Workshop #1 Part 2 - Grand River Conservation Authority

PROCESS LOADING EVALUATION &
SLUDGE ACCOUNTABILITY
• Step through the Performance Evaluation
protocol;
• Provide training in two components of
evaluation:
– Process loading evaluation
– Sludge accountability analysis.

Two-Step Protocol
COMPOSITE CORRECTION PROGRAM
STEP 1
COMPREHENSIVE PERFORMANCE
EVALUATION (CPE)
STEP 2
COMPREHENSIVE TECHNICAL
ASSISTANCE (CTA)

CPE OUTCOME
• Identify, Classify, & Prioritize Major Performance
Limiting Factors (5-8)
• Classifies Design of Plant:
• Type I (Adequate)
• Type II (Marginal)
• Type III (Inadequate)
• Determine Suitability for Follow-up Technical
Assistance
• Findings presented at end of on-site activities;
•Recommendations NOT Provided

CPE EVALUATORS
• Design assessment experience
• Operations experience
• “Interview” skills i.e. tact;
• Freedom/authority to address
admin/management issues

Scheduling
• Initial Set-up Activities
• On-Site Evaluation
‣ minimum 2 evaluators
‣ typically 5 continuous working days
• Follow-up CPE Report

CPE As Skills Development
• Initial half day workshop
• Participants support trainers:
‣ “arms-length” from day-to-day operation
‣ Maximum of 5-6 participants
‣ Commitment for entire week;
‣ Initially, trainers responsible for outcome;
‣ Allow time for debriefing
‣ CPE Exit Briefing is joint responsibility.
• Participants debrief training experience.

CPE:
REFERENCES
• US EPA Handbook
• Ontario CCP Handbook

Other:
RESOURCES (con’t)
Plant Name:
Date Prepared:
Prepared By:
9-Nov-09
Phil Wilson
Step #1: Determine SOTR & alpha (based on system type)
• ISCO Flow Measurement Handbook
INPUT #1: OUTPUT #1:
Fine bubble, total floor
• Metcalf & Eddy
ά
• US EPA Design Manual
INPUT #2:
On Phosphorus
OUTPUT
Removal
#2:
Temp 20 o C K 0.847
Diffuser Depth 14.4 feet AOTR/SOTR 0.42
• Excel spreadsheet templates
System SOTR 6.25 lb O 2 /wire.HP.h
0.5 [no units]
Mixed Liquor D.O. 2.0 mg/L AOTR 2.65 lb O 2 /wire.HP.h
Elev
572 feet
Dunville WPCP
Step #2: Determine AOTR (based on temperature, diffuser depth, D.O. and elevation)
Figure 1: Dunville WPCP PPG Step#3: Determine OTC (based on HP available)
Total HP 180 Criteria HP OTC 3,900 kg O 2 /d
Unit Process (rating criteria) Size Units Stnd Max Units Base Increment Max
Aeration HRT (6 h) m 3 h 11,600
BOD Loading (0.5 kg BOD5/m 3 /d) m 3 kgBOD5/m 3 /d 7,792 2,640 10,432
Step#4: Determine Oxygen Demand At Peak Monthly Flows
INPUT #3: OUTPUT #3: Max Month
O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN) HP kgO2/kg BOD5 rev/d 8,714 1,125 9,839
Sec. Clar. SOR (24 m 3 /m 2 /d) m 2 m 3 /m 2 /d 11,400
Chlorine Contact (30 min) m 3 NA 7,800
Aerobic Digester (35 d & 17.6 m3/d) m 3 d 7,700
Sludge Lagoons (180 d at 18 m3/d) m 10,700
Sludge Disposal (assumed) NA 5,698
Annual Avg Flow 6,101 m 3 /d Carbon OD 1,147 kg O 2 /d
Max Month Avg Flow 8,251 m 3 /d Nitrogen OD 1,271 kg O 2 /d
Annual Avg Raw BOD 5 139.0 mg/L Total OD 2,418 kg O 2 /d
Annual Avg Dunnville Raw TKNWPCP PPG for CAS 33.5 (Updated mg/L - Nov. 2009)
Base Max Design 7728 5-Yr Flow 5698 Aug. 08-Jul. 09 6101
Step#5: Determine Rated Capacity (based on Evaluation Criteria for O 2 Availability)
INPUT #4: OUTPUT #4:
Aeration Selection HRT (6 h) Nitrify use BOD5 &
11,600
TKN O2 Avail Criteria 1.0
Rated Capacity 9,839 m 3 /d
BOD Loading (0.5 kg BOD5/m3/d)
O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN)
Sec. Clar. SOR (24 m3/m2/d)
0 2,000 4,000 6,000 8,000 10,000 12,000
7,792
8,714
11,400
2,640
1,125
Design 7,728 m 3 /d
Design 7728
7,728 0
7,728 100
5-Yr Flow 5,698 m 3 /d
5-Yr Flow 5698
5,698 0
5,698 100
Aug. 08-Jul. 09 6,101 m 3 /d
Aug. 08-Jul. 09 6101
6,101 0
6,101 100
Chlorine Contact (30 min)
7,800
Aerobic Digester (35 d & 17.6 m3/d)
7,700
Sludge Lagoons (180 d at 18 m3/d)
10,700
Sludge Disposal (assumed)
5,698
Annual Average Flows (m 3 /d)

• Kick-off Meeting
• Plant Tour
OVERVIEW OF STEPS
• Data Summaries & Performance Checks
• Major Unit Process Capabilities
• Personnel Interviews
• Determine Limiting Factors
• Exit Meeting
GRCAWorkshop
Tools

KICK-OFF MEETING
• Explain objectives, approach & timing
• Gain support for evaluation
• Schedule interviews with plant & admin
personnel
• Identify information needs:
‣ C. of A.
‣ Historical monitoring data (12 months)
‣ O&M manual
‣ Budget information
‣ Other engineering studies

PLANT TOUR
• Become familiar with plant and layout
• Preliminary assessment of operational
flexibility
• Initial information on performance, process
control, and maintenance
• Evaluator debriefing after plant tour

Plant Tour
• Conventional activated sludge with UV disinfection;
• Filter press dewatering & lime stabilization;
What questions will you be asking on your plant tour of
the facility below?

DATA GATHERING
• Data Collection Forms from Handbooks:
‣ Preliminary Plant Information
‣ Administrative Data
‣ Design Data
‣ Operational Data
‣ Maintenance Data
‣ Performance Data
• Main Focus:
‣ “How does this affect plant
performance?”

Flows ( m3/d)
14,000
12,000
10,000
Caledonia WPCP Flows
Raw Flows
Nominal Design
Max Day = 12,168 m 3 /d
Max Day
PE Flow
8,000
6,000
4,000
2,000
0
Annual Average = 3,376 m 3 /d
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08

CBOD (mg/L)
NH3 (mg/L)
TSS (mg/L)
TP (mg/L)
Caledonia WPCP Effluent TSS
Caledonia WPCP Effluent TP
C of A TSS Eff TSS Eff Obj TSS
C of A TP Eff TP Eff Obj TP
30
0.35
25
0.30
20
0.25
15
0.20
0.15
10
0.10
5
0.05
0
0.00
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Caledonia WPCP Effluent CBOD
Caledonia WPCP Effluent NH3
C of A CBOD Eff CBOD Eff Obj CBOD
Eff NH3
CofA
30
25
20
2.50
2.00
1.50
15
10
1.00
5
0.50
0
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
0.00
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08

Process Loading
Rate at which contaminants are added is
determined by “process loading”
– Loading = Flow x Concentration
– Loading Plant Capacity & Sludge production
Example: Organic loading
PE BOD 5 = 200 mg/L
= 200/1000 kg/m 3 = 0.200 kg/m 3
Flow = 5,000 m 3 /d
BOD 5 Loading = ?
BOD 5 Loading = 0.200 kg BOD 5 /m 3 x 5,000 m 3 /d
= 1000 kg BOD 5 /d

Questions
• If a dairy moves to town, what likely
happens to BOD 5 loading to the plant?
• If one train of a plant is shut down for
maintenance, what happens to the BOD 5
loading to the other trains?
• When flows increase during a storm,
what happens to BOD 5 loading?
• Should CBOD 5 or TBOD 5 be used to
calculate organic loading to a plant?

PROCESS LOADING EVALUATION
(12-months of Data)
Calculate per Capita flows and Loads:
‣ 350-500 L/d per person
‣ 80 g/d BOD 5 per person;
‣ 90 g/d TSS per person
Calculate ratios:
‣ Wastewater/Water: 0.7-0.9
‣ Peak Day/Annual Avg Flow: 2.5-3 - ?
‣ TSS/BOD 5 : 0.8 – 1.2
‣ TKN/BOD 5 : 0.1-0.2
‣Etc.
• Spot check of flow metering (if required)

Exercise #2
Background:
• Plant is a 546 m 3 /d extended aeration package plant
• Typically staffed less than 4 hours per day
Data:
• Population served = 1065
• Annual average plant flow = 429 m 3 /d
• Average influent BOD 5 = 98 mg/L = 0.098 kg/m 3
Reference Information:
• Per Capita Flows = 350 -500 L/person.d
• Per Capita Organic Loading = 80 g BOD 5 /capita.d
• 1 m 3 = 1000 L
• 1 kg = 1000 g

Questions?
1.) Calculate average per capita flow to plant
(in L/person.d) and compare to typical:
Per capita flow (L/person.d)
= flow (m 3 /d)x 1000 L/m 3 / population
= 429 m 3 /d x 1000 L/m 3 / 1065 persons
= 403 L/person.d
Typical = 350-500 L/person.d
Therefore, reported plant flows are within
typical

Questions?
2.) Calculate average per capita BOD 5 loading (in
g/person.d) to the plant and compare to typical
Per capita BOD 5 loading (kg/person.d)
= flow (m 3 /d) x concentration (kg/m 3 )/population
= 429 m 3 /d x 0.098 kg/m 3 / 1065 persons
= 0.039 kg BOD 5 /person.d
Per capita BOD 5 loading (g/person.d)
= 0.039 kg BOD 5 /person.d x 1000 g/kg
= 39 g BOD 5 /person.d
Typical = 70 – 90 g BOD 5 /d
Therefore, plant’s per capita BOD 5 loading is less
than typical

Questions?
3.) Based on the population and the typical per capita
BOD 5 loading, estimate the raw BOD 5 ( in mg/L).
Estimated BOD 5 loading (kg/d) =
= Population x Per Capita BOD 5 loading (g/person.d) /1000 (g/kg)
= 1065 persons x 80 g/person day /1000 g/kg
= 85.2 kg/d BOD 5
Flow = 429 m 3 /d
Estimated Concentration (kg/m 3 )
= Estimated load (kg/d) / flow (m 3 /d)
= 85.2 kg/d / 429 m 3 /d = 0.200 kg/m 3
Estimated Concentration (mg/L)
= Estimated concentration (kg/m 3 ) x 1000 (mg/L/kg/m 3 )
= 0.200 (kg/m 3 ) x 1000 (mg/L/kg/m 3)
= 200 mg/L BOD 5

Questions?
4.) Something doesn’t “add up”. What follow-up
information would you ask for?
• What are the raw TSS concentrations and hence the
TSS/BOD 5 and per capita TSS loadings?
• What are the raw TKN concentrations and hence the
TKN/BOD 5 ratio?
• How are the raw samples collected (grab vs
composite vs. flow proportioned composite), how
often, and when?

SLUDGE ACCOUNTABILITY ANALYSIS
Purpose:
‣ Verify plant data
‣ Assess monitoring & reporting practices
‣ Help with rating sludge storage, treatment &
disposal capacities.
Steps:
‣ Obtain 12-months sludge production from
plant records (“reported sludge production”)
‣ Estimate “projected” sludge production based
on removal mechanisms;
‣ Compare “projected” vs. “reported”;
‣ Within +15% ok

“Reported” Sludge Production
Plant Flow = 3,000 m 3 /d
Concentration = 20 mg/L = 0.020 kg/m 3
Unintentional Wastage = 3,000 m 3 /d x 0.020 kg/m 3 = 60 kg/d
Primary Aeration Basin Secondary
WAS
Sludge Flow = 10 m 3 /d
Concentration = 3% = 30,000 mg/L = 30 kg/m 3
RAS
Unintentional Wastage = 10 m 3 /d x 30 kg/m 3 = 300 kg/d
Effluent
Solids
Co-Thickened
Primary & WAS
Sludge
“Reported” Sludge Production =
Unintentional Wastage + Intentional Wastage
“Reported Sludge= Unintentional + Intentional
= 60 kg/d + 300 kg/d = 360 kg/d

“Projected” Sludge Production
Primary Sludge:
based on TSS removal rates across the primary
Biological Sludge:
based on BOD 5 removal rates across the basin
Primary Aeration Basin Secondary
Chemical Sludge:
based on coagulant addition rates to basin
“Projected Sludge” = “Primary” + “Biological” + “Chemical”

Primary Sludge Production
• Raw TSS = 200 mg/L
• PE TSS = 100 mg/L
• Flow = 1,000 m 3 /d
• Primary Sludge =
Flow (m 3 /d) x (Raw TSS – PE TSS) mg/L / 1000 mg/L/kg/m 3
= 1,000 m 3 /d x (200 – 100)/1000 kg/m 3
= 1,000 m 3 /d x 0.10 kg/m 3
= 100 kg/d

Biological Sludge Production
• PE BOD 5 = 110 mg/L
• SE BOD 5 = 10 mg/L
• Flow = 1,000 m 3 /d
• Biological Sludge Production Ratio (SPR) (for CAS w/primary)
= 0.70 kg TSS /kg BOD 5-removed
• Biological Sludge =
Flow (m 3 /d) x (PE BOD 5 – SE BOD 5 ) mg/L / 1000 mg/L/kg/m 3 x SPR
= 1,000 m 3 /d x (110 – 10)/1000 kg/m 3 x 0.70
= 1,000 m 3 /d x 0.10 kg/m 3 x 0.70
= 70 kg/d

Chemical Sludge Production
• Alum Dosage Rate = 1000 mL/min
= 1000 mL/min x 1440 min/d / 1000 mL/L
= 1440 L/d / 1000 L/ m 3
= 1.44 m 3 /d
• Weight of Alum Added per day
= Volume Added per day x Specific Gravity
= 1.44 m 3 /d x 1,330 kg/m 3
= 1,915 kg/d
• Weight of Al+3 Added per day
= Weight of Alum per Day x %Al +3 (w/w)
= 1915 kg/d x 4.3%
= 82.3 kg/d

Chemical Sludge Production
• Chemical Sludge Production Ratio
= 4.79 kg TSS /kg Al +3 (for alum)
• Chemical Sludge Production
= Weight of Al +3 addition (kg/d) x SPR
= 82.3 kg/d x 4.79
= 394.5 kg/d

EXAMPLE RESULTS
REPORTED:
Source
Secondary By-pass
Effluent
Co-thickened WAS + Primary
PROJECTED:
Source
Primary Sludge
Biological Sludge
Chemical Sludge
SUDGE ACCOUNTABILITY:
Amount (kg)
24, 000
180, 000
3, 247, 000
3, 451, 000
Amount (kg)
2, 677, 000
2, 589, 000
284, 000
5, 550, 000
(PROJECTED – REPORTED)
PROJECTED
X 100% = +38%

Exercise #3
Background:
• Plant is an extended aeration package plant (no primary)
• No coagulant addition for TP removal;
Data:
• Annual average flow rate = 3,200 m 3 /d
• BOD 5 : Raw = 110 mg/L; Effluent = 6 mg/L
• TSS: Effluent = 9 mg/L
• Waste sludge: Volume = 35 m 3 /d Conc. = 3,400 mg/L
Reference Information:
Remember!: 1000 mg/L = 1 kg/m 3
Process Type: SPR (kg TSS/kg BOD 5 r)
Activated sludge w/o Primary:
Conventional 0.85
Extended Aeration 0.65

Questions
1.) Calculate the average daily unintentional sludge wasted
(in effluent TSS) as kg/d:
Wastage (kg/d) = flow (m 3 /d) x ESS (mg/L) / 1000 mg/L/kg.m 3
= 3,200 m 3 /d x 9/1000 kg/m 3
= 28.8 kg/d
2.) Calculate the average intentional sludge wasted as kg/d:
Wastage (kg/d) = waste flow (m 3 /d) x waste concentration (kg/m 3 )
= 35 m 3 /d x 3,400/1000 kg/m 3
= 119.0 kg/d
3.) Calculate total reported sludge production (1+2):
Total reported (kg/d) = unintentional (kg/d) + intentional (kg/d)
= 28.8 kg/d + 119.0 kg/d
= 147.8 kg/d

4.) Calculate the projected sludge production:
Rate of BOD 5 removed (kg/d) = Flow (m 3 /d) x (Raw – Effluent) kg/m 3
= 3,200 m 3 /d x (110 – 6)/1000 kg/m 3
= 3,200 m 3 /d x 0.104 kg BOD 5 /m 3 = 332.8 kg/d
Choose SPR for applicable process
SPR = 0.65 (extended aeration)
Biological Sludge Production
= SPR x BOD 5 Removal Rate
Biological Sludge Production
= 0.65 x 332.8 kg/d = 216.3 kg TSS/d
5.) Calculate sludge accountability (%) & compare to +
15%
Sludge Accountability
= (projected – reported)/projected x 100%
= (216.3 – 147.8)/216.3x100% = + 32%
Sludge Accountability falls outside + 15%

Questions
6.) The sludge accountability doesn’t close (i.e. outside
+ 15%). What follow-up information would you ask
for?
Information related to monitoring of the waste sludge:
flows and frequency & analysis of waste solids
Information related to monitoring of effluent TSS.
Any observations that effluent TSS may be higher than
reported i.e. sludge in chlorine contact chamber, etc.

Operating Parameter Evaluation
Parameter
Typical Range
(M & E 1991)
CAS* EA** OD***
Plant X
SRT Total
(d)
F/M
(kg BOD 5
/d
per kg
MLVSS)
MLSS
(mg/L)
3-15 20-30 10-30 67
0.2-0.5 0.05-0.15 0.05-0.3 0.05
1,000 –3,000 3,000-5,000 1,500-5,000 4,800
HRT
(h)
4-8 18-36 8-36 24.6
* CAS = Conventional Activated Sludge; ** EA = Extended Aeration; *** OD
= Oxidation Ditch

MAJOR UNIT PROCESS EVALUATION
• Potential of major units to treat flows and
loads
• Identifies the “weakest link” i.e. most limiting
unit
• Assigns a “rated capacity” the annual
average flow which can be treated by that unit
• Establish plant type:
• I – Capable
• II – Marginal
• III – Not Capable

Performance Potential Graph
Flow
Unit Process
100 200 300 400 500 600
Aeration Basin
620
Capable: > 100% Current
Secondary Clarifier
400
Marginal: 80-100% Current
Sludge Handling
200
Not Capable:

CPE PPG CALCULATIONS

FAPCC
Annual Average Flows (m 3 /d)
0 5,000 10,000 15,000 20,000 25,000 30,000
Prim.Clar. SOR (24 m3/m2/d)
25,272
Aeration HRT (4-6 h)
12,964
BOD Loading (0.5-0.6 kg BOD5/m3/d)
13,283
O2 Avail. (1.4 kgO2/kg BOD5 rem.)
39,300
Sec. Clar. SOR (24 m3/m2/d)
25,224
UV Disinfection (45,400 @ peak)
22,700
Filter Press (1 unit @ 96 h/wk)
35,300
Sludge Haulage (on demand)
17,665
Base Max Current 17665 m3/d Nominal Design 22700 m3/d

Dunnville WPCP PPG for CAS
Base Max Design 7728 m3/d Current Flow 5137 m3/d
0 2,000 4,000 6,000 8,000 10,000 12,000
Aeration HRT (6 h)
11,600
BOD Loading (0.5 kg BOD5/m3/d)
7,600
O2 Avail. (1.0 kgO2/kg TBOD5 + 4.6 TKN)
6,600
Sec. Clar. SOR (24 m3/m2/d)
11,400
Chlorine Contact (30 min)
7,800
Aerobic Digester (35 d & 2.0%)
3,200
Sludge Lagoons (180 d at 4% solids)
9,000
Sludge Disposal (assumed)
5,100
Annual Average Flows (m 3 /d)

INTERVIEWS
• Previous steps complete prior to interviews
• Staff interviewed
• All plant staff
• Key administrators
• Interviews in private and information is kept
confidential
• Maintain performance focus
• Debrief interviews

PERFORMANCE LIMITING FACTORS
• Checklists with definitions provided in
Handbook
• Four Categories
• Operations
• Design
• Maintenance
• Administration
• Rating System
• A: Major Long Term Effect
• B: Minimum Routine Effect or Major Periodic
Effect
• C: Minor Effect

PRIORITIZE FACTORS
• A & B Factors only
• Purpose:
• Summarize Plant Status
• Basis for Follow-up Activities

FACTORS MEETING

COMMON FACTORS
• Lack of Application of Concepts and Testing to Achieve
Process Control
• Inadequate process monitoring and testing
• No routine for sludge wasting to support process control
• Inadequate Sludge Wasting and Disposal
• Limited on-site storage
• Inadequate land approved to spread sludge
• Inability to measure waste sludge
• Inappropriate Management Policies
• Inadequate plant staffing
• Focus on maintenance and housekeeping

EXIT MEETING
• Plant/Administrative Personnel
• Present Preliminary Findings
• Summarize Factors: A & B
• “Tell it like it is” with respect
• Potential for follow-up

Outline:
• Introduction
REPORT
• Facility Background
• Performance Assessment
• Major Unit Process Evaluation
• Performance Factors

• Kick-off Meeting
• Plant Tour
SUMMARY
• Data Summaries & Performance Checks
• Major Unit Process Capabilities
• Plant Personnel Interviews
• Determine Limiting Factors
• Exit Meeting
Focus of Today’s Workshop:
Process Loading Evaluation
Sludge Accountability
Focus of Nov. Workshop:
Major Unit Process Capabilities =
PPG