utilization of an operations and maintenance manual for

AMI Conference on Worker Safety, Human Resources and AMI Conference on Worker Safety, Human Resources and the Environmentthe Environment

April 7, 2009April 7, 2009

John Meyer, P.E., Director of Environmental AffairsJohn Meyer, P.E., Director of Environmental AffairsJohn Morrell & CompanyJohn Morrell & Company

Utilization of an Operations Utilization of an Operations and Maintenance Manual for and Maintenance Manual for

Process OptimizationProcess Optimization

The Value of an O&M ManualThe Value of an O&M Manual

•• I need an I need an O&M Manual O&M Manual for my two for my two teenagers! teenagers!

The Value of an O&M ManualThe Value of an O&M ManualAn up to date O&M manual providesAn up to date O&M manual provides::A good understand system design capabilitiesA good understand system design capabilitiesA baseline for establishing operational Key A baseline for establishing operational Key Performance Indicators (Performance Indicators (KPIsKPIs))A baseline for optimizing system operationsA baseline for optimizing system operationsKnowledge to keep equipment runningKnowledge to keep equipment runningKnowledge to better trouble shoot atypical issuesKnowledge to better trouble shoot atypical issuesKnowledge to avoid costly mistakesKnowledge to avoid costly mistakesMost importantly, you can maintain 100% Most importantly, you can maintain 100% compliance!compliance!

John Morrell John Morrell -- Sioux Falls, SDSioux Falls, SD

•• Primary TreatmentPrimary Treatment•• Anaerobic TreatmentAnaerobic Treatment•• Activated SludgeActivated Sludge•• Sludge Thickening and DewateringSludge Thickening and Dewatering•• Final Effluent FilterFinal Effluent Filter•• Chlorine Contact ChamberChlorine Contact Chamber•• Dechlorination Dechlorination –– sodium bisulfitesodium bisulfite•• Effluent Pumped to Big Sioux RiverEffluent Pumped to Big Sioux River•• Alternative Discharge from DAF to POTWAlternative Discharge from DAF to POTW

Screw PumpsScrew Pumps

•• The screw The screw pumps lift pumps lift wastewater wastewater to to preliminary preliminary treatment treatment system system equipment. equipment.

Bar Screen & Grit RemovalBar Screen & Grit Removal

•• The The preliminary preliminary treatment treatment system system consists of a consists of a bar screen and bar screen and grit removal grit removal auger for large auger for large solids removal. solids removal.

Rotary ScreenRotary Screen

•• The rotary The rotary screen screen removes removes smaller smaller solids prior solids prior to the DAF. to the DAF.

Dissolved Air Flotation (DAF)Dissolved Air Flotation (DAF)

•• The DAF The DAF tanks float tanks float solids and solids and remove remove grease prior grease prior to anaerobic to anaerobic treatment. treatment.

Anaerobic LagoonsAnaerobic Lagoons

•• The anaerobic The anaerobic lagoons, provide a lagoons, provide a high degree of high degree of waste stabilization waste stabilization and are used for and are used for flow equalization flow equalization during low during low production production periods. periods.

Aeration BasinsAeration Basins

•• Microorganisms Microorganisms biologically biologically metabolize organic metabolize organic wastes wastes ––carbonaceous BOD carbonaceous BOD removal.removal.

•• Nitrification Nitrification ––biological conversion biological conversion of ammonia to of ammonia to nitrate.nitrate.

Final ClarifiersFinal Clarifiers

•• Floating scum is Floating scum is skimmed and skimmed and removed.removed.

•• Settled sludge is Settled sludge is collected, returned, collected, returned, and wasted.and wasted.

•• Clarified effluent is Clarified effluent is discharged to final discharged to final effluent filter.effluent filter.

Final Effluent FiltersFinal Effluent Filters

•• Final polishing Final polishing to remove to remove remaining remaining solids that solids that flow over the flow over the final clarifier final clarifier weir.weir.

Design CriteriaDesign Criteria

•• Know what your system is designed to accomplish under Know what your system is designed to accomplish under variable conditionsvariable conditions

•• Document capacity of all unit operationsDocument capacity of all unit operations•• Maintain current and accurate PFDs, P&IDs, and asMaintain current and accurate PFDs, P&IDs, and as--built built

drawingsdrawings•• Document alarm condition set pointsDocument alarm condition set points•• Document design raw flow and pollutant loading levelsDocument design raw flow and pollutant loading levels•• Provides new operators and managers quick Provides new operators and managers quick

understanding of system capabilitiesunderstanding of system capabilities•• Provides basis to go back to production for water Provides basis to go back to production for water

conservation and pollutant source reduction focus!conservation and pollutant source reduction focus!

Permit Conditions:Permit Conditions:

•• Document Permit LimitsDocument Permit Limits

•• Document monitoring requirementsDocument monitoring requirements

•• Document reporting requirementsDocument reporting requirements

•• Document record keeping requirementsDocument record keeping requirements

DAF DAF –– Design Parameters:Design Parameters:

•• Flow: 2 gpm per square foot surface area.Flow: 2 gpm per square foot surface area.

•• Hydraulic Retention Time (HRT) = 45 Hydraulic Retention Time (HRT) = 45 –– 60 minutes, including 60 minutes, including recycle flowrecycle flow

•• Solids Loading: 4 Solids Loading: 4 -- 8 lbs TSS per hour per square foot surface area.8 lbs TSS per hour per square foot surface area.

•• Sludge generation: Volume dependent on influent loading and % Sludge generation: Volume dependent on influent loading and % solids.solids.

•• Recycle Water Flow Rate >= 0.5 x Influent Flow Rate (gpm)Recycle Water Flow Rate >= 0.5 x Influent Flow Rate (gpm)

DAF DAF -- Operational KPIsOperational KPIs

•• Goal: Create White Water and Float SolidsGoal: Create White Water and Float Solids•• Recycle Air PressureRecycle Air Pressure•• Recycle Water Flow RateRecycle Water Flow Rate•• Chemical Dosage RatesChemical Dosage Rates•• Real Key = Effluent TurbidityReal Key = Effluent Turbidity

DAF DAF -- System OptimizationSystem Optimization

•• Whitewater system performance (pressure in air saturation tank aWhitewater system performance (pressure in air saturation tank and recycle nd recycle water flow rate);water flow rate);

•• Optimize chemical feed dosage to achieve desired water quality, Optimize chemical feed dosage to achieve desired water quality, cost;cost;

•• Optimize skimmer speed to thicken sludge;Optimize skimmer speed to thicken sludge;

•• Optimize water level on beach with weir adjustment to thicken slOptimize water level on beach with weir adjustment to thicken sludge;udge;

•• Preventive maintenance per manufacturer specifications;Preventive maintenance per manufacturer specifications;

•• Dewater and clean cell thoroughly to minimize the potential of sDewater and clean cell thoroughly to minimize the potential of septic sludge eptic sludge bottom layer.bottom layer.

DAF DAF –– System OptimizationSystem Optimization

•• Sioux Falls added a Sioux Falls added a new air receiver new air receiver tank to maintain air tank to maintain air pressure and pressure and volume on the DAF volume on the DAF tankstanks

•• Also added a new Also added a new chemical feed chemical feed system, changed system, changed chemistry, and chemistry, and reduced chemical reduced chemical cost by cost by approximately approximately $200,000 per year$200,000 per year. .

Anaerobic Lagoons Anaerobic Lagoons –– Design Design Parameters:Parameters:•• Hydraulic Retention Time (HRT) = Low Rate, seven (7) days is optHydraulic Retention Time (HRT) = Low Rate, seven (7) days is optimalimal

•• BOD Loading: 20 lbs/day BOD removal per 1,000 cubic feet is optBOD Loading: 20 lbs/day BOD removal per 1,000 cubic feet is optimal.imal.

•• Sludge blanket depth: No more than a quarter of the total lagooSludge blanket depth: No more than a quarter of the total lagoon depth is n depth is optimal.optimal.

•• Anaerobic effluent alkalinity >800 mg/LAnaerobic effluent alkalinity >800 mg/L

•• Anaerobic effluent volatile acid < 200 mg/LAnaerobic effluent volatile acid < 200 mg/L

•• Anaerobic effluent pH >6.8 S.U.Anaerobic effluent pH >6.8 S.U.

Anaerobic Lagoons Anaerobic Lagoons -- Operational Operational KPIsKPIs•• Goal: Degrade high organic strength waste and Goal: Degrade high organic strength waste and

generate biogas for beneficial use generate biogas for beneficial use •• Hydraulic Retention Time (days)Hydraulic Retention Time (days)•• Lagoon Water TemperatureLagoon Water Temperature•• Effluent AlkalinityEffluent Alkalinity•• Effluent Volatile AcidsEffluent Volatile Acids•• Effluent pHEffluent pH•• BOD RemovalBOD Removal•• Quarterly Sludge JudgeQuarterly Sludge Judge

Anaerobic Lagoons Anaerobic Lagoons -- System System OptimizationOptimization•• Sioux Falls maximizes influent BOD Load through DAF Sioux Falls maximizes influent BOD Load through DAF

chemical dose rate modificationschemical dose rate modifications•• Maximize water temperature though insulation, hay Maximize water temperature though insulation, hay

bales, and lagoon coverbales, and lagoon cover•• Maximize HRT through a new sludge removal systemMaximize HRT through a new sludge removal system•• Optimize alkalinity/volatile acid ratio through lime Optimize alkalinity/volatile acid ratio through lime

additionaddition•• Maximize BOD removal, biogas boiler utilizationMaximize BOD removal, biogas boiler utilization•• This allows optimization of biogas generation and This allows optimization of biogas generation and

utilization saving our Sioux Falls plant approximately utilization saving our Sioux Falls plant approximately $1,500,000 per year on fuel costs$1,500,000 per year on fuel costs

Anaerobic Lagoon TemperaturesAnaerobic Lagoon Temperatures

•• Installed hay Installed hay bails and bails and insulationinsulation

•• Increased winter Increased winter anaerobic anaerobic effluent effluent temperatures by temperatures by 8 degrees F. 8 degrees F.

Anaerobic Lagoon Sludge RemovalAnaerobic Lagoon Sludge Removal

•• Previously Previously used used RotoRoto--Rooter to Rooter to transport transport anaerobic anaerobic sludge to belt sludge to belt filter press.filter press.


•• Automated Automated pumping pumping system system allows year allows year round sludge round sludge removal.removal.


•• Reduced Reduced transportation transportation costs by costs by approximately approximately $240,000 per $240,000 per year year

Aeration Basin Aeration Basin –– Design Parameters:Design Parameters:

•• Organic Loading Rate = 15 lbs BOD/day per 1,000 ftOrganic Loading Rate = 15 lbs BOD/day per 1,000 ft22 for extended for extended aeration aeration

•• Mean Cell Retention Time: >20 days, more for nitrificationMean Cell Retention Time: >20 days, more for nitrification

•• MLSS Concentration: 3,500 mg/L summer; 5,000 mg/L winter.MLSS Concentration: 3,500 mg/L summer; 5,000 mg/L winter.

•• DO Concentration: >1.5 mg/L for carbonaceous BOD removal, >2.0 DO Concentration: >1.5 mg/L for carbonaceous BOD removal, >2.0 mg/L for nitrification.mg/L for nitrification.

•• Aeration basin effluent alkalinity >100 mg/L for nitrificationAeration basin effluent alkalinity >100 mg/L for nitrification

•• F/M Ratio: 0.05 F/M Ratio: 0.05 –– 0.150.15

Aeration Basins Aeration Basins -- Operational KPIsOperational KPIs

•• Goal: Create environment for microorganisms to flourishGoal: Create environment for microorganisms to flourish•• Visual Observations (color/foam)Visual Observations (color/foam)•• Microscope (young/old sludge)Microscope (young/old sludge)•• MLSSMLSS•• F/MF/M•• DO DO –– Carbonaceous BOD RemovalCarbonaceous BOD Removal•• DO DO –– NitrificationNitrification•• AlkalinityAlkalinity•• pH range: 6.8 to 7.2pH range: 6.8 to 7.2•• Water TemperatureWater Temperature

Aeration Basins Aeration Basins –– System System OptimizationOptimization•• Optimize DO concentration for carbonaceous BOD Optimize DO concentration for carbonaceous BOD

removal and ammonia removal to save blower energy removal and ammonia removal to save blower energy costs.costs.

•• Maintaining a 1.5 mg/L DO in the first stage of aeration Maintaining a 1.5 mg/L DO in the first stage of aeration as opposed to >4.0 mg/L will save money. as opposed to >4.0 mg/L will save money. For example::(50 HP)(0.7456 KW/HP)(8760 hrs/yr)($0.05/KWhr) = $16,329/year(50 HP)(0.7456 KW/HP)(8760 hrs/yr)($0.05/KWhr) = $16,329/year

•• OnOn--line DO probes to assure enough air for nitrificationline DO probes to assure enough air for nitrification•• Alarm and autodialer for quick response to low DO Alarm and autodialer for quick response to low DO

situationsituation


•• John Morrell, John Morrell, Sioux Falls Sioux Falls increased increased sludge wasting sludge wasting rates to reduce rates to reduce the MLSS from the MLSS from 7,500 mg/L in 7,500 mg/L in August 2007 to August 2007 to 3,800 mg/L in 3,800 mg/L in June 2008.June 2008.


•• We also We also installed installed dissolved dissolved oxygen meter oxygen meter and probes in and probes in basins 1&2 to basins 1&2 to help monitor help monitor and maintain and maintain proper D.O. proper D.O. levels.levels.

Secondary Clarifier Secondary Clarifier –– Design Design Parameters:Parameters:•• Surface Overflow Rate = 800 Surface Overflow Rate = 800 gpdgpd per ftper ft22 (at design peak (at design peak

hourly flow) optimal for two stage nitrificationhourly flow) optimal for two stage nitrification

•• Solids Loading Rate = 35 lbs TSS/days per ftSolids Loading Rate = 35 lbs TSS/days per ft22 (max)(max)

•• RAS Concentration RAS Concentration –– typically double MLSS.typically double MLSS.

•• Sludge Blanket Depth <= 4 feetSludge Blanket Depth <= 4 feet

•• Side Water Depth >=12 feet is optimal Side Water Depth >=12 feet is optimal

Secondary Clarifiers Secondary Clarifiers -- Operational Operational KPIsKPIs

•• Goal: Settle Solids, Return and WasteGoal: Settle Solids, Return and Waste•• Visual ObservationsVisual Observations•• Sludge Blanket DepthSludge Blanket Depth•• WAS Discharge RateWAS Discharge Rate•• RAS ConcentrationRAS Concentration

Secondary Clarifiers Secondary Clarifiers –– System System OptimizationOptimization

•• Regulate WAS pumping rate for sludge blanket Regulate WAS pumping rate for sludge blanket depth controldepth control

•• Add polymer as needed to improve settlingAdd polymer as needed to improve settling•• Judiciously add chlorine to kill filamentous Judiciously add chlorine to kill filamentous

bacteria, when observedbacteria, when observed•• Chemical addition for pH control as necessaryChemical addition for pH control as necessary•• John Morrell, Sioux Falls reduced sludge blanket John Morrell, Sioux Falls reduced sludge blanket

depth from 10 feet to 1.5 feet and significantly depth from 10 feet to 1.5 feet and significantly improved effluent qualityimproved effluent quality

Operational KPI and System Operational KPI and System Optimization Optimization -- SummarySummary

•• John Morrell can discharge to the City of Sioux Falls as a John Morrell can discharge to the City of Sioux Falls as a backup to NPDES discharge. By monitoring our backup to NPDES discharge. By monitoring our operational operational KPIsKPIs and optimizing our system, our and optimizing our system, our discharge to the City decreased from:discharge to the City decreased from:

•• 2007: 19% of total flow 2007: 19% of total flow •• 2008: 8% of total flow 2008: 8% of total flow •• 2009: 3% of total flow, year to date2009: 3% of total flow, year to date•• This relates to a reduction in cost of $275,000 from 2007 This relates to a reduction in cost of $275,000 from 2007

to 2008 and a projected reduction of a further $100,000 to 2008 and a projected reduction of a further $100,000 from 2008 to 2009.from 2008 to 2009.

Preventive Maintenance to Keep Preventive Maintenance to Keep Equipment RunningEquipment Running

•• PumpsPumps•• Sludge PressSludge Press•• Aeration BlowersAeration Blowers•• Aeration Diffusers (Annual PM Aeration Diffusers (Annual PM –– Diffuser Diffuser

Replacement)Replacement)•• Final Filter (Quarterly PM Final Filter (Quarterly PM –– Media Depth)Media Depth)•• Maintenance Management SystemMaintenance Management System•• Document PM completionDocument PM completion

Trouble ShootingTrouble Shooting

•• Shock Loads Shock Loads –– high organic loadinghigh organic loading•• Toxic Loads Toxic Loads –– pH, salt, cleaning chemicalpH, salt, cleaning chemical•• Sludge Settling Issues Sludge Settling Issues –– filamentous bacteriafilamentous bacteria•• Sludge die off Sludge die off –– addition of cultured bacteriaaddition of cultured bacteria•• Incomplete NitrificationIncomplete Nitrification•• Microtrace, Novozymes Biological, Inc., Salem, Microtrace, Novozymes Biological, Inc., Salem,

VA VA –– spore tracer study for anaerobic lagoons to spore tracer study for anaerobic lagoons to define flow patterns and identify short circuitingdefine flow patterns and identify short circuiting

Avoid Costly Mistakes Avoid Costly Mistakes -- Final Final Effluent Filter Effluent Filter •• Fall 2007, we Fall 2007, we

removed and removed and Replaced 2000 Replaced 2000 cubic feet of cubic feet of gravity filter gravity filter sand media.sand media.

•• Replaced four Replaced four leaking filter leaking filter backwash backwash valves.valves.

Avoid Costly Mistakes Avoid Costly Mistakes –– Final Final Effluent FilterEffluent Filter•• For years, we did not keep filter media cleanFor years, we did not keep filter media clean•• For years, we did not conduct annual filter media For years, we did not conduct annual filter media

evaluationsevaluations•• Removed and replaced all filter media, but did not follow Removed and replaced all filter media, but did not follow

manufacturers recommendation on backwash flow manufacturers recommendation on backwash flow pattern verificationpattern verification

•• Did not monitor filter media depth after replacement.Did not monitor filter media depth after replacement.•• Filter media depth decreased from 30Filter media depth decreased from 30”” to 4to 4”” in 6 monthsin 6 months•• Filled up anaerobic splitter box, caused flow restriction Filled up anaerobic splitter box, caused flow restriction

and reduced anaerobic lagoon operational efficiencyand reduced anaerobic lagoon operational efficiency•• Second time around, we did it right and updated O&M Second time around, we did it right and updated O&M

Manual so this will not happen again!Manual so this will not happen again!

Maintain 100% ComplianceMaintain 100% Compliance

•• By maintaining an up to date O&M manual you By maintaining an up to date O&M manual you can:can:

•• Better understand system design capabilitiesBetter understand system design capabilities•• Establish operational Key Performance IndicatorsEstablish operational Key Performance Indicators•• Optimize system operationsOptimize system operations•• Keep equipment runningKeep equipment running•• Better trouble shoot atypical issuesBetter trouble shoot atypical issues•• Avoid costly mistakesAvoid costly mistakes•• Most importantly, you can maintain 100% Most importantly, you can maintain 100%

compliance!compliance!

SummarySummary

•• Lack of adherence to O&M Manual Lack of adherence to O&M Manual recommendations can be costly. recommendations can be costly.

•• A good O&M Manual provides a valuable A good O&M Manual provides a valuable benchmark to compare actual operations benchmark to compare actual operations to intended operations and assists in to intended operations and assists in process optimization.process optimization.

utilization of an operations and maintenance manual for

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