PROCESS LOADING EVALUATION & SLUDGE ACCOUNTABILITY

Step through the Performance Evaluation protocol; Provide training in two components of evaluation: Process loading evaluation Sludge accountability analysis.

Two-Step Protocol
COMPOSITE CORRECTION PROGRAM

STEP 1 COMPREHENSIVE PERFORMANCE EVALUATION (CPE)

STEP 2 COMPREHENSIVE TECHNICAL ASSISTANCE (CTA)

CPE OUTCOME
Identify, Classify, & Prioritize Major Performance
Limiting Factors (5-8) Classifies Design of Plant: Type I (Adequate) Type II (Marginal) Type III (Inadequate) Determine Suitability for Follow-up Technical Assistance Findings presented at end of on-site activities; Recommendations NOT Provided

CPE EVALUATORS
Design assessment experience Operations experience Interview skills i.e. tact;

Freedom/authority to address admin/management issues

Scheduling
Initial Set-up Activities On-Site Evaluation minimum 2 evaluators typically 5 continuous working days Follow-up CPE Report

CPE As Skills Development

Initial half day workshop
Participants support trainers: arms-length from day-to-day operation Maximum of 5-6 participants Commitment for entire week; Initially, trainers responsible for outcome; Allow time for debriefing CPE Exit Briefing is joint responsibility. Participants debrief training experience.

REFERENCES
CPE: US EPA Handbook Ontario CCP Handbook

Other:

RESOURCES (cont)
Plant Name: Date Prepared: Prepared By:

Dunville WPCP
9-Nov-09 Phil Wilson Step #1: Determine SOTR & alpha (based on system type) OUTPUT #1: System Fine bubble, total floor SOTR

ISCO Flow Measurement Handbook Metcalf & Eddy US EPA Design Manual On Phosphorus Removal Excel spreadsheet templates
INPUT #1: INPUT #2: Mixed Liquor D.O. Elev 2.0 mg/L 572 feet AOTR
Figure 1: Dunville WPCP PPG
Unit Process (rating criteria)

6.25 lb O2/wire.HP.h 0.5 [no units]

Step #2: Determine AOTR (based on temperature, diffuser depth, D.O. and elevation) OUTPUT #2: Temp 20 oC K 0.847 Diffuser Depth 14.4 feet AOTR/SOTR 0.42 2.65 lb O2/wire.HP.h

Total HP

Size

Step#3: Determine OTC (based on HP available) Criteria 180 HP OTC

Units m3 m3 Stnd Max Units Base

Increment

Max

3,900 kg O2/d

Aeration HRT (6 h) BOD Loading (0.5 kg BOD5/m3/d)

Step#4: Determine Oxygen HP INPUT #3: 3 2 Sec. Clar. SOR (24 m /m /d) m2 3 Annual 6,101 m /d Chlorine Contact (30 min) Avg Flow m3 3 Aerobic Digester (35 d & 17.6 m3/d) m 3 Max (180 d at Avg Flow 8,251 m /d Sludge LagoonsMonth 18 m3/d) m
O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN) Sludge Disposal (assumed)

h 11,600 3 kgBOD At Peak Monthly Flows 10,432 7,792 2,640 Demand5/m /d kgO2/kg BOD5 rev/d m3/m2/d NA d NA 8,714 1,125

OUTPUT #3: Max Month 11,400 Carbon OD 1,147 kg O2/d 7,800 Nitrogen OD 10,700
5,698 7,700

9,839

1,271 kg O2/d 2,418 kg O2/d

Design
3 7,728 m /d

Annual Avg Raw BOD5

139.0 mg/L Annual Avg Dunnville WPCP PPG for CAS (Updated - Nov. 2009) Raw TKN 33.5 mg/L
Base Max Design 7728 5-Yr Flow 5698

Total OD

Step#5: Determine Rated Capacity (based on Evaluation Criteria for O 2 Availability) 3 0 2,000 4,000 6,000 8,000 10,000 12,000 5-Yr Flow 5,698 m /d INPUT #4: OUTPUT #4: 5-Yr Flow 5698 11,600 5,698 0 Aeration HRT (6 h) Selection Nitrify use BOD5 & TKN O2 Avail Criteria 1.0 100 3 5,698 Rated Capacity 9,839 m /d 7,792 2,640 BOD Loading (0.5 kg BOD5/m3/d)
Aug. 08-Jul. 09
3 6,101 m /d

Aug. 08-Jul. 09 6101

Design 7728 7,728 0 7,728 100

O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN) Sec. Clar. SOR (24 m3/m2/d) Chlorine Contact (30 min) Aerobic Digester (35 d & 17.6 m3/d) Sludge Lagoons (180 d at 18 m3/d) Sludge Disposal (assumed)
5,698

8,714

1,125

Aug. 08-Jul. 09 6101 6,101 0 6,101 100

11,400

7,800

7,700

10,700

Annual Average Flows (m3/d)

OVERVIEW OF STEPS
Kick-off Meeting
Plant Tour Data Summaries & Performance Checks Major Unit Process Capabilities Personnel Interviews Determine Limiting Factors Exit Meeting
GRCAWorkshop Tools

KICK-OFF MEETING
Explain objectives, approach & timing Gain support for evaluation Schedule interviews with plant & admin personnel Identify information needs: C. of A. Historical monitoring data (12 months) O&M manual Budget information Other engineering studies

PLANT TOUR
Become familiar with plant and layout
Preliminary assessment of operational

flexibility
Initial information on performance, process control, and maintenance

Evaluator debriefing after plant tour

Plant Tour
Conventional activated sludge with UV disinfection; Filter press dewatering & lime stabilization; What questions will you be asking on your plant tour of the facility below?

DATA GATHERING
Data Collection Forms from Handbooks: Preliminary Plant Information Administrative Data Design Data Operational Data Maintenance Data Performance Data Main Focus: How does this affect plant performance?

Caledonia WPCP Flows

Raw Flows Nominal Design Max Day PE Flow

14,000 12,000
Flows ( m3/d)

Max Day = 12,168 m3/d

10,000 8,000 6,000 4,000 2,000 0

Annual Average = 3,376 m3/d

Ju l-0 7 Au g07 Se p07 O ct -0 7 N ov -0 7 D ec -0 7 Ja n08 Fe b08 M ar -0 8 Ap r-0 8 M ay -0 8 Ju n08

CBOD (mg/L)

TSS (mg/L)

10

15

20

25

30

10

15

20

25

30

0 Caledonia WPCP Effluent CBOD

C of A CBOD Eff CBOD Eff Obj CBOD

Caledonia WPCP Effluent TSS

C of A TSS Eff TSS Eff Obj TSS

Ju l-0 7 Au g07 Se p07 O ct -0 7 N ov -0 7 D ec -0 7 Ja n08 Fe b08 M ar -0 8 Ap r-0 8 M ay -0 8 Ju n08

Ju l-0 7 Au g07 Se p07 O ct -0 7 N ov -0 7 D ec -0 7 Ja n08 Fe b08 M ar -0 8 Ap r-0 8 M ay -0 8 Ju n08

NH3 (mg/L)

TP (mg/L)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.00

0.50

1.00

1.50

2.00

2.50 Caledonia WPCP Effluent NH3

Eff NH3 CofA

Caledonia WPCP Effluent TP

C of A TP Eff TP Eff Obj TP

Ju l-0 7 Au g07 Se p07 O ct -0 7 N ov -0 7 D ec -0 7 Ja n08 Fe b08 M ar -0 8 Ap r-0 8 M ay -0 8 Ju n08

Ju l-0 7 Au g07 Se p07 O ct -0 7 N ov -0 7 D ec -0 7 Ja n08 Fe b08 M ar -0 8 Ap r-0 8 M ay -0 8 Ju n08

Process Loading
Rate at which contaminants are added is determined by process loading
Loading = Flow x Concentration Loading Plant Capacity & Sludge production

Example: Organic loading

PE BOD5 = 200 mg/L = 200/1000 kg/m3 = 0.200 kg/m3 Flow = 5,000 m3/d BOD5 Loading = ?

BOD5 Loading = 0.200 kg BOD5/m3 x 5,000 m3/d = 1000 kg BOD5/d

Questions
If a dairy moves to town, what likely happens to BOD5 loading to the plant? If one train of a plant is shut down for maintenance, what happens to the BOD5 loading to the other trains?

When flows increase during a storm, what happens to BOD5 loading?

Should CBOD5 or TBOD5 be used to calculate organic loading to a plant?

PROCESS LOADING EVALUATION (12-months of Data)

Calculate per Capita flows and Loads: 350-500 L/d per person 80 g/d BOD5 per person; 90 g/d TSS per person

Calculate ratios: Wastewater/Water: 0.7-0.9 Peak Day/Annual Avg Flow: 2.5-3 - ? TSS/BOD5: 0.8 1.2 TKN/BOD5: 0.1-0.2 Etc. Spot check of flow metering (if required)

Background: Plant is a 546 m3/d extended aeration package plant Typically staffed less than 4 hours per day
Data: Population served = 1065 Annual average plant flow = 429 m3/d Average influent BOD5 = 98 mg/L = 0.098 kg/m3

Exercise #2

Reference Information: Per Capita Flows = 350 -500 L/person.d Per Capita Organic Loading = 80 g BOD5/capita.d 1 m3 = 1000 L 1 kg = 1000 g

Questions?
1.) Calculate average per capita flow to plant (in L/person.d) and compare to typical: Per capita flow (L/person.d) = flow (m3/d)x 1000 L/m3 / population = 429 m3/d x 1000 L/m3 / 1065 persons = 403 L/person.d Typical = 350-500 L/person.d Therefore, reported plant flows are within typical

Questions?
2.) Calculate average per capita BOD5 loading (in g/person.d) to the plant and compare to typical Per capita BOD5 loading (kg/person.d) = flow (m3/d) x concentration (kg/m3)/population = 429 m3/d x 0.098 kg/m3 / 1065 persons = 0.039 kg BOD5/person.d Per capita BOD5 loading (g/person.d) = 0.039 kg BOD5/person.d x 1000 g/kg = 39 g BOD5/person.d Typical = 70 90 g BOD5/d Therefore, plants per capita BOD5 loading is less than typical

Questions?
3.) Based on the population and the typical per capita BOD5 loading, estimate the raw BOD5 ( in mg/L). Estimated BOD5 loading (kg/d) = = 1065 persons x 80 g/person day /1000 g/kg = 85.2 kg/d BOD5 Flow = 429 m3/d Estimated Concentration (kg/m3) = Estimated load (kg/d) / flow (m3/d) = 85.2 kg/d / 429 m3/d = 0.200 kg/m3 Estimated Concentration (mg/L) = Estimated concentration (kg/m3) x 1000 (mg/L/kg/m3) = 0.200 (kg/m3) x 1000 (mg/L/kg/m3) = 200 mg/L BOD5
= Population x Per Capita BOD5 loading (g/person.d) /1000 (g/kg)

Questions?
4.) Something doesnt add up. What follow-up information would you ask for? What are the raw TSS concentrations and hence the TSS/BOD5 and per capita TSS loadings? What are the raw TKN concentrations and hence the TKN/BOD5 ratio? How are the raw samples collected (grab vs composite vs. flow proportioned composite), how often, and when?

SLUDGE ACCOUNTABILITY ANALYSIS

Purpose: Verify plant data Assess monitoring & reporting practices Help with rating sludge storage, treatment & disposal capacities. Steps: Obtain 12-months sludge production from plant records (reported sludge production) Estimate projected sludge production based on removal mechanisms; Compare projected vs. reported; Within +15% ok

Reported Sludge Production

Plant Flow = 3,000 m3/d Concentration = 20 mg/L = 0.020 kg/m3 Unintentional Wastage = 3,000 m3/d x 0.020 kg/m3 = 60 kg/d

Primary

Aeration Basin

Secondary

Sludge Flow = 10 m3/d

WAS

Effluent Solids

RAS Concentration = 3% = 30,000 mg/L = 30 kg/m3

Unintentional Wastage = 10 m3/d x 30 kg/m3 = 300 kg/d

Co-Thickened Reported Sludge Production = Primary & WAS Unintentional Wastage + Intentional Wastage Reported Sludge= Unintentional + Intentional Sludge
= 60 kg/d + 300 kg/d = 360 kg/d

Projected Sludge Production

Primary Sludge: based on TSS removal rates across the primary Biological Sludge: based on BOD5 removal rates across the basin Primary Aeration Basin Secondary

Chemical Sludge: based on coagulant addition rates to basin

Projected Sludge = Primary + Biological + Chemical

Primary Sludge Production

Raw TSS = 200 mg/L PE TSS = 100 mg/L Flow = 1,000 m3/d Primary Sludge =
Flow (m3/d) x (Raw TSS PE TSS) mg/L / 1000 mg/L/kg/m3

= 1,000 m3/d x (200 100)/1000 kg/m3 = 1,000 m3/d x 0.10 kg/m3 = 100 kg/d

Biological Sludge Production

PE BOD5 = 110 mg/L SE BOD5 = 10 mg/L Flow = 1,000 m3/d Biological Sludge Production Ratio (SPR) (for CAS w/primary) = 0.70 kg TSS /kg BOD5-removed Biological Sludge =
Flow (m3/d) x (PE BOD5 SE BOD5) mg/L / 1000 mg/L/kg/m3 x SPR

= 1,000 m3/d x (110 10)/1000 kg/m3 x 0.70 = 1,000 m3/d x 0.10 kg/m3 x 0.70 = 70 kg/d

Chemical Sludge Production

Alum Dosage Rate = 1000 mL/min = 1000 mL/min x 1440 min/d / 1000 mL/L = 1440 L/d / 1000 L/ m3 = 1.44 m3/d

Weight of Alum Added per day = Volume Added per day x Specific Gravity = 1.44 m3/d x 1,330 kg/m3 = 1,915 kg/d
Weight of Al+3 Added per day = Weight of Alum per Day x %Al+3 (w/w) = 1915 kg/d x 4.3% = 82.3 kg/d

Chemical Sludge Production

Chemical Sludge Production Ratio = 4.79 kg TSS /kg Al+3 (for alum) Chemical Sludge Production = Weight of Al+3 addition (kg/d) x SPR = 82.3 kg/d x 4.79 = 394.5 kg/d

EXAMPLE RESULTS
REPORTED: Source Secondary By-pass Effluent Co-thickened WAS + Primary PROJECTED: Source

Amount (kg) 24, 000 180, 000 3, 247, 000 3, 451, 000 Amount (kg)
2, 677, 000 2, 589, 000 284, 000

Primary Sludge Biological Sludge Chemical Sludge

SUDGE ACCOUNTABILITY: (PROJECTED REPORTED) X 100% = +38% PROJECTED

5, 550, 000

Background: Plant is an extended aeration package plant (no primary) No coagulant addition for TP removal; Data: Annual average flow rate = 3,200 m3/d BOD5: Raw = 110 mg/L; Effluent = 6 mg/L TSS: Effluent = 9 mg/L Waste sludge: Volume = 35 m3/d Conc. = 3,400 mg/L Reference Information: Remember!: 1000 mg/L = 1 kg/m3 Process Type: SPR (kg TSS/kg BOD5 r) Activated sludge w/o Primary: Conventional 0.85 Extended Aeration 0.65

Exercise #3

Questions
1.) Calculate the average daily unintentional sludge wasted (in effluent TSS) as kg/d: Wastage (kg/d) = flow (m3/d) x ESS (mg/L) / 1000 mg/L/kg.m3 = 3,200 m3/d x 9/1000 kg/m3 = 28.8 kg/d 2.) Calculate the average intentional sludge wasted as kg/d:
Wastage (kg/d) = waste flow (m3/d) x waste concentration (kg/m3)

= 35 m3/d x 3,400/1000 kg/m3 = 119.0 kg/d 3.) Calculate total reported sludge production (1+2):
Total reported (kg/d) = unintentional (kg/d) + intentional (kg/d)

= 28.8 kg/d + 119.0 kg/d = 147.8 kg/d

4.) Calculate the projected sludge production:

Rate of BOD5 removed (kg/d) = Flow (m3/d) x (Raw Effluent) kg/m3

= 3,200 m3/d x (110 6)/1000 kg/m3 = 3,200 m3/d x 0.104 kg BOD5/m3 = 332.8 kg/d Choose SPR for applicable process SPR = 0.65 (extended aeration) Biological Sludge Production = SPR x BOD5 Removal Rate Biological Sludge Production = 0.65 x 332.8 kg/d = 216.3 kg TSS/d

5.) Calculate sludge accountability (%) & compare to + 15% Sludge Accountability = (projected reported)/projected x 100% = (216.3 147.8)/216.3x100% = + 32% Sludge Accountability falls outside + 15%

Questions
6.) The sludge accountability doesnt close (i.e. outside + 15%). What follow-up information would you ask for? Information related to monitoring of the waste sludge: flows and frequency & analysis of waste solids Information related to monitoring of effluent TSS. Any observations that effluent TSS may be higher than reported i.e. sludge in chlorine contact chamber, etc.

Operating Parameter Evaluation

Typical Range (M & E 1991) Parameter SRT Total (d) F/M (kg BOD5/d per kg MLVSS) MLSS (mg/L) HRT (h) Plant X

CAS*
3-15 0.2-0.5

EA**
20-30 0.05-0.15

OD***
10-30 0.05-0.3 67 0.05

1,000 3,000

3,000-5,000

1,500-5,000

4,800

4-8

18-36

8-36

24.6

* CAS = Conventional Activated Sludge; ** EA = Extended Aeration; *** OD = Oxidation Ditch

MAJOR UNIT PROCESS EVALUATION

Potential of major units to treat flows and loads Identifies the weakest link i.e. most limiting

unit
Assigns a rated capacity the annual

average flow which can be treated by that unit

Establish plant type: I Capable II Marginal III Not Capable

Performance Potential Graph

Flow

Unit Process
Aeration Basin

100

200 300 400 500 600

620

Capable: > 100% Current Secondary Clarifier 400 Marginal: 80-100% Current Sludge Handling 200 Not Capable: <80% Current Current Flow Design Flow = 480 = 640

CPE PPG CALCULATIONS

FAPCC
Annual Average Flows (m3/d)
0 Prim.Clar. SOR (24 m3/m2/d) Aeration HRT (4-6 h) BOD Loading (0.5-0.6 kg BOD5/m3/d) O2 Avail. (1.4 kgO2/kg BOD5 rem.) Sec. Clar. SOR (24 m3/m2/d) UV Disinfection (45,400 @ peak) Filter Press (1 unit @ 96 h/wk) Sludge Haulage (on demand) Base Max
17,665 25,224 22,700 35,300 12,964 13,283 39,300

5,000

10,000

15,000
25,272

20,000

25,000

30,000

Current 17665 m3/d

Nominal Design 22700 m3/d

Dunnville WPCP PPG for CAS

Base Max Design 7728 m3/d Current Flow 5137 m3/d

2,000

4,000

6,000
11,600

8,000

10,000

12,000

Aeration HRT (6 h) BOD Loading (0.5 kg BOD5/m3/d) O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN) Sec. Clar. SOR (24 m3/m2/d) Chlorine Contact (30 min) Aerobic Digester (35 d & 2.0%) Sludge Lagoons (180 d at 4% solids) Sludge Disposal (assumed)
5,100 3,200 7,800 7,600

6,600

11,400

9,000

Annual Average Flows (m /d)

INTERVIEWS
Previous steps complete prior to interviews Staff interviewed All plant staff Key administrators Interviews in private and information is kept confidential Maintain performance focus Debrief interviews

PERFORMANCE LIMITING FACTORS Checklists with definitions provided in

Handbook Four Categories Operations Design Maintenance Administration Rating System A: Major Long Term Effect B: Minimum Routine Effect or Major Periodic Effect C: Minor Effect

PRIORITIZE FACTORS
A & B Factors only Purpose:

Summarize Plant Status

Basis for Follow-up Activities

FACTORS MEETING

COMMON FACTORS Lack of Application of Concepts and Testing to Achieve Process Control Inadequate process monitoring and testing No routine for sludge wasting to support process control Inadequate Sludge Wasting and Disposal Limited on-site storage Inadequate land approved to spread sludge Inability to measure waste sludge Inappropriate Management Policies Inadequate plant staffing Focus on maintenance and housekeeping

EXIT MEETING
Plant/Administrative Personnel
Present Preliminary Findings Summarize Factors: A & B

Tell it like it is with respect

Potential for follow-up

REPORT
Outline:

Introduction

Facility Background
Performance Assessment

Major Unit Process Evaluation

Performance Factors

SUMMARY
Kick-off Meeting
Plant Tour

Focus of Todays Workshop: Process Loading Evaluation Sludge Accountability

Data Summaries & Performance Checks Major Unit Process Capabilities Plant Personnel Interviews Determine Limiting Factors Exit Meeting
Focus of Nov. Workshop: Major Unit Process Capabilities = PPG