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  • Williamtown RAAF Base Sewage Treatment Works

    Operation and Maintenance Manual Spotless P&F Pty Ltd

    01 April 2008

  • Williamtown RAAF Base Sewage Treatment Works Prepared for

    Spotless P&F Pty Ltd Prepared by Maunsell Australia Pty Ltd Level 11, 44 Market Street, Sydney NSW 2000, PO Box Q410, QVB Post Office NSW 1230, Australia T +61 2 8295 3600 F +61 2 9262 5060 www.maunsell.com ABN 20 093 846 925

    01 April 2008

    © Maunsell Australia Pty Ltd 2008 The information contained in this document produced by Maunsell Australia Pty Ltd is solely for the use of the Client identified on the cover sheet for the purpose for which it has been prepared and Maunsell Australia Pty Ltd undertakes no duty to or accepts any responsibility to any third party who may rely upon this document. All rights reserved. No section or element of this document may be removed from this document, reproduced, electronically stored or transmitted in any form without the written permission of Maunsell Australia Pty Ltd.

  • Quality Information Document Williamtown RAAF Base Sewage Treatment Works

    Ref 60025938

    Date 01 April 2008

    Prepared by Brendan Short

    Reviewed by DN Chaudhary

    Revision History

    Authorised Revision Revision Date Details Name/Position Signature

    0 22/11/2007 Draft Luke Opray

    1 01/04/2008 Final Submission Luke Opray

  • Table of Contents Part A - Introduction 1 1.0 Description and Use of this Manual 1

    1.1 General 1 1.2 Other Sources of Information 1 1.3 Work Classification 1 1.4 Subdivision of this Manual 2

    2.0 Purpose of the Sewage Treatment Plant 3 2.1 Operating Goals 3 2.2 Process Reliability 3 2.3 Effective Operation 5

    3.0 STP Upgrade History 6 3.1 General 6 3.2 Original STP 6 3.3 Upgrade Phase 1 6 3.4 Upgrade Phase 2 7 3.5 Upgrade Phase 3 7

    4.0 Description of STP 8 4.1 STP Influent / Effluent 8

    4.1.1 Influent 8 4.1.2 Effluent 9

    4.2 STP Components 9 4.3 General Description of the Plant Processes 9

    Part B - Operation 11 5.0 Inlet Works 11

    5.1 General Description 11 5.2 Operating Goals 11 5.3 Operation 11 5.4 Maintenance 15 5.5 Troubleshooting 16 5.6 Monitoring Performance 16

    6.0 Primary Sedimentation Tanks 17 6.1 General Description 17 6.2 Operating Goals 17 6.3 Operation 18 6.4 Maintenance 18 6.5 Troubleshooting 19 6.6 Monitoring Performance 20

    7.0 Trickling Filters and Humus Tanks 21 7.1 General Description 21 7.2 Operating Goals 21 7.3 Operation 22 7.4 Maintenance 22 7.5 Troubleshooting 23 7.6 Monitoring Performance 25

    Williamtown RAAF Base Sewage Treatment Works 01 April 2008

  • 8.0 Sludge System 26 8.1 Principles of Anaerobic Digestion 26 8.2 General Description 27 8.3 Operating Goals 28 8.4 Operation 29

    8.4.1 Normal Operation 29 8.4.2 Digester Start-up 32

    8.5 Maintenance 33 8.6 Troubleshooting 34 8.7 Monitoring Performance 35

    9.0 Odour Control 37 9.1 General Description 37 9.2 Operating Goals 37 9.3 Operation 37 9.4 Shutdown Procedure for Chemical Dosing Units 39 9.5 Troubleshooting 39

    10.0 Disinfection Facility 40 10.1 General Description 40 10.2 Operating Goals 40 10.3 Operation 40 10.4 Maintenance 41 10.5 Troubleshooting 42 10.6 Monitoring Performance 42

    11.0 Effluent Disposal 43 11.1 General Description 43 11.2 Operating Goals 43 11.3 Maintenance 43 11.4 Troubleshooting 43

    12.0 Instrumentation and Controls 44 12.1 General Description 44 12.2 Electrical Controls 44

    12.2.1 Grit Handling System 44 12.2.2 Screening Facility 44 12.2.3 Hydraulic Booster System 45 12.2.4 Controls 45

    12.3 Maintenance 45 13.0 Monitoring STP Performance 47

    13.1 General Description 47 14.0 Services 49

    14.1 General Description 49 14.2 Maintenance 49

    15.0 Safety Precautions and Hygiene 50 15.1 General Safety Practices 50 15.2 Chlorine 50 15.3 Personal Hygiene 51

    Part C - Maintenance Guidelines 52

    Williamtown RAAF Base Sewage Treatment Works 01 April 2008

  • 16.0 Preventive Maintenance 52 16.1 General 52 16.2 Establishment of Programme 52 16.3 Maintenance Schedule 53 16.4 Equipment Categories 56 16.5 Servicing Procedures and Checklists 56 16.6 Records and Cost Accounting 57

    17.0 Repair Maintenance 58 17.1 General 58 17.2 Records and Cost Accounting 58

    18.0 Maintenance Management 59 18.0 Maintenance Management 59

    18.1 Housekeeping 59 18.2 Tools, Spare Parts and Lubricants 59 18.3 Protective Coatings 60

    Appendix A: List of Technical Words 61 Appendix B: Reference Material 64 Appendix C: Drawings 65 Appendix D: Manufacturers Manuals from Upgrade Phase 1* 66 Appendix E: Manufacturers Manuals from Upgrade Phase 2* 67 Appendix F: Manufacturers Manuals from Upgrade Phase 3* 68 Appendix G: Recommended Monitoring Program 69 *refer to Section 3.0 for details on Upgrade Phases

    Williamtown RAAF Base Sewage Treatment Works 01 April 2008

  • Part A - Introduction

    1.0 Description and Use of this Manual Section Outline

    1.1 General

    1.2 Other Sources of Information

    1.3 Work Classification

    1.4 Subdivision of this Manual

    1.1 General This operations manual for the Williamtown Sewage Treatment Plant is subdivided into parts as follows: Part Title A Introduction B Operation C Maintenance Guidelines Appendix A List of Technical Words Appendix B Reference Material Appendix C Drawings Appendix D Manufacturers’ Manuals from Upgrade Phase 1* Appendix E Manufacturers’ Manuals from Upgrade Phase 2* Appendix F Manufacturers’ Manuals from Upgrade Phase 3* Appendix G Recommended Monitoring Program The manual contains information on the function, design and operation of each system and process in the plant, as well as general maintenance guidelines. Equipment records, planned maintenance information and equipment manufacturers instructions are not included. The arrangement of the manual is detailed further in 1.4. A monitoring program recommended as part of a review of the monitoring system undertaken in February, 2008, is included in Appendix G.

    1.2 Other Sources of Information There are a number of sources of information relating specifically to this plant which will help personnel involved in the plant’s operation. They should be used in conjunction with this manual and are listed below: 1. Manufacturer’s Maintenance Guidelines, Volumes 1-3, 1986 2. Contract Specifications, Volumes 1 and 2. 3. Approved Shop Drawings

    1.3 Work Classification The work to be performed at the plant can be divided into the following four categories:

    Williamtown RAAF Base Sewage Treatment Works 01 April 2008 Page 1

  • 1. Operation 2. Housekeeping 3. Preventive Maintenance 4. Corrective Maintenance Operation includes control of the treatment process, minor checking and adjustment of equipment, preparation of reports, and operating records, conducting laboratory control tests, and application of the test results and recorded date to plant functions.

    1.4 Subdivision of this Manual As described in 1.1, this manual is divided into three parts; Part A, B and C. Part A (Introduction) describes the operating manual and lists other information and documentation that may be of assistance to operating and maintenance personnel. It also discusses a philosophy of plant operation. In addition, Part 1 documents the purpose and upgrades history, and describes the sewage treatment plant (STP) processes. Part B (Operation) describes the function, design and operation of each system and process in the plant. Operating personnel should become thoroughly familiar with the information contained in Part B before operating major plant components or systems, particularly the outline of safety precautions. In some instances it may be necessary for an operator to refer to manufacturer’s instructions for additional information on the operation of a particular item of mechanical equipment. Each Chapter in Part B describes a system or process in the plant, divided into sections, with sections being further subdivided into sub-sections. In general, section headings include: 1) General description: A general description of the system and the facilities provided, including

    relevant design information. 2) Operating Goals: The basic functions of the system; the criteria on which operating decisions

    should be based. 3) Operation: A description of how the system operates including procedures to be followed by the

    operator. 4) Maintenance: Routine maintenance, including procedures related to operation and housekeeping

    which should form part of the operating routine. 5) Troubleshooting: A list of possible problems and appropriate remedies. 6) Monitoring Performance: Method of sampling and testing to monitor the performance of the

    process. Part C contains general maintenance guidelines.

    Williamtown RAAF Base Sewage Treatment Works 01 April 2008 Page 2

  • 2.0 Purpose of the Sewage Treatment Plant Section Outline

    2.1 Operating Goals

    2.2 Process Reliability

    2.3 Effective Operation

    2.1 Operating Goals An ideal plant operator should display the following attributes: 1) Knowledge of the owner’s objectives and the criteria by which the state of the plant and manner

    of its