PROCESS SOLUTION & MINIMUM ASSET STANDARDS

Wastewater Treatment

DETAILS OF DOCUMENT CONTROL AUTHOR: Risk & Value Project Manager NAME: Owen James Document Reviewer: Name: Document Authoriser: Name:

DATE:

REV 1.0 1.1

DATE 29/07/08 03/11/08

Who OJames PGreen

REASON FOR CHANGE First Issue Clarification of P-removal descriptions

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CONTENTS 1 INTRODUCTION & OVERVIEW...........................................................3 2 PROCESS SELECTION.......................................................................4 2.1 PROCESS SELECTION MATRIX .....................................................................6 3 MINIMUM STANDARDS....................................................................8 3.1 3.2 3.3 3.4 PRINCIPLE......................................................................................................... 8 WHOLE LIFE COST EVALUATION (NPC ANALYSIS)..........................................................8 GENERAL REQUIREMENTS FOR ALL SITES.....................................................................8 SPECIFIC REQUIREMENTS PROCESS DEPENDENT............................................................8

1 DEVIATION PROCESS.....................................................................15

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INTRODUCTION & OVERVIEW

The purpose of this document is to define the starting point for process selection and define high level minimum asset standards for those processes and to explain how they fit in the process of capital appraisal and delivery. The document is intended for use by various parts of the business. The matrices in this document define what you need rather than what you want. There will be circumstances when deviations will be required however, these deviations will be justified through risk economics. Asset Planners Provides a high level guide to asset needs that can be used in asset plans and workbook submissions. Operational Manager Provides a baseline of process selection & min standards Capital delivery engineers (ops cap & major capital delivery) Provides a first point of reference in the capital delivery process and also provides the baseline of asset requirements.

The application of Minimum Standards is an integral part of an essential process of identifying the right solution to risks & issues in the business. The key steps in the process are: Quantify risk Using the business impact matrix and R&V risk Assessment. An approach of root cause analysis should be used to methodically understand factors that are out of control. See R&V HAWK pages for more information . . . ) To manage or resolve risk. Check root causes against trouble shooting guides available via HAWK
(see http://hawk/Vol_Eng/DG/WWProcessTroubleShootingGuides .xls).

Identify Root cause

Review operational solutions

Review against process selection matrix Understand Minimum Standard Document and justify any required deviations

Where there is no further operational solution or only high cost operational solutions, what is the least cost capex solution? (Table 1 in this document) High level Minimum Standards for process solutions selected. For more detailed descriptions, see engineering standards pages on HAWK. (Table 2 in this document It is important to understand the rationale for any deviation from process selection standard or asset standard. This will be documented in the R&V report.

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PROCESS SELECTION

The process selection matrix below indicates desired processes for new works or new streams. In any option evaluation phase the solution indicated in this table needs to be the first consideration and any deviations from this need to be justified in terms of risk economics and or NPV analysis. While this table provides general guidance all solutions must be chosen on the basis of whole life costs balancing capex, opex and carbon footprint to obtain the optimum balance between risk and cost. 1. Site specific circumstances will dictate that deviations from this matrix are required. This includes sludge treatment requirements where process selection may be influenced by where and how sludge is treated. 2. The boundaries to the population equivalent bandings should be taken as a guide. For example where a PE is just below a banding threshold (e.g. 4500 PE) then an assessment may need to be considered on the requirement for process selection in the next banding. 3. Further information on the content of each process is indicated in section 6 on minimum standards. 4. The processes indicated in bold indicate the first choice / minimum standard. Further options are provided if first choice is ruled out. The rationale for this will still need to be documented. 5. The consents indicated in the table are indicative only. There may be intermediate consent limits or site specific consents that require special consideration. 6. Descriptive consents dont generally have numeric limits set to them however there is a growing acceptance that they will treat to a numeric equivalent of 60mg/l of solids, 40mg/l of BOD and in some cases 20mg/l of ammonia. This should be taken into consideration when using the line for descriptive consents. 7. Trickling filters will always require primary and humus settlement in addition to the filter beds. 8. An activated sludge plant will always require final settlement (clarifiers) however the inclusion of primary settlement should be on the basis of whole life costs balancing the energy and sludge disposal costs against and other opex against the capital cost. Modifications of the activated sludge process may also be considered that include internal clarification (eg SBRsetc) but only on the basis of lowest whole life cost and risk mitigated as above. 9. A removal of Iron to <3mg/l will require tertiary solids removal. 10.Energy the minimisation of energy usage on site must be considered and also the maximization of energy recovered from sludge. 11.Odour Odour control and septicity implications needs to be considered. Where necessary process covers, venting and appropriate treatment

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should be provided. However, the requirement for odour control must be minimised as far as possible. 12.

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2.1 PROCESS SELECTION MATRIX Table 1 - Process Selection Matrix Note: A clear idea of the sludge disposal route is essential before selecting the main process streams.
Ref indicative consent standard population equivalent (see note 2 above) <250 (a) P1 Descriptive (see note 6 above) No NH3 and (SS >20; BOD >15) or
UWWTR consent inc 75%COD removal

250 1,000 (b) n/a

1,000 5,000 (c) n/a

5,000 10,000 (d) n/a

10,000 50,000 (e) n/a screening & grit Storm tank + TF7 or ASP (carbonaceous) (see note 8)

50,000 100,000 (f) n/a

Flow Balancing Aerated Lagoon or SAF or RBC or TF

P2

Balancing tank/Septic tank Reedbed storm handling above 250pe Aerated Lagoon or RBC or SAF Or trickling filter7 Co-settled primary & humus Storage to 3,000PE Storage only to 3000 pe Balancing tank + Storm separation + TF (nitrifying)7 or SAF / RBC Also consider SBR or aerated nitrifying lagoon

screening & grit Storm tank TF7 Or ASP (see note 8)

screening & grit Storm tank TF7 Or ASP (see note 8)

screening & grit Storm tank + ASP (carbonaceous) (see note 8)

S1

Sludge handling (TF works) Sludge handling (ASP type works)

Co-settled primary & humus Gravity thickening Storage Separate primary & SAS sludge SAS: Drum thickening Blending & Storage screening & grit storm tank TF (nitrifying)7 or ASP (nitrifying)8 or SBR screening & grit Storm tank or TF (nitrifying)7 ASP (nitrifying)8

S2

Co-settled primary & humus Gravity thickening Sludge treatment Separate primary & SAS sludge Primary sludge: PFT SAS: Drum thickening Blending & sludge treatment screening & grit Storm tank ASP (nitrifying)8

P3

Ammonia down to 5 mg/l (SS / BOD as above)

Balancing tank SAF / RBC Also consider aerated lagoon

or SBR Or add tertiary nitrification to existing plant plastic media filter or nitrifying sand filter or SAF or BAF

P4

Ammonia consent < 5mg/l

SAF or SBR above 500pe

Preliminary as above (P3) ASP (nitrifying) or add tertiary nitrification to existing plant as above

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Table 1 Process Selection Matrix (Continued)

ID Consent <250 (a) 250 1,000 (b) As above (P3) plus Reedbed or Short retention Lagoon 1,000 5,000 (c) 5,000 10,000 (d) As above plus Reedbeds or continuous back wash sandfilter 10,000 50,000 (e) As above plus Tertiary Continuous backwash Sand Filter or Batch Sand Filter 50,000 100,000 (f)

P5

Solids <20 but >15mg/l

As above plus Tertiary Batch type sand filter

P6

Solids <15 mg/l P consent to 2mg/l (or 80% removal for UWWTR) Fe Consent >3mg/l

As (P3) plus Continuous backwash sandfilter As above (P3 or P2 as appropriate) plus ferric sulphate dosing to primary tank As above (P7) Plus backup dosing (see design guide) Note: on critical sites where process problems exist tertiary solids separation may be required, if so backup dosing is located in this position No tertiary Separation is required for Activated Sludge As above (P3 or P2 as appropriate) plus TF=> Ferric sulphate to Primary settlement tank (PST) AS=> Ferrous chloride to aeration tank

As (P8) above

P7

P8

P consent to 1mg/l

As above (P7) Plus backup dosing (see design guide) Note: on critical sites where process problems exist tertiary solids separation may be required, if so backup dosing is located in this position No tertiary Separation is required for Activated Sludge

As P7e Or Biological P removal if sufficient VFA in crude / Fermenter. (model required)

P9

Fe consent 3mg/l (see note 9)

As above (P3) for TF plus Tertiary Reedbeds / lagoons or other tertiary solids separation No tertiary Separation is required for Activated Sludge

As above (P3) for TF plus Tertiary solids separation No tertiary Separation is required for Activated Sludge

Other consents including the requirement for N removal or disinfection are not covered by this matrix but should be considered on a case by case basis. Notes for this table are on Page 4 of this document.

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MINIMUM STANDARDS

3.1 Principle For each process above these standards will detail what you get as part of that process in terms of standby & contingency and ancillary type assets (e.g. lighting , access, building, duty / standby etc.) 3.2 Whole Life Cost Evaluation (NPC analysis) In all schemes the NPC of all options, including operational solutions must be evaluated and considered. Whole life period should be taken as 40 yrs. The guidelines in this document are for new additional process units and thus application of the guidelines to existing works should only be considered if final effluent compliance and works serviceability are at risk 3.3 1. General Requirements for All Sites Health and Safety is a primary concern and where possible simple access arrangements should be arranged. Elevated access to process units should be avoided if possible on the basis of both H&S and cost. Sockets to be provided for mobile generators for equipment necessary to maintain final effluent compliance. Fixed generators to be considered on sites above 30,000 PE. Where fixed generators are installed consideration must be given to triad avoidance and peak lopping. Energy use must be minimised where possible through use of high efficiency motors etc. Telemetry to be provided in accordance with MTPC version 9.2. Need for a water supply to be investigated and if necessary has to comply with AW byelaw requirements. In addition, use of final effluent for wash-water use needs consideration. Access road length to be minimized and finished appropriate for usage with no curbs or drainage. Septic tank / RBC sites consider permanent pipeline for removal of sludge rather than road to site. Fencing to be provided as appropriateNo fencing if possible Low risk areas (where vandal and safety ok)-wooden post/rails Medium risk-Weld Mesh High risk areas- Security fencing Control equipment to be housed in kiosks rather than buildings unless shared with process plant. Site areas to be minimized and finished with cost and low maintenance surfaces. Access pathways also to be considered. Consider insulation requirements on exposed sludge & wash water pipelines & valves. Sludge pipelines to be 150mm or greater. Site entrance signage to be provided to include AW contact details. Site lighting should be avoided as much as possible however lighting is required for key plant items and on H&S basis. Washroom and toilet facilities to be provided at permanently manned sites and by evaluation on smaller sites. Auto-emptying of storm tanks must be justified by a business case linked to compliance TSFR Flow meters & other instrumentation will be in accordance with POSWASTES Sampling chambers and equipment will be in accordance with POSWASTES 3.4 Specific Requirements Process Dependent For specific requirements relating to individual processes selected refer to the tables below. For more detailed specific standards refer to Engineering Standards on HAWK.

2. 3. 4. 5. 6. 7. 8. 9. o o o o 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

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Table P1 Descriptive works

ID D1 D2 D3 D4 D5 Descriptive Works Septic tank Flow balancing Aerated lagoon SAF RBC GRP vessel & tanker connection point If lagoon then part of lagoon otherwise septic tank 2 lagoons earth banked, butyl rubber lined. Floating wind powered aerator. Package Plant (as per Design guide) Package RBC

Table P2 No Ammonia Consent (SS>20, BOD >15mg/l)

ID Process < 1,000 (a) SB1 SB2 Balance tank Septic tank GRP vessel with flow regulator Tanker connection point GRP vessel & tanker connection point Mesh bags above 250PE. Other screening only if consent requires. Only if consent requires screen n/a Single plot with basic distributor & collector channels If consent requires. Storm plot / tanks If storm tanks then require storm return mechanism & high level & overflow alarm 1,000 5,000 (b) Tank with flow regulator Method of flushing / cleaning. n/a duty combined screen with hydraulic bypass (manually raked 25mm) Duty compactor n/a Single plot with basic distributor & collector channels If consent requires. Storm plot / tanks If storm tanks then require storm return mechanism & high level & overflow alarm Population Equivalent 5,000 10,000 (c) Tank with flow regulator Method of flushing / cleaning. n/a duty fine screen (6mm 2d) with hydraulic bypass (manually raked 25mm) Duty washer compactor Mechanical Grit Trap n/a Storm tank with auto drain & return. Basic Cleaning facilities (eg hydrant). n/a n/a Duty / standby fine screen (6mm 2d) & hydraulic unscreened bypass duty / standby washer compactor Crossflow detritor - duty only n/a Storm tank with auto drain & return downstream of flow recording & UWWTR sample point / upstream of PST. Cleaning facilities. 10,000 50,000 (d) n/a n/a Duty / Assist / standby (6mm 2d) Band Screens for 6DWF & unscreened bypass duty / standby washer compactor crossflow detritors n/a Storm tank with auto drain & return downstream of flow recording & UWWTR sample point / upstream of PST. Cleaning facilities. 50,000 100,000 (e)

SB3

Screening Screenings handling Grit Removal Reedbed Storm Handling Storm Handling (See note 15 above)

SB4 SB5 SB6

SB7

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Table P2 No Ammonia Consent (SS>20, BOD >15mg/l) (Continued)

ID Process < 1,000 (a) 2 lagoons in series earth banked, butyl rubber lined. Floating wind powered aerator. Package Plant (as per Design guide) Package Plant (as per DSG) 1 circular radial GRP tank. No scraper. With manual desludge. Single Conventional single pass filter. Media to choice influencing retaining walls. Syphon / drive. No sensor. n/a Single tank with manual desludge. Radial flow FST with sludge blanket detectors & rotation sensor. Manual RAS control. >50m3/d TSFR to meet MCERTS. Agreed sample points. 1,000 5,000 (b) n/a Package Plant (as per Design guide) up to 2500 pe n/a 1 circular radial GRP tank. No scraper. With manual desludge. Conventional single pass filter. Media to choice influencing retaining walls. Syphon / drive. Rotation sensor n/a Single tank with manual desludge. Radial flow FST with sludge blanket detectors & rotation sensors. Manual RAS control. >50m3/d TSFR to meet MCERTS. Agreed sample points. n/a 5,000 10,000 (c) n/a 10,000 50,000 (d) n/a 50,000 100,000 (e)

SB8

Aerated lagoon

SB9 SB10

SAF RBC Primary Settlement

n/a n/a 2 tanks Radial flow Autodesludge where applicable Rotation sensor to telemetry Two Conventional single pass filter. Media to choice influencing retaining walls. Syphon / drive. Rotation sensor n/a Two tanks with auto desludge Radial flow FST with sludge blanket detectors & rotation sensors. Auto RAS control. >50m3/d TSFR to meet MCERTS. Agreed sample points.

n/a n/a 2 tanks Radial flow Autodesludge Rotation sensor to telemetry Minimum of 2 Filters

n/a n/a Multiple radial flow tanks with auto desludge. Rotation sensor to telemetry Minimum of 2 Filters

SB11

SB12

Trickling Filter

SB13 SB14

ASP
(carbonaceous)

Compare type based on NPC If blowers then D(A)S blowers. Aerated selector. DO control, Telemetry / SCADA As PST (SB11) Radial flow FST with sludge blanket detectors & rotation sensors. Auto RAS control. >50m3/d TSFR to meet MCERTS. Agreed sample points. As PST (SB11) Radial flow FST with sludge blanket detectors & rotation sensors. Auto RAS control. >50m3/d TSFR to meet MCERTS. Agreed sample points.

Humus Settlement Final Tanks (after ASP) (Clarifiers) General

SB15

SB16

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Table S1/S2 Sludge Handling

ID Process < 1,000 (a) SH1 Sludge Storage Sludge storage - one month or tanker load whichever is smaller. 1,000 5,000 (b) Glass coated steel tank with thickening facility with 7 days storage. 5,000 10,000 (c) Glass coated steel tanks with thickening facility with 14 days storage. 10,000 50,000 (d) Sludge tanks with thickening facility with 14 days storage. 50,000 100,000 (e) Sludge tanks with picket fence thickening with 14 days storage. & separate Mechanical SAS thickening (eg aqua belt).

SH2 SH3

Thickener Blending

Table P3 Ammonia down to 5mg/l (SS >20 & BOD>15)

ID Process < 1,000 (a) A1 Balance tank / septic tank Septic tank as above. 2 lagoons earth banked, butyl rubber lined. Floating wind powered aerator + forced aeration on timer control. Floating SAF. As above See Grit matrix As above Package Plant (as per Design guide) Package Plant (as per DSG) 1 radial flow with No scraper manual desludge. 1,000 5,000 (b) Only if necessary and then balance tank as above 5,000 10,000 (c) Only if necessary and then balance tank as above none 10,000 50,000 (d) none 50,000 100,000 (e)

A2

Aerated nitrifying lagoon

n/a

n/a

n/a

n/a

A3 A4 A5 A6 A7

Screening Grit Removal Storm Handling SAF RBC

As above See Grit matrix As above Package Plant (as per Design guide) up to 2500 pe n/a 2 radial flow. No scraper Manual desludge

As above See Grit matrix As above n/a n/a 2 tanks Radial flow Autodesludge where applicable Rotation sensor to telemetry

As above See Grit matrix As above n/a n/a Two tanks Radial flow PST Autodesludge Rotation sensor to telemetry

As above See Grit matrix As above n/a n/a Multiple radial flow tanks with auto desludge. Rotation sensor to telemetry

A8

Primary Settlement

Table P3 Ammonia down to 5mg/l (SS >20 & BOD>15) Continued

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ID

Process Trickling Filter (nitrifying) ASP (Oxidation Ditch)

< 1,000 (a) As above but with recirculation Oxidation ditch as simpled lined structure . Timer control. DO Alarm

1,000 5,000 (b) As above but with recirculation Oxidation ditch as lined puddled clay . DO control basic feedback. 2 probes to average.

5,000 10,000 (c) As above but with recirculation n/a

10,000 50,000 (d) n/a

50,000 100,000 (e)

A9

A10

A11

ASP (nitrifying)

Package plant ASP

Package plant ASP

Conventional ASP with tapered aeration & integral anoxic zone. Single lane DO & ammonia control. Duty / Standby blowers*. SBR as package upto 7000PE. Process SBR at higher PE. 3 units min. Must have clarifier/ humus tank. Radial flow Manual desludge Rotation sensor to telemetry Single (2x at higher pe) radial flow, RAS return with flow control D/ S RAS pumps. BAF as GRP tank duty only in split tank configuration. D/S blower & pump

Conventional ASP with tapered aeration & integral anoxic zone. Single lane DO & ammonia control. Duty / Standby blowers*.

Conventional ASP with tapered aeration & integral anoxic zone. Single lane DO & ammonia control Duty / /Standby blowers.

A12

SBR

SBR as package

SBR as package

Bespoke designed system

Bespoke designed system

A13

Humus Settlement

Radial flow tank. Manual desludge.

Radial flow tank. Manual desludge

n/a

n/a

A14

Final Tanks (after ASP)

radial flow dependent on Fixed rate RAS return with no control D/S RAS pumps. n/a

Single radial flow Fixed rate RAS return with no control D/S RAS pumps. BAF as GRP tank duty only in split tank configuration. Box spare for blower & pump.

2 x radial flow with RAS return with flow control. D/A/S RAS pumps. BAF as GRP tank duty only in split tank configuration. D/S blower & pump

2 or more radial flow with RAS return with individual tank flow control. D/A/S RAS pumps. BAF as GRP tank duty only in split tank configuration. D/S blower & pump

A15

BAF

Note * - Ensure that blower capacity is matched appropriately to the flow and load conditions.

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Table P4 Ammonia less than 5mg/l

ID Process < 1,000 (a) AA1 AA2 AA3 AA4 ASP (nitrifying) SAF SBR Tertiary Nitrification 1,000 5,000 (b) 5,000 10,000 (c) 10,000 50,000 (d) 50,000 100,000 (e)

As above (A11) plus FE monitoring (inc Turbidity & Amm) As above (A6) As above (A12) n/a As above (A15)

Table P5/P6 Solids < 20mg/l

ID Process < 1,000 (a) Twin plots of nominal loading area. Distributor & collector channels. Single lagoon. 4 days capacity. Single Duty unit only unless no other storage of effluent avialable. D/S pumps & compressors. (See MAS on HAWK) n/a 1,000 5,000 (b) Twin plots of nominal loading area. Distributor & collector channels. 2 lagoons in series. 4 days capacity total + by pass to 2nd lagoon Duty only units single unit to 2,000PE & lagoon / storage available otherwise multiple units. D/S pumps in Pumps, D/S compressors (See MAS) n/a 5,000 10,000 (c) Twin plots of nominal loading area. Distributor & collector channels. n/a 10,000 50,000 (d) n/a n/a n/a n/a 50,000 100,000 (e)

SS1 SS2

Tertiary Reedbed Short Retention Lagoon Continuous Backwash Sandfilters Batch type sandfilter
(rectangular rapid gravity type)

SS3

Duty only multiple units. D/S pumps & compressors (See MAS)

Duty only multiple units. D/S pumps & compressors (See MAS)

n/a

SS4

n/a

TBD

TBD

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Table P7/P8 Inclusion of P consent

ID Process < 1,000 (a) Phosphorous Consent to 2 mg/l Ferric Sulphate dosing on TF only Single point dosing to Primary tank inlet chamber D/S Dosing lines & pumps Flow control (See Detailed MAS for further information for sites to 25,000pe) Single point dosing to Primary tank inlet chamber D/S Dosing lines & pumps Flow control As above (PP1) except dosing to settled sewage or RAS or pre aeration if crude 1,000 5,000 (b) 5,000 10,000 (c) 10,000 50,000 (d) 50,000 100,000 (e)

PP1

PP2 PP3

Ferrous Chloride Dosing Biological P removal

As above (PP1) except dosing to settled sewage or RAS or pre aeration if crude Bespoke design

Phosphorous Consent to 1 mg/l PP4 Dosing As PP1 or PP2 above but with backup dosing (see design guide for more information). Common chemical storage tank for both main dosing and backup (trim) dosing. Dedicated duty only dosing lines & pumps for the backup dosing.

Table P9 Iron Consent < or = 3mg/l Trickling Filters

ID Process Tertiary Reedbed Lagoons Tertiary Clarification Tertiary Sand Filters < 1,000 (a) FE1 FE2 FE3 FE4 As SS1 above As SS2 above TBD As SS3 & SS4 above 1,000 5,000 (b) As SS1 above As SS2 above TBD As SS3 & SS4 above 5,000 10,000 (c) As SS1 above As SS2 above TBD As SS3 & SS4 above 10,000 50,000 (d) As SS1 above As SS2 above TBD As SS3 & SS4 above 50,000 100,000 (e) As SS1 above As SS2 above TBD As SS3 & SS4 above

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DEVIATION PROCESS

Changes and deviations will be managed within the existing governance as outlined in the diagram below.

Other policy c (e.g. POSW Regulatory change

Notes:
a) A standard will need to be submitted to the ASF if: i) It is a new standard that has an implication on operating or maintenance risk. ii) There is a capex or opex implication associated with that standard. b) A standard will need to be submitted to CIG if: i) There is an associated significant increase in Capex or Opex (> approx 50k AMP4 implication). ii) There is an associated significant increase in residual risk (> approx. 50k per year programme implication) c) A deviation approval will need to be submitted to CIG in a highlight report if it leads to a change in time, cost or quality (see the process for highlight & exception reporting).

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