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T. A. Madigan July 28, 1989
BIOPONDS OPERATING MANUAL - REVISED
Attached is the revised Bioponds Operating Manual for your use and reference.
T. A. Madigan
-J
Co-op Process Engineer
tjs
cc: RWS, DCS, DAM, JBA, MHW(7), RBN, FGJ
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VAB.0001135476
WASTEWATER TREATMENT SYSTEM OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
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AUGUST, 1983
REVISED JULY, 1989
VAB.0001135477
BIOPONDS OPERATING MANUAL
Table of Contents I. INTRODUCTION
II. PROCESS DESCRIPTION III. SAFETY
IV. STARTUP PROCEDURES V. NORMAL OPERATION
VI. pH UPSETS VII. POWER FAILURES VIII. BIODISC TROUBLESHOOTING
IX. ACID SPILLS AND LEAKS X. OIL DISCHARGE TO SEWERS
XI. OUTFALL EXCURSIONS
XII. SHUTDOWN PROCEDURES APPENDIX A - WASTEWATER TREATMENT TERMINOLOGY APPENDIX B - API SEPARATOR OPERATION DIAGRAMS
VAB.0001135478
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
I. INTRODUCTION
Wastewater from the Vinyl, Compound and Plasticizer areas of the Plant is
discharged to the bioponds for physical and biological treatment prior to
discharge to James Creek. The Plant has an NPDES permit from the State
of Mississippi which outlines quantities of water contaminants that can
be discharged from the bioponds. Table I Summarizes these limitations.
Pollutants which are primarily treated for include ph, BOD and TSS
In
addition, there is incidental priority pollutant removal.
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Figure I shows a simplified process flow diagram for the bioponds. Drawing SD-2880-42-1-D presents a more detailed process flow diagram for the Pond 3 and biodisc units. The following summary briefly describes the major units at the bioponds, and their primary functions.
A. Pond 1 Pond 1 consists of two concrete settling basins that separate PVC resin from the wastewater. The resin collects in the bottom of the basins and is periodically reclaimed by the resin reclaim system.
B. Pond 3 Pond 3 is a small equalization lagoon in which the wastewater ph is adjusted and fertilizer is added prior to biological treatment.
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I. INTRODUCTION (Continued)
A
Biodisc The biodisc is the initial stage of biological treatment. The unit consists of three rotating biological contactors which are highly aerated and remove approximately 60% of the influent Biological Oxygen Demand (BOD).
D. Pond 4 Pond 4 is a highly mixed and aerated lagoon that accomplishes further BOD removal.
E. Pond 5 Pond 5 is a large and partially aerated lagoon in which biological Total Suspended Solids (TSS) from Pond 4 settle out and are biodegraded. A small amount of final BOD removal occurs in Pond 5.
F. Pond 6 Pond 6 is a small lagoon prior to the outfall that settles out minor quantities of biological TSS that carry over from Pond 5. Treated wastewater flows from Pond 6 to James Creek.
VAB.0001135480
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TABLE I
BIOPONDS WASTEWATER DISCHARGE REQUIREMENTS
The Plant has a wastewater permit from the State of Mississippi which outlines the quantities of water contaminants that the Plant can discharge to James Creek, and the frequency by which the Plant must monitor the discharge for these contaminants. These quantities and other discharge requirements are summarized below:
Parameter
Limitation
Monitoring Frequency
BOD, Monthly Average - December 1 through April 30 - May 1 through November 30
32 ppm (431 lbs/day) 26 ppm (357 lbs/day)
Once/Week Once/Week
BOD, Daily Maximum - December 1 through April 30 - May 1 through November 30
43 ppm (800 lbs/day) 40 ppm (774 lbs/day)
Once/Week Once/Week
COD, Monthly Average - December 1 through April 30 - May 1 through November 30
1,461 lbs/day 1,212 lbs/day
Once/Week Once/Week
COD, Daily Maximum - December 1 through April 30 - May 1 through November 30
2,712 lbs/day 2,523 lbs/day
Once/Week Once/Week
Suspended Solids, Monthly Average
674 lbs/day
Once/Week
Suspended Solids, Daily Maximum
1,396 lbs/day
Once/Week
Ammonia, Monthly Average
13 lb s/day
Once/Week
Ammonia, Daily Maximum
28 lb s/day
Once/Week
Flow
C ontinuously
Temperature
< 95 F
Once/Week
ph
6.0 - 9.0
Once/Week
Dissolved Oxygen
> 6.0 ppm
Once/Week
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BIOPONDS OPERATING "MANUAL ABERDEEN CHEMICAL PLANT
II. PROCESS DESCRIPTION (Refer to Drawing PT-423-42-1-L) A. Pond 1 Water from the vinyl operations area gravity flows to two parallel concrete settling basins (Pond 1) at an average flow rate of 925 gpm. At the inlet of Pond 1 is a small diversion box with isolation valves that can divert wastewater to either the east or the west basin. The discharge from each basin joins together into a common line and gravity flows to Pond 3.
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The primary purpose of Pond 1 is to collect PVC resin by gravity settling. While one basin is being filled with resin, the other basin is typically blocked in and being dredged. The two basins are alternately filled and dredged as needed. The dredged resin is reclaimed by the Plant and sold as a low grade product.
Fertilizer Addition System Water from Pond 1 gravity flows to a concrete mixing sump, NCS-101, which is at the inlet of Pond 3. Wastewater from the boiler house, compound, and plasticizer areas bypasses pond 1 and flows directly to the concrete mixing sump at the inlet of pond 3. Ammonia is added continuously to the sump in order to fertilize the water prior to biological treatment. Nitrogen is needed for the growth of microorganisms on the biodisc and in Ponds 4 and 5.
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II. PROCESS DESCRIPTION (Continued) B. Fertilizer Addition System (Continued) 1. Ammonia Anhydrous ammonia is stored under pressure in a 1500 gallon horizontal tank located inside of the acid dike. Ammonia vapor from the tank passes through a pressure regulator, a fine metering valve and a rotameter and is then bubbled into the bottom of the mixing sump. The ammonia feed rate is set according to the ammonia concentration in Pond 5, which assures that the feed is sufficient for acceptable biological treatment. A feed rate of approximately 20 lbs/day of ammonia is typical.
Sulfuric Acid Addition System 1. pH Control System
The pH control system maintains the pH of the wastewater m Pond 3 between 6.5 and 10.0 pH units. Concentrated (66 Baume) sulfuric acid is used to neutralize water with a high pH, however there are no provisions to neutralize water with a low pH. Gravity feed through a 1 1/2" PVC line is used to transfer the sulfuric acid to the mixing sump of Pond 3. The 1 1/2" acid transfer line is run in a concrete trench which drains to Pond 3, this serves to contain any acid that may be spilled due to line leakage.
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C. Sulfuric Acid Addition System (Continued) 1. pH Control System (Continued) Acid feed is controlled by the 3/4" and 1 1/2" plug valves located in parallel on the discharge of the day tank. Both the 3/4" and the 1 1/2" valves are air-actuated ON/OFF alloy 20 plug valves. Gate valves located immediately down stream of the control valves are used to regulate the flow.
The pHis controlled by monitoring the incoming wastewater with
pH probe, NPHE-102, located in the Pond 3 mixing sump. A
second pH probe, NPHE-101, is located on the discharge of Pond
3 and is used to monitor the pond 3 exist pH for alarm
conditions. The following are the respective set points.
Pond 3 In
3/4" Plug Valve
Open 8.0
Close 7.0
1 1/2" Plug Valve
10.0
9.0
Pond 3 Out
Alarms
Pump Shut down
Low 7.0
4.0
High 10.0
12.0
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BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
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C. Sulfuric Acid Addition System (Continued) 1. pH Control System (Continued) During a high pH condition it may be necessary to add sulfuric acid directly to Pond 4.
2, Sulfuric Acid Level Indication Two bubbler type Tank-O-Meter gauges are used for level indication in the large storage tank and the day tank. Air pressure applied in a 3/4" carbon steel pipe installed from top to bottom in each tank is used to measure the amount of head on the tank. The air pressure is provided from a manual air pump.
D. Pond 3 Pond 3 acts as an equalization lagoon for the biodisc influent. The pH and waste strength peaks are smoothed out in order to minimize shocks to the biodisc. Pond 3 has a theoretical residence time of 13 hours, however, it's actual residence time is approximately 1 hour because of channeling. The water from Pond 3 gravity flows to the biodisc pump-out sump, NCS-102.
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT PROCESS DESCRIPTION (Continued) E. Biodisc
The biodisc feed pump transfers wastewater from the pump-out sump to the biodisc. The pump, 72-550, or its spare, 72-551, operate on level control. A level controller maintains a set level of water in the pump-out sump by modulating a butterfly valve on the discharge of the biodisc feed pumps. If the level controller fails and the level in the pump-out sump drops too low, a float operated low level switch will shut off the biodisc feed pump.
Once in the biodisc sump, the wastewater is brought into contact with the rotating biological surfaces of three biodisc shafts. The inlet and outlet weirs of the sump are mounted such that the shafts are 40 percent submerged in the water. The discs are covered with a thin film of microorganisms, referred to as biomass, which removes BOD from the water. As the surface rotates, wetted biomass passes through the atmosphere in order to aerate the biomass. This transfer of oxygen is necessary to maintain an aerobic (in the presence of oxygen) process
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PROCESS DESCRIPTION (Continued)
E. Biodiscs (Continued)
The biodisc shafts are rotated by an air drive system. The air is
supplied to the biodisc by an air blower, 49-556, or its spare, 49-
557.
The blower supplies 705 scfm at 4.5 psig, of which 250
cfm/shaft is needed to keep the shafts rotating at 1.5 rpm. The air
is blown into the bottom of the biodisc sump through diffuser nozzles
located underneath the biodisc shafts. The air bubbling up through
the biodisc sump fills cups on the periphery of each shaft, and the
shafts are rotated by the buoyancy effect of the air in the cups.
A valve on the inlet to the air blowers regulates the air flow to
the biodisc, which in turn sets the speeds of the rotating shafts.
The speed of the three shafts are monitored by shaft speed
indicators, which activate an alarm if the speed of any shaft falls
below 1.0 rpm. If the shaft speed is allowed to remain below 1.0
rpm, an excessive and uneven amount of biomass could occur and result
in structural damage. A low shaft speed could also allow solids to
settle and accumulate in the biodisc sump. There is no high speed
alarm, but the shafts should not be rotated faster than 1.8 rpm.
The air drive system has other functions besides rotating the shafts. The bubbling of air through the wastewater helps to maintain aerobic conditions in the biomass, and it also causes microorganisms to slough off of the discs. This sloughing off is why the concentration
VAB.0001135487
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
II. PROCESS DESCRIPTION (Continued) E. Biodisc (Continued) of suspended solids in the water increases as it passes through the biodisc sump. The sloughing off of biomass is beneficial since it promotes fresh biomass growth and it regulates the biomass weight. If the biomass weight becomes too great however, the air feed to the biodisc can be sharply increased in order to slough off excess biomass. This is referred to as sheer shock.
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F. Pond 4 Water gravity flows from the biodisc sump to Pond 4, where it is further treated for BOD removal. Pond 4 is a highly mixed and aerated lagoon. There are seven small aerators located around the periphery on the pond which mix and aerate the water in order to supply oxygen for microbial growth. Floes of micro-organisms are kept in suspension by the swirling water flow around the periphery of the pond, which also helps to increase residence time in the pond.
G. Pond 5 Water gravity flows from Pond 4 to Pond 5 for final treatment before discharge to James Creek. Pond 5 is a large, partially mixed and aerated lagoon that primarily biodegrades biological solids that carry over from Pond 4. There are two large surface aerators on Pond 5 that aerate portions of the pond. A small amount of BOD removal
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT PROCESS DESCRIPTION (Continued) G. Pond 5 (Continued)
place in the aerated zone of the pond and dead biological material is digested by anaerobic processes on the bottom of the pond. H. Pond 6 Water gravity flows from Pond 5 to Pond 6, and is then discharged to James Creek. Minor amounts of suspended solids that carryover from pond 5 are settled out in Pond 6. The discharge from Pond 6 gravity flows to James Creek over a series of steps in a cascade formation, which aerates the effluent in order to increase the dissolved oxygen content of the discharge.
VAB.0001135489
BIOPONDS OPERATING "MANUAL
III. SAFETY
ABERDEEN CHEMICAL PLANT
A. Ammonia
1. Description
Ammonia is a colorless gas which is soluble in water. It is
known for its pungent odor which is detected as low as 1 ppm.
Ammonia gas does not generally present a fire hazard, as it
is used in this operation, since considerable preheating is
required before ignition and combustion are possible.
Inhalation of small amounts of ammonia does not represent a
health hazard since it is absorbed by the respiratory tract
and quickly metabolized into nontoxic substances. However,
exposure to higher concentrations (300-500 ppm) will cause
irritation of the respiratory tract and the membranes covering
the eyelids and eyeballs. Extreme concentrations (2500 ppm)
can cause severe eye damage as well as death.
Ammonia
solutions can be encountered at the mixing sump
Strong
ammonia solutions are corrosive to skin tissue.
.2 Sources
ammonia storage tank, the ammoniator above ground pipes carrying ammonia could cause high concentrations in the immediate area. Ammonia gas could also present a hazard at the mixing sump if the ammoniator was releasing more ammonia gas than the water could absorb. Ammonia solution at the mixing sump
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BIQPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
Ill. SAFETY (Continued)
A. Ammonia (Continued) 2. Sources (Continued) it could be splashed around by the mixer.
3. Handling Procedures When dealing with high concentrations of ammonia gas, which could result from a leaking pipe fitting or a ruptured tank, respirators should be worn. If there is a possibility of contact with ammonia solution, rubber gloves and eye protection should be worn.
4. First Aid In case of exposure to a high concentration of ammonia gas, the victim should get fresh air and report to first aid. In case of contact with ammonia solution, the affected areas should be thoroughly rinsed with fresh water and contaminated clothing should be removed. The victim should report to first aid if the affected areas show any adverse reactions. If ammonia solution gets into the eyes, they should be flushed with fresh water and the victim should report to first aid.
VAB.0001135491
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BIQPQNDS OPERATING "MANUAL
ABERDEEN CHEMICAL PLANT
III. SAFETY (Continued)
B. Sulfuric Acid
1. Description
Sulfuric acid is a viscous, oily liquid with a strong chemical
attraction to water. Because of this attraction, it rapidly
draws the water out of living tissue causing its destruction.
If the tank holding the acid is not tightly sealed, the acid
can draw water out of the atmosphere. This can cause the upper
layer of acid to become diluted.
Although concentrated
sulfuric acid will not attack iron, the diluted acid will.
When this attack occurs, hydrogen gas is evolved and an
explosion hazard is created.
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2. Sources Exposure to sulfuric acid can occur at the storage tank, the mixing sump, the control valves, or along the above ground pipes which carry the acid.
3. Handling Procedures a. Face shield, rubber gloves, full body slicker suit and adequate foot protection should be worn whenever dealing with sulfuric acid.
VAB.0001135492
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BIOPQNDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
III. SAFETY (Continued)
B. Sulfuric Acid (Continued)
3. Handling Procedures (Continued)
b. Fire and Explosion Hazard - An open flame should not be
used around the sulfuric acid tank, especially near the
vent pipe unless the tank has been vented of any possible
hydrogen gas. Sulfuric acid in non-flammable, but is
highly reactive and capable of igniting finely divided
combustible materials on contact.
In higher
concentrations, ignition may occur on contact with
combustible materials such as sawdust and oil rags.
c. Water or caustic solutions should never be added to
sulfuric acid because of the violent reaction and
spattering. When diluting, always add acid to water.
Never add water to the acid.
d. Adding water to a PVC line filled with acid will cause
the line to melt from the heat of reaction.
4. First Aid Affected areas should be rinsed with fresh water and contaminated clothing removed. The victim should report to first aid.
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
III. SAFETY (Continued)
D. Vinvl Chloride
1. Description
Vinyl chloride is a flammable gas with a sweet odor. Mild
exposure will cause symptoms resembling alcoholic intoxication
while acute exposures will cause lightheadedness, nausea, and
dulling of the senses.
Vinyl chloride is regarded as a
carcinogen by the U. S. Environmental Protection Agency.
2. Sources Wastewater entering the biodisc unit contains vinyl chloride, which is air stripped out of the water in the biodisc sump. VCM contaminated air is then present inside of the biodisc shaft covers. Without proper ventilation of the shaft covers, the contaminated air leaks out of the shaft covers through various openings and disperses around the vicinity of the biodisc.
3. Handling Procedures Without proper ventilation of the biodisc shaft covers, the area in the vicinity of the biodisc is a vinyl chloride exposure hazard. Employees are not to walk near the biodisc without proper respiratory protection, unless the shaft covers are fully ventilated or the biodisc blowers are shut off. Hot work should not be performed near the biodisc unless the biodisc blowers are shut off and the area has been determined to be free of organic vapors.
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
III. SAFETY (Continued)
D. Vinvl Chloride (Continued) 4. First Aid The victim should get fresh air.
E. Me th ane 1. Description Methane is a colorless, odorless gas. It is an asphyxiant as well as an extreme fire hazard.
2. Sources
If the biodisc is shut down but the basin is not pumped out
as specified in the shutdown procedures, the contents may begin
to be degraded by anaerobic processes.
These biological
reactions produce methane gas. Although the chances of this
happening are small, it is important to mention this
possibility because of the enclosed nature of the biodisc.
Handling Procedures It should be made certain that there is not accumulation of methane in the biodisc prior to using an open flame near a door or vent of the biodisc enclosure. An explosion meter would be the best instrument to use to determine if a hazard exists. Instruments designed to detect the presence of hydrocarbons could also be used. However, these will give results which
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT III. SAFETY (Continued)
E. Methane (Continued) will require some interpretation by the user in order to determine if an explosion hazard exists.
4. First Aid The victim should get fresh air and report to the first aid station.
VAB.0001135496
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
V. STARTUP PROCEDURES A. Pond 1 1. Remove the outlet isolation baffle on the basin to be operated. 2. Open the inlet isolation valve on the basin to be operated. 3. Make sure that the Pond 1 bypass sewer is blocked out. There is a manway east of Pond 1 that has a board in it for this purpose.
Ai /
B. Fertilizer Addition System 1. Start mixer 51-559. 2. Fill the ammonia tank with anhydrous ammonia. 3. Open the 3/4 inch valve between the ammonia tank and the ammoniator. 4. Open the ammoniator needle valve and adjust the flow through the flowmeter to 25% of scale.
C. pH Control System 1. Put strip chart paper in the pH recorders. 2. Turn on the power to the pH controller and the recorders. 3. Calibrate pH probes NPHE-101 and 102 with pH buffer solutions of 7 and 10 as follows. a. Immerse the pH probe in a jar filled with pH 7 buffer solution. b. Adjust with calibration knob on the controller until the indicator read a pH of 7.
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BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
IV. STARTUP PROCEDURES (Continued)
C. pH Control System (Continued) c. Rinse the probe with water. d. Immerse the pH probe in a jar filled with pH 10 buffer solution. e. Adjust the span knob on the controller until the indicator read a pH of 10. f. Rinse the probe with water and repeat steps a through e.
4. Set the channel 1 (Pond 3 outlet) alarm and setpoints as follows. a. Set the channel 1 test/run switch on test and record the pH reading. b. Turn the high pH alarm and high Ph setpoint knobs fully clockwise, and the low pH alarm and low pH setpoint knobs fully counter clockwise. Turn the deadband knobs fully counter clockwise. c. Turn the calibration knob until the pH indicator reads 4.0. Turn the low pH setpoint knob until the low pH setpoint LED glows. d. Turn the calibration knob until the pH indicator reads 5.0. Turn the low pH alarm knob until the low pH alarm LED glows.
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VAB.0001135498 i
BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT IV. STARTUP PROCEDURES (Continued)
C. pH Control System (Continued) e. Turn the calibration knob until the pH indicator reads 10.0. Turn the high pH alarm knob until the high pH alarm LED glows. f. Turn the calibration knob until the pH indicator reads 12.0. Turn the high pH setpoint knob until the high pH setpoint LED glows. g- Return the calibration to the pH reading recorded in a step a, and switch the test/run switch to run.
5. Set the channel 2 (Pond 3 inlet) setpoints as follows. a. Set the channel 2 test/run switch to test and record the pH reading. b. Turn the high and low pH setpoint knobs and the deadband knobs fully clockwise. c. Turn the calibration knob until the pH indicator reads 9.0. Turn the low pH setpoint knob until the low pH setpoint LED glows. d. Turn the calibration knob until the pH indicator reads 7.0. Turn the deadband knob adjacent to the low pH setpoint knob until the low pH setpoint LED turns off. e . Turn the calibration knob until the pH indicator reads 10.0. Turn the setpoint knob until the high pH setpoint LED glows.
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BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
IV. STARTUP PROCEDURES (Continued)
c. pH Control System (Continued)
f Turn the calibration knob until the pH indicator reads
8.0. Turn the deadband knob adjacent to the high pH
setpoint knob until the high pH setpoint LED turns off.
g Return the calibration to the pH reading recorded in step a, and switch the test/run switch to run.
6 . Fillthe sulfuric acid day tank with 93% sulfuric acid.
7 . Valves BV-105, 106, 107, 108, 112 and 113 should be opened to
allow acid transfer between the day tank and control valves.
Opening valves BV-110 and BV-111 will allow acid into Pond 3
inlet. (See attached drawings Acid-2 and Acid-3).
.8 Insure that the day tank vent valve BV-115 is open.
9. The 3/4" plug valve CV-102 is intended to control the pH under
normal operation or where large amounts of caustic have not
dumped
optimum
104 should be open enough to bring down a pH as high as 9.2,
but not so open where it brings
down
At
proper control the chart recorder should show an even
oscillation between the approximate pH values of 9.0 and 6.0.
The 1 1/2-inch valve is primarily used in times of excessive
caustic dumping, the gate valve, CV-103, should be adjusted
to maintain a pH oscillation between 11.3 and 4.5.
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BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
IV. STARTUP PROCEDURES (Continued)
D. Pond 3 Pond 3 requires no special attention during startup, except that the discharge isolation valve needs to be open.
E. Biodisc 1. Inspect the biodisc air diffusers to make sure that they are all intact. Remove any trash from the biodisc sump. 2. Close the pressure gauge drain valves on the air blowers and the biodisc feed pumps. 3. Start the air flow to level controller NLC-101. 4. Turn the bearing flush water to biodisc feed pumps 72-550 and 75-551. 5. Open the 8-inch discharge valves on biodisc feed pumps 72-550 and 72-551. 6. Turn on biodisc feed pump 72-550 and set the pump in automatic. Fill the biodisc sump with water. 7. Set the biodisc sump and effluent weirs such that the water level in the sump is approximately 1 foot below the shafts. 8. Set the level controller NLC-101 such that the level in biodisc feed sump NCS-102 is 6 inches above the low level float switch setpoint. Checkout the low level switch by pushing down the float and watching to see if biodisc feed pump 72-550 shuts off.
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STARTUP PROCEDURES (Continued)
E. Biodisc (Continued)
9. Turn off biodisc feed pump 72-550 and turn on biodisc feed pump
72-551 in automatic. Check out the low level switch for 72-
551.
10.
Grease the biodisc shaft bearings.
11. Open the 6-inch valve on air blower 49-556 discharge.
12. Fully open all three 4-inch butterfly valves on the air
dispersion lines.
13. Close the butterfly valve on the suction of air blower 49-556,
and turn on 49-556. When the blowers gets up to speed, open
the suction valve partially in order to put a load on the
blower.
14. Check the blower piping for leaks.
15. Set the shaft speeds at 1.0 rpm by adjusting the suction valve
on air blower 49-556.
Adjust the low shaft speed alarm
setpoint screw at each shaft so that there is a low shaft speed
alarm condition when the shaft speed falls below 1.0 rpm.
16.
Set the shaft speeds at 1.2 - 1.4 rpm by further opening the
suction valve on air blower 49-556.
NOTE: While the biodisc is operating, VCM in the water will be air
stripped. Respiratory protection is needed while working in
the vicinity of the biodisc, unless proper ventilation of the
biodisc shaft covers is available.
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IV. STARTUP PROCEDURES (Continued)
F. Ponds 4. 5. and 6 1. Turn on the seven small aerators on Pond 4. 2. Turn on one of the large aerators on Pond 5. 3. Make sure that the isolation valve between Ponds 5 and 6 is open, and the Pond 6 bypass valve is shut.
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BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
NORMAL OPERATION The following checks and adjustments should be made at the bioponds during routine operating conditions. Operating data from several of these checks must be recorded on the Utilities Log Sheet.
A
A. Pond 1 1. The solids level in the two settling basins should be checked weekly by Process Engineering. 2. The settling basins become effectively full at a solids level of approximately 75%. When a basin becomes 75% full, the basin should be blocked in and dredged.
B. Fertilizer Addition System 1. Check and record the ammonia and phosphate concentrations at the Pond 5 effluent weir daily using the chemical snap tubes. The snap tube test procedures are written on the snap tube boxes. If the snap tube color cannot be determined because of cloudiness, grab a cleaner sample and perform the test over again. Other test methods may be used to check the ammonia concentration, provided the Mechanical Superintendent approves the methods. 2. If the Pond 5 ammonia concentration is 0.5 ppm or more, set the ammonia feed rate at 30% (10 Ibs/day) . If the Pond 5 ammonia concentration is less than 0.5 ppm, set the ammonia feed rate at 70% (23 lbs/day).
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V. NORMAL OPERATION (Continued)
B. Fertilizer Addition System (Continued) 3. Check the level in the ammonia tank daily, 4, Ammonia should be purchased when the ammonia tank level drops to 12". Ammonium Nitrate can be purchased from the local co op and added manually as an alternative to anhydrous ammonia.
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C. pH Control
1. Calibrate the portable pH meter at least once daily using pH
buffer solutions of pH 7 and 10.
2. Check and record the pH at the outlets of Pond 3, 4, 5 and 6
once each shift using the portable pH meter. The checks must
be made at the following locations:
Pond No.
Location
Normal pH Range
3 Southwest corner
5.0 - 10.0
4 Middle of west bank
6.5 - 9.0
5 Effluent weir
7.0 - 8.0
6
Effluent weir, east of road
7.0 - 8.0
3. Check the calibration of the Pond 3 stationary pH probes once
each shift by comparing the pH readings indicated by the
portable and stationary pH meters. If the stationary pH meter
reading differs from the portable pH meter reading by 0.5 pH
units or more, clean the stationary pH probe (if needed) and
recalibrate the stationary pH probe. (See STARTUP PROCEDURES
for pH probe calibration procedures).
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ABERDEEN CHEMICAL PLANT NORMAL OPERATION (Continued) C. pH Control (Continued)
4. Check the sulfuric acid day tank level at least once each shift, and top off the day tank as needed. Record the quantity of sulfuric acid used each shift.
5. The sulfuric acid tank should be refilled whenever the tank level falls to 24". Check the large sulfuric acid tank level at least once each week.
6. Chart paper in the pH recorder should be replaced every 30 days.
D. Biodisc
1. Check and record the rpm of the biodisc shafts once each shift
and adjust the speeds as required
When reading the shaft
speed meter, be sure to wait at least 15 seconds whenever the
shaft selector switch is changed. The meter needs this time
to stabilize after every shaft selection change. The shaft
speeds should be kept in the range of 1.2
1.6 rpm by
adjusting the position of the butterfly valve on the suction
line of the air blowers.
.2 If the shaft speed varies during each rotation, a shaft
imbalance may exist. In most cases the imbalance will even
out with time, however if a variation of more than 0.2 rpm
persists over several days of operation, air shock the biodisc
using the procedure given in Section VIII.
VAB.0001135506
A
RTQPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
V. NORMAL OPERATION (Continued)
D. Biodisc (Continued)
3. Check and record the air blower discharge pressure, motor
amperage and the biodisc feed pump discharge pressure. Listen
to the blower and pump for unusual noises that could indicate
mechanical problems. These checks should be made at least once
each day.
4. Weigh the biodisc shafts at least once each week using the
following shaft weighing procedure.
a. Loosen the nuts on the north shaft bearing of each
biodisc shaft 2-3 turns. These nuts can be left loose
at all times if desired.
b. Connect the hand hydraulic pump to the load cell fitting
at the shaft to be weighed.
c. Shut the relief valve on the hand hydraulic pump.
d. Apply pressure with slow steady strokes of the hand pump.
The pressure rises steadily until the shaft bearing is
lifted off the base. The pressure then remains constant
until the bearing reaches the nuts, after which is
increases sharply.
Stop pumping before the bearing
reaches the nuts in order to prevent damage to the
hydraulic pump. Record the constant pressure reading.
The pressure reading should be in the range of 700-1400
psig, which can be converted to pounds of biomass if
VAB.0001135507
i
A
BIOPONDS OPERATINGJ1ANUAL
ABERDEEN CHEMICAL PLANT
V. NORMAL OPERATION (Continued)
D. Biodisc (Continued) e. Open the relief valve
pump
disconnect the pump from the load cell fitting.
f. Weigh the other biodisc shafts in the same manner.
Changes in the pressure readings taken from week to week
will indicate loss or gain of biomass on the biodisc
E. Ponds 4 and 5 Aeration 1. Check to see that at least five of the small aerators on Pond 4 and one of the large aerators on Pond 5 are running. Make this check twice each shift. Listen to the aerators for unusual noises which could indicate mechanical problems.
F. Outfall Measurements 1. Check and record the outfall flow totalizer reading once each day. Record the time when the reading was taken. 2. Change the outfall flowmeter circular chart every day. Record the date and the time when the chart was changed on the chart. 3. Check and record the outfall pH every week. The portable pH probe must be calibrated in the lab before the outfall pH is measured, and a pH probe calibration form must be filled out. The outfall pH must be measured on the west side of the road.
VAB.0001135508
A
BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
V. NORMAL OPERATION (Continued)
F. Outfall Measurements (Continued)
4. Check and record the outfall temperature and dissolved oxygen
concentration every week with the dissolved oxygen meter.
Calibrate the dissolved oxygen meter using the procedure
written on the back of the dissolved oxygen meter.
The
temperature and dissolved oxygen measurements must be made at
the bottom of the step cascade, where the last waterfall
impacts on the concrete.
G. Water Sampling Process Engineering is responsible for taking the following water samples: 1. In plant analysis consists of chemical oxygen demand (C.O.D.) samples at Pond 3 in, biodisc in, biodisc out, pond 4 out, pond 5 out, and pond 6 wier every Monday, Wednesday, and Friday. The G. C. Lab is responsible for C.O.D. analysis. Every Tuesday dissolved oxygens and temperatures should be taken at pond 5 in, pond 5 out, and pond 6 weir. 2. Sampling steps 3 through 5 are required for the NPDES form that is submitted to Mississippi Department of Natural Resources. A 24-hour composite sample must be taken every week at the outfall. Flow totalizer readings must be recorded when the sampler is taken out of the sampler. The sample must be kept
VAB.0001135509
i
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
A
NORMAL OPERATION (Continued)
G. Water Sampling (Continued) 2. refrigerated throughout the sampling period and during transit
to Enviro-Lab. At Enviro-Lab the sample is analyzed for COD,
BOD, TSS, 0-P02 and NH3.
3. Pit 1 and 2, referred to as outfalls 003 and 002, are analyzed
bi-monthly for pH, TSS, flow, and temperature. The B.A.C.,
outfall 004, is monitored bi-monthly for pH, flow, and
temperature. 4. Samples for base neutrals and volatile organics are taken
quarterly and set to the M.S.U. lab for analysis. The volatile
organics sample is a grab sample taken in the green-capped 4
oz. glass jars.
The base neutrals sample is a 24-hour
composite taken in an acid cleaned quart glass jar. Aluminum
foil must be placed under the cap to seal the bottle.
5. Twice a year a seven-day bio-assay test is required where
pimephales promelas and ceriodaphnia dubia reproduction is
evaluated.
VAB.0001135510 l
A
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
V. NORMAL OPERATION (Continued)
H. Sulfuric Acid Unloading Procedures Industrial strength sulfuric acid is one of the most dangerous of acids to handle. For this reason it must be handled with extreme caution and with awareness of the danger to anyone who may come in contact with it.
The utility operator is responsible for making sure that the sulfuric acid tank has the capacity to hold the acid load. The yard operator is responsible for:
a) watching the driver to insure safe operation, b) opening and closing the fill line valve on the large acid
tank, c) providing proper and safety equipment to the driver when
The following rules apply, in general, to sulfuric acid unloading: 1) Protective clothing must be worn during initial transfer by both the operating personnel and the truck driver. a) face shield b) safety glasses c) rubber gloves d) slicker suit 2) Unloading of sulfuric acid will be accomplished only during daylight hours.
VAB.0001135511
i
BIOPONDS OPERATING "MANUAL ABERDEEN CHEMICAL PLANT
V. NORMAL OPERATION (Continued)
H. Sulfuric Acid Unloading Procedures (Continued) 3) The driver and operator must remain with the trailer at all times. 4) All tools and equipment are to be kept in safe operating conditions. 5) All deficiencies in valving or safety equipment should be reported to supervisory personnel.
The step-by-step unloading procedure is as follows: 1) Weigh-in trailer and fill outweigh ticket, the driver's paperwork must verify contents and quantity of gallons contained. 2) Obtain a "Sulfuric Acid Unloading Form" from clipboard in office and notify Utilities Supervisor. The top portion of form is filled out by utility operator, signed, dated, and returned for checklist. 3) Instruct truck driver of the required safety items and location for unloading. 4) Insure driver has all necessary safety equipment and that trailer has a working "pop-off" valve. 5) After the trailer is properly spotted, both the truck driver and operator must put on all safety equipment. 6) The operator will completed the checklist item on the "Sulfuric Acid Unloading Form" and sign it. Be sure that
VAB.0001135512
l
BIO PONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
NORMAL OPERATION (Continued)
H. Sulfuric Acid Unloading Procedures (Continued)
6) truck driver signs it also. 7) The yard operator will inspect all hoses and fittings
to be sure they are safe and designed for sulfuric acid.
The hoses should be cross-linked polyethylene, Hypalon
rubber, or teflon-lined and should have no holes or
patches. The fittings should be made of stainless steel
or black Iron and should be free of nicks or dents.
Gaskets are to be Teflon or hard rubber.
8) Instruct the driver to connect hose from plant unloading line to his trailer.
9) Open the air supply valve and regulate the pressure to
30 psi.
10)
When trailer gauge reaches 10 psi, open the bulk tank
unloading valve. Be sure to wear protective gear at this
point.
11) 12)
Instruct driver to open his unloading valve. The in line relief valve is set to relieve at 30 psi
which prevents over pressuring of the trailer.
13)
When trailer empties, allow sufficient time for the acid to empty out of the unloading line.
14)
Any leaks or drips that develop during unloading should be repaired. If a leak cannot be repaired, every effort
should be made to contain it.
VAB.0001135513
BIOPONDS OPERATING -MANUAL
ABERDEEN CHEMICAL PLANT
NORMAL OPERATION (Continued)
H. Sulfuric Acid Unloading Procedures (Continued)
15)
Insure trailer pressure gauge reads "0" before closing
off air supply valves and disconnecting from trailer.
16)
Close all unloading valves including one on storage tank.
17)
Bleed down trailer before disconnecting product lines.
Wear protective gear to disconnect hoses.
18)
Provide water from water hose for driver to wash up
hoses.
19) All wash down should be contained in acid dike.
20)
Instruct driver to return to scales for re-weighing and
paperwork.
VAB.0001135514
SULFURIC ACID UNLOADING FORM
A
BULK STORAGE TANKINCHES
PERMISSION TO UNLOAD
BOILER HOUSE PERSONNEL_____________________
DATE
_________
The above items must be checked and form filled out by boiler house personnel.
CHECKLIST FOR YARD OPERATORS
AIR HOSES INSPECTED
YES
NO
MATERIAL UNLOADING LINE HOSE FITTINGS
YES YES
NO NO
HOSE GASKETS SAFETY CLOTHING WORN
YES YES
NO NO
SAFETY BOOTS
YES
NO
SAFETY RUBBER GLOVES
YES
NO
FACE SHIELD
YES
NO
Any spill of one (1) gallon or more must be reported to Utilities Supervisor.
Yard Operator's Signature
Truck Driver's Signature
Date
This form must accompany paperwork up-front for proper filing.
VAB.0001135515 I
To Utility Technicians and Yard Operators
Interoffice Communication
From: Date:
Subject:
Morris Williams
ANHYDROUS AMMONIA (NH,)
VIS1A
(ACCOUNT NO. 744-0900-0-0011)
Anhydrous Ammonia (NH3) Unloading Procedures Information and guidelines for use in handling and unloading.
1. You will find an attached material safety data sheet and a copy of the check sheet.
.2 Some history and information about storage tanks.
A. Tank capacity 1500 gallons.
B. Size 4 feet in diameter by 15 feet long.
C. Sight glass visible part is 11 inches off bottom
of tank. Do not fill above top of sight glass. Example: 1000 gallons equals 6400 pounds. Should show about 19 inches in sight glass which would be 30 inches in tank. 3. Yard Operator weighs tank in and notifies the utility tech or supervisor. 4. Unloading truck to storage tank. A. Utility tech is to verify: 1. That the tank is ready and will hold the
amount to be put into it. 2. That the safety shower and eve wash are in
good condition. 3. That a water hose is hooked up and ready for
use if needed. B. Utility Technician:
1 The truck driver has been trained on what and how to do the handling and unloading of their truck.
2 The driver is required to have the following
on his truck: a. A.P. Mfg. date and test rated hose.
Dated within 5 years of date. b. 5 gallons of clean water. c. Ammonia mask with 2
for NH3 d. Must be wearing safety of leather
shoes.
VAB.0001135516
Anhydrous Ammonia Paee 2
When unloading, hook-ups and disconnects. a. Utility Supervisor and driver to fill
out check sheet, sign and date. b. Driver must know location of safety
shower, eye wash and water hose. c. Must wear face shield, chemical
. rubber or impoervious to ammonia gloves and clothing to cover skin. d. Unload only in daylight hours.
Morris H. Williams, Utility Supervisor Dan Miller, Mechanical Superintendent
A
VAB.0001135517 l
ANHYDROUS AMMONIA UNLOADING FORM CHECK SHEET
The following items have been checked and permission given to unload Anhydrous Ammonia into bulk storage tank.
BULK STORAGE TANK (SIZE 4' DIAMETER BY 15' LONG) INCHES IN SIGHT GLASS(VISIBLE PAIR IS 11" ABOVE BOTTOM OF TANK)
AIR HOSES INSPECTED
YES
NO
MATERIAL UNLOADING HOSES
YES
NO
HOSE FITTING
YES
NO
HOSE GASKETS
YES
NO
AMMONIA GAS MASK W/2 SPARE CANISTERS ON TRUCK
YES
NO
SAFETY CLOTHING WORN
YES
NO
SAFETY BOOTS OR LEATHER SHOES
YES
NO
SAFETY RUBBER GLOVES OR GLOVES IMPERVIOUS TO AMMONIA
YES
NO
FACE SHIELD AND GOGGLES
YES
NO
SAFETY SHOWER LOCATED AND OKAY
YES
NO
AMMONIA WEIGH 1 GALLON =6.4 POUNDS TANK CAP = 1500 GALLONS = 9600 POUNDS
UTILITY OPERATOR SIGNATURE
UTILITY SUPERVISOR
TRUCK DRIVER SIGNATURE
DATE ISSUED 9-29-86 MHW
VAB.0001135518 i
VI.
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
pH UPSETS A. Chem Wash Controls
1. Whenever spent chem wash is to be dumped to the sewer, the Vinyl Department must notify the Utility Technician in advance. The chem wash strength must also be reported to the Utility Technician.
2. IF CHEM WASH OR CAUSTIC SODA IS SPILLED OR "LOST" ANYWHERE IN THE PLANT, THE UTILITY TECHNICIAN MUST BE NOTIFIED IMMEDIATELY.
3. Chem wash dump from the old and new modules must not occur on the same day and should be two days apart.
A
B. Acid Addition 1. Check to make sure that the pH controller is opening and closing CV-101 and CV-102 at the proper set points. 2. Inspect the Pond 3 inlet pH chart recorder, it should show an even oscillation between pH 6,0-9j0 with 3/4" and a pH range of 5.0 - 110.0 when controlling with the 1 1/2". If the pH is not being properly controlled, adjust gate valves CV-103 and CV-104 as outlined in the pH startup procedures. 3. If the system is still unable to feed enough acid the control valves or line could be plugged with debris. Attempt to clean the line by opening and closing gate valves CV-103 and CV-104. If the acid line is still plugged, the line may be cleared with air pressure.
VAB.0001135519 I
BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
I. pH UPSETS (Continued)
B. Acid Addition (Continued)
NOTE: The day tank relief valve set pressure is psig.
4. In the event of a continued inability to feed acid, it will
be necessary to manually feed acid to Pond 4 if the pH reaches
9.0. Add the acid in 20 to 30 gallon increments.
5. In the event of a low pH condition check to make sure that CV-
101 or CV-102 have not become stuck open.
If the raw
wastewater pH has persistently been in the range of 2.0 to 6.0
for long periods of time, the incinerator is the likely cause
of the problem. Notify the Vinyl Department and have the
incinerators checked out.
6. If the pH in Ponds 3 or 4 drops suddenly and the raw wastewater
pH has not been low, then an acid spill is likely. Notify the
Utilities Supervisor immediately is the Pond 4 pH falls below
6.5. In minor cases the problem can be corrected with bags
of soda ash, however, a severe spill may warrant the dumping
chem wash or caustic soda down the sewer. The Utilities
Supervisor or the Mechanical Superintendent will need to
arrange corrective action of this sort with the Vinyl or
Compound Departments. Be sure to turn off the acid addition
system when dumping the chem wash or the caustic soda.
VAB.0001135520
A
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
VII. POWER FAILURES A. Less Than Six Hours 1. The bioponds can operate without power for less than six hours without any major problems. When the power returns, the breakers for all of the pumps, aerators, and blowers must be reset. 2. The pH should be monitored in all of the Ponds as usual, and acid may need to be added to Pond 4 manually if the pH in Pond 4 reaches 9.0.
B. More Than Six Hours 1. If the power is out for more than six hours, the biodisc sump must be drained. The portable trash pump at the boilerhouse must be used to pump water out of the biodisc sump and into Ponds 3 or 4. The biodisc sump must be empty twelve hours after the power is lost, otherwise permanent damage will result to the biodisc shafts. If the biodisc sump is not empty twelve hours after the power is lost, it will be acceptable to drain the sump through the 6" drain valves on the south side of the sump. THIS STEP IS NOT TO BE CONSIDERED UNLESS ALL OTHER ATTEMPTS TO DRAIN THE BIODISC PROPERLY HAVE FAILED.
VAB.0001135521 I
BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
VIII. BIODISC TROUBLESHOOTING
A. Inadequate Air Flow Rate
1. If one of the biodisc shafts turns slower than 1.2 rpm,
increase the air flow rate by opening the blower inlet
butterfly valve one notch. Check the speeds again, and then
open the valve more notches if necessary.
2. Check to make sure that the blower piping does not leak. The
underwater piping in the biodisc sump can be checked out by
opening the shaft cover doors and observing the pattern of the
rising air bubbles in the biodisc sump.
3. Check the air filters on the suction of the blowers to make
sure that they are not plugged.
Dirty air filters will
restrict the volume of air delivered to the biodisc.
A
B. Excess Biomass
1. If one or more of the biodisc shafts weighs greater than 1400
psig (load cell pressure reading), the biodisc needs to be
stripped.
Use the following procedure to air strip the
biodisc.
a. Open the 6-inch discharge valve on the spare air blower
(whichever blower is not running at the time).
b. Close the inlet butterfly valve on the spare air blower.
c. Turn on the spare air blower and open the inlet butterfly
valve three notches.
VAB.0001135522
l
A
BIOPONDS OPERATING MANUAL
ABERDEEN CHEMICAL PLANT
VIII. BIODISC TROUBLESHOOTING (Continued)
B. Excess Biomass (Continued) d. Two hours later open the inlet butterfly valve even further until the biodisc shafts are turning 1.6 - 1.8 rpm. Do not turn the biodisc shafts faster than 1.8 rpm, otherwise permanent damage could occur to the shafts. G . Air strip the biodisc for twenty-four hours and then shut off one of the air blowers. f. Reset the shaft speeds to make sure that the shaft weights have dropped below 1,000 psig.
.2 If air stripping does not succeed in reducing the biodisc shaft
weights, caustic strip the biodisc using the following procedure. a. Shut off the biodisc feed pumps. b. Carefully add drummed caustic soda to the biodisc sump
until the pH in the biodisc sump is greater than 11. c . Spin the biodisc shafts at 1.2 - 1.6 rpm in the high pH
water until the shaft weights are below 1,000. d Turn on one of the biodisc feed pumps.
Monitor the pH in Pond 4 closely, and manually add acid to Pond 4 if necessary.
VAB.0001135523
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
VIII. BIODISC TROUBLESHOOTING (Continued)
C. Power Failure 1. If an air blower shuts off for some reason, turn on the spare air blower as soon as possible. 2. In the event that both air blowers are out of service, following the procedures in the POWER FAILURE Section of this Manual.
A
D. Abnormal Biomass 1. If a biodisc shaft becomes lopsided and turns irregularly (shaft speed varies 0.2 rpm or more during a single revolution), strip the biodisc. 2. If the biodisc develops a whitish color, strip the biodisc. 3. If BOD removal across the biodisc is consistently below 60%, strip the biomass.
VAB.0001135524
i
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
X. OIL DISCHARGE TO SEWERS
A. Oil that is discharged to the process sewers will collect on Ponds 1 and 3. If the oil is left on the Ponds, it will slowly dissolve and result in an increased BOD loading to the bioponds. If oil is discovered on these ponds, it should be skimmed off promptly and placed in drums. The skimmed oil should be dumped into the waste oil sump on the east side of the API Separator.
VAB.0001135525
BIOPONDS OPERATING MANUAL ABERDEEN CHEMICAL PLANT
XII. SHUTDOWN PROCEDURES
A. Fertilizer Addition System 1. Close the isolation valve on the top of the ammonia tank. 2. Shut off phosphoric acid pumps 72-552 and 72-553. 3. Close the isolation valve on the phosphoric acid day tank. 4. Open the phosphoric acid line bleeders and drain the lines. Connect a water hose to the bleeder and flush the pumps and acid lines to Pond 3 with water. Drain the acid lines after being flushed.
B. pH Control System 1. Shut off sulfuric acid pumps 72-553 and 72-555. Turn off pH controller/NPHRC-101. 2. Close the isolation valve on the sulfuric acid day tank. 3. Open the sulfuric acid line bleeders and drain the lines. Connect an air hose to the bleeder and carefully blow the remaining acid out of the lines. Connect a water hose to the bleeder and flush the pumps and acid lines to Pond 3 with water. Drain the acid lines after being flushed.
C. Biodisc 1. Shut off pumps 72-550 and 72-551. 2. Shut off blowers 49-556 and 49-557. 3. Shut off air to the level controller NLC-101.
VAB.0001135526
BIODISC OPERATING MANUAL ABERDEEN CHEMICAL PLANT XII. SHUTDOWN PROCEDURES (Continued)
C. Biodisc (Continued) 4. Pump out the biodisc sump to Pond 3 using the portable trash pump. The sump must be empty within 12 hours of shutdown.
D. Ponds 4. 5, and 6 1. Turn off the aerators on Ponds 4 and 5.
VAB.0001135527
APPENDIX A
WASTEWATER TREATMENT TERMINOLOGY
BOD
The term BOD means Biological Oxygen Demand, which is the quantity of
oxygen that bugs (microorganisms) need to digest certain water
contaminants. These water contaminants are food to the microorganisms.
Microorganisms, like most every living organism, need oxygen to digest
their food.
If the food supply increases, then the population of
microorganisms will increase as well and more oxygen will be consumed.
Likewise, if the food supply increases, then the population of
microorganisms will decrease and less oxygen will be consumed. The BOD
of wastewater is proportional to the food content of the wastewater (for
microorganisms) for all practical purposes.
In water, dissolved oxygen (DO) is the primary source of oxygen for aquatic life. If water with a high BOD is not aerated, the microorganisms will quickly consume all of the available DO and most of the aquatic life will virtually suffocate. The BOD of a wastewater discharge to a receiving stream will consume DO in the stream, which could have detrimental effect on the aquatic life in the stream. In a wastewater treatment system, the DO is continuously replenished by heavy aeration of the water.
At Conoco's Aberdeen, MS Plant, BOD loading to the bioponds is caused by chemicals such as alcohols, plasticizers, calcium stearate, AMS, miscellaneous oils, etc. The higher the BOD, the higher the concentration of these chemicals in the water, and vice versa. In general, the API Separator is the major source of BOD to the bioponds, therefore the flow out of the API Separator needs to be minimal.
VAB.0001135528
A
APPENDIX A WASTEWATER TREATMENT TERMINOLOGY COD The term COD means Chemical Oxygen Demand, which is very similar to BOD. COD is measured in wastewater in order to more quickly estimate BOD, since the COD test takes 2 hours and the BOD test takes 5 days. The COD at the Aberdeen Plant is typically 2.5 times greater than the BOD. For example, if BOD at the outfall needed to be known as soon as possible, a COD sample may be run to quickly estimate the BOD. If the COD concentration is determined to be 100 ppm, then the BOD concentration is probably around 40 ppm.
C. pH pH is a measure of acidity and alkalinity in water. Acid has a pH of 0, caustic has a pH of 14, and a neutral water has a pH of 7. If acid is added to water, the pH will fall from 7 to some value between 1 and 7. Likewise, if caustic is added to water, the pH will rise from 7 to some value between 7 and 14. For most practical purposes, pH is not related to BOD (i.e. caustic soda does not have much BOD). pH is a condition of water, somewhat similar to temperature.
The pH of wastewater needs to be kept as close to 7 as possible in order for microorganisms to grow. If the pH of the wastewater gets too high or too low, the microorganisms will die. A similar reaction will occur if the water temperature get too high or too low.
VAB.0001135529
APPENDIX A
WASTEWATER TREATMENT TERMINOLOGY
D. Nutrients (Fertilizer)
Microorganisms need certain nutrients in order to grow, similar to the
human need for vitamins and minerals.
Ammonia and phosphoric acid
(nitrogen and phosphorous) are added to the wastewater prior to biological
treatment in order to supply the microorganisms their necessary nutrients.
If the nutrient feed is too low, then the microorganisms will not be able
to digest all of the available food. On the other hand, if the nutrient
feed is too high, other problems will occur.
A major result of
overfertilization is algae growth. Algae is a slimy green substance that
is highly undesirable in wastewater treatment systems and streams.
E. TSS TSS means total suspended solids, which is solid material that is in suspension in wastewater. In a biological treatment system, TSS is a measure of the microorganism population in the water. The microorganisms typically collect in small clusters, which are visible as grayish-green solids in the water. If the water has a high TSS, then the microorganism population is presumably high, and vice versa. TSS fluctuations are common due to food fluctuations, however sudden TSS drops can indicate problems in the system.
TSS can also be present in other forms, such as PVC resin in suspension. TSS that is not biological in nature will typically have a detrimental effect on biological treatment if allowed to get into the biological treatment system in significant amounts.
VAB.0001135530
APPENDIX B - API SEPARATOR OPERATION
(Refer to Figure A) Normal Operation 1. The API Separator should be kept as clean of oil as reasonably
possible. If there is a steady stream of oil into the API Separator, notify the P-1 Operator and look for problems such as leaking valves, overflowing tanks, etc. 2. When skimming the API Separator, try to skim slowly so that a minimal amount of water will be skimmed along with the oil. Never use compressed air or other means to move the oil from the north end to the south end. 3. The flow through the API Separator should be checked daily. If there is an abnormally high and persistent flow through the API Separator, notify the P-1 Operator and look for sources of excess water flow to the API Separator.
Skimming Procedures
1. Make sure that there is enough freeboard in the skim tank before
skimming the API Separator.
.2
Open valve 1, 2, and 5
Make sure that valves 3, 4, and 6 are
closed.
3 Make sure that the bearing flush water for the skim pump is on.
4 Turn on the power to the skim pump.
5 Skim oil off of the API Separator using the skimmer at the south end
of the API Separator. The skim pump will transfer the oil to the
skim tank when the level in the skim sump rises.
6 When skimming is complete, shut off the power to the ski pump
close valve 2.
VAB.0001135531
APPENDIX B - API SEPARATOR OPERATION C. Oil Transfer To T-450
1. Notify the plasticizer operator before oil is transferred to T-450. The plasticizer operator will indicate whether T-450 has enough freeboard to receive the material to be transferred.
2. Turn on the power to the skim pump. 3. Open valves 1, 6, 7, and 8 and close valve 2 if material is to be
transferred from the API Separator to T-450. Open valves 1, 3, 5, 6, 7, and 8 and close valve 2 if material is to be transferred from the skim tank to T-450. 4. While transferring material from the skim tank to T-450, be careful that the skim sump does not fill to rapidly and backflow into the API Separator. 5. When transfer is complete, close valve 3 (if open), shut off the skim pump and close valves 6 and 7.
VAB.0001135532
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