planning and commissioning waste water treatment plants

8/2/2019 Planning and Commissioning Waste Water Treatment Plants

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NOT MEASUREMENTSENSITIVE

MIL-HDBK-35320 AUGUST 1996

MILITARY HANDBOOK

PLANNING AND COMMISSIONINGWASTEWATER TREATMENT PLANTS

AMSC N/A AREA FACR

Distribution Statement A. APPROVED FOR PUBLIC RELEASE:DISTRIBUTION IS UNLIMITED.


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ABSTRACT

This handbook provides guidance on commissioning wastewater

treatment facilities to Air Force environmental, engineering, andoperations personnel. The guide covers the essential activitiesinvolved in commissioning treatment plants: planning,programming, design, construction, and inspection and performancecommissioning. This instruction complements the relatedactivities of wastewater treatment plant design, construction,and operation, while emphasizing the procedures unique tofacilities commissioning. Thus, the handbook presents guidanceinformation on required engineering studies, cost estimation,scheduling, recordkeeping, startup testing, performancecertification, training, and operations manual preparation.


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FOREWORD

This handbook guides the reader in commissioning wastewater

treatment facilities. It is intended to be consistent with U.S.Army Corps of Engineers Regulation ER 1110-345-723, Engineeringand Design Systems Commissioning Procedures.

Recommendations for improvement are encouraged. Submitrecommendations for changes or improvements to this handbook onAF Form 847, Recommendation for Change of Publication, throughmajor commands (MAJCOM) to HQ AFCESA/CES, 139 Barnes Dr., TyndallAFB, FL 32403-5319.

THIS HANDBOOK SHALL NOT BE USED AS A REFERENCE DOCUMENT FORPROCUREMENT OF FACILITIES CONSTRUCTION. IT IS TO BE USED IN THE

PURCHASE OF FACILITIES ENGINEERING STUDIES AND DESIGN (FINALPLANS, SPECIFICATIONS, AND COST ESTIMATES). DO NOT REFERENCE ITIN MILITARY OR FEDERAL SPECIFICATIONS OR OTHER PROCUREMENTDOCUMENTS.


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COMMISSIONING CRITERIA MANUALS

Criteria Manual Title

AFM 88-11 Domestic Wastewater Treatment (Vol. 3)

ER 1110-345-723 Engineering and Design Systems CommissioningProcedures

MIL-HDBK-XXX Wastewater Design Handbook

MIL-HDBK-XXX Wastewater Operations & Maintenance (O&M)Handbook

MIL-HDBK-1005/8 Domestic Wastewater Control


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PLANNING AND COMMISSIONINGWASTEWATER TREATMENT PLANTS

CONTENTS

Page

ABSTRACT ................................................. ii

FOREWORD ................................................ iii

COMMISSIONING CRITERIA MANUALS ........................... iv

Section 1 INTRODUCTION.............................. 11.1 Scope..................................... 1

1.2 Purpose................................... 11.3 Commissioning Procedures.................. 1

Section 2 FACILITIES PLANNING....................... 22.1 Objectives................................ 22.2 Requirements.............................. 22.2.1 Facility Changes.......................... 22.2.2 Compliance Requirements................... 22.3 Problem Definition and Probable

Corrective Actions ..................... 22.3.1 OMTAP Study............................... 22.3.2 Regulations Review........................ 3

2.3.3 Additional Studies........................ 32.4 Environmental Deficiencies Reporting...... 42.5 Funding................................... 4

Section 3 PROGRAMMING............................... 53.1 Prior Approval and Validation............. 53.2 Requirements and Management Plan (RAMP)... 53.2.1 Advanced Planning with RAMP............... 53.2.2 RAMP Project Management................... 53.2.3 RAMP Review and Distribution.............. 63.3 Engineering Studies....................... 63.4 Future Air Force Requirements............. 63.5 Evaluation of Alternatives................ 7


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Page

3.5.1 Publicly Owned Treatment Works (POTW)Connection. ............................ 7

3.5.2 Economic Analysis......................... 73.6 Environmental Assessment (EA)/Environmental

Impact Statement (EIS) Initiation. ..... 83.7 Support Documentation..................... 83.7.1 Required Cost Line Items.................. 93.7.2 Additional Cost Information............... 93.7.3 Environmental Compliance Certificate..... 103.7.4 Cost Estimate Models..................... 103.8 Facility Requirements.................... 103.8.1 Future Requirements...................... 103.8.2 Facility Input and Printed Design

Guidance .............................. 10

3.9 Regulatory Agency Participation.......... 11

Section 4 DESIGN................................... 124.1 Design Initiation........................ 124.2 Design Engineer Selection and

Responsibilities. ..................... 124.3 Project Monitoring....................... 124.4 References............................... 134.5 Project Definition....................... 134.6 Construction Documents................... 144.7 WWTP Performance Criteria................ 154.7.1 Performance Certification................ 15

4.7.2 Notification............................. 154.8 O&M Manuals.............................. 154.8.1 Manual Development Responsibilities...... 164.8.1.1 System Operating Manual Submission....... 164.8.1.2 EOM&RM Submission........................ 164.8.1.3 Manual Format............................ 164.8.2 System Operating Manual Content.......... 164.8.3 EOM&RM Content........................... 184.8.4 DMEL..................................... 194.9 Operator Training Program................ 194.9.1 System Operating Training Plan........... 194.9.2 Contractor Training Program.............. 20

4.10 Permit Applications...................... 204.11 Operator Participation During Design..... 21


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Page

4.12 Design Reliability and Maintainability(R&M). ................................ 22

4.13 Project Construction Cost Estimate....... 224.14 Regulatory Agency Review................. 23

Section 5 CONSTRUCTION............................. 245.1 Construction Startup..................... 245.2 Permits and Clearances................... 245.3 Title II Construction Services........... 245.4 Operator Involvement During Construction. 245.5 Construction Schedule.................... 245.6 As-Built Documentation and Record

Drawings. ............................. 255.6.1 Record Retention......................... 25

5.6.2 Record Accessibility..................... 25

Section 6 INSPECTION COMMISSIONING................. 266.1 Startup Program.......................... 266.2 Inspections (Prefinal and Final)......... 266.3 Liability for Performance................ 276.4 Final Operating Permits.................. 276.5 Dry and Wet Runs......................... 276.5.1 Dry Run Inspection....................... 276.5.2 Wet-Run Tests............................ 286.6 Facility Walk-Through.................... 28

Section 7 PERFORMANCE COMMISSIONING................ 30

7.1 Post-Startup Program..................... 307.2 Training................................. 307.2.1 Training Responsibilities and Notice..... 307.2.2 Scope of Training........................ 307.3 WWTP Operation Performance Period........ 317.4 Performance Certification................ 327.5 SOPs..................................... 337.5.1 SOP Submission........................... 337.5.2 Processes Requiring SOPs................. 337.5.3 Elements of SOPs......................... 337.5.4 SOP Format............................... 347.6 O&M Service Contract Documentation

(Optional). ........................... 347.6.1 Performance Work Statement............... 34


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Page

7.6.2 Bid Form................................. 357.6.3 Cost Estimate............................ 35

APPENDICES

APPENDIX A Wastewater Treatment Plant ManagementChecklist.................................... 36

APPENDIX B Federal Guidelines: Design, Operationand Maintenance of Wastewater TreatmentFacilities (PB-215-494)...................... 40

APPENDIX C MILCON Cycle Flowchart....................... 62

APPENDIX D MILCON Process Diagram....................... 63

APPENDIX E Capdet PC, A Computer Program for the Designand Cost Estimation of WastewaterTreatment Plants............................. 64

APPENDIX F Infiltration/Inflow - I/I Analysis andProject Certification (PB 85231165/AS)....... 68

APPENDIX G Technical Bulletin: Design Criteria forMechanical, Electric, and Fluid System andComponent Reliability (EPA-430-99-74-001).... 76

APPENDIX H EPA Handbook for Improving POTW Performance,Table of Contents and Appendix H, Design-Related Performance-Limiting Factors Identifiedin Actual CPEs (EPA-625/6-84-008)........... 126

APPENDIX I Table of Contents - WWTP System OperatingManual...................................... 148

APPENDIX J Table of Contents - Wastewater EquipmentMaintenance and Repair Manual............... 151

APPENDIX K Pre-Startup Inspection Record............... 153

REFERENCES .............................................. 154

GLOSSARY ................................................ 158


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Section 1: INTRODUCTION

1.1 Scope. This handbook serves as a planning guide for

commissioning wastewater treatment plants (WWTPs). Adequateplanning prevents unnecessary construction delays and costlymodifications and ensures efficient plant operation. Guidance ispresented in general terms; you must integrate site-specificrequirements. Appendix A provides a checklist for schedulingtasks and assigning responsibility. This checklist may be copiedor changed to suit your requirements.

1.2 Purpose. The purpose of precommissioning is to preparefor a successful commissioning. Adequate programming, design,and construction will accomplish this goal. This handbookassumes the traditional method of project delivery; criteria and

requirements are presented accordingly. In-house design or otherapproved delivery methods such as Fast Track or Design-Build arenot precluded. Most, if not all, of the requirements andguidance presented in this handbook are appropriate for theseother methods.

1.3 Commissioning Procedures. A WWTP must be operated inaccordance with the project design requirements. Sections 6 and7 describe requirements for commissioning a WWTP, includingverification of system operation to the component level.


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Section 2: FACILITIES PLANNING

2.1 Objectives. Planning is the first step in

precommissioning a WWTP. It involves identifying requirements,defining deficiencies, identifying possible corrective actions,and reviewing environmental regulations. Planning will determinethe need for the proposed facilities. Life-cycle cost (LCC)analysis will ensure that alternatives are based on total cost ofownership. Facilities planning will demonstrate that theselected alternative is the most economical means of meeting therequirements. Design-related performance-limiting factors willidentify potential problems. Electrical, hydraulic, andmechanical design criteria will provide for component and systemreliability. Planning is primarily the responsibility of thebase environmental flight. Base engineering and operations

flights should assist as necessary in initiating studies andrequesting project funding and approval.

2.2 Requirements. The requirement for a new or upgradedWWTP may result from changing conditions at the facility or fromcompliance deficiencies identified during facility evaluations.

2.2.1 Facility Changes. Existing facilities may beinadequate because of a recent or upcoming change in mission andmay require replacement due to physical condition or ineffectivetechnology.

2.2.2 Compliance Requirements. The WWTP may be out ofcompliance with environmental regulatory requirements and requirea new or upgraded facility to correct the deficiency. Thecompliance requirement can be identified through an EnvironmentalCompliance Assessment and Management Program (ECAMP) audit or anOperations, Maintenance, and Training Assistance Program (OMTAP)study. New or pending regulatory requirements may also indicate acompliance deficiency.

2.3 Problem Definition and Probable Corrective Actions

2.3.1 OMTAP Study. Conduct an OMTAP study, if one has not

already been performed. This study assures that problems are


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significant and eliminates the possibility that they areoperational in nature, requiring only minor modifications.

2.3.2 Regulations Review. Next, review all applicableenvironmental regulations to ensure the project will correct alldeficiencies. This review also ensures that appropriatedischarge standards will be met. If pending regulatoryrequirements are well defined and unlikely to change, they alsoshould be considered to ensure long-term compliance.

2.3.3 Additional Studies. Further studies may be needed tobetter define the scope and nature of corrective action. Studieshelp define existing conditions and should be conducted before

the evaluation of alternatives, when possible (par. 3.5).

Many publications helpful in identifying needed studiesare available from the Environmental Protection Agency (EPA),professional societies, and other sources. One example is PB-215-494, Federal Guidelines: Design, Operation and Maintenanceof Wastewater Treatment Facilities, published by the FederalWater Quality Administration (FWQA). Although dated and directedtoward municipalities, this publication still contains usefulguidance. Part A of PB-215-494 deals with concepts and studiesthat should be used in planning and project definition (PD);Part A is included in this handbook as Appendix B.

Several types of studies may be required before a

project can be properly defined:

a) Toxicity reduction evaluations.

b) Industrial waste minimization studies (pollutionprevention).

c) Wastewater pretreatment requirements. (An existingbase wastewater regulation should address pretreatmentrequirements and be updated at the completion of the project.)

d) Wastewater characterization and toxicityidentification evaluations. (Armstrong Laboratory at Brooks AFB,Texas, can assist with this effort.)


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e) Infiltration/inflow (I/I) studies (flow reduction).

f) WWTP siting.

g) Effluent reuse and disposal alternatives.

2.4 Environmental Deficiencies Reporting. Identifyfacility deficiencies early in the planning effort and reportthese deficiencies on environmental reports such as the FederalAgency Pollution Abatement and Prevention Project Plan (commonlyknown as the A-106 report) as required by AFI 32-7002,Environmental Information Management System. The A-106 is aplanning tool used to identify, track, and report pollutionabatement projects that will enable the Air Force to meetenvironmental requirements.

2.5 Funding. Studies are funded with Operation andMaintenance (O&M) or Environmental Compliance money. Majorupgrades are funded with military construction (MILCON) money.Environmental Compliance money may be used for O&M or MILCON aslong as requirements and supporting documentation are providedwhen the funds are requested. Projects must be approved by thebase Facilities Utilization Board, then sent to the major command(MAJCOM) for review.


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Section 3: PROGRAMMING

3.1 Prior Approval and Validation. The requiring MAJCOM

must approve and recommend a WWTP MILCON project to the AirStaff. Before projects are programmed in the Air Force budget,Headquarters Air Force Civil Engineer Support Agency, SystemsEngineering Directorate (AFCESA/CES) may review them foradherence to technical design standards and criteria. The AirStaff will not approve MILCON WWTP projects without an adequateevaluation of conditions and alternatives. Headquarters AirForce Directorate of Environmental Quality (HQ USAF/CEV) mustalso validate environmentally funded projects by confirmingcompliance requirements. The Air Force Directorate of MilitaryConstruction (AF/CEC) then validates project requirements and theAir Force Resource Allocation Process approves the requirements.

AF/CEC notifies the requiring MAJCOM of an approved project byissuing a Planning Instruction (PI). The PI is the Command'sformal notification to begin design on the project. At theirdiscretion, the Command authorizes the extent of designactivities with the Design Manager (DM).

3.2 Requirements and Management Plan (RAMP)

3.2.1 Advanced Planning with RAMP. Finalization of a RAMPsignals the start of the advanced planning phase of a project.ETL 95-2, Preparation of Requirements and Management Plan (RAMP)Packages for Military Construction (MILCON) Program Projects,

offers guidance on preparation of the RAMP package. The RAMPprovides project planning information to the Design Agent (DA),the DM, and the designer. It contains project description, data,criteria, requirements, and cost information to supportprogramming and design of the MILCON WWTP project. The MAJCOM isresponsible for completing the RAMP, but an Architect-Engineer(A-E) may assist with the preparation.

3.2.2 RAMP Project Management. The DM accomplishes theproject management plan portion of the RAMP. The MAJCOM or FieldDesign Instruction (DI) should be issued to the DM no later than30 days prior to completion of the RAMP to allow the DM to

authorize the DAs participation in preparing the project


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management plan. This 30-day lead also allows initiation of alladministrative actions before starting the design.

3.2.3 RAMP Review and Distribution. The RAMP must bereviewed by the DM within 60 days of PI issuance. The contentsmust agree with the PI, DI, and DD Form 1391, MilitaryConstruction Project Data. The DM then must send the RAMP to theDA for distribution to the designer. The designer must see theRAMP before the predefinition conference (PC) in order to knowand understand the AF requirements. The MILCON design process andtimeline are depicted in flowcharts provided in Appendices Cand D. These charts are illustrations from the AF ProjectManager's Guide for Design and Construction, available from AirForce Center for Environmental Excellence (AFCEE/CM), Brooks AFB,Texas. The RAMP should be used in negotiating the design

contract and completing the PD phase of the project.

3.3 Engineering Studies. Complete wastewater

characterization and other studies (par.2.3.3) required to fillidentified deficiencies. Some studies will take considerabletime and should be initiated early in the planning process.Copies of the studies must be submitted to both the baseenvironmental and engineering design organizations for review andcomment.

3.4 Future Air Force Requirements. Review the BaseComprehensive Plan (BCP) to ensure the WWTP project supports

other planned facility expansions. Other on-base organizationsshould also have the opportunity to provide input, particularlywhere related to unit mission changes not detailed in the BCP.Future requirements that can affect the WWTP project include, butare not limited to, the following:

a) Base population increase or decrease

b) Mission change

c) Pending change in regulatory requirements

d) Planned change in industrial discharge from processmodification, material substitution, or functional changes


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3.5 Evaluation of Alternatives. An evaluation of projectalternatives should include nonconventional projects andinnovative solutions to the problem. All solutions must consider

pollution prevention, recycling, wastewater reuse, and long-termenvironmental compliance requirements. Operability andmaintainability as well as LCCs and environmental compliance mustbe considered. Each alternative must be reviewed by baseengineering personnel, graded on each criterion, then ranked.After ranking, the best alternative shall be presented to baseorganizations, higher headquarters, local, state, and Federalagencies for review and comment. A-E services are typically usedfor this effort. The A-E may also be used for the review ofengineering studies (par.2.3.3), the development of facilityrequirements (par. 3.8), and the preparation of the RAMP (par.3.2).

3.5.1 Publicly Owned Treatment Works (POTW) Connection.Develop and consider costs for connecting to a POTW whenproposing new construction or rehabilitating or expanding anexisting facility. HQ AFCESA/CES can assist with connection costanalysis. POTW connection and service costs must be compared tothe design, construction/rehabilitation, and operational costs ofthe proposed on-site alternative.

Connecting to a POTW shall be the preferred alternativewhen the life-cycle costs are favorable: 125 percent or lessthan the cost of the proposed on-site system. This bias for

connecting to the POTW is justified by the high cost of meetingfuture environmental requirements, added restrictions for on-sitesystems, increasingly complex plants, and the need for skilledand certified operators.

3.5.2 Economic Analysis. Conduct economic analyses as partof the design process to ensure that selection of designalternatives is not based solely on construction cost butincludes least life-cycle or total cost of ownership. The depthand degree of formality of these analyses shall be determined ona case-by-case basis to ensure that analysis costs areproportional to project magnitude. Results of previous analysis

involving the alternatives under consideration may be used inlieu of a new analysis, if the analysis assumed similar design


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conditions, used appropriate criteria and methods, and usedadequately updated and detailed documentation. All economicanalyses and/or other justification for the selection of a design

alternative, regardless of the method used, shall be clearlydocumented in the appropriate section of the project designanalysis. In addition, a separate stand-alone document orappendix describing the details of the study (method, criteria,assumptions and data used; calculations; results; andconclusions) shall also be provided.

All analyses shall consider the total LCC for designalternatives, where the LCC includes all costs associated with analternative over its expected life including, but not limited to,construction/procurement, energy, maintenance, operation, repair,alteration, and disposal costs. The present value discounting

approach, as described in AFMAN 65-506, Economic Analysis, shallbe used unless otherwise specified by other AF instructions, bypublic law, or by AF Engineer Technical Letters (ETLs). Theanalysis period shall be the date of the study through theeconomic life of the alternative or 25 years from the BeneficialOccupancy Date, whichever is less. Base cash flow on actualcalendar dates on which events and costs/savings are projected orscheduled to occur. Base estimates for all costs/savings onactual prices in effect on the date of study (constant date-of-study dollars).

3.6 Environmental Assessment (EA)/Environmental Impact

Statement (EIS) Initiation. The initiation process for the EAand EIS is the Environmental Impact Analysis Process (EIAP). TheEIAP must be completed to ensure compliance with the NationalEnvironmental Policy Act. This process is detailed in AFI 32-7061, Environmental Impact Analysis Process. Preparation of anEA typically requires 6 to 9 months. When a CategoricalExclusion or a Finding of No Significant Impact is notappropriate, then a full EIS must be prepared. The preparationof an EIS typically takes 12 to 18 months. Allow time tocomplete the EIAP before final project approval and funding.

3.7 Support Documentation. The primary programming

document is DD Form 1391. This document is used to request andjustify the WWTP project, as required by AFI 32-1032, Planning


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and Programming Real Property Maintenance Projects UsingAppropriated Funds. DD Form 1391 details the project scope,cost, and any unusual features.

3.7.1 Required Cost Line Items. Include the followingseparate line items, described in later paragraphs, on DD Form1391 as part of Item 9, Cost Estimate:

a) Systems O&M and component O&M manuals (estimated at$50,000 to $150,000).

b) Contract startup, training, and performanceoperating period (estimated at $150,000 to $250,000).

c) Lab test equipment and other items funded outside

MILCON. Separate funding for these items must be requested butthe items may be shown here.

3.7.2 Additional Cost Information. Complete the followingitems in Block 11 of DD Form 1391:

a) Summarize the alternative analysis described inpar.3.5 (may be attached). The summary must address innovativesolutions and the alternative of connecting to a POTW.Guidelines and instructions on economic analysis must also befollowed.

b) Designate the Environmental Compliance Level. Thethree levels follow:

(1) Level I: currently out of compliance.

(2) Level II: known future compliancerequirements.

(3) Level III: compliance enhancement.

c) Address Level I and II designations. A Level I designationmust be supported with noncompliance documentation fromregulators or an official AF assessment. Level II designation

must be supported with the date of future noncompliance and thespecific regulation, standard, or other documentation.


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3.7.3 Environmental Compliance Certificate. An EnvironmentalCertificate of Compliance must be completed and attached to theDD Form 1391 package. This certificate addresses siting and

environmental issues of the project and is completed by the baseenvironmental planning section.

3.7.4 Cost Estimate Models. Computer software is availableto help with cost estimation. Initial cost can be estimatedusing the Environmental Compliance POM Handbook, available fromAFCESA/CES, or other cost models. Detailed cost models such asCAPDET PC can also be used during the PD phase so that theparametric cost estimates reflect the more detailed projectrequirements. Information on the CAPDET PC program can be foundin Appendix E.

3.8 Facility Requirements. Decide as early as possiblewhat design features will be included in the project,particularly Government-furnished equipment (GFE) or supplies.Because of the difficulties in managing GFE, their use is notrecommended.

3.8.1 Future Requirements. Proper WWTP sizing shouldincorporate applicable future requirements identified in par.3.4. The cost of increased plant size to accommodate high I/Irates must be balanced against the cost of correcting the I/Iproblem. A good guide is the EPA publication Infiltration/Inflow - I/I Analysis and Project Certification (see Appendix F).

3.8.2 Facility Input and Printed Design Guidance. Plantoperators and AF engineering staff must provide input on thefacility requirements. Information from such publications asAFM 88-11, Vol. 3, Domestic Wastewater Treatment, should beincorporated. Another important publication is Design ofMunicipal Wastewater Treatment Plants, Vols. I & II, publishedjointly by the Water Environment Federation (WEF) as Manual ofPractice No. 8 and the American Society of Civil Engineers (ASCE)as the Manual and Report on Engineering Practice, No. 76.Operation of Wastewater Treatment Plants: A Field Study TrainingProgram, prepared by California State University, Sacramento, for

the EPA (1990), addresses the concerns of WWTP operators. Thesesources may be used by civil engineering programming personnel in


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determining facility requirements for the WWTP project. Facilityrequirements necessary for design definition include, but are notlimited to, the following:

a) Size and numbers of equipment items (to includepiping)

b) Office and classroom area and operating space

c) Security features (fences and alarms)

d) Safety features (sprinkler systems, eye washes, andchlorine alarms)

e) Parking and traffic requirements

f) Laboratory facilities

g) Laboratory equipment

h) Supply storage area and supplier/operator access

i) Degree of automation

3.9 Regulatory Agency Participation. Lines ofcommunication and points of contact must be established. The AFand DA must provide information to local, state, and Federalregulatory agencies. Regulatory agencies must be involved in the

project review process to ensure compliance with regulationsthroughout the design and construction phases. Accurate andcomplete records of correspondence must be kept to substantiatedischarge limits and other criteria agreed to by the regulators.Firm discharge limits are needed because the limits dictatetreatment options. Attempt to design to standards that willremain unchanged for as long as possible.


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Section 4: DESIGN

4.1 Design Initiation. The Field DI will be issued to the

DM by the requiring MAJCOM. The DI may be issued at any timeafter the MAJCOM receives a PI from AF/CEC. The DI is theauthority to start design actions. These actions include designengineer selection, award, site investigation, and design.

4.2 Design Engineer Selection and Responsibilities. Thefirst phase of the design process is the selection of a designengineer. The engineer designs the WWTP and develops performancecriteria, prepares manuals and training plans, developsconstruction cost estimates, and conducts project oversight.Designing a WWTP is complex and manpower-intensive. Normally anA-E is contracted for the project; however, in-house design is

feasible where experienced designers are available. As an initialtask, the A-E should review and validate wastewatercharacterization and design-basis loadings. The same A-E isoften used for many tasks, including PD, design, contractdocument development, construction oversight, preparation ofSystem Operating Manuals, startup, performance operating period,operator training, and project consultation. Constructionoversight may be limited to the specialized review of treatmentequipment and design problems. This handbook assumes that thesame A-E will complete all tasks. However, time, funding, andother constraints often dictate different arrangements.

4.3 Project Monitoring. The A-E shall use the bestengineering practice. This means that documents shall be clear,concise, and unambiguous. Overly complex facilities andoperations must be avoided. Simplicity is especially importantregarding instruments and controls. In some cases, limitedautomation and monitoring may provide the best results.Monitoring should be compatible with base control systems, ifpractical. Treatment components and systems should provideoperational flexibility and allow for future expansion. Thefacility must be capable of modification or expansion withoutexcessive cost. To reduce costs of adding structures, modularconcepts can be used. Perhaps more important is the capability

to meet changes in discharge requirements. New requirementscould include discharge limits on additional parameters and lower


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discharge limits on existing parameters. Modifications couldalso be required to meet new regulations, such as air quality orland disposal restrictions.

4.4 References. The following reference documents arehelpful in WWTP project design:

a) PB-215-494 (see Appendix B).

b) EPA-430-99-74-001, Technical Bulletin: DesignCriteria for Mechanical, Electrical, and Fluid Systems andComponent Reliability (included as Appendix G).

c) EPA-625/6-84-008, Handbook for Improving POTWPerformance. In particular, see Appendix H, Design-Related

Performance-Limiting Factors (included as Appendix H in thisguidance).

d) AFM 88-11, Vol. 3.

e) AFI 32-7061.

f) AFMAN 65-506.

g) Design of Municipal Wastewater Treatment Plants,Vols. I & II (WEF and ASCE joint publication).

4.5 Project Definition. The A-E shall prepare and submit aPD to the contracting officer. The PD is equivalent to a 10 to15 percent design. The PD shall be used to apply for the WWTPfinal operating permits (par. 6.4). As soon as the PD has beenprepared, the National Pollutant Discharge Elimination System(NPDES) permit applicant shall make contact with the properregulatory agencies to ensure acceptance of the proposedtreatment train and expedite the procurement of this permit (par.4.14).

The designer will develop the detailed technical andfunctional aspects of the project consistent with RAMP planningrequirements. WWTP site issues will be resolved and the

parametric cost estimate validated and revised when necessary.These tasks are completed in the PD phase. A sample statement of


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work for PD can be found in CTL 90-1, Management of the MILCONPlanning and Execution Process. User involvement during the PDphase is important and will help minimize later changes. All

requirements, criteria such as ETLs, and scope are set duringthis phase and used to complete the design and prepare contractdocuments. The PD shall include, but is not limited to, thefollowing elements:

a) A brief description of the wastewater treatmentprocess train, including pretreatment, headworks, primaryclarifiers, biological treatment, final clarifiers, disinfection,effluent disposal, and solids handling

b) Design criteria

c) Simplified process and instrumentation (P&I)diagrams

d) A preliminary wastewater plant hydraulic profile

e) Preliminary site planning

f) Preliminary site grading

g) Plant performance criteria (par.4.7)

h) Negotiated discharge standards

4.6 Construction Documents. The A-E shall prepare designdrawings, specifications, construction cost estimates, and othercontract documents only after the approval of the PD by the AFDM. During this phase, the A-E shall provide, at a minimum, thefollowing services:

a) Preparing construction drawings and specificationsshowing the character and extent of the project based on theapproved PD document. Design review meetings are normally a partof this process.

b) Preparing an estimated total project cost based on

the construction drawings and specifications (par.4.13).


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c) Furnishing all necessary engineering data requiredto apply for construction and regulatory permits from local,state, and Federal authorities.

d) Furnishing to the DA the specified number of copiesof drawings, specifications, and other contract documents.

4.7 WWTP Performance Criteria. A POTW project built usingEPA grant funds requires performance certification by law andregulation (Clean Water Act, Section 204[d]; 40 Code of FederalRegulations [CFR] 35.2218). The certification requirement wasestablished to build high quality treatment works that complywith the enforceable requirements of the Clean Water Act. AFWWTP projects will also follow this performance quality concept.

4.7.1 Performance Certification. The A-E shall beresponsible for developing detailed plant performance criteria.The A-E shall specify the range of discharge values expected fromthe project design. The range of input parameters shall beobtained from the base data used to develop the project designspecifications. A performance test should be developed todemonstrate plant flexibility and performance under a range ofinput parameters and different weather conditions. The plantmust meet final permit effluent quality limits under anticipatedoperational conditions. Some of the conditions and inputparameters can be artificially created. Others, such as weatherconditions, can be demonstrated only over a period of time. A

performance certification report will be required from the A-E atthe end of the performance period. The performance period shouldnormally extend from 3 to 12 months.

4.7.2 Notification. Specifications should state that advancenotice is required before startup and performance testing isinitiated. Such notice will allow base civil engineering (BCE)personnel and operators to be present during startup and testingof the system components. The startup program is explained inpar.6.1.

4.8 O&M Manuals. The operation, maintenance, and repair

information for the WWTP shall be incorporated into two separatemanuals, a System Operating Manual and an Equipment Operating,


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Maintenance, and Repair Manual (EOM&RM). Guidelines forsubmission of these manuals will be in accordance with ETL 89-2,Standard Guidelines for Submission of Facility Operating and

Maintenance Manuals. U.S. Army Corps of Engineers Regulation ER25-345-1, Systems Operation and Maintenance Document, alsoaddresses this requirement using a slightly different approach.

4.8.1 Manual Development Responsibilities. By definition, aWWTP is a complex system and requires two types of manuals. TheA-E will develop the System Operating Manual. The contractor willprovide the EOM&RM in accordance with instructions specified bythe A-E.

4.8.1.1 System Operating Manual Submission. The A-E willprovide to the DA the first draft of the System Operating Manual

upon design completion. The final System Operating Manual shallbe completed and submitted to the DA 60 days before the startupdate. The DA will deliver the manual to the constructionmanagement section to be held until completion of the EOM&RM.The construction contractor shall complete the manual inaccordance with the instructions specified by the A-E.

4.8.1.2 EOM&RM Submission. EOM&RMs will be prepared andsubmitted to the DA 30 days before the startup date. Copies ofthe approved manuals will be forwarded by the construction agent(CA) to the base construction management section, which willforward them, along with the System Operating Manuals, to the

appropriate operations branch work centers.

4.8.1.3 Manual Format. Manuals shall be bound in three-postbinders with tab dividers, in 8-1/2- by 11-inch format. Largedrawings shall be folded and punched to fold out as bound orshall be inserted into a bound pouch. All written portions ofmanuals shall be provided in 3-1/2-inch floppy diskettes andshall be prepared in a word processing software specified by theAF DM. This information shall be prepared by the A-E for theSystem Operating Manual and provided by the contractor for theEOM&RM.

4.8.2 System Operating Manual Content. The System OperatingManual shall provide full and detailed information regarding the


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design criteria and sizing of facilities; standard operatingprocedures (SOPs); description and operation of unit processes;process troubleshooting; regulatory requirements, including

reports and records; sampling and laboratory procedures; plantstaffing; emergency operations; and safety and housekeepingprocedures. Appendix I presents an example table of contentsfrom a System Operating Manual. Also included in this manualshall be sections describing or explaining these elements:

a) P&I diagrams.

b) Single line drawings to show

(1) Color-coded piping for all treatment facilityprocess lines indicating flow direction and location of all

control valves and gates. A complete set of G-tab drawings--showing the locations of all base collection lines, liftstations, force mains, manholes, oil/water separators, and otherunique facilities connected to the system--is normally maintainedseparately at the WWTP.

(2) A simplified electrical schematic of thecontrol system and electrical equipment.

(3) Operating specifications for all pumpingsystems.

c) NPDES permit requirements, along with appropriatestate and Federal regulations and reporting requirements.Information on stream water quality standards should also beprovided for the discharge location.

d) The normal operating process of each component,along with an explanation of its relationship to the othercomponents. Process control and monitoring instrumentationshould be explained and control and valve status charts for thevarious operating modes should be included. The routineoperator's tasks should be described. (See par.7.5.)

e) Process theory and laboratory control testing andmonitoring.


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f) Safety issues and emergency operating procedures(in a separate chapter). Supporting utility systems andalternate power sources should also be described.

g) The requirements for daily operating logs andmaintenance records.

h) Manpower requirements, along with job descriptionsand training and certification requirements.

i) A list of technical references.

4.8.3 EOM&RM Content. The A-E or construction contractorshall prepare instructions based on the information provided bythe equipment vendors in accordance with the construction

specifications. The information must include performance sheetsand graphs for the installed equipment, catalog cuts showingapplication information, installation information showing minimumacceptable requirements, O&M requirements, descriptions ofstarting and stopping procedures, repair information, and a partslist. Specifications shall direct the contractor to prepare theas-built master equipment list by adding the manufacturer's name,the address and phone number of the local representative, and thepart/model/serial number to the design master equipment list(DMEL).

Appendix J includes an example table of contents from

an EOM&RM. The chapter dedicated to Auxiliary Systems shallinclude service support systems not part of the wastewatertreatment process but essential to keeping the processfunctioning as intended. This chapter shall address thefollowing topics:

a) Potable water

b) Power distribution and standby

c) Heating, venting, and air conditioning

d) Fire protection and detection


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e) Nonpotable water

f) Telephone and intercom

4.8.4 DMEL. The A-E shall also prepare a DMEL. The A-E DMELshall include the item name, identification number, andconstruction specification section number for all major pieces ofequipment.

4.9 Operator Training Program. The A-E shall beresponsible for the preparation of the system operating trainingprogram and for the definition of contractor (equipmentmanufacturer) training requirements in accordance with the plansand specifications (see also par. 7.2.2). This requirement isalso addressed in U.S. Army Corps of Engineers Regulation ER 25-

345-1. Training is especially important for base operations butshould be considered even if the WWTP will be contractor-operated. Training videos prepared during the training periodwould also be beneficial for later review and for new operators.

4.9.1 System Operating Training Plan. The A-E shall definesystem operating training requirements. The training may beimplemented by the A-E or the construction contractor. Thetraining plan should include training materials for formaltraining and for operator self-training courses. The A-E shallprepare the training program plan for the overall system andmajor components of the WWTP. The A-E shall detail the minimum

number of hours and types of instruction to be provided for theoverall system and for each subsystem. At a minimum, the BCEoperations flight should review the training plan (par.4.11).This training program plan shall include the following elements:

a) The names, background, and experience of eachinstructor who will participate in the formal implementation ofthe training program.

b) An on-site classroom training program. Trainingshall be conducted between the hours of 7:30 a.m. and 4:00 p.m.,Monday through Friday, unless a different schedule is approved in

writing by the contracting officer.

c) An on-site hands-on training program.


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d) An off-site training program. Off-site trainingshall include visits to similar wastewater treatment facilitiescurrently in operation, if feasible.

The A-E or contractor shall provide all equipment,material, and trained personnel necessary to visually and audiblyrecord all field and classroom training sessions. The proposedrecording system shall be of one manufacturer and of studioquality and shall be approved by the contracting officer prior toits use. Upon completion of training programs, three copies ofthe recordings shall be furnished to the contracting officer.The recording shall be identified, indexed, and placed inapproved storage containers. This task may be excluded from theA-E contract if the base has capabilities to perform the workspecified herein.

4.9.2 Contractor Training Plan. The A-E shall preparetraining specifications detailing the minimum number of hours andtypes of instruction to be provided by the equipmentmanufacturer/vendor and contractor for each subsystem and pieceof equipment warranting training. This specification shallrequire the following provisions:

a) Contractor-provided, qualified, competentinstructors for formal training of Government operators

b) On-site classroom training

c) Off-site training, if needed

4.10 Permit Applications. The DA and DM are responsible forreviewing all construction permit applications (normally preparedby the A-E) and submitting them to the BCE for signature. Thepermit applications are then forwarded to the required regulatoryagencies for approval and permit issuance. The base must alsosubmit applications for a new or revised environmental operating(discharge) permit if the permit authority decides one isrequired for the new facility or to apply the new dischargelimits. During this process, all correspondence shall be

carefully documented and files retained by all parties for futurereference. The project should not go to bid or award, nor should


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a Notice to Proceed be issued, until appropriate permit approvalhas been obtained or reasonable assurance of approval has beenprovided. The following permits may be needed for the WWTP

project:

a) NPDES/State Pollution Discharge Elimination Systempermit (for construction and operation)

b) Local or regional connection application andpretreatment requirement certification, together with stateindirect discharge permit or other permit to discharge to a POTW

c) Sewage lagoon, leaching fields, and septic tankpermits

d) Stormwater runoff permit for the plant constructionsite

e) Air quality permit

4.11 Operator Participation During Design. During thedesign phase, the A-E shall make provisions for involvement andparticipation of the WWTP O&M staff. The DM, ConstructionManager (CM), and O&M staff will form a review team. The majorfunction of the team is to provide input or feedback to the A-Efrom review of the design of the facilities. All input andfeedback will be coordinated through proper, established

channels. The group shall provide input on the following issues,at a minimum:

a) Project definition

b) Construction documents

c) Monitoring process during construction

d) Preparation of O&M manuals

e) Training program

f) Plant startup


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4.12 Design Reliability and Maintainability (R&M). The DAshall provide the A-E with a copy of ETL 88-4, R&M DesignChecklist. The A-E shall complete all applicable sections of the

checklist. The ETL contains design checklists for use indeveloping functional, reliable, and maintainable facilities andsystems constructed by and for the AF. The objective of the ETLis to adequately address R&M during design. Low initialinvestment cost has traditionally been the overriding concern innew construction. This narrow view often results in high O&Mcosts, including manpower, over the life of the WWTP. The bestway to include R&M considerations is to involve operations

personnel in the design review (par.4.11).

4.13 Project Construction Cost Estimate. The A-E isresponsible for developing a detailed cost estimate for

construction of the project. The estimate should include, but isnot limited to, the following materials and services:

a) Materials for construction

b) Manpower for construction

c) Overhead

d) Travel

e) Value engineering

f) Title II inspection services

g) Preparation of regulatory permits

h) O&M requirements of facility (12 months)

i) Outside laboratory testing requirements inaccordance with regulatory requirements

j) Design from A-E

k) Retaining a designer/consultant to provide services

during the construction and startup period of the treatmentfacilities

l) Consumable items during operations (chemicals)


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m) Preparation of O&M manuals

An initial cost estimate shall be prepared by the A-E

and delivered to the AF Contracting Officer at the completion ofthe conceptual design (10 percent design phase). Another costestimate, reflecting the changes during design, will be deliveredto the AF Contracting Officer at the 100 percent design phase. Afinal cost estimate will be delivered to the AF ContractingOfficer at the final inspection and it shall reflect the costchanges during construction.

4.14 Regulatory Agency Review. Federal, state, and localregulatory agencies must be contacted and afforded everyopportunity to review and comment on the design package duringthe design stages. Their involvement will ensure compliance at

all phases and help to control construction change orders as wellas to keep the project on schedule and within budget. It willalso facilitate final permit approvals. Meetings with regulatorsand any review comments must be recorded and the records must beretained. The DA, A-E, and base environmental staff must beinvolved in negotiating discharge standards with the regulators.All agreements, disagreements, and discussions with theregulators must be documented and included in the PD.


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Section 5: CONSTRUCTION

5.1 Construction Startup. The construction phase begins

after the project has been approved, the construction permit hasbeen obtained, and the construction contract has been awarded. Apreconstruction/pre-performance conference is held at the jobsite to establish local ground rules covered by the contract(such as labor standards clauses), rules not covered by thecontract (base regulations), and rules directly related tocontractor actions and interactions on the base. Air ForceFederal Acquisition Regulations Supplement (AFFARS) Subpart5342.5 requires this conference. It is important for the DA andthe base to obtain a construction permit from the appropriateregulatory agency prior to construction contract award. Plantoperator involvement during the construction period is also

beneficial. The lack of appropriate construction permits canresult in project delays and contractor claims.

5.2 Permits and Clearances. The contractor shall obtainfrom the BCE the appropriate base permits or clearances forutilities, safety, and all base environmental issues. Wastewatertreatment facilities may be operated under interim permitconditions. A construction permit can include a temporaryoperating permit issued for 6 months or longer for initialoperation of the facility following substantial completion ofconstruction. The construction contractor must comply with theterms of any applicable permits.

5.3 Title II Construction Services. It is desirable toretain the design A-E for Title II construction services and theinitial performance period.

5.4 Operator Involvement During Construction. The CMshould coordinate site visits for O&M personnel duringconstruction to allow key operations personnel to become familiarwith the location, controls, and operation of the systems andequipment. When the operations personnel identify concerns ordeficiencies, these should be referred to the CM, the BCE, and,when necessary, the MAJCOM for resolution.

5.5 Construction Schedule. The construction schedule mustinclude milestones. Critical permit application and approval


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dates, regulatory inspection time, and permit expiration datesshould be indicated on this schedule. If the project completiondate is driven by a Federal Facility Compliance Agreement, the DA

must ensure the construction completion date meets the regulatoryrequirements.

5.6 As-Built Documentation and Record Drawings

5.6.1 Record Retention. The construction contractor shallmaintain a record copy of the specifications at the site. Amaster equipment list, addenda, change orders, and shop drawingsshall also be available. A set of full-size contract drawingsmust be marked to show any deviations made during constructionand kept at the site. Any buried or concealed feature or utilityrevealed during the course of the construction must also be

shown.

Special attention shall be given to recording allhorizontal and vertical locations. This is important for allburied utilities that differ from the locations indicated or thatwere not indicated on the contract drawings. These recorddrawings shall be supplemented by detailed sketches, where neededor directed, to indicate fully the work as actually constructed.

5.6.2 Record Accessibility. Record drawings shall beaccessible to the CM and the DA at all times during theconstruction period. A set of such record drawings shall be

delivered to the DA within 15 days after completion. The DA isresponsible for delivering a set of these drawings to the DM andBCE. These drawings shall be stamped "AS-BUILT DRAWING," "ASCONSTRUCTED," or "RECORD DRAWING."


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Section 6: INSPECTION COMMISSIONING

6.1 Startup Program. The design A-E or construction

contractor is responsible for preparation of startup proceduresfor the WWTP. AF operators, construction contractor personnel, A-E operations staff, or contract operations personnel may be usedto complete startup activities. The DM/CM will indicate whichresources will be used for each particular project. Startupprocedures shall be prepared and submitted to the DA/CA forapproval by the DM/CM when construction is 90 percent complete.The following startup procedures, at a minimum, are required:

a) A plan and schedule to meet equipment andperformance tests, including dates and test periods. The CA mustknow the test dates in advance to arrange for observation by

interested base personnel.

b) Delivery of EOM&RM, spare parts lists, publicationson the equipment and materials, and suppliers and servicecontacts.

c) Pre-startup training requirements to coverlaboratory, classroom, and hands-on training.

d) A plan to bring the treatment system to theoperational level.

6.2 Inspections (Prefinal and Final). All appropriate AFpersonnel must be notified about the date, time, and location ofthe prefinal and final inspections. These inspections willprovide the final opportunity to question the constructioncontractor. AF treatment plant operations personnel will attendthe inspections. The CA prepares a list of deficiencies, knownas the "punch list," that were identified during the prefinalinspection. These items are to be corrected before the finalinspection. The final inspection verifies that corrections havebeen made and that the project has been completed in accordancewith the approved plans, specifications, and change orders. Thefinal inspection is accomplished after the wet-run test.


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6.3 Liability for Performance. After correction of theconstruction deficiencies and final inspection, meetingperformance criteria is the primary responsibility of the design

A-E. Meeting these criteria does not include correction of anylatent construction deficiencies detected during the performanceperiod. In any case, when responsibility is not clear, the CAmust direct the contractor and designer to correct the deficiencyand determine responsibility later.

6.4 Final Operating Permits. All permits shall befinalized and, when possible, obtained at least 60 days before

the expiration date of the construction permit (par.3.1).Permits may include, but are not limited to, the final NPDESpermit, final air quality permit, fish and wildlife permit, andnoise permit.

6.5 Dry and Wet Runs

6.5.1 Dry Run Inspection. Before the final inspection, theconstruction contractor shall conduct a dry-run inspection oninstalled equipment and systems. The manufacturer'srepresentative, plant operator, and AF construction managementrepresentative shall attend. A form similar to the Pre-StartupInspection Record included as Appendix K shall be used todocument the dry-run inspection. This form shall be prepared bythe A-E prior to the inspection and approved by the CM prior tothe inspection.

During the inspection, the manufacturer'srepresentative or construction contractor shall check theequipment for proper mounting, direction of rotation or travel,proper lubrication with the type of lubricants recorded andproperly filed, clearances, alignments, undue noise andvibration, safety devices, and general operation. The contractorshall remove all rags, stones, paper, and other debris; check forobstructions in the piping; check all gates and valves for properoperation and seating; and ensure all safety chains and guardsare in place. Malfunctions shall be scheduled for correctiveaction and time shall be arranged for the operator's dry-run

training and the wet-run testing of the facilities.


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6.5.2 Wet-Run Tests. The construction contractor shallconduct wet-run tests after the dry-run inspection and before thefinal inspection. The same form used in the dry-run inspection

shall be used in the wet-run tests (Appendix K). Fresh watershall be used for the test. The test will include the followingtasks:

a) Checking all piping and valves for leaks

b) Inspecting operation of all gates and valves

c) Inspecting all pumps

d) Operating all mechanical devices under hydraulicload

e) Inspecting disinfection facilities

f) Observing laboratory sampling and testing equipment

g) Checking all electronic/pneumatic instrumentationfor proper operation

h) Inspecting all flow meters, temperature andpressure indicators, and other sensors

i) Inspecting all weir levels and adjusting forstartup

All deficiencies found during the inspection andtesting should be corrected before startup. The contractor mustdemonstrate that all equipment is properly broken in, allequipment not to be used immediately is properly protected, andall laboratory equipment is inspected for proper calibration andoperation. The A-E is responsible for providing the completedPre-startup Inspection Record to the AF CA at the finalinspection.

6.6 Facility Walk-Through. As soon as the plant isoperating and AF facility acceptance has occurred, a ribbon-

cutting ceremony followed by a walk-through should be scheduled.This walk-through will ensure understanding of the project by all


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concerned and will enhance community relations. Invitedpersonnel should include, but not be limited to, MAJCOMEngineering; the Installation Commander; the BCE; the regional

EPA representative; local and state regulators; local communityleaders; the A-E representative; and the construction contractor.


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Section 7: PERFORMANCE COMMISSIONING

7.1 Post-Startup Program. Post-startup activities include

confirming that the WWTP is operating as planned and establishingtraining programs and SOPs to ensure continued facilityoperation.

7.2 Training. The operator training programs prepared bythe A-E during the design period shall be implemented duringpreparation for startup, during startup, and during the contractperformance period, if necessary. The training process will be acontinuous process and will include monitoring of WWTP staffperformance. Additional training required or recommended by theA-E shall be added to the operator training program.

7.2.1 Training Responsibilities and Notice. Training will beconducted by the A-E, the construction contractor, the equipmentvendors or their representatives, or a combination of these asapproved in the training plan and specified in respectivecontracts. System and equipment O&M manuals should be deliveredin advance (30 days minimum) and available for startup testingand training. Base operating personnel must be given advancenotice (2 weeks minimum) of training to have time to adjusttheir schedules.

7.2.2 Scope of Training. All training conducted during thecommissioning period shall consist of refining the skills

required for routine and nonroutine O&M of the WWTP facilities.This training shall include, but not be limited to, the followingcategories:

a) Plant operation and process control

b) Plant maintenance procedures

c) Laboratory control - sampling and analysis

d) Records and reports

e) Emergency operating procedures

f) Management and administration


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g) Maintenance management system

h) Inventory control system

i) Building and ground maintenance

j) Budgeting and cost accounting

k) Plant electrical systems

l) Safety

m) Computer and control systems

n) Industrial user monitoring

7.3 WWTP Operation Performance Period. The design A-E orconstruction/operations contractor shall be responsible for theO&M of the WWTP during the required performance period. The A-Eor contractor shall demonstrate efficient operation of the WWTP,in compliance with the project performance standards. Assignmentof O&M responsibility during the performance period may vary fromproject to project, depending on the size, type, and complexityof the project and the needs of the AF. Typical A-E orconstruction/operation contractor responsibilities may include,but are not limited to, the following tasks:

a) Directing the operation of the treatment works.(Note: to "direct" does not mean to establish a daily "in charge"presence at the treatment works or to assume the role of employeesupervisor or chief operator.)

b) Revising the O&M manual to reflect actual operatingexperience.

c) Training operators.

d) Providing engineering consultation.

e) Reviewing laboratory procedures.

f) Conducting periodic site visits to ensure properoperations on smaller WWTPs.

g) Checking process units, sewers, facilities, flows,etc., to ensure proper operation.


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h) Preparing ongoing records of plant performance,including tables and graphs monitoring influent quantity andquality, effluent quality, and unit processes control parameters.

7.4 Performance Certification. The plant performancecriteria developed by the design A-E during design of thefacilities shall be tested, and a performance certification

report prepared in accordance with par.4.7. During theperformance period, the design A-E shall observe and evaluateplant operations and provide advice and assistance to achievesatisfactory plant performance. The design A-E shall advise theAF if the project is meeting performance standards. If it isnot, the A-E shall provide the reasons for not meeting thesestandards. The design A-E shall be responsible for anycorrective action necessary to bring the project into compliance

with performance criteria. Liability for performance isdiscussed in par.6.3. If plant operation does not meet thecriteria, the A-E shall prepare and submit the following items:

a) A corrective action report. This report shallinclude an analysis of the cause of the project's failure to meetthe performance criteria and an estimate of the nature, scope,and cost of corrective action required to bring the project intocompliance.

b) A schedule for undertaking corrective action in atimely manner.

c) The scheduled date by which the A-E will be able tocertify the project meets performance criteria.

At the end of the performance period, and afterperformance certification, the AF accepts responsibility for theWWTP. Following the guidance in this handbook will ensure theA-E has met the design and performance requirements.


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7.5 SOPs

7.5.1 SOP Submission. The A-E shall provide the contracting

officer a draft of the SOPs at 50 percent construction completionand the final draft of the SOPs 30 days prior to constructioncompletion. At the end of the performance period, the A-E shallalso provide a site-tested, final SOP for each major component ofthe treatment plant.

7.5.2 Processes Requiring SOPs. The SOPs are part of the

system O&M manuals (par.4.8.2) and may require revision toreflect actual operating experience. SOPs shall be prepared forall processes including, but not limited to, those listed below:

a) Pumping stations

b) Screening removal and disposal

c) Grit removal

d) Primary treatment

e) Biological treatment

f) Advanced treatment

g) Sludge handling system

h) Tank drainage system

i) Fuel storage and distribution system

j) Potable water system

k) Plant water system

l) Power distribution system

m) Standby power system

7.5.3 Elements of SOPs. Each SOP shall contain, at aminimum, the following elements:


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a) A component numbering identification system foreach valve, control point, and unit process

b) Descriptions of normal valve settings, flowdiversions, and operational requirements

c) Descriptions of routine operating proceduresincluding startup, break-in, normal operation, regulating,controlling, stopping, shutdown, emergency, special visualobservations, and recordkeeping

d) Descriptions of routine safety procedures andpotential danger areas

7.5.4 SOP Format. One final set of SOPs shall be printed on

durable 8-1/2- by 11-inch paper. Graphics, photos, andillustrations shall be used to the greatest practical extent.The SOPs shall not be more than 10 pages in length each, andshall be ring-bound with a plastic protective cover. All writtenportions of the SOPs shall be provided to the contracting officeron a 3-1/2-inch diskette and shall be prepared in a wordprocessing software specified by the AF DM.

7.6 O&M Service Contract Documentation (Optional). The A-Eshall prepare contract documents for use by the Government in thesolicitation of bids from qualified contractors. These documentswill cover O&M of the WWTP for the base period in full compliance

with regulatory requirements. Two optional periods of 12 monthseach shall be included in the bid package. These servicecontract documents shall include, but not be limited to, theperformance work statement, the bid form, and the cost estimate.

7.6.1 Performance Work Statement. The performance workstatement will address these topics:

a) Equipment and facilities operation, maintenance,

and repair, in accordance with O&M manuals (par.4.8.3)

b) Building and facility maintenance in accordance

with O&M manuals (par.4.8.3)

c) Staffing and training requirements


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d) Government-furnished services and property

e) Tools and spare parts in accordance with O&M

manuals (par.4.8.3)

f) Consumable requirements, including chemicals andfuels

g) Permit requirements

h) Analytical testing requirements

7.6.2 Bid Form. The bid form shall list unit price items,for major components only, for the base period. Unit price itemsfor the O&M of major components shall be listed on a monthly

basis for the base period and for the two optional periods of12 months each.

7.6.3 Cost Estimate. The A-E shall develop an estimate forthe cost of operating and maintaining the WWTP for a 12-monthperiod. The cost estimate shall be prepared on a cost-per-monthbasis.


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WASTEWATER TREATMENT PLANT MANAGEMENT CHECKLIST

WASTEWATERTREATMENT PLANTMANAGEMENT CHECKLIST DATE: ________________________ PAGE 1

OF 4

PROJECTNAME:BY:___________________________

PARAGRAPH DESCRIPTION DATE COMPLETED RESPONSIBILITY COMMENT

NO. SCHEDULED ACTUAL OFFICE/PHONE NO.

2 Facilities Planning

2.2 Requirement identification (BCP, NOV,ECAMP)

OPR:OCR:

2.3 Problem definition OPR:OCR:

2.3.2 Regulatory requirements review OPR:OCR:

2.3.3 Additional engineering studies OPR:OCR:

2.4 A-106 report OPR:OCR:

2.5 Environmental compliance funding OPR:OCR:

3 Programming

3.2 Requirements and Management Plan (RAMP) OPR:OCR:

3.3 Engineering studies review OPR:OCR:

3.4 Future requirements review OPR:OCR:

3.5 Evaluation of alternatives OPR:OCR:

3.6 EA/EIS Initiation OPR:OCR:


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OF 4

PROJECTNAME:BY:___________________________



3.7 DD Form 1391 and supporting documents OPR:OCR:

3.8 Determine facility requirements (size,space, automation, etc.)

OPR:OCR:

3.9 Regulatory agency participation OPR:OCR:

4 Design

4.5 Project definition completed OPR:OCR:

4.6 Construction documents OPR:OCR:

4.7 WWTP performance criteria OPR:OCR:

4.8 O&M manuals OPR:OCR:

4.9 Operator training program OPR:OCR:

4.10 Permit applications OPR:OCR:

4.11 O& M operator review and participationduring design

OPR:OCR:

4.12 Design reliability and maintainability OPR:OCR:


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OF 4

PROJECTNAME:BY:___________________________



4.13 Project construction cost estimate OPR:OCR:

4.14 Regulatory agency review OPR:OCR:

5 Construction

5.2 Construction permit approved OPR:OCR:

5.3 Title II construction services OPR:OCR:

5.4 Operator involvement during construction OPR:OCR:

5.5 Construction schedule OPR:OCR:

5.6 As-built documents OPR:OCR:

6 Inspection Commissioning

6.2 Completion of construction and prefinalinspection

OPR:OCR:

6.3 Liability for performance OPR:OCR:

6.4 Final operating permits OPR:OCR:


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OF 4

PROJECTNAME:BY:___________________________



6.5 Dry-run inspection and wet-run test OPR:OCR:

6.2, 6.5 Final inspection OPR:OCR:

6.6 Ribbon cutting and facilities walk-through OPR:OCR:

7 Performance Commissioning

7.2 Training program implementation OPR:OCR:

7.3 WWTP operation performance period OPR:OCR:

7.4 Performance certification OPR:OCR:

7.5 Standard operating procedures (SOPs) OPR:

OCR:7.6 Operation and maintenance service contract

documentation (optional)OPR:OCR:


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MAJCOM

MAJCOM

DocumentPreparation 100%

ProjectDefinition

In-HouseA-E Contract

DesignAgent

DesignReview

DM

MAJCOM MAJCOM

DesignReview

COMPLETEENVIRONMENTAL

ANALYSIS

MAJCOM MAJCOM

Cost

DM

MAJCOM

DM

ConstrAgent

BidRev

AppAuth

WhenRequired

AdvAuth

Bid Opening

AwardConstrAgent 100%

CM, MAJCOM & BCE

AcceptFacility

FacilityTransfer

BCE

CM

MAJCOM

Final

Cost

FC

Funds

Requestfor

AdditionalFunds

forChanges

Change

Ord

er

Approval

Construction

MAJCOMCECM

Adv

Auth

PresidentCongress

Hearings

Budget

Sign

Auth/

Appr

OSDSAF

CECD

MAJCOM

Final

1391

DM

CECM

Cost

CECM

SAF

Congress

21 DayNoticePeriod

2807

2807

DesignAuth

&DD1391

Cost

MAJCOM

AdjBES

BES/ DD1391

Cost

PI

PI

Cost

DI&RAMP

MAJCOMCE

DMBCEFacilityBoardUser

DD1391

DD1391

Requirem

ents,

Validation

BCE

Siting

IDNeeds

Design

ProgrammingPlanningParametric Cost Est

AF 1178

Surveillance

Parametric

Cost Estimate


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CY-3 CY-2 CY-1

J F M A M J J A S O N D J

CY

FY-3 FY-2 FY-1 FY

Award & Construction

Advertise

Base 1391 MAJCOM Programming15 Aug

Review FAs

15 JanPresidents Budget

15 SepBES Exhibits

Air Force POMDevelopment

Requirements & MgmtPlan + Parametric Est

Air Force BudgetPreparation

BudgetReview

Congressional Review

A-E Selection ProjectDefinition Project Design

31 JanSubmit 1391sP.I. Issued


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APPENDIX G

76

TECHNICAL BULLETIN

DESIGN CRITERIA FOR MECHANICAL, ELECTRIC,AND FLUID SYSTEM AND COMPONENT RELIABILITY

Supplement to Federal Guidelines for Design,Operation, and Maintenance of Waste Water

Treatment Facilities

Office of Water Program OperationsU. S. Environmental Protection Agency

Washington, D. C. Z0460

For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402 - Price 85 cents


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FOREWORD

In response to the recent clean water legislation, this country willundertake an unprecedented building program for new and improvedmunicipal wastewater treatment works. It is the responsibility ofthe EPA to ensure that the Federal funds authorized under Title II ofPL 92-500 for this program will be justifiably spent. Accordingly,we must ensure that these works have been designed with a high degreeof technical excellence and will operate effectively day in and dayout. As a part of this effort, this Technical Bulletin provides anational standard to help ensure that unacceptable degradation of theworks' effluent does not occur from time to time as a result ofperiodic maintenance or the malfunctioning of mechanical, electric,and fluid systems and components.

To assure a workable and effective document, we have involved allsectors of the wastewater treatment industry in the development andreview of this Technical Bulletin. In this regard, I particularlywish to thank the EPA Technical Advisory Group for Municipal WasteWater Systems for their advice and counsel.

The design criteria contained in this Technical Bulletin are meant tobe specific enough to have force and meaning, yet have administrativeflexibility so as to permit innovation as to how the intent of thecriteria will be met in each individual case. It is our intent toupdate and revise these criteria as experience dictates.

I am confident that through the continued efforts and cooperation ofthe engineering profession, the objective of improved reliability ofwastewater treatment works will be achieved.

Robert L.SansomAssistant Administratorfor Air and Water Programs


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TABLE OF CONTENTS

Page

Foreword i

Purpose 1

Applicability of Technical Bulletin 1

Definitions 2

Terms Used in Specifying Criteria 4

Reliability Classification 5

100. Works Design Criteria 7

200. System Design Criteria 14

210. Wastewater Treatment System 15220. Sludge Handling and Disposal System 30230. Electric Power System 38240. Instrumentation and Control Systems 47250. Auxiliary Systems 49


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DESIGN CRITERIA FOR MECHANICAL,ELECTRIC, AND FLUID SYSTEM AND

COMPONENT RELIABILITY

Purpose

The purpose of this Technical Bulletin is to amplify and

supplement the Federal Guidelines for Design, Operation, and

Maintenance of Wastewater Treatment Facilities with regard to

establishing minimum standards of reliability for mechanical,

electric, and fluid systems and components. This Technical Bulletin

provides reliability design criteria for wastewater treatment works

projects seeking Federal financial assistance under PL 92-500.

Applicability of Technical Bulletin

New treatment works and additions or expansions to existing

treatment works shall comply with this Technical Bulletin. Portions

of existing works, for which the addition or expansion is dependent

for reliable operation, shall comply with this Technical Bulletin to

the degree practicable. There may be some treatment works for which

fulfillment of some of the design criteria may not be necessary or

appropriate. There will be other cases in which these criteria are

insufficient, and additional criteria will be identified by the

Regional Administrator. It is expected that additional criteria may

be needed for unusual environmental conditions and for new processes.

Within this context, the design criteria should be used as a

reference, allowing additions or deletions as an individual case may

warrant.

A basic requirement specified in these criteria is component

backup. However, system reliability can also be attained through

flexibility in the design and operation of systems and components.


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This document does not attempt to define requirements for system

flexibility.

Definitions

The following definitions apply to the terms used in this

Technical Bulletin:

Component - A single piece of equipment which performs a specific

function in the wastewater treatment works. In this context a

component may be an entire piece of process equipment (e.g.,

sedimentation basin or vacuum filter) or may be a single piece of

equipment