INDUSTRIAL WATER TREATMENT REFERENCE & OPERATION MANUAL

FOR

TENARIS
Houston, TX Project # !"#$

DMP CORPORATION #!! %r&'nt %()*+ Roc, H-((, Sout. C'ro(-n' /01$/ U+S+A+

TA%LE OF CONTENTS
Introduction Contacting DMP for Assistance Batch Treatment Process Neutralization Tank "ater #ec$cle %DI& '$stem DI 'torage Tank Chemical (eed '$stem Chemical #e*uirements Pre,aration of -$drochloric Acid Pre,aration of Precoat (ilter Press "et (ilter Cakes Cloth "ashing /0a,oration Main Control Panel CP2 Batter$ #e,lacement Alarms 3 "arnings Pum, Counter DMP ,- 'ensors Cleaning 'ensors Cali5rating 'ensors 6ar Testing Air 7ance 'am,le Collection Anal$sis #e,orts 8ee,ing #ecords "aste9ater 'egregation Concentrates Pre0entati0e Maintenance "hat is ,-: "arrant$ #eturning Com,onents (A;<s 2 4 5 ! 5 ) + 2! 2 22 2) 2. 14 15 42 41 44 4. 4+ 5! 5 54 5. )2 )1 )4 )4 )+ 42 44 45 4)

INTRODUCTION
The ,ur,ose of this manual is to familiarize the o,erator 9ith the DMP "aste Treatment '$stem= This manual 9ill not train $ou on 9hat 5uttons to ,ush in s,ecific situations= Training on the o,erator interface> control ,anel and e*ui,ment is ,ro0ided during the startu, ,hase of the ,ro?ect= No 9aste9ater treatment s$stem can function ,ro,erl$ 9ithout a ca,a5le and trained o,erator= The ,osition re*uires an o,erator ca,a5le of learning and understanding the tried and ,ro0en ,rinci,les utilized in the DMP s$stem= The ,osition also re*uires monitoring of the s$stem> sim,le testing of 9ater from the s$stem> maintaining records as re*uired 5$ regulator$ agencies> ordering of the treatment su,,lies> ,erforming normal and ,re0entati0e maintenance and trou5leshooting the treatment s$stem> if a ,ro5lem arises= As 9ith o,erating all e*ui,ment> o,timum results can onl$ 5e achie0ed as the o,erator gains e@,erience= During the learning stages> the o,erator 9ill 5ecome familiar 9ith the follo9ing areasA = 8no9ledge of 9aste generating streams a= 'ources 5= Contaminants 2= (lo9 'chematic%s& 1= /*ui,ment su,,lied 4= Instrumentation a= 2ses 5= Cali5ration c= Cleanu, 5= Treatment chemistr$ )= Chemical reactions 4= Processing the 9aste9ater through the treatment s$stem a= Pum,ing to the s$stem 5= (lo9 coordination c= Concentrated dum,s = 2= Dum,ing schedules Bleed rates

4 .= 2,sets and mistreatment a= Causes 5= Corrections += #ecord kee,ing a= Im,ortance 5= #e*uirements != Pre0enti0e maintenance = Check lists 2= Bood housekee,ing 1= 'afet$ /m,hasis is on the o,erator> since he or she has a 0er$ im,ortant role in controlling the DMP treatment s$stem= As the o,erator learns the s$stem it 5ecomes easier to run efficientl$ and attention to the s$stem is reduced to ,eriodic checks= The amount of time this takes 9ill 5e de,endant on the 5ackground of the o,erator and the amount of time he or she can dedicate to o,erating the s$stem during startu, and the earl$ o,eration of the s$stem=

Cont'ct-n2 DMP 3or Ass-st'nce

DMP4s Tec.n-c'( Ser)-ce De5'rt6ent c'n 7e re'c.e* Mon*'&8Fr-*'& 7et9een t.e .ours o3 " AM 'n* : PM e'stern st'n*'r* t-6e 't "!! "#:8 :! 0 or "!$ $/#8/#! + Ask for the Tec.n-c'( Su55ort De5'rt6ent 9here *ualified ,ersonnel 9ill 5e a0aila5le to ans9er $our *uestions and hel, trou5leshoot ,ro5lems 9ith the s$stem= In order to hel, $ou *uickl$ and efficientl$ 9e re*uest that $ou ha0e the follo9ing information a0aila5le 5efore $ou contact DMPA W.o &ou 're Cour name Cour com,an$ name and location Cour ,ro?ect num5er %4 or 5 digit num5er located on all schematics& F(o9 Sc.e6't-c %(ue5r-nt;s< This 9ill ena5le $ourself to 5e looking at the same diagrams%s& that 9e are looking at= DMP E(ectr-c'( Sc.e6't-c As a5o0e> 5oth ,arties can 5e looking at the same diagrams at the same time= H')e &our TECH L-n, ;-3 '55(-c'7(e< connect-on o5er't-on'( If $our s$stem is e*ui,,ed 9ith DMPDs T/C- 7ink %/lectronic 'er0ice Call E,tion& 9e are a5le to look at $our s$stem ,rograms from our facilit$= Man$ times it is necessar$ for us to look at the ,rograms in order to sol0e a ,ro5lem *uickl$= Make 'ure = Po9er is on to an$ connection de0ices %router> modem> hu5> etcF& 2= If using a tele,hone line 0erif$ it is connected to the modem %the tele,hone line must 5e a direct connection from the tele,hone com,an$ to the DMP control ,anel= If there is a fa@ or another ,hone connected to the DMP ,hone line 9e ma$ not 5e a5le to connect to the s$stem&= H')e s5ec-3-c -n3or6't-on on t.e 5ro7(e6 're' e@& GI am ha0ing a ,ro5lem 9ith m$ filter ,ress ,um, 9hich is ,um, (P(PHA=G e@& GM$ ,- ,ro5e in Neutralizer I2 does not seem to 5e reading correctl$=G He(53u( re6-n*ers If $ou ha0e 5een 9orking 9ith a s,ecific ,erson on a ,ro5lem ,lease ask for that ,erson first= If the ,erson $ou re*uested is not a0aila5le someone else 9ill 5e a5le to assist $ou or lea0e a detailed message for that ,erson= I3 &ou nee* to or*er 5'rts or .')e ' 5r-c-n2 =uest-on 5(e'se 's, 3or t.e s5're 5'rts *e5'rt6ent+ If $ou 9ant to re*uest a P7C or -MI ,rogramming change ,lease fa@ the changes to DMP ser0ice at %.!1& 124H5441= This 9ill ena5le DMPDs control staff to re0ie9 the re*uest and inform $ou if the change%s& are feasi5le=

%'tc. Tre't6ent Proce*ure

'ingle Batch Tank '$stem

Batch treatment is used to treat highl$ concentrated 9aste streams or 9aste streams that change fre*uentl$= The goal is to fill the treatment tank 9ith a kno9n amount> ?ar test the 5atch> treat the 5atch and em,t$ the tank= Ence the tank is em,t$ a ne9 5atch of 9aste can 5e treated= C.e6-c'( Tre't6ent Process E,erator starts and monitors the automated 5atch treatment ,rocess from the o,erator interface at the DMP control ,anel= Instructions are read from the o,erator interface screens= Eil free 9aste9ater is to 5e transferred to the 5atch treatment tank for ,rocessing= "ater 9ill come from ',ent Alkaline or ',ent Acid tanks= The follo9ing ste,s e@,lain the 5atch treatment ,rocess Pro0ided the sum,> or holding tank> has reached the start ,um, le0el> the s$stem feed ,um,%s& should start ,um,ing into the 5atch tank= "hile the 5atch tank is filling> make sure there are enough chemicals a0aila5le to treat the 5atch= Ence the 5atch treatment tank full le0el control is acti0ated> the 5atch is read$ to 5e ,rocessed= GE8 to TreatG 9ill a,,ear on the o,erator interface= Ence the 9orking 5atch tank has reached the full le0el> an$ additional flo9 9ill 5e di0erted to the 9aste9ater holding tank for storage until the ne@t 5atch is read$ to 5e ,rocessed= The 9aste9ater 9ill continue to fill the 9aste holding tank unless a 5atch ,rocess has 5een com,leted and is no9 a0aila5le to 5e filled= At that ,oint> the ,um, from the 9aste holding tank> along 9ith the 9aste9ater feed> 9ill fill the 5atch tank= Insert the ,- ,ro5e into the treatment tank= The ,- of the solution to 5e treated 9ill 5e indicated on the o,erator interface screen= NoteA Pro5es should 5e cleaned andJor cali5rated each 5atch to insure ,ro,er treatment until a cali5ration schedule is esta5lished 5ased on e@,erience= Turn the 5atch treat tank mi@er to the MAN2A7 ,osition to allo9 the solution to mi@ thoroughl$ %A,,ro@imatel$ 5 minutes&= Dra9 a sam,le for ?ar testing to determine treata5ilit$ ,rocess> and chemical reagent dosages re*uired to treat 5atch= NoteA #efer to ?ar testing ,rocedures section of this manual=

7 Conduct ?ar testing ,rocedure on sam,le and record amount of chemical reagents re*uired to treat the 5atch ,ro,erl$= Calculate the settings re*uired for tank ca,acit$ 5eing treated= #ecord this information= 'et u, the ,rocess in the 5atch treatment control screen of the o,erator interface= H 'elect 'te,s and Pauses H /nter amount of gallons re*uired for each treatment chemical= H /nter ,- set ,oints= H /nter times for mi@ 3 age> mi@ after floc and settling= H Place BT Mi@er into Auto= 'tart the treatment c$cle 5$ ,ressing G'tart TreatmentG= 2,on com,letion of the settling stage> the BT screen 9ill dis,la$ GTreatment Com,leteG T.e c.e6-c'( tre't6ent 5ort-on o3 t.e 7'tc. -s no9 co65(ete 'n* re'*& 3or tr'ns3er to t.e 3-(ter 5ress or 3(o9 t.rou2. tre't6ent s&ste6+

Tre't6ent Notes
Ence the o,erator has treated a num5er of 5atches> the treatment ,rocess 9ill 5egin to 5e familiar and ma$ 5e similar in chemical makeu,= This is 9here ,ro,er ?ar testing can result in sa0ed time 5$ reducing or eliminating ,auses 5et9een treatment ste,s= Ence the treatment is com,lete remo0e ,ro5e%s& from tank and store ,ro,erl$ in an a,,ro,riate container of li*uid %9ater or 5uffer solution is 5est&= This 9ill a0oid ,ro5e failure from ha0ing the ,ro5es e@,osed to air for an e@tended ,eriod of time= The ne@t automatic 5atch ,rocess can 5e started again after the tank em,t$ le0el is deacti0ated=

M'nu'( Tre't6ent
Cour s$stem ma$ 5e e*ui,,ed 9ith a manual treatment mode= If so> either 5atch ma$ 5e treated 5$ manuall$ adding chemicals and mi@ing from the o,erator interface= Manual Treatment Steps 'elect Manual Treatment Mode= To run mi@er select Manual mode= 'elect 9hich chemical to add and turn ,um, on= NoteA Pum, 9ill continue to run until turned off= #e,eat a5o0e ste,s as needed to treat the 5atch=

Force Tre't6ent Co65(ete

"hen 5utton is ,ressed the s$stem 9ill assume the 9ater is treated in the Batch Tank and not allo9 further addition of chemicals=

Reset Tre't6ent Co65(ete

"hen 5utton is ,ressed the s$stem 9ill assume the 9ater is untreated in the Batch Tank and allo9 addition of treatment chemicals=

S(u*2e De9'ter-n2 Process

All ,hases of the 5atch treatment are no9 com,lete and the decanting of the 5atch tank can 5egin= The filter ,ress can decant the clear 9ater from a5o0e the settled sludge through the decant 0al0es or to use the 5ottom dra9Hoff 0al0e to ,um, all of the decant 9ater and the sludge through the filter ,ress= Ne@t> select GDecantK> or GNE DecantK=

Turn the ,ress on= The first stage of ,rocessing the 9ater through the filter ,ress is to either ,recoat the cloths or start the initial fill of the ,ress= 'econd stage of the filter ,ress c$cle is to decant the clear 9ater from a5o0e the settled sludge through the decant 0al0es %Decant& or to use the 5ottom dra9Hoff 0al0e to take all of the decant 9ater along 9ith the sludge through to the filter ,ress %No Decant&= "hen a decant le0el control is deacti0ated> the suction of the filter ,ress feed ,um, 9ill 5e transferred to the ne@t decant 0al0e le0el of the tank= This 9ill continue until the last decant le0el control is deacti0ated> and the ,um, is transferred to the 5ottom dra9Hoff 0al0e of the 5atch tank= "hen the filter ,ress c$cle is com,leted> the filter ,ress is no9 read$ to dum,= The $ello9 light on to, of the DMP control ,anel 9ill illuminate to alert the o,erator= Preco't NoteA It is e@tremel$ im,ortant that the filter ,ress cloths are ,recoated ,ro,erl$ to a0oid 5linding of the cloths= The ,recoat tank should ha0e 5een made u, ,re0iousl$ ,er make u, instructions= 'hould all of the sludge 5e remo0ed from the 5atch tank and the filter ,ress is not full> the lo9 le0el control 9ill 5e deacti0ated> and the ,ress 9ill enter a rec$cle mode> 9ith the filtrate 9ater returning to the ,recoat tank= This is to maintain ,ressure inside the ,ress to make certain that the ,recoat does not release from the cloths and allo9 the ,recoat and sludge to sli, to the 5ottom of the filter cake cham5er> e@,osing the cloths to contamination and 5linding= "hen the ne@t treatment ,rocess is com,lete> the ,ress 9ill continue on in the stage 9here it left off 5efore recirculation= If the filter ,ress fills> and there is still sludge a0aila5le to 5e ,rocessed> the ,recoat tank must 5e made u, again ,rior to starting filter ,ress to ,rocess another load= "hen all the sludge has 5een remo0ed from the treatment tank> the tank em,t$ le0el 9ill 5e deacti0ated and the GTreatment Com,leteG dis,la$ed on the screen 9ill turn off= This is an indication that another 5atch ma$ 5e transferred to the 5atch tank for ,rocessing=

10

S(u*2e De9'ter-n2 Notes

The filter ,ress c$cle 9ill start onl$ 9hen the GTreatment Com,leteG for the a,,ro,riate tank is dis,la$ed on the status screen= It is ,ossi5le to turn the filter ,ress on during a treatment c$cle= If this is done> B/ '2#/ to ha0e the filter ,ress C7E'/D 9ith the h$draulics= This is not recommended unless the o,erator includes this as a standard ,rocedure along 9ith ,ro,er filter ,ress ,re,aration= #efer to the filter ,ress section of this manual for ti,s on cleaning and ,erformance=

11

Neutr'(->'t-on Tre't6ent Mo*u(e E=u-56ent

The neutralization module includes the follo9ing com,onentsA = #eactor tank 2= Mi@er= 1= 7e0els= 4= ,- control 9ith sensor= 5= Chemical feed deli0er$ s$stem for addition of acid and caustic= Instrumentation and chemical feed control e*ui,ment su,,lied for neutralization treatment modules are used to ad?ust the ,- of the 9aste9ater= The ,- ranges are esta5lished to insure o,timum conditions during the dionization stage= Anal$sis is ,erformed 5$ 0erif$ing the ,- in the reactor 9ith an outside cali5rated ,- meter=

5H Contro(
The ,- control ,rocess has t9o set ,oints that control the reagent feed ,um,s to ad?ust the ,- of the 9aste stream as re*uired= -igh 'et ,oint 7o9 'et ,oint H H Adds Acid to Lower ,Adds Caustic to Raise ,-

7ogic using the in,ut from the ,- ,ro5e com,ares the ,- reading from the o,erator entered set ,oints= "hen the ,- reading is greater than the -i 'et ,oint> the logic in the P7C 9ill acti0ate the air solenoid for the Acid ,um,> and the automatic 0al0e on the discharge side of the ,um,> to add Acid to the neutralizer tank= Acid 9ill continue to feed until the ,- reading is less than the -igh set ,oint= "hen the ,- reading is less than the 7o9 set ,oint> caustic 9ill feed until the ,- reading is greater than the 7o9 'et ,oint=

12

W'ter Rec&c(e ;DI A?%< S&ste6

Dilute rinse 9ater is transferred into TH %/mergenc$ -olding 3 (lo9 /*ualization Tank&= There is also a ta, 9ater feed line if 9ater or dilution is necessar$= Process 9ater is fed through the neutralizer> high micron filters> car5on> lo9 micron filters> cation resin and anion resin= The end result is DI 9ater that is used for regeneration and for the ,rocess= After a certain amount of flo9 the resins 9ill e@haust and 9ill not 5e ca,a5le of ,roducing DI 9ater= At this ,oint regeneration is needed to 5ring the resins 5ack to o,erating condition= The time 5et9een resin e@haustions 9ill de,end on the flo9 rate and *ualit$ %conducti0it$& of the incoming ta, 9ater= -igh micron filters Dual filters are ,ro0ided to catch an$ fine ,articles that ma$ ,ass through the neutralization s$stem= Ene filter is run at a time= "hen a filter 5ecomes dirt$ the stand5$ filter should 5e o,ened and the dirt$ filter should 5e re,laced= This 9ill ensure constant o,eration= The filters are manuall$ controlled 9ith 0al0ing= T$,icall$ a 2!,si or greater change in ,ressure 9ould call for changing the filter= Car5on (ilters AJB Process 9ater ,asses through car5on to remo0e an$ solids and detergents= /ither one or 5oth filters can 5e running= 'election 9ill de,end on the o,erating conditions= The filters should 5e ,eriodicall$ 5ack9ashed= It is recommended the car5on 5e re,laced e0er$ ) months or 9hen a test of the 9ater discharge sho9s suds 9hen shaken %noting detergents ,assing through the car5on&= Back9ash "hen a filter re*uires 5ack9ash DI 9ater 9ill run u, through the filter to 5e 5ack9ashed= This 9ill remo0e an$ de5ris at or near the to, of the filter= All 5ack9ash 9ater 9ill 5e treated in the Batch '$stem= Back9ash is determined 5$ runtime or ,ressure increase= E0er time the o,erator 9ill esta5lish a 5ack9ash schedule= Note the DI s$stem 9ill not o,erate during the 5ack9ash ,eriod= 7o9 micron filters Dual filters are ,ro0ided to catch an$ fine ,articles that ma$ ,ass through the car5on s$stem= Ene filter is run at a time= "hen a filter 5ecomes dirt$ the

13 stand5$ filter should 5e o,ened and the dirt$ filter should 5e re,laced= This 9ill ensure constant o,eration= The filters are manuall$ controlled 9ith 0al0ing= T$,icall$ a 2!,si or greater change in ,ressure 9ould call for changing the filter= Cation 3 Anion AJB #esin Columns "ater is de ionized 5$ running through resin that remo0es the ,ositi0e and negati0e ions= The ,ath of the 9ater takes it through a Cation resin then an Anion resin= "ater lea0ing the Anion resin 9ill 5e the final ,roduct= As ions are remo0ed the resin 5ecomes less ca,a5le of remo0ing more ions= At some ,oint the resin 9ill not 5e ca,a5le of remo0ing an$ ions and the outgoing 9ater *ualit$ 9ill dro,= Ence this ha,,ens the resin needs to 5e regenerated 9here the ions are remo0ed from the resin> 9hich 5rings the resin 5ack to a usea5le state= T9o sets of columns are ,ro0ided so that one set can al9a$s 5e o,erating 9hile the other set is in regeneration or in stand5$= #egeneration #egeneration is the cleaning ,rocess for the resin= Chemicals are added to the columns and are allo9ed to sit %contact time& on the resin for a ,eriod of time= The chemicals are then rinsed out of the columns= This ,rocess releases the ions from the resin= The solution that is rinsed out of the columns is concentrated %containing the chemical and the ions& and 9ill 5e treated in the Batch '$stem= -$drochloric Acid is added to the Cation resin and Caustic 'oda is added to the Anion resin for regeneration= The ste,s for regeneration are as follo9s Acid Dra9 Note the st acid dra9 9ill start 5$ running 9ater onl$ to the column to agitate the resin for acid addition=
st st

Acid 'oak

2nd Acid Dra9 2nd Acid 'oak Cation #inse Caustic Dra9 Note the st caustic dra9 9ill start 5$ running 9ater onl$ to the column to agitate the resin for caustic addition=
st

14
st

Caustic 'oak

2nd Caustic Dra9 2nd Caustic 'oak Anion #inse 3 'ettle /ach ste, 9ill ha0e a timed set ,oint= Ence set the times generall$ do not need to 5e changed= A ste, can 5e ski,,ed 5$ ,utting zero as a set ,oint= It is im,ortant that the o,erator understands the ,rocess and 0erifies that chemicals 9ere dra9n into the s$stem during regeneration= Periodicall$ the o,erator should check the s,ecific gra0it$ of the chemistr$ mi@ture to make sure it is 9ithin an e@,ected range= 'et ,oints and s,ecific gra0it$<s 9ill 5e determined at start u,= Determining #egeneration The *uantit$ and t$,e of resin ,ro0ides a certain amount of ion holding ca,acit$> 9hich is referred to as the Brams ca,acit$= Ence this ca,acit$ is reached the resin 9ill no longer 5e a5le to remo0e ions and ,roduce DI 9ater= "e can determine ho9 man$ grams are 5eing used 5$ tracking the incoming conducti0it$ and outgoing flo9 rate= As these num5ers increase more grams are 5eing used u,= Ideall$ 9e 9ant to make the grams set ,oint a little lo9er than the calculated num5er so the resin ne0er com,letel$ e@hausts= #egeneration can also 5e determined using other set ,oints such as total flo9 through the resin> outgoing conducti0it$> runtime or ,-= An$ of the triggers can 5e disa5led if $ou do not 9ant to use them= /ach of the a5o0e triggers can 5e set on the o,erator interface= Ideall$ the grams set ,oint 9ill 5e used and the other set ,oints 9ill 5e set as 5acku, in case something a5normal ha,,ens= 'tarting #egeneration It is u, to the o,erator to 5egin regeneration= Before starting regeneration $ou should 0erif$ there is enough chemistr$ a0aila5le and 9alk through the s$stem to 0erif$ manual 0al0e ,ositions= 2nder normal o,eration one of the regeneration triggers %such as grams& 9ill signal that regeneration is re*uired for a column= "hen this ha,,ens the other set of columns 9ill go onine %assuming the$ are in stand5$&=

15 Press the #egen 'tart 5utton to 5egin a regeneration se*uence= Ence the regeneration is com,lete the columns 9ill go into stand5$ mode 9hich means the$ are read$ to run= Manual Mode #egeneration #egeneration can also 5e started at an$ time 5$ ,lacing the column into #egen mode= This is 5asicall$ a manual regeneration start= Ence the regeneration has started $ou must ,lace the column 5ack into Auto if $ou 9ant the s$stem to o,erate normall$= If $ou kee, the s9itch in #egen the columns 9ill turn Eff once the regeneration is com,lete= #egen #eset If a column is in regeneration $ou can ,ress the #egen #eset 5utton to com,lete the regeneration= The column 9ill go into stand5$ mode and think that the resin has 5een regenerated so onl$ use this feature if it is necessar$= #egen Trigger #eset Pressing this 9ill zero out grams used> gallons used and runtime for that s,ecific column= Eut,ut Di0ersion Control DI 9ater 9ill 5e di0erted if the out,ut conducti0it$ is a5o0e the set ,oint or if the out,ut ,- is 5elo9 the set ,oint= After regeneration there ma$ 5e a ,eriod of high out,ut conducti0it$ as some of the regeneration chemistr$ ma$ not ha0e 5een com,letel$ rinsed out= If the outlet conducti0it$ is a5o0e the set ,oint or outlet ,- is 5elo9 the set ,oint 9ater 9ill 5e di0erted to the 7ift 'tation until the reading is 9ithin range=

16

DI Stor'2e T'n,
The DI storage tank holds DI 9ater to 5e used throughout the facilit$ and for regeneration= Pum,s DITPHA 3 B 9ill circulate the 9ater 5ack to the tank and ,ro0ide ,ressurization to the DI feed ,i,es for DI 9ater usage= "ater 5eing circulated is run through a 2L lam, to kee, the 9ater clean= Pum,s DITPHA 3 B 9ill not run if the tank is at a lo9 le0el=

17

C.e6-c'( Fee* S&ste6

Chemical feed ,um,s are utilized to deli0er reagent chemicals from the chemical feed tanks to the treatment tanks in the DMP '$stem= All chemical feed ,um,s o,erate on demand from the control center= Acid and Alkali ,um,s recei0e their signal from the DMP Control Center 5ased on in,ut from the ,- instrument s$stems= ChemH and (locculant ,um,s o,erate 5ased on feed rates in,ut from the o,erator at the interface= Determining the Pum, 'ettingsA Benerall$> a 9ide degree of feed control is a0aila5le 5$ 0ar$ing the ,arameters of reagent concentration> andJor ,um,ing rate= "ith the DMP Pum, Counter '$stem the ad?ustment of the ,um,ing rate is easil$ and accuratel$ made from the o,erator interface= The o,erator sets the ,- set ,oints 5ased on information the$ get from ?ar tests the$ ha0e ,erformed and from e@,erience the$ ha0e gained o,erating the DMP "aste9ater '$stem= The feed rates for chem%s& and floc are set 5$ the o,erator through the interface= The o,erator decides the feed rate for those ,um,s 5ased on information the$ get from ,erforming ?ar tests and e@,erience the$ gain from o,erating the DMP "aste9ater '$stem= 'tronger reagents at slo9er ,um,ing rates reduce reagent refill fre*uenc$= -o9e0er> care must 5e taken 9hen mi@ing stronger reagents= If the reagent is too strong damage to the s$stem could result= If the stronger reagent is ,um,ed too fast the correction ma$ 5e too large and cause the sensing meters to o0ershoot and start an o,,osite correction= This is 9asteful= Treatment tank mi@ers should 5e running at all times 9hile the DMP '$stem is running= This 9ill insure that the reagents are thoroughl$ mi@ed 9ith the 9aste9ater= If $ou desire to change the reagent concentration ,lease call DMP Technical 'u,,ort=

18

Re'2ents Use* -n W'ste W'ter Tre't6ent

It is 0er$ im,ortant for the o,erator to 5ecome familiar 9ith the material safet$ data sheets for all the reagents 5eing used= Most of them are strong and hazardous= 8no9ing 9hat to do for accidental contact and acting *uickl$ 9ill minimize ,ossi5le serious damage and in?ur$= Be sure to use ,rotecti0e clothing and face shields 9hen 9orking 9ith strong chemicals= A 6o6ent (on2er to 7e s'3e 6'& 5re)ent ' (-3et-6e o3 cost(& re2ret+ Chemicals are corrosi0e to e*ui,ment= Chemical s,ills should 5e cleaned u, and the area of the s,ill flushed 9ith 9ater immediatel$= /@,erience further sho9s us that ,urchasing de,artments often 5u$ reagent materials in ,ackages or grades that cost more than necessar$= Eur reagent outline discusses standard ,ackages and ,urities necessar$ for 9aste9ater treatment= A 5rief re0ie9 of man$ of the reagents used in "aste "ater Treatment= Not all of the reagents listed 5elo9 are necessar$ for $our s$stem %refer to startu, list of chemicals&= Acid> 'ulfuric 'ulfuric acid is a 0er$ hea0$> oil$ li*uid> 9hich is corrosi0e to all ,arts of the 5od$= It is usuall$ a0aila5le in 5 gallon car5o$s> 55 gallon drums> and 5ulk size= 'ulfuric acid is a0aila5le in se0eral commercial ,urities= "aste9ater treatment onl$ re*uires a technical grade= 'ulfuric acid is used to lo9er ,- in 9aste treatment a,,lications= Caustic 'oda %'odium -$dro@ide& Caustic soda is a 0er$ strong alkali> 9hich is 0er$ corrosi0e to all ,arts of the 5od$= It is usuall$ a0aila5le in 4!! ,ound or 5!! ,ound drums as 5eads or flakes or as 5!M li*uid= The dr$ form is eas$ to handle as 5eads or flakes= 'e0eral grades or ,urities are a0aila5le= "aste9ater treatment again onl$ re*uires a technical commercial grade= 7arger users of caustic soda fre*uentl$ 5u$ a li*uid form called 5!M li*uid= The dense li*uid contains a5out )=4 ,ounds in each gallon= %A 55 gallon drum 9eighs 4!! ,ounds and contains a5out 15! ,ounds of caustic&= 7i*uid caustic freezes at )2 degrees (ahrenheit=

19 Diatomaceous /arth A form of h$drated silica> also called fossil silica and infusorial earth= 2sed in 9aste treatment as a ,recoat or 5od$ feed for the filter ,ress= (erric Chloride 42 degrees BaumeD (erric Chloride is a 0er$ corrosi0e acidic material> 9hich is sold in the li*uid form= Care should 5e taken to clean u, s,ills and flush them 9ith 9ater= "aste9ater onl$ re*uires a commercial or technical grade= The standard strength usuall$ a0aila5le is 42N> 9hich contains a,,ro@imatel$ 4=) l5= of ferric chloride in a gallon= Ether strengths are a0aila5le 9ith less (erric Chloride in a gallon %1+ degrees O 4=! l5=P 2) degrees O 2=4 ,ounds&= It is used as a treatment chemical= -$drochloric Acid %Muriatic Acid& This is a 0er$ corrosi0e fuming li*uid> strong irritant to e$es and skin> use ,rotecti0e clothing> face shield and mask 9hen handling acids= Pol$mer %Pol$electrol$te Coagulant& Pol$mer is an organic chemical necessar$ in 9aste treatment= There are man$ grades and t$,es of ,ol$mer= It is a0aila5le in 5oth the li*uid form and the ,o9der form= The li*uid is eas$ to use= The ,o9der re*uires e@tra e*ui,ment and s,ecial skills for its use= Not all flocculants 9ork in 9aste9ater treatment= Ene of the 5est is a ,roduct a0aila5le from DMP called DMP 41H =

20

C.e6-c'( Re=u-re6ents
The follo9ing chemicals 9ill 5e used directl$ from drums or totes and are not diluted= Caustic 'oda %for treatment and DI regeneration& 5!M Concentration (iltered #a$on or 7o9 Chloride Brade 'ulfuric Acid 25M Concentration or less -$drochloric Acid %for DI regeneration& 12M "ater "hite or 7o9 Brade Iron (locculant != M Concentration Anionic Pol$mer ChemH (erric Chloride 15 Q 4!M> 42 degree Baume

21

Pre5'r't-on o3 H&*roc.(or-c ;Mur-'t-c< Ac-*

%Commercial Brade& USE FOR PH SENSOR AND FILTER PRESS CLOTH CLEANIN@

Re3er to MSDS 3or 6ore -n3or6't-on= = 2= 1= (ill container or tank 9ith re*uired amount of 9ater= 'lo9l$ add the re*uired amount of -$drochloric Acid= Mi@ solution thoroughl$=

W'rn-n2A (ailure to follo9 this ,rocedure could cause a 0iolent reaction= A(9'&s add acid to 9ater> ne)er 9ater to acid= 'olutions stronger than 2!M 0olume get 0er$ hot and 9ill ruin associated e*ui,ment= We'r 3'ce6's,, 2(o)es, 'n* 5rotect-)e c(ot.-n2+ A DILUTE -$drochloric Acid %-C7& solution is recommended for ,ro5e cleaning> filter ,ress cloth cleaning %9hen fouled 9ith metal h$dro@ide solids& and sand filter cleaning= #ecommended makeu, is !M H 2!M Acid 9ith 9ater=

22

Pre5'r't-on o3 Preco't
%Diatomaceous earth& Re3er to MSDS 3or 6ore -n3or6't-on+ = (ill reagent mi@ing tank 2J1 full of 9ater= 2= Turn on mi@er= 1= 'lo9l$ add the re*uired amount of ,recoat makeHu,= 4= Add 9ater to fill tank> 9ithin 1G of the to,= 5= 8ee, mi@er on at all times to kee, ,recoat material in solution until 9ater le0el is 5elo9 the mi@er= Do not allo9 mi@er to run 9ith solution 5elo9 ,ro,eller= This can damage the mi@er=

We'r 3'ce6's,, 2(o)es, 'n* 5rotect-)e c(ot.-n2+ Normal concentration is != to !=1 ,ounds ,er s*uare foot of filter surface area= C'(cu('t-onA H Measure length of one cloth in feet 2 H '*uare result of % & %s*uare feet of one cloth& 1 H Multi,l$ %2& 5$ num5er of cloth surfaces on ,ress %s*uare feet of ,ress& 4 H Multi,l$ %1& 5$ != 5 H Multi,l$ %1& 5$ !=1 ) H #esults of %4& and %5& is $our recommended range of material to use Example %cloth is 2=4 feet long and there are 54 cloth surfaces& H 2=4 feet is the length of each cloth 2 H 2=4 s*uared O 5=.4 s*uare feet J cloth 1 H 5=.4 s*uare feet J cloth R 54 cloth surfaces O 1 5 s*uare feet total 4 H 1 5 s*uare feet R != l5= O 1 =5 l5= 5 H 1 5 s*uare feet R !=1 l5= O +4=5 l5= ) H #ecommended amount of ,recoat is 5et9een 1 =5 and +4=5 ,ounds A good starting ,oint 9ould 5e to meet 5et9een the 0alues and use around )! ,ounds= NoteA All reagent mi@ing ratios are a0erage concentrations= The$ ma$ 5e ad?usted as conditions re*uire or ,ermit

23

T.e F-(ter Press

Intro*uct-on The sludge de9atering e*ui,ment su,,lied 5$ DMP is a recessed> gasketed> ,lateHt$,e ,ressure filter ,ress= The sludge is transferred from the clarifier or sludge thickening tank to the filter ,ress 5$ means of an air o,erated dia,hragm ,um,= During the startu, c$cle of the sludge de9atering ,rocess the ,um, 9ill c$cle *uickl$ until the filter cham5ers start to fill= As the c$cle ,rogresses> the solids 5uild u, in the filter cham5er and the ,um, c$cle slo9s do9n= Increased ,ressure is re*uired to ,ass the 9ater through the filter cake= The sludge de9atering c$cle 0aries 5ased on the t$,e of sludge 5eing generated= A0erage filter ,ress c$cle is a,,ro@imatel$ 4H. hours= To remo0e the cake from the filter ,lates sim,l$ o,en the filter and allo9 the filter cake to dro, out= If the sludge cake does not dro, out> use the s,atula ,ro0ided to dislodge the cake or to scra,e off the filter cloths=

24

T.e DMP Press M'n'2er

De9atering ,reci,itated 9aste is accom,lished 9ith a filter ,ress= The de9atering characteristics of the ,reci,itate can 0ar$ de,ending on changes to the com,osition of the 9aste treated= The DMP Press Manager is a ,rocess that reacts to the 0aria5le characteristics of the ,reci,itate and fills the ,ress in the shortest ,ossi5le time= This is accom,lished 5$ integrating feed ,ressure> feed flo9 rate> and feed 0olume= (eed ,ressure is ad?usted to maintain the ma@imum feed 0olume= The ,ress fills uniforml$ and de9atering is ma@imized 5$ ,re0enting ,remature ,late surface 5linding that causes soft cakes= The result is the a5ilit$ to consistentl$ ,roduce the highest filter cake solids ,ossi5le in the shortest time= Total de9atering time is reduced= The 9aste9ater treatment o,erator is full$ informed a5out the condition of the de9atering ,rocess= DMP Press Manager also detects dirt$ filter cloths> ,lugged filter ,ress feed lines> hast$ or ,oor settling> or a condition kno9n as channeling or rat hole= All functions of the ,ress manager reside in the control center= DMPDs /lectronic 'er0ice Call E,tion %T/C- 7ink& allo9s a DMP 'er0ice Center e@,ert to anal$ze the ,ress and sludge condition if necessar$ to hel, the o,erator= O5er't-on o3 t.e DMP Press M'n'2er The o,eration and set u, for the ,ress manager is accessed from the -MI= To locate the e*ui,ment select the main menu or s$stem o,erations ,age and select the filter ,ress o,tion= (rom the filter ,ress screen the control o,tions are to turn the filter ,ress on or off and ad?ust the o,eration ,arameters for the filter ,ress feed= O5er't-on P'r'6eters The controls for the ,ress manager can 5e ad?usted to suit $our a,,lication= This 9ould de,end on $our s$stem o,eration= Precoat 'tage (irst loading ste, is set to a s,ecific time and ,ressure= T$,icall$ the settings are for 5 to 2! minutes at 15 to 4! ,si= This 9ould a,,l$ for s$stems 9ith a ,recoat ste, and to s$stems 9ithout a ,recoat= The first ste, 9ould 5e the same in either s$stem=

25 'ludge 'tage The ne@t ste, is to look for a certain ,um,ing rate ,er minute= If that ,um,ing rate is not achie0ed then increase the c$cle 5$ a certain ,ercent or ,ressure= This ste, 9ill continue until the filter ,ress is full= Example Pum, should ha0e at least 5 c$cles ,er minute= If so> then kee, the ,ressure the same= If not> increase the ,ressure 5$ 5 ,si= Press at Pressure %PAP& 'tage The last setting is for determining 9hen the ,ress is full= The DMP Controller is looking for 9hen the ,ress ,um, has more than one c$cle in a gi0en ,eriod of time= If the c$cle rate is less than the ,reset amount> the ,ress is full= Example Pum, should c$cle more than once in 1! seconds= If so> then kee, running= If not> then the fill c$cle is com,lete= If the ,ress fill c$cle is com,lete then air 5lo9 do9n 5egins= Air Blo9do9n Air is 5lo9n through the ,ress and ,i,ing for a ,eriod of time %t$,icall$ !H2! minutes& at a lo9 ,ressure %t$,icall$ 4! ,si&= Ence 5lo9do9n is com,leted the ,ress c$cle is done and read$ to o,en= DMP Contro( Center -s '7(e to *eter6-ne 5ro7(e6s 9-t. t.e (o'*-n2 c&c(e & F-(ter Press (ilter Press "arning A Too much 0olume ,um,ed to the filter ,ress during the initial loading stage= Possi5le causes can includeA - Clogged suction line - 'er0ice 0al0e%s& or ,neumatic 0al0e%s& closed on the suction line to the ,um, - Bottom 5alls on the filter ,ress ,um, ha0e de5ris in them (ilter Press "arning 2A Not enough 0olume ,um,ed to the filter ,ress during the initial loading stage= Possi5le causes can includeA - Not enough air to the ,um, - Pum, counter on ,ress ,um, not 9orking

26 Clogged discharge line 'er0ice 0al0e%s& or ,neumatic 0al0e%s& closed on the discharge line of the ,um, or filter ,ress (ilter cloths are fouled

(ilter Press "arning 1A The ,ressure on the DMP Press Manager is not changing ,ressure during the loading c$cle fast enough= Possi5le causes can includeA - The 5all checks in the 5ottom of the ,um, ha0e de5ris in them - 'ludge has Grat holedG and is onl$ ,ulling 9ater - There is little or no sludge to ,um, (ilter Press "arning 4A The loading ste,s are changing to fast= Possi5le causes can includeA - 'ludge densit$ has increased %not necessaril$ 5ad& - Poorl$ treated sludge - Pum, counter on ,ress ,um, not 9orking - Cloths are 5linded or fouled - Press is full %not em,tied last c$cle& Note: T.e 9'rn-n2s 9-(( not sto5 t.e o5er't-on o3 t.e 3-(ter 5ress+ It -s 5oss-7(e to .')e 6u(t-5(e 9'rn-n2 con*-t-ons eB-st 't t.e s'6e t-6e+ @ener'( M'-nten'nce The DMP Press Manager uses Gdr$ airG 9hich is generated at DMP Main Panel= The e*ui,ment used is a filter regulator set to !! ,si= (rom the filter regulator it through a !=! micron coalescing filter 9ith a ,ressure differential indicator= The filter for the coalescing filter should 5e changed once e0er$ si@ months or 9hene0er the indicator 5egins to sho9= After coalescing the air goes through a no maintenance mem5rane dr$er to finish ,re,aring the air for the DMP Press Manager Controller= NoteA If the s$stem is o,erated 9ithout the coalescing filter in ,lace the 9arrant$ is LEID on the dr$er and the DMP Press Manager Lal0e= Both units 9ould ha0e to 5e re,laced= The onl$ other maintenance is to kee, a +! 9eight non detergent oil in the oiler for the filter ,ress ,um,= NoteA 'et oiler to deli0er one dro, e0er$ t9o to four minutes of filter ,ress ,um, o,eration=

27

Wet F-(ter C',es

Pro7(e6 The filter ,ress feed ,um, stalls out and the air 5lo9 do9n c$cle is com,leted= -o9e0er> 9hen the filter ,ress is o,ened> the cake is solid near the cloth 5ut 9ater$ near the center of the cake> or the contents are 0er$ soft or Gsou,$G= (iltration> as a,,lied in a 9aste treatment s$stem is the ,rocess of remo0ing the solids from a ,reconditioned sludge slurr$= The li*uid ,asses through the filter cloths tra,,ing the solids and forming the sludge cake= "ith less li*uid content in the filter cake> the hauling and dis,osal costs 9ill 5e lo9er= C'uses There are se0eral things that can contri5ute to a 9et or sou,$ filter cake= The most fre*uent causes are as follo9s= = Im,ro,erl$ conditioned sludge due to im,ro,er treatment= It is im,ortant that the solution 5e ,ro,erl$ treated 9ith all the necessar$ chemicals added as re*uired> to ,roduce an easil$ de9atered sludge= #educing chemicals too much has 5een found to 5e a ma?or cause of im,ro,erl$ conditioned sludge= 2= The initial ,um, ,ressure is too high= The sludge is fed to the ,ress to fast= This can cause ,articles to form tightl$ on the filter cloth that can cause 5linding out in the ,ores in the cloth= The filter ,ress ,um, should 5e started out slo9l$ to allo9 the cake to start to form slo9l$> and then the ,ressure is increased at s,ecific inter0als= 1= 7ast stage air control 0al0e im,ro,erl$ set %4 stage ,ress onl$&= #eset 0al0e ,er instructions in manual= 4= Pressure s9itch ,ressure set too lo9> or ,ress at ,ressure time set too lo9= #eset or change time as re*uired= 5= Eil in sludge forming an im,ermea5le la$er= Call DMP=

28

)= Im,ro,er ,recoat of filter cloths %9hen e*ui,,ed&= The ,recoat is designed to act as the filter media instead of the actual filter cloths= The ,recoat is ,um,ed into the filter ,ress and coats the filter cloth= The ,recoat stage is ,erformed 5efore the sludge slurr$ is ,um,ed to the ,ress= Insure that the ,recoat filter media is of sufficient concentration to coat the filter cloths com,letel$= The dosage ma$ 0ar$ from = to =1 l5sJft 2 5ased on re*uirements= %'ee the make u, of ,recoat section of this manual& Note: (lo9 must not 5e interru,ted during the changeo0er from ,recoat c$cle to sludge c$cle= This 9ill ,re0ent the ,recoat from falling off the filter cloth= Al9a$s tr$ to a0oid a ,ressure dro, across the cloths until a self su,,orting cake thickness can 5e 5uilt u,=

29

C(ot. W's.-n2
(ilter cloths ,ro0ided 9ith the filter ,ress ha0e 5een selected s,ecificall$ for the use of de9atering metal h$dro@ide sludgeDs= Care and maintenance of the filter cloths is a 0er$ im,ortant factor influencing the ,erformance of the filter ,ress= To eliminate the ,ossi5ilit$ of damaging the filter cloth> the nona5rasi0e n$lon ,addle furnished 9ith the ,ress should 5e used to remo0e an$ cake that has not fallen free= "hen o,erating a filter ,ress> the filter cloth is the initial 5arrier that se,arates solids from li*uidP therefore> the filter cloth must remain ,orous to ,ro0ide high filtration rates= During normal o,eration the filter cloth graduall$ 5ecomes fouled 9ith solids from the sludge 5eing filtered= This is a normal occurrence= These solids ma$ ,lug the ,ores in the filter cloth directl$ or indirectl$= Indirect ,lugging occurs 9hen the solids ,enetrate the t9isted fi5ers that make u, the filter cloth and increase their diameter= #egardless of the method> cloth ,lugging is a normal occurrence of all filtration= The material that ,lugs the filter cloth must 5e remo0ed ,eriodicall$ to maintain satisfactor$ filter o,erations= 'atisfactor$ o,eration ,ro0ides high filtration rates and drier filter cakes= C(e'n-n2 t.e C(ot.s The o,timum 9ashing c$cle for each filter must 5e determined 5$ o,erational e@,erience gained in the s,ecific filter ,ress a,,lication= (ilter cloth 9ashing is re*uired 9hen one of the follo9ing factors indicate ,lugging has occurred to an e@tent that 9ill interfere 9ith satisfactor$ ,rocess results= = Initial high filtration ,ressure= 2= Increased filtration c$cles= 1= #educed ,ercent solids content of cake= There are t9o ,rimar$ effecti0e methods of cleaning the filter cloths= = Pressure 9ashing H Ink> starch 3 late@= 2= Acid 9ashing H Metal h$dro@ides= Ether effecti0e methods includeA - Detergent 9ashing H Eil 3 grease= - Bleach H /@cess ,ol$mer=

30

Pressure W's.-n2
Certain sludgeDs such as starch> ink 3 late@ 9aste> are not effecti0el$ cleaned using acid> and must 5e ,ressure 9ashed onl$= DMP suggests that a ,ressure 9asher of 25!! P'I ca,a5ilit$ is used 9ith cold 9ater=

Ac-* W's.-n2
Acid 9ashing has ,ro0en most effecti0e in the cleaning of filter cloths ,lugged 9ith metal h$dro@ide solids= Acid 9ashing is recommended in cases 9here filter cloth is ,lugged e@tensi0el$= There are t9o methods of acid cleaning= Both methods must 5e conducted 9ith great care utilizing all of the ,recautions re*uired in the handling of acids including the use of safet$ e*ui,ment and clothing= Method I This method re*uires a corrosi0e resistant tank of sufficient ca,acit$ to su5merge the entire filter ,late and large enough to hold the re*uired amount of ,lates to 5e ,rocessed at one time and diluted h$drochloric acid> also kno9n as muriatic acid= /@treme care must 5e taken 9hen handling the acid= Add the concentrated acid to 9ater to o5tain a 25M solution 5$ 0olume of the concentrated acid= Re6e67er '(9'&s '** 'c-* to 9'ter+ Lolume concentrated acid 1 Lolume 9ater Process: Clean filter cloths of all sludge cake 9ith nona5rasi0e n$lon scra,er ,ro0ided= Immerse entire ,late in diluted concentrated acid solution for t9o hours= #emo0e Plates and rinse thoroughl$= #einstall ,lates in filter frame in ,ro,er se*uence> H1H H1H H1 etc= Plates are identified 5$ the num5er of drilled dim,les in each ,late= -eadliner ,late 9ill ha0e to 5e cleaned in ,lace on the filter ,ress=

31 Method II This method re*uires additional o,tional e*ui,ment in order to 9ash the filter cloths in ,lace on the filter ,ress= Acid storage tank of sufficient ca,acit$ to fill ,ress and allo9 for recirculation= 7o9 ,ressure acid corrosion resistant ,um,= Plum5ing re*uired to isolate ,ress from stream and allo9 for recirculation and draining of acid solution=

Process: Clean all filter cloths of all sludge cake 9ith nona5rasi0e n$lon scra,,er ,ro0ided= Close filter ,ress= Isolate filter feed line from dia,hragm sludge feed ,um, 9ith 0al0e ,ro0ided= Close filtrate return discharge 0al0e= E,en acid recirculation line 5ack to acid storage tank= E,en acid feed line to filter ,ress= 'tart acid feed ,um,= It 9ill take considera5le time to fill all of the ca0ities of the ,ress 5efore acid 9ill return to storage tank= Continuall$ ins,ect filter ,ress for leakage during filling and recirculating= Allo9 ,um, to recirculate for t9o hours= Turn off acid feed ,um,= Close manifold 0al0es re*uired to ,urge acid solution 5ack to acid storage tank= E,en air ,urge line 0al0e to ,urge acid from filter ,ress= E,en filtrate drain line 0al0e to sum,= E,en feed line 0al0e to filter ,ress from dia,hragm sludge feed ,um,= (ilter ,ress is no9 read$ to 5e returned to ser0ice=

32

Deter2ent W's.-n2
Detergent 9ashing has ,ro0en most effecti0e in the cleaning of filter cloths ,lugged 9ith oils= Detergent 9ashing is recommended in cases 9here filter cloth is ,lugged e@tensi0el$= Method: This method re*uires additional o,tional e*ui,ment in order to 9ash the filter cloths in ,lace on the filter ,ress= 'torage tank of sufficient ca,acit$ to fill ,ress and allo9 for recirculation= 7o9 ,ressure corrosion resistant ,um,= Plum5ing re*uired to isolate ,ress from stream and allo9 for recirculation and draining of detergent solution=

Make up: The size of the cleaning tank has 5een determined according to the size of the filter ,ress installed= (ill tank to 2J1 le0el 9ith ta, 9ater= Add 5o@ of standard ,o9dered detergent and mi@=

Process: Clean all filter cloths of all sludge cake 9ith nona5rasi0e n$lon scra,,er ,ro0ided= Close filter ,ress= Isolate filter feed line from dia,hragm sludge feed ,um, 9ith 0al0e ,ro0ided= Close filtrate return discharge 0al0e= E,en detergent recirculation line 5ack to acid storage tank= E,en detergent feed line to filter ,ress= 'tart detergent feed ,um,= It 9ill take considera5le time to fill all of the ca0ities of the ,ress 5efore detergent 9ill return to storage tank= Continuall$ ins,ect filter ,ress for leakage during filling and recirculating= Allo9 ,um, to recirculate for t9o hours= Turn off detergent feed ,um,= Close manifold 0al0es re*uired to ,urge detergent solution 5ack to detergent storage tank= E,en air ,urge line 0al0e to ,urge detergent from filter ,ress= E,en filtrate drain line 0al0e to sum,= E,en feed line 0al0e to filter ,ress from dia,hragm sludge feed ,um,= (ilter ,ress is no9 read$ to 5e returned to ser0ice=

33

%(e'c. W's.-n2
Bleach 9ashing has ,ro0en most effecti0e in the cleaning of filter cloths ,lugged 9ith e@cess ,ol$mer fouling= Bleach 9ashing is recommended in cases 9here filter cloth is ,lugged e@tensi0el$= Method: This method re*uires additional o,tional e*ui,ment in order to 9ash the filter cloths in ,lace on the filter ,ress= 'torage tank of sufficient ca,acit$ to fill ,ress and allo9 for recirculation= 7o9 ,ressure corrosion resistant ,um,= Plum5ing re*uired to isolate ,ress from stream and allo9 for recirculation and draining of 5leach solution=

Make up: The size of the cleaning tank has 5een determined according to the size of the filter ,ress installed= (ill tank to 2J1 le0el 9ith ta, 9ater= Dilute J2 gallon of 5=25M 5leach %NaECl& ,er cu5ic feet of filter ,ress area= 2=5 gallons ! gallons

/@am,leA 5 cu ft filter ,ress O 2! cu ft filter ,ress O Process: -

Clean all filter cloths of all sludge cake 9ith nona5rasi0e n$lon scra,,er ,ro0ided= Close filter ,ress= Isolate filter feed line from dia,hragm sludge feed ,um, 9ith 0al0e ,ro0ided= Close filtrate return discharge 0al0e= E,en 5leach recirculation line 5ack to acid storage tank= E,en 5leach feed line to filter ,ress= 'tart 5leach feed ,um,= It 9ill take considera5le time to fill all of the ca0ities of the ,ress 5efore detergent 9ill return to storage tank= Continuall$ ins,ect filter ,ress for leakage during filling and recirculating= Allo9 ,um, to recirculate for t9o hours= Turn off 5leach feed ,um,= Close manifold 0al0es re*uired to ,urge 5leach solution 5ack to detergent storage tank= E,en air ,urge line 0al0e to ,urge 5leach from filter ,ress=

34 E,en filtrate drain line 0al0e to sum,= E,en feed line 0al0e to filter ,ress from dia,hragm sludge feed ,um,= (ilter ,ress is no9 read$ to 5e returned to ser0ice=

35

E)'5or't-on
"ater that is discharged from the filter ,ress cannot 5e retreated and used in the s$stem= This flo9 is run through an e0a,orator= "ater 9ill fill the (ilter Press (iltrate Tank= The 9ater is then ,um,ed into the e0a,orator 9hen called for= The ma?orit$ of the 9ater is e0a,orated 9hile a ,ortion is concentrated and hauled off= The e0a,orated 9ater is sent through a condenser and cooling s$stem= The ,roduct is distillate> 9hich is sent 5ack to the s$stem for treatment= #efer to the /0a,orator manual for o,eration instructions=

36

M'-n Contro( P'ne(

The main control ,anel is the GBrainsG of the 9aste treatment s$stem= It is designed to automaticall$ control the functions of the e*ui,ment su,,lied 9ith the treatment s$stem= To maintain the control ,anel ,ro,erl$> the o,erator must kno9 and understand all of the circuits and functions that 9ere designed into the s,ecific control ,anel= 'u,,lied 9ith the treatment s$stemA = 2= 1= 4= 5= Instruction manuals /*ui,ment manuals /lectrical schematics (lo9 schematics /*ui,ment la$out dra9ings

"ith this information the o,erator 9ill 5e a5le to understand the functions of the control ,anel and related e*ui,ment= The control ca5inet is e*ui,,ed 9ith man$ com,onents includingA motor starters> ,rogramma5le controller %P7C&> o,erator interface unit %-MI> MMI> EIP&> etc= The s$m5ols used for these com,onents can 5e located in the electrical schematic= 8no9ing and understanding ho9 the circuits o,erate is a 0alua5le aid in trou5leshooting= Contro( P'ne( Co65onents Transformer%s& 3 Po9er 'u,,lies T$,icall$ onl$ one ,o9er dro, is necessar$ to the control ,anel= The transformer%s& 9ill take that ,o9er and con0ert it to the necessar$ 0oltages= Programma5le 7ogic Controller %P7C& #ecei0es in,uts from different locations of the treatment s$stem and controls out,uts according to 9hate0er functions are necessar$ 5ased on the in,uts= E,erator Interface Panel %EIP& or -uman Machine Interface %-MI& The de0ice is mounted in the face of the control ca5inet= It is ho9 the o,erator controls and monitors the s$stem= This 9ould include and filter ,ress control> ,- and E#P readings> le0els in tank> status of ,um,s> 0al0es> mi@ers> filter ,ress stages> etc=> and other im,ortant information=

37 E0erload ,rotection 'e0eral t$,es of ,rotection are su,,lied in the control ,anel for safet$= = Main Disconnect Breaker a= Manual disconnect 5= Thermal o0erload 2= 7o9 Loltage a= Indi0idual circuit ,rotection is su,,lied 5$ circuit o0erload fuses= 1= -igh Loltage %1 ,hase motors& a= Indi0idual motor starters 5= Thermal o0erload ,rotection Terminal connections 3 field 9iring All field 9iring is num5ered according to the electrical schematic> and connected to the terminal stri,s located in side the control ,anel= 'olenoids /lectric acti0ated air solenoids for controlling air ,um,s> 0al0es> etc=> are located inside the control ,anel or at certain field ,oints for ,um,s and 0al0es= #ela$s Are used 9hen a higher Am, dra9 is re*uired than a P7C unit can ,ro0ide= Dr$ Contact Pro0ided for customer use for ,um,sJ0al0es not in DMP '$stem= Chart #ecorders The recorders are a0aila5le for ,-> E#P> flo9 rate and other readings= The$ sim,l$ record the signal on ,a,er or screen of 9hat the ,ro5e reads= Alarms 3 Indicators An audi5le alarm 9ill sound during alarm conditions along 9ith a red alarm indicator=

38 A $ello9 indicator 9ill illuminate 9hen a filter ,ress c$cle is com,lete= (ilter Press Transducer If e*ui,,ed a transducer 9ill take an air su,,l$ and regulate it 0ia an electrical signal to the filter ,ress feed ,um,= An air dr$er is su,,lied to ,ro0ide high *ualit$ air= Air Conditioner An AJC unit is ,ro0ided u,on re*uest or on s$stems that re*uire lo9er o,erating tem,eratures=

39

E8Contro((er? !
The /HController is the ,rimar$ interface 5et9een the o,erator and the 9ater treatment s$stem= The main ,anel uses a gra,hic dis,la$ for information transfer= The e*ui,ment is generall$ referred to as the E,erator Interface Panel %EIP& or -uman Machine Interface %-MI& and consists of an industrial com,uter> soft9are and a screen= 7og In The /HControllerJ ! has a securit$ ,rogram 9hich allo9s multi,le o,erators each 9ith different ,ass9ords as 9ell as different securit$ le0els= The o,erator ,ass9ords can 5e changed 5$ the s$stem administrator= This 9ill allo9 ,ersonalized access for each o,erator or a grou, of o,erators= The ,rimar$ function of ha0ing different logins for each ,erson is due to the function called G/0ent TrackerG= The e0ent tracker monitors and records all e0entsP ,um,s that are turned on and off> 9hen alarms sounded> 9hen the alarm ackno9ledged> 9hen the alarm condition 9as satisfied ?ust to name a fe9= The information is tracked 5$ time and o,erator= Alarm 'tatus Alarm status tells the o,erator 9here and 9hat the ,ro5lem isP lo9 chem tank> loss of air ,ressure> high le0el in a tank> etc= Chemical Costing Chemical costing is a real time tracker of chemical cost 5ased on in,ut from the ,um, as to 9hat 0olumes of chemicals ha0e ,um,ed= Chemical (eed #ates Chemical feed rates are the 0olume of chemicals to 5e ,um,ed= The set ,oints are generall$ in gallons> gallons ,er minute> and gallons ,er hour> *uarts or *uarts ,er hour= Concentrate (eed #ates The interface 9ill allo9 the o,erator to feed a certain amount of s,ent concentrates %generall$ in gallons ,er hour&= The dis,la$ 9ill sho9 0olume ,um,ed and set flo9 rate= #inse (lo9 #ates The interface 9ill allo9 the o,erator to feed a certain amount of rinse 9aters %generall$ in gallons ,er minute&= The dis,la$ 9ill sho9 0olume ,um,ed and set flo9 rate= Trending 3 Data Collection Charts se0eral functions of the s$stem o0er a ,eriod of time= Data is sa0ed and can 5e ,ut into s,readsheet form for e0aluation and record kee,ing=

40 Pre0entati0e Maintenance E,erator can in,ut 0alues for s$stem to 9arn of u,coming maintenance on s$stem com,onents= IJE 'creen 9ill sho9 current status of in,uts and out,uts= This is a good tool for trou5leshooting= '$stem 'tatus Benerall$ colors are used to de,ict action= Breen H Action is occurring> ,um, running etc= #ed H Alarm condition

The e(ectr-c'( sc.e6't-c is the ,rimar$ source of information regarding the ,h$sical la$out= All of the 9iring> fuses and air lines are la5eled according to the electrical schematic= "hen trou5leshooting the s$stem ,lease ha0e the electrical schematic ,resent= The main ,anel usuall$ includes the follo9ing utilities Com,ressed air= #efer to the e*ui,ment la$out for s,ecific air re*uirement= Communication line re*uired for DMP Cor,oration to 5e a5le to contact the main ,anel= This is t$,icall$ a LPN or D'7 line= Note: If using a tele,hone line it needs to 5e either a direct dial u, or go through an automated s9itch5oard= The line should 5e suita5le for a fa@ machine to 9ork= Three ,hase ,o9er 9ith earth groundH,o9er source for larger mi@ers and 5lo9ers= 2! L H ,o9er source for P7C and controls 24LDC H ,o9er for in,uts and signal 9ire

Note: The main ,anel is t$,icall$ the onl$ ,o9er dro, to the s$stem= That ,o9er is transformed into other 0oltages=

41 O5er'tor Inter3'ce ;HMI or OIP< The o,erator is a5le to select control o,erations through a mouse or the touch screen= Note: Care should 5e taken 9hen using the touch screen= Do not use shar, o5?ects to touch the screen and 5e careful a5out dirt$ hands 9ith chemical on them 9hen using the touch screen= An$ o5?ect that high lights 9ith a 5o@ around it can 5e mani,ulated for action= This 9ould include ,um,s> 0al0es> set ,oints and other 0aria5les= The screen is connected to an industrial PC that runs the screen soft9are and communicates 9ith the P7C= Data collection files are stored in the PC= Pro2r'66'7(e Lo2-c Contro((er ;PLC< /m,lo$s o,erators< set ,oints and in,uts to automaticall$ react to treatment= The /HControllerJ ! controls all as,ects of the DMP s$stem= If a,,lica5le the 5atter$ needs re,lacement e0er$ 2 months=

42

CPU %ATTERC MAINTENANCE

The P7C Controller is designed to ,ro0ide trou5leHfree o,eration= -o9e0er> occasionall$ situations re*uiring correcti0e action do occur and it is im,ortant to 5e a5le to *uickl$ identif$ the source of such situations and correct them= Ene of the most common situations is the CME' memor$ 5ackHu, 5atter$= (ailure of the 5atter$ 5ackHu, can result in CME' memor$ loss in the e0ent of ,o9er failure= If the 5atter$ fails and ,o9er is lost re,rogramming of the CP2 ma$ 5e necessar$= The follo9ing ,re0entati0e maintenance measures are recommended= 'tock in the control ,anel a s,are lithium 5atter$ or locate in an area 9here it is readil$ a0aila5le= Maintain ,o9er on to the ,rogramma5le controller at all times % ! 0olts&= /sta5lish a dail$ ,re0entati0e maintenance check of the ,rogramma5le controller and insure against 5ackHu, 5atter$ loss= Co65'ct Lo2-B Is E8 light on: Is #2N light on: Is BATT %5atter$& light on: Is (7T %fault& light off:

An$ one of the conditions listed a5o0e can 5e cause for concern= If the 5atter$ light is on re,lace the 5atter$ at once= After re,lacing the 5atter$> e@amine the ,rogram or test the s$stem o,eration= If a fault is located contact DMP= Crisis Maintenance Ls= Pre0entati0e Maintenance Although all 5atteries are dated and manufacturers ha0e esta5lished shelf life times and o,eration times for their 5atteries> it is unkno9n ho9 man$ times the 5atter$ has 5een called for 5ackHu,= 'ince the$ are not rechargea5le the remaining life of the 5atter$ is not kno9n= DMP therefore recommendsA 8ee, ,o9er on unit at all times= #e,lace 5atter$ $earl$ 9hether needed or not= The 5atter$ re,lacement cost is minimal 9hen com,ared to re,rogramming cost and do9n time incurred=

43

%'tter& Re5('ce6ent
To re,lace the 5atter$ ,roceed as follo9s= Co65'ct Lo2-B - #e,lace 5atter$ 9ith ,o9er EN= - #emo0e 5atter$ door 5$ sliding it for9ard= - 2n,lug 5atter$ 9ire harness connector and remo0e 5atter$= - Plug in ne9 5atter$ connector and install ne9 5atter$= - Close 5atter$ door 5$ sliding it 5ack until it clicks into ,osition=

WARNING Observe the following precautions when handling a Lithium battery !o not discard the battery in fire !o not attempt to recharge the battery "he battery may burst or burn or release ha#ardous materials $A%"ION !o not attempt to remove the circuit board from its module housing &ailure to observe this caution may result in an electrostatic buildup and discharge resulting in damage to 'O( circuits !ischarge of the non) rechargeable Lithium battery may occur if the board contacts a conducting surface* causing loss of memory contents

44

A('r6s & W'rn-n2s

Alarm conditions are indicated audi5l$ and 0isuall$= There is a 5ell or horn at the main ,anel for the audi5le alarm and a red light on to, of the main ,anel for 0isual alarm= "hen there is an alarm condition 5oth audi5le and 0isual alarm 9ill acti0ate= The o,erator can ackno9ledge the alarm and that sto,s the audi5le from ringing> 5ut the red light 9ill remain on until the alarm condition is corrected= There is an audi5le reminder= If the alarm condition e@ists for se0eral minutes the alarm tone 9ill sound for se0eral seconds= The reminder 9ill continue until the alarm is corrected= "arnings are generall$ indicated 9ith a $ello9 indicator on the screen along 9ith a message= "arnings are meant to notif$ the o,erator of ,ossi5le ,ro5lems 9ith the s$stem= The s$stem 9ill not shut do9n 9ith a 9arning= NoteA Not '(( '('r6s or 9'rn-n2s 9-(( '55(& to &our s&ste6+ Loss o3 A-r "hen air su,,l$ to either the main control ,anel or main solenoid ,anel dro,s 5elo9 a ,reset ,ressure an alarm 9ill sound= T$,icall$ set to 4! ,si an ad?usta5le ,ressure s9itch in the ,anel 9ill cause the alarm= I65'ct on t.e s&ste6 %flo9& The main feed ,um,%s& 9ill shut do9n flo9 to the s$stem until a minimum air ,ressure is restored= Ence ,ro,er air ,ressure is restored the alarm 9ill cease= The main feed ,um,%s& 9ill return to normal o,eration= I65'ct on t.e s&ste6 %5atch& Treatment to the s$stem 9ill sto, until a minimum air ,ressure is restored= Ence ,ro,er air ,ressure is restored the alarm 9ill cease= Treatment 9ill return to normal o,eration= Lo9 Le)e( C.e6-c'( T'n, "hen one %or more than one& chemical tank 5ecomes lo9 the alarm 9ill sound= This ,re0ents the s$stem from treating 9ithout the ,ro,er amounts of chemicals= I65'ct on t.e s&ste6 %flo9& The main feed ,um,%s& 9ill shut do9n flo9 to the s$stem until the chemical tank%s& are filled to a5o0e the lo9 le0el= The main feed ,um,%s& 9ill return to normal o,eration= I65'ct on t.e s&ste6 %5atch& Treatment to the s$stem 9ill sto, until the chemical tank%s& are filled to a5o0e the lo9 le0el= Treatment 9ill return normal o,eration=

45 H-2. Le)e( C.e6-c'( T'n, "hen one %or more than one& chemical tank 5ecomes near an o0erflo9 le0el the alarm 9ill sound= I65'ct on t.e s&ste6 If there is an automatic 9ater or chemical fill the ,rocess 9ill cease so that the tank does not o0erflo9= If the tank is 5eing filled manuall$ the o,erator must shut off the source= H-2. Le)e( -n ' Ho(*-n2 T'n, "hen the le0el in a holding tank 5ecomes high the alarm 9ill sound= Action must 5e taken to a0oid a tank o0erflo9= The alarm is sho9n as either -igh 7e0el GTank NameG or -igh 7e0el GPum,%s& that remo0e 9ater from the tank= %/@am,leA -=7= /mergenc$ -olding Tank or -=7= P! A 3 P! B=& I65'ct on t.e s&ste6 The s$stem 9ill kee, running or filling %as long as there are no other shutdo9n alarms& to tr$ and lo9er the tank= If e*ui,,ed> ,um,s that feed the tank 9ill also shut do9n= No M-B-n2 If a mi@er 5reaker tri,s an o0erload signal 9ill tell the s$stem them mi@er is not running= M-stre't6ent If ,- andJor E#P readings 5ecome out of set ,oint range> reagents are added to ad?ust the s$stem= If the s$stem is not 5ack in range 9ithin three minutes the mistreatment alarm 9ill sound= I65'ct on t.e s&ste6 The main feed ,um,%s& 9ill shut do9n flo9 to the s$stem until the ,-JE#P is ad?usted 5ack into range= Ence the ,-JE#P is 5ack in range the alarm 9ill cease= The main feed ,um,%s& 9ill return to normal o,eration= H-2. Le)e( %'tc. T'n, If for an$ reason the full le0el in a 5atch tank fails the tank 9ill fill until it reaches high le0el= Ence in high le0el the alarm 9ill sound= I65'ct on t.e s&ste6 "hen in high le0el the feed 0al0e to the 5atch tank 9ill close along 9ith an$ other sources to the tank %as long as the 0al0es are in auto&= H-2. Pressure Me*-' F-(ters The media filters ha0e a high ,ressure set ,oint on the -MI= If ,ressure increases ,ast the set ,oint an alarm 9ill sound=

46 I65'ct on t.e s&ste6 The main feed ,um,%s& 9ill shut do9n flo9 to the s$stem= The sand filter feed tank 9ill drain 0ia sand filter feed ,um,%s& until a lo9 le0el= The ,um,%s& 9ill shut do9n= Ta, 9ater 9ill fill the tank until a start le0el is attained= The ,um,%s& 9ill turn on and 5ack9ash the sand filter %2 sand filters& or each sand filter %1 or more sand filters&= This generall$ 5rings the ,ressure do9n= If the ,ressure is still too high additional 5ack9ashing 9ill 5e necessar$= An acid cleaning ma$ 5e necessar$ if the high ,ressure still ,ersists %Call DMP if the filters ha0e gotten to the ,oint for further guidance&= H-2. Le)e( Me*-' F-(ter Fee* T'n, If the le0el in the media filter feed tank 5ecomes high the alarm 9ill sound= I65'ct on t.e s&ste6 The main feed ,um,%s& 9ill shut do9n flo9 to the s$stem so the media filter ,um,%s& ma$ lo9er the le0el in the feed tank= Ence the le0el is 5elo9 high range the main feed ,um,s 9ill return to normal o,eration= Loss o3 Pr-6e "hen a centrifugal ,um, 9ith a ,riming circuit did not ,rime= I65'ct on t.e s&ste6 The s$stem 9ill shut do9n until the ,rimar$ circuit is reset and restarted= Run'9'& Pu65 If a ,um, counts more strokes then ,rogrammed 5$ the o,erator the alarm 9ill sound= This alarm detects suction ,ro5lems or a 5reak in the discharge line= I65'ct on t.e s&ste6 Pum, 9ill shut do9n until alarm is ackno9ledged and restarted= Pu65 5roB& A('r6 Certain ,um,s are re*uired to achie0e an amount of strokes ,er minute= If the stroke count is not met the alarm on the screen= If the alarm is sho9n the o,erator should 0erif$ that the ,um, is running and the DMP ,um, counter is sending a signal to the control ,anel= Run'9'& Pu65 A('r6 Certain ,um,s c$cle on and off due to time and the re*uired amount of li*uid to 5e ,um,ed= If the ,um, strokes the re*uired amount too *uickl$ the alarm 9ill a,,ear on the screen and the ,um, 9ill shut do9n= This 9ill ,re0ent a large mess if a ,i,e has 5roken=

47 Pu65;s< On Too Lon2 W'rn-n2 If a chemical addition ,um, runs for a certain time 9ithout sto,,ing the 9arning 9ill a,,ear on the screen= This ma$ indicate a ,ro5lem 9ith a counter or ,ro5e=

48

A-r Pu65 Counter

ProB-6-t& S9-tc. Introduction The ,ro@imit$ s9itch is used to count the strokes of a ,ositi0e dis,lacement ,um,> such as the air dia,hragm ,um,s used on the chemical feed deli0er$ s$stem= The information from the s9itch is stored in the P7C 9here the con0ersion is made to dis,la$ the gallons ,er hour %BP-& or gallons ,er minute %BPM& for 5oth dis,la$ on the E,erator Interface> as 9ell as control of the ,um, 0ia setting the rate of ,um,ing from the E,erator Interface= !asic Procedure The ,ro@imit$ s9itch is located on the air 0al0e assem5l$ on the air dia,hragm ,um,= It can 5e found 5$ locating the incoming air su,,l$> and then looking for shrink tu5ing leading into the air 0al0e assem5l$= The ,ro@imit$ s9itch is installed 5$ threading into the ,lug of the air 0al0e assem5l$= It is additionall$ held in 5$ a dou5le nut against the ,lug= To ad?ust the s9itch ,roceed as follo9sA "ith the ,um, running 7oosen the dou5le nut on the threaded ,art of the s9itch= Turn the s9itch clock9ise until the light of the a,,ro,riate in,ut %use the electrical schematic& is illuminated 9ith e0er$ stroke of the ,um,= If the in,ut light is illuminated constantl$> turn the s9itch counterclock9ise until the in,ut light illuminates 9ith e0er$ stroke of the ,um,= Tighten the dou5le nuts to secure=

Pro,er ad?ustment is essential to insure chemical feed deli0er$ to the treatment s$stem= This ,rocedure should 5e ,art of $our ,re0entati0e maintenance schedule=

49

DMP 5H Sensors
Man$ treatment reactors use ,- sensors to control addition of chemicals= The sensors are one of he most critical ,ortions of the s$stem and must 5e in good o,erating condition at all times= The DMP ,- sensors are designed and look the same= Belo9 is a list of the com,onents= Pro5e 'taff This is the com,lete unit> 9hich consists of the electrical connection 5et9een the transmitter and fle@ ca5le> ,i,e of sufficient length to su5merse the unit in the tank> transmitter and electrode= The fle@ ca5le has a ,lug in connector> 9hich connects to a conduit 5o@ near the ,ro5e staff location= This allo9s for a *uick connectJdisconnect of the ,ro5e staff= The connection ma$ 5e hard 9ired on older s$stems or s$stems 9ith e@cessi0e corrosion= Transmitter This ,iece connects to the ,i,e on the ,ro5e staff= The electronics are housed in the unit and the ca5le for connection runs out of the to, into the ,i,e of the ,ro5e staff= /lectrode The electrode is the interface 5et9een the solution 5eing measured and the transmitter= Care must 5e taken 9ith the electrode face since it is relati0el$ thin glass and can 5reak= The electrode cannot 5e ser0iced outside of cleaning= T$,ical electrode life is ) months to 2 $ears 5ut is de,endant on the solution it is 5eing used in and the care it recei0es= /lectrical Connections There are a fe9 electrical connection ,oints on the sensor circuit= If the sensor is not functioning each connection should 5e checked= If a 9ire is loose> 5roken> touching another 9ire or corroded then it ma$ need to 5e re,aired= T$,ical connection ,oints are at the to, of the ,ro5e staff> on the male ,lug at the end of the fle@ ca5le %remo0e ru55er 5oot and ca,&> on the female end of the ,lug %inside the conduit 5o@& and in the main control ,anel= #efer to the electrical schematics for a detailed la$out= Trou5leshooting If a sensor is not reading correctl$ %9ithin one ,- unit& check the follo9ingA - Is ,ro5e staff ,lugged in: - Is electrode clean and cali5rated: - Is glass on electrode 5roken: %re,lace electrode& - Are all electrical connections E8: If all of the a5o0e check out then the transmitter ma$ need to 5e re,laced=

50

C(e'n-n2 5H E(ectro*es
Periodicall$ electrodes 9ill need to 5e cleaned= If a sensor is not reading 9ell> cali5rating or has e@cessi0e 5uildu, follo9 one of the ,rocedures 5elo9= /ach sensor should 5e checked at least once ,er da$ and cleaned or cali5rated if necessar$= Ac-* C(e'n-n2 %Most Common& Acid clean 9hen a 5uildu, of solids is noticed on the electrode or the sensor is not reading or cali5rating 9ell= H Pre,are a dilute -$drochloric %Muriatic& Acid solution 9ith 9ater % ! ,arts 9ater to ,art Acid&= H Place the sensor in the solution and let sit for 5 minutes= H #emo0e the electrode and rinse in 9ater= H #e,eat a5o0e ste,s if the electrode is not clean= H Cali5rate sensor 5efore ,lacing 5ack into ser0ice= H Use c'ut-on 9.en 9or,-n2 9-t. HCL

Deter2ent C(e'n-n2 Detergent clean 9hen a 5uildu, of oil or grease is noticed on the ti, of the electrode= H H H H H Pre,are a solution of detergent and 9ater %1 ,arts 9ater to detergent& Place the electrode in the solution and let sit for 5 minutes= #emo0e the electrode and rinse in 9ater= #e,eat a5o0e ste,s if the electrode is not clean= Cali5rate sensor 5efore ,lacing 5ack into ser0ice= ,art

H'n* C(e'n-n2 %Enl$ 9hen necessar$& -and clean electrode ti, 9hen acid or detergent cleaning does not 9ork= 2se onl$ a soft cloth to 9i,e 5uildu, off of the electrode= An$thing a5rasi0e could damage the electrode=

51

C'(-7r't-n2 5H Sensors
'ensors should 5e cali5rated 9hen the$ do not read correctl$= It is recommended to check each sensor dail$ in a kno9n solution and cali5rate if necessar$= (ollo9 the cali5ration directions on the DMP E,erator Interface to ,erform a cali5ration= Cou must use ,- 4 and ,- ! 5uffer solutions to cali5rate ,- sensors= The DMP s$stem is s,ecificall$ set u, for these 5uffers= (resh 5uffer solution should 5e used for e0er$ round of cali5ration as the solution 9ill get contaminated from e@,osure and continual mo0ement of electrodes from one solution to another= If a cali5ration is out of limits make sure the correct 5uffer solutions are 5eing used and that the sensor is o,erating correctl$=

52

D'r Test-n2
The ,hrase G6ar TestingG is commonl$ used in the 9aste treatment industr$= It is used in reference to a method that 9ill determine treata5ilit$ of a solution or esta5lish a se*uence of ste,s re*uired to achie0e treata5ilit$= 6ar Testing is used as a tool to determine 9h$ ,ro,er treatment is not 5eing achie0ed= In G6ar TestingG a small ,ortion of the sam,le or 9aste stream is used= The a0erage size of the G6ar TestG sam,le ma$ 0ar$ from !! to !!! milliliters= This also allo9s for smaller 0olume additions of treatment chemicals= It is easier to 9ork 9ith a small sam,le= G6ar TestG e*ui,ment re*uired can 0ar$ from an ela5orate la5orator$ setu, 9ith 5urettes> ,i,ettes> multistation 5eaker mi@ing station> etc=> or it can 5e scaled do9n to a sim,le kno9n 0olume container such as a glass or ,lastic ?ar> along 9ith a means of determining a,,ro@imate 0olume of additions of the treatment chemicals and an ine@,ensi0e ,- meter= The G6ar TestG ,rocedure can 5e used in a 5atch treatment t$,e s$stem or it can 5e used to du,licate the ,rocess in a continuous flo9 s$stem= Minimum e*ui,ment re*uired for 6ar TestingA Beakers to -old "aste (or Test H H H H H H H H 1 5eakers 5!! ml to !!! ml de,ending on size of sam,le ) 5eakers of 25! ml ca,acit$ for treatment chemicals se0eral ,lastic s,oons for stirring Porta5le ,- meter Dis,osa5le ml ,i,ette %,lastic in J4 ml increments& -e@a0alent chrome test kit %if testing for -e@a0alent Chrome& Potassium 'tarch ,a,er for 5leach %if testing for C$anide& Ether ,orta5le or *uick tests as necessar$

Cr-ter-' 3or ' success3u( tre't6ent 're 's 3o((o9sA H H H H Clear su,ernate %9ater on to, of sludge&= NoteA a slight tint to the 9ater is E8 as long as the 9ater is clear= T$,ical for inks are a ,ink> orange or cham,agne color= Particle size once the flocculant is added= 7arger ,articles take much less time to form a filter cake= #ate of settling H ho9 fast does the sludge se,arate and settle= Lolume of sludge after it settles= NoteA T$,ical flo9 through is 5M H 1!M 5$ 0olume in the 5eaker= /@A !! ml in a 5!! ml 5eaker is 2!M 5$ 0olume=

53 H T$,ical 5atch tank 9ill 0ar$ de,ending on 9aste= Possi5le 5M to +5M sludge 5$ 0olume=

54

D'r Test Proce*ure 3or %'tc. T'n,

The 5elo9 is a 5asic outline for a ?ar test ,rocedure= Do not limit $our test to the 5elo9 0alues= There are s,ecial cases that re*uire a gross e@cess of chemicals to treat the 9ater= DMP Technical 'er0ice and 7a5orator$ is a0aila5le for *uestions concerning ?ar testing= 'am,le sizeA The sam,le should 5e re,resentati0e of the 5atch tank size= 5!!! gallon 5atch tank should use a 5!! ml sam,le size 2!!! gallon 5atch tank should use a 2!! ml sam,le size= 2sing the a5o0e ratio ml of chemical addition is e*ual to ! gallons of chemical in the 5atch tank= To determine $our o9n ratio use the follo9ing formula= gallons in 5atch tank chemicals into sam,le size in ml R ml of chemicals from ?ar test O gallons of the 5atch tank

NoteA Enl$ change 0aria5le 9ith each test= The 0aria5les> 9hich can 5e modified> are amount of chemH %chem=H2 etcF&> ,range and flocculant dosage= NoteA Make sure the sam,les are 9ell mi@ed %se0eral minutes& 5efore ,ulling from the tank "ith three sam,les add the follo9ing to the sam,les as a starting ,oint= 'am,le I A add R ml of chemH 'am,le I2A add C ml of chemH 'am,le I1A add S ml of chemH Then raise the ,- to R on each of the sam,les and add 'am,le I A add R ml of (locculant 'am,le I2A add R ml of (locculant 'am,le I1A add R ml of (locculant 7et the sam,les settle for se0eral minutes then 0isuall$ ins,ect the results= #efer to the criteria for successful ?ar test to determine if more testing is necessar$= If unsuccessful 9ith the first set of tests re,eat and change onl$ one 0aria5le= If 0ar$ing the chemH is unsuccessful then 0ar$ the ,- or amount of flocculant=

55 T$,ical ,- ranges are )=5 to 4=!> .=5 to +=5 or !=5 H =!= If using chemicals not recommended 5$ DMP ,lease ask $our chemical su,,lier for their recommendations on treatment=

56

D'r Test-n2 F(occu('t-on Met.o*

Ad?usting the ,ro,er amount of flocculant to 5e added is 5est done 0isuall$= "hen the flocculant DMP 41H is added to treated and neutralized 9ater> the ,reci,itated contaminants congeal to form larger ,articles that 9ill 5ecome o50ious 9hen looking in the flocculator= The ,ro,er formation of the flocculated 9aste is go0erned 5$ 5oth the ,- and the distri5ution of the flocculant to ,ro,erl$ treated and neutralized 9aste= The e@treme ,- range for the o,eration of DMP 41H is 5=5 to 2=!P the o,timum range is 4=5 to +=!= /0en though flocculation 9ill occur out of the o,timum range> the sta5ilit$ of the flocculated ,articles is ad0ersel$ affected= DMP has de0ised a relati0el$ sim,le test for ,ro,er GflocG de0elo,ment= This consists of collecting t9o clear containers %2!!H5!! ml& of flocculated 9aste= #a,idl$ stir one of the containers 9ith a scoo, or stick for a fe9 seconds= The GflocG should reHform to a,,ro@imatel$ the consistenc$ of the other containers= If the ra,id stirring 5reaks u, the GflocG or makes it cream$> the GflocG is incorrect= The most likel$ reason for the cream$ condition of the TflocK is a too high ,-= Normal additions of flocculant are in the range of one gallon of DMP 41H concentrate ,er !!! to 1!!! gallons of 9ater treated= /@cessi0e amounts of solids to 5e ,reci,itated can re*uire e0en stronger concentrations of flocculant= Normal and a0erage *uantities of sludge 9ill re,resent from 5 to 1!M of an$ 9aste 0olume 9hen settled=

Sett(-n2
Pro,erl$ flocculated 9aste 9ill ha0e large curds of ,reci,itated contaminants= "hen the mi@er is sto,,ed> settling 9ill ra,idl$ occur= The time re*uired 0aries greatl$> 5ut is t$,icall$ minute for sludgeJ9ater se,aration> to 2! minutes for com,lete settling= If settling takes too long or no settling occurs> ?ar test the 9aste 5efore the neutralization stage 5$ getting a sam,le of the 9aste 5efore treatment= Certain 9astes do not form the t$,e of ,articles that 9ill readil$ settle= 6arHtest using different amounts of chemH addition> different t$,es of chemH > or change the ,- settings= Call DMP for hel,> or send us a sam,le of the 9aste to 5e e0aluated=

57 'ometimes the amount of solids is so great that ra,id settling cannot occur= This 9ill 5e e0ident if the sludge takes o0er 2! minutes to see sludgeJ9ater se,aration at the to, of the ?ar= If this is the case> go 5ack to the source of the 9aste to see if the 9aste streams ha0e changed= If ,ossi5le> check to see if an$ concentrated 9aste has 5een dum,ed into the rinse stream=

58

AIR LANCE
An air lance or air 9and as it is sometimes called is a useful tool in the 9aste treatment area= It consists of a length of PLC ,i,e> a,,ro@imatel$ 1! feet of fle@i5le air line and an air flo9 control 0al0e= An air lance is used to agitate sludge 5eds in clarifiers> sludge thickeners and lamella t$,e clarifier ho,,ers= It is es,eciall$ useful in cleaning the lamella ,lates= 'ome sludges are 0er$ gelatinous and 9ill not slide to the 5ottom of the clarifiers to 5e dra9n off and de9atered= This is es,eciall$ true of sludges that ha0e an e@cess of flocculant= This condition is noticea5le in clarifiers and sludge thickeners 9hen an area of the sludge 5ed de0elo,s a cone t$,e ca0it$ in the 5ed= This is due to 9ater and sludge taking the ,oint of least resistance 9hen 5eing dra9n off for de9atering or the ne9 sludge is rat holing through the sludge 5ed= This condition can 5e noticed in the slant ,late t$,e clarifiers %lamella& 5$ sludge 5uild u, in the ,lates or solids ,assing u, through some of the ,lates and 9hen increasing the sludge dra9Hoff does not hel, the condition= Air lancing is to 5e done onl$ 9hen the flo9 through the s$stem has 5een shut off and the 9ater le0el in the clarifier has 5een lo9ered enough to insure that sludge cannot 5e s,lashed o0er into the discharge stream= Control air 0olume through the air lance carefull$= A small amount of air can generate sufficient agitation to loosen the sludge 9ithout 0iolent agitation and s,lashing= NoteA Not '(( s&ste6s 're 5ro)-*e* 9-t. 'n '-r ('nce+ It -s s-65(e to 6',e -3 &ou 3-n* -t necess'r&=

59

S'65(e Co((ect-on
There are t9o t$,es of sam,les that can 5e collected= The first is untreated 9ater and the other is treated effluent= The goal of collecting a sam,le of untreated 9ater is to determining e*ui,ment sizing and treatment method= The collection of treated 9ater is used for anal$sis to determine com,liance 9ith $our discharge ,ermit= The t9o sam,les re*uire 0er$ different methods of collection and 5oth are e*uall$ critical= The first> collection of untreated 9ater> is to collect a sam,le that is as much like t$,ical 9aste9ater as ,ossi5le= "e realize that this ma$ 5e 0er$ difficult or e0en im,ossi5le> 5ut it is 0er$ im,ortant to get the most re,resentati0e sam,le that is ,ractical= 'ince $ou are more familiar 9ith the s,ecific situation than DMP is> $ou can 5e the 5est ?udge of ho9 to collect a good sam,le= DMP can offer some suggestions that ma$ 5e hel,fulA The sam,le sent should 5e re,resentati0e of a0erage contamination le0els on the 9aste stream= Common sense should 5e used to ,ro0ide a t$,ical 9aste stream sam,le= A sam,le to 9eak ma$ result in a 9aste9ater treatment s$stem that is to small to kee, u, 9ith the 9aste9ater ,roduction= A sam,le that is to strong ma$ lead us to s,ecif$ larger e*ui,ment resulting in a higher ,rice than necessar$= "aste9ater is sometimes generated continuousl$ %9hen rinsing ,arts> for e@am,le& 5ut more often is generated in 5atches as the result of 9ashing do9n e*ui,ment or dum,ing tanks= If there is a single collection ,oint 9here all the 9aste9ater goes %such as a sum,& then this is the 5est ,lace to collect the sam,le= If there is no collection ,oint then it ma$ 5e necessar$ to take multi,le sam,les from 0arious locations and mi@ them together= Again> $ou 9ill 5e the 5est ?udge of ho9 to accom,lish this= If the a,,ro@imate 0olumes of 9aste9ater from each source are kno9n then $ou can com5ine these multi,le sam,les ,ro,ortionatel$= A com,osite sam,ler can also automaticall$ collect sam,les at regular time inter0als if no flo9 monitoring e*ui,ment is a0aila5le= Ether9ise a sam,le should 5e collected hourl$ %a minimum of once an hour& during ,roduction and cleanHu,= These indi0idual sam,les 9ould then 5e com5ined to make a com,osite sam,le= 'hould the o,eration 5e a 5atch ,rocess se0eral sam,les ma$ need to 5e taken during the 5atch discharge and 9ash do9n c$cle= Note that the ,ollutant concentration ma$ 5e 0er$ high at the 5eginning of a 9ash c$cle and diminish at almost nothing at the end= 'am,les should 5e collected in a clean container and anal$zed as soon as ,ossi5le after the collection date= #ecord the time that the sam,le 9as taken= "e 9ould like to ha0e as much information as ,ossi5le regarding 9here the

60 sam,les 9ere taken> ho9 the$ 9ere taken> and 9hat 0olume or flo9 the$ re,resent= All rinse 9ater %or 9ash do9n& sam,les should 5e mi@ed together and !H2! liters %2H5 gallons& of sam,le sent to DMP to 5e used for testing and anal$sis= 'ome sam,les should 5e frozen and then ,ro,erl$ ,ackaged ,rior to shi,ment= This 9ill hel, ,reser0e the sam,les for anal$sis= The sam,les should 5e shi,,ed 5$ the *uickest method a0aila5le %ne@t da$ 2P'> (ed/@ or D-7 for e@am,le&= "aste9ater ma$ 5e *uite dilute 9hen generated 5$ 9ashing do9n e*ui,ment or ma$ 5e *uite concentrated if there is a tank full of some ,rocess chemical or a nonHo0erflo9ing rinse tank= If there are tanks of concentrated material that are sometimes dum,ed then it is a good idea to collect a small se,arate sam,le re,resenting the dum,= The size of the dum, and the dum, fre*uenc$ should 5e recorded= A 25!H5!! ml= sam,le should 5e taken ?ust ,rior to the dum,ing of this concentrate if ,ossi5le= 'uch concentrate sam,les should 5e ke,t se,arate from the com,osite sam,le= If the sam,le is taken from a sum, or ,it it ma$ necessar$ to mi@ the sum, 5efore sam,ling in order to collect solids that ha0e settled to the 5ottom= -o9e0er> if the sum, contains a large accumulation of solids it ma$ 5e 5etter not to mi@ first so that the sam,le does not contain an unusuall$ large amount of solids= It is u, to $ou to decide 9hich a,,roach 9ould gi0e the more realistic sam,le= "hen sam,ling from a sum, or collection ,it it is im,ortant not to gra5 floating oil and grease= "e need the 9ater H not the oil= In a treatment s$stem floating material 9ill 5e remo0ed ahead of the s$stem= It is im,ortant for us to kno9 that the oil$ material 9ill 5e ,resent 5ut 9e do not need a sam,le consisting of oil$ material= There is also the collection of sam,les from a treatment s$stem that is in o,eration= T$,icall$ 9e 9ant a sam,le of untreated 9ater in the *uantit$ of 2 liters= 'am,les for a (lo9 Through '$stem A t9o liter sam,le of untreated 9ater= A one liter sam,le from the flocculation tank 9hile it is in o,eration= A one liter sam,le from the clarifier= Ene small zi,lock 5ag of sludge from the filter ,ress= 'am,les from a Batch Treat '$stem A t9o liter sam,le of untreated 9ater= A one liter sam,le of treated 9ater= Method of treatment

61 ;uantit$ of chemicals= Ene small zi,lock 5ag of sludge from the filter ,ress= The other sam,le is for anal$sis of treated effluent 9ater= De,ending on the t$,es of anal$sis to 5e run> the sam,les should 5e ,reser0ed accordingl$ to insure that accurate test results are o5tained= 'am,le ,reser0ation methods are largel$ ,- de,endentP therefore an accuratel$ cali5rated ,- meter is essential to the ,rocess= The follo9ing sam,le ,reser0ation ste,s should 5e follo9ed= 'am,le containing metals onl$ = Determine and record ,- 0alue of sam,le= 2= #ecord date and time sam,le taken= 1= Measure !!! ml sam,les into clean ,ol$eth$lene 5ottles= 4= Decrease ,- to less than t9o %2& 9ith a kno9n amount of concentrated nitric acid= #ecord ,- 0alue and amount of concentrated nitric acid added= 5= 'eal containers= )= Cooler and ice are not necessar$= 'am,les containing c$anide = Determine and record ,- 0alue of sam,le 2= Collect sam,le in clean ,lastic 5ottles of !!! ml size or larger= 1= Add 2 ml of ! N sodium h$dro@ide ,er !!! ml of sam,le= %,- should 5e greater than or e*ual to 2=& 4= #ecord ,- 0alue and amount of sodium h$dro@ide added= 5= 'eal containers= )= Cooler and ice are not necessar$=

62 'am,les containing oil and grease = #ecord ,- of sam,le= 2= Collect sam,le in clear glass 5ottles of 5!!m size or larger= 1= 'eal container= 4= 7a5el 5ottle= 5= Cooler and ice are not necessar$= ,- Anal$sis 'am,le should 5e collected in a clean container anal$zed as soon as ,ossi5le after collection date= #ecord the time that the sam,le 9as taken= 'am,le 5ottle should not 5e o,ened 5efore anal$sis= I3 &ou .')e 'n& *ou7t on 9.'t to *o 5(e'se cont'ct DMPEs L'7or'tor& or Tec.n-c'( Ser)-ce 3or 2u-*'nce+

63

An'(&s-s Re5orts
Anal$sis re,orts are used to determine ho9 9ell a treatment s$stem is o,erating and as a 0er$ im,ortant tool in trou5leshooting and correcting treatment ,ro5lems= There are t9o t$,es of sam,ling ,erformed on most treatment s$stems= Com,osite 'am,le This is a sam,le that is accumulated 5$ taking a small sam,le of the flo9 o0er a s,ecific ,eriod of time= It can 5e dra9n on a time or ,ro,ortion to flo9 5asis= Anal$sis of the com,osite sam,le 9ill tell $ou ho9 the s$stem o,erated during this ,eriod of time= This anal$sis is usuall$ the one that is re*uired in $our re,orting ,rocedures= Bra5 'am,ling This is a sam,le that is taken at random= The anal$sis of this sam,le 9ill tell $ou ho9 the s$stem is o,erating at the time the sam,le 9as taken= Bra5 sam,les are also taken at s,ecific treatment tanks in the s$stem to determine if ,ro,er treatment has taken ,lace using s,ot test kits> such as test kits for free c$anide> he@a0alent chrome> etc= In order for an anal$sis re,ort to 5e an effecti0e tool in trou5leshooting it must contain all the information on all the ,arameters of concern in the 9aste 5eing treated= 'am,les should 5e la5eled 9ith all ,ertinent information relating to the sam,leP such as> location> date and t$,e of sam,le= If the sam,le is to 5e ,reser0ed> this information should 5e ,art of the anal$sis re,ort=

64

Fee5-n2 Recor*s
The im,ortance of kee,ing records cannot 5e o0er stressed and is done for the follo9ing reasons= H H H H It is re*uired under $our /n0ironmental Protection Agenc$ discharge ,ermit= It 9ill make the o,erator more efficient in that he 9ill 5e a5le to ,redict the chemicals re*uired= If treatment difficulties are encountered> the information is essential for ra,id trou5leshooting= It reduces the chances for mistakes=

65

W'ste9'ter Stre'6 Se2re2't-on, Co((ect-on 'n* W'ter M'n'2e6ent

"aste9ater from the ,roduction ,rocess is often a 5lend of rinses and concentrates from the 0arious ste,s in the ,rocess= This 9aste9ater is contaminated 9ith a 0ariet$ of chemicals= These chemicals are to@ic> hazardous and their discharge is regulated= "aste 9ater treatment 5egins at the source of contamination and good 9ater management= Eccasionall$ the total effluent is treated 9ithout se,arations or 9ith sim,le se,aration of the rinse com,onents and the ,eriodic dum,s of the s,ent concentrated solutions= In most ,rocesses> ho9e0er> the 9aste 9ater contains certain contaminants such as c$anide> he@a0alent chrome> chelating and com,le@ing agents 9hich re*uire s,ecial treatment= This is accom,lished 5$ stream segregation= "aste9ater CategoriesA Based on the ,rocess 5eing treated the 9aste9ater streams ma$ 5e segregated into the follo9ing categories= 'ome of the streams ma$ 5e com5ined at the collection ,oints to utilize their 9aste ,lus 9aste characteristics= A= AcidJAlkali #inses Enl$ those rinses after cleaning or acid and ,ickling ste,s 9hich do not contain an$ chemicals that re*uire s,ecial treatment= B= Chrome #inses Enl$ those rinses after chrome ,lating> chromating ste,s or chrome sealing= C= C$anide #inses Enl$ those rinses after c$anide ,lating or c$anide strikes and rinses 5earing c$anide contamination= D= Chelated #inses Enl$ those rinses after ,rocesses that are contaminated 9ith chelating or com,le@ing agents= /= Ink "aste #inses Enl$ those rinses from 9ash do9n 9ater from a (le@ogra,hic ,rinting machine= (= 'tarch "aste #inses

66 Enl$ those rinses from a corrugating machine 9ash 9ater> a starch kitchen> or a 5ad starch 5atch= NoteA 'tarch is 0er$ high in solids content and should 5e treated as though it 9ere a concentrate= B= Concentrated Alkali Dum,s Process dum,s of those s,ent solutions that contain concentrated alkali such as soak > electrocleaners> and degreasers= -= Concentrated Acid Dum,s Process dum,s of those s,ent solutions that contain concentrated acid such as acid cleaners> acid ,ickle 5aths> etc= I= Concentrated Chromium Dum,s Process dum,s of those s,ent solutions that contain concentrated chromium such as contaminated chrome 5aths> chromating solutions or chromium 5ased 5right di,s= 6= Concentrated C$anide Dum,s Process dum,s of those s,ent solutions that contain concentrated c$anide such as strike solutions> s,ent ,lating 5aths or those ,rocesses that contain concentrated c$anide= 8= Concentrated Chelate or Com,le@ing Agent Dum,s Process dum,s of those s,ent solutions that contain high concentrations of chelaters or com,le@ing agents such as s,ent electroless co,,er or electroless nickel 5aths= An$ other ,rocesses that are highl$ chelated or com,le@ed should 5e collected at this ,oint= 7= 'tagnant or DragHout #inses If these solutions cannot 5e reused 5ack in the ,rocess the$ should 5e di0erted to the a,,ro,riate concentrated collection ,oint= M= Miscellaneous Process Dum,s Man$ other 0arious chemicals are used in ,rocesses that cannot 5e indiscriminatel$ dum,ed into the 9aste treatment stream= Consult DMP concerning their makeHu, and for recommended dis,osal= These ma$ 5e classified under the categor$ of sol0ents> ,aint stri,,ers> ammonia> riston> etc= N= Cooling "ater Dis,osal Cooling 9ater used in air com,ressors> ,resses and refrigeration is considered as nonHcontact 9ater and usuall$ ma$ 5e dis,osed of directl$ to the domestic se9er s$stem 9ithout treatment= It is a good 9ater

67 management ,olic$ to in0estigate alternate uses for this 9ater in nonH critical rinse areas= Di0erting this 9ater to the treatment s$stem 9ill increase the loading of the s$stem and increase treatment cost= E= "ater Management Controlled rinse 9ater flo9s and scheduled dum,s of s,ent solutions can directl$ reduce the treatment cost of the 9aste treatment s$stem= Controlled rinse 9ater flo9 rates can 5e accom,lished 9ith the installation of flo9 restrictors or dole 0al0es at selected flo9 rates eliminating the use of e@cess 9ater= P= -olding Tanks 'egregated 9aste streams are collected and held in tanks or sum,s designated for each stream= These tanks 9ill also act as e*ualization tanks to minimize 0arious surges of flo9> ,- and concentration of the 9aste stream= ;= Concentrated 'olution Control Concentrated solutions are introduced into the contaminated 9aste stream under controlled flo9 rates and conditions= The ,oints of introduction are determined 5$ the t$,e of solution> treata5ilit$ desired and ma@imizing the effect of the solution in the 9aste ,lus 9aste 0alue in the treatment ,hase=

68

Concentr'tes
The definition of concentrates in industrial 9aste9ater treatment refers to an$ solution that is to 5e ,rocessed through the 9aste9ater treatment s$stem o0er and a5o0e the normal le0el of solids and contamination ,resent in the running rinse 9aters that are re*uired to ,roduce a *ualit$ ,roduct= These can 5e classified in the follo9ing categoriesA H H H H H H H H ',ent ,lating 5aths= ',ent cleaners= ',ent acid solutions= Li5rator$ or tum5ling 9aste= ',ent ,icklingJ5right di,,ing solution= Decanted solutions= #egeneration solutions H D=I= 9ater or ion e@change columns= Ether solutions that might shock or o0erload the treatment s$stem=

Man$ of the solutions discussed are 0er$ hea0il$ chelated to accom,lish the ,ur,ose for 9hich the$ 9ere intended= 2ncontrolled addition of these solutions into the 9aste9ater treatment s$stem can u,set> shock or interfere 9ith the ,ro,er treatment of the 9aste stream= Most treatment s$stems are designed to treat these concentrates from information deri0ed from treata5ilit$ studies on the effect of the ,articular concentrate on the 9aste stream= G6ar TestingG is the most common and sim,lest method of treata5ilit$ stud$ used to determine the treata5ilit$ of the concentrate including the methods> treatment chemicals re*uired and ,rocedure of treatment= There are three methods for dealing 9ith the concentrates= -aul Eff In some cases it has 5een determined that it is more economicall$ feasi5le to haul the 9aste off site= Batch Treatment Concentrated solutions are collected in a s,ecificall$ designed tank that is e*ui,,ed> as re*uired> to treat the t$,e of concentrate to 5e treated as determined 5$ treata5ilit$ studies= All treatment ,rocedures can 5e conducted in this tank> from ,retreating the solution to the ,oint it can 5e 5led to the treatment s$stem 9ithout shocking the s$stem to com,lete treatment including sludge remo0al and de9atering=

69 Concentrate -olding TanksA /ngineering studies determine the sizing of the holding tanks and *uantit$ re*uired> e=g=> acid> alkali and miscellaneous= The sizing and 5leed rate of the holding tanks are designed around the dum,ing schedule> esta5lished 5$ the ,rocess and the im,act on the treatment s$stem= In man$ cases the 9aste ,lus 9aste ,rinci,le can 5e em,lo$ed reducing treatment cost 5$ 5leeding t9o or more of the concentrates together to react 9ith each other and assist in treatmentA H Acid to streams that are treated at lo9 ,-= H Alkali to streams that are treated at high ,-= H Acid to alkali> or alkali to acid streams> to assist in neutralization= The 5leedHin rate of the concentrates is determined 5asicall$ 5$ the follo9ing conditions H Bleed to the 9aste stream onl$ 9hen main 9aste9ater streams are flo9ing through the s$stem= H The t$,e of concentrate and im,act on the 9aste stream= H 'ludge generation of the concentrate= H -olding ca,acit$ of concentrate holding tanks 5ased on dum, schedule re*uirements= Most concentrates can 5e treated economicall$ and ,ro,erl$ in the 9aste treatment s$stem= It is the dut$ of the o,erator to control the method and 5leedH in rate of the concentrate to a0oid shocking of the s$stem= Mistreatment> e@cessi0e chemical usage> e@ceeding the sludge loading design of the s$stem> and shutting do9n the treatment s$stem due to mistreatment cause dela$s in ,rocessing normal 9aste9ater streams and ,ossi5le ,roduction shut do9ns= Ru(e o3 T.u67 Bleed in rate shall not e@ceed != M of the normal rinse 9ater flo9= This should ,re0ent an$ u,set conditions or mistreatments= Example #inse flo9 rate O 2! BPM or %2! R )!& 2!! BP2!! BP- R != O 2! BP- of Concentrate 5leed

70

Pre)ent't-)e M'-nten'nce
Pre0entati0e maintenance ,rograms should 5e set u, to minimize costl$ shut do9ns and re,airs due to e*ui,ment failure= /*ui,ment manuals are su,,lied to assist $ou in setting u, $our maintenance ,rogram= The manuals should 5e filed in an area that is easil$ accessi5le 5$ all concerned 9ith maintenance= /ach e*ui,ment manual should 5e re0ie9ed to understand the o,eration of the indi0idual ,arts= ',ecial attention should 5e gi0en to the trou5leshooting and re,air section= It lists ,ro5lems> causes and corrections= These areas should 5e incor,orated into the ,re0entati0e maintenance ,rogram as ,art of the ins,ection routine or maintenance ,rocedure= DMP suggests a dail$ ins,ection of the treatment s$stem and associated e*ui,ment= This dut$ is usuall$ assigned to the treatment s$stem o,erator 5ecause heJshe has dail$ contact 9ith the e*ui,ment= The o,erator is a9are 9hether the e*ui,ment is functioning ,ro,erl$ or if it is e@,eriencing ,ro5lems in s,ecific areas= E,erator *'-(& ins,ection should include H H Ins,ect all ,lum5ing for leaks or e@cessi0e 0i5ration= 'olution leaks ha0e 5een a ma?or contri5uting factor to electrical com,onent failure= Ins,ect all ,um,ing stations A& Pum, E,eration B& 'eal 7eakage C& /@cessi0e Noises %5earings> etc=& D& Priming Circuit E,eration /& 'uction 7eaks (& Lal0e 'ettings Closed or im,ro,erl$ set 0al0es can contri5ute to ,um, failure= Closed ,riming circuit 0al0es can contri5ute to seal failure= 'uction leaks effect efficienc$ of ,um, %4M suction air leak reduces ,um, efficienc$ 4!M& Ins,ect all mi@er o,erations A& Mi@er E,eration B& /@cessi0e 0i5ration or noises %5earings> etc=& C& Position mounting 5olts or locks %loose mi@er can damage associated e*ui,ment&= Air or h$draulic leaksA Ins,ect all e*ui,ment re*uiring use of air or h$draulic oil=

71 H 7u5rication ,ointsA Ins,ect all areas 9here lu5rication oilers are installed and airJ9ater se,arators are re*uired= Drain as re*uired=

H H

Clean> cali5rate and check set ,oints of treatment sensors as re*uired= Maintain ins,ection and maintenance records or logs= These records can 5ecome 0alua5le tools in the maintenance ,rogram 5$ indicating 9hat areas should re*uire more attention= 'cheduled maintenance ,rograms should 5e determined from information deri0ed fromA A& Treatment o,erator ins,ection re,orts B& /*ui,ment manual recommendations C& Ether ,re0entati0e maintenance ,rograms in effect

A s,are ,arts in0entor$ should 5e maintained on site> es,eciall$ of items that cannot 5e ,urchased locall$ or are long lead time deli0er$ items= E,erator 6ont.(& ins,ection should include H H H /@ercise all 5all 0al0es to ,re0ent freezing= Check ,i,e unions for tightness= Thorough 9alkthrough of e*ui,ment to check for li*uid or air leaks or an$ a5normalities=

E,erator &e'r(& ins,ection should include H H #e,lace P7C 5atter$ Tr$ to clean out the s$stem if $ou ha0e an$ do9n time= This 9ould include draining of tanks and remo0ing an$ solids 5uildu,=

As Nee*e* ins,ection should include H H H H Clean u, the s$stem as s,ills occur or it 5ecomes dirt$ #e,lace filter ,ress cloths #e,lace media in an$ filters #e,lace an$ 5ag or cartridge filters

72

73

W.'t -s 5HG
,- is a 0alue taken to re,resent the acidit$ or alkalinit$ of an a*ueous solutionP it is defined as the logarithm of the reci,rocal of the h$drogen ion concentration of a solutionA ,- O log HHHHHHH U-VW Pure 9ater is the standard used in arri0ing at this 0alue= 2nder ordinar$ conditions 9ater molecules dissociate into the ions -V and E-H 9ith recom5ination at such a rate that 9ith 0er$ ,ure 9ater at 22 degrees C there is a concentration of o,,osite charged ions of J !>!!!>!!! mole ,er liter= This is commonl$ e@,ressed 5$ sa$ing that ,ure 9ater has a ,- of 4> 9hich means that its concentration of h$drogen ions is e@,ressed 5$ the e@,onent 4> 9ithout its minus sign= "hen acids or h$dro@$lHcontaining 5ases are in 9ater solution the$ ionize more or less com,letel$> furnishing 0ar$ing concentrations of -V and E-H ions> res,ecti0el$> to the solution= 'trong acids and 5ases ionize much more com,letel$ than 9eak acids and 5asesP thus strong acids gi0e solutions of ,to 1> 9hile solutions of 9eak acids ha0e a ,- of a5out )= 'trong 5ases gi0e solutions of ,- 2 or 1> 9hile 9eak 5ases gi0e solutions of ,- a5out .= As the ,- scale is logarithmic> the inter0als are e@,onential> and thus re,resent far greater differences in concentration than the 0alues themsel0es seem to indicate= %'ee ta5le&= #atio of -V or E-H Concentration to That of Pure "ater at 22 C >!!!>!!! !!>!!! !>!!! >!!! !! ! ! !! >!!! !>!!! !!>!!! >!!!>!!!

,Lalue Acid side %e@cess of -V ions& 2 1 4 5 ) 4 . + ! 2 1

Neutralit$ Alkaline side %e@cess of E-H ions&

74 7i*uid Pure "ater 'ea "ater /lectro,lating Bath !=! N -C !=! N NaE!= N acetic acid != N N-4EBastric ?uices 2rine Blood Milk 'oil %o,timum for cro,s& ,- Lalue 4= .=5 H ! )=5 H 5 2= 2= 1= = 2= 5H4 4=1 H 4=5 )=5 H 4 )H4

In acidH5ase titrations> changes in ,- can 5e detected 5$ indicators %*=0=& such as meth$l orange> ,henol,hthalein> etc= Changes in ,- are also measured 9ith a ,- meter= ,- control is of critical im,ortance in a large num5er of industrial o,erations such as 9ater ,urification> chrome tanning ,rocess for leather> in ,reser0ation of food ,roducts> in electro,lating 5aths> d$eing> agriculture> and numerous other instances=

75

W'rr'nt&
/*ui,ment not manufactured 5$ DMP Cor,oration> 5ut furnished 9ith e*ui,ment of DMPDs manufacture shall 5e limited to 9hate0er 9arrant$ is e@tended 5$ the manufacturer and transfera5le to the 5u$er or 9hate0er 9arrant$ 9as agreed to during the ,urchase ,hase of the ,ro?ect= These 9arrant$ ,eriods and conditions ma$ 5e o5tained from the manufacturerDs literature or 5$ contacting the manufacturer or DMP= DMP 9ill assist the 5u$er in o5taining satisfaction under 9arrant$ conditions if re*uired= #eturn Procedures H Bu$er ,rom,tl$ notifies DMP on disco0er$ of the defects or failure> stating> 9here a,,lica5le> the ,roduct t$,e and serial num5ers and full$ descri5ing the circumstances gi0ing rise to the claim= DMP must recei0e such notification 9ithin the a,,lica5le 9arrant$ ,eriod in order for 9arrant$ to a,,l$= H Bu$er 9ill 5e issued a return authorization num5er %#MA& and instructions for shi,ment= DMP 9ill not acce,t an$ shi,ments 9ithout return authorization num5ers= H DMP 9ill not acce,t an$ shi,ment that contains com,onents that ha0e not 5een thoroughl$ cleaned of all hazardous or to@ic materials= Pum,s> 0al0es> fittings etc== 'hi,ment 9ill 5e returned immediatel$ collect if such conditions are disco0ered after recei,t of shi,ment= H Bu$er shall return e*ui,ment as instructed along 9ith 9ritten information stating all ,ertinent information regarding circumstances for 9arrant$ consideration= H /*ui,ment shall 5e returned 9ith all trans,ortation charges ,re,aid= DMP 9ill not acce,t collect freight ,ackages= H /*ui,ment shall 5e re,aired or re,laced under 9arrant$ if manufacturerDs e@amination of such e*ui,ment discloses to its satisfaction that the defects or failure ha0e not resulted from an$ negligence> misuse> im,ro,er o,eration> accident> unauthorized re,air or alteration= ManufacturerDs determination of the cause and nature of the failure of the e*ui,ment shall 5e final= H If manufacturer finds that 5u$er has returned e*ui,ment 9ithout cause> manufacturer shall notif$ 5u$er and return the e*ui,ment at 5u$erDs e@,ense= In addition> manufacture ma$> at its sole discretion im,ose a charge for testing and e@amination of an$ e*ui,ment so returned= H Manufacturer does not su,,l$ re,lacement or loaner e*ui,ment during re,air or 9arrant$ consideration ,eriod= Bu$erDs s,are ,arts in0entor$ should 5e used during this ,eriod=

76

Return Proce*ure
/*ui,ment returned to DMP for an$ reason must 5e accom,anied 5$ a #eturn Materials Authorization Num5er or #MAI= An$ return to DMP 9ithout an #MAI 9ritten on the ,ackage%s& or ,acking sli,%s& 9ill not 5e acce,ted 5$ our shi,,ing de,artment= To o5tain an #MAI H H H Call DMP and s,eak 9ith either the ',are Parts or Technical 'er0ice De,artment Descri5e the ,ro5lem and ,art%s& $ou need hel, 9ith If it is determined that the ,art%s& need to 5e sent to DMP an #MAI 9ill 5e issued to $ou=

Mark ,ackage%s& andJor ,acking sli,%s& 9ith #MAI and send to DMP

77

Fre=uent(& As,e* Huest-ons A7out

%ATCH TREATMENT SCSTEMS
NoteA Not all s$stems 9ill ha0e Precoat

"-AT I' T-/ P#EC/D2#/ (E# C7/ANINB AND CA7IB#ATINB T-/ Ph P#EB/' AND -E" E(T/N '-E27D T-I' B/ DEN/: Clean ,ro5e in dilute muriatic acid %-C7& andJor detergent= Do not use an$thing that is a5rasi0e> such as a 9ire 5rush= (ollo9 the ,rocedure on the o,erator interface unit using ne9 4 and ! 5uffer solutions= Be sure to rinse the ,ro5e thoroughl$ after each solution=

2=

"-/N '-E27D T-/ C-/MICA7 (//D TAN8' B/ MAD/ 2P: Before starting an$ treatment or ?ar testing= Cou do not 9ant to get into the middle of a treatment and run out of chemicals=

1=

"-AT I' C-/MH AND "-C I' IT 2'/D: ChemH is a ,reci,itation aid used to tie u, contaminates 9ith other solids in the 9aste9ater= It 5onds 9ith the metals and increases the ,articles in size 9here the$ 9ill ,reci,itate out= (erric Chloride andJor Calcium Chloride are common chemicals used=

4=

"-AT I' (7ECC27ANT AND "-C I' IT 2'/D: (locculant is a 9ater solu5le ,ol$mer material= It is used to take a grou, of ,articles> surround them> 9here as the$ 5ecome large> hea0$ and 9ill settle out *uickl$.

5=

"-AT I' CA2'TIC 'EDA AND "-C I' IT 2'/D: Caustic soda> also referred to as 'odium -$dro@ide is used strictl$ for ,control= Caustic raises ,-=

78 )= "-AT A#/ ,- '/TPEINT' AND -E" DE I '/T T-/M: 'et ,oints are used to control the ,- range in a tank= Cour lo9 set ,oint is $our lo9 num5er and $our high set ,oint is $our high num5er= In other 9ords if $ou 9anted to hold a ,- range of )=! to 4=! $ou 9ould ,rogram in )=! as $our lo9 set ,oint and 4=! as $our high set ,oint= 4= -E" E(T/N DE I N//D TE C-ANB/ T-/ '/TPEINT': Cou 9ould change $our set ,oints 5ased on $our ?ar testing or if $ou needed a different ,- in $our reuse 9ater= 8ee, in mind $our reuse tank and $our 5atch tanks are totall$ inde,endent of each other= The ,- does not necessaril$ change going from the 5atch tank to the reuse tank= .= "-AT I' T-/ P2#PE'/ E( 6A#HT/'TINB AND -E" DE I ACCEMP7I'- T-I': 6ar testing is done to calculate the amount of chemicals and the ,- range needed to treat a ,articular 5atch= 6ar testing is treating the 9aste9ater identical to the s$stem 5ut on a small scale= It is done ste, 5$ ste, so that $ou ma$ 0isuall$ see 9hat takes ,lace during the ,rocess= Cou ha0e to 5e a5le to successfull$ ?ar test 5ecause $ou are the one 9ho 9ill ,rogram in the amount of chemicals needed and the ,- range for the 5atch 5ased on the ?ar test= This is done to kee, chemical cost to a minimum= += "-AT T-#// MAIN IT/M' AM I 7EE8INB (E# IN 6A# T/'TINB: A& B& C& != Clarit$ of the "ater H Most im,ortant Particle 'ize H Im,ort Lolume of 'ludge H Concern

"-AT A#/ T-/ T-#// LA#IAB7/' IN 6A# T/'TINB: A& B& C& ,- #ange Amount of ChemH Amount of (locculant

-E" MANC DI((/#/NT 6A# T/'T' '-E27D B/ DEN/: A minimum of three or until $ou are successful= 8ee, in mind it is eas$ to redo the ?ar test 5ut it is not so eas$ to retreat an entire 5atch tank=

2=

"-AT '-E27D B/ DEN/ I( A C-/MICA7 P2MP ADD' ME#/ T-AN "-AT"A' P#EB#AMM/D:

79 This is an indication that the ,ro@imit$ s9itch needs ad?usting= #efer to the manual on this ,rocedure= 1= "-/N '-E27D MAN2A7 EP/#ATIEN B/ '/7/CT/D L/#'2' A2TEMATIC EP/#ATIEN EN LA7L/'> MIR/#' E# P2MP' The manual mode o0errides certain safeguards in the ,rogram= It should onl$ 5e used 5$ *ualified ,ersonnel= 4= -E" 7ENB '-E27D T-/ B=T= MIR/# #2N B/(E#/ 'TA#TINB A BATC-: It should run in manual !H 5 minutes= The ,ur,ose of this is to gra5 a 9ell mi@ed sam,le for ?ar testing= After that is done it should 5e set to automatic= 5= "-/N '-E27D T-/ D/CANT LA7L/' B/ 2'/D: After the 5atch has settled> if the solution is 5elo9 the decant and the ,ress is em,t$> $ou should select decant= The o5?ect is to get rid of the most 9ater as *uickl$ as ,ossi5le= )= -E" DE T-/ D/CANT LA7L/' EP/#AT/: The decant 0al0es are controlled 5$ their associated le0el controls= 4= "-AT A#/ T-/ T#/ATM/NT PA2'/' AND "-/N '-E27D T-/C B/ 2'/D: Pauses ena5le $ou to do ?ar tests 5et9een the stages of treatment> if necessar$= 'electing ,ause or no ,ause must 5e done 5efore starting the treatment c$cle= .= "-C I' T-/ (I7T/# CA8/ "/T: A& Is the 9aste treated ,ro,erl$: Is the su,ernate clear in the 5atch tank or ?ar test: Is enough floc added to hel, the solids settle: Is the ,- in the correct range: Check $our c$cle set ,oints= Are the filter cloths 5linded: 'ee the ne@t *uestion I += Is the ,ress ,recoated ,ro,erl$:

B& C& D&

80 /& Is the filter ,ress ,um, leaking air out of the e@haust or around a seal 9hile in the late stages:

+=

"-C DE/' IT TA8/ 2 -E2#' TE (I77 MC P#/'' "-/N IT 2'/D TE TA8/ EN7C 5H) -E2#': A& The cloths need to 5e cleaned= If the$ are fouled 9ith oil use detergent= If the$ are fouled 9ith floc use 5leach= If the$ are fouled 9ith late@> ink or starch use a cold 9ater ,ressure 9asher 21!!H1!!! ,si= If the$ are fouled 9ith metal h$dro@ide sludge then used dilute -Cl= X 'ee the instruction manual for details= B& C& The ,um, is ha0ing a mechanical ,ro5lem= Is the 9ater treated ,ro,erl$:

2!=

-E" E(T/N '-E27D T-/ P#/CEAT TAN8 B/ D2MP/D: The ,recoat tank should 5e dum,ed a5out e0er$ third time=

2 =

"-/N '-E27D T-/ P#/CEAT TAN8 B/ MAD/ 2P: It should 5e made u, ?ust 5efore an em,t$ ,ress is started=

22=

-E" 7ENB '-E27D T-/ P#/CEAT MIR/# #2N: 7et it run for 5H ! minutes 5efore the ,ress is started and then once stage one is com,leted turn the mi@er off=

21=

-E" M2C- P#/CEAT I' N/C/''A#C: A general rule is != to !=1 l5s= ,er s*uare foot of filter surface area= "hen a load is em,tied from the ,ress there should 5e a good la$er of ,recoat material on the cake= It 9ill 5e a5out J. of an inch thick= The 5ottom ma$ 5e a little more and the to, a little less> 5ut it should 5e 9ell co0ered=

24=

"-AT "E27D -APP/N I( T-/ P#/'' I' T2#N/D E(( B/(E#/ IT I' CEMP7/T/ AND I( T-I' -APP/N' "-AT '-E27D B/ DEN/:

81

A&

De,ends on 9hen the ,ress is turned off= If it 9as near the end of the c$cle> $ou ha0e t9o o,tions= /m,t$ the ,ress and the cake ma$ 5e some9hat soft= #estart the ,ress> 5ut do not make u, an$ ne9 ,recoat= 7et the ,ress finish the c$cle=

B&

If the ,ress is turned off earl$ in the c$cle then the 5est thing is to em,t$ the ,ress= The ,recoat material 9ill not sta$ on the cloth and e@,ose cloths to ra9 sludge if it is restarted= This can 5e some9hat mess$= It is also a good idea to 9ash the cloths 9ith 9ater to rinse the sludge off the cloths 5efore closing and restarting=

25=

"-AT I' T-/ P2#PE'/ E( T-/ AI# B7E" DE"N AND "-AT CE27D /((/CT T-/ TIM/ AND P#/''2#/ '/TTINB: Air 5lo9 do9n is designed to remo0e an$ e@cess 9ater from the ,i,ing on the filter ,ress= This includes the 4 corner drain ,orts= Air 5lo9 do9n DE/' NET D#C the cake= If the ,ress is not full> it is ,ossi5le to ha0e a great deal of 9ater come out of the ,ress e0en after the air 5lo9 do9n is com,lete= The recommended time is set for 5 minutes and the ,ressure is 4!H5! ,si=

2)=

"-AT -APP/N' I( T-/ P#/'' I' #2NNINB AND T-/ BATC- TAN8 /MPTI/' B/(E#/ T-/ P#/'' I' (277: The filter ,ress 9ill go into a state called lo9 le0el rec$cle= This means that 9ater is ,um,ing from the ,recoat tank through the filter ,ress and returning to the ,recoat tank= The ,ur,ose of this stage is to kee, ,ressure through the ,ress so that the ,recoat material does not dro,=

24=

"-AT A7A#M' A#/ EN DMP 'C'T/M: T-/ BA'IC A7A#M' EN DMP 'C'T/M' A#/A A& 7oss of air H shuts the s$stem do9n= B& 7o9 le0el chem feed H sto,s all treatment= C& -igh le0el alarm H sto,s all ,um,s feeding that ,articular tank=X X Pro0iding that the ,um,s are controlled 5$ the DMP control ,anel=

2.=

"-AT I' A P#ERIMITC '"ITC-:

82 This is a magnetic s9itch on the airside of the ,um,= The s9itch counts the num5er of strokes of the ,um,> 9hich in turn is controlled 5$ the P7C= This is dis,la$ed as gallons used> ,urged or flo9 rates as re*uired= 2+= "-AT MAINT/NANC/ N//D' TE B/ DEN/ EN T-/ 'C'T/M: A& B& C& D& /& (& Normal cleanu, of the s$stem Changing the 5atter$ in the CP2 %Ence a $ear& Draining the filter regulators Ins,ecting ,um,s and lines for leaks #e,air an$ leaks (ill oilers %if e*ui,,ed&