managing process monitoring datawioa.org.au/documents/waterworks/waterworksmay2014.pdf · when the...

May 2014

Managing Process Monitoring Data

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Editorial CommitteePeter Mosse, Editor [email protected]

George Wall [email protected]

Direct mail to:Peter Mosse WaterWorks Editor c/o WIOA, 22 Wyndham Street Shepparton, Vic 3630

Advertising & ProductionAustralian Water Association (AWA) Publications, Level 6, 655 Paci�c Highway, PO Box 222, St Leonards, NSW 1590

WaterWorks is the publication of the Water Industry Operators Association of Australia (WIOA). It is published twice yearly and distributed with AWA Water Journal. Neither WIOA nor AWA assume responsibility for opinions or statements of facts expressed by contributors or advertisers.

Contributions WantedWaterWorks welcomes the submission of articles relating to any operations area associated with the water industry. Articles can include brief accounts of one-o� experiences or longer articles describing detailed studies or events. Submissions may be emailed to [email protected] or [email protected]

WATERWORKS DECEMBER 2010 3

Over the past few years at WIOAConferences and Workshops, we have raisedthe issue of the often confusing way that theconcentration of aluminium-basedcoagulants such as alum (aluminiumsulphate) or aluminium chlorohydrate(ACH) is quoted.

For example the concentration of alumcan be expressed as mg/L alum, mg/L dryalum, ppm V, mg/L Al2O3. This makes itvery difficult for operators when they arediscussing doses to be sure the numbersbeing quoted are comparable.Unfortunately some newer operators are notreally aware that such differences even exist!

There is also a tendency to compare dosesof alum and ACH directly without anyappreciation of the differences in the natureof the chemicals. ACH containsapproximately 23% w/w aluminium(strictly Al2O3) while alum containsapproximately 8% w/w aluminium (strictlyAl2O3). Therefore since it is the aluminiumthat does the work in coagulation, there isclearly more aluminium in ACH than inalum. In other words the doses cannot be compared directly.

If we look back into the history of theproduction of alum we can start tounderstand where this confusing situationstarted. Alum was produced from bauxite oralumina under the direction ofmetallurgists, and the strength of liquidalum was expressed as “percent weightAl2O3” (aluminium oxide) rather than“percent weight aluminium” or “percentageweight aluminium sulphate”. The reason forthis was that the starting material in theproduction of alum was aluminium oxide.(i.e. bauxite or alumina)

Of course there are straight forwardfactors you can apply to convert from onemethod of reporting to another, e.g.multiply the concentration in percentageweight/weight Al2O3 by 0.53 to get

weight/weight aluminium. But that justadds to the confusion!

If we consider the chemical structure ofalum it gets even more interesting. Alum isa strange beast. In Australia, we understandalum to have the chemical formulaAl2(SO4)3.18H2O, i.e. it has eighteen watermolecules (water of hydration) attached toit. By the way, this results in the Aussieversion of alum having the molecularweight of around 666, which for those ofyou who are fans of Iron Maiden will recall,is the Sign of the Beast!

However, you’ll find American alumoften has 14- or even 14.3-H2O’s! In theUK, it can have 16- or even 21-H2O’s! Sowhat are we really dealing with? A mess!

We would like to propose to theAustralian Water Industry and, theAustralian manufacturers of aluminium-based coagulants in particular, that weadopt the convention of “percentweight/weight aluminium” as the preferredway of quoting chemical strength.

We would also like to suggest thatOperators and others working in watertreatment start quoting alum and other Al-based coagulant doses as “mg/Laluminium”. Once the suppliers come onboard it will be much easier to progressfrom the chemical supplier’s documents tothe actual dose in the plant.

The other important benefit of thisapproach is that it would be very easy tocompare doses of alum with say ACH. Allthe aluminium based coagulants would beon a “level playing field” as all doses wouldbe quoted using the same unit, mg/L Al.

This method has already been pretty-welladopted for ferric-based coagulants such asferric chloride, PFS® and others. So whynot do it for aluminium-based coagulants?

To progress this idea further, we wouldlike some feedback from Operators, theguys and gals who actually have to workwith and dose these chemicals in water andwastewater treatment facilities! Let us knowwhat you think.

In the mean time we will try to take thisup with the chemical manufacturers,possibly WSAA, and other stakeholders.

In the interim, cheers and happy jar-testing!!

Editorial CommitteePeter Mosse, Editor [email protected]

George Wall [email protected]

Direct mail to: Peter Mosse WaterWorks Editorc/-WIOA, 22 Wyndham StreetShepparton Vic 3630

Advertising & ProductionHallmark EditionsPO Box 84, Hampton, Vic 318899 Bay Street, Brighton, Vic 3186Tel (03) 8534 5000 Fax (03) 9530 8911Email: [email protected]

WaterWorks is the publication of the Water IndustryOperators Association of Australia (WIOA). It ispublished twice yearly and distributed with WaterJournal. Neither the WIOA nor the AWA assumeresponsibility for opinions or statements of factsexpressed by contributors or advertisers. All materialin WaterWorks is copyright and should not bepublished wholly or in part without the writtenpermission of the Editor.

Contributions WantedWaterWorks welcomes the submission of articlesrelating to any operations area associated with thewater industry. Articles can include brief accountsof one-off experiences or longer articles describingdetailed studies or events. These can be emailed toa member of the editorial committee or mailed tothe above address in handwritten, typed or printedform.

OFFICIAL JOURNAL OF THE WATER INDUSTRY OPERATORS ASSOCIATION OF AUSTRALIA

CONTENTSEditorial 3

Sewer Repairs Over Shoalhaven River 4

Lamella Clarifier Trials At Dinner Plain 6

The Switch 9

How’s Your Pipe? 11

Rehabilitation of Sewers for the Future 14

E D I T O R I A L

ALUMINIUM, YOUR TIME HAS COME!

Peter Mosse and Peter Gebbie

OUR COVERClockwise from top left: Winner of the 2010 “TopOpShot Award” submitted by Greg Whorlow – PlenumEntry, GWM Water – Greg wins a Coles Myer voucher for $200; Runner Up submitted by David Barry– Read the Sign! Aqualift P/L wins a set of WIOA practical guide books; Building Blocks (Editor’s Note– Apologies to the company that submitted these, I lost the email); Digester on the Move – Wannon Water.

Water Works December 2010a 25/11/10 8:39 AM

�e enhanced biological phosphorus removal (EBPR) activated sludge process has a reputation for variable performance. Unfortunately this proved to be the case when the Noosa Sewage Treatment Plant (STP) was commissioned in November 1997, and for several years afterwards. �e challenge with optimising EBPR is that multiple factors in�uence process performance, including:• In�uent sewage COD characteristics,

particularly the quantity and type of volatile fatty acids (VFA);

• Need for an anaerobic zone that is free of nitrate and oxygen inputs;

• Minimising the recycle of P released during sludge stabilisation and dewatering;

• Su�cient population of polyphosphate accumulating organisms (PAO) and minimising growth of competing glycogen accumulation organisms (GAO);

• Ensuring the bioreactor pH remains in the slightly alkaline range;

• Su�cient aeration capacity to maintain suitable dissolved oxygen (DO) levels in the aeration zone during peak diurnal loads;

• Bioreactor temperature is also important, although the operator typically has no practical control of this variable.

�is paper reports on a research and optimisation program that was carried out at Noosa STP. �e Noosa STP is located 150km north of Brisbane. It serves a population of about 50,000 EP and treats an average dry weather �ow of 10 ML/d. It is located in a popular tourist area and the in�uent sewage has a predominantly domestic character. �e e�uent quality requirements are as follows:• Total nitrogen < 5 mg/L (50 percentile);• Total phosphorus < 1 mg/L (50 percentile);• Faecal coliforms < 10 cfu/100 mL (50

percentile). �e BNR bioreactors were operated in a �ve-stage Bardenpho con�guration (anaerobic-anoxic-aerobic-anoxic-aerobic) with a sludge age of 10 days. �e mixed liquor temperature ranged from 20°C to 28°C. Molasses was dosed into either the fermenter or directly into the anaerobic zone of the bioreactors during di�erent stages

of operational trials. No alum or ferric were added to the process, although lime was used for treatment of the sludge dewatering �ltrate.

Importance of Propionate

Early EBPR research highlighted the importance of readily biodegradable, soluble COD and VFA as substrates for PAOs. When diurnal pro�les of in�uent sewage VFA and phosphate and e�uent phosphate were monitored at Noosa STP, the sensitivity of EBPR performance to VFA was apparent (Figure 1). �e ratio of VFA:P in the in�uent showed a sudden decrease at peak �ows, which coincided with breakthrough of unremoved phosphate at the outlet of the bioreactors. However, the duration of the phosphate breakthrough peak did not match the duration of the low VFA:P ratio, and these results may have also been in�uenced by bioreactor hydraulics (e.g. short-circuiting) and low DO in the aerobic zone during peak load. �e VFA output from the fermenter was excluded from the data shown in Figure 1, but did not show any signi�cant diurnal variation and did not a�ect the trend. �is pattern of behaviour was con�rmed by repeated sampling on di�erent days, and Figure 1 shows a typical diurnal pro�le. When the Noosa STP was commissioned in November 1997 it appeared that the in�uent was not favourable for reliable EBPR, and supplementary acetate dosing was implemented. Initially acetate dosing worked well, as shown by results obtained during 1998 (Figure 2). However, in 1999 increasing variability in EBPR was observed and, more importantly, phosphorus removal was not improved by simply increasing the acetate dose. �e period of poor EBPR in 1999–2000 coincided with the primary sedimentation tanks and fermenter being out of service for odour control modi�cations (Figure 2). �e fermenter was out of service from November 1998 to April 2000, during which time the acetate dosing was increased to compensate for the loss of VFA production. Further, there was only a slight improvement in plant performance when the fermenter was returned to service in April 2000, while acetate dosing continued.

CONTENTSNoosa�STP�BNR�Optimisation� 3

Look�After�Your�Floc�� 6

Paperless�WTPS�For�South�Gippsland� 10

Operational�Data�Management�At�Wannon�Water�14

Pilot�Plants�Guide�SA�Water�Filter�Upgrades� 17

Look�Out�At�Hypo�Sites� 21

WATERWORKS MAY 2014 3

W A S T E T R E A T M E N T

NOOSA STP BNR OPTIMISATION

Michael �omas

Our cover photograph shows Happy Valley Water Filtration Plant Supervisor, Chris Copley, inspecting the underdrain pilot plant used to evaluate underdrain and support gravel configurations. See the article by Jason West on page 17.

OUR COVER

4 WATERWORKS MAY 2014

� e high operating cost associated with acetate dosing, coupled with the unsatisfactory EBPR performance, ultimately led to a search for an alternative carbon source that was locally available, economical and fermentable. � e outcome was that molasses dosing into the fermenter was implemented in December 2000. Continued analysis of the fermenter outlet showed high concentrations of propionate as a result of molasses dosing, and the e� uent phosphorus was generally maintained below 0.5 mg/L since July 2001 (Figure 2). Analysis of the VFA species present in the raw sewage and fermenter outlet provided another important clue to understanding EBPR at Noosa. � e VFA fraction in the raw sewage was typically 85% acetate and 10% propionate, whereas in the fermenter e� uent it was 40% acetate and 45% propionate, and obviously the acetate that was dosed contained 100% acetate. � erefore, when the fermenter was out of service and poor EBPR performance was occurring, the predominant type of VFA was acetate. When the fermenter

was in service and good EBPR performance occurred, the VFA supply contained a signi� cant concentration of both propionate and acetate. � is highlighted the potential importance of propionate.

Effect of pH

Another signi� cant factor that may have contributed to improved EBPR was the implementation of magnesium hydroxide (Mg(OH)2) dosing into the sewer network for odour control. � is happened progressively from September 2002 onwards, and its e� ect can be observed in the increasing in� uent sewage pH (Figure 3). � e in� uent sewage pH has been maintained above 8.0 since May 2004, and this has coincided with an extended period of stable EBPR performance. � is highlighted the potential for pH control to provide a mechanism for optimising bio-P. Extensive independent studies have shown that PAO growth is favoured and EBPR performance is improved at pH levels around 8.0.

Based on the results shown in Figures 2 and 3, the relative importance of propionate and a bioreactor pH of 8 for ensuring reliable EBPR cannot be de� nitively resolved. However, the improvement in P removal that followed the implementation of molasses dosing indicates that a supply of propionate was potentially more important for developing and maintaining an active PAO population.

PAO and GAO Population Dynamics

GAOs and PAOs can co-exist within the BNR-activated sludge population and are known competitors for the limited supply of VFA typically present in the in� uent to BNR plants. It is also likely that variability in EBPR performance is caused by variations in the relative population sizes of PAOs and GAOs, rather than variations in the biochemistry of a � xed population of PAOs. PAOs and GAOs can be identi� ed and counted under a microscope if a sample of mixed liquor is stained with speci� c � uorescent stains. Initial results for the Noosa STP biomass con� rmed the presence of signi� cant numbers of GAOs. As EBPR performance improved from 2001 onwards, the population of PAOs was observed to increase. � ese observations provided strong evidence that the variability in EBPR performance was due to variations in the populations of PAOs and GAOs. In order to control this variability it would be necessary to control the growth of GAOs. Extensive laboratory-scale investigations comparing acetate and propionate utilisation by mixed cultures of PAOs and GAOs have been carried out during the last 10 years. In virtually all cases, better EBPR was obtained with propionate, or a mix of propionate and acetate, than with acetate alone. Further, it was found that the acetate-fed reactors were dominated by GAOs and the propionate-fed reactors were dominated by PAOs. � erefore, the importance of speci� c VFA species in the microbial population dynamics has been con� rmed. So under certain feed conditions, di� erent types of GAOs can potentially compete with PAOs. However, PAOs in enriched cultures can e� ectively utilise both acetate and propionate. Consequently it was shown that alternating the feed source between acetate and propionate produces a highly enriched culture of PAOs. � us it appears that although some GAOs may be capable of utilising propionate, they cannot compete e� ectively for propionate against PAOs. � ere are also PAOs that can utilise lactate. � ese may be important where

02468

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Figure 1. Effect of diurnal sewage VFA:P ratio on P removal.

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Acetate Dosing to Bioreactor Molasses Dosing to Fermenter

Fermenter Out Of Service

Figure 2. Variable P removal with acetate dosing and improved P removal with molasses dosing.


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molasses dosing is used to provide carbon. Fermentation of molasses produces lactate as well as acetate and propionate. A further question arose regarding why a signi� cant number of laboratory-scale studies have achieved successful EBPR when fed with acetate. Since many of the investigations were carried out at water temperatures of 20°C in Europe, the US

and Japan, it is possible that PAOs have a competitive advantage over GAOs to use acetate at cooler temperatures.

However, in warmer climates such as Queensland and South Africa, it appears that GAOs have a competitive advantage over PAOs for acetate utilisation. Temperature sensitivity studies have con� rmed that PAO growth is encouraged

at cooler temperatures and GAO growth at warmer temperatures.

Conclusion

Based on the work at Noosa STP, one signi� cant factor contributing to achieving stable EBPR was the relative growth of PAOs and GAOs in the mixed liquor as determined by the speci� c type of VFA in the in� uent to the bioreactor. � e PAOs seem to have a competitive advantage to use propionate, whereas the GAOs have a competitive advantage to use acetate. Fermentation of molasses provided a suitable balance of VFAs to favour PAO growth at Noosa STP. � e other factors were the pH and temperature in the bioreactor. PAOs have a competitive advantage at temperatures less than 20°C and at alkaline pH values in the range of 7.5 to 8.0.

The Author

Michael � omas ([email protected]) is Treatment Technology Manager at Unitywater in Queensland.

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Effluent Total P I nfluent pH 46 per. Mov. Avg. (Effluent Total P )

Mg(OH )2 Dosing to Sew er

Figure 3. Increased infl uent sewage pH coincided with stable P removal.


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Many problems associated with poor performance of a water treatment plant (WTP) go right back to the beginning, namely the initial formation of �oc and the subsequent treatment of that �oc. For maximum removal of pathogens and other contaminants in a treatment plant, coagulant addition and mixing, and the coagulation and �occulation steps, must be optimised. Part of that optimisation is to manage the growth of the �oc. Floc formation can be a delicate process. After the initial rapid or �ash mix of the water with the coagulant and the formation of pin �oc, the subsequent growth of the �oc to the size required for gravity separation or �otation needs to be managed carefully. After the turbulent coagulant mixing stage, gentle mixing is required to grow �oc particles into a suitable size. Flocculation time needs to be just right to grow the required �oc size – not too long and not too short. Floc is fragile. Mixing for too long will tend to overgrow the �oc. Large �oc tends to be more fragile, particularly where alum is used alone. Floc can be strengthened with careful use of polymer, but poor use of polymer or addition of polymer at the wrong time can hinder �oc formation or compromise �lter beds. Growing �oc can be damaged and, unfortunately, once damaged most �oc do not regrow e�ectively. �is has been con�rmed and clearly demonstrated in laboratory-based research studies.

But let’s have a look at some actual WTP case studies and examples.

WTP1

Figure 1 shows the delivery point from a channel carrying �occulated water into a clari�er. �e delivery point had been relatively recently modi�ed in a capital upgrade at the plant. �e original connection had little or no turbulence, however the modi�cation introduced signi�cant turbulence. Figure 2 shows two beakers. One has been sampled just before the over�ow weir into the clari�er and the other from just beyond the turbulent area shown in Figure 1. �e jar on the left shows the �oc formed in the channel prior to the weir. �e beaker

on the right shows the smashed �oc at the bottom of the in�ow point. �e �oc in the beaker on the right did not reform when placed on a jar-test machine.

WTP2

Figure 3 shows two jars that have been mixed gently on a jar-test machine at 30 rpm (a typical mixing speed for a jar-test for �occulation). One was sampled just after the

inline static mixers in the plant; the other sample was taken following “�occulation”. Figure 4 shows the �occulation volumes provided at the plant. In an attempt to provide increased �occulation time, the water utility increased the �occulation volume by doubling the length of the pipe coil and also adding the �occulation tank shown in the right-hand panel of Figure 4.

LOOK AFTER YOUR FLOCPeter Mosse

Figure 1. The modified inflow to a clarifier at a WTP, clearly showing the turbulent conditions the floc must survive.

Figure 2. Dip samples taken from the process flow stream shown in Figure 1.

W A T E R T R E A T M E N T


Clearly the � oc is damaged irreversibly in the passage through the in-pipe and tank � occulation volumes. � e most likely culprit for this damage is the shear stress imparted to � oc by the many 90o bends and valves that had been installed. � ese were included to allow maximum � exibility in using none, part or all of the � occulation volume. However, the damage could also have been done in the pipe coil itself. � e velocity in the pipe loop needs to be < 0.5 m/s or thereabouts to ensure that only su� cient energy is provided to build � oc and not shear them.

WTP3

Figure 5 shows water leaving a well- designed � oc tank upstream of a dissolved air � otation/� ltration (DAFF) WTP. � e tank contains well-formed � oc suitable for DAF separation. � e passage of the � occulated water over the sharp weir edge shears the � oc. Luckily in this case, the DAF was able to � oat the � oc satisfactorily and achieve a low � oated water turbidity of around 0.3 NTU, even though the � oc had been partly damaged. While this operation is satisfactory, an operator would need to be aware that with changing raw water conditions the results may not be as good and some action may be required.

WTP4

Figure 6 shows a � occulation tank with just too much mixing energy. Dip samples taken from the top of the � oc tank directly above the inlet (see arrow in Figure 6), the bottom of the down-pipe leaving the � oc tank and the inlet to the central well of the clari� er all showed evidence of signi� cant � oc shearing. Jar-testing showed that the � oc appeared to be able to repair and produce good quality water. It is interesting to note that at this plant polyDADMAC is used as the only coagulant. � is may be an advantage of using polyDADMAC over alum at this WTP in that � oc reformation can occur.

WTP5

� e last case study is one provided by Peter Gebbie (Principal Process Engineer with SMEC) and one he has talked about at a WIOA Seminar on Coagulation and Flocculation. � e WTP concerned had two solids-contact clari� ers, each with a central mechanical � occulation zone, and one sludge-blanket clari� er with in-situ � occulation. � e raw water was dosed with a cationic polymer and then distributed to the three clari� ers. � e problem was that

the water from the solids-contact clari� ers had a high turbidity of 5 to 6 NTU, which impacted badly on � lter run times compared to the sludge-blanket clari� er with a turbidity of 0.5 NTU. Inspection showed that the mechanical � occulators in the solids-contact clari� ers had been turned o� because the operator felt that � occulation occurred in the pipeline delivering the chemically-dosed water to the clari� er and that the � occulators were not necessary. Jar-testing quickly con� rmed that � occulation would work as long as proper mixing occurred. Figure 7 shows two jars with the dosed water. � e one on the left shows the product quality after � occulation with

mixing. � e one on the right shows the result when no mixing was used and con� rmed the poor quality water from the clari� cation step.

Figure 3. Two samples from the process stream that have been placed on a jar-test machine at 30 rpm for approximately 12 minutes. The jar on the left was sampled just after the static mixers, the jar on the right after the fl occulation structures shown in Figure 4.


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� is isn’t really an example of looking after your � oc, but about giving it a chance to grow in the � rst place. It is also likely that damage was being done to any � oc that had started to form as it passed along the pipe to the clari� er.

Summing Up

So when trouble strikes – or indeed, whenever you are optimising a plant – check your dosing with a jar-test, making sure that the test conditions have been customised to mimic your plant – i.e. rough assessment of mixing energies and mixing and � occulation times. If you have no dedicated mixing structures, then mix in the jar at, say,

Figure 5. The exit point from the fl occulation tank showing the sharp weir and lower water level leading to turbulent fl ow and probable shearing.


Figure 6. A very high-energy fl occulation tank.

Figure 4. Flocculation at this plant occurs in a 200m pipe coil (left) and a fl occulation tank (right).

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Superior Service

Competitive Pricing

Maximum Corrosion

Protection

State-of-the-art,

Real time reporting

Talk to an Integra Representative regarding our services and systems.

www.integrawater.com.au

South Australia (08) 8345 1111

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130 rpm. However, if there is a static inline mixer or a rapid mix device, use, say, 180 rpm. If there is a dedicated � ash mixer in the plant, then use 200 to 220 rpm in the jar test. If there is tapered mixing energy in the � occulation tanks, then also mimic that in your jar test. If you only have 10 minutes’ � occulation time at typical � ows, then don’t use a 20-minute � occulation time in the jar test – just make it 10 minutes.

� en once you have seen what is theoretically possible based on careful jar-testing, take dip samples in the plant and place them on the jar-test machine at 25 to 30 rpm (just enough to keep the � oc suspended) and have a look at the results.

You might be surprised, but it will point you in the direction you need to take to sort the plant out.

Make sure you know your plant and understand exactly what happens to the � oc you have created. Once formed, take every measure to look after your � oc! After all, good � oc formation is essential to optimum performance of your WTP.

Figure 7. Comparison of correctly fl occulated water (at left) and poorly (none) fl occulated water at right.


Integra has been established in the water treatment industry for over 25 years and provides services and solutions for all aspects of water. From traditional chemical treatment through to Wastewater and reuse, packaged membrane filtrationplants, as well as the production of specialised cleaning chemicals.

With manufacturing facilities in Sydney, Adelaide and Victoria, we can provide tailored solutions from beginning to end.

Integra continues to be at the forefront of innovation, both in the development of new services and practices, as well as the creation of new water treatment products to serve the industrial and commercial sectors.

W A S T E W A T E R A N D R E U S E

C L E A N I N G A N D H Y G I E N E S O L U T I O N S

P R E - T R E A T M E N T / F I LT R A T I O N

C H E M I C A L W A T E RT R E A T M E N T

Site Expertise

Superior Service

Competitive Pricing

Maximum Corrosion

Protection

State-of-the-art,

Real time reporting

Talk to an Integra Representative regarding our services and systems.

www.integrawater.com.au

South Australia (08) 8345 1111

Victoria (03) 9205 8888

Western Australia (08) 9314 2022

Queensland (07) 3422 2333

New South Wales (02) 9574 0000

Asia (+60) 3 2726 2687


South Gippsland Water (SGW) operates 10 water treatment plants (WTPs) servicing 22 towns over an area of 4,000 square kilometres in South East Victoria. SGW is a relatively small regional water utility with a limited revenue base and a limited number of employees. For the past 13 years, an ongoing challenge in managing drinking water quality at SGW has been the quantity of data and the need to process and report on it. Monitoring and collecting data is relatively easy, however, analysing it and using it to e�ectively manage the operation of the plants is more di�cult. �e system had grown to include multiple databases for the separate management of internal, external and on-line monitoring data, which was very ine�cient. Something needed to be done.

Requirements

SGW established a number of requirements for an information management system: • Relatively inexpensive compared

to alternative software;• Advanced data analysis and reporting

capabilities;• Able to integrate and report on data

from di�erent sources such as SCADA, and internal and external laboratory

data, without the need for SGW sta� to enter the data;

• Electronic �eld entry of data or other information;

• Database development could be carried out in-house without the need for either internal or external IT resources;

• Able to manage non-numerical data such as operational comments and calibration checks;

• A proven track record. SGW evaluated a number of di�erent database options and selected the Hach Water Information Management Solution (WIMS). �e system met the requirements with proven performance in approximately 1,000 utilities operating in the heavily regulated environment of the US water industry. To date, the initial process of development and implementation of the Hach WIMS software has taken approximately 30 person days for a single WTP. SGW has employed a graduate student for a period of three months to roll out the WIMS in the remaining nine WTPs and 11 WWTPs. At the conclusion of this time, the project will be completed including the migration of 10 years of data from SCADA, external and internal data sources.

What Does It Offer?

�e WIMS o�ers all the usual things you would expect from a modern database with easy data entry, calculations and trending, but it also o�ers more. �e “Do it Yourself” Approach

�e WIMS has an impressive help function, including videos that talk the user through speci�c help subjects. �ere are also lots of shared report templates. �is has allowed SGW operations sta�, without IT help, to easily design and customise the data entry forms and reports – all it takes is a quick chat with an operator to �nd out what they need, and then our water quality sta� deliver it. �e result is customised forms for each plant (Figure 1). Control point parameters can be highlighted in colour to quickly alert the operator to any issues at their plant. One really nice feature is that trend information for any of the data on the data entry sheet can be obtained simply by clicking on the parameter. Figure 1 shows an example of a data entry form speci�c for the Foster WTP, along with a pop-up trend generated by clicking on the �ltered water turbidity parameter. It does not matter if the data was monitored online, by bench testing or by contract laboratory analysis – it can all

be accessed through the WIMS without the need to log on to the SCADA system.Why Do I Have So Much Paperwork?

Unfortunately, in my role as Water Quality Manager, I have been guilty of creating all sorts of paper forms to record water quality data, meter readings, site security inspections, reservoir levels, dam inspections, chemical monitoring and more. �e WIMS system allows the creation of a ‘Paperless Treatment Plant’. Electronic forms have been designed in consultation with operators to look like paper forms (Figure 2). �e only di�erence is we

PAPERLESS WTPS FOR SOUTH GIPPSLAND

Bryan Chatelier

Figure 1. An example of the Foster WTP data entry sheet and a quick reference trend.

M A N A G I N G P R O C E S S M O N I T O R I N G D A T A


have removed the paper. Using laptops, tablets or mobile phones, the operator can complete any required data entry from a desk, bench or in the �eld (Figure 3), saving time and minimising data entry errors. Can I Trust �e Data?

�e electronic forms have been developed with entry limits to warn the operator when entries are outside a normal range. After prompting, if entries are accepted that are outside the entry range, the data will be italicised in the data entry form. If a result is entered that is outside a compliance or regulatory limit, the data will then be presented in a bold font.

If you are concerned about the accuracy of the data that has been recorded, a history of all entries and deletions is available. A record of changes includes the identi�cation of the user, date and time. How Much Easier Can It Get?

If you thought that having to manually enter test results took a lot of time, the WIMS has the ability to automatically enter sample information and test results into the database. Basically, the operator just needs to collect the sample and conduct the analysis. All the information such as sample location, sample time and operator ID is automatically transferred

to the database. If that wasn’t good enough, the sample result is also directly transferred to the database. �e dream of a ‘Paperless Treatment Plant’ is now closer to becoming a reality.Adding Result Comments

Where data has been entered into database forms, operators are able to enter speci�c result comments. Once a result comment is entered, the entry is then indicated by a red square on the data entry form. If desired, �ltering and reporting functions are also available to operators to allow for searching of speci�c comments of interest.What Does All �is Data Mean?

To be useful, data needs to be analysed and converted to process management information. �e WIMS is powerful. Listed below are just a few examples SGW has experimented with at this early stage of implementation. �ere are many more.• performance based on the percentage of time that �lters do or do not comply with adopted �lter turbidity standards (Figures 4 and 5). - Turbidity data during �lter-to-

waste operation after a backwash can simply be discarded from the detailed statistical analysis.

• Filter inspections: Forms and reports to record critical information collected during �lter inspections. Such information includes media depths and type, calculated and design �ltration rates, and calculated and design backwash rates.

• Filter backwash: Forms and reports to record backwash pro�les, �lter run times, ripening periods, media shake test results and media expansion results.

• Jar-testing records: Permanent records of all jar-tests performed that can then be assessed by search tools for future reference.

• Chemical dose rates: On-line trending of dose rates used for comparison with water quality data.

• Standardisation of chemical concentration calculations (i.e. mg/L or ppm, speci�c gravity, % active constituent).

• Calculation of chemical costs and optimisation of chemical usage.

• Overlaying data from di�erent sources. For example, SCADA and laboratory testing data can be easily overlaid as time-series trend graphs.

Figure 2. Examples of the electronic forms for chemical dose rate calculations (left) and meter readings (centre and left).


Figure 3. Examples of direct data entry for a drop test (left) and a flow meter reading (right).


Figure 5. A Monthly Analysis Report. Note that the plant in question only has one filter.


Figure 4. A Daily Operations Summary Report.


Farewell, Dear Diary!

Hardcopy treatment plant diaries are no longer required with the WIMS. Electronic logbooks are available so operators can record information as they require. Filters can be used to search for particular topics, dates or operator IDs.

Using the electronic logbook, the operator can now review the status of a treatment plant from a remote location prior to taking responsibility for the plant.� is allows the operator to become familiar with any ongoing issues at the plant and is particularly helpful where they may be solely responsible for managing a number of treatment facilities.

Reporting

� is is where the system really starts to shine brightest.

Early Warning Reporting

Rather than waiting for a result to exceed a control point limit, if a test result is heading in the wrong direction but is still below a limit, the system will notify the operator.

Now operators can respond to the abnormal trend before the result becomes a problem.Performance Reporting (Operator, Manager, Board)

A family of reports can be quickly generated. Figure 4 shows an example of a Daily Operations Summary Report that can be provided by email or directly to a smart phone so the operator can better determine the activities and sequence of those activities for the day.

While all this information is available on SCADA systems using scheduled reports, the operator does not have to waste valuable time logging onto the treatment plant control system. � e report can be easily con� gured to include whatever data the operator requires – e.g. water safety data and plant operational data. In a similar way, Water Quality Managers need an accurate and concise summary. � ese are easily designed and once set up are automatically emailed to the Water Quality Manager and, if required, the Operations GM each month.

Figure 5 shows an example of a Monthly Analysis Report. So far it only includes detailed � lter performance data. Work is currently underway to include chlorine control point performance and daily minimum Ct summaries.

Senior Management and Board Reports

Finally, there are plans to con� gure Senior Management and Board Reports in a simple tra� c light format that allows the General Managers and Board to quickly see WTP � lter and disinfection performance.

Conclusions

Data entry, analysis and reporting has been revolutionised at SGW. We are well on the way to ‘Paperless Treatment Plants” and are reaping the bene� ts of fully informed statistical reporting to all levels of operation and management.

The Author

Bryan Chatelier ([email protected]) is the Water Quality Manager at South Gippsland Water in Victoria.


E: [email protected]: (02) 9647 2700

For more details go to www.pump-facts.com.au

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Nine years ago I began my career in the water industry. Right from that �rst day I realised there was so much more to the industry than I had imagined. As time went on, I wanted to understand more about how the treatment plants worked and how to optimise them. Optimising plants often required using data that wasn’t online and, therefore, not on SCADA, so manually typing weeks or months of log sheet data into spreadsheets was the only way to do it. �ere had to be a better way.

Ten years ago Wannon Water (WW) and Goulburn Valley Water (GVW) combined to address this issue. �ey found what they thought was a suitable solution. However, the vendor was based overseas, the system was quite complex and the lack of su�cient resources meant the technology was outdated before the system was fully built. In 2011, WW and GVW employed the services of a Victorian company to deliver a modern, industry-speci�c system. In 2013 that system, Aquantify, arrived.

Understanding what an operator needs has been an important design feature of the Aquantify system.

Operators dislike time-wasting Once the operator is logged onto the network, starting Aquantify requires a single click. Data entry is quick and easy.

Operators only want what they need On the Data Results screen, the operator simply chooses the site and the data required to be entered for the day appears. �e schedule can be changed in real time (on the spot) if additional data is required or if some data is not required.

Result entry order can be de�ned Pending tests can be ordered for a particular site to coincide with the order in which the operators perform their duties. No more searching through lists of pending tests. Operators can enter the information in the order they collect it.

Entering DataAquantify can be used to store a wide range of data types. �ese include:• External laboratory data; • In-house water quality data such

as turbidity, colour, iron and pH;• Meter readings and calculated volumes;• Winter storage levels, rainfall data, visual

inspections and irrigation volumes;• Safety shower/integrity/security checks,

generator start-ups;• Instrument cleaning and calibration.

Data entry can be via pre-selected drop-down options. Operational checks such as security checks, visual inspections and calibrations can be added; the operator chooses their response from a drop-down list (Figure 1).

Reporting Features

For any sort of plant improvement or troubleshooting, trending is essential. Online monitoring is trended on SCADA

systems. However, external laboratory data and internal process monitoring data is often not adequately trended. �e data management package o�ers a wide range of trending features.

Graphing Trends

On the Data Results screen, when an operator clicks on a test result, historical data is displayed on a graph (Figure 2). �e Viewport at the top of the graph allows you to determine the time frame over which the results are displayed. �ere is also a box around the data, which is represented on the graph, and you can move the box to have historical data appear on the graph if detail is needed. �e timeline gives the operator much more information than the Viewport. For example, Figure 3 shows the data is fairly constant with a few spikes. However, the timeline presentation shows there has been an initial increase followed by a steadier period and, �nally, a decrease in the parameter. �is increase might be due

OPERATIONAL DATA MANAGEMENT AT WANNON WATER

Catherine HufWinner of the Hepburn Prize for Best Paper Overall at the 2013 Victorian WIOA Conference

Figure 1. Drop-down options can be used to enter data.

Figure 2. The Aquantify data entry screen and the two trend screens.



to seasonal variation or a subtle process failing. �is graph is of apparent colour for raw water. �e operator could use the slider to go back to when the levels were this high in the past, and then look

at the coagulant dosing for the same time period to see what dose rate was used in the past as a response to the increase in colour. Having this operational data at hand could be a very quick aid to help alter plant operation. Long-term improvements in plant performance can also be seen with the graphs. Figure 4 shows the long-term improvement in colour removal from a clari�er. Long-term trends of this type very quickly show the success or failure of an operational change. What if an operator wanted to graph more than one parameter at a time?

�e reporting tool is simple yet powerful. Report templates can be quickly created. �is can be done easily on the Data Results screen with a few clicks. When selected, a report template will quickly produce a table and graph (Figure 5). �e operator then uses the template each time they want to view the same information in the same

way. �e data presented can be modi�ed by the operator, for example the date range, or sample points can be modi�ed.

Trends Including External Laboratory Data

Aquantify also houses external laboratory data, which is imported into the system. �is allows for comparison of in-house testing results with external laboratory results. External data is easily distinguishable from in-house data by the external “dot” (Figure 6). An operator can �lter this data in or out.

Adding and Viewing Comments

Comments can be added to any data entry (Figure 7). If a comment is added to a test, it is clearly visible by a speech bubble. An operator can hover the mouse over the speech bubble to read the comment (Figure 8). Comments can be easily added to any report if required.

Setting Limits on Test Results

Alert and maximum limits can be placed on any test parameter. When a limit is breached, a pop-up appears (Figure 9) and the operator enters comments. �e comments can then be automatically emailed to a pre-determined list of relevant people. �e limits can be operational limits or HACCP limits.

Calculations

Flow volumes, dose rates, mixed liquor suspended solids and sludge age can all be calculated from the data entered by the operator. �e functionality of calculations is very similar to Excel spreadsheets. A calculator icon appears beside all tests

Figure 4. Trends can show improved operational performance over time.

Figure 5. Example of how reports can be created with multiple parameters.


Figure 6. External laboratory data can be easily identified and comparisons can be made with in-house data.

Figure 3. Viewing long-term trends on the Viewport.


that are calculated (Figure 10). Results for calculations appear automatically, when all the data relating to them has been entered.

iPhone/iPad App

An App has recently been created that allows direct data entry. Data can be entered using the App (Figure 11) even if the phone is out of range. �e data will automatically be imported into the system when the phone comes back in range.

ConclusionsHaving lots of data at your �ngertips makes plant control and improvement in plant performance a much easier task. After years in the water industry I believe I have found a better method, o�ering maximised and optimised plant control in an e�cient and reliable way.

The AuthorCatherine Huf ([email protected]) is Manager – Treatment Monitoring and Reporting at Wannon Water in Victoria.


Figure 7. Comments are added by the operator.

Figure 8. Comments can be viewed by hovering over the thought bubble icon.

Figure 9. A pop-up appears for the operator when a limit is exceeded.

Figure 10. The calculator icon appears next to tests that are calculated results.

Figure 11. The results entry screen for the iPhone.

Editor’s Comment

�is edition of WaterWorks includes two articles on development of data storage and analysis software for process monitoring data.

In an industry like ours where the data capture and recording requirements are similar no matter where in the country we are located, it is a real shame that we have not been able to collaborate better to develop a standardised package. �is could have avoided individual Water Utilities spending large amounts of money and, in several cases, committing considerable amounts of time independently developing data handling and reporting capabilities.

In 1995, almost two decades ago, I was involved with a Water Utility that developed a Water Quality Database for entering and reporting formal compliance monitoring data. In the following years this was improved and became the Water Quality Database for veri�cation monitoring data and the Plant Operations Database for process monitoring data. Since that time many other utilities have trodden the same pathway. Several have followed one path with one supplier or programming company, only to ditch the product when it was clear the product was unsuitable or the cost unsustainable.

�ey have then had to reinitiate the project a second time. Even the Water Treatment Alliance, of which I was project manager, “wasted” many tens of thousands of dollars in trying to develop a �lter turbidity monitoring and reporting product, one which the programming company just could not deliver. In the end we switched our approach and developed an Excel-based product with the help of a Water Treatment specialist company in New Zealand who knew exactly what we wanted. �ose products (WTAnalyser Filtration and WTAnalyser Disinfection) are available free of charge on the WIOA website.

One wonders how many resources, time and e�ort could have been saved if a cooperative venture had been implemented at the start. For all those still to travel down this path, be very careful about developing your own product. Look for something that is mature and well-credentialed and in use at a number of other Water Utilities. �e two articles in this edition may help you.

Having said all this, the good thing is that �nally in Australia some momentum has developed for decent data storage and analysis of process monitoring data; and reporting on the process monitoring is starting to become a routine part of water industry operations.


�e Happy Valley (850 ML/d) and Hope Valley (276 ML/d) Water Filtration Plants (WFPs) treat and distribute drinking water to 70% of Adelaide. �ese plants treat a combination of local catchment and River Murray water using conventional alum coagulation, sedimentation and media �ltration. Both plants have been supplying treated water for over 25 years and, while still meeting their design performance speci�cations, are now �nding it di�cult to reliably achieve the more stringent turbidity targets set by the health regulators. �e Hope Valley �lters are the rapid gravity type using anthracite, sand and a gravel support layer on top of a plenum/nozzle underdrain system. During backwashing with sequential air and water, numerous ‘boils’ were noticed. �ese were later determined to originate from leaking plenum hold-down beams and broken nozzles. �e boils were accompanied by stagnant zones, indicating possible ine�ective backwashing (Figure 1). �is in turn could lead to preferred �ltration paths and impact on �ltered water turbidity performance. �e plant experienced very long �lter ripening periods that would be symptomatic of such channelling. Happy Valley WFP also employs rapid gravity �lters, but utilises a mono-media sand con�guration on top of separate air pipe and water pipe lateral systems embedded within a gravel support structure. While the plant did not experience any signi�cant �lter ripening issues, it struggled to maintain its �ltered water turbidity target of 0.15 NTU, especially during high demand periods when the �lters were experiencing high loading rates. As part of SA Water’s Cryptosporidium Risk Management Strategy, �lter probing and diagnostic �lter inspections were undertaken at both plants. �e Hope Valley �lter inspections revealed signi�cant intermixing of sand and gravel, as well as a number of blocked and broken nozzles. �e Happy Valley �lter inspection revealed signi�cant gravel migration (Figure 2), inter-mixing of sand (Figure 3) and large quantities of sand partially blocking the air laterals.

How Do We Fix The Problems?

Without understanding the mechanism of failure, it was di�cult for SA Water to embark on a strategy that replaced like for like. An extensive consultation process was embarked on involving plant operators, treatment engineers, asset managers and engineering consultants.

At Hope Valley, operators noted the OH&S risks associated with entering the plenum space to undertake routine inspections. Treatment engineers had concerns that the available depth of the �lter was not su�cient to perform a backwash procedure that would allow a rising wash that utilises combined air and water. Nor did the available �lter height

PILOT PLANTS GUIDE SA WATER FILTER UPGRADES

Jason West

Figure 2. Happy Valley Filter 16 gravel and media profile before refurbishment.

W A T E R F I L T R A T I O N

Figure 1. A backwash at the Hope Valley WFP before refurbishment, showing the uneven air scour pattern.


allow the appropriate depth of gravel to be employed to prevent inter-mixing with the sand and subsequent deleterious e�ects on the underdrain system. �e operators also felt that the backwash process could be improved if a combined air and water wash was employed instead of sequential air and water. �e Happy Valley plant is a signi�cantly larger plant than Hope Valley and any changes to the underdrain systems would come at a much greater capital cost. �e principal question that required answering was: “Is the gravel disturbance a result of a single catastrophic event, or is it a condition that has evolved over many years?” �e team believed that some aspect of the backwash process was the cause of the gravel disturbance, probably related to the combination of air scour and high water �ow rates. �e team also felt that the large sand diameter used at the plant (1.5mm e�ective size) did not provide the best potential to achieve the target �ltered water turbidity into the future. It was agreed that SA Water should embark on some extensive pilot plant work to uncover the likely causes of gravel disturbance at Happy Valley and also to select the most appropriate �lter media.

Pilot Work

Two separate pilot rigs were designed and built, each for di�erent purposes.1. A 1.3m wide x 1.2m deep x 2.6m high

tank called the ‘Underdrain Rig’ (Figure 4, see also the cover photo) was designed as a mini replica of the full-scale plant’s underdrain system and media. Its purpose was to repeatedly backwash

the media to simulate up to 20 years of backwashing, and also to view what mechanical and hydraulic forces may be experienced throughout the vessel.

A key requirement of the design was to allow the viewer to witness any disturbance of the �nest layer of gravel that separates the coarse gravel from the sand media. �is layer is called the ‘barrier layer’ and its integrity must remain intact to avoid sand migrating down through the coarse gravel to the underdrain system, where it can potentially block the ori�ces in the

air laterals. To make this easier to witness, SA Water painted the barrier layer green to allow it to be clearly distinguished from other gravel and media.

2. A four-column clear PVC pilot Filter Rig (Figure 5) was used to help determine the most appropriate media to achieve the desired �ltered water quality. Four media types were investigated: (a) the existing 1.5mm mono-media sand; (b) 1.2mm mono-media sand; (c) 0.9mm mono-media sand; and (d) dual media anthracite/sand.

Figure 4. The pilot Underdrain Rig at Happy Valley WFP.


Figure 3. One of the Happy Valley WFP filters showing gravel migrating towards the surface.

Figure 5. The Happy Valley WFP pilot Filter Rig showing the green-coloured barrier layer.


On-line particle counters and low-range turbidity analysers were installed and results logged and trended. Parameters such as Unit Filter Run Volume, Head Loss, Filtered Water Turbidity and Particle Counts (<15 µm) were used to help assess the performance of each media type.

Results

Unfortunately the Underdrain Rig trials could not replicate the gravel disturbance that was observed in the full-scale plant. However, the outcomes of the trials provided some interesting discoveries. It was clear that the air scour pattern was extremely localised and provided minimal media agitation, despite appearing to vigorously agitate the media when looking at the surface of the water from above the tank (Figures 6 and 7).

Another interesting discovery was the impact of the gravel con�guration. �e traditional tapered (large gravel at the bottom to �ne at the top) design of gravel proved ine�ective in maintaining the integrity of the barrier layer. However, when an ‘hour-glass’ gravel con�guration was used (large gravel at the bottom, to �ne then coarse again at the top), no barrier layer disturbance was witnessed.

�e �lter sand moves up and down like a table-tennis ball blown and suspended by a vacuum blower. It goes up but then comes down. �e larger gravel stays put and doesn’t move. What is important is keeping the barrier layer stable. Having coarse gravel above the barrier layer does just that. It is assumed that the added weight of the top layers of coarse gravel was providing stability to the entire gravel support structure.

�e Happy Valley media selection trials also revealed some interesting results. Following approximately three months of trialling, it became clear that the mono-media 1.2mm e�ective size (ES) sand provided the overall best performance and proved to be the most robust media type for the plant conditions experienced during that time.

Dual media was trialled but o�ered shorter run-time and increased ripening periods with no added turbidity bene�t. �e reason for this is not clear, however it may have been associated with the application of �lter aid polymer. �e Happy Valley plant utilises deep �lter beds, allowing the luxury of being able to achieve an L/d ratio > 1000 and still retain the existing treatment strategy that employs the addition of a �lter aid polymer.

The Next Step

Clearly the pipe lateral underdrain system at Happy Valley contained a number of design de�ciencies such as extreme air lateral pipe lengths (22m) and poor air distribution across the �lter. An alternative and a�ordable solution needed to be found. A review was undertaken on di�erent underdrain types and a fact-�nding mission to the US and Manila led to the selection of a dual lateral ‘�lter block’ underdrain (Figure 8) as the preferred technology. While relatively new to Australia, this technology is well established in the US and Europe, where it occupies a substantial portion of the underdrain technology used on new and existing surface water treatment plants. �e advantages of the �lter block design were determined as follows:• allowed room to add more gravel and/ or media into the existing �lter structure without signi�cant modi�cations;

Figure 8. A filter block underdrain showing the primary and secondary chambers and the media retention plate on top.


Figure 6. The Happy Valley WFP pilot Underdrain Rig showing localised cleaning only. Figure 7. Top of the Underdrain Rig during an air scour.


• �e number of air ori�ces (10mm diameter drilled holes) for backwashing increased at Happy Valley from 12 per m2 to 237 per m2, indicating improved air/water dispersion across the �lter;

• Less risk of gravel disturbance, resulting from high localised air and water velocity in the gravel layers;

• Proven record in retro-�tted �lters.

�e Hope Valley �lters are relatively shallow and incorporating support gravels with an hour-glass con�guration would limit the available space for media �ltration. It was decided that a media retention plate be installed in lieu of the gravel layers. �e media retention plate is a 19mm-thick layer of fused HDPE beads (~0.5mm ES) that allows sand down to 0.45mm in diameter to be laid directly on top of it, eliminating the need for up to 450mm of support gravel.

Filter Blocks

�e �lter blocks selected for both sites have dimensions approximately 42cm x 96cm x 20cm. �e blocks are connected end-to-end and grouted in place (Figure 9). Additional anchoring is provided by steel reinforcing bars embedded in the grout to avoid any tendencies to lift. When connected together, the blocks form a lateral arrangement much like any other. However, the design of the blocks is such that during a backwash the air and water enter a primary chamber �rst, then a secondary chamber (Figure 8) before being released into the media. �e result of this is an equalising of pressures and �ows across the lateral, thereby avoiding the hydraulic di�erences typically found in ordinary pipe lateral arrangements.

�e �ume (entry) block is bonded to an ori�ce plate that contains a small opening to the top of the primary chamber to allow air to enter, and a larger opening to the bottom of the primary chamber to allow water to enter. �e air and water are then distributed across the lateral sections of the block, and then distributed evenly through a series of holes up through the gravel/media layers. Comprehensive computational �ow dynamic (CFD) modelling was undertaken to model the �ow across the entire �lter bed during the design phase of the project to con�rm that the theoretical �ow variability was less than �ve per cent of the average. It is extremely important that an air scour test be performed on the installed blocks to identify any blockages or �ow irregularities before the media is loaded into the �lter. Air scour tests (Figure 10) were performed before gravel was installed and a backwash performed before the sand/anthracite was added. For comparison, Figure 11 shows the pattern that was occurring prior to the refurbishment.

Conclusions

�e installations at Hope Valley and Happy Valley WFPs are complete and nearing the �nal stages of the proving period. �e block underdrain systems have demonstrated e�ective and even water and air distribution during the backwash process, and have been shown to be a very capable technology for retro-�tting to old �lters.

The Author

Jason West ([email protected]) is Manager – Water Design and Standards with SA Water.

Figure 9. Laying the filter block underdrains at the Hope Valley WFP. Figure 10. The refurbished air scour pattern at Happy Valley WFP.

Figure 11. The air scour pattern at Happy Valley WFP prior to refurbishment.



Over the years I have attended many disinfection sites. In this brief article I would like to alert those of you with responsibility for running or managing sodium hypochlorite (hypo) disinfection sites of some of the common problems I see and what to look out for and avoid.Housekeeping and Tidiness

Good ‘housekeeping’ and tidiness are generally indications that the operator cares about his role and the outcomes of his plant. �e performance of the system is likely to be more reliable and accurate as a result. Materials Need To Be Fit for Purpose

• Avoid brass, stainless steel or aluminium wherever chemical contact is required. Figure 1 shows a stainless steel �tting that has been used to pass ‘hypo’ through it. It lasted only several weeks.

• Fittings used for plumbing and purchased from local hardware shops tend to be cheap. Black poly �ttings are usually Low Density Poly Ethylene (LDPE) and not High Density Poly Ethylene (HDPE). Even some HDPE �ttings can vary in quality. �e use of black poly �ttings is not a good practice. �ese break down quickly, particularly in hot, dry areas. PVC or PVDF should be used (Georg Fischer PVC �ttings are recommended).

Dosing Transfer Lines

Black HDPE tubing, while suitable for use with hypo, usually only lasts 12–18 months and regular replacement is recommended. PVDF or Te�on tubing, while more expensive, will last for four to six years. When the tubing breaks down, small ‘pin-holes’ occur that spray out over other nearby equipment, sometimes causing severe damage. To avoid this happening, add an additional sleeve of larger tubing over the dosing line. Be aware though that this only sends the leaked chemical to the lowest end of the sleeving.

Cracked �ttings at the ends of dosing lines will lead to further problems even when they appear not to be leaking, as these have become ‘pressure compromised’.Chemical Storage

Brown ‘scum’ marks inside the storage container (Figure 2) are evidence that

maintenance doesn’t include the cleaning of the storage vessel. �ey may also indicate the quality of the chemical being used (or the lack of it). �ese marks can also highlight the presence of contaminants such as iron and, to some extent, manganese in the water used to make up the diluted chemical. Dosing Pumps

�e presence of white crusty deposits around the wet end of the pump (Figure 3) indicates a past leak and a need for servicing. Regular pump inspections can save money and avoid unnecessary mess.

It is also worth noting the pump

LOOK OUT AT HYPO SITES!Derek Braden

Figure 2. Brown scum marks inside the storage vessel indicate lack of cleaning.

Figure 1. A stainless steel fitting that was used for hypo.

H Y P O D I S I N F E C T I O N

Figure 3. A white, crusty deposit indicates a leak.


display. Generally, if the dosing pump has a display then it has some ‘smarts’ available. If not, then it is generally a basic pump and may only have low-level external control capability.

Always maintain the Model Numbers label on the pump. If this becomes lost or unreadable, obtaining replacement parts may be di� cult and delay any repairs. Another alternative is to write down

Figure 4. Recommended arrangement of pressure relief and pressure regulation valves.

Figure 5. Dosing point with a butt-mounted injection point.

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the details somewhere where they can’t be lost, such as an asset register.

� e dosing pump should pump through a Pressure Regulation Valve (or ‘Load’ Valve) (Figure 4), set at a pressure that is higher than the mains pressure (or dosing point pressure). � is maintains a constant ‘back pressure’ on the dosing pump and pipe work, which prolongs the pump life and helps with the precision of the dosing. It also helps prevent chemical siphoning from the chemical tank.

Also highly recommended is a Pressure ‘Relief ’ Valve located before the Pressure Regulation ‘Load’ Valve (Figure 4). � is is set to a pressure just below the pump rating and higher than the Pressure Load Valve. In situations where a dosing line becomes blocked or compressed, the excess pressure

is automatically bled back into the chemical tank, avoiding catastrophic bursts or pump damage. Regular checks should be undertaken to ensure that the bleed has NOT been activated and that the process is not being diverted. If it is, further investigation for blockages in the dosing line should be immediately looked for.

Injection Point

Injection of chemicals should not be directly into a water main. A ‘Withdrawable Lance’ should be used that has the appropriate length to pass beyond all � ttings and reach well into the water to provide better mixing (minimu m 10% of inside pipe diameter). Figure 5 shows a poorly set up dosing point with a butt-mounted injection point and Figure 6 a Withdrawable Lance assembly

Access to the check-valve incorporated in this Lance is mandatory, as it is the most important part of the discharge line and needs to be changed every 12 months. It is the most likely place to � nd a blockage, especially where calci� cation problems are known (Figure 7).

The AuthorDerek Braden ([email protected]) is the Managing Director of C-Tech Services in Melbourne.

Figure 6. A Withdrawable Lance assembly.

Figure 7. Example of a blocked check valve (top) and a new check valve (bottom).

H Y P O D I S I N F E C T I O N

MCBERNS TRUSTED SUPPLIER OF ODOUR FILTERS & SEALED SAFETY COVERS MCBERNS HAS A LARGE RANGE OF

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MCBERNS SEALED SAFETY LIDS WITH 4-SIDE VOID PROTECTION WILL IMPROVE YOUR SAFETY.

PRODUCTS YOU CAN TRUST!

MCBERNS PTY LTD Working Towards a Safer Workplace & a Better Environment!

11 TECTONIC CRESCENT KUNDA PARK QLD 4556 AUSTRALIA ABN 56 060 984 107 www.mcberns.com PH: 61 7 5445 1646 FAX : 61 7 5445 1743 [email protected]

For 23 years McBerns has been a trusted supplier to the Water & Wastewater and Industrial Sectors.

We provide Safe, Fast and Economical Solutions for Odour Problems, Maintenance and Workplace Health & Safety Issues.

Our products are Designed & Manufactured in Australia.

McBerns holds Quality Management Systems Certification meeting the ISO:9001:2008; AS/NZS4801:2001 and ISO14001:2004.

QA CERTIFICATION

MEMBERS OF

JUST RELEASEDZC4000

TREATS EXTREME H2S LEVELS &

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