INCEPTOR Standard Operation and Maintenance Manual

OPERATION
AND
MAINTENANCE
SYSTEM MANUAL
INCEPTOR™ 15K WWTP
WASTEWATER TREATMENT PLANT
Apptech Solutions
3993 Daugherty Road
Salem, Virginia 24153
Phone: 540-380-5600
OPERATION
AND
MAINTENANCE
SYSTEM MANUAL
INCEPTOR™ 15K WWTP
Apptech Solutions
3993 Daugherty Road
Salem, Virginia 24153
Phone: 540-380-5600
TABLE OF CONTENTS
Chapter 1 Introduction .................................................................................. 1-1
Disclaimer............................................................................................... 1-2
Chapter 2 Terms and Definitions ....................................................................... 2-1
Chapter 3 Product Overview ............................................................................ 3-1
Chapter 4 Operator and Managerial Responsibility .................................................. 4-1
Qualifications for Plant Operators .................................................................. 4-1
Operator Responsibilities ............................................................................. 4-1
Owner/Managerial Responsibilities ................................................................. 4-2
Work Schedule and Educational Opportunities .................................................... 4-3
Chapter 5 Safety .......................................................................................... 5-1
OSHA ..................................................................................................... 5-1
General safety ......................................................................................... 5-1
Electrical ................................................................................................ 5-2
Explosion and Fire ..................................................................................... 5-2
Trips and Falls .......................................................................................... 5-3
Cuts, Abrasions, and Other Injuries ................................................................. 5-3
Lifting and Handling Injuries ......................................................................... 5-3
Confined Spaces ....................................................................................... 5-3
Oxygen Deficiency and Toxic Gases ................................................................. 5-4
Chemicals ............................................................................................... 5-5
Chemicals – General Tips and Guidelines .......................................................... 5-5
Chlorine (Gas) .......................................................................................... 5-6
Sodium Hypochlorite .................................................................................. 5-6
Sodium Sulfite .......................................................................................... 5-7
Sulfur Dioxide .......................................................................................... 5-7
General References ................................................................................... 5-7
Biohazards .............................................................................................. 5-7
Laboratory Hazards .................................................................................... 5-8
Mechanical Equipment Hazards ...................................................................... 5-9
Dropping Tools/Equipment into Wastewater ...................................................... 5-9
Personal Protective Equipment (PPE) ............................................................... 5-9
Chapter 6 Wastewater Overview ....................................................................... 6-1
Physical Characteristics............................................................................... 6-1
Operation and Maintenance Manual for INCEPTOR™ 15k WWTP © 2015 Apptech Solutions, LLC
i
Chemical Characteristics ............................................................................. 6-2
Biological Characteristics ............................................................................. 6-3
Summary of Typical Domestic Wastewater Characteristics ..................................... 6-6
Chapter 7 Specific Model Description ................................................................. 7-1
The INCEPTORTM 15K WWTP .......................................................................... 7-1
WWTP Performance ................................................................................... 7-1
Primary Clarifier .................................................................................... 7-2
Flow EQ .............................................................................................. 7-2
Anoxic Bioreactor ................................................................................... 7-3
MBBR.................................................................................................. 7-3
Secondary Clarifier ................................................................................. 7-4
Ancillary Equipment ................................................................................ 7-5
Chapter 8 Operations and Maintenance ............................................................... 8-1
Overview ................................................................................................ 8-1
System Chambers ...................................................................................... 8-3
Primary Clarifier/Sludge Holding (PC) ........................................................... 8-3
Overview........................................................................................... 8-3
Process Description .............................................................................. 8-3
Required Maintenance for Normal Operation ................................................ 8-4
Control Testing ................................................................................... 8-6
Expected Performance .......................................................................... 8-7
Flow Equalization (FEQ) ........................................................................... 8-8
Overview........................................................................................... 8-8
Process Description .............................................................................. 8-8
Methods of Control ............................................................................... 8-8
Control Testing ................................................................................... 8-8
Operational Considerations ..................................................................... 8-9
Chamber Maintenance ..........................................................................8-10
Anoxic Bioreactor (ABR) ..........................................................................8-11
Overview..........................................................................................8-11
Process Description .............................................................................8-11
Methods of Control ..............................................................................8-15
Control Testing ..................................................................................8-15
Expected Performance .........................................................................8-16
ii
Moving Bed Biological Reactor (MBBR) .........................................................8-18
Overview..........................................................................................8-18
Control Testing ..................................................................................8-22
Expected Performance .........................................................................8-23
Secondary (Final) Clarifier (SC) ..................................................................8-24
Overview..........................................................................................8-24
Clarifier Scum Removal System ...............................................................8-25
Components ........................................................................................8-26
Blower Assembly.................................................................................8-26
Linear Air Pumps ................................................................................8-26
Diffusers ..........................................................................................8-26
MBBR Media Screens ............................................................................8-27
Secondary Clarifier Scum Removal System ..................................................8-27
Effluent Filter Assembly ........................................................................8-27
Metering Equipment ............................................................................8-28
Pulse Lift Pump ..................................................................................8-28
Anoxic Mixer (Pulse Lift Mixer) ................................................................8-29
Centrifugal Pumps ...............................................................................8-29
System Startup .....................................................................................8-34
Clean Water Testing ............................................................................8-34
MBBR ..............................................................................................8-34
Physical Characteristics Reference for Startup Operations ...............................8-35
Aeration and Mixing Adjustments .............................................................8-36
Air Lift Pump Adjustments .....................................................................8-37
Foaming ...........................................................................................8-38
Operations & Maintenance .......................................................................8-39
Routine Adjustments ..............................................................................8-39
Physical Characteristics Reference for Normal System Operations ......................8-40
Summary of Observations ......................................................................8-41
iii
Solids Control ....................................................................................8-43
Abnormal Conditions and Corrective Action .................................................8-44
Emergency Operations ..........................................................................8-46
Maintenance & Monitoring Schedule – All Chambers/Components .......................8-46
Electrical Controls .................................................................................8-49
Functional Description ..........................................................................8-49
Operation .........................................................................................8-49
Records and Reports ..............................................................................8-49
Chapter 9 Limited Warranty ............................................................................ 9-1
Chapter 10 References and Bibliography ............................................................10-1
Chapter 11 Index ........................................................................................11-4
Appendix A - OSHA fact sheet .......................................................................... A-1
Appendix B - Equipment Manuals ...................................................................... B-1
Appendix C - Spare Equipment ......................................................................... C-1
Appendix D - Forms ...................................................................................... D-1
Appendix E - Control Panel ............................................................................. E-1
Appendix F - System Drawings .......................................................................... F-1
Appendix G - Process Calculations .....................................................................G-1
Appendix H - Standard Operating Procedure (SOP).................................................. H-1
iv
CHAPTER 1 INTRODUCTION
This manual is the primary reference for operation and maintenance of the INCEPTOR™
Wastewater Treatment Plant System. The purpose of this text is to provide information,
techniques and references necessary for proper and efficient operation of the system. The
system operator should become familiar with the arrangement and content of this manual in
order to quickly access specific information when needed. This manual is comprised of
several major components encompassing general information about the product(s) used in the
treatment facility; responsibilities of staff and management; safety; system design;
operations and maintenance; and appendices including permits, regulatory requirements,
manufacturer’s manuals, and other related items to benefit site operator(s) and managers.
The manual is also designed as a reference for treatment system troubleshooting and
monitoring in the event of unusual or abnormal conditions. It is important to note that this
text serves only as a guide. The key to satisfactory outcomes is the manner in which the
operator interprets and utilizes the information provided. Therefore a successful and
efficient treatment process is based primarily upon the operator’s personal ability, acquired
knowledge, and experience level when making system-related decisions and operational
adjustments.
It is also important to note that not every treatment plant reacts to a waste stream the same
way. Sewage is basically the same from one locality to another; however, there are variables
that may change the manner in which a system should be operated. For instance, the pH of
the local public or private water supplies will have an effect on the treatment process. If
there are industrial waste streams introduced into the facility (other than domestic), special
monitoring and operational procedures is necessary. Shock loads with pH or toxic extremes
will cause serious system imbalances and could kill the biological mass. Additionally, seasonal
changes can also play a role in how the bacteriological activity performs. This manual will
guide the operator in coming up with adaptations, adjustments, and solutions to the
aforementioned facility-specific variables and conditions.
1-1
DISCLAIMER
This manual addresses both standard operational procedures and emergency operations in
the event of system failure. The information contained is only as effective as the person
who utilizes and applies it to plant operations and maintenance. The operational staff must
understand that every situation is different and, although every attempt has been made to
provide the best guidelines possible, there may be variations between real life scenarios and
examples contained in this manual. Therefore, the operator must still rely on experience
and industry knowledge, exercising sound judgment, and is fully responsible for actions and
decisions related to the functionality of the wastewater treatment plant. Apptech
Solutions, LLC is relieved of any and all liability associated with the operations and
maintenance of this wastewater treatment facility as a direct or indirect result of operator’s
or owner’s misinterpretation or incorrect application of concepts contained in this manual.
1-2
CHAPTER 2 TERMS AND DEFINITIONS
Unless otherwise specified within the context of this manual, the terms contained in this
glossary shall have the following meanings:
Abandonment – Discontinued use of a system component(s) by removal or rendering
inaccessible and inoperable
Absorptive surface – Plane of native soil where hydraulic properties change
Activated sludge – Highly concentrated mass of live organisms in a suspended-growth aerated
and mixed environment
Activated sludge process – Wastewater treatment process that uses activated sludge to
biologically convert non-settleable (suspended, dissolved, and colloidal) organic materials to
a settleable state using aerobic and facultative microorganisms; typically followed by
clarification and sludge return
Aeration, diffused – Process of introducing air bubbles under pressure into a treatment unit
using a compressor or blower and a diffuser
Aerobic – Having molecular oxygen (O2) as a part of the environment, or a biological process
that occurs only in the presence of molecular oxygen; see also anaerobic, anoxic
Aerobic treatment unit (ATU) – Treatment component that utilizes oxygen to degrade or
decompose wastewater, with or without mechanical means
Alternating drainfields – Final treatment and dispersal component that is comprised of
multiple soil treatment areas which are independently dosed
Alternative onsite wastewater treatment system – Onsite system that is not a conventional
system as described by local regulatory code
Anaerobic – Absence of molecular oxygen (O2) as a part of the environment, or a biological
process that occurs in the absence of molecular oxygen
Anoxic – Condition in which all constituents are in the reduced form (no oxidants present);
Note: Conditions in a septic tank are generally anaerobic, but not anoxic; see also aerobic
and anaerobic
Area engineer – The licensed professional engineer at the Department of Environmental
Quality (or Health) who serves the area where a sewerage system or treatment works is
located and is responsible for review and approval of construction plans and related materials
Backflow prevention device – Any device, method, or configuration used to prevent a
reversal of flow
Back siphonage – A form of backflow which occurs as a result of negative pressure
Bacteria, aerobic – Bacteria that can metabolize only in the presence of molecular oxygen
Bacteria, anaerobic – Bacteria that is able to metabolize in the absence of molecular oxygen
Bacteria, facultative – Bacteria that can metabolize with or without molecular oxygen
present in the environment
2-1
Bacteria, mesophilic – Bacteria which grow best at temperatures between 20 and 50 degrees
C (68 and 122 degrees F) with optimum growth between 25 and 40 degrees C (77 and 104
degrees F)
Bacteria, psychrophilic – Bacteria which grow best at temperatures between 10 and 30
degrees C (50 and 86 degrees F) with optimum growth between 12 and 18 degrees C (54
and 64 degrees F)
Bacteria, thermophilic – Bacteria which grow best at temperatures between 35 and 75
degrees C (95 and 167 degrees F) with optimum growth between 55 and 65 degrees C (131 and
149 degrees F)
Biochemical oxygen demand, five-day (BOD5) – Quantitative measure of the amount of
oxygen consumed by bacteria while stabilizing, digesting, or treating biodegradable organic
matter under aerobic conditions over a five-day incubation period; expressed in milligrams
per liter (mg/L)
Biomass – Total mass of living organisms. Typically referred to as the combination of
activated sludge and biofilm.
Biofilm – Thin coating of microbial growth, organic matter, and microbial secretions on a solid
substrate particle
Biosolids – A sewage sludge that has received an established treatment for required pathogen
control and is treated or managed to reduce vector attraction to a satisfactory level and
contains limited levels of pollutants, such that it is acceptable for use by land application,
marketing or distribution
Bulking – The inability of sludge solids to separate from the liquid under quiescent conditions;
under aerobic conditions may be associated with the growth of filamentous organisms, low
DO, or high sludge loading rates; under anaerobic conditions, may be associated with
attachment of gas bubble to solids
Chemical oxygen demand (COD) – Amount of the organic matter in wastewater that can be
oxidized by a very strong chemical oxidant; typically measured by a standard test using
dichromic acid as the oxidant
Clarification – Process or combination of processes that uses separation (settling and
flotation) to remove suspended solids from wastewater
Coliform bacteria – Group of bacteria that constitute most of the intestinal flora of warm
blooded animals (including the genera Klebsiella sp., Enterobacter sp.) and are used as water
pollution indicator organisms
Coliform bacteria, fecal – Indicator bacteria common to the digestive systems of warm-
blooded animals that is cultured in standard tests to indicate either contamination from
sewage of the level of disinfection; generally measured as number of colonies/100 mL or most
probable number (MPN)
Coliform, total (TC) – Measurement of water quality expressed as the number of colony-
forming unit (cfu) of Coliform bacteria per unit volume
Constructed wetland – Pretreatment component that incorporates appropriate moisture
tolerant vegetation and consists of one or more lined basins where wastewater undergoes
some combination of physical, chemical, and/or biological treatment; configurations include
free surface and submerged flow configurations
2-2
Conventional system – Refers to a typical onsite wastewater treatment system (OWTS) as
defined at the local or regional level
Counter, alarm – Device used to record the number of times an alarm has been activated
Counter, cycle – Device used to record the number of times a component or device has been
activated (e.g., activation of a pump followed by deactivation is one cycle)
Counter, event – Device used to record the number of times a component or device has been
activated or deactivated
CTC – A Certificate to Construct; this certificate will normally be in the form of a letter
granting authorization for construction
CTO – A Certificate to Operate issued in accordance with the provisions of the SCAT
regulations. This certificate will normally be in the form of a letter granting authorization for
operation
Critical areas/waters – Areas/waters in close proximity to shellfish waters, a public water
supply, recreation or other waters where health or water quality concerns are identified by
the Virginia Department of Health or the State Water Control Board
Conventional design – The designs for unit operations (treatment system component) or
specific equipment that has been in satisfactory operation for a period of one year or more,
for which adequate operational information has been submitted to the DEQ or Health
Department to verify that the unit operation or equipment is designed in substantial
compliance with the SCAT regulations. Equipment or processes not considered to be
conventional may be deemed as alternative or non-conventional.
Detention time – Average length of time a unit volume of wastewater or a suspended particle
remains in a tank or chamber; mathematically, it is the volume of water in the tank divided
by the flow rate through the tank (assuming ideal hydraulic conditions)
Director – The Director of the Department of Environmental Quality, Department of Health,
or an authorized representative
Discharge (when used without qualification) – Discharge of pollutant
Disinfection – Process used to destroy or inactivate pathogenic microorganisms in
wastewater, rendering them non-infectious
Disinfection, ultraviolet (UV) – Process used to inactivate microorganisms by irradiating them
with ultraviolet light to disrupt their metabolic activity, thus rendering them incapable of
reproduction
Dissolved oxygen (DO) – Amount of molecular oxygen (O2) dissolved in water, wastewater, or
other liquid; commonly expressed as a concentration in milligrams per liter (mg/L), parts per
million (ppm), or percentage of saturation
Distribution, drip – Application of effluent over an infiltrative surface via pressurized
emitters and associated devices and parts (pump, filters, controls, and piping)
Distribution, gravity – Using the force of gravity to convey wastewater or effluent to one or
more components or devices; gravity distribution to trenches may be parallel
Dosing, timed – Configuration in which a specific volume of effluent is delivered to a
component based upon a prescribed interval, regardless of facility water use
2-3
Drip emitter – Drip distribution device that dispenses effluent to the infiltrative surface at a
predictable rate
Drip field – Above or below grade soil treatment area where final treatment and dispersal
occurs via application of effluent to the infiltrative surface via pressurized drip tubing
utilizing emitters
Effluent limitations – Any restrictions imposed by the Board on quantities, discharge rates,
and concentrations of pollutants that are discharged from point sources into surface waters,
waters of the contiguous zone, or the ocean
Emulsification – Suspension of solids as a result of decreased surface tension due to the
presence of an emulsifying agent or some substance that alters or prohibits normal microbial
activity
Exceptional quality bio-solids – Bio-solids that have received an established level of
treatment for pathogen control and vector attraction reduction and contain known levels of
pollutants, such that they may be marketed or distributed for public use.
Floc – Collection of smaller particles agglomerated into larger particles as a result of
chemical, physical, or biological treatment; the larger particles can be more readily settled
or filtered out of the effluent
Flow equalization – System configuration that includes sufficient effluent storage capacity to
allow for uniform flow to a subsequent component or vessel despite variable flow from the
source
Indirect discharger –A nondomestic discharger introducing pollutants to a POTW
Industrial wastes – Liquid or other wastes resulting from any process of industry,
manufacturer, trade or business, or from the development of any natural resources
Kilo-pound (ksi) – One ksi is equal to 1,000 psi, combining the prefix kilo with the
abbreviation psi. Example: 3 ksi is equal to 3,000 psi.
Land application – The distribution of treated wastewater of acceptable quality, (“effluent”),
supernatant from bio-solids-use facilities, or stabilized sewage sludge of acceptable quality
(“bio solids”) upon or into the land with a uniform application rate for the purpose of
assimilation, utilization, or pollutant removal; Note: Bulk disposal of stabilized sludge in a
confined area, such as a landfill, is not land application
Licensee – An individual holding a valid license issued by the Board for Waterworks and
Wastewater Works Operators
Licensed operator – A licensee in the class of the treatment works who is an operator at the
treatment works
Loading rate, organic – Biodegradable fraction of chemical oxygen demand (biochemical
oxygen demand, biodegradable FOG, and volatile solids) delivered to a treatment component
in a specified time interval expressed as mass per time or area; e.g., pounds per day or
pounds per cubic foot per day (pretreatment); pounds per square foot per day (infiltrative
surface or pretreatment); Note: Typical residential system designs assume biochemical
loading equals organic loading
Local review – A program for obtaining advance approval by the director of an owner’s local
plans/specifications for future connections to, or extensions of, existing sewage systems,
along with an implementation plan, in lieu of obtaining a CTC and CTO for each project
within the overall scope of the plan
2-4
Mixed liquor suspended solids (MLSS) – Concentration of suspended solids in mixed liquor,
expressed in milligrams per liter (mg/L)
Moving Bed Biological Reactor (MBBR) – An activated sludge process with the addition of a
media product for biological film attachment. Types of media include plastic spheres,
cylindrical tubes, or other designs that contain a large surface area for biological film
attachment and growth. The reactor utilizes an air source (blower/compressor) to facilitate
mixing of the media, activate sludge, and food source along with oxygen to produce and
maintain biological growth
Nitrification – Biological oxidation of ammonium (NH4+) to nitrate (NO2-) and nitrate (NO3-), or
a biologically induced increase in the oxidation state of nitrogen
Nitrogen – Essential chemical element and nutrient for all life forms; molecular formula (N2)
constitutes 78 percent of the atmosphere by volume; nitrogen is present in surface water and
groundwater as ammonia (NH3), nitrite (NO2-), nitrite (NO3-), and organic nitrogen; excess
levels of nitrogen in marine areas may contribute to eutrophication
Operate – The act of making a decision on one's own volition (i) to place into or take out of
service a unit process(s) or (ii) to make or cause adjustments in the operation of a unit
process(s) at a treatment works
Operating staff – Individuals employed or appointed by any owner to work at a treatment
facility; Note: The above definition includes all licensees whether the license held is
appropriate for the classification/ category of the treatment works or not
Operator – Any employed or appointed individual designated by the owner as being in
responsible charge (supervisor, shift operator, or a substitute) whose duties include testing or
evaluation to control treatment works operations; Note: Not included in the above definition
are superintendents or directors of public works, city engineers, or other municipal or
industrial officials whose duties do not include the actual operation or direct supervision of
a treatment works
Owner – A political subdivision including (but not limited to) sanitation district commissions
and authorities and any public or private institution, corporation, association, firm or
company organized or existing under the laws of this or any other state or country, or any
officer or agency of the United States, or any person or group of persons acting individually or
as a group that owns, operates, charters, rents, or otherwise exercises control over or is
responsible for any actual or potential discharge of sewage, industrial wastes, or other wastes
to state waters, or any facility or operation that has the capability to alter the physical,
chemical, or biological properties of state waters
Pathogens – Organisms that cause infectious disease in warm-blooded beings
Permit – A CTC or a CTO license
pH – Measure of the acid or base quality of water that is the negative log of the hydrogen ion
concentration; the scale ranges from 1-14, with a pH of 7.0 being neutral, 14.0 being strongly
alkaline (basic), and 1.0 being strongly acidic
Pretreatment – Any component or combination of components that provides treatment of
wastewater prior to conveyance to a final treatment and dispersal component or for reuse;
this treatment is often designed to meet primary, secondary, tertiary, and/or disinfection
treatment standards
2-5
Primary sludge – Sewage sludge removed from primary settling tanks, readily thickened by
gravity thickeners
Point source – Any discernible, confined and discrete conveyance including (but not limited
to) any pipe, ditch, channel, tunnel, conduit, well, discrete fissure, container, rolling stock,
concentrated animal feeding operation, landfill leachate collection system, vessel or any
other floating craft from which pollutants are or may be discharged; Note: This definition
does not include return flows from irrigated agriculture or agricultural storm water runoff
Pollutant – Solid waste, incinerator residue, filter backwash, sewage, garbage, sewage
sludge, munitions, chemical wastes, biological materials, radioactive materials (except those
regulated under the Atomic Energy Act of 1954, as amended (42 USC 2011 et seq.) heat,
wrecked or discarded equipment, rock, sand, cellar dirt, and industrial, municipal and
agricultural waste discharged into the water
Pollution –Alteration of the physical, chemical or biological properties of any state waters
that will, or is likely to, create a nuisance or render such waters (i) harmful or detrimental or
injurious to public health, safety or welfare, or to the health of animals, fish or aquatic life;
(ii) unsuitable with reasonable treatment for use as present or possible future sources of
public water supply; or (iii) unsuitable for recreational, commercial, industrial, agricultural or
for other reasonable uses; provided that: (a) an alteration of the physical, chemical or
biological property of state waters, or either a discharge, or a deposit, of sewage, industrial
wastes, or other wastes to state waters by any owner, which by itself is not sufficient to
cause pollution, but which, in combination with such alteration of, or discharge, or deposit to
state waters by other owners is sufficient to cause pollution; (b) the discharge of untreated
sewage by any owner into state waters; and (c) contributing to the contravention of standards
of water quality are pollution
Reliability – A measure of the ability of a component or system to perform its designated
function without failure or interruption of service
Responsible charge – Designation by the owner of any individual to possess the duty and
authority to operate a treatment works
Sequencing batch reactor (SBR) – Component in which batch type suspended-growth
(activated sludge) processes are carried out in the same tank in stepwise order (e.g. fill,
treat, settle, decant, draw)
Settled sewage – Effluent from a basin in which sewage is held or remains in quiescent
conditions for 12 hours or more and the residual sewage sludge is not reintroduced to the
effluent following the holding period; Note: Sewage flows not in conformance with the
aforementioned conditions providing settled sewage shall be defined as non-settled sewage
Sewage – The water-carried and non-water-carried human excrement, kitchen, laundry,
shower, bath or lavatory wastes, separately or together with such underground, surface,
storm and other water and liquid industrial wastes as may be present from residences,
buildings, vehicles, industrial establishments or other places
Sewage sludge or sludge –Any solid, semisolid, or liquid residues which contain materials
removed from municipal or domestic wastewater during treatment including primary and
secondary residues; Note: Also included in this definition are other residuals or solid wastes
consisting of materials collected and removed by sewage treatment, septage and portable
toilet wastes; Liquid sludge contains less than 15% dry residue by weight and dewatered
sludge contains 15% or more dry residue by weight
2-6
Sewerage system or sewage collection system –A sewage collection system consisting of
pipelines or conduits, pumping stations and force mains and all other construction, devices
and appliances appurtenant thereto, used for the collection and conveyance of sewage to a
treatment works or point of ultimate disposal
Sludge management – The treatment, handling, transportation, use, distribution or disposal
of sewage sludge
Solids, total suspended (TSS) – Measure of all suspended solids in a liquid, typically expressed
in mg/L; to measure, a well-mixed sample is filtered through a standard glass fiber filter and
the residue retained on the filter is dried to a constant weight at 217 to 221 degrees F (103 to
105 degrees C); the increase in the weight of the filter represents the amount of total
suspended solids
State waters – All surface and underground water wholly or partially within or bordering the
State or within its jurisdiction
Subsurface disposal – A sewerage system involving the controlled distribution of treated
sewage effluent below the ground surface in a manner that may provide additional treatment
and assimilation of the effluent within the soil so as not to create a point source discharge or
result in pollution of surface waters
Surface waters – All State waters that are not ground water as defined in Section 62.1-255 of
the Code of Virginia
Toxic pollutant – Any pollutant listed as toxic under Section 307(a) (1) or, in the case of
sludge use or disposal practices, any pollutant identified in regulations implementing Section
405(d) of the Clean Water Act
Treatment, biological – Process involving the metabolic activities of bacteria and other
microorganisms in the breakdown of complex organic materials into simpler, more stable
substances
Treatment, chemical – Process involving the addition of chemicals to obtain a desired result,
such as precipitation, coagulation, flocculation, pH adjustment, disinfection, or sludge
conditioning
Treatment, primary – Physical treatment processes involving removal of particles, typically
by settling and flotation with or without the use of coagulants; (e.g. a grease interceptor or a
septic tank provides primary treatment)
Treatment, secondary – Biological and chemical treatment processes designed to remove
organic matter; a typical standard for secondary effluent is BOD and TSS less than or equal to
20mg/L each on a 30-day average basis
Treatment, tertiary – Advanced treatment of wastewater for enhanced organic matter
removal, pathogen reduction, and nutrient removal; Note: Typical standards for tertiary
effluent vary according to regulatory requirements
Treatment works – Any device or system used in the storage, treatment, disposal or
reclamation of sewage or combinations of sewage and industrial wastes including (but not
limited to) pumping, power and other equipment and their appurtenances, septic tanks and
any works, including land, that are or will be (i) an integral part of the treatment process or
(ii) used for ultimate disposal of residues or effluents resulting from such treatment
2-7
Ultraviolet – Light waves beyond the visible spectrum; used for disinfection of water and
wastewater
Wastewater, commercial – Non-toxic, non-hazardous wastewater from commercial
establishments, including but not limited to commercial food preparation operations, that is
similar in composition to domestic wastewater, but which may have one or more of its
constituents exceed typical domestic ranges
Wastewater treatment systems, decentralized – Treatment system for collection,
treatment, and dispersal/reuse of wastewater from individual homes, clusters of homes,
isolated communities, industries, or institutional facilities, at or near the point of waste
generation
Wastewater treatment system, onsite (OWTS) – Wastewater treatment system relying on
natural processes and/or mechanical components to collect and treat sewage from one or
more dwellings, buildings, or structures and disperse the resulting effluent on property owned
by the individual or entity
Water quality standards – The narrative statements for general requirements and numeric
limits for specific requirements, which describe the water quality necessary to meet and
maintain reasonable and beneficial uses
2-8
CHAPTER 3 PRODUCT OVERVIEW
The INCEPTORTM presents the superior choice for wastewater treatment due to its unique
wastewater treatment process and one-of-a-kind Structurally Reinforced Polyethylene (SRPE)
vessel. By utilizing SRPE it is possible to fabricate large and robust packaged wastewater
treatment systems that can be installed in a flexible final configuration custom designed for
every specific application. The use of SRPE for tankage and HDPE for chamber walls
combined with Polyvinyl Chloride (PVC) and Polyethylene (PE), fluid and aeration piping
results in a system configuration that will not corrode, rust, or degrade due to extreme
fluctuations in pH and/or exposure to corrosive wastewater gases.
All INCEPTORTM system designs utilize air driven components for aeration, mixing and
pumping; thus, there are no internal mechanical or electrical components. The external
blower is the only mechanical component for supplying air to the biological processes and
moving fluids. The system, structurally engineered for direct burial, is corrosion resistant,
lightweight, watertight, energy efficient, and easily installed and operated – all of which
results in a very cost effective and robust form of wastewater treatment for normal and high
strength applications. As can be easily ascertained, the use of SRPE and all plastic internal
components permits the ability to provide a truly sustainable treatment system with a
substantially longer service life. The INCEPTORTM possesses a service life of approximately 75
years even in harsh coastal environments, a life cycle that is two to three times longer than
comparable steel and concrete packaged wastewater treatment systems.
The systems are designed for residential, commercial, industrial and municipal wastewater
applications. In addition to standard designs, the SRPE can be customized to fit specific
requirements that may differ in wastewater strengths with more stringent discharge limits or
unique regulatory requirements.
Key advantages that set the INCEPTORTM apart from industry competitors is its unique and
lightweight system design, standard off-the-shelf component vessels, a variety of models with
treatment capacities from 2,000–250,000+ GPD; fast turn-around time from final design to
installation; minimal equipment required for installation; highly efficient treatment vessels
requiring a reduced foot print of space; low energy consumption; and ease of operation and
maintenance.
Behind the superior product stands a team of experts ready and willing to assist the end user
with system operations and maintenance in any manner necessary. From the engineer to the
installer to the startup/onsite training specialist, the entire team’s collective goal is to foster
an excellent working relationship with the customer and, together, establish the very best
treatment process that successfully meets all industry standards and discharge requirements.
The team is most appreciative of its customers who selected the INCEPTORTM Wastewater
Treatment Plant and look forward to providing ongoing support and excellent service.
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CHAPTER 4 OPERATOR AND MANAGERIAL RESPONSIBILITY
The facility owner/manager is required to contract with or hire a wastewater operator who is
product-certified to service and maintain the system. Other required certifications mandated
by State and/or federal law must also be held, in addition to the product certification.
Regardless of the process employed or equipment provided, the design objectives of a
wastewater treatment plant are met only through the diligent efforts and interest of the
people who operate and maintain the facility.
Efficient and economical functionality of the system requires both operational and managerial
personnel, with responsibilities of both groups being clearly defined. It may be feasible that
operator(s) of the treatment system be contracted to provide maintenance services for
system equipment (unless other qualified persons are on staff) while owner(s) be considered
managerial personnel. Everyone involved should be mindful of the responsibilities and
potential challenges of one another, such that all parties work together harmoniously and
efficiently to achieve optimal system performance. The goal to provide the best effluent
possible to meet or exceed the discharge limits should always be the main focus.
The wastewater plant operator is responsible for all functions of the treatment facility.
A thorough understanding of the mechanical and treatment processes, as well as an
awareness of potential hazards involved with various stages of the treatment system is an
essential requirement.
QUALIFICATIONS FOR PLANT OPERATORS

The wastewater plant operator should have:
• thorough knowledge of the operating characteristics and maintenance requirements of

a wastewater treatment plant;
• knowledge of hydraulic, chemical, and mechanical principles pertinent to the
operation of a wastewater treatment plant;
• knowledge of the occupational hazards and safety precautions of the work;
• ability to observe and inspect mechanical equipment during plant operations to detect
defects and apply appropriate remedial measures;
• ability to understand and follow oral and written instructions and diagrams;
• ability to keep records and prepare and submit reports in a timely fashion;
• understanding of and willingness to use a variety of special safety devices such as
inhalators, safety belts, special gloves, and related PPE;
• skill in the operation and care of tools and equipment appropriate to the work;
• willingness to obtain appropriate certification for the treatment plant operations.
OPERATOR RESPONSIBILITIES
In most cases, the operator will work onsite for limited time intervals; however, must adhere
to and/or accomplish the following for proper system operation, maintenance, and
monitoring:
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• Periodically inspect the wastewater treatment system
• Perform field tests to determine facility performance and record results on proper
bench sheets
• Make treatment facility control adjustments as required
• Maintain the appearance of the plant or see that such work is performed by others
• Maintain neat and accurate records of operation and maintenance
• Submit reports in a timely manner to State and federal agencies as required
• Submit reports to local authorities as required
• Advise owner/managerial staff of all potential problems in operation and maintenance
of the wastewater treatment plant and pump station
• Take appropriate action to correct deficiencies immediately
• Report overflows to the proper agencies and follow the regulation requirements for
such occurrences
• Recognize equipment safety hazards and promote and practice safe operating
procedures
• Provide adequate materials and supplies to properly operate the wastewater
treatment system
• Use material and supplies in an economical manner
OWNER/MANAGERIAL RESPONSIBILITIES
The owner/managerial staff are ultimately responsible for the total management and
operation of the wastewater collection, treatment, and disposal. The owner/managerial staff
should utilize personnel, equipment, and available funds to ensure the efficient operation of
the treatment plant. The owner/managerial staff should work with operators to ensure all
phases of the treatment facility are operated efficiently.
The following tasks and responsibilities shall rest with the owner/managerial staff:
• Ensure efficient wastewater treatment plant operation and maintenance

• Maintain adequate operational and management records
• Establish and maintain a harmonious working relationship with the operator and/or
contract company (operator team)
• Periodically inspect the system, observe operational practices, and address any
problems with operator(s)
• Encourage operator(s) to bring all problems to managerial attention
• Assist in preparing reports of tests, findings and recommendations
• Provide adequate working conditions, safety equipment (PPE), and proper tools for use
by the operational staff
• Implement personnel and safety policies as related to the treatment plant
• Plan for future needs
• Secure funding to ensure the facility meets all local, State and federal regulations
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WORK SCHEDULE AND EDUCATIONAL OPPORTUNITIES
The wastewater treatment plant must be manned according to the number of hours it takes
to ensure proper and efficient operations that meet all regulatory requirements. Minimum
requirements are mandated by State and/or federal law based upon factors such as daily flow
and specific treatment processes. Facility work schedules for operators should be established
accordingly.
For proper plant maintenance and monitoring of the various treatment processes, it is highly
recommended that the operator establish a routine for daily and weekly checks according to
specific standards for the size and process controls necessary to ensure plant functionality
and efficiency.
The operator(s) should attend courses, seminars, and other available educational
opportunities to expand upon industry knowledge and skills. In most cases, continuing
education credits are required to maintain certifications. Educational opportunities are also
essential to stay abreast of new technology and industry regulations.
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CHAPTER 5 SAFETY
OSHA
Throughout this segment on safety, there are multiple references made to written materials
from the Operational Safety and Health Administration (OSHA) which are included in the
Appendices. OSHA is the main federal agency charged with the enforcement of safety and
health legislation. For more information regarding OSHA, visit their website at
www.osha.gov.
GENERAL SAFETY
Safety is the responsibility of everyone, operations personnel and management alike, and
must be considered a top priority with due training, funding, and overall attention by those in
policy-making authority. Potential safety hazards absolutely exist with wastewater treatment
plant operations and maintenance, resulting in bodily injury or death. Accidents or incidents
involving equipment, noxious gases, chemicals, and wastewater-associated bacteria and
viruses are a few of the more common contributors to safety hazards when industry-
recommended steps and basic safety precautions are not taken seriously and practiced
consistently. Therefore, all persons engaged in the operation of a wastewater treatment plant
should be familiar with safety practices that pertain to the industry as well as the facility
where the plant is located.
Unauthorized persons should never be allowed within the parameters of a wastewater
treatment plant. A locked fence around the plant is highly recommended and is the best
safeguard for people, equipment, and the treatment process itself. Hazardous energies must
be controlled such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal (and
others) for the safety of both the public and those charged with monitoring, servicing, and
maintaining various components of the wastewater treatment plant.
(For additional information see “OSHA FactSheet – Lockout/Tagout” in Appendix A)
All safety issues and incidents should be handled and reported in accordance with the policies
and procedures set forth by the facility where the treatment plant is located.
It is highly recommended that facility management stress the importance of good
housekeeping practices relative to general safety. A list of available safety supplies and
equipment (examples: protective gloves, hard hats, coveralls, rope, harnesses, fire
extinguishers, first aid kits, etc.), along with their onsite locations, should be compiled and
clearly posted for the benefit of wastewater treatment plant personnel.
Emergency contacts and telephone numbers should also be posted within plain view so that
all personnel have quick and easy access.
The following pages describe most (but may not include all) of the major safety hazards
associated with wastewater treatment plant systems:
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ELECTRICAL
There are electrical components associated with the operation of a wastewater treatment
plant. Examples include the control panel, blowers, monitoring devices, generators, etc.
General electrical safety procedures and precautions are applicable and consistent adherence
is vital for prevention of malfunctions and accidents.
Since some of the mechanical equipment in the treatment facility may be powered by
electricity, personnel should adhere to the following guidelines:
• Do not ground oneself in water or on pipes or drains. Avoid them when working near
electricity.
• Allow only authorized personnel to work on electrical equipment.
• Keep all electrical controls accessible and identified.
• Lock and tag the switches when working on mechanical equipment powered by
electrical sources that could be turned on by another person. (For additional
information see “OSHA FactSheet – Lockout/Tagout” in the Appendix A)
• When there is a question about any potential electrical hazard, seek advice from
authorized personnel prior to exposing oneself to danger.
• Ground all electric tools.
• Remain mentally focused on the electrical task at all times.
(For additional information see “OHSA FactSheet – Working Safely with Electricity” in the
Appendix A.)
EXPLOSION AND FIRE

With electrical systems and the possible presence of methane gas associated with the
operation of a wastewater treatment plant, explosion and fire must be considered a potential
safety hazard. Methane gas accumulation is produced by anaerobic bacteria breaking down
sewage (waste products) generally found in a septic tank or primary clarifier of an anaerobic
digester. To reduce this risk, wastewater treatment personnel should take steps to ensure
that vents are free of bird nests, bee nests, rodent beds, and other blockages. When there is
a buildup of sludge that has exceeded standard levels, the production of methane could be
elevated to unsafe levels and will not vent properly.
In the event of a fire within the parameters of the treatment plant, it is crucial to know the
location and function of a fire extinguisher, and exactly how to properly operate it.
Emergency service organizations can provide training on the correct use and types of fire
extinguishers required for proper application. They can also recommend the placement and
size of fire extinguishers. Fire extinguishers should be inspected and tested annually.
Recharges should be performed when an extinguisher is used and the equipment returned to
its proper location as soon as possible.
Wastewater treatment plant personnel should never smoke or produce open flame while
working in or around the treatment units.
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Applicable policies and procedures of the facility where the wastewater treatment plant is
located should be followed in the event of an explosion or fire emergency.
(For additional information see “OSHA FactSheet – Fire Safety in the Workplace” in the
Appendix A).
TRIPS AND FALLS

To reduce the risk of tripping and falling within the parameters of the wastewater treatment
plant, it is important that debris be promptly noted and removed, weeds controlled, and
grass kept mowed and grounds maintained. Tools, equipment, cables, wires, among other
items should never be left lying on the ground as these items may become tripping hazards.
To prevent falling into a treatment vessel when hatches are open, it is important to utilize
extreme caution, remaining safety conscious and alert at all times. Safety should always be
the first consideration when walking through the plant area, maintaining the system,
performing testing, and other related activities. Hatches should be closed and secured with
the proper hardware immediately upon completion of work. Never should wastewater
treatment plant operations personnel leave the area, even briefly, while hatches are open. It
is imperative that no unauthorized persons be present within the parameters of the
wastewater treatment plant at any time.
CUTS, ABRASIONS, AND OTHER INJURIES

Physical injuries may be defined as any type of cut, bruise, sprain, broken bone, burn, bite,
or infection. Such injuries may occur by the handling of objects, plummeting objects, falls,
stepping on or striking objects, working on or with machinery, or heat exposure (including
fire, steam, etc.). Physical injuries are usually caused by some action, lack of action, or
defect that led to an accident brought about by failure to practice accepted safe procedures,
unsafe personal factors, or unsafe mechanical or physical conditions. All physical injuries
should be treated promptly by qualified personnel and reported in accordance with applicable
policies and procedures set forth by the facility where the wastewater treatment plant is
located.
LIFTING AND HANDLING INJURIES

For safe lifting and handling of heavy or awkward items and materials associated with the
wastewater treatment process, strict adherence to the old rule, “Lift with your legs and not
your back” is essential to the prevention of injuries. Requesting assistance from others as
needed and/or the use of specialized equipment for material handling is also highly
recommended.
CONFINED SPACES
A confined space is one that is just large enough to enter and perform assigned work. It
has limited or restricted ways to enter or exit and is not designed to be occupied continuously
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by a worker. The atmosphere within a confined space must be tested using equipment that
is designed to detect the chemicals which may be present at levels that are well below the
defined exposure limits. Access requires that a confined space entry permit be obtained
beforehand, as potential hazards include the presence of dangerous or fatal gases,
insufficient oxygen, and collapse of the tank and entrapment of personnel, all of which could
result in bodily injury or death.
(For additional information see “OSHA FactSheet – Procedures for Atmospheric Testing in
Confined Spaces” in the Appendix A)
OXYGEN DEFICIENCY AND TOXIC GASES

In operating/monitoring the wastewater treatment plant, the greatest risk from noxious
gases, vapors, and oxygen deficiency hazards is associated with system leaks and underground
structures that are considered confined spaces.
(For additional information, see section entitled “Confined Spaces” in this chapter, and
OSHA FactSheet “Procedures for Atmospheric Testing in Confined Spaces” in Appendix A)
Oxygen deficiency and toxic gas hazards are inherent within a wastewater treatment system
but, once recognized, they are readily corrected or at least guarded against by proper
warnings, postings, and general safety practices.
Gases are the normal state of elements and compounds such as oxygen or methane. On
the other hand, vapors (or noxious gases) from substances such as gasoline, may be directly or
indirectly injurious or destructive to the health or life of human beings.
Gas hazards are divided into three principal classes: (a) burning or explosive, (b)
asphyxiation, and (c) poisoning. A noxious gas may fall into any one or all of these
categories. For example, nitrogen is innocuous, nonflammable, and falls into class (b);
methane is innocuous, but is flammable and suffocating, and falls into classes (a) and (b); and
carbon monoxide is flammable, suffocating, and poisonous and falls into classes (a), (b)
and (c). Gases and vapors have been classified as: (a) asphyxiates when breathed in high
concentration, either mechanically or chemically, excluding oxygen, or (b) irritants
which may injure lungs and air passages, inducing inflammation.
Extreme care must be taken to prevent explosions caused by combustible gases or vapors.
Deep underground structures should be vented and tested before they are entered. The
safest approach to the operation of a wastewater treatment system is to possess a good
knowledge base and understanding of sewer gases, where they are found, and procedures and
equipment for minimizing their danger. Sewer gases are the by-products of biological
activity. Bacteria grow on the slime, which accumulates within the system. These bacteria
thrive, either aerobically or anaerobically, on the organic matter in the wastewater.
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CHEMICALS
There are a variety of chemicals associated with the wastewater treatment plant operation
and maintenance process. It is important to note that chemicals, in general, can be
extremely volatile in the workplace. When misused, mishandled, or certain established
precautions and procedures are not consistently followed, chemicals should be considered
extremely dangerous. A number of unfortunate situations related to chemicals could
potentially occur resulting in inhalation, spills, explosions, and burns, causing serious bodily
injury and even death. Chemicals should be handled only by those educated in chemical
safety.
One should always be thinking about safety when working with chemicals. Along with
chemical-specific guidelines, the following basic safety tips are also applicable:
CHEMICALS – GENERAL TIPS AND GUIDELINES

• Make certain all chemicals are labeled correctly and clearly. There can be no margin
for error or having to guess if a container holds the correct chemical needed.
• Secure lids to prevent accidental spills and put chemical away in the proper location
after use.
• When chemicals are used in enclosed or confined areas, ensure that proper ventilation
exists such that air flows freely in the space.
• Always wear protective goggles to prevent a chemical splash from burning the
eyes.
• Always wear gloves to prevent chemical burns to the hands.
• To prevent inhalation of airborne chemicals, always wear a protective mask.
• Be familiar with the nearest location of an eye wash station and how to properly flush
eyes.
• If a spill occurs that gets on clothing, the garment(s) should be removed immediately
to prevent or reduce skin injury.
• Keep all flammable chemicals away from any heat source or electrical appliance.
• Always read and adhere to manufacturer’s guidelines and warnings pertaining to
specific chemicals and products.
• Have local emergency numbers posted where all staff members may see them.
• Report any chemical-related incidents/accidents according to the established policies
and procedures set forth by the facility where the wastewater treatment plant is
located.
Although a variety of chemicals may be used in and around a wastewater treatment plant
operation, from maintenance equipment fluids to cleaning agents, only the major industry-
specific, operation-related chemicals are addressed below for precautions and safe and
proper handling by the operator:
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CHLORINE (GAS)
Compressed liquefied chlorine gas has been used in the disinfection of wastewater discharge
for many years. While the chemical is widely-used and very effective, it can be deadly if not
handled properly with extreme caution.
Chlorine is a greenish-yellow gas with excellent disinfecting properties when in an aqueous
solution. However, the chemical may potentially be quite dangerous. Chlorine accidents
occur when gaseous fumes are inadvertently released into the atmosphere and are typically
caused by equipment failure and carelessness. Chlorine gas has a very pungent odor such that
is easily detected even in small doses. Exposure to dosages less than four parts per million
should not cause physiological disorders. However, large concentrations can be fatal,
especially if the fumes are laden with moisture. The victim will unknowingly inhale large
quantities of molecular chlorine, resulting in the production of pulmonary edema. This is
essentially death by drowning while the victim is asleep.
Inhalation of dry chlorine gas is much more common and easily noticed. Upon
inhalation, gas affects the throat by immediately causing a constrictive sensation. The body
attempts to prevent gas from entering the lungs. The constrictive sensation is a warning sign
that the victim should immediate vacate the area to prevent further inhalation.
SODIUM HYPOCHLORITE
Sodium hypochlorite is an active chlorine solution (<10%) used in the water and wastewater
industry as a disinfectant for treated waters. In the wastewater process, the final effluent is
treated to a level that will destroy illness- and disease-causing pathogens.
The chemical may be harmful if not properly handled resulting in exposure. Sodium
hypochlorite may gain access into the body by ingestion and through inhalation of its vapors.
If ingested, a burning sensation, sore throat, and cough may be experienced, in addition to
abdominal pain and vomiting. If eyes or skin are affected, redness and pain could result.
When this chemical is inhaled, the throat and respiratory system may be affected causing a
cough and throat soreness.
When working with sodium hypochlorite, the generation of a mist should be prevented at all
times. In case of spillage, personal protective items should always be worn and self-
contained breathing apparatus utilized. Proper ventilation in the area where the chemical is
used is also of great importance. Wash away spills with plenty of water. Do not absorb in
saw-dust or other combustible absorbents.
Sodium hypochlorite should be stored in a cool, dark place away from acids.
(For additional information, see OSHA FactSheet “Personal Protection Equipment – PPE” in
Appendix A)
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SODIUM SULFITE
Sodium sulfite (Na2 SO3) is a compound used in the wastewater industry primarily for de-
chlorination of a treatment facility utilizing a chlorine compound or gas chlorine for
disinfection. De-chlorination is generally required before discharging effluent to waterways,
spray irrigation systems, and sub-surface applications.
Inhalation of sodium sulfite may result in labored breathing and wheezing. In sensitized
individuals, ingestion of even minute quantities may lead to serious problems and medical
attention should be sought immediately.
Spilled sodium sulfate should be swept into containers, if appropriate, moistened first to
prevent dusting. The remainder should be washed away with plenty of water. In case of
spillage, personal protective items should always be worn and a P2 filter respirator used for
harmful particles.
Sodium sulfate should be stored in a dry place away from strong oxidants.
(For additional information see OSHA FactSheet “Personal Protection Equipment – PPE” in
Appendix A)
SULFUR DIOXIDE
In the wastewater treatment process, sulfur dioxide is a chemical that is commonly used to
remove chlorine prior to discharge to a waterway, land application, or onsite system.
Sulfur dioxide is a colorless erosive gas with an irritating pungent odor, similar to rotten eggs
or burnt matches. The odor makes the chemical possible to detect even at low
concentrations.
Sulfur dioxide can be dangerous if improperly handled and should be treated much the same
as chlorine.
(For additional information, see the section entitled “Chlorine” in this chapter).
GENERAL REFERENCES
When working with the aforementioned chemicals, one should follow all general guidelines
for safe handling and also make reference to the substance manufacturer’s Material Safety
Data Sheet (MSDS) for additional warnings, recommendations, and first aid information.
(For additional information, see “Chemical Safety – General Tips and Guidelines”
under Chapter IV – SAFETY)
BIOHAZARDS
(Bacterial-type and Viral Infections)
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Persons who come into contact with wastewater are exposed to all of the hazards of
waterborne diseases, countless numbers of pathogenic (disease-producing) bacteria,
*bloodborne pathogens (wastewater may contain blood components), as well as the danger of
infected wounds. Contact always presents a potential health hazard. Diseases caused by
viruses or bacterial infections include typhoid fever, cholera, amoebic dysentery, and other
intestinal disorders. Wastewater may contain spirochetes which cause jaundice and pus-
producing organisms. Tetanus and skin infections must also be safeguarded against.
Operators of a wastewater treatment plant may be exposed to body infections whenever
wastewater, sludge, screenings, and other potentially infectious materials are handled.
Laboratory sampling and testing constitutes a health risk, as such activities may place the
operator in direct contact with potentially infectious sewage. Consequently, extra
precautions must be taken to avoid contact with or accidental ingestion of contaminated
material.
The operator must realize the same precautions should be taken with plant effluent as with
raw wastewater. Organisms still exist in post-treatment wastewater, as does the possibility
of infection. Good hygienic practices are a must. Gloves and eye protection should be worn
to help protect the skin and eyes. Hands should be washed with disinfecting soap to avoid
disease. Special care should be taken not to place hands into the mouth, eyes or nose after
handling wastewater as this can lead to infection. Washing becomes vital when the
operator’s hands are burned, chapped, or contain an open wound, regardless of how small.
Personal protective equipment (PPE) should always be worn when cleaning treatment plant
components, handling filters, sludge, influent or effluent.
It is recommended that all persons who are potentially at risk by nature of responsibility for
wastewater treatment plant operations be inoculated against infections contracted from
exposure to wastewater. It is also recommended that tetanus booster shots be received at
periodic intervals. If applicable, consult with the Health or Human Resource Officer(s) where
the wastewater treatment plant is located for facility-specific policies and procedures
regarding employee inoculation.
(For additional information see “OSHA FactSheet – Personal Protective Equipment (PPE)
Reduces Exposure to Bloodborne Pathogens” in the Appendix A)
LABORATORY HAZARDS
Laboratory sampling and testing constitutes a possible health hazard as there is a chance that
the operator may come into direct contact with potentially infectious sewage. Consequently,
extra precautions must be taken to avoid accidental ingestion of or contact with
contaminated materials. Rubber gloves and eye protection should be worn when handling
wastewater for testing purposes.
In the laboratory, it is important to ensure that equipment and containers are kept clean and
that contamination is not brought about through carelessness. Mouth pipetting is prohibited.
Laboratory glassware is never to be used for drinking. Precautions should b taken to avoid
breaking glassware. If a breakage occurs, the glass must be carefully handled and disposed of
properly to prevent cuts or puncture wounds.
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(For additional information see “OSHA FactSheet – Laboratory Safety – OSHA Laboratory
Standard” in the Appendix A)
MECHANICAL EQUIPMENT HAZARDS

All moving mechanical parts of any piece of equipment should be guarded by a shield or other
suitable safety device. A typical example is the enclosure surrounding a V-belt drive. The
plant operator must ensure that no work is performed on or near any machinery that lacks a
safety guard. Loose clothing and accessories such as ties or jewelry should not be worn
around any moving mechanical equipment. Absolutely no mechanical equipment should be
repaired or adjusted while in operation. A lock-out/tag-out program should be adhered to
when taking mechanical equipment out of service for maintenance.
(For more information see“OSHA FactSheet – Lockout/Tagout” in the Appendix A)
DROPPING TOOLS/EQUIPMENT INTO WASTEWATER

Extra care must be taken not to drop objects down into access openings or component vessels
within the wastewater treatment plant. When using a tool or equipment item in or over an
open vessel, secure it with a lanyard attached to a fixed object above grade in case it slips
out of the hand. When using this method, the item may be easily retrieved if dropped. Once
retrieved, the tool or object should be thoroughly cleaned with soap and water and may be
disinfected with a five percent chlorinated solution. If the dropped tool or object is made of
metal and was not secured with a lanyard, it could be possible to retrieve it by using a heavy
magnet on a rope. If the item is not retrievable, the incident must be documented to alert
all personnel as the situation could potentially interrupt or interfere with normal system
operations until a suitable plan may be devised for removal of the object.
PERSONAL PROTECTIVE EQUIPMENT (PPE)

PPE reduces the possibility of injury to persons responsible for the operation and maintenance
of a wastewater treatment plant. Protective clothing and equipment is required for specific
jobs under OSHA standards to reduce the risk of injury to the body, head, face, eyes, ears,
hands, arms, legs, and feet.
Appropriate respirators must be used to protect against adverse health effects caused by
breathing contaminated air.
(For more information, see “OSHA FactSheet – Personal Protective Equipment” in Appendix
A)
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BASIC SAFETY GUIDELINES FOR THE OPERATIONS AND MAINTENANCE OF A
• All persons responsible for the operation and maintenance of the wastewater
treatment plant should be familiar with applicable safety guidelines, policies,
procedures, and possess a good understanding of accident prevention.
• Never work while under the influence of intoxicating beverages and/or drugs.
• Never work while abilities are impaired by fatigue, illness, or other factors that could
lead to accidents, injury, or death.
• Horseplay of any sort should not be tolerated.
• Workers should perform no maintenance or treatment operations beyond the scope of
personal ability, unless specific instructions from a knowledgeable qualified person are
received.
• All those who operate or maintain a wastewater treatment plant should thoroughly
cleanse any portion of the body that comes into contact with poisonous or potentially
infectious substances such as wastewater.
• All those who operate or maintain a wastewater treatment plant should become
familiar with the location and operation of fire extinguishers and safety equipment.
• Hard hats should be worn at all times where the danger of falling objects exists.
• Eye shields or goggles should be worn in areas where a potential hazard exists to the
safety and health of one’s eyes.
• Gasoline or other highly flammable liquids should not be used for cleaning purposes
and should be properly stored.
• All injuries or accidents should be reported immediately to the appropriate personnel
for the facility where the wastewater treatment plant is located.
• The emergency number – 911 – should be posted adjacent to all telephones along with
the appropriate telephone numbers for the facility at which the wastewater treatment
plant is located.
• All areas within the wastewater treatment plant should be kept clean and free of
known safety hazards.
• System hatches should be locked at all times to prevent unauthorized entry which
could result in potentially serious injuries or death.
• Electrical work should be performed only by qualified individuals.
• All equipment should be locked out and tagged before work to mechanical equipment
begins.
• Wastewater treatment plant chambers should never be entered alone or without first
conducting confined space entry procedures.
• There should always be a safety designee outside the wastewater treatment plant if
workers need to enter
NOTE: Entry into the wastewater treatment plant requires that a confined space entry
permit be obtained beforehand, as potential hazards include the presence of dangerous or
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fatal gases, insufficient oxygen, and collapse of the tank and entrapment of personnel, all of
which could result in bodily injury or death.
• Gloves should be worn to prevent contact with bacteria and viruses to skin.
NOTE: If an individual does come into contact with wastewater, to decrease the risk of
bodily injury or death, all contaminated clothing should be immediately removed, the
affected area washed thoroughly with soap and water, and a call placed immediately to the
person’s physician of choice.
• Always wash hands thoroughly after working on the treatment system.

• Clothing that has come into contact with untreated wastewater should be washed
separately from other laundry.
• Weeds should be controlled and vegetation kept mowed around the treatment system
to prevent hiding places for snakes, rodents, and other creatures and insects that
could cause harm to personnel.
• All debris should be removed from the treatment plant area.
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CHAPTER 6 WASTEWATER OVERVIEW
Water becomes wastewater when it is contaminated by domestic use or applications where
commercial businesses and industry introduces a variety of substances classified as impurities
or pollutants. Waste produced by humans is natural, the easiest to treat and dispose of in an
environmentally acceptable manner. Treatment processes become more complex in cases
where waste is mixed with substances that are more challenging to treat (greases or
detergents from industrial sites, for example).
Wastewater must be treated to prevent disease-causing organisms from entering the
environment. Potential diseases caused by improperly treated waste include tetanus,
hepatitis, cholera, and gastroenteritis, among others.
There are five major wastewater sources with very specific characteristics: human and animal
waste; household waste; industrial waste; storm water runoff; and groundwater infiltration.
Each source has its own set of treatment parameters and challenges.
Water may contain a variety of composition-changing waste substances, dramatically altering
its original characteristics and appearance. Understanding the physical characteristics of
wastewater is very important and considered a key factor in evaluating a treatment process
to determine whether or not the system is functioning properly. Chemical characteristics can
quickly change in the waste stream and cause harm to the treatment process without
warning. Biological characteristics are one of the main reasons for treating wastewater.
Conversely, biological organisms also aid in the process of treatment. Periodic control testing
enables a wastewater operator to determine the health of a treatment facility and make
sound operational decisions in the event of a plant upset. Specific details concerning
wastewater characteristics are as follows:
PHYSICAL CHARACTERISTICS
Color:
Wastewater is typically gray in color with a somewhat cloudy appearance, but can change
significantly if allowed to go septic or it contains substances or matter other than domestic
waste.
Odor:
Fresh domestic wastewater has a musty odor, but can change significantly if allowed to go
septic or it contains substances or matter other than domestic waste. In a septic state, the
odor will be similar to a rotten egg, which is associated with the production of hydrogen
sulfide.
Temperature:
Wastewater will normally be close to the temperature of the contributing water supply unless
the manner in which it is used causes the temperature to be increased or decreased. For
instance, domestic heating by hot water sources and certain industrial and commercial
processes can result in a higher wastewater temperature. Temperature control is important
6-1
as it can affect biological activity in the wastewater treatment process. Higher wastewater
temperatures may cause increased biological activity, changing its capacity for holding
oxygen, and decreasing oxygen solubility.
Flow:
The volume of wastewater is normally expressed in terms of gallons per person per day.
Expected design flows of 100 to 200 gallons per person are typically used. Other factors may
also be used when describing flow based upon the classification of wastewater source
(industrial, domestic, etc).
CHEMICAL CHARACTERISTICS
Alkalinity:
Alkalinity is a measurement for determining the neutralizing capability of wastewater.
Alkalinity is essential to buffer the wastewater during the biological processes, neutralizing
the pH.
Biochemical Oxygen Demand (BOD5) :

BOD5 is a strength measurement of biodegradable matter. The analysis is normally run over a
five day period. The range for domestic wastewater is 100 to 300 mg/L. BOD5 can vary
greatly, from quite low to very high depending upon the waste stream treated. An example
of higher strengths may include industries handling meat products where BOD5 often ranges
higher than 1,000 mg/L.
Carbonaceous Oxygen Demand (CBOD5):

CBOD5 measures the amount of biodegradable organic carbon matter. The analysis is usually
run over a five day period in an incubator at 200 C. The incubator is used to prevent oxidation
of nitrogen compounds. The results are generally lower than the BOD5 analysis.
Dissolved Oxygen (DO):

DO is the amount of oxygen dissolved in wastewater. Typical wastewater contains relatively
low concentrations of DO. The presence of DO is critical to maintaining aerobic conditions in
treatment processes. Wastewater that does not contain DO is either anoxic or septic.
Other Dissolved Gases:

Other dissolved gases may include carbon dioxide and hydrogen sulfide.
Nitrogen:
Nitrogen in untreated wastewater will exist in the form of organic nitrogen and/or ammonia
nitrogen. The sum of these may be measured which is known as Total Kjeldahl Nitrogen
(TKN). Wastewater generally contains 20-85 mg/l of nitrogen; 8-35 mg/l of organic nitrogen;
and 12-50 mg/l of ammonia nitrogen.
pH:
6-2
pH is expressed on a scale of 1 to 14, with seven being considered neutral. Lower than 7 is
considered an acidic condition, and above seven a basic condition. For proper wastewater
treatment, the pH should normally be in the 6.5 - 9.0 range.
Phosphorus:
Phosphorus is essential to biological activity. It must be present in minimal quantities or
secondary treatment processes will not perform efficiently. A range of 6-20 mg/l is
considered normal. Phosphorus compounds are found in detergents and can have a negative
impact on the wastewater treatment process. Excessive amounts of phosphorus discharge
from a facility can damage streams and produce an excessive amount of algal growth.
Solids:
Most pollutants found in wastewater may be identified or classified as solids. The treatment
process is generally designed to remove or convert solids to a form that is stable or
removable. Solids are classified by their chemical composition (either organic or inorganic) or
physical characteristics (settleable, floatable, or colloidal). The total solids concentration in
wastewater normally ranges from 350 to 1200 mg/l.
• Settleable Solids – Solids that settle because they are heavier than water.
• Floatable Solids – Solids that float because they are lighter than water.
• Colloidal Solids – Solids that will not rise to the surface or settle to the bottom when
the flow is quieted.
• Suspended Solids (TSS) – Solids that consist of settleable, floatable, and colloidal
types. The concentration range for TSS in wastewater is normally 100 to 350 mg/l.
• Dissolved Solids – Solids that will pass through a glass fiber filter. Concentration
levels in wastewater are generally between 250 and 850 mg/l.
• Organic Solids – Solids which will burn when the sample is placed in a furnace for 15
minutes at 550 0C. These solids contain carbon, hydrogen, oxygen, and nitrogen.
Dissolved solids and suspended solids will contain organic solids.
• Inorganic Solids – Solids that remain after placement in a furnace for 15 minutes
at 550 0C. Dissolved solids and suspended solids will contain inorganic solids.
• Total Solids – Solids that are made of organic and inorganic dissolved and suspended
solids.
Water:
Water makes up 99.5 – 99.9 percent of domestic wastewater. This percentage may be altered
in cases where the composition of the waste streams is affected by such factors as an industry
contribution.
BIOLOGICAL CHARACTERISTICS
6-3
Aerobic Organism:
Aerobic organisms are present in free or dissolved oxygen conditions. They are extremely
important in biological processes using extended aeration technologies.
Algae:
Algae are small plants that utilize photosynthesis process to produce oxygen.
Anaerobic Organism:
Anaerobic organisms can survive only when there is no free of dissolved oxygen present. They
are found in septic tanks and sludge digesters specifically designed to use this particular
biological process.
Anoxic Organism:
Anoxic organisms use combined oxygen from nitrate and nitrite compounds. The anoxic
wastewater treatment process utilizes raw wastewater and return activated sludge (RAS)
which are combined in a vessel containing only a mixing device, without aeration, before
entering into an aerobic treatment zone.
Attached Growth:
Attached growth technologies work on the principle that organic matter is removed from
wastewater by microorganisms. They grow on the filter media (materials such as gravel, sand,
peat, or specially woven fabric or plastic), essentially recycling the dissolved organic material
into a film that develops on the media. Attached growth filters act as secondary treatment
devices following a primary treatment. Raw wastewater must be treated first to remove
larger solids and floating debris as such material can plug filters. There are two basic designs
of attached growth systems; those that hold the media in place, allowing the wastewater to
flow over the bed (such as trickling filters), or those where the media is in motion relative to
the wastewater (e.g., rotating biological disks).
Bacteria:
Bacteria are single-cell microscopic plants. They may be pathogenic or nonpathogenic in
nature. In the wastewater treatment process, bacteria are essential to removing pollutants
from the waste stream.
Facultative Organisms:
Facultative organisms are those that can function in the presence or absence of free or
dissolved oxygen.
Filamentous Bacteria:
Filamentous bacteria grow in a thread or filamentous form and are often branched. They have
a greater surface area exposed to the DO and/or BOD outside of the floc surface. Many
filamentous bacteria are strict aerobes and cannot adsorb BOB under anoxic conditions.
Excess growth of filamentous bacteria interferes with settling, compaction and concentration.
6-4
Flagellated Protozoa:
Flagellated protozoa are microorganisms with a single, long hair-like projection (flagella)
which is used to produce motion and attract food.
Free-swimming Ciliated Protozoa:
Free-swimming ciliated protozoa are microorganisms with tiny hair-like projections (cilia)
used to produce motion and attract food.
Fungi:
Fungi are microscopic plants generally found in highly-polluted waters. They do not contain
sufficient nitrogen or phosphorus.
Pathogenic Organisms:
Pathogenic organisms cause disease in humans and/or animals.
Protozoa:
Protozoa are microscopic animals that are a critical part of the purification process and used
to determine the condition of waste treatment processes.
Rotifers:
Rotifers, normally found in a well operated treatment plant, may be used as an indicator of
the facility’s performance. They are microscopic life forms that are associated with cleaner
waters.
Stalked Ciliated Protozoa:
Stalked ciliated protozoa are microorganisms that attach themselves to floc particles
(activated sludge floc matter). They have tiny hair-like projections (cilia) which are used to
attract food.
Suspended Growth:
Suspended growth treatment systems freely suspend microorganisms in wastewater. Such
systems use biological treatment processes in which microorganisms are maintained in
suspension within the liquid, converting the organic matter or other constituents into gases
and cell tissue. The most common type of aerobic operation is the suspended growth
treatment system. Suspended growth technologies are conventional sludge treatment
systems that use various process modes, ranging from conventional, extended aeration,
contact stabilization, sequencing batch, and single sludge, which are available for polishing
anaerobically treated effluents.
Virus:
A virus is a microorganism which may be either pathogenic or nonpathogenic in nature. They
are extremely fragile and die quickly when removed from a host organism
6-5
SUMMARY OF TYPICAL DOMESTIC WASTEWATER CHARACTERISTICS
Characteristic: Description and/or Range:
Color Gray
Odor Musty
Dissolved Oxygen Less than 1.0 mg/l
pH 6.5 – 9.0
TSS 100 – 350 mg/l
BOD5 100 – 300 mg/l
COD 200 – 500 mg/l
Flow 100 – 200 gallons/person/day
Total Nitrogen 20-85 mg/l
Total Phosphorus 6 – 20 mg/l
Fecal Coliform 500,000 to 3,000,000/100 ml
6-6
CHAPTER 7 SPECIFIC MODEL DESCRIPTION
THE INCEPTORTM 15K WWTP

The INCEPTORTM 15K wastewater treatment plant (WWTP) is designed to receive untreated
raw wastewater from residential, commercial, agricultural or industrial users as specified for
the project and provide advanced wastewater treatment such that high quality effluent may
be discharged to (A) a suitable alternative subsurface, (B) drain field (such as a gravel trench
or drip irrigation system), (C) to a receiving stream or body of water (direct discharge), (D)
spray irrigation system (to approved re-use and reclamation areas that would benefit from
irrigation water), or (E) a facility re-use system (including grey water, rinse and cooling water
applications).
The design for this project utilizes existing polyethylene storage tanks for flow equalization
and sludge storage in conjunction with the INCEPTOR™ packaged treatment system.
The INCEPTORTM 15K WWTP is designed to treat up to 15,000 GPD of wastewater possessing the
specifications noted in the following tables:
WWTP PERFORMANCE
PARAMETERS INFLUENT EFFLUENT
CONCENTRATION CONCENTRATION
Flow 15,000 GPD -
BOD5 250 mg/L <30 mg/L
TSS 250 mg/L <30 mg/L
Total Kjedhal 50 mg/L N/A
Nitrogen (TKN)
- <10 mg/L
Fats, Oils, Greases 50 mg/L N/A
(FOG)
pH 6.5 – 8.5 6.5 – 8.5
The INCEPTOR 15K possesses the following general description and operational
characteristics. The reader is encouraged to review system drawings and photos that further
detail the description of this system and how it it’s intended to function. Please note that
the following descriptions also make reference to the systems P&ID drawings and
Programmable Logic Controller (PLC) operational program.
7-1
PRIMARY CLARIFIER
Wastewater flows through the inlet port into the Primary Clarifier/Sludge holding chamber
where solids, trash, grit, and fats, oils, and grease are separated from the waste stream.
Gross solids, trash, and grit settle to the bottom of the Primary Clarifier and undergo an
anaerobic digestion process that will form a layer of sludge. Floatables in the form of grease
and scum will rise to the surface and are retained in the Primary Clarifier by an effluent
filter. Primary Treatment provides partial BOD, TSS, and Nitrogen removal. The Primary
Effluent then flows through an effluent filter assembly (equipped with a high water float
alarm) for further treatment in downstream chambers. Periodic pumping of the Primary
Clarifier is required to maintain a healthy sludge balance in the Primary Clarifier
compartment.
Inputs Outputs
EFA1 HWA (on filter) - -
Alarms – Alarm shall sound and illuminate during a high water condition.
Controls – N/A
Notes – N/A
FLOW EQ
Effluent from the upstream filters enters the equalization chamber which provides temporary
storage of peak wastewater flows. A duplex pump station provides additional mixing and
pumping to downstream treatment processes. A high water float provides alarming capability
in the event of a high water condition. Hatches are located at the influent and effluent ends
of the tank for inspection and access. Influent is pumped forward to the Anoxic Bioreactor
using a Time Dose method to achieve an average daily flow volume.
Inputs Outputs
FA1-FS1 LOW (1’-6”) P1, P2 LOW ON (2.9 min)
FA1-FS2 MIDDLE (2’-0”) OFF (30 min) MIDDLE ON (6.3
min)
FA1-FS3 HIGH (8’-0”) HIGH ON (16 min)
Alarms – Alarm shall sound and illuminate during a high water condition.
Controls – These pumps alternated with each call to run. If one HOA is in the OFF position
then the other one will run. If either the Flow EQ low float is up, the flow EQ middle float is
up, or the flow EQ high float is up for one minute then one flow EQ pump will run for the
dosing ON time then off for the dosing OFF time. The flow EQ ON time is determined by the
7-2
floats. The second flow EQ pump will turn on if the flow EQ high float is up for more than 15
minutes. Both pumps will continue to dose.
Notes – Operator can adjust on/off times to meet desired flow patterns.
ANOXIC BIOREACTOR
Primary Effluent pumped from the Flow Equalization chamber is discharged to an Anoxic
bioreactor where advanced biological treatment begins. The Primary Effluent provides an
organic food source for living microorganisms that colonize and populate the Bioreactor. The
microorganisms consume the incoming organic food source, which reduces BOD
concentrations and removes nitrogen pollutants present in the waste stream. Pumped Primary
Effluent mixes with the anoxic biomass and a nitrified biomass pumped from the downstream
MBBR bioreactor chamber; the anoxic mixing process is a proven biological treatment process.
Anoxic biomass then flows by gravity to the downstream MBBR Bioreactor. A pH probe
installed in the Anoxic chamber monitors pH levels in the biological treatment process giving
the operator real time information reflective of the biological activity and treatment
efficiency. Both Return Activated Sludge and Mixed Liquer is pumped back into the Anoxic
bioreactor.
Inputs Outputs
FA2 HWA (9’-3”) - -
pH1 LOW (5.5); HIGH - -
(8.5)
Alarms – Alarm shall sound and illuminate during a high water condition or if pH is out of the
specified range.
Controls – N/A
Notes – Diaphragm valves are used to control the pumping rate of the pulse lift pumps and are
located in the air valve vault. Flowrates are determined by the operator to control sludge
recycle and age.
MBBR
Treatment in the Aerobic Bioreactor consists of pressurized air injection into the aerobic
biomass by way of an electrical blower assembly. A fixed film biological treatment process
provides advanced digestion of organics by allowing a biological film attached to a free
floating plastic media to form and thrive. The biofilm utilizes oxygen from the aeration
system and organic food sources from the influent wastewater to complete the treatment
process. The fixed film biology represents a higher-order robust biology capable of excellent
BOD and Nitrogen treatment. A pump located within the MBBR bioreactor provides biomass
pumping of the nitrified wastewater; the nitrified biomass is pumped upstream to the Anoxic
reactor for further nitrogen treatment (see #3 above). This internal nitrate recycle process
7-3
provides nitrogen removal capability which further enhances the overall effluent quality. The
free floating plastic media are retained in the aeration tank through the use of plastic media
retention screens specifically sized and installed to prevent media transport upstream or
downstream of the bioreactors. An ORP (oxidation-reduction potential) probe and
Temperature sensor provide real time information regarding DO levels and wastewater
temperatures. This information assists the operator in optimizing treatment efficiency and
reducing energy consumption.
Inputs Outputs
ORP1 LOW (50 mA) - -
T1 LOW (60°F) - -
Alarms – Alarm shall sound and illuminate if ORP or pH is out of the specified range
Controls – N/A
Notes – N/A
SECONDARY CLARIFIER
After biological treatment, the treated wastewater flows by gravity to a multi-stage
Secondary Clarifier for final treatment. In the Secondary Clarifier, sloughed biofilm
discharged from the plastic fixed film media combined with free floating biomass will settle
by gravity to the bottom of the Secondary Clarifier. A Positive displacement air lift pump will
pump the concentrated solids and biomass back to the Anoxic Chamber in the form of return
activated sludge (RAS) or to the Sludge Digester by an electric, submersible pump in the form
of waste activated sludge (WAS). An air lift scum removal system system provides scum
removal from the Secondary Clarifier water surface. The highly treated and clarified
wastewater then gravity flows through a final Effluent Filter Assembly (equipped with a high
water alarm) where it can be disposed of in a proper and permitted manner.
Inputs Outputs
EFA2 HWA (on filter) P3 ON (2); OFF(1440)
Alarms –N/A
Controls – Sludge pump runs based off of ON/OFF timers scaled to minutes settable via the
HMI. Entering a "0" into either setting will cause it to run continuously.
Notes – Diaphragm valves are used to control the pumping rate of the pulse lift pumps and are
located in the air valve vault. Flowrates are determined by the operator to control sludge
recycle and age.
7-4
ANCILLARY EQUIPMENT
Duplex blowers are used to provide aeration to both biological processes and pumping. Each
blower pair alternates at a predetermined rate, set by the operator.
Inputs Outputs
FA3 - BMA1/2 ON (0), OFF(0)
- - BPLP1/2 ON (0), OFF(0)
Alarms – An indicator shall light up on the HMI to indicate that Goundwater is present.
Controls – Blowers run based off of ON/OFF timers scaled to minutes settable via the HMI.
Entering a "0" into either setting will cause it to run continuously.
Notes – Operator should monitor aeration and adjust timers accordingly once biological
processes have reached optimal conditions. Operator shall manually alternate blowers.
7-5
CHAPTER 8 OPERATIONS AND MAINTENANCE
OVERVIEW
The INCEPTOR™ 15K Wastewater Treatment Plant (WWTP) utilizes the following chambers for
treating a waste stream. To function efficiently each must receive proper monitoring and
maintenance, thus ensuring a successful plant operation. In addition to Mobile INCEPTOR™
components and chambers, several existing tanks were utilized in the configuration of this
system as identified below:
• Primary Clarifier (PC)

• Flow Equalization (FEQ)
• Anoxic Moving Bed Biological Reactor (ABR)
• Moving Bed Biological Reactor (MBBR)
• Secondary Clarifier (SC)
These main chambers/vessels are described in greater detail throughout this chapter.
Operations and control techniques of each chamber, information about normal and abnormal
conditions, testing, and other important topics are covered.
Although the INCEPTOR™ is designed for minimal and simple maintenance, a routine
maintenance program is necessary to ensure longevity and proper operation. Once plant
startup is complete, time becomes of the essence to plan for and schedule routine
maintenance, ensuring continued efficiency of operation. Timely inspections and thorough,
accurate recordkeeping is essential to a good maintenance program. Once established,
operators and managerial personnel should become familiar with daily, monthly and yearly
maintenance requirements and all related recordkeeping.
Provided the pipelines and ancillary systems upstream of the WWTP remain unclogged and the
blowers functional, the INCEPTOR™ is essentially an automatic unit. The chambers of
™
the INCEPTOR involving wastewater flow are pumped and or gravity fed. Generally only
basic system inspections and observations are required. The wastewater operator should
visually inspect each stage of the treatment process for condition changes beyond what is
established as normal or routine.
It is important that electrical power be shut off prior to the inspection of any mechanical or
electrical equipment within the system. Additionally, equipment manuals for motors, drives,
pumps and other equipment manufactured by outside vendors should be referenced prior to
inspection and maintenance.
8-1
The INCEPTOR™ is equipped with a wall- or rack-mounted control panel which contains the
alarm system (Internet monitoring and email alarm features), and electrical controls. The
alarm circuit monitors electrical components of the system, water levels, and analytical
parameters. In the event of a malfunction, the audible and visual alarms provide localized
notification. The SCADA system transmits alarms via the Internet, generating Email
notifications and/or text messages.
Routine maintenance of the entire system and surrounding area includes daily cleaning,
washing down of access risers, inlet screens, and outlet filters. The inherent plastic material
properties of the system promote easy cleanup. Additionally, weeds should be controlled and
vegetation kept mowed around the treatment system. The grade should be maintained at a
minimum of 3 inches below access riser tops.
8-2
SYSTEM CHAMBERS
PRIMARY CLARIFIER/SLUDGE HOLDING (PC)
OVERVIEW
The primary clarification chamber is the first treatment component in the wastewater
treatment process. There are no moving parts or mechanical equipment, making it a
relatively simple aspect of the operation.
Wastewater enters the primary clarification chamber and velocity is slowed to approximately
one foot per minute.
Solids are heavier than water so they will settle to the bottom, while those that are lighter
will float to the top. When the wastewater leaves the chamber, it passes through an effluent
filter assembly, trapping suspended materials that did not settle or float. This is generally
classified as trash that should not be directly discharged into other treatment units.
PROCESS DESCRIPTION
When wastes enter the primary clarification chamber, slowing down and moving slowly
toward the discharge end of the unit, it takes approximately 6 to 8 hours before reaching the
effluent filter system. While heavy solids settle to the bottom of the chamber, the lighter
matter such as greases and oils will float on top.
Inside the upper

portion of the
chamber
Floatable solids
(grease and other
matter)
8-3
The primary clarification chamber is primarily a sludge containment chamber. The sludge
may be allowed to collect over a period of time before being removed and disposed of in a
proper manner. During the containment period, the settable solids decompose anaerobically.
The system should be monitored frequently for buildup of floatable matter and settable
solids.
REQUIRED MAINTENANCE FOR NORMAL OPERATION

A gravity primary clarification chamber is the least demanding of the treatment system.
However, at some point it is necessary to remove buildup of floatable matter and settleable
solids.
Visual observations are required to monitor effluent quality and determine when the solids
need to be removed. Observations must be carefully recorded. Such records help to
determine the frequency of solids removal operations.
Access points are located on the chamber’s top to allow removal of accumulated solids. A
baffle is located prior to the discharge filters to help prevent floatable matter from entering
the filter chamber, and aids in collecting it on the water’s surface for removal. During visual
inspections, it is recommended that scum be hosed down to break it up, allowing the solids to
resettle. It is also recommended that floatable matter be removed prior to removal of the
sludge. The floatables will be on top and, therefore, easier to remove before the liquid
depth is reduced during the sludge removal process.
A Sludge-Judge or other solids measuring device should be used to probe the chamber and
visually determine the sludge depth. Several points of access are usually available for
monitoring the depth. The vents located between the inlet and outlet hatches may be also
be used for this purpose. The vent elbows may be removed for accessing the chamber. If
the physical test indicates an average sludge depth of 25% or greater, the chamber should be
pumped to remove only the sludge. As much of the floatable solids as possible should be
removed during operation.
Caution: Never pump the entire contents from the chamber. This could cause the vessel to
float if the ground water is high and it will take longer for the unit to refill and begin
discharging to the bioreactor.
Effluent filters are located under the

hatch at the discharge end of the
primary vessel. Filters require diligent
ongoing inspection for proper
operation to ensure they are not
plugged with grease and debris. In
order to clean, each filter is pulled
straight up using the mounted handle.
Once removed, they should be placed
8-4
in a container with an internal basket made with fine screen which filters out debris when
washed. Never wash the filter over the filter chamber access. After cleaning, the filter should
be realigned into the filter housing and the cartridge firmly pressed downward until it seats
into place. If the unit is not seated properly, the ball check valve will not be fully opened to
allow proper flow to enter the chamber. Hosing down the general filter area is also a good
housekeeping practice.
Filter cartridge removed Typical filter cartridge

that needs to be cleaned
Right > Filter housing with the cartridge removed.
Note the red ball check located in the bottom. This

keeps wastewater from entering the housing while
the cartridge is removed for cleaning
8-5
CONTROL TESTING
Because the primary clarification chamber is a simple part of operation, testing is not usually
performed. However, depending upon the regulatory requirements of the area in which the
unit is installed, local, state or federal control testing requirements may apply.
The following table may be considered when monitoring the primary clarification chamber;
however, in some cases, testing parameters and frequency may vary from that described
below:
PARAMETER LOCATION FREQUENCY

Settleable Solids Primary Influent Weekly
pH Primary Influent Weekly
Primary Effluent
Alkalinity Primary Effluent Weekly
Temperature Primary Influent Weekly
Primary Effluent
BOD5 Primary Effluent Monthly
TSS Primary Effluent Monthly
Total Nitrogen (N) Primary Effluent Quarterly
Abnormal Operation(s)
Condition: The effluent contains more than normal solids

Possible causes:
• Chamber has become overloaded (hydraulic and/or organic)

• Chamber needs cleaning (sludge level is greater than 25% of chamber volume)
• Overactive anaerobic solids digestion
Possible solutions:
• Expand capacity (add another chamber)

• Remove sludge and scum
• Remove sludge or take vessel off line – (need more than one chamber in operation to
perform this task)
8-6
Condition: Fluid level in the chamber is high (high water alarm) and overflowing at the
effluent filters
Possible cause:
• Effluent filters are plugged with debris

• Heavy influent from outside sources
Possible solution:
• Remove filters and clean or replace

• Locate heavy flow contributor(s)
EXPECTED PERFORMANCE
When operated properly, the primary chamber may be expected to produce an effluent that
indicates a reduction in BOD5 and TSS. Treatment of domestic waste streams provides the
standards to which all operational levels are measured.
8-7
FLOW EQUALIZATION (FEQ)
OVERVIEW
Wastewater flows (from Primary Clarifier) into the equalization (FEQ) chamber where it is
temporarily contained. Equalization is a process of storing wastewater during peak periods of
discharge from homes, businesses, and industries when water usage is high. Stored
wastewater may then be released at a controlled rate in order to prevent hydraulic shock to
the biological treatment units within the system.
PROCESS DESCRIPTION
As flow enters the FEQ chamber, it is pumped using a time-dose method based on the water
level in the tank. Pump on times are determined by the operator and selected by the float
indicators or level transducer.
Flow equalization is the process of slowly distributing the influent at a steady controlled rate
to prevent hydraulic overloads and provide an ongoing food source for biological activity.
METHODS OF CONTROL
Duplex alternating centrifugal electric pumps provide constant flow rate pumping to the
downstream treatment process, making it possible to pump continuously. The pumps are
controlled with a three-float system consisting of an LOW float, MIDDLE float, and a HIGH
float/high water alarm.
To move wastewater out of the EQ chamber, dual centrifugal pumps are utilized with a time-
dose method, allowing continuous transfer of the food source to the next phase of the
treatment process. If one pump fails, the second will maintain service until the failed pump
is repaired or replaced.
Additionally, should the system experience a shock load of toxins, the EQ acts as a front line
defense, providing partial anaerobic treatment and creating a more stable food source.
(For additional information, see “Centrifugal Pumps” under the main heading “Components”
in Chapter 8. Also reference the manufacturer’s manuals in Appendix B.)
CONTROL TESTING
The FEQ chamber is a simple aerated holding chamber prior to the treatment processes. Due
to the biological activity taking place, the FEQ requires minimal sampling and testing to
determine treatment efficiency. However, depending upon regulations governing the area in
which the system is installed, local, state or federal control testing requirements may be
applicable.
The following table may be considered when monitoring the EQ chamber; however, in some
cases, testing parameters and frequency may vary from that described herein (recommended
minimum):
8-8
Temperature EQ Effluent Quarterly
pH EQ Effluent Quarterly
Alkalinity EQ Effluent Quarterly
Dissolved Oxygen EQ Effluent Quarterly

TSS EQ Effluent Quarterly
BOD5 EQ Effluent Quarterly
Field testing including pH, dissolved oxygen and temperature can be conducted onsite and
sample hold limitations are not applicable. Other samples for outside laboratory analysis
must be collected in approved containers with required preservatives and placed immediately
on ice for transport to an approved laboratory. Specific protocol related to sample hold time
limitations and other factors regarding the collection, containing, handling and transport of
lab samples may be obtained from professionals at the approved laboratory utilized for
services.
OPERATIONAL CONSIDERATIONS
pH - Depending upon wastewater characteristics, typical chemical feed systems may include
simple soda ash, sodium bicarbonate, and/or floc agents necessary to adjust pH and alkalinity
levels. pH values should be maintained within specified parameters to achieve optimal
nutrient removal capabilities. Soda ash or sodium bicarbonate may be utilized to stabilize
pH, increase buffering capacity and alkalinity for improved treatment and achieving discharge
pH requirement. pH monitoring and fine-increment adjustments are necessary to maintain
chemical feed pump settings so as to not overdose the system with pH additive. The stock
solution of pH additive is generally composed of 25# soda ash or sodium bicarbonate to 50
gallons of water. Chemical pump set points should begin with the output setting at
approximately 25%. Minor incremental adjustments should then be made until pH has
stabilized within the range of 7.5 to 8.5, with only a very minimal degree of variance once
the treatment process is stable and optimal performance achieved.
Stabilizing the alkalinity prevents pH levels from plummeting below normal ranges through
the aeration tank which may cause a decrease in microbiological activity. An absence of
de-nitrification (if this process is utilized) is typically remedied in two or three days by adding
back alkalinity to replace what is lost. To compensate for low alkalinity, soda ash or sodium
bicarbonate may be added to the influent of the FEQ chamber. There is a connection point
on the influent side of the FEQ chamber to connect the chemical feed system, allowing for a
8-9
complete mix of the pH/alkalinity additive prior to the anoxic phase (if applicable) of the
treatment process.
CHAMBER MAINTENANCE
Maintenance includes keeping the chamber risers washed down to minimize formation of bio-
growth on the side walls and lid, thus reducing odors and controlling insects.
8-10
ANOXIC BIOREACTOR (ABR)
OVERVIEW
The anoxic bioreactor provides advance treatment relative to nitrogen removal.

Incoming food sources (BOD) from the EQ are utilized to facilitate facultative microbiological
growth and metabolism. Microorganisms consume the incoming organic food source, which
reduce BOD concentrations in the waste stream. The pre-anoxic MBBR receives nitrified
biomass from the downstream fixed film bioreactor in the form of return sludge collected in
the secondary clarifier and MLSS (Nitrate) pumping systems. A benefit of recirculation is the
recovery of alkalinity where approximately half lost during nitrification is recovered which
may eliminate the need for chemical dosing system in low alkalinity wastewaters. A pH probe
is installed in the pre-anoxic bioreactor providing real-time information indicative of
biological activity and treatment efficiency.
PROCESS DESCRIPTION
The pre-anoxic bioreactor is a separate chamber which is mixed, but not aerated. Mixing is
accomplished with the use of a PLP mixer assembly. The pre-anoxic zone is a non-aerated
basin where dissolved oxygen levels are kept below 0.5 mg/l and must be as close to 0 mg/L
as possible. A target operating point would be 0.2 or less. In an anoxic zone, the oxygen
source to microorganisms is supplied by the nitrate (NO3) compounds.
The pre-anoxic de-nitrification process is the conversion of nitrate (NO3) to nitrogen gas (N2).
This is accomplished by heterotrophic bacteria reducing the nitrate (NO3) for its oxygen
component under anoxic conditions to break down organic substances.
Nitrogen
• Nitrogen gas makes up nearly 80% of life sustaining air

• Nitrogen gas is not toxic
• Nitrogen compounds such as ammonia (NH3) are toxic in high concentrations
• Nitrogen containing compounds like cyanide (CN-) are lethal in very small
amounts
Nitrogen in Water
• Ammonia (NH3 as a gas or NH4+ ions)

• Organic nitrogen (urea, fecal matter)
• Nitrate (NO3-) and nitrite (NO2-)
• Total Kjeldahl Nitrogen (TKN) is the combination of ammonia and organic
nitrogen
8-11
Removal of Nitrogen from Wastewater
In its various forms, nitrogen can deplete dissolved oxygen in receiving waters, stimulate
aquatic plant growth, exhibit toxicity toward aquatic life, present a public health hazard, and
affect the suitability of wastewater for reuse purposes. Wastewater effluents containing
nutrients such as nitrogen and phosphorus can cause eutrophication, the excessive growth of
plant and/or algae blooms in lakes, streams and rivers. Nitrate is a primary contaminant in
drinking water and can cause a human health condition called Methemoglobinemia (Blue Baby
Syndrome). This condition may occur when the conversion of nitrate to nitrite by nitrate-
reducing bacteria takes place in the gastrointestinal tract. Oxidation by nitrite of iron in
hemoglobin forms methemoglobin.
Typical permit limits vary with regards to nitrogen compounds in wastewater effluent, but all
are based upon location of final discharge. A wastewater plant that discharges to a spray
field may not have a limit on nitrogen while a plant that discharges to percolation ponds may
have an effluent nitrate limit of 12 mg/L. A treatment plant that discharges to a nearby
stream or river may have a total nitrogen limit of 3 mg/L, or a unionized ammonia limit of 0.2
mg/L. However, depending upon the regulatory requirements of the area in which the unit is
installed, local, state or federal control testing requirements may apply.
In order to stay within required parameters, treatment plants must be operated to not only
remove CBOD and TSS, but convert nitrogen compounds to less noxious forms as well. Many
new package plants are being built with anoxic tanks which require different process control
methods than basic extended aeration treatment plants. If a treatment plant does not have
an anoxic tank, cycling the aeration blowers on and off may be necessary to create an anoxic
zone or allow time for de-nitrification in the aeration tank. Systems with an anoxic bioreactor
chamber utilize a PLP mixer assembly to provide the required mixing. The mixer utilizes
waste air from the main blower providing air to the MBBR.
Depending upon environmental variables such as temperature and pH, nitrogen enters a
treatment plant in a variety of forms:
Ammonification
Through a process called hydrolysis, organic nitrogen begins conversion to ammonia or
ammonium. The form of nitrogen depends on pH and temperature. When the pH of the
wastewater is acidic (<6.9) or neutral (7.0), the majority of the nitrogen is ammonium (NH4+).
When the pH increases over 8.0, the nitrogen is mostly ammonia (NH3). Typically, by the time
the wastewater enters the treatment plant, most of the organic nitrogen has been converted
to ammonium.
Nitrification
Nitrification is the biological conversion of ammonium to nitrate nitrogen. It is a two-step
process. First, bacteria known as Nitrosomonas convert ammonia and ammonium to nitrite.
8-12
Next, bacteria called Nitrobacteria finish the conversion of nitrite to nitrate. The
reactions are generally coupled and proceed rapidly to the nitrate form; therefore, nitrite
levels at any given time are usually low.
Nitrosomonas and Nitrobacteria are bacteria known as “Nitrifiers”. Nitrifiers are strict
aerobes, meaning they must have free dissolved oxygen to perform their work, and are only
active under aerobic conditions. It requires approximately 4.6 pounds of oxygen for every
pound of ammonia converted to nitrate. The growth rate of Nitrifiers is affected by the
concentration of dissolved oxygen (DO) and, at DO less than 0.5 mg/L, the growth rate is
minimal. Typical operational guidelines call for a minimum DO concentration of 1.0 mg/L at
peak flow and an average daily DO concentration of 2.0 mg/L. For nitrification to occur,
oxygen should be well distributed throughout the aeration tank and levels not fall below 2.0
mg/L. Given that Nitrifiers are autotrophy that grow much slower and must compete with
the heterotrophy for available DO, it is not uncommon to have concentrations at higher
ranges of 4 to 6 mg/L for BOD oxidation, and still have sufficient DO remaining to allow the
Nitrifiers to oxidize the ammonia (NH3).
The process of nitrification produces acid. This acid formation lowers the pH of the mixed
liquid suspended solids (MLSS) and may cause a growth rate reduction of nitrifying bacteria.
The optimum pH for Nitrosomonas and Nitrobacteria is between 7.5 and 8.5. Nitrification
stops when pH levels are at or below 6.0. Approximately 7.14 pounds of alkalinity (as CaCO3)
are consumed per pound of ammonia oxidized to nitrate.
Water temperature also affects the rate of nitrification. Nitrification reaches a maximum
rate at temperatures between 30 and 35 degrees C (86oF and 95oF). At temperatures of 40oC
(104oF) and higher, nitrification rates fall to near zero.
Sludge age and mixed liquor levels are also integral components in the nitrification process.
When performing sludge age calculations (MCRT or SRT) to determine the detention time
required for nitrification, the capacity of the oxic (aerated) portion of the plant should be
used.
Toxicity and sources of inhibition to microorganisms present problems to nitrifying organisms.
Some of the most toxic compounds to Nitrifiers include cyanide, thiourea, phenol and metals
like silver, mercury, nickel, chromium, copper and zinc. Some of these compounds can enter
a treatment plant from landfill leachate and septage.
De-nitrification
De-nitrification is an anaerobic respiration process in which nitrate serves as the electron
acceptor. In simpler terms, de-nitrification occurs when oxygen levels are depleted and
nitrate becomes the primary oxygen source for microorganisms. When bacteria break apart
nitrate (NO3-) to gain the oxygen (O2), the nitrate is reduced to nitrous oxide (N2O) and
nitrogen gas (N2). Since nitrogen gas has low water solubility, it tends to escape as gas
bubbles. These gas bubbles can become bound in the settled sludge in clarifiers and cause
the sludge to rise to the surface.
8-13
Process
There are several ways to force bacteria to perform the work of de-nitrification. Processes
may be designed specifically for nitrification/de-nitrification using anoxic tanks (selectors) or
timers controlling aeration blowers to turn them on and off.
Nitrate is produced by the aeration zone as an oxygen source for facultative bacteria in the
breakdown of raw wastewater in the anoxic basin. The first process in the treatment train is
a pre-anoxic basin where influent wastewater, return sludge from the clarifier, and nitrate-
rich mixed liquor pumped from the effluent end of the aeration tanks are mixed together.
The influent wastewater serves as the carbon source for bacteria, return activated sludge
from the clarifier provides microorganisms, and the anoxic recycle pumps provide nitrate as
an oxygen source.
The anoxic basin is mixed, but not aerated. Submersible mixers are generally used on small
systems whereas floating mechanical types are used in municipal or larger plants.
In order to drive the de-nitrification process, organic matter is added to the anoxic basin.
Since most of the organic matter present in raw wastewater has been consumed through the
aeration tank by aerobic and facultative bacteria, a supplement must be added to the anoxic
basin. Many facilities employ a re-aeration zone after the anoxic basin to release nitrogen
gas bound in the sludge, and freshen up the mixed liquor before it enters the clarifier. This is
the case in systems where an MBBR is utilized.
Conditions Required for Effective De-nitrification

Conditions that affect the efficiency of the de-nitrification process include nitrate
concentration, anoxic conditions, presence of organic matter, pH, temperature, alkalinity and
the effects of trace metals.
Since denitrifying bacteria are facultative organisms, they can use either dissolved oxygen or
nitrate as an oxygen source for metabolism and oxidation of organic matter. If dissolved
oxygen and nitrate are present, bacteria will use the dissolved oxygen first. This occurs as
dissolved oxygen is readily available and yields more energy to the organisms.
Another important aspect of de-nitrification is the presence of organic matter to drive the de-
nitrification reaction. Organic matter may be in the form of raw wastewater, food processing
wastes, or chemical sources such as methanol, ethanol, acetic or citric acid. When these
sources are not present, bacteria may depend on internal (endogenous) carbon reserves as
the organic matter.
An advantage of de-nitrification is the production of alkalinity and an increase of pH.
Approximately 3.0 to 3.6 mg of alkalinity (as CaCO3) is produced per milligram of nitrate
reduced to nitrogen gas. Optimum pH values for de-nitrification are between 7.5 and 8.5.
Temperature affects the growth rate of denitrifying organisms, with greater growth rate at
higher temperatures. De-nitrification can occur between 5 to 30oC (41oF to 86oF), and these
rates increase with temperature and type of organic source present. The highest growth
rates are found when using methanol or acetic acid. Denitrifying organisms are generally less
8-14
sensitive to toxic chemicals than Nitrifiers, and recover from toxic shock loads quicker than
Nitrifiers.
METHODS OF CONTROL
The influent waste stream provides an organic food source for living microorganisms that
colonize and populate in the anoxic bioreactor. The microorganisms consume the incoming
organic food source which reduces the BOD concentrations and removes nitrogen pollutants
present in the waste stream. Nitrified biomass is pumped from the downstream MBBR
chamber where it mixes with the carbon source found in influent. The flow is pumped
utilizing a PLP assembly that produces 48.53 gpm at 11.00 pulses per minute. The return flow
rate may be varied by adjusting the air flow rate to the pump. Flow should be returned to
the anoxic chamber at a rate of 2 to 4 times Q (total flow per day), which is 21 to 42 gpm.
A pH probe installed in the anoxic chamber provides the operator with real-time information
for proper system monitoring.
CONTROL TESTING
The absolutely essential tests to monitor and control the nitrogen cycle are pH, alkalinity,
ammonia (NH3), nitrite (NO2) & nitrate (NO3).
The first sampling point would be the raw influent or primary effluent if there is a primary
clarifier in the system. Typically the wastewater entering the facility will be high in alkalinity
and ammonia (NH3) with very little to no nitrite (NO2) or nitrate (NO3). A quick way to
determine if there is a need to perform alkalinity addition is to multiply the ammonia by 7.1
mg/L. If the result exceeds the influent alkalinity concentration, then the addition of soda
ash, sodium bicarbonate, or lime to the system is essential. This is important because, when
the process of converting ammonia (NH3) to nitrate (NO3) starts in the aeration tank, many
hydrogen ions will be released. When alkalinity drops below 50 mg/l, pH can drop
dramatically. The pH of the aeration tank should never be allowed to drop below 6.5.
Biological activity will be inhibited and toxic ammonia (NH3) can bleed right through the
system.
The next established sampling points are in the aeration tank. The length of the tank will
dictate how many sampling points are required. Generally three are designated, at the front,
middle and end of the aeration tank.
The final sampling point is the plant effluent prior to chlorination. There should never be less
than 50 mg/L of alkalinity. The pH should never be out of the permitted range. Ammonia
(NH3) should have extremely low concentrations. Nitrite (NO2) should be very low to non-
detectable and the majority of the nitrogen will be in nitrate (NO3) form.
A decrease in the aeration tank pH due to insufficient alkalinity causing ammonia (NH3) to
bleed through the system may result in a decrease in the microbiological activity. An
inability to completely nitrify is due to a lack of dissolved oxygen. Contributing factors are
8-15
the abundance of mixed liquor suspended solids, mean cell residence time, and cold
temperatures, all of which may inhibit the nitrification cycle.
High ammonia (NH3) discharges can affect toxicity testing. High nitrite (NO2) levels will
cause a tremendous chlorine demand making disinfection difficult, jeopardizing fecal coliform
limits. Leaving sludge that is high in nitrate (NO3) too long in the secondary clarifier can
cause the sludge blanket to rise to the surface when the nitrogen gas is released. This can
cause problems and may jeopardize TSS limits.
Once this ammonia (NH3) has been converted to nitrate (NO3), it can be removed from the
system (de-nitrification performed). An anoxic zone has to be established within the
treatment facility. Regardless of where this is done, the principles of operating an anoxic
zone will always be the same.
In light of the biological activity taking place in the Anoxic bioreactor, minimal sampling and
testing to determine treatment efficiencies should be performed. However, depending upon
the regulatory requirements of the area in which the unit is installed, local, state or federal
control testing requirements may apply.
The following table may be considered when monitoring the anoxic tank; however, in some
cases, testing parameters and frequency may vary from that described herein (recommended
minimum):
pH Chamber Quarterly
Dissolved Oxygen Chamber Quarterly
Total N Chamber Quarterly

Temperature Chamber Quarterly
Field testing including pH, dissolved oxygen and temperature are conducted onsite and
limitations and other factors regarding the collection, containment, handling and transport of
services.
Dissolved oxygen levels must be as close as possible to 0.0 mg/l. To avoid septicity while
starting up an anoxic bioreactor, a safe target point for dissolved oxygen levels is 0.2 mg/L.
A good operational goal is 0.1 to 0.2 mg/l.
The pH of the anoxic zone should be close to or above neutral and never drop below 6.5.
8-16
There must be a carbon source. Raw influent usually works fine but some plants have to
supplement the carbon source by injecting methanol or ethanol. It takes about 2.0 - 2.5 parts
methanol for every part nitrate (NO3) for robust de-nitrification.
The mixed liquor suspended solids concentration must be kept in balance with the food
supply. In other words, the food to microorganism ratio should be in the proper range (on
the low end) for the type of process utilized.
Heterotrophic bacteria need a carbon source for food. Heterotrophy utilizes oxygen the
easiest way possible using the following sequence: free/dissolved oxygen, nitrate (NO3), and
then sulfate (SO4). If the zone has no free or dissolved oxygen, the microorganisms have to
acquire an oxygen source by breaking down the nitrate (NO3) that are returned to the anoxic
zone in the activated sludge. As the microorganisms utilize the nitrate (NO3) as an oxygen
source to break down the carbon, their source of food, nitrogen gas, will be released to the
atmosphere.
Microorganisms + Carbon + Nitrate (NO3) = Nitrogen Gas (N2) + Oxygen (O2) + 3.6 parts
Alkalinity.
CHAMBER MAINTENANCE
8-17
MOVING BED BIOLOGICAL REACTOR (MBBR)
OVERVIEW
The Moving Bed Biological Reactor (MBBR) or aerobic bioreactors utilize a submerged free
floating plastic media to foster the growth of fixed film biology, biofilm, which attaches
primarily to its interior surfaces. The fixed film biology represents a high-order biological
treatment process capable of nitrification and advanced BOD removal. By design, suspended
biomass media create a large surface area for biofilm growth. The open structure design,
featuring cross members or a frame work supporting an outside wall, enables biomass to be
plentiful and improves mass transfer efficiency (food to microorganism ratio). MBBR
chambers are equipped with a diffused aeration system, media supply, and media retention
screens at the discharge pipe. The air to the diffused aeration system and mixed liquor
suspended solids (MLSS) is supplied by a regenerative blower system.
Typical MBBR vessel

installation
8-18
PROCESS DESCRIPTION
The MBBR chamber utilizes the activated sludge process and attached biological growth to
freely-suspended media as secondary treatment. The biological slime, biofilm, that develops
on the media is similar to that found on a trickling filter or rotating biological reactor.
The MBBR and integrated fixed film activated sludge (IFAS) processes employ the same proven
biofilm technologies as in all MBBR systems, but within a conventional activated sludge
process. The MBBR/IFAS process consists of thousands of mobile biofilm carriers (media) each
establishing a high density population of bacteria which naturally removes constituents such
as ammonia and nitrogen.
Close-up of
the media
The media shown in this MBBR is

new and does not have a bio-
growth. The blower is off.
The blower is running and the

aeration process in operation. Note
the RAS is light in color, indicative of
minimal buildup of sludge and
biomass.
8-19
Wastewater is mixed with biomass to form MLSS. The MLSS is aerated for a specific length of
time during which ample opportunity for sufficient contact must be provided for the bacteria
to adsorb or digest and assimilate or oxidize the food material before the wastewater is
discharged from the chamber. The MLSS flows into the secondary clarifier where solids
separate from the water. Solids are returned to the influent as return activated sludge (RAS)
in the pre-anoxic chamber to begin the process over again. Failure to periodically waste the
RAS will result in loss of solids in the discharge of the clarifier. Proper sludge management is
essential to optimal performance of the system.
The MBBR utilizes a simple blower system as an air supply to provide a mixing source and
oxygen for both the activated sludge and biofilm growth on the media. The air pressure
generated by the blower also operates the MLSS PLP assembly to transfer MLSS to the head-
works or waste activated sludge (WAS) to the sludge holding tank.
The biological treatment process is affected by and dependent upon a number of factors
including:
• growth rate of biological organisms

• chemistry of biological activity
• pH and/or toxic conditions
• temperature
• raw wastewater strength
• nutrient supply
• dissolved oxygen supply
• detention time
• mixing effectiveness
• settling characteristics
A general understanding of these factors and their relationships is necessary for the operator
to recognize, interpret, and evaluate various aspects of the treatment process.
The biological treatment system is dependent upon living organisms being brought into
contact with organic materials contained in raw sewage in an environment favorable for
oxidation. This is known as an aerobic system and the bacteria in wastewater are known as
aerobes. The microorganisms of an aerobic system are both plant (bacteria, fungi, algae) and
animal (protozoa, rotifers, crustaceans, and nematodes).
From a physical standpoint, the microbial growth may be classified as dispersed, attached,
and flocculent, all of which reduce the organic content of wastewater in various treatment
processes. For example, flocculent growths are predominant in activated sludge systems;
attached growths are found in trickling filters; and dispersed growth in stabilization lagoons.
The treatment process accomplishes very little unless there is a sufficient population of living
microorganisms. Normal wastewater contains some of the microorganisms, but the number is
usually far too small to do the work required. Therefore, it is necessary to add more
organisms and distribute them throughout the wastewater so that the process functions
efficiently.
8-20
The required biological culture may be developed initially by seeding the system with
bacteria-rich water from an outside source. The microorganism culture is composed of
varieties of bacteria and other forms of biological life. Thus, the development of the culture
for any specific wastewater is dependent upon the type and concentration of organic
materials present, the original seed, the nutrient supply, and other environmental factors.
Variations of these parameters are likely to cause certain life forms, specific to the plant
involved, to predominate.
During the aeration period, the bacteria consume waste matter in the raw wastewater,
resulting in the growth of new bacterial cells. The removal of waste organic materials from
the water is accomplished by a progressive process. Some bacteria attack the original
complex substances to produce new cell material and simpler compounds as waste by-
products. Other types of bacteria use the less complex waste products to produce even more
cell bacteria and still simpler waste product compounds. The process continues until the final
waste products can no longer be used as food for the bacteria.
The development of a biological culture is a cumulative process. Thus the population of
microorganisms gradually increases in the aerated tanks until equilibrium is reached between
biological solids growth and solids being discharged to the clarifier.
The MBBR, a biological treatment system based on a suspended growth process utilizing
activated sludge and moving media for attached growth, is a sensitive component of the
overall WWTP and includes two important elements – mixing and aeration. It is important for
the operator to understand mixing and aeration in order to apply operational techniques for
process control:
Mixing
Primary effluent from the EQ is mixed with the biological mass in the anoxic bioreactor and
then to the MBBR. The biomass contains large numbers of healthy organisms which can break
down or oxidize organic matter. Mixing brings the organic matter (food) and the organisms
together, called “mixed liquor”. he concentration of solids in this mixture is called
“mixed liquor suspended solids” (MLSS).
Aeration
Aeration provides the mixing and oxygen needed to keep the process aerobic. Air is added
to the tank by diffusion (creating a bubbling effect by stainless steel coarse air diffusers at
the bottom of the tank).
During aeration organisms break down the organic matter, producing more organisms and
solids which become part of the biomass. At the same time, biomass solids collide with each
other forming larger more settleable solids.
METHODS OF CONTROL
Oxygen-Reduction Potential (ORP) probes are located in both MBBR’s to provide the operator
with real-time information. The ORP contains a sensor that measures electrical charges from
particles called ions which are converted to millivolts (mV). Such charges may be either
positive or negative. Wastewater treatment plants must nitrify to reduce nitrogen or
8-21
ammonia. When the ORP reading is +100 to +350 mV, oxidation of ionized ammonia (NH4+) to
nitrate (NO3-) has taken place.
Maintenance is required for optimal performance of media retention screens installed in the
MBBR’s at the discharge piping which prevent media from exiting the chamber. Media screens
should be routinely checked and kept free of debris to prevent clogging. Should blinding
occur, potentially resulting in a backup, a high water alarm float is provided which should be
set to activate when water levels reach a depth no greater than 50% of the overall height
from the invert of the media screen.
Aeration
Dissolved oxygen (DO) levels should be checked frequently with a hand-held DO meter
at varying depths and adjustments made accordingly. It is ideal to maintain a
minimum of 2.0 mg/l of dissolved oxygen in the bioreactors. Dissolved oxygen
concentrations may run higher given the MBBR process. It is not uncommon to have
DO levels in excess of 4 or 5 mg/L. If aeration rates are changed or solids removed
(WAS), the system should be permitted to run at least 48 hours (or longer) before
making any further adjustment. Solids level and return rates are the controlling
factors in maintaining a dissolved oxygen balance.
Mixed Liquor Suspended Solids (MLSS)
The Mixed Liquor Suspended Solids (MLSS) in the bioreactor should remain within a
minimum range of 500 to 1,000 mg/l. Sludge return rates should be increased or
decreased as necessary to keep MLSS within the recommended range; however, sludge
depths in the clarifier should not exceed recommended levels.
CONTROL TESTING
Given the operational ease of the system, only simple testing is generally performed for
control purposes. However, depending upon regulations governing the area in which the unit
is installed, local, state or federal requirements may necessitate additional testing
parameters and frequencies. The following table may be considered for purposes of
monitoring and control – (recommended minimum):

% Settleability (MLSS) MBBR at discharge port Monthly
MLSS (mg/L) MBBR at discharge port Monthly
pH MBBR at discharge port Monthly
8-22
Alkalinity MBBR at discharge port Monthly
DO MBBR at discharge port Monthly
Temperature MBBR at discharge port Monthly
Field testing including pH, dissolved oxygen and temperature are conducted onsite and
limitations and other factors regarding the collection, containment, handling and transport of
services.
When operated efficiently, the MBBR’s may be expected to produce an effluent that indicates
a reduction in BOD5 and TSS. Treatment of domestic waste streams provides the standards to
which all operational levels are measured.
The following table indicates industry standards for domestic waste; however, it should be
noted that results will vary somewhat with other waste streams such as industry or
commercial:
PARAMETER OPERATIONAL GOAL

% Settleability (MLSS) 30% – 70%
pH 6.5 – 8.0
Alkalinity >50 mg/L
MLSS 500 -1000 mg/L
DO > 2.0 mg/L
CHAMBER MAINTENANCE
8-23
SECONDARY (FINAL) CLARIFIER (SC)
OVERVIEW
The secondary clarifier provides effluent clarification and separation of settled biomass and
sloughed biofilm from the MLSS. The sloughed biofilm is discharged from the plastic fixed
film media and combined with free floating biomass creating return activated sludge (RAS).
Over time RAS accumulation becomes waste activated sludge (WAS). The waste sludge
eventually stabilizes once the MBBR biomass becomes stable and balanced within the media.
PROCESS DESCRIPTION
The MLSS flows from the MBBR into the secondary clarifier. The sloughed biofilm and free
floating activated sludge settle by gravity and are concentrated in the hopper bottom
secondary clarifier. A RAS PLP assembly returns the concentrated solids and biomass to the
MBBR for further nutrient removal and waste management. The air pressure generated by the
main blower supplying air to the MBBR operates the PLP assembly. A separate centrifugal
pump wastes sludge back to the sludge digester.
The process occurring in the secondary clarifier may be broken down into three phases:
separation, return, and waste. It is important for the operator to understand how these steps
work in order to apply operational techniques for process control:
Separation
After aeration, the MLSS must be separated from the concentrated activated sludge (return
and waste) and the residual waters. This is accomplished by settling in the secondary
clarifier. During settling, solids collide together, forming larger particles. This process,
known as flocculation, creates the larger solids which, as they settle, remove the finer
particles that tend to make treated wastewater cloudy or turbid.
Return
When the activated sludge settles, it becomes thicker or more concentrated and forms a layer
(blanket) of thick solids on the bottom of the clarifier. This blanket is withdrawn and
returned to the head of the bioreactor to begin the process again. This flow is called “return
activated sludge” (RAS). Failure to remove RAS can quickly cause a septic return and/or high
solids concentration in treated effluent. The sludge blanket depth may be checked using a
core sampler.
Waste
If organisms and solids are not removed periodically, the number or organisms present
becomes too large for the available food, resulting in starvation and death. This causes
process upsets and poor effluent quality. The permanent removal of solids from the activated
sludge process is known as wasting. Wasting must be carefully controlled to balance the
available organic matter (food), the organisms, and the oxygen they require.
8-24
METHODS OF CONTROL
RAS is pumped from stage one with the use of a PLP assembly which returns the sludge back
to the pre-anoxic bioreactor. Flow rates for the PLP assembly in stage one is equal to 9
pulses per minute, or 10.84 gpm.
WAS is pumped to the anaerobic sludge digester for additional biological treatment.
Separate air control valves to the PLP assemblies may be adjusted to control the number of
cycles each one pumps. Therefore, the flow rate may be set by the amount of air each pump
receives.
CLARIFIER SCUM REMOVAL SYSTEM

The standard PLP scum removal assembly should be checked for normal operation and to
ensure the intake is below the water surface for proper scum removal. If required, the
system may be adjusted vertically until the water level is above the intake and the system is
operational. An air control valve to the scum pump may be adjusted to control the number of
pump cycles.
CHAMBER MAINTENANCE
Maintenance includes keeping the chamber riser washed down to minimize formation of bio-
growth on the side walls and lid. This process should take place only when there is no
discharge to prevent solids from being carried out of the system. When conducting a cleaning
operation, the skimmer should be lowered to remove floating solids faster. Once the process
is accomplished, the skimmer setting should be returned to normal operation.
8-25
COMPONENTS
BLOWER ASSEMBLY
Both regenerative and positive displacement blowers are low maintenance components,
requiring a minimal operational budget. Unlike most other plants, this system has no internal
moving parts and relies only on electrical service for the blower. Therefore the blower is the
only component subject to mechanical or electrical failure. The blowers have a typical life
expectancy of 5 to 7 years. They are non-proprietary standard stock items, easily procured
through any number of equipment vendors.
Pressure relief valves are installed on all blowers to prevent excessive pressures from
developing when closed or partially closed during plant operations or maintenance. The
valves should be kept clean and checked monthly to ensure free operation. Air inlet filters
are installed on all blowers to reduce noise and clean incoming air. Filters should be cleaned
monthly and replaced as necessary.
The potential of electrical failure of the blower may be minimized by fully enclosing the unit.
Although enclosure is optional, without it the blower is susceptible to overheating or shorting
out due to moisture or dirt. Enclosure vent screens should be cleaned frequently to ensure
unrestricted air flow. Blockage of air to the inlet or vent could reduce the efficiency of the
treatment process if oxygen is not allowed to replenish for aeration. If enclosing the unit is
not elected, the filter should be checked more regularly and life expectancy may be reduced.
In addition to the aforementioned recommendations pertaining to blower assembly
maintenance, it is equally important the operator review manufacturer’s O&M manuals and
provide maintenance as specified.
(For additional information, see the manufacturer’s manuals in Appendix B.)
LINEAR AIR PUMPS

Linear air pumps are utilized for aeration of flow equalization chambers on smaller systems,
when specified. These units are utilized whenever possible due to their efficient operation,
minimal maintenance and rebuild capabilities.
(For additional information, see the manufacturer’s manual in Appendix B.)
DIFFUSERS
Depending upon specific requirements and application of the aeration system(s), stainless
steel course or fine air diffusers may be utilized. These are standard off-the-shelf
components and require minimal, if any, maintenance. The stainless steel diffusers typically
have a life expectancy of over twenty years.
8-26
(For specifications and additional information on diffusers utilized with this model, see
drawings under Appendix G and/or manufacturer’s manual under Appendix B.)
MBBR MEDIA SCREENS

Retention screens are installed at the MBBR discharge port to keep media inside the chamber
and prevent it from exiting.
The MBBR media screens are constructed from stainless steel heavy gauge mesh. Air scour
from the MBBR diffused aeration system and the ample size of the MBBR media retention
screen will ensure a maintenance free screening system.
SECONDARY CLARIFIER SCUM REMOVAL SYSTEM

The secondary clarifier is equipped with a standard manual air lift scum removal system. The
intake of the system is below the water surface and can be operated by manually opening a
4-inch PVC ball valve. The scum layer is pumped to the EQ chamber where it can undergo the
treatment process again. The scum layer can be broken down biologically over time. Once
the scum layer has been removed, the operator should close the control valve to resume
normal operation.
The scum removal system should be checked periodically, even when there is no scum to
remove, to make sure the system is functional. Weekly inspection is recommended.
EFFLUENT FILTER ASSEMBLY

Effluent filter assemblies, Polylok PL-525 and PL-625 filters, are located under the hatch at
the discharge end of the primary and secondary clarifier chambers respectively. Filters
require diligent ongoing inspection for proper operation to ensure they are not plugged with
grease or other debris. In order to clean, each filter is pulled straight up using the mounted
handle and cleaned in a container to capture the waste. The waste should then be disposed
of in an approved manner.
Once removed, they should be placed in a container with an internal basket made with fine
screen which filters out debris when washed. After cleaning, the filter should be realigned
into the filter housing and the cartridge firmly pressed downward until it seats into place. If
the unit is not seated properly, the ball check valve will not be fully opened to allow proper
flow to enter the chamber and be discharged. If not cleaned properly, wastewater can
backup into the chamber and overflow. Hosing down the general filter area is also a good
housekeeping practice.
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Typical filter cartridge removed
All filter assemblies, whether single or in combination, are equipped with a Polylok Filter
Alarm and SmartFilter Control Switch. The Polylok filter alarm and switch provides a visual
and audible notification of impending filter and chamber servicing. The filter alarm switch
activates when the filter cartridge is near capacity on solids that have built up through the
filtering process. The filter alarm switch sends a signal to the alarm panel activating a high
water alarm.
METERING EQUIPMENT
When specified, the system is equipped with sensing and monitoring devices to continuously
monitor pH/ORP, Dissolved Oxygen (DO) and Temperature. Standard pH/ORP sensors are
installed in the Anoxic Bioreactor chamber. Standard DO and temperature sensor devices are
installed in the MBBR bioreactor chamber. The pH/ORP monitoring devices detect and
transmit pH levels in the anoxic bioreactor. pH monitoring permits the wastewater operator
to evaluate mixed liquor pH concentrations and provide manual or automatic pH
adjustment. The DO sensors give real time information relative to the DO concentrations in
the aerobic bioreactor and when specifically connected to the PLC may permit automatic
control of the aeration system to either increase or decrease DO concentrations and to
conserve energy by only providing aeration when needed. The temperature probe provides
the operator with real time water temperature monitoring which is important to the operator
respective of denitrification. All of the sensing equipment when combined with a PLC can be
configured with set points that will activate alarms and notify the operator if a specific
condition requires further attention or possible adjustment. All of the sensing equipment is
important relative to successful biological treatment of the wastewater.
PULSE LIFT PUMP

The positive displacement air lift pumps, are made entirely of plastic with no internal moving
parts and are highly reliable and easily operated. The pump operates by utilizing air provided
through the blower system. The piston action scours the return line and forbids the buildup of
any biomass within the pump and discharge piping. Pumps are utilized as RAS pumps when the
8-28
Primary Clarifier is included in the same vessel as the Secondary Clarifier, MLSS Pumps, or
mixers.
Routine maintenance of these pumps includes removal of the systems that use plastic unions
and cleaning the pumps with water, only as needed. Pumps of this type normally operate for
years before they are ever removed, cleaned, and reinstalled.
ANOXIC MIXER (PULSE LIFT MIXER)

Anoxic chambers are used to facilitate denitrification using bacteria to convert nitrates to
nitrites and finally to nitrogen gas which is released from the chamber. Proper Agitation is
required to blend the chamber contents to increase process efficiencies. The Geyser Starburst
Mixer is the ideal mixer for use in anoxic chamber. The mixer is the first of its kind providing
unrivaled mixing and uniform blending of the chamber utilizing large air bubbles. Unlike
horizontal mixers, side-entering mixers and submersible mixers, the Geyser Starburst provides
efficient intermixing of the chamber contents and does not employ any gear reducers,
submerged bearings or submerged seals. The mixer operates off of air from the linear air
pump. The mixer does not clog, and it does not require maintenance. The use of the mixer
combined with the circular shape of the vessel eliminates short circuiting and dead spots in
the anoxic chamber.
The mixer is easily adjusted utilizing a simple valve. The cycling of the air releases should be
adjusted to maintain good mixing while not exceeding DO levels of 0.1 mg/L.
CENTRIFUGAL PUMPS
Centrifugal pumps are supplied in the EQ chamber. Manufacturer’s equipment manuals should
always be referenced for product-specific information.
Common Operating Problems

The following table addresses operating problems that may be experienced with pumps and
motors and offers solutions that should prove helpful in making necessary corrections:
Problem: Pump is not running

CAUSE: CURE:
Main breaker on pump is not on Turn on if in the fully off position
Control switch is off Set HOA switch on auto
8-29
Float switch failure Replace float switch
Problem: Circuit breaker for the pump motor has tripped

CAUSE: CURE:
Motor is shorted or burned out Check for overloading; repair motor
Ambient temperature inside control panel Reduce temperature in panel
too high
Rubbing or jammed impellers Inspect impellers; align or clean
them
Mechanical seal problem Replace mechanical seal
Problem: Reduced rate of discharge or no discharge

CAUSE: CURE:
Pump clogged Pull pump and check for debris in the
impeller and remove debris
Piping clogged Check to see that all valves are fully
open; then check for clogged pipes
Speed of motor too slow Check for low voltage; check motor
windings
Impeller clogged Disassemble the pump and clean the
impellers
Pump air-locked (no discharge) Bleed air from pump; verify wet well
low-level cut off
Problem: Vibrating or noisy pump

CAUSE: CURE:
Strain on pump frame Check for unsupported piping
Foundation insecure Secure properly
Worn bearings Inspect; replace
Misalignment Check and correct
Shaft bent Replace shaft
Problem: Overheating of pump motor

CAUSE: CURE:
8-30
Worn bearings Replace bearings
Dry bearings Lubricate bearings
Excessive grease Remove grease
Pump Replacement
In the event of pump failure, an available spare should be installed without delay. When
replacing the pump, the following steps are recommended for proper installation:
1. Shut off power at the main control panel and follow lockout/tag-out procedures.
(For additional information, see “OSHA FactSheet–Lockout/Tagout” in Appendix A.)
2. Disconnect the pump wiring in the junction box located adjacent to the pump station wet
well and insulate ends of all wires.
3. Submersible Pump Only: Attach a pull line to the wires of the pump. Pulling the wires back
into the wet well allows easy wire retrieval back to the junction box from the spare pump
installation.
4. Submersible Pump Only: Use a hoist or boom truck to pull the pump unit from the wet well.
This task should be performed with caution. Pressure should be applied on the lifting chain
or cable and the attached cable shaken and/or pulled back and forth. Doing so will dislodge
the seal on the pump connection. Keep applying pressure to the chain or cable as the seal
is being dislodged. Once it has broken free, continue to lift pump from wet well.
5. Set the old pump aside and prepare for installation of the spare.
6. Compare the two pumps. The transfer of guide rail assemblies and discharge connection is
required in some cases. Make sure these are installed prior to setting the spare pump.
7. Pull and reconnect wires to the junction box.
8. Turn on the power source.
9. Check pump’s rotation. If not correct, switch two of the three wires.
10. Start pump manually and check the amperage across all three phases. If amp draw is
normal, place the HOA switch in the automatic position.
Startup and Shutdown Procedures
Preliminary Steps
The following steps provide general guidance associated with startup and shutdown of the
pumps:
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1. Planning ahead
• When starting up a pump, ensure the pump(s) are properly installed and connected
before opening the discharge valve(s).
When removing a pump, make certain there is another unit in service for
continuation of adequate flow.
2. Checking control switches (HOA)
• When starting up a piece of equipment, check to make certain all local and panel
switches are connected with the unit and associated equipment is in OFF position.
• When shutting down a piece of equipment open and label breakers and local power
disconnects for all associated equipment and instrumentation. Label using proper
lock-out/tag-out procedures.
(For additional information, see “OSHA FactSheet–Lockout/Tagout” in Appendix A.)
3. Cleaning units
• Before startup and after shutdown, it may be necessary to clean the unit. Use
all applicable safety precautions.
4. Preparing equipment
• Close all breakers and local power disconnects to all equipment and
instrumentation.
• Prepare the equipment for startup according to instructions in the manufacturer’s
O&M manuals.
5. Setting controls
• For normal operation, set level controls as appropriate.
• For alternate operation, set level controls as needed to implement the chosen
process control strategy.
Placing a Pump in Service
1. Follow procedure as outlined under “Preliminary Steps” subheading earlier in this
chapter.
2. Install the repaired or new pump into the wet well.
3. Open the appropriate discharge valve.
4. Close the pump’s main disconnect power switch.
5. Place the appropriate control switch in the AUTO position.
Removing a Pump From Service
1. Follow procedure as outlined under “Preliminary Steps” subheading earlier in this
chapter.
2. Open the pump’s control main disconnect power switch.
3. Place the appropriate pump’s control switch in the OFF position.
4. Close the appropriate discharge valve to isolate the pump being removed from service.
5. Remove the pump for necessary repairs.
8-32
6. Replace the pump as soon as possible.
Maintenance
Lubrication or other maintenance of the pump is not required as the motor is oil-filled and
connected directly to the impeller. Mechanical seals are located at two points above the
impeller which protects the motor’s electrical windings.
A general inspection of the rail system should be performed to ensure there has been no damage
from pump removal/installation activity. The rails should be kept free from debris and grease
buildup.
From time to time it is necessary to replace the pump unit due to reduced efficiency or failure.
A hoisting device may be used in the process of pump removal to prevent back injury. The wet
well bottom should be washed down periodically to help remove any solids buildup or debris
which could cause pump damage. If debris is discovered, for safe removal, the proper
procedures for confined spaces are applicable. Only qualified persons should be allowed to
enter and remove the debris.
Safety Notice: The perimeter of entry risers should remain clear of debris at all times to
prevent trips and falls. Whenever an entry riser is open, the area should never be left
unattended. Additionally, warning signs and barriers may be utilized for increased safety
when risers are open. When working with tools, they should be secured with lanyards or other
devices to prevent accidentally dropping into the chamber. When cleaning pump control
floats, safety restraint apparatus should be utilized to prevent falling head first into the
chamber.
(For more information, see “Pump Replacement” in this chapter, “Confined Spaces” in
Chapter V – SAFETY, and OSHA FactSheet – “Procedures for Atmospheric Testing in Confined
Spaces” in Appendix A.)
(For additional pump information, see the manufacturer’s manual in Appendix B.)
(For additional pump control details, see “Control Panel” – Appendix F.)
8-33
SYSTEM STARTUP
CLEAN WATER TESTING

All system startups include a clean water test prior to the introduction of a waste stream. It is
recommended that a 48 hour test be performed for all systems equal to and less than 10,000
GPD and for a full week on systems larger than 10,000 GPD. The intent of the clean water test
is to ensure functionality of all components prior to commissioning the system into full
operation. The manufacturer should be contacted immediately to provide assistance if any
components are found not to be performing as required.
The initial process of checking the system involves a number of components. Examples may
include activation of the blower system(s), verifying the aeration system is functioning
correctly, and checking centrifugal pumps (if supplied), disinfection system(s), and control
panel functions.
NOTE: Following the clean water testing period, the system should be filled to 100 percent
capacity with clean water prior to the scheduled date and time of system startup.
MBBR
Following the process of clean water testing and verifying that all components are functional,
approximately fifty percent (50%) of the MBBR media initially supplied will be installed by the
startup representative prior to commissioning the system to full operation. The remaining
media will be added gradually over time by the facility operator and the following guidelines
apply:
• Operator Monitoring – It takes time for biofilm to develop on the existing media.
When the operator observes the media mixing and falling out of suspension, it is time
to add more.
• Media Addition – Media should be added incrementally to the MBBR to prevent it from
mounding or pocketing in the chamber. The process of installing the remaining supply
typically takes four to eight weeks; however, depending upon the size of the system,
characteristics of the waste stream, and biofilm development rates, this process may
take more or less time.
8-34
The MBBR unit awaits the
addition of the media
which is supplied in large
bags as seen here.
The media is added over
time, not all at once.
Due to variable flows and wastewater influent characteristics, all treatment plants require
different mixing, aeration and pump settings. Subsequently, field adjustments are necessary
over a number of weeks following startup to balance the system.
Adjustments to system operations are typically dictated based upon color and odor of the
plant and its effluent. The system should be closely monitored and adjusted until an efficient
operating condition is achieved.
The MBBR treats wastewater by a biological process and, therefore, requires that sufficient
naturally-occurring bacteria be present in the treatment system. The
development of adequate bacteria growth typically takes between six to ten weeks from the
date the system is placed online. During this critical time the system requires daily attention
by the owner or operator to continually monitor, adjust, and optimize this process.
Systems with wastewater influent characteristics beyond residential strengths may require
seeding with mixed liquor from an outside source such as a treatment plant already in
operation. Seeding expedites the biological processes.
If seeding of the system is deemed necessary, a good source of quality mixed liquor
suspended solids (MLSS) should be located within a reasonable distance of the WWTP. The
MLSS should be fresh and delivered within a time span not to exceed 12 hours (from source to
WWTP) due to the fact that microorganisms cannot survive without a sufficient oxygen
source.
CAUTION: It is important that the vehicle in which the MLSS is hauled be carefully pre-
cleaned, free of any and all matter, debris, or residue from previous hauls, particularly
septic operations. This is absolutely essential to ensure that no foreign material, objects, or
other matter is present in the MLSS upon delivery, which could be unintentionally introduced
into the system via a chamber of the Mobile INCEPTOR and adversely affect plant operations.
PHYSICAL CHARACTERISTICS REFERENCE FOR STARTUP OPERATIONS

The following physical characteristics reference table is a tool that may be utilized to assist
the operator during and after startup with achieving system efficiency:
8-35
RETURN
BIO-REACTOR CLARIFIER ADJUST-
INFLUENT COLOR SLUDGE ODOR CONDITION
COLOR COLOR MENT
COLOR
Dark
Dark Efficient
Gray Brow Clear Earthy
Brown Operation
n
Dark Excessive
Dark
Gray Brow Clear Earthy Foaming in Spray Down
Brown
n Bioreactor
Reduce
Dark
Light Solids in
Gray Brow Murky Musty RAS rate
Brown Effluent
n
Light Floating Increase Scum

Light Light Removal Rate
Gray Brow Musty Solids in
Brown Brown
n Clarifier
Light Over- Reduce

Gray Red Red None
Brown Aeration Aeration
Insufficient Increase
Gray Black Black Black Septic
Aeration Aeration
AERATION AND MIXING ADJUSTMENTS

The blower is sized according to aeration and pumping requirements for a specific system
based upon design criteria. However, the actual loading of the plant at startup may vary
significantly.
The level of dissolved oxygen and degree of mixing in the bioreactor is a direct result of
the amount of air released through the diffusers. Depending upon loading, the amount of air
provided may be adjusted by the blower’s pressure relief valve and/or a combination of
timers to control the blower run cycle. By adjusting the run cycle of the blower, the
introduction of oxygen may be controlled to increase or decrease mixing and stabilize the
oxygen level. A minimum of 2.0 mg/l of dissolved oxygen in the MBBR’s should be
8-36
maintained. The dissolved oxygen levels should be checked frequently with a hand-held DO
meter at varying depths and at all access points over the length of the chamber (using an
average of the results as a base line), with adjustments made accordingly. If aeration rates
are changed, the system should be permitted to run at least 48 hours (or longer) before
making any further adjustments. Some WWTP models may have controls that are not
adjustable, meaning the PLC has preloaded settings.
AIR LIFT PUMP ADJUSTMENTS

RAS Air Lift Pump Adjustment:
The RAS positive displacement air lift pumps and the optional surface scum removal systems
(if supplied) utilize air from the main line to the diffusers. The pump rates are easily adjusted
using standard in-line ball or needle valve controls. Settings should be monitored to ensure
proper operation after making adjustments.
At startup, the RAS air line should be adjusted to approximately 10% to 20% open for the first
week or until the plant begins to build up solids. This will slow the amount of flow entering
the secondary clarifier which increases the detention time, keeping the water movement to a
minimum. The result is better settling of solids and reduced short circuiting. Once the solids
concentrations have improved, the air control valve should be further opened until the RAS
return is somewhat “heavy” in appearance. Monitoring of the sludge depth in the secondary
clarifier should be frequent (weekly, or more often) during the start up period. Sludge depth
should be maintained between one and two feet. If sludge depth increases to three feet, the
return rate should be increased. Sludge depths greater than three feet may cause the
development of septic conditions . The color and odor of the return sludge and MLSS will
indicate the development of solids. As solids begin to develop, the color of the mixed liquor
in the bioreactor should change from gray to a light brown, and the odor should become a
non-offensive earthy smell like a well-maintained compost pile.
Once the WWTP is completely filled with water, activate the main aeration blower and verify
that aeration system is functioning correctly as specified elsewhere. The operator will need
to monitor the WAS pumping rate once biological treatment is established and may need to
slightly increase or decrease the WAS pumping rate to match biological treatment needs and
to maintain the highest efficiency in clarifier operation. It is important that the WAS pump
does not pump too fast as the sludge will not have time to settle and solids will be permitted
to discharge from the system.
8-37
Example of air control Example of inlet
valves used to flush ports from the
buildup of bio solids MBBR (not
from the MBBR standard on all
effluents screens (not chambers)
standard on all vessels)
Air control
valve for air-
lift pump
Positive
Displacement
Air-lift pump
MLSS Air Lift Pump Adjustment
The MLSS pumping system works in the same fashion as the RAS pumping
systems. Calibration of the pumping unit shall be accomplished in the exact same
fashion as the WAS pumping systems.
FOAMING
Foaming is common of all plants at startup and develops on the bioreactor surface due to the
mixing action and large amounts of air being diffused. Once activated sludge develops,
foaming will reduce significantly or entirely. Foam will also carry over to the secondary
clarifier. The foam may be broken up utilizing the water pressure of a garden hose sprayer
and this should be done often to reduce odors and help make the solids resettle. Caution
should be exercised when breaking up foam in the secondary clarifier to prevent solids from
being discharged, and this should be done only during periods when flow through the system
is minimal or stopped altogether.
8-38
This is excessive foaming due to low MLSS
concentrations and the absences of a food source. The
white foam is from the MBBR. The black color is the
result of dried foam and the solids contained within.
Foam may be broken apart utilizing water pressure.

Caution should be exercised during the process of
spraying so as not to allow solids to carry through the
discharge.
OPERATIONS & MAINTENANCE
ROUTINE ADJUSTMENTS
It is possible to develop a good understanding of how well the system is working and when
adjustments are necessary just by observing the color and odor of the influent, bioreactor,
and secondary clarifier. The system should be closely monitored and adjusted until an
efficient operating condition is achieved and maintained.
8-39
PHYSICAL CHARACTERISTICS REFERENCE FOR NORMAL SYSTEM OPERATIONS
The following table is a tool that may be utilized to assist the operator in making system
adjustments to achieve optimal plant efficiency:
BIO- RETURN
INFLUENT CLARIFIER ADJUST-
REACTOR SLUDGE ODOR CONDITION
COLOR COLOR MENT
COLOR COLOR
Dark Dark Efficient

Gray Clear Earthy
Brown Brown operation
Saturating
dose of
Excessive CL2 in the
foaming in bioreactor
Dark Dark bioreactor to kill the
Gray Clear Earthy
Brown Brown due to filamentou
filamentous s bacteria;
bacteria Increase
MLSS
pump rate
Adjust
scum
Floating removal
Dark Dark lumps of system;
Gray Clear Earthy Clean
Brown Brown grease in
clarifier or install
grease
trap
Layer
Dark Dark of sludge Increase

Gray Clear Musty visible near
Brown Brown RAS rate
surface of
clarifier
Dark Light Light Solids in Reduce

Gray Musty
Brown Gray Brown effluent RAS rate
Floating
Light Light Light Slightly Adjust
Gray solids in
Brown Brown Brown musty scum
clarifier
8-40
removal
system
Slightly Inadequate
Light Increase
Gray Black Black return of
Brown septic RAS rate
sludge
Insufficient Increase
Light aeration;
Gray Gray Gray None solids in
Gray Increase
system RAS rate
Light Over Reduce

Gray Red Red None
Brown Aeration aeration
Increase
Insufficient aeration;
Gray Black Black Black Septic Check
Aeration blower
filters
Press reset
on starter;
No air Check V-
rising in belt;
Gray Black Black -------- Septic bioreactor; Check
Blower not circuit
running breaker;
Check
power
Maximum
aeration;
Septic Check
Black Black Black Black Septic
wastewater influent
for toxic
materials
SUMMARY OF OBSERVATIONS
The following table identifies and explains many of the specific conditions observed with the
MBBR and secondary clarifier and aids in determining any correction action required:
8-41
LOCATION/CONDITION: OBSERVATION: MEANING:
MOVING BED BIOLOGICAL REACTOR (MBBR):
Chocolate Brown Normal
Color Black Low DO – Septic
Tan High Clay – Sand Content
Musty Normal Operation

Odor
Rotten Egg Septic
Crisp White Normal Operation
Under-oxidized Solids
White, Billowing Young Sludge
Foam Low MLSS
Over-oxidized Solids
Thick, Greasy Old Sludge
High MLSS
Smooth, Uniform Normal Operation
Mixing None Aeration Too Low
Non-uniform Diffusers Need Repair
SECONDARY CLARIFIER:
Smooth, Uniform Normal Operation
Over-oxidized Solids
Settling
Discreet Particles Old Sludge
High MLSS
8-42
Billowing Solids Short Circuits
None Bulking
Constant Normal Conditions
Blanket Depth Solids Becoming Less

Increasing Dense or More Solids
(Thickness of or Hydraulic Overloads
Solids in Clarifier) Solids Becoming More
Decreasing
Dense or Less Solids
None Normal Operation
Straggler Floc Recent Rapid Growth
Solids Carryover Pin Floc Old Sludge, High Solids
Ash Floc Extremely Old Sludge
Entire Blanket Bulking or Hydraulic Overload
SOLIDS CONTROL
Periodic pumping is necessary to remove sludge and sloughed-off bacteria from the system.
Sludge is wasted from the MBR chamber to the digester chamber and removed by an approved
waste hauler. Sludge is wasted periodically to the sludge digester by opening the feed line
control valve to the digester and closing the RAS line valve feeding the MLSS chamber. After
wasting a predetermined amount of RAS, the feed line valve should be opened to the anoxic
chamber and the WAS line valve closed to the sludge digester. The RAS return goes back to
the normal run mode.
The simplest analysis for solids control is the 30-minute settleometer test. This test should be
performed routinely to observe the relative quantity of solids in the MBBR and ensure that
sludge is settling properly. A sample of mixed liquor (MLSS) should be collected from the end
of the bioreactor just before the flow enters the secondary clarifier, then placed into a 1,000
ml settleometer and allowed to settle for 30 minutes. Observing how particles stick together
and settle will help determine the quality of the sludge. The settleometer test
indicates how sludge is settling in the secondary clarifier, as well as quantity percentages.
The percent or quantity (milliliters) of sludge per liter should be logged and this information
used as a record of the amount of sludge in the system. Solids should be wasted to the
sludge digester when tests indicate settleable solids are greater than 500 ml in 30 minutes
(50%). Close monitoring in this case is indicated. A good range for MLSS is between 30%
and 70%. Established guidelines should be utilized for corrective adjustments and action for
8-43
sludge management. The pumping of solids from the digester should be performed by an
approved Service Provider.
ABNORMAL CONDITIONS AND CORRECTIVE ACTION

If a problem presents with the MOBILE INCEPTOR™, it usually requires a simple correction.
The general troubleshooting guide to follow lists causes and corrections for potential
problems that may arise. However, should an issue occur that is not addressed in the
following table, contact Customer Support directly if it cannot otherwise be determined or
solved:
PROBLEM: POSSIBLE CAUSE: CORRECTION:
Clean intake screens on blower

Air intake is blocked. housing. Check air filter on blower for
blockage.
The air discharge line Check discharge line and vent line
or vent line is visually or with drain cleaning
blocked. equipment for obstructions.
The system is flooded

Determine cause of flooding and
and a high water
correct.
alarm was installed.
The failure indicator light Determine if blower failure was
on the control panel is on, caused by an obstructed intake or
discharge line.
and the alarm sounds.
Check to see whether circuit
The blower has failed.
protection device for blower has
tripped.
Refer to blower manufacturer’s O&M

manual.
The power cable to

the blower has been Have a certified electrician check the
damaged or is not wiring to the blower.
connected properly.
Push reset button to silence alarm, if

An alarm condition has provided.
The audible alarm is on.
occurred. Inspect system for possible cause for
alarm.
8-44
Blower motor bearing Remove blower and have blower motor
has failed. serviced.
Blower motor is making a loud
whining or grinding noise. A foreign object has
Remove blower for service and check
entered blower
condition of air filter.
housing.
There is an Check the effluent piping and

obstruction in the compartment ports visually or with
Wastewater is backing up
discharge line or a drain cleaning equipment for an
compartment port obstruction and correct.
Check the maximum flow rate to the

The flow rate to the
system to see that it is within normal
system is too high.
limits.
Influent is backing up
The tank needs Check the sludge depth in all
into the sewer system
chambers. If the depth is too great,
and/or a pump out
have the tank pumped out and, if
is required. necessary, cleaned.
Manual scum removal system Clogged inlet Remove clog with sewer cleaning rod
in secondary clarifier not Clogged discharge Remove clog with sewer cleaning rod
working properly (if equipped) pipe. or water jet equipment
Clogged RAS/WAS
Remove and clean pump assembly.
pump discharge pipe.
Solids in Effluent
Excessive RAS rate. Reduce air intake rate.
System overloaded. Increase aeration or analyze influent.
Excess fats, oils and

Clean grease trap.
grease.
Floating Solids Clogged RAS/WAS
pump Remove and clean pump assembly.
discharge pipe.
Uneven aeration Clogged air intake

Remove and clean diffuser assembly.
and mixing pipe.
Clogged pump
Remove and clean pump assembly.
RAS/WAS or MLSS discharge pipe.
not pumping Inadequate air
Increase air intake rate.
pressure.
8-45
Refer to blower manufacturer’s O&M
Blower not operating.
manual.
The blower and air

Check blower, vents, and air piping for
piping are not
proper operation.
operating correctly.
There is an offensive Check the maximum flow rate BOD

load rate to system to see that it is
odor emanating within design limits.
The system is
overloaded. Check the quality and contents of the
flow into the system for any abnormal
or prohibited substances
EMERGENCY OPERATIONS
In the event of an alarm notification, the operator should perform a site visit promptly to
investigate the alarm condition. Electrical problems and possible blockages of pipes should
be investigated. If possible, the operator should perform needed repairs or modifications to
the system. If the cause of the problem cannot be found, or more extensive maintenance of
the system is required immediately, the operator should quickly evaluate the water level and
determine if there is danger of a system overflow. If overflow is imminent, the
operator should notify the owner that further wastewater cannot be delivered to the system.
A temporary shutdown of the discharging facility may be required in such a case. Overflows
and spills of the system may have serious health ramifications and result in penalties levied
by regulatory organizations.
If the system is overflowing, provisions should be made quickly in an attempt to contain the
overflow with rapid construction of berms or dikes and/or contacting a pump and haul
contractor for assistance. Spills should be contained in as small an area as possible.
Absorbent pillows or snakes may be used to soak up a spill if not too large. A supply of
absorbent pillows and a commercial floor dry product should be kept onsite for small spills.
MAINTENANCE & MONITORING SCHEDULE – ALL CHAMBERS/COMPONENTS

In the following table, the major points of required maintenance and frequency are
summarized for the chambers/components of a wastewater treatment plant.
Note: This is a general schedule and may not be all inclusive for every system model. It
may also contain items that are non-applicable.
8-46
COMPONENT FREQUENCY PROCEDURE
Do visual inspection of filters for debris

Bi-Weekly
build-up and clean as necessary.
Primary Clarifier
Check sludge depth. If total of sludge and
Bi-Monthly floatable solids is 50% of water depth,
remove solids.
Material should be scraped/hosed into a

Primary Filter System Bi-Weekly container and disposed of properly. DO
NOT PLACE BACK INTO VESSEL.
Check transfer pumps for proper

operation.
Equalization Tank Weekly
Check aeration system for proper
operation.
Anoxic Bioreactor Weekly Check for proper mixing.
Ensure blower operation is functioning

properly.
Blower(s) Weekly
Maintain per manufacturer’s
recommendations.
Monitor: pH, DO, settleability of MLSS.
Remove MLSS (or RAS) if percent solids is

too high (as needed).
Clean media screens.

MBBR Bioreactor Weekly
Scour MLSS pump screen by closing
discharge ball valve for five minutes.
Perform control testing as noted in the

MBBR Control Testing Chart.
Bi-Weekly WAS to Primary Clarifier – Ensure return

Secondary Clarifier
(Monday/Thursday) flow is adequate and check quality
8-47
visually. Hose down/break up foamy
matter, use caution.
Pump solids from chamber whenever

As Required
Primary Clarifier is pumped.
(Other maintenance details should be obtained from manufacturer’s O&M manuals found in
Appendix B.)
8-48
ELECTRICAL CONTROLS
FUNCTIONAL DESCRIPTION
The local control panel contains a Programmable Logic Controller (PLC), in addition to an
external light and horn to indicate alarms. The PLC controls the operation of pumps and
blowers, and is programmable for pump run times and alternation of dual systems. The panel
also provides Hand/Off/Auto mode switches for pumps and blower units, which work in
conjunction with the PLC. The control panel is equipped with sensors and alarm components
that automatically monitor blower and pump operations, and high/low water indicators,
activating the alarm system under certain conditions. An emergency stop switch is located on
the front of the panel to allow for a complete manual shutdown of the system should such
measures prove necessary during an emergency event. A silencing switch is provided
to locally stop an audible alarm. The activated light indicator will be present until the source
of the alarm has been addressed.
OPERATION
(For additional information, see the manufacturer’s manual in Appendix E.)
RECORDS AND REPORTS

Trends and specific patterns may be realized over time and corresponding control methods
specifically developed to assist in the best operation of the plant. The following records
should be maintained and used as an operational guide:
• Visual observations
• Dates of general maintenance
• Flow rates (if available)
• Operational activities – (i.e. sludge removal quantities, floatable solids removal, best
solutions for correcting specific operational problems)
• Control testing as specified
The operator is responsible for completing data sheets pertaining to the operation of the
system and maintaining such records in an organized manner. This includes log sheets on
which information should be recorded during each plant inspection. The log is utilized for
documenting regular visits to the site as well as other pertinent information. The operator
should record the date, arrival and departure times, and sign the log each visit. The log
should also include daily, monthly and yearly inspection reports. Operators are required to
initial each completed task on the list.
Multiple copies of blank log sheets and inspection forms may be placed in a three ring binder
and used to record conditions and inspection information, maintained by the operator at all
8-49
times. If a new operator is employed, the log and all records should be disclosed to
management so that these vital systems of recordkeeping may be appropriately presented
and explained to the new operator.
(Samples of various operator reporting forms are located in Appendix D.)
8-50
CHAPTER 9 LIMITED WARRANTY
Apptech Solutions, LLC warrants all new INCEPTORTM systems against defects in materials and
workmanship for a period of one year commencing upon the date of shipment from the
factory.
If a component is proven defective or fails to perform as specified when operating at design
conditions during the warranty period, and if the equipment has been installed and is being
operated and maintained in accordance with the written instructions provided by Apptech
Solutions, LLC will repair or replace at its discretion such defective components free of
charge. Apptech Solutions, LLC reserves the right to require the defective component be
returned, freight prepaid, for evaluation at the factory before allowing a claim. The cost of
labor and all other expenses resulting from replacement of the defective component and from
installation of components furnished under this warranty and regular maintenance items such
as filters shall be borne by the owner. This warranty does not cover components that have
been (I) damaged by flooding, (II) damaged due to disassembly by unauthorized persons,
improperly installed, misuse or lighting, (III) damaged due to altered or improper wiring or
overload protection, or (IV) damaged externally. Typical consumables such as filters, fuses,
V-belts, grease and oil are not covered under this warranty. This warranty applies only to the
Apptech Solutions, LLC system as supplied by Apptech Solutions, LLC and does not include any
of the electrical wiring, yard piping, or any other part of the treatment or disposal system.
APPTECH SOLUTIONS, LLC SHALL NOT BE HELD RESPONSIBLE FOR ANY DAMAGES CAUSED BY
DEFECTIVE MATERIALS OR COMPONENTS, OR FOR LOSS INCURRED BECAUSE OF THE
INTERRUPTION OF SERVICE, OR ANY OTHER SPECIAL, CONSEQUENTIAL, OR INCIDENTAL
DAMAGES OR EXPENSES ARISING FROM THE MANUFACTURER, SALE, USE OR MISUSE OF THE
SYSTEM. THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES. ANY WARRANTY
THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESSED WARRANTIES. ANY WARRANTY IMPLIED
BY LAW, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, IS IN EFFECT ONLY FOR THE WARRANTY PERIOD SPECIFIED ABOVE. NO
REPRESENTATIVE OR PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR TO ASSUME
FOR APPTECH SOLUTIONS, LLC ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITS
PRODUCTS.
Apptech Solutions, LLC reserves the right to revise, change or modify the construction and/or
design of the Apptech Solutions, LLC system, or any component part or parts thereof, without
incurring any obligation to make such changes or modifications in present equipment.
Apptech Solutions, LLC is not responsible for consequential or incidental damages of any
nature resulting from such things as, but not limited to, defect in design, material, or
workmanship, or delays in delivery, replacements or repairs.
9-1
CHAPTER 10 REFERENCES AND BIBLIOGRAPHY
Activated Sludge Process Control – Part I – 4th Edition

Virginia Water Control Board, Richmond, Virginia
October 2008
Activated Sludge Process Control – Part II – 3rd Edition

June 2004
Concepts of Activated Sludge – 4th Edition

October 2008
Decentralized Wastewater Glossary – 2nd Edition

The Consortium of Institutes for Decentralized Wastewater Treatment
October 20009
Extended Aeration Package Plants – 2nd Edition

May 2011
Fixed Film Treatment Processes

October 2006
General Information on Nitrogen

Florida Rural Water Association
Manual of Wastewater Operations

The Texas Water Utilities Association
Lancaster Press, Inc., Lancaster, Pennsylvania
January 1975
10-1
Operation of Wastewater Treatment Plants – 7th Edition
California State University, Sacramento, California
2008
Primary Treatment
Pump Maintenance for Wastewater Treatment Plants

1990
Residential Onsite Wastewater Treatment System – 2nd Edition

Consortium of Institutes for Decentralized Wastewater Treatment
Midwest Plan Services
2008
Safety Program Planning – 2nd Edition

February 1999
Sampling and Testing for Small Treatment Plants – 3rd Edition

February 1999
Septic Tanks and Sand Filters – 2nd Edition

1990
Small Wastewater System Operations and Maintenance

California State University, Sacramento, California
1997
Pipeline – Winter 2004, Vol. 15, No. 1

The Attached Growth Process – An Old Technology Takes on New Forms
10-2
National Small Flows Clearinghouse
2004
Understanding the Basic Principles of Nitrogen

Robert Scott, Wastewater Technician for the
Atlantic States Rural Water & Wastewater Association
10-3
CHAPTER 11 INDEX
A G
Abnormal Conditions and Corrective Action ...... 8-44
General References.................................... 5-7
Aeration and Mixing Adjustments................... 8-36
General safety.......................................... 5-1
Air Lift Pump Adjustments .......................... 8-37
Ammonification ..................................... 8-12
Ancillary Equipment ................................... 7-5 L
Anoxic Bioreactor ............................... 7-3, 8-11
Anoxic Mixer (Pulse Lift Mixer) ..................... 8-29 Laboratory Hazards .................................... 5-8
Lifting and Handling Injuries ......................... 5-3
Limited Warranty ...................................... 9-1
B Linear Air Pumps ...................................... 8-26
Biohazards .............................................. 5-7
Blower Assembly ...................................... 8-26 M
Maintenance & Monitoring Schedule – All
C Chambers/Components ........................... 8-46
MBBR ....................................... 7-3, 8-18, 8-34
Centrifugal Pumps .................................... 8-29
MBBR Media Screens .................................. 8-27
Chamber Maintenance ......... 8-10, 8-17, 8-23, 8-25
Mechanical Equipment Hazards ...................... 5-9
Chemical Characteristics ............................. 6-2
Metering Equipment .................................. 8-28
Chemicals ............................................... 5-5
Methods of Control .............. 8-8, 8-15, 8-21, 8-25
Chemicals – General Tips and Guidelines ........... 5-5
Chlorine (Gas) .......................................... 5-6
Clarifier Scum Removal System ..................... 8-25 O
Clean Water Testing .................................. 8-34
Components ........................................... 8-26 Operation .............................................. 8-49
Confined Spaces........................................ 5-3 Operational Considerations ........................... 8-9
Control Testing ..................... 8-6, 8-8, 8-15, 8-22 Operations & Maintenance .......................... 8-39
Cuts, Abrasions, and Other Injuries ................. 5-3 Operations and Maintenance ......................... 8-1
Operator and Managerial Responsibility ............ 4-1
Operator Responsibilities ............................. 4-1
D OSHA ..................................................... 5-1
Overview ................ 8-1, 8-3, 8-8, 8-11, 8-18, 8-24
Diffusers................................................ 8-26
Owner/Managerial Responsibilities .................. 4-2
Disclaimer ............................................... 1-2
Oxygen Deficiency and Toxic Gases ................. 5-4
Dropping Tools/Equipment into Wastewater ...... 5-9
E P
Personal Protective Equipment (PPE) ............... 5-9
Effluent Filter Assembly ............................. 8-27
Physical Characteristics ............................... 6-1
Electrical ................................................ 5-2
Physical Characteristics Reference for Normal
Electrical Controls .................................... 8-49
System Operations................................. 8-40
Emergency Operations ............................... 8-46
Physical Characteristics Reference for Startup
Expected Performance ................. 8-7, 8-16, 8-23
Operations .......................................... 8-35
Explosion and Fire ..................................... 5-2
Primary Clarifier ....................................... 7-2
Process Description ......... 8-3, 8-8, 8-11, 8-19, 8-24
F Product Overview ...................................... 3-1
Pulse Lift Pump ....................................... 8-28
Flow EQ ................................................. 7-2
Flow Equalization (FEQ) .............................. 8-8
Foaming ................................................ 8-38 Q
Functional Description ............................... 8-49
Qualifications for Plant Operators ................... 4-1
11-4
R Sulfur Dioxide .......................................... 5-7
Summary of Typical Domestic Wastewater
Records and Reports.................................. 8-49 Characteristics ...................................... 6-6
References and Bibliography ........................ 10-1 System Chambers ...................................... 8-3
Required Maintenance for Normal Operation ...... 8-4 System Startup ........................................ 8-34
Routine Adjustments ................................. 8-39
T
S Terms and Definitions ................................. 2-1
Safety.................................................... 5-1 The INCEPTORTM 15K WWTP .......................... 7-1
Secondary (Final) Clarifier ........................... 8-24 Trips and Falls .......................................... 5-3
Secondary Clarifier .................................... 7-4
Secondary Clarifier Scum Removal System ........ 8-27
Sodium Hypochlorite .................................. 5-6
W
Sodium Sulfite .......................................... 5-7 Wastewater Overview ................................. 6-1
Solids Control .......................................... 8-43 Work Schedule and Educational Opportunities .... 4-3
Specific Model Description ........................... 7-1
11-5
APPENDIX A - OSHA FACT SHEET
• “Procedures for Atmospheric Testing in Confined Spaces”

• “Working Safely with Electricity”
• “Fire Safety in the Workplace”
• “Laboratory Safety”
• “Lockout/Tagout”
• “Personal Protective Equipment”
• “Personal Protective Equipment (PPE) Reduces Exposure to Bloodborne Pathogens”
A-1
APPENDIX B - EQUIPMENT MANUALS
• Signet pH/ORP Sensors

• Republic Regenerative Blowers
• Liberty Pumps
• EDI MaxAir Diffusers
• Polylok PL Filters
• Conery Mercury Float Switches
• MBBR Media
B-1
APPENDIX C - SPARE EQUIPMENT
RECOMMENDED SPARE EQUIPMENT

The system utilizes a minimal amount of mechanical equipment. The following is a list of
factory recommended spare parts and the quantity that should be kept in stock per the
number of units sold. The quantities listed are minimums recommended. If field experience
suggests additional components or quantities are required, this list may be expanded.
Quantity Description
Various Fuses for control panel
C-1
APPENDIX D - FORMS
• Anoxic Bioreactor Monthly Operations Report

• Daily Inspection Log
• Flow Equalization Monthly Operations Report
• MBBR Monthly Operations Report
• Operator’s Comments Log
• Secondary Clarifier Monthly Operations Report
• Solids Management Monthly Operations Report
• Wastewater Treatment Daily Operations Report
D-1
APPENDIX E - CONTROL PANEL
E-1
APPENDIX F - SYSTEM DRAWINGS
F-1
APPENDIX G - PROCESS CALCULATIONS
G-1
APPENDIX H - STANDARD OPERATING PROCEDURE (SOP)
INCEPTOR 15K Wastewater Treatment Facility
STANDARD OPERATING PROCEDURE (SOP)

This SOP outlines in simplistic terms basic daily operational procedures pertinent to improving
and maximizing performance of their wastewater treatment system. The SOP offers guidelines
for system monitoring, minor adjustments to operational controls, field analyses, and accurate
reporting and recordkeeping. This document is only intended to serve as a guide or reference
for the designated operator, by no means taking the place of sound day-to-day judgment or
hands-on experience gained by regular and conscientious work onsite. Although the SOP should
prove a valuable tool, it is not designed to be an independent all-inclusive how-to booklet for
every situation or condition related to the waste treatment process. It is also not intended as
a replacement for the previously-provided Operations and Maintenance (O&M) manual. Rather
the two reference sources should be utilized in combination. Furthermore, no SOP or any other
quick reference tool can substitute for knowledge acquired only through hours of committed
self-study and/or taking advantage of continued education opportunities in the wastewater
industry.
Importance of Reporting and Recordkeeping Tools
It is strongly recommended that the following forms be utilized as part of the monitoring,
inspection, and analysis process, and to establish an accurate, consistent, and organized system
of reporting and recordkeeping:
• Daily Inspection Log – Items listed on the inspection report promote general
awareness and provides a valuable field record of system functionality and operational
trends over time. The content and layout of the log provides a user-friendly
approach and ease to field reporting. Additionally, information may be
straightforwardly transferred to the “Wastewater Treatment Daily Operations Report”.
By design, specific items of data are conveniently recorded on each form in a
comparable, nearly parallel format.
• Operator’s Comments Log – This is a simple and informal narrative tool for use in the
field to quickly jot down thoughts or self reminders regarding the system, or note
descriptions of sounds or observations of significance. This information may prove
H-1
instrumental in troubleshooting, identifying problems or abnormal conditions which
could potentially lead to equipment failures, plant upsets, or other occurrences to be
avoided if at all possible. Important events such as sludge pumping may be
documented using the “Operator’s Comments Log”, along with information regarding
corrections, modifications, or improvements made in the field.
• Wastewater Treatment Daily Operations Report – A formal daily record of field

testing results, observations, and required reporting.
• Wastewater Treatment System Monthly Operations Report - A formal monthly record

of field testing results, observations, and required reporting.
To reiterate and expand upon previously-noted benefits, the consistent and proper use of forms
on a daily and monthly basis provides an opportunity for the operator and management alike
to better recognize system changes and trends; troubleshoot more effectively, correctly
identify and address problems; and even predict when maintenance activities such as sludge
wasting will likely be necessary.
Consistent and accurate recordkeeping is often essential to effective managerial planning and
assessing future needs based upon reviewing and analyzing data and documentation over a
period of time.
Operator’s Daily “Walk-Through” of the Wastewater

Treatment Plant
Primary Clarifier
1. Open the access hatches on the vessel.
2. Note water color, odor, level, and flow in the chamber. Inspect the inlet for floatable
materials such as grease, rags, plastic bags, etc. (If conditions warrant based upon
the amount and thickness of the matter, prompt removal should be scheduled.)
Conditions/observations should be noted on the “Operator’s Comments Log” and/or
“Daily Inspection Log” as appropriate.
3. Check the effluent filters by removing a minimum of one unit for visual inspection. If
a grease accumulation, fibers, or other matter cover the unit, promptly clean the
filters. To do so, hold the filter over a trash can outfitted with some type of screening
device to collect the material, and hose off thoroughly. (DO NOT HOSE OFF THE
FILTERS OVER THE CHAMBER ACCESS due to the probability that matter washed off
the filters will be allowed to go down into the filter holders which, in turn, travels
directly to the MBBR, thus increasing the likelihood of stoppages occurring in the
H-2
media effluent screens.) Once cleaned, position each filter back into the filter holder.
Note the completion of this process on the “Daily Inspection Log” and/or any
significant conditions/observations on the “Operator’s Comments Log” as appropriate.
4. Check the primary sludge depth with a Sludge Judge utilizing the access points to take
measurements. On the “Wastewater Treatment Daily Operations Report”, a place is
provided to record sludge depths. These figures are to be averaged and results
recorded on the form. Later, such data will be recorded on the monthly report as
well. If the average is equal to or greater than 25% of the total depth, prompt
removal of the sludge should be scheduled on the earliest available date.
5. When solids are pumped out, an estimated volume (in gallons) of the sludge removed
should be recorded on the “Wastewater Treatment Daily Operations Report” the very
day on which pumping occurs, then later this information should be included in the
monthly report as well. The “Operator’s Comments Log” may also be utilized for
related narrative as needed.
6. Always recap vents and secure all hatches.
Flow Equalization (EQ)
1. Open access hatch.
2. Note water color, odor, and level in the chamber.
3. If water level appears high, immediately check the EQ air lift pump for a malfunction.
The water level should be normal providing the pump is cycling correctly. If not,
check the blower operation. If the blower system is functioning properly, check the
air control valve to make sure the air flow to the pump is adequate.
4. Note the completion of this process on the “Daily Inspection Log” and/or any
significant conditions/observations recorded on the “Operator’s Comments Log” as
appropriate.
5. Secure hatch.
Anoxic Bioreactor
2. Visually inspect the waste stream and the RAS flow from the secondary clarifier. If
the flow is not consistent or there appears to be reduced volume, check the setting on
H-3
the air control ball valve located on the air supply line located in the secondary
clarifier. Be aware of splashing that may occur in the treatment process.
3. Note water color, odor, and level in the chamber.
4. If water level appears high, immediately check the effluent media screens for
blockage. Use a broom or brush device to remove build-up of matter on the exterior.
Readjust cleaning schedule if this continues to be an issue.
5. Check analytical probes (if supplied). Clean and calibrate as necessary.
6. Hose and clean as necessary.
7. Note the completion of this process on the “Daily Inspection Log” and/or any
appropriate.
8. Secure hatch.
Moving Bed Biological Reactor (MBBR)
1. Open access hatches on both ends of the vessel.
2. Visually inspect the MLSS and RAS. Note water color, odor, and level in the chamber.
Also note suspension or submersion and appearance of the media. If water level
appears high, immediately check the media screens at the end of the MBBR. Use a
broom or brush to remove build-up of matter on the exterior. Readjust cleaning
schedule if this continues to be an issue.
3. Observe aeration in the MBBR. There should be a good rolling and mixing action of the
media and liquid. If the water is moving either sluggishly or not at all, or there is
reduced or absent rolling action, check the blower to ensure proper function. If air
movement is not sufficient or appears abnormal, check the blower filter which could
be restricting air volume. Be mindful of recommended cleaning frequencies and other
maintenance activities as identified in the manufacturer’s equipment manual, located
under Appendix B of the Operations and Maintenance manual. In addition, other
information regarding the blower operation may be found in Chapter 8 of the
Operations and Maintenance manual. There are also related check point items listed
on the “Daily Inspection Log” that must be addressed.
4. The flow rate of the RAS should be such that only 1 – 3 feet of sludge is present in the
bottom of the final clarifier at any given time. Too little air will cause the sludge to
H-4
accumulate, become sticky, and cling to the surfaces of the chamber. Such highly
undesirable conditions result in the system becoming septic. In addition to the above,
related items also appear on the “Daily Inspection Log” that must be addressed.
Record sludge depth measurements on the “Wastewater Treatment Daily Operations
Report” and later the “Wastewater Treatment System Monthly Operations Report”.
Any observations or notes related to the MBBR may also be recorded on the
“Operator’s Comments Log” as appropriate.
5. Chapter 8 of the Operations and Maintenance manual may also be referenced for
information regarding the MBBR–identifying abnormalities and seeking corrective
action recommendations.
Secondary Clarifier
2. Note any significant or abnormal foam accumulation, appearance and characteristics,

as well as the color and clarity of the effluent water. Please note that caution must
be exercised when hosing down or breaking up foam in the clarifier to prevent solids
from overflowing the weirs. Foam control activity should be performed only when the
water level is below the weirs and/or at the time when sludge is also being removed
from the primary clarifier. Record any observations and conditions of significance on
the “Operator’s Comments Log”.
3. The flow rate of the RAS should be such that only 1 – 3 feet of sludge is present in the
bottom of the final clarifier at any given time. Too little air will cause the sludge to
accumulate, become sticky, and cling to the surfaces of the chamber. Such highly
undesirable conditions result in the system becoming septic. In addition to the above,
there are related items on the “Daily Inspection Log” which must also be addressed.
Record sludge depth measurements on the “Wastewater Treatment Daily Operations
Report” and later the “Wastewater Treatment System Monthly Operations Report”.
Any observations or notes related to the MBBR may also be recorded on the
“Operator’s Comments Log” as appropriate.
4. If the depth reaches 3-feet and the pump is returning the RAS at maximum flow rate,
some of the sludge will need to be wasted (removed) from the system. In addition,
there will be pin floc discharging in the effluent stream. Removal may be
accomplished by wasting sludge to the primary clarifier. From the primary chamber,
an approved waste hauler may remove all sludge.
Frequent checks with the Sludge Judge should be performed to keep track of how
much has been removed and/or accumulated. It is important to remove only small
quantities at a time. For a small system, only 200 to 300 gallons should be removed at
H-5
any given time before allowing the system time to readjust. Continue monitoring for
several days.
NEVER SHOULD ALL OF THE SLUDGE BE REMOVED FROM THE SYSTEM.
4. If there is a scum accumulation on the water’s surface, open the scum removal
system’s control valve to transfer the scum to the EQ chamber. Once the scum has
been removed, shut the control valve off to return the system to normal operation.
Note the completion of this process on the “Daily Inspection Log” and/or any
appropriate.
5. Do a final visual sweep of the area and ensure that all hatches are secure before
leaving the facility.
H-6

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OPERATION

INCEPTOR™ 15K WWTP

WASTEWATER TREATMENT PLANT

INCEPTOR™ 15K WWTP

WASTEWATER TREATMENT PLANT

QUALIFICATIONS FOR PLANT OPERATORS

• thorough knowledge of the operating characteristics and maintenance requirements of

• Ensure efficient wastewater treatment plant operation and maintenance

EXPLOSION AND FIRE

TRIPS AND FALLS

CUTS, ABRASIONS, AND OTHER INJURIES

LIFTING AND HANDLING INJURIES

OXYGEN DEFICIENCY AND TOXIC GASES

CHEMICALS – GENERAL TIPS AND GUIDELINES

MECHANICAL EQUIPMENT HAZARDS

DROPPING TOOLS/EQUIPMENT INTO WASTEWATER

PERSONAL PROTECTIVE EQUIPMENT (PPE)

• Always wash hands thoroughly after working on the treatment system.

Biochemical Oxygen Demand (BOD5) :

Carbonaceous Oxygen Demand (CBOD5):

Dissolved Oxygen (DO):

Other Dissolved Gases:

Characteristic: Description and/or Range:

THE INCEPTORTM 15K WWTP

• Primary Clarifier (PC)

PRIMARY CLARIFIER/SLUDGE HOLDING (PC)

Inside the upper

REQUIRED MAINTENANCE FOR NORMAL OPERATION

Effluent filters are located under the

Filter cartridge removed Typical filter cartridge

Right > Filter housing with the cartridge removed.

Note the red ball check located in the bottom. This

PARAMETER LOCATION FREQUENCY

Condition: The effluent contains more than normal solids

• Chamber has become overloaded (hydraulic and/or organic)

• Expand capacity (add another chamber)

• Effluent filters are plugged with debris

• Remove filters and clean or replace

Temperature EQ Effluent Quarterly

Dissolved Oxygen EQ Effluent Quarterly

BOD5 EQ Effluent Quarterly

The anoxic bioreactor provides advance treatment relative to nitrogen removal.

• Nitrogen gas makes up nearly 80% of life sustaining air

• Ammonia (NH3 as a gas or NH4+ ions)

Conditions Required for Effective De-nitrification

PARAMETER LOCATION FREQUENCY

Total N Chamber Quarterly

Typical MBBR vessel

The media shown in this MBBR is

The blower is running and the

• growth rate of biological organisms

Mixed Liquor Suspended Solids (MLSS)

PARAMETER LOCATION FREQUENCY

MLSS (mg/L) MBBR at discharge port Monthly

pH MBBR at discharge port Monthly

Temperature MBBR at discharge port Monthly

PARAMETER OPERATIONAL GOAL

Alkalinity >50 mg/L

MLSS 500 -1000 mg/L

DO > 2.0 mg/L

CLARIFIER SCUM REMOVAL SYSTEM

LINEAR AIR PUMPS

MBBR MEDIA SCREENS

SECONDARY CLARIFIER SCUM REMOVAL SYSTEM