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Operation Manual
TownWMF/WTP/SPS
(Expanded in full)
Copyright © Goulburn Valley Water 2009
document.docx
Town WMF/ WTP/SPS Operation Manual RevisionsNote: With each edit to this document, the following must be completed in the next available blank row.
Date Description of Change Initiator of Change
Date Updated
22/11/17 Review of DC&C IIO 22/11/17
12/09/17 Review of General process element
IIO 12/09/17
16/06/15 Name review IIO 16/06/15
02/10/14 Review and update formatting of template
IIO 02/10/14
15/04/14 Review and update template IIO 15/04/14
10/10/12 Review and update template IIO 10/10/12
25/07/11 Review and update template Citect Functional diagrams
IIO 25/07/11
21/03/11 Review and update template IIO 21/03/11
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 2 of 51Review Date: Last Modified Date: 22 November 2017
document.docx
document.docx -Table of Contents
TOWN WMF/ WTP/SPS OPERATION MANUAL REVISIONS..................................2
TOWN WMF/WTP /SPS - PROCESS FLOW DIAGRAM........................................6
GENERAL............................................................................................7
GENERAL PURPOSE AND TARGETS....................................................7Performance Targets......................................................................................7
GENERAL SAFETY.............................................................................7
GENERAL DESIGN CRITERIA AND COMPONENTS.................................7
GENERAL MONITORING....................................................................7
GENERAL MAINTENANCE..................................................................8
GENERAL NORMAL OPERATION.........................................................8
GENERAL PROCESS CONTROL...........................................................8
GENERAL MANUAL OPERATION.........................................................8Manual Override.............................................................................................8
GENERAL EMERGENCY......................................................................8Plant Crash Stop.............................................................................................8Site Specific....................................................................................................9
“PROCESS ELEMENT A”.....................................................................10
“PROCESS ELEMENT A” PURPOSE AND TARGETS.............................10
“PROCESS ELEMENT A” DESIGN CRITERIA AND COMPONENTS..........10
“PROCESS ELEMENT A” NORMAL OPERATION..................................14Start-up........................................................................................................15Standard Operation Procedures...................................................................15Shutdown.....................................................................................................15
“PROCESS ELEMENT A” PROCESS CONTROL....................................15
“PROCESS ELEMENT A” MANUAL OPERATION..................................15Manual Override...........................................................................................15Start-up........................................................................................................16Standard Operation Procedures...................................................................16Shutdown.....................................................................................................16
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 3 of 51Review Date: Last Modified Date: 22 November 2017
document.docx“PROCESS ELEMENT A” TROUBLESHOOTING....................................16
“PROCESS ELEMENT A” EMERGENCY...............................................17
“PROCESS ELEMENT B”.....................................................................18
“PROCESS ELEMENT B” PURPOSE AND TARGETS.............................18
“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTS..........18
“PROCESS ELEMENT B” NORMAL OPERATION..................................22Start-up........................................................................................................23Standard Operation Procedures...................................................................23Shutdown.....................................................................................................23
“PROCESS ELEMENT B” PROCESS CONTROL....................................23
“PROCESS ELEMENT B” MANUAL OPERATION..................................23Manual Override...........................................................................................23Start-up........................................................................................................24Standard Operation Procedures...................................................................24Shutdown.....................................................................................................24
“PROCESS ELEMENT B” TROUBLESHOOTING....................................24
“PROCESS ELEMENT B” EMERGENCY...............................................25
“PROCESS ELEMENT C”.....................................................................26
“PROCESS ELEMENT C” PURPOSE AND TARGETS..............................26
“PROCESS ELEMENT C” DESIGN CRITERIA AND COMPONENTS...........26
“PROCESS ELEMENT C” NORMAL OPERATION..................................30Start-up........................................................................................................31Standard Operation Procedures...................................................................31Shutdown.....................................................................................................31
“PROCESS ELEMENT C” PROCESS CONTROL.....................................31
“PROCESS ELEMENT C” MANUAL OPERATION..................................31Manual Override...........................................................................................31Start-up........................................................................................................32Standard Operation Procedures...................................................................32Shutdown.....................................................................................................32
“PROCESS ELEMENT C” TROUBLESHOOTING....................................32
“PROCESS ELEMENT C” EMERGENCY...............................................33
“PROCESS ELEMENT D”.....................................................................34
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 4 of 51Review Date: Last Modified Date: 22 November 2017
document.docx“PROCESS ELEMENT D” PURPOSE AND TARGETS.............................34
“PROCESS ELEMENT D” DESIGN CRITERIA AND COMPONENTS..........34
“PROCESS ELEMENT D” NORMAL OPERATION..................................38Start-up........................................................................................................39Standard Operation Procedures...................................................................39Shutdown.....................................................................................................39
“PROCESS ELEMENT D” PROCESS CONTROL....................................39
“PROCESS ELEMENT D” MANUAL OPERATION..................................39Manual Override...........................................................................................39Start-up........................................................................................................40Standard Operation Procedures...................................................................40Shutdown.....................................................................................................40
“PROCESS ELEMENT D” TROUBLESHOOTING....................................40
“PROCESS ELEMENT D” EMERGENCY...............................................41
LIST OF FIGURES...............................................................................42
LIST OF TABLES.................................................................................43
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 5 of 51Review Date: Last Modified Date: 22 November 2017
document.docx
Town WMF/WTP /SPS - Process Flow DiagramFigure 1: Town Site Process Flow Diagram
Supply an up to date copy of the process flow diagram for the site.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 6 of 51Review Date: Last Modified Date: 22 November 2017
GEN
ERAL
document.docx
GENERAL
Refer to Citrix for the Town Name WTP SCADA screens.
Click here for the Town Name WTP Schematic diagram.
Click here for the Town Name Functional Diagrams.
GENERAL PURPOSE AND TARGETSProvide a short statement describing the purpose and a general description of the process elements in the treatment sequence.The performance targets are the treatment and reliability objectives of the plant, typically key performance indicators, license and objective limits, and reliability requirements.
Click here for the Safe Drinking Water Targets.
Click here for the Sewer Pump Station Targets.
Performance Targets No mechanical failure for 6 months
GENERAL SAFETYClick here for the Occupational Health and Safety Targets.
Site Plans of Premises May 2017
GENERAL DESIGN CRITERIA AND COMPONENTSClick here for the Equipment Manuals and Glossary.
GENERAL MONITORINGRefer to Aquantify.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 7 of 51Review Date: Last Modified Date: 22 November 2017
GEN
ERAL
document.docx
GENERAL MAINTENANCERefer to MyData maintenance schedule.
GENERAL NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA controls for operation under normal conditions.Add photos where possible.
Use this numbering system. E.g.
GENERAL PROCESS CONTROL
GENERAL MANUAL OPERATION
Manual OverrideProvide a general overview of all the process elements of the SPS, WMF, WTP where the plant may be operated manually.
GENERAL EMERGENCY
Plant Crash StopIf a problem exists with the operation of the plant specific processes (there can be one or more processes) can be crashed via the Regional SCADA system (provided user of Regional SCADA has sufficient privileges). This action would normally only occur in an emergency situation where water entering certain processes in the plant is outside specifications or there are problems associated with the pumping operation. Usually it would be used where it would take an extended period of time for an operator to attend the site. Using the crash stop would stop the process and allow an operator greater time to reach the site. To crash the plant, complete the following: Open the WTP overview Regional SCADA page
Press the Crash Control Symbol button Select the desired system to crash Press the Crash button
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 8 of 51Review Date: Last Modified Date: 22 November 2017
GEN
ERAL
document.docxIf the problem rectifies itself the crash can be reset by an operator on site pressing the Crash Stop Reset button (either on the switchboard or Plant SCADA system). Alternatively the crash can be reset via Regional SCADA system by:
Pressing the Enable button
Site Specific
Provide a general overview of the processes which may result in the site being crashed:
EMERGENCY RESPONSE PROCEDURES In case of spill refer to the EMS procedure - Spill Control(Require SOI for emergency pumping)
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 9 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT A”Figure 2: Describe photo here.Insert a photo of Process Element .A.
“PROCESS ELEMENT A” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.
Summarise the performance targets for Process Element A in the above list.
Table 1: Pumping Station Details
Parameter Measurements
Top of slab
Delivery Internal Pipe Diameter
Delivery Pipe I.L
Inlet Pipe Diameter
Inlet Pipe I.L
Wet Well Floor R.L.
Modify this table as required.
“PROCESS ELEMENT A” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 10 of 51Review Date: Last Modified Date: 22 November 2017
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document.docxTable 2: “Process Element A” Design Criteria and Components
Main Components Function Design Criteria
Flowmeter Measures flow Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Step Screen "Step" type screen to remove debris from effluent inlet
Manufacturer:Type:Weight:Size:Width:Serial No:
Screen Drive Shaft mounted worm-geared motor
Type:Motor:
Air Blower Source of air for air scouring
Manufacturer: _____Type: ___Air flow: ___ m3/hourPressures to ___ PSI
Pump and Motors To collect sewerage from catchment and discharge to pump station #?? catchment
Pump Duty: ___L/s @ ___ m Total Head, ___ Static HeadManufacturer: _____Pump Classification: ___Type: _______Pump Curve No: _____Issue: _______ mm impeller; Type ___Outlet diameter: _____mmPump Weight: ___ kgSerial No: _____Motor
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 11 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
Manufacturer: _____Type: _____Serial No: _____RPM:____Rated at: _____ kW
Turbidity Meter Measures filtered / raw water turbidity
Manufacturer: _____Type: ___Required turbidity readings range: 0-20 NTU
Analyser Measures filtered water Manufacturer: _____Type: ___
Actuators and Gearboxes Controlled open/Close operation of pump Discharge
Actuator Manufacturer:___Type:___Gearbox Manufacturer:___Type:___Ratio:___Serial:__
Dissolved Oxygen Analyser
Manufacturer:Type:Serial No:
Sump Pump Pumps water out of dry well space
Manufacturer: _____Type: ___
Dosing Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 12 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
_____ RPMPump Weight: ___ kgSerial No: _____
Metering Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barSerial No: _____
Service Water Pump Manufacturer:Type:Serial No:
Internal Delivery Pipe To deliver flow from pump to the outlet of the pump station.
Manufacturer: _____Type: ___Diameter:____ mmMaterial: ____Pressure class: ____Length: ____ m
Rising Main To deliver flow from pump station ?? to pump station ?? or Manhole ??
Manufacturer: _____Type: ___Diameter: ____ mmMaterial: _____Pressure class: PN___Length: ____m
Tank Alum storage Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 13 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
1 X Lifting Equipment To allow for the removal of pumps from the wet well for routine and non-routine maintenance
S/S Guide Rails and lifting chainsSize of Chains: ___
Chlorinator Manufacturer: _____Type: ___Serial Number: ____Maximum ___/ __Hr
Gas Feeder Manufacturer: ____Type: ____Capacity: ____
Vacuum Regulators Manufacturer: ____Type: ____
Soft Starter Reduces the excess current during initial power-up of an electric motor
Manufacturer: ____Type: ____
Irrigation Flow Meter Measures flow ... Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Valve Manufacturer:Type:Max Pressure:
VSD to control the speed of the motor within its operating range
Manufacturer: ____Type: ____
Filter Manufacturer: ____Type: ____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 14 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
PLC Manufacturer: ____Type: ____
Generator Convert mechanical energy to electrical energy
Manufacturer:Type:Motor Size: ____kWRate Voltage:Fuel Type:Fuel Tank Capacity:Fuel Consumption:Dimensions:Weight:Serial No:
Air Compressor To supply compressed air to the air actuator valves within the plant and to supply compressed air to the DAF vessel
Manufacturer:Type:Serial No:
Hydro Cyclone Manufacturer:Type:Serial No:
Bay Outlet Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Filter Media Each filter removes floc and other matter.
Explanation of types and depths?
Manufacturer:Type:Dual Type:Multiple Depths:Volume:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 15 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
Nozzles Manufacturer:Type/Model No:
Cathodic protection Manufacturer:Type:
Groundwater Bore Ground Works Number:Date Drilled:Casing Outside Diameter:Casing Inside Diameter:Casing Wall Thickness:Casing Type:Apertures:Screened From – To:Bore Depth:
Air conditioner Manufacturer:Type:
Door Specifications Door Type:Spindle:Head Pressure:Actuator:Clear Water Way:Operating Level:Door Material:Weight:Handwheel direction:
Baffle Comment on orientation Manufacturer:Type:Material:Size:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 16 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT A” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.
Use this numbering system. E.g.
Figure 3: Describe photo here.
Under normal operating conditions, the
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 17 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT A” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.
“PROCESS ELEMENT A” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.
Figure 3: Describe photo here. Utilise this numbering system for additional photos.
Manual Override
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 18 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT A” TROUBLESHOOTING
Table 3: “Process Element A” Troubleshooting Guide
Problem Cause Solution/Action
Note: All electrical work is to be carried out by qualified electricians only.
Complete this table and add/remove rows where necessary.
“PROCESS ELEMENT A” EMERGENCY
Table 4: “Process Element A” Emergency Guide
Condition Actions
PLC Failure Contact GVW Operations IT Department
Power Failure Restore powerElectrician and/orPower company
Complete this table and add/remove rows where necessary.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 19 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT B”Figure 4: Describe photo here.Insert a photo of Process Element B.
“PROCESS ELEMENT B” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.
Summarise the performance targets for Process Element B in the above list.
Table 5: Pumping Station Details
Parameter Measurements
Top of slab
Delivery Internal Pipe Diameter
Delivery Pipe I.L
Inlet Pipe Diameter
Inlet Pipe I.L
Wet Well Floor R.L.
Modify this table as required.
“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 20 of 51Review Date: Last Modified Date: 22 November 2017
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document.docxTable 6: “Process Element B” Design Criteria and Components
Main Components Function Design Criteria
Flowmeter Measures flow Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Step Screen "Step" type screen to remove debris from effluent inlet
Manufacturer:Type:Weight:Size:Width:Serial No:
Screen Drive Shaft mounted worm-geared motor
Type:Motor:
Air Blower Source of air for air scouring
Manufacturer: _____Type: ___Air flow: ___ m3/hourPressures to ___ PSI
Pump and Motors To collect sewerage from catchment and discharge to pump station #?? catchment
Pump Duty: ___L/s @ ___ m Total Head, ___ Static HeadManufacturer: _____Pump Classification: ___Type: _______Pump Curve No: _____Issue: _______ mm impeller; Type ___Outlet diameter: _____mmPump Weight: ___ kgSerial No: _____Motor
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 21 of 51Review Date: Last Modified Date: 22 November 2017
“PRO
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document.docx
Main Components Function Design Criteria
Manufacturer: _____Type: _____Serial No: _____RPM:____Rated at: _____ kW
Turbidity Meter Measures filtered / raw water turbidity
Manufacturer: _____Type: ___Required turbidity readings range: 0-20 NTU
Analyser Measures filtered water Manufacturer: _____Type: ___
Actuators and Gearboxes Controlled open/Close operation of pump Discharge
Actuator Manufacturer:___Type:___Gearbox Manufacturer:___Type:___Ratio:___Serial:__
Dissolved Oxygen Analyser
Manufacturer:Type:Serial No:
Sump Pump Pumps water out of dry well space
Manufacturer: _____Type: ___
Dosing Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 22 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
_____ RPMPump Weight: ___ kgSerial No: _____
Metering Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barSerial No: _____
Service Water Pump Manufacturer:Type:Serial No:
Internal Delivery Pipe To deliver flow from pump to the outlet of the pump station.
Manufacturer: _____Type: ___Diameter:____ mmMaterial: ____Pressure class: ____Length: ____ m
Rising Main To deliver flow from pump station ?? to pump station ?? or Manhole ??
Manufacturer: _____Type: ___Diameter: ____ mmMaterial: _____Pressure class: PN___Length: ____m
Tank Alum storage Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 23 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
1 X Lifting Equipment To allow for the removal of pumps from the wet well for routine and non-routine maintenance
S/S Guide Rails and lifting chainsSize of Chains: ___
Chlorinator Manufacturer: _____Type: ___Serial Number: ____Maximum ___/ __Hr
Gas Feeder Manufacturer: ____Type: ____Capacity: ____
Vacuum Regulators Manufacturer: ____Type: ____
Soft Starter Reduces the excess current during initial power-up of an electric motor
Manufacturer: ____Type: ____
Irrigation Flow Meter Measures flow ... Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Valve Manufacturer:Type:Max Pressure:
VSD to control the speed of the motor within its operating range
Manufacturer: ____Type: ____
Filter Manufacturer: ____Type: ____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 24 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
PLC Manufacturer: ____Type: ____
Generator Convert mechanical energy to electrical energy
Manufacturer:Type:Motor Size: ____kWRate Voltage:Fuel Type:Fuel Tank Capacity:Fuel Consumption:Dimensions:Weight:Serial No:
Air Compressor To supply compressed air to the air actuatorated valves within the plant and to supply compressed air to the DAF vessel
Manufacturer:Type:Serial No:
Hydro Cyclone Manufacturer:Type:Serial No:
Bay Outlet Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Filter Media Each filter removes floc and other matter.
Explanation of types and depths?
Manufacturer:Type:Dual Type:Multiple Depths:Volume:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 25 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
Nozzles Manufacturer:Type/Model No:
Cathodic protection Manufacturer:Type:
Groundwater Bore Ground Works Number:Date Drilled:Casing Outside Diameter:Casing Inside Diameter:Casing Wall Thickness:Casing Type:Apertures:Screened From – To:Bore Depth:
Air conditioner Manufacturer:Type:
Door Specifications Door Type:Spindle:Head Pressure:Actuator:Clear Water Way:Operating Level:Door Material:Weight:Handwheel direction:
Baffle Comment on orientation Manufacturer:Type:Material:Size:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 26 of 51Review Date: Last Modified Date: 22 November 2017
“PRO
CESS
ELE
MEN
T B”
document.docx
“PROCESS ELEMENT B” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.
Use this numbering system. E.g.
Figure 3: Describe photo here.
Under normal operating conditions, the
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 27 of 51Review Date: Last Modified Date: 22 November 2017
“PRO
CESS
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T B”
document.docx
“PROCESS ELEMENT B” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.
“PROCESS ELEMENT B” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.
Figure 5: Describe photo here. Utilise this numbering system for additional photos.
Manual Override
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 28 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT B” TROUBLESHOOTING
Table 7: “Process Element B” Troubleshooting Guide
Problem Cause Solution/Action
Note: All electrical work is to be carried out by qualified electricians only.
Complete this table and add/remove rows where necessary.
“PROCESS ELEMENT B” EMERGENCY
Table 8: “Process Element B” Emergency Guide
Condition Actions
PLC Failure Contact GVW Operations IT Department
Power Failure Restore powerElectrician and/orPower company
Complete this table and add/remove rows where necessary.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 29 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT C”Figure 6: Describe photo here.Insert a photo of Process Element A
“PROCESS ELEMENT C” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.
Summarise the performance targets for Process Element A in the above list.
Table 9: Pumping Station Details
Parameter Measurements
Top of slab
Delivery Internal Pipe Diameter
Delivery Pipe I.L
Inlet Pipe Diameter
Inlet Pipe I.L
Wet Well Floor R.L.
Modify this table as required.
“PROCESS ELEMENT C” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 30 of 51Review Date: Last Modified Date: 22 November 2017
“PRO
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document.docxTable 10: “Process Element C” Design Criteria and Components
Main Components Function Design Criteria
Flowmeter Measures flow Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Step Screen "Step" type screen to remove debris from effluent inlet
Manufacturer:Type:Weight:Size:Width:Serial No:
Screen Drive Shaft mounted worm-geared motor
Type:Motor:
Air blower Source of air for air scouring
Manufacturer: _____Type: ___Air flow: ___ m3/hourPressures to ___ PSI
Pump and Motors To collect sewerage from catchment and discharge to pump station #?? catchment
Pump Duty: ___L/s @ ___ m Total Head, ___ Static HeadManufacturer: _____Pump Classification: ___Type: _______Pump Curve No: _____Issue: _______ mm impeller; Type ___Outlet diameter: _____mmPump Weight: ___ kgSerial No: _____Motor
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 31 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
Manufacturer: _____Type: _____Serial No: _____RPM:____Rated at: _____ kW
Turbidity Meter Measures filtered / raw water turbidity
Manufacturer: _____Type: ___Required turbidity readings range: 0-20 NTU
Analyser Measures filtered water Manufacturer: _____Type: ___
Actuators and Gearboxes Controlled open/Close operation of pump Discharge
Actuator Manufacturer:___Type:___Gearbox Manufacturer:___Type:___Ratio:___Serial:__
Dissolved Oxygen Analyser
Manufacturer:Type:Serial No:
Sump Pump Pumps water out of dry well space
Manufacturer: _____Type: ___
Dosing Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 32 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
_____ RPMPump Weight: ___ kgSerial No: _____
Metering Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barSerial No: _____
Service Water Pump Manufacturer:Type:Serial No:
Internal Delivery Pipe To deliver flow from pump to the outlet of the pump station.
Manufacturer: _____Type: ___Diameter:____ mmMaterial: ____Pressure class: ____Length: ____ m
Rising Main To deliver flow from pump station ?? to pump station ?? or Manhole ??
Manufacturer: _____Type: ___Diameter: ____ mmMaterial: _____Pressure class: PN___Length: ____m
Tank Alum storage Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 33 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
1 X Lifting Equipment To allow for the removal of pumps from the wet well for routine and non-routine maintenance
S/S Guide Rails and lifting chainsSize of Chains: ___
Chlorinator Manufacturer: _____Type: ___Serial Number: ____Maximum ___/ __Hr
Gas Feeder Manufacturer: ____Type: ____Capacity: ____
Vacuum Regulators Manufacturer: ____Type: ____
Soft Starter Reduces the excess current during initial power-up of an electric motor
Manufacturer: ____Type: ____
Irrigation Flow Meter Measures flow ... Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Valve Manufacturer:Type:Max Pressure:
VSD to control the speed of the motor within its operating range
Manufacturer: ____Type: ____
Filter Manufacturer: ____Type: ____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 34 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
PLC Manufacturer: ____Type: ____
Generator Convert mechanical energy to electrical energy
Manufacturer:Type:Motor Size: ____kWRate Voltage:Fuel Type:Fuel Tank Capacity:Fuel Consumption:Dimensions:Weight:Serial No:
Air Compressor To supply compressed air to the air actuatorated valves within the plant and to supply compressed air to the DAF vessel
Manufacturer:Type:Serial No:
Hydro Cyclone Manufacturer:Type:Serial No:
Bay Outlet Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Filter Media Each filter removes floc and other matter.
Explanation of types and depths?
Manufacturer:Type:Dual Type:Multiple Depths:Volume:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 35 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
Nozzles Manufacturer:Type/Model No:
Cathodic protection
Groundwater Bore Ground Works Number:Date Drilled:Casing Outside Diameter:Casing Inside Diameter:Casing Wall Thickness:Casing Type:Apertures:Screened From – To:Bore Depth:
Air conditioner Manufacturer:Type:
Door Specifications Door Type:Spindle:Head Pressure:Actuator:Clear Water Way:Operating Level:Door Material:Weight:Handwheel direction:
Baffle Comment on orientation Manufacturer:Type:Material:Size:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 36 of 51Review Date: Last Modified Date: 22 November 2017
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“PROCESS ELEMENT C” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions. Add photos where possible.
Use this numbering system. E.g.
Figure 3: Describe photo here.
Under normal operating conditions, the
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 37 of 51Review Date: Last Modified Date: 22 November 2017
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“PROCESS ELEMENT C” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.
“PROCESS ELEMENT C” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element. Insert photos where possible.
Figure 7: Describe photo here. Utilise this numbering system for additional photos.
Manual Override
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 38 of 51Review Date: Last Modified Date: 22 November 2017
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“PROCESS ELEMENT C” TROUBLESHOOTING
Table 11: “Process Element C” Troubleshooting Guide
Problem Cause Solution/Action
Note: All electrical work is to be carried out by qualified electricians only.
Complete this table and add/remove rows where necessary.
“PROCESS ELEMENT C” EMERGENCY
Table 12: “Process Element C” Emergency Guide
Condition Actions
PLC Failure Contact GVW Operations IT Department
Power Failure Restore powerElectrician and/orPower company
Complete this table and add/remove rows where necessary.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 39 of 51Review Date: Last Modified Date: 22 November 2017
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“PROCESS ELEMENT D”Figure 8: Describe photo here.Insert a photo of Process Element D.
“PROCESS ELEMENT D” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.
Summarise the performance targets for Process Element D in the above list.
Table 13: Pumping Station Details
Parameter Measurements
Top of slab
Delivery Internal Pipe Diameter
Delivery Pipe I.L
Inlet Pipe Diameter
Inlet Pipe I.L
Wet Well Floor R.L.
Modify this table as required.
“PROCESS ELEMENT D” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 40 of 51Review Date: Last Modified Date: 22 November 2017
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document.docxTable 14: “Process Element D” Design Criteria and Components
Main Components Function Design Criteria
Flowmeter Measures flow Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Step Screen "Step" type screen to remove debris from effluent inlet
Manufacturer:Type:Weight:Size:Width:Serial No:
Screen Drive Shaft mounted worm-geared motor
Type:Motor:
Air blower Source of air for air scouring
Manufacturer: _____Type: ___Air flow: ___ m3/hourPressures to ___ PSI
Pump and Motors To collect sewerage from catchment and discharge to pump station #?? catchment
Pump Duty: ___L/s @ ___ m Total Head, ___ Static HeadManufacturer: _____Pump Classification: ___Type: _______Pump Curve No: _____Issue: _______ mm impeller; Type ___Outlet diameter: _____mmPump Weight: ___ kgSerial No: _____Motor
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 41 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
Manufacturer: _____Type: _____Serial No: _____RPM:____Rated at: _____ kW
Turbidity Meter Measures filtered / raw water turbidity
Manufacturer: _____Type: ___Required turbidity readings range: 0-20 NTU
Analyser Measures filtered water Manufacturer: _____Type: ___
Actuators and Gearboxes Controlled open/Close operation of pump Discharge
Actuator Manufacturer:___Type:___Gearbox Manufacturer:___Type:___Ratio:___Serial:__
Dissolved Oxygen Analyser
Manufacturer:Type:Serial No:
Sump Pump Pumps water out of dry well space
Manufacturer: _____Type: ___
Dosing Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 42 of 51Review Date: Last Modified Date: 22 November 2017
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Main Components Function Design Criteria
_____ RPMPump Weight: ___ kgSerial No: _____
Metering Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barSerial No: _____
Service Water Pump Manufacturer:Type:Serial No:
Internal Delivery Pipe To deliver flow from pump to the outlet of the pump station.
Manufacturer: _____Type: ___Diameter:____ mmMaterial: ____Pressure class: ____Length: ____ m
Rising Main To deliver flow from pump station ?? to pump station ?? or Manhole ??
Manufacturer: _____Type: ___Diameter: ____ mmMaterial: _____Pressure class: PN___Length: ____m
Tank Alum storage Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 43 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
1 X Lifting Equipment To allow for the removal of pumps from the wet well for routine and non-routine maintenance
S/S Guide Rails and lifting chainsSize of Chains: ___
Chlorinator Manufacturer: _____Type: ___Serial Number: ____Maximum ___/ __Hr
Gas Feeder Manufacturer: ____Type: ____Capacity: ____
Vacuum Regulators Manufacturer: ____Type: ____
Soft Starter Reduces the excess current during initial power-up of an electric motor
Manufacturer: ____Type: ____
Irrigation Flow Meter Measures flow ... Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm
Valve Manufacturer:Type:Max Pressure:
VSD to control the speed of the motor within its operating range
Manufacturer: ____Type: ____
Filter Manufacturer: ____Type: ____
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 44 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
PLC Manufacturer: ____Type: ____
Generator Convert mechanical energy to electrical energy
Manufacturer:Type:Motor Size: ____kWRate Voltage:Fuel Type:Fuel Tank Capacity:Fuel Consumption:Dimensions:Weight:Serial No:
Air Compressor To supply compressed air to the air actuatorated valves within the plant and to supply compressed air to the DAF vessel
Manufacturer:Type:Serial No:
Hydro Cyclone Manufacturer:Type:Serial No:
Bay Outlet Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____
Filter Media Each filter removes floc and other matter.
Explanation of types and depths?
Manufacturer:Type:Dual Type:Multiple Depths:Volume:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 45 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
Main Components Function Design Criteria
Nozzles Manufacturer:Type/Model No:
Cathodic protection Manufacturer:Type:
Groundwater Bore Ground Works Number:Date Drilled:Casing Outside Diameter:Casing Inside Diameter:Casing Wall Thickness:Casing Type:Apertures:Screened From – To:Bore Depth:
Air conditioner Manufacturer:Type:
Door Specifications Door Type:Spindle:Head Pressure:Actuator:Clear Water Way:Operating Level:Door Material:Weight:Handwheel direction:
Baffle Comment on orientation Manufacturer:Type:Material:Size:
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 46 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT D” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.
Use this numbering system. E.g.
Figure 3: Describe photo here.
Under normal operating conditions, the
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 47 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT D” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.
“PROCESS ELEMENT D” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.
Figure 9: Describe photo here. Utilise this numbering system for additional photos.
Manual Override
Start-up
Standard Operation Procedures
Shutdown
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 48 of 51Review Date: Last Modified Date: 22 November 2017
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document.docx
“PROCESS ELEMENT D” TROUBLESHOOTING
Table 15: “Process Element D” Troubleshooting Guide
Problem Cause Solution/Action
Note: All electrical work is to be carried out by qualified electricians only.
Complete this table and add/remove rows where necessary.
“PROCESS ELEMENT D” EMERGENCY
Table 16: “Process Element D” Emergency Guide
Condition Actions
PLC Failure Contact GVW Operations IT Department
Power Failure Restore powerElectrician and/orPower company
Complete this table and add/remove rows where necessary.
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 49 of 51Review Date: Last Modified Date: 22 November 2017
document.docx
LIST OF FIGURESFigure 1: Town Site Process Flow Diagram.........................................................6Figure 2: Describe photo here..........................................................................10Figure 3: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................15Figure 4: Describe photo here..........................................................................18Figure 5: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................23Figure 6: Describe photo here..........................................................................26Figure 7: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................31Figure 8: Describe photo here..........................................................................34Figure 9: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................39
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 50 of 51Review Date: Last Modified Date: 22 November 2017
document.docx
LIST OF TABLESTable 1: Pumping Station Details.....................................................................10Table 2: “Process Element A” Design Criteria and Components.......................10Table 3: “Process Element A” Troubleshooting Guide......................................16Table 4: “Process Element A” Emergency Guide..............................................17Table 5: Pumping Station Details.....................................................................18Table 6: “Process Element B” Design Criteria and Components.......................18Table 7: “Process Element B” Troubleshooting Guide......................................24Table 8: “Process Element B” Emergency Guide..............................................25Table 9: Pumping Station Details.....................................................................26Table 10: “Process Element C” Design Criteria and Components.....................26Table 11: “Process Element C” Troubleshooting Guide....................................32Table 12: “Process Element C” Emergency Guide............................................33Table 13: Pumping Station Details...................................................................34Table 14: “Process Element D” Design Criteria and Components....................34Table 15: “Process Element D” Troubleshooting Guide....................................40Table 16: “Process Element D” Emergency Guide............................................41
Created By: Infrastructure Information Officer Version: 8Approved By: Asset Performance Manager Page 51 of 51Review Date: Last Modified Date: 22 November 2017