERENCES
Manual of Wastewater
Operations, Texas
Water Utilities
Association
Manual of Instruction
For Sewage Treatment
Plant Operators,
New York State
Department of Health
Chlorine Manual
Chlorine Institute
X X X X X X
X X X X X
235
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SECTION XXIII
APPENDICES
237
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ASSOCIATED EPA PROGRAMS
The Environmental Protection Agency is developing several manuals to
assist in the proper operation and maintenance of municipal wastewater
treatment plants. These manuals may be useful in preparing an 0 & M
Manual.
A Planned Maintenance Management Program, Project No. 11010 GWI
Estimating Staffing for Municipal Wastewater Treatment Facilities,
Contract No. 68-01-0328.
Estimating Laboratory Needs For Municipal Wastewater Treatment Facilities,
Contract No. 68-01-0328
Emergency Operating Procedures for Municipal Wastewater Treatment Facil-
ities, Contract No. 68-01-0341
Maintenance Management Systems for Municipal Wastewater Facilities,
Contract No. 68-01-0341
Emergency Response Program for Municipal Wastewater Treatment Facilities -
State and Local Aspects, Contract No. 68-01-0341
Start-up of Municipal Wastewater Treatment Plants, Contract No. 68-01-0341
Middle Management Concepts for Municipal Wastewater Operations, Contract
No. 68-01-0341
Procedural Manual for Evaluating The Performance of Wastewater Treatment
Plants, Contract No. 68-01-0107
Safety In The Design, Operation and Maintenance of Wastewater Treatment
Works, Contract No. 68-01-0324
238
-------
Design Criteria for Mechanical, Electric, and Fluid System and Component
Reliability, Contract No. 68-01-0001.
Methods for Chemical Analysis of Water and Waste, GPO Stock No. 5501-0067,
239
*U.S. GOVERNMENT PRINTING OFFICE: 1V73 546-309/31 ;_3
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