PART III DESIGN STANDARDS FOR BOTTLED WATER, BULK WATER HAULING

PART III

DESIGN STANDARDS FOR BOTTLED WATER,BULK WATER HAULING, WATER VENDING MACHINES

AND RETAIL WATER FACILITIES

INTRODUCTION

DEP rules and regulations at 25!Pa. Code Chapter!109, Safe Drinking Water, includes definitions forbottled water systems, bulk water hauling systems, vended water systems and retail water facilities.Subchapter!J of Chapter!109 contains regulations which apply specifically to these systems. Becausemany drinking water standards are established based on the consumption of two (2) liters of waterper day, the department intends to regulate as bottled water systems only those systems whichprovide water in one>half gallon (1.9!liter) or larger containers. Smaller containers generally are usedto market beverages or pharmaceuticals and are regulated under other state and federal food anddrug laws. Vending machines are not exempt under this interpretation due to the lack of controlover the volume of drinking water obtained by the customer.

383>2126>303 / November 1, 1997 / Page III>1

PART III

CHAPTER 1 > APPLICATIONS FOR PERMITS

1.0 General

The purpose of this chapter is to outline the design requirements and permit application procedureswhich are to be followed when applying for a bottled water system, bulk water hauling system,vended water system or retail water facility permit. Design and construction standards which DEPconsiders to be acceptable for these systems have been provided in the subsequent chapters ofPart!III. Other designs will be considered where the applicant can demonstrate to the satisfaction ofthe department that the alternative design will be capable of providing drinking water thatconsistently meets DEP standards.

1.1 Permit Requirements

Under the provisions of Subchapter J, Section 109.1005 of the Safe Drinking Water Regulations, aperson may not construct or operate a bottled water or vended water system, retail water facility orbulk water hauling system without first obtaining a permit from DEP. Furthermore, no person maysubstantially modify a bottled water or vended water system, retail water facility or bulk waterhauling system operated under a public water system permit without first obtaining a permitamendment from DEP.

1.1.1 Coverage

The following projects must be submitted to DEP for review and approval:

a. All facilities of any new bottled water or vended water system, retail water facilityor bulk water hauling system;

b. Any addition to or modification of an existing bottled water or vended watersystem, retail water facility or bulk water hauling system which will or may affectthe quality and/or quantity of the supply. The following major modificationsrequire the submission of a complete permit application as outlined in Section 1.4.Minor modifications must be discussed with the appropriate regional watersupply engineer to determine the extent of the information which must besubmitted to obtain DEP approval;

Major Modifications Minor Modifications

New sources Changes in treatment chemicals

New types of product or product lines Interconnections for bulk water

Additions or deletions of treatment Replacement of storage tank or reservoir techniques or processes linings/coatings

Addition of vending machines not Addition or modification of bulk certified by the National Automatic carrier vehicles and standpipes Merchandising Association (NAMA)

Construction of prefabricated Pumping stations storage tanks (except for well pumps)

Transmission mainsStorage reservoirs

Permit transfers

Repair of water vending machines andaddition of a new NAMA certified machine


c. Persons proposing to install National Automatic Merchandising Association(NAMA) certified water vending machines on an existing community water systemsource shall obtain a separate and distinct permit>by>rule for each DEP region inwhich the water vending machines will be located.

1.1.2 Application Fees

Applications for a permit or for a major modification as outlined in Section 1.1.1 must beaccompanied by a check in the amount of §750, payable to the "Commonwealth ofPennsylvania." A system purchasing finished water, as its only source of water, from anapproved community water system, shall submit a fee of §300. Out>of>state bottledwater systems submitting proof of out>of>state approval must submit a fee of §100.

1.1.3 Construction and Operation Permits

In administering the permit requirements of DEP Safe Drinking Water Regulations, theBureau of Water Supply Management has implemented a two>part approval process.Upon approval of the plans, modules and other design documents, a construction permitwill be issued approving the construction or modification in accordance with theapproved plans. This approval will be valid for a period of two years unless substantialwork is initiated. Upon completion, the public water supplier is required to submit acertificate of construction completion to DEP stating that construction or modificationwas completed in accordance with approved plans. This statement must be signed bythe professional engineer or other person responsible for the work. Upon receipt of thecertification, DEP will inspect the facility and issue an operations permit when theconstruction has been satisfactorily completed.

1.1.4 Revisions to Approved Plans

Any deviations from approved plans or specifications affecting the hydraulic capacity,operation or the type of water treatment processes, or the quality of finished water,must be approved by DEP before such changes are made. Revised plans or specificationsshould be submitted in time to allow the review and approval of such plans orspecifications before any construction work which will be affected by such changes isbegun.

1.1.5 Department's Review and Permit Coordination

Under the requirements of the Safe Drinking Water Regulations, DEP must grant or denya permit within 120 days of receipt of a complete application. In order to comply withthis requirement DEP will not accept an application for review until the application isdetermined to be complete. As other department, state or inter>state environmentalagencies may require approvals, applicants and their consultant engineers are advised tohold a preliminary engineering conference with the regional water supply engineer toidentify and coordinate these approvals. Failure to satisfy any permit coordinationrequirements could result in the refusal of an application or the denial of a permit.

1.1.6 Chemicals and Materials

Under the requirements of Section 109.606 of the Safe Drinking Water Regulations, allchemicals or materials (i.e., paints, coatings, liners, etc.) which may come in contact withthe raw or finished drinking water must be acceptable to DEP. Chemicals used by apublic water supplier which may come in contact with or affect the quality of the waterand which are certified for conformance with ANSI/NSF Standard 60 (Drinking WaterTreatment Components, Health Effects, National Sanitation Foundation) are acceptable.


Materials to be used in construction or modification of a public water system includingwaterline extensions which may come in contact with or affect the quality of the waterand which are certified for conformance with ANSI/NSF Standard 61 (Drinking WaterSystem Components, Health Effects, National Sanitation Foundation) are acceptable.

1.2 Sources

It is DEP policy to require the use of the best available source(s) of supply taking intoconsideration the current technology in water treatment needed to provide a safe and potablewater for human consumption. In selecting the source or sources of water to be used, thedesigning engineer must prove to the satisfaction of DEP that the water which is to bedelivered to the consumers will consistently meet the drinking water standards of DEP.

1.2.1 Analyses of Proposed Sources

As a minimum, all new sources of drinking water must be sampled and tested for all DEPMaximum Contaminant Levels (MCLs). Other parameters which a sanitary survey maydetermine as having a potentially adverse impact on the quality of the raw water alsoshould be included in the analyses so that background information for futurecomparison is available.

1.2.1.1 Laboratories

All physical, chemical, microbiological and radiological analyses must beperformed by a laboratory certified by DEP.

1.2.1.2 Surface Water Sources

At least three sets of samples so spaced that the high, average and low streamflows will be sampled shall be taken to reflect the effects of variousmeteorological, geological and hydrological conditions. Samples shall betaken during a minimum time interval of six months and preferably one year.

1.2.1.3 Groundwater Sources

For all new drinking water sources, at least one set of samples shall becollected at the termination of the 48>hour pump test and analyzed for DEPMCLs. Applicants or their consulting engineer should notify the Bureau ofWater Supply Management regional Technical Services Section Chief (seeTable III>1.1) at least 48 hours prior to starting the pump test. Applicants arefurther advised to contact their respective river basin commission to verify theneed to conduct a longer (i.e., 72>hour) pump test.

1.2.1.4 Finished Water Sources

At least one set of samples should be collected and tested for all DEP MCLs.The results of analysis obtained from the source/selling water system may beused to satisfy this requirement provided the samples were collected andanalyzed within the routine monitoring schedule for that category ofparameters. The results submitted should be from samples collected as closeto the proposed point of interconnection as possible, and preferably from theexact location.


1.2.2 Surface Water Sources

Surface water sources are defined as all water open to the atmosphere or subject tosurface runoff, or sources which are directly influenced by surface water, which mayinclude springs, infiltration galleries, cribs or wells. The term excludes finished water.

Whether there is direct influence by surface water may be determined on a case by casebasis. Direct influence may be indicated by:

a. Significant and relatively rapid shifts in water characteristics such as turbidity,temperature, conductivity, or pH (which also may change in groundwater but at amuch slower rate) which closely correlate to climatological or surface waterconditions;

b. The presence of insects or other microorganisms, algae, organic debris, or large>diameter pathogens such as Giardia lamblia.

Where surface>water sources are proposed to be used as a source of drinkingwater, a water allocation permit must be obtained from DEP. Applicants areadvised to obtain the water allocation permit prior to preparation of plans andspecifications.

1.2.2.1 Source Quality

A sanitary survey and study shall be made of the factors, both natural andman>made, which will affect the quality of the water at the source. Theresults of the sanitary survey shall be submitted to DEP. Such survey andstudy shall include, but not be limited to:

a. Obtaining samples over a sufficient period of time to assess thebacteriological, physical, chemical and radiological characteristics ofthe water;

b. Determining future uses and their effects on the stream orimpoundments;

c. Determining the degree of control over the watershed that can beexercised by the owner;

d. Assessing the degree of hazard or vulnerability to the supply byaccidental or deliberate spillage of materials that may be toxic,harmful or detrimental to treatment processes.

1.2.2.2 Intakes

Where used, intake structures shall:

a. Be designed to handle the maximum anticipated daily demand withdue consideration to operation under minimum head conditions.

Intakes at pumping stations should be protected by at least two sets ofremovable, stationary screens, or by a traveling screen. Screen open>ings should be small enough to exclude all matter which will clog;

b. Have protection against clogging by sediment, debris or ice, andagainst damage due to wave action and flotation;


c. Have a velocity of flow through the inlet structure such that frazil icewill be held to a minimum, generally not to exceed 0.5 feet persecond;

d. Have inspection manholes every 100 feet for pipe sizes large enoughto have visual inspections;

e. Be able to withdraw water from more than one level if quality varieswith depth;

f. Have separate facilities for release of less desirable water held instorage;

g. Be accessible during adverse weather conditions.

1.2.2.3 Impoundments and Reservoirs

a. Site selection shall give consideration to:

(1) Topography and geology;

(2) Storage capacity required;

(3) Safety;

(4) Water rights;

(5) Raw water characteristics;

(6) Proximity to sources of pollution;

(7) Accessibility during adverse weather conditions.

b. Site preparation shall provide:

(1) Removal of brush and trees to a level of 10 feet above theanticipated high water elevation;

(2) Protection from floods during construction.

c. Site Construction

Where earth disturbance will occur, an Erosion Control Plan must bedeveloped and retained at the construction site for the duration ofthe earth moving activities.

1.2.3 Groundwater Sources

Groundwater includes all water from dug, drilled, bored, jetted or driven wellsand infiltration galleries. Springs which emerge at the surface within the confinesof a springhouse also can be considered groundwater, but only after extensiveevaluations of the geological conditions and catchment area are conducted.Groundwater sources subject to direct influence by surface water may beclassified as surface water sources and may require treatment as a surface water


source. Water suppliers and their consultants are advised to consult with DEP toestablish the minimum level of treatment which will be required.

1.2.3.1 Quality

Sanitary surveys conducted for the selection of locations for wells, springs,or infiltration galleries shall consider the following items:

a. Character of local geology, size and topography of catchment area,and slope of ground surface and groundwater table;

b. Nature, and distance of local sources of pollution such as animal feedlots, landfills, privies, sink holes, sewer lines and industrial facilities;

c. Extent of drainage area likely to effect or contribute water to thesupply, population density, land use and waste disposal methods inthe drainage area;

d. Proximity to flood plain or impoundments which may cause flooding;

e. Proximity of other existing wells.

1.2.3.2 Location and Protection

Minimum distances from a well to possible sources of pollution shall begreat enough to provide assurances that subsurface flow of contaminatedwater will not reach the well. Each proposed site should be field surveyedto evaluate the character and location of possible sources ofcontamination, types of geologic formations present, depth to the waterbearing aquifer, direction of groundwater flow and the effect ongroundwater movement by well pumping.

a. Location

DEP shall be consulted during the location of a proposed well todetermine the required separation between existing and potentialsources of contamination.

b. Protection

Protection of the proposed new well site should be provided throughownership, easements or zoning. Water suppliers should control allland within a radius of 100!feet of the source and any additional landwhich a sanitary survey may deem affects the supply. It is stronglyrecommended that the water supplier develop a wellhead protectionplan in accordance with Appendix A of Part II (Community SystemDesign Standards) of this manual and other guidance given by DEP.

1.2.3.3 Testing and Records

a. Yield and drawdown tests shall:

(1) Be performed on every well;

(2) Have the test method clearly indicated in the specifications;


(3) Have a test pump capacity at least 1.5 times the yield anticipated;

(4) Provide for continuous pumping for at least 48 hours;

(5) Provide the following data:

(a) Test pump capacity>>head characteristics,

(b) Static water level,

(c) Depth of test pump setting,

(d) Time of starting and ending of test cycle;

(6) Provide recordings and graphic evaluations of the following:

(a) Pumping rate(s),

(b) Pumping water level,

(c) Drawdown,

(d) Water recovery rates and levels;

(7) Provide for samples of water to be collected for qualitydetermination at the end of the 48>hour test period.

b. Samples and Records

During drilling and completion of the well, a detailed log or comple>tion form (available from the department©s Bureau of Topographicand Geologic Survey) is to be completed and returned to thedepartment as required under Chapter!107 (Drilling Water Wells) ofthe department©s rules and regulations. Formation samples should bemaintained and turned over to the water system owner. The log shallcontain information on: the reference elevation; depth, thicknessand type of formations penetrated; rates of penetration; drill holediameters and depths; water levels; depth and description of wellcasing; well screen type, size and levels of placement whereappropriate; depth of grouting with type and quantity used; locationof any blast shots and the drawdown results of the 48>hour pump test.

c. Plumbness and Alignment

Every well shall be tested for plumbness and alignment in accordancewith AWWA©s Standard A>100>90. The test method and allowabletolerances shall be clearly stated in the specifications.

As a minimum, a 40>foot section of pipe or rigid dummy of the samelength, having an outside diameter of not more than one>half inchless than the inside diameter of the well casing or hole being tested,should move freely throughout the length of the well casing or holeto the lowest anticipated pump setting.


1.2.3.4 General Well Construction

a. Minimum Protected Depths

All drinking water supply wells and observation wells shall beconstructed in such a manner so as to be watertight to such depths asmay be necessary to exclude pollution from surface runoff and frompolluted aquifers above the aquifer being used as a source of supply.

b. Temporary Casings

Temporary casings used for construction shall be capable ofwithstanding the structural load imposed during its installation andremoval.

c. Well Casing Material

Protective casing of wrought iron or steel shall have minimum weightsand thickness as specified in AWWA©s Standard A>100>90. Well casingmaterial other than wrought iron or steel must be resistant to thecorrosiveness of the water and to the stresses to which it will besubjected during installation, grouting and operation. Casing andgrouting materials must be compatible.

(1) Ferrous casings shall:

(a) Be new pipe meeting ASTM or API specifications for waterwell construction;

(b) Have additional thickness and weight if minimum thickness isnot considered sufficient to assure reasonable lifeexpectancy of the well;

(c) Be capable of withstanding forces to which it is subjected;

(d) Be equipped with a drive shoe when driven;

(e) Have full circumferential welds or threaded pipe joints.

(2) Nonferrous casing shall meet appropriate ANSI/ASTM or NSFstandards for well casing applications as outlined in AWWA©sStandard A>100>90. Nonferrous casing materials shall not impartany taste, odor or toxic substances to the well water. Nonferrouscasing, if used, shall not be driven. The casing shall be placed aminimum of five (5) feet into the consolidated formation with aminimum annular opening of three (3) inches larger than theoutside diameter of the casing so that grout can be placed inaccordance with Section!1.2.3.4g.

d. Packers

Packers shall be of materials that will not impart taste, odor, toxicsubstances or bacterial contamination to the well water.


e. Screens

Well screens, when used, shall:

(1) Provide the maximum amount of open area while stillmaintaining structural strength;

(2) Have the size of openings in the screen based on a sieve analysis ofthe material contained in the surrounding geological formationor gravel pack;

(3) Be constructed of materials resistant to damage by chemicalaction of groundwater or cleaning operations;

(4) Have sufficient diameter to provide adequate specific capacity andlow aperture velocity. Usually, the entrance velocity should notexceed 0.1 feet per second;

(5) Be installed so that the pumping water level remains above thescreen under all operating conditions;

(6) Be designed and installed to permit removal or replacementwithout adversely affecting water>tight construction of the well;

(7) Be provided with a bottom plate or wash down bottom fitting ofthe same material as the screen.

f. Blasting and Chemical Conditioning

In general, specifications covering the blasting or chemicalconditioning of wells shall be submitted to DEP for approval.

(1) Blasting procedures shall be included in the project specificationsand specify:

(a) Depth, number, frequency and size of charges;

(b) Cleaning procedures.

(2) Chemical conditioning procedures shall be included in thespecifications as to method, equipment, chemicals, testing forresiduals, disposal of wastes and inhibitors used.

g. Grouting Requirements

All permanent well casings shall be surrounded by a minimum of1.5!inches of grout to a minimum depth of 20!feet from the groundsurface, or into the impervious subsurface formation which caps theaquifer, whichever is deeper, or as otherwise specified inSection!1.2.3.5.


(1) Neat cement grout1

Grout shall consist of a mixture of API Spec.!10, Class G cement (orClass!B similar to ASTM C150 Type!II) and water in the ratio offive!gallons of water per 94!lb. sack of cement weighing approxi>mately 118!lbs/cu. ft. A maximum of six!percent, by weight,bentonite and two!percent, by weight, of calcium chloride may beadded.

(2) Pozmix>cement grout1

Grout shall consist of a mixture of 50!percent by volume ofPozzolan!A (74!lbs/cu. ft) and 50!percent by volume of APISpec.!10, Class!G cement with 5.8!gallons of water per 84!lbs. ofmixture. To this mixture may be added a maximum oftwo!percent, by weight, bentonite and a maximum of twopercent, by weight, of calcium chloride, at the discretion of thecontractor.

(3) Concrete grout1

Grout shall contain 5.3 sacks of portland cement (ASTM!C150Type!II) per cubic yard of concrete and a maximum of sevengallons of water per 94!lb. sack of cement. The maximum slumpshall be four!inches. The aggregate shall consist of 47!percentsand and 53!percent coarse aggregate, conforming to ASTMDesignation C>33. The maximum size aggregate should be0.75!inches. Concrete seal shall not be placed in an annulus of lessthan three!inches.

(4) Sand cement grout1

Grout shall consist of a mixture of portland cement (ASTM!C150Type!II), sand and water in the proportion of not more than twoparts, by weight, of sand to one part of cement with not morethan six gallons of water per 94!lb. sack of cement.

(5) Application

(a) All grouting shall be performed by adding the mixture, fromthe bottom of the annular opening upward, in onecontinuous operation, until the annular opening is filled.

(b) When the annular opening is less than four inches, groutshall be installed under pressure by means of a grout pumpin one continuous operation.

(c) After grouting is applied, work on the well shall bediscontinued until the grout has properly set.

1. From AWWA©s Standard for Water Wells A>100>90


(6) Guides

The protective casing must be provided with sufficient guideswelded to the casing to permit unobstructed flow and uniformthickness of grout.

h. Upper Terminal Well Construction

(1) Permanent casing for all groundwater sources shall project at least12!inches above the pumphouse floor or concrete apron and atleast 18!inches above final ground surface.

(2) Where a well house is constructed, the floor surface shall be atleast six!inches above the final ground elevation.

(3) The top of the well casing at sites subject to flooding shouldterminate at least three!feet above the highest known floodelevation or as may be directed by DEP.

i. Well Development

Every well shall be developed to remove the native silts and clays,drilling mud and/or the finer fraction of the gravel pack.Development should continue until the maximum specific capacity isobtained from the completed well.

j. Capping

A properly fitted, firmly driven, solid wooden plug shall be theminimum acceptable method of capping a well until pumpingequipment is installed. A welded metal plate is preferred.

k. Well Abandonment

(1) Abandoned wells and test wells which are not to be used shall besealed by such methods as necessary to restore the controllinggeological conditions which existed prior to construction. The wellabandonment procedures outlined in AWWA©s Standard A>100>90should be followed.

(2) Wells to be abandoned shall:

(a) Be sealed to prevent undesirable exchange of water fromone aquifer to another;

(b) Preferably filled with neat cement grout;

(c) Have fill materials free from foreign or toxic materials.

1.2.3.5 Aquifer Types and Special Construction Methods

a. Gravel Pack Wells

(1) Gravel pack shall be well rounded particles, 95 percent siliceousmaterial, that are smooth and uniform, free of foreign material,


properly sized, washed and disinfected immediately prior to orduring placement.

(2) Gravel pack shall be placed in one uniform continuous operation.

(3) Gravel refill pipes, when used, shall be Schedule!40 steel pipeincorporated within the pump foundation and terminated withscrewed or welded caps at least 12!inches above the pump housefloor or concrete apron.

(4) Gravel refill pipes located in the grouted annular opening shall besurrounded by a minimum of 1.5 inches of grout.

(5) Protection from leakage of grout into the gravel pack or screenshall be provided.

b. Sand or Gravel Wells

(1) If clay or hard pan is encountered above the water bearingformation, the permanent casing and grout shall extend throughsuch materials.

(2) If a sand or gravel aquifer is overlaid only by permeable soils, thepermanent casing and grout shall extend to at least 20 feet beloworiginal or final ground elevation, whichever is lower.

(3) If a temporary outer casing is used, it shall be completelywithdrawn as grout is applied.

c. Limestone or Sandstone wells

(1) Where the depth of mantle is more than 50 feet, the permanentcasing shall be firmly seated in uncreviced or unbroken rock.

(2) Where the depth of mantle is less than 50 feet, the depth of casingand grout shall be at least 50!feet or as determined by DEP.

d. Naturally Flowing (Artesian) Wells

(1) Flow shall be controlled.

(2) Permanent casing and grout shall be provided.

(3) If erosion of the confining bed appears likely, an inner casingjoined watertight to the protective casing shall be provided.

e. Radial Water Collectors

(1) Locations of all caisson construction joints and portholeassemblies shall be indicated.

(2) The caisson wall shall be reinforced to withstand the forces towhich it will be subjected.


(3) Provisions shall be made to assure that radial collectors areessentially horizontal.

(4) The top of the caisson shall be covered with a watertight floor.

(5) All openings in the floor shall be curbed and protected fromentrance of foreign material.

(6) The pump discharge pipe shall not be placed through the caissonwalls.

f. Infiltration Lines

(1) Infiltration lines may be considered only where geologicalconditions preclude the possibility of developing an acceptabledrilled well.

(2) The area around infiltration lines shall be under the control of thewater supplier for a distance acceptable to DEP.

(3) Flow in the lines shall be by gravity to the collecting well.

g. Dug Wells

(1) Dug wells may be considered only where geological conditionspreclude the possibility of developing an acceptable drilled well.

(2) A watertight cover shall be provided.

1.2.3.6 Well Pumps, Discharge Piping and Appurtenances

a. Line Shaft Pumps

Wells equipped with line shaft pumps shall:

(1) Have the pump structure effectively sealed to the well casing toprevent entrance of surface water;

(2) Have the casing firmly connected to the pump structure or havethe casing inserted into a recess extending at least one>half inchinto the pump base;

(3) Have the pump foundation and base designed to prevent waterfrom coming into contact with the joint.

b. Submersible Pumps

Where a submersible pump is used:

(1) The top of the casing shall be effectively sealed against theentrance of water under all conditions of vibration or movementof conductors or cables;

(2) The electrical cable should be firmly attached to the riser pipe at20!foot intervals.


c. Discharge Piping

(1) Discharge piping shall:

(a) Have control valves and appurtenances located above thepump house floor when an above ground discharge isprovided;

(b) Be protected against the entrance of contamination;

(c) Be equipped with a check valve, a shut off valve, a pressuregauge, a means of measuring flow, and a sampling taplocated at a point where positive pressure is maintained;

(d) Where applicable, be equipped with an air release>vacuumrelief valve located upstream from the check valve, withexhaust/relief piping terminating in a downturned positionat least 18!inches above the floor and covered with a24>mesh corrosion resistant screen;

(e) Be valved to permit test pumping and control of each well;

(f) Have all exposed piping, valves and appurtenances protectedagainst physical damage and freezing;

(g) Be properly anchored to prevent movement;

(h) Be protected against surge or water hammer.

(2) The discharge piping should be provided with a means ofpumping to waste, but shall not be directly connected to a sewer.

d. Pitless Well Units

(1) Pitless units shall:

(a) Be shop>fabricated from the point of connection with thewell casing to the unit cap or cover with compression fittingscertified by the Water Systems Council under RecommendedStandards (PAS>1);

(b) Be threaded or welded to the well casing;

(c) Be of watertight construction throughout;

(d) Be of materials and weight at least equivalent andcompatible to the casing;

(e) Have field connection to the lateral discharge from thepitless unit of threaded, flanged or mechanical jointconnection;

(f) Terminate at least 18 inches above final ground elevation orthree feet above highest known flood elevation or as DEPdirects.


(2) The design of the pitless unit shall make provision for:

(a) Access to disinfect the well;

(b) A properly constructed casing vent meeting therequirements of Section!1.2.3.6e;

(c) Facilities to measure water levels in the well;

(d) A cover at the upper terminal of the well that will preventthe entrance of contamination;

(e) A contamination>proof entrance connection for electricalcable.

(3) If the connection to the casing is by field weld, the shop>assembled unit must be designed specifically for field welding tothe casing. The only field welding permitted will be that neededto connect a pitless unit to the casing.

(4) The grouting of wells using pitless units shall conform to theapplicable criteria of Sections 1.2.3.4g and 1.2.3.5 except thatgrout only shall be placed to a level immediately below the pointwhere the adapter is connected to the well casing.

e. Casing Vent

Provisions shall be made for venting the well casing to theatmosphere. The vent shall terminate in a downturned position, at orabove the top of the casing or pitless unit in a minimum one>inchdiameter opening covered with a 24>mesh, corrosion resistant screen.The pipe connecting the casing to the vent shall be of adequate size toprovide rapid venting of the casing.

f. Water Level Measurement

(1) Provisions shall be made for periodic measurement of water levelsin the completed well;

(2) Installation of permanent water level measuring equipment shallbe made using corrosion resistant materials attached firmly to thedrop pipe or pump column and in such a manner as to prevententrance of foreign materials.

g. Observation Wells

Observation wells shall be:

(1) Constructed in accordance with the requirements for permanentwells if they are to remain in service after completion of a watersupply well;

(2) Protected at the upper terminal to preclude entrance of foreignmaterials.


1.3 Treatment

All treatment processes used in the manufacturing of bottled water or water from vendingmachines or retail water facilities are subject to the approval of DEP. DEP recognizes that thedesign standards and criteria specified in PART II, Chapter 4 of the Public Water Supply Manualmay not apply to bottled water and vended water systems or retail water facilities. However,information on each unit process must be submitted in sufficient detail to allow DEP toadequately evaluate each water treatment process proposed. DEP Public Water SupplyModules (form 3800>FM>WSM0077) are to be used for that purpose.

1.3.1 Required Treatment

Section!109.605 of Chapter!109, Safe Drinking Water, has established the followingminimum treatment requirements for all new sources and for existing sources whenevera modification increases available water supply.

1.3.1.1 Surface Water Sources

a. Public water systems shall provide conventional filtration designed andoperated in accordance with standards established in Chapter!4, Part!II ofthe Public Water Supply Manual.

b. DEP may permit the use of direct filtration, slow sand filtration anddiatomaceous earth filtration, if studies, including studies whereappropriate are conducted and demonstrate that the minimum treatmentdesign standard of 99 percent removal of Giardia cysts and a 99!percentremoval of viruses can be achieved consistently, reliably and practicallyunder appropriate design and operating conditions.

c. Other filtration technologies may be permitted after on>site studies,including pilot studies where appropriate, demonstrate that thetechnology can consistently achieve the minimum treatment designstandard.

d. The public water system shall provide disinfection capable of a total of99.9!percent inactivation of Giardia cysts and a 99.99!percent inactivationof viruses prior to the first user of the system. The CT factors andmeasurement methods established by the EPA are the criteria to be usedin determining compliance with this minimum treatment design standard.

1.3.1.2 Ground Water Sources

Public water systems shall provide continuous disinfection.

1.4 Procedures for Obtaining a Permit

Applications for a bottled water, bulk water hauling, vended water system or retail waterfacility permit shall be submitted in writing on forms provided by DEP and be accompanied byplans, specifications, engineer's report, raw and finished water quality analyses and other data,information or documentation reasonably necessary to enable DEP to adequately evaluate theproposal.

1.4.1 Registered Engineer

The party desiring to construct, add to, or modify a water supply shall engage theservices of an engineer registered as a professional engineer and legally qualified to


practice in Pennsylvania, who is competent in the design and construction of watersupply facilities. The plans, specifications, and engineer's report must be prepared byhim or under his supervision.

1.4.2 Preliminary Engineering Conference

A preliminary conference with the regional water supply engineer should be held forprojects which include new sources of supply or treatment facilities. This conference willbe helpful to the applicant in making the necessary contacts for other permits whichmay be required.

1.4.2.1 Scope

Subjects appropriate to the project as covered in Section!1.4.3.1, Engineer'sReport, should be discussed in the preliminary engineering conference.

1.4.2.2 Preliminary Plans

Location maps, layout sketches and other illustrative material should beincluded.

1.4.2.3 Preliminary Report

A report presenting the proposed design data should be included in thematerial presented in the preliminary conference. If a conference is not held,it is advisable to submit a preliminary report at least 30!days prior topreparation of final plans.

1.4.2.4 Department Advice

Advice given by the regional water supply engineer or the engineering staffof the appropriate county health department is not to be construed asrepresenting official approval by DEP. Favorable consideration of design datasubmitted at a preliminary conference or in a preliminary report in no mannerwaives the legal requirements for the submission of final plans, specifications,and an engineer's report in support of the application for a permit, nor does itwaive the right of DEP to require modification of plans which in its judgmentdo not conform to good engineering practice or its requirements.

1.4.3 Submission of Application

In>state bottled water, bulk water hauling, vended water systems and retail waterfacilities must submit their applications, reports, final plans and specifications induplicate to the appropriate regional office listed in Table III>1.1. Applicants shouldallow at least 90!days for processing of the application. In some regions, a third copy ofthe application data may be necessary for submission to a county health department orriver basin commission.

Out>of>state bottled water and bulk water hauling applications shall be submitted tothe Bureau of Water Supply Management, P. O.!Box!8467, Harrisburg, PA!17105>8467 forreview.

Documents submitted for approval of a major modification shall include: (a)!application,(b)!modules, (c)!engineer's report, (d)!detailed plans, (e)!specifications, (f)!water qualityanalyses, (g)!permit fee and (h)!copies of labels where appropriate. The modules,specifications and front cover or flyleaf of each set of plans, shall bear the signature and


imprint of the seal of the registered engineer by or under whom prepared. In addition,each plan submitted shall bear an imprint or a legible facsimile of such seal.

Applicants for a bottled water system permit also will be required to submit an analysisof the quality of the manufactured water for each water product to be sold prior to finalapproval. This analysis must be for all parameters as outlined in Section 1.4.3.4. A copyof each label to be affixed to a bottled water product must also be submitted. This labelmust meet the requirements of Section!109.1007 of the Safe Drinking WaterRegulations. Applicants also must submit proof that the system is in compliance with thestandards of the Food and Drug Administration contained in 21 CFR Part 129 (relating toprocessing and bottling of bottled drinking water).

1.4.3.1 Engineer's Report

As a minimum, the engineer's report shall consist of completed copies of theappropriate modules furnished by DEP. All modules pertaining to the projectmust be included.

A comprehensive engineer's report, covering the following items, shall beprepared where major construction or modification of a water system isproposed.

a. General Information shall include:

(1) A description of the existing and proposed water system;

(2) A description of the area to be served;

(3) Where earth moving activities will be involved, an Erosion andSedimentation Control Plan which meets the requirements ofChapter!102 of DEP rules and regulations must be submitted.

b. Sources of Water

Describe the proposed source or sources of water supply to be used, thereasons for their selection, and provide information as follows:

(1) Surface>Water Sources:

(a) Summarized data on the quality of the raw water with specialreference to fluctuations in quality, changing meteorologicalconditions, stream flow, etc.,

(b) Hydrological data, stream flow and weather records,

(c) Reliable yield, including all factors that may affect it,

(d) Maximum flood flow, together with approval for safety featuresof the spillway and dam from the Bureau of WaterwaysEngineering

(e) Description of the watershed, noting any existing or potentialsources of contamination (i.e., sewerage treatment plants,industrial facilities, etc.) which may affect water quality;


(2) Groundwater Sources:

(a) Sites considered and quality of raw water at each site,

(b) Advantages of the site selected,

(c) Elevations with respect to surroundings and flood plain,

(d) Probable character of formations through which the source is tobe developed,

(e) Geologic conditions affecting the site,

(f) Summary of any source exploration, test well depth, method ofconstruction, placement of liners or screen, test pumping ratesand their duration, water levels and specific yield,

(g) Sources of possible contamination such as sewerage facilities,highways, railroads, landfills, outcroppings of consolidated water>bearing formations, chemical facilities, waste disposal wells, etc.;

(3) Finished Water Sources:

Finished water obtained from an approved public water system isconsidered to be raw water for purposes of an application. Applicantsproposing to use finished water as their source of supply must provideinformation on the quality of the water. The results of analysessubmitted shall be from samples collected at the point closest to theproposed point of interconnection.

c. Proposed Treatment Processes

Summarize the adequacy of the proposed processes and the unithydraulics for each treatment process to be used.

d. Automation

Where appropriate, provide supporting data justifying automaticequipment, including the servicing and operator training to be provided.

e. Waste Disposal

Discuss the various wastes from the water hauling, bottling or treatmentfacilities, their volume, proposed treatment and methods of disposal.

1.4.3.2 Detailed Plans

Plans shall be legible and shall be drawn to a scale which will permit allnecessary information to be correctly shown. The size of the plans should notbe larger than 36 inches by 50 inches. The plans shall include topographicmaps, general layouts, plan views, elevations, sections and supplementaryviews, which, together with the specifications, provide the information forthe contract and construction of the works. The topographic map shallinclude the location of the existing and potential sources of pollution listed inthe engineer's report.


The plans should include the datum used; the north point; boundaries of themunicipalities; water districts or specified areas to be served; land area ownedby the purveyor; topography of the drainage area and site, including wells,springs, streams, lakes, dams and reservoirs; the location, dimensions andelevations of structures and piping; the location and outline form ofequipment; flood levels; and the diameter and depth of well casings andliners. Each plan shall bear a suitable title showing the name and address ofthe company served, the scale in feet, a graphic scale, the date, and the name,address and seal of the design engineer.

1.4.3.3 Specifications

Complete, detailed technical specifications shall be supplied for each majormodification, including:

a. All additional laboratory facilities and equipment;

b. The type and design of chemical feed systems and grades of chemicals tobe used;

c. All paints, coatings or other materials which will come into contact withdrinking water during and after construction.

1.4.3.4 Water Quality Analyses

All bacteriological, inorganic, organic and radiological laboratory analysesmust be performed by laboratories certified by DEP in accordance with theanalytical techniques adopted by the United States Environmental ProtectionAgency under the federal act or methods approved by the department.Contact the Bureau of Water Supply Management, P.O. Box 8467, Harrisburg,PA 17105>8467 or the regional offices (see Table III>1.1) for the current list ofDEP's Maximum Contaminant Levels.


TABLE III>1.1

DEP REGIONAL OFFICES

Region Region Headquarters Counties Supervised

Southeast Suite 6010 Lee Park555 North LaneConshohocken, PA 19428Phone: 610>832>6059

*Bucks, *Chester, Delaware,Montgomery, Philadelphia

Northeast 2 Public SquareWilkes>Barre, PA 18711>0790Phone: 717>826>2511

Carbon, Lackawanna, Lehigh,Luzerne, Monroe, Northampton,Pike, Schuylkill, Susquehanna,Wayne, Wyoming

Southcentral One Ararat Blvd.Room 101>103Harrisburg, PA 17110Phone: 717>657>4586

Adams, Bedford, Berks, Blair,Cumberland, Dauphin, Franklin,Fulton, Huntingdon, Juniata,Lancaster, Lebanon, Mifflin, Perry,York

Northcentral 208 West Third Street, Suite 101Williamsport, PA 17701Phone: 717>327>3675

Bradford, Cameron, Centre,Clearfield, Clinton, Columbia,Lycoming, Montour,Northumberland, Potter, Snyder,Sullivan, Tioga, Union

Southwest 400 Waterfront DrivePittsburgh, PA 15222>4745Phone: 412>442>4217

*Allegheny, Armstrong, Beaver,Cambria, Fayette, Greene, Indiana,Somerset, Washington,Westmoreland

Northwest 230 Chestnut StreetMeadville, PA 16335>3481Phone: 814>332>6899

Butler, Clarion, Crawford, Elk,*Erie, Forest, Jefferson, Lawrence,McKean, Mercer, Venango, Warren

*County Health Departments


PART III

CHAPTER 2 > BOTTLED WATER SYSTEMS

2.0 General

The purpose of this chapter is to provide minimum acceptable standards on the design ofbottled water systems. This information has been taken, in part, from standards established bythe Food and Drug Administration, 21 CFR Part 129 (Processing and Bottling of BottledDrinking Water) and from the technical manuals published by the International Bottled WaterAssociation. Other designs may be approved by DEP provided that the applicant candemonstrate that the alternate design will be capable of providing a consistently reliable, safequality of drinking water to the public.

2.1 Sources of Supply

All water for bottling and operating a bottled water system shall be from a source approved byDEP. Purchase of water from a permitted public water supply system also must be approved byDEP.

2.2 Buildings and Facilities

2.2.1 Siting

The location of a bottled water plant shall be such that it is free from any conditionswhich may result in the contamination of finished water, the equipment used in themanufacturing process, or the primary containers.

2.2.2 Plant Design and Construction

2.2.2.1 General

Bottled Water Plants should:

a. Be designed and constructed to allow proper installation of equipment,facilitate maintenance, and provide for the sanitary operation of thebottle water operation;

b. Have floors which are smooth, impervious and properly drained. All drainsshall be equipped with traps and grills;

c. Have joints between walls and floors which are tight and impervious;

d. Have walls and ceilings which are smooth, of a light color, and easilycleaned;

e. Have no fixtures, ducts, or pipe suspended over work areas that may allowcondensate to contaminate the product or bottling equipment.

2.2.2.2 Bottling Room

The bottling room should be separated from other plant facilities or storageareas by tight walls, ceilings, and self>closing doors to protect againstcontamination. Conveyor openings shall not exceed the size required topermit passage of containers. Joints between floors and walls should becovered. Doors, windows, and all outside openings into bottling rooms shall


be screened and/or otherwise protected against entry of insects, birds,rodents, dust, and airborne contamination. Where air curtain blowers areused, they should be located inside the bottling room so that cleaner air willbe moved through the filter and around the bottles.

2.2.2.3 Bottle Washing Area

A separate enclosed room should be provided for the washing and sanitizingof containers for bottled drinking water. The washing and sanitizingequipment should be positioned within the room to minimize any possiblepost>sanitizing contamination of the containers before they enter thebottling room.

2.2.2.4 Bottle Storage and Chemical Storage

a. Bottles

Adequate clean, dry storage areas or facilities shall be provided forcontainers, closure materials, paper for wrapping, adhesives and otherproduction materials to provide protection from dust, insects, chemicalsor other sources of contamination. The materials should be stored onpallets above the floor away from the wall to facilitate cleaning. Partiallyused cartons of containers, caps or other closure materials shall beresealed between uses.

b. Chemicals

Separate storage facilities shall be provided for chemicals used incontainer sanitizing operations, equipment sanitizing and/or generalplant sanitation. Separate areas should be provided for each chemical,properly labeled and ventilated where appropriate. Where toxic orhazardous chemicals are used, the requirements in Part II, Section 5.2 ofthis manual shall be followed.

2.2.2.5 Dressing and Locker Rooms

Adequate facilities shall be provided for the orderly storage of the clothingand personal belongings of employees where employees routinely changeclothes within the establishment. Such designated areas should be providedfor each sex and shall be located outside the bottling room, bottling washingroom, bottle storage areas and utensil washing areas.

2.2.2.6 Ventilation

a. Adequate ventilation shall be provided to minimize condensation or theaccumulation of noxious fumes in processing rooms, bottling rooms, andin container washing and sanitizing areas. This equipment shall not createconditions that may contribute to product contamination. Positivepressure ventilation in bottling rooms is recommended.

b. Ventilation systems for chlorine gas rooms shall comply with Part II,Sections 5.4.3.2 and 5.4.3.3 of this manual.

2.2.2.7 Lighting

Adequate lighting, either natural or artificial, must be provided in all areaswhere finished water is examined, processed, or stored, and where equipment


and bottles are cleaned. A minimum of 50>foot candles must be provided inany product inspection station. Light bulbs, fixtures, skylights, or other glasssuspended over exposed product in any step of preparation shall be of thesafety type or otherwise protected to prevent product contamination in caseof breakage.

2.2.2.8 Sanitary Facilities

a. Each bottled water manufacturing establishment shall have available,conveniently located washroom facilities which are separate from anyroom or rooms where bottled water is manufactured or packaged andfrom areas where bottles are sanitized or stored.

b. Each washroom shall provide toilets, urinals and lavatories appropriatefor the number of employees. Handwashing facilities shall be equippedwith hot and cold running water under pressure, hand cleansing soap ordetergent, and approved sanitary towels or other approved hand>dryingdevices. Washrooms shall have self>closing doors and windows or aventilation system to the outside.

c. Wastewater disposal facilities must be acceptable to or approved by DEP.

2.3 Treatment

All treatment processes used in the manufacturing of water for bottling must be approved byDEP. It is recognized that the design requirements specified in Part II, Chapter 4 of this manualmay not apply to bottled water systems; however, information on each unit process must besubmitted in sufficient detail to allow DEP to adequately evaluate the bottled water treatmentsystem. DEP's Public Water Supply Modules are to be used for this purpose.

Bottled water systems shall be designed to provide an adequate quality of water to the public.The design shall ensure that the system will, upon completion, be capable of providing waterthat complies with the primary and secondary MCLs and treatment techniques established inSection 109.1002 of DEP's Safe Drinking Water Regulations (relating to MCLs and treatmenttechnique).

Bottled water systems shall provide continuous disinfection for groundwater sources. Refer toChapter!3 of Part!IV (Noncommunity System Design Standards) of this manual for designstandards on ultraviolet light systems.

2.4 Equipment

2.4.1 Materials of Construction

Contact surfaces of equipment used in the processing, storage, handling andtransportation of finished water shall be of a material which can be easily cleaned andwithstand the repeated application of sanitizing chemicals. Only safe, nontoxiclubricants shall be used on equipment which may come into contact with the productwater and are required to receive periodic lubrication.

2.4.2 Storage Tanks

Storage tanks shall be of the type which can be securely closed to exclude foreign matterand shall be adequately vented through inverted air filters. Any liner or coating used in araw or finished water storage tank must be acceptable to DEP.


2.4.3 Sanitizing Systems

Sanitizing systems for equipment and bottles should be provided. Where temperature isan important factor in the operation of the sanitizing operation, at least twotemperature gauges shall be provided in the system for monitoring purposes.

2.4.3.1 Steam in an Enclosed System

Steam sanitizing shall occur at a temperature of at least 170∞F for no less than15 minutes or at least 200∞F for no less than five!minutes. Steam used incontact with product water>contact surfaces shall be free from any materialsor additives other than those allowed in 21 CFR 173.310 or as otherwiseapproved by DEP.

2.4.3.2 Hot Water in an Enclosed System

Hot water sanitizing shall occur at a temperature of at least 170∞F for no lessthan 15 minutes or at least 200∞F for for no less than five!minutes.

2.4.3.3 Chemical Sanitizers

Chemical sanitizers shall conform with 21 CFR 178.1010 or otherwise beacceptable to DEP.

a. The preferred method will be to clean by exposing all surfaces to not lessthan 2Ω!percent caustic solution at a minimum temperature of 120∞F fornot less than one!minute where high velocity jets are used and for not lessthan three!minutes where soaker type bottle washers are used, followedby a thorough rinsing with operations water or product water.

b. Acceptable alternate procedures are to sanitize with 100 ppm chlorinewater solution at 75∞F for not less than 30 seconds, or sanitize with200!ppm approved quaternary ammonium water solution at 75∞F for notless than two!minutes.

2.4.4 Rinse Facilities

Finished water rinse facilities shall be provided to remove any traces of the chemicalsused in the chemical sanitizing process. The design shall be such that only disinfectedwater shall be used for this purpose.

2.5 Containers and Closures

Containers and closures for bottled water shall comply with the requirements of 21 CFRParts!170 through!189.

2.5.1 Containers

All bottled water containers shall be made of a nontoxic material which is readilycleanable and not subject to deterioration or leaching of injurious substances whensubjected to sanitizing operations.

2.5.1.1 Single Service

Single>service containers shall be stored in a manner to protect their sanitarycondition until used.


2.5.1.2 Multiservice

Multiservice containers shall be adequately cleaned, sanitized and inspectedimmediately prior to being filled.

2.5.2 Closures

All bottles shall be provided with nontoxic, tamper>proof seals or caps which are notsubject to deterioration or leaching of injurious substances. Only new screw, snap, orcrown caps may be used without sanitizing, and only when received clean and keptprotected from contamination.

2.6 Tanker Trucks

Tanker trucks used in transporting bulk water for bottling shall comply with the designrequirements in Chapter 3 of this part on Bulk Water Hauling Systems.

2.7 Laboratory Equipment

Sufficient laboratory equipment and testing facilities shall be provided to allow for the routinetesting necessary to assure proper operation. In addition to equipment for the routine testingof the water for bottling, the appropriate equipment needed to test all cleansing andsanitizing solutions used in the bottling operation shall be available. Laboratory equipmentshould not be located in the bottling room or bottle washing area.

The laboratory equipment requirements specified in Part II, Section 2.4 of this manual shouldbe followed.


PART III

CHAPTER 3 > BULK WATER HAULING SYSTEMS

3.0 General

The purpose of this chapter is to provide basic information on the design of water hauling tanktrucks which will be used to transport bulk water from a DEP approved source of supply to thecustomers point of use or storage. This information has been taken, in part, from the "3>ASanitary Standards for Stainless Steel Automotive Milk and Milk Products Transportation Tanksfor Bulk Delivery and/or Farm Pick>Up Service.'' Though the use of milk trucks for waterhauling purposes is a generally accepted practice, each truck must have the interior of the tankthoroughly cleaned and inspected with an ultraviolet lamp each time water is to betransported. Tanks previously used to transport petroleum products, toxic materials or otherdeleterious substances shall not be used to haul drinking water.

3.1 Sources

All sources of water used for bulk water shipment must be approved by DEP and are subject tothe quality and treatment requirements outlined in Chapter!109 of DEPπs rules and regulationsrelating to Safe Drinking Water. Where new groundwater or surface water sources aredeveloped as part of a bulk water hauling system, the design standards outlined in Chapter!1of this part shall apply.

3.2 Tank Trucks

3.2.1 Construction Materials

3.2.1.1 Tanks

All water contact surfaces should be of stainless steel of the American Iron andSteel Institute (AISI) 300 series or corresponding Alloy Casting Institute (ACI)types or stainless steel that is nontoxic and nonabsorbent and which underconditions of intended use is equally resistant as stainless steel of theAmerican Iron and Steel Institute (AISI) 300 series or corresponding AlloyCasting Institute (ACI) types.

3.2.1.2 Noncontact Surfaces

Noncontact surfaces should be of a waterproof, corrosion resistant materialwhich is nonabsorbent, durable and easily cleaned.

3.2.1.3 Gaskets and Seals

Plastic, rubber, and rubber>like materials may be used for water transfertubing, bearings, seals and gaskets provided that they comply with the foodadditives and indirect food additives provisions of 21 CFR Parts 170 through189.

3.2.2 Fabrication

3.2.2.1 Outer Shell

The outer shell should be smooth and effectively sealed except for a vent orweep hole. The vent or weep hole shall be located in a position that willprovide drainage from the outer shell and shall be insect proof.


3.2.2.2 Outlets

Each tank or compartment shall have a separate outlet. The outlet should beof welded construction except that a rolled>on fitting may be used on theterminal end. The outlets shall provide complete drainage of the tank orcompartments.

3.2.2.3 Manhole Opening and Covers

Manhole openings should be not less than 16 inches by 20 inches oval or 18inches in diameter. Each manhole shall provide an effective seal to prevententrance of contaminants. Where air vents are installed, they shall bedesigned so they are easily removable and readily cleaned. Manhole covergaskets shall be removable and cleanable.

3.2.2.4 Baffles

Where used, baffles shall not interfere with the free drainage of the tank.They shall be permanently attached to the tank and have no sharp edges.Baffles shall be designed that walk>through accessibility is provided to allareas for inspection and cleaning.

3.2.2.5 Cabinets

Transfer tubing storage cabinets shall be dust tight and, doors should beequipped with a compression type closing device. Gasket material for sealingdoors may be installed on the face of the cabinet except along a drainagearea, where it shall be attached to the doors. A roof overhang or suitable dripmolding should be provided over the cabinet doors. Where transfer tubing isstored, a means should be provided to support the loose end of the tubingabove the cabinet floor to ensure proper sanitation.

3.3 Water Loading Stations

Filling stations should be designed in such a way as to prevent backflow that may contaminatethe feed water supply.

3.4 Transfer Tubing

Single lengths of transfer tubing should not exceed eight!feet except where adequateprovisions have been made to clean greater lengths. A sanitary closure shall be furnished forthe open ends of the tubing.


PART III

CHAPTER 4 > VENDED WATER SYSTEMS

4.0 General

The purpose of this chapter is to provide minimum acceptable standards on the design of watervending machines. This information has been taken, in part, from standards established by theNSF International (NSF) (Standard 25 > Vending Machines for Food and Beverages) and theNational Automatic Merchandising Association's Vending Machine Evaluation Manual. Otherdesigns may be approved by DEP provided the applicant can demonstrate the alternate designwill be capable of providing a consistently reliable, safe quality of drinking water to the public.

4.1 Coverage

For the purposes of this chapter, the following definition of a water vending machine shallapply:

Water Vending Machine > Any self>contained, self>service device which, upon insertion of acoin, paper currency, token, card, key, or other similar means or through manual operation,dispenses unit servings of water, either in bulk or in packages, without the necessity ofreplenishing the device between each vending operation.

This definition is not meant to include machines which dispense carbonated soft drinks, coffee,tea, soup, milk, chocolate drinks or fruit juices which are regulated by DEP under Title!7,Chapter 80, Department of Agriculture (Food Vending Machines).

4.2 Sources

All sources of drinking water must be approved by DEP and sampled and tested for theparameters specified by DEP's new>source sampling requirements. Vending machines whichwill obtain their source water from the distribution system of an approved public water systemmay submit the results of analyses obtained by the source/selling water system whensubmitting an application for a permit. The analyses must have been conducted within theappropriate routine monitoring schedule and conducted by a laboratory certified by DEP.Source water analyses are not required from water vending machines which meet the specialpermit>by>rule requirements.

4.3 Vending Machine Design

Vending machines shall comply with the following design and construction standards or theirequivalent.

A. NSF Standard!25, Vending Machines for Food and Beverages.

B. National Automatic Merchandising Association's Vending Machine Evaluation Manual.

4.3.1 Exterior

The exterior of the vending machine shall be designed to facilitate cleaning and toprevent the entrance of dust, dirt, insects and rodents.

4.3.1.1 Materials

The materials of construction shall be durable, study, easily cleaned andcapable of withstanding the corrosive effects of cleaning chemicals. Paints or


other materials used in fabrication shall not impart an odor, color, taste, ortoxic substance to the dispensed water.

4.3.1.2 Surfaces

External surfaces, including corners, joints and seams shall be sealed andsmooth to eliminate sharp edges which might cause accidents or interferewith proper cleaning and drainage.

4.3.1.3 Doors and Covers

Doors and covers shall be tight fitting and, if necessary, gasketed to preventthe entrance of dust, moisture, insects and rodents.

4.3.1.4 Ventilation Openings

All ventilation openings shall be effectively screened and accessible forcleaning. Screening size shall not be less than 16>mesh per inch except formotor compartments which shall not be larger than eight!mesh per inch.

4.3.1.5 Water Vending Openings

Customer service openings shall be designed to minimize the entrance ofcontaminants, insects and rodents. Bulk water vending machines shall have aself>closing door or panel to protect the water during the vending stage.

4.3.1.6 Service Connections

All service connections through an exterior wall (i.e., water, electrical, etc.)shall be grommeted or sealed to prevent the entrance of insects or rodents.

4.3.2 Interior

All interior surfaces and component parts of the vending machine shall be designed andconstructed to permit easy cleaning.

4.3.2.1 Materials

All interior surfaces of the machine shall be of smooth, nontoxic, corrosion>resistant and nonabsorbent material, and shall be capable of withstandingrepeated cleaning and sanitizing by normal procedures.

4.3.2.2 Accessibility

All containers, valves, pipes, tubes, fittings, faucets, discharge nozzles andother water>contact components shall be accessible for cleaning andinspection by disassembly with simple tools such as an open>end wrench orscrewdriver. When disassembled, all surfaces shall be visible for inspectionand cleaning.

4.3.2.3 Water Reservoirs

Water reservoirs, when installed as a separate internal component of thevending machine, shall meet the following requirements:

a. Be removable from their in>use position;


b. Have covers which are flanged to overlap the container opening;

c. Have covers which are sloped to provide drainage whenever condensationmay form;

d. Have outlet tubing which can be easily removed from the basin;

e. Have floats and assemblies, where provided, which are smooth, nontoxicand easily cleaned.

4.3.2.4 Water Supply System

The materials and method of installation of all water piping, connections andfittings which, in field use, will be directly connected to a potable watersupply shall conform to local plumbing codes and the source water systemrequirements.

4.3.2.5 Waste Containers

Containers shall be provided for the collection of drip, spillage, overflow orother internal wastes. Waste containers shall be leak proof, readilyremovable, easily cleanable and corrosion resistant.

4.3.2.6 Protection of Source Water Supply

The potable water supply to vending machines shall be protected frombackflow and back pressure from in>machine water by means of properlyinstalled cross>connection control and backflow prevention device.

4.3.2.7 Drains

Drains shall be effectively protected against the entrance of insects androdents by the use of a 16>mesh screen or an effective trap.

4.3.2.8 Drainage to Sewers

Wastewaters discharged to a sewer shall be through a minimum air gap oftwo inches.

4.4 Treatment

4.4.1 Filters

Water treatment devices installed by the manufacturer should be of the disposable typeor of a type that can be readily disassembled with ordinary tools for cleaning, sanitizingor replacement of the active elements.

4.4.2 Activated Carbon

Activated carbon if used should be virgin carbon. Carbon which complies with the NSFStandard!61 or any other certification organization as stringent as NSF is acceptable.

4.4.3 Disinfection

Vended water shall be disinfected prior to delivery into the customer©s container.Chlorine, chlorine compounds, ozone and ultraviolet (UV) light or other methodsacceptable to DEP may be used provided the appropriate contact times are provided.


Water supplied by the source/selling water system is considered to be raw water andmust be disinfected prior to dispensing from the vending machine.

4.4.3.1 Ultraviolet Radiation

a. UV systems may be used provided they comply with the Food and DrugAdministration's requirements under 21 CFR 179.39 and the NSFStandard!55. UV systems of the Class A type, as approved by NSF underStandard 55, are acceptable to DEP.

b. Machines using UV shall be equipped with a sensor to shut off themachine if the lamp burns out or the intensity of the effective radiation at2,537 Angstrom units falls below 13,000 microwatt seconds per squarecentimeter based on the manufacturer's recommended flow rate.

c. UV lamp assemblies shall be designed to permit intensity testing with aportable unit while avoiding direct eye exposure to radiation during thetest.

4.4.3.2 Ozone

Ozone may be used provided that its application complies with the Food andDrug Administrations requirements under 21 CFR 184.1563.

4.5 Machine Location

Vending machines shall be located in a room, area or space which can be maintained in a cleancondition and which is protected from overhead leakage or condensation from water,wastewater, or sewer piping. Each vending machine shall be located so that the space aroundthe machine and the space under the machine, unless effectively sealed to the floor, can bereadily cleaned and so that insect and rodent harborage is not created. The floor area on whichvending machines are located shall be reasonably smooth and be capable of withstandingrepeated washings and scrubbings. The space and immediate surroundings of each vendingmachine shall be maintained in a clean condition.

4.6 Machine Markings

Water vending machines shall display, in a position clearly visible to customers, the followinginformation:

A. The name of the owner/operator;

B. The full address of the owner/operator;

C. A telephone number that can be used to obtain further information, service, or registercomplaints;

D. A statement describing the treatment processes and chemicals used;

E. A statement indicating the source of raw water.


PART III

CHAPTER 5 > RETAIL WATER FACILITIES

5.0 General

The purpose of this chapter is to provide minimum standards acceptable to DEP on the designof retail water facilities. This information has been taken, in part, from standards establishedby the Food and Drug Administration, 21 CFR Part 129 (Processing and Bottling of BottledDrinking Water) and NSF (Standard 25 > Vending Machines for Food And Beverages). Otherdesigns capable of providing a consistently reliable, safe quality of drinking water to the publicalso may be approved by DEP.

5.1 Coverage

For the purpose of this chapter, the following definition of a retail water facility shall apply:

Retail Water Facility > A public water system (PWS) which provides water for bottling withoutthe use of a water vending machine by dispensing unit servings of water in containers,whether or not the container is provided by the customers.

5.2 Sources of Supply

All water for bottling at a retail water facility shall be from a source approved by DEP andsampled and tested for the parameters outlined on DEPπs Maximum Contaminant Levels (MCL)list.

Retail water facilities which will obtain their water from an approved public water system maysubstitute for this testing the results of analyses obtained by the source/selling water systemwhen submitting an application for a permit. The analyses must have been conducted withinthe appropriate routine monitoring schedule of the source water system by a laboratorycertified by DEP.

5.3 Buildings and Facilities

5.3.1 Siting

The location of a retail water facility shall be such that it is free from any conditionswhich may result in the contamination of the finished water, the equipment used in themanufacturing process, or the primary containers.

5.3.2 Facility Design and Construction

5.3.2.1 General

Retail Water Facilities should:

a. Be designed and constructed to allow proper installation of equipment,facilitate maintenance, provide for sanitary operation, and preventcontamination of the finished water, process equipment or containers;

b. Have floors which are smooth, impervious and properly drained, withtraps and grills as necessary;

c. Have joints between walls which are tight and impervious;


d. Have walls and ceilings which are smooth, of a light color and easilycleaned;

e. Have no fixtures, ducts or pipe suspended over work areas that may allowcondensate to contaminate the product or bottling equipment.

5.3.2.2 Bottle Washing Area

A separate enclosed area should be provided for the washing and sanitizingof containers for retail drinking water. The washing and sanitizing equipmentshould be positioned within the room to minimize any possible post>sanitizing contamination of the containers before they enter the bottlingarea.

5.3.2.3 Container Storage and Chemical Storage

a. Retail Containers

If containers are provided for customers use, adequate, clean, dry storageareas or facilities shall be provided for containers and containerpreparation materials to assure protection from dust, insects, chemicals orother sources of contamination. The materials should be stored on palletsabove the floor away from the walls to facilitate cleaning. Partially usedcartons or containers, caps or other closure materials shall be resealedbetween uses.

b. Chemicals

Separate storage facilities shall be provided for chemicals used incontainer sanitizing operations, equipment sanitizing and/or generalfacility sanitation. Separate areas should be provided for each chemical,properly labeled, and ventilated where appropriate. Where toxic orhazardous chemicals are used, the requirements in Part II, Section 5.3 ofthis manual shall be followed.

5.3.2.4 Ventilation

a. Adequate ventilation shall be provided to minimize condensation or theaccumulation of noxious fumes in processing or retail areas. Ventilationequipment shall not create conditions that may contribute to productcontamination. Positive pressure ventilation in bottling rooms isrecommended.

b. Ventilation systems for chlorine gas rooms shall comply with Part II,Section 5.4.3.3 and 5.3.2 of this manual.

5.3.2.5 Lighting

Adequate lighting, either natural or artificial, must be provided in all areaswhere finished water is examined, processed, or sold, and where equipmentand bottles are cleaned. A minimum of 50>foot candles must be provided inany product inspection station. Light bulbs, fixtures, skylights, or other glasssuspended over exposed products in any step of preparation shall be of thesafety type or otherwise protected to prevent product contamination in caseof breakage.


5.3.2.6 Sanitary Facilities

a. If available, washroom facilities shall be separate from any room or roomswhere bottled water is manufactured or packaged and from areas wherebottles are sanitized or stored.

b. Wastewater disposal facilities must be acceptable to or approved by DEP.

5.4 Treatment

All treatment processes used in the purification of water at retail water facilities must beapproved by DEP. It is recognized that the design requirements specified in Part II, Chapter 4may not apply to retail water facilities; however, information on each unit process must besubmitted in sufficient detail to allow DEP to adequately evaluate the retail water treatmentsystem. DEP's Public Water Supply Modules are to be used for this purpose.

For retail water facilities using pre>assembled treatment devices, those whose treatmentdevices have been evaluated and certified by a third party organization such as NSF will beconsidered acceptable. Equipment used in the treatment of drinking water should beapproved under the appropriate NSF standards: 42>Drinking Water Treatment Units: AestheticEffects, 43>Chemical Feeding and Processing Equipment, 44>Cation Exchange Water Softeners,53>Drinking Water Treatment Units: Health Effects, 55>Ultraviolet Water Treatment Systems,58>Reverse Osmosis Drinking Water Treatment Systems and 62>Drinking Water DistillationSystems.

Disinfection of the water must be provided immediately prior to filling the containers.Chlorine, compounds, ozone and ultraviolet light or other methods acceptable to thedepartment may be used provided that the appropriate contact times are provided. Watersupplied by the source/selling water system is considered to be raw water and must bedisinfected prior to dispensing to the customer's containers.

5.5 Equipment

5.5.1 Materials of Construction

Contact surfaces of equipment used in the processing, storage, and handling of finishedwater shall be of a material which can be easily cleaned and withstand the repeatedapplication of sanitizing chemicals. Only safe, nontoxic lubricants shall be used onequipment which may come into contact with the product water and are required toreceive periodic lubrication.

5.5.2 Storage Tanks

Storage tanks shall be of the type which can be securely closed to exclude foreign matterand shall be adequately vented through inverted air filters. Any liner or coating used in araw or finished water storage tank must be acceptable to DEP.

5.5.3 Sanitizing Systems

Sanitizing systems for equipment and bottles should be provided. Where temperature isan important factor in the operation of the sanitizing operation, at least twotemperature gauges shall be provided in the system for monitoring purposes.

5.5.3.1 Steam in an Enclosed System

The minimum exposure temperature and duration shall be 170∞F for fiveminutes. Steam used in contact with product water>contact surfaces shall be


free from any materials or additives other than those allowed in 21!CFR173.310 or as otherwise approved by DEP.

5.5.3.2 Hot Water in an Enclosed System

The minimum exposure temperature and duration shall be at least 170∞F forno less than 15!minutes or at least 200∞F for no less than five minutes.

5.5.3.3 Chemical Sanitizers

Chemical sanitizers shall conform with 21 CFR 178.1010 or otherwise beacceptable to DEP.

a. The preferred method will be to clean by exposing all surfaces to not lessthan 2Ω percent of caustic solution at a minimum temperature of 120∞F fornot less than one minute where high velocity jets are used, and not lessthan three minutes where soaker>type bottle washers are used, followedby a thorough rinsing with operations water or product water, or

b. Acceptable alternative procedures are to sanitize with 100 ppm chlorinewater solution at 75∞F for not less than 30 seconds, or

c. Sanitize with 200 ppm approved quaternary ammonium water solution at75∞F for not less than two minutes.

5.5.4 Rinse Facilities

Finished water rinse facilities shall be provided to remove any traces of the chemicalsused in the chemical sanitizing process. The design shall be such that only disinfectedwater shall be used for this purpose.

5.6 Containers and Closures

Containers and closures for retail water shall comply with the requirements of 21 CFR Parts 170through 189.

5.6.1 Containers

All retail water containers shall be made of a nontoxic material which is readilycleanable and not subject to deterioration or leaching of injurious substances whensubjected to sanitizing operations. Containers shall be stored in a manner to protecttheir sanitary condition until used.

5.6.2 Closures

All containers shall be provided with nontoxic, tamper>proof seals or caps which are notsubject to deterioration or leaching of injurious substances. Only new screw, snap, orcrown caps may be used without sanitizing, and only when received clean and keptprotected from contamination.

5.7 Tanker Trucks

If tanker trucks are used in transporting bulk water to the facility, the truck shall comply withthe design requirements in Chapter 3 of this part on Bulk Water Hauling Systems.


APPENDIX A

OPERATION AND MAINTENANCE STANDARDS


PART III

APPENDIX A > CHAPTER 1

OPERATION AND MAINTENANCE STANDARDS FOR BOTTLED WATER

1.0 General

The purpose of this chapter is to provide basic guidelines on the operation and maintenance ofbottled water manufacturing facilities. This information has been taken in part, from standardsestablished by the Food and Drug Administration under 21!CFR Part!129 (processing andbottling of bottled drinking water) and from technical manuals published by the InternationalBottled Water Association. DEP's community water supply ™operation and maintenance∫requirements, as they apply to bottled water systems, also have been incorporated into thischapter.

1.1 Records

Properly kept records are a valuable tool for making adjustments in operation andmanagement of a bottled water system. Good records also serve as proof of performance forjustifying the expenditure of money and resolving disputes where there are concerns overwater quality. The following are the types of records that should be maintained at a bottledwater plant:

1.1.1 Plant and Equipment

All design drawings, specifications and all construction documents should be retained ina safe location for the life of the facility regardless of any changes. Detailed records as tothe manufacturer, make, model and date installed for each piece of equipment and thepersons installing the equipment also should be retained. Repairs of any kind also shouldbe recorded.

1.1.2 Operation

Records should be maintained of all inspections, cleaning and sanitizing activities whichshould include the names of the persons involved, date, time, and the results of theinspection or activity. These records should be maintained for at least three years.Sanitary surveys conducted on the source(s) of raw water should be retained for not lessthan 10!years.

Water quality analysis data for each source, each product and any intermediate samplesare to be retained. Bacteriological and turbidity analysis data are to be retained for atleast five years; and chemical, radiological and organic analysis data are to be retainedfor at least 10 years. All water quality analysis data should clearly indicate which testswere done in>house and which were done by DEP approved laboratories. In addition toidentifying the person(s) conducting the tests, the laboratory procedure or thetechnique used should be recorded.

1.1.3 Chemicals

Accurate records are to be kept on all types of chemicals used in the plant, when andfrom whom purchased, and where and how they are stored. Where hazardous or toxicchemicals are involved, it is recommended that access be restricted to essential personneland that detailed records be retained on their purchase and use. Daily records on theamount of each chemical used should be kept and retained for at least two years.


1.1.4 Personnel

Bottled water manufacturers should maintain up>to>date records for each of itsemployees. Records should include the employee's name, address, telephone number,emergency phone number, date hired, education, medical history, criminal record, andinformation of any physical disabilities. These records should be retained for at leastfive!years.

1.1.5 Emergency Response

A critical element in the operation of any drinking water system is the ability to respondto an emergency situation. For that reason it is very important that the owners andoperators maintain accurate and up>to>date records on the names, addresses, telephonenumbers and responsibilities of each individual employed. Emergency response plansshould be updated at least annually and should provide specific information on theresponsible officials for each shift. Detailed instructions on how to implement a productrecall and initiate public notification should be provided in the emergency responseplan.

1.2 Buildings and Grounds

Buildings, fixtures, and other physical facilities of the plant must be kept in good repair and areto be maintained in a sanitary condition. Cleaning operations should be conducted in such amanner as to minimize the danger of contamination of product and product contact surfaces.Only materials required for the proper operation and maintenance of the plant and equipmentare to be stored in the plant. These materials shall be properly identified and stored in a safemanner.

1.2.1 Buildings

a. Buildings must be vermin>proof and kept in good repair. Only pesticides approvedfor use by the Food and Drug Administration and/or registered with the U.S.Environmental Protection Agency shall be used for vermin control.

b. Walls and ceilings in bottling areas must be kept clean. Overhead structures,fixtures, and ducts in nonbottling areas are to be kept free from accumulations ofdust and other contaminants.

c. Floors are to be kept clean and free of waste, litter, and extraneous material.Floors in the bottling areas should be cleaned daily and sanitized with a 200 ppmchlorine solution.

d. Doors and windows must be kept clean and in good repair.

e. Ventilation equipment should not create conditions that may contribute toproduct contamination by airborne contaminants and must be kept free ofaccumulation of dust and grease.

f. Washrooms must not be utilized for storage of garments, food products, utensils,or packaging and wrapping materials. Hot and cold running water; powdered,liquid, or bar soap; and single>use sanitary towels are to be provided. The toiletroom and fixtures are to be maintained in a sanitary condition and kept in goodrepair at all times. Signs informing employees to wash their hands after using thewashrooms must be posted in a visible location.

g. Where employee locker and lunchrooms are provided, they are to be separatedfrom plant operations and/or storage areas and be equipped with self>closing


doors. The rooms shall be maintained in a clean and sanitary condition withrefuse containers provided. Packaging or wrapping material or other processingsupplies must not be stored in locker or lunchrooms.

h. Storage facilities must be kept clean and dry, and provide protection from splash,insects, dust, and other contaminants.

i. All refuse must be stored in properly identified, covered containers.

1.2.2 Grounds

The grounds about a bottled water plant under the control of the operator must be keptfree from conditions which may result in the contamination of the product water ormanufacturing facilities. This is to be achieved by:

a. Prompt elimination of any litter, waste or refuse, within the immediate vicinity ofthe plant buildings that may attract or provide a breeding place or harborage forrodents, insects and other pests;

b. The elimination or control of air pollutants (i.e., dust, engine exhaust) that maycontribute to the contamination of the product during its manufacture;

c. Adequately draining areas that may cause contamination through seepage or byproviding a breeding place for insects or microorganisms;

d. Where plant grounds are bordered by land not under the operator©s control ofthe kind described in subparagraphs a, b, and c of this section, additional caremust be exercised by increased plant inspections, extermination, or other meanswhich will ensure exclusion of pests, dirt, and other contaminants.

1.3 Sanitary Operations

1.3.1 Whenever air under pressure is directed at product water or a product water>contactsurface, it must be free of oil, dust, rust, excessive moisture, and extraneous materials.

1.3.2 The product water>contact surfaces of all multiservice containers, utensils, pipes andequipment used in the transportation, processing, handling and storage of bottledwater shall be clean and adequately sanitized. All product water>contact surfaces are tobe inspected by plant personnel as often as necessary to evaluate the sanitary conditionof such surfaces and to take appropriate action to assure they are kept free of scale,evidence of oxidation, and other residue. The presence of any contaminants, scale,residue, or oxidation will be sufficient reason to reject the container or utensil fromfurther use or until properly cleaned.

1.3.3 After cleaning, all multiservice containers, utensils and disassembled piping andequipment must be stored in such a manner as to assure drainage and be protected fromcontamination.

1.3.4 Single>service containers and caps or seals shall be stored in sanitary closures and keptclean and dry until used. Prior to use they must be examined and as necessary, washed,rinsed, and sanitized.

1.3.5 Filling, capping, closing, sealing, and packaging of containers shall be done in a sanitarymanner to preclude contamination of the bottled drinking water.


1.4 Processes and Controls

1.4.1 Treatment of Product Water

The manufacture of bottled water by distillation, ion>exchange filtration, ultraviolettreatment, reverse osmosis, or any other process shall be done in a manner to achievethe optimum level of treatment. All facilities and treatment processes approved bypermit from DEP shall be operated and maintained in accordance with DEP's rules andregulations. Chemicals approved under NSF Standard 60 are accepted. Product watersamples shall be taken after processing and prior to bottling, and analyzed as often as isnecessary to assure uniformity and effectiveness of the treatment processes. Thefollowing recommendations are provided for each treatment process:

a. Distillation

Feed water with a high hardness should be deionized prior to distillation topreclude rapid and excessive scale buildup in the evaporator. Scale buildupreduces evaporator efficiency. Sufficient boiler blow>down also should beprovided to reduce scale buildup.

To maintain the quality of the distilled water, a conductivity meter should beinstalled in the product line. Conductivity should be recorded at start>up and thenregularly (e.g., hourly) during a production run. The conductivity of the finishedwater should be less than 10 micromhos.

b. Ion exchange

Prior to start>up, the ion exchange resins should be conditioned before puttinginto service. Maintaining demineralization efficiency of a two>bed system is veryimportant. This could be carried out in the following manner:

(1) Cation Unit

(a) Backwash the unit using reverse flush (upward) to remove trapped solidsand prevent packing/channeling.

(b) Proceed with normal regeneration, by passing a strong acid solution(sulfuric or hydrochloric acid) downward through the resin.

(c) Rinse by passing rinse water downward to flush out minerals and excessacid.

(2) Anion Unit

(a) Backwash the unit using reverse flush to remove trapped solids andprevent packing/channeling.

(b) Proceed with normal regeneration, by passing a strong base solution, suchas caustic soda (sodium hydroxide) or soda ash (sodium carbonate)downward through resin. The type of base used depends on resin used.

(c) Rinse by passing rinsed water downward to flush out minerals and excessbase.

The operating, regeneration procedures and flow rates specified by themanufacturers should be followed to ensure proper operation of the units.


As a minimum the conductivity of the water from the deionizing units should bechecked at start>up and every hour. Preferably, automatic controls should be usedto shut off the system when a preset level of conductivity is exceeded. Records ofeach regeneration should be kept and the number of gallons produced per cyclerecorded.

c. Maintenance of Filters

The manufacturer's service and maintenance guidelines should be followed whenservicing filters. Particulate filters should be changed regularly (cartridge type) orbackflushed (sand, or mixed>media) to reduce particulate matter and ensure ahigh clarity water. All backwash should be done with finished product water. Aturbidity of 0.1 NTU or less is highly desirable. When carbon filters are used fortaste and odor control, the bed must be backwashed regularly to dislodgetrapped particulates and reverse carbon compaction. Sanitation of carbon bedswith chlorine is not recommended. Such a procedure could result in possiblerelease of chlorinated organics into the product water. Backflushing regularly issufficient.

After performing maintenance on a particulate filter, test for filter performanceand measure the pressure drop across the filter. The quality of the product watershould be tested by measuring turbidity, total suspended solids (TSS), andheterotrophic plate count.

d. Maintenance of UV Systems

Only ultraviolet light systems of the class A type, as approved by NSF underStandard 55, are acceptable to DEP. The operation, maintenance and installationof these units must follow the recommendations outlined in that standard. Theultraviolet lamps should warm up for at least five minutes before allowing theiruse in treating water. The following routine maintenance is recommended for UVdisinfection systems:

(1) The quartz jacket of the lamp should be wiped at least once a month;

(2) Lamps should be replaced when the intensity meter indicates less than50!percent of the rated lamp intensity;

(3) Check UV intensity of 253.7 nm daily;

(4) Check accuracy of intensity meter monthly.

e. Maintenance of Reverse Osmosis (RO) Units

(1) Fouling of Membrane

RO units should be preceded by one micron particulate filters. For water frommunicipal sources, a polishing filter usually is sufficient. Pretreatment of feedwater is essential to prevent membrane fouling. For cellulose acetatemembranes, an acid feed often is required to prevent the formation ofcarbonate scale. For hard feed water, a water softener or a polyphosphatefeed which keeps the hardness minerals from precipitating out of themembrane may be used. It is advisable to periodically flush the system with adetergent solution to remove builtup solids.


(2) Temperature of Feed Water

RO units are temperature>sensitive. Since membranes will degrade muchmore quickly at elevated temperatures, water temperature must be kept at2∞C to 35∞C for cellulose acetate and polyamide, 2∞C to 30∞C for cellulosetriacetate, and 2∞C to 45∞C for thin film composite. However, lowering feedwater temperature dramatically reduces the production rate of productwater. As a rule of thumb, a 2∞C reduction in water temperature reduces theflow of product water by three percent.

(3) Pressures

RO units are very pressure sensitive. It is very important to maintain designpressure drop because a reduction in this operating variable not only reducesproduction but also allows more salt passage. Back pressure can build up as aresult of deliberate throttling, causing the same effect of increased saltpassage. Control of transmembrane pressure is critical to optimumperformance.

(4) Monitoring RO System

To maintain a consistent quality of product water, an RO system must becarefully monitored. Records of hourly measurements are recommended forpH, feed water temperature, feed water TDS, chlorine, product TDS, pumppressure, product flow, brine flow, polyphosphate feed (if used), and softenerrecords (if used).

1.4.2 Equipment Maintenance

All tanks, pipelines, and equipment used to store, handle, and transport water must beinspected, maintained, cleaned, and sanitized (see Section 3.3 for storage tanks).

1.4.3 Containers

a. Multiservice containers (i.e.,!containers which are intended by the bottler formore than one use) shall be adequately cleaned, sanitized, and inspected justprior to being filled, capped and sealed. Containers found to be unsanitary ordefective by the inspection are to be reprocessed or discarded. All multiservicecontainers shall be washed, rinsed, and sanitized by mechanical washers or byother methods giving adequate sanitary results. Mechanical washers should beinspected as often as is necessary to assure adequate performance. Records ofphysical maintenance, inspections and conditions found, and performance of themechanical washer are to be maintained by the plant operators.

b. Multiservice shipping cases (i.e.,!shipping cases which are intended by the bottlerfor more than one use) should be maintained in such condition as to assure theywill not contaminate the primary container or the product water. Adequate dry orwet cleaning procedures should be performed as often as necessary to maintainthe cases in satisfactory condition.

1.4.4 Cleaning and Sanitizing Solutions

Cleaning and sanitizing solutions utilized by the plant shall be sampled and tested by theplant at least daily to assure adequate performance in the cleaning and sanitizingoperations. Records of these tests are to be maintained by the plant operators.


1.4.5 Cleaning and Sanitizing Bottling Room

The bottling room must be thoroughly cleaned and sanitized daily. Upon completionthere should be no dust, grease, or oil film on the exterior of the processing equipment.

At the finish of each daily bottling run, bottle caps should be removed from the capper,cap bowl, and bin and placed into a sealed container. Caps only should be handled bypersons wearing sterile gloves or with clean hands sanitized with a disinfectant.

At the end of each day's operation, the filling room should be cleaned as follows:

a. Brush off dust and debris from conveyor;

b. Sweep floor and remove all unnecessary items, such as unfilled bottles and bottlecrates;

c. Use detergent solution to wash frames on fillers and capper. Rinse with productwater;

d. Scrub floor (and walls if needed) with detergent solution and nylon brush. Hosedown entire floor and walls;

e. Clean floor drain;

f. Clean all windows and window sills inside and outside of the filling rooms;

g. Carefully wipe off electrical panels, light fixtures, and other surfaces not directlyhoseable with a damp cloth. This includes top of filler, nozzle hoses, air hoses,!etc.,because vibration of operating conveyor, filler or capper can knock loose dust intoproduct.

Before the start of bottling, the filler room should be sanitized each day. Bottling linesand the interiors of filler nozzles should be sanitized with ozonated water of at least0.1!ppm or preferably > 0.35 ppm, or chlorine solution of about 50 ppm.

1.4.6 Sanitizing Operations

a. Sanitizing Bottles

Sanitizing operations must be adequate to effectively sanitize the product water>contact surfaces and any other critical area. Plant operators are to maintain arecord of the strength of the sanitizing solution and the time the agent was incontact with the surface being sanitized. The following times and strengths areconsidered a minimum:

(1) Steam in enclosed system > At least 170∞F for no less than 15 minutes or at least200∞F for no less than five minutes;

(2) Hot water in enclosed system > At least 170∞F for no less than 15 minutes or atleast 200∞F for no less than five minutes;

(3) Chemical sanitizers shall be equivalent in bactericidal action to a two>minuteexposure of 50!ppm of available chlorine at 57∞F when used as an immersionor circulating solution. Chemical sanitizers applied as a spray or fog shall haveas a minimum 100!ppm of available chlorine at 57∞F or its equivalent inbactericidal action;


(4) 0.1 ppm ozone water solution in an enclosed system for at least five minutes.

b. Sanitizing Capper, Bottle Shield and Filler Spout

Capper, chute, filler spouts, and bottle shields should be sanitized with 200!ppmchlorine. The following procedures should be performed immediately beforebottling:

(1) Capper > Moisten sponge with sanitizing solution and apply to all surfaces ofthe capper coming into contact with caps;

(2) Capper Chute > Moisten sponge in sanitizing solution and apply to insidesurfaces of chute;

(3) Filler Spouts > Moisten sponge with sanitizing solution and apply to all outsidesurfaces of spouts;

(4) Bottled Shields > Moisten sponge with sanitizing solution and apply tounderside surfaces of shields. Remove corrosion or foreign material if found;

c. Sanitizing Floor of Bottling Room

Bottling room should be sanitized every night as the last step in cleaning bottlingroom. The following procedure is recommended:

(1) Materials > Tank>type sprayer with 200!ppm chlorine.

(2) Procedure > After normal cleaning, spray entire floor with fine mist of chlorinespray. Do not rinse chlorine>sanitized floor.

1.4.7 Filling, Capping, or Sealing

During the process of filling, capping or sealing either single>service or multiservicecontainers, the performance of the filler, capper or sealer is to be monitored. Filledcontainers are to be visually or electronically inspected to assure that they are sound,properly capped or sealed, coded and labeled. Containers which are not satisfactoryshall be reprocessed or rejected. Fillers must be kept free from scale, evidence ofoxidation and residue, and are to be sanitized on a daily basis using the cleaning andsanitizing procedures specified in 3.3A.2 under Appendix!A of this part of the manual.The filler reservoir shall be kept covered at all times.

In accordance with filler manufacturer's instructions, any parts which are not designedto be cleaned in>place should be disassembled and removed. All of these parts are to becleansed and sanitized prior to reassembly using appropriate cleansing and sanitizingprocedures,as specified in 1.4.6a above.

All surfaces of the filler which do not contact water are to be cleaned manually so as torender all surfaces clean and free of any residues.

The filler should be prepared and all appropriate connections made in accordance withthe filler manufacturer's instructions to place the filler in the clean>in>place mode. Toprepare the filler, the following procedures should be followed:

a. An alkaline cleaning solution of appropriate strength should be recirculatedthrough the filler to provide effective cleaning of all product contact surfaces,with minimum recirculation time of 20 minutes at a temperature between140∞F!and 170∞ F;


b. The cleaning solution must be drained and followed with a product water rinse>to>drain for the removal of all residual cleaner. This step may be preceded by theapplication of an acidified rinse prior to the product water rinse in order toneutralize any residual alkalinity on the water contact surfaces.

Following reassembly of all parts, the filler is to be sanitized in>place inaccordance with procedures specified in 1.4.6a.

1.4.8 Quality Assurance Procedures

To assure that the plants production of bottled drinking water is in compliance withDEP's requirements, the plant should conduct the following tests. All tests must beperformed by laboratories certified by the DEP.

Test for microbiological contaminants weekly and for all other primary maximumcontaminant levels annually. Where a surface source is used, plants shall monitor forturbidity every four hours. Source water from other than a public water system shouldbe analyzed for VOCs and unregulated contaminants annually. Systems which fluoridateshall conduct operational monitoring for fluoride at least once each day. At least onceeach three months, a bacteriological swab and/or rinse count should be made from noless than four containers and closures selected just prior to filling and sealing. Three ofthe four samples should not exceed more than one bacteria per milliliter of containercapacity and not over one colony per square centimeter of closure area, and should befree of coliform organisms.

1.4.9 Packaging Processes

Packaging processes and materials shall not transmit contaminants or deleterioussubstances to the bottled water and shall conform to the applicable food additiveregulations in CFR Title 21 and NSF Standard 61.

a. Containers and closures for bottled water must be manufactured from approvedmaterials.

b. Only sanitary, nontoxic lubricants shall be used on container contact surfaces.

1.4.10 Storage Facilities

Clean, dry storage facilities must be provided for containers, closure materials, paper forwrapping, adhesives and other production materials to prevent contamination. Thematerials are to be stored on pallets above the floor and away from any wall to facilitatecleaning.

1.5 Personnel

The plant management shall take all reasonable measures and precautions to assure thefollowing:

A. Cleanliness > All persons, while working on bottled water preparation facilities orequipment which manufactures and packages bottled water should:

1. Wear clean outer garments and maintain a high degree of personal cleanlinesswhile on duty;

2. Wash their hands thoroughly in a proper hand>washing facility before startingwork, after each absence from the work station, and at any other time when the


hands may have become soiled or contaminated. Hands are to be sanitized atfrequent intervals using a sponge saturated with an approved sanitizing solutionor by immersing the hands in the solution at capping, packing and faucetinstallation stations;

3. Remove all insecure jewelry and, during periods where the process is manipulatedby hand, remove from hands any jewelry that cannot be adequately sanitized;

4. If gloves are used, maintain them in an intact, clean and sanitary condition. Suchgloves should be of an impermeable material except where their usage would beinappropriate or incompatible with the work involved;

5. Wear hair nets, headbands, caps, or other effective hair restraints;

6. Not store clothing or other personal belongings, or drink beverages in areaswhere the bottled water product is exposed or in areas used for washingequipment or utensils;

7. Consume food only in designated dining areas. Areas where product waterutensils or manufacturing equipment are stored shall not be designated as adining area;

8. Not use tobacco in any form during production. Employees are to use tobaccoonly in designated areas. An employee tobacco>use area shall not be designatedfor that purpose if the use of tobacco may result in contamination of productwater, equipment utensils, or other items needing protection;

9. Take any other necessary precautions to prevent contamination of the productwater with microorganisms or foreign substances including, but not limited to,perspiration, cosmetics, chemicals or medicines.

B. Disease Control > No person affected by disease of a communicable form, or whileaffected with boils, sores, infected wounds, or other abnormal sources ofmicrobiological contamination, shall be permitted to work in a bottled water plant.

C. Education and Training > Personnel responsible for identifying sanitation failures orproduct contamination should have sufficient background education or experience, orcombination thereof, to provide a level of competency necessary for overseeing theproduction of safe bottled drinking water. Workers and supervisors should receiveappropriate training in proper operating techniques and bottled water protectionprinciples. The international Bottled Water Association©s ™Technical Training Course™ orits equivalent is an example of acceptable basic course for this requirement. This courseshould be taken at least annually.

D. Supervision > Responsibility for assuring compliance by all personnel with therequirements of this part should be assigned to competent supervisory personnel. Thisperson should receive appropriate training for this purpose.

E. Activities > Activities unrelated to the bottling process such as sleeping, eating, etc. areprohibited in all working and storage areas.

F. Sanitizing Hands > It is essential for workers to keep hands clean and sanitized whenworking on the ™clean™ side of the bottling plant. Hand>washing facilities should beconveniently located in the bottling area. If no hand>washing stations are convenient,dip stations or sanitizers should be provided.


PART III


OPERATION AND MAINTENANCE STANDARDS FOR VENDED WATER SYSTEMS

2.0 General

The purpose of this chapter is to provide standards for the operation and maintenance ofdrinking water vending machines. This information has been taken in part from standardsestablished by the National Automatic Merchandising Association (NAMA) and NSF. Readersalso are referred to Part V of DEP's Public Water Supply Manual for additional operation andmaintenance standards which may apply to their system.

2.1 Machine Location

A. Drinking water vending machines are to be located in a room, area or space which canbe maintained in a clean condition. The immediate area in which the equipment islocated is to be well lighted and ventilated. In addition, the counter or floor where themachines are located must be smooth, of cleanable construction, and be capable ofwithstanding repeated washing and scrubbing.

B. Each machine is to be located so that the space around and under the machine can beeasily cleaned and maintained.

2.2 Employee Training

The owners/operators of drinking water vending machines must provide competent andproperly>trained staff to oversee the operation and routine maintenance of the machines.Personnel are to be trained in the specific types of processes and equipment used in theirmachines. Those individuals operating reverse osmosis filters, deionization units, or wherechemicals are added to the water are to receive specific training on the operation of thesesystems.

2.3 Operations and Maintenance Plan

Each vended water system must develop an Operations and Maintenance (O & M) Plan, whichincludes a testing program covering the routine servicing of each water vending machine(WVM). Copies of the service manuals containing cleaning and sanitization procedures, fieldtesting procedures, component replacement schedules and component servicing instructionsare to be included in the O & M Plan. In addition, the O & M Plan should contain at least thefollowing information:

A. A description of the treatment processes used in each machine as identified by theirmodel number;

B. A detailed explanation of the system's normal operation procedures;

C. Information on the frequency and procedures for maintaining and cleaning themachine;

D. Staffing and training;

E. Records and reporting system;

F. Safety program and emergency response plan;


G. Manufacturer's manuals.

The O & M Plan should be reviewed and updated at least yearly and revised to reflectchanges in the operation and maintenance of the machines. The plan should be boundand placed in locations which are readily accessible to the vending water system'spersonnel, and must be presented upon request to DEP.

2.4 Service and Maintenance

At every service, inspect all interior parts and surfaces of the water vending machine inaccordance with the service manual. The vending stage and dispensing nozzle must bethoroughly cleaned and sanitized each time the machine is serviced. All exterior surfaces are tobe well maintained and visibly clean. A record of all cleaning and maintenance operations shallbe kept by the operator for each water vending machine and is to be available for inspectionupon request. A copy of the cleaning and servicing records should be kept inside each machine.

A. Maintenance Schedule

The following guidelines are recommended minimums. However, cleaning will varydepending on local water conditions and the amount of water produced. Each watervending machine must be maintained individually in accordance with its own particularlocation requirements. At every service:

1. General Internal Cleaning

a. Thoroughly inspect all inside surfaces of the machine to be sure they are clean.

b. Wash, rinse and sanitize the dispensing nozzle. Clean the vending stagethoroughly; then wash, rinse and sanitize the stage.

2. Check Operational Parameters

a. Check all lines for leaks.

b. Check dates of all replaceable components in conformation with change>outschedule and replace outdated and/or used up components. These wouldinclude the following items: coarse prefilter(s), carbon filter(s) or block(s), ROand DI systems (if applicable), and UV light intensity. Follow themanufacturerπs instructions to replace, as needed, indicated by but notlimited to change in vended water quality, flow rate, pressure or as scheduledaccording to their individual rated capacities, etc.

c. Check the finished product water storage tank, if applicable. Follow themanufacturer's cleaning and servicing instruction.

d. Cycle the drinking and/or purified water and check volume and applicablephysical parameters. Record the reports on the operating report.

3. General External Cleaning

a. Clean the outside surface of the machines with a safe, nontoxic industrialcleaner. Follow the manufacturer's instructions.


2.5 Sampling

NAMA approved machines connected to an approved community water system are eligible fora permit>by>rule. For such permitted machines, the vended water from each machine shall bemonitored for total coliforms once every month. In addition, the vended water system shallsample the vended water for lead, cadmium and total dissolved solids (TDS) annually.

For non>NAMA approved machines or machines connected to an unapproved communitywater system, the vended water from each machine shall be monitored for total coliforms onceevery week. In addition, each year the vended water system shall sample the vended waterfrom one>third of the system's water vending machines for all primary MCLs so that allmachines are sampled once every three years. All water analyses must be done by a laboratorycertified by DEP.

Any water vending machine having a water sample which exceeds an MCL for any parameter isto be taken out of use until it is serviced and subsequent check samples indicate a level belowthe MCL.

A more frequent analysis of the above should be done by the water vending machine system ifthere is concern that the vended water is being affected by contaminants in the source water.

Samples for analysis should be collected by laboratory personnel or individuals who have beentrained in proper collection techniques. To simulate actual dispensing conditions, noextraordinary flushing should be conducted prior to the collection of the samples. Any watervending machine having a positive>coliform water sample shall be taken out of service until it iscompletely serviced and all water contact parts are sanitized. An additional sample withacceptable results is to be obtained prior to placing the machine in service.

Vending machines utilizing silver>impregnated carbon filters in the treatment process shouldbe tested for silver at least once every six months. Any water vending machine having a samplewhich exceeds 0.05 mg/L of silver is to be taken out of use until it is serviced and subsequentsamples for silver are below this standard.


PART III


OPERATION AND MAINTENANCE STANDARDS FOR BULK WATER HAULERS

3.0 General

The purpose of this section is to provide basic information on the operation and maintenanceprocedures for bulk water hauling systems. Information for this section has been taken in partfrom the Pennsylvania Department of Agriculture standards. Readers also should refer toPart!V of DEP's Public Water Supply Manual for additional information on the operation andmaintenance requirements that apply to public water supply systems.

3.1 Operations

Tank trucks, loading and unloading facilities, and other equipment used to transport bulkwater are to be maintained clean and sanitary at all times. Tanks previously used to transporttoxic materials, petroleum products, or other deleterious substances shall not be used to hauldrinking water.

3.2 Records

A. Daily records are to be maintained for each vessel which include the number of gallonsdelivered and all cleansing and sanitizing or sanitizing activities conducted on the tanktruck exterior, interior, risers, connections, pumps, hoses, etc.

B. Such records shall include date, time and location of pickup or delivery, concentration ofresidual disinfection, and the results of any other water quality analysis which areconducted.

3.3 Storage Tanks

There should be ample room around a tank for inspection and maintenance. Bulk waterstorage tanks used to transport and store water shall be inspected, maintained, cleaned andsanitized according to the following guidelines:

A. Storage Tanks

1. Storage tanks should be inspected for cleanliness on a monthly basis and shall bekept free of scale, evidence of oxidation, and residue.

2. Storage tanks also should be cleaned on a monthly basis by sanitizing with one ofthe following:

(a) Chlorine water solution of 200 ppm for a minimum of five minutes;

(b) Spray wet surface with 200 ppm chlorine water solution. This is to be used onsurfaces that are not reached by the above soaking treatment;

(c) 0.1 ppm ozone water solution for not less than 10!minutes contact time;

(d) Flushing with product water for at least 30 minutes.


B. Maintaining Tanks

Tanks for water transport or storage must be maintained in good repair and regularlysanitized to prevent microbiological contamination of the water. Before entering a tankto work on the interior surfaces, the following precautions are to be taken:

1. Notify a foreman or other responsible employee that tank is out>of>service andwork is being performed inside it;

2. Lock all valves to the tank;

3. Verify that tank is free of water, air pressure, and vacuum;

4. When using an electrical cord with light, cord must be waterproof with noinsulation breaks, properly grounded and have a shielded bulb;

5. Set up a small forced>draft blower outside the tank to blow air into the tank via aflexible duct. The suction of blower should be placed so that exhausted air fromthe tank will not be recirculated into the tank.

C. Cleaning/Sanitizing Tanks

The following steps are necessary for cleaning tanks:

1. Isolate tank from other tanks and lines by closing valves. Inspect valves fortightness and leaks;

2. Carry out safety precautions as outlined in Section!B;

3. Remove, clean, and re>install air filter and vent piping;

4. Add approximately 50!gallons of 100 to 200!ppm chlorine solution on to the tank.If done by spray, allow 15 to 20!minutes contact time;

5. If wrench is used for removing spray heads, be careful not to drop the wrench.Tank linings are thin, delicate coverings and are easily broken by a droppedwrench;

6. Rubber boots may be worn only after washing them in 200 to 400!ppm chlorinesolution. Be sure that no dirt is on the soles of the boots;

7. Inspect linings and fittings;

8. Remove and clean spray heads, if present;

9. Sanitize sight glass or plastic tube by pumping chlorine solution upward throughit. If tube needs scrubbing, remove it for cleaning, sanitizing, and rinsing withdisinfected product water;

10. In all tanks, always start at the highest point so that ™dirt'' doesn't fall on to areasalready scrubbed. For horizontal tanks, start scrubbing at the top of the inside endpanel, dipping the brush into the chlorine solution frequently. For vertical tanks,start scrubbing at top;

11. Scrub manhole cover and gasket (replace and seal, if spray system is used);

12. Drain scrubbing solution from tank;


13. Rinse with 100 ppm chlorinated water followed by rinse with product water. Uselightly chlorinated product water (0.2 to 0.5!ppm) if this water is to be stored inthe tank. Rinse until test shows the tank to be clean and free of impurities;

14. Close all drains;

15. Put tank into use, or alternatively for distilled water tanks, add about 1/6 tank ofwater;

For purified water, frequency of tank cleaning may be reduced by ozonating atnight once each one to two days as long as tank is made of stainless steel or othermaterial resistant to ozone oxidation. In this way, bacteria growth may becontrolled in water storage tanks over long periods.

D. Cleaning Tank Air Vent Filters

Storage tank air filters should be dismantled, cleaned, and sanitized, or the elementreplaced each time the tank is scrubbed. Each time the filter is removed, clean filterpiping by dismantling.

3.4 Bulk Transport and Transfer Procedures

3.4.1 Sanitation

a. Prior to filling, tank interior should be cleaned, flushed with potable water,sanitized with not less than 100 ppm chlorine water solution for a contact periodof not less than 20 minutes, and rinsed with potable water. The dome cover shallbe closed immediately after cleaning.

b. Tanks used for the transport of dairy products must have the interior of the tankinspected with a black lamp (ultraviolet) after cleaning and flushing as outlined in3.4.1a above. Tanks shall be rejected for use when odors or contaminants arefound or suspected.

c, All hoses, connections, and fittings shall be sanitized with a concentrated solutionof chlorine (three ounces of 5>1/4!percent household bleach to two gallons ofwater) by brushing solution on all exposed parts.

3.4.2 Fluid Transfer

a. Tank trucks or tank trailers should be filled through the fitting on the inner domecover when the tail pipe cannot be used.

b. Water quality in the tank, after 20 to 30!gallons have been delivered into thetank, should be checked as follows:

(1) Stop filling;

(2) Open discharge valve;

(3) Inspect water as it discharges. If water has unpleasant odor and/or looks dirty,it shall be rejected for use;

(4) Check disinfectant residual.

c. When these checks indicate satisfactory water quality, proceed to fill the tank.


d. The dome cover shall be closed and sealed after filling to volume desired.

e. The tank discharge valve cover shall be closed and sealed after filling.


PART III


OPERATION AND MAINTENANCE STANDARDS FOR RETAIL WATER FACILITIES

4.0 General

The purpose of this chapter is to provide basic guidelines on the operation and maintenance ofretail water facilities. This information has been taken in part, from standards established bythe Food and Drug Administration under 21 CFR Part!129 (processing and bottling of bottleddrinking water) and NSF International (NSF). Readers also are referred to Part V of DEP's PublicWater Supply Manual for additional operation and maintenance standards which may apply totheir system.

4.1 Records

The following are the types of records that should be maintained at a retail water facility.

4.1.1 Facility and Equipment

All design drawings, specifications and all construction documents should be retained ina safe location for the life of the facility regardless of any changes. Detailed records as tothe manufacturer, make, model and date installed for each piece of equipment and thepersons installing the equipment also should be retained. Repairs of any kind also shouldbe recorded.

4.1.2 Operation

Records should be maintained of all inspections, cleaning and sanitizing activities whichshould include the names of the persons involved, date, time, and the results of theinspection or activity. These records should be maintained for at least three years.Sanitary surveys conducted on the source(s) of raw water should be retained for not lessthan 10 years.

Water quality analysis data for each source, each product and any intermediate samplesalso are to be retained. Bacteriological and turbidity analysis data are to be retained forat least five years; chemical, radiological and organic analysis data are to be retained forat least 10!years. All water quality analyses data should clearly indicate which tests weredone in>house and which were done by DEP approved laboratories. In addition toidentifying the person(s) conducting the tests, the laboratory procedure or techniqueused should be recorded.

4.1.3 Chemicals

Accurate records are to be kept on all types of chemicals used in the facility, when andfrom whom purchased, and where and how stored. Where hazardous or toxic chemicalsare involved, it is recommended that access be restricted to essential personnel and thatdetailed records be retained on their purchase and use. Daily records on the amount ofeach chemical used should be kept and retained for at least two years.

4.1.4 Personnel

Retail water facilities should maintain up>to>date records for each of their employees.Records should include the employeeπs name, address, telephone number and otherpertinent background information. These records should be retained for at least fiveyears.


4.1.5 Emergency Response

A critical element in the operation of any drinking water system is the ability to respondto an emergency situation. For that reason, it is very important that the owners andoperators maintain accurate and up>to>date records on the names, addresses, telephonenumbers and responsibilities of each individual employed. Emergency response plansshould be updated at least annually. Detailed instructions on how to implement aproduct recall and initiate public notification should be provided in the emergencyresponse plan.

4.2 Buildings and Grounds

Buildings, fixtures, and other physical facilities must be kept in good repair and are to bemaintained in a sanitary condition. Cleaning operations should be conducted in such a manneras to minimize the danger of contamination of product contact surfaces. Only materialsrequired for the proper operation and maintenance of the facility and equipment are to bestored in the facility. These materials shall be properly identified and stored in a safe manner.

4.2.1 Buildings

a. Buildings must be vermin>proof and kept in good repair. Only pesticides approvedfor use by the Food and Drug Administration and/or registered with the U.S.Environmental Protection Agency shall be used for vermin control.

b. Walls and ceilings in the facility must be kept clean. Overhead structures, fixtures,and ducts are to be kept free from accumulations of dust and other contaminants.

c. Floors are to be kept clean and free of waste, litter, and extraneous material.Floors in the filling areas should be cleaned daily and sanitized with a 200 ppmchlorine solution.

d. Doors and windows must be kept clean and in good repair.

e. Ventilation equipment should not create conditions that may contribute toproduct contamination by airborne contaminants and must be kept free ofaccumulation of dust and grease.

f. Storage facilities must be kept clean and dry, and provide protection from splash,insects, dust, and other contaminants.

g. All refuse must be stored in properly identified, covered containers.

4.2.2 Grounds

The grounds about a retail water facility under the control of the operator must be keptfree from conditions which may result in the contamination of the product water ormanufacturing facilities. This is to be achieved by:

a. Prompt elimination from within the immediate vicinity of the facility buildings ofany litter, waste or refuse that may attract or provide a breeding place orharborage for rodents, insects and other pests.

b. Adequately draining areas that may otherwise cause contamination throughseepage or by providing a breeding place for insects or microorganisms.


4.3 Sanitary Operations

4.3.1 Whenever air under pressure is directed at product water or a product water>contactsurface, it must be free of oil, dust, rust, excessive moisture, and extraneous materials.

4.3.2 Containers and caps or seals shall be stored in sanitary closures and kept clean and dryuntil used. Prior to use they must be examined and as necessary, washed, rinsed, andsanitized.

4.3.3 Filling, capping, closing, sealing, and packaging of containers shall be done in a sanitarymanner to preclude contamination of the retail drinking water.

4.4 Processes and Controls

4.4.1 Treatment of Product Water

The treatment of retail water by distillation, ion>exchange filtration, ultraviolettreatment, reverse osmosis, or any other process shall be done in a manner to achievethe optimum level of treatment. All facilities and treatment processes approved bypermit from DEP shall be operated and maintained in accordance with DEP©s rules andregulations. Chemicals approved under NSFπs Standard!60 are accepted. Product watersamples shall be taken and analyzed as often as necessary to assure uniformity andeffectiveness of the treatment processes.

4.4.2 Equipment Maintenance

All tanks, pipelines, and equipment used to store and handle water must be inspected,maintained, cleaned, and sanitized (see Section 3.3 for Storage Tanks).

4.4.3 Containers and Washing Equipment

Containers shall be adequately cleaned, sanitized, and inspected just prior to beingfilled, capped and sealed. Containers found to be unsanitary or defective by theinspection are to be reprocessed or discarded. All multiservice containers shall bewashed, rinsed, and sanitized by mechanical washers or by other methods givingadequate sanitary results. Mechanical washers should be inspected as often as necessaryto assure adequate performance. Records of physical maintenance, inspections andconditions found, and performance of the mechanical washers are to be maintained bythe plant operators.

4.4.4 Cleaning and Sanitizing Solutions

Cleaning and sanitizing solutions utilized by the facility shall be tested by the plant atleast daily to assure adequate performance in the cleaning and sanitizing operations.Records of these tests are to be maintained by the facility operators.

4.4.5 Cleaning and Sanitizing Bottling Area

The bottling area must be thoroughly cleaned and sanitized daily. Upon completionthere should be no dust, grease, or oil film on the exterior of the processing equipment.

4.4.6 Sanitizing Operations

a. Sanitizing Containers

Sanitizing operations must be adequate to effectively sanitize the product water>contact surfaces and any other critical area. Facility operators are to maintain a


record of the strength of the sanitizing solution and the time the agent was incontact with the surface being sanitized. The following criteria are consideredminimums:

(1) Steam in enclosed system > At least 170∞F for no less than 15 minutes or at least200∞F for no less than five minutes;

(2) Hot water in enclosed system > At least 170∞F for no less 15 minutes or at least200∞F for no less than five minutes;

(3) Chemical sanitizers shall be equivalent in bactericidal action to a two>minuteexposure of 50!ppm of available chlorine at 57∞F when used as an immersionor circulating solution. Chemical sanitizers applied as a spray or fog shall haveas a minimum 100!ppm of available chlorine at 57∞F or its equivalent inbactericidal action;

(4) 0.1!ppm ozone water solution in an enclosed system for five minutes.

b. Sanitizing Capper, Bottle Shield and Filler Spout

Capper, capper chute, filler spouts, and bottle shields should be sanitized with200!ppm chlorine. The following procedures should be performed immediatelybefore bottling:

(1) Capper > Moisten sponge with sanitizing solution and apply to all surfaces ofthe capper coming into contact with caps;

(2) Capper Chute > Moisten sponge in sanitizing solution and apply sponge toinside surfaces of chute;

(3) Filler Spouts > Moisten sponge with sanitizing solution and apply to all outsidesurfaces of spouts;

(4) Bottle Shields > Moisten sponge with sanitizing solution and apply tounderside surfaces of shields. Remove corrosion or foreign matter if found.

c. Sanitizing Floor of Filling Area

Filling area should be sanitized every night as the last step in cleaning bottlingarea. The following procedure is recommended:

(1) Materials > Tank>type sprayer with 200 ppm chlorine;

(2) Procedure > After normal cleaning, spray entire floor with fine mist of chlorinespray. Do not rinse chlorine>sanitized floor.

4.4.7 Filling, Capping, or Sealing

During the process of filling, capping or sealing containers, the performance of the filler,capper or sealer is to be monitored. Filled containers are to be visually or electronicallyinspected to assure they are sound, properly capped or sealed, coded and labeled.Containers which are not satisfactory shall be reprocessed or rejected. Fillers must bekept free from scale and evidence of oxidation and residue, and are to be sanitized on adaily basis using the cleaning and sanitizing procedures specified in Section!4.4.6a. Thefiller reservoir shall be kept covered at all times.


In accordance with filler manufacturer's instructions, any parts which are not designedto be cleaned in>place should be disassembled and removed. All of these parts are to becleansed and sanitized prior to reassembly using appropriate cleansing and sanitizingprocedures, as specified in Section!4.4.6a.

All surfaces of the filler which do not contact water are to be cleaned manually to renderall surfaces clean and free of any residues.

The filler should be prepared and all appropriate connections made in accordance withthe filler manufacturer's instructions to place the filler in the clean>in>place mode. Toprepare the filler, the following procedures should be followed:

a. An alkaline cleaning solution of appropriate strength should be recirculatedthrough the filler to provide effective cleaning of all product contact surfaces,with minimum recirculation time of 20 minutes at a temperature between 140∞Fand 170∞F;

b. The cleaning solution must be drained and followed with a product water rinse>to>drain for the removal of all residual cleaner. This step may be preceded by theapplication of an acidified rinse prior to the product water rinse in order toneutralize any residual alkalinity on the water contact surfaces.

Following reassembly of all parts, the filler is to be sanitized in>place in accordance withprocedures specified in Section!4.4.6a.

4.4.8 Quality Assurance Procedures

To assure that the production of retail drinking water is in compliance with DEP'srequirements, the facility should conduct the following tests. All tests must beperformed by laboratories certified by the DEP.

a. Test for microbiological contaminants weekly and for all other primary maximumcontaminant levels annually. Source water from other than a public water systemshould be analyzed for VOCs and unregulated contaminants annually. Facilitieswhich fluoridate shall conduct operational monitoring for fluoride at least onceeach day. At least once each three months, a bacteriological swab and/or rinsecount should be made from no less than four containers and closures selected justprior to filling and sealing. Three of the four samples should not exceed morethan one bacteria per milliliter of container capacity and not over one colony persquare centimeter of closure area, and should be free of coliform organisms.

4.4.9 Packaging

Packaging processes and materials shall not transmit contaminants or deleterioussubstances to the bottled water and shall conform to the applicable food additiveregulations in CFR Title 21 and NSF Standard 61.

a. Containers and closures for retail water must be manufactured from approvedmaterials.

b. Only sanitary, nontoxic lubricants shall be used on container contact surfaces.

4.4.10 Storage Facilities

Clean, dry storage facilities must be provided for containers, closure materials, paper forwrapping, adhesives and other production materials to prevent contamination. The


materials are to be stored on pallets above the floor and away from any wall to facilitatecleaning.

4.5 Personnel

The facility management shall take all reasonable measures and precautions to assure thefollowing:

A. Cleanliness > All persons while working on retail water preparation facilities orequipment which manufactures and packages retail drinking water should:

1. Wear clean outer garments and maintain a high degree of personal cleanlinesswhile on duty;

2. Wash their hands thoroughly in a proper hand>washing facility before startingwork, after each absence from the work station, and at any other time when thehands may have become soiled or contaminated;

3. Remove all jewelry;

4. Maintain gloves, if used, in an intact, clean and sanitary condition. Such glovesshould be of an impermeable material except where their usage would beinappropriate or incompatible with the work involved;

5. Wear hair nets, headbands, caps, or other effective hair restraints;

6. Consume food only in designated dining areas. Areas where product waterutensils or manufacturing equipment are stored shall not be designated as adining area;

7. Not use tobacco in any form during production. Employees are to use tobaccoonly in designated areas. An employee tobacco>use area shall not be designatedfor that purpose if the use of tobacco may result in contamination of productwater, equipment, utensils, or other items needing protection;

8. Take any other necessary precautions to prevent contamination of the productwater with microorganisms or foreign substances including, but not limited to,perspiration, cosmetics, chemicals or medicines.

B. Disease Control > No person affected by disease of a communicable form, or whileaffected with boils, sores, infected wounds, or other abnormal sources ofmicrobiological contamination, shall be permitted to work in a retail water facility.

C. Education and Training > The owners/operators of retail water facilities must providecompetent and properly trained staff to oversee the operation and routine maintenanceof the facility. Personnel are to be trained in the specific types of processes andequipment used in their facilities. Those individuals operating reverse osmosis filters,deionization units, or where chemicals are added to the water are to receive specifictraining on the operation of these systems.

D. Sanitizing Hands > It is essential for workers to keep hands clean when working on"clean'' side of the facility. Hand>washing facilities should be conveniently located in thebottling area. If no hand>washing stations are convenient, dip stations or sanitizershould be provided.


4.6 Operations and Maintenance Plan

Each retail water facility must develop an Operations and Maintenance (O & M) Plan whichincludes a testing program covering the routine servicing of each treatment unit. Copies of theservice manuals containing cleaning and sanitization procedures, field testing procedures,component replacement schedules and component servicing instructions are to be included inthe 0&M Plan. In addition, the O&M Plan should contain at least the following information:

A. A description of the treatment processes used;

B. A detailed explanation of the facilities normal operation procedures;

C. Information on the frequency and procedures for maintaining and cleaning unitprocess;

D. Staffing and training;

E. Records and reporting system;

F. Safety program and emergency response plan;

G. Manufacturer's manuals.

The O & M Plan should be reviewed and updated at least yearly and revised as necessary toreflect changes in the operation and maintenance of the facility. The plan must be bound andplaced in locations which are readily accessible to the facilityπs personnel, and must bepresented upon request to the department.

4.7 Service and Maintenance

Where water dispensing machines are used, each machine is to be serviced at intervalsspecified by the manufacturer. At each service, all interior parts and surfaces of the machineare to be cleaned and sanitized in accordance with the service manual. All exterior surfaces areto be well>maintained and visibly clean. A record of all cleaning and maintenance operationsshall be kept by the operator for each machine and is to be available for inspection uponrequest.


Commonwealth of Pennsylvania

Department of Environmental Protection

An Equal Opportunity Employer

PART III DESIGN STANDARDS FOR BOTTLED WATER, BULK WATER HAULING

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Transcript of PART III DESIGN STANDARDS FOR BOTTLED WATER, BULK WATER HAULING