DOCUMENT TITLE:

OPERATING MANUAL
Leachate Treatment Plant Step 2
Aerobic Pond
(English)

Particular Technical Spesification

5.7.2 Operation and maintenance manual
TABLE OF CONTENTS
1 GENERAL 5
1.1 Purpose of this document 5
1.2 Wastewater treatment plant information 5
1.3 Site 6
1.4 Owner 6
1.5 Consultant 6
1.6 Contractor 6
1.7 Operator 6
1.8 Producen 7
1.9 Operating License 7
1.10 Limits in operation of the wastewater treatment plant 7
1.11 Design data of the wastewater treatment plant 7
1.12 Pictograms, safety symbols 8

2 BASIC GUIDELINES 13
2.1 Intended use 13
2.2 Reasonably foreseeable faulty application 13
2.3 Duties of the owner 14
2.4 Duties of the operators 14
2.5 Tasks of the operators 14
2.6 Qualification of the operators 15
2.7 Warranty and liability 15

3 IMPORTANT SAFETY INFORMATION 16

3.1 General safety rules 16
3.2 Personal Protective Equipment (PPE) 16
3.3 Working with chemicals 17
3.4 Working with electrical equipment 17
3.5 Working with mechanical equipment 18
3.6 Particularly hazards 18
Hazard due to release of hydrogen sulphide (H2S) 18
Hazard due to release of chlorine gas 19
Hazard due to asphyxiation in confined spaces 20
Hazard due to contact with wastewater 20
Hazard due to acoustic emission 20
3.7 Residual risk 21

4 SAFETY CONCEPT OF THE WASTEWATER TREATMENT PLANT 22

4.1 General 22

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 4.2 M&E installation and tests 22
4.3 Self-monitoring of wastewater feed and discharge parameters 22
4.4 Monitoring of process parameters 22
4.5 Emergency shutdown / Emergency stop buttons 23
4.6 Leakages 23
4.7 Tank overfill protection 24
4.8 Chemical storage tanks overfill protection 24
4.9 Over pressure in pipework 24
4.10 Further security and protection utilities 24
4.11 Freeze protection 25

5 CONTROL OF WASTEWATER TREATMENT PLANT 26

5.1 Block Diagram 26
5.2 Control of HMI 26
5.3 Operator Duties 26
Plant walk around 27
Process monitoring 27
Sample Collection 28
Sample Analysis 28
Biological Process Control 29
Determining inlet flow rate to the plant 32
Maintaining biomass levels and sludge wastage 33
Operation of the Ultrafiltration 33
5.4 General Operating Procedures 41
Plant start up 41
Plant shut down 44
Responding to power failure 45
Responding to an emergency stop 46
Responding to a fast stop 46

6 PLANT HMI SYSTEM 46

Instrument Pop-Up Menu 53
Biology operation 53
Cooling System 56
Blower Control 56
Alarm Triggering and Trending 56
6.2 Auto Mode of devices 57
6.3 Manual Mode of devices 57

7 PLANT MAINTENANCE AND FAULTS 58

7.1 Regular light maintenance 58
Calibration and cleaning of instrument 59

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 Cleaning/changing of filters/strainers 59
Blower inspection 60
Blowing down compressor bowl 60
CIP of membranes 60
Light maintenance of dosing pumps 60
Inspection of safety shower and eyewash 60
7.2 Inspection of tanks, sumps, vessels 61
7.3 Basic Maintenance 61
7.4 Faults and Mal-Functions 61
7.5 Failures 62
7.6 Life cycle 62
7.7 Decommissioning 62
7.8 Dismantling and disposal of the wastewater treatment plant 63

8 CONSUMABLES AND WEAR & SPARE PARTS 64

8.1 Chemicals 64
8.2 Wear & Spare Parts 64
8.3 Disposal 64

9 SIGNATURE SHEET 65

10 ANNEX 66

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1 GENERAL
1.1 Purpose of this document
The purpose of this Operating Manual, with all appendices and documentation (OEM-manuals,
drawings, lists, etc.) of the installed equipment, is to provide a single documentation with compre-
hensive plant information such safety and operation instructions, drawings, functional specifica-
tion, equipment data/manuals and others. The Owner has to carry out a risk assessment of the
entire wastewater treatment plant area to determine potential hazard zones and implement
method statements to minimise the risks.

The Operating Manual was written in accordance with the:

 Machinery Directive 2006/42/EC
 Pressure equipment Directive 97/23/EC

Always keep the Operating Manual at the plant, accessible to operators and maintenance per-
sonnel. The safety notes in this Operating Manual are mandatory.

INFORMATION
This document does not release the owner of the wastewater treatment plant
of its obligation to perform its own risk assessment for the operation of the
wastewater treatment plant, to draw up an emergency plan, operating and
working instructions and to carry out recurring safety instructions.

INFORMATION
Prerequisite for the safe use and trouble-free operation of the system is the
knowledge of basic safety precautions and safety regulations. This operation
manual, in particular the safety instructions, have to be observed by all per-
sons working in the immediate vicinity of the plant. In addition, also all rele-
vant local rules and regulations for accident prevention have to be noticed.

1.2 Wastewater treatment plant information

Leachate Treatment Plant
BIOMEMBRAT® Process
Malang (Java), Indonesia
UU2498
Year of construction: 2020

Short description of the process.

KFW Tender submitted data for the design of a Leachate Treatment Plant (LTP) from a new
municipal solid waste (MSW) landfill “Malang” in Indonesia. The leachate amount is 375 m³/day
(15.6 m³/h). The main process description is referred to the Control Philosophy document of
Leachate Treatment Plant (LTP) Malang for Step 2.

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1.3 Site
PT. PP (Persero), Tbk.
Kantor Keet PP Proyek ERIC Malang
TPA Supit Urang, Kelurahan Mulyorejo, Kecamatan Sukun
65147 Kota Malang

1.4 Owner
Satker Pelakasana Prasarana Permukiman
Wilayah II Provinsi Jawa Timur
Jl. Raya Menganti Wiyung PO.BOX 89/SB-KR
Surabaya

1.5 Konsultan Supervisi

Fichtner Gmbh & Co.KG
70191 Stuttgart Local Court HRA 9277

1.6 Contractor
PT. PP (Persero), Tbk.
Divisi Infrastruktur 2
Plaza PP- Lt. 5
Jl. Let. Jend. T.B. Simatupang,
No. 57 Pasar Rebo
Jakarta Timur
Indonesia

1.7 Operator
Dinas Lingkungan Hidup Kota Malang
Jl. Bingkil No.1, Kelurahan Ciptomulyo, Kecamatan Sukun, Kota Malang, Provinsi Jawa
Timur, 65148 (0341) 366385 dlh@malangkota.go.id

1.8 Producen
Head Office:
WEHRLE Umwelt GmbH
Bismarckstraße 1-11
D – 79312 Emmendingen
Germany
Tel: +49 (0) 7641 585-0
Tel: +49 (0) 7641 585-400 (service department)
Fax: +49 (0) 7641 585-106
www.wehrle-umwelt.com

1.9 Operating License

The wastewater treatment plant operation requires an official water permit for discharge to wet-
land (LTP Malang Step 3). It is the Owner’s responsibility to apply for this license/permit.

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1.10 Limits in operation of the wastewater treatment plant
The wastewater treatment plant has been designed and built for the following function and limits:
 Location see section 1.2
 Absolute altitude 506 m asl
 Ambient temperature 18°C – 31°C
 Wind load 1.8m/s – 3.7m/s
 Battery limits according to P&IDs

1.11 Design data of the wastewater treatment plant

The wastewater treatment plant has been designed and built for the following wastewater feed
and discharge parameters:

Wastewater feed parameter unit values

Flow (hourly) [m³/h] 12.5
(daily) [m³/d] 300
(annual) [m³/a] 109,500
BOD5 (max) [mg/l] 10,000
COD (max) [mg/l] 20,000
BOD5/COD ratio [-] ≥ 0,3
NH4-N (max) [mg/l] 2,000
P-total (max) [mg/l] Not given
Chloride (max) [mg/l] Not given
TSS (max) [mg/l] Not given
pH (max) [-] 6–8
N-total (max) [mg/l] Not given
Electrical Conductivity (max) [µs/cm] 20,000

Wastewater discharge parameter to Wetland unit Values

BOD5 [mg/l] < 100
COD [mg/l] < 1,000
NH4-N [mg/l] <5
NO2-N [mg/l] N/A
P- total [mg/l] 80
Cl [mg/l] N/A
TSS [mg/l] <5
pH [-] 6–8
N-total [mg/l] < 100
Electrical Conductivity [µs/cm] 20,000

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1.12 Pictograms, safety symbols
Some of the following pictograms will be used in the Operating Manual and at the wastewater
treatment plant to draw attention to any information, dangerous situation and/or residual risks.

WARNING
Disregard of pictographs and the respective safety instructions can lead to
danger to life and limb and to the environment.

The pictograms have to be kept clean all the time. In case they have been worn down, the picto-
grams need to be replaced.

Hazard pictograms
Pictogram / Sign Code Description
Flammable gases, aerosols, liquids or solids
Self-reactive substances and mixtures
Pyrophoric liquids and solids, Organic peroxides
GHS02
Self-heating substances and mixtures
Substances and mixtures, which in contact with water emit
Flame flammable gases

GHS03 Oxidising gases, liquids and solids.

Oxidising

Corrosive to metals
Skin corrosion
GHS05
Severe eye damage
Corrosive
Corrosion

GHS06 Acute toxicity (Cat 1-3)

Skull and cross-

bones
Acute toxicity (Cat 4)
Skin and eye irritation
GHS07 Skin sensitisation specific target organ toxicity
Respiratory tract irritation
Exclamation mark
Narcotic effects

Respiratory sensitisation
Germ cell mutagenicity
GHS08 Carcinogenicity
Reproductive toxicity specific target organ toxicity
Health hazard Aspiration hazard

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 GHS09 Hazardous to the aquatic environment.

Environment
Warning pictograms
Pictogram / Sign Code Description

Taking care regarding the hazard specified by the supple-

W001
mentary sign.
General warning

W008 Taking care when in vicinity of a drop

Risk of falling

Virus or toxin
W009
Taking care to avoid exposure to a biological hazard.
Biological hazard

Taking care to avoid a slippery surface or being aware of

W011
it, taking care to avoid slippery.
Slippery surface

W012 Taking care to avoid coming into contact with electricity.

Electricity

Taking care to avoid coming into contact with toxic mate-

W016
rial.
Toxic material

Taking care to avoid coming into contact with a hot sur-

W017
face.
Hot surface

Taking care when in the vicinity of machinery with moving

W018 mechanical parts which may start automatically and thus
unexpectedly.
Automatic start-up

Taking care to avoid causing a fire by igniting flammable

W021
material.
Flammable material

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 Warning sign for places where explosive atmospheres
D-W021
may occur.
Explosive atmos-
pheres

W023 Taking care when handling corrosive substances.

Corrosive substance

Prohibition pictograms
Pictogram / Sign Code Description

Hazard: Fire or explosion caused by lit cigarettes or other

smoking materials or harm from the smoke.
P002
No smoking!
No smoking
Hazard: Fire or explosion caused by an open flame, open
ignition source or smoking.
P003
Not having an open flame or open ignition source and not
No open flame smoking.

This symbol means that these areas may only be entered

D-P006
by authorized personnel.

No entry

Hazard: Electromagnetic field

P013
Turning the mobile phone off or not switching it on.
No activated mobile
phone

Hazard: Ingestion of dangerous substances by food and

drink contaminated at a designated area.
P022
No eating or No eating or drinking! / Do not eat or drink!
drinking

Hazard: Change of the current energetic or mechanical

state of a machine or equipment.
P031
Do not alter the state No switching!
of the switch

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 Mandatory pictograms
Pictogram / Sign Code Description

M001 Attention (General mandatory sign)

Refer to instruction manual / Instruction manual must be

M002
read

M003 Ear protection must be worn

M004 Eye protection must be worn.

M008 Safety footwear must be worn.

M009 Safety gloves must be worn.

M010 Safety overalls must be worn.

M011 Hands must be washed.

M014 Safety helmets must be worn.

M017 Respiratory protection must be worn.

M018 Safety harness must be worn.

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 Skin has to be protected with an appropriate barrier
M022
cream.

Fire safety pictograms

Pictogram / Sign Code Description

F001 Indicates the location of a fire extinguisher.

Fire extinguisher

Rescue or first aid pictograms

Pictogram / Sign Code Description

Indicates the location of first aid equipment or facilities or

E003
staff.
First aid

E004 Indicates the location of an emergency telephone.

Emergency
telephone

E012 Indicates the location of a safety shower.

Safety shower

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2 BASIC GUIDELINES
2.1 Intended use
INFORMATION
The wastewater treatment plant was designed and built according to cur-
rent applicable European Directives, EN-standards and regulations and for
the treatment of wastewater as described in chapter 1.10. The treatment of
wastewater of different composition and other characteristics or wastewater
from other sites is not intended and detrimental consequences or damages
due to this or other non-conforming use of the plant are not covered by
manufacturer.
Any different or additional use is considered as inappropriate. The manu-
facturer is not liable for any risk and damage in this case, the wastewater
treatment plant can be used only:
 In accordance with instructions
 In adherence to inspections and maintenance requirements
 In safe manner
 In proper state; any affecting faults have to be removed immediately

2.2 Reasonably foreseeable faulty application

WARNING
Improper use may be hazardous and can cause lead to danger to life
and limb and to the environment:
 Operating in an explosive atmosphere (EX zones)
 Operating in Hazard Zones without PPE
 To exceed the specified limits for wastewater volume and concentra-
tions for the normal operation (see also chapter 2.1)
 To deactivate the safety installations

Additions or alterations:
The guarantee and liability of the manufacturer end in the case of any unauthorized alterations or
changes of the machine/plant. This also applies to the welding of the primary structures.

Spare and wear parts, auxiliary materials:

The use of spare and wear parts from other manufacturers/suppliers may also be hazardously.
Use only original parts or manufacturer approved parts. There is no acceptance for damages
resulting from the use of not approved spare and wear parts or auxiliary materials.

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2.3 Duties of the owner
INFORMATION
The owner is obliged to:
 perform its own risk assessment for the operation of the wastewater
treatment plant, to draw up an emergency plan, operating instructions
and work instructions and to carry out recurring safety instructions
 allow working in the plant only to those persons who have as a mini-
mum, but not limited to:
1. relevant knowledge of the work safety and accident prevention
and have received from the owner the safety-, operating- and
working instruction.
2. read the safety instructions and warnings in this manual, under-
stood, and have confirmed by their signature (see appendices).
3. have been trained by the manufacturer

2.4 Duties of the operators

INFORMATION
All persons who are authorized to work in the plant perform the following
before work beginning to:
 Observe the regulations on work safety and accident prevention and
have received from the owner the safety-, operating- and working in-
struction.
 have been instructed and trained by the manufacturer and read the
safety instructions and warnings in this manual and confirm by signa-
ture that they have understood it (see section 9 – Signature sheet).
Participation in teaching and training has to be confirmed in a report
sheet.

2.5 Tasks of the operators

The main tasks are:
 Normal operation: plant and process control, regular inspection plus controlling plant
performance
 Laboratory work: analytical laboratory work
 Light Maintenance: calibration of instruments, filter change, cleaning of membranes
 Maintenance: oil change, belt change, repair work of process components
 Malfunction rectification: fault detection and removal finding and rectification

The plant can optionally be operated by one or more persons. It is recommended to train and
instruct of at least two people, who can represent each other in case of illness/holiday.

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2.6 Qualification of the operators
Trained staff, laboratory technician, mechanics,
Task
electrician
Commissioning only by manufacturer
Normal operation trained staff, manufacturer
Laboratory work laboratory technician
Light Maintenance trained staff
Maintenance mechanics, electrician
Malfunction rectification trained staff (consult manufacturer)

2.7 Warranty and liability

Warranty and liability shall apply as set up in the contract. Warranty and liability claims for per-
sonal injury and property damage are excluded when they have one of more of the following
causes:
 Improper use of the plant
 Improper operation and maintenance of the plant
 Operating the system with defective safety devices or not properly mounted or non-func-
tioning safety and protection devices
 Failure to follow the instructions regarding operation and maintenance
 Unauthorized modifications on the plant
 Insufficient monitoring of machine parts subject to wear
 Improperly executed repairs
 Disaster events beyond human control and acts of God
 Use of untrained personnel
 Treatment of non-contractual wastewater

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3 IMPORTANT SAFETY INFORMATION
A wastewater treatment plant consists of several individual units and components. All related
operating instructions and safety rules of the individual units or components are included in the
OEM documentation of the equipment supplier. There is very important to the plant operator to
get used to the entire instruction manual and to find out – if needed – the respective regulation to
be complied.
Please report all faults immediately to your supervisor. Faults under warranty have to be sent to
the manufacturer with the attached appropriate note of malfunction.

3.1 General safety rules

INFORMATION
 Wear appropriate Personal Protective Equipment (PPE).
 Never dismantle safety installations without permit.
 Only work with safe machinery, tools, plants and ladders. Faults with
the equipment have to be reported immediately to the line manager.
 Repair works on machinery; electrical equipment and the general in-
stallation have to be done by qualified personnel only.
 Be careful when using fire and open light appliances.
 Be aware of work that takes place on higher level, i.e. the roof access
platforms, as there is always the risk of objects falling down
 Plan the work before it commences.
 Minimise the likelihood of incidents by inspecting the plant in pairs.

3.2 Personal Protective Equipment (PPE)

INFORMATION
The owner must provide as a minimum the following protective equipment
to the operators which are working on the plant:
 Hard Hat
 Eye and Face Protection
 Rubber Gloves
 Safety Shoes
 Rubber Boots
 Rubber Apron
 Fall Protection
 Ear Protection
 Skin Protection Agents
 Mobile Gas Warning Device if entering confined spaces – e.g. CH4,
CO2, H2S monitor for entering into hazard zones, e.g. tanks, sumps,
ducts, etc.

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3.3 Working with chemicals
WARNING
 Make yourself familiar with relevant risks, before working with any
chemicals.
 The corresponding datasheets (MSDS/COSHH) should be displayed
near chemical storage.
 The necessary warning and signs/pictograms should be clearly dis-
played.
 Always follow the recommended safety precautions and use the recom-
mended PPE.
 Before working with chemicals check the functionality of the safety
shower and eyebath.
 Drip losses or spillages during filling have to be eliminated and dis-
posed according to the corresponding datasheets (MSDS/COSHH).

There is an emergency shower in close proximity of the biocide tank. An eye wash bottle is avail-
able in UF container.

3.4 Working with electrical equipment

WARNING
Make yourself familiar with the risks, before working with any electrical
equipment.

Consider the following instructions before use of all electrical equipment:

 No damage to the connections.

 The wires in the cable should be covered and not damaged.
 There should be a rubber sleeve at the cable-equipment connection.
 Check switches for obvious damage and tight fit.
 Check the housing for external damage.
 To pull a power cable from the socket only the plug shall be pulled.
 Turn on/switch off the devices only with the switch, never by removing the plug connec-
tions.
 Use only explosion protected (ATEX rated) power tools and lights in areas where an ex-
plosive atmosphere may occur.
 Low voltage or isolation transformers must be placed outside the room when working in
small spaces.
 Make sure that cables are not tripping hazards and are well routed so that they can’t be
damaged.
 Increased electrical hazard exists when working in, on and between electrically conductive
parts which can be like in containers, on walls and pipes from iron girders. Furthermore,
an increased electrical hazard is also in wet, damp or hot workplaces.

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3.5 Working with mechanical equipment
ATTENTION
Make yourself familiar with the risks, before working with any mechanical
equipment. Sources for accidents like bruise, crushing, trapping of body
parts are:
 Actuated valves
 Filters
 Belt and chain drives
 Shaft couplings
 Pumps
 Blowers

Consider the following instructions before carrying out the following works:

 Make sure when working on any plant equipment that it is switched off, isolated from
power, pressure-less as well as locked off before any work commences. Make sure that
the plant equipment can’t be reconnected before work has been terminated.
 Make sure that nobody is staying in the danger zone when working near cranes.
 The additional safety features as protective grids for moving parts must not be taken from
the equipment unless measures have been put in place and it is safe to do so.
 Use only explosion protected (ATEX rated) power tools and lights in areas where an ex-
plosive atmosphere may occur.
 Use only spark-proof tools in areas where an explosive atmosphere may occur.
 Keep the floor free of grease, oil and moisture and eliminate tripping hazards or objects
lying around because of slip danger.

3.6 Particularly hazards

In this chapter the focus is lead on hazards that may occur during commissioning, normal oper-
ation, maintenance, malfunction, decommissioning and dismantling of the wastewater treat-
ment.
The entry of these zones (e.g. ducts, sumps and tanks, etc.) during commissioning, normal oper-
ation, maintenance, malfunction, decommissioning and dismantling is only allowed for persons
who have passed a special training to be permitted for entry.
Hazard due to release of hydrogen sulphide (H2S)
DANGER
Hydrogen sulphide is a highly toxic gas that spreads in low concentrations
the typical smell of rotten eggs. The toxic effect is due to the fact that it
destroys the haemoglobin (red blood pigment) of the body, leading to a pa-
ralysis of the intracellular respiration. In contact with mucous membranes
and tissue fluid H2S also forms alkali sulphides, which heavily irritate the
affected areas. Since hydrogen sulphide is heavier than air, it tends to ac-
cumulate in sinks

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 Besides methane and carbon dioxide anaerobic microorganisms also form
hydrogen sulphide from sulphur (e.g. SO4) as a by-product of their metabo-
lism. It can occur as both, gaseous compound and dissolved in the liquid.
Hydrogen sulphide is formed by anaerobic microorganisms which appear in
stagnant wastewater. Location that favour the growth of these organisms in
wastewater plants are ducts, sumps, tanks, pipework, etc. which contains
stagnant wastewater or that have been decommissioned but not drained.

At gas concentrations as low as 0.5 ppb H 2S can be perceived by the human nose. At higher
concentrations >100 ppm an anaesthesia of the odour receptors occurs. Due to this fact hydrogen
sulphide and the dangers emanating from it are no longer noticeable. The following table presents
an overview of typical symptoms of H2S intoxication.

H2S concentration exposure and symptoms

< 100 ppm POISONING after several hours of exposure
POISONING after less than one hour of exposure
> 100 ppm
development of pulmonary oedema
DANGER TO LIFE after 30 minutes of exposure
app. 500 ppm
short-term increase in respiration followed by respiratory apnoea
app. 1 000 ppm DANGER TO LIFE after a few minutes of exposure
DEATH occurs within a few minutes of exposure
> 1 000 ppm
unconsciousness, respiratory disorders, convulsions
app. 5 000 ppm DEATH occurs within a few seconds of exposure

Hazard due to release of chlorine gas

DANGER

The membrane filtration system must be cleaned at regular intervals. Differ-

ent membrane cleaners are used for this. Among others, a hypochlorite
cleaner and acidic cleaner is used. Both cleaners should be never be mixed
together and used together at the same time due to the risk of formation of
toxic chlorine gas.

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 Hazard due to asphyxiation in confined spaces
DANGER
The entry of confined spaces, e.g. ducts, sumps, tanks, etc. during commis-
sioning, normal operation, maintenance, malfunction finding, decommis-
sioning, dismantling and disposal purposes is only allowed for persons who
have passed a special training to be permitted for entry.
To minimize and prevent the likelihood of an accident, additional precautions
and measures have to be in place. This includes:
 Minimise the likelihood of incidents by inspecting ducts, tanks etc. in
pairs.
 Ensure that ducts, tanks etc. have been opened with an adequate
lead time before entering.
 Ensure that ducts, tanks etc. have been cleaned and that gassing has
calmed down before entering.
 Ensure that adequate air supply in the ducts, tanks etc. exists
 Wear appropriate PPE and a personal gas analyser when entering a
duct, tank etc.
 Entry is only allowed by the use of the OWNERS permitting sys-
tem.
The OWNER has to carry out a risk assessment of the entire wastewater treatment plant area to
determine potential hazard zones and implement method statement to minimize the risks.

Hazard due to contact with wastewater

WARNING
Wastewater can contain substances which are classified as Hazardous Sub-
stances as well as active microorganisms.
The wastewater carries the risk of infections or of endangering the environ-
ment due to uncontrolled release.
Therefore, appropriate PPE must be worn when directly getting in contact
with wastewater and an uncontrolled release of wastewater has to be
avoided.
To prevent the likelihood of infections, precautions have to be in place. This
means that sufficient vaccination for the operators has to be stated by the
company doctor.
Open wounds have to be covered by plasters/band aids to avoid direct con-
tact.

Hazard due to acoustic emission

ATTENTION
The process involves noise emitting aggregates. This acoustic emission
carries the risk of injuries, especially when aggregates (e.g. blowers, com-
pressors, pumps) are installed in a closed application environment.

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 In case of uneasiness, leave the noisy area and contact the line manager,
if necessary.
To minimise the likelihood of an injury, precautions have to be in place.
This means that the PPE for working in this area must be worn before
entering. This includes the use of ear protection.

3.7 Residual risk

In order to minimalize the residual risks, the following measures described hereafter have to be
carried out:

Plant Maintenance and Cleaning

Danger Point Danger Description Measure
Valves with actuator Bruising of limbs (hands, fin- Valves have to be depressurized
gers) and to be made electricity-free
Shaft couplings of motor - Capture of clothing or hairs Only tight work clothes;
driven items (e.g. pumps, - General injury by unfore- Hair tied up and tied together;
blowers, etc.) seen starting of the mo- Made the aggregate electricity-
tor/unit free and provide a safeguard to
prevent unintentional restart
Belt and chain actuator Tapering and catching Only tight work clothes;
Hair tied up and tied together;
Made the aggregate electricity-
free and provide a safeguard to
prevent unintentional restart
Noise inside Building / Damage of sense of hearing Wear ear-protection
Container

All Other Life Phases

Danger Point Danger Description Measure
All live parts Electric shock from indirect Periodic visual inspection of the in-
contact (fault condition in stallation with triggering of protec-
parts, insulation failure) tion devices, isolation measure-
ments have to be carried out
All electrical consumers Flying sparks, overheating, Regular insulation measurements
fire (also after a short circuit) and their documentation.
Contact with activated Infection Vaccination by the company doc-
sludge and leachate See section 3.6.4 tor, see section 3.6.4
Methane present Explosion hazard See section 3.6.5
See section 3.6.5
Objects falling down from Objects falling down from Operators has to wear PPE
tanks tanks; e.g. tools, nuts/bolds, (hard head)
other items
Noise inside UF Con- Damage of sense of hearing Wear ear-protection
tainer
Vibration Loosening of parts Regular inspection

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4 SAFETY CONCEPT OF THE WASTEWATER TREATMENT PLANT
4.1 General
INFORMATION
This chapter describes the safety precautions and possible malfunction. In
addition, the proposed measures to remedy of the malfunctions will be
shown. Basically, process-related problems should lead to automatic shut-
down of the affected plant part, i.e. the progress of this part of the plant
should be immediately interrupted. Faults will be reported to the appropriate
control system.

4.2 M&E installation and tests

The wastewater treatment plant was built by the manufacturer or by the companies commissioned
by him in accordance with good engineering practice and applicable rules and regulations.
The production of pipes and their connections has been carried out by appropriately qualified
personnel. After installation, a visual inspection will be done by the manufacturer or its repre-
sentative. Any detected defects will be corrected. The following tests will be made and docu-
mented:
 Leak testing of all tanks
 Pressure test on all pressurized piping

The delivery of the switchgear and all units of electrical equipment and measuring instruments
have been carried out by appropriately qualified personnel. After installation, a visual inspection
will be done by the manufacturer or his representative. Any detected defects will be corrected.
The following tests will be made on all live parts and documented:
 Measurement of earth resistance
 Isolation measurement

4.3 Self-monitoring of wastewater feed and discharge parameters

All required parameters for wastewater feed and discharge have to be observed at regular inter-
vals by the plant operator. This requires the regular sampling at the required points and the anal-
ysis of the parameters in the laboratory. The analysis results have to be documented by the op-
erator in the given lab-sheets. More details about sample collection and sample analysis could
be found in chapter 5.3.3 and 5.3.4.

4.4 Monitoring of process parameters

Many process parameters will be continuously measured and monitored by the PLC (program-
mable logic controller). The process parameters will be summarized in the P&ID’s flow diagram
and the measurement device list. The following will be monitored, e.g.:
 Pressure in pipework
 Level in tanks
 Flow in pipework
 pH, oxygen, etc. in pipework and tanks

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  Functional status of the pumps, blower, etc.
The electrical measurements will be shown and recorded on the HMI (human machine interface).

4.5 Emergency shutdown / Emergency stop buttons

INFORMATION
All operators shall make themselves familiar with the exact position of the
Emergency Stop bottoms.

The emergency shutdown can be triggered by pushing one of the emergencies stop buttons lo-
cated in the following areas:
 Electrical cabinets
 Operating panel in Ultrafiltration Container
 Entrance to Ultrafiltration container (machinery room)
 Near blowers
 Near chemicals filling stations
 Building by biological reactor
 On top of the Biological reactor

Once an emergency stop button is pushed all pumps, blowers, compressors, etc. will stop and
automated valves will move to it default position.

To reset the system the alarm has to be reset as well as the system by pushing reset emergency
stop button on the HMI.

4.6 Leakages
Leakages can be detected visually or due to the following changes in the process (displayed on
the HMI):
 Unexpected level drop in tank
 Unexpected pressure drops in pipework

In the event of leakage, the operator must take immediate action, for example:
 Switch off the affected part of the plant
 Shut down defective pipes by closing valves
 shut down affected units (e.g. pumps) by closing the valves
 shut off affected tanks
Note: immediate report any leakage to the Manufacturer.

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4.7 Tank overfill protection
The process tanks (biology tank, permeate tank, wash tank) are equipped with an overflow pipe
to protect the tanks against overfilling.

4.8 Chemical storage tanks overfill protection

The biocide and antifoam are equipped with sensors which will activate if the tank is overfilled. A
visual and audible indication on detection of overfill will be given at the local alarm light and at the
local horn.

INFORMATION
It is important to monitor the overfill alarm, especial during the filling process
of a chemical tank. If a overfill alarm arises during the filling process of a
chemical tank, the filling process must be immediately stopped. If this does
not happen the tank can overflow with the result of a chemical spillage onto
the ground.

4.9 Over pressure in pipework

All pipes will be designed to obtain the maximum operating pressure which can occur. Addition-
ally, critical plant items and pipework are equipped with pressure transmitters to monitor the pres-
sure. In case of overpressure and alarm will be released and the dedicated plant item will be
automatically switched off.

4.10 Further security and protection utilities

The following safety and protective devices are installed on dangerous zones of the machine:

Danger zone Safety and protection device

Rotating shafts or belts Covering of the shaft
Protruding parts such as cable trays or
Equipped with edge protection and marking
conduit lines
Equipped with circuit breaker, local isolators
All electrical motors
or local plugs
Blowers, compressors Equipped with acoustic enclosures
Application and use of only media-resistant
Storage and dosing of chemicals
materials
Water or sludge-filled tanks or reactors Equipped with railings or cover
High-pressure pipework is equipped with a
pressure-relief valve, in case of an overpres-
High pressure pipework
sure (>4,2 bar) the valve will release the
pressure from the pipework.

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 WARNING
In case of faulty safety and protective devices:
Faulty safety and protective devices can cause dangerous situations. For
this reason
 switch off the machine immediately,
 provide a safeguard to prevent unintentional restart,
 disconnect supply of compressed air and electricity.

All Safety and protective devices have to be checked on a regular basis as

part of plant inspection.

Note: immediate report any faulty safety and protective devices to the Man-
ufacturer.

4.11 Freeze protection

The building, container, kiosks are equipped with electric heaters. In addition, specific pipes and
tanks at the wastewater treatment plant are equipped with insulation and trace heating.
The plant normally operates at the following temperature:
 Wastewater feed temperature 20 – 28°C
 Biology: 25 – 37°C
 Ultrafiltration: 20 – 42°C

In the event of plant shutdown or de-energization for longer duration during winter times, the
operator has to drain all pipework and tanks, which are filled with water to minimize the risk of
bursting of the pipework and tanks.

INFORMATION
The water pipework connected to cooling tower as well as the cool-
ing tower and heat exchanger has to be drained during winter to
minimize the risk of bursting of the pipework.

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5 CONTROL OF WASTEWATER TREATMENT PLANT

5.1 Block Diagram

The wastewater treatment plant (Step 2) works as shown in the following schematic block dia-
gram.

Leachate from
LTP Malang Step 1

Denitrification Nitrification Nitrification

UF Permeate to LTP
tank tank tank Ultrafiltration
Malang Step 3
295 m³ 950 m³ 950 m³

Excess Sludge to
Sludge Dewatering

Refer to the P&ID´s for more detailed information on all equipment and operation of the Leachate
Treatment Plant. The Leachate Treatment Plant installation essentially consists of several major
components as follows:
Biological Treatment and Filtration
 Denitrification tank
 Nitrification tank
 Aeration system
 Ultrafiltration
Auxiliary Systems
 Biocide dosing
 Antifoam Dosing
 Cooling system
 Instrument Air
 Cleaner

5.2 Control of HMI

For detailed instructions on controlling the HMI please refer to sections 8.

5.3 Operator Duties

On a day to day basis the requirements for operating the plant are as follows.

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 Plant walk around
Step Action
Review HMI for current operating status and alarms. Log all alarms in plant log-
1
book. Respond to alarms as required.
2 Check wastewater levels in anaerobic pond.
3 Check dissolved oxygen, temperature and pH in biology
If UF loop is operating check pressure, circulation flow and permeate flow. If not
4
check trends for last operating data.
Walk around plant inspecting all pipework and tanks for leaks. Listen to operating
5
equipment for unusual noises. Log and report any issues.
6 Check for foam in nitrification tank. Act accordingly.

Process monitoring
In order to understand how the plant is operating and to ensure compliance operating data must
be collected. This takes two forms:

 Process data including flows, levels, pressures etc.

 Analytical data

Step Action
1 Monitor all plant items in data sheet and record data
2 Review anomalies and discuss with manufacturer if cause or severity is unknown
3 Perform analysis as specified. Record data.
4 Review anomalies and discuss with manufacturer if cause or severity is unknown
5 Determine COD and ammonia sludge loading based on data.
Send record sheets (XLS-files) for process data and analysis on a fortnight basis to man-
ufacturer.

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 Sample Collection
For normal analysis three different samples are required. These are:

 Wastewater
 Biological sludge
 Permeate UF

Note that when collecting samples that correct PPE is worn to mitigate the hazards posed by the
sample material. At least eye protection and suitable gloves are required.

Step Action
1 Take clean sample bottle and place sample hose into bottle
2 Open required valve and fill sample bottle. Close valve.
3 Shake bottle and discard contents safely
4 Fill bottle again.

The collection points for various samples are:

 Leachate – B1Z1K07 while inlet pump is running

 Sludge – Valve B1N1H12 while jet pump is running
 UF Permeate – Valve U1F1H08 while UF in operation

Sample Analysis
The analytical requirements are detailed below:

Parameter Inlet Biology Permeate UF

COD Min. three times a week --- Min. three times a week
NH4-N Daily --- Daily
NO2-N --- --- Min. three times a week
NO3-N --- --- Min. twice a week
Total Nitrogen Min. once a week --- Min. once a week
TS Min. once a week Min. twice a week Min. twice a week
Chloride Min. once a week --- Min. once a week
PO4-P Min. three times a week --- Min. three times a week
pH Min. once a week --- Min. once a week
Conductivity Min. once a week --- Min. once a week
Alkalinity Min. three times a week --- Min. three times a week

Page 28/66
 WARNING
 Note that many of the chemical reagents used in the analysis of sam-
ple are hazardous
 Ensure that you are aware of all hazards by reading the COSHH as-
sessment
 Wear appropriate PPE when handling samples and when handling
chemical reagents

There are the following main types of analysis required:

5.3.4.1 Analysis using Hach Lange cuvettes and reagents

COD, NH4-N, NO2-N, NO3-N, Total Nitrogen, PO4-P and Chloride
Follow the instructions on the inside of the cuvette boxes.

5.3.4.2 Quick tests using test strips

NO2-N and NO3-N
Follow the instructions provided with test strips.

5.3.4.3 Direct measurement using instruments

pH and conductivity
Follow the instructions provided with equipment.

5.3.4.4 Titration analysis

Alkalinity
Follow the instructions provided with test kit.

5.3.4.5 Moisture content analysis

Total solids
Follow the instructions provided with equipment.

Biological Process Control

The biological process is designed to do:

 remove COD to discharge levels to the LTP Malang Step 3 (Wetland)

 remove ammonium to discharge levels to the LTP Malang Step 3 (Wetland)

5.3.5.1 COD Removal

COD removal is relatively straightforward and there are rarely issues which will compromise
this. Nevertheless, care should be taken to ensure that the plant is operating within design COD
sludge loading. This should be calculated on a daily basis.

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In order to maintain adequate COD removal, ensure that:
 pH is kept between 6.8 and 7.5
 Dissolved oxygen is above 1.5 mg/l
 Phosphorus levels in the UF permeate are at least 2 - 3 mg PO4-P/l, in case
of lower values the dosing of phosphoric acid is required

5.3.5.2 Nitrification and Denitrification

The nitrification process is less stable than the COD removal process and as such requires
more care. Try to ensure:

No sudden changes in nitrogen load to the plant

Avoid sudden changes to the nitrogen load to the plant as the nitrification process may not be
able to adapt quickly enough to prevent increases in permeate ammonium

Ammonium loads lower than 0.06 kg N / kg MLSS

This is a theoretical limit beyond which the plant might be stressed. It is possible to operate at
higher loadings, but extra vigilance is required

Temperatures between 28°C and 38°C

Nitrifying organisms are temperature sensitive. At lower temperatures their activity is greatly re-
duced, and lower rates of nitrification will be seen. Temperatures above 35°C lead to reduced
nitrification capacity. Temperatures above 38 °C should be definitely avoided.

pH between 6.8 and 7.5

pH has a strong effect on nitrification rates. Operation beyond the optimum pH range could lead
to inhibition by free ammonia or nitrous acid (see below).

Dissolved oxygen above 1.5 mg/l

Nitrifying organisms are especially sensitive to low oxygen concentrations. For this reason,
maintaining elevated dissolved oxygen concentrations

Minimal inhibition by free ammonia

Ammonium in the final permeate will be in equilibrium with free ammonia which is inhibitory for
nitrifying organisms. This equilibrium is dependent on pH, temperature and the concentration of
ammonium. In order to avoid inhibition, operate the plant at a pH .0 and try to maintain no am-
monium in permeate. Figure 1 shows the inhibition of the overall nitrification process as a func-
tion of NH3, HNO2 and pH.

Minimal inhibition by free nitrous acid

Nitrite in the final permeate will be in equilibrium with free nitrous acid which is inhibitory for nitri-
fying organisms. This equilibrium is dependent on pH, temperature and the concentration of ni-
trite. In order to avoid inhibition, operate the plant at a pH ̴7.0 and try to maintain no nitrite in
permeate.

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 Figure 1. Inhibition of the overall nitrification process as a function of NH 3, HNO2 and pH
(Source: M. Henze, Wastewater Treatment)

Sudden increases in the nitrite or ammonium levels in treated effluent indicate that there is some
issue with the nitrification/denitrification process. In these cases, it is important to determine if the
cause of the increase is an increase in nitrogen load to the plant or a decrease in the nitrifying
capacity.

The nitrification process leads to a decrease in pH as H+ ions are released, and the natural alka-
linity of the wastewater is consumed. In order to counteract this, pH control using the addition of
caustic soda is employed. Full details of how this system operates can be found in the Attachment:
Functional Specification.

The greater the degree of nitrification, the greater is the fall in pH and thus greater is the con-
sumption of caustic soda. In order to minimise this, a pre-denitrification step is included within the
wastewater treatment plant. UF retentate containing nitrate is recycled back to the beginning of
the biological process and mixed with incoming wastewater.

Denitrifying organisms utilise the readily degradable organic component of the wastewater to re-
duce nitrate to nitrogen gas. This has the benefit of recovering a proportion of the alkalinity and
thus reduces caustic demand. To promote the rate of denitrification a carbon source can be
added. This provides additional readily degradable matter for the denitrifying organisms and
means that more denitrification can occur.

The rate of denitrification can be adjusted by varying the dosing rate of the carbon source. This
is a question of plant optimisation and the decision to increase or decrease denitrification would
be based on the relative costs of caustic soda and carbon source.

5.3.5.3 Aeration System Control and Foam Control

Aeration is provided by blower(s), jet pump(s) and injection nozzle array(s). For information on
the control of the aeration system see the attachment Functional Specification - Set Points of the
measurement B1N1M03.

The primary means of controlling foam is the foam tank. The control of the level in foam tank and
antifoam dosing is described in the attachment Functional Specification - Set Points. Care should
be taken to ensure that antifoam is not overdosed as this might have a detrimental effect on the

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ultrafiltration and aeration system. Dosage rates should not exceed 40 ml per m 3 of incoming
wastewater. Only manufacturer approved antifoam agents shall be used. Failure to do so could
invalidate warranty.

Determining inlet flow rate to the plant

Assuming that the ultrafiltration does not limit hydraulic capacity there are two factors which will
determine the flow through the plant.

5.3.6.1 Availability of wastewater

The biological process performs better under steady conditions. Therefore, if wastewater levels
are low care should be taken to minimise the flow rate to the plant so that wastewater supply
does not run out for significant periods.

5.3.6.2 Capability of biological process to handle leachate

The most common limitation of the biological treatment capacity of the plant will be the nitrifica-
tion capacity of the biomass. It is the responsibility of the operator to fully understand the treat-
ment capacity of the plant on any given day. This is a function of the following:

 Mass of biomass in plant – the more biomass available the more the plant can
treat. However, care should be taken to ensure correct biomass levels are main-
tained - see section 5.3.7
 Health of biomass – A healthy unstressed biomass will have a higher treatment
capacity than an unhealthy one – see section 5.3.7
 Foaming – If foaming is persistent it might lead to a reduction in the aeration ca-
pacity of the plant as blower speeds are reduced to control foaming level.
 Theoretical limitation of COD loading – Maintaining an adequate COD sludge load-
ing is essential. Too high sludge loading could lead to overloading and reduction
in aeration quantity. Maintaining a sludge loading of approximately 0.1 to 0.25 kg
COD removed per kg MLSS is essential. This might require modifying MLSS con-
centrations either by allowing the biomass to grow or wasting biomass if COD
sludge loading is too low.
 Theoretical limitation of nitrification capacity – There is an upper nitrogen sludge
loading limit of approximately 0.06 kg N per kg of biomass. In terms of capacity this
will vary as the biomass concentration varies. It is the responsibility of the operator
to understand this limit and where it stands on any given day.

Regular analysis of the biomass concentration allows the operator to determine the operating
limits of the plant. Analysis of wastewater quality then provides the information required to deter-
mine correct loadings and flows to the plant.

Note: It is critical that variations in loading to plant are kept to a minimum. Ideally variations of
±10% are acceptable. Anything beyond this could cause major issues with the biological pro-
cess. The operator must anticipate changes to loadings caused by changes in wastewater qual-
ity and adapt inlet flows accordingly i.e. as concentrations increase the operator should de-
crease flows so that the inlet loading to the plant does not increase at a rate greater than 10%
and vice versa.

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 Maintaining biomass levels and sludge wastage
As the biomass consumes organic matter in the wastewater, new biomass is grown. Usual
growth rates are 0.15 to 0.30 kg biomass per kg of COD removed. The COD which enters the
plant in the form of a carbon source should also be included in this figure.

This growth rate should be regularly (twice a week) monitored as higher than normal growth
rates may indicate a problem such as overdosing of carbon source or high suspended solids in
the inlet. At the design loadings for the plant the MLSS should be maintained at no more than
15 g/l. This will require regular wasting of excess sludge.

However, should the loadings to the plant decrease as wastewater volumes dropped the operat-
ing MLSS of the plant should be reduced to keep COD sludge loadings in the optimal range of
0.1 to 0.2 kg COD removed/kg MLSS. By keeping the MLSS high while the inlet loading drops,
this leads to a reduction in the COD sludge loading. A too low sludge loading can cause prob-
lems for the biological process including:

 Development of filamentous organisms

 Higher levels of endogenous respiration and increased aeration costs
 Increased foaming
 Reduced ultrafiltration performance

Excess sludge should be removed on a regular basis. This can be removed either by the sludge
dewatering system or directly from the biology tank at drain valve of the tank. Note that if a
tanker is removing excess sludge from the coupling then no suction can be applied by the tank.

Operation of the Ultrafiltration

The UF comprises of one loop which is filled with six modules. Each module has a membrane
surface area of 38.2 m 2. Therefore, there is a potential surface area of 229.2 m 2.
Normal operation of the plant requires the following:

Daily monitoring of circulation flow U1F1M02

A fall in circulation flow usually indicates that the loops are beginning to block. Further action,
such as membrane cleaning, is required.

Daily monitoring of circulation pressure U1FxM01

An increase circulation pressure usually indicates that the loops are beginning to block. Further
action, such as membrane cleaning, is required. A fall in circulation pressure when the commis-
sioning filter is in place indicates the commissioning filter is blocking.

Daily monitoring of permeate flow and calculation of flux rate

If permeate flow begins falling this indicates the loop may be fouling. Cleaning might be re-
quired. However, it is best to normalise the permeate flow to the membrane area in use as an
indicator of loop performance. This requires dividing the flow in litres per hour by the membrane
area (38.2 m2). The result, termed the flux rate, allows comparison to other plants. If the flux
rate falls below 75 l/m 2h then cleaning might be required.

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Daily monitoring of permeate quality
The permeate should be checked daily for turbidity. High turbidity indicates one or more mem-
brane tubes have failed and are passing sludge. Repair of the module requires manufacturer
input.

Regular water rinses (fortnightly)

Regular water rinses help to lift any build-up of fouling material from the membrane surface
without the requirement for chemical cleans. The frequency of these rinses will depend on the
performance of the plant.

Chemical cleans monthly to two months depending on requirement

Chemical cleans help remove more persistent fouling and precipitation on the membrane wall.
The sequence of the chemical clean will vary depending on the type of fouling. The most com-
mon chemical clean is an enzyme wash which takes approximately three hours. Further cleans
might be required if enzyme washes are not sufficient. These would include washes with acids,
alkalis, or hypochlorite.

WARNING
 Note that many of the chemical reagents used in the analysis of sam-
ple are hazardous
 Ensure that you are aware of all hazards by reading the COSHH as-
sessment
 Wear appropriate PPE when handling samples and when handling
chemical reagents. Consult COSHH assessments for further guid-
ance.

For basic cleaning the following sequence is recommended:

1. Flush
2. Water Rinse (ca. 15 Min)
3. Neutral cleaning (60 Minutes)
4. Flush
5. Water Rinse (ca. 15 Min)
6. Alkali clean (60 Minutes) *
7. Flush
8. Water Rinse (ca. 15 Min)
*Alkali clean could be combined with Hypochlorite clean. In such a case the cleaning time
should be 120 Minutes.
When required, the basic cleaning could be extended by:
9. Flush
10. Acid clean (60 Minutes)
11. Flush
12. Water Rinse

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The detailed description of each step could be found in Tables below.
DANGER
The hypochlorite clean should be never combined with the acid clean
due to the risk of formation of toxic chlorine gas.

5.3.8.1 Neutral Clean

Step Action
1 Stop UF loop and wait for it to flush
2 Flush loop again to remove residual solids
3 Perform reference water rinse and record loop circulation flow U1F1M02, circulation
pressure U1F1M01 and permeate flow U1P1M02 at a temperature of 20 °C
4 Stop rinse and begin chemical mixing sequence.
5 Wearing appropriate PPE take canister of neutral cleaning agent N10 to the cleaner
dosing point.
7 Place cleaning pump in the installed cleaning bucket and open valve U1H1V01A/B.
8 Switch on pump and flush pump and pipework with water. Switch off pump.
9 Open N10 canister and place cleaning pump inside canister.
10 Switch on pump and dose enough N10 to make a 1% solution in the cleaning tank.
Under normal operating conditions the cleaning cycle will run at 55% which is equiv-
alent to 660 litres. In this case add 6.6 litres of N10. IT IS ESSENTIAL THAT THE
FILLING VOLUME IS CHECKED AS THIS CAN BE ADJUSTED IF REQUIRED.
11 Once required volume is pumped into tank stop pump and place into bucked of wa-
ter. Close cleaner canister and return to drip tray.
12 Turn on pump and flush lines.
13 Stop pump and close valve U1H1V01A/B.
14 Wait 2 minutes and then begin chemical rinsing sequence
15 Allow rinse sequence to run to 40 °C as shown on U1S1M02 and then stop rinse.
Do not allow temperature to exceed 41 °C. Note that depending on the starting tem-
perature of the water the time taken to reach 40 °C might vary.
16 Every fifteen minutes record wash temperature U1S1M02, loop circulation flow
U1F1M02, circulation pressure U1F1M01 and permeate flow U1P1M02.
17 Perform flush on loop and then repeat step 3 to determine effectiveness of clean.
18 The loop is now ready for operation.
19 Tabulate all recorded data and send to manufacturer.

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5.3.8.2 Alkali Clean

Step Action
1 Stop UF loop and wait for it to flush
2 Flush loop again to remove residual solids
3 Perform reference water rinse and record loop circulation flow U1F1M02, circulation
pressure U1F1M01 and permeate flow U1P1M02 at a temperature of 20 °C
4 Stop rinse and begin chemical mixing sequence.
5 Wearing appropriate PPE take canister of alkali cleaning agent to the cleaner dos-
ing point.
7 Place cleaning pump in a bucket of water and open valve U1H1V01A/B.
8 Switch on pump and flush pump and pipework with water. Switch off pump.
9 Open cleaner canister and place cleaning pump inside canister.
10 Switch on pump and dose enough cleaner to make a 0.5% solution in the cleaning
tank. Under normal operating conditions the cleaning cycle will run at 55% which is
equivalent to 660 litres. In this case add 3.3 litres of alkali cleaner. IT IS
ESSENTIAL THAT THE FILLING VOLUME IS CHECKED AS THIS CAN BE
ADJUSTED IF REQUIRED.
11 Check pH. If below 10 add more cleaner in a controlled manner by regularly testing
pH between additions. DO NOT EXCEED pH 11.
12 Once required volume is pumped into tank stop pump and place into bucked of wa-
ter. Close cleaner canister and return to drip tray.
13 Turn on pump and flush lines.
14 Stop pump and close valve U1H1V01A/B.
15 Wait 2 minutes and then begin chemical rinsing sequence
16 Allow rinse sequence to run to 40 °C as shown on U1S1M02 and then stop rinse.
Do not allow temperature to exceed 41 °C. Note that depending on the starting tem-
perature of the water the time taken to reach 40 °C might vary.
17 Every fifteen minutes record wash temperature U1S1M02, loop circulation flow
U1F1M02, circulation pressure U1F1M01 and permeate flow U1P1M02.
18 Perform flush on loop and then repeat step 3 to determine effectiveness of clean.
19 The loop is now ready for operation.
20 Tabulate all recorded data and send to manufacturer.

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5.3.8.3 Hypochlorite Clean
Step Action
1 Stop UF loop and wait for it to flush
2 Flush loop again to remove residual solids
3 Perform reference water rinse and record loop circulation flow U1F1M02, circulation
pressure U1F1M01 and permeate flow U1P1M02 at a temperature of 20 °C
4 Stop rinse and begin chemical mixing sequence.
5 Wearing appropriate PPE take canister of hypochlorite agent to the cleaner dosing
point.
7 Place cleaning pump in a bucket of water and open valve U1H1V01A/B.
8 Switch on pump and flush pump and pipework with water. Switch off pump.
9 Open cleaner canister and place cleaning pump inside canister.
10 Switch on pump and dose enough cleaner to make a 0.1% solution in the cleaning
tank. Under normal operating conditions the cleaning cycle will run at 55% which is
equivalent to 660 litres. In this case add 0.6 litres of hypochlorite cleaner. IT IS
ESSENTIAL THAT THE FILLING VOLUME IS CHECKED AS THIS CAN BE
ADJUSTED IF REQUIRED.
11 Check Cl2 concentration using quick test strips. If below 20 mg/l add more cleaner
in a controlled manner by regularly testing Cl2 concentration between additions. Aim
for 40 – 50 mg/l. DO NOT EXCEED 100 mg/l.
12 Once required volume is pumped into tank stop pump and place into bucked of wa-
ter. Close cleaner canister and return to drip tray.
13 Turn on pump and flush lines.
14 Stop pump and close valve U1H1V01A/B.
15 Wait 2 minutes and then begin chemical rinsing sequence
16 Allow rinse sequence to run to 40 °C as shown on U1S1M02 and then stop rinse.
Do not allow temperature to exceed 41 °C. Note that depending on the starting tem-
perature of the water the time taken to reach 40 °C might vary.
17 Every fifteen minutes record wash temperature U1S1M02, loop circulation flow
U1F1M02, circulation pressure U1F1M01 and permeate flow U1P1M02.
18 Perform flush on loop and then repeat step 3 to determine effectiveness of clean.
19 The loop is now ready for operation.
20 Tabulate all recorded data and send to manufacturer.

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5.3.8.4 Acid Clean

Step Action
1 Stop UF loop and wait for it to flush
2 Flush loop again to remove residual solids
3 Perform reference water rinse and record loop circulation flow U1F1M02, circulation
pressure U1F1M01 and permeate flow U1P1M02 at a temperature of 20 °C
4 Stop rinse and begin chemical mixing sequence.
5 Wearing appropriate PPE take canister of acid cleaning agent to the cleaner dosing
point.
7 Place cleaning pump in a bucket of water and open valve U1H1V01A/B.
8 Switch on pump and flush pump and pipework with water. Switch off pump.
9 Open cleaner canister and place cleaning pump inside canister.
10 Switch on pump and dose enough cleaner to make a 0.5% solution in the cleaning
tank. Under normal operating conditions the cleaning cycle will run at 55% which is
equivalent to 660 litres. In this case add 3.3 litres of acid cleaner. IT IS ESSENTIAL
THAT THE FILLING VOLUME IS CHECKED AS THIS CAN BE ADJUSTED IF
REQUIRED.
11 Check pH. If above 3 add more cleaner in a controlled manner by regularly testing
pH between additions. DO NOT GO BELOW pH 2.
12 Once required volume is pumped into tank stop pump and place into bucked of wa-
ter. Close cleaner canister and return to drip tray.
13 Turn on pump and flush lines.
14 Stop pump and close valve U1H1V01A/B.
15 Wait 2 minutes and then begin chemical rinsing sequence
16 Allow rinse sequence to run to 40 °C as shown on U1S1M02 and then stop rinse.
Do not allow temperature to exceed 41 °C. Note that depending on the starting tem-
perature of the water the time taken to reach 40 °C might vary.
17 Every fifteen minutes record wash temperature U1S1M02, loop circulation flow
U1F1M02, circulation pressure U1F1M01 and permeate flow U1P1M02.
18 Perform flush on loop and then repeat step 3 to determine effectiveness of clean.
19 The loop is now ready for operation.
20 Tabulate all recorded data and send to manufacturer.

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5.3.8.5 Loop conservation

Step Action
1 Stop UF loop and wait for it to flush
2 Flush loop again to remove residual solids
3 Wearing appropriate PPE take canister of conserving agent to the cleaner dosing
point.
4 Place cleaning pump in a bucket of water and open valve U1H1V01A/B.
5 Switch on pump and flush pump and pipework with water. Switch off pump.
6 Open cleaner canister and place cleaning pump inside canister.
7 Switch on pump and dose enough cleaner to make a 2% solution in the cleaning
tank. Under normal operating conditions the cleaning cycle will run at 55% which is
equivalent to 660 litres. In this case add 13.2 litres of conserving agent. IT IS
ESSENTIAL THAT THE FILLING VOLUME IS CHECKED AS THIS CAN BE
ADJUSTED IF REQUIRED.
8 Once required volume is pumped into tank stop pump and place into bucked of wa-
ter. Close conserving agent canister and return to drip tray.
9 Turn on pump and flush lines.
10 Stop pump and close valve U1H1V01A/B
11 Wait 2 minutes and then begin chemical rinsing sequence
12 Stop rinsing sequence after 10 minutes.
13 The loop is now ready for storage.

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5.3.8.6 Exchanging and removing modules and dummies

INFORMATION
Note – observe manual handling procedures when removing or replacing
modules.

Step Action
1 Stop loop and flush
2 Rinse loop and perform chemical clean if module to be sent to manufacturer
3 Isolate UF circulation pump and UF wash pump and place all loop items into man-
ual
4 Close valve U1F1K06
5 Attach hose to loop drain valve U1F1H07 and run to drain
6 Open vent valve U1F1H13
7 Open drain valve U1F1H07
8 Remove all water from loop
9 Remove required U-bends, permeate connections and module restraints
10 Remove module and replace.
11 If replacing a dummy module with a membrane module, ensure that new permeate
connections are made up. If replace a membrane module with a dummy module,
ensure that original permeate connections are blinded.
12 Replace required U bends, permeate connections and module restraints
13 Attach water hose to loop drain valve U1F1H07
14 Attach hose to vent valve U1F1H13 and run to drain
15 Turn on water to fill loop
16 Keep water running until water comes from vent valve
17 Turn off water and close valves U1F1H07 and U1F1H13.
18 Check all connections for leaks
19 Open valve U1F1K06
20 Put all loop items into automatic
21 Remove isolation from UF circulation pump and UF wash pump
22 Flush loop, record loop data and check for leaks.
23 Perform short water rinse on loop and check for leaks. Record loop operating data
24 The loop is now ready for operation

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5.4 General Operating Procedures
Plant start up
This procedure is for starting the plant. It assumes that the plant is already seeded with sludge.

5.4.1.1 Consult manufacturer of intention to restart plant

If the plant was switched of for a longer time (5 days) the manufacturer must be consulted be-
fore restating the plant.

5.4.1.2 Turn on power and check panel

Table 18
Step Action
1 Before switching on power ensure manual valves for inlet pump line, jet pump line,
UF feed line and blower line are fully open as these may start automatically. Refer
to valve position guide in appendix for guidance. Alternatively isolate these items if
it is important, they do not start.
2 Before switching on power, get an electrically trained operator to check all items in
panel are switched on.
3 Switch on power on main isolator. If blower, jet pump and UF feed pump were in
auto mode before shutting down they will begin automatically.
4 HMI will initiate automatically. To control plant log in.

5.4.1.3 Start critical plant items

Some items may initialise automatically if they were set to AUTO before shutdown and if irrele-
vant interlocks are disengaged.
Table 19
Step Action
1 Ensure trace heating and tank heating is in operation. Respond accordingly.

2 Check biology level is within acceptable limits i.e. above SP1 so that jet pump can
start. Respond accordingly.
3 If not already done check valve positions for clear run and put jet pump B1N1P01
and blower B1L1V01A into automatic.
4 Check jet pump pressure is within acceptable limits. Normal operation is between
1.2 and 1.4 bar.
5 If not already done check valve positions for clear run and put UF feed pump into
automatic
6 Check UF feed flow and pressure are within acceptable limits. Normal flow is ap-
proximately 300 m³/h. Normal pressure is about 0.6 bar although higher pressures
are possible if U1R1K01 is used to regulate pressure in the loop.
7 Wait one hour and check pH and DO are within acceptable limits. pH should be be-
tween 6.7 to 7.5 and DO should be over 1.5 mg/l. Confirm pH reading by taking
sample and checking in lab. Respond accordingly.

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5.4.1.4 Check/start chemical dosing
Table 20
Step Action
1 Check antifoam levels
3 Put antifoam dosing into automatic on HMI. Confirm settings on pump to achieve
desired flow of between 0.2 and 0.74 l/d. This can be achieved by varying stroke
length, frequency or run time (On HMI). Generally, it is advisable to run with maxi-
mum stroke length and vary the other two parameters.
4 Check for presence of foam at top of nitrification tank
5 Check caustic soda, phosphoric acid, sulphuric acid acid, antifoam, antiscaling and
carbon source levels on HMI and local
6 Check dosing lines are open with no closed valves especially after the pumps. Re-
fer to valve position list for guidance.
7 Put caustic soda, sulphuric acid acid and antiscaling dosing into automatic on HMI.
Depending on the expected load to the plant the settings may require modification.

5.4.1.5 Prepare inlet system

Table 21
Step Action
1 Check level in balance tank is high enough to allow inlet pump B1Z1P01 to start.
Level must be above SP1.
2 Check inlet filter is clean - see table 15
3 Check valve positions on inlet line for clear run. Refer to loop position list for guid-
ance.

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5.4.1.6 Prepare ultrafiltration system

Table 22A
Step Action
1 Check total solids in the nitrification tank if this is not known.
3 Fill wash tank with water to setpoint SP4 by opening valve U1S1K01 in manual and
filling to required level. Close valve and put into automatic.
4 Put all loop items into automatic. This will include:

U1Z1P01
U1S1H01
U1F1K01
U1F1K02
U1F1K11
U1F1K12
U1F1P01
U1P1K07
U1S1K09
U1S1K10
U1F1K09
U1F1K10
U1P1P01
U1P1K09

5 Flush loop
6 Fill wash tank with water to SP4 by opening valve U1S1K01 in manual and filling to
required level. Close valve and put into automatic
7 Start UF loop in manual to check function.
8 Check loop flow and pressure. Flow should be greater than 300 m 3/h with five mod-
ules and pressure should be between 2.8 to 3.5 bar. Respond accordingly
10 Put loop into automatic control

5.4.1.7 Prepare system for feeding

Table 23
Step Action
1 Check DO and pH of nitrification tank again
2 Check ammonium, alkalinity, COD and total nitrogen in the balance tank if these are
not known.
3 Take sample of permeate and check for COD, NH 4N, NO2N, pH, TS, alkalinity and
turbidity (visual). Respond accordingly.
4 Check that nitrification tank level is low enough to accept leachate. If not wait until
UF reduces level to below SP4
5 Set biology flow to correct amount and put inlet pump into automatic
6 Check inlet flow and pressure

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 Plant shut down
These instructions are to be followed if the plant needs to be powered down for any reason – for
example to work on the power supply. It is not intended as a decommissioning guide.

Note: The biological process cannot be shut down for extended periods of time. Shutdowns for
longer than one hour require a reduced flow to prevent plant becoming overloaded. Refer to
manufacturer for guidance on setting inlet flow after shutdowns in excess of one hour.

Careful consideration needs to be given to ambient temperatures to ensure freezing of chemical

storage tank and dosing lines. These might need to be emptied and drained.

Consideration also needs to be given to the ultrafiltration. In this case refer to the component
manufacturers storage and conservation requirements.

Table 24
Step Action
1 Stop inlet flow to biology and put inlet pump into manual and OFF
2 Put UF in manual mode, Stop UF loop and flush
3 Follow conservation guidance on loop if shutdown is extended – see table 10
4 Put antifoam pump into manual OFF
5 Put biocide pump into manual OFF
6 Shut down jet pump and put into manual OFF
7 Shut down blower and put into manual OFF
8 Shut down UF feed pump and put into manual OFF
9 Shut down instrument air compressor and put into manual OFF
10 Power down system

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 Responding to power failure
INFORMATION
The facility is to be continuously supplied with an electrical power.
The unexpected power outages could lead to equipment damage,
blockage of membranes and damages of the process.

Following a power failure there are a number of critical items which should be addressed as
soon as possible. These are:

Sludge must be removed from the system as soon as possible, ideally within 15 minutes of
power failure and no more than one hour from power failure. If the power has returned and the
HMI is powered up do the following:

Table 25
Step Action
1 Clear all alarms associated with the loop
2 Ensure all loop items are in automatic
3 Initiate flush of loop. Monitor flow (U1F1M02) and pressure (U1F1M01) of loop dur-
ing flushing and record data. If there is serious fouling or plugging of the mem-
branes, then flow might be quite low (<80 m 3/h) and pressure high (>2 bar). If the
fouling is serious it might initiate a fast stop via high pressure or low flow (Refer to
Attachment - Functional Description – Set points of U1F1M01 and U1F1M02 for
more guidance). In this case proceed with flushing the loop manually as outlined in
table 26.
4 The loop is now in a safe condition
5 When time allows, but before return to normal operation, perform rinse on loop to
determine operational characteristics (see loop operational section).
6 Record all data and contact manufacturer

If power has not returned and will not for some time, then:
Table 26
Step Action
1 Attach water hose to loop drain valve U1F1H03.
2 Attach hose to loop vent valve U1F1H13 and run it to drain.
3 Open both valves and turn on water.
4 Keep water running until water coming from vent valve is clear.
5 Turn off water and close valves U1F1H03 and U1F1H13.
6 When power returns follow steps in table 25 to make loop safe and then refer to
start up sections restart remainder of plant.

Maintaining the temperature of the carbon source tank and dosing lines is absolutely critical es-
pecially if the ambient temperature is low. Therefore, it is critical to check that these items are
functional after a power cut. If a power cut is likely to continue for extended periods further steps
must be taken such as draining of dosing lines or even removing the contents of the tank if nec-
essary.

The performance of the biological performance will reduce after long periods of shutdown. If a
power cut has persisted for extended periods of longer and the aeration system has been
turned off for longer than an hour then care must be taken when restarting flow to the plant. In
these situations, consult the manufacturer for best practise.

Once these critical items are addressed it is then possible to restart the plant as specified in the
plant start-up sections.

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 Responding to an emergency stop
Table 27
Step Action
1 Determine reason for the emergency stop and address this
2 Once it is safe to restart the plant check which E-Stop button was activated and de-
activate this. Press “Emergency Stop Reset” on HSS screen on HMI.
Clear all alarms
3 Refer to table 25 to make loop safe
4 Refer to plant start up sections to restart plant items. No analysis should be re-
quired if shutdown has been for a short period of time.
5 Inform manufacturer of incident

Responding to a fast stop

Table 28
Step Action
1 Determine cause of fast stop and eliminate
2 Refer to table 25 make loop safe
3 Restart loop in automatic
4 Inform manufacturer of incident

6 PLANT HMI SYSTEM

This figures below show the main HMI screen:

 Main Screen
 Biology System
 Ultrafiltration System
 Auxiliary Systems
 Overview Cabinets
 Plant Control
 Trending
 Interlocks
 Operating Hours
 Alarm List

Page 46/66
 Figure 2: Exemplary Overview – Main screen

The screen overview gives an overview over the whole plant and level in the anaerobic pond.

Page 47/66
 Figure 3: Exemplary Biological Process

The screen biology gives an overview over the inlet of the biology and the components directly
linked to the biology. The inlet pump B1Z1P01A/B could be regulated as described in Attach-
ment Functional Specification. Next to the biology tank the jet pump line is displayed. The jet
pump circulates water between the tank and the ejector systems (aeration system). In this line
there are several instruments. The pH value, the temperature and the oxygen value of the biol-
ogy tank are measured here.

Figure 4: Exemplary Ultrafiltration

Page 48/66
The screen ultrafiltration shows the operation of UF Loop together with UF Wash tank and UF
permeate tank. The permeate recirculation pump U1P1P01 could be regulated as described in
Attachment Functional Specification. The excess sludge valve U1R1K02 is also shown here.

Figure 5: Exemplary Auxiliary Systems

Screen Auxiliary Systems show the auxiliary systems for the biological process, including dos-
ing of biocide, antifoam, cooling system and aeration. All aggregates could be regulated as de-
scribed in Attachment Functional Specification.

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 Figure 6: Exemplary Overview Cabinet

Screen Overview Cabinet shows the condition of the electrical cabinet and the power supply
condition.

Figure 7: Exemplary Plant Control

Screen Plant control shows the sequences for the ultrafiltration.

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Figure 8: Exemplary Trending

Figure 9: Exemplary Interlocks

Page 51/66
Figure 10: Exemplary Operating Hours

Figure 11: Exemplary Alarm history

Page 52/66
 Instrument Pop-Up Menu
All Analogue instruments are shown on the HMI Screen.
 Process value which will be used in the PLC
 Measured value: reading at the probe
 Bypass (Simulation) value: used to overwrite the Measured value
 MaxMax Setpoint* initiates alarms
 Max Setpoint* initiates warnings
 Setpoint 1 – 4*
 Min Setpoint* initiates warnings
 MinMin Setpoint* initiates alarms

* all set points are active only at auto mode, thus when operating the pump or aggregate in
manual mode the special attention should be paid to avoid damage

The plant is equipped with various instruments which are measuring the process parame-
ters as pressure, level, flow, temperature, pH, oxygen (see also P&ID’s plus Instrument list).
The instrument values are fed back to the PLC for process control. The control of the plant
will be achieved via various set-points which are described in detail in the attached Func-
tional Specification. At the HMI the measured values can be seen on the individual instru-
ments pup-ups

Figure 12: Example of an instrument pop-up

Biology operation

6.1.2.1 Controller Inlet Biology

The Inlet pump B1Z1P01A/B is equipped with a frequency converter. It can be operated either
by fixed feed flow (A), variable speed depending on the leachate collecting tank level (B) or by
fixed level biology (C).

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Fixed Feed Flow (A)
The Inlet pump B1Z1P01A/B works tending to a fixed flow value at B1Z1M04 to be defined in
the PID controller.

The operator can select a MAX target flowrate for the influent flow, so that B1Z1M04 will not ex-
ceed the defined MAX target value.

In addition, an ON/OFF timer can be utilised if lower flows than the minimum are required.

Variable speed depending on the leachate collecting tank level (B)

The biology feed pump B1Z1P01 should convey the nominal value of the feed flow. The nomi-
nal value is calculated by the PLC. The real value is flow measurement B1Z1M04. The system
is equipped with a nominal value adjustment, which controls the flow by the level B1Z0M01.
Nominal value decreases by high level and increases by low level. A function of both levels is
created.

The formula is:

Nominal value feed flow [m³/h]
If A < B F=D
If B ≤ A ≤ C F = D + (E-D) * (A-B) / (C-B)
If A > C F=E

F: Nominal value feed flow [m³/h]

A: actual value level leachate collecting tank B1Z0M01 [%]
B: low level [%]
C: high level [%]
D: MIN factor [m³/h]
E: MAX factor [m³/h]

The level for “high level” and “low level” and MIN and MAX factors have to be inserted.
Fixed Biology Level (C):
The pump will try to keep a fixed biology level at B1N1M02 to be defined in the PID controller.

Allowed Setpoint = x for PID-Controller: SP3 ≤ x ≤ Max from the instrument B1N1M02

6.1.2.2 Ultrafiltration Control

The biomass is pumped from the nitrification tank to the UF Loop via UF feed pump U1Z1P01.
The UF feed flow is monitored by the flow meter U1Z1M01.

The UF Plant can be disabled or enabled for UF AUTOMATIC ON/OFF depending on the level
of the nitrification tank (B1N1M02). For this function, at the HMI the selection can be done be-
tween UF-start-up Auto/Manual.

The UF Loop has the following operation modes. They can be selected on the HMI system:
 UF–Loop ON
 UF-Loop OFF
 UF-Loop FLUSH
 UF-Loop water RINSE (run time)

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  Chemical Cleaning (2 steps: PREPARATION OF CLEANING and CHEMICAL
CLEANING sequence) (run time)

Each operation mode will be commanded by an automated sequence from the PLC, specified in
the Attachment Functional Specification. The automated sequence will OPEN and CLOSE auto-
matic valves and switch ON / OFF pumps, depending on the operation mode.

All components of the Ultrafiltration can be set into manual and automatic operation. For auto-
matic operation of the Ultrafiltration all components need to be in auto.

From time to time, the Ultrafiltration needs to be rinsed or a chemical cleaning should be done.
If necessary, the buttons need to be pushed and the cleaning is started. The chemical cleaning
is divided in two steps, the first step is only mixing the chemicals by the wash pump and the
second step is rinsing the modules with chemical solution.

A flush can be done manually and is always done after the Ultrafiltration in turned off. The rins-
ing and cleaning time can be pre-selected and is also counted on this page. If required addi-
tional flushed can also be done (for example, if the sludge is really viscous).

In case a fast stop of the ultrafiltration needs to be done, press the button fast stop and confirm
that a fast stop should be done.

Page 55/66
 Cooling System
The cooling system consisting of the cooling pump B1H11P01, cooling water pump B1H11P02,
heat exchanger B1H11W01, and cooling tower with the ventilator B1H11W02 should be started
manually if the temperature in nitrification gets too high. For operational details of the above
consumers see Attachment Functional Specification.

Blower Control
There are two ways to operate the blowers: according to the oxygen concentration or full speed.

Blower B1L1V01A: according oxygen concentration

The motor speed (rpm.) of the blower is automatically adjusted through the PLC according to the
manually pre-selected set value for the oxygen concentration in the bioreactors, via a frequency
converter. For more details see Attachment Functional Specification, set points B1N1M03.

In manual mode the operator can adjust a fixed frequency for the blower B1L1V01A, independent
on the oxygen concentration in the bioreactor.

Blower B1L1V01B: full speed

The blower B1L1V01B will be operated with a soft starter and is always running with full speed in
AUTO-mode. For more details see Attachment Functional Specification, set points B1N2M03.

Standstill heating B1L1X02A and B1L1X02B for blowers

The standstill heating is automatically switched ON when the blower is switched OFF, and auto-
matically switched OFF when the blower is switched ON.

Alarm Triggering and Trending

6.1.5.1 Alarm Triggering

 Alarm sign on HMI.

 The visual alarm can only be reset after the fault has disappeared.
 Alarms are visualized on the HMI on the dedicated Alarm page

6.1.5.2 Trending
The values from the analogue instrument will be trended onto a trending system. This
trending allows the operator to retrospectively monitor the plant

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6.2 Auto Mode of devices
INFORMATION
Generally, the plant needs to run in auto mode. The auto mode is described
in detail in the attached Functional Specification. Changes to the set points,
which are established during commissioning, can only take place after writ-
ten confirmation of the Manufacturer. If changes to the control are made
without the consent of the Manufacturer, the operator must take due care to
avoid any damage to aggregates.

6.3 Manual Mode of devices

INFORMATION
The plant can be run in manual mode. This allows controlling different equip-
ment. The items should only be operated in manual-mode for special rea-
sons, e.g. commissioning, maintenance or repair work. The operator needs
to make himself fully aware about the potential consequences before he
puts a unit or single plant equipment in manual-mode. Any damage caused
by manual-mode operation is not the responsibility of the Manufacturers.

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7 PLANT MAINTENANCE AND FAULTS
The plant is a leachate treatment plant, according to the BIOMEMBRAT ® process. It is an auto-
mated process. The control of the plant is explained in detail in the Functional Specification, P&ID
diagrams and also in this document.
The plant was designed for the treatment of leachate as described in chapter 1.10. The treatment
of wastewater of different composition and other characteristics is not intended and detrimental
consequences or damages due to this or other non-conforming use of the plant are not covered
by the Manufacturer.

The maintenance of the wastewater treatment plant and its individual process components has
to be performed according to the recommendations of the manufacturer and according the spec-
ifications of the components supplies.

Please report all faults immediately to your supervisor. Faults under warranty have to be sent to
the manufacturer with the attached appropriate note of malfunction.
Please consider that self-repair or attempts of third parties without approval from the manufacturer
will exclude any warranty claim against the manufacturer.
Only original spare parts shall be used.

Spare and wear parts, auxiliary materials:

The use of spare and wear parts from other manufacturers/suppliers may also be hazardously.
Use only original parts or manufacturer approved parts. There is no acceptance for damages
resulting from the use of not approved spare and wear parts or auxiliary materials.

The maintenance of individual units is to be performed according to the specifications in the at-
tached supply documentation and is to be recorded in a diary or a maintenance operation sheet
and has to be signed. These records have to be sent quarterly to the manufacturer. Improper
maintenance can lead to limitations in equipment and technical security, the operating system
and the warranty

Please consider that self-repair or attempts of third parties without approval from the manufacturer
will exclude any warranty claim against the manufacturer.
Only original spare parts shall be used.

7.1 Regular light maintenance

Most parts of the plant are generally maintenance free. However, there are light maintenance
tasks which should be performed on a regular basis. An additional maintenance regime is sup-
plied in the appendices.

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 Calibration and cleaning of instrument
pH sensor
Step Action
1 Use transmitter to generate a calibration or cleaning signal so that no alarms will be
issued – see OEM’s instructions for details
2 Close valves B1N1H10 and B1N1H11 on jet pump bypass
3 Carefully remove sensor from pipe. Note this part will be pressurised.
4 Follow OEM’s cleaning, calibration or replacement instructions in the relevant man-
ual
5 Log all relevant calibration data
6 Carefully replace sensor
7 Slowly open valves B1N1H10 and B1N1H11 on jet pump bypass

Dissolved oxygen sensor

Step Action
1 Use transmitter to generate a calibration or cleaning signal so that no alarms will be
issued – see OEM’s instructions for details
2 Close valves B1N1H10 and B1N1H11 on jet pump bypass
3 Carefully remove sensor from pipe. Note this part will be pressurised.
4 Follow OEM’s cleaning, calibration or replacement instructions in the relevant man-
ual
5 Log all relevant calibration data
6 Carefully replace sensor
7 Slowly open valves B1N1H10 and B1N1H11 on jet pump bypass

Cleaning/changing of filters/strainers
The inlet filter B1Z1F10A/B is equipped with a 0.8- or 1.2-mm filter to remove any large solids
contained within the leachate. This will over time begin to block. A pressure instrument is provided
which automatically detects when the pressure drop across the filters is too high. When this hap-
pens, a warning is initiated. If pressure continues to rise, then an alarm will be initiated, and the
inlet pump will be shut down.

It is preferable that an alarm is not initiated so daily cleaning of the used filters is recommended.
If it is found very little accumulation of solids takes place over a period of a day then the interval
for cleaning can be increased to every two days or so on.

The method for cleaning is as follows:

Step Action
1 Set inlet pump B1Z1P01A/B in Manual Mode and turn it off
2 Close valves B1Z1K09A/B
3 Gently release pressure in filter by opening vent valve B1Z1H11A/B
4 Open valve B1Z1H11A/B to drain filter body
5 Open filter body
6 Remove filter and clean
7 Replace filter and close filter body
8 Close valves B1Z1H11A/B
9 Open valve B1Z1K09A/B
10 Set inlet pump B1Z1P01A/B Auto Mode. Pump should start automatically if no inter-
locks are preventing it.

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 Blower inspection
Table 16
Step Action
1 Check and record filter inlet pressure: max 45 mbar
2 Check outlet pressure and record alongside blower speed
3 Check and record oil level
Blowing down compressor bowl
The instrument air compressor B1L1V01A/B is equipped with an automatic drain down valve
B1L1H01A/B. The function of this can be tested by holding the test button for two seconds.

CIP of membranes
See section 5.3.8.

Light maintenance of dosing pumps

ATTENTION

From time to time light maintenance will be required on the dosing pumps.
The chemicals dosed by these pumps pose significant hazards. Therefore:

 Consult MSDS and COSHH assessments

 Wear correct PPE
 Ensure you are aware of locations of eye wash and emergency showers
 Ensure pumps are isolated electrically and mechanically
 Ensure chemical dosing lines are drained safely
 Wash down any drips or spills inside dosing chamber and ensure there
are no chemical residues on any surface.

From time to time air might become entrained in the pump head of all the diaphragm dosing
pumps (U1H1P01A/B and B1H6P01). This could have the effect of reducing or stopping flow.
Turning the red knob on the multifunction valve removes pressure on the delivery side of the
pump and can help to remove entrained air.

Alternatively, a small hose can be connected to the bleed valve (No tag as this is incorporated
with the pump) and the bleed valve can be opened. Refer to OEM documentation for detailed
guidance on this procedure.

Inspection of safety shower and eyewash

Check the operation of the emergency shower:
 At least monthly during warm months and weekly during winter
 Prior to any bulk chemical delivery
 Prior to working on a dosing system

Check eyewash bottles on a regular basis.

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7.2 Inspection of tanks, sumps, vessels
The inspections of tanks/vessels, chemical storage tanks, sumps, etc. is to be performed accord-
ing to national requirements/directives and supplier recommendations (see supplier documenta-
tion). If no requirements exist, the following should apply:

 Balance tanks: every two years

 Sumps: every year
 Chemical storage tanks: every three years
 Process tanks: every five years
 Process tanks equipped with sacrificial anodes: every year (only inspection of anodes)

7.3 Basic Maintenance

A plant checked and maintained on a regular basis is essential for a reliable system.
Generally, all procedures for maintenance from the documentation of the OEM supplier
have to be adhered to.
Main works include the following:
 Instrument (e.g. pH, O2 probe) cleaning and calibration
 check V belt blower, readjust if necessary
 check mechanical seals for leaks
 bearing changes
 greasing of motors
 oil changes of blowers and gear boxes
A periodic inspection of all plant equipment can prevent faults and malfunctioning. The Op-
erating Manual and the manuals from the suppliers should be followed.
Analysis from the leachate (feed, biology, discharge) of the plant shall be made on a regular
basis, to indicate the performance of the treatment plant.
Refer to the maintenance instructions in the vendor documentation. All the maintenance
and services carried out, and any faults/malfunctions should be well documented. This is to
avoid a later dispute about the execution of periodic maintenance/service.

7.4 Faults and Mal-Functions

Any faults or malfunctions of the plant should be reported immediately, in writing, to the
responsible person within WEHRLE.
The different control loops and alarm functions can be found in the Functional Specification
and the P&IDs, in combination with the instrument, valve and electrical consumer lists. An
alarm will be initiated in case of failure of a limit switch from the automated valves, which
are equipped with theses switches.
Alarms initiated by instruments, pumps and valves are displayed on the operator panel.
These alarms are automatically logged on the process control system. Malfunction of pro-
cess equipment (e.g. pumps, blowers, etc.) should be immediately reported to the Manu-
facturer.

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 The Operator has to have a maintenance procedure including an onsite spares store man-
agement in place to ensure a quick response time in case of equipment failure.

7.5 Failures
All failures of the plant equipment, which fall under warranty, have to be handed in a written
report to the Manufacturer. The Operator can use non-conformance report sheets. Im-
portant operating protocols have to be attached to the report.
The Operator has to contact the Manufacturer within 24hrs in case of a total failure of the
plant or part failures of the plant or process equipment.
Faults of single instruments, valves and pumps can be detected on the HMI, if they are fitted
with an alarm function. The P&ID as well as the instrument list can help identifying these
items.
All pumps are fitted with a motor overload switch, which gives an alarm when overload is
detected. Valves with position switch will also produce an alarm if faulty.
The occurring alarm will be displayed on the alarm screen of the HMI. As faulty items can
cause problems to the process, it is vital to get them repaired. Maintenance and repair in-
structions of the components will be in the supplier documentation.

7.6 Life cycle

The operating life of the wastewater treatment plant can be divided into the following phases and
the following responsibilities:
Operating life Responsibilities
Installation WEHRLE Umwelt GmbH
Commissioning WEHRLE Umwelt GmbH
Normal operation PT PP (Persero), Tbk
Maintenance PT PP (Persero), Tbk
Malfunction PT PP (Persero), Tbk
Decommissioning PT PP (Persero), Tbk
Dismantling PT PP (Persero), Tbk
Disposal PT PP (Persero), Tbk

7.7 Decommissioning
For the decommissioning of the plant for longer than 1 week, the operator needs to consult the
manufacturer. An incorrect decommissioning procedure could cause damage to plant items.
WARNING
If the plant is out of operation and the wastewater is stored in tanks, sumps,
pipework, etc. for a longer period, H2S and methane can be produced from
anaerobic microorganisms, which can grow in stagnant wastewater. When
too much H2S or methane volatises into the ambient air, a toxic and explo-
sive atmosphere can develop. Therefore, all tanks and pipework have to be
emptied when the plant is not in operation for a longer period (more than 5
days).

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 Functionality of ventilation equipment for the building/container has to be
checked in regular intervals.

7.8 Dismantling and disposal of the wastewater treatment plant

INFORMATION
The dismantling of the wastewater treatment plant must be performed by
qualified company only.
The disposal of the items, parts, functional units and plant materials may
also only be performed by qualified companies to avoid possible harm and
danger to environment and health.

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8 CONSUMABLES AND WEAR & SPARE PARTS
8.1 Chemicals
INFORMATION
Years of experience in the field of wastewater treatment lead to a specific
choice of suppliers of chemicals.
The necessary chemicals have been assessed regarding efficiency and per-
formance as well as their biological compatibility.

Chemical Supplier
Antifoaming: DREWPLUS 46000 Ashland
Membrane cleaner: AC 10 Wehrle
Membrane cleaner: AL 10 Wehrle
Membrane cleaner: HC Wehrle
Membrane cleaner: AC 30 Wehrle
Membrane cleaner: AL 30 Wehrle
Biocide: WUG V Wehrle
A change to different chemicals during warranty is only acceptable after contacting the Man-
ufacturer.

ATTENTION
The chemicals with a higher concentration than mentioned above
should never be used because of the limited resistance of tanks, fit-
tings and pipework.

8.2 Wear & Spare Parts

The Operator has to have a maintenance procedure including an onsite wear & spares store
management in place to ensure a quick response time in case of equipment failure. Only
original wear & spare parts shall be used. The use of spare and wear parts from other
Manufacturers/Suppliers may also be hazardously. Use only original parts or Manufacturer
approved parts. There is no acceptation for damages resulting from the use of not approved
spare and wear parts or auxiliary materials.

8.3 Disposal
INFORMATION
The disposal of used chemicals should only be done by fully accredited
companies or they should be sent to an authorised dealership. Please note
the documentation provided by the supplier.

9 SIGNATURE SHEET
The signatures also refer to chapter 2.4 “Duties of the ”.

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Owner :

PPK PPLP Wilayah I Jawa Timur

Konsultan :

Fichtner

Kontraktor :

PT PP (Persero) Tbk

Operator TPA:

DLH Malang Municipality

The following personnel employed by the Operator are in charge of operating the
wastewater treatment plant. They prove by signing that they have read and understood this
document including all safety notifications.

Name Company Signature

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10 ANNEX

 Control Philosophy

 Functional Specification

 Flow Diagrams

 Plant Layouts

 Lists

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