Contractor Template for O & M Manual · Web viewUNCONTROLLED COPYTemplate for Operations Manual...

Operation Manual

TownWMF/WTP/SPS

(Expanded in full)

CONFIDENTIAL

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Town WMF/ WTP/SPS Operation Manual RevisionsNote: With each edit to this document, the following must be completed in the next available blank row.

Date Description of Change Initiator of Change

Date Updated

15/05/18 Updated logo on front page JB 15/05/18

14/05/18 Review of DC&C IIO 14/05/18

22/11/17 Review of DC&C IIO 22/11/17

12/09/17 Review of General process element

IIO 12/09/17

16/06/15 Name review IIO 16/06/15

02/10/14 Review and update formatting of template

IIO 02/10/14

15/04/14 Review and update template IIO 15/04/14


25/07/11 Review and update template Citect Functional diagrams

IIO 25/07/11


Created By: Infrastructure Information Officer Reference Number:Approved By: of 53Review Date: date Last Approved: date

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document.docx -Table of Contents

TOWN WMF/ WTP/SPS OPERATION MANUAL REVISIONS..................................2

TOWN WMF/WTP /SPS - PROCESS FLOW DIAGRAM........................................6

GENERAL............................................................................................7

GENERAL PURPOSE AND TARGETS....................................................7Performance Targets......................................................................................7

GENERAL SAFETY.............................................................................7

GENERAL DESIGN CRITERIA AND COMPONENTS.................................7

GENERAL MONITORING....................................................................7

GENERAL MAINTENANCE..................................................................8

GENERAL NORMAL OPERATION.........................................................8

GENERAL PROCESS CONTROL...........................................................8

GENERAL MANUAL OPERATION.........................................................8Manual Override.............................................................................................8

GENERAL EMERGENCY......................................................................8Plant Crash Stop.............................................................................................8Site Specific....................................................................................................9

“PROCESS ELEMENT A”.....................................................................10

“PROCESS ELEMENT A” PURPOSE AND TARGETS.............................10

“PROCESS ELEMENT A” DESIGN CRITERIA AND COMPONENTS..........10

“PROCESS ELEMENT A” NORMAL OPERATION..................................16Start-up........................................................................................................17Standard Operation Procedures...................................................................17Shutdown.....................................................................................................17

“PROCESS ELEMENT A” PROCESS CONTROL....................................17

“PROCESS ELEMENT A” MANUAL OPERATION..................................17Manual Override...........................................................................................17Start-up........................................................................................................18Standard Operation Procedures...................................................................18Shutdown.....................................................................................................18


document.docx“PROCESS ELEMENT A” TROUBLESHOOTING....................................18

“PROCESS ELEMENT A” EMERGENCY...............................................18

“PROCESS ELEMENT B”.....................................................................20

“PROCESS ELEMENT B” PURPOSE AND TARGETS.............................20

“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTS..........20

“PROCESS ELEMENT B” NORMAL OPERATION..................................26Start-up........................................................................................................27Standard Operation Procedures...................................................................27Shutdown.....................................................................................................27

“PROCESS ELEMENT B” PROCESS CONTROL....................................27

“PROCESS ELEMENT B” MANUAL OPERATION..................................27Manual Override...........................................................................................27Start-up........................................................................................................28Standard Operation Procedures...................................................................28Shutdown.....................................................................................................28

“PROCESS ELEMENT B” TROUBLESHOOTING....................................28

“PROCESS ELEMENT B” EMERGENCY...............................................28

“PROCESS ELEMENT C”.....................................................................30

“PROCESS ELEMENT C” PURPOSE AND TARGETS..............................30

“PROCESS ELEMENT C” DESIGN CRITERIA AND COMPONENTS...........30

“PROCESS ELEMENT C” NORMAL OPERATION..................................36Start-up........................................................................................................37Standard Operation Procedures...................................................................37Shutdown.....................................................................................................37

“PROCESS ELEMENT C” PROCESS CONTROL.....................................37

“PROCESS ELEMENT C” MANUAL OPERATION..................................37Manual Override...........................................................................................37Start-up........................................................................................................38Standard Operation Procedures...................................................................38Shutdown.....................................................................................................38

“PROCESS ELEMENT C” TROUBLESHOOTING....................................38

“PROCESS ELEMENT C” EMERGENCY...............................................38

“PROCESS ELEMENT D”.....................................................................40


document.docx“PROCESS ELEMENT D” PURPOSE AND TARGETS.............................40

“PROCESS ELEMENT D” DESIGN CRITERIA AND COMPONENTS..........40

“PROCESS ELEMENT D” NORMAL OPERATION..................................46Start-up........................................................................................................47Standard Operation Procedures...................................................................47Shutdown.....................................................................................................47

“PROCESS ELEMENT D” PROCESS CONTROL....................................47

“PROCESS ELEMENT D” MANUAL OPERATION..................................47Manual Override...........................................................................................47Start-up........................................................................................................48Standard Operation Procedures...................................................................48Shutdown.....................................................................................................48

“PROCESS ELEMENT D” TROUBLESHOOTING....................................48

“PROCESS ELEMENT D” EMERGENCY...............................................48

LIST OF FIGURES...............................................................................50

LIST OF TABLES.................................................................................51


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Town WMF/WTP /SPS - Process Flow DiagramFigure 1: Town Site Process Flow Diagram

Supply an up to date copy of the process flow diagram for the site.


GEN

ERAL

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GENERAL

Refer to Citrix for the Town Name WTP SCADA screens.

Click here for the Town Name WTP Schematic diagram.

Click here for the Town Name SPS Functional Diagrams.

GENERAL PURPOSE AND TARGETSProvide a short statement describing the purpose and a general description of the process elements in the treatment sequence.The performance targets are the treatment and reliability objectives of the plant, typically key performance indicators, license and objective limits, and reliability requirements.

Click here for the Safe Drinking Water Targets.

Click here for the Sewer Pump Station Targets.

Performance Targets No mechanical failure for 6 months

GENERAL SAFETYClick here for the Occupational Health and Safety Targets.

Site Plans of Premises May 2017

GENERAL DESIGN CRITERIA AND COMPONENTSClick here for the Equipment Manuals and Glossary.

GENERAL MONITORINGRefer to Aquantify.


http://sharepoint.gvwater.vic.gov.au/kb/OMManuals/Equipment%20Manuals/Forms/AllItems.aspx

http://sharepoint.gvwater.vic.gov.au/emergency/Response/Forms/AllItems.aspx?RootFolder=%2Femergency%2FResponse%2FEvacuation&FolderCTID=0x0120003EF64B5337586D4DBEA72FB0DD50F487&View=%7B1628F00D-49FA-4FD2-AD34-319B2C06C72D

http://sharepoint.gvwater.vic.gov.au/kb/OMManuals/General%20Targets/Forms/AllItems.aspx



http://sharepoint.gvwater.vic.gov.au/kb/OMManuals/SPS%20Functional%20Diagrams/Forms/AllItems.aspx

http://sharepoint.gvwater.vic.gov.au/kb/Sustainable%20Excellence/Forms/AllItems.aspx?RootFolder=http%3A%2F%2Fsharepoint.gvwater.vic.gov.au%2Fkb%2FSustainable%20Excellence%2FDWQMS%2FE02%20Assessment%20of%20the%20Drinking%20Water%20Supply%20System%2FE2C1%20WATER%20SUPPLY%20SYSTEM%20ANALYSIS%2FWater%20Supply%20System%20Flow%20Diagrams&FolderCTID=0x012000FF1C078B2051B145A80973B34E503ECF

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GENERAL MAINTENANCERefer to MyData maintenance schedule.

GENERAL NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA controls for operation under normal conditions.Add photos where possible.

Use this numbering system. E.g.

GENERAL PROCESS CONTROL

GENERAL MANUAL OPERATION

Manual OverrideProvide a general overview of all the process elements of the SPS, WMF, WTP where the plant may be operated manually.

GENERAL EMERGENCY

Plant Crash StopIf a problem exists with the operation of the plant specific processes (there can be one or more processes) can be crashed via the Regional SCADA system (provided user of Regional SCADA has sufficient privileges). This action would normally only occur in an emergency situation where water entering certain processes in the plant is outside specifications or there are problems associated with the pumping operation. Usually it would be used where it would take an extended period of time for an operator to attend the site. Using the crash stop would stop the process and allow an operator greater time to reach the site. To crash the plant, complete the following: Open the WTP overview Regional SCADA page

Press the Crash Control Symbol button Select the desired system to crash Press the Crash button


GEN

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document.docxIf the problem rectifies itself the crash can be reset by an operator on site pressing the Crash Stop Reset button (either on the switchboard or Plant SCADA system). Alternatively the crash can be reset via Regional SCADA system by:

Pressing the Enable button

Site Specific

Provide a general overview of the processes which may result in the site being crashed:

EMERGENCY RESPONSE PROCEDURES In case of spill refer to the EMS procedure - Spill Control(Require SOI for emergency pumping)


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“PROCESS ELEMENT A”Figure 2: Describe photo here.Insert a photo of Process Element .A.

“PROCESS ELEMENT A” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element A in the above list.

Table 1: Pumping Station Details

Parameter Measurements

Top of slab R.L.

Delivery Internal Pipe Diameter

Delivery Pipe I.L.

Inlet Pipe Diameter

Inlet Pipe I.L.

Wet Well Floor R.L.

Modify this table as required.

“PROCESS ELEMENT A” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.


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document.docxTable 2: “Process Element A” Design Criteria and Components

Main Components Function Design Criteria

Flowmeter Measures flow Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm

Step Screen "Step" type screen to remove debris from effluent inlet

Manufacturer:Type:Weight:Size:Width:Serial No:

Screen Drive Shaft mounted worm-geared motor

Type:Motor:

Air Blower Source of air for air scouring

Manufacturer: _____Type: ___Air flow: ___ m3/hourPressures to ___ PSI

Pump and Motors To collect sewerage from catchment and discharge to pump station #?? catchment

Pump Duty: ___L/s @ ___ m Total Head, ___ Static HeadManufacturer: _____Pump Classification: ___Type: _______Pump Curve No: _____Issue: _______ mm impeller; Type ___Outlet diameter: _____mmPump Weight: ___ kgSerial No: _____MotorManufacturer: _____


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Type: _____Serial No: _____RPM:____Rated at: _____ kW

Turbidity Meter Measures filtered / raw water turbidity

Manufacturer: _____Type: ___Required turbidity readings range: 0-20 NTU

Analyser Measures filtered water Manufacturer: _____Type: ___

Actuators and Gearboxes Controlled open/Close operation of pump Discharge

Actuator Manufacturer:___Type:___Gearbox Manufacturer:___Type:___Ratio:___Serial:__

Dissolved Oxygen Analyser

Manufacturer:Type:Serial No:

Sump Pump Pumps water out of dry well space

Manufacturer: _____Type: ___

Dosing Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW_____ RPM


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Pump Weight: ___ kgSerial No: _____

Metering Pump Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barSerial No: _____

Pump Set Other components in addition to the normal pump configuration

Manufacturer: _____Type: ___Pump Duty: _____/hr @ _____ barOutlet diameter: _____mmRated at: _____kW_____ RPMPump Weight: ___ kgSerial No: _____

Service Water Pump Manufacturer:Type:Serial No:

Internal Delivery Pipe To deliver flow from pump to the outlet of the pump station.

Manufacturer: _____Type: ___Diameter:____ mmMaterial: ____Pressure class: ____Length: ____ m

Rising Main To deliver flow from pump station ?? to pump station ?? or Manhole ??

Manufacturer: _____Type: ___Diameter: ____ mmMaterial: _____Pressure class: PN___Length: ____m


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Tank Alum storage Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____

1 X Lifting Equipment To allow for the removal of pumps from the wet well for routine and non-routine maintenance

S/S Guide Rails and lifting chainsSize of Chains: ___

Chlorinator Manufacturer: _____Type: ___Serial Number: ____Maximum ___/ __Hr

Gas Feeder Manufacturer: ____Type: ____Capacity: ____

Vacuum Regulators Manufacturer: ____Type: ____

Soft Starter Reduces the excess current during initial power-up of an electric motor

Manufacturer: ____Type: ____

Irrigation Flow Meter Measures flow ... Manufacturer: _____Type: ___Required Flow range: ___ l/secDiameter: ___ mm

Valve Manufacturer:Type:Max Pressure:


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VSD to control the speed of the motor within its operating range


Filter Manufacturer: ____Type: ____

PLC Manufacturer: ____Type: ____

Generator Convert mechanical energy to electrical energy

Manufacturer:Type:Motor Size: ____kWRate Voltage:Fuel Type:Fuel Tank Capacity:Fuel Consumption:Dimensions:Weight:Serial No:

Air Compressor To supply compressed air to the air actuator valves within the plant and to supply compressed air to the DAF vessel


Hydro Cyclone Manufacturer:Type:Serial No:

Bay Outlet Manufacturer: _____Type: ___Nominal capacity: _____ LDimensions: _____ m diameter x _____ m deepMaterial: _____

Filter Media Each filter removes floc Manufacturer:Created By: Infrastructure Information Officer Reference Number:Approved By: of 53Review Date: date Last Approved: date

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and other matter.

Explanation of types and depths?

Type:Dual Type:Multiple Depths:Volume:

Nozzles Manufacturer:Type/Model No:

Cathodic Protection Manufacturer:Type:

Groundwater Bore Ground Works Number:Date Drilled:Casing Outside Diameter:Casing Inside Diameter:Casing Wall Thickness:Casing Type:Apertures:Screened From – To:Bore Depth:

Air conditioner Manufacturer:Type:

Door Specifications Door Type:Spindle:Head Pressure:Actuator:Clear Water Way:Operating Level:Door Material:Weight:Handwheel direction:

Baffle Comment on orientation Manufacturer:Type:


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Material:Size:

“PROCESS ELEMENT A” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.


Figure 3: Describe photo here.

Under normal operating conditions, the

Start-up

Standard Operation Procedures

Shutdown


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“PROCESS ELEMENT A” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.

“PROCESS ELEMENT A” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.

Figure 3: Describe photo here. Utilise this numbering system for additional photos.

Manual Override

Start-up



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Shutdown

“PROCESS ELEMENT A” TROUBLESHOOTING

Table 3: “Process Element A” Troubleshooting Guide

Problem Cause Solution/Action

Note: All electrical work is to be carried out by qualified electricians only.

Complete this table and add/remove rows where necessary.

“PROCESS ELEMENT A” EMERGENCY

Table 4: “Process Element A” Emergency Guide

Condition Actions

PLC Failure Contact GVW Operations IT Department

Power Failure Restore powerElectrician and/orPower company



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“PROCESS ELEMENT B”Figure 4: Describe photo here.Insert a photo of Process Element B.

“PROCESS ELEMENT B” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element B in the above list.



Top of slab R.L.


Delivery Pipe I.L.

Inlet Pipe Diameter

Inlet Pipe I.L.

Wet Well Floor R.L.


“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.


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document.docxTable 6: “Process Element B” Design Criteria and Components






Type:Motor:






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and other matter.










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Material:Size:

“PROCESS ELEMENT B” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.




Start-up


Shutdown


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“PROCESS ELEMENT B” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.

“PROCESS ELEMENT B” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.


Manual Override

Start-up



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Shutdown

“PROCESS ELEMENT B” TROUBLESHOOTING

Table 7: “Process Element B” Troubleshooting Guide




“PROCESS ELEMENT B” EMERGENCY

Table 8: “Process Element B” Emergency Guide

Condition Actions





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“PROCESS ELEMENT C”Figure 6: Describe photo here.Insert a photo of Process Element A

“PROCESS ELEMENT C” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element A in the above list.



Top of slab R.L.


Delivery Pipe I.L.

Inlet Pipe Diameter

Inlet Pipe I.L.

Wet Well Floor R.L.


“PROCESS ELEMENT C” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.


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document.docxTable 10: “Process Element C” Design Criteria and Components






Type:Motor:






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and other matter.










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Material:Size:

“PROCESS ELEMENT C” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions. Add photos where possible.




Start-up


Shutdown


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“PROCESS ELEMENT C” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.

“PROCESS ELEMENT C” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element. Insert photos where possible.


Manual Override

Start-up



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Shutdown

“PROCESS ELEMENT C” TROUBLESHOOTING

Table 11: “Process Element C” Troubleshooting Guide




“PROCESS ELEMENT C” EMERGENCY

Table 12: “Process Element C” Emergency Guide

Condition Actions





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“PROCESS ELEMENT D”Figure 8: Describe photo here.Insert a photo of Process Element D.

“PROCESS ELEMENT D” PURPOSE AND TARGETSProvide a short statement of the purpose and a general description of the process element in the treatment sequence.Performance targets are typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element D in the above list.



Top of slab R.L.


Delivery Pipe I.L.

Inlet Pipe Diameter

Inlet Pipe I.L.

Wet Well Floor R.L.


“PROCESS ELEMENT D” DESIGN CRITERIA AND COMPONENTSIn the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.


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document.docxTable 14: “Process Element D” Design Criteria and Components






Type:Motor:






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and other matter.










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Material:Size:

“PROCESS ELEMENT D” NORMAL OPERATIONProvide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.Add photos where possible.




Start-up


Shutdown


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“PROCESS ELEMENT D” PROCESS CONTROLDescribe the potential process adjustments, the resulting consequences and the steps involved in making these plant adjustments.

“PROCESS ELEMENT D” MANUAL OPERATIONProvide a general overview of the manual plant start-up, operation and shut down procedures for the process element.Insert photos where possible.


Manual Override

Start-up



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Shutdown

“PROCESS ELEMENT D” TROUBLESHOOTING

Table 15: “Process Element D” Troubleshooting Guide




“PROCESS ELEMENT D” EMERGENCY

Table 16: “Process Element D” Emergency Guide

Condition Actions





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LIST OF FIGURESFigure 1: Town Site Process Flow Diagram.........................................................6Figure 2: Describe photo here..........................................................................10Figure 3: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................17Figure 4: Describe photo here..........................................................................20Figure 5: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................27Figure 6: Describe photo here..........................................................................30Figure 7: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................37Figure 8: Describe photo here..........................................................................40Figure 9: Describe photo here. Utilise this numbering system for additional photos..............................................................................................................47


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LIST OF TABLESTable 1: Pumping Station Details.....................................................................10Table 2: “Process Element A” Design Criteria and Components.......................10Table 3: “Process Element A” Troubleshooting Guide......................................18Table 4: “Process Element A” Emergency Guide..............................................18Table 5: Pumping Station Details.....................................................................20Table 6: “Process Element B” Design Criteria and Components.......................20Table 7: “Process Element B” Troubleshooting Guide......................................28Table 8: “Process Element B” Emergency Guide..............................................28Table 9: Pumping Station Details.....................................................................30Table 10: “Process Element C” Design Criteria and Components.....................30Table 11: “Process Element C” Troubleshooting Guide....................................38Table 12: “Process Element C” Emergency Guide............................................38Table 13: Pumping Station Details...................................................................40Table 14: “Process Element D” Design Criteria and Components....................40Table 15: “Process Element D” Troubleshooting Guide....................................48Table 16: “Process Element D” Emergency Guide............................................48


Contractor Template for O & M Manual · Web viewUNCONTROLLED COPYTemplate for Operations Manual...

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