Attachment_2_-_O&M_Maint._Manual_final.pdf

USCG Jonesport Station WTF Operation & Maintenance Manual

227179 Northeast Civil Solutions Scarborough, ME October 31, 2013 woodardcurran.com

COMMITMENT & INTEGRITY DRIVE RESULTS

ATTACHMENT 2

USCG Jonesport Station WTF (227179) i October 31, 2013 Operation & Maintenance Manual Woodard & Curran

TABLE OF CONTENTS

SECTION PAGE NO.

1. INTRODUCTION ......................................................................................................................................1-1

1.1 Operation and Maintenance Manual User Guide............................................................................... 1-1

1.2 Updates and Revisions to the O&M Manual ...................................................................................... 1-1

1.3 General Abbreviations ......................................................................................................................... 1-1

1.4 Operations Personnel .......................................................................................................................... 1-2

1.4.1 Treatment/Operations References...................................................................................................... 1-2

1.5 General Description of Facility ............................................................................................................ 1-2

1.6 Design Flow.......................................................................................................................................... 1-5

1.7 Clearwell Volumes & Dimensions ....................................................................................................... 1-5

2. GENERAL FACILITY OPERATION AND CONTROL...........................................................................2-1

2.1 SCADA Control System Overview ...................................................................................................... 2-1

2.1.1 SCADA Access .................................................................................................................................... 2-3

2.1.2 SCADA System Troubleshooting ........................................................................................................ 2-3

2.2 Alarms................................................................................................................................................... 2-3

2.3 Equipment Run Timers ......................................................................................................................2-10

2.4 Hand-Off-Remote (HOR) Selector Switches ....................................................................................2-10

2.5 Equipment Status Indication..............................................................................................................2-11

2.6 Control Panel Monitoring & Alarms...................................................................................................2-11

2.6.1 Loss of 120 VAC Power.....................................................................................................................2-11

2.6.2 Uninterruptable Power Supply (UPS) Fault ......................................................................................2-11

2.6.3 Uninterruptable Power Supply (UPS) Low Battery ..........................................................................2-11

2.7 Electrical Power Supply .....................................................................................................................2-11

2.7.1 WTF Emergency Generator ..............................................................................................................2-12

2.8 Automatic Transfer Switch (ATS)......................................................................................................2-12

2.8.1 ATS Main Operator Panel..................................................................................................................2-12

2.9 General Chemical Feed System Operation......................................................................................2-12

2.9.1 Chemical Information .........................................................................................................................2-12

2.9.2 Chemical Dilution and Mixing ............................................................................................................2-13

2.9.3 Metering Pump Feed Rate ................................................................................................................2-14

2.9.4 Chemical Use Estimate .....................................................................................................................2-15

3. FILTRATION SYSTEM ............................................................................................................................3-1

3.1 Raw Water Supply ............................................................................................................................... 3-1

3.2 Filtration System Overview.................................................................................................................. 3-2

3.3 Filter Operation..................................................................................................................................... 3-3

3.4 Forward Flow/ Filtered Water Production ........................................................................................... 3-7

3.4.1 Polymer Feed ....................................................................................................................................... 3-7

3.4.2 Filter Turbidity Monitoring .................................................................................................................... 3-7

3.5 Backwash ............................................................................................................................................. 3-7

3.5.1 Air Scour ............................................................................................................................................... 3-8

3.5.2 Backwash ............................................................................................................................................. 3-8

3.5.3 Filter to Waste ...................................................................................................................................... 3-8

USCG Jonesport Station WTF (227179) ii October 31, 2013

3.5.4 Example Manual Backwash Sequence .............................................................................................. 3-9

3.5.5 Backwash Rate and Volume ............................................................................................................... 3-9

4. DISINFECTION & PH CONTROL ...........................................................................................................4-1

4.1 General ................................................................................................................................................. 4-1

4.2 Sodium Hypochlorite System .............................................................................................................. 4-1

4.2.1 Sodium Hypochlorite System Controls ............................................................................................... 4-3

4.3 Soda Ash System................................................................................................................................. 4-4

4.4 Finish Water Analytical System........................................................................................................... 4-5

5. HIGH LIFT PUMPING ..............................................................................................................................5-1

5.1 High Lift Pump System ........................................................................................................................ 5-1

5.2 Auxiliary Pump ..................................................................................................................................... 5-3

5.3 Pier Water Supply ................................................................................................................................ 5-5

6. SAMPLING AND REPORTING...............................................................................................................6-1

6.1 Drinking Water Program Compliance Sampling................................................................................. 6-1

6.2 Drinking Water Program Reporting..................................................................................................... 6-1

6.3 Process Control Sampling ................................................................................................................... 6-1

7. GENERAL SAFETY.................................................................................................................................7-1

7.1 Safety Laws and Regulations.............................................................................................................. 7-1

7.2 Physical Injury ...................................................................................................................................... 7-1

7.2.1 Back Protection .................................................................................................................................... 7-1

7.2.2 Hearing Protection ............................................................................................................................... 7-1

7.2.3 Eye Protection ...................................................................................................................................... 7-2

7.3 Confined Space Entry .......................................................................................................................... 7-2

7.4 Electrical Hazards ................................................................................................................................ 7-2

7.5 Machine Guarding................................................................................................................................ 7-3

7.6 Lock-Out and Tag-Out Procedures..................................................................................................... 7-4

8. PREVENTATIVE MAINTENANCE..........................................................................................................8-1

8.1 Lubrication ............................................................................................................................................ 8-1

8.2 Electrical Maintenance......................................................................................................................... 8-2

8.3 Good Housekeeping ............................................................................................................................ 8-2

8.4 Preventative Maintenance Schedule .................................................................................................. 8-2

LIST OF TABLES

TABLE PAGE NO.

Table 1-1: USCG Jonesport WTF Production Information ..............................................................................................1-5

Table 1-2: Tank Volumes & Dimensions ..........................................................................................................................1-5

Table 2-1: Chemical Mixing and Dilution Rates .............................................................................................................2-14

Table 2-2: Metering Pump Calibration Table..................................................................................................................2-15

USCG Jonesport Station WTF (227179) iii October 31, 2013

Table 2-3: Chemical Use Estimate..................................................................................................................................2-15

Table 3-1: Clarifier Vessel Media Schedule .....................................................................................................................3-2

Table 3-2: Filter Vessel Media Schedule..........................................................................................................................3-2

Table 3-3: Filter System Valve Operation Summary........................................................................................................3-6

Table 3-4: Filter System Equipment Operation Summary...............................................................................................3-6

Table 3-5: Backwash Rate Temperature Correction Factors ........................................................................................3-10

Table 4-1: CT Values for Inactivation of Giardia cysts by Free Chlorine at 10°C..........................................................4-2

Table 4-2: Contact Time Table..........................................................................................................................................4-2

Table 6-1: Recommended Process Control Testing ........................................................................................................6-2

Table 7-1: OSHA Maximum Noise Exposure Guidelines ................................................................................................7-2

Table 8-1: Pump PM Schedule .........................................................................................................................................8-3

Table 8-2: Valve PM Schedule..........................................................................................................................................8-3

Table 8-3: Chemical Feed PM Schedule..........................................................................................................................8-4

Table 8-4: Instrumentation PM Schedule .........................................................................................................................8-4

Table 8-5: Compressed Air PM Schedule ........................................................................................................................8-5

Table 8-6: Filter System PM Schedule .............................................................................................................................8-5

Table 8-7: Distribution System PM Schedule...................................................................................................................8-5

LIST OF FIGURES

FIGURE PAGE NO.

Figure 1-1: WTF Schematic...............................................................................................................................................1-4

Figure 2-1: SCADA Control System Overview.................................................................................................................2-1

Figure 2-2: SCADA Menu Screen.....................................................................................................................................2-2

Figure 2-3: SCADA Navigation and Help Screen.............................................................................................................2-3

Figure 2-4: Alarm History...................................................................................................................................................2-4

Figure 2-5: Alarm Setup Screen 1.....................................................................................................................................2-5

Figure 2-6: Alarm Setup Screen 2.....................................................................................................................................2-6

Figure 2-7: Alarm Setup Screen 3.....................................................................................................................................2-7

Figure 2-8: Alarm Setup Screen 4.....................................................................................................................................2-8

Figure 2-9: Communications Systems Overview .............................................................................................................2-9

Figure 2-10: Run Time Screen ........................................................................................................................................2-10

Figure 3-1: Raw Water Screen..........................................................................................................................................3-1

USCG Jonesport Station WTF (227179) iv October 31, 2013

Figure 3-2: Filter Control Screen.......................................................................................................................................3-3

Figure 3-3: Filter System Valve Operation Summary ......................................................................................................3-5

Figure 4-1: Chemical Feed Control Screen......................................................................................................................4-4

Figure 5-1: High Lift Pump Control Screen.......................................................................................................................5-2

Figure 5-2: Hydropneumatic Tank Sight Glass ................................................................................................................5-3

Figure 5-3: Auxiliary Pump Starter Panel .........................................................................................................................5-4

Figure 5-4: Auxiliary Pump Backflow Protector ................................................................................................................5-5

Figure 5-6: Pier Backflow Preventer Station ....................................................................................................................5-6

APPENDICES

Appendix A: Equipment List

Appendix B: Sampling Schedule

Appendix C: Monthly Operating Reports

USCG Jonesport Station WTF (227179) 1-1 October 31, 2013

1. INTRODUCTION

1.1 OPERATION AND MAINTENANCE MANUAL USER GUIDE

This Operation and Maintenance (O&M) Manual provides the information necessary to operate and maintain the United States Coast Guard (USCG) Jonesport Station drinking water treatment facility (WTF) located on Bridge Street in Jonesport, Maine. Where applicable this manual will reference other manuals or documents such as equipment manufacturer’s O&M documents, WTF standard operating procedures, safety guidelines, and other applicable policies.

1.2 UPDATES AND REVISIONS TO THE O&M MANUAL

The operation of the processes at the WTF may change with time because of changing water characteristics, changing regulating authority requirements, and/or the incorporation into the treatment processes of additional or new equipment. As changes occur, this Operation and Maintenance Manual must be updated to describe the changes.

1.3 GENERAL ABBREVIATIONS

General abbreviations that are used throughout the O&M manual are summarized below.

Control Panel (CP): Local control panels include but are not limited to: CP-101 (Main Control Panel).

Operator Interface Terminal (OIT):

Operator interface terminal located in main control panels (see above). The OITs are either touch-screen or key pad panel views.

Control System: The Control System consists of all hardware, software, programming and equipment/instrumentation setup required to control and operate the process equipment.

“Local” or “Hand” Operation will be initiated by a push button or selector switch located in the field adjacent to the piece of equipment or on the front of the bucket.

“Remote Manual” Operation allows an operator to control a piece of equipment (e.g. start/stop or open/close) from the equipment’s OIT or main SCADA terminal.

“Remote Automatic” Operation allows an operator to control the operation of a piece of equipment (e.g. start/stop or open/close) based on control logic programmed into the PLC.

HOR/HOA: Hand-Off-Remote/Hand-Off-Automatic

PLC: Programmable Logic Controller

{##} Brackets {} denote an operator adjustable software set point

USCG Jonesport Station WTF (227179) 1-2 October 31, 2013

1.4 OPERATIONS PERSONNEL

The WTF is a Contract-operated facility. Contractor contact information is provided below and should be updated annually or with any staffing changes:

Contractor:

Contact Name:

Contact Phone:

Contact Mobile Phone:

Contact Email:

Operator qualifications are based on rules set by the Drinking Water Program (DWP) of the Maine Department of Health and Human Services, Division of Human Health. As of 2013, a Treatment Class III and a Distribution Class I license is required to meet DWP operator licensing requirements.

The station also designates the Engineering Petty Officer as responsible for coordinating with the contract operator, maintaining records, and arranging for maintenance as needed. To date, the Engineering Petty Officer has not required a water treatment operator license.

On-call plumbing and distribution system services are currently provided by:

J.L. Huntley, Inc., of Machias, Maine.

1.4.1 Treatment/Operations References

The following is a list of recommended resources for water treatment plant operators:

“Water Treatment Operator Training Handbook, 3rd Edition” published by the American Water Works Association (AWWA).

“Small Systems Guide to Safe Drinking Water Act Regulations” published by United States Environmental Protection Agency, Office of Ground Water and Drinking Water, September 2003.

The following is a list of recommended laboratory procedural method resources for water treatment plant operators:

Standard Methods for the Examination of Water and Wastewater, Water Environment Federation, 601 Wythe Street, Alexandria, Virginia 22314-9990, latest edition, telephone: (800) 666-0206.

1.5 GENERAL DESCRIPTION OF FACILITY

The USCG Jonesport system is classified as a Community Water System (CWS), serving approximately 25 people. Most of the service population is comprised of members of the Coast Guard that are stationed in Jonesport or members of the crew of the Moray, as well as family members using government housing.

The Moray is a cutter that is based out of the Jonesport Station.

As a CWS, the Jonesport facility is regulated under the Federal Safe Drinking Water Act, which is administered by the Drinking Water Program (DWP) of the Maine Department of Health and Human Services, Division of Human Health. The USCG WTF operates as Public Water Supply (PWS) Identification Number ME0091830.

The DWP assigns a Field Inspector and Compliance Officer to each regulated water system. The DWP staff contact information is provided below:

USCG Jonesport Station WTF (227179) 1-3 October 31, 2013

DWP Field Inspector: Rychel McKenzie (207) 592-4826

DWP Compliance Officer: Lindy Moceus (207) 287-8402

The USCG Jonesport facility’s drinking water source is classified as a “groundwater source under the direct influence of surface water” (GWUDI) due to its close proximity to an adjacent pond and subsequent susceptibility to rapid changes in water quality. This classification requires treatment according to the Federal Surface Water Treatment Rule, which requires the use of a filtration process for most water sources.

The USCG Jonesport Station’s water source is from a stone-lined dug well located approximately 1,700 feet north of the station’s water treatment building. As-built plans of the dug well, aka cistern, describe it as approximately 20 feet inside diameter and 14 feet deep, with a brick parapet riser supporting a wooden cover. The cover was replaced by the USCG staff with a welded aluminum conical-shape cover in 1998 with a lockable hatch cover and vent opening. The piping from the cistern to the station appears to be 4-inch diameter unlined cast iron pipe, which is likely 50 years old.

Raw water from the cistern is treated by an upflow clarifier and downflow pressure filter. A coagulant is added prior to the clarifier to aid in particulate removal. Following filtration, sodium hypochlorite is added to provide disinfectant residual. Filtered water is stored in an approximately 20,000-gallon, four-chambered concrete clearwell. The clearwell is located beneath a storage building adjacent to the maintenance garage and water treatment equipment room.

Finish water is pumped into the distribution system by high lift pumps. Soda ash (sodium carbonate) is added to increase the finished water pH. System distribution pressure is sustained by two approximately 700-gallon hydropneumatic tanks.

The following figure is a schematic representation of the treatment system and components.

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USCG Jonesport Station WTF (227179) 1-5 October 31, 2013

1.6 DESIGN FLOW

The design flows that were used in the system design are provided in the table below.

Table 1-1: USCG Jonesport WTF Production Information

Production Category Capacity

Production Rate 12-15 gallons per minute Plant Capacity 17,000-21,000 gallons per day Average Use 2,500 gallons per day

1.7 CLEARWELL VOLUMES & DIMENSIONS

The WTF tank volumes and dimensions are summarized in the following table. The side water depth refers to the distance from the respective tank effluent weir invert to the tank floor.

Table 1-2: Tank Volumes & Dimensions

Tank (Each) Length

(ft) Width

(ft) Max. Water Depth (ft)

Volume (gallons)

Clearwell 18 18.25 8 19,700

Using the dimensions above, the clearwell has a volume of approximately 2,462 gallons per foot of depth.

USCG Jonesport Station WTF (227179) 2-1 October 31, 2013

2. GENERAL FACILITY OPERATION AND CONTROL

This section describes general facility control and (SCADA) system operation. The subsequent sections provide an outline of each specific area of the WTF including the respective process equipment and associated controls. Refer to each of the respective sections in this manual for specific details of SCADA process control, alarms, common system operating parameters and system troubleshooting.

2.1 SCADA CONTROL SYSTEM OVERVIEW

The SCADA control system provides several different functions including process control, data logging, alarm tracking, alarm acknowledgement, reporting, and a variety of other useful tools and process information. The SCADA control system will be described in more detail in subsequent sections.

Figure 2-1 below provides an illustration of the System Overview screen, which includes most of the treatment equipment and processes and their associated control functionality in the SCADA system.

Figure 2-1: SCADA Control System Overview

Figure 2-2 and 2-3 below shows a list of all of the screens included in the system via the USCG Jonesport control system Menu screen and Navigation and Help screen:

USCG Jonesport Station WTF (227179) 2-2 October 31, 2013

Figure 2-2: SCADA Menu Screen

USCG Jonesport Station WTF (227179) 2-3 October 31, 2013

Figure 2-3: SCADA Navigation and Help Screen

2.1.1 SCADA Access

The SCADA system has local operator interface terminal (OIT) in the facility, located on the main control panel. The system is password-protected to prevent unauthorized controls modifications.

Remote access for the Contract Operator is accomplished by logging into the control system’s webport via telephone connection. Refer to the SCADA system Operation and Maintenance Manual for access instructions.

2.1.2 SCADA System Troubleshooting

For support and troubleshooting of the Plant’s SCADA system, please refer to the SCADA System Operation and Maintenance Manual.

2.2 ALARMS

As shown in Figure 2-2, the control system provides a dedicated Alarm Summary selection link on the screen menu. Extensive alarm control and functionality has been provided as part of the control system.

The control system has a dedicated menu that will allow the operators to “Enable” or “Disable” each alarm in the WTF for each respective piece of equipment or system. All alarms have an operator adjustable time delay in units of “Seconds” prior to alarm activation. The length of the alarm delay

USCG Jonesport Station WTF (227179) 2-4 October 31, 2013 periods are operator adjustable based on the desired signal response times. The alarm delays should be adjusted as required to provide system protection while avoiding nuisance alarms. Alarm enable/disable, delays, and dial-out/warning adjustments are password protected. Figure 2-4, shows an example of the alarm history display and log which is provided by the control system. Figure 2-5-through 2-8 illustrate each of the alarms at the WTF via (CP-101) as well as the current settings with respect to over-rides, dial-outs, and delays.

Figure 2-4: Alarm History

USCG Jonesport Station WTF (227179) 2-5 October 31, 2013

Figure 2-5: Alarm Setup Screen 1

USCG Jonesport Station WTF (227179) 2-6 October 31, 2013

Figure 2-6: Alarm Setup Screen 2

USCG Jonesport Station WTF (227179) 2-7 October 31, 2013

Figure 2-7: Alarm Setup Screen 3

USCG Jonesport Station WTF (227179) 2-8 October 31, 2013

Figure 2-8: Alarm Setup Screen 4

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USCG Jonesport Station WTF (227179) 2-10 October 31, 2013

2.3 EQUIPMENT RUN TIMERS

The SCADA system monitors and displays the total ‘lifetime’ run time for all motors in units of ##,###.# hours, as well as hours run in the current and last day of operation. Figure 2-6 below shows an overview of the elapsed time meters for each piece of equipment.

The following figure shows the Run Time screen for monitoring of the elapsed run time of each piece of equipment for maintenance purposes.

Figure 2-10: Run Time Screen

2.4 HAND-OFF-REMOTE (HOR) SELECTOR SWITCHES

In general, Hand-Off-Auto (HOA) or Hand-Off-Remote (HOR) switches are provided for each major piece of process equipment and are mounted near the equipment. When the HOA or HOR switch is NOT in “Auto” or “Remote”, (switch in “Off” or ‘Hand”) the SCADA system does not control operation of the respective piece of equipment.

When the local HOA or HOR switch is in the “Hand” position, the unit will run regardless of the settings at the SCADA system. When in “Hand” the equipment will run at full speed. “Hand” operation is intended only for maintenance, for equipment jog and testing/troubleshooting procedures ONLY.

USCG Jonesport Station WTF (227179) 2-11 October 31, 2013

In the event of a problem with the control system, it is recommended that the treatment system be run manually and continuously staffed as necessary to produce water until the control system is back online, which under most circumstances will be within 24 hours.

When the equipment is running with the HOA in the “Hand” position, only the basic equipment safety measures are operable. These safety measures will prevent damage (e.g. motor overloads and basic interlocks) to the equipment or system but will not provide equivalent functionality to the PLC-based control system.

When the local selector switch is in the “Off” position the equipment will be “Off”.

When in “Auto” or “Remote” the equipment can be operated through the control system in one of the following two modes:

Remote Manual – “RM”

Remote Automatic – “RA”

2.5 EQUIPMENT STATUS INDICATION

The SCADA system displays the status of all equipment, valves, and analog instrumentation. Status indication includes whether or not the equipment is energized/running, valve position open/closed, and the value of analog inputs along with their respective units of measure. All analog inputs also include a graphical depiction of the measured quantity in proportion to the scale of the range (e.g. water level in a tank). Liquid levels in all tanks are also displayed in depth (feet) and in volumes of (gallons as determined by tank geometry).

2.6 CONTROL PANEL MONITORING & ALARMS

Critical status points are monitored and alarmed within the Control Panels as follows.

2.6.1 Loss of 120 VAC Power

The PLC will monitor the status of the incoming 120 VAC power feed via a discrete input. When the PLC detects a loss of the 120 VAC power feed, a “Loss of 120 VAC Power” alarm will be displayed.

2.6.2 Uninterruptable Power Supply (UPS) Fault

The PLC will monitor the status of the UPS in the control panel via discrete input. When the UPS reports a fault in any of the control panels, a “UPS General Fault” alarm will be displayed.

2.6.3 Uninterruptable Power Supply (UPS) Low Battery

The PLC will monitor the status of the UPS battery in the control panel via discrete input. When the PLC detects a low battery condition in the UPS, a “UPS Low Battery” alarm will be displayed.

2.7 ELECTRICAL POWER SUPPLY

The following sections provide an overview of the electrical systems at the WTF. Whenever working with electricity the operator should ensure proper safety precautions are taken including lock-out and tag-out procedures.

The main electrical service for the facility runs underground from Bridge Street and enters the Water Treatment Room along the West wall. From there, it is routed through the Pier Control Box (circuit breaker) to the step-down transformer. A separate 480V feeder extends to the Pier Power Panel.

USCG Jonesport Station WTF (227179) 2-12 October 31, 2013

Following the step-down transformer, the electrical service runs to the Main Panel (MP) on the West wall of the Water Treatment Room. The MP provides power distribution to the various buildings throughout the facility as well as EP-1, the breaker panel for the water treatment system, located on the same wall as the MP. EP-1 feeds EP-2 as a subpanel, which also serves as a circuit breaker panel for WTP equipment.

2.7.1 WTF Emergency Generator

Under normal conditions the WTF is fed via 480 volt, 3-phase, 60 Hertz power Utility power that is stepped down (via transformer located in the Water Treatment Room) to 120/208V, 3-phase, 60 hertz. In the event of a utility power failure, the facility is equipped with an emergency generator. Upon loss of Utility power the WTF is equipped with an Automatic Transfer Switch (ATS) which will automatically transfer the power feed to the WTF generator. Backup power is provided only to the distribution panels EP-1 and EP-2, not the entire station. This allows the water treatment system to remain online and maintain potable water production.

2.8 AUTOMATIC TRANSFER SWITCH (ATS)

The generator has an Automatic Transfer switch (ATS). The ATS is used to protect the critical electrical equipment components necessary for treatment against loss of power. As mentioned, the electrical systems normal power supply source (Utility Power) is backed up by a secondary standby generator emergency power source (Genset). The ATS is connected to both the (Utility Power) and (Genset) electrical feeds. The ATS supplies each location with power from one of these two sources. In the event that power is lost from the “Primary Source” (Utility Power), the ATS changes the electrical power feed to the “Secondary Source” (Genset). The transfer is automatic and once a steady supply of “Primary Source” power is restored, the electrical feed will automatically transferred back to the “Primary Source”.

Following the switch back to Utility Power the system will initiate a generator engine shutdown cycle.

The automatic transfer switch consists of three basic elements:

Main contacts to connect and disconnect the electrical load to and from the source of power

A transfer mechanism to affect the switching of the main contacts from source to source

Supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelligence necessary for the power switch and related circuit operation

2.8.1 ATS Main Operator Panel

For a detailed description of generator and ATS operation and testing procedures consult the O&M manual for the Onan Emergency Generator and Automatic Transfer Switch.

2.9 GENERAL CHEMICAL FEED SYSTEM OPERATION

2.9.1 Chemical Information

The facility uses the following water treatment chemicals:

1. Sodium Hypochlorite

2. Soda Ash

3. Coagulant Aid Polymer – Aries 1144 Polyamine

USCG Jonesport Station WTF (227179) 2-13 October 31, 2013

Refer to the Material Data Safety Sheets (MSDS) for a complete discussion of safety and handling issues associated with these chemicals. The MSDS should be maintained in a separate binder at the WTF that is readily available.

In order to maintain compliance with Drinking Water Program rules, each of these chemicals must be certified under the National Sanitation Foundation (NSF) Standard 60.

Sodium hypochlorite, also referred to as bleach or hypo, is a common disinfectant. It can be purchased in multiple forms, with 12.5% available chlorine being the most common in municipal installations, but 6% available chlorine is available as well. Sodium hypochlorite strength degrades with time, so chemical that has been stored for extended periods will not have the same effect as newly-purchased hypo. Due to the low volume of use at this facility and the short shelf life of sodium hypochlorite, it is recommended that purchases of this chemical do not exceed that necessary for a 30-45 day period.

Soda Ash, or sodium carbonate, is a common pH control chemical. It is generally shipped in dry bagged form, with 40-50 pound bags being typical. This chemical can be stored for extended periods provided it is protected from moisture and excess humidity. It must be mixed with water at specific ratios prior to being injected. Mixing instructions are provided in the following section.

The facility previously used caustic soda, or sodium hydroxide, as the pH control chemical. This chemical is severely hazardous and was discontinued due to operator safety concerns.

The coagulant aid, Aries 1144 Polyamine, is used to enhance particulate removal by the filtration system.

This chemical is necessary to achieve the required filter performance. It must also be diluted with water before use to ensure adequate performance.

2.9.2 Chemical Dilution and Mixing

Each of the treatment chemicals is mixed or diluted with treated water prior to being injected. The following table provides the typical mixing ratio or dilution rate of each chemical for this facility. These ratios may be altered to improve chemical feed pump performance and modifications should be noted herein.

USCG Jonesport Station WTF (227179) 2-14 October 31, 2013

Table 2-1: Chemical Mixing and Dilution Rates

Chemical/Purchase Strength Diluted Percent Strength (mg/L)

Chemical to Water Mix

Ratio

Sodium Hypochlorite – 6% Strength 0.15% (1,500 mg/L)

1 gal:

40 gal water

Sodium Hypochlorite – 12.5% Strength 0.15% (1,500 mg/L)

1 gal:

83 gal water

Soda Ash – Dry, Bagged 100% Strength 12.5% (125,000 mg/L)

1 lb:

1 gal water

Coagulant Aid Polymer - Aries 1144 Neat Solution 2.0 % (20,000 mg/L)

1 gal:

50 gal water

2.9.3 Metering Pump Feed Rate

The metering pump feed rate for each chemical system is dependent on the desired dose as well as the chemical dilution rate and water flow rate. The following formula is used to calculate the feed rate of a chemical feed pump:

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Calibration of the chemical metering pumps will simplify making future adjustments of the chemical doses. Calibration means determining and recording the pumped flow for a given speed and stroke length. The following procedure is recommended for calibrating the pumps. A stop watch is needed to perform the calibration. Calibrating the metering pumps should be done at startup and then annually or whenever the pump is serviced

Follow the manufacturer’s instructions for operating the pumps. The general steps are listed below:

1. Read the manufacturer’s manual for each chemical metering pumps.

2. Check that all valves on the suction and discharge piping are in their proper positions for running the pumps in a calibration mode. Use a graduated cylinder as a calibration column and make sure that it is filled, insert the suction tubing into the graduated cylinder.

3. Set up the calibration table with pump speeds as column headings and pump stroke lengths as row headings (refer to Table 2-2 for a blank table).

4. Adjust the pump speed at the OIT and stroke length as per manufacturer’s recommendations.

5. Perform calibration test at given pump setting.

Note the initial volume in the calibration column. Start the pump and stop watch simultaneously.

After at least 500 ml have been pumped, record the exact volume pumped and time needed to pump

it. Calculate the flow at the selected pump speed and stroke length and record the results in the table.

USCG Jonesport Station WTF (227179) 2-15 October 31, 2013

For example, assume the pump speed was set to 25% and the stroke length was 50%. At this setting, suppose 500 ml were pumped in 300 seconds. The flow equaled:

Flow = 500 ml 300 seconds/60 seconds/minute = 100 ml/min

6. Repeat tests at new pump settings. Adjust the speed and/or stroke for the next setting. Stop the pump and refill the calibration column. Repeat the test at the new settings until the table is complete.

Table 2-2: Metering Pump Calibration Table

Stroke Length Pump Speed

25% 50% 75% 100%

25%

50%

75%

100%

2.9.4 Chemical Use Estimate

Chemical usage is manually monitored by the operator logging gallons of neat chemical used and the change in feed tank volume. The following table is an estimate for monthly and annual use based on the average daily production volume listed in Section 1.

Table 2-3: Chemical Use Estimate

Chemical Est. Monthly

Use Est. Annual

Use

Sodium Hypochlorite – 6% Strength (12.5% Strength)

1.25 gal

(0.6 gal)

16 gal

(8 gal)

Soda Ash – Dry, Bagged 1.5 lbs 18 lbs

Coagulant - Aries 1144 Neat Solution

0.15 gal 2 gal

USCG Jonesport Station WTF (227179) 3-1 October 31, 2013

3. FILTRATION SYSTEM

3.1 RAW WATER SUPPLY

Raw water is conveyed to the Filtration System via the cast iron piping between the cistern (source) and Water Treatment Room.

The Raw Water Pump (P-100) boosts flow that otherwise proceeds by gravity through the filtration system. The Raw Water Pump is a constant-speed (C/S) pump and has a Hand/Off/Remote selector switch. When in Remote Automatic, the pump is controlled by the SCADA system to maintain a set level in the clearwell, shutting off at an adjustable high level setpoint.

The flow rate through the filter can be regulated by a manually-adjusted ball valve on the filter discharge line, prior to the filter flow meter. This valve is generally set as needed to provide the target flow 13 gpm and does not require regular adjustment.

A Raw Water screen, shown in the figure below, shows the layout and controls available at the SCADA

OIT.

Figure 3-1: Raw Water Screen

USCG Jonesport Station WTF (227179) 3-2 October 31, 2013

3.2 FILTRATION SYSTEM OVERVIEW

The filtration system was manufactured by Fluid Systems International, Inc. of Williamsport, Pennsylvania. The company is now known as Wagner Fluid Systems and based in Pittsburgh, PA.

The system consists of a pressure upflow clarifier vessel (sometimes referred to as a roughing filter) and a pressure filter vessel. The clarifier uses a coarser media and the addition of a polymer coagulant aid to cause particles in the water to form larger flocs through agitation and mixing that can be removed by filtration. The filter unit uses a finer gravel media, sand, and anthracite coal in progressively smaller gradations to remove the flocs and particulate matter. The media was replaced in 2013 with products from Holliston Sand Company according to the following schedules:

Table 3-1: Clarifier Vessel Media Schedule

Media Size Volume (ft3) Number of 50 lb bags

1/4” x 1/8” natural stone 3 6

1/2” x 1/4” natural stone 4 8

3/4” x 1/2” natural stone 4 8

1-1/2” x 3/4” natural stone 5 10

Table 3-2: Filter Vessel Media Schedule

Media Size Volume (ft3) Number of 50 lb bags

Anthracite 0.9mm UC<1.7 6 6

Sand 00S, 0.45 to 0.55mm, UC<1.7 3 6

4S, 1/8” x 1/16” gravel 2 4

1/2” x 1/4” natural stone 2 4

3/4” x 1/2” natural stone 2 4

1-1/2” x 3/4” natural stone 2 4

Both filtration vessels are 2 foot diameter. Based on a standard allowable surface loading rate for the type of media installed in these filters (5 gpm per square foot of surface area), the capacity of the filter system is 15.7 gpm. Flow should not exceed this capacity, as the efficacy of filtration may be affected. The system is generally run at 13 gpm.

Following filtration, sodium hypochlorite is added for disinfectant residual and soda ash is added for pH adjustment before filtered water enters the clearwell. Disinfection and subsequent processes are discussed in Section 4.

In addition to the system Overview Screen included in the previous section, the following is the Filter control screen.

USCG Jonesport Station WTF (227179) 3-3 October 31, 2013

Figure 3-2: Filter Control Screen

3.3 FILTER OPERATION

Filter operational control is provided by control of the solenoid and pneumatic valves, the raw water and backwash pumps, and the air blower. All solenoid and pneumatic valves are configured as open/close valves used for isolation. Most of the control valves are spring-return, fail-closed valves. A few are fail open valves, including valves #101-103 and #107. Manual valves provide control of the flow rate through the system and do not generally require adjustment beyond the initial setting. Controlling the combination of actuated valves determines the operating status of the filter. The following is a list of operating states (modes):

Forward Flow – Filtered Water Production

Backwash – Filter

Backwash - Clarifier

Filter To Waste

Standby

Under Automatic control and the clearwell level is below the low level (Start) setpoint, the filter system will run in Filtered Water Production Mode until either the clearwell level exceeds the high level (Stop)

USCG Jonesport Station WTF (227179) 3-4 October 31, 2013 setpoint or an operator-specified filter runtime limit and/or turbidity limit is reached. Upon reaching the operator-specified runtime limit {XX hours} the control system will alarm to notify operations staff to begin the backwash process, but will remain in Forward Flow Mode. If the turbidity measured by AE/AIT-301 exceeds an operator-specified setpoint {0.35 NTU} for an operator-specified time period {15 minutes}, the control system will automatically switch the filter system to Standby Mode and issue a High Turbidity alarm.

Please note that regulations for this system call for a maximum allowable turbidity of 1.0 NTU in the produced water and for 95% of samples to be less than 0.35 NTU. The system should not produce water until turbidity is less than 0.35 NTU, i.e. the Filter to Waste mode discussed in the following sections should be long enough so that turbidity readings are below 0.35 NTU when the system is brought into Forward Flow mode.

The backwash process will be commenced by local operator input. The control system will provide automatic control of backwash steps. These modes require close monitoring of the process to ensure adequate backwashing and the subsequent returning of the filter to production through the Filter to Waste mode. The required flow rate and volume of backwash water is discussed later in this section.

A “Standby” mode allows the filter to remain idle, in the “ready position” until it is either backwashed or brought online in “Forward Flow”.

The control system will provide a “Remote Manual/Remote Auto” status selection for each control valve.

When in “Remote Manual, an “Open/Close” (also noted as On/Off) status selection for each solenoid or pneumatically-actuated valve. The opening and closing time of the control valves is determined by the air release rate for pneumatic valves and is set at each individual valve. Sufficient opening and closing time should be provided by the pneumatic controls to prevent water hammer and filter upsets.

Under normal conditions the valves should be in set in “Remote Auto” and under automatic control. The control system will determine the required valve setting based on the filter operation mode.

The following figure shows the Valve Control Screen.

USCG Jonesport Station WTF (227179) 3-5 October 31, 2013

Figure 3-3: Filter System Valve Operation Summary

The following tables list the position of each control valve and filter equipment status for each filter mode. Each mode is described in more detail in the following sections.

USCG Jonesport Station WTF (227179) 3-6 October 31, 2013

Table 3-3: Filter System Valve Operation Summary

Operational Mode

Valve ID Function Forward Flow

(Standby)

Air Scour - Filter

Backwash

- Filter

Air Scour

- Clarifier

Backwash - Clarifier

Filter to Waste

FCV-101 Raw Water Feed Open Closed Closed Closed Closed Open

FCV-102 Clarifier Discharge Open Closed Closed Open Open Closed

FCV-103 Filter Inlet Open Open Open Closed Closed Open

FCV-104 Drain Closed Open Open Open Open Closed

FCV-105 Clarifier Backwash Closed Closed Closed Closed Open Closed

FCV-106 Filter Backwash Closed Closed Open Closed Closed Closed

FCV-107 Filter Discharge Open Closed Closed Closed Closed Closed

FCV-108 Filter to Waste Closed Closed Closed Closed Closed Open

SV-110 Air Scour – Clarifier Closed Closed Closed Open Closed Closed

SV-111 Air Scour - Filter Closed Open Closed Closed Closed Closed

FCV-109 Filter System Discharge to

Clearwell

Open (Closed)

Closed Closed Closed Closed Closed

Table 3-4: Filter System Equipment Operation Summary

Operational Mode

Pump ID Function Forward Flow

(Standby)

Air Scour –

Filter

Backwash

– Filter

Air Scour

– Clarifier

Backwash

– Clarifier

Filter to Waste

P-100 Raw Water Pump On (Off) Off Off Off Off On

P-113 Backwash Pump Off Off On Off On Off

B-118 Air Scour Blower Off On Off On Off Off

P-114 Polymer Feed Pump On Off Off Off Off On

P-115 Hypo Feed Pump On Off Off Off Off Off

P-116 Soda Ash Feed Pump On Off Off Off Off Off

USCG Jonesport Station WTF (227179) 3-7 October 31, 2013

3.4 FORWARD FLOW/ FILTERED WATER PRODUCTION

Forward flow through the filtration system is governed by the Filter Discharge Control Valve (FCV-109).

When in “Remote Auto” and “Forward Flow” Mode, the Filter Discharge Control Valve will be opened by the control system at an operator-specified low clearwell level {5.5 ft} and deactivated at an operator-specified high clearwell level {7.5 ft}, as measured by the clearwell level transducer…