MN4 Control Philosophy 15-04-2024

MN4 STP Control Philosophy
1. INTRODUCTION 2
2. ABBREVIATIONS 3
3. OBJECTIVE 5
4. DESCRIPTION OF CONTROL PHILOSOPHY 5
4.1. General comments 5
4.2. Water line 6
4.2.1. Inlet chamber 6
4.2.2. Metering chamber 1 (FM1) 6
4.2.3. Coarse screening 7
4.2.4. Inlet pumping station 8
4.2.5. Fine screening 9
4.2.7. Sand and Grease removal 11
4.2.8. Main distribution chamber 12
4.2.10. ICEAS tank and Air blowing area (BBL) 12
4.2.11. Balance tank 13
4.2.13. Drainage pumping station 15
4.2.14. Filtration 16
4.2.15. Backwash pumping station 17
4.2.16. UV channel 17
4.2.17. Chlorine process unit 18
4.2.19. Service water line 19
4.2.20. Odor control for Pre-treatment – OC1 20
4.3. Sludge line 22
4.3.1. Sludge tank 22
4.3.2. Sludge thickener and polymer dosing pump (PD1) 23
4.3.3. Sludge mixing tank 24
4.3.4. Sludge dewatering and polymer dosing pump (PD2) 25
4.3.5. Supernatant pumping station 26
4.3.6. Odor control for sludge line – OC2 26
5. CODES AND STANDARDS 28
6. LANGUAGE & SYSTEM OF MEASUREMENTS 28
7. TAGS AND CODES IN P&ID 29
8. REFERENCES 30
ANNEX I: CONTROL PHILOSOPHY FOR SBR 31
ANNEX II: CONTROL PHILOSOPHY FOR UV 49
INTRODUCTION
In order to clarify the operation control of the plant, it is elaborated this document, which includes all the necessary information.
Table 1. Process template.

1. ABBREVIATIONS
The following abbreviations are used in the document:
ICH Inlet Chamber
FM1 Metering chamber 1
CSB Coarse Screening Building
IPS Inlet Pumping Station
FSB Fine Screening Building
SGR Sand & Grease Chamber
BBA Air Blowing Area (Sand & Grit)
DCH Distribution chamber ICEAS
BBL Air Blowing Building ICEAS
SBR ICEAS Tank (Aeration Tank)
BTA Balance Tank / Intermediate Pump Station
DPS Drainage Pumping Station
FBL Filtration facility
BPS Backwash pumping station
UVC UV Channel
UVB UV Control Building
CCT Chlorine Contact Tank
CHB Chlorine Storage Building (NaOCl) & Pumping Station
FDC Final Distribution Chamber
SWL Service water line
SLT Sludge Tank
STH Sludge Thickener

PD1 Polymer dosing unit for Sludge Thickener
SMT Sludge Mixing Tank
SPS Supernatant Pumping Station
SLD Sludge Dewatering
PD2 Polymer dosing unit for Sludge Dewatering
SLB Sludge silos building
OBL Operation Building
OC1 Odor Control Footing Pad (Pre-treatment facilities)
OC2 Odor Control Footing Pad (Sludge facilities)
WBF Weigh Bridge
DWT Drinking water tank
FFB Fire Fighting Building
SCADA Supervisory Control and Data Acquisition

Human Machine Interface
HMI
PLC Programmable Logic Controller
2. OBJECTIVE
The aim of the current document is to clarify and establish the basic control philosophy in order to facilitate the
understanding of the STP operation.
3. DESCRIPTION OF CONTROL PHILOSOPHY
3.1. General comments
• The different stages and process unit are completely automated, as it is defined below; however, the system is equipped with
manual, remote and field control.
The manual control allows the operator to control different variables of the system like, time basis, flows, levels, concentrations,
etc. according with his experience.
• The following control philosophy description should be considered as a guide.
• Control of pumps operation should be through electronic level sensor supported with float switch to operate the pumps in
case of sensor´s breakdown.
• Pumps operation through float switch system should be separated from PLC to enable pumps operation through floaters in
case of PLC breakdown. However, the float switch is connected to the control logic/system as “fail safe”.
3.2. Water line
3.2.1. Inlet chamber
From Haer Channel – To Flow Metering Chamber 1
Intake work is constructed directly on Haer Channel which has a section of 3.10 x 3.10 m.
There are two penstocks; the first one is located at STP inlet, from where a box culvert drives the raw water to the STP. This penstock
is able to control the inlet flow to the STP. The opening of the gate is controlled by the section- velocity flowmeter FM1.
The second is a penstock located on Haer Channel, which purpose is to actuate as a weir penstock in order to maintain the
required water level in case of low incoming flows from Haer Channel. This way water level can be raised and water can be
properly diverted to the STP. In case of high incoming flows from Haer Channel, the second penstock could be completely opened.
The flow to the STP is:
• Maximum flow: 13,333.33m3/h.

• Average flow: 8,333.33m3/h.
• Minimum flow: 4,166.67m3/h.
Control equipment:
Ultrasonic level transmittal US 1 pcs
Float switch LS 2 pcs

3.2.2. Metering chamber 1 (FM1)
From Inlet Chamber – To Coarse Screen Building
This chamber containing flowmeter which is based on the ultrasonic correlation method, where individual velocities are detected
in different levels of the flow section. A real 3D flow profile is calculated in real time and is indicated in a reproducible and
verifiable manner on the flowmeter display.
It is taken into account different factors such as channel shape, discharge behavior and wall roughness for computing the flow.
3.2.3. Coarse screening

From Flow Metering Chamber 1 – To Inlet Pumping Station
Once the water passes through the inlet flowmeter FM-1, continues by the box culvert to the inlet chamber of CSB. On this
chamber, the water flows by the screening channels (2+1) located on CSB, passing through the coarse screen unit (CN) which have an
opening water flow width of 20mm.
COARSE SCREEN (CN)
The screens are controlled by level difference measurements located up and downstream of the coarse screens. lf a specified level
difference is achieved the screenings conveyor is put into operation and the screen is cleaned. As a backup system, an additional
timer interval is set to activate the cleaning process even if the specified level difference is not yet achieved.
For the cleaning of the coarse screen there is installed a washing valve (BA) actuated with a solenoid (SA) which starts when the
coarse screen (CN) washing operation is on.
SCREW CONVEYOR (SC)
The screenings are discharged into the first screw conveyor (parallel to the screen) (1+1) and driven to the second screw conveyor
(perpendicular to the screen) (1+1), which brings the screenings to the washing and compacting unit (WP) (1+1).
When screenings are compacted, they are poured into the skips (WC), where they are stored.
The screw conveyor (SC) and the washing and compacting unit (WP) work on a time basis regarding the coarse screen (CN)
operation.
BYPASS
On this process unit, it is considered a bypass which is located after an overflow weir.
When water reaches the crest level of the weir, the water pass over the weir and the bypass channel starts working.
This channel contains an emergency coarse screen which has an opening width of 50 mm and it is able to treat the peak flow
(13,333m3/h).
This coarse screen is connected to the screw conveyor (SC), and the operation of this channel is the same as the other coarse
screen channels.
Control equipment
Conductivity (CSB inlet chamber) CD 1 pcs
pH Analyzer (CSB inlet chamber) HP 1 pcs
Ultrasonic level transmittal before CN US 2+1 pcs

Ultrasonic level transmittal after CN US 2+1 pcs
Ultrasonic level transmittal (before CN bypass) US 1 pcs
Ultrasonic level transmittal (after CN bypass) US 1 pcs
3.2.4. Inlet pumping station
From Coarse Screen Building – To Fine Screen Building
After the CSB the water arrives to the distribution chamber of the IPS.
On this chamber, the water is pumped to FSB by the screw pumps (SP) (2+1).
In order to achieve great plant reliability, the distribution chamber of the IPS, is divided into three parts which can be isolated by
penstocks (PE). This is necessary for any necessary maintenance and repair work on screw pumps (SP).
SCREW PUMP (SP)
This process unit is controlled by ultrasonic level transmittals (US) located on channels which purpose is to control the functioning
of screw pumps, in order to maintain a constant level (around 2m water deep in the filling point) on inlet chamber of IPS for all the
situations (minimum/average/ peak flow).
According with FM1 and the level on inlet chamber of IPS the screw pumps (SP) spin with different velocity and one by one
regulating the flow which enters to the STP. So, VFD control the operation frequency of the engines of the screw’s pumps.
In case of ultrasonic level transmittal breakdown, it is possible to control the screw pumps in accordance to the water level
fluctuation and the signal provided by the float switches installed in the channels.
Control equipment
Float Switch (on channels IPS) LS 6x (2+1) pcs
Ultrasonic level transmittal US 2+1 pcs
3.2.5. Fine screening
From Inlet Pumping Station – To Sand & Grease Removal
The pumped water is discharge into the FSB.
On this building there is a distribution chamber from where water flows into fine screen channels (2+1), and where there are
located the fine screens (FN). The fine screens unit (FN) has an opening width of 6mm.
FINE SCREEN (FN)
When water raises a specified level, the ultrasonic level transmittal (US) sent a signal to MCC-1, and the motor of the screen (CN) is
started in order to remove the screenings.
The screens are controlled by level difference measurements located up and downstream of the coarse screens. lf a specified level
difference is achieved; the screenings conveyor is put into operation and the screen is cleaned. As a backup system, an additional
timer interval is set to activate the cleaning process even if the specified level difference is not yet achieved.
SCREW CONVEYOR (SC)
The screenings are discharged into a screw conveyor (SC) (1+1) which brings them to the washing and compacting unit (WP) (1+1).
When screenings are compacted, they are poured into the skips (WC), where they are stored.
The screw conveyor (SC) and the washing and compacting unit (WP) work on a time basis regarding the fine screen (FN) operation.
BYPASS
On this process unit, it is considered a bypass for overflows for the raw water before FSB, which is located after a weir.
When water reaches the crest level of the weir, the water pass over the weir and the raw water is driven to the FM-5 before being
discharge to Batha channel.
The flow which passes through the bypass is controlled by a flowmeter (FM5) based on the ultrasonic correlation method. This
Bypass is able to treat the peak flow (13,333m3/h).
Control equipment
Ultrasonic level detector (Before FN) US 2+1 pcs
Ultrasonic level detector (After FN) US 2+1 pcs
Gas detector H2S ID 1 pcs
From Fine Screen Building – To Batha Channel
The FM5 is located on Fine Screen Building by-pass, in order to control the by-pass flow to Batha Channel.
This flowmeter is based on the ultrasonic correlation method, where individual velocities are detected in different levels of the
flow section. A real 3D flow profile is calculated in real time and is indicated in a reproducible and verifiable manner on the
flowmeter display.
3.2.7. Sand and Grease removal

From Fine Screen Building – To Main Distribution Chamber
The screened water arrives then to SGR distribution chamber, where it is driven into the SGR channels (2+2).
On this process unit the sand and the grease are removed from water in order to continue with the biological treatment.
SGR BRIDGE
The SGR bridge (SG) is controlled with limit switches which controls when SGR bridge (SG) has to change it direction.
According with SGR Bridge, the vertical submerged pump (VP) located under the bridge (SG) starts running in order to remove the
sand from the water in process.
Finally, the scraper located on the bridge (SG) works according to the direction of the movement of the bridge. When bridge goes
forward, the scraper goes down in order to collect the grease. When bridge goes back, the scraper motor keeps the scraper up.
SGR BLOWERS
When SGR bridge (SG) starts running, a signal is sent to MCC1 and rotator lobe blowers (RL) located on BBA starts working in
order to introduce air to the SGR channel in order to increase the segregation of sand.
SAND CLASSIFIER
The pumped mixture of water and sand from SGR is driven by a channel to the sand classifier (CL).
According to the working time of SGR Bridge (SG), a time basis control the operation of sand classifier (CL). This equipment is
in charge of separate the water from the sand, and collect this last one on the skips (WC).
GREASE TRAP
The collected grease is redirected to the grease trap.
The grease is pumped to a tank, where it is stored till it pumped to a tanker truck for its proper treatment.
The float switch is connected directly to the pump then to control system and in case of damage of the float switch, the pump
stops immediately.
Control equipment
Float switch on SGR inlet chamber LS 1 pcs
Position switch for degriter bridge ZS 4+4 pcs
Pressure switch with manometer on BBA blowers PW 2+2 pcs
Float switch on GTP tank LS 1 pcs
Float switch on grease store tank LS 1 pcs
3.2.8. Main distribution chamber
From Sand & Grease Removal – To Flow Metering Chamber 2
In the distribution chamber the flow from grit removal is distributed into three pipes which carry the water in process to the SBR
aeration tanks.
Water in process from SGR is collected on Main distribution chamber (DCH), where three flowmeters and three downward
opening penstocks weir are installed in order to equally split the flow to the different ICEAS tanks, even when one of the 12 tanks
would be out of service. The number of SBRs in service is known by the signal of the limit switches of the SBR entrance penstock.
As commented, it is possible to find two situations, the first one is when 12 SBR are working, and the second one when 11 SBR are
working. On the first situation the flow on each pipe should be (Q grit/3), however on the second situation the flow should be
(Qgritx4/11) on two of the three pipes and on the third one flow should be (Qgritx3/11).
The downward penstock (PE) level is established according to the flow measures by the three flowmeters (FM2) located
downstream and the ultrasonic level transmittal (US) located on DCH.
Control equipment
From Main Distribution Chamber – To ICEAS Tank
The water from Main distribution chamber of SBR, pass through one of the three flowmeters.
flowmeter display.
3.2.10. ICEAS tank and Air blowing area (BBL)
From Flow Metering Chamber 2 – To Balance Tank
The control philosophy is defined by the supplier on Annex 1.
3.2.11. Balance tank
From ICEAS Tank – To Flow Metering Chamber 3
The BTA balances the intermittent flow from the SBR decants (AW), in order to ensure that downstream flow to the tertiary and
disinfection plant is continuous.
The BTA is composed of three independent tanks which contain two axial pumps (AP) whose operation philosophy is described
below, but in general it depends on the number of duties SBR tanks.
The STP usually work with 12 duty SBR tanks but while one of the tanks is out of service, the balance tank pumping station
shall have a different operation pattern.
12 Duty SBR
Under normal operation, i.e. 12 duty SBR, pumping station is proposed to be controlled on level in the Balance Tank, the capacity
requirement under these conditions is lower so tank operation can be more flexible.
Under this hypothesis, the operation control of the pumping station allows the level in the Balance Tank to fluctuate without
altering the Interstage Pump flowrate. Only if the level rises above or falls below a dead-band would the Interstage Pump speed up
or slow down respectively.
The axial pumps shall be operated automatically, continuously adjusting to the inflow rates (water level) to the balance tank.
Operating time per day shall be 24 hours working in continuous operation 7 days per week.
Set Point control level of balance tank has been fixed at 70% full (SP level). The level fluctuates within a band due to damped
response to intermittent SBR decants. Under this hypothesis of water level fluctuating around this SP level inside a narrow band, 4
duty pumps shall have capacity enough to pump the peak flow.
Operation description under 12 duty SBR, water level fluctuating around this SP level:
- Increasing flowrate:
o 69.44 m³/min – 116.10 m³/min: 2 control duty pumps to achieve SP level.
o 116.10 m³/min – 174.15 m³/min: Start duty pump 3, as level start to rise because 2 pumps are insufficient.
Control duty pumps 1, 2 and 3 to achieve SP level.
o 174.15 m³/min – 232 m³/min: Start duty pump 4, as level start to rise because 3 pumps are insufficient.
Control duty pumps 2, 3 and 4 to achieve SP level.
- Decreasing flowrate:
o 174.15 m³/min – 232 m³/min: 4 duty pumps running. 3 control duty pumps to achieve SP level.
o 116.10 m³/min – 174.15 m³/min: Stop duty pump 4, as level start to fall because duty pumps 1, 2 and 3 are
sufficient. Control duty pumps 1, 2 and 3 to achieve SP level.
o 69.44 m³/min – 116.10 m³/min: Stop duty pump 3, as level start to fall because duty pumps 1 and 2 are sufficient.
Control duty pumps 1 and 2 to achieve SP level.
11 Duty SBR
In case that one of the 12 SBRs should be out of service, the tank capacity requirement will increase significantly so the pumping
operation flexibility will be restricted in order to ensures that a uniform pumping flow will be maintained even when the inflow to
the balance tank will be reduced due to the lack of decanted flow from the out of service tank.
Under this hypothesis, it is not valid the operation philosophy of maintain the tank level fluctuating within a narrow band around
the Set Point, in this case, the operation control of the tank shall pursue to get higher tank level just before the gap in the
decanted flows during the decanted phase of the out of service tank.
When the pumping flow is the same as the STP incoming flow (plus return liquors) the system will evolve in such way that tank
level will be rising during the decant period of the duty SBR chambers and it will store water enough to ensure that the pumping
station will maintain the same flow even during the decant period of the out of service SBR chamber.
When a SBR is selected out of operation, the Balance Tank control system will switch to N-1 Mode. This comprises 3 operations:
- Set Point Level: Change the level setpoint to about 100% of the tank operational capacity and allow the level in the
Balance Tank to rise slightly. This provides additional balancing volume. Operation description is the same thank
described for achieving 70% full level.
- Missing Decant Slot Control: At the start of the time when the missing decant slot is scheduled to start, switch from Set
Point Level Control to Missing Decant Slot Control. This period will last for the duration of the decant slot (60 minutes for
Normal Cycle and 45 minutes for High Flow Cycle). During this time the pumps will continue to operate, but rather than
slow down due to the falling level, they will speed up to try to maintain a similar flowrate. The balance tank level signal
will be linked via a proper algorithm to control the VFD pumps speed.
- Level Recovery Control. At the end of the time when the missing decant slot is scheduled to stop, switch from Missing
Decant Slot Control to Level Recovery Control. This period will last from the end of the missing decant slot to the start of
the next decant slot (180 minutes for Normal Cycle and 135 minutes for High Flow Cycle). During this time the
intermediate pumps will be controlled to increase the Balance Tank level at a linear rate from the level at the end of the
missing decant slot to 100% full at the start of the next missing decant slot. If the cycle time switches between Normal
and High Flow, the linear recovery level will be adjusted accordingly.
Under this operation hypothesis, water level in the tank will vary significantly. Pumping flow rate is the same as under the 12 SBR
operation case.
In case of ultrasonic level transmittal (US) breakdown it will be possible to control the axial pumps in accordance to the water level
fluctuation and the signal provided by the float switches installed in the tank.
Final axial pumps Supplier shall develop a complete pumping operation control based on the basic operation philosophy described
above.
Control equipment
Ultrasonic level transmittal US 2+1 pcs
Float switch LS 8+4 pcs
From Balance Tank – To Filtration Building
The flow from BTA is controlled by the FM3.
flowmeter display.
3.2.13. Drainage pumping station
From BTA & ICEAS Tank drainage – To inlet chamber of Coarse Screen Building
This pumping station receives the return water and the drain water from SBR, BTA, FBL and UVC. The level is controlled by an
ultrasonic level transmittal (US) located on the chamber, and according to it, the water is pumped by the submersible vertical
pump (1+1) (VP) to the distribution chamber of the Coarse Screen Building (Inlet Works).
Technical data
Electromagnetic flowmeter EF 1 pcs
3.2.14. Filtration
From Balance Tank – To UV Channel
From balance tank, water in process is pumped to FBL where there are installed the disc filters (FI) (9+3) on a common channel.
This disc filter could be isolated using the penstock (PE) located at disc filter (FI) inlet, and the process unit could be bypassed using
the final PE which brings the water to the collector chamber of FBL.
At this process unit, the remaining filterable substances is removed by filtration, when water in process passes through the disc
filter.
The overflow water passes through a weir installed at the end of filtration building, which pour the water into the UV process unit.
DISC FILTER
During normal filtration the unit (FI) is static, which means that there is no power consumption, but when the inlet water level
rises to a predetermined level, a backwash sequence is initiated.
The backwash sequence initiates both the Disc filters drive to rotate the drum and the backwash pump to provide high- pressure
water for the cleaning jets.
During the backwash cycle filtration is continuous.
When the inlet water level falls below the indicated level the backwash sequence continues for approximately 20 seconds.
Control equipment
Float switch on main chamber LS 2 pcs
Float switch on disc filters LS 8+4 pcs
Limit switch on disc filters ZS 8+4 pcs
Pressure switch with manometer PW 8+4 pcs
Manometer MA 8+4 pcs
Turbidimeter TU 1 pcs
3.2.15. Backwash pumping station
From Filtration Building – To inlet chamber of Fine Screen Building
Backwash water from filtration is driven to backwash pumping station in order to be pumped to the FSB distribution chamber.
There is a level measurement type ultrasonic level transmittal (US) on BPS chamber which indicates the level of water.
According to the water level, submersible centrifugal vertical pumps (VP) (2+1) are activated one by one in order to pump the
water to the FSB distribution chamber. The outlet pipe from BPS is connected to SPS pipe before to arrive to FSB.
Control equipment
Pressure Switch with manometer PW 2+1 pcs

3.2.16. UV channel
From Filtration Building – To Chorine Contact tank
Filtered water from FBL arrives to distribution chamber of UVC where is 2+1 channels.
The control philosophy of UV process unit is defined by the supplier on Annex 2.
3.2.17. Chlorine process unit
From UV Channel – To Flow Metering Chamber 4 / To Service Water Line
Water in process from UV channel is discharged to CCT distribution chamber, where there are (3+1) chlorine contact tanks.
The chlorine contact tank is based on the peak flow and while one of the compartments is out of service the minimum retention
time should be 30 min.
CHLORINE STORAGE BUILDING
The dosing point for the effluent disinfection is situated in the feed Channel to the distribution chamber of CCT and served by a
dosing pump (DP) (1+1).
The NaOCl dosing rate is automatically adjusted proportionally to the plant flow (feed forward control), supported by a residual
chlorine measurement (AC) at the outlet of the CCT.
The hypochlorite dosing pump operation is made from the following operation parameters:
• Q = Flow in the outlet pipe.

• Dose = Total Active chlorine dose.
• Concentration (%) = Commercial product concentration (Cl2 content).
• Density= Commercial product density.
The previous operation parameters could be modified from the control PC by the plant operator, in exception if Q which is
imposed by the flowmeter on the effluent pipe.
In any case, the dosing rate is adjusted in order to get a free residual chlorine concentration of 0.5 mg/l on the effluent water.
The exact dosing quantity is determined after measurements of the initial chlorine demand.
The dosing and the control equipment is located in a closed building located directly adjacent to the three NaOCl storage tanks (SK).
The building is cooled in order to avoid higher temperature which causes Cl2 degradation.
For safety reasons the sodium hypochlorite storage tanks are located within a basin. In case of damage or leakage of one of the
storage tanks no chemical will enter the dosing area or the sewer system of the plant.
The facility is located close to the CCT which keep the length of the respective dosing lines very short. CHLORINE CONTACT
TANK
In order to allow a complete reaction of chlorine upstream of the effluent measuring point a CCT is provided. The
rectangular tank provides a retention time of 30 minutes referring to the peak flow.
The effluent sampling point for the automatic sampling device and the online monitoring for the parameter residual chlorine (AC) is
located in the outlet chamber of the collection chamber of CCT.
The chlorine measurement is connected to the NaOCl dosing control loop in order to graduate the NaOCl dosage.
Control equipment
Residual chlorine analyzer AC 1 pcs
Float switch on CCT LS 4 pcs
Displacer (Internally mounted) on Storage tank DL 2+1 pcs
Pressure Switch with manometer PW 1+1 pcs
Rotameter RO 1+1 pcs
From Chlorine Contact Tank – To Final Distribution Chamber
The water from CCT, pass through the outlet channel where there is located the flowmeter.
This flowmeter is based on the ultrasonic correlation method, where individual velocities are detected in different levels of the flow
section. A real 3D flow profile is calculated in real time and is indicated in a reproducible and verifiable manner on the flowmeter
display.
3.2.19. Service water line
From Chlorine Contact Tank – To different stages of the STP
The service water system is fed with tertiary effluent from the CCT effluent and its capacity is sufficient to meet the peak service
water demand.
The service water is pumped by centrifugal pumps (CP) to the different stages of the STP. If low pressure is detected by the
pressure switch with manometer (PW), the centrifugal pump (CP) starts run.
The following buildings are served by the service water system:
• Coarse screen building

• Fine screen building
• Chlorine storage building
• Sludge thickener
• Sludge dewatering
• Polymer dosing unit for STH y SLD
Control equipment
Pressure switch with manometer PW 3 pcs
3.2.20. Odor control for Pre-treatment – OC1
From ICH / CSB / IPS / FSB / FM5 / SGR
The odor to be treated on OC1 is collected on pre-treatment line from CSB, IPS, FSB and SGR by an odor line with negative
pressure.
In order to achieve high removal efficiency in the odorous air treatment facility, the odor control strategy pursued in the STP is
focus on minimizing the quantity of odorous air which is to be handled and treated. In this sense, in order to ensure these highly
concentrated odorous air flows, the respective structures are encapsulated and the foul air is only be drawn off the encapsulated
parts.
Additionally, process buildings are served by a forced ventilation system providing at least an air exchange rate of 4 per hour. The
process buildings connected to OC1 are the coarse screenings skips building (coarse screens are located outside) and the fine
screening building. This ventilation is connected to the odor treatment system.
The ventilation system uses fresh air with air exchange rates between 4 times per hour up to 12 times per hour, depending of the
fact whether respective structure need regular attendance or not. Thus, the air exchange rates, have been selected according to
the odor and corrosion potential of the respective structure.
The treatment system consists of two independent treatment trains of a combined-stage scrubber (NaOH) system followed by
carbon filter.
CAUSTIC SCRUBBER
The blower (BO) impulses the air to the caustic scrubber (CT), where the air is washed with liquid composed by drinking water and
sodium hydroxide. The recirculation pump (NP) collects the water from the bottom of the scrubber, pumped to the diffusers
located at scrubber top and pulverized over the odorous air. The recirculation pump (NT) presents a non-temporized operation.
Regarding the sodium hydroxide pump (NP), it is used in order to maintain a determined level of pH on the scrubber liquid.
Regarding the pH analyzer (HP) located on the recirculation line this pump (NP) is activated or deactivated.
On the other hand, the level of liquid on caustic scrubber (CT) is measured with the displacer (DL) internally mounted. According with
it, we have the following situations:
• High level. Diaphragm valve (DI) is closed.

• Low level. Diaphragm valve (DI) is open.
• Low level. Recirculation pump (NP) is stopped.
In order to monitor fouling of the scrubber (CT) it is considered a differential pressure measurement (IP) device which purpose is to
monitor the pressure drop over the scrubber (CT). Hereby clogging of the beds can be determined and action can be taken.
CARBON FILTER
Once the air passes through the caustic scrubber it arrives to the impregnated non regenerable carbon filter in order to finish the
odor treatment.
The air goes across the carbon filter (CR) and the odor particles remain on the carbon.
In order to monitor fouling of the carbon filter (CR) it is considered a differential pressure measurement (IP) device which purpose
is to monitor the pressure drop over the carbon filter (CR). Hereby clogging of the beds can be determined and then replaced.
Odor control equipment
Pressure switch with manometer before CF PW 1+1 pcs
Pressure switch with manometer after CF PW 1+1 pcs
Thermal mass flowmeter (Before scrubber) TF 1 pcs
Gas detector (Odor inlet) ID 1 pcs
Differential pressure measurement on caustic scrubber IP 2x1 pcs
Pressure switch with manometer after recirculation pump PW 2x(1+1) pcs
Electromagnetic flowmeter EF 2x1 pcs
pH analyzer on recirculation line HP 2x1 pcs
Gas detector (Caustic scrubber) ID 2x1 pcs
Pressure switch with manometer after charge pump PW 1 pcs
Displacer (Internally mounted) on CT DL 1+1 pcs
Pressure switch with manometer after dosing pumps PW 1 pcs
Rotameter RO 1 pcs
Thermal mass flowmeter (Carbon filter) TF 2x1 pcs
Differential pressure measurement on carbon filter IP 2x1 pcs
Displacer (Internally mounted) on carbon filter DL 2x1 pcs
Gas detector (Carbon filter outlet) ID 1 pcs
3.3. Sludge line
3.3.1. Sludge tank
From ICEAS Tank – To Sludge Thickener
Sludge is pumped by the SAS pumps (VP) from biological treatment (SBR tanks) to the sludge tank.
This tank is divided in two chambers which are provided with two horizontal agitators (AH) each, in order to maintain the
homogeneity on the sludge cake.
The sludge is pumped by the positive displacement pump (PP) located on STH for it treatment.
Control equipment
3.3.2. Sludge thickener and polymer dosing pump (PD1)
From Sludge Tank – To Sludge Mixing Tank
Surplus activated Sludge from SBR is store on SLT until it is pumped in order to be treated by the thickener.
The thickening has been designed to process the daily SAS amount of the design load case in 18 hours a day, 7 days a week with
(3+2) gravity belt thickener (BT).
SLUDGE THICKENER
The operation of the gravity belt thickener is the following:
1. Gravity belt thickener (BT) starts.

2. On a time, basis, regarding the gravity belt thickener (BT) starts, polymer dosing pump (DP) starts. The value of polymer
dosage is automatically controlled; however, it could be programmable from the MCC2 by the operator, having in account
the sludge flow and the MLTSS concentration.
3. On a time, basis, regarding the gravity belt thickener (BT) start, positive displacement pump (PP) starts.
4. Gravity belt thickener (BT) stops and washes.
a. Once the positive displacement pump (PP) and polymer dosing pump (DP) are stopped, the ball valve (BA)
located on service water line is opened, for the gravity belt thickener (BT) washing.
b. On a time, basis, once the positive displacement pump (PP) and polymer dosing pump (DP) are stopped, the
gravity belt thickener (BT) is stopped and the ball valve (BA) from service water closed.
POLYMER DOSING UNIT
This equipment is for the polymer preparation and it is controlled from a level basis, regarding the level on polymer dosing unit
tank.
According to the level detected by the float switch (LS) located on the tank, the multiscreen feeder (MF) is stopped or started and
the actuated ball valve (BA) closed or open, if it is high or low respectively.
On the other hand, the polymer dosing unit (PD) includes three vertical agitators (AR) for the polymer preparation.
It is used drinking water for the polymer preparation.
Control equipment
Pressure switch with manometer on common line PW 1 pcs
Turbidity analyzer on STH TB 1 pcs
Pressure switch with manometer after PP PW 3+2 pcs
Electromagnetic flowmeter after PP EF 3+2 pcs

TSS analyzer after PP TS 3+2 pcs
Manometer before polymer dosing unit MA 2x1 pcs
Electromagnetic flowmeter before polymer dosing unit EF 2x1 pcs
Float switch after screw feeder on polymer dosing unit LS 2x1 pcs
Float switch on polymer dosing unit LS 2x4 pcs
Pressure switch with manometer after DP PW 3+2 pcs
Rotameter on PD1 RO 3+2 pcs
Electromagnetic flowmeter on PD1 EF 3+2 pcs
3.3.3. Sludge mixing tank
From Sludge Thickener – To Sludge Dewatering
From sludge thickener the sludge is sent to SMT where it remains until it is pumped by the positive displacement pump (PP) of the
SLD.
The SMT is divided in two chambers which are provided with one horizontal agitator (AH) each, in order to maintain the
homogeneity of the sludge cake.
Control equipment
3.3.4. Sludge dewatering and polymer dosing pump (PD2)
From Sludge Mixing Tank – To Sludge Silos
Sludge cake from STH is stored on SMT until it is pumped in order to be treated by the decanter centrifugal. Three of the four
decanter centrifuges is on duty.
SLUDGE DEWATERING
The operation of the centrifugal decanter is the following:
1. Centrifugal decanter (DE) starts.
2. On a time, basis, regarding the centrifugal decanter (DE) start, polymer dosing pump (DP) starts. The value of polymer
dosage is automatically controlled; however, it could be programmable from the MCC2 by the operator, having in account
the sludge flow and the MLTSS concentration, measured by the TSS analyzer (TS).
3. On a time, basis, regarding the decanter centrifugal (DE) start, positive displacement pump (PP) starts.
4. On a time, basis, regarding the decanter centrifugal (DE) start, screw conveyors (SC) to sludge silos (SS) start.
5. Decanter centrifugal (DE) stop and wash.
a. Once the positive displacement pump (PP) and polymer dosing pump (DP) are stopped, the gate valve (AT)
located on service water line is opened for the decanter centrifugal (DE) washing.
b. On a time, basis, once the positive displacement pump (PP) and polymer dosing pump (DP) are stopped,
the decanter centrifugal (DP) is stopped and the gate valve (AT) from service water closed.
c. Once the decanter centrifugal (DE) is stopped, the screw conveyors (SC) to sludge silos (SS) are stopped.
POLYMER DOSING UNIT
This equipment is for the polymer preparation and it is controlled from a level basis, regarding the level on polymer dosing unit
tank.
According with the level detected by the float switch (LS), the multi screw feeder (MF) is stopped or started and the actuated ball
valve (BA) closed or open, if it is high or low respectively.
On the other hand, the polymer dosing unit (PD) includes three vertical agitators (AR) for the polymer preparation.
It is used drinking water for the polymer preparation.
Control equipment
Pressure switch with manometer on common line. PW 1 pcs
Pressure switch with manometer after PP PW 3+1 pcs
Electromagnetic flowmeter on SLD EF 3+1 pcs
TSS analyzer after PP TS 3+1 pcs
Gas detector ID 1 pcs
Manometer before polymer dosing unit MA 2x1 pcs
Electromagnetic flowmeter before polymer dosing unit EF 2x1 pcs
Float switch after screw feeder on polymer dosing unit LS 2x1 pcs
Float switch on polymer dosing unit LS 2x4 pcs
Pressure switch with manometer after DP PW 3+1 pcs
Rotameter on PD2 RO 3+1 pcs
Electromagnetic flowmeter on PD1 EF 3+1 pcs
3.3.5. Supernatant pumping station
From Sludge & Sludge Mixing Tank drain line / Sludge Thickener return water line – To Fine Screen Building
This pumping station receives the return water and the drain water from the sludge building.
The level is controlled by an ultrasonic level transmittal (US) located on the chamber, and according with it, the water is pumped
by the submersible vertical pump (2+1) (VP) to the FSB distribution chamber along with the BPS water.
Control equipment

3.3.6. Odor control for sludge line – OC2
From DCH / FM2 / SLT / STH / SMT / SPS / SLD / SLB
The odor to be treated on OC2 is collected on sludge line from DCH, FM2, SLT, STH, SMT, SPS, SLD and SLB by an odor line with
negative pressure.
In order to achieve high removal efficiency in the odorous air treatment facility, the Oduor control strategy pursued in the STP is
focus on minimizing the quantity of odorous air which is to be handled and treated. In this sense, in order to ensure these highly
concentrated odorous air flows, the respective structures is encapsulated and the foul air will only be drawn off the encapsulated
parts.
Additionally, sludge building is served by a forced ventilation system providing at least an air exchange rate of 4 per hour. This
ventilation is connected to the odor treatment system.
The ventilation system uses fresh air with air exchange rates between 4 times per hour up to 12 times per hour, depending of the
fact whether respective structure need regular attendance or not. Thus, the air exchange rates, have been selected according to
the odor and corrosion potential of the respective structure.
The treatment system consists of two independent treatment trains of a combined-stage scrubber (NaOH) system followed by
carbon filter.
CAUSTIC SCRUBBER
The blower (BO) impulses the air to the caustic scrubber (CT), where the air is washed with liquid composed by drinking water and
sodium hydroxide. The recirculation pump (NP) collects the water from the bottom of the scrubber, pumped to the diffusers
located at scrubber top and pulverized over the odorous air. The recirculation pump (NT) presents a non-temporized operation.
Regarding the sodium hydroxide pump (NP), it is used in order to maintain a determined level of pH on the scrubber liquid.
Regarding the pH analyzer (HP) located on the recirculation line this pump (NP) is activated or deactivated.
On the other hand, the level of liquid on caustic scrubber (CT) is measured with the displacer (DL) internally mounted. According
with it, we have the following situations:
• High level. Diaphragm valve (DI) is closed.

• Low level. Diaphragm valve (DI) is open.
• Low level. Recirculation pump (NP) is stopped.
In order to monitor fouling of the scrubber (CT) it is considered a differential pressure measurement (IP) device which purpose is to
monitor the pressure drop over the scrubber (CT). Hereby clogging of the beds can be determined and action can be taken.
CARBON FILTER
Once the air passes through the caustic scrubber it arrives to the impregnated non regenerable carbon filter in order to finish the
odor treatment.
The air goes across the carbon filter (CR) and the odor particles remain on the carbon.
In order to monitor fouling of the carbon filter (CR) it is considered a differential pressure measurement (IP) device which purpose
is to monitor the pressure drop over the carbon filter (CR). Hereby clogging of the beds can be determined and then replaced.
Odor control equipment
Pressure switch with manometer before CF PW 1+1 pcs
Pressure switch with manometer after CF PW 1+1 pcs
Thermal mass flowmeter (Before scrubber) TF 1 pcs
Gas detector (Odor inlet) ID 1 pcs
Pressure switch with manometer after recirculation pump PW 2x(1+1) pcs
Electromagnetic flowmeter EF 2x1 pcs
pH analyzer on recirculation line HP 2x1 pcs
Gas detector (Caustic scrubber) ID 2x1 pcs
Pressure switch with manometer after charge pump PW 1 pcs
Displacer (Internally mounted) on CT DL 1+1 pcs
Pressure switch with manometer after dosing pumps PW 1 pcs
Rotameter RO 1 pcs
Thermal mass flowmeter (Carbon filter) TF 2x1 pcs
Displacer (Internally mounted) on carbon filter DL 2x1 pcs
Gas detector (Carbon filter outlet) ID 1 pcs
4. CODES AND STANDARDS

Vendors shall ensure that the provision of the Works is in accordance with current internationally recognized standards, codes and
recommendations included in the item 5.2 Vol II of the ER´s. The current editions of the standards, codes and recommendations
issued by the ER´s enlisted organizations shall apply for the design, construction, testing and commissioning of the Works.
International Standards (shall prevail).
5. LANGUAGE & SYSTEM OF MEASUREMENTS

English language shall be used on all project documents.
International units shall be used on all project documents and instrument scales.
6. TAGS AND CODES IN P&ID
Tags for equipment:
Tags for equipment instruments are specified as follows:
Letter codes for identification function of plant/equipment instruments as follows, which are according to ISA 5.1:
Note 1: For explanation of tags/symbols, please refer to “Process and Instrumentation Diagram Details” drawing.
7. REFERENCES
- RFP V-II. Manfouha Sewage Treatment Plant Forth Stream. Request for proposal. Volume-II: Employer's
requirements.
- RFP V-III. Manfouha Sewage Treatment Plant Forth Stream. Request for proposal. Volume-III: Annexes to Employer's
Requirements.
- Awarded Bid Proposal. Drawings, P&ID´s, Conceptual Design Report and Technical Clarifications,
documents, 1 and 2.
- Bidders Clarifications, Documents 1 and 2.
ANNEX I: Control philosophy for SBR
25
Table of Contents
1.0 Introduction..................................................................................................................... 33
2.0 Abbreviations.................................................................................................................. 34
3.0 SBR and ICEAS Process ............................................................................................... 35
3.1 Basin Design................................................................................................................ 35
3.2 ICEAS Process Overview ............................................................................................ 36
3.3 Basin Layers ................................................................................................................ 37
3.4 Basin Hydraulics and Loading...................................................................................... 37
3.5 Nitrification Process Operation ..................................................................................... 37
3.6 ICEAS Cycle Time – NIT Process, 12 Basins .............................................................. 37
3.7 High Flow Mode Cycle Transitions ............................................................................... 41
4.0 Equipment Operation ..................................................................................................... 42
4.1 Control System ............................................................................................................ 42
4.2 Decanters .................................................................................................................... 42
4.3 Blowers ........................................................................................................................ 42
4.4 Air Valves..................................................................................................................... 43
4.5 Aeration Systems ......................................................................................................... 43
4.6 Surplus Activated Sludge (SAS) Pumps ...................................................................... 43
4.7 Level Sensing Equipment ............................................................................................ 43
4.8 Total Suspended Solids (TSS) Instrumentation ........................................................... 44
4.9 pH Instrumentation ....................................................................................................... 44
4.10 Dissolved Oxygen (DO) Control System ................................................................... 44
4.11 Solids Retention Time (SRT) Control System, SIMS ................................................ 44
5.0 Plant Specifics ................................................................................................................ 46
5.1 Plant Design Parameters ............................................................................................. 46
5.2 Dissolved Oxygen Control Setpoints ............................................................................ 47
5.3 Surplus Activated Sludge (SAS) Pump Setpoints ........................................................ 48
5.4 Unit Processes Following the Sanitaire System ........................................................... 48
26
1.0 Introduction
Xylem – Sanitaire Products is the provider of the Sanitaire process and associated
equipment. This Operational Description describes the basic operation of the process and
is specific to the following plant:
Project Name: Manfouha STP

Project Location: Manfouha, Saudi Arabia
Sanitaire Number: 16-8914AC
Process, Basins: NIT, 12-Basin
This document will be used in conjunction with the Functional Design Specification (FDS)
for the system. This document is a process overview, whereas, the FDS will describe in
detail the control of each system component, interlocks between components, operating
ranges and how to change control setpoints.
27
2.0 Abbreviations
The following abbreviations apply to this Operational Description and the FDS for the
control logic for the plant.
ADWF Average Dry Weather NDNP Nitrification/Denitrification/Phosphorus

Process Auto Automatic Control NH3-N Ammonia - Nitrogen
BOD Biochemical Oxygen NIT Nitrification
Process BOD 5 Biochemical Oxygen
Demand - 5 day NO2-N Nitrite -
Nitrogen BWL Bottom Water Level
NO3-N Nitrate - Nitrogen
CBOD Carbonaceous Oxygen COAO Close-Off-Auto-Open
COD Chemical Oxygen ORP Oxidation-Reduction Potential
DO Dissolved Oxygen PID Proportional Integral Derivative
EQ Equalization P&ID Piping and Instrumentation Diagram
ETM Elapsed Time Meter PC Personal Computer
FDS Functional Design PD Positive Displacement
F/M Food to Microorganism PDWF Peak Dry Weather Flow
FS Float Switch PLC Programmable Logic Controller
ft feet PWWF Peak Wet Weather Flow
gpd gallons per day RAS Return Activated Sludge
HMI Human-Machine
HOA Hand-Off-Auto SBR Sequencing Batch Reactor
HOR Hand-Off-Remote SCADA Supervisory Control and Data Acquisition
HRT Hydraulic Retention SOR Standard Oxygen Requirements
I/O Inputs/Outputs SOTE Standard Oxygen Transfer Efficiency
ICEAS Intermittent Cycle Extended Aeration SRT Sludge Retention Time
kg kilogram SSV Settled Sludge Volume
lb pound SVI Sludge Volume Index
Lps Liters per second SWD Side Water Depth
LT Level Transducer TKN Total Kjeldahl Nitrogen
m meter TN Total Nitrogen
3
m /day cubic meters per TP Total Phosphorus
MCC Motor Control TWL Top Water Level
mg/L milligrams per Liter (parts per VFD Variable Frequency Drive
million,
MLSS Mixed Liquor Suspended WWTP Wastewater Treatment Plant
MLVSS Mixed Liquor Volatile Suspended °C degrees
Celcius NDN
Nitrification/Denitrification
3.0 SBR and ICEAS Process
The sequencing batch reactor (SBR) process is a modification of a conventional activated

sludge plant. The SBR process allows the unit processes of react, settle, and discharge
to occur sequentially in one basin. As a result, the “footprint” of a SBR is typically much
smaller than that of a conventional activated sludge plant. The Intermittent Cycle
Extended Aeration System (ICEAS) process is a modification of a conventional SBR.
The ICEAS process allows continuous inflow of wastewater into the treatment basins
during all phases of the cycle. The continuous inflow is an advantage over conventional
SBRs in that it optimizes biological treatment by supplying a constant food source for the
process and equalizes the flow loadings in multiple-basin systems. A cycle consists of
different phases (react, settle, and decant) during which treatment takes place. The
cycles operate continuously in each basin to meet the treatment goals of the plant.
3.1 Basin Design
An ICEAS basin has two compartments: a pre-react zone and a main-react zone. The
pre- react zone acts as a biological selector and receives the continuous influent flow.
The two compartments are separated by a baffle wall that spans the tank width and has
openings at the basin floor. The baffle wall prevents short circuiting and allows the two
zones to be hydraulically connected as it directs the flow to enter the main-react zone at
the bottom of the basin.
3.2 ICEAS Process Overview
The following is a brief process overview of the three phases common to all Sanitaire cycles:
1.) React, 2.) Settle, and 3.) Decant.
React Phase
During the react phase, raw wastewater

flows into the pre-react zone continuously
to react with the mixed liquor suspended
solids. Depending on the process scheme,
the basin contents are aerated, anoxically
mixed, allowed to react anaerobically, or a
combination thereof. As the basin continues
to fill, biological oxidation/reduction
reactions take place simultaneously to treat
the wastewater.
Settle Phase
During the settle phase, basin agitation from

the react phase (i.e. aeration or mixing) is
stopped to allow the solids to settle to the
bottom of the basin. Raw wastewater
continues to flow into the pre-react zone as
the main-react zone settles. As the solids
settle, a clear layer of water will remain on
top of the basin.
Decant Phase
During the decant phase, the decanter

rotates downward to draw off the clarified
supernatant and discharge it to the effluent
line. Raw wastewater continues to flow
into the pre-react zone as the main-react
zone is decanted. Sludge is typically
wasted from the basin during this phase in
the cycle.
3.3 Basin Layers
The picture illustrates the three stratified layers that are

formed in each basin at the end of the settle phase and
beginning of the decant phase. The sludge blanket
forms on the bottom of the basin as the mixed liquor
suspended solids (MLSS) settle. A buffer zone of 1 Buffer
metre acts to buffer the sludge blanket from the volume
Sludge Blanket
that will be removed during the decant phase. The
drawdown is the top layer of clear liquid that remains
after the MLSS settle and is the maximum volume that
will be drawn off during the decant phase.
3.4 Basin Hydraulics and Loading
During all phases of the ICEAS cycle, raw influent (usually screened and degritted) flows
into the basin. To allow equal loading, flow is split equally to all basins by a splitter box.
Since influent flow is continuous, the ICEAS process can be operated in a single basin
allowing for basins to be taken out of service for maintenance or during low flow/loading
conditions.
The ICEAS basins are designed to handle the average dry weather flow (ADWF), the
peak dry weather flow (PDWF), and the peak wet weather flow (PWWF) as specified in
the design parameters. Flow enters the basin continuously and the treated effluent
leaves the basin intermittently (only during the decant phase). Two time-based cycles are
used to hydraulically process the flow. The normal cycle will process the ADWF and the
PDWF. The high flow cycle has time periods that are 25 percent shorter than the normal
cycle to process flows above the PDWF up to the PWWF.
3.5 Nitrification Process Operation
The nitrification (NIT) process operates to remove BOD, TSS, and ammonia-nitrogen
(NH3-N) through nitrification. In the NIT process, the react phase consists of aeration
periods to supply oxygen to the biomass for BOD oxidation and nitrification.
3.6 ICEAS Cycle Time – NIT Process, 12 Basins

The ICEAS process will complete one normal cycle every 240 minutes or 4 hours. Each
cycle is divided into 120 minutes of react phase, 60 minutes of settle phase, and 60
minutes of decant phase. The react phase is divided into three 40-minute periods of
aeration or “air on”, which have adjustable blower run times. The twelve basins are
staggered in their respective timelines as shown in the cycle chart below.
The high flow mode cycle is 180 minutes or 3 hours in duration as shown in the cycle
chart below. The high flow cycle has time periods that are reduced by 25 percent of the
normal cycle time periods. Each of the three periods in the react phase are 30 minutes
instead of 40 minutes and the settle and decant phases are each 45 minutes as shown in
the cycle chart below. The total reacts, settle and decant times per day remain the same
as the normal cycle.
It is only the duration per cycle that is changed to accommodate higher flows and process
more flow in a shorter amount of time.
ICEAS 12-Basin NIT Normal Cycle: 240 minutes (4 hours)

0 40 80 120 180 240
AIR ON AIR ON AIR ON SETTLE DECANT

SBR #1 (0-40 min) (0-40 min) (0-40 min) (60 min) (60 min)
120 180 240/0 40 80 120
SETTLE DECANT AIR ON AIR ON AIR ON

SBR #2 (60 min) (60 min) (0-40 min) (0-40 min) (0-40 min)
60 80 120 180 240/0 40 60
AIR ON AIR ON SETTLE DECANT AIR ON AIR ON

SBR #3 (20-40 min) (0-40 min) (60 min) (60 min) (0-40 min) (0-20 min)
180 240/0 40 80 120 180
DECANT AIR ON AIR ON AIR ON SETTLE

SBR #4 (60 min) (0-40 min) (0-40 min) (0-40 min) (60 min)
220 240/0 40 80 120 180 220
DECANT AIR ON AIR ON AIR ON SETTLE DECANT

SBR #5 (40-60 min) (0-40 min) (0-40 min) (0-40 min) (60 min) (0-40 min)
240/
100 120 180 40 80 100
AIR ON SETTLE DECANT AIR ON AIR ON AIR ON

SBR #6 (20-40 min) (60 min) (60 min) (0-40 min) (0-40 min) (0-20 min)
40 80 120 180 240/0 40

AIR ON AIR ON SETTLE DECANT AIR ON
SBR #7 (0-40 min) (0-40 min) (60 min) (60 min) (0-40 min)
160 180 240/0 40 80 120 160
SETTLE DECANT AIR ON AIR ON AIR ON SETTLE

SBR #8 (40-60 min) (60 min) (0-40 min) (0-40 min) (0-40 min) (0-40 min)
200 240/0 40 80 120 180 200
DECANT AIR ON AIR ON AIR ON SETTLE DECANT

SBR #9 (20-60 min) (0-40 min) (0-40 min) (0-40 min) (60 min) (0-20 min)
80 120 180 240/0 40 80
AIR ON SETTLE DECANT AIR ON AIR ON

SBR #10 (0-40 min) (60 min) (60 min) (0-40 min) (0-40 min)
20 40 80 120 180 240/0 20
AIR ON AIR ON AIR ON SETTLE DECANT AIR ON

SBR #11
(20-40 min) (0-40 min) (0-40 min) (60 min) (60 min) (0-20 min)
140 180 240/0 40 80 120 140
SETTLE DECANT AIR ON AIR ON AIR ON SETTLE

SBR #12 (20-60 min (60 min) (0-40 min) (0-40 min) (0-40 min) (0-20 min)
ICEAS 12-Basin NIT High Flow Mode: 180 minutes (3 hours)
0 30 60 90 135 180

SBR (0-30 min) (0-30 min) (0-30 min) (45 min) (45 min)
#1
90 135 180/0 30 60 90

SBR (45 min) (45 min) (0-30 min) (0-30 min) (0-30 min)
#2
45 60 90 135 180/0 30 45
AIR ON AIR ON
AIR ON SETTLE DECANT AIR ON
SBR (15-30
(0-30 min) (45 min) (45 min) (0-30 min)
(0-15 #3
min) min)
35 1 180/0 30 60 90 135

SBR (45 min) (0-30 min) (0-30 min) (0-30 min) (45 min)
#4
180/
65 1 30 60 90 135 165
DECANT
SBR #5(30-45 (0-30 min) (0-30 min) (0-30 min) (45 min) (0-30 min)
min)
180/
75 90 135 30 60 75
AIR ON AIR ON
SETTLE DECANT AIR ON AIR ON
SBR #6(15-30 (45 min) (45 min) (0-30 min) (0-30 min)
(0-15
min) min)
30 60 90 135 0/180 30
AIR ON AIR ON SETTLE DECANT AIR ON

SBR #7 (0-30 min) (0-30 min) (45 min) (45 min) (0-30 min)
120 135 180/0 30 60 90 120
SETTLE
SBR #8(30-45 (45 min) (0-30 min) (0-30 min) (0-30 min) (0-30 min)
min)
150 180/0 30 60 90 135 150
DECANT
SBR #9 (15-45 min) (0-30 min) (0-30 min) (0-30 min) (45 min)
(0-15
min)
180/
60 90 135 30 60
AIR ON SETTLE DECANT AIR ON AIR ON

SBR #10 (0-30 min) (45 min) (45 min) (0-30 min) (0-30 min)
15 30 60 90 135 180/0 15
AIR ON AIR ON
AIR ON AIR ON SETTLE DECANT
SBR #11(15-30 (0-30 min) (0-30 min) (45 min) (45 min)
(0-15
min) min)
105 135 180/0 30 60 90 105
SETTLE
SBR #12 (15-45 min) (45 min) (0-30 min) (0-30 min) (0-30 min)
(0-15
min)
The duration of the react phase in the 4-hour and 3-hour cycles allows air to be directed
into one basin at a time by the operation of motorized air control valves. This allows for
the “Duty” blower to cycle between the two basins. When Basin #1 is in the react phase
and receiving air, Basin #2 is in an “air off” period or the settle or decant phase. When
Basin #2 is in the react phase and receiving air, Basin #1 is in an “air off” period or the
settle or decant phase.
Basins #3 and #4, #5 and #6, #7 and #8, #9 and #10, and #11 and #12 operate similarly.
3.7 High Flow Mode Cycle Transitions
The system switches from normal cycle operation to high flow mode operation when the
level sensing equipment in a basin detects a water level that corresponds to a flow that is
above PDWF. After the high flow mode is initiated, the system will stay in the high flow
mode until the basin that indicated a high flow event has completed its cycle (end of
decant phase) and completed another full high flow mode cycle.
At the completion of the full high flow mode cycle for that basin, the system will switch
back to normal cycle operation if no basins are indicating water levels that correspond to
a flow above PDWF. If a basin detects high water levels that indicate a flow above
PDWF, the system will stay in the high flow mode until normal cycle water levels return.
The system can switch into high flow mode at any time during the normal cycle. The
system cannot, however, switch from high flow mode back to the normal cycle until the
completion of the high flow mode cycle for the initiating basin.
4.0 Equipment Operation
The following sections contain brief descriptions of the equipment operation for the ICEAS
process. More detailed descriptions are found in the FDS.
4.1 Control System
The control system for the ICEAS NIT process has a control panel, which contains the
programmable logic controller (PLC), a human-machine interface (HMI), control switches,
indicator lights, power connection, etc. The motor starters and variable frequency drives
(VFDs) for the equipment are housed in a separate motor control center (MCC), which is
provided by the bidding contractor. The PLC contains the logic to operate the process
equipment when the equipment is in automatic control. The HMI is an operator interface
that communicates with the PLC to display system status, allow setpoint adjustments, and
perform alarm handling.
4.2 Decanters
Each basin has a decanter installed on the wall opposite the pre-react zone. The
decanter operates to remove clarified effluent from the top layer of the basin (drawdown)
during the decant phase of the cycle. The drawdown is defined by the top water level
(TWL) and the bottom water level (BWL). When the decanter is not operating, it remains
in a parked position above the TWL, which eliminates the possibility of solids carryover
during other phases in the cycle. In the park position, the decanter can act as a clarifier
weir in the event of a power outage.
The decanter is mechanically operated by the use of an electro-mechanical actuator that

is mounted on the basin walkway for easy access. The actuator moves the decanter
between the top and bottom limit switches whenever the decanter is in operation. The
decanter speed is controlled through the use of a variable frequency drive (VFD). As a
result, the decanter discharge rate will be relatively constant from the time the decanter
enters the water to the time it reaches the BWL.
During the end of the settle phase, the decanter will travel from the park position to the
TWL. When decant phase is started, the decanter will travel from the TWL to the BWL in
the allotted time to remove the drawdown volume from the basin. Since influent flow to
the plant varies, the water level in the basin at the start of each decant phase will be at
differing levels above BWL. Consequently, during the decant phase, the decanter will
travel downward for a period of time before reaching the water surface. Also mounted on
the decanter in front of the weir is a floatable scum guard that operates to exclude floating
material during the decant phase.
4.3 Blowers
Eight centrifugal, variable vane blowers operate to supply air to the aeration system. Each
blower has modulating inlet and outlet guide vanes for controlling the output air flow. Each
blower is capable of delivering 100 percent of the air requirements to the process in one
basin at a time. Six blowers operate as the “Duty” blowers for each pair of basins and the
other two operate as the “Standby” blowers. The blowers can alternate duty on a weekly
basis
.
4.4 Air Valves
Each basin has a motorized air valve, which will operate to allow air to enter a basin at
certain time. The two air valves for basin #1 and #2 will operate in an alternating
sequence during blower operation; when one valve is open, the other one is closed, etc.
The air valves divert air between this pair of basins when blower operation is required in
the cycle. Basins #3 and #4, #5 and #6, #7 and #8, #9 and #10, and #11 and #12
operate similarly.
4.5 Aeration Systems
Each basin has a complete fine bubble aeration system, which operates to deliver
diffused air to the process. The aeration system only receives air when the air valve for
the basin is open. A solenoid valve connected to the aeration system periodically opens
and closes to allow the aeration system to purge and depressurize. The duration that the
solenoid valve is open for purging and depressurizing is operator adjustable through the
HMI. In addition to the automatic purge, the aeration system has a manual purge valve
that the operator can use as needed.
4.6 Surplus Activated Sludge (SAS) Pumps
Each basin has Duty/Standby submersible pumps, which operate to waste sludge from
the basin during the decant phase of the cycle. The surplus activated sludge (SAS) pump
total run time, start time, number of wasting periods, and time between run times are
adjustable through the HMI located on the ICEAS control panel.
4.7 Level Sensing Equipment
A level transducer and float switch are installed in each basin. The level transducer
continuously indicates the basin water level at the HMI. The PLC uses the water level
reading to calculate the corresponding flow rate into the basin. If the basin water level
indicates that a flow above the PDWF is entering the basin, the system will transition into
the high flow cycle.
The float switch has two functions. One function is to signal a high level in the basin and
force the system into a settle phase to allow a minimum of 30 minutes of settle time prior
to the water level overtopping the decanter. The second function is to signal that the
system must transition into the high flow cycle if the level transducer has not already
signaled this to take place.
4.8 Total Suspended Solids (TSS) Instrumentation
There are two total suspended solids (TSS) meter installed in each basin. The probes
send a reading back to the PLC via an analyzer at the basin. The TSS values are
continuously indicated at the HMI.
4.9 pH Instrumentation
There are 2 pH probes installed in each basin. The probes send a reading back to the
PLC via an analyzer at the basin. The pH probe continuously indicates the basin pH value
at the HMI. The historical pH values will also be trended on at the SCADA.
4.10 Dissolved Oxygen (DO) Control System
The dissolved oxygen (DO) control system regulates the DO in the basin by controlling
the blower operation. Each basin has a DO probe and analyzer. The analyzer sends the
signal received from the probe in the basin to the PLC indicating the DO concentration in
parts per million (ppm), which is the same as milligrams per liter (mg/L). High, low, and
target DO setpoints in ppm are selected and entered at the HMI. Blower operation is
regulated by the PLC based on the DO setpoints. When the high DO setpoint has been
reached, there is a time delay before the blower will respond that is operator adjustable
through the HMI. The goal of the system is to achieve a constant DO concentration
without over- or under-aerating the process during the aeration periods in the react
phase.
4.11 Solids Retention Time (SRT) Control System, SIMS
The solids retention time (SRT) control system regulates the SRT in the basin by
controlling the wasting rate. The wasting rate is controlled by adjusting the SAS pump
run time. During “High Flow” mode, the actual pump run time is reduced proportionally to
match the cycle time, which results in the same amount of sludge wasted per day in all
cycle modes. The SAS pump can be selected to run up to three separate times during
the cycle and the operator can select the time between the wasting periods. The purpose
of running the pump more than one time per cycle is to avoid pumping clear water as
biomass close to the pump is removed. The SAS pump start time, run time, number of
run periods and time between the run times are operator adjustable on the operator
interface.
Each basin has a total suspended solids (TSS) probe. The analyzer will read the signals
from the four in-basin TSS probes and send the signal received from the probe in the
basin to the PLC indicating the TSS concentration in milligrams per liter (mg/L), which
represents the MLSS concentration. The wasting line from the basin has a common pipe
that will have an in- line TSS probe. The in-line TSS probe has a separate analyzer and
will measure the SAS concentration when the SAS pumps operate to waste solids from
the basins. A flow meter will be installed in the SAS line to determine the volume of
sludge wasted. Using the flow and SAS TSS measurements, the PLC calculates the
mass of TSS wasted.
There are four different SIMS control modes available to control the wasting cycles.
Three of the SIMS operating modes utilize TSS measurements in the system to adjust the
mass of solids wasted to maintain a target value, and the fourth option maintains a
constant pump run time per day regardless of the measurements of the TSS probes in the
system. For any of the three automatic SIMS control modes, when the
measured/calculated value is above the target setpoint, the PLC will increase the SAS
pumping time incrementally. The reverse is true if the measured/calculated value is
below the target setpoint; the PLC will decrease the SAS pumping time incrementally.
The goal of the SIMS system is to maintain a consistent target value without wasting too
much or too little solids, which provides a stable biomass population.
MLSS Mode
When SIMS is set to operate in MLSS Mode, the PLC automatically adjusts the SAS
pump run time to maintain a user-defined MLSS concentration in the basin. A target
MLSS concentration is entered at the HMI.
SRT Mode
When SIMS is set to operate in SRT Mode, the PLC automatically adjusts the SAS pump
run time to maintain a user-defined SRT or Sludge Age in the basin. A target SRT is
selected and entered at the HMI. SAS pump operation is regulated by the PLC based on
the SRT setpoint and the calculated SRT using data from the solids monitoring
instruments.
Smart SRT Mode

Smart SRT Mode uses the basin temperature and the target effluent ammonia level
combined with an operator selectable safety factor to determine the optimum SRT for the
basin to operate at and automatically adjusts the SAS pump run time to maintain a
consistent SRT or Sludge Age in the basin.
Time Mode
When SIMS is set to operate in Time Mode, the PLC operates the SAS pump for a user-
defined run time during each cycle, regardless of the measurements of the TSS probes
in the system. A SAS pump run time per cycle is entered at the HMI.
5.0 Plant Specifics
The specifics for the Manfouha STP are briefly described in this section. Refer to the Contract
Documents for more details regarding the overall process at the plant.
5.1 Plant Design Parameters
The Manfouha STP has been designed based on the following influent wastewater
characteristics and site conditions. These parameters have been used for basin design
and the process criteria.
ADWF 210,353 m3/day
PDWF 255,000 m3/day
PWWF 336,564 m3/day
BOD5 Conc. (at 20°C) 343 mg/L
BOD Loading 72,087 kg/day
TSS Conc. 374 mg/L
TSS Loading 78888 kg/day
NH4-N 26 mg/L
NH4-N 5410 kg/day
Total Phosphorus Conc. 7 mg/L
Total Phosphorus Loading 1557 kg/day
Alkalinity required (minimum) 182 mg/L
Wastewater Temperature, Min 20 °C
Wastewater Temperature, Max 35 °C
The ICEAS NIT process has been designed to meet the following effluent requirements
on a 30-day arithmetic average.
BOD5 Conc. (at 20°C) 10 mg/L

TSS Conc. 10 mg/L
NH3-N Conc. 1 mg/L
TN Conc. 14 mg/L
39
To meet the effluent requirements, the ICEAS NIT process has the following basin design.
Number of Basins 12 basins 11 basins

Basin Length 62.0 m 62.00 m
Basin Width 47.0 m 47.00 m
TWL 5.87 m 5.95 m
BWL 4.95 m 4.95 m
Basin Volume at BWL 14,231 m3 14,231 m3
Basin Volume at TWL 16,860 m3 17,099 m3
To meet the effluent requirements, the ICEAS NIT process has been designed with
the following parameters for each basin.
F/M Ratio 0.097 kg BOD/kg MLSS-day 0.097 kg BOD/kg MLSS-day

SVI (after 30 min settle) 150 mL/gm (max) 150 mL/gm (max)
MLSS (at BWL, design loading) 4,332 mg/L 4,718 mg/L
HRT 0.94 days 0.94 days
SRT 12 days 12 days
Normal Decant Rate 58.48 m3/min 58.48 m3/min
Peak Decant Rate 81.22 m3/min 81.22 m3/min
SAS Produced (mass) 5,184 kg/day/basin 5,655 kg/day/basin
SAS Produced @ 0.85% solids 610 m3/day/basin 665 m3/day/basin
5.2 Dissolved Oxygen Control Setpoints
For nitrification to occur, it is important to maintain DO concentrations in the basin around

2 ppm during the aeration periods in the react phase. The following DO Setpoints are
recommended for design conditions and can be adjusted by the operator through the
HMI.
Parameter Setpoint Value

Enable/Disable DO On
Control
High DO Setpoint 3.0 ppm
Target DO Setpoint 2.0 ppm
Low DO Setpoint 1.0 ppm
High DO Off Delay 2 minutes
More information on changing setpoints is located in the controls FDS.

5.3 Surplus Activated Sludge (SAS) Pump Setpoints
To maximize the concentration of solids in the waste to be removed from the basin, it is
recommended that the SAS pump operate near the end of the decant phase. This will
allow the solids the most time to settle and compact. The NIT process decant phase
takes place in each basin from minute 180 to minute 240 (60 minutes total). It is
recommended that the SAS pump start time be around minute 200. One wasting event is
recommended and is sufficient for the process needs if wasting is under five minutes. Two
wasting times with a ten minute break is recommended for wasting for five to fifteen
minutes. If wasting is needed for fifteen minutes or more, three wasting times are
recommended with ten minutes breaks. If coning or a lighter wasting towards the end of
the wasting time is occurring, several wasting periods could be implemented to alleviate
the problem.
Under manual SIMS control, the operator must monitor the MLSS level in the basin in
conjunction with the system solids retention time (SRT) and food-to-microorganism (F/M)
ratio to adjust the waste sludge pump run time accordingly. A change in sludge settling
characteristics must also be considered when setting the SAS pump run time. The SAS
pump selected for the plant has a capacity around 113 L/s. Based on the design
parameters for the plant, it is estimated that 610 m3/day of waste at 8,500 mg/L MLSS
should be wasted from each basin to maintain an SRT of approximately 12 days. This
calculates to running the SAS pump for approximately 15 minutes per cycle. The
following SAS pump setpoints are recommended for design conditions and can be
adjusted by the operator through the HMI.
Parameter Setpoint
First Starting Time Minute 200
Total Wasting Time 15 minutes
# of Wasting Periods 2
Time Between Wasting Periods 10
Under automatic control, SIMS uses the operator input target SRT and information
coming in from the probes. Automatic control allows the SIMS control logic to alter the
wasting to make the target SRT and actual SRT match. Additional information on SIMS
is located in the SIMS O&M Manual.
More information on changing setpoints is located in the FDS.
5.4 Unit Processes Following the Sanitaire System
The unit processes that follow the Sanitaire system at the plant include the following
general items:
Unit Process Comments

DURON Controlled by WEDECO
During the decant phase, the treated flow will leave the basins through the decanter and
flow through the tertiary treatment process before it is discharged into receiving water
ANNEX II: Control philosophy for UV
1 INTRODUCTION
The control philosophy details all the major items of the Three Channel Duron UV System
provided under this contract and describes the manner in which they operate.
1.1 OBJECTIVE OF DOCUMENT

The control philosophy is intended to be used throughout the period of the Contract to
inform the Contractor, Consulting Engineer, and End User of the manner in which the
UV system will operate.
1.2 COPYRIGHT
Information contained in this document is the property of Xylem WEDECO and must
not be copied or submitted to a third party without prior consent and shall be used only
as a reference to work by Xylem WEDECO.
1.3 TREATMENT PROCESS

The Xylem WEDECO Ultraviolet (UV) disinfection system provides the disinfection
process for a Wastewater Treatment Plant.
43
2 PROCESS AND SYSTEM OVERVIEW
2.1 THE UV DISINFECTION PROCESS
In sufficient dose, UV radiation around 254nm is lethal to all micro- organisms. The
effectiveness of UV radiation is due to its ability to cause rearrangements in the genetic
material of micro-organisms. This prevents the micro-organism from reproducing and if
the micro-organism cannot reproduce, it is to all intents and purposes dead.
The detailed mechanism by which UV deactivates micro-organisms is beyond the scope

of this discussion.
Treated effluent from the main works is directed through an UV Channel, where it is
exposed to UV radiation in a series of UV Banks. Each Bank is composed of several
modules. Each module is comprised of 12 UV lamps, similar in appearance to fluorescent
lighting tubes. These lamps, housed in quartz sleeves for protection are placed in the UV
Channel, at a 45 degree incline in the direction of water flow. As the effluent passes
through these lamps the micro-organisms within the water are exposed to UV radiation to
leave them inactive, or dead, when discharged from the channel.
2.2 PRINCIPLE OF OPERATION

The intensity of the UV radiation and the time that the effluent water is in contact with the
UV radiation determines the UV dose that is being given to the micro-organisms. The
effectiveness of the UV disinfection would be normally be expressed as the ratio between
the number of living micro- organisms measured within the effluent prior the UV banks to
the number of living micro-organisms measured within the effluent after the UV banks.
Received UV Dose is defined as follows:
D=I*T
Where:
D = Dose (mJ/cm²)
I = UV intensity (mW/cm²) T = Residence
Time (s)
Listed below are UV Dose Definitions (For NWRI and UVDGM projects, UV Dose is
referred to as RED).
44
Term Description Source
Minimum Design The minimum design UV This is the minimum
UV Dose/RED Dose/RED that must be design UV dose/RED
applied per Contract required by the
Specification. specifications. This is
a fixed pre-set value
entered via the HMI
by WEDECO
Offset UV ‘Safety Factor’ added to Fixed pre-set value
Dose/RED Minimum Dose/RED to entered via the HMI
determine the Target by the Supervisor or
Dose/RED. This ensures WEDECO
that the Received
Dose/RED is always above
the Minimum Dose/RED.
Target UV Setpoint determined by Calculated value:
Dose/RED adding the Minimum Minimum Design UV
Design UV Dose/RED and Dose/RED + Offset
the Offset UV Dose/RED. UV Dose/RED
The target UV dose/RED is
compared with the
Received Dose/RED to
determine number of
banks required for UV
disinfection.
Received UV The actual UV Dose/RED Calculated
Dose/RED being received by the Dose/RED: Sum of
effluent at any given time Received Dose/RED
by all UV banks within from all UV banks in
channel. operation within
channel.
45
2.3 UV INTENSITY
UV intensity is the measurement of the UV output of a lamp measured in mW/cm².
The UV intensity is measured continuously by a UV sensor located in each bank. The

module in the middle of bank houses the UV sensor.
During the lifetime of a UV lamp, the measured UV intensity will vary due to several
factors. These factors include lamp aging, fouling of quartz sleeves and the UVT of the
water. As a UV lamp ages, an increase in operational hours will result in a diminished UV
output from the lamp. This decreasing lamp output will be observed as a decreasing UV
intensity measured by the UV sensor. Water quality plays a key role in the ability of UV
light to penetrate the water column surrounding a UV lamp. Two areas in which water
quality plays an important role in UV intensity monitoring include fouling and percent
transmittance.
Inorganic (aluminum, magnesium, manganese, iron, and hardness) and organic (oil and
grease) constituents within the influent to a UV reactor may adversely impact the ability of
the UV light to pass into the water from the UV lamps due to deposition of these
constituents on quartz sleeves. This deposition leads to a coating of the quartz sleeve,
known as fouling. Fouling reduces the amount of UV light within the UV bank and
therefore will decrease the UV intensity as measured by the UV sensor and decrease the
disinfection efficiency of the UV system. Fouling can also occur on the UV sensor tube
window, resulting in a decreased UV intensity measurement.
The percentage of UV light at 254 nm not absorbed while passing through the water
column, typically measured via a 1 cm path length, is known as the UV Transmittance
(UVT). Natural components of water, such as dissolved materials, turbidity and
suspended solids, absorb UV light. Suspended solids also scatter UV light. The
absorption and scattering effects of these water components decrease the ability of UV
light to penetrate water, thus decreasing the UVT. Lower UVT values will result in a
decreased UV distribution, a lower UV intensity as measured by the sensor and thus a
decreased UV dose delivered by the system.
2.4 RESIDENCE TIME

The residence time is the amount of time that the micro-organisms are in contact with
the UV light. Head loss and velocity calculations ensure that
46
optimal hydraulic conditions exist in the channel. The residence time of each bank is
calculated by dividing the irradiated UV bank volume by the water flow rate within the UV
channel.
T = V/Q
Where:
T = Residence time, s
V = Bank Volume
Q = Flow rate
2.5 WATER FLOW RATE, Q

The UV system requires a flow rate to calculate UV dose. The flow rate will be calculated
as a function of the outlet position feedback, width of penstock, and water level measured
by the ultrasonic level sensor #2. The ultrasonic sensor is located after the last bank.
There is a flow rate signal per channel.
Unit of Flow Rate for UV English Unit: GPM

PLC Metric Unit: m3/hr
(for control purposes)
Flow Rate displayed on English Unit: GPM and MGD
UV HMI (for monitoring Metric Unit: m3/hr and LPD
purposes)
3 UV SYSTEM COMPONENTS
3.1 DURON MODEL NUMBER
The Duron model number is shown in the format below:
DURON A i B – C x D
Where:
A = Number of Lamps in UV Bank
B = Number of Modules Wide in a Bank
C = Number of Banks in a Channel
D = Number of Channels
i = in
3.2 UV CHANNEL (D)

The treated effluent from the main works is directed through a UV channel with a series of
banks of UV lamps.
47
3.3 UV BANK (C)
Within the channel, there are 4 banks of UV lamps. Each bank has 4 modules that
hold the UV lamps.
The Banks within the channel are identified alphabetically: A,B,C,D starting from the
channel inlet.
3.4 UV MODULES (B)

Each bank has 4 modules which hold the UV lamps. The modules within a bank are
identified numerically as 1 - 4. Each module may holds 12 lamps.
The modules consist of several components:

1. Lamp cable
2. UV Intensity sensor (only one per bank)
3. Safety switch for module lif ted
4. Safety switch for safety cover removed
5. Module Lift Motor ( if equipped)
6. Quartz sleeve wiper rings
7. UV Intensity sensor wiping brushes
8. Pneumatic W iping System:
a. Reed switches on the wiping actuator cylinder. The reed switch
located on the lamp cable side of module is the Wiper at Rest Position
Switch. The reed switch located on farthest away of lamp cable is the
W iper at End Position Switch
b. Wiping pneumatic cylinder actuator
3.5 UV LAMPS
The UV lamps used are Xylem WEDECO variable output lamps. The UV Lamps are
low-pressure high power type with an arc length of 143 cm. The UV Lamp produces an
output of UV Light at a wavelength of 254 nm which is nearly proportional to the variable
power settings from the electronic lamps ballast.
48
The UV lamp (4) is enclosed in a quartz sleeve (2) closed at one end and appropriately
sealed using end plugs.
The quartz sleeve is a single piece of clear fused quartz circular tubing. The electrical
connections to the lamp module are made at one end through a watertight connector (1)
with ribbed cap nut providing a positive handgrip for tightening and loosening without the
need for any tools.
3.6 UV SENSOR
The UV intensity is measured continuously by a UV sensor located on one of the modules
within each bank. The UV sensor is housed in the module located in the middle of the
bank and it is monitored by an Eco Touch.
3.7 UV BALLAST
The UV lamps are ignited and controlled by Xylem WEDECO electronic ballast, known as
the Eco ray TDS 60 ballast.
The UV ballasts are installed in specially designed racks located in the UV system
enclosure. Each ballast card powers two lamps that are side by side in a module. An on-
board microprocessor performs the following features: lamp power control, pre-heating
control, 10 ignition attempts, and lamp status monitoring.
When the ballast card is first energized, it will power the lamps at 100% for a time period.
Then the ballast card will follow the 50% to 100% controls given by the UV System PLC to
ensure that adequate dose control is maintained.
3.8 LMS-FLEX BOARD

The LMS-FLEX distributes the three-phase voltage and neutral as well as the digital bus
to six TDS ballasts. The LMS-FLEX monitors the operational status of the ballasts per
rack and interfaces with the Eco Touch.
3.9 TERD BOARD

The TERD Board is an I/O module that distributes the discrete inputs, discrete outputs,
analog inputs, and analogue outputs to the Eco Touch. There is a TERD board located in
each Ballast 48 enclosure.
3.10 ECOTOUCH
The Eco Touch is a universal controller that interfaces the UV PLC with the ballasts, UV
sensor, and TERD Board I/O. The Eco Touch communicates with the UV PLC via
Ethernet IP. The Eco Touch communicates with the ballasts via the LMS-FLEX board.
There is an Eco Touch in each Ballast 48 enclosure.
49
Listed below are the parameters passed through the Eco Touch and UV PLC.:
• Lamp Status
• Lamp Power from the PLC
• UV intensity of bank in W/m².
• TERD Board I/O
3.11 WATER LEVEL CONTROL

The UV system is provided with a means to maintain proper water level to for optimum UV
disinfection. In addition, the water level must not go too high as this can result in un-
disinfected water flowing through the channel.
3.11.1 DOWNWARD OPENING OUTLET PENSTOCK

The water level in the UV channel is measured using an Ultrasonic Level sensor
#1 that is located before Bank A. The ultrasonic sensor sends a 4-20mA
analogue signal to the UV PLC that is relative to the actual water level.
The water level in the UV channel is controlled by an outlet penstock and it is

considered downward opening. Therefore, lowering the penstock is referred to as
Opening. Raising the penstock is referred to as Closing.
The UV PLC controls the outlet penstock by pulsing it open or close based on the
water level setpoint and actual water level. There are four control points that the
water level is compared to for controlling the outlet penstock:
• Water Level High Setpoint

= Water Level SP + (Deadband / 2)
• Water Level Very High Setpoint
= Water Level SP + ((Pulse Range / 2 – (Deadband / 2))
• Water Level Low Setpoint
= Water Level SP - (Deadband / 2)
• Water Level Very Low Setpoint
= Water Level SP - ((Pulse Range / 2) – (Deadband / 2))
The Deadband is defined as the range around the water level setpoint that the
penstock will not move.
The Pulse Range is defined as the range outside of the deadband where the
penstock is pulsed to open or close. If the water level is outside of the pulse
range, then the penstock is forced to open or close continuously.
50
Listed below are the different scenarios for maintaining water level setpoint:
• The water level is greater than the water level high setpoint, the UV PLC
pulses the outlet penstock to open for a time period. The time period will not
exceed the value set by the ‘Outlet Penstock Maximum Pulse Time’
parameter.
• The channel level is greater than the water level very high setpoint, the UV
PLC forces the outlet penstock to open continuously until the water level is
less than the water level very high setpoint.
• The channel level is less than the water level low setpoint, the UV PLC pulses
the outlet penstock to close for a time period. The time period will not exceed
the value set by the ‘Outlet Penstock Maximum Pulse Time’ parameter.
• The channel level is less than the water level very low setpoint, the UV PLC
forces the outlet penstock to close continuously until the water level is greater
than the water level very low setpoint.
The ‘Outlet Penstock Maximum Pulse Time’ is the maximum time period that the
penstock is pulsed to open or close. The further away the water level is from the
High setpoint or Low Setpoint, the longer the pulse time.
When a penstock has completed an open or close cycle, the UV PLC will wait for
an ‘Outlet Penstock Break’ time period before comparing the actual water level to
the water level setpoint. This ensures that excessive penstock movement does
not occur.
3.12 AUTOMATIC WIPING SYSTEM

To maintain UV transmittance efficiency, the UV system is equipped with an automatic
wiping system. The wiping system is operated with pneumatic controls.
3.12.1 PNEUMATIC WIPING SYSTEM

Each module within a bank has its own pneumatic cylinder. The quartz sleeves,
which hold and protect the UV lamps, are wiped by PTFE or SS rings. They
remove most deposits from the quartz sleeves and prevent degradation of the UV
intensity.
The wipers for each module of a bank are made to traverse the length of the
quartz sleeves. The position of the wiper arm will be proved with proximity
switches located at the pneumatic cylinder. The start and maintenance position
are referred to as the ‘Rest
Position’. The end of lamp position is referred to as the ‘End Position.’
In order for the pneumatic Automatic Wiping System to wipe a bank of lamps, the
following must be true:
• Water Level in Channel is OK (no low water level alarms exist)
• All modules within UV bank are not lifted
• The module covers within the UV bank are installed correctly.
• Air Pressure not low
When the UV PLC calls to wipe a bank, the wiper solenoid for the bank is
energized. All of the module wipers within the bank are driven to the Wiper at End
position. The UV PLC detects when all the wipers reach the Wiper at End position
and de-energizes the wiper solenoid to bring the wipers back to the Wiper at Rest
position.
These two traverses, from Rest position to End position and bank to Rest
position, constitutes a single wipe cycle of the lamps. The operator can adjust the
number of wipe cycles that comprise a wipe of the bank.
When a wipe cycle for a bank is completed, the UV PLC begins the wipe cycle for
the next bank. When all banks in the UV system have been wiped, then the
Wiping Sequence Timer begins.
The operator can adjust the time interval between bank wipes as well as system
wipes.
If the UV System is experiencing low UV intensity alarms (for PSS projects) or low
S/So alarms (for NWRI and UVDGM projects), then the operator may need to do
one or both of the following:
• Decrease wiping intervals

• Increase number of wipes
NOTE: When a UV intensity low alarm or low S/So alarm is first generated, the
UV PLC initiates a bank wipe.
The wiping sequence can be executed manually via the HMI. There are two
ways to manually wipe the UV lamps:
• UV BANK MANUAL WIPE
A UV bank can be wiped manually by pressing the MANUAL WIPE
pushbutton for the respective bank. The UV PLC will wipe the bank for the
number of cycles set on the HMI.
• UV BANK WIPE (MAINTENANCE)
If there is a problem with the wiper system, the operator can troubleshoot the
wiping function for each bank. The operator can press the Bank ‘y’ Wipe
Maintenance pushbutton on the HMI. The first function that will appear will be
to EXTEND wiper. When the EXTEND pushbutton is pressed, the wiper
solenoid is energized and moves the wiper arm to the WIPER END position.
The operator must press the RETRACT pushbutton to de-energize the wiper
solenoid to allow the wiper arm to return to WIPER REST position. The wiper
failure alarms are inhibited when the automatic wiper system is in
maintenance mode.
For the module that holds the UV sensor, there are brushes attached to the wiper
arm that will clean the UV sensor. When a wipe sequence is performed for a
bank, the UV intensity is frozen to prevent shadowing and false UV intensity
readings.
3.12.1.1 PNEUMATIC SYSTEM

The pneumatic Automatic Wiping System requires a pneumatic system to
provide air provide instrument quality air at 65 – 90psi. The pneumatic
system will be a dedicated air compressor supplied by WEDECO
The WEDECO pneumatic option includes the following features: dedicated
compressor, receiver tank, automatic recovery from mains power failure,
manual pressure regulator, auto drain valve on receiver, filters, air dryer (if
required)
There is an air pressure switch located in the wiper solenoid box at the
channel to detect low air pressure. The air pressure low alarm is displayed
on the UV HMI.
3.13 MODULE LIFT CONTROL BOX

There is a Module Lift Control Box located next to the UV channel. The operator can
lift a module out of the channel for maintenance purposes.
Electric Module Lift Control Box
The operator can lift a module out of the channel for

maintenance purposes.
To lift a module, refer to the Module Lift Procedure

located in Section 6.7.
Components on the Electric Module Lift Control Box
Module Lift push buttons:

Press and hold the Up-arrow switch to lift the
module.
Press and hold the Down arrow switch to
lower the module.
When the push button is released, the module stops
traveling.
Pilot Light: Module Lift Drive Failure

Color: Red
Failure indicates that the module lift drive has failed
54
Module Drive Failure Reset button:
Press to reset module lift drive failure
With the Full Maintenance selector switch at the

OFF position, the Fully Lifted Switch stops the
module while it is being lifted.
With the Full Maintenance selector switch at the

ON position, the module can be lifted pass the Fully
Lifted Switch. This allows the operator to lift the
module completely out of the channel.
NOTE: Use a crane to safely remove the

module out of the channel.
3.14 INLET PENSTOCK

The UV channels are equipped with inlet penstocks to isolate the channels.
- Inlet penstocks with actuator:
• The UV PLC automatically opens/closes the inlet penstocks depending on UV
dosing and flow conditions. The UV PLC also opens the inlet penstocks when a
new channel has a low water level condition and needs to be filled up. Once the
water reaches the low water level probe, then the inlet penstock closes to allow
the lamps to warm up for 10 minutes. After 10 minutes, the inlet penstocks open
fully for UV disinfection.
• The UV PLC monitors the open/close status of the inlet penstocks. The end-
user can open/close the inlet penstocks from remotely at the UV HMI or locally
at the actuator. If the inlet penstock is closed, then the channel is considered
not available for UV disinfection.
1.1 CUSTOMER COURTESY RELAYS
The UV system offers six customer courtesy relays for monitoring purposes. The relays
are commonly used by end-users that may not have a SCADA system with Ethernet
protocol.
UV System Running Relay: When the relay is energized, at least one bank is in
operation.
Low Priority Alarm Relay: When the relay is de-energized, there is at least one Low
Priority Alarm present. Low Priority alarms are provided for events that have little
effect on the UV disinfection process and water works process but do need immediate
attention. Refer to Section 10 to view which alarms are considered Low Priority
alarms.
High Priority Alarm Relay: When the relay is de-energized, there is at least one High
Priority Alarm present. High Priority alarms are provided for events that have a major
effect the UV disinfection process and/or the water works process. They can reflect
failure of equipment or failure of the disinfection process. Refer to Section 10 to view
which alarms are considered High Priority alarms.
Critical Instrument Failure Relay: When the relay is de-energized, there is at least
Critical Instrument Failure present. The following alarms trigger the Critical Instrument
Failure Relay
-Signal Failure: Channel ‘x’ Bank ‘y’ UV Intensity
-Signal Failure: Flow Rate (if applicable)
-Signal Failure: UV Transmittance Monitor (if applicable)
-Signal Failure: Channel ‘x’ Ultrasonic Level Sensor (if applicable)
UV Dose Failure Relay: When the relay is de-energized, the UV System Dose/RED is
below the minimum design UV Dose/RED setpoint for a time period.
1.2 ADDITIONAL ITEMS
1.2.1 UPS-UNINTERRUPTABLE POWER SUPPLY

In the event of a power loss to the ICA enclosure, the UPS provides backup power to
the UV PLC, HMI, and other ICA components.
In the event of a power loss to the ICA enclosure and there is power to the Ballast
Distribution Enclosures, the UV PLC continues to control and monitor the UV system
under UPS power.
In the event of a power loss to the ICA enclosure and there is no power to the Ballast
Distribution Enclosures, the UV lamps for the respective enclosures are OFF.
However, the UPS provides backup power to the UV PLC and HMI to prevent loss of
HMI trending and alarms.
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MN4 STP Control Philosophy

Table 1. Process template.

ICH Inlet Chamber

FM1 Metering chamber 1

CSB Coarse Screening Building

IPS Inlet Pumping Station

FSB Fine Screening Building

FM5 Metering chamber 5

SGR Sand & Grease Chamber

FM2 Metering chamber 2

BBA Air Blowing Area (Sand & Grit)

DCH Distribution chamber ICEAS

BBL Air Blowing Building ICEAS

SBR ICEAS Tank (Aeration Tank)

BTA Balance Tank / Intermediate Pump Station

DPS Drainage Pumping Station

FM3 Metering chamber 3

FBL Filtration facility

BPS Backwash pumping station

UVB UV Control Building

CCT Chlorine Contact Tank

CHB Chlorine Storage Building (NaOCl) & Pumping Station

FM4 Metering chamber 4

FDC Final Distribution Chamber

SWL Service water line

SLT Sludge Tank

STH Sludge Thickener

SMT Sludge Mixing Tank

SPS Supernatant Pumping Station

SLD Sludge Dewatering

PD2 Polymer dosing unit for Sludge Dewatering

SLB Sludge silos building

OBL Operation Building

OC1 Odor Control Footing Pad (Pre-treatment facilities)

OC2 Odor Control Footing Pad (Sludge facilities)

WBF Weigh Bridge

DWT Drinking water tank

FFB Fire Fighting Building

SCADA Supervisory Control and Data Acquisition

3. DESCRIPTION OF CONTROL PHILOSOPHY

3.1. General comments

• The following control philosophy description should be considered as a guide.

3.2. Water line

3.2.1. Inlet chamber

From Haer Channel – To Flow Metering Chamber 1

The flow to the STP is:

• Maximum flow: 13,333.33m3/h.

Ultrasonic level transmittal US 1 pcs

Float switch LS 2 pcs

From Inlet Chamber – To Coarse Screen Building

3.2.3. Coarse screening

COARSE SCREEN (CN)

SCREW CONVEYOR (SC)

Conductivity (CSB inlet chamber) CD 1 pcs

pH Analyzer (CSB inlet chamber) HP 1 pcs

Ultrasonic level transmittal before CN US 2+1 pcs

Ultrasonic level transmittal (before CN bypass) US 1 pcs

Ultrasonic level transmittal (after CN bypass) US 1 pcs