METHOD STATEMENT: WASTEWATER TREATMENT PLANT PROCESS

ASSESSMENT

Table of Contents

1. Method Statement: Wastewater Treatment Plant Process Assessment .......................................... 2

2. PROCESS OPERATIONS - Process Configuration ............................................................................... 4
3. PROCESS OPERATIONS – Process Control Preliminary Treatment .................................................... 5
2.1 Preliminary Treatment – Screening and disposal ............................................................................ 5
4. PROCESS OPERATIONS – Process Control Primary Treatment.......................................................... 9
4.1 Primary Treatment – Sedimentation and Pond systems ................................................................. 9
5. PROCESS OPERATIONS – Process Control Seconday Treatment ..................................................... 12
5.1 Secondary Treatment – Bio-filters, activated sludge and humus tanks ........................................... 12
6. PROCESS OPERATIONS – Process Control Tertiary Treatment ........................................................ 19
6.1 Tertiary Treatment – Chemical disinfection, maturation ponds and final effluent quality analysis .. 19
7. PROCESS OPERATIONS – Process Control Sludge Treatment.......................................................... 24
7.1 Tertiary Treatment – Thickening, dissolved air flotation, dewatering and destabilization ............... 24
8. PROCESS OPERATIONS: SAFETY AND MAINTENANCE .................................................................... 29
8.1 SAFETY AND MAINTENANCE ................................................................................................ 29
9. PROCESS OPERATIONS – CHECKLISTS ........................................................................................... 30
9.1 Checklist 1 ( Flow Diagram) ........................................................................................................... 30
9.2 Checklist 2 (Primary Assessment)................................................................................................... 31
10. PROCESS OPERATIONS – CHECKLISTS....................................................................................... 32
10.1 Checklist 1 ( Flow Diagram).......................................................................................................... 32
10.2 Checklist 2 (Primary Assessment) ................................................................................................. 33
9. References: ................................................................................................................................... 34
9.1 Peter King ................................................................................................................................... 34
9.2 LA Boyd and AM Mbelu................................................................................................................ 34

1
1. Method Statement: Wastewater Treatment Plant Process Assessment
Method Statement: Wastewater Treatment Plant Process Assessment

Introduction:

The purpose of this assessment is to evaluate the wastewater treatment plant's process
effectiveness, identify areas for improvement, and ensure compliance with regulatory
requirements.

Assessment Criteria:

1. Influent Quality

- Flow rate
- pH
- Temperature
- BOD (Biochemical Oxygen Demand)
- COD (Chemical Oxygen Demand)
- TSS (Total Suspended Solids)
- Nutrient levels (N, P)

2. Process Effectiveness Treatment

- Removal efficiency of contaminants (e.g., bacteria, viruses, parasites)

- Water quality parameters (e.g., pH, turbidity, hardness)
- Sludge quality

3. Treatment Plant Operations

- Plant capacity utilization

- Flow rates and hydraulic loading
- Chemical dosing and control
- Sludge management

4. Water Quality Monitoring

- Frequency and types of water quality tests

- Compliance with regulatory standards

2
 - Monitoring equipment calibration and maintenance

5. Maintenance and Repair

- Regular maintenance schedules

- Equipment condition and performance
- Repair history and downtime

6. Safety and Security

- Personnel training and safety procedures

- Emergency response plans
- Access control and security measures

7. Energy Efficiency and Sustainability

- Energy consumption and costs

- Water conservation measures
- Waste management and minimization

8. Regulatory Compliance

- Adherence to national and local regulations

- Permit requirements and reporting

Assessment Methodology:

1. Review of plant design, operation and maintenance records

2. Interviews with plant operators and management
3. Observations of plant operations and maintenance activities
4. Water sampling and analysis
5. Review of monitoring data and regulatory reports

Evaluation and Reporting:

1. Assess the treatment plant's overall performance

2. Identify areas for improvement and provide recommendations
3. Develop a prioritized action plan for implementation
4. Provide a comprehensive report detailing findings, conclusions and recommendations

Assessment Tools:

1. Checklists for plant operations, maintenance and safety

2. Water quality monitoring equipment
3. Data analysis software

3
4. Regulatory guidelines and standards

Assessment Frequency:

The assessment should be conducted annually or as required by regulatory agencies.

2. PROCESS OPERATIONS- Process Configuration

PROCESS OPERATIONS - Process Configuration

Notes (the what, why and how) Look for :
Flow Diagram
To understand how the WWTW has been structured and should be a flow diagram of the WWTW
operated, it is important that a flow diagram is on hand at the works.
Examples of flow diagrams are set out. The Process Manager should
draw this diagram and explain it to the other Process Controllers.
Capacity
To plan for future developments and know how much wastewater confirmation of the design
can be accommodated at the WWTW, it is essential to know the capacity or at least that an
design capacity of the works. Copies of the design drawings and estimation has been carried
manuals should therefore be on hand at the WWTW. If these are not out
available then the Process Manager should get an estimate by
measuring the various tanks. This could even be done by pacing out
the length (l) and width (w) of the tanks or measuring with a tape
measure and using a long stick of known length to get an estimate of
the depth (d). The capacity of a unit is then: capacity = (L x W x D)

4
3. PROCESS OPERATIONS – Process Control Preliminary Treatment

2.1 Preliminary Treatment – Screening and disposal

PROCESS OPERATIONS - Process Control Preliminary treatment

Notes (the what, why and how) Look for :
Screens
Materials such as rags, plastic and foreign materials can significantly interfere with the treatment
processes or damage the plant equipment if not removed. These solids are removed by means of
screening. The screened materials are hazardous and must be safely disposed of to prevent human
health concerns, fly breeding and odours.
Manual screen

The screens may need to be cleaned regularly to prevent the build- screens that are free of debris-
up of debris. A significant head loss (in other words, a flow that is a hand rake and wheelbarrow
much lower than normal) through the screens is an indication that that are easily accessible and
debris is clogging the screens. Overflow at the head of works or a in working order
point further upstream may also indicate clogged screens. A hand
rake and wheelbarrow should always be available. If the hand rake is
missing teeth it will not adequately clean the screens. The
wheelbarrow should not have holes at the bottom. The Process
Controller must request the Process Manager to purchase a new
hand rake and wheelbarrow as required.
Automated Screen

5
A significant head loss (a flow rate that is much lower than normal) screening components that
through the screens indicates that debris is clogging the screens and are free of obstructions,
the screens may need to be cleaned more often do not allow debris unusual sounds or vibration
to build up. Use of the manual control will allow immediate
observation of the operation of the manually cleaned bar screens or
other equipment even though these may be inactive when the
inspection begins.

PROCESS OPERATIONS - Process Control Preliminary treatment

Notes (the what, why and how) Look for :
Screeching could indicate scraping of the screen or lack of lubrication a maintenance schedule that
of the chain or drive mechanism while thumps could indicate broken is implemented for the
or loose components. The Process Controller should report any screens  screenings that are
unusual vibrations and/or sounds to the Process Manager or washed to remove organics
maintenance personnel. To ensure that the mechanical screens and wash water that is
operate optimally, a maintenance schedule should be drawn up. It returned to the WWTW
may be that the suppliers of the screen recommend a maintenance screenings that are pressed
schedule. before disposal
Grit Removal
Grit material can include sand, silt, glass, small stones as well as other large-sized organic and
inorganic substances (detritus). Excess grit can cause operational problems such as pump blockages
and high organic concentrations in the digesters and/or reactors. Grit removal is therefore essential to
protect moving mechanical equipment and pumps from abrasion and to reduce blockages.
Manually cleaned channels
A spade is used to manually remove the accumulated grit from the channels that are clear of grit,
channel that has been closed and drained. Grit should be placed into channels that are in working
a container such as a wheelbarrow or large bin for easy removal. The order, i.e. one can be used
Process Controller must therefore ensure that both channels are in while the other is closed for
working order by maintaining the channels regularly and request the manual removal of grit.
Process Manager to purchase a new spade and disposal container as a spade and container that are
required. easily accessible for grit
storage Mechanical/
automated cleaned channel
Mechanical/Automated cleaned channels

6
A noisy, uneven movement of the channel cleaning scraper may in-line mechanism that is
indicate a problem with the grit removal. moving smoothly, channels
A low recovery of grit may mean that the grit scraper system is that are clear of grit channels
operating at low speeds or there is another problem with the that are in working order, i.e.
scraper system. one can be used while the
other is closed for manual
removal of grit
Automated de-gritters
Automated de-gritters use centrifugal force in a cone-shaped unit to a pump in working order
separate grit from wastewater by creating a vortex. A pump is
required to remove a slurry of grit near the upper perimeter of the
de-gritter onto a conveyor which then discharges to a container such
as a large bin.
Screenings and grit disposal

Screenings and grit left lying around will cause nuisance conditions non nuisance conditions
such as odours and will encourage fly breeding. It should therefore (odours and fies), grit or
be disposed of into a suitable container such as a large dustbin that screenings lying around,
can be closed. It is important to ensure that no screenings are left covered bins that are used for
lying around on the ground. At small WWTWs screenings and grit storage of grit, proof that grit
can be buried in trenches. These trenches must immediately be and screenings buried on site
covered with soil once screenings and grit have been disposed of. are covered daily
Where larger volumes of screenings and grit are collected, the
screenings must be disposed of to a permitted waste site.
Flow

7
As a WWTW is designed to treat a specific volume of wastewater per day, it is important to know how
much wastewater is entering so as not to overload the plant
Flow metering

Changes in the volumes entering the plant will alert the Process flow measurement knowledge
Controller to possible problems upstream of the works, e.g. at a of flow in relation to design
pump station. It is also important to know when the peak flow capacity, the flow mechanism
arrives at the WWTW. Flow is typically measured just after the and determine whether it is in
screens and grit removal processes and it is important to note that working order and is
one of the conditions of an authorisation will be that the flow is calibrated.
measured. In other words flow measurement is a legal requirement.
Normal’ raw wastewater is a light grey colour. If the wastewater
entering the WWTW is of a darker or different colour or appearance
(e.g. oily), it could be an indication of industrial discharges to sewer
which may be illegal and may contain a substance/s that could be
harmful to the biological organisms of the WWTW.
Flow balancing
Flow balancing, also called flow equalisation, is used to overcome mixers – are they working?
the operational problems caused by flow rate variations and to aerators – are they working, if
improve the performance of the downstream unit processes. In in place?
other words, flow balancing is simply the damping of flow rate pumps – are they working?
variations so that a constant or nearly constant flow rate can be odours – are odours controlled
achieved. Balancing tanks can be located before or after primary
sedimentation. If placed after primary sedimentation, fewer
problems with sludge and scum occur. If placed before primary
sedimentation, mixing must be in place to prevent solids deposition
and aeration may be needed to prevent odours.

8
4. PROCESS OPERATIONS – Process Control Primary Treatment

4.1 Primary Treatment – Sedimentation and Pond systems

PROCESS OPERATIONS - Process Control Primary Treatment

Notes (the what, why and how) Look for :
Primary sedimentation
The main purpose of primary sedimentation is to allow separation of the solid and liquid phase
fractions in the wastewater. It removes the readily settleable solids which are mainly organics as well
as the floating material such as fats, oils and grease. The settled solids are known as primary sludge.
The process therefore reduces the suspended solids content of the influent wastewater. Even though
the volume of primary sludge is only about 2% of the total influent wastewater volume, it makes up
approximately 30 to 40% of the organic load received (expressed as COD) and some 40 to 60% of the
suspended solids loading
Primary sedimentation tanks (PST)

Look and listen to all moving parts to determine if the equipment is inflow that should be light
functioning properly. Odd vibrations or noises could be an indication grey in colour, overflow at the
that a piece of equipment needs maintenance or replacement. If weirs that is similar where
there is more than one (1) PST, it is good practice to ensure that the more than one (1) PST is
flow to the PSTs is equally distributed. This can easily be checked by present, weirs in good
observing the overflow at the weirs – it should be similar. Weirs condition, scum or floating
should be level to ensure uniform overflow of settled wastewater sludge layer, layer of
along the PST weirs. Check that the surface scum layer is being fats/grease/oil, a schedule for
properly skimmed off and that there is no sign of belching. If the desludging and check that it is
scum is not being skimmed off adequately, it could mean that: implemented

1. Scrapers are worn or damaged

2. Sludge may be decomposing in the PST

9
3. There is return of well-nitrified waste activated sludge.

It is important to adhere to the schedule of desludging. Septic sludge

(black in colour with a very ‘gassy’ odour) may indicate that there is:
 inadequate rate of sludge scraper system so that the run time of
scraper system should be increased;  an insufficient rate of sludge
pumping so that the frequency and duration of sludge pumping
should be increased. Pre-fermentation may however mean that the
sludge would be darker than normal.

Process sampling should be undertaken on samples from the PSTs -

daily if the capacity of the works is >20 Ml/day or twice a week if
smaller.  Suspended Solids (SS)  Total and Volatile Solids (TS and
VS)  Chemical Oxygen Demand (COD)  Imhoff cone tests on
settleable solids in influent and effluent  % dry solids in sludge
underflow.

Records should be kept of preventative maintenance procedures

including:

Lubrication schedules
Spare parts (required and available)
Stoppages and malfunctions
Pond systems
Pond systems are relatively shallow bodies of wastewater in which the self-purification of processes of
water are used under controlled conditions to purify raw or settled wastewater.
Oxidation Ponds

Pond systems may be aerobic and anaerobic and at least four ponds ponds operated in series
should be linked in series. Short-circuiting means that the the presence of short-
wastewater is following a course through the ponds that would circuiting
mean that the detention time of the wastewater in the pond is aerators - are they working if
inadequate to allow any biological purification to occur, so that the present?
final effluent will be of very poor quality. Often, floating mechanical evidence of desludging - is it
aerators are used to add air (oxygen) to one or more ponds to assist done periodically to a
with the biological processes.

10
 schedule and is sludge
The advantage of a floating aerator is that it is portable and can be correctly disposed of?
easily removed or moved from place to place. Sludge buildup occurs area around the ponds – is it
in the first pond so that it will need to be desludged from time to well maintained?
time. visible erosion around the
ponds.
The pond will need to be emptied and the sludge will need to be
removed. It is therefore important that there is a parallel pond to
which the influent can be diverted while desludging occurs. All
sludge must be disposed of responsibly in accordance with the
relevant authorisation in place.

The area around the ponds must be kept clean and tidy. Any solids
that have passed through the inlet must be removed from the
surface of the ponds and disposed of with the grit and screenings if
these are removed prior to the ponds. No solids should be allowed
to accumulate on the side of the ponds.

11
5. PROCESS OPERATIONS – Process Control Seconday Treatment

5.1 Secondary Treatment – Bio-filters, activated sludge and humus tanks

PROCESS OPERATIONS - Process Control Secondary Treatment
Notes (the what, why and how) Look for :
Attached growth processes
Aerobic attached-growth treatment processes are those processes that utilise microorganisms that
grow on a medium, such as stones and discs, to remove organic matter found in wastewater. They can
also be used to achieve nitrification – the conversion of ammonia to nitrate/nitrite.
Trickling filters (also known as biofiters)

It is important to be able to access the top of the trickling filter to access to the top of the filter
observe the rotating arm and distribution of the wastewater. movement of the rotating
distributor arm – is it smooth?
A slow or stopped arm may be due to: insufficient flow clogged arms
or orifices (small holes in the distributor arms) clogged distributor distribution of wastewater to
arm vent pipe bad main bearing the distributor arms not being level the filter media through the
the distributor rods hitting the media. Uneven distribution may be rotating distributor arm – is it
due to clogged orifices on the distributor arms. even?

Uneven distribution may cause the problems described above. It is filter media – is it free of
therefore important to know the flows entering the works so that ponding?
the flows can be evenly distributed, or filters taken off-line if
necessary. underdrains - are they clear of
any obstructions?
Ponding may be due to: excessive biological growth thus not
allowing the wastewater to flow through adequately poor media
poor housekeeping.

The underdrains need to be kept clean to allow free flow of the

effluent from the filter. Material that has fallen off the filter material

12
and collected in the underdrains of the filter must be cleared often
and disposed of with the screenings and grit. Inorganic material
should be removed from the filter media.

Unpleasant odours could indicate that excessive organic load is

causing anaerobic decomposition in the filter or that there is
insufficient
Rotating biological contactors (RBC)
These aerobic attached-growth treatment processes are also known the motor - is it working?
as disk systems as they consist primarily of a set of disks, made of
some man-made material mounted on a shaft that is mounted over the disk system – does it
the wastewater that is being treated. rotate freely at a steady rate?

The shaft needs to rotate slowly so that the disks are immersed in the sludge return pump - is it
the wastewater for a short period of time before returning to the air. working?

This ensures that a biological slime develops on the disks in a the ammeter - does it
manner similar to that of the biological filter. In time, this slime falls fluctuate as the disk turns?
off and falls into the wastewater where it has to be settled out and
removed/recycled. In this respect in order for the RBC to work floating sludge in the final
adequately, all the instrumentation needs to be in working order. settling tank?

The shaft must turn at a steady rate of rotation and not move
unevenly.

The ammeter should not fluctuate (the needle move backwards and
forwards) as the disk turns. Look for: Clumps of floating sludge may
indicate that the sludge return pump is not working or that the
sludge is sticking to the sides of the settling tank and not reaching
the pump inlet.

PROCESS OPERATIONS - Process Control Secondary Treatment

Notes (the what, why and how) Look for :
Activated Sludge Processes
The activated sludge process (ASP) is a biological process of developing an activated mass of
microorganisms capable of stabilizing waste aerobically. Organic waste is introduced into a reactor
where a bacterial culture (biomass) is maintained in suspension. The reactor content is referred to as
the ‘mixed liquor’ or activated sludge.
Activated sludge

13
Visual observation of the ASP is very important. The colour, smell records of the sludge age
and appearance of the biomass give a good indication of whether
the ASP is working well. scum on the surface

The control of the solids retention time (SRT) (sludge age) is one of records of he MLSS (mg/l)
the most important controls in the activated sludge process.
records of the DO
The mass of organisms in terms of actual sludge in the aeration basin
can be expressed as the concentration of the sludge (kg.m-3 or g.ℓ - dark brown biomass (colour)
1) multiplied by the volume of the basin in m3.
an earthy smell
The product is the mass of sludge in kg. The mass of surplus sludge
wasted per day can be expressed in kg per day (kg/d). Under stable clean bunded chemical dosing
operating conditions the mass of surplus sludge produced per day area
must equal the mass of sludge wasted per day. Typical sludge age is
15 days. records of daily process
monitoring as appropriate to
Controlling the SRT at 15 days means regulating the amount of the ASP
sludge wasted per day such that the average retention time of the
sludge in the system is 15 days. The sludge wasted per day must then on-line equipment - is it in
be 1/15 of the mass of sludge in the aeration basin. working order and calibrated;
are calibration certificates
The mixed liquor suspended solids (MLSS) concentration is one of available?
the most important routine control tests for an ASP. Knowledge of
the MLSS is necessary to know whether the solids loading on the aerators - are they in working
clarifier are within suitable limits. In other words, will the mixed order?
liquor settle adequately in the clarifier? The typical range for MLSS is
2 500 – 4 500 mg/ℓ. Recycling – is it taking place
and is a record of the correct
Chemical dosing for ASP Chemical dosing may be required at certain ratio of inflow to sludge
plants to assist with phosphate removal. recycle maintained?

The coagulating characteristics of the chemicals lead to the

production of a clear effluent. A number of chemicals are effective

14
for the removal of phosphates including: alum, ferric chloride, ferric
sulphate and ferrous sulphates.

It may take some experimentation to determine the best point of

application for the particular chemical and the Process Controller
should get guidance from the chemical distributor. In this respect it is
important to purchase chemicals from a reputable company.

Based on the experimentation the Process Controller will then know:

Where to dose the particular chemical

- How much chemical to dose
- When to dose (i.e. the frequency per day).
- In all cases where chemicals are used, storage will be
needed.
- Due to the nature of the chemicals used in the ASP, the
chemicals must be stored in a bunded area so that if spillage
does occur the chemical will be contained and can be
cleaned up more easily.
- The ASP, being a biological system, is extremely sensitive to
change (e.g. pH, temperature).
- Daily process monitoring is therefore essential to ensure that
the processes are working adequately and to optimize the
process to achieve a good quality final effluent.

Parameters to measure include:

- Chemical Oxygen Demand

- Nitrate
- Ammonia
- Dissolved oxygen
- Suspended solids
- pH
- Total dissolved solids
- Ortho-phosphat

If field or on-line equipment is used, it must be correctly and

accurately calibrated as per the specifications from the supplier. An
example of this is a dissolved oxygen (DO) meter.

The control of dissolved oxygen (DO) in the aeration basin is

important for:

Saving energy by avoiding excessive input of oxygen

Removal of nitrogen and phosphates from wastewaters where over-

aeration of the activated sludge can decrease the removal rate of
these nutrients

15
Sludge with good settling characteristics

Improvement in effluent quality.

The ammonia should be monitored in the final effluent. If ammonia
concentration is undetectable then cut back on aeration until the
ammonia rises, but not exceeding 1 mgℓ-1.

The ideal range of DO concentration varies with the SRT,

temperature and the need for nitrification. An indication of correct
aeration is the concentration of the ammonia in the effluent. Over-
aeration will result in an effluent with ammonia concentration that is
virtually non-detectable.

Aeration in the activated sludge process serves to: introduce oxygen

into solution for the bacteria mix the incoming raw or suspended
wastewater with the contents of the basin keep the bacterial mass in
suspension.

For adequate operation of the activated sludge process, it is

important that the incoming raw wastewater is in contact with the
bacterial mass while the dissolved oxygen is distributed throughout
the basin.

Elimination of dead spots is therefore important. Recycle in the

activated sludge process is very important in maintaining the MLSS
in the system and to avoid loss from the clarifier. In certain instances
where biological nutrient removal is practiced, recycle is essential for
both phosphate and nitrogen removal. It is important to ensure that
the ratio of inflow to sludge recycle (s-recycle) is maintained at 1:0.8
to 1

16
PROCESS OPERATIONS - Process Control Secondary Treatment
Notes (the what, why and how) Look for :
Clarification/ secondary settling
Clarification, also known as secondary sedimentation/settling, is required after the aerobic oxidation
processes encountered with trickling filters and activated sludge plants. In both cases the purpose is
to clarify the effluent and prevent solids carry-over to the water resource (e.g. river).
Humus tanks
Humus tanks are used for clarification following trickling filters. The clean scum troughs
amount of settleable humus solids is relatively small (ranging from 3-
4% of the primary sludge). clean effluent weirs and
baffles
The clear overflow from the humus tank is the treated effluent that
will undergo disinfection prior to disposal and the underflow, which working sludge withdrawal
contains the settled sludge solids, is the sludge return or recycle equipment
stream.

The functioning of the humus tank can affect that of the biofilter. In
order to avoid gasification or denitrification of the sludge, the sludge
must be removed quickly. Solids in the overflow would indicate that
settling is not occurring properly.
Clarifier/ secondary settler
Clarifiers, also known as secondary settlers, are used after the ASP. trends of the SVI test
Sludge from the ASP is in suspension and must be settled out in the
clarifier to produce two streams, i.e. the sludge and the clear clean effluent weirs/channel
effluent.
clean launders
The Sludge Volume Index (SVI) is an indicates the settleability of
activated sludge, i.e. the test gives an indication of the ease with operational desludging
which the sludge will settle and could be used by the Process equipment
Controller as a tool in the operation of the plant.
limited scum on the surface of
SVI test: the clarifier

Consists of pouring mixed liquor into a 1 000 ml cylinder and an operational scum draw-off
allowing it to settle for 30 minutes. The level of the sludge is then system
measured (a). The MLSS (b) of the sludge is measured at the same
time. The SVI is expressed as the density of sludge after settlement clear overflow
(mℓ.g-1). This is obtained by dividing the volume determined in (a)
by the mass (b) and is expressed in mℓ.g-1, i.e. the better the sludge
compacts, the lower the SVI.

The weirs/launders of the clarifiers need to be kept clean to ensure

uniform overflow rates. For the clarifier to operate optimally, the
mechanical equipment must be in working order and therefore must
be maintained.

17
Scum on the surface of a clarifier could indicate:
- Worn scraper blades
- Blocked scum hoppers
- An inadequate scum removal frequency. Desludging must
take place in a manner that will optimize the clarifier
operation and produce a clear effluent.
Solids in the effluent may be due to :
- Hydraulic overload;
- a low sludge recycle; or
- excessive solids loading. If the scum draw-off system is not in
working order scum will accumulate on the surface and
overflow with the final effluent.

18
6. PROCESS OPERATIONS – Process Control Tertiary Treatment

6.1 Tertiary Treatment – Chemical disinfection, maturation ponds and final effluent quality analysis

PROCESS OPERATIONS - Process Control Tertiary Treatment

Notes (the what, why and how) Look for :
Tertiary treatment
Raw wastewater is a hazardous waste containing human pathogens and while each unit process
reduces the number of microorganisms, high numbers of pathogenic organisms will still remain even
after the best possible biological treatment. The goal of disinfection therefore is to remove or
inactivate pathogenic microorganisms. However, disinfection is not synonymous with sterilisation, in
which all organisms are killed. The primary pathogenic micro-organisms targeted for inactivation
include bacteria, viruses and protozoan cysts. It is therefore very important to have disinfection
process/equipment in place and in working order. The possible methods of wastewater effluent
disinfection are many and include natural processes (predation and normal death), environmental
factors (salinity and solar radiation) and methods having certain industrial applications (ultrasonics
and heat). The systems for disinfection are also therefore numerous. This guideline however deals
only with the most commonly used systems in South Africa.
Chemical disinfection
While the chemical disinfection systems are numerous, the use of the dosing equipment is in
chlorine is currently still the dominant disinfectant used at WWTWs working order, e.g. the little
either in the form of gas or solids such as sodium or calcium ball in the rotameter is moving
hypochlorite (HTH).
no chlorine can be smelled
Depending on the type of chemical being dosed, the equipment may
differ. For example:  Gas chlorinators basically consist of a vacuum relevant training has been
regulator with adjustable gas flow measurement via a float tube and given to the Process
an ejector on a pressure water line. Controller/s

The water passes through the ejector creating a vacuum so that the residual chlorine level is being
chlorine gas is sucked into water at the ejector and into solution. measured in the final effluent
This solution is then added to the final effluent at a suitable point. using the DPD method

The amount of gas drawn into the water at the ejector is regulated the contact tank is clean (i.e.
by a valve and measured on the float tube. not sludged up) and free of
algae
 Hypochlorite solutions may be drip fed or dosed via a metering
pump final effluent samples are
 On very small WWTW tablet dispensers (HTH) can be used Apart taken in accordance with
from being corrosive, chlorine is also very poisonous. water use authorization.

All personnel working with chorine must undergo relevant training

on the use and handling of chlorine often on offer from the supplier.
Should other chemicals such as bromine be used, the same should
apply.

19
Aquatic life is very sensitive to chlorine so there are standards set for
discharges to a water resource. The common test undertaken for
chlorine determination is known as the DPD method* and will give
an indication of whether the chlorine concentration in the final
effluent is too high.
Each water use authorisation has a condition that specifies standards
that have to be met in terms of the quality of the final effluent.
These would include, but not be limited to, the following
parameters:

- Chemical Oxygen Demand

- Ammonia - Nitrates
- Faecal coli
- pH - Ortho-phosphate
- Residual chlorine
- Suspended solids

The frequency of monitoring for compliance will also be stipulated in

the water use authorisation, however for performance monitoring of
the WWTW, it may be necessary to monitor these parameters more
frequently.

The contact tank is where the chemicals do the job of disinfecting

the final effluent. Solids in the effluent can interfere with this
process.

Sludge build-up also occurs due to settlement of solids because of

the reaction with the chemical. It is therefore very important that
the contact chamber is desludged at least every two weeks to ensure
that adequate kill of pathogens occurs.

*DPD Method: this method test kits use a powder or tablet chemical
DPD (N,N diethyl-p-phenylene diamine) that causes a color change
to pink in the presence of chlorine. The field worker uses a color
wheel/chart to visually match the color to a numerical free or total
chlorine reading. The test kit can be used to measure free chlorine
and/or total chlorine, with a range of 0-3.5 mg/L, equivalent to 0-3.5
ppm (parts per million).

20
PROCESS OPERATIONS - Process Control Tertiary Treatment
Notes (the what, why and how) Look for :
Constructed wetlands
Herbicidal and insecticidal treatment to control the development of reeds are planted
undesirable weed species, algae and aphids may be done. It is,
however, important to know what effect these may have on the reed growth is controlled
quality of water that is leaving the wetland. using a schedule

Each water use authorisation has a condition that specifies standards selective seeding and planting
that have to be met in terms of the quality of the final effluent. is undertaken periodically
These would include, but not be limited to:
- Chemical Oxygen Demand samples are taken according
- Ammonia to relevant authorization
- Nitrates
- Faecal coli herbicidal and insecticidal
- pH treatment is practiced
- Ortho
- phosphate
- Residual chlorine
- Suspended solids

The frequency of monitoring for compliance will also be stipulated in

the water use authorisation, however for performance monitoring of
the WWTW, it may be necessary to monitor these parameters more
frequently.
Maturation ponds
Maturation ponds give a final ‘polish’ to effluents before discharge. overflow is clear
They are used to improve the bacteriological quality of the final
effluent and can also act as a buffer in the event of a breakdown at no erosion is observed
the works. If used after a process such as the activated sludge
process, a series of maturation ponds can reduce the bacteriological the banks of the ponds are
count considerably. protected against erosion

The water use authorisation will give specific conditions with respect
to the quality of the final effluent and the frequency at which
sampling must take place.

The ponds and surrounds should be kept neat and tidy to minimize
nuisance conditions which include rats, snakes and insect
infestations.

Due to the fact that the ponds are shallow, plant growth is common
and needs to be controlled.

21
PROCESS OPERATIONS - Process Control Tertiary Treatment
Notes (the what, why and how) Look for :
FINAL EFFLUENT
Environmental and human health is dependant on good quality effluent being discharged to a water
resource or disposed of to the environment as for example, irrigation water.
Sampling frequency
In order to get an understanding of the effluent quality, it is Sampling frequency:
important to take final effluent samples daily and to record the
results to get a trend. daily

Sampling on a frequency less than this would render the overall weekly
interpretation of the results meaningless.
bi-weekly
All authorisations contain conditions which stipulate the frequency
of monitoring and the parameters to be measured. At least pH, COD, monthly Sampling lo
phosphate, nitrate, ammonia, suspended solids and faecal coliforms
and electrical conductivity should be monitored.

A consistently good effluent indicates that the wastewater works is

running well.
Sampling location
Regardless of whether a WWTW discharges effluent or disposes of it Sampling location:
in another manner such as irrigation, the final effluent quality must
be known. upstream of WWTW

Where effluent is discharged, the sampling locations are very point of discharge
important and there should be at least three sampling locations.
- Upstream of the WWTW to indicate the quality of the water downstream of WWTW
in the river before the WWTW

- At the point of discharge to understand the quality of

effluent being discharged to the water resource in
comparison to the river water quality

- Downstream of the WWTW to understand the impact that

the discharge is having on the water resource.

22
PROCESS OPERATIONS - Process Control Tertiary Treatment
Notes (the what, why and how) Look for :
Final effluent quality
At least pH, COD, phosphate, nitrate, ammonia and faecal coliforms, records of final effluent quality
electrical conductivity and suspended solids should be monitored.
compliance figure
A consistently good effluent indicates that the wastewater works is
running well. While in terms of any authorisation, the final effluent a graphical record of final
quality compliance should be 100%, it is expected that non- effluent quality
compliance will occur at some stage for various reasons. In this
respect it is reasonable that the final effluent from a wastewater
works should comply at least 80% of the time for all parameters
measured.

The results need to be interpreted against the authorisation

conditions. The Process Manager must understand how to calculate
the % compliance and keep a graphical record of the monthly
compliance per parameter.

How to calculate compliance per parameter:

(Sum of monthly results that comply per parameter) x 100 = %

compliance (Number of samples taken)

23
7. PROCESS OPERATIONS – Process Control Sludge Treatment

7.1 Tertiary Treatment – Thickening, dissolved air flotation, dewatering and destabilization
PROCESS OPERATIONS: PROCESS CONTROL SLUDGE TREATMENT
Thickening
The main reasons for thickening sludge prior to digestion are:

- To maximize the use of the available digester capacity in the digestion of the solids (i.e. water
takes up space)
- To prevent the dilution of the feed material which could cause difficulty in the utilization of
the food by the bacteria
- To reduce the amount of heat required in a heated digester
- To prevent the washout of solids and micro-organisms from hydraulically overloaded digester
- To prevent the dilution of the generated alkaline buffer in the digester as this could cause pH
instability.

Regardless of the type of sludge, the concentration of the thickened solids should be high enough to
promote effective digestion, but not too thick to adversely affect pumping and mixing of the sludge in
the digester.

In smaller plants, thickening is achieved in the primary settling/sedimentation tank or in the sludge
digestion unit. In larger plants there may be a separate thickener, e.g. gravity and dissolved air
flotation thickeners.

Thickening is also important in the dewatering process.

Gravity thickening
Notes (the what, why and how) Look for :
It is important for the operating staff to familiarise themselves with mechanical equipment -
the manufacturer’s instructions for operating the gravity thickener. working order

For the thickener to operate optimally, the mechanical equipment a schedule for sludge draw -off
must be in working order and therefore must be maintained.
adequate skimming of scum
Scum problems are often encountered when the sludge is kept too
long in the gravity thickener. It is therefore important to draw off records of settleable solids
sludge at regular intervals. (overflow) and total solids
(sludge underflow)
In case of scum problems, it may be necessary to fit a high-pressure
spray that covers a portionof the tank. Grease build-up in underflow feed to the thickener - should
lines is also a potential problem especially in works where no grease be continuous
and fat removal is practised in the PST.
chemicals used for
Grease and fat particles cling to the sludge particles and settle out. conditioning - are they
High-pressure water hoses can be used to flush out the sludge lines. adequately stored in a bunded
area?

24
A plant Imhoff cone test of the settleable solids in the supernatant
liquor from the thickener and a total solids analysis of the sludge overflow - excessive solids are
underflow rapidly indicate the efficiency of the thickening process. not being carried over

In order to optimize the frequency and duration of desludging, a

total solids test should be carried out on the underflow.

The feed to the gravity thickener should be as near to continuous as

possible.

This promotes a stable sludge blanket and also tends to reduce

gasification and the resultant floating sludges.

Chemicals such as polymers (usually powder that must be mixed),

lime (powder that must be mixed) or ferric chloride (liquid in a tank)
may be added to the sludge beforehand to aid in the thickening
process. These should be kept within a bunded area to contain spills.
It is important that excessive solids are not carried into the overflow.
Dissolved air flotation
Establish the required inflow rate of sludge and adjust if necessary. air compressors - are in
working order
The DAF system consists of three main unit processes:
valves and pressure gauges -
 The pressurisation system are in working order
 The flotation tank
 The recycle system. leaks in the pipes and
pumpssurface skimmers on
Should there be a malfunction in any one of these units, then the the flotation tanks - are
system will not function. working adequately

he rising sludge is guided upwards and outwards by the tiny bubbles clarified liquor - free of solids
to form a floating scum, which is removed from the surface by
skimmers. records of settleable solids
(overflow) and total solids
The surface skimmers are set at a level above the water level to (sludge underflow)
allow float to form above the water surface. This allows drainage of
the upper float layer, and thickening. Solids in the clarified liquor chemicals used for
may be an indication that desludging is not being done often conditioning – are they safely
enough. stored in a bunded area?

Results of total and volatile solids from tests done on composited underflow - few solids are
samples from the feed to the thickener and the underflow from the carried over
thickener provide information on the solids loading rate to the
thickener and the anaerobic digester respectively and also on the
degree of thickening achieved.

25
Suspended solids on composited samples of the overflow liquor
from the thickener provide information on the success of the
thickening operation.

Chemicals such as polymers (usually powder that must be mixed),

lime (powder that must be mixed) or ferric chloride (liquid in a tank)
may be added to the sludge beforehand to aid in the thickening
process.

These should be kept within a bunded area to contain spills. The

underflow should not contain a large concentration of solids and if
present, this is an indication that there is a problem somewhere in
the process.

PROCESS OPERATIONS: PROCESS CONTROL SLUDGE TREATMENT

DEWATERING
Sludge is a mixture of solid matter, both organic and inorganic, and water. The amount of solids in this
mixture, or suspension, is usually defined as the ratio of the mass of dry solids to the total mass of the
sludge and is expressed as a percentage. Dewatering is therefore important in reducing the volume of
sludge to be disposed. Example: 1 ton of wet sludge with 4% solids content will contain only 40 kg of
solids when completely dried out.
Filter press/belt press
Notes (the what, why and how) Look for :
Flocculent is added to the thickened sludge to aid in the dewatering locculent - stored safely and
process. It is usually supplied as a powder and needs to be mixed. In within a bunded area
this respect it must be correctly stored in an area where the
chemical can be contained, should there be any spills from the bags. belt presses - in working order
If belt presses are being used for dewatering sludge, they must be
kept in working order to avoid the problem of sludge building up. records of feed to the presses
The visual quality of the filtrate and washwater will give an - measured
indication of how well the presses are working. A poor visual quality
filtrate will indicate that there is a problem with the feed or the records of the quality of the
presses themselves. If debris is allowed to collect in the sludge lines, filtrate and washwater
blockages will occur and the sludge will not reach the drying beds
causing problems upstream of the drying beds. An important aspect sludge lines - are they free of
of bed maintenance is the raking and leveling of the bed. Water that debris?
drains from the sludge will cement the sand particles and lead to
increased resistance to filtration in the sand and eventually, sludge on the beds - is it raked
complete blockage. The walls and floors of the drying beds need to to keep it level?
be inspected regularly and maintained. Cracks that form due to
settlement or for any other reason, lead to the leakage of sludge or walls of the drying beds – are
drainage water. The drying beds should be weeded on a regular basis they intact?

26
as weeds slow down the drying process. Each time sludge is
removed after drying, a few millimetres of sand is lost. The sand beds – a they free of weeds?
therefore needs to be replaced at regular intervals to compensate
for this loss. An excessive dewatering time could indicate that the a schedule for replacement of
draining and piping system is blocked or broken. Samples for analysis sand as dried sludge is
of total solids of composite samples of feed sludge and dried sludge removed
must be taken per bed.
the draining system and piping
Maintain records of: - is it working?

drying time per bed

thickness of sludge layer added and date of application

malfunctions

climatological records (e.g. rainfall).

records of total solids determination

PROCESS OPERATIONS: PROCESS CONTROL SLUDGE TREATMENT

Stabilisation
The wastewater solids are treated in the anaerobic digesters after primary sedimentation and
thickening. This process of digestion converts the raw sludge from a smelly putrescible nature to a
substance that is relatively odour-free, readily dewaterable and sufficiently stabilised to be disposed of
without causing nuisance conditions.
Anaerobic digestion
Notes (the what, why and how) Look for :
The 2-stage biological process utilizes acid forming bacteria which level of the grit and sand in
convert the organic matter to organic acids which are then converted the digester
to methane (CH4) and carbon dioxide (CO2) by methane forming
bacteria. It is important that the organic acids formed in the first records of alkalinity
stage are converted to methane at the same rate at which they are measurement
formed. If not, instability will occur and ultimately digester failure.
bottom draw-off – working
Parameters to measure: - Feed rate - Volatile acids - Alkalinity -
Volatile Acids/Alkalinity ratio - pH value - Biogas production rate - records of sludge retention
Volatile solids reduction - Temperature - Volatile solids loading rate - time
Hydraulic retention time Carbon dioxide content of the biogas
schedule for filling and wasting

27
Biogas management: The main constituents of gas produced in a unusual noises
digester are methane (60-75%) and carbon dioxide (25-40%) with
small amounts of nitrogen (1-5%), hydrogen sulphide and hydrogen. schedule for supernatant and
sludge withdrawal
A typical gas handling system comprises: - digester cover pressure
and vacuum relief devices - water trap - flame trap - pressure pressure gauges - in working
regulator - gas meter - check valve - pressure gauges - waste gas order
burner - gas holder (this may be as a floating roof on the digester or pressure relief device- in
it my be a separate gas holder) working order

If mixing of the digester is done by means of gas recirculation, then a colour of the flame - yellow
compressor will be required. with blue at the base

It is important to note that biogas and air can form an explosive records of relevant parameters
mixture monitored

For this reason it is very important to do monthly checks on: records of compliance to
current sludge guidelines
- pressure and vacuum relief devices
- valves and gauges records of maintenance of
and to keep records of: pressure and vacuum relief
- the maintenance of the above devices
- the gas flow rate between the digester and the gas holder. If
the volume of the gas in the gas holder seems lower than records of maintenance of
expected, then it is important to check for valves and gauges

records of gas flow rate from

the digester to the gas holder

28
8. PROCESS OPERATIONS: SAFETY AND MAINTENANCE

8.1 SAFETY AND MAINTENANCE

PROCESS OPERATIONS:
Notes (the what, why and how) Look for:
Maintenance Operations
Maintenance schedule
A planned maintenance schedule is essential to ensure that maintenance schedule
mechanical equipment is always in working order. A schedule needs
to be drawn up and implemented by the Process Manager. records that it is implemented
Housekeeping
The area around all the unit processes must be kept clean and tidy. paved areas - free of weeds
No solids that may be removed from the processes, and in particular
the grit and screenings area, should be allowed to accumulate on the grass - kept short
side. Sludge disposal areas It is imperative that good housekeeping is
practiced around the areas where sludge is being dewatered and/or evidence of rodents
stored prior to disposal to ensure that no odours and pests such as
flies and rats occur. flies

areas around each unit

process - neat and tidy
Standby equipment
Standby equipment such as pumps and motors should be kept on standby equipment – in
site so that when a pump/motor needs maintenance, the standby working order
can be put in place and the operation of the works will not be
disrupted. It is imperative to ensure that standby equipment is record of who does the
available and in working order. maintenance
Malfunctions
It is important to keep a record of all malfunctions or mechanical record of malfunctions – is it
equipment that is broken, the date when they were reported and reported and is date of repair
when the repair was done. In this respect it is important to ensure on hand?
that the necessary spare parts are kept on site.
Maintenance Personnel
Suitably qualified fitters and electricians should always be available – evidence of suitably qualified
they do not have to be on site but should be available to report to fitters and electricians
the WWTW within a reasonable timeframe.

29
9. PROCESS OPERATIONS – CHECKLISTS

9.1 Checklist 1 ( Flow Diagram)

In order to understand the flow through at the WWTWs to be inspected, all Inspectors should complete
this checklist at the start of an inspection or in the office in preparation for the inspection. The flow
diagram could then be completed while walking through the WWTW. All Process Managers and Process
Controllers should complete this checklist when first being employed at the WWTW and again if any
upgrades are done to the WWTW.

UNIT PROCESS Tick Number

PRELIMINARY Screens Manual
TREATMENT mechanical
PROCESSS Grit Removal Manually cleaned
channels
Mechanically cleaned
Automated de-gritters
Flow measuring device
Flow balancing/equalization basin/tank

PRIMARY TREATMENT Primary settling

PROCESS Oxidation pond system
Flow balancing

SECONDARY Trickling filters

TREAMENT PROCESSES Activated sludge
Rotating biological contactors
Secondary settler humus tank
clarifier

TERTIARY Disinfection (e.g. chemical, UV)

TREATMENTPROCESSES Constructed wetlands
Maturation pond/s

SLUDGE TREATMENT Dewatering filter/belt press

PROCESSES drying beds
Thickening Gravity
dissolved air flotation
Digestion

30
 9.2 Checklist 2 (Primary Assessment)

The primary assessment should be undertaken by an Inspector who has at least 5 years experience in
the overall management of a WWTW or is registered at least as a Class IV Process Controller.

Performance Area Aspects to consider Notes (use a separate page if

necessary)
1 Mechanical  Mechanical equipment
assessment  Maintenance schedule and
Implementation
2 Final effluent  Looks and smells good
 Results are displayed
graphically Note: take a final
effluent sample at this time
and send to an independent
laboratory for analysis; do
field tests as appropriate (e.g.
residual chlorine using DPD
tablets) and interpret the
results once received
3 Biological treatment  Attached growth media (e.g.
process stones, disks) is in good
condition and does not have a
bad smell
 Activated sludge - mixed liquor
looks good and smells earthy
4 Good housekeeping  Areas around unit processes
are kept clean and tidy
 Chemical storage areas are
Bunded
5 Disposal of solids  Screenings, detritus and
sludge are correctly disposed
of in accordance with relevant
authorisations
6 Paper work  Water use authorisation is in
place and conditions
stipulated are implemented
 Contracts for sludge disposal
are in place
7 Safety issues  Obvious safety hazards

31
10. PROCESS OPERATIONS – CHECKLISTS

10.1 Checklist 1 ( Flow Diagram)

In order to understand the flow through at the WWTWs to be inspected, all Inspectors should complete
this checklist at the start of an inspection or in the office in preparation for the inspection. The flow
diagram could then be completed while walking through the WWTW. All Process Managers and Process
Controllers should complete this checklist when first being employed at the WWTW and again if any
upgrades are done to the WWTW.

UNIT PROCESS Tick Number

PRELIMINARY Screens Manual
TREATMENT Mechanical
PROCESSS Grit Removal Manually cleaned
channels
Mechanically cleaned
Automated de-gritters
Flow measuring device
Flow balancing/equalization basin/tank

PRIMARY TREATMENT Primary settling

PROCESS Oxidation pond system
Flow balancing

SECONDARY Trickling filters

TREAMENT PROCESSES Activated sludge
Rotating biological contactors
Secondary settler humus tank
Clarifier

TERTIARY Disinfection (e.g. chemical, UV)

TREATMENTPROCESSES Constructed wetlands
Maturation pond/s

SLUDGE TREATMENT Dewatering filter/belt press

PROCESSES drying beds
Thickening Gravity
dissolved air flotation
Digestion

32
 10.2 Checklist 2 (Primary Assessment)

The primary assessment should be undertaken by an Inspector who has at least 5 years experience in
the overall management of a WWTW or is registered at least as a Class IV Process Controller.

Performance Area Aspects to consider Notes (use a separate page if

necessary)
1 Mechanical  Mechanical equipment
assessment  Maintenance schedule and
implementation
2 Final effluent  Looks and smells good
 Results are displayed
graphically Note: take a final
effluent sample at this time
and send to an independent
laboratory for analysis; do
field tests as appropriate (e.g.
residual chlorine using DPD
tablets) and interpret the
results once received
3 Biological treatment  Attached growth media (e.g.
process stones, disks) is in good
condition and does not have a
bad smell
 Activated sludge - mixed liquor
looks good and smells earthy
4 Good housekeeping  Areas around unit processes
are kept clean and tidy
 Chemical storage areas are
bunded
5 Disposal of solids  Screenings, detritus and
sludge are correctly disposed
of in accordance with relevant
authorisations
6 Paper work  Water use authorisation is in
place and conditions
stipulated are implemented
 Contracts for sludge disposal
are in place
7 Safety issues  Obvious safety hazards

33
 9. References:

9.1 Peter King

Peter King Has a BSc (Chem) and GDE (Civil) and has retired with more than 40 years’ experience in
water treatment, wastewater treatment and groundwater recharge with treated effluent.

He has lectured at the N Level, T level and has been external Examiner to 4th year Civil Engineering
students.

He is a retired Senior Fellow of the Water Institute of Southern Africa and Fellow of the Chartered
Institution of Water and Environment and is a Chartered Water and Environmental Manager.

He was Editor of the Newsletter of the former Association of Water Treatment Personnel from 1985 to
1999, He remains dedicated to the professionalization, education and upgrading of Process Controllers in
both the water and wastewater field.

9.2 LA Boyd and AM Mbelu

Guideline for the Inspection of Wastewater Treatment Works Report to the Water Research Commission
by LA Boyd and AM Mbelu Golder Associates Africa WRC Report No TT 375/08 January 2009

34