Boat Operating Instructions

Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 1 of 41
Project Name Darvill Waste Water Treatment Works Upgrade

Project
2013/136 (113248)
Number
Project To Increase the Waste Water Treatment Capacity From 65
Intention 𝑀𝑙/𝑑𝑎𝑦 to 200 𝑀𝑙/𝑑𝑎𝑦
Appointment 01-08-2014
Key Project
Commencement 01-08-2014
Dates
Completion
Consulting
Hatch
Engineer
Main Contractor Group Five – Coastal
Contractors
Sub-Contractor
Version
Number
Originated By Reviewed By Approved By Approved By

(Group Five) (Group Five) (Group Five) (Hatch)
Zahraa Goolam- Michael Mc Kenna
Name
Hussain
Designation Student Mech. MEIP Manager
Engineer
Signature
Date 14/05/2018
 Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
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Table of Contents
LIST OF TABLES ....................................................................................................................................................... IV
LIST OF FIGURES ..................................................................................................................................................... IV
LIST OF NOTES ........................................................................................................................................................ IV
LIST OF ABBREVIATIONS .......................................................................................................................................... V
1 GENERAL METHOD AND PRINCIPLE OF OPERATION ........................................................................................ 1
1.1 DESIGN BRIEF AND REQUIRED PURPOSE ............................................................................................................... 1

1.1.1 R.A.S Pump Station ................................................................................... Error! Bookmark not defined.1
1.1.2 Ventilation and Air Conditioning ............................................................. Error! Bookmark not defined.2
1.2 OUTPUT OR FUNCTIONALITY ............................................................................................................................... 2
1.3 PRINCIPLE AND METHOD OF OPERATION .............................................................................................................. 4
1.3.1 Remote Auto Operation .......................................................................................................................... 4
1.3.2 Remote Manual Operation ................................................................................................................... 45
1.3.3 Local Manual Operation ......................................................................................................................... 5
2 GENERAL PROCESS SAFETY INSTRUCTIONS ..................................................................................................... 6
2.1 IDENTIFICATION HAZARDS (HIRA) ....................................................................................................................... 6

2.2 PPE REQUIREMENTS ......................................................................................................................................... 9
2.3 IMMEDIATE ACTION PLAN .................................................................................................................................. 9
2.3.1 Electrical Equipment in MCC Rooms ...................................................................................................... 9
2.4 EVACUATION PLAN.......................................................................................................................................... 10
2.4.1 Evacuation Routes and Key Locations .................................................................................................. 11
2.4.2 Emergency Evacuation .......................................................................................................................... 12
2.4.3 Emergency Contact Numbers ............................................................................................................... 13
2.5 PRESSURE OR POTENTIAL ENERGY RELIEF ........................................................................................................... 15
2.6 HAZARDOUS MATERIAL INFORMATION................................................................................................................ 15
2.7 ALARMS, TRIPS AND INTERLOCKS ....................................................................................................................... 15
2.8 ANY OTHER SAFETY RELATED INFORMATION ....................................................................................................... 17
3 OPERATING INSTRUCTIONS........................................................................................................................... 19
3.1 NORMAL OPERATIONAL PROCEDURES INCLUDING AUTOMATIC AND MANUAL OPERATIONS ...................................... 19
3.1.1 Return Activated Sludge Pumps............................................................................................................ 19
3.1.2 Bilge Pump ............................................................................................................................................. 29
3.2 RAS PUMP STATION VENTILATION SYSTEM ........................................................................................................ 34
3.2.1 Pre-Start-Up Checks .............................................................................................................................. 34
3.2.2 Remote Auto Operation ........................................................................................................................ 34
3.2.3 Remote-Manual Operation ................................................................................................................... 34
3.2.4 Local Operation ..................................................................................................................................... 35
3.2.5 Normal operating condition/readings .................................................................................................. 35
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3.2.6 Emergency shut-down........................................................................................................................... 35

3.2.7 Isolation ................................................................................................................................................. 35
3.2.8 Troubleshooting..................................................................................................................................... 35
3.3 SAMPLING, CALIBRATION AND MEASUREMENTS .................................................................................................. 36
3.3.1 Sampling and Measurement................................................................................................................. 36
3.3.2 Calibration ............................................................................................................................................. 36
4 HANDOVER DOCUMENTATION ..................................................................................................................... 36
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List of Tables
Table 1-1 Output or Functionalities for System Definitions .................................................................. 23
Table 1-2 Specific Equipment Set Points (SP) .......................................................................................... 3
Table 2-1 Hazardous Identification Risk Assessment............................................................................... 7
Table 2-2 Electrical Equipment Safety Action Plan .................................................................................. 9
Table 2-3 Alarms, trips and interlocks description ................................................................................ 15
Table 2-4 RAS Pumps Specific Alarms, Trips and Interlocks................................................................... 16
Table 2-5 Bilge Pumps Specific Alarms, Trips and Interlocks ................................................................. 17
Table 3-1 Troubleshooting of RAS Pump ............................................................................................... 27
Table 3-2 Troubleshooting of the Bilge Pump ....................................................................................... 33
List of Figures
Figure 2-1 Emergency Response Structure ........................................................................................... 10
Figure 2-2 Emergency Evacuation Diagram ........................................................................................... 12
Figure 3-1 RAS Pump Local/PLC Switch ................................................................................................. 21
Figure 3-2 Automated Valves Local or Remote Control ........................................................................ 21
Figure 3-3 Suction Valve on Both SCADA and in the Field ..................................................................... 22
Figure 3-4 RAS Sump Level .................................................................................................................... 22
Figure 3-5 RAS Pump Interlock Alarm Status ......................................................................................... 23
Figure 3-6 Resetting Alarm Conditions .................................................................................................. 23
Figure 3-7 RAS Pump Field Panel ........................................................................................................... 26
Figure 3-8 Bilge Pump Local/PLC Switch ................................................................................................ 30
Figure 3-9 Bilge Pump Interlocks ........................................................................................................... 30
Figure 3-10 Bilge Pump Alarm Reset ..................................................................................................... 31
Figure 3-11 Bilge Pump Local Control Panel .......................................................................................... 32
List of Notes
1. Flowrate out of the RAS pump station to be confirmed by updated FDS …………………………... Page 8
2. Time of duty rotation to be changed with an updated FDS ………………………………………..……... Page 8
3. Valve opening time to be updated with an updated FDS ……………………………………………...…... Page 9
4. Outstanding information from Gauche Air ………………………………………………………..………...…... Page 9
5. Evacuation Plan to be updated with updated the Emergency Response Plan & Procedures
Template from Umgeni Water ……………………………………..…………………………..………...………..... Page 17
6. Outstanding documentation from Gauche Air ……………………………………………...………………... Page 41
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Revision Number
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List of Abbreviations
Abbreviations Definition
BOV Blow Off Valve
COD Chemical Oxygen Demand
DO Dissolved Oxygen
EC Emergency Coordinator
ER Emergency Response
FBDA Fine Bubble Diffused Air Aeration
FE Final Effluent
HIRA Hazardous Identification Risk Assessment
HMI Human Machine Interface
IGV Inlet Gate Valve
LCP Local Control Panel
MCC Motor Control Centre
MEIP Mechanical, Electrical, Instrumentation and Piping
MLSS Mixed Liquor Suspended Solids
OUR Oxygen Uptake Rate
P&ID Piping and Instrumentation Diagram
PLC Programmable Logic Controller
PST Primary Settling Tank
RAS Return Activated Sludge
SCADA Supervisory control and data acquisition
SP Set Points
SST Secondary Settling Tanks
UW Umgeni Water
VSDs Variable Speed Drives
VVD Variable Vane Diffuser
WAS Waste Activated Sludge
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1 General Method and Principle of Operation

1.1 Design Brief and Required Purpose
Digester FOGS (Fats Oils Grease and Sludge) Pump Station
The FOGS Pump station forms part of an integrated system that pumps FOGS received from the inlet
works and PSTs (Primary Settlement Tanks) into the digesters for anaerobic digestion.
The boat structure comprises of a settling tank, a scraper that removes the FOGS from the settling
tank and drops it onto a conveyer belt that conveys the FOGS into the hoppers thereafter two positive
displacement pumps are used to transfer the FOGS to the digesters. Suction pipework comes from
the inlet works and PSTs and discharge pipework eventually lead to the digesters. There are also
break disks installed that are activated when a blockage is experienced. A bilge pump will be used for
drainage.
FOGS enters the boat in two ways, the inlet works FOG pump station and the FOGS from the PSTs will
enter the settling compartment where it is thought that there shall be enough settling time for the
Fats, Oil, Grease and Scum to separate from the water. FOGS Separator Trolley Drive, is used to
scrape the FOGS that has floated to the surface up the beach and onto the FOGS Separator Conveyor.
The FOGS Separator Conveyor, is used to deliver the FOGS that has been scraped off the surface of
the boat structure to the FOGS Hoppers, and ultimately the FOGS Digester Feed Pumps. FOGS
Digester Feed Pumps are designed to operate on a duty/standby arrangement. The duty pump shall
be defined by the chute position proximity switch ZS-1026 and ZS-1027. The level in hopper 1 and
hopper 2 shall be monitored by means of an ultrasonic level transmitter, When the sludge feed batch
is started, as determined by the level in the Thickened sludge sump which is located in the Digester
Feed Pump Station.
The method of control of the pump station is by means of the Supervisory Control and Data
Acquisition (SCADA) system, which is situated in the control room, it is not equipped with its own
Programmable Logic Controller (PLC), and rather it is controlled by PLC 11 which receives
communication from PLC 18 located in the SSPSthe SSPS and Digester complex respectively. Blended
sludge shall be fed into each digester on a batch system. This batch will be based on the mass as
measured by FIT-1801. A high level on the thickened sludge sump level LIT-1804 shall initiate a batch
feed process, at which point PLC 18 sends a request to PLC 11. PLC 11 confirms that the Hopper level
is sufficient and that at least 1 digester valve is open.
The FOGS Digester feed pumps are designed for one duty and one standby, however there are no
interlocks from preventing both running simultaneously once the duty discharge valve 11-M-1067 or
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11-M-1068 is fully open, the duty FOGS Digester Feed Pump 11-M-1061 or 11-M-1063 shall start and
run until 11-LT-1025L reads 30% ##%, or 11-LT-1026L reads 30% ##%, as the case may be, is reached.
The pumps shall then stop, and continue to operate on an on/off basis providing least one digester
feed valve, 18-XV-1801, or 18-XV-1814, or 18-XV-1823 or 18-XV-1827 is open and one digester feed
pump 18 –M-1824 or 18-M-1825 is running. The temperature of the pump is monitored by a
temperature probe TIT1061 and TIT1063TAG!! and has a upper limit of 60 ⁰C.
1.2 Output or Functionality

FOGS Digester Feed Pumps will operate on a Duty/Standby arrangement. Duty pump is determined by
distribution chute sensor ZS-1026/1027 position. It therefore remains the responsibility of the
operator to ensure duty is rotated on a regular basis. Chute position is changed manually. An alarm
shall be raised on the SCADA if the duty machine, as selected by the chute position is not healthy and
ready to run.
When a request is sent by PLC 18 to PLC 11 the PLC shall check the levels of the hopper as well as to
make sure the line is clear of inhibition. If the system is healthy PLC 11 will signal the pump to start.
At least one digester inlet valve must be open at all times. Failure to open a digester 5, 6, 7 or 8 inlet
valve when the FOGS digester feed pumps are called to run shall raise an alarm.
Feed to digesters shall be on a batch process, as monitored by FT-4002, which shall be adjustable
from SCADA. Once a batch to a digester has been completed, the inlet valve of the following on-line
digester shall open. Once this inlet valve is open the inlet valve of the previous valve shall close,
maintaining at least 1 open valve at all times. This process shall be controlled by PLC 18, but is
relevant to the understanding required to run the Digester FOGS Feed Pumps.
To ensure system performance remains acceptable, the adjustment of various operating parameters
is usually limited to users with adequate skill to be able to make informed decisions when adjusting
the relevant parameters. The recommended level of authority of various users to change various
operating parameter set points is listed in
Table 0-1Table 1-1 below:
Table 0-1 Output or Functionalities for System Definitions

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PARAMETER TO BE CHANGED USER
Maximum and minimum set points Engineer and technician
The High and Low Process Set points Superintendent
Section Reset e.g. Upon system failure because of Senior Operator

power cut or system overload
Motor Reset Operator
Motor Start/Stop Operator
Isolation of Systems Senior Operator
The RAS pumps specific operating SP are listed in Table 0-2Table 1-2. Note that many of these are
required for the safe operation of the RAS pumps and should only be adjusted in consultation with
the manufacturer.
Table 0-2 Specific Equipment Set Points (SP)
ITEM MINIMUM MAXIMUM Formatted Table

TAG NUMBER OUTPUT/ FUNCTIONALITY
NO. SP SP
Proximity switches to monitor the distances of the
1. ZS 1026 N/A N/A
trolley.
Proximity switches to monitor the distances of the
2. ZS 1027 N/A N/A
trolley.
Chute proximity sensor.Lever to direct the fogg into the
3. CHT1003 N/A N/A
different hoppers.
4. HP 1003 N/A N/A Hopper feeding screw pumps.
5. LT1025 10% 95% Level transmitter regulating the hopper.
6. M1081 N/A N/A Motor driving the screw pump.
7. SCRF1010 N/A N/A Positive displacement pump.Screw compressing fog.
8. TIT1063M1062 N/A 60 Pump temperature transmitter
10. TIT1061P1013 N/A 60 Pump temperature transmitter
11. BDSK1002 N/A N/A Break disk for
12. DV1003 N/A N/A Diaphragm valve
13. M1067 N/A N/A Diaphragm valve actuator
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14. M1063 N/A N/A Diaphragm valve actuator

15. HP1004 N/A N/A Hopper feeding screw pumps.
16. LT1026 10% 95% Level transmitter regulating the hopper.
17. M1064
18. SCRF1011 Screw compressing fog.
19. P1014
17.20. BDSK1003 N/A N/A Break disk
18.21. DV1004 N/A N/A Diaphragm valve
22. M1000
23.
1.3 Principle and Method of Operation

The digester FOGS pumps can be operated on three modes of operation, namely:
i. Remote auto operation

ii. Remote manual
iii. Local manual operation
1.3.1 Remote Auto Operation

In this mode, PLC uses the process variables from the specific area such as the hopper level, the
digester batch feed line, as well as, process variables from other areas relevant to the oil separators
such as the thickened sludge, to automatically open or close valves and start or stop motors to
operate the plant within pre-determined settings and values. Selection of this mode enables
automatic control under PLC software actuation. All process and safety interlocks are active. THIS IS
THE NORMAL MODE OF OPERATION.
1.3.2 Remote Manual Operation

When operating in this mode, all system interlocks will be active. If manual operation of an area
needs specific system interlocks to be overridden, this can be done from the SCADA with correct level
password. Remote manual operation allows the operator to manually operate the plant from the
SCADA. The operator can open or close valves and start or stop motors.
THIS MODE OF OPERATION IS NORMALLY CHOSEN FOR MAINTENANCE PURPOSES, DURING

COMMUNICATION, NETWORK OR CONTROL SYSTEM FAILURES. It is safer practice to attempt operating
any set of equipment in this mode before opting for Local manual mode.
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1.3.3 Local Manual Operation

This mode of operation overrides all system interlocks. For operating in this mode, the operator is
required to operate all equipment from site by selecting LOCAL with the LOCAL/PLC switch for each
piece of equipment. Only safety interlocks are active in this mode of control. THIS MODE OF
OPERATION IS NORMALLY CHOSEN FOR MAINTENANCE PURPOSES, DURING COMMUNICATION,
NETWORK OR CONTROL SYSTEM FAILURES.
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2 General Process Safety Instructions

2.1 Identification Hazards (HIRA)
Specific risks that will be present during the operations and maintenance of the RAS Pump Station:
1. Pumps not stopping during interlock operation: pumps not stopping during interlock operation will
lead to over flow of the pipes to the biological reactors. In addition, excess suction from the wet
well occurring, leading to the wet well running dry, resulting in the pumps to run with no sludge
consequently damages the pumps.
2. Valves not opening or closing during interlock operation: if valves are closed and the pump
continues to run, there will be excess pressure build up in the pipe, causing leakages and possible
pipe bursts.
3. Occurrence of water hammer in the event of an emergency stop on the pumps: a water hammer is
a shock wave that travels down the pipe due to a sudden change in flow. As the emergency stop is
a very sudden change in flow there is a significant pressure rise. This may lead to pipe bursts,
structural damage and/or pump damage.
4. Leaking pipes: The pipes are filled with RAS which is a hazardous material containing pathogens, if
the pipes are leaking do not handle the sludge directly use the relevant PPE and fix pipes ASAP.
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Table 2-1 Hazardous Identification Risk Assessment

A INJURY SEVERITY B FREQUENCY OF OCCURRENCE RATING
No Injury 0 Has not occurred in last two years RISK CLASSIFICATION RISK VALUE
Minor laceration, wound (first aid case) 2 Occurs very seldom LOW 0---6
More severe injury medical attention 4 Occurs occasionally MEDIUM 6---16
Serious injuries, broken bones, amputation etc. 8 Occurs often HIGH 16---32
Loss of life / fatality 10 Could / has happened CRITICAL 32---40
C POTENTIAL DAMAGE OR LOSS D ENVIRONMENT ACTION REQUIRED

Supervision, training, certification, method/risk
Good
No damage, minimal costs R10 – 100 0 No effect LOW assessments, safe work procedures training,
instruction.
toolbox talks.
Competent supervision, training certification, Change
Minor damage, small costs R100 –
2 Minor effect MEDIUM method/risk assessments, safe work procedures method,
1000 Spillage, noise,
training, toolbox talks. mitigate
water, dust/
vapours, fauna Competent supervision, training certification, Change
Med damage, stoppage (On-site repair) Serious effect
4 and flora HIGH method/risk assessments, safe work procedures method,
medium cost R1000 – 5000 (Short term)
training, toolbox talks. mitigate.
Close competent supervision, training Intolerable,
More serious damage/ loss/ delay < Very serious effect certification, method/risk assessments, safe work change
8 CRITICAL
R5000 ± (Long term) procedures, PJO’s, work permits, training, and method,
toolbox talks. transfer risk.
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Risk Ratings
Task Hazard/ Associated Risk Control Measures
A B C D RR
Opening/Activating the Slips and falls when using cat-ladder that  Ensure that safety shoes are clean, free of mud or water.
Valves on the Plant could lead to serious injuries to employees.  Ensure that safety harness is used where at climb is above 1.5m and hook it as you climb up, both hands 4 2 4 2 32
to be holding firm on the rails.
Working/walking in the Slips and falls on floors made slippery by  Ensure the surface/walkways are clear of trips and falls, i.e. pipes, extension cables, etc.
2 2 2 2 16
plant sewage.  Ensure surface is dry; clean any spillage immediately and safety footwear is always on.
Working on the plant Overhead loads from hoists.  Prior to hoisting any material, ensure that communication is clear amongst your team that you intend
with overhead hoist People coming in contact with the load. hoisting material/load.
Loads falling on people.  Ensure no one will be on the way or under the hoisted material, display signs or activate alarm/siren
within the plant before hoisting; the siren will serve a warning to unaware employees.
4 2 4 2 32
 The meaning of the siren needs to be known by all plant users/visitors prior to going to the plant.
(Induction).
 The plant area is strictly hard hat area, this reduces injuries to people should any objects hoisted are
accidentally dropped or fall.
Plant Operation Contact with moving machinery.  Ensure that you have enough knowledge or information of what’s to be done.
 Ensure that prior to manually opening any machinery to clear or release any blockage the machinery has
completely locked out to prevent an automatic start that could cause injuries.
4 2 4 2 32
 When you done, please be satisfied that you have close and all moving components are tightly closed
before restarting.
 Wear appropriate PPE for the task.
Working in the Plant Diseases caused by infectious agents present  Ensure that when working in the plant you always wear your PPE, mandatory PPE being safety shoes,
in the raw sewage. appropriate musk, appropriate hand gloves, hard hat and reflective clothing.
Diseases caused by toxins released by  Avoid eating or drinking in the area.
infectious agents.  Wash your hands and sanitise immediately upon leaving the plant.
 Check with your SHE personnel for appropriate immunisation when working at the plant.
Dermatoses caused by exposure of the skin
to wastewater.  Always wear long sleeves clothing, avoid any skin contact with any chemicals or sludge splashes, should 4 2 4 2 32
that happen please leave the area and rinse yourself thoroughly with clean water and soap.
 Notify your supervisor or SHE representative and get medical help should you experience or notice any
of the following. Respiratory (asthma, chronic bronchitis, and chronic sinusitis), gastronomic (abdominal
pain and bloating, nausea, vomiting, diarrhoea, constipation), skin (skin rash, ulcer on the skin) or
systemic (a headache, fever, chest pain or discomfort, muscle spasms)
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2.2 PPE Requirements

Standard site PPE should be worn whilst working at the RAS Pump Station. The minimum PPE
requirements include:
 Hard hat
 Safety shoes/gumboots
 Visible vest
 Overalls
 Gloves and Nose masks (when cleaning)
 Safety harness (if working at heights)
 Ear plugs
2.3 Immediate Action Plan

2.3.1 Electrical Equipment in MCC Rooms
Table 2-2 outlines the safety precautions that are required in MCC 15 room to ensure the safety of all
personnel working in the MCC room and RAS pump station.
Table 2-2 Electrical Equipment Safety Action Plan
Item
Do’s Don’t
no.
1. Switch OFF the main switch in an emergency Don't work inside motor control panels
2. Keep the MCC room clean. Don't try to adjust control devices
Don't switch OFF the main switch or other
circuit breakers unnecessarily. This causes
3. Keep visitors out of the MCC room
abnormal wear and tear and can lead to back-up
battery failure
Keep a logbook or diary and let service persons
Don’t keep on starting motors which keep on
4. fill in their Particulars, dates and the work, which
tripping. Report the problem.
they have done.
Read the voltmeters and ammeters daily.
Don’t keep on resetting equipment, which keep
5. Report any abnormal occurrence or motor noise
on tripping. Report the problem.
immediately to servicepersons.
Don't work on any pump set before switching off
Be present in or around the station when pumps
6. the starter main switch and pressing the lock-
are in operation.
stop button on the motor.
7. Lock the MCC room when not in operation. Don’t touch rotating shafts or machine Parts.
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Item
Do’s Don’t
no.
8. Keep electrical equipment and motors dry Don't leave operating equipment unattended.
Don't let untrained persons operate pumping
9.
equipment.
10. Don’t run pumps dry.
11. Don’t unnecessarily switch pumps on and off.
2.4 Evacuation Plan1

The operation and maintenance evacuation plan has been developed by Umgeni Water (UM), refer to
the “Emergency Response Plan & Procedures Template: Darvill Wastewater Works”. The structure
for the emergency response (ER) is depicted below in Figure 2-1, the structure illustrates the manner
in which the incident is reported and escalated at the site level to the Umgeni Water Head Office.
Each role player responsibility is defined in terms of dealing with the emergency situation at hand.
Figure 2-1 Emergency Response Structure
1
Evacuation Plan to be updated with updated the Emergency Response Plan & Procedures Template
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In the event of an incident, the individual that discovers it will report it to the responsible
management member, namely the supervisor/ manager/ systems manager/ work superintendent,
depending on the working environment. The responsible management member will then analyse the
situation and activate the emergency procedure, or notify the emergency coordinator (EC) to make a
decision. In cases that warrant so, the ER team and plan will be activated and the relevant response
will be taken, the local emergency services will be utilised as required.
The EC is then to inform and give details of the incident to the UW BCM coordinator. Depending on
the severity of the incident the BCM coordinator will inform the crisis management team (CMT)
leader and decisions will be made to activate the CMT and procedure.
2.4.1 Evacuation Routes and Key Locations

The evacuation routes and key locations are as follows:
1. Command Centre: The control room acts as a command centre in the event of an emergency.
However, if the control room cannot be used the main gate guard house will be used as the
command centre.
2. Forward Control Point: The forward return point is to be used by the fire department on site
and will be located at the command centre. The primary purpose of the forward control point
is to act as a location where the ER team can convey information to the Fire department and
other emergency services.
3. Emergency Assembly Points: a minimum of two (2) assembly points are located within each
workstation, i.e. a primary point, located on site, and a secondary point for large-scale
evacuations, located at a suitable distance away from buildings or working areas,
alternatively, the secondary point could be located off-site. The following locations act as an
emergency assembly points, refer to Figure 2-2 below:
a. Assembly Point A: From the alum dosing area, through to the aerators, proceeding to the
main buildings passing through to the workshops and go left.
b. Assembly Point B: From the alum dosing area, through to the aerators, proceeding to the
main buildings passing through to the workshops and go right to the canteen.
c. Assembly point C: From the chlorine area, through to the main pump station, proceed to
the head of works, and go right to the inlet.
From the Digester area, through to the PST and go straight to the inlet.
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Figure 2-2 Emergency Evacuation Diagram
2.4.2 Emergency Evacuation

There are three evacuation plans based on the mobility of the personnel namely: general personnel,
mobility impaired personnel and hearing or visually impaired personnel. For other more specific
emergency procedures refer to the UW “Emergency Response Plan & Procedures Template: Darvill
Wastewater Works” document, in Appendix C.
1. General Evacuation Procedure for all personnel

Upon hearing the alarm or the following notification by the ER team to evacuate the
building/premises, DO NOT PANIC!
Step 1. Stop all activities.

Step 2. Time permitting:
 Secure vital/confidential documents and valuable items
 In the event of a fire, close windows and doors, switch off air-conditioning
 In the event of a bomb scare, open doors and windows, but close blinds/curtains
 If using machinery and/or electrical equipment – isolate or switch off
Note: If you are in an operations environment – do not shut down the plant
Step 3. Evacuate the premises via demarcated escape routes, proceed to your assembly points
(refer to Section 2.4.1). Please remember, depending on the type and extent of the event,
your EC may ask that you proceed to the secondary assembly point to avoid danger.
Step 4. Where applicable, take your visitors with you and assist disabled persons in the area.
Step 5. If you are unsure or require any assistance, your area’s EC / fire marshal/fire warden will be
able to assist you.
Step 6. Do not run, walk in an orderly manner and assist others where needed.
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Step 7. Keep away from any "Disaster" area.

Step 8. At the assembly point
 Gather with other individuals from your department/division for roll call
 The EC will take roll call to identify any missing persons
 Remain at the assembly point, do not re-enter the building until further instructions are
given by senior management
2. Personnel with Mobility Impairments

In the event of an emergency evacuation situation, other staff members will assist any persons with
mobility impairment. If no one is available to assist, remain where you are or move to a nearby area
of refuge if this is required for your safety. Await assistance from the EC or other ER team members.
3. Personnel with Hearing or Visual Impairments

In the event of an emergency evacuation situation, persons with communication disabilities such as
hearing or visual impairment may not be aware of any emergency situation and the need to carry out
ER procedures. It is the responsibility of surrounding staff members to assist such persons and ensure
that they are able to safely evacuate the building /premises.
2.4.3 Emergency Contact Numbers

2.4.3.1 Fire services
Name Contact Number Extra Details
FIRE DEPARTMENT (033) 845 5911
Ricky Pillay 082 804 4411
2.4.3.2 Medical services
MEDI CLINIC – HOWICK PRIVATE
033 – 3302456
HOSPITAL
GREY’S 033 – 8973000
MEDI CLINIC – PMB 033 – 8453700
ST ANNE’S – PMB 033 – 8975000
ESCOURT 036 – 3427000
PROVINCIAL AMBULANCE 10177
ER 24 084 124
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2.4.3.3 Police and Security services

Enforce Security Services 033 – 342 1347
Loop Street - SAP 033 - 8452400
Alexander Road - SAP 033 – 8457700
Hilton - SAP 033 – 8456521
Flying Squad 10111
2.4.3.4 Miscellaneous services

Eskom 0860 037 566
NCP ( Chlorine Emergency) 011-9762115 or 011-9213333
Nomvuyo Zulu – Disaster
Management Msunduzi 072 525 1228
Municipality
Mike Amod - Disaster
Management Msunduzi 079 874 4637
Municipality
Ethekwini Municipality 031 - 3610000
2.4.3.5 Umgeni Water Contacts

Cyril Gamede 033 341 1041 / 082 771 1840 Overarching BCP Team Leader
Thandeka Zulu 033 – 719 7300 / 083 383 2135 Deputy Overarching BCP Team Leader
Ingrid Cawood 033 341 1244 / 083 292 5060 BCM Coordinator
Dan Naidoo 031 719 7300 / 083 272 4436 Deputy BCM Coordinator
Steve Gillham 033 341 1164 / 083 453 0240 GM: Engineering & Scientific Services
Msizi Cele 033 3411308 / 060 5773 246 GM: Operations
Thami Hlongwa 033 341 1507 / 082 818 8300 GM: Finance
Mokete Mayongo 033 3411011 / 060 521 7475 GM: Corporate Services
Thulasizwe Shangase 033 341 1012 / 083 459 8550 GM: Human Resource
Nonhlanhla Gumbi 033 341 1006 / 083 244 2310 GM: Supply Chain Management
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Sipho Zulu 033 341 1135 /082 437 3329 GM: Property Services
Bradley Sampson 033 346 1583 / 083 642 7733 GM: ICT
Sunil Maharaj 083 274 3013 96290) Regional Manager
Eric Nene 083 345 6708 (6265) Area Manager
Ntsiki Baai 083 289 1450 (6372) Asset Manager
Mulalo Murigwathoho 078 801 1181( 6965) Systems Manager
Goodman Ngcemu 084 444 3815 (6897) Superintendent DARVILL WWW
2.5 Pressure or Potential Energy Relief

Equipment Possible Cause Action Plan
Mechanical Pumps High pressure buildup Pressure relief valve
Bilge pump High-pressure buildup Pressure relief valve
2.6 Hazardous material information

The return activated sludge present in the RAS system contains potentially harmful bacteria and
pathogens, and may be harmful to the personnel’s health. Caution should be taken when handling the
return activated sludge and the relevant PPE should be worn.
2.7 Alarms, Trips and Interlocks
Table 2-3 identifies each of the alarm categories proposed for the system and the level of
acknowledgment necessary.
Table 2-3 Alarms, trips and interlocks description
CATEGORY DESCRIPTION
LEVEL 0 Where there is a change in operation status of equipment and instrumentation
(NOTIFICATION) on the plant during normal operating mode. The alarm is generated as a line
statement on the ALARM SCREEN in BLUE print.
LEVEL 1 An alarm condition that warns the Senior Operator of impending negative
(FAILURE) impact on process performance, plant integrity, personnel safety or
environmental safety. The alarm is generated as a line statement on the ALARM
SCREEN in RED print. The text will change to BLUE print if the ALARM CONDITION
is rectified before the Senior Operator acknowledges the alarm. The Senior
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Operator must acknowledge the alarm.

LEVEL 2 An alarm condition that warns the Senior Operator of severe negative impact on
(CRITICAL FAILURE) process performance, plant integrity, personnel safety or environmental safety.
This alarm is generated as a yellow POP-UP SCREEN that must be acknowledged
by the Senior Operator.
NB: For plant equipment specific trips and interlocks, please refer to FDS documents found in
Operation and Maintenance Manual, R.A.S Pump Station, Volume 2, File XXX.
NB: After a trip, the operator should first investigate and rectify the cause of the trip before the
equipment can be restarted.
 Investigate and rectify the cause of the trip.

 Clear the alarms on the SCADA by pressing the reset bottom.
Table 2-4 and Table 2-5 identifies the specific alarms, trips and interlocks, the associated equipment
and the severity of each trip, of the RAS pumps and bilge pump respectively.
Table 2-4 RAS Pumps Specific Alarms, Trips and Interlocks
ITEM EQUIPMENT
EQUIPMENT TRIP DISPLAYED ON SCADA CATEGORY
NO. TAG
1. - Mains Off Level 2
2. - Emergency Stop Level 2
3. MS-2004A/B/C VSD Fault Level 2
TT-2001A/B
4. TT-2002A/B PTC Fault Level 2
TT-2003A/B
5. FT-2057/8 No Flow Level 1
TT-2001C/
6. Grunfos Fault Level 2
2002C/ 2003C
7. M-2107/8/9 Auto Level 1
8. PIT-2006/7/8 Duty Pump Level 1
ZS-2027/28/
9. Delivery Line Route Off Level 2
29/33
10. M-2107/8/9 Delivery Valve Open Level 1
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11. ZS-2024/5/6 Suction Valve Open Level 1

12. LT-2002 RAS Sump Level LL Level 1
Table 2-5 Bilge Pumps Specific Alarms, Trips and Interlocks
ITEM EQUIPMENT
EQUIPMENT TRIP DISPLAYED ON SCADA CATEGORY
NO. TAG
1. - Mains Off Level 2
2. - Emergency Stop Level 2
3. M-2123 E300 TRIP Level 1
4. Earth Leakage Level 2
5. M-2123 Comm Loss Level 1
6. M-2123 Auto Level 1
7. LS-2004 Start Level Level 2
2.8 Any Other Safety Related Information
It is to be noted that whether you are the owner, operator, or maintenance person for this machine,
safety is your responsibility. You are responsible for operating and maintaining this equipment in
compliance with these instructions and for using common sense. It is extremely important that you
read, understand, and follow the safety messages and regulations carefully before handling the
machine.
The following special messages warn of potential hazards or to call attention to information that
clarifies or simplifies a procedure.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING/ATTENTION
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
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CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE addresses practices not related to physical injury including certain environmental hazards, potential
damage or loss of data.
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3 Operating Instructions
3.1 Normal Operational Procedures Including Automatic and Manual Operations
3.1.1 Return Activated Sludge Pumps
There are 3 RAS pumps, two duty and one standby, that can be operated in the aforementioned
modes of operation. For equipment general operation, maintenance and fault finding, refer to
Operation and Maintenance Manual, Return Activated Sludge Pump Station Area, Volume 2. For specific
control philosophy refer to the Functional Design Specification, Volume 2.
3.1.1.1 Pre-Start-Up Checks

Step 1. Ensure all valves (manual and automatic) relevant for operation are in correct position.
Step 2. Check to see that all rear covers, top plates and bus-bar covers are installed and closed.
Step 3. Close all front doors of the MCC on all starter panels and instrument panels, as well as, the
main door of the main switch as this door is interlocked with the main switch and it is not
possible to switch the main power on with this door open or slightly open.
Step 4. Confirm power is available to all panels and auxiliary equipment.
Step 5. Emergency stops are at rest from the LPC.
Step 6. Check to see that persons are not working on motors or pumps before start-up.
Step 7. Do not operate faulty pumps, motors or open shaft pump sets. Have them repaired.
Step 8. Start operating equipment from Upstream. Please note the Process flow needs to be
studied and understood before doing this.
Step 9. No unauthorised persons are allowed to operate or modify units. Proper training must be
provided to any personnel operating the units.
Step 10. Ensure an emergency evacuation plan is in place and that all personnel are familiar with the
evacuation procedures including the location of the assembly point.
Step 11. Investigate, evaluate and acknowledge any alarms recorded on the SCADA before clearing
them.
3.1.1.2 Remote Auto Operation

3.1.1.2.1 Purpose
To operate the Pump in Remote Auto from the control room/SCADA
3.1.1.2.2 Sequence Steps

Step 1. The operator ensures that Duty/Standby pumps are switched into PLC mode, as illustrated
in Error! Reference source not found..
Step 2. The operator ensures that all actuated valves are switched to auto mode, as illustrated in
Figure 3-2.
Step 3. The operator ensures that suction valves KGV-2062A/2062B/2062C are fully open (confirm
both on the SCADA and field), as illustrated in Figure 3-3.
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Step 4. The operator ensures that discharge valves KGV-2056A/2056B/2056C are open.
Step 5. The operator is to bleed the pressure lines of any air by opening the relevant valves GV-
2001/2002/2003.
Step 6. From the SCADA, the operator ensures wet well water level is between operating limits, as
illustrated in Figure 3-4.
Step 7. From the filed the operator is to check that the wet well is free from any debris.
Step 8. From both the SCADA and field, the operator ensures at least one delivery line is available
and valves KGV-2059A/2059B are in the correct position for flow through desired delivery
line, and if pump 2 is running that the relevant valves KGV-2057/2058
Step 9. Check the alarm status of the duty/standby motors by clicking on the motors, as illustrated
in Figure 3-5.
Step 10. Reset any present alarm conditions, as illustrated in Figure 3-6.
Step 11. PLC Confirm duty call as required by LT-2002 (With Control Band).
Step 12. Start available duty pump- check for lowest hours for non-running pump (runs at minimum
speed).
Step 13. When discharge valve fully opens, PLC runs motor at set speed (motors accelerate until set
point is reached).
Step 14. Second Duty pump required as determined by the level transmitter LT-2002, at the sump
level of 60%.
Step 11.1. From SCADA, Operator confirms pump is available- check for lowest hours for non-
running pump.
Step 11.2. From the field and SCADA, operator confirms the relevant suction valve KGV-
2056A/B/C is open.
Step 11.3. PLC reduces speed of running pump to minimum speed (motor decelerates to
minimum speed).
Step 11.4. When duty P1 is at minimum speed, PLC starts duty P2 on minimum speed (both
motors run at minimum speed.)
Step 15. Second duty pump no-longer required as determined by the level transmitter LT-2002, at
the sump level of 45%.
Step 12.1. PLC reduces speed of both motors down to minimum speed.
Step 12.2. When both pumps are running at minimum speed, PLC closes discharge valve of
motor required to stop (both pumps running at minimum speed).
Step 12.3. When discharge valve reaches 10% of open position, PLC stops motor (remaining
pump runs at minimum speed).
Step 12.4. When discharge valve closed and motor stopped, PLC increases speed of remaining
motor to required set point (set point determined by Level transmitter).
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Figure 3-1 RAS Pump Local/PLC Switch
Figure 3-2 Automated Valves Local or Remote Control

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Figure 3-3 Suction Valve on Both SCADA and in the Field
Figure 3-4 RAS Sump Level
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Figure 3-5 RAS Pump Interlock Alarm Status
Figure 3-6 Resetting Alarm Conditions
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3.1.1.3 Remote Manual Operation

To start the RAS Pump Station in Remote Manual from the Control Building.
3.1.1.3.1 Purpose
To operate the RAS Pumps in remote manual mode from the SCADA.

Step 1. The Operator ensures that Duty /Standby pumps are switched into PLC mode, as illustrated
in Error! Reference source not found..
Step 2. The operator ensures that all automated valves are switched to auto mode, as illustrated in
Figure 3-2.
Step 3. The operator ensures that suction valves KGV-2062A/2062B/2062C are fully open, confirm
on the SCADA and in the field, as illustrated in Figure 3-3.
Step 4. The operator ensures delivery valves KGV-2056A/2056B/2056C are fully open.
Step 5. From the SCADA, the operator ensures level from the LT-2002 is between operating limits of
45-60%, as illustrated in Figure 3-4.
Step 6. From the SCADA and in the field the operator ensures at least one delivery line is open by
the valves KGV-2059A/2059B being in the correct position for the flow through desired
delivery line, and if pump 2 is running the relevant valves KGV-2057/2058.
Step 7. The Operator checks the alarm status of the duty/standby motors by clicking on the motor,
as illustrated in Figure 3-5.
Step 8. Operator resets any present alarm conditions, as illustrated in Figure 3-6.
Step 9. The Operator sets speed reference.
Step 10. PLC starts pump (runs at minimum speed).
Step 11. PLC Confirm duty call as required by LT-2002 (With Control Band)
Step 12. When discharge valve fully open, PLC runs motor at set speed (motors accelerate until set
point is reached).
Step 13. Second Unit is started as per above Sequence Step 6-Step 12
Step 14. Operator stops pump initiated.
Step 15. PLC closes discharge valve.
Step 16. When discharge valve reaches 10% open position, PLC stops pump (pump decelerates).
Step 17. Second unit stopped as per above Sequence Step 14-Step 16.
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3.1.1.4 Local Manual Operation

3.1.1.4.1 Purpose
To start the RAS Pump Station in Local Manual from the field.

Step 1. Operator ensures Duty/Standby pumps are switched into LOCAL mode, as illustrated in
Error! Reference source not found..
Step 2. The operator ensures that all automated valves are switched to local mode, as illustrated in
Figure 3-2.
Step 3. From the field, the operator ensures suction valves KGV-2062A/2062B/2062C are fully open,
as illustrated in Figure 3-3.
Step 4. From the field, the operator is to ensure that the discharge valves KGV-2056A/2056B/2056C
are open.
Step 5. The operator is to bleed the pressure lines of any air by opening the relevant valves GV-
2001/2002/2003.
Step 6. Operator ensures level is between operating limits 45-60%, as illustrated in Figure 3-4.
Step 7. From the field, the operator ensures at least one delivery line is available and valves KGV-
2059A/2059B are in the correct position for flow through desired line, and if pump 2 is
running that the relevant valves KGV-2057/2058.
Step 8. Operator checks the alarm status of the duty/standby motors by clicking on the motor, as
illustrated in Figure 3-5.
Step 9. The operator resets any present alarm conditions, as illustrated in Figure 3-6.
Step 10. Operator sets speed of 35Hz referenced from the field, on the speed controller as illustrated
in Figure 3-1.
Step 11. Operator starts pump and confirms that the pump is steady at 35Hz (pump accelerates
incrementally to set speed) on field panel, as illustrated in Figure 3-1.
Step 12. Using the speed control dial, illustrated in Figure 3-1, the pump speed is increased
incrementally until the SP is reached.
Step 13. Second Unit Started as per above sequence Step 8-Step 11.
Step 14. Operator stops pump initiated (pump decelerates).
Step 15. Operator closes discharge valve.
Step 16. Second Unit stopped as per above sequence in Step 14-Step 15.
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Figure 3-7 RAS Pump Field Panel
3.1.1.5 Shut-Down
3.1.1.5.1 Shut-down and Operation Checks
Step 1. Close all front doors of the MCC on all starter panels and instrument panels, as well as the
main door of the main switch as this door is interlocked with the main switch or warning
alarms.
Step 2. Stop all equipment from Upstream until downstream. Please note the Process flow needs to
be studied and understood before doing this.
Step 3. Ensure all manual or isolation valves relevant for operation are opened/closed.
3.1.1.6 Isolation
The below procedure defines the isolation points on events of maintenance, troubleshooting, and or
re-outing checks deemed by the process or operations requirements.
Step 1. Senior operator is to identify the need of isolation of a specific pump line. To maintain the
load, only one pump line should be isolated at a time, generally the standby pump.
Step 2. The operator should set the relevant pump into local mode, as illustrated in Error! Reference
source not found..
Step 3. The pump should be slowed down incrementally using the speed control dial, as illustrated
in Figure 3-1, and eventually stopped.
Step 4. The senior operator is to then close valves KGV-2062A/2062B/2062C and KGV-
2056A/2056B/2056C depending on the pump line that is being isolated.
Step 5. Let out excess sludge between the isolation valves by opening the gate valves GV-
2001/2002/2003 to the drain, depending on the pump line.
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3.1.1.7 Troubleshooting
Table 3-1 Troubleshooting of RAS Pump
Fault Cause Remedy

Re-establish power supply. Start
1. Pump does not start or
a) No power supply. the pump manually and check
stops without visible cause.
contactor operation.
a) Missing phase. Re-establish all phases.
If the fault does not disappear
b) Pump momentarily
automatically, find the cause and
overloaded.
remedy the fault.
c) Impeller clogged by
Clean impeller as required.
impurities.
2. Pump does not start or Set the motor protective circuit
stops. The control panel of d) Motor protective circuit
breaker as required according to
the controller indicates that breaker not set correctly.
rated current.
the motor protective circuit Insufficient motor cooling. Re-
breaker or protection e) Thermal switches tripped out.
establish motor cooling.
equipment has tripped out. f) Moisture switch in motor Contact an authorised service
tripped out. workshop.
Contact an authorised service
g) Motor cable defective.
workshop.
Re-establish correct voltage supply.
h) Fluctuating voltage. Permissible deviation is - 10 %/+ 10
%.
Interchange two phases to the
a) Wrong direction of rotation.
motor.
b) Impeller loose or worn. Tighten or replace the impeller.
c) Pump or pipework blocked by
Clean as required.
impurities.
Measure the differential pressure
and compare the value with the
d) Pump head too high.
3. Pump runs but does not pump curve. Remove the blockage
deliver the rated flow in the discharge pipe
e) Valves closed or blocked.
Clean or replace valves as required.
Non-return valve not operating
Vent the pump and suction pipe.
f) Air in pump or suction pipe. Increase the stop level in the tank.
g) Pumped liquid too dense Dilute the liquid.

h) Pump not properly connected Pump down the liquid level in tank.
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to auto coupling. Lift out the pump and relocate the

pump on the auto coupling.
Repair the pipework.

i) Leakage in pipework.
Check function and repair as
j) Pump tank flushing system
required.
inadvertently activated.
a) Clogged pump causes motor-
Clean the pump.
protective circuit breaker to trip
out.
Allow pump to cool. Clean the
b) Overheated motor causes
pump.
4. Pump starts, but stops thermal switches to trip out.
immediately.
Clean or set level switch or replace
c) Level switch out of
as required.
adjustment or defective.
Check for any blockages in the pipe
d) No flow alarm/ interlock.
line.
a) Pump partly choked by
Clean the pump.
impurities
Interchange two phases to the
b) Wrong direction of rotation. motor.
c) Pump operates outside Re-establish proper operating

specified operating range. conditions.
5. Pump vibrating or emitting Repair the pump or contact an
d) Pump defective.
excessive noise authorised workshop, if necessary.
e) Pump not properly connected Pump down the liquid level in tank.
to auto coupling. Lift out the pump and relocate the
pump on the auto coupling.
f) Pump cavitates. Clean the suction pipe.
g) Base stand, auto coupling,
Install the components correctly.
ring stand or guide rails not
installed correctly.
a) Lower mechanical seal Contact an authorised service
6. Oil watery or emulsified.
leaking. workshop.
a) Upper mechanical seal Contact an authorised service
7. Low oil level.
leaking. workshop.
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3.1.2 Bilge Pump

The Bilge pump operates on a start-stop mode. For equipment general maintenance and fault finding,
refer to Operation and Maintenance Manual, Return Activated Sludge Pump Station Area, Volume 2.
For specific control philosophy refer to the Functional Design Specification, Volume 2.
3.1.2.1 Pre-Start-Up Checks

Step 1. Check to see that all rear covers, top plates and bus-bar covers are installed and closed.
Step 2. Close all front doors of the MCC on all starter panels and instrument panels, as well as, the
main door of the main switch as this door is interlocked with the main switch and it is not
possible to switch the main power on with this door open or slightly open.
Step 3. Confirm power is available to all panels and auxiliary equipment.
Step 4. Emergency stops are at rest from the LPC.
Step 5. Check to see that persons are not working on motors or pumps before start-up.
Step 6. Do not operate faulty pumps, motors or open shaft pump sets. Have them repaired.
Step 7. No unauthorised persons are allowed to operate or modify units. Proper training must be
provided to any personnel operating the units.
Step 8. Ensure an emergency evacuation plan is in place and that all personnel are familiar with the
evacuation procedures including the location of the assembly point.
Step 9. Investigate, evaluate and acknowledge any alarms recorded on the SCADA before clearing
them.
3.1.2.2 Remote Auto Operation
3.1.2.2.1 Purpose
To operate the bilge pumps in remote auto mode
Step 1. The operator must ensure the bilge pump, is switched into PLC mode, as illustrated in Figure
3-8, and select AUTO on the SCADA.
Step 2. Check the alarm status of the pump by clicking on the pump, as illustrate in Figure 3-9.
Step 3. Reset any present alarm conditions, as illustrate in Figure 3-10.
Step 4. The PLC will confirm sump level using LSH-2004, when reached high level i.e. level > 60%,
the Bilge pump will start automatically
Step 5. Bilge pump continues to run, until low level is reached, this will be confirmed by LSL-2004 at
level < 30%
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Figure 3-8 Bilge Pump Local/PLC Switch
Figure 3-9 Bilge Pump Interlocks
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Figure 3-10 Bilge Pump Alarm Reset
3.1.2.3 Remote Manual Operation

3.1.2.3.1 Purpose
To operate the bilge pumps in remote manual mode
Step 1. The operator must ensure the bilge pump, is switched into PLC mode, as illustrated in Figure
3-8, and select manual on the SCADA.
Step 2. Check the alarm status of the pump by clicking on the pump, as illustrated inFigure 3-9.
Step 3. Reset any present alarm conditions, as illustrated in Figure 3-10.
Step 4. Confirm sump level using LSH-2004, when high level, i.e. level > 60%, is reached, start Bilge
pump on SCADA.
Step 5. Monitor Bilge pump running until low level is reached, i.e. level > 30%, confirming the level
using the LSL-2004 displayed on SCADA.
Step 6. Stop Bilge pump.
3.1.2.4 Local Manual Operation

3.1.2.4.1 Purpose
To operate the bilge pump in Local manual mode
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Step 1. The operator must ensure Bilge pump, are switched into Local mode, as illustrated in Figure
3-8.
Step 2. The operator must ensure level is above low set point.
Step 3. Using the Local Control panel, as illustrated in Figure 3-11, located next to the bilge pump
start the pump
Step 4. Start/stop Bilge pump as corresponding to high and low volume in the sump.
Figure 3-11 Bilge Pump Local Control Panel
3.1.2.5 Shut-Down Procedure

3.1.2.5.1 Normal Stopping of the Bilge Pump
Step 1. Close all front doors of the MCC on all starter panels and instrument panels, as well as the
main door of the main switch as this door is interlocked with the main switch or warning
alarms.
Step 2. Stop all equipment from Upstream until downstream. Please note the Process flow needs to
be studied and understood before doing this.
3.1.2.5.2 Emergency Stop of the Bilge Pump

Step 1. Press the emergency stop button located on the LCP, as illustrated in Figure 3-11.
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3.1.2.6 Troubleshooting
Table 3-2 Troubleshooting of the Bilge Pump
Fault Cause Remedy

a) No power supply. Connect the power supply.
b) The pump was stopped by the level
Adjust or replace the level switch.
switch.
1. The motor does c) The fuses have blown. Replace the fuses.
not start. d) The motor protection/thermal relay Wait until the motor protection trips in
has tripped. again/reset the relay.
e) The impeller is blocked by impurities. Clean the impeller.
f) Short circuit in the cable or motor. Replace the defective part.
a) The liquid temperature is too high. Use another pump type.
b) Impeller blocked or partly blocked by
2. The motor Clean the pump.
impurities.
protection/thermal
c) Phase failure. Call an electrician.
relay trips after a
d) Too low voltage. Call an electrician.
short time of
e) Overload setting of the motor-
operation. Adjust the setting.
protective circuit breaker too low.
f) Incorrect direction of rotation. Reverse the direction of rotation.
a) The pump is partly blocked by
Clean the pump.
impurities.
b) The outlet pipe or valve is partly
Clean the outlet pipe.
blocked by impurities.
3. The pump runs c) The impeller is not properly fixed to
Tighten the impeller.
constantly or gives the shaft.
too little water. d) Incorrect direction of rotation. Reverse the direction of rotation.
e) Incorrect setting of level switch. Adjust the level switch.
f) The pump is too small for the
Replace the pump.
application.
g) The impeller is worn. Replace the impeller.
a) The pump is blocked by impurities. Clean the pump.
b) The outlet pipe or non-return valve is
Clean the outlet pipe.
4. The pump runs blocked by impurities.
but gives no water. c) The impeller is not properly fixed to
Tighten the impeller.
the shaft.
d) Air in pump. Vent the pump and the outlet pipe.
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The pump inlet is not completely

submerged in the pumped liquid.
e) The liquid level is too low.
Submerge the pump in the liquid or
adjust the level switch.
f) The level switch does not move freely. Make the level switch move freely.
3.2 RAS Pump Station Ventilation System2
The Ventilation system can be operated in the aforementioned modes of operation. For equipment
general maintenance and fault finding, refer to Operation and Maintenance Manual, RAS Pump Station,
Volume 2.
3.2.1 Pre-Start-Up Checks

No unauthorised persons are allowed to operate or modify units. Proper training must be provided to
any personnel operating the units.
Step 1. Before operating the units ensure that the fans are clear of any obstacles
Step 2. Check for any loose or damaged electrical wiring, repair or replace if needed
Step 3. Check the water supply line into the individual water tanks by motoring the pressure gauge.
3.2.2 Remote Auto Operation

3.2.2.1 Purpose
To operate the ventilation system in Remote auto
3.2.2.2 Sequence of Operation Steps

3.2.3 Remote-Manual Operation
3.2.3.1 Purpose
To operate the ventilation system in Remote manual
2
Outstanding documentation from Gauche Air
Document Number
Group Five
G5-113248-12.07-001
Revision Number
01
Page Number
3.2.4 Local Operation

3.2.4.1 Purpose
To operate the ventilation system in local
3.2.5 Normal operating condition/readings

3.2.6 Emergency shut-down
3.2.7 Isolation
3.2.8 Troubleshooting
Document Number
Group Five
G5-113248-12.07-001
Revision Number
01
Page Number
3.3 Sampling, Calibration and Measurements
3.3.1 Sampling and Measurement

Samples of the RAS can be taken from the drains at GV-2001/2002/2003 or at GV-2052/2053, for
testing of the quality of the sludge.
3.3.2 Calibration
Flow meters and pressure indicators to be calibrated as per Operation and Maintenance Manual,
Return Activated Sludge Pump Station Area, Volume 2. For specific control philosophy refer to the
Functional Design Specification, Volume 2.
4 Handover documentation
To be included on completion.

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Project Name Darvill Waste Water Treatment Works Upgrade

Originated By Reviewed By Approved By Approved By

LIST OF FIGURES ..................................................................................................................................................... IV

LIST OF NOTES ........................................................................................................................................................ IV

LIST OF ABBREVIATIONS .......................................................................................................................................... V

1 GENERAL METHOD AND PRINCIPLE OF OPERATION ........................................................................................ 1

1.1 DESIGN BRIEF AND REQUIRED PURPOSE ............................................................................................................... 1

2 GENERAL PROCESS SAFETY INSTRUCTIONS ..................................................................................................... 6

2.1 IDENTIFICATION HAZARDS (HIRA) ....................................................................................................................... 6

3.2.6 Emergency shut-down........................................................................................................................... 35

4 HANDOVER DOCUMENTATION ..................................................................................................................... 36

1 General Method and Principle of Operation

1.2 Output or Functionality

Table 0-1Table 1-1 below:

Table 0-1 Output or Functionalities for System Definitions

PARAMETER TO BE CHANGED USER

Maximum and minimum set points Engineer and technician

The High and Low Process Set points Superintendent

Section Reset e.g. Upon system failure because of Senior Operator

Motor Start/Stop Operator

Isolation of Systems Senior Operator

Table 0-2 Specific Equipment Set Points (SP)

ITEM MINIMUM MAXIMUM Formatted Table

14. M1063 N/A N/A Diaphragm valve actuator

1.3 Principle and Method of Operation

i. Remote auto operation

1.3.1 Remote Auto Operation

1.3.2 Remote Manual Operation

THIS MODE OF OPERATION IS NORMALLY CHOSEN FOR MAINTENANCE PURPOSES, DURING

1.3.3 Local Manual Operation

2 General Process Safety Instructions

Table 2-1 Hazardous Identification Risk Assessment

C POTENTIAL DAMAGE OR LOSS D ENVIRONMENT ACTION REQUIRED

2.2 PPE Requirements

2.3 Immediate Action Plan

Table 2-2 Electrical Equipment Safety Action Plan

11. Don’t unnecessarily switch pumps on and off.

2.4 Evacuation Plan1

Figure 2-1 Emergency Response Structure

2.4.1 Evacuation Routes and Key Locations

Figure 2-2 Emergency Evacuation Diagram

2.4.2 Emergency Evacuation

1. General Evacuation Procedure for all personnel

Step 1. Stop all activities.

Step 7. Keep away from any "Disaster" area.

2. Personnel with Mobility Impairments

3. Personnel with Hearing or Visual Impairments

2.4.3 Emergency Contact Numbers

MEDI CLINIC – PMB 033 – 8453700

ST ANNE’S – PMB 033 – 8975000

ESCOURT 036 – 3427000

PROVINCIAL AMBULANCE 10177

2.4.3.3 Police and Security services

2.4.3.4 Miscellaneous services

2.4.3.5 Umgeni Water Contacts

2.5 Pressure or Potential Energy Relief

2.6 Hazardous material information

2.7 Alarms, Trips and Interlocks

Table 2-3 Alarms, trips and interlocks description

Operator must acknowledge the alarm.

 Investigate and rectify the cause of the trip.

Table 2-4 RAS Pumps Specific Alarms, Trips and Interlocks

11. ZS-2024/5/6 Suction Valve Open Level 1