ESTABLISHING A WASTEWATER TREATMENT OPERATIONAL CONTROL DOCUMENTATION PLATFORM SUITABLE FOR SOUTH AFRICAN CONDITIONS

ESTABLISHING A WASTEWATER TREATMENT OPERATIONAL CONTROL DOCUMENTATION PLATFORM SUITABLE FOR SOUTH AFRICAN CONDITIONSWH Rssle, KA Samson, J de Danschutter, K Dijkstra

Utilities, Water and Sanitation Department 16 May 2016

2WISA 2016 Rossle et alContentIntroductionBackground: The City of Cape Town WW BranchChallenges: Scattered process control informationSolution: Information PlatformProcess Controller Operational Handbook (PCOH)- workshops, development, examplesDashboards - development, examplesKey factorsConclusions

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IntroductionWastewater (WW) treatment process controllers operate multi-million rand wastewater treatment works (WWTW) 24 hours per day and 365 days a year.What, why, when, where and how must it be done, and who will be doing the tasks?Conventional Operation and Maintenance (O&M) manuals do not address all these aspects, specifically to identify who will be involved to perform tasks.Basic Principles: 1. RACI (Responsible, Accountable, Consulted, Informed) 2. RD (Responsible, Duty)

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Background to the City of Cape Town (CCT) WW Branch3.9 million residents, 2455 km2 service area and 27 WWTWs.Age of infrastructure decades old to brand new.Range of technologies for liquid and sludge treatment:From basic such as pond systems, RBCs, Bio-filters, and from conventional activated sludge to full EPBNR incorporating MBR, with a range of disinfection options including maturation ponds, UV, chlorine gas, chlorine products.From basic systems such as solar drying beds to 32 sludge dewatering filter belt presses at 10 WWTWs.Range of final effluent reuse options:From onsite grounds use to irrigation of golf courses, grass cultivation, agriculture, industrial reuse, sea buffer ponds, to aquifer recharge options.These activities require process control 24/7/365.

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Challenge: Scattered Process Controllers InformationSouth African context: Post commissioning plant specific process control training not readily available on a sustainable basisInstitutional knowledge gapInformation management needs strengtheningMore so a challenge at smaller plants :South Africa about 80% of WWTW smaller than 10 M/d treatment capacityCCT - about 50% of WWTW smaller than 10 M/d treatment capacity

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Solution: Information PlatformsTwo levels of information challenges identified in the CCT WW Branch:PLANT SPECIFICA WWTW manager deals every month with over 100 different documentsRequires process and operational plant specific assistance move away from routine process status monitoring to process performance evaluationProcess Controller Operational Handbooks (PCOH)WW BRANCH MANAGEMENTOverall indicators of compliance and performance, such as process, finance, HR, OHSA, legislative Give input and focus into OPEX, CAPEX and housing / industrial / commercial developments planningDashboardsWISA 2016 Rossle et al6

7WISA 2016 Rossle et alWHAT TO DO?

4-day planning workshop for PCOH development

Workshop Method

CCT WW Branch and World Waternet facilitated an initial workshop:

Train the trainer principle to develop CCT ModeratorsInteractive participation from all levels of plant personnel to share knowledge and experiencesOwnership of handbook createdPersonnel are both teachers and studentsLecture room and plant (theory and practice)

Outcome: Produced a framework of a Handbook. WWTW personnel then developed it into full handbooks, final editing now in progress.

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First workshop to develop PCOHWISA 2016 Rossle et al9

PCOH unit processes content to categorise work

10WISA 2016 Rossle et alTotal Quality Management

Task allocationPlan-Do-Check-Act cycle (PDCA)Maintenance, Health and SafetyTask-Risk-Analysis (TRA)

Skills development

The PCOH is structured to be suitable as a reference manual for training for new and existing personnel

Content of the PCOHSignature control page on receipt of PCOH and on completion of training on the different unit processesMunicipal informationPlant and catchment historyFlow diagrams (generic and plant specific)BenchmarksHydraulic loading and diurnal profiles (MDWF, AF, ADWF, PDWF, PWWF)Mass balance (Design and actual removal, screenings, grit, sludge, nutrients)Electricity audit (Actual and theoretical)Chemical use (Consumption related to process flow)Unit processes tasks allocation - RACI and referenced to SOPModerators and workshop team Organogram (DWS classifications)Plant Layout with Notice Boards, Sampling Points, Electricity Metering PointsLegislative Appointments (OHSA, GD)Documentation list and Handbook version control Contact / emergency numbersReferences

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EXAMPLE Tasks, Maintenance and Administrative Planning12WISA 2016 Rossle et al

TasksManagerAssistant ManagerPrincipal Process ControllerSenior Process ControllerProcess ControllerProcess OperatorH & S Rep.WI #Do sludge blanket height test.IICARN/AN/AWI-0060

Duties and responsibilities

Maintenance Planning

Activity (What?)Responsible (Who?)Workflow (How?) for Senior, Process Controller and Process AssistantTimeframe (When?)SOP to be usedCleaning launders and weirsProcess ControllerClean launder and weir and record the activity in the shift logbookWeeklyFSK SOP0005- SST Cleaning

Activity (What?)Responsible (Who?)Workflow (How?) for Senior, Process Controller and Process AssistantTimeframe (When?)SOP to be usedReadings (paper/data recording logger)Process ControllerProcess Controller and shift assistant takes readings as per log sheet. Process Controller updates the data spreadsheet.DailyQEP15: Record keeping

Administrative Planning

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EXAMPLE: Catchment of WWTW (pumps stations and reticulation)

EXAMPLE Location of notice boards, electricity meters, sampling points14WISA 2016 Rossle et alEXAMPLE: Plant layout and sampling points location similar for electricity meters, notice boards etc.

EXAMPLE: Plant layout and location of notice boards, sampling points, electricity meters

EXAMPLEPCOH 15WISA 2016 Rossle et al

DASHBOARDS: In-house developed dashboards for monitoring process performance using Excel based spreadsheetsOperational DataMonitor CompliancePerformance of process units according to benchmarkingHistorical trendingMultiple parametersVarious information sources to be integrated electronicallyLIMS (laboratory)Internet (flow)SAP (maintenance, cost, personnel, OHSA Budget Training)DWS GD site (classification)Manual dataDashboards were developed in-house by Operational Superintendents. Expensive software not required.

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DASHBOARD EXAMPLE 1: Training (Works skills plan), SAP

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Intervention vs Cost/#Designation vs. NameCost per DesignationTotal Cost per WWTW Plant

DASHBOARD EXAMPLE 2: Maintenance, SAP

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DASHBOARD EXAMPLE 3: Compliance, LIMS19WISA 2016 Rossle et al

DASHBOARD EXAMPLE 4: Electricity, SAP and internet / manual20WISA 2016 Rossle et al

Key factors for implementation of information platformIntegration of process control and branch management information platform focusUniform handbook format to maintain consistency and corporate identity with plant specific content Continuity Central persons to co-ordinateInternal Resources Adequate operators logbookStudents and in service trainees assistIn house programming skills of personnel to be utilisedSupport Senior management WWTW personnel

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Benchmarking: Linking PCOH and Dashboards Example 122WISA 2016 Rossle et al

Benchmarking:Linking PCOH and DashboardsExample 223WISA 2016 Rossle et al

ConclusionsUse vast knowledge and diverse skills of all available personnel. Learned skill / training now documented for future use. Retention of information.Implement the principle of RACI Responsible, Accountable, Consulted, Informed.Solution to scattered information:Weekly dashboards updateQuarterly benchmark auditAnnual review of PCOH combined with the annual process audits An information platform is a tool used to inform all personnel in CCT WW Branch of fundamental aspects involved in the complex business of treating municipal wastewater.

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AcknowledgementsCo-authors Handbook editorsModerators and workshop teamsDashboard developersColleagues at Head Office and all the WWTWsWorld Waternet

For queries contact werner.rossle@capetown.gov.za

Thank You