------- ------- ------- THE ON-SITE OPERATOR TRAINING PROGRAM This assistance is truly affordable, too: the community need pay nothing but the price of any larger improve- ments that troubleshooters might recommend. A TARGETED SOLUTION AT A PRICE THAT'S RIGHT The On-Site Operator Training Program is also a bargain for the nation as a whole. The average federal expendi- ture per facility is about $6,000. The 104(gXl) program regularly brings failing plants into compliance with their water quality goals. Some are plants whose municipal managers were ready to abandon them and build a new facility. Clearly, a $2 million program that saves just one community per year from major capital costs is well worth its price tag. How can the program operate so thriftily? One reason is its low administrative costs. EPA makes grants directly to each State. Program managers in the appropriate environmental department either carry out the plant evaluations themselves or contract these tasks out to private local firms or universities. The staff stays small: typically two or three people per State. A PEER RELATIONSHIP MAKES TROUBLESHOOTING WORK The On-Site Operator Training Program has generated a tremendous amount of trust and cooperation at the grass- roots level. Prescriptions for plant improvement are never "cook-book" or theoretical. Most "104" trou- bleshooters and Regional coordinators have actually been wastewater treatment plant operators. These expert evaluators know what they're talking about They bring knowledgeable, hands-on solutions to each plant they visit Operators and municipal managers are eager to listen to these visitors who speak their language, understand their concerns, and fix their problems. THE PROGRAM IS EXTREMELY POPULAR Although participation in this low-key program is com- pletely voluntary and publicity is limited to small mail- ings and word-of-mouth advertising, community re- sponse has been enthusiastic. Training center staff in each State make annual commitments as to the number of plants they will serve, but demand runs high. Over the past couple of years, trainers have been exceeding an- nual goals by 150%—often within the original grant budget for the year! More than 2400 plants have been served to date, and between 500 and 600 are being added every year. THE SUCCESS RATE IS OUTSTANDING The most recent program evaluation showed that of the 2,525 troubled plants getting technical assistance since 1983, 50% achieved compliance with their assigned water quality standards. Twenty-five percent more made dramatic improvements in other areas. WHAT DO "104(g)" TRAINERS EVALUATE? 1. Existing Facilities, for • Performance Limitations • Existing Capacity 2. Process Control, for • Adjustment • Physical Correction 3. Laboratory Work, for • Adequate Equipment • Correct Sampling Techniques and Analyses 4. Staffing Adequacy, for • Appropriate Size • Level of Expertise 5. Financial Systems, for • User Charge Adequacy • Replacement Strategies ------- THE ON-SITE OPERATOR TRAINING PROGRAM How does the On-Site Operator Training Program de- fine "success"? Most people first think of a clean effluent from the plant This is indeed an important measure, and one that is often attained. The program is tapped by many communities with other plant and town management problems as well. And by still others that are ready to write off a failing plant but are willing to try one last-ditch effort to turn it around. What kind of successes can troubleshooters claim for these partici- pants? "It costs money to talk to engineers, but we get good free advice from the (104(g)' trainer" Greg Durbin, Crystal Mountain Treatment Plant Crystal Mountain, Washington Stories featuring both compliance achievement and other successes appear in this pamphlet. In brief, those "other" successes can be: • Improved operations, maintenance, and appearance; • Improved harmony between plant staff and town managers; • Reduction in operator turnover, a benefit for both the plant and the profession; • Improved utilization of staff; • Enhanced expertise in lab and process control; • Small-scale plant repairs that boost longevity or streamline process control; • Establishment of better financial systems and sinking funds; Cost containment; Identification of design and construction problems; Stop-gap improvements in poor effluent to at least minimize the problem until permanent measures can be taken; Corrective and preventive maintenance systems that extend equipment life. SUCCESSES FALL INTO THREE CATEGORIES When Regions were asked to provide information on the "stars" of the "104(g)" program, the success stories they provided were rich in diversity and innovation. Solu- tions to problems seemed to be the most useful and logical way to organize the data, and three categories soon revealed themselves: 1. Training —Improving operators' and man- agers' understanding of their plant and its processes; 2. Facility Correction—Making simple, low- cost, physical adjustments and improvements that cor- rect performance; and 3. Facility Management—An "other" cate- gory that includes the management of such factors as infiltration and inflow, finances, communications, staff- ing, and industrial loading. Sample success stories follow. A full spectrum of the preeminent successes contributed by the Regions is displayed in the center of this booklet: virtually every State boasts at least one. Indeed, On-Site Operator Training troubleshooters believe that some measure of success was achieved in every single plant they visited. ------- ------- APPROACHES TO SUCCESS: TRAINING TRAINERS DISCOVER A WIDE RANGE OF PROBLEMS Training and management approaches account for at least 70% of "104" successes. In many cases, the plant design is not faulty: its poor performance usually has a human cause. Still, troubleshooters in the On-Site Operator Training Program deploy their training func- tion for far more than sizing up individual expertise. When these evaluators listen to an operator's concerns, watch his procedures, read his reports, and note his mistakes and omissions, they learn a great deal about the facility's soundness. They take stock of the plant's community support, equipment, staffing, budget and users. The need for customized training at small treatment plants is intense and has everything to do with commu- nity size. Plants in the 0.1 to 1.0 mgd range are the most basic level of sewage treatment. Operator turnover is high. Operators move to the larger plants and often don't stick around to train their replacements. Low budgets mean discouraging salaries. The result small plants are usually staffed by novices and employee morale is often lacking. So the On-Site Operator Training Program is a low- budget solution for small communities. Training and technical assistance does make a difference at a fraction of the cost of an enforcement action. As a testament to that claim is the fact that half the communities visited were permit violators brought back into compliance by O&M trainers. This clearly measurable success is tending to drive program activities toward achieving compliance, although it is clear from the stories in this book that many different kinds of successes have been attained. Experience at hundreds of plants makes it safe to say that: • Most small-scale wastewater treatment plant problems can be easily fixed; • Even at plants where effluents aren't bad, performance still can be dramatically improved; • Training cannot be an afterthought: towns can't spend millions on a plant upgrade and neglect to train the operator, • Training must not be theoretical or long- distance: effectiveness is directly related to hands-on demonstration; and • Training is a morale booster it shows plant operators that their labors are worthy of respect, • Training must go hand-in-hand with getting local officials involved in the day- to-day operation of the plant Training leads very straightforwardly to improvements in plant performance. The success stories that follow focus on training within the walls of the treatment works, training that improves the ability and expertise of plant operators. The equipment repair issues and community-related wastewater management issues that also arise as part of many plant evaluations have their own success stories and are discussed separately. "If it would not have been for a dedicated effort by the Technical Assistance Team our town would stitt be in non-compliance and paying stiff fines. They came in and worked with our wastewater staff and solved many operational problems in a relatively short time. This pleased our town administrator, DHEC personnel, and saved the tax payers many hundreds of dollars" Jody Wilson, Wastewater Superintendent, Manning, South Carolina ------- SUCCESS STORIES: TRAINING TRAINING: IMPROVED OPERATOR UNDER- STANDING IS KEY TO PROGRAM SUCCESS Bloomfield, New Mexico Plant Size: 0.9 mgd Treatment Type: Activated Sludge FROM MURKY GRAY TO "BEST EFFLUENT EVER" Bloomfield's conventional activated sludge plant was in a serious state of upset when the "104(g)" trainers arrived for an evaluation. A murky dark grey effluent was discharging from the secondary clarifiers and a black sludge had accumulated in the system as far as the chlorine contact chamber. Process performance had been poor for more than a year and had recently become worse due to continued operator error. BOD in effluent samples had fluctuated widely: 69 mg/1 at one time; 115 mg/1 at another. The field trainer closely examined process control and showed operators how to correct the situation. They: • Accelerated the wasting schedule and adjusted the sludge blanket to optimum depth; • Reduced D.O. in the aeration basins to promote floccing and settling; • Cleaned the black sludge from the aeration basin and the chlorine contact chamber, and • Improved laboratory analysis techniques to bring accuracy to effluent quality data. Within several weeks the Bloomfield plant had attained acceptable effluent quality. Two more months of edu- cating operators and fine tuning the process resulted in the plant turning out its best effluent ever. Before After Permit BOD mgll 69-115 10 30 Boone, Iowa Plant Size: 5.5 mgd Treatment Type: Trickling Filter PLANT UPGRADE LEAVES OPERATORS WITH OBSOLETE EXPERTISE What happens when a plant upgrade leaves operators with obsolete expertise? The "104(g)" evaluators dis- covered this situation in Boone, Iowa where the waste- water plant had been recently upgraded. The upgrade included the use of aerated sludge holding basins. Operators were unfamiliar with operation and mainte- nance of various new laboratory items and related proce- dures, and were experiencing difficulty with EPA audit sample protocols and lab procedures related to plant Excellent O&M practices keep the final effluent well within permitted levels at the Atlantic Plant in Virginia Beach, Virginia. ------- SUCCESS STORIES: TRAINING discharge monitoring. In addition, staff were having problems with the aerated sludge holding basins - - a new technology at the plant Trainers from Kirkwood Community College educated Boone staff on: • Aerated sludge holding tank operation and monitoring (Additional blower capacity was added to improve oxygen transfer and reduce odors); • BOD and NH3 lab procedures and trouble shooting; • Standard methods lab procedures; and • Use of lab equipment (D.O. and pH meters, analytical balance, incubator, water distilla- tion and deionizing equipment). Fifty-two hours of training over a year and a half consid- erably improved the performance of the lab and im- proved overall operations at the plant Now in compli- ance, the Boone facility proudly displays the following before and after data: his predecessor. As a result the "104" evaluator logged numerous problems with laboratory procedures, process control, maintenance, and financial management Discharge Monitoring Report pMR) data, required by the plant's permit, were based on improper laboratory procedures; therefore, it was not surprising that the Br- idgeport plant had never reported or been cited for effluent violations. Even though no enforcement sword hung over their heads, town managers were enthusiastic about improving plant performance and getting their new operator trained right from the start The "104" troubleshooter helped update lab equipment and proto- cols, develop a sludge disposal program, and bring equipment maintenance up to date. Unlike most troubled plants, Bridgeport never seemed to be in violation because of questionable monitoring data. Genuine improvements in plant operations have now been made bringing with them valid DMRs of which the town can be proud. BOD mgll TSS mgll Before 70 54 After 16 22 Permit 30 30 Bridgeport, Washington Plant Size: 0.2 mgd Treatment Type: Oxidation Ditch NO VIOLATOR, WASHINGTON PLANT STILL RECOGNIZED ITS NEED FOR HELP The local press release said that Bridgeport's new waste- water treatment plant operator had literally turned plant operations around. The new operator had inherited a troubled 20-year-old plant. It was suffering from low maintenance and a lack of problem-solving on the part of The attention paid to maintenance is evident at this Ohio wastewater treatment plant. ------- SUCCESS STORIES: TRAINING Buchanan Village, New York Plant Size: OSS mgd Type Treatment: Activated Sludge OPERATOR TRAINING FOSTERS CONTINUING SUCCESS Excessive suspended solids were the chronic problem that brought "104(g)" evaluators to Buchanan Village's wastewater treatment plant. The facility had been in violation of New York's Pollution Discharge Elimination System limits for eight consecutive months. Would education on improved process control turn the tide? Plant managers and operators were enthusiastic about the possibility. O&M troubleshooters found an old plant in fairly good shape, but process control was shaky. The final clarifiers were septic and very turbid. The operator was collecting few samples and analyzing little data, and was controlling sludge wasting via settleability. The result was poor settling and a turbid effluent. Furthermore, sludge had not been hauled from the plant in over two years. Periodic industrial "slug" loading and infiltration/inflow (1/1) prob- lems aggravated the situation. While they made recommendations for controlling fac- tors outside the plant, O&M evaluators decided to focus attention on quick-payback parameters like training and process control. Together with plant personnel, they: • Developed a comprehensive testing program that covered MLSS, D.O., blanket depth, settleability, flow data, and micro- scopic and physical observations; • Designed a strategy for controlling return and wasting rates; • Instituted the collection of 6-hr, composite samples of influent and effluent; • Put the second clarifier on line; and • Initialed a complete preventive mainte- nance program. The program's recommendations and actions resulted in cleaner effluent for Buchanan Village, well within per- mit limitations. Plant personnel now fully understand their facility's characteristics and needs, and success is expected to continue. Clanks Summit, Pennsylvania Plant Size: \2 mgd Treatment Type: Extended Aeration CLASSIC TRAINING OF EAGER STAFF WINS COMPLIANCE A diagnostic evaluation targeted Clarks Summit early as a likely candidate for improvement through training. Readily identifiable problems, an interested plant staff, and the sudden availability of new lab equipment all con- spired to make this Pennsylvania plant a priority candi- date for assistance. Pumps and other essential equipment should be installed in pairs whenever possible to minimize the amount of time which the plant must be shut down for repairs. Operations at Clarks Summit suffered due to inadequate laboratory procedures, unsatisfactory process control strategies (particularly sludge wasting), and limited flexi- bility in plant processes and sludge handling capabili- ------- ties. The approach took three main avenues: in-plant technical assistance, laboratory training, and classroom training. The results? The activated sludge process has been considerably improved, and lab procedures and quality control are now exceptional. The plant is well in compli- ance, with effluent data as follows: Before After Permit BODS mgll 71 10 22 TSS mgll 46 16 25 NH3 mgll 0.4 1.0 1.5 Green River, Utah Plant Size: 03 mgd Treatment Type: Lagoon FAST, CONCENTRATED TRAINING PROTECTS LOCAL ECONOMY The operator of the treatment plant contacted the Utah Valley Community College Operator Training Center seeking assistance to problems affecting his plant. He was under intense pressure because the plant process had been upset and the resulting severe odors had nearly ruined the tourist trade. This was a particularly severe problem as the town's economy was dependent almost entirely upon the tourist trade. Arrangements were made for the outreach trainer and the operator to meet at the plant During the evaluation the trainer observed that the four lagoons had low pH and dissolved oxygen levels. It was found that a lack of understanding of the plant's processes had caused the upset. The primary cell was overloaded and the storage cell had developed a serious filamentous algae condi- tion, which had caused the odor problem. Training was provided in pH and D.O. testing and their relation to process control was also presented to the operator. Strategies for assisting the operator in running the plant such as the use of irrigation return flows were developed. Offensive odors have now been eliminated and the com- munity is no longer angry over the situation at the treatment plant The plant has been operating without in- cident since the on-site assistance was provided Green River is an example of the ability of the "104" program to respond on short notice to operators who find them- selves in difficulties or situations with which they have had little or no experience. Waverly, Illinois Plant Size: 0.4 mgd Treatment Type: Activated Sludge (Walker Process Package Plant) IMPROVED UNDERSTANDING OF PROCESS CONTROL GETS OUTSTANDING RESULTS Why do package plants frequently get mixed reviews on performance and cost effectiveness? One answer might be the one found at Waverly, Illinois: process control was out of control. State "104" investigators deter- mined that the facility should be capable of meeting interim permit limits by a wide margin, yet BODS was in violation and the City's data showed frequent violations of fecal coliform bacterial limits. Recommendations from the "104" trainer focused on plant-wide monitoring and process improvements. The City of Waverly: • Improved chlorination techniques to provide adequate disinfection; • Upgraded laboratory equipment, sampling procedures, and reporting methodologies to achieve valid lab results; • Increased solids wasting, optimized drying beds and kept the sludge blanket under control; ------- SUCCESS STORIES: TRAINING • Changed the existing complete mix aeration system to an extended aeration system, eliminating short circuit- ing and reducing solids loading; and • Eliminated use of a polishing pond that was actually degrading effluent quality. Improving process control and educating staff on how to monitor and maintain it led to dramatic improvements at the Waveriy plant All problem parameters achieved not just interim, but final permit limit compliance within a year of the initial evaluation. West Rutland, Vermont Plant Size: 0325 mgd Treatment Type: Extended Aeration STARVING A SYSTEM TO DEATH When West Rutland's major industry closed its doors, the town suffered a severe economic setback. One of the first victims of the municipal belt tightening was the sewage treatment plant Within a few years the effects of an inadequate budget began to take their toll. The facilities began to decline and operators came and went with increasing frequency. By the time "104" help was accepted, the plant was run by a single, part-time opera- tor. Pump stations and mechanical systems were poised on the brink of disaster. The treatment process was in disarray and permit violations were routine. Suddenly, things changed. The town elected new man- agers who, while still frugal, began system improve- ments. Notable among them were infiltration/inflow repairs to the sewer system and a decision to ask for help from the "104" program. The troubleshooter got a receptive welcome. West Rutland hired two plant operators who were new, green, and anxious to learn. Municipal officials, too, were en- thusiastic about the training sessions, and several partici- pated with good effect A change in attitude, mutual cooperation, and delivery at a most receptive moment these all spelled success in West Rutland. The system was transformed from a failure to an award winner it received 2nd place in 1987's Green Mountain Water Pollution Control Asso- ciation (GMWPCA) competition and an EPA Region I Operation and Maintenance Excellence award in 1988. The results were outstanding: • Fully certified operators; • Excellent maintenance system-wide; • Good quality effluent; • A sufficient O&M budget; and • A new sinking fund for costly replacement and repair. 1 Adequate, well maintained solid handling equipment is essential to successful plant operation. 10 ------- APPROACHES TO SUCCESS: FACILITY CORRECTION TAILORED EQUIPMENT MODIFICATION GETS PLANTS TO RUN CORRECTLY When people aren't the problem behind poor plant performance, equipment often is. The On-Site Opera- tor Training Program clearly doesn't have the budget to provide assistance concerning large-scale facility cor- rections. Traditionally, though "704" troubleshooters have helped fix small deficiencies, sometimes with startling success. Bigger problems have been turned over to the community, often urging their recommen- dations through to completion. Many of the hardware problems evaluators discover can be traced back to basic omissions at the design stage that ultimately come home to roost with a community that had blind faith in its plant design. It occurs to neither operator nor town manager that the hardware could be the problem. But plant operators may simply not be getting what they need for wastewater success from the outset Unfortu- nately, many design firms don't give enough attention to "Success means being able to quantify the value of training by moving a treat- ment facility from non-compliance, through on-site diagnosis and train- ing" Jack Samson, EPA Program Director, Wastewater Training Grants designing an effective system for small towns. They often prescribe off-the-shelf technology and methods or try to scale back a design intended for a much bigger city without tailoring it One of the major problems that result is lack of system flexibility. When large designs are rescaled for small towns, a ten-clarifier system can become a large one- clarifier system, with no room built in for equipment failure. Furthermore, small systems are often patched A well maintained state certified lab has helped make the Somerset-Baker treatment plant in New York an O&M award winner. together with "mix and match" equipment, often over- sized for their needs. What "104" troubleshooters bring to each small system is a creative ability to tailor the plant's equipment to on- site needs. Most of them have been in numerous small towns and facilities and really understand their needs and capabilities. They reposition a pipe here, change the function of a clarifier there, take a problem aerator off line, rearrange the system to make it more efficient. They install baffles, level weirs, identify leaking tanks. And these O&M evaluators are often amazed and impressed at the initiative operators have themselves shown in jerry-rigging and repairing problem equip- ment. In many cases, troubleshooters and operators have tinkered with the physical plant until they get it to run right, often circumventing really major problems with effluent quality and facility design. The success stories that follow reflect the creativity and, in some cases, humor that arise from their interactions. 11 ------- SUCCESS STORIES: FACILITY CORRECTION Barnesville, Georgia Plant Size: 0.75 Treatment Type: Activated Sludge CHEMICAL ADJUSTMENT FORESTALLS EQUIPMENT INSTALLATION Sometimes physical plant correction can be forestalled by corrective chemical treatment. This turned out to be the case in Barnesville, where frequent high flows aggra- vated solids billowing in the final clarifier. These escaping solids were degrading effluent quality. The "104" facilitator determined that the key problem was poor baffling in the clarifier, and considered installing baffles. First, however, chemical treatment was at- tempted. Chemical dosage requirements were analyzed, and liq- uid alum was metered into the clarifier. Billowing ceased almost immediately as the process was locked into proper equilibrium. As settling rates began to capture solids efficiently, the dosage to the clarifier was reduced. Within two months, sludge quality was re- stored and the sludge mass control program had "kicked in." Improvements were more dramatic than recorded data might indicate, since it is very likely that operators didn't take their samples when the clarifiers were billowing. Clayton Village, New York Plant Size: 030 mgd Treatment Type: Activated Sludge A BREATH OF FRESH AIR When a smelly sewage treatment plant offends the summer tourists, it's time to call for help. New York's Clayton Vil- lage had experienced the olfactory re- sults of low plant D.O. levels for years. In addition, the plant had violated BODS and TSS limits on several occasions. Attempts to fix the problem had failed until the "104" troubleshooter showed up. He installed a new blower and more diffusers to improve oxygen transfer. He also recommended operational im- provements, a preventive maintenance scheme, and a public relations campaign. The result? The odors are gone, BODS and TSS levels have plummeted, and everyone got to tour the treatment plant Clayton Village is savoring the sweet smell of success. 104(g)(l) Training Results: Barnesville, GA Before After Permit Estherwood, Louisiana Plant Size: 0.08 Treatment Type; Overland Flow REPAIRS CURTAIL INUNDATION AND CLEAN EFFLUENT This tiny system, which had neither a certified operator nor a discharge permit, was plagued with excessive wet weather flows. The system was designed at 0.08 mgd, but at times was inundated at from 0.25 to 0.4 mgd. When troubleshooting began, drainage ditches were severely eroded, untamed grass and weeds were crowd- ing out purifying vegetation, and the chlorination system was inoperable. 12 ------- SUCCESS STORIES: FACILITY CORRECTION The "104" trainers immediately initiated routine grass cutting, repaired erosion damage, and began alternating usage of the two overland flow plots. They rehabilitated the chlorination system and tackled the leaky collection system. Fifty-nine major sources of inflow were discov- ered. Repairs reduced wet weather flows by up to 80%. Results: • Infiltration/inflow reduced by an average of 55%; • Power consumption at lift stations was cut 40%; and • Estherwood's system is now very clean: BODS ranges from 6-14 mg/1; TSS from 4-20 mg/I, and fecal coliform is always < 10/100 ml. Garberville, California Plant Size: 0.06 mgd Treatment Type: Unaerated ponds with percolation ponds SEEKING THE RIGHT LEVEL FOR SUCCESS Sometimes facility correction can be brilliantly simple. The Regional Water Quality Control Board had issued "Those two fellows, from Chicago, came down and did a fine piece of work. They solved the problem and saved us money." Jimmy Wright, Mayor Linton, Indiana "cease and desist" orders to the Garberville plant be- cause of frequent bacterial violations. This was serious business: effluent from gravelly percolation ponds was entering a source of downstream water supply. Why was chlorine demand so high, so widely variable, and so often ineffective? The trainers discovered that effluent was being drawn off near the bottom of the third- stage pond. The result high levels of suspended organic solids in the stream to be chlorinated! The two troubleshooters recommended that the drawoff pipe be modified to allow control of the depth at which effluent could be removed. After several months, the final effluent flowing to the Eel River was well within permit limitations. Heppner, OR Plant Size: 0.250 mgd Treatment Type: Trickling Filter THE 590 SOLUTION The old trickling filter plant at Heppner, Oregon was consistently violating fecal coliform limits. The plant has no recycle, and its overworked operator was removing sludge from the clarifier only once a day. The troubleshooting team helped the operator work on the chlorine system. They removed the chlorine solution line from the clarifier and rerouted it to the trickling filter discharge line, rigging its end with a 590 garden sprayer nozzle. In addition, the operator began removing sludge twice daily. The Heppner plant came into compliance within three site visits. And there wasn't a single complaint about the cost. 13 ------- SUCCESS STORIES: FACILITY CORRECTION Julesburg, Colorado Plant Size: 0.25 mgd Plant Type: Trickling Filter TIMELY ACTION AVERTS PROBLEM manhole in two open channels. The clean and dirty streams were separated by a wall just 8" high! A blockage or power outage would back up the influent and allow it to spill into the clean-water channel in a very short time. When the "104" troubleshooter arrived in Julesburg, he found an odd design "glitch" in the system. Sewage- filled influent and final effluent passed through the same Kennebunkport, Maine Plant Size: 0.7 mgd Treatment Type: Extended Aeration BETTER COMPOST IN JUST 14 DAYS! Composting sludge is supposed to reduce odors, but Kennebunkport, Maine received more than 100 com- plaints a year about its smelly treat- ment works. This 0.7 mgd ex- tended aeration plant used wood chips to provide bulk to composting sludge, but odor-control techniques were keeping the compost wet. The "104" troubleshooter sug- gested replacing wood chips with wood ash from a nearby biomass boiler and changing the air flow to the piles. Success was dramatic and improved further when opera- tors began using a special strategy for controlling compost tempera- ture. Kennebunkport is now pro- ducing dry sludge compost in only 14 days. The program evaluator recommended that a cement wall be built, and the town administrators grudgingly agreed. Because the facility wasn't staffed at night, the wall was designed to hold back 12 hours of average nighttime flow. There the new wall sat. And sat And sat... until one summer night there was a major power outage at the plant. Next morning, the surprised operator found 13 hours of influent flow backed up in the system: two inches from the top of the wall! The result: A contamination disaster headed off by timely corrective action. Sand Creek, Wisconsin Plant Size: 0.0075 mgd Treatment Type: Two Cell Stabilization Pond A LOW-PRESSURE APPROACH The tiny two-cell stabilization pond system in Sand Creek, Wisconsin was designed simply for a very small flow: 0.0075 MGD. But the system had not had a dis- charge from its primary to its secondary treatment cell since it was started up in 1978! Sand Creek couldn't get a new discharge permit because its plant wasn't operat- ing as designed: It never achieved secondary treatment. About 7^00 gallons was leaking from the bottom and sides of the primary tank every day. Proposals to reline or modify the cell were rejected as being too costly. The O & M troubleshooter suggested dropping the water level in the primary cell by one foot to relieve hydraulic pressure on the seal. Success was startling: a continuous discharge of between 3,000 and 19,000 gallons a day began immediately! Effluent BODS dropped to below 30 mg/1. The pressure was off Sand Creek. 14 ------- SUCCESS STORIES: FACILITY CORRECTION Sandy Hook, Kentucky Plant Size: 0.07 mgd Treatment Type: Extended Aeration PLANT CORRECTIONS MEET WATER QUALITY STANDARDS AND CUT COSTS The Sandy Hock treatment plant was out of compliance. Operations were in a slump: the surge tank did nothing more than "slug load" the treatment process, and effluent from a nonfunctional sand filter was bypassing the chlorine contact tank. Low dissolved oxygen prevailed plant-wide. Effluent quality was poor and operating costs were very high. The on-site evaluators determined that physical correc- tion of the plant could improve its performance and efficiency considerably. They: • Converted the surge tank into an extension of the aeration tank, thus eliminating the surge pumps; • Retired the useless sand filter, converting it to a post aeration basin; • Restored use of the chlorination basin; • Rehabilitated the aeration system; and • Recycled supernatant from the aerobic digester. These improvements cut electricity and in-plant water costs dramatically. The much-improved effluent was used for washdown and chlorine feed During these adjustments, the operator quickly learned the concepts of process control, solids management and sludge dis- posal that further improved effluent quality. Results: • 50% reduction of electricity costs; • 100% reduction of water costs for washdown and chlorine feed; and • BODS and TSS concentrations of less than 10 mg/1 and an ammonia-nitrogen concentration of less than 0.05 mg/1. "My community has benefited in three areas from technical assistance and the State Training Action Plan : certification upgrade, more effective personnel scheduling, and certifica- tion in backflow prevention." Laura Thomas, Mayor Ridgeway, South Carolina Tionesta, Pennsylvania Plant Size: 0.25 mgd Treatment Type: Rotating Biological Contactor (RBQ COMPLIANCE ACHIEVED WITH A FLICK OF THE SWITCH In Tionesta, the "104" trainer showed plant staff that a simple solution can often be the answer to a big problem. Tionesta's sewage treatment plant experienced hydrau- lic overloads almost daily, even in dry weather. These high flows frequently flooded the RBC units and also resulted in the plant being bypassed. While the old combined sewer system contributed some inflow and infiltration, the on-site troubleshooter dis- covered that most of the "real" infiltration/inflow prob- lem was caused by the improper setting of a pump station float switch. It caused the station to pump only when full, and the resulting periodic surge overflowed the plant This situation was exacerbated by the improper setting of the overflow weir, which allowed surges to flood the RBCs. The evaluator also scheduled sludge pumping to the drying beds before wasting from the final clarifiers, and arranged more frequent sludge withdrawal. This ended the problem of overflowing digester contents reentering the influent and organically overloading the RBC. The results? Correction allowed the plant to operate as designed. Furthermore, effluent quality improved. After adjustment, the plant consistently stayed in compliance. 15 ------- 16 ------- APPROACHES TO SUCCESS: FACILITY MANAGEMENT FACILITY MANAGEMENT: LOOKING OUTWARD FROM THE PLANT Facility management covers a wide spectrum of con- Lack of Control Over Users—High or toxic loads, cems. Most of them relate to problems outside the plant shocks from "slug" loading by industry. itself. O&M evaluators can quickly size up the level of expertise of the staff and the adequacy of system design. Poor Communication—Poor morale of staff, unex- If plant performance is notably poor, and in-plant equip- pressed or unmet needs. ment and staffing aren't major problems, it's time to look elsewhere for the solution. Inadequate maintenance is an in-plant problem, but it usually relates back to inadequate staffing or budget. Facility management problems from outside the plant can include: The success stories that follow reflect this wide diver- sity of "other" problems that are neither purely equip- Poor Administration—Inadequate budget, sharing of ment- or purely staff-related. plant personnel with other departments, lack of atten- tion to and care of plant, no financial strategies for replacement and repairs, inadequate user charges. High Flows—Bad infiltration and inflow problems in the collection system. CLUES ON EXISTENCE OF FACILITY MANAGEMENT PROBLEMS Rundown, unkempt plant and poor morale - - Poor support from local officials. Severe fluctuations in effluent quality Slug loading from industry. General poor performance without staff and equipment problems Inadequate maintenance. Frequent washouts, overpowering of system Infiltration/Inflow problems. 17 ------- SUCCESS STORIES: FACILITY MANAGEMENT Abbeville, South Carolina Plant Size: 1.0 mgd Treatment Type: Trickling Filter AUTOMOTIVATION IN SOUTH CAROLINA out of funding in a recent year and resorted to the Town's account at a local junk yard. The staff at the South Carolina Environmental Training Center are still debat- ing the pros and cons of this type of repair but agree that the idea of this rear end serving another useful purpose was pleasing to everyone. This 1.0 mgd trickling filter plant has the most unusual looking primary clarifier drive in the entire state of South Carolina. As one enters the gate, the piece of equipment stands out proudly on one axle jutting out almost two feet above the clarifier access walkway. Connected to an electric motor with gear reducer by a standard V-belt and defying all the rules of normal wastewater treatment plant equipment is a 1958 Pontiac Bonneville rear end. A true case of "doing your best with what you have available" has become the talk of the entire South Caro- lina Technical Assistance Team. Investigation has re- vealed that the operator-in-charge of this plant had run Booneville, NC Plant Size: 0.10 mgd Treatment Type: Extended Aeration TOWN CLERK ATTENDS WASTEWATER SCHOOL Encouraged by the "104" trainer, Booneville, North Carolina's Town Clerk decided to sign up for wastewa- ter school. The Clerk supervises the wastewater operator and the plant budget. She acknowledges that Booneville has had trouble keeping a certified operator on board, so she is going for certification herself. In the meantime, she's backing up the ca- pable operator now serving this small extended aeration plant. Caruthers, California Plant Size: 0.1 mgd Treatment Type: aerated lagoons/stabilization ponds INTEREST AND ATTENTION MOTIVATE DEMORALIZED PLANT The Caruthers treatment plant was proclaimed a virtual disaster upon initial evaluation. The "104" trainer found 20 years of accumulated solids and debris that nearly filled the weed-choked lagoons. Odors were rampant, access to the treatment area was wide open, and the operator complained that no one had offered any concern or advice about the facility for many years. Caruthers is an almost classic example of the impact of concerned interest and attention. The operator didn't know what he was expected to do and felt that no one cared anyway. Advice and attention from the "104" troubleshooter mo- tivated the operator's activity. Within 5 months he had cleaned out one lagoon and was operating it properly while the other awaited solids removal. Odor problems were considerably improved and the plant looked much better. The operator continued to upgrade the Caruthers system over the next year. While the plant isn't a showplace yet, it is vastly improved in terms of both performance and aesthetics. 18 ------- SUCCESS STORIES: FACILITY MANAGEMENT " / doubt very much whether we could have been an award winning plant without the On-Site Operator Training Program." Narrowsburg, New York Plant Size: 0.1 mgd Treatment Type: Sand Filtration of Septic Tank Effluent POOR MAINTENANCE "UPSTREAM" CAUSES DIRTY INFLUENT Jack Young, Division Manager, Cheyenne Dry Creek Plant Cheyenne, Wyoming Hardwick, Vermont Plant Size: 037 mgd Treatment Type: Aerated Lagoon MANAGEMENT "UPGRADE" EXTENDS PLANT'S LONGEVITY Hardwick, Vermont almost slipped through the cracks of the "104" program because its technical violations were minor. But Hardwick persisted in its requests and a troubleshooter was detailed to the small village. Organi- zation of the wastewater "department" was in disarray. No wastewater budget existed, nor were there any main- tenance or replacement programs. The operator reported to the street department and often worked there. The evaluator got right to work on financial and manage- ment problems. The operator and the municipal manag- ers were all trained. They accepted a sinking fund plan for capital expenditures over the next ten years and earmarked revenues for replacement and repair. A wastewater budget now exists. The village increased the operator's hours and limited them to wastewater work. Good maintenance techniques and schedules are in place. The success here is not technical, but perennial, Hardwick's wastewater treatment plant is going to last! Narrowsburg runs an innovative/alternative facility that processes influent that comes directly from about 250 septic tanks through sand filters before discharging to the Delaware River. Designed for 100,000 gpd, the plant started experiencing ponding problems in its sand beds at only 43,000 gpd. Fortunately, before effluent quality had suffered, the facility called for technical assistance. The O&M troubleshooter identified two major prob- lems. First, the two on-line sand filter beds were being overloaded while the other two were being cleaned. Understaffing at the plant meant the out-of-service beds could not be cleaned quickly; the result was ponding under a heavy hydraulic load. Second, dirty influent was clogging the sand filters. The existing septic tanks were to serve as primary treatment, but as sludge built up in them, solids were overflowing to the plant The septic tanks had never been pumped out as was required to keep the system operating as designed. Money had never been budgeted for septic tank pumping. The evaluator's recommendations were simple and-highly effective: • Staff up and mount an intensive cleaning effort on the sand bed filters. Keep cleaning regularly; and • Pump out overloaded septic tanks. Once all four beds were clean and on-line and two heavily loaded septic tanks were pumped, the facility handled an average of 61,000 gpd without ponding problems. Effluent quality remained good: BOD was 11.5 mg/1 and TSS was 3 mg/1. The "104" facilitator recommended that identified infdtration/inflow prob- lems be eliminated to keep hydraulic loads down to man- ageable levels during wet weather. 19 ------- SUCCESS STORIES: FACILITY MANAGEMENT Sandwich, Illinois Plant Size: 0.95 mgd Treatment Type: Activated Sludge INDUSTRIAL "SLUG" DISCHARGES SHOCK SMALL SYSTEM It's a common story in wastewater management the "mystery" polluter who shocks the local treatment plant regularly with slug discharges. The offender is usually an industry on which the town relies economically. In Sandwich, Illinois, the 0.95 mgd activated sludge plant was out of compliance due to poor process control, sludge wasting, and shock discharges to the system. The "104" troubleshooter helped operators improve those areas within their control, but it took an enforcement meeting, set up by the "104" trainer, to get town admin- istrators to find and control the offending polluters. later. That's when operating Socorro's existing facility to its real capacity became a precondition of the desired grant Plant performance and condition improved dra- matically as the city acted upon the trainer's recommen- dations. Socorro: • Promoted a capable operator to a position of responsibility for the plant • Hired a new lab technician who began to generate credible data; • Increased user charges by 25%; • Enacted a sewer use ordinance; • Established an O&M program for the collection system; and • Improved process control and added 25% aeration capacity. The old plant is doing its job again. Effluent BOD and TSS, which had been ranging over 30 mg/1 during the previous year, were controlled to 9 mg/1 BOD and 16 mg/1 TSS. Plant odors have been much reduced and staff morale is up. Socorro, New Mexico Plant Size: 1.0 mgd Treatment Type: Activated Sludge PLANT REHABILITATION SAVES MILLIONS A steadily growing population and a deteriorating plant effluent had convinced Socorro city managers that they needed a completely new treatment plant They believed that the old plant could no longer meet permit limits. When the 104" troubleshooter arrived to see what could be done to improve performance, he found an uninterested city administration. Socorro was already on the priority list for a construction grant! The on-site evaluator found plenty of other problems too: disorganized plant operation, poor process control, low operator morale, offensive plant odors, and erratic effluent quality. Although he pushed for improvements, measurable results didn't occur until several months Spring Green, Wisconsin Plant Size: 0.260 Treatment Type: Oxidation Ditch. OIL IN TROUBLED WATERS Heavy thick foaming in the aeration basin and floating solids in the clarifier greeted the "104" troubleshooter when he arrived at the Spring Green facility. By the time the plant called for help, solids settling was out of control and getting worse: 600-700 ml/I one month, 800-900 ml/1 the next Sludge was being wasted only once or twice a month. 20 ------- SUCCESS STORIES: FACILITY MANAGEMENT The on-site evaluator saw immediately that high grease loads were entering the plant. Seventeen food service businesses were inspected for grease control violations and ordered to use grease traps correctly. At the same time, plant operators sprayed foam with a dilute chlorine solution 2-3 times a day. Meanwhile, the troubleshooter experimented with chlo- rinating the return activated sludge to attack turbidity and filamentous bacteria. After several unsuccessful tries, he nit upon an unorthodox chemical addition point the mixed liquor overflow to the final clarifier. Success was achieved within 24 hours. These solutions, combined with a long-term program of regular sludge wasting, cleaned up Spring Green's prob- lems. Within a couple of weeks, technical assistance had brought a troublesome plant well within 30/30 permit limits: BODS was 15 mg/1 and TSS stood at 10 mg/1. Thurmont, Maryland Plant Size: 1.0 mgd Treatment Type: Oxidation Ditch Superior, Arizona Plant Size: 3.0 mgd Treatment Type: Contact Stabilization OPERATIONS HAMPERED BY UNEXPRESSED NEEDS Superior, Arizona wanted to bring its plant into compli- ance. If only their wastewater operator could tell them how! The "104" trainer discovered an unschooled plant operator running a "seat of the pants" system. Lacking operational training and unaware of the required testing equipment, he was unable to express plant needs to the people able to supply them. The trainer worked closely with both the operational and budgeting needs and improved expertise and hardware within the plant ONCE BYPASSED PLANT NOW SQUEAKY CLEAN When high flows fouled the sand filters with solids at the Thurmont's wastewater treatment plant, the result was "a truly nasty mess." So the operator bypassed the plant whenever flows exceeded 75% of capacity. The "104" trainer found the Thurmont plant seriously understaffed. No one was doing mechanical or electrical maintenance. The chief operator was torn between doing lab work and plant operations. The spiragester could not be made to work, no matter what wasting schedule was tried, and septic sludge was flowing un- controlled into the downstream works. Solids washed out to the sand filters at only 60% of design capacity. Thurmont staff were trying, but were overwhelmed. The troubleshooter: • Implemented a data collection program that began to reveal the true capability of each unit process; • Taught the operators the relationship between data trends and process stability; • Retired troublesome equipment from service; • Suggested hiring a part-time lab assistant; and • Devised a high-flows strategy and helped solve infil- tration/inflow problems. No sludge washouts occurred after the trainer began improvements, and the plant works at flows up to 1.2 mgd. The lab assistant has substantially relieved staffing pressures, and all participants have the time and under- standing to run a successful plant Thurmont is in compliance and its effluent is five times cleaner than required! 21 ------- SUCCESS IN EVERY REGION The treatment plants listed in this table are those which were identified as "success stories" by EPA Regional Offices and submitted to assist in the development of this brochure. They represent only a fraction of the "success stories" of the 104(g)(1) program. Region T J. n m Plant Seymour, CT Activated Sludge Thomaston, CT Activated Sludge Mass. Maritime Academy, MA Activated Sludge Huntington, MA Activated Sludge Kennebunkport, ME Activated Sludge Zambamo Memorial Hosp., Rl Extended Aeration Hardwick, VT Aerated Lagoon West Rutland, VT Extended Aeration Arcade, NY Trickling Filter Blooming Grove, NY Activated Sludge Buchanan, NY Activated Sludge Camden, NY Oxidation Ditch Clayton, NY Activated Sludge Fulton, NY Trickling Filter Kings Acres, NY Biotower Montgomery, NY Oxidation Ditch Narrowsburg, NY I/A Walton, NY Trickling Filter George's Creek, MD Oxidation Ditch Hagerstown, MD Activated Sludge Indian Head, MD Activated Sludge Sharptown, MD Extended Aeration Thurmont, MD Oxidation Ditch Westminster, MD Activated Sludge Alexandria, PA Activated Sludge Clarks Summit, PA Extended Aeration Ml Pocono, PA Activated Sludge Saxonburg, PA Extended Aeration Tionesta, PA RBC Towanda, PA Contact Stab. Boydton, VA Activated Sludge Cape Charles, VA Contact Stab. Success Training X X X X X X X X X X X X X X X X Facility Correction X X X X X X X X X X Mgmt. X X X X X X X X X X X X X 22 ------- SUCCESS IN EVERY REGION Region TV J. T V Plant Clifton Forge, VA Trickling Filter McKenny, VA Extended Aeration Elizabeth, WV Aerated Pond Follansbee, WV Extended Aeration Friendly, WV Oxidation Ditch Glen Rogers, WV Oxidation Ditch Hepzibah, WV Oxidation Ditch Harpers Ferry, WV Extended Aeration Shepherdstown, WV Extended Aeration Atlantic Beach, FL Contact Stab. Lake Alfred, FL Contact Stab. Barnesville, GA Activated Sludge Fairbum, GA Activated Sludge Campbellsburg, KY Extended Aeration Sandy Hook, KY Extended Aeration Booneville, NC Extended Aeration Kershaw, SC Oxidation Ditch Manning, SC Activated Sludge Ridgeway, SC Extended Aeration Riverton, IL Contact Stab. Minooka, IL Oxidation Ditch Pekin, IL Contact Stab. Somonauk, IL Extended Aeration Villa Grove, IL Extended Aeration Goreville, IL Contact Stab. Aurthur, IL Contact Stab. Sandwich, IL Activated Sludge Waverly, IL Activated Sludge Centralia, IL Contact Stab. Carlisle, IN Extended Aeration Barrett, MN Extended Aeration Morgan, MN Trickling Filter Spring Green, Wl Oxidation Ditch Sand Creek, Wl Stab. Pond Success Training X X X X X X X X X X X X X X X X X X Facility Correction X X X X X X Mgmt. X X X X X X X X X X X X X X X X X X 23 ------- SUCCESS IN EVERY REGION Region VI vn vm Plant Garland City, AR Lagoon Mountain Pine, AR Lagoon Calico Rock, AR Extended Aeration Basile, LA Extended Aeration Elton, LA Oxidation Ditch Port Barre, LA Extended Aeration Folsom, LA Extended Aeration Estherwood, LA Overland Row Blanchard, LA Oxidation Ditch Bloomfield, NM Activated Sludge Aztec, NM Extended Aeration Reserve, NM Activated Sludge Socorro, NM Activated Sludge Broken Bow, OK Activated Sludge Coweta, OK Extended Aeration Checotah, OK Oxidation Ditch Whitehouse , TX Extended Aeration Waller, TX Oxidation Ditch Cottonwood, TX Lagoon Boone, IA Trickling Filter Stuart, IA Trickling Filter Hartford, IA Aerated Lagoon Baldwin City, KS Oxidation Ditch Exeter, MO Oxidation Ditch Walthill, NE Activated Sludge Osmond, NE Activated Sludge Burwell, NE Trickling Filter Clark, SD Oxidation Ditch Keystone, SD Slab. Pond Julesburg, CO Trickling Filter Elizabeth, CO Aerated Lagoon Green River, UT Lagoon Hurricane, UT Lagoon Success Training x " X X X X X X X X X X X X X X X X X X X X X Facility Correction X X X X X X X X X Mgmt. X X X X X X X X X X 24 ------- SUCCESS IN EVERY REGION Region IX X Plant Superior, AZ Contact Stab. Patagonia, AZ Extended Aeration East Yolo, CA Activated Sludge Dos Palos, CA Aerated Ponds Fort Bragg, CA Trickling Filter Garberville, CA Unaerated Ponds Caruthers, CA AerJStab. Ponds Riverdale, CA Aerated Ponds Sanger, CA Activated Sludge Nanakai, HI Activated Sludge Wahiawa, HI Activated Sludge Ahuimanu, HI Activated Sludge Juliaetta, ID Extended Aeration Harrison, ID Activated Sludge Arlington, OR Activated Sludge Tillamook, OR RBC Heppner, OR Trickling Filter East Sound, WA Activated Sludge Morton, WA Oxidation Ditch College Place, WA Activated Sludge Zillah, WA Oxidation Ditch Bridgeport, WA Activated Sludge Success Training X X X X X X X X X X X X X Facility Correction X X X X Mgmt. X X X X X X 25 ------- THE ON-SITE OPERATOR TRAINING PROGRAM THE ON-SITE OPERATOR TRAINING PROGRAM: A GRASS-ROOTS SUCCESS The On-Site Operator Training Program is: Meeting the wastewater O&M needs of often overlooked communities; Supporting the water-quality mandates of the Clean Water Act; Applying creativity and the personal touch to technical assistance outreach; Helping to build a professional community of capable wastewater operators; Helping local officials; Establishing State training programs; and Protecting State and Federal investment in infrastructure. Program staff are looking forward to many more suc- cess stories over the coming years. For more informa- tion on the program, write: Office of Municipal Pollution Control Planning and Analysis Division (WH-546) Environmental Protection Agency 401 M Street, S.W. Washington, D.C. 20460 (202) 382-5810 26 ------- |