Sample Operations & Maintenance Manual - Usalama Water Project

USALAMA WATER PROJECT

OPERATIONS & MAINTENANCE MANUAL COMPILED BY ENGINEERS WITHOUT BORDERS – NEW YORK JUNE 2014 [email protected]

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Claire Wang

TABLE OF CONTENTS Contacts p. 3 Summary p. 4 Safety p. 5-6 Operations and Maintenance Checklist p. 7-9 Tank Inspection and Maintenance p. 10-11 Water Treatment p. 12-14 Monthly Team Meeting Guideline p. 15 Record Keeping p. 16 Append ix :

Water System Photographs Tank Inspection Drawings Water Treatment Calculations

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CONTACTS

In case of questions or emergency, the following people can be contacted.

A f f i l ia t ion Name Phone Number Emai l

Usalama Primary School Chairman / Village Headman

Jackson Maweu 0720974666 [email protected]

EWB-NY Project Lead Claire Wang +1 347-272-3487 [email protected]

EWB-NY Technical Lead Patrick Farnham + 708-738-1359 [email protected]

EWB-NY Chapter President Jessica Miller +1 718-986-5927 [email protected]

KIMAWASCO Director Kimeu Ndundu 0726-838-730 [email protected]

KIMAWASCO Project Manager Joseph Kilonzu 0729312628

KIMAWASCO Technical Manager Elijah Mzungu 0721623856

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SUMMARY

This document explains how to maintain and operate the water distribution system for the community of Usalama. It is followed by an Appendix with more details and photographs.

The goal of Engineers Without Borders - New York (EWB-NY) and the Usalama community was to restore the water system so that it would service the five (5) existing water kiosks and make water more easily accessible for the community. Water from the system is used for drinking, among other uses, so a treatment procedure utilizing chlorine was implemented. The system is maintained consistently by two designated maintenance workers, and operators at each kiosk.

The system consists of storage, distribution and treatment components:

S torage : Concrete masonry water storage tank with 40,000 Liters of storage

Galvanized iron (GI) pipe fittings and gate valves at tank

Float valve at tank

Tank access door

D is t r ibu t ion : PVC piping GI piping

Five kiosks with brass faucets

T rea tment : Chlorine measurement/dispensing containers

The five kiosks and original piping were installed by the African Medical Research Foundation (AMREF) in 2008. EWB-NY constructed the new water tank and installed new piping to reroute the distribution system between 2013 and 2014. The drawings compiled by EWB-NY show the constructed system, and the photographs show the construction process.

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SAFETY !

Use GLOVES AND SAFETY GLASSES when handling chlorine

Wear rubber gloves and safety glasses when handling the hypochlorite powder. This will prevent skin and eyes from burning when the hypochlorite is transferred from the storage container (50 kg tin) to the 5 liter jugs used for creating the stock solution. Personnel handling the chlorine stock solution as well as the kiosk operators should wear gloves for protection during all handling of the solutions.

Use GLOVES when handling paint or PVC glue.

Wear gloves when using PVC pipe cement or bitumastic paints. Only use these unstable chemicals in a well-ventilated area. Do not let the chemicals touch the skin or eyes.

Do not inha le ca lc ium hypoch lor i te

Open the hypochlorite containers only in areas with good ventilation (in the open air, and not indoors). Breathing in hypochlorite fumes can cause coughing and lung irritation. Nausea, dizziness, and vomiting are signs that somebody has been exposed to these fumes for a long time. Being continuously exposed to hypochlorite fumes will cause PERMANENT lung damage. Hypochlorite is good for treating water, but it is harmful in high, undiluted concentrations.

Keep away f rom ch i ld ren and an ima ls .

Carefully clean any spilling of the powder or stock solution, to prevent the spilled chemical from harming other people or animals.

PERSONAL PROTECTION It is very impor tant to use the correct persona l protect i ve equipment (PPE) when work ing on the water system. Fo l low these ru les to remain safe whi le perform ing

ma intenance or rout ine sys tem opera t ion.

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SAFETY

!

!

IF YOUR EYES OR SK IN ARE EXPOSED D IRECTLY TO CALC IUM HYPOCHLORITE POWDER OR STOCK SOLUTION

If calcium hypochlorite or the stock solution comes in contact with the eyes or skin, carefully flush out of eyes or rinse affected skin with clean water for at least ten (10) minutes or longer if irritation remains. Seek professional medical attention if irritation persists.

IF YOU CONSUME CALC IUM HYPOCHLORITE POWDER OR STOCK SOLUT ION If calcium hypochlorite or the stock solution is consumed by drinking or eating, IMMEDIATELY drink large quantities of water and seek professional medical attention. DO NOT induce vomi t ing .

F IRST AID

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OPERATION AND MAINTENANCE CHECKLIST

KEY

PIPING SYSTEM

WATER TREATMENT

SAFETY WATER TANK

These tasks should be followed at different frequencies (daily, weekly, monthly, semi-yearly, and yearly) to keep the water system running smoothly. When these tasks are completed, mark the task and date completed in a separate book. Use the photographs in the Appendix of this manual to compare the condition of the water system.

1. DAILY TASKS

TASK # TASK CATEGORY FOLLOW-UP TASK

1.1 Log water usage at kiosks

Compare total amount of water used to amount on water bill. Perform 3 .3 , 3 .4 , 3 .6 , and 3 .7 if kiosk water usage and water bill do not match. Use the water usage data to analyse seasonal demand.

1.2 Make chlorine stock solution

Liquid chlorine stock solution will be made as needed, using the instructions in the Water Treatment section of this manual.

1.3 Record hypochlorite usage

The amount of hypochlorite powder should be recorded as a check against water purchased.

1.4 Maintain proper hypochlorite storage

Keep hypochlorite containers in a location out of direct sunlight, away from heat sources, and sealed against air exchange.

1.5 Maintain safety standards

Use gloves/glasses and adequate ventilation during handling of undiluted hypochlorite to avoid injury.

2 . WEEKLY TASKS


2.1 Monitor kiosk operators’ dosing operations

Check that the proper amount of diluted chlorine is being added to each jerrican. See the instructions in the Water Treatment section of this manual for the proper amounts.

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KEY

PIPING SYSTEM

WATER TREATMENT

SAFETY WATER TANK

3. MONTHLY TASKS


3.1 Log water meter readings

Compare meter readings with kiosk water use. Perform 3 .3 , 3 .4 , 3 .6 , and 3 .7 if the water meter reading and kiosk water use do not match.

3.2 Log flow rate at kiosks

Perform 3 .3 , 3 .4 , 3 .6 , and 3 .7 if the flow rate seems remarkably low.

3 .3 Walk along pipeline (Perform if required by 3.1 or 3.2)

Check for leaks and exposed pipes. Repair damaged pipe and cover exposed pipe as needed.

3 .4 Check valves, fittings, and taps (Perform if required by 3.1 or 3.2)

Check for leaks and tight seal of valves at the tank and along the pipeline. Open and close the valves. Clean valves if necessary. Refer to the photos in the Appendix for the condition that the valves, fittings and taps should be in.

3.5 Inspect interior of tank for solids buildup

Clean interior of tank yearly or as needed.

3 .6 Inspect tank for cracking or spalling (Perform if required by 3.1 or 3.2)

Refer to the Tank Inspection section of this manual to complete these inspection tasks. See the Tank Inspection drawings in the Appendix of this manual for details.

3 .7 Inspect float switch (Perform if required by 3.1 or 3.2)

Check for rust, and test the float switch by hand to make sure that the hinge is working. See the Appendix of this manual for a photograph to compare to.

3.8 Clean tank exterior

Sweep tank roof with broom to prevent dust and dirt from entering tank during opening of access door.

3.9 Monthly Team Meeting

Conduct a monthly meeting of all Operation and Maintenance Personnel, according to the Monthly Team Meeting Guideline within this manual.

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KEY

PIPING SYSTEM

WATER TREATMENT

SAFETY WATER TANK

4 . SEMI-YEARLY TASKS


4.1 Clean valves

Clean any solid material out of the valves at the tank, either by flushing with water or cleaning by hand.

5 . YEARLY TASKS


5.1 Clean tank interior

Drain tank during system shutdown using cleanout valve. Scrape, scrub, and rinse walls and floor of tank to remove sediment and deposits.

5.2 Restock hypochlorite stock

Purchase enough hypochlorite to continue chlorination operations at kiosks.

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TANK INSPECTION AND MAINTENANCE !!!

1. Wal l and S lab Cracks

Observa t ions C racks are visible on the roof, wall (both vertical and diagonal cracks) and slab; a l l a t the same t ime . What th is means : SEVERE R ISK • Tank is settling unevenly on ground,

OR: • Ground slab has been undermined by erosion from wind or water.

What you shou ld do : • Fill below the slab with compacted soil Provide additional soil around the perimeter of tank

2. Spal l ing

Observa t ions Spalling: Concre te is ch ipped or break ing o f f from the bottom of the roof slab inside the tank What th is means : LOW R ISK Reinforcing bars have rusted and expanded What you shou ld do : 1. Carefully remove loose concrete with a hammer. 2. Remove rust from reinforcing bars with wire brush. 3. Place mortar over reinforcing bars to protect them from future corrosion.

3 . Hor izonta l Wal l Cracks

Observa t ions Hor izonta l c racks are visible between stone layers in the wall mortar beds. What th is means : MODERATE R ISK There is small movement between the stone courses. What you shou ld do : 1. Determine if it is a full-depth crack. Inspect the ins ide and outs ide o f the

tank wa l l . If the tank is leaking from a crack, it is a full-depth crack. 2. Remove plaster and waterproofing from affected area. 3. Patch full depth cracks by applying new mortar. 4. Re-plaster and waterproof surface of wall.

This section describes some of the problems that may arise during the tank’s use, the possible causes of these problems, and suggested solutions. See the drawings at the Appendix of this manual for the drawings that are referenced in this table.

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TANK INSPECTION AND MAINTENANCE !!!

4 . Cracks extending f rom openings

Observa t ions Cracks are occurring radially outward from wall pipe penetrations or at the corners of the roof hatch opening. What th is means : LOW R ISK There are local stresses within the wall/slab, which are not likely to weaken the structure. However, any cracks that are big enough to allow water through will continue to deteriorate the concrete and stone. What you shou ld do : Patch cracks to prevent water infiltration. Use grout and a waterproofing sealer as needed.

5 . Sudden or large cracks

Observa t ions Large cracks, long or wide, or sudden cracking anywhere on the structure are visible. What th is means : SEVERE R ISK Large cracks may indicate that the tank will fail very soon. What you shou ld do : 1. Reduce the amount of water in tank 2. Prevent anyone from going on top of tank

6 . Cracks a f ter the tank is f i l led wi th water

Observa t ions Cracking occurs soon after the tank is put in to use (for example, after it is filled for the first time). Note: small hairline cracks are expected in concrete and stone What th is means : SEVERE R ISK The material is failing to resist the load. What you shou ld do : 1. Monitor carefully 2. Determine extent of cracking and make sure it is not getting worse

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WATER TREATMENT

Water t reatment process

Maintenance team

Purchases chlorine

Creates chlorine stock solution

(see instruct ions)

Distributes stock solution (5 Liter container) to

kiosk operators

K iosk operator

Puts chlorine solution into each jerrican and fills jerrican with water (see instruct ions)

Customer Waits for 30 minutes before drinking chlorinated water

A member of the water system maintenance team should make

the chlorine solution out of Tropical Chloride of Lime (TCL) powder

and water. The Kiosk Operators will then dispense this solution

into individual jerricans at the kiosks.

Follow the instructions in this manual to create and distribute the

chlorine stock solution.

TCL Powder can be purchased from: Nairobi Ironmongers Ltd Homabay Road, Industrial Area P O Box 43524, Nairobi 00100 Tel: 254 20 555 879 / 558 805 Fax: 254 20 555 854 Email: [email protected]

CHLORINE HANDLING TIPS Use gloves and safety goggles when handling the hypochlorite powder. Do not inhale calcium hypochlorite powder. Keep away from children. Store and prepare the solution in a dry , wel l-vent i l ated place . Keep away from the sun, moisture, and flammable material. Exposure to moisture may react with the powder and cause burns, or produce dangerous chlorine gas. The chlorine solution must be kept in a dark container, so that it does not react with light. Do not keep the chlorine solution for longer than one week.

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How$to$Make$Chlorine$Stock$Solution$(5L):$Jinsi%ya%Kutengeneza%Mchanganyiko%wa%Chlorine,%(Lita%tano):%

Obtain'67%'Calcium'Hypochlorite'Powder'in'50'kg'tin'(kes'$12,000)'from'Nairobi'Ironmongers,'Ltd.'(or'other'approved'vendor)'as'needed'and'store'away'from'sunlight'in'a'dry'area.'

Nunua%67%%Calcium%Hypochlorite%Powder%ulio%kwenye%mkebe%wa%kilo%hamsini(50kg)%kwa%shilingi%12,000%kwenye%Duka%liitwalo%Nairobi%Ironmongers%Ltd,%ama%duka%lolote%lingine.Hifadhi%mahali%pakavu%pasipo%na%jua%kali.%

Nairobi$Ironmongers$Ltd'Homabay'Road,'Industrial'Area''P'O'Box'43524,'Nairobi'00100'

Tel:'254'20'555'879'/'558'805'Fax:'254'20'555'854'

Email:'[email protected]'

Steps& &1. Scoop'three'(3)'

Tablespoons'of'calcium'hypochlorite'powder'into'5=liter'jug.'Then,'add'water.''

'Chota&vijiko&&vidogo&vitatu&vya&Calcium&Hypochlorite&powder&kisha&weka&kwenye&jagi&iliyo&ya&na&maji&lita&tano(5lita)

'

2. Shake'5=liter'jug'vigorously'for'one'(1)'minute.'

Tingisha&hii&jagi&iliyo&na&maji&lita&tano&kwa&nguvu&ili&uchanganye&&kwa&muda&wa&dakika&moja.&

''

3.''''''''Set'5=liter'jug'aside'for'thirty'(30)'minutes'before'distributing'to'each'kiosk.'

'Ngoja&dakika&thelathini(30&min)&kabla&upeleke&mchanganyiko&huo&ulio&kwanye&jagi&ya&lita&tano(5l)&kwenye&kila&kiosk.

Wait'30'Minutes!'Ngoja'dakika'Thelathini(30'min)!'

4.'''''''Keep'out'of'sunlight.'DO'NOT'inhale.'(Concentration'of'5=liter'jug'stock'solution'='4,756'mg/L).'&Hifadhi&mahali&pasipo&Jua&kali(Mchanganyiko&lita&tano(5lita)&=&4,756mg/L)&

'

Prepared'by'Engineers'with'Borders,'New'York'Professionals'Chapter'For'the'Usalama'Water'Project,'Kenya'(2014)'

'

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How$to$Dispense$Chlorine$Stock$Solution$(5L)$into$Jerrican:$

Jinsi%ya%akitoa%chlorine%hisa%ufumbuzi%(5L)%Katika%Jerrican:$

Store&concentrated&chlorine&stock&solution&in&a&secure&area&away&from&direct&sunlight&and&dispense&the&solution&into&each&Jerrican&according&to&the&instructions&below.&

Kuhifadhi%kujilimbikizia%chlorine%hisa%ufumbuzi%katika%eneo%salama%mbali%na%jua%moja%kwa%moja%na%akitoa%

ufumbuzi%katika%kila%Jerrican%kwa%mujibu%wa%maelekezo%ya%chini.%

Steps:$$1. Scoop&two$(2)$teaspoons&of&concentrated&stock&solution&into&big&(20L)&Jerrican,&then&fill&with&water.&

Scoop%mbili%(2)%chai%ya%ufumbuzi%kujilimbikizia%hisa%Katika%kubwa%(20L)%Jerrican.%

Scoop&one$(1)$teaspoon&of&concentrated&stock&solution&into&small&(10L)&Jerrican,&then&fill&with&water.&Scoop%moja%(1)%kijiko%cha%ufumbuzi%kujilimbikizia%hisa%Katika%ndogo%(10L)%Jerrican.%

&

&&&

&

&

&&&

&&

2. Allow&Jerrican&to&mix&while&carrying&home.&&Mixing&time&=&30&minutes&before&drinking.&(Chlorine&Dosage&=&2.5&mg/L,&or&2.5&ppm)&&Kuruhusu%kuchanganya%wakati%Jerrican%Kubeba%mtu.%%Kuchanganya%wakati%=%dakika%30%kabla%ya%kunywa.%%(Klorini%Kipimo%=%2.5%mg%/%L,%au%2.5%ppm)%%Mbili.%Jerrican%Ruhusu%kwa%kuchanganya%wakati%kufanya%mtu.%%

Kuchanganya%wakati%=%dakika%30%kabla%ya&kunywa.&&(Klorini&Kipimo&=&2.5&mg&/&L,&au&2.5&ppm)&

&

Prepared&by&Engineers&with&Borders,&New&York&Professionals&Chapter&For&the&Usalama&Water&Project,&Kenya&(2014)&&

%

For$Big$(20L)$Jerrican:$2$teaspoons$Kwa%kubwa%(20L)%Jerrican%vijiko%2!

$

For$Small$(10L)$Jerrican:$1$teaspoon$Kwa%ndogo%(10L)%Jerrican%vijiko%1!

$

Concentrated&Stock&Solution&

Concentrated&Stock&Solution&

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MONTHLY TEAM MEETING GUIDELINE Frequency : This meeting should be held at least once per month. All Operation and Maintenance Team members (kiosk operators, maintenance personnel, etc.) must attend, and anyone who is interested in learning about the project should be encouraged to attend as well. This meeting should not go on for a lengthy period, unless real concerns are being discussed. Purpose : The purpose of this meeting is to encourage effective communication between the Operation and Maintenance team whilst promoting safe and correct operation of the water distribution system. This is only a guideline and team members should feel free to express their concerns and raise issues in order to improve the process. ***P lease respect everyone who a t tends th is meet ing , by conduct ing i t in a fa i r and organ ized manner*** Ge t t ing s tar ted : Each month a different team member will take his/her turn to be the host, and this individual will conduct the meeting according to the guidelines provided below. Step 1: G ree t and we lcome a l l a t tendees to the meeting, say a little prayer if you would like. Step 2: Sa fe ty . . . It is important for all team members to be aware of their environment and other people working around them at all times. Team members should use personal protective equipment such as gloves and goggles when it is appropriate. Review information from the Safety section of the Operation and Maintenance manual.

• Tools: Be cautious when working on high surfaces, and with tools. Prevent injury to yourself as well as the people around you. Give an example of a possible injury that can occur when using tools.

• Chemicals: Be careful when handling any chemicals, as it can be harmful to humans and animals if it is inhaled or comes into contact with the surface of your body including your eyes. Give an example of how an injury can occur when working with chemicals.

Step 3: Per formance . . . Ask the team the following questions and discuss it with the team:

• Has the team followed the Operation and Maintenance Manual accurately in the past month? • Has the team reported any incidents/problems with the water system, and did you get feedback? Was

the problem resolved? • What can we do to improve the way we operate the system? • Are all team members contributing to the process as they should be and how can we work better as a

team? After asking and discussing the questions above, set a goal for the team if necessary, and try to achieve it before the next meeting. Ensure that you discuss previous goals that were set for the team last month. Step 4: Progress . Congratulate your team on doing a good job, and thank everyone for attending. Go around asking each person who attended if they have any questions and end the meeting once everyone has had an opportunity to speak.

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RECORD KEEPING

Keep a record of this information. This information will be useful for when calculating revenue from water sales, and planning the operating budget.

WATER BILL • Amount of water recorded on monthly bill • Total cost of water for the month • Unit price of water

K IOSK-BASED WATER USAGE • Date water was sold • Volume of water sold each day at each kiosk • Unit price water was sold at • Total revenue from water sales per month

CHLORINE PURCHASES • Dates that chlorine was purchased and delivered • How much chlorine was purchased

PURCHASES FOR MAINTENANCE AND REPAIR • Description of maintenance or repair task • Date that maintenance or repair was performed • List of items purchased for maintenance or repair, and cost; including materials and tools. (For example:

shovels, concrete, PVC glue…) • Cost and description of labor for maintenance or repair.

MONTHLY TEAM MEETINGS See guidelines for the Monthly Team Meetings inside this manual. Record the date of the meeting and names of everyone who attended.

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USALAMA WATER PROJECT OPERATIONS & MAINTENANCE MANUAL

APPENDIX • WATER SYSTEM PHOTOGRAPHS • TANK INSPECTION DRAWINGS • WATER TREATMENT CALCULATIONS

PHOTOGRAPHS Tank 1.Typical Inlet 2.Typical outlet (show fittings, valves, valve box)

PHOTOGRAPHS 3. Float valve 4. Tank access door

PHOTOGRAPHS 5. Tank in general

PHOTOGRAPHS P ip ing

PVC P ipe - typical connection of two PVC pipes, with the label of the PVC pipe brand shown.

PVC P ipe - Pipes should never be connected using too much glue. If too much glue is used, it will clog the pipe, as shown here.

DIAGONAL AND VERTICAL CRACKSIN THE WALL MAY INDICATE THATTHE TANK IS SETTLING UNEVENLY.

1. SIMULTANEOUS WALL AND SLAB CRACKS

CRACKS ON TOP OF ROOF TANKMAY INDICATE THAT THE TANK ISSETTLING UNEVENLY.

2. SPALLING ON BOTTOM OF ROOF SLAB

SPALLING CONCRETEFROM UNDERSIDE OF ROOFSLAB MAY INDICATERUSTING REINFORCEMENT.

3. HORIZONTAL WALL CRACKS

HORIZONTAL CRACKS BETWEENLAYERS MAY INDICATE DIFFERENTIALMOVEMENT BETWEEN COURSES.

4. CRACKS EXTENDING FROM OPENINGS

CRACKS THAT OCCURR RADIALLY OUTWARDFROM OPENINGS ARE FROM LOCALIZEDSTRESSES IN THE WALL OR SLAB.

5. SUDDEN OR LARGE CRACKS

CRACKS ON TOP OF PILASTER OR ONBOTTOM OF SLAB MAY INDICATEEXCESSIVE LOADING - PEOPLE SHOULDGET DOWN IF THEY ARE ON TANK.

IF SUDDEN OR LARGE CRACKS APPEAR UNLOAD TANK -REMOVE WATER, MAKE SURE PEOPLE ARE NOT ON TANK

WATER TREATMENT Deta i led Ch lor ine Di lut ion ca lcu lat ions If characteristics of hypochlorite powder, size of mixing jug, volume of jerrican, or required chlorine dosage changes, the new amount of chlorine to be used can be calculated by substituting the new value into the below equations. Chlor ine Solut ion (4 ,756 mg hypoch lor i te /L) Given that

• Powder 670,000 mg/kg hypochlorite per mass • Density of hypochlorite: 0.8 g/cm3 = 0.8 g/ml

Calculation for concentration of hypochlorite in 5L jug:

670,000mgkg !∗ !X5!L = 4,756mgL

Rearrange and solve:

X = !4,756mgL !∗ !5!L670,000mgkg

= 23,780670,000 = 0.035!kg

Mass!of!powder! = !X! = !0.035!kg

Conversion to tablespoons:

0.035!kg ∗ 1000 gkg

0.8 gmL ∗ 14.79!mL/tbsp

= 3!tbsp

Powder!to!add! = !3!tablespoons

Je r r i can D is in fec t ions Dosage Ca lcu la t ion Equation for calculating the concentration of dosage (2.5 mg/L) in 20 L jerrican:

4,756mgL ∗ X20!L = 2.5!mg/L

Rearrange and solve:

X =2.5mgL ∗ 20!L4,756mgL

= 504,756 = 0.105!L

Volume!of!Chloride!Solution!to!use! = !0.105!L

Conversion to teaspoons:

0.105!L!×1,000mlL4.93 mltsp

= 2.1!tsp

Amount!of!Chloride!Solution!to!add!

= !2!teaspoons

Sample Operations & Maintenance Manual - Usalama Water Project

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