Contractor Template for O & M Manual

Operation Manual

Town

WMF/WTP/SPS

(Expanded in full)

CONFIDENTIAL

Template for Operations Manual Version 9

Town WMF/WTP/SPS Operation Manual Revisions

Note: With each edit to this document, the following must be completed in the next available blank row.

Date / Description of Change / Initiator of Change / Date Updated
15/05/18 / Updated logo on front page / JB / 15/05/18
14/05/18 / Review of DC&C / IIO / 14/05/18
22/11/17 / Review of DC&C / IIO / 22/11/17
12/09/17 / Review of General process element / IIO / 12/09/17
16/06/15 / Name review / IIO / 16/06/15
02/10/14 / Review and update formatting of template / IIO / 02/10/14
15/04/14 / Review and update template / IIO / 15/04/14
10/10/12 / Review and update template / IIO / 10/10/12
25/07/11 / Review and update template

Citect
Functional diagrams

/ IIO / 25/07/11
21/03/11 / Review and update template / IIO / 21/03/11

Template for Operations Manual Version 9 -
Table of Contents

Town WMF/ WTP/SPS Operation Manual Revisions

Town WMF/WTP /SPS - Process Flow Diagram

GENERAL

GENERAL PURPOSE AND TARGETS

Performance Targets

GENERAL SAFETY

GENERAL DESIGN CRITERIA AND COMPONENTS

GENERAL MONITORING

GENERAL MAINTENANCE

GENERAL NORMAL OPERATION

GENERAL PROCESS CONTROL

GENERAL MANUAL OPERATION

Manual Override

GENERAL EMERGENCY

Plant Crash Stop

Site Specific

“PROCESS ELEMENT A”

“PROCESS ELEMENT A” PURPOSE AND TARGETS

“PROCESS ELEMENT A” DESIGN CRITERIA AND COMPONENTS

“PROCESS ELEMENT A” NORMAL OPERATION

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT A” PROCESS CONTROL

“PROCESS ELEMENT A” MANUAL OPERATION

Manual Override

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT A” TROUBLESHOOTING

“PROCESS ELEMENT A” EMERGENCY

“PROCESS ELEMENT B”

“PROCESS ELEMENT B” PURPOSE AND TARGETS

“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTS

“PROCESS ELEMENT B” NORMAL OPERATION

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT B” PROCESS CONTROL

“PROCESS ELEMENT B” MANUAL OPERATION

Manual Override

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT B” TROUBLESHOOTING

“PROCESS ELEMENT B” EMERGENCY

“PROCESS ELEMENT C”

“PROCESS ELEMENT C” PURPOSE AND TARGETS

“PROCESS ELEMENT C” DESIGN CRITERIA AND COMPONENTS

“PROCESS ELEMENT C” NORMAL OPERATION

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT C” PROCESS CONTROL

“PROCESS ELEMENT C” MANUAL OPERATION

Manual Override

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT C” TROUBLESHOOTING

“PROCESS ELEMENT C” EMERGENCY

“PROCESS ELEMENT D”

“PROCESS ELEMENT D” PURPOSE AND TARGETS

“PROCESS ELEMENT D” DESIGN CRITERIA AND COMPONENTS

“PROCESS ELEMENT D” NORMAL OPERATION

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT D” PROCESS CONTROL

“PROCESS ELEMENT D” MANUAL OPERATION

Manual Override

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT D” TROUBLESHOOTING

“PROCESS ELEMENT D” EMERGENCY

LIST OF FIGURES

LIST OF TABLES

Created By: Infrastructure Information Officer / Reference Number:
Approved By: / Page 1 of 52
Review Date: date / Last Approved: date

Contractor Template.docx

TownWMF/WTP /SPS- Process Flow Diagram

Figure 1: Town SiteProcess Flow Diagram

Supply an up to date copy of the process flow diagram for the site.

Created By: Infrastructure Information Officer / Reference Number:
Approved By: / Page 1 of 52
Review Date: date / Last Approved: date

Contractor Template.docx

GENERAL

Refer to Citrix for the Town Name WTP SCADA screens.

Click here for the Town Name WTP Schematic diagram.

Click here for the Town NameSPS Functional Diagrams.

GENERAL PURPOSE AND TARGETS

Provide a short statement describing the purpose and a general description of the process elements in the treatment sequence.

The performance targets are the treatment and reliability objectives of the plant, typically key performance indicators, license and objective limits, and reliability requirements.

Click here for the Safe Drinking Water Targets.

Click herefor the Sewer Pump Station Targets.

Performance Targets

No mechanical failure for 6 months

GENERALSAFETY

Click here for the Occupational Health and Safety Targets.

Site Plans of Premises May 2017

GENERALDESIGN CRITERIA AND COMPONENTS

Click here for the Equipment Manuals and Glossary.

GENERAL MONITORING

Refer to Aquantify.

GENERAL MAINTENANCE

Refer to MyData maintenance schedule.

GENERALNORMAL OPERATION

Provide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA controls for operation under normal conditions.

Add photos where possible.

Use this numbering system. E.g.

GENERALPROCESS CONTROL

GENERALMANUAL OPERATION

Manual Override

Provide a general overview of all the process elements of the SPS, WMF, WTP where the plant may be operated manually.

GENERALEMERGENCY

Plant Crash Stop

If a problem exists with the operation of the plant specific processes (there can be one or more processes) can be crashed via the Regional SCADA system (provided user of Regional SCADA has sufficient privileges). This action would normally only occur in an emergency situation where water entering certain processes in the plant is outside specifications or there are problems associated with the pumping operation. Usually it would be used where it would take an extended period of time for an operator to attend the site. Using the crash stop would stop the process and allow an operator greater time to reach the site. To crash the plant, complete the following:

Open the WTP overview Regional SCADA page
Press the Crash Control Symbol button
Select the desired system to crash
Press the Crash button

If the problem rectifies itself the crash can be reset by an operator on site pressing the Crash Stop Reset button (either on the switchboard or Plant SCADA system). Alternatively the crash can be reset via Regional SCADA system by:

Pressing the Enable button

Site Specific

Provide a general overview of the processes which may result in the site being crashed:

EMERGENCY RESPONSE PROCEDURES

In case of spill refer to the EMS procedure - Spill Control

(Require SOI for emergency pumping)

Created By: Infrastructure Information Officer / Reference Number:
Approved By: / Page 1 of 52
Review Date: date / Last Approved: date

Contractor Template.docx

“PROCESS ELEMENT A”

Figure 2:Describe photo here.

Insert a photo of Process Element .A.

“PROCESS ELEMENT A”PURPOSE AND TARGETS

Provide a short statement of the purpose and a general description of the process element in the treatment sequence.

Performance targetsare typically the good operation objectives of the process element and NOT the whole plant. These typically are the process element operation settings, objective limits, and reliability requirements.

The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element A in the above list.

Table 1: Pumping Station Details

Parameter / Measurements
Top of slab / R.L.
Delivery Internal Pipe Diameter
Delivery Pipe / I.L.
Inlet Pipe Diameter
Inlet Pipe / I.L.
Wet Well Floor / R.L.

Modify this table as required.

“PROCESS ELEMENT A”DESIGN CRITERIA AND COMPONENTS

In the table below, provide a description of the main components, their functions and normal settings (including size capacity and design assumptions). Supply the manufacturers contact details and provide links to equipment product manuals.

Table 2: “Process Element A” Design Criteria and Components

Main Components / Function / Design Criteria
Flowmeter / Measures flow / Manufacturer: _____
Type: ___
Required Flow range: ___ l/sec
Diameter: ___mm
Step Screen / "Step" type screen to remove debris from effluent inlet / Manufacturer:
Type:
Weight:
Size:
Width:
Serial No:
Screen Drive / Shaft mounted worm-geared motor / Type:
Motor:
Air Blower / Source of air for air scouring / Manufacturer: _____
Type: ___
Air flow: ___ m3/hour
Pressures to ___ PSI
Pump and Motors / To collect sewerage from catchment and discharge to pump station #?? catchment / Pump Duty: ___L/s @ ___ m Total Head, ___ Static Head
Manufacturer: _____
Pump Classification: ___
Type: ______
Pump Curve No: _____
Issue: _____
__ mm impeller; Type ___
Outlet diameter: _____mm
Pump Weight: ___ kg
Serial No: _____
Motor
Manufacturer: _____
Type: _____
Serial No: _____
RPM:____
Rated at: _____ kW
Turbidity Meter / Measures filtered / raw water turbidity / Manufacturer: _____
Type: ___
Required turbidity readings range: 0-20 NTU
Analyser / Measures filtered water / Manufacturer: _____
Type: ___
Actuators and Gearboxes / Controlled open/Close operation of pump Discharge / Actuator Manufacturer:___
Type:___
Gearbox Manufacturer:___
Type:___
Ratio:___
Serial:__
Dissolved Oxygen Analyser / Manufacturer:
Type:
Serial No:
Sump Pump / Pumps water out of dry well space / Manufacturer: _____
Type: ___
Dosing Pump / Manufacturer: _____
Type: ___
Pump Duty: _____/hr @ _____ bar
Outlet diameter: _____mm
Rated at: _____kW
_____ RPM
Pump Weight: ___ kg
Serial No: _____
Metering Pump / Manufacturer: _____
Type: ___
Pump Duty: _____/hr @ _____ bar
Serial No: _____
Pump Set / Other components in addition to the normal pump configuration / Manufacturer: _____
Type: ___
Pump Duty: _____/hr @ _____ bar
Outlet diameter: _____mm
Rated at: _____kW
_____ RPM
Pump Weight: ___ kg
Serial No: _____
Service Water Pump / Manufacturer:
Type:
Serial No:
Internal Delivery Pipe / To deliver flow from pump to the outlet of the pump station. / Manufacturer: _____
Type: ___
Diameter:____ mm
Material: ____
Pressure class: ____
Length: ____ m
Rising Main / To deliver flow from pump station ?? to pump station ?? or Manhole ?? / Manufacturer: _____
Type: ___
Diameter: ____ mm
Material: _____
Pressure class: PN___
Length: ____m
Tank / Alum storage / Manufacturer: _____
Type: ___
Nominal capacity: _____ L
Dimensions: _____ m diameter x _____ m deep
Material: _____
1 X Lifting Equipment / To allow for the removal of pumps from the wet well for routine and non-routine maintenance / S/S Guide Rails and lifting chains
Size of Chains: ___
Chlorinator / Manufacturer: _____
Type: ___
Serial Number: ____
Maximum ___/ __Hr
Gas Feeder / Manufacturer: ____
Type: ____
Capacity: ____
Vacuum Regulators / Manufacturer: ____
Type: ____
Soft Starter / Reduces the excess current during initial power-up of an electric motor / Manufacturer: ____
Type: ____
Irrigation Flow Meter / Measures flow ... / Manufacturer: _____
Type: ___
Required Flow range: ___ l/sec
Diameter: ___mm
Valve / Manufacturer:
Type:
Max Pressure:
VSD / to control the speed of the motor within its operating range / Manufacturer: ____
Type: ____
Filter / Manufacturer: ____
Type: ____
PLC / Manufacturer: ____
Type: ____
Generator / Convert mechanical energy to electrical energy / Manufacturer:
Type:
Motor Size: ____kW
Rate Voltage:
Fuel Type:
Fuel Tank Capacity:
Fuel Consumption:
Dimensions:
Weight:
Serial No:
Air Compressor / To supply compressed air to the air actuator valves within the plant and to supply compressed air to the DAF vessel / Manufacturer:
Type:
Serial No:
Hydro Cyclone / Manufacturer:
Type:
Serial No:
Bay Outlet / Manufacturer: _____
Type: ___
Nominal capacity: _____ L
Dimensions: _____ m diameter x _____ m deep
Material: _____
Filter Media / Each filter removes floc and other matter.
Explanation of types and depths? / Manufacturer:
Type:
Dual Type:
Multiple Depths:
Volume:
Nozzles / Manufacturer:
Type/Model No:
Cathodic Protection / Manufacturer:
Type:
Groundwater Bore / Ground Works Number:
Date Drilled:
Casing Outside Diameter:
Casing Inside Diameter:
Casing Wall Thickness:
Casing Type:
Apertures:
Screened From – To:
Bore Depth:
Air conditioner / Manufacturer:
Type:
Door Specifications / Door Type:
Spindle:
Head Pressure:
Actuator:
Clear Water Way:
Operating Level:
Door Material:
Weight:
Handwheel direction:
Baffle / Comment on orientation / Manufacturer:
Type:
Material:
Size:

“PROCESS ELEMENT A”NORMAL OPERATION

Provide a general overview of the normal plant start-up,operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.

Add photos where possible.

Use this numbering system. E.g.

Figure 3: Describe photo here.

Under normal operating conditions, the

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT A”PROCESS CONTROL

Describe the potential process adjustments, the resulting consequencesand the steps involved in making these plant adjustments.

“PROCESS ELEMENT A”MANUAL OPERATION

Provide a general overview of the manual plant start-up, operation and shut down procedures for the process element.

Insert photos where possible.

Figure 3: Describe photo here. Utilise this numbering system for additional photos.

Manual Override

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT A”TROUBLESHOOTING

Table 3: “Process Element A” Troubleshooting Guide

Problem / Cause / Solution/Action

Note: All electrical work is to be carried out by qualified electricians only.

Complete this table and add/remove rows where necessary.

“PROCESS ELEMENT A” EMERGENCY

Table 4: “Process Element A” Emergency Guide

Condition / Actions
PLC Failure / Contact GVW Operations IT Department
Power Failure / Restore power
Electrician and/or
Power company

Complete this table and add/remove rows where necessary.

Created By: Infrastructure Information Officer / Reference Number:
Approved By: / Page 1 of 52
Review Date: date / Last Approved: date

Contractor Template.docx

“PROCESS ELEMENT B”

Figure 4:Describe photo here.

Insert a photo of Process Element B.

“PROCESS ELEMENT B” PURPOSE AND TARGETS

Provide a short statement of the purpose and a general description of the process element in the treatment sequence.

The performance targets are often different from the overall plant targets as the process element is only a step in a process chain to achieving the plant targets.

Summarise the performance targets for Process Element B in the above list.

Table 5: Pumping Station Details

Parameter / Measurements
Top of slab / R.L.
Delivery Internal Pipe Diameter
Delivery Pipe / I.L.
Inlet Pipe Diameter
Inlet Pipe / I.L.
Wet Well Floor / R.L.

Modify this table as required.

“PROCESS ELEMENT B” DESIGN CRITERIA AND COMPONENTS

Table 6: “Process Element B” Design Criteria and Components

“PROCESS ELEMENT B” NORMAL OPERATION

Provide a general overview of the normal plant start-up, operation and shut down procedures for the process element. Include SCADA and SCADA controls for operation under normal conditions.

Add photos where possible.

Use this numbering system. E.g.

Figure 3: Describe photo here.

Under normal operating conditions, the

Start-up

Standard Operation Procedures

Shutdown

“PROCESS ELEMENT B” PROCESS CONTROL

Describe the potential process adjustments, the resulting consequencesand the steps involved in making these plant adjustments.

“PROCESS ELEMENT B” MANUAL OPERATION