WQ0035784_Final O&M Plan_20240724

OPERATIONS AND
MAINTENANCE MANUAL

DYNALIFT ULTRAFILTER (UF)
WASTEWATER
TREATMENT SYSTEM

Prepared for:
Cottages of Boone Water Reuse Project
Boone, NC

Prepared by:
DYNATEC SYSTEMS INC.
909 Jacksonville Road
Burlington, NJ 08016
609 387 0330

August, 2013
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -4-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Table of Contents
Table of Contents ........................................................................................................... 4
Safety Notes: .................................................................................................................. 7
Precautions ..................................................................................................................... 8
Water Quality Guidelines ............................................................................................... 9
Membrane Preservation and Storage ........................................................................... 10
Short-Term Shutdown: Less Than 8 Hours .......................................................................... 10
Intermediate Shutdown: Less than 1 Week .......................................................................... 10
Long-Term Shutdown: More Than 1 Week .......................................................................... 10
Controls ........................................................................................................................ 11
PLC Controls ........................................................................................................................ 11
Operation ...................................................................................................................... 12
Membrane Cleaning ..................................................................................................... 14
Introduction ........................................................................................................................... 14
When Cleaning is Required .................................................................................................. 14
Types of Fouling ................................................................................................................... 14
Automatic Cleaning Process ................................................................................................. 14
Cleaning Time ....................................................................................................................... 16
Cleaning Solutions ....................................................................................................... 17
Cleaning Chemicals ...................................................................................................... 17
Memcleen A .......................................................................................................................... 17
Chemical Calculation: ........................................................................................................... 17
Chlorine................................................................................................................................. 17
Chemical Calculation: ........................................................................................................... 18
Factory Assistance ....................................................................................................... 18
Membrane Chemical Compatibility ............................................................................. 19
Appendix A. UF System Specifications ...................................................................... 20
Appendix B. Operator Interface Screens ..................................................................... 24
Main Menu ................................................................................................................... 25
Alarm History .............................................................................................................. 26
Raw Waste ................................................................................................................... 28
System Feed Pumps ..................................................................................................... 29
Screen Effluent Tank Level Set Points ........................................................................ 30
Rotary ScreenSetup ...................................................................................................... 32
UV Setup Screen .......................................................................................................... 34
Screen Transfer Pumps ................................................................................................ 35
Aeration Blowers ......................................................................................................... 37
Blowers Setup .............................................................................................................. 39
Blower PID Tuning ...................................................................................................... 42
Circulation Pumps ........................................................................................................ 43
Circulation Pumps Setup .............................................................................................. 44
Permeate & Backwash ................................................................................................. 46
Backwash Pumps Setup ............................................................................................... 48
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -5-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Effluent Transfer Pumps Setup .................................................................................... 50
Backwash Tank Level Set Points ................................................................................. 51
Chemical Feed .............................................................................................................. 53
Carbon Dosing Pumps Setup ....................................................................................... 54
Caustic Dosing Pumps Setup ....................................................................................... 55
PAC Dosing Pumps Setup ........................................................................................... 57
Membrane Cleaning System ........................................................................................ 58
Cleaning System Valves Setup .................................................................................... 59
Cleaning System Set Points ......................................................................................... 61
Maintenance ................................................................................................................. 63
UF Master Control ....................................................................................................... 67
UF Operational Set Points ............................................................................................ 69
UF Data Logging ......................................................................................................... 71
UF Flush Pumps Setup ................................................................................................. 72
UF Sludge Valve Setup ................................................................................................ 73
UF Permeate Pump Setup ............................................................................................ 74
UF Permeate Pumps PID Tuning ................................................................................. 76
UF Valves Setup .......................................................................................................... 77
Anoxic Tank & Aeration .............................................................................................. 80
Anoxic Tanks Mix/RAS Pumps Setup ......................................................................... 81
System Tanks Level Set Points .................................................................................... 82
Appendix D. Alarm List and Troubleshooting ............................................................ 85
1 Rotary Brush Screen Tank High Level ................................................................. 85
2 Bioreactor A High Level ....................................................................................... 85
3 Bioreactor B High Level ....................................................................................... 85
4 Anoxic Tank A High Level................................................................................... 85
5 Anoxic Tank B High Level ................................................................................... 86
6 Backwash Tank High Level .................................................................................. 86
7 Backwash Tank Low Level .................................................................................. 86
8 EQ Tank Low Level.............................................................................................. 86
9 Aeration Blowes Cooling Fan Overload ............................................................... 86
10 Aeration Blower Cooling Fan Failure................................................................... 87
11 Process Blower Overheat ..................................................................................... 87
12 Process Air Bioreactors High Temperature .......................................................... 87
13 Process Air Membranes High Temperature .......................................................... 88
14 Circulation Pump Failure to Run .......................................................................... 88
15 Circulation Pump Overload .................................................................................. 88
16 Circulation Pump Low Suction Pressure .............................................................. 88
17 Drum Screen Failure to Run ................................................................................. 89
18 Dynalift Feed Valve Failure.................................................................................. 89
19 Test ........................................................................................................................ 90
20 Dynalift Air Flow High ......................................................................................... 90
21 Dynalift Drain Valve Failure ............................................................................... 90
22 Dynalift Air Flow Low ........................................................................................ 90
23 Dynalift SHUTDOWN! High Trans-Membrane Pressure .................................... 90
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -6-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
24 Backwash Pumps Overload .................................................................................. 91
25 Backwash Pump Failure to Run ............................................................................ 91
26 Dynalift SHUTDOWN! Low Permeate Flow....................................................... 91
27 System feed Pumps Overload ............................................................................... 92
28 System feed Pump Seal Failure ............................................................................ 92
29 System feed Pump Failure to Run ........................................................................ 92
30 Screen Transfer Pumps Overload ......................................................................... 92
31 Screen Transfer Pump Failure to Run ................................................................... 93
32 Dynalift SHUTDOWN! Bioreactor Low Level .................................................... 93
33 Dynalift High Permeate Flow .............................................................................. 94
34 Bioreactor A High Air Flow ................................................................................. 94
35 Dynalift Low Trans-Membrane Pressure.............................................................. 94
36 Bioreactor Low Air Flow ...................................................................................... 94
37 Anoxic Tank High ORP ........................................................................................ 95
38 Bioreactor Low Level ........................................................................................... 95
39 Anoxic Tank Low ORP ........................................................................................ 95
40 Bioreactor Low Dissolved Oxygen ....................................................................... 96
41 Bioreactor High pH ............................................................................................... 96
42 Dynalift Circulation Pump Low Suction Pressure ................................................ 96
43 Bioreactor High Dissolved Oxygen ...................................................................... 97
44 Dynalift SHUTDOWN! High Feed Pressure ........................................................ 97
45 Dynalift Low Feed Pressure.................................................................................. 97
46 Dynalift High Permeate Pressure .......................................................................... 98
47 Dynalift Low Permeate Pressure .......................................................................... 98
48 Permeate Pump High Pressure .............................................................................. 98
49 Permeate Pump Low Pressure .............................................................................. 99
50 Process Air Bioreactor High Pressure................................................................... 99
51 Process Air Membrane High Pressure .................................................................. 99
52 Process Air Bioreactor Low Pressure ................................................................... 99
53 Process Air Bioreactor Low Pressure ................................................................. 100
54 Effluent Pump Failure to Run ............................................................................ 100
55 E-STOP Pressed .................................................................................................. 100

Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -7-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com

Safety Notes:
WARNING!
Pumps used in this system start and stop automatically during normal operation. Always stop
the drive unit before beginning any repair work on it. Make sure that the motor cannot
accidentally be started by any means during repairs. Refer to individual manufacturers’
instruction manuals (see separate binder) for more specific information.
Failure to follow the above procedure may result in personal injury and/or property
damage!
WARNING!
Chemical metering pumps and feeders that convey hazardous media must be decontaminated
prior to any maintenance work on them. Refer to individual manufacturers’ instruction manuals
(see separate binder) for more specific information.
Failure to follow the above procedure may result in personal injury and/or property
damage!
WARNING!
Cleaning and pH adjusting chemicals used in this installation may be harmful. Manufacturer’s
material safety data sheets (MSDS) and handling instructions should always be followed. Use
eye and skin protection when handling chemicals.
Failure to follow the above procedure may result in personal injury and/or property
damage!
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -8-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Precautions
No silicone-containing agents are to be introduced into the system. Use of these materials
in any quantity will cause irreversible membrane fouling.
NOTE: Antifreeze and defoamers may contain silicone and should therefore never be
allowed into the system.
Refer to Appendix A. System Specifications for maximum temperature to which the
standard membrane elements should be subjected. Do not exceed this temperature or
irreversible damage can occur.
Refer to Appendix A. System Specifications for the pH range over which the membranes
may be subjected during normal operations, and during cleaning.
The system must be protected from freezing. Failure to do so will cause damage to the
membrane elements and will cause damage to other system components.
Membrane elements should never be allowed to dry out. At all times the membrane
elements must remain wet. Damage from membrane dry out is irreversible.
Do not process any solvents or chemicals harmful to the membranes. Consult factory
prior to introducing any solvent.
Abnormal concentrations of strong oxidizers (chlorine, hydrogen peroxide, etc.) must not
be present in process water on a continuous basis. Consult factory for allowable
concentrations.
Coarse or abrasive particles should be prevented from entering the system, since they
may damage system components. A 1/8-inch screen in the process pump suction line (by
others) generally provides sufficient protection.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -9-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Water Quality Guidelines
Incoming water quality (process water) will affect membrane performance. High water
hardness is often identified as a major source of excessive membrane fouling.
Water containing salts of hardness or other sparingly soluble salts must not be used for
cleaning membranes. Soft or deionized water must be used. Both hot and cold water
supplies to the cleaning tank must contain less than 3 grains of hardness (51 parts per
million (ppm) of CaCO3).
Note: We do not recommend the use of permeate for either cleaning of the membrane
system.
Iron, aluminum, and manganese in cleaning water will reduce the performance of the
cleaning solution. Generally, iron concentrations should be less than 0.3 ppm, aluminum
less than 1 ppm, and manganese less than 0.05 ppm.
At no time during process operations should the pH of process fluid be below pH 3.0 or
above pH 11.0. Operation outside of these parameters will compromise membrane life.
Silica compounds naturally occur in many waters. Please check your water source for the compounds
listed in the table below:

Table 1. Silica Compounds
Name Formula Occurrence Effect on Membrane
Soluble silica SiO2 Naturally in many
waters
Does not foul
Suspended silica SiO2 Naturally in many
waters
Does not foul
Silicates M2O
xSiO2
yH20
Water treatment, food
additives, detergents
Forms fouling films quickly, but is
cleanable with caustic soda
Microcrystalline silica
(diatomaceous earth)
SiO2 Filter aid Irreversible pore plugging
Colloidal silica SiO2 Common in rivers
and well waters
At pH below 7.0 gels and fouls
membranes irreversibly. At pH
above 7.0 fouls in presence of salts
(non-fouling without salts).
Silicones Polysiloxanes Antifoamers Irreversible fouling by adsorption
and film formation.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -10-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Membrane Preservation and Storage
All membranes are shipped with small amounts of deionized water and a preservative.
Modules can be initially stored in a sheltered area, protected from freezing and sealed as shipped
until ready for use. Do not allow the membranes to dry out.

After installation, the elements must be preserved, as recommended below, if the system must
be shutdown.
Short-Term Shutdown: Less Than 8 Hours
The Dynalift system drains and backwashes at every shutdown. It is safe to leave it this
condition for up to 8 hours. The membranes will be filled only on the permeate and will slowly
permeate out much of the water until the membranes are dry.
Intermediate Shutdown: Less than 1 Week
If the Dynalift s ystem is to be shut down for an extended period it MUST be kept filled to
prevent drying out. It must be cleaned using the standard cleaning process before refilling with
potable water. The manual drain valve should be closed to prevent loss of the water due to a
power failure. The system can then be filled from the chemical feed system potable water valve
by manually activating it from the HMI screen.
Long-Term Shutdown: More Than 1 Week
For long-term shut-down, the following steps are recommended:
1. A thorough chemical cleaning of the membranes.
2. Impregnation of the membranes in 1,000 ppm sodium metabisulfite and replace every
three months.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -11-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Controls
PLC Controls
All controls are located in the Motor Control Center (MCC) and the attached Main Control
Panel (MCP) section. The MCP section houses the programmable logic controller (PLC), and
associated I/O components for the MCC motor controls. All other skids and sub-systems are
controlled via Ethernet remote I/O panels located on each skid, or near the instrumentation. The
PLC performs all the logic required for the automatic operation of the components. The
Human/Machine Interface (HMI) panel provides all control and status for the entire system. The
workstation is installed in the door of the Main Control Panel. Specific operation of the PLC
program is described in the Appendices for this job. User manuals for the individual controls are
enclosed in the Manufacturer’s literature section of this manual.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -12-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Operation
The following is a general description of the wastewater treatment process based on the
Dynalift MBR system.

The effluent from the Equalization Tank is processed through a series of treatment units prior
to being discharged as reuse water. The process can be broken down into the following steps:

1. Solids Separation – The wastewater from the Equalization Tank pump passes through a
rotary brush screen with a 1mm mesh to remove large solids. The solids removed are directed
back to the sewer. The brush screen is equipped with an intermittent water flush on the
discharge chute to prevent solids from building up there. The screen and the holding tank
beneath it have large overflow pipes to prevent any possibility of an overflow out of the
screen. In addition the sludge wasting back to the sewer is directed into the screen discharge
to help flush solids to the sewer. Three transfer pumps, one for each biological train and a
common installed spare, located outside the screen room, send the filtrate to the Anoxic
Tanks for each train.
2. Anoxic Zone – Wastewater from the transfer pumps flows into the Anoxic Tanks and mixes
with the mixed liquor circulating in the system. A mix/recycle pump recirculates the mixed
liquor through a circular slot at the bottom of the tank. The high velocity flow sweeps the
bottom from the center out and causes circulation up the side of the tank and down through
the center again. A proportioning valve in the pump suction allows sludge from the Aeration
tank to be returned to the anoxic zone bringing the Nitrates produced by oxidation back into
the anoxic tank. The anoxic tank is kept in a low oxygen condition. Bacteria in the
wastewater are starved for oxygen so they break down the Nitrates (NO3) to get the oxygen
they need. This process releases Nitrogen into the air. The tank is sealed and vented to the
outside of the building. The anoxic zone is also provided with a supplemental carbon feed to
provide a food source for the bacteria for low flow conditions, or if not enough BOD is
available.
3. Aerobic Zone – Most of the mixed liquor returns directly from the membranes into the
Bioreactor. The mixed liquor passing through the Anoxic tank also overflows into the
Bioreactor. Most of the aeration for the bioreactor comes from the air introduced into the
membranes. DO control is provided by a DO sensor and additional aeration of the
bioreactor. Aeration is by cylindrical EPDM fine bubble diffusers radiating from a common
header at the center of the tank. The design is such that maintenance of the diffusers can be
performed from the top of the tank without entering the tank.
4. Membrane Separation – The mixed liquor is circulated from the bioreactor through the
membrane skids and returning into the Anoxic Tank and Bioreactor by a low head centrifugal
pump. The membranes are a tubular style consisting of many small tubes contained in a
number of 8" diameter PVC housings. The mixed liquor flows inside of all of the small
tubes and clean water permeates through the walls of the tubing into the outer shell. A pump
on each membrane skid collects the permeate and sends it into the common backwash tank.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -13-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
An air diffuser at the bottom of each membrane module introduces air into the mixed liquor
to cause turbulence which helps scour the membrane surfaces to reduce fouling.
5. Backwash System – The permeate in the backwash tank goes out through an overflow pipe to
the qualitative instrumentation final UV disinfection system. Permeate is stored in the tank
to be used periodically to backwash the membrane to prevent fouling. After a set number of
backwashes a flush is also performed. During the flush the mixed liquor in the membranes is
pumped back into the bioreactor a backwash is performed along with water flushing of the
air diffusers at the bottom of each membrane. If sludge wasting is enabled then some mixed
liquor will also be diverted back to the sewer.
6. Chemical Cleaning – Occasionally the membranes need to be chemically cleaned to remove
scaling and other foulants that regular backwashing cannot remove. This process is
completely automatic, except for filling the chemical tanks, and is initiated by the operator.
The Dynalift to be cleaned is first stopped, which always initiated an extended backwash.
Then the operator presses the cleaning button and the system cycles through a multi-step
process of draining, filling, adding chemical, refreshing chemical, and then performing a
second cleaning with a different chemical. A button on the HMI allows the operator to
determine whether the membrane skid goes back on line automatically at the end of a
cleaning cycle, or simply sits empty in a cleaned condition. Note that if it is to remain off for
more than 8 hours or so it should at the very least be filled with potable water and not left
dry.
7. Final Disinfection – The permeate discharge passes through an enclosed UV (Ultraviolet)
light disinfection unit then out to discharge. This UV is nothing more than a backup safety
system as Ultrafiltration membranes have pores that are too small for bacteria or viruses to
pass through. So unless there is a serious membrane breach there is nothing for it to kill.
Note that in this system qualitative instrumentation has been installed upstream of the final
UV that the operator can use to determine whether the water produces is suitable for reuse.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -14-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Membrane Cleaning
Introduction
The early establishment of an effective cleaning regime for the membrane is fundamental to
the long-term successful operation of the treatment system. If successful cleanings are not carried
out when the system is new and maintained over the life of the system, the system will not
operate to satisfactory performance. In addition, cleaning will be required more frequently.
When Cleaning is Required
There are two occasions when a cleaning cycle should be carried out.

1. When TMP has risen to the point which has been determined to indicate t he system is
excessively fouled. This TMP value will be different for every jobsite, as it is based on
the characteristics of the wastewater, and not the performance of the membrane.
2. Whenever the system will be shut down for more than a few hours.
Types of Fouling
There are two basic types of fouling that may normally occur:

1. Organic, where typically oil or other organic material has fouled the membrane by
causing a gel layer to form on the surface of the membrane, preventing or slowing the
flow of water through the membrane.
2. Inorganic, where salts and/or metals are present in the waste, or have precipitated in the
waste, and have plugged the pore structure of the membrane, reducing permeate flow.
Automatic Cleaning Process
This system features an Automatic Cleaning process that is initiated by the operator. The
operator starts the process by first pressing the Stop button for the Dynalift A or B, to be cleaned.
Then the operator presses the Clean button, which sends you to the Cleaning Screen

Pressing the Start touch button on the cleaning screen begins the automated process. The steps in
this process are as follows:
1. If the backwash tank is not filled then the Potable Water Valve opens and fills the Cleaning
Tank with potable water to the Full Level.
2. The Membrane Drain Valve closes and the membrane skid fills Pump starts to circulate water
through the membranes to flush out any remaining mixed liquor. The Cleaning Pump stops
and the Membrane Drain Valve again opens and allows the membranes to drain for a time
period. Then the Cleaning Pump restarts to remove the last of the dirty water from the
cleaning tank.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -15-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
3. The Backwash Tank fills with water from the potable water source, and permeate from the
other Dynalift if it is in operation. If this process takes too long (greater than 30 minutes), an
alarm sounds, the operator is shown the failed step number, and the cleaning process aborts.
4. The normal backwashes for both Dynalifts are inhibited. The appropriate Dynalift drain
valve opens, the backwash valve opens, and a long backwash occurs until the Backwash
Tank has reached the Reuse Low Level. If this process takes too long (greater than 30
minutes), an alarm sounds, the operator is shown the failed step number, and the cleaning
process aborts.
5. Repeat step 1 (fill backwash tank).
6. Repeat step 2 (backwash).
7. The Bleach Valve opens and fills the cleaning tank with the bleach solution. If this process
takes too long, an alarm sounds, the operator is shown the failed step number, and the
cleaning process aborts.
8. The Cleaning Pump starts and bleach is circulated through the membranes for the specified
cleaning time. During this time the Backwash Tank is also being refilled. During the
circulation the Membrane Air Valve opens briefly at the specified intervals and for the
specified length of time to provide additional agitation. If the level in the Cleaning Tank
should drop too low an alarm will sound, and the operator will be shown the failed step
number, and the cleaning process will abort.
9. Stop the Cleaning Pump and open the Membrane Drain Valve and drain the Dynalift
completely for a timed period. Then restart the Cleaning Pump to remove all the bleach
solution.
10. Inhibit the normal backwashes and backwash the Dynalift to drain until the Backwash Tank
reaches the Reuse Low Level point.
11. Refill the Backwash tank with potable water and permeate if the other Dynalift is running.
12. Open the Clean Water Valve and fill the cleaning tank to the Flush Level. Start the Cleaning
Pump and pump the contents of the cleaning tank to drain.
13. The Citric Valve opens and fills the Cleaning Tank with the citric solution. If this process
takes too long, an alarm sounds, the operator is shown the failed step number, and the
cleaning process aborts.
14. The Cleaning Pump starts and citric solution is circulated through the membranes for the
specified cleaning time. During this time the Backwash Tank is also being refilled. During
the circulation the Membrane Air Valve opens briefly at the specified intervals and for the
specified length of time to provide additional agitation. If the level in the Cleaning Tank
should drop too low an alarm will sound, and the operator will be shown the failed step
number, and the cleaning process will abort.
15. The Cleaning Pump stops and the Membrane Drain Valve opens to drain the cleaning
solution out completely. Then the Cleaning Pump restarts to drain the rest of the Cleaning
Tank.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -16-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
16. The normal backwashes for both Dynalifts are inhibited. The appropriate Dynalift drain
valve opens, the backwash valve opens, and a long backwash occurs until the Backwash
Tank has reached the Reuse Low Level. If this process takes too long (greater than 30
minutes), an alarm sounds, the operator is shown the failed step number, and the cleaning
process aborts.
17. Repeat step 1 (fill backwash tank).
18. Repeat step 16 (backwash).
19. Open the Clean Water Valve and fill the Cleaning Tank to the Flush Level. Start the
Cleaning Pump and pump the contents of the cleaning tank to drain.
20. Show the operator that the cleaning was successful, and indicate that the manual valves ALL
need to be returned to their normal positions before starting the system.
Change the manual valves for the Dynalift that was cleaned.
a. For Dynalift A
i. Throttle V107, V108 as required
ii. Open V603
iii. Close V109, V602
b. For Dynalift B
i. Throttle V207, V208 as required
ii. Open V703
iii. Close V209, V702

Cleaning Time
The time that a cleaning procedure is left to run depends on the process being carried out.
Water temperature plays a large part in the time required for a successful cleaning. It may be
necessary to increase cleaning times during cold weather. Additional cleaning time beyond two
hours or so is usually not very helpful for Chlorine or Caustic cleaning. Additional cleaning time
may very helpful for acid cleaning when trying to remove scaling. Overnight is a very good idea
if possible.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -17-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Cleaning Solutions
Warning: Most of the chemicals listed are hazardous in some way. ALWAYS, carefully
observe the manufacturers recommendations, and take appropriate safety steps such as
the use of gloves, goggles, protective clothing, etc.
Always follow the recommended concentrations and other directions for each chemical found
later in this chapter.
There are a wide variety of cleaning chemicals available, but the most commonly used are the
following:
Cleaning Chemicals
Memcleen A
This acidic wash chemical is used to remove scaling from the membrane.

Note: Memcleen A is a mild acid and as such care should be taken in handling, using
gloves and safety glasses where appropriate
Chemical Calculation:

(Desired Memcleen A Concentration % by volume) = Injector Ratio
Setting 100

Example: Recommended Memcleen rate is 3%, then the calculation is as follows:

3 = 33.33 = 33:1
100

Chlorine
This wash procedure is used to remove stubborn organic material.

Ensure that the chemicals are measured accurately or membrane damage could occur.
Do not exceed five hundred parts per million (500 PPM) total Chlorine.
Note: Sodium hypochlorite is an extremely strong oxidizer and as such care should be
taken in handling, using gloves and safety glasses where appropriate
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -18-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Chemical Calculation:

(Chlorine Concentration in %) x 10,000 = Injector Ratio
Desired Parts Per Million
1. Example: If the Chlorine concentration as supplied is 12.5%, then the calculation is as
follows:

(12.5) x 10,000 = 250 = 250:1 500

Factory Assistance
If after carrying out all the above steps, the system still cannot be cleaned, submit the records
of all the steps that you have carried out, along with the results of each to the factory, and
assistance will be provided in further work to determine the best method for system cleaning.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -19-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
www.dynatecsystems.com
Membrane Chemical Compatibility
Please refer to the attached compatibility chart for information on chemical compatibility with
the materials of construction of your Dynatec Systems Inc. system.

Table 2. Chemical Compatibility
Chemical Compatibility G – good
F – fair,
N – Not recommended
Aliphatic hydrocarbons G
Aromatic hydrocarbons G
Chlorinated solvents N
Aprotic solvents N
Alcohols G
Organic acids G
Esters F
Aldehydes F
Ethers G
Ketons N
Cellosolves G
Salts and buffers G
Sodium hypochlorite N
Hydrogen peroxide, less than 0.5% concentration F
Phenols G
Silicones N
Alkali, temperature, and pH dependent G
Inorganic acids G
Amines F
If you suspect any of the above chemicals that received an F or N rating are present in the
waste stream, please contact Dynatec Systems Inc. for further direction.
Operations and Maintenance Manual Ultrafilter Wastewater Treatment System -20-

DYNATEC SYSTEMS, INC.• 909 Jacksonville Road • Burlington • New Jersey • 0 8016 •
(609) 387 -0330 • FAX [phone]
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Appendix A. UF System Specifications
Table A- 1. System Specifications
Item Qty Description Parameter
1 DRAWINGS
1.1 System P&I 211113I00
1.1.1 Membrane Skid P&I 211113I10
1.2 Electrical 211113E00

2 2 SYSTEM FEED GRINDER PUMPS
2.1 Manufacturer Wilo
2.2 Model # MTC 32 F76.75/30-3-460-60-2
2.3 Type Submersible grinder
2.4 Rating 75 GPM @ 25 ft.
2.5 Speed 3480
2.6 Motor 3 HP
2.7 Power 460v/3ph/60hz

2 1 ROTARY SCREEN
3.1 Manufacturer Or-Tec
3.2 Model # ODS8
3.3 Type Mechanical Brush
3.4 Perforation 1 mm
3.5 Motor ½ HP
3.6 Power 460v/3ph/60hz

3 3 SCREEN WASTE TRANSFER PUMP
4.1 Manufacturer G&L
4.2 Model # 9SH4C45C5
4.3 Type Centrifugal
4.4 Housing Stainless Steel
4.5 Seal Silicon Carbide / Silicon Carbide
4.6 Speed 1750
4.7 HP 1/2
4.8 Rating 50 GPM @ 22 ft.
4.9 Power 460v/3ph/60hz

4 3 UF MEMBRANE CIRCULATION PUMP
4.1 Manufacturer Sulzer
4.2 Model # CPT22-4
4.3 Type Centrifugal
4.4 Impeller Duplex Stainless Steel
4.5 Seal Dynamic
4.6 Housing Duplex Stainless Steel
4.7 Speed 1160
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Table A- 1. System Specifications
Item Qty Description Parameter
5.8 Hp 5
5.9 Rating 660 GPM @ 15 ft.
5.10 Power 460v/3ph/60hz

5 12 AIRLIFT MEMBRANE MODULES
6.1 Type Xflow F4385-38PRV
6.2 Arrangement 2 pass, 6 in parallel
6.3 Feed Pressure 5 psi
6.4 Pressure differential (TMP) 2 psi typical
6.5 pH range – process 3.0 – 10.5
6.6 pH range – clean 2.0 – 11.0
6.7 Maximum Operating Temperature 120° F
(Note: Continuous operation at combined high temperature and high or low pH will
shorten membrane life)

6 2 ANOXIC TANK RAS MIX PUMP
7.1 Manufacturer Paco
7.2 Type Centrifugal
7.3 Housing Cast Iron
7.4 Seal Double with Seal Pressurizer
7.5 Speed 900
7.6 HP 3
7.7 Rating 600 GPM @ 15 ft.
7.8 Power 460v/3ph/60hz

8 2 PROCESS BLOWER
8.1 Manufacturer Kaeser
8.2 Model Number CB 131C
8.3 Type Positive Displacement
8.4 Rating 560 scfm @ 8.5 psi
8.5 Motor HP 40
8.6 Power 460v/3ph/60hz

8 2 UV SYSTEM
9.1 Manufacturer Severn Trent
9.2 Model Number 8102-HO-100
9.3 Intensity 2.2 Kw
9.4 Material 316 Stainless Steel
9.5 Power 120v/1ph/60hz

10 2 BIOREACTOR TANK
10.1 Tank Size & Type 10,500 gallon HDPE

11 2 ANOXIC TANK
11.1 Tank Size & Type 9,150 gallon HDPE
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Table A- 1. System Specifications
Item Qty Description Parameter

12 1 POST-ANOXIC TANK
12.1 Tank Size & Type 10,500 gallon HDPE

13 1 PERMEATE BACKWASH TANK
13.1 Tank Size & Type 600 gallon HDPE

14 3 BACKWASH PUMP
14.1 Manufacturer G & L
14.2 Model # 23SH4J52J5
14.3 Type Centrifugal
14.4 Impeller Stainless Steel
14.5 Seal Silicon Carbide / Silicon Carbide
14.6 Housing Stainless Steel
14.7 Speed 1750
14.8 Hp 5
14.9 Rating 400 GPM @ 22 ft.
14.10 Power 460v/3ph/60hz

15 2 CHEMICAL FEED PUMP
15.1 Manufacturer LMI
15.2 Model # AA961-363SI
15.3 Type Diaphragm
15.4 Rating 2 gph @ 50 psi
15.5 Power 120v/1ph/60hz

16 5 CHEMICAL FEED PUMP
16.1 Manufacturer LMI
16.2 Model # P161-363SI
16.3 Type Diaphragm
16.4 Rating 2 gph @ 50 psi
16.5 Power 120v/1ph/60hz

17 2 CHEMICAL FEED PUMP
17.1 Manufacturer Dosatron
17.2 Model # D14MZ2AFPII
17.3 Type Water Powered
17.4 Rating 0.05 – 14 gpm @ 7 – 85 psi

18 2 CHEMICAL FEED PUMP
18.1 Manufacturer Dosatron
18.2 Model # D14MZ10VFPII
18.3 Type Water Powered
18.4 Rating 0.05 – 14 gpm @ 7 – 85 psi

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Table A- 1. System Specifications
Item Qty Description Parameter
19 CONTROLS
19.1 1 Control Cabinet/Motor Control Motor Control Center
19.2 Location Local
19.3 Type Allen Bradley

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Appendix B. Operator Interface Screens
This chapter describes the Human/Machine Interface (HMI) as supplied with this project. This
installation has one touch screen HMI which controls both trains.
CAUTION! When looking at the HMI you must be very careful not to accidently push
any buttons that start or stop processes or change set points. In the case of set points if
you suddenly find yourself at a screen asking for a numerical input ALWAYS PRESS
CANCEL TO EXIT!

SYSTEM OPERATIONAL HMI SCREENS
The following HMI screens are used to control the common operations of the Dynalift System
shared by membranes A & B. These include the screen, waste transfer pumps, blowers,
backwash pumps, reuse pump, and chemical feed skid.

All screens are touch screens and you should NEVER use anything but clean fingers to
operate the screen. Pencils and other objects will permanently damage the screen. When leaving
the system unattended it is a very good idea to always leave a screen showing which has a
pictorial view on it. These screens only have navigational buttons on them. Someone curiously
touching the screen will see it suddenly change, but no harm will be done. This is not true of
screens which have pushbuttons or set points.
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Main Menu
This screen is the main screen that takes you to all other screens for the Dynalift system. This
screen is always reached by the Main Menu key from any other screen.

Figure 1. Main Menu
The Alarm Indicator in the upper right corner shows if there are any alarms currently active
for both A and B Dynalifts. If there are it turns red and blinks. When an alarm is active the
Alarm Indicator will appear on every screen. The Active Alarms button on the left side will show
you which alarms are still active.
All setup screens, all setpoints and tank level setpoints can be accessed from this screen by
pressing the corresponding blue buttons. As a button is pressed a list of available screens will
pop-up.

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Alarm History
The Alarm History screen pops up every time an alarm occurs.

Figure 2. Alarm History
The Acknowledge & Silence button on this screen silences the alarm horn and also
acknowledges the alarm. Alarms that are brief and latch up so they are not missed will not be
cleared though. The Reset All Alarms button will clear any alarms not currently active. Note
that if an alarm won’t clear by using Reset All Alarms it means the alarm condition still exists.
The alarm list is in order by occurrence, newest alarms on top. Pressing reset causes alarms
that no longer are active to be removed from the list. The Alarm History button on the upper left
allows you to scroll through the entire history of alarms, or clear out them all.
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The large blank indicator on the upper right of the screen is a warning that pops up if you try
to enter a set point that that is out of range. For instance a high level that is lower than a low
level set point. You can silence this alarm simply by using the Previous Screen button.

The Main Menu takes you back to the main menu. Note that all other screens have most of
these navigation buttons and function the same way.
The Alarm indicator in the upper right corner shows if there are any alarms currentl y active
for both A and B Dynalifts. If there are, it turns red and blinks.
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Raw Waste
This screen shows the Equalization Tank, feed pump, brush screen, chute flush and transfer
pumps.

Figure 3. Raw Waste Screen

The status indicators show whether the pumps are on or off and whether the chute flush
solenoid is open.

The level indicators show the level in the Equalization Tank and the screen tank.

The navigation buttons on the right take you to the main menu or back to the previous screen.
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System Feed Pumps
This screen controls the Equalization Tank pumps.

Figure 4. System Feed Pumps

The status indicator shows whether the pump is running.

The feed pumps run continuously as long as either train is in operation

The navigation buttons on the right take you to the main menu or back to the previous screen.

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Screen Effluent Tank Level Set Points
This screen can be accessed by pressing the Tank Level Setpoints button on the Main Menu
screen.
It controls the starting and stopping of the Equalization Tank feed pump (if connected) and
the waste water transfer pumps P5001A, B, and S.

Figure 5. Screen Effluent Tank Level Set Points

Both of the A and B Dynalifts are fed by a pump in the Equalization Tank. Influent is pumped
up to the Brush Screen where screened liquid falls into the screening pump tank.

The set point buttons on the left control the start, stop and alarming of the feed pump
operation. As long as the level in the brush screen tank is between the start and stop set points,
the wet pump will continue to run. Note that the buttons are arranged vertically according to how
the set points values would be.

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The two buttons to the right permit the waste water transfer pumps to run if either train A or B
is calling for feed. The buttons are arranged vertically according to how the set points values
would be.

The navigation buttons on the right take you to the main menu or back to the previous screen.

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Rotary ScreenSetup
This screen controls the brush screen and its chute flush solenoid.

Figure 6. Brush Screen Setup

Both of the A and B Dynalifts are fed by the Brush Screen.

The HOA switches here and on the drawer of the Motor Control Center are for TESTING
only! Be sure to return the HOA switch to Auto when done testing. No part of a Dynalift system
should ever be attempted to run in a manual mode. Great damage can occur.

The screen run time totalizer can be reset from the Maintenance screen if major repairs have
been performed.

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The Screen Off Delay button allows the operator to set how long the screen continues to run
after the demand for feed to the system has stopped. This keeps solids from remaining in the
screen.

The navigation buttons on the right take you to the main menu or back to the screen that you
came from.
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UV Setup Screen
This screen controls the brush UV units.

Figure 7. UV Units Setup

The status indicator shows whether the UV unit is on or off.

The off delay timer set point button controls how long the lamps remain on after flow stops.
Turning lamps on and off greatly shortens their life. Leaving them on without flow may cause
them to overheat. The time was set by Dynatec for 1 hour as this was tested to be a safe time.
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Screen Transfer Pumps
This screen controls the operation of the three screenings pumps located outside the screen
room. This spare pump is common to both the A and B Dynalifts.

Figure 8. Screen Transfer Pumps

The transfer pumps A & B are dedicated to the A & B trains respectively. A cannot feed B,
and vice versa. The S pump is an installed spare for both the A & B pumps.

The level indicator at the top shows the level in the screen tank. Refer to the level set points
screen to see what levels actually allow these pumps to run.

The HOA switches here and on the drawer of the Motor Control Center are for TESTING
only! Be sure to return the HOA switch to Auto when done testing. No part of a Dynalift system
should ever be attempted to run in a manual mode. Great damage can occur.

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When the S pump is selected for Auto A or Auto B operation then the A or B pump is
automatically disabled. Note the warning label that pops up over the HOA control telling you
that the manual valves MUST be adjusted to direct the flow appropriately.

The run time totalizers can be reset from the maintenance screen in the event of major repairs.

The navigation buttons on the right take you to the main menu or back to the previous screen.

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Aeration Blowers
This screen shows the operation of the blowers which supply air to the Membrane Skids and
the Bioreactors for both the A and B Dynalifts.

Figure 9. Aeration Blowers
There are three blowers installed in this system. Each blower can operate independently.
Each blower has a start and stop button on the blower control screen. The status indicator shows
which blower is actually running.

The blowers are controlled by the pressure transmitter located on the Process Air Header.
The blower speed is controlled by a VFD (variable frequency drive) such that the pressure in the
header remains constant at all times.

With a constant air pressure a simple globe valve controls the air flow to each membrane skid
at a constant design flow of 60 CFM.

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Air to the Bioreactors is controlled by the DO probe in each Bioreactor and the associated
pinch valve.

The Setup Screen navigation button takes you to the blower controls and set points.

The navigation buttons on the right take you to the main menu or back to the previous screen.

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Blowers Setup
This screen controls the blowers which supply air to the Membrane Racks and the Bioreactors
for both the A and B Dynalifts.

Figure 10. Blower Setup

There are three blowers installed in this system. Each blower has a start and stop button. The
status indicators show which blowers are actually running. Each blower has a cooling fan. The
blowers cannot operate in Auto without a cooling fan running. Operating the blower in Hand
without a cooling fan running may damage the blower through overheating.

The HOA switches and manual speed control for fans and blowers here and on the drawer of
the Motor Control Center are for TESTING only! Be sure to return the HOA switch to Auto
when done testing. No part of the Dynalift system should be run in a manual mode. Great
damage can occur.

All three blowers came equipped with check valves on the discharge.
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The off line blower should always be shut down, it’s filter cleaned, and fogged with oil
immediately to prevent seizing due to corrosion.

The blowers are controlled by the pressure transmitter located on the Process Air Header.
The blower speed is controlled by a VFD (variable frequency drive) such that the pressure in the
header remains constant at all times. Positive Displacement blowers have a minimum operational
speed due to lubrication issues. This means you may here the relief valves pop o ff when the
demand for air falls very low.

The indicators at the top of this screen show the current speed for each blower and the current
header pressure.

The pressure alarm set point buttons allow you to adjust the where the alarms occur. These
alarms have time delays on them that keep short term pressure changes from causing nuisance
alarms.

The manual speed set point buttons allow the blowers to be speed controlled while in the
Forced On mode. Blowers should NEVER be operated on line this way. All blowers must be
operated in Auto or damage may occur.
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Dissolved Oxygen setpoints for the bioreactors can be accessed from this screen.

Figure 11. Dissolved Oxygen Setpoints

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Blower PID Tuning

Figure 12. Blower PID Tuning
The speed of the blowers is controlled by a single PID loop. The Discharge Pressure Setpoint
button allows you the change the header pressure. Raising or lowering the discharge pressure
will immediately change the air flow to the membrane skids. A set point change requires
changing the globe valve opening to maintain 60 cfm to the membranes.

It is very important that the system have enough pressure to overcome the static head in the
membranes and the bioreactor, plus all pressure losses due to valves and piping etc. If there is
not enough pressure the flow to the membranes or bioreactors can suddenly stop, with a big risk
of plugging the membranes. Reducing air pressure to optimize energy efficiency can be very
risky and should only be done with very close monitoring.

The Kp, Ki, Kd, and DB set points control how the PID loop functions in controlling the
blower speed. PID loop tuning is more art than science. Adjusting these set points should be left
to someone skilled in the art of PID tuning.
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Circulation Pumps
This screen shows the operation of the circulation pumps for both the A and B Dynalifts.

Figure 13. Circulation Pumps
The circulation pumps are set up similarly to the waste transfer pumps, in that the middle
pump is a spare for both the A and B Dynalifts. Pump A and Pump B can only be enabled for
Dynalift A and Dynalift B respectively. Pump S can be enabled for either Dynalift.

The status indicators show which automatic valves are opened or closed and which pumps are
running. The two pressure indicators show the suction pressure to each pump. Since the level in
the bioreactors varies over a range of just a few inches the pressure transmitters are a good
indicator of whether the strainers are fouled and are alarmed for that purpose.

Using the spare pump for either train A or train B requires the repositioning of multiple
manually operated valves.
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Circulation Pumps Setup
This screen controls the circulation pumps for both the A and B Dynalifts.

Figure 14. Circulation Pumps Setup
Pump S is a spare for both the A & B trains. If pump S is selected by Auto A or Auto B the A
or B pumps are automatically disabled. Note the warning banners that pop up over the HOA
buttons for the disabled pump telling you to reposition the manual valves.
CAUTION! Selecting a circulation pump also involves changing manual valves to
direct flow through the selected pumps.
The indicators at the top show which pumps are operating. The pressure indicators on both
sides of the screen show the current suction pressure.

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The pressure set point buttons on each side of the screen are for the suction pressure for the A
& B trains respectively. The upper buttons set warning alarms while the lower buttons set alarms
that also shut the respective trains down to avoid damage. The pressure transmitters are
compound and can read vacuum, so a value of zero for shutdown is acceptable.
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Permeate & Backwash
This screen shows the operation of the backwash and reuse pumps, for both A and B
Dynalifts.

Figure 15. Permeate & Backwash

Only one backwash pump is used at a time with the other one turned off. Manual valves
direct the flow through the appropriate pump. The Dynalifts are backwashed independently, and
can have different schedules. The PLC handles conflicts in the schedules automatically, by
inhibiting one or the other backwash briefly. The effluent transfer pumps operate from high and
low setpoints in the permeate tank. The 3-way valve AV-3006 in the discharge of the reuse
pumps normally directs permeate to the dosing tank. High level in the dosing tank will redirect
the permeate flow to the 14-day storage tank.
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CAUTION! Selecting a Backwash Pump also involves changing manual valves to
direct flow through the selected pump.
The indicators show which automatic valves and pumps are currently operating. The flow
indicators show the gross permeate flow from each membrane skid. This flow will always be
greater than the net flow from the plant because some permeate is used for backwash and
diffusers flush.
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Backwash Pumps Setup
This screen controls the operation of the backwash pumps for both A and B Dynalifts.

Figure 16. Backwash Pumps Setup

The service backwash pump is selected by the selector switch shown here. Manual control of
the potable water fill valve and the reuse pump are also located here. Backwash pumps can
NEVER be safely operated in manual mode! Membrane damage can easily occur by running the
backwash pumps at the wrong time. These buttons are only for testing purposes and must be
used with great care.
CAUTION! Selecting a Backwash Pump also involves changing manual valves to
direct flow through the selected pump.
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The indicators show which pump is operating.

The potable water fill valve provides water to the backwash for cleaning a train if the other
train is also shutdown and not providing permeate. Its operation is automatic during the cleaning
cycles.

The run time indicators can be reset from the maintenance screen.
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Effluent Transfer Pumps Setup
This screen controls the operation of the effluent transfer pumps and permeate diverter valve.

Figure 17. Effluent Transfer Setup
The effluent transfer pumps P-3002 and P-3003 operate from high and low setpoints in the
permeate tank. The 3-way valve AV-3006 in the discharge of the reuse pumps normally directs
permeate to the dosing tank. High level in the dosing tank will redirect the permeate flow to the
14-day storage tank.

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Backwash Tank Level Set Points
This screen can be accessed by pressing the Tank Level Setpoints button on the Main Menu
screen.
It controls the operation of the backwash and reuse pumps based on Backwash tank level.

Figure 18. Backwash Tank Level Set Points

The indicator at the top middle of the screen shows the level of water in the backwash tank
from the transmitter mounting level.

The High Level Alarm warns of a problem of permeate not leaving the tank at the rate
required.

The Make Up Water Shutoff Level controls the potable water fill valve when it is in Auto.
This level is used to ensure water is available for backwashes during the cleaning process even if
neither train is operating.
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The Backwash Pump Start Level is the minimum level at which the pumps will be allowed to
start.
The Backwash Pump Stop Level shuts off the backwash and reuse pumps if the level falls too
low in the tank.
The backwash pumps operating level should always be set higher than the cleaning make-up
level in the tank.

The low level alarm warns of the low level condition.

The Reuse Pump Start & Stop levels allow the reuse pump to operate if water is available in
the backwash tank.

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Chemical Feed
This following screens control the operation of the dosing pumps used to add chemicals to
both the A & B Dynalift trains.

Figure 19. Chemical Feed Screen
The status indicators show which pumps are actually running (green) or if it is currently off
(red).
CAUTION! When leaving this screen be SURE that each pump is left in the
appropriate mode! Do NOT leave any pump in hand mode, it will NOT stop running!
Each train has its own chemical feed pumps (except for the Post-anoxic tank ORP control).
The navigation buttons take you to the appropriate screens for both trains.
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Carbon Dosing Pumps Setup

Figure 20. Carbon Dosing Pumps Setup
The Supplemental Carbon dosing pumps are turned on and off by the ORP probe in the
Anoxic and Post-anoxic Tanks respectively. A high ORP can be reduced by dosing carbon. The
amount of carbon is set manually by the speed and stoke of the pumps. The pumps can operate
even if a train is not operating.
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Pressing the ORP Setpoints button will bring up this screen:

Figure 21. ORP Setpoints
Caustic Dosing Pumps Setup

Figure 22. Caustic Dosing Pumps Setup
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The Caustic Pumps are controlled by the pH probe in the bioreactor. A PID loop proportionally
operates the pump speed to keep the pH at the set point value. The pump can operate even if a
train is not operating.

Pushing the Pumps PID Tuning button will bring up the PID tuning screen:

Figure 23. Caustic Pumps PID Tuning

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PAC Dosing Pumps Setup

Figure 24. PAC Dosing Pumps Setup
The Poly Aluminum Chloride pumps are used to remove phosphorus if required. It operates
whenever the waste transfer pump for that train operates. The amount dosed in is set by manually
adjusting the speed and stroke of each pump.
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Membrane Cleaning System
This screen shows the valves and pumps located on the chemical feed skid that are used for
the automatic cleaning process.

Figure 25. Membrane Cleaning System

The status indicators show whether the valves are open or closed.

The chemical pumps are water powered and started and stopped automatically by the solenoid
valves. The manual valves in front of the chemical pumps control the speed of the pumps. The
pumps should not click more than 30 times per minute.

The navigation buttons return you to where you were, or take you to the cleaning valves
screen for A or B.
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Cleaning System Valves Setup
This screen controls the valves located on the chemical feed skid that are used for the
automatic cleaning process. Even though not a part of the chemical feed skid, the Backwash
Water Make-up Valve is included on this screen, since it is mostly used during cleaning.

Figure 26. Cleaning System Valves Setup

The status indicators show whether the valves are open or closed.

The valves cannot be opened simultaneously. However care should be exercised to avoid
mixing chemicals. Always use the water valve to flush the lines between chemicals if the valves
are operated manually. The cleaning process performs this task automatically.

The navigation buttons on the right take you to the main menu or back to the previous screen.
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The status indicators show which valves actually open (green) or closed (red).

CAUTION! When leaving this screen be SURE that each valve is left in the AUTO
mode! Do NOT leave any valve in hand mode.
These valves only open during the automatic cleaning cycle to fill the system with cleaning
chemicals. The two chemical valves start the water powered dosing pumps to pull chemicals
from the supply tanks.

The water valve may be used manually, along with the chemical feed valve on the membrane
skid to fill a membrane with clean water for short term storage.

The Backwash Tank Make Up Valve is also only used during the cleaning cycle if no
permeate is available for flushes because both trains are down.
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Cleaning System Set Points
This screen controls the operation of the cleaning process and cleaning skid valves for trains
A and B. Each train has separate setpoints, but the screens are identical for either train with
exception of train designation (A or B) or screen background color (pink for train A and yellow
for train B).

Figure 27. Cleaning System Set Points

The set point buttons for Cleaning are common to both trains. The cleaning fill level set point
is used to set the bottom header pressure that correlates to the membranes being full of water or
chemicals. It is desirable to fill them until the permeate level is up into the tee at the top of the
membrane where you can no longer see it. Setting this value too high though will cause the
water or chemicals to overflow into the top header and the set point value will never be reached,
causing a cleaning alarm.

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The empty level set point is used to determine that water or chemicals have been successfully
drained so the next step can proceed. It should be slightly above zero to reduce nuisance
problems.
The Maximum cleaning temperature only come into play if a very long cleaning is carried out
and the membrane heats up from flush pump energy. In the event the maximum temperature is
reached in any step the cleaning process will automatically proceed to the next step.

The Flush Pump Set Points control the operation of the flush pump only during cleaning.
Flush circulation time is used to ensure a thorough flush before moving to the next cleaning step.

The drain time is how long the pump can run when pumping water out of the membrane back
into the bioreactor.

The Chemicals Set Points control how long each chemical stays in the membrane. The
indicators also show how much time remains before the chemical step completes.

The final Backwash time sets how much backwashing is done after a chemical cleaning. Be
sure that the time is not so long that the low level in the backwash tank set point shuts down the
cleaning process and prevents it from completing!

The two duration indicators show the duration that the each chemical was in the membranes
during the previous cleaning, not this one.
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Maintenance
The Maintenance screen allows you to disable certain functions while doing maintenance on
the system.

Figure 28. Maintenance

This screen can only be reached by someone with the system password.

The Horn Enabled button enables or disables the horn and light when pressed. This also
disables the output of remote alarms. The Alarm Indicator in the upper right corner of all
operational screens still indicates when an alarm occurs. Pressing the button again re-enables the
horn and light. The system should NOT be left with the horn and light disabled.

The Pushbutton For Panel Settings takes you to internal settings for the HMI display. These
include setting the brightness, setting whether the screen goes blank when unattended, etc.

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The Alarm Horn Test button forces an alarm condition which will sound the horn and light,
and cause the remote alarms if enabled. This alarm condition will also show up in the Alarm
Indicator in the upper right corner of the display, and also will get logged on the Alarm History
screen.

The Current Time buttons allow you to adjust for daylight savings time if desired.

The system flow totalizers show the total permeate and sludge flows since the system was
started up. In the case of the permeate these are gross flows from each membrane and this
number will be considerably larger than the net flow shown by the effluent flow meter. These
totals can be reset here.

The Pump & Equipment Hours totalizers may all be reset here if desired.
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Dynalift Train
This screen shows all of the operating parameters for the Dynalift membrane skid. Note that
the screens are identical for either train with exception of train designation (A or B) or screen
background color (pink for train A and yellow for train B).

Figure 29. Dynalift Train

The light blue buttons are navigation buttons that take you to other screens as indicated by
their title.

The numbers in titled grey boxes are real-time data displaying their current values.
1. Time Until next Backwash - indicates the time until the next backwash and how many
backwashes must occur before a flush occurs.
2. Backwashes Until Next Flush – Shows the number of backwashes until a more
aggressive flush and backwash will occur.
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3. FT1002A GPM – Current permeate flow rate from the A membrane skid. Note that is
gross flow, and the actual flow leaving the system is less because some permeate is
used for backwashes, diffuser flushing, and screen chute flushing.
4. FT1001A CFM – Air flow into the A membrane diffusers. This flow is set by the Red
handled brass globe valve located on the end of the skid. It remains relatively constant
at around the design flow of 60 CFM.
5. PT1001A PSI – Feed pressure to the bottom membrane header.
6. PT1002A PSI – Permeate pressure in the membranes
7. TMP PSI – Trans Membrane Pressure, the differential pressure across the membranes.
There is a mounting height correction applied so it will not exactly equal PT1001A-
PT1002A.
8. TT1001A F – Temperature of the mixed liquor in the membrane.
9. FT7800A GPM – Flow rate of sludge leaving the system during sludge wasting.

The pump and valve tags are either red or green, indicating Closed/Off or Open/Running.

The orange indicators showing here only appear on the actual screen when that function is
active.
The gray numerical indicators on the upper left show the time remaining until the next
automatic backwash cycle and how many backwashes until a more aggressive flush and
backwash will occur.

The indicator on the upper right shows three possible modes, Stopped (in red), Running (in
green), Cleaning (in green).

The yellow button at the lower right takes you to the same screen for the B membrane skid.

This is a very good screen to leave displayed when the plant is unattended. The only buttons
on this screen are navigation buttons. Touching a button by accident will not start or stop
anything, it will only take you to another screen.
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UF Master Control
This screen controls the operation of the A train, including cleaning.

Figure 30. UF Master Control

The picture above shows all indicators and buttons that can appear on this screen. Some of
them are hidden during operation (Cleaning operation buttons are hidden during process mode).

Starting and stopping the train is done from here, and all the important data points are shown.
The TMP graph helps to understand how the train is running by letting you see how the TMP
changes between backwashes and flushes.

The Process/Cleaning selector chooses what is being done. While both A and B train can run
together, they can NOT be cleaned at the same time!

When cleaning has been selected some additional indicators and buttons become visible.
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One button advances the cleaning step manually. This is useful if a cleaning was interrupted
and you need to restart in the middle. The Restart Mode button lets you tell the train to go back
on line after the cleaning, if the cleaning was successful. If you don’t press the button the system
will sit empty following the cleaning.

The indicator at the bottom left shows what step the cleaning is in.

The orange warning banner over the TMP graph pops up after a power failure if automatic
restart was selected on the maintenance screen.

The navigation buttons take you to where you were, to set up, or the membrane screen.
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UF Operational Set Points
This screen controls the normal operation of train A.

Figure 31. UF Operational Set Points

The feed pressure set points on the left are critical to the safe operation of the membranes.
For this reason you have high and low warning alarms as well as high and low shutdown alarms.
The warning alarms should be set close to the normal operation values as possible without
causing nuisance alarms. The shutdown alarms should be set only a little higher and lower.

The TMP set points in the center are critical to the safe operation of the membranes. For this
reason you have high and low warning alarms as well as high and low shutdown alarms. The
warning alarms should be set close to the normal operation values as possible without causing
nuisance alarms. The shutdown alarms should be set only a little higher and lower.
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The TMP offset value set point accounts for the mounting height difference between the Feed
pressure transmitter and the permeate pressure transmitter. TMP should read zero with the
membranes sitting partially filled with water.

Membrane Air flow is critical if it stays high or low for a long period of time (1 hour). Both of
these set points shut the train down if they are reached.

The permeate pump delay set point provides time for permeate flow to be established by
gravity flow alone before the permeate pump tries to increase the flow.

The flush pump run time set point is the maximum amount of time the flush pump can run in
the event it doesn’t go off automatically by the pressure sensor indicating the membrane is
empty.

The low cutoff pressure set point is used to tell the flush pump the header is empty.

The Backwash Interval Timer set point sets the time between backwashes.

The Backwash Duration timer set point sets how long the backwash pump runs during each
backwash.

The Backwash Flush Counter set point determines how many backwashes will occur before
the flush step in added into the backwash sequence.

The Backwash Stop Duration timer set point allows a longer or shorter backwash to be used
whenever the train shuts down.

The Process Temperature High set point provides a warning if the mixed liquor is getting too
hot.

The Process Temperature Low set point provides a warning if the mixed liquor is getting too
cold for the biology to work correctly.

The Power Fail Auto Restart Button allows you choose whether the train auto-restarts after a
power failure or waits for the operator to restart it.

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UF Data Logging
This screen shows all the analog data for the membrane train.

Figure 32. UF Data Logging

The data shown on this screen is also being logged to the USB memory. Each day at
Midnight a new file is started. The file can be opened using Excel and graphing al the data. This
can be useful for troubleshooting in the future. The 16 GB USB stick holds about 3 years worth
of data and the HMI puts up an alarm message if it fills up.
Press UP or DOWN arrows to view available trends.
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UF Flush Pum ps Setup
This screen controls Flush Pump for both trains A and B.

Figure 33. UF Flush Pumps Setup

The indicator shows whether the pumps are running. They only run for less than a minute
about once an hour typically.

The HOA buttons are for testing only. Be sure to put the pump back in auto or the train will
not run.

The hour meter can be reset from the maintenance screen.
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UF Sludge Valve Setup
This screen controls wasting of sludge from the membrane train.

Figure 34. UF A Sludge Valve Setup

The sludge flow indicator shows the flow through the flow meter common to both trains.
Sludge totals from the flow meter are accumulated by the PLC separately for each train.

The start and stop buttons determine whether sludge wasting will occur each day. Once
started sludge wasting will start every day, unless stopped.

Sludge wasting starts each day at the time set on this screen. Some sludge is wasted during
each flush until the Desired Sludge Waste amount is reached. This reduces the impact on the
Biomass as only a small percentage of the total for each day is wasted at any one time.

There are two accumulator totals, one for the current day, and one for the total for this train.
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UF Permeate Pump Setup
This screen controls the permeate pump only for the membrane train.

Figure 35. UF A Permeate Pump Setup

The permeate pumps is driven by a VFD and the pump is controlled by a flow meter and PID
loop to operate at a constant flow rate, set by the flow set point on this screen.

The permeate pump is run against a constant restriction provided by a V-Port ball valve on the
pump discharge. Without this restriction the membrane would gravity permeate out at a rate
high than might be required. This valve must be carefully adjusted to provide a wide range of
flows over the normal operating speed of the pump.

The pump can be programmed to achieve three different permeate flow rates, depending on
the level in the Equalization Tank.
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At low level the permeate flow rate will slow down, and at high level the pump will speed up,
producing higher permeate flow rate.

The runtime indicator can be reset from the maintenance screen.

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UF Permeate Pumps PID Tuning
This screen controls the permeate pump only for both trains A and B.

Figure 36. UF Permeate Pumps PID Tuning

Either permeate pump is driven by a VFD and the pump is controlled by a flow meter and
PID loop to operate

The Kp, Ki, Kd, and DB set points control how the PID loop functions in controlling the
pump flow. PID loop tuning is more art than science. Adjusting these set points should be left
to someone skilled in the art of PID tuning.

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UF Valves Setup
This screen controls the automatic valves for the Dynalift unit.

Figure 37. UF Valves Setup, Page 1
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Figure 38. UF Valves Setup, Page 2

All the valves on these screens have an indicator to show whether they are open or closed.
Valves that have limit switches get this status from the limit switches. Valves that do not have
limit switches indicate whether they are in the energized position or not. If a valve with limit
switches is not either fully open or fully closed it will indicate an error.

Be sure to always return all valves to the correct operating mode (auto) before exiting from
this screen!

The Bioreactor Isolation valve is located at the bottom of the Bioreactor before the strainer. It
spring closes in the event of a power failure as a backup to the Membrane Feed Valve so that the
biomass is not accidentally lost into the sewer.

The Dynalift Feed Valve is located between the circulation pump and the membrane rack. It
is spring closed and held open during normal operation. During a flush dump cycle this valve
closes briefly while the membranes are drained. It operates typically once an hour.
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The Concentrate Return Valve is held open during normal operation. It only closes during the
cleaning cycle to retain the cleaning chemicals in the membranes.

The Dynalift Drain Valve is a spring opened valve. It is normally held closed, and opens
during a power failure or when the system is stopped to drain the membranes. Note that a manual
valve is provided for long term shutdowns where you don’t want a power failure draining the
preservative out of the membranes.

The Chemical Valve is normally closed and only opens during portions of the cleaning cycle
to allow chemicals or flush water to fill the membranes.

The Drain Flush valve is normally closed and opens briefly during the flush cycle to direct
mixed liquor from the flush pump back into the Bioreactor.

The Cleaning Valve is normally closed and opens during the cleaning cycle to direct cleaning
solution circulated by the flush pump into the top of the membranes.

The Vent Valve is spring closed and normally stays that way. During a backwash cycle it is
opened briefly to purge air out of the permeate side of the membranes to ensure the permeate
side of the membranes stay full.

The Diffuser Flush valve is normally closed and opens during the backwash portion of the
flush dump cycle. This allows permeate water to be forced into the diffusers to flush out any
solids that may be forming.

The Backwash Valve is normally closed. During a backwash the valve opens briefly to allow
the backwash pump to pump permeate back through the membrane.

The Permeate Valve is held open during normal operation. During each backwash cycle it
closes briefly to prevent the backwash pump from pushing permeate back through the permeate
pump.

The Membrane Air Valve is normally closed and held open during normal operation to
provide air to the membrane air diffusers. Do NOT leave this valve open with empty
membranes! The air will quickly dry out the membranes doing permanent damage to them.
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Anoxic Tank & Aeration
This screen depicts the anoxic tank and bioreactor system. Systems A and B are identical with
exception of nomenclature.

Figure 39. Anoxic Tank & Aeration
ORP, pH and DO setpoints can be accessed from the Main Menu screen.
In addition, ORP setpoints can be accessed from the Carbon Dosing Pumps setup screen, pH
setpoints can be accessed from the Caustic Dosing Pump setup screen and DO setpoints link can
be found on the Blowers setup screen.
Setup of the RAS pumps can be accessed from the Main Menu screen.
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Anoxic Tanks Mix/RAS Pumps Setup

Figure 40. Anoxic Tanks Mix.RAS Pumps Setup
The Recycle Activated Sludge (RAS) pumps operate all the time, regardless whether their
corresponding Dynalift train is running or not.

Position of the RAS valve is determined empirically, based on ORP level in the anoxic tank.
Position is set manually. Currentl y operation of the valves in HAND and AUTO position is
identical.
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System Tanks Level Set Points
The following setpoint screens can be accessed from the Main Menu:

Figure 41. Equalization Tank Level Setpoints

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Figure 42. Post-anoxic Tank Level Setpoints

Figure 43. Sludge Tank Level Setpoints

Figure 44. Dosing Tank Level Setpoints

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Appendix D. Alarm List and Troubleshooting
The following is a list of the alarm codes the system can generate, what they mean, and
possible corrective action.
1 Rotary Brush Screen Tank High Level
This alarm can be activated by both the level transmitter and the redundant high level float
switch in the screenings tank for both the A and B Dynalifts. This alarm indicates that the tank is
being filled by the feed pumps faster than the screenings pumps are removing the wastewater.
Possible causes for this alarm are:
Failure of the drum screen tank level transmitter.
Failure of one or more of the screenings pumps. Check alarm history for pump related
failure messages.

2 Bioreactor A High Level
This alarm is activated by the level transmitter in the bioreactor. This alarm is unlikely to
happen in normal operation. This alarm affects both the A and B Dynalifts as they share a split
feed flow. It shuts off the screenings pumps, except if the pumps are running in hand from the
HOA switch on the MCC. It could happen if:
One or more of the system feed pumps in EQ tank 1 are left running in Hand from the
HOA switch on the MCC.
The set point for pump shutoff is set too high.

3 Bioreactor B High Level
Same as bioreactor A high level above.

4 Anoxic Tank A High Level
This alarm is activated by a non adjustable float switch in the anoxic tank. It is very unlikely
to occur in normal operation. This alarm affects both the A and B Dynalifts as they share a split
flow from EQ tank 1. It shuts off both the system feed pumps in EQ tank 1 and the screenings
pumps, except if the pumps are running in hand from the HOA switch on the MCC. It might
occur if:
The level set points for the bioreactor were to be set to a very high level.
The level transmitter in the bioreactor failed and was showing a low level when in
fact the level was high. This would keep the system feed pumps running.
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5 Anoxic Tank B High Level
Same as tanks A above.

6 Backwash Tank High Level
This alarm is activated by both the level transmitter in the backwash tank and a redundant
float switch. It is highly unlikely in normal operation since the tank overflows to discharge
permeate. This alarm would indicate a blockage in the discharge pipe, or a closed valve.

7 Backwash Tank Low Level
This alarm is activated by the level transmitter in the backwash tank. This alarm shuts off the
backwash pump to prevent seal damage. The pump will be used again when the level rises to the
Backwash Tank Reuse Level Low set point (figure 36). However this would indicate that the
membranes are not being properly backwashed, which could lead to serious plugging in a short
time. It can be caused by:
A backwash rate greater than the permeate production rate from the membranes.
A permeate reuse rate greater than the permeate production rate from the
membranes.

8 EQ Tank Low Level
This alarm is activated by the level transmitter in EQ tank. It would most likely be caused by
leaving the system feed pump(s) in Hand position.

9 Aeration Blowes Cooling Fan Overload
This alarm is activated by any overload contacts on each of the cooling fan starters in the
MCC. It indicates a problem with one of the cooling fans, and the fan will be shutdown. In a
short time the affected blower will overheat. Holding your hand over the cooling air outlet of
running blower will identify the one that has failed. You should switch to the backup blower
immediately. Opening the noise cover on the blower also may allow you to keep the blower
running without overheating. If nothing is done the blower overheat switch will eventually shut
the blower down, which could cause serious membrane plugging and loss of the biomass in the
bioreactor.
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10 Aeration Blower Cooling Fan Failure
This alarm is activated by the auxiliary contact on the motor starter in the MCC. . It can be
caused by:

The HOA switch being left in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil
A broken wire
A bad output relay on the PLC IFM card
A blown fuse in the IFM card,
A bad output in the PLC output module itself.

See the previous alarm for immediate actions to take.

11 Process Blower Overheat
This alarm is activated by the overheat switch which is part of the temperature gauge mounted
on top of the blower. It can be caused by failure of the blower cooling fan as described above, or
by a restriction in the airflow through the blower, as would happen if the filter was very dirty.

This alarm is the last defense against the blower being destroyed so it will shut the blower
down. This will lead to many other alarms due to a lack of process air.

12 Process Air Bioreactors High Temperature
This alarm is activated by the temperature transmitter located on the process blower air header
between blowers 1 and 2. This alarm is a warning, it does not stop the blower. However if the
temperature continues to rise the blower will stop when the temperature reaches the Blower
Temperature High Stop set point. Blowers compress the air raising its temperature. Possible
causes for this alarm are:
High ambient air temperature.
Significant obstruction in the air intake duct work to the blower.

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13 Process Air Membranes High Temperature
Same a process air temperature A above.

14 Circulation Pump Failure to Run
This alarm is activated by the auxiliary contact on the motor starter contactor in the MCC.
This alarm puts the A Dynalift into Stop, to prevent the membranes from plugging. It can be
caused by:
The HOA switch being left in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil.
A broken wire.
A bad output relay on the PLC IFM card.
A blown fuse in the IFM card.
A bad output in the PLC output module itself.

This alarm functions the same as the previous alarm for circulation pump 1, except that it
stops the A or B Dynalift based on which Dynalift the pump has been selected for.

15 Circulation Pump Overload
This alarm is activated by any of the overloads on the circulation pumps tripping. It is
informational only. The affected pump will be stopped by the Circulation Pump Failure alarm.
This alarm lets you know why.

16 Circulation Pump Low Suction Pressure
This alarm is activated by the suction pressure switch located between the circulation pumps
and the strainer. It works for pumps 1 and 2. The causes for this alarm are:
Suction strainer is clogged.
One of the three valves in the suction line are closed.
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17 Drum Screen Failure to Run
This alarm is activated by the current sensor located in the Safety Relay panel on the wall in
the screenings room. This alarm shuts down the system feed pumps to keep them from
continuing to send wastewater to the drum screen and overflowing on to the floor. The system
will soon run out of wastewater and a low level in the bioreactors will shut both the A and B
Dynalifts off. It indicates the drum screen is not running because:

The E-stop on the Safety Panel has been pressed.
The Safety Panel Start button has NOT been pressed.
One of the safety switches on the drum screen doors is not detecting the magnet.
The HOA switch on the MCC is in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil in the MCC
A burned out contactor coil in the safety control cabinet
A broken wire
A bad output relay on the PLC IFM card
A blown fuse in the IFM card,
A bad output in the PLC output module itself.
The UPS in the PLC cabinet is off.
A fuse in the UPS output is blown.

18 Dynalift Feed Valve Failure
This alarm is activated by the limit switches in the Open/Close beacon on top of the fee d
valve. It indicates that the rotation of the valve has failed to reach one of the limit switches,
either open or closed. The system does not stop running. The valve should be examined
immediately for problems.

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19 Test
This alarm is activated by the Alarm Test touch button on the Maintenance screen. Its
purpose is to test that the alarms work properly and that the horn and light can sound. The
switch is a toggle, you must press it a second time to clear the alarm.

20 Dynalift Air Flow High
This alarm is activated by the pitot tube differential pressure sensor located in the galvanized
pipe that feeds air to the A Dynalift membranes. It is informational only. It just tells you that for
some reason you are using more air than previously. This may indicate a valve has been adjusted
differently.

21 Dynalift Drain Valve Failure
This alarm is activated by the limit switch on top of the valve actuator. It indicates that the
drain valve has not properly closed. This could result in the loss of all the biomass in the
bioreactor back into EQ tank 1. For this reason this alarm shuts down the A Dynalift and closes
the Bioreactor Isolation valve.

22 Dynalift Air Flow Low
This alarm is activated by the pitot tube differential pressure sensor located in the galvanized
pipe that feeds air to the A Dynalift membranes. It indicates that the membranes are not getting
enough air and plugging may be occurring. The rotameters near the blowers indicate the actual
air flow in CFM. This condition may be caused by:
Low process blower pressure.
A closed valve.
Plugging of the membrane air diffusers.

23 Dynalift SHUTDOWN! High Trans-Membrane Pressure
This alarm is sensed by the PLC calculating the difference between the membrane feed
pressure and the membrane permeate pressure. This pressure difference is what drives the
permeate through the membrane. A high TMP indicates fouling of the membrane, and can lead
quickly to plugging. The usual course of action is to chemically clean the membranes using the
automated cleaning process.

This alarm puts the A Dynalift into stop.

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24 Backwash Pumps Overload
This alarm is activated by the overload relay located in the MCC. It indicates that the
backwash pump has overloaded. Since the backwash pump actually pumps only very clean
permeate and runs for just 5 seconds it is unlikely to get thi s alarm in normal operation. It could
be caused by:

Something broken inside the pump, like a seized bearing.
One fuse blown in the MCC which single phases the motor.

25 Backwash Pump Failure to Run
This alarm is activated by the auxiliary contact on the motor starter in the MCC. It indicates
the backwash pump has failed to run. This could be caused by:

The HOA switch on the MCC is in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil in the MCC.
A broken wire.
A bad output relay on the PLC IFM card.
A blown fuse in the IFM card.
A bad output in the PLC output module itself.

26 Dynalift SHUTDOWN! Low Permeate Flow
This alarm is activated by the flow meter on the backwash skid. It may be caused by:
The HOA switch for the permeate pump on the MCC is in the Off position.
The permeate pump is in disabled mode.
A clogged or defective flow meter.
A blown fuse on the control transformer in the MCC bucket.
A broken wire.
A bad output relay on the PLC IFM card.
No analog (4 to 20 ma) speed signal from the PLC.
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A blown fuse in the IFM card.
A bad output in the PLC digital output module or analog output module

27 System feed Pumps Overload
This alarm is activated by any of the overloads tripping for the system feed pumps in EQ tank
1 and 2. You will also get a failure to run alarm for the specific pump, so this alarm helps you
troubleshoot that problem. This alarm may be caused by:
Clogging of the system feed pump.
A bearing failure in the pump.

28 System feed Pump Seal Failure
This alarm is activated by a sensor inside the system feed pump. It works by sensing the
resistance across two probes. Water reaching the probes shorts them out and the sensing relays
in the MCC then trigger the alarm. The pump with the failed seal should be disabled and
removed from the EQ tank immediately before more serious damage can occur.

29 System feed Pump Failure to Run
This alarm is activated by the auxiliary contact on the motor starter in the MCC. It can be
caused by:
The HOA switch on the MCC is in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil in the MCC.
A broken wire.
A bad output relay on the PLC IFM card.
A blown fuse in the IFM card.
A bad output in the PLC output module itself.

30 Screen Transfer Pumps Overload
This alarm is activated by any of the overloads tripping for the pumps in the screening tank.
You will also get a failure to run alarm for the specific pump, so this alarm helps you
troubleshoot that problem. This alarm may be caused by:
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Clogging of the pump.
A bearing failure in the pump.
A broken wire feeding the pump.
Overload relay set too low for motor rating.

31 Screen Transfer Pump Failure to Run
This alarm is activated by the auxiliary contact on the motor starter in the MCC. It can be
caused by:
The HOA switch on the MCC is in the Off position.
The overload relay tripped in the MCC.
A blown fuse on the control transformer in the MCC bucket.
A burned out contactor coil in the MCC.
A broken wire.
A bad output relay on the PLC IFM card.
A blown fuse in the IFM card.
A bad output in the PLC output module itself.

32 Dynalift SHUTDOWN! Bioreactor Low Level
This alarm is activated by the submersible level transmitter in the Bioreactor A tank. The set
point should be set below the lowest system feed pump turn on point. This alarm also puts
Dynalift A into Stop mode to prevent losing all the biomass, or concentrating up the MLSS to a
level that plugs the membrane. This alarm may be caused by:

Pumping off sludge without shutting the A Dynalift down.
Failure of one or more of the system feed pumps.
Failure of the rotary screen.
Failure to restart the rotary screen after servicing.
Failure of one or more of the screening pumps.
A valve left close in the piping from the screening pumps to the anoxic tank.
Failure of the level transmitter in the bioreactor.
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33 Dynalift High Permeate Flow
This alarm is activated by the flow meter on the backwash skid. It is highly unlikely to get
this alarm in normal operation. It is provided simply so you can bracket your normal flows with
alarm points in the event something unusual were to occur. It can be caused by:
Alarm set point too low for normal operational fluctuation.
Permeate pump in Hand with flow rate set high.
Permeate flow setting set points too high.

An unused alarm point in the Dialer Critical indicator pages.

34 Bioreactor A High Air Flow
This alarm is activated by the pitot tube differential pressure transmitter located in the
galvanized pipe feeding process air to the bioreactor. This alarm could be caused by:
Low level in the bioreactor.
Broken or missing diffusers in the bioreactor.

35 Dynalift Low Trans-Membrane Pressure
This alarm is sensed by the PLC calculating the difference between the membrane feed
pressure and the membrane permeate pressure. This pressure difference is what drives the
permeate through the membrane. A low TMP alarm can be caused by:
Alarm set point too high for low flow TMP conditions.
Failure of the Membrane Feed Pressure transmitter.
Failure of the Permeate Pressure transmitter.
Failure of the Permeate Pump
Failure of the Circulation Pump.

36 Bioreactor Low Air Flow
This alarm is activated by the pitot tube differential pressure transmitter located in the
galvanized pipe feeding process air to the bioreactor. This alarm could be caused by:
Closed or poorly adjusted valves in the galvanized piping to the bioreactor.
An increase in the level of the bioreactor which raises the pressure needed to push
air into the bioreactor.
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Clogged diffusers in the bioreactor.
Low air pressure in the process air header
Failure of the process air blower.
Alarm set point too high for normal flow change due to automatic valve operation.

37 Anoxic Tank High ORP
This alarm is activated by the ORP sensor in the side of the Anoxic Tank. This alarm may be
caused by:
High DO in Bioreactor.
Excessive air to the membranes.
Lack of carbon to feed bacteria.

38 Bioreactor Low Level
This alarm is a warning activated by the submersible level transmitter in the Bioreactor A
tank. The set point should be set below the lowest system feed pump turn on point. This alarm
may be caused by:
Pumping off sludge without shutting the A Dynalift down.
Failure of one or more of the system feed pumps.
Failure of the rotary screen.
Failure to restart the rotary screen after servicing.
Failure of one or more of the screening pumps.
A valve left close in the piping from the screening pumps to the anoxic tank.
Failure of the level transmitter in the bioreactor.

39 Anoxic Tank Low ORP
Low DO in Bioreactor.
Lack of adequate mixing in Anoxic Tank.

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40 Bioreactor Low Dissolved Oxygen
This alarm is activated by the Dissolved Oxygen (DO) transmitter in the Bioreactor A tank.
Under normal operation the DO level wanders up and down between the DO high set point and
the DO low set points. This alarm may be caused by:

A system disturbance such as starting the system up, or shutting it down for maintenance.
Bioreactor air pulse valves in Hand (closed)
Pulse valve limits set wrong.
Failure of the open pulse valve.
Failure of the bioreactor air blower.
Out of calibration DO transmitter. The DO transmitter has an electrolyte filler that must
be replaced periodically.

41 Bioreactor High pH
This alarm is activated by the pH transmitter installed on the side of the bioreactor A near the
platform. Under normal operation the pH of the incoming waste water is slightly above 7.0. A
caustic injection system has been provided to compensate for possible low pH but is most likely
not needed. If the injection system is running then the like causes of this alarm would be:

pH set point too high.
Caustic pump stroke set too high.
Caustic pump PID loop not tuned properly.

42 Dynalift Circulation Pump Low Suction Pressure
This alarm is activated by the pressure transmitter in the circulation pump suction header. It
can be caused by:
Strainer clogged.
Strainer valve closed.
Set point too high.
Bioreactor isolation valve closed

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43 Bioreactor High Dissolved Oxygen
This alarm is activated by the Dissolved Oxygen (DO) transmitter in the Bioreactor A tank.
Under normal operation the DO level wanders up and down between the DO high set point and
the DO low set points. This alarm may be caused by:

A system disturbance such as starting the system up, or shutting it down for maintenance.
Air pulse valves in Off (open).
Air pulse valve limits too high or too wide.
Out of calibration DO transmitter. The DO transmitter has an electrolyte filler that must
be replaced periodically.

44 Dynalift SHUTDOWN! High Feed Pressure
This alarm is activated by the pressure transmitter located at the center of the feed header on
the membrane rack. In normal operation the pressure here is reduced to a little less than the
static head required (about 5.06 psi) to overflow water into the top header, because the air
injected at the bottom of the membrane makes the water less dense. This alarm could be caused
by:

Loss of air flow to the membrane rack.
Plugging of the membrane which increases the resistance of water flow through the
membranes.
Failure of feed pressure transmitter.

45 Dynalift Low Feed Pressure
This alarm is activated by the pressure transmitter located at the center of the feed header on
the membrane rack. In normal operation the pressure here is reduced to a little less than the
static head required (about 5.06 psi) to overflow water into the top header, because the air
injected at the bottom of the membrane makes the water less dense. This alarm could be caused
by:

Clogged suction strainer on circulation pump inlet.
Closed Bioreactor Isolation valve.
Circulation pump failure, or worn impellor.
Feed valve failure.
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Drain valve failure in the open position.
Very low level in the Bioreactor.

46 Dynalift High Permeate Pressure
This alarm is activated by the pressure transmitter located at the center of the permeate header
on the membrane rack. This alarm is likely only during the backwash cycle which occurs
frequently. During the backwash cycle the permeate valve on top of the backwash skid closes,
the backwash valve opens, and the backwash pump starts, forcing permeate backwards through
the membrane. The butterfly valve above the backwash pump is throttled to keep the backwash
pressure not more that 14.7 psi to avoid damaging the membrane. This alarm can be caused by:

The backwash pump throttling valve is too far open.
The membrane is very badly fouled (TMP would be very high)
Membrane is badly plugged.

47 Dynalift Low Permeate Pressure
This alarm is activated by the pressure transmitter located at the center of the permeate header
on the membrane rack. The permeate pump on the backwash skid pulls permeate out of the
membrane skid, except during backwash. This alarm could be caused by:

Excessive permeate flow rates.
Badly fouled membranes.

48 Permeate Pump High Pressure
This alarm is activated by the pressure transmitter located in the discharge pipe above the
permeate pumps on the backwash skid. The permeate pump pumps permeate into the backwash
tank through a diaphragm valve at the top of the backwash skid that provides some back pressure
so that the permeate won't just gravity flow through the pump into the backwash tank at a rate
greater than desired. This alarm can be caused by:

Very high permeate rate.
Permeate flow control diaphragm valve closed too far.
Permeate pump HOA switch in Hand and speed set high.
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49 Permeate Pump Low Pressure
This alarm is activated by the pressure transmitter located in the discharge pipe above the
permeate pumps on the backwash skid. The permeate pump pumps permeate into the backwash
tank through a diaphragm valve at the top of the backwash skid that provides some back pressure
so that permeate won't just gravity flow through the pump into the backwash tank at a rate
greater than desired. This alarm can be caused by:
Very low permeate rate.
Permeate flow control diaphragm valve opened too far.
Failure of the permeate pump

50 Process Air Bioreactor High Pressure
This alarm is activated by the pressure transmitter located on the Bioreactor process air header
behind the blowers. This transmitter controls the speed of the blower selected for the bioreactors
to maintain a constant pressure. A high pressure alarm could be caused by:

The alarm set point is too low.
The blower set point has been raised.
The PID loop is poorly tuned.
Valves closed on the lines going to the bioreactors.
Blower HOA switch in hand and speed set too high.
Failure of the blower relief valve.

51 Process Air Membrane High Pressure
This alarm works the same as Process Air Bioreactor High Pressure above (alarm 114).

52 Process Air Bioreactor Low Pressure
This alarm is activated by the pressure transmitter located on the process air header behind the
blowers. This transmitter controls the speed of the blower to maintain a constant pressure. A
low pressure alarm could be caused by:

Blower pressure set point too low.
Alarm set point too high.
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Failure of blower relief valve.
Failure of blower to run.
Valves opened to bioreactor and membrane so far that the blower cannot keep up.

53 Process Air Bioreactor Low Pressure
This alarm works the same as Process Air Bioreactor Low Pressure above (alarm 119)

54 Effluent Pump Failure to Run
This alarm is activated by the run contact on the motor starter in the MCC bucket for this
pump. the alarm could be caused by:

MCC bucket switch turned off.
MCC HOA switch in off position.
Over load relay tripped.

A failure of the battery charging circuit to recharge the battery.

55 E-STOP Pressed
This alarm is activated by pressing the E-stop. It is included merely to log in the alarm
history that someone pushed the E-stop. This may help explain an unintended shut down for
which no other cause can be found.

E n v i r o l i n k
THE COTTAGES OF BOONE WWTP
AND
ENVIROLINK, INC.
OPERATION AND MAINTENANCE MANUAL
Cottages of Boone Wastewater Treatment Facility
Residuals Management Plan
This document serves as The Cottages of Boone Wastewater Treatment Facility Residual
Management Plan and will remain on site at the wastewater treatment facility for review
by The State of North Carolina DEQ personnel.
The Cottages of Boone wastewater facility pumps sludge from the activated sludge
treatment process to its onsite 36,166-gallon aerobic digestion storage tank for further
treatment to meet the 503 Regulations. The treatment process currently sends about
1000 gallons of sludge daily to the digester holding tank and is aerated for proper
treatment. The air is periodically turned off and the sludge is allowed to settle, and the
supernate is decanted from the tank to allow more room in the digester. This process
is continued until the tank reaches the 70% full mark and can no longer be decanted.
Once the digester holding tank reaches the 70% full mark, the operator will schedule
to have the tank emptied by contracted pump companies.
The following companies are approved to haul digested sludge from the Cottages of
Boone digester to the City of Boone wastewater treatment facility for final disposal.
 A1 Appalachian Pumping - [phone]
124 Cheyenne Ln
Boone, NC 28607
 Triple T Pumping - [phone]
1372 NC-194
Boone, NC 28607
Doby's Septic — [phone]
712 S. Jefferson Ave
West Jefferson, NC 28694
All records of pumping activities including, date, time, gallons removed, location of
final disposal, and company performing the hauling activities will be kept on site at
the wastewater treatment facility for no less than 5 years.
The Cottages of Boone WWTP
PROCEDURES FOR CLEANUP AND REPORTING OF SEWAGE SPILLS
PURPOSE:
To protect the citizens of North Carolina, and the environment by ensuring a timely and
thorough response to Sanitary Sewer Overflows (SSOs) and Bypasses from the treatment
facility.
SCOPE:
This procedure applies to The Cottages of Boone employees or contractors that, in the course
of their work may deal with SSOs and bypasses. At a minimum, these procedures will be
reviewed on an annual basis or whenever revised guidance from state or federal authorities
dictate a revision is necessary.
REFERENCES:
A. 40 Code of Federal Regulations (CFR) Part 122-124. The Clean Water Act, 1969.
B. North Carolina General Statute 143.215.1
C. Title 15A, North Carolina Administrative Code, Subchapter 2H .0100-.0200
D. Title 15A, North Carolina Administrative Code, Subchapter 2T Section .0500
E. Title 15A, North Carolina Administrative Code, Subchapter 2B .0506(a)
F. NC DEQ Wastewater System Permit # WQ0035784.
RESPONSE TIME REQUIREMENTS:
Utility Outage or Spill Response Time: Upon notification of a spill or utility outage in the
collections system or treatment plant, Envirolink, Inc. shall respond and take action to
safeguard life and the property during business hours and non-business hours.
NOTIFICATIONS:
Per Condition IV.13 of the Permit, any spill that reaches surface waters must be
reported by telephone to the Winston-Salem Regional Office at [phone] as soon
as possible, but in no case more than 24 hours.
The following procedures also all for sewage spill of 1,000 gallons or more to surface
waters of the State, per N.C.G.S. 143.215.1C. (Note: Conveyances such as drainage
ditches and storm sewers are considered waters of the State).
 For discharges of 1,000 gallons or more of untreated wastewater to
surface waters, issue a press release within 48 hours of first knowledge to
the Newspaper.
 For discharges of 15,000 gallons or more of untreated wastewater to surface
waters, shall publish a public notice captioned "NOTICE OF DISCHARGE OF
UNTREATED SEWAGE" within 10 days after NCDEQ has determined the
counties that are significantly affected by the discharge and approved the form
and content of the notice and the newspapers in which the notice is to be
published. See N.C.G.S. 143.215.1C for additional information.
REPORTING SSOs:
Before any SSO or bypass is reported to the State, the ORC or the Backup ORC must visit and
evaluate the spill site within 24 hours. Once the spill site has been evaluated by the ORC or the
Backup ORC, the responsible person should discuss the spill, determine estimated volumes and
causes before calling the Division within the 24 hour time frame.
Containment
Upon learning of such an occurrence, the first priority shall be to assess the situation and
mobilize resources necessary to remove the blockage or untreated discharge, contain the
SSO, and stabilize the overflow condition to the max extreme. Notification should be made
to the ORC at this time. As soon as the extent of the SSO or bypass has been determined, a
containment berm or a dam should be established at the lower edge of the SSO or bypass, or
at an area that meets the needs of containment and clean up operations. The containment dam
should be large enough to prevent breaching in dry weather conditions.
Force Main or Inaccessible Gravity Sewer Spill
In the event a spill occurs at a pump station with no bypass capability or at a force main or
gravity sewer where no access to a dump point exists, pump and haul or bypass operations
will be considered. Where pump and haul operations are deemed the best solution, sewer will
be collected from the closest tanker access point for continuous loading operations while
causing minimum environmental damage. Consideration should be made for traffic control,
noise, access, etc.
24 hour Pump Service Providers & Repair
1. Godwin Pumps Phone # [phone]
2. Blue Ridge Motor Repair Phone# [phone]
3. Charles R Underwood Phone# [phone]
24 hour Pump and Haul Tanker Services
1. Triple T Phone# [phone]
2. Appalachian Pumping Phone# [phone]
3. Doby's Septic Phone# [phone]
4. Envirolink, Inc. Phone# [phone]
**See attached Pump and Haul Record Form-Complete for each load
For Spills involving Asphalt or Concrete
1. Set up containment at or near any threatened storm drainage system; Every attempt
should be made to prevent the spill from entering the drainage structures.
2. Spread dry sand or absorbent material to a depth of 1 inch. Let stand for one hour and
sweep up. If moisture or grease is still present, repeat.
3. After removing the contaminated material, wash down the area with high water pressure
and a mild bleach solution and then pump residue back into the sewer system.
4. If the spill enters a storm drainage structure, a Reportable Spill has occurred and
therefore a Spill Report should be filed with NC DEQ and treated as a SSO affecting
Waters of the State. Reported volumes would include the initial estimated spill; plus any
flush water used; minus the calculated amount removed from storm drain system.
SSO or Bypass affecting Waters of the State
I. Take conductivity and dissolved oxygen readings of the receiving stream to determine the
proper placement of a darn within the intervals on the Conductivity Readings Form.
While taking the conductivity readings, be sure to notate them on the Spill &
Conductivity Reporting Form. The dam needs to be constructed near a manhole or at a
location which is accessible to the jet/vacuum truck. Placement of the dam should be at a
point where the lowest conductivity reading is measured.
2. Build the dam using dirt that is capable of handling creek and hydrant flow without
breaching during dry weather conditions. Position two pumps at the darn capable of
handling creek and hydrant flow with one pump in use and the second as backup. Have a
backhoe at the site with additional material at all times so that the earthen dam can be
rebuilt if a breach does occur. Pump SSO release from the dam into the manhole.
3. Put up warning tape, "Danger Do Not Enter" from the SSO site to the pump site on both
sides of the creek in populated areas. In unpopulated areas restrict access where there is
any chance of human contact with the SSO.
4. Flush the stream with de-chlorinated water from a sufficient number of hydrants to
remove the waste product from the creek. Continue to pump and flush the stream until the
conductivity measurements or readings are equivalent to upstream receiving stream or
hydrant water conductivity readings, whichever is higher. Make sure that all readings
taken during cleanup are recorded on the Spill & Conductivity Reporting Form and
taken within the intervals on the form.
5. If there is rip-rap in the creek, wash down with high water pressure until there is no
noticeable waste residue remaining on or within the rip-rap structure.
6. If the creek flows into a body of water used for recreation and/or drinking water supply,
notify the affected officials as soon as possible.
7. Continue periodic monitoring of conductivity and Dissolved Oxygen readings. All
additional readings should be notated on the Spill and Conductivity Reporting Form.
Take an upstream and downstream fecal coliform every 24 hours as needed until the
waterway is restored to pre-event condition.
SSO not reaching Waters of the State
I. In open areas spread powdered lime heavily over the spill site, till into the ground and then
repeat the procedure again but not within 24 hours of predicted rain fall event. Seed the
disturbed area and place straw over the tilled area. Soil may need to be removed and
replaced with clean fill material for a large spill where the ground has become saturated.
SSO REPORTING PROCEDURES
I. Upon discovery of a possible SSO or bypass, notify the ORC or Back up ORC
David Rogers (ORC) Cell# 828-734-1314
Matthew Hukill (Area Manager) Cell# 704-775-6128
Madelyn Mills (Public Notification Coord.) Office# 984-365-9160
2. The individuals listed above will be the Point of Contact between The Cottages of Boone
and NC DEQ or the Division of Emergency Management on SSO or bypass matters.
These individuals will report overflows from any sewer line or pump station, or the
bypass of any wastewater treatment system or any component thereof If Media
communications become apparent, the Executive Director will be the POC for all Media
questions.
3. Reportable spills must be called into NC DEQ (336-776-9800) within 24 hours of
first knowledge of discharge. Document on the Spill Report Form the date, time,
incident number and person contacted.
4. During weekends and holidays when DEQ cannot be reached, The Division of
Emergency Management will be called at 1-800-858-0368 providing the
information requested. Document on the Spill Report Form the date, time, and
person contacted. Upon arriving to work after the weekend or a holiday, DEQ
should be contacted to receive the incident number for the reported spill.
5. The ORC/Backup ORC should be notified immediately so they have an opportunity to
visually see the spill. This will allow the ORC/Backup ORC to provide better estimated
volumes. The ORC or the Backup ORC is also required by the Collection System
Permit to visit the spill site.
6. The ORC/Backup ORC must fill out the State approved Sanitary Sewer Overflow Form.
A legible copy will be faxed within five (5) days to NC-DEQ, Winston Salem Regional
office (336-776-9800). If the Director of Operations is unavailable, the ORC will ensure
that the necessary paperwork is completed. Records of spills, including those that are not
required to be reported will be maintained for at least three (3) years and will be made
available to NC-DEQ staff upon request.
AVAILABLE MATERIALS FOR SSO
Portable Generators
Drop Cords
Portable Electric Lights
Electric Submersible Pumps
Gas Mud Pumps
Powdered Limestone
Fire Hose Sections
6" By-Pass Pump
Sewer Jet
Vacuum Truck
Tractor Backhoe
Dump Trucks
Flex Suction/Discharge Hose
Air Compressor
Lime
Water Quality Stream Monitoring Devices
Dissolved Oxygen/pH/Conductivity Meter

SSO TELEPHONE CONTACT NUMBERS
NC-DEQ (Winston Salem Regional Office) 336-776-9800
NC Division of Emergency Management 1-800-858-0368
Envirolink, Inc. 252-235-4900
David Rogers (ORC) 828-734-1314
Christy Hodgen, (Manager, Cottages of Boone) 601-900-3599
Madelyn Mills (Public Notification Coordinator) 984-365-9160

Spill and Conductivity Reporting Form
Location of Spill: _____________________
Time of Spill: ______________ AM or PM
Time of Clearing Spill: ________ AM or PM

Date of Spill:

Date of Clearing Spill: _______________

Cause of Spill: __________________________________________________________
Did spill reach surface water?: Time ORC was notified:
Conductivity/DO Readings
Initial DO Initial
Conductivity
2nd
DO
2nd
Conductivity
3rd
DO
3rd
Conductivity
Entry Point
Time Recd.

50'
Downstream

Time Recd.

100'
Downstream

Time Recd.

150'
Downstream

Time Recd.

200'
Downstream

Time Recd.

250'
Downstream

Time Recd.
**Note: 2nd and 3rd readings are to be taken during cleanup.
**More readings may be necessary depending upon the size of the spill and the time period in
which the stream is being flushed to maintain water quality.

Pump and Haul Record
Date: Page of
Tanker
Company
Tanker
Capacity
Drivers
Name
License
Plate#
Destination Time
Loaded

Spill Incident Report Form
Facility: _________________________ Incident# ________________
Owner: The Cottages of Boone Region: Winston Salem Regional Office
City: _Boone _________________________County: Watuga ________________
Source of SSO __________ Sanitary Sewer _________ Pump Station
Specific Location of SSO (example: Lift Station # 1, manhole on Main Street, etc)
Incident Start Date: Time: AM or
PM
Incident End Date:

Time: AM or
PM
Estimated Duration rounded to the nearest hour __________ hour(s)
Estimated volume of the SSO ___________ gallons
Did SSO reach surface waters? _____ Yes _____ No
Volume reaching surface water ______ gallons
Surface Water Name Did the SSO result in a fish kill?
If so, what is the estimated number of fish killed?
Specific Cause of the SSO:
Natural Disaster _______ Grease _____________________ Roots
__ Inflow & Infiltration ____ Pump Station Equip Failure _____ Power Outage
Vandilism Debris in Line _______________ Other
Explaination: ________________________________________
Immediate 24-hour verbal notification reported to:
(Name) ______________________________________
____ DEQ ________ Emergency Management
Date: Time: AM or PM

Safety Standard Operating Procedures
For
Envirolink, Inc.
1.0 PURPOSE:
The purpose of this document is to clearly define objectives and safety standards for Envirolink, Inc.
operations personnel and The Cottages of Boone wastewater facility. These objectives and quality
standards are established as a framework to effectively carry out Envirolink, Inc.'s safety protocol and
safety of the system.
SAFETY MEASURES
Quality Standards
 All signage, gates, and security systems shall be inspected monthly. Deficient signs
and/or post shall be identified to the client in writing within 24 hours.
 Sign obstructions such as weeds, trees, shrubs, or other debris will be identified to the
client within 24 hours.
 Any damage or depreciation of signs, gates, and security
Safety Equipment
 Safety glasses
 Safety toe shoes
 DOT Class 3 Safety Vest
 Hearing Protection
 Work Gloves
Dos and Don'ts
 Never operate equipment on slopes greater than 15'
 Never mow on wet grass. Tires may lose traction causing loss of control
 Never place hands or feet near rotating parts or under machine
 Never wear loose clothing or jewelry
 Always wear required PPE
 Always maintain unit is a safe operating condition
Quality Standards
 Supervisors will ensure all personnel are trained in all safety procedures.
 Staff will be certified prior to operating any equipment
Safety SOP Created By: DLS Version: 01
SOP# Approved By: Date Created:
Hazard Identification
 Slips, Trips & Falls from debris, wet surfaces uneven terrain ...etc..
 Traffic
 Sharp waste material such as glass, nails, sticks ...etc.
 Seasonal Hazards (Temperature, Ice/Snow, Storms)
Safety SOP Created By: DLS Version: 01
SOP# Approved By: Date Created:
THE COTTAGES OF BOONE
ONSITE WASTEWATER SYSTEM
NOTES
SITE NOTES:
1. PROJECT ADDRESS: 615 FALLVIEW LANE, BOONE, NC 2860E
2,
TOTAL ACREAGE: 50.3MACRES
3. DEED BOOKAND PAGE: 1921, 0464
4, PROJECT PIN NUMBER(S): 2900-22-8691
S. EXISTING TOPO INFOSHOWN WAS PROVIDED BY: BROOKS ENGINEERING ASSOCIATES, PA
6. EXISTING BOUNDARY INFO PROVIDED BY: BROOKS ENGNEERING ASSOCIATES, PA
1. LATITUDE / LONGITUDE: 36.2D5133, 41.103993
GENERAL NOTES:
1. CONTRACTOR SHALL PROTECT ADJACENT PROPERTIES, THE GENERAL PUBLIC AND ALL OF THE OWNER'S
FACILITIES AND SHALL BE RESPONSIBLE FOR THE REPAIR OF ALL DAMAGES WHICH OCCUR DURING
CONSTRUCTION.
2. LOCATION OF ALL EXISTING UTILITIES, AS SHOWN HEREON, ARE APPROXIMATE ONLY. NO GUARANTEE IS
MADE OR TAME 0 BY THE LOCATION REFLECTED IN THE PLANS. IT IS THE CONTRACTOR'S
RESPONSIBILITY TO VERIFY THEME, SIZE AND LOCATION OF ALL UTILITIES AND OTHER FEATURES
WHICH MAY AFFECT CONSTRUCTION OR THE INTENDED FUNCTION OF THE DESIGN. CONTRACTOR SHALL
NOTIFY DESIGNER PRIOR TO CONSTRUCTION IF EXISTING CONDITIONS DIFFER FROM THAT INDICATED
IN THE PLANS.
3. NOS TREAM OR WETLAND DISTURBANCE SHALL OCCUR WITHOUT A ARMY CORPS OF ENGINEERS PERMIT.
9. THE ESCAPE OF SEDIMENT FROM THE SITE SHALL BE PREVENTED BY THE INSTALLATION OF EROSION
CONTROL MEASURES AND PRACTICES MUOR TO, OR CONCURRENT WITH, LAND DISTURBING ACTIVITIES.
5. ANY EXCESS CUT MATERIAL DEVELOPED IN THE CONSTRUCTION OF THIS SITE SHALL BE DISPOSED OF QI
AN APMROPMTELY PERMITTED SPOIL SITE. CONTRACTOR TO PROVIDE PROOF OF PERMITS PRIOR TO
CONSTRUMDN.
6, ANY ALTERATION TO THE PUNS MUST BE APPROVED BY THE PROJECT ENGINEER, OR APPROPRIATE
AGENCY PRIOR W THE COMMENCEMENT OF WORK.
1, THE CONTRACTOR SHALL OBTAIN, AND PAY FOR, PRIOR TO BEGINNING ANY WORK, ALL PERMITS AND
LICENSES NECESSARY TO ACCOMPLISH THE WORK.
8. CONTRACTOR(5) SHALL BE RESPONSIBLE FOR ADEQUATE SUPERVISION TO PREVENT DAMAGE AND
MOVEMENT FROM EQUIPMENT WORKING AROUND CONSTRUCTION STAKES, THESE CONSTRUCTION
STAKES SHALL REMAIN IN PLACE AND BE PROTECTED UNTIL OWNER APPROVES THEIR REMOVAL. ANY
STAKES THAT HAVE BEEN DISPLACED AS A RESULT OF CONSTRUCTION ACTIVITY ARE TO BE REPLACED
BY A LICENSED LAND SURVEYOR ENGAGED BY THE CONTRACTOR AT NO COST TO THE OWNER.
9. THE ENGINEER WILL NOT BE CONTINUOUSLY PRESENT IN THE FIELD, IT IS SPECIFICALLY UNDERSTOOD
THAT HE DOES NOT UNDERTAKE NOR ASSUME ANY OBLIGATION FOR SUPERVISION OF CONSTRUCTION,
SAFETY MEASURES TAKEN DURING THE COURSE OF CONSTRUCTION, RESPONSIBILITY FOR SCHEDULING
THE WORK FOR INSURING COMPLETE COMPLIANCE WITH THE CONTRACT DOCUMENTS AND/OR ALL CODE
REQUIREMENTS, RULES AND REGULATION OF ANY PUBLIC OR PRIVATE AUTHORITY HAVING
JURISDICTION OVER THE WHOLE OR ANY PART OF THE WORK. MAMMON, THE ENGINEER NETTHER
UNDERTAKES, ASSUMES, NOR GUARANTEES THE WORK AND/OR PERFORMANCE OF THE CONTRACTOR.
INSPECTION SCHEDULE:
1. NO CONSTRUCTION SMALL COMMENCE PRIOR TO A PRECONSDLUCTION MEETING WITH THE OWNER,
THE CONTRACTOR, THE ENGINEER, AND A REPRES MTATIVE OF THE APPROVING JURISDICTION.
2. ALL SHOP DRAWINGS SHALL BE SUBMITTED AT OR PRIOR TO THE PREWNSTRUCTION MEETING.
3. ENGINEER TO BE CALLED FOR PERIODIC INSPECTIONS.
4, CALL ENGNEEMNG PRIOR TO COVERING UNDERGROUND STRUCNREE FOR MNAL MSPECRONS,
5, REFER TO MANUFACTURERS SPEOMCATION MANUAL AND STATE AND LOCAL STANDARDS FOR
AODITIONAL REQUIREMENTS AND STANDARDS.
PROJECT MAP
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APARTMENTS
WATAUGA COUNTY 3
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CONTACTS
R
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CLIENT:
6
ENVIROLINK, INC.
ENGINEER:
BROOKS ENGINEERING ASSOCIATES, PA
)ONE
TO UNVILLEi\ NC 705 PROJECT SITE
NC/y
NC 321
NTS
VICINITY MAP
NC 705
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SURVEYOR:
BROOKS ENGINEERING ASSOCIATES, PA
NO.: TITLE:
WO C EET
PROCE955{d1EM4Tl^6 XYDMU
CONTACTINFO:
DON FELLER
OFELLER V E NVIROLIN KINCCOM
4700 HOMEWOOD COURT SUITE 108
RALEIGH, NC 21609
CONTACTINFO:
MARK BROOKS, PE
MBROONS®BROOKSBA.COM
828-2T14100
15 ARLINGTON STREET
ASHEVILLE, NC 2880E
IIdu'CS€><f7i 1*
PSEXTONGBROOKSEA,CON
82823E-9hJ0
15 ARLINGTON STREET
ASHEVILLE, NC 28801
SHEET INDEX
NO.: TITLE:
IC. -LE

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KEYNOTES:
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1 EQU0.LRARON TANK.
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PROPOSED 4':2':4" PVC SOH. 10 SUPPLY LINE FROM EQUALQARON TANK TO INFLUENT
SCREEN.
OINFLUENT SCREEN.
® BLOWERS.
OSCREENING PUMPSKID.
© MAIN POWER SUPPLY PANEL AND BACK UP POWER TRANSFER SWITCH.
O(2) ANOXIC REACTOR TANK.
O(2) AEROBIC REACTOR TANK.
OPOST ANOXIC REACTOR TANK.
10 MEMBRANE ENID ASSEMBLY.
SS MEMBRANE CIRCULATION PUMP SKID.
12 CHEMICAL FEED SKID.
13 BACKWASH SKID AND PERMEATE TANK.
14 UV SYSTEM.
Q-11-DIMETER.
1 IRRIGATION DOSE FILTRATION AND PUMP SKID,
/
S IRRIGATION DOSE TANK.
/
SB 2'x2' FL00R DRAIN (TYP.).
/
19 9' PYC DRAIN PIPE FROM FLOOR D-TO SUMP PUMP.
® TANK85UMPPUM1
/
Q 2" SCH. 40 PVC FROM GRINDER/SUMP PUMP TO EQUALIZATION TANK.
/
®Z 2" PVC DRAIN LINE FROM S-DAY UPSET TANK TO EQUALIZATION TANK,
QV PVC OPAIN LINE FROM L.DAY WET WEATHER TANK TO DOSE TANK.
® RAINWRDT" RAIN GOUGE TO INITIATE WET WEATHER STORAGE.
/
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WATER TREATMENT BUILMW(BY OTHERS).
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SWMPSTE0.
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3S W M STORMWATER DRAIN PIPE,
2 10" ADS STORM INLET 0YP.).
33 YARD INLET CTYP.).
3 18" DRAINAGE HDPE PIPE.
pSECURITY FENCING,
36 SLUDGE HOLDING TANK.
BACKUP ZO W GENERATOR.
PROPOSEDORBINOXMODEL20-3636RATRACTUATEDVALVE.
/
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3g PROPOSED 90% OUTLET PIPE, 2" SCH ED PVC WITH GATE VALVE AT
O
CONNECTION.
PROPOSED 4" DRAIN LINE FROM DRUM SCREEN ROOM
L41/ PROPOSED T" LINE FROM 90%OUTLET PERE TO TANK B SUMP PUMP
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EQUALIZATION
FORCE MAIN FROM TANK
COLLECTION SYSTEM
1=
AVG, FLOW = 72.9 GPM
PEAK FLOW = 145.8 GPM
SCHEMATIC FLOW DIAGRAM
NTS
15 GPM (S MIN.) — BACK FLUSH LINE FROM DISC FILTER
MBR
TURBIDI.
IRRIGATION
METER
DOSE TANK
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1.�
MAX. DOSE = 118.6 GPM
DISC SKID WET WEATHER STORAGE MAX FLUSH = 86,6 GPM
WITH PUMPS INITIATED BY HIGH WATER
LEVEL IN DOSE TANK DUE TO
CYCLE INTERUPTION BY RAIN
GAUGE
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WASTEWATER TREATMENT PLANT DETAILS -Environmental Services• �N.n�,x�.mn,

C::tTL SERIES 30
ORBINOX
VALVE SOLUTIONS IN MORE THAN 7E COUNTRIES
The TL (SER.30) model knife gate is a bi-directional wafer valve designed for media with high consistency.
The double seat design assures a non -clogging shut off on either normal or reverse flow. The valve is used in
a wide range of demanding applications in industries such as:
Pulp & Paper • Power Plants
Wastewater Treatment Plants • Etc.
Chemical plants
Sizes: DN 2"/50mm to DN 40"/1000mm (larger diameters on request)
Working pressure: DN 2"/ 50mm to DN 5"/ 125mm 150psi/(10 kg/cm2)
DN 6"/150mm to DN 10"/ 250mm 1 15psi/ (8 kg/cm2)
DN 12"/300mm to DN 16"/ 400mm 90psi/ (6 kg/cm2)
DN 18"/450mm 75psi/ (5 kg/cm2)
DN 20"/500mm to DN 24"/ 600mm 60psi/ (4 kg/cm2)
DN 28"/700mm to DN 40"/1000mm 30psi/ (2 kg/cm2)
Standard flange connection:
DIN PN 10 and ANSI B16.5 (class 150)
Other flange connections are available on request such as:
DIN PN 6 DIN PN 16 DIN PN 25
BS "D" and "E" ANSI 125
Directives:
For EU Directives and other Certificates, please see the document:
Directives and Certificates Compliance - Knife Gate Valves -
Catalogues and Datasheets
All valves are tested prior to shirmpina in accordance with the standard developed by the Quality Control Department at ORBINOX.
Part: Material:
1- Body GJL250 / GJS400 CF8M
2- Body GJL250 / GJS400 CF8M
3- Gate AISI 304 AISI 316
4-Seat Metal/Metal or EPDM
5- Packing PTFE Im re . Synth. Fibre (ST)+O-ring
6- Gland Follower AlunI 211/50mm to DN
12"/300mm)
Ductile Iron (DN 1411/350mm to
DN 40"11000mm)
CF8M
7- Seat Retainer Ring AISI 304 AISI 316
8- Yoke Carbon Steel - Epoxy Coated
9- Stem Stainless Steel
10- Stem nut Brass
11- Friction washer Brass
12- Handwheel GJS400 (GGG40)
13- Stem Protector Epoxy -coated Carbon Steel
14- Cap Plastic
15- Gasket Aramid fibres
16- Nut Zinc plated Carbon Steel
Reserves the right to change specifications without notice
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
www.orbinox.com
OBX 05/21
Rev.13
TL (SER.30)_1
TL SERIES 30
BODY:
Wafer style cast two-part bolted body, both internally machined, with reinforcing ribs in larger
diameters for extra body strength.
The stainless steel version valves include internal high density polyethylene sliders (HMWPE)
that ensure smoother gate traveling.
Full port design to allow a greater flow capacity and to guarantee a minimal pressure drop.
SELFCLEANING GATE:
Stainless steel as standard. One piece through -going gate with o-port design. When closing, the
gate cuts and moves a disc of material downwards, which is again returned to the flow when
opening. Gate is polished on both sides to avoid jamming and to ensure a greater seal between
the gate with both packing and seat.
The thickness and/or the material of the gate can be changed on request for higher pressure
requirement
SEAT: (resilient)
Unique design that mechanically locks the seal in the interior of the valve body with a
stainless steel retainer ring. Standard EPDM also available in different materials such as
Viton, PTFE, etc.
PACKING:
Double stuffing box with several layers of braided fibre plus an EPDM o-ring, with an easy
access and adjusting packing gland ensuring a tight seal. Long -life braided packing is
available in a wide range of materials.
STEM:
The standard stainless steel stem offers a long corrosion resistant life. For rising stem
handwheel actuators only, a stem protector is provided for additional protection against dust
while the valve is in the open position.
ACTUATORS:
All actuators supplied by ORBINOX are interchangeable, and supplied with a standard
mounting kit for installation purposes on site.
YOKE or ACTUATOR SUPPORT:
Made of EPDXY coated steel (stainless steel available on request). Compact design makes it
extremely robust even under the most severe conditions.
EPDXY COATING:
The epoxy coating on all ORBINOX cast iron and carbon steel valve bodies and components
is electrostatically applied making the valves to be corrosion resistant with a high quality
finished surface. The ORBINOX standard colour is RAL-5015 blue.
GATE SAFETY PROTECTION:
ORBINOX automated valves are provided with gate guards in accordance with EU Safety
Standards. The design feature prevents any objects from being caught accidentally while the
gate is moving.
ONLY IN EUROPE
Reserves the riqht to chanqe specifications without notice
ORBINOX
VALVE SOLInION5 IN MARE THAN 70 CQVNTRIES
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
OBX 05/21
Rev.13
TL (SER.30)_2
www.orbinox.com
1::FTL SERIES 30
Bonnet (Fig.1):
Assures tight seal to atmosphere for using with hazardous gas or fluids.
Reduces packing maintenance
Diamond port:
Excellent flow regulation.
Flush ports:
Allow for cleaning of solids trapped within the body cavities that can obstruct the
flow or prevent the valve from closing. Depending on the process, purging can be
made with air, steam, liquids, etc.
Other materials of construction:
Special alloys such as AISI 317 (1.4449), 254SM0 (1.4547), Hastelloys,
etc.
Fabricated valves:
ORBINOX designs, produces and delivers special fabricated valves for special process
conditions (big sizes and/or high pressures)
Square port (Fig.2):
Greater flow capacity for bulk material. Designed for equipment with square
flange connections
Fig.2
Reserves the riqht to chanqe specifications without notice
ORBINOX
VALVE sQIWIQN$ IN MARE THAN 70 CQUNTRIE$
Fig.1
Valve components can be protected or coated for a longer life expectancy,
depending on the application of the valves and the valve service conditions.
At ORBINOX we can offer alternative treatments and coatings for the different
valve components to improve their properties against abrasion (Stellite,
polyurethane...), against corrosion (Halar, Rilsan, galvanizing...) and against
adherence (polishing, PTFE... ).
We recommend to contact our technical department
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
OBX 05/21
Rev.13
TL (SER.30)_3
www.orbinox.com
EM TL SERIES 30
MANUAL:
Handwheel (rising stem)
Handwheel (non -rising stem)
Chainwheel
Bevel Gear
Lever
Others (square nut...)
All actuators supplied by ORBINOX are interchangeable
Used on pneumatic actuated valves
SINGLE ACTING (SPRING RETURN)
Available from
DN 211/50mm to DN 12"/300mm
Supply pressure:
min. 75 psi/ (5 kg/cm2)
max. 150 psi/ (10 kg/cm2)
Options:
Pneumatic or electric fail open T
Pneumatic or electric fail close
Other options on request
DOUBLE ACTING WITH AIR TANK
Available for all valve sizes
Supply pressure:
min. 50 psi / (3.5 kg/cm2)
max. 150 psi / (10 kg/cm2)
Options:
i
Pneumatic or electric fail open
Pneumatic or electric fail close
Other options on request
AUTOMATIC:
Electric (rising & non -rising stem)
Pneumatic (single & double-acting)
Hydraulic
Mechanical stops
Locking device
Manual override
Solenoid valves
Positioners
Limit switches
Proximity switches
Floor stands
Stem extensions
Wide range of valve extensions available
We recommend consultation with our technical department.
ORBINOX
VALVE SOLWIQN$ IN MARE THAN 70 CQUNTRIEs
OBX 05/21
Reserves the riqht to chanqe specifications without notice Rev.13
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL (SER, 30)_4
www.orbinox.com
C:3 T L SERIES 30
ORBINOX
VALVE sQIWIQNs IN MARE THAN 70 CQUNTRIEs
SEAT / SEALS PACKING
Metal/Metal >482 >250 High temp./Low tightness PTFE impregn. synth. fibre (ST) 482 250 2-13
EPDM (E) 248 120 Acids and non mineral oils Braided PTFE (TH) 500 260 0-14
NBR (N) 248 120 Resistance to petroleum products Graphited (GR) 1112 600 0-14
FKM-FPM (V) 392 200 Chemical service/High temp. Ceramic fibre (FC) 2192 1200 --
VMQ (S) 482 250 Food service/ High temp.
PTFE (T) 482 250 Corrosion resistance NOTE: all types include an elastomere O-ring (same material as seal),
excluding TH, GR and FC
More details and other materials under request
B
Cast Iron Stainless Steel
METAL / METAL
Used for applications with high temperature or applications where tight shutoff is not required. k
The stainless steel version includes HMW polyethylene seat sliders that ensure a smoother gate Ip
traveling 4,6r` Iw
I
DN 2"/50 - e/150 DN8"/200-24"/600
METAL / METAL, TYPE IIBII
Two replaceable reinforced "B" type rings (available in AISI 316, Ni-hard, CA15.... ) protect the
seat in abrasive services. HMW polyethylene seat sliders for smoother gate traveling (stainless steel
version only) rl
DN 2"/50 - ell50 DN 8"/200 - 24"/600
RESILIENT, TYPE "A"
The standard resilient seat design consists of an elastomer seal fixed to the valve body with a
replaceable stainless steel retainer ring. Temperature limitations according to seat material
selected. Verify the above chart or contact our technical department for more information.`
F
HMW polyethylene seat sliders for smoother gate traveling (stainless steel version only) Wi IT, a T
DN2"/50- ell 50 DN 8"/200 - 24"/600
RESILIENT, TYPE "B"
1
Resilient seat design with an elastomer seal fixed to the valve body with two reaplaceable +
reinforced seal retainer rings (available in AISI 316, Ni-hard, CA15,...) that protect the seat in V1
abrasive services. Temperature limitations according to seat material selected. Verify the above , [.
chart or contact our technical department for more information. HMW polyethylene seat sliders
for smoother gate traveling (stainless steel version only) DN 2"/50-6"/150 DN 8"/200-24"/600
DEFLECTION CONE "C"
Deflects the media away from any valve internal exposed parts such as gate guides, seats, etc.
Different types of material available such as AISI 316, CA15, Ni-Hard, etc. Installed at flow inlet,
deflection cones protect the seat. They slightly reduce the inlet bore and the face-to-face dimensions
also increase:
DN 2"/50mm to DN 10"/250mm X=0.35"/9mm ',I-!..
DN 12"/300mm to DN 24"/600mm X=0.47/12mm
OBX 05/21
Reserves the riqht to chanqe specifications without notice Rev.13
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL (SER, 30)_5
www.orbinox.com
CCJITL SERIES 30
Standard manual actuator
Consists of:
Handwheel: Epoxy coated Cast Iron
Floor stand
Stem
Stem nut
Stem protector
Available from DN 211/50mm to DN 241I/600mm
Options (on request):
Locking Device
Extensions
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNIRIE$
2"/50 1,57140 5,98/152 4/100 4,33/110 5,07/129 1,85/47 8,86/225 16,88/429 9,13/232 26/12
2,5"/65 1,57140 6,57/167 4/100 4,52/115 5,79/146 1,85/47 8,86/225 17,75/451 10,04/255 30/14
3"/80 1,96/50 7,16/182 4/100 4,88/124 6,37/162 1,85/47 8,86/225 18,74/476 12,20/310 35/16
411/100 1,96/50 7,95/202 4/100 5,52/140 7,36/187 1,85/47 8,86/225 20,35/517 14,44/367 44/20
5"/125 1,96/50 8,50/216 4/100 6/150 8,30/211 1,85/47 8,86/225 23,66/601 17,00/432 64/29
6"/150 2,36/60 9,48/241 4/100 6,89/175 9,33/237 1,85/47 8,86/225 25,67/652 19,56/497 77/35
8"/200 2,36/60 11,57/294 4,80/122 8,07/205 12,16/309 2,64/67 12,20/310 32,36/822 25/635 137/62
10"/250 2,75/70 14,01 /356 4,80/122 9,64/245 14,33/364 2,64/67 12,20/310 40,03/1017 30,59/777 197/89
12"/300 2,75/70 16,14/410 4,80/122 11,02/280 16,30/414 2,64/67 12,20/310 43,38/1102 35,62/905 242/110
14"/350 3,78/96 18,62/473 7,75/197 12/300 19,13/486 2,60/66 16,14/410 50,63/1286 41,22/1047 384/174
16"/400 3,93/100 21,18/538 7,75/197 13,77/350 21,10/536 2,60/66 16,14/410 54,56/1386 46,10/1171 586/266
18"/450 A,17/106 23,15/588 7,91/201 16,53/420 23,15/588 2,60/66 21,65/550 62,32/1583 51,22/1301 718/326
20"/500 4,33/110 25,43/646 7,91/201 17,71/450 25,51/648 2,60/66 21,65/550 65,86/1673 57,52/1461 820/372
24"/600 4,33/110 25,43/754 7,91/201 20,86/530 29,44/748 2,60/66 21,65/550 77,28/1963 67,36/1711 981/445
Reserves the right to change specifications without notice
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
OBX 05/21
Rev.13
TL (sER.30)_6
www.orbinox.com
CM:TL SERIES 30
Recommended for installation where space is limited
Consists of:
Handwheel
DN 21I/50mm - DN 121I/300mm: aluminium
DN >141I/350mm: GJS400 (GGG40)
Stem
Yoke bushing
Stem nut fixed to the gate
Available from DN 211/50mm to DN 241I/600mm
Options (on request):
Locking Device
Extension
Square Nut Drive
x
kQ
C
air,
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNIRIE$
2"/50 1,57140 5,98/152 4,92/125 4,33/110 5,66/144 2,48/63
OG
8,86/225
H
12,48/317 9,13/232
2,5"/65 1,57140 6,57/167 4,92/125 4,52/115 6,33/161 2,48/63 8,86/225 13,34/339 10,04/255
3"/80 1,96/50 7,16/182 4,92/125 4,88/124 6,96/177 2,48/63 8,86/225 14,33/364 12,20/310
4"/100 1,96/50 7,95/202 4,92/125 5,52/140 7,95/202 2,48/63 8,86/225 15,94/405 14,44/367
5"/125 1,96/50 8,50/216 4,92/125 6/150 8,89/226 2,48/63 8,86/225 17,28/439 17,00/432
6"/150 2,36/60 9,48/241 4,92/125 6,89/175 9,92/252 2,48/63 8,86/225 19,29/490 19,56/497
8"/200 2,36/60 11,57/294 5,60/142 8,07/205 12,48/317 2,87/73 12,20/310 23,42/595 25/635
10"/250 2,75/70 14,01/356 5,60/142 9,64/245 14,64/372 2,87/73 12,20/310 27,16/690 30,59/777
12"/300 2,75/70 16,141410 5,60/142 11,02/280 16,61/422 2,87/73 12,20/310 30,51/775 35,62/905
14"/350 3,78/96 18,62/473 7,75/197 12/300 20,03/509 3,85/98 16,141410 35,71/907 41,22/1047
16"/400 3,93/100 21,18/538 7,75/197 13,77/350 22,00/559 3,85/98 16,14/410 39,64/1007 46,10/1171
18"/450 A,17/106 23,15/588 7,91/201 16,53/420 24,05/611 3,85/98 21,65/550 44,44/1129 51,22/1301
20"/500 4,33/110 25,43/646 7,91/201 17,711450 26,41/671 3,85/98 21,65/550 47,99/1219 57,52/1461
24"/600 4,33/110 25,43/754 7,91/201 20,86/530 30,35/771 3,85/98 21,65/550 55,07/1399 67,36/1711
Reserves the right to change specifications without notice
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
OBX 05/21
Rev.13
TL (SER.30)_7
www.orbinox.com
CM:TL SERIES 30
Recommended for elevated installations
Consists of:
Chainwheel: Epoxy coated Cast Iron
Stem
Stem nut
Stem protector
Available from DN 211/50mm to DN 241I/600mm
Options (on request):
Locking Device
Extension
Non -rising Stem
k
a
C
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNIRIE$
2"/50 1,57140 5,98/152 3,94/100 4,33/110 5,07/129 10,15/258
00
8,86/225
A
16,88/429 9,13/232
2,5"/65 1,57140 6,57/167 3,94/100 4,52/115 5,79/146 11,02/280 8,86/225 17,751451 10,04/255
3"/80 1,96/50 7,16/182 3,94/100 4,88/124 6,37/162 12/305 8,86/225 18,74/476 12,20/310
4"/100 1,96/50 7,95/202 3,94/100 5,52/140 7,36/187 13,66/347 8,86/225 20,39/518 14,44/367
5"/125 1,96/50 8,50/216 3,94/100 6/150 8,30/211 14,96/380 8,86/225 23,66/601 17,00/432
6"/150 2,36/60 9,48/241 3,94/100 6,89/175 9,33/237 16,97/431 8,86/225 25,66/652 19,56/497
8"/200 2,36/60 11,57/294 4,8/122 8,07/205 12,16/309 21,18/538 12/300 32,36/822 25/635
10"/250 2,75/70 14,01 /356 4,8/122 9,64/245 14,33/364 24,92/633 12/300 40,04/1017 30,59/777
12"/300 2,75/70 16,14/410 4,8/122 11,02/280 16,30/414 28,26/718 12/300 43,38/1102 35,62/905
14"/350 3,78/96 18,62/473 7,75/197 12/300 19,13/486 32,20/818 17,87/454 50,59/1285 41,22/1047
16"/400 3,93/100 21,18/538 7,75/197 13,77/350 21,10/536 36,14/918 17,87/454 54,52/1385 46,10/1171
18"/450 4,17/106 23,15/588 7,91/201 16,53/420 23,15/588 40,94/1040 17,87/454 62,09/1577 51,22/1301
20"/500 4,33/110 25,43/646 7,91/201 17,711450 25,51/648 44,48/1130 17,87/454 65,82/1672 57,52/1461
24"/600 4,33/110 25,43/754 7,91/201 20,86/530 29,44/748 51,57/1310 17,87/454 77,24/1962 67,36/1711
OBX 05/21
Reserves the right to change specifications without notice Rev.13
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL (SER.30)_8
www.orbinox.com
CM:TL SERIES 30
Recommended for valves larger than DN 14°/350mm and
working pressures greater than 50psi/(3.5 kg/cm2)
Consists of:
Stem
Yoke
Bevel Gear Actuator with Handwheel
Standard Ratio 4:1)
Available from DN 811/200mm to DN 241I/600mm
Options (on request):
Locking Device
Extension
Chainwheel
Non -rising stem
x
C
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNIRIE$
8"/200 2,36/60 11,57/294 4,80/122 8,07/205 12,16/309 23,00/584 12/300 39,13/994 7,87/200 25/635
10"/250 2,75/70 14,01/356 4,80/122 9,64/245 14,33/364 26,73/679 12/300 42,87/1089 7,87/200 30,59/777
12"/300 2,75/70 16,14/410 4,80/122 11,02/280 16,30/414 29,29/744 12/300 45,43/1154 7,87/200 35,62/905
14"/350 3,78/96 18,62/473 7,75/197 12/300 19,13/486 32,91/836 18/450 60,47/1536 10,62/270 41,22/1047
16"/400 3,93/100 21,18/538 7,75/197 13,77/350 21,10/536 36,85/936 18/450 64,40/1636 10,62/270 46,10/1171
18"/450 4,17/106 23,15/588 7,91/201 16,53/420 23,15/588 41,65/1058 18/450 69,21/1758 10,62/270 51,22/1301
20"/500 4,33/110 25,43/646 7,91/201 17,71 /450 25,51 /648 45,19/1148 18/450 72,75/1848 10,62/270 57,52/1461
24"/600 4,33/110 25,43/754 7,91/201 20,86/530 29,44/748 52,28/1328 18/450 79,84/2028 10,62/270 67,36/1711
OBX 05/21
Reserves the right to change specifications without notice Rev.13
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL (SER.30)_9
www.orbinox.com
CM:TL SERIES 30
The standard pneumatic actuator (double acting on -off cylinder) consists on:
0 < 12"/ 300mm: Aluminum barrels
O > 14"/ 350mm: Composite barrels
Aluminum end covers
Stainless Steel (AISI 304) piston rod
Nitrile coated steel piston
Available from DN211/ 50mm to DN 24"/600mm
x
Supply Pressure: min. 50psi/(3,5 kg/cm2) - max. 150psi/(10 kg/cm2).
Actuator designed with 90psi/(6 k9/cm2) air supply
For valves installed in a horizontal position, we recommend Utype support
plates and/or actuator support
Options (on request):
Hard anodized barrel and covers
Stainless Steel barrel and covers
Over / Undersized cylinder
Manual override a
Fail Safe System c
Limit switches
Instrumentation (on request):
Positioners
Solenoid valves
Flow regulators
Air preparation units
G
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNWIE$
2"/50 1,57/40 5,98/152 4/100 4,33/110 9,13/232 5,07/129 7/178 4,53/115 16,41/417 30/14 C4"-2.44"/(100-62) 114"G
2,5"/65 1,57/40 6,57/167 4/100 4,52/115 10,04/255 5,79/146 7,60/193 4,53/115 17,87/454 35/16 C4"-3.03"/(100-77) 114" G
3"/80 1,96/50 7,16/182 4/100 4,88/124 12,20/310 6,37/162 8,31/211 4,53/115 19,56/497 40/18 C4"-3.74/(100-95) 114"G
4"/100 1,96/50 7,95/202 4/100 5,52/140 14,44/367 7,36/187 9,09/231 4,53/115 21,96/558 51/23 C4"-4.52"/(100-115) 114"G
5"/125 1,96/50 8,50/216 4/100 6/150 17,00/432 8,30/211 10,67/271 5,51/140 24,88/632 75/34 CS"-5.52"/(125-143) 4"G
6"/150 2,36/60 9,48/241 4/100 6,89/175 19,56/497 9,33/237 11,65/296 5,51/140 27,87/708 90/41 CS"-6.61"/(125-168) 4" G
8"/200 2,36/60 11,57/294 4,80/122 8,07/205 25/635 12,16/309 14,09/358 6,89/175 34,33/872 160/73 C6.30"-8.66"/(160-220) 1/a' G
10"/250 2,75/70 14,01/356 4,80/122 9,64/245 30,59/777 14,33/364 16,85/428 8,66/220 40,82/1037 231/105 C8"-10.62"/(200-270) 3/8" G
12"/300 2,75/70 16,14/410 4,80/122 11,02/280 35,62/905 16,30/414 18,82/478 8,66/220 46,1All 172 282/128 C8"12.60"/(200-320) 3/8" G 14"/
350 3,78/96 18,62/473 7,75/197 12/300 41,22/1047 20,08/510 21,61/549 10,90/277 53,50/1359 456/207 C10"-14.76-/(250-375) 3/8" G 16"/
400 3,93/100 21,18/538 7,751197 13,77/350 46,10/1171 22,05/560 23,58/599 10,90/277 59,40/1509 662/300 C10"-16.73"/(250-425) 3/8" G 18"/
450 4,17/106 23,15/588 10,63/270 16,53/420 51,22/1301 23,94/608 26,77/680 15,03/382 67,24/1708 833/378 C12"-18.70"/(300-475) 1/2" G 20"/
500 4,33/110 25,43/646 10,63/270 17,71/450 57,52/1461 26,30/668 28,74/730 15,03/382 72,75/1848 981/445 C12"-20.67"/(300-525) 1/2"G 24"/
600 4,33/110 25,43/754 10,63/270 20,86/530 67,36/1711 31,33/796 34,64/880 17,48/444 86,85/2206 1365/619 C14"-24.60"/(350-625) 3/4" G Reserves
the right to change specifications without notice ORBINOX
CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, www.
orbinox.com ORBINOX
INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL OBX
05/21 Rev.
13 SER.
30)_1 0
C::PrTL SERIES 30
Consists of:
Electric motor
Rising stem
Motor support yoke
acc. to ISO 5210/DIN 3338
The standard electric motor is equiped with:
Manual emergency operation
Limit switches (open/closed)
Torque switches
Available from DN 211/50mm to DN 24'I/600mm
For valves installed in a horizontal position, we recommend
U type support plates and/or actuator support
Wide range of types and brands available to meet
customer's needs
Option:
Non rising stem
ORBINOX
VALVE $OL1/rION$ IN MARE 1 70 COUNIRIE$
2"/50 1,57/40 5,98/152 4/100 4,33/110 5,07/129 14,05/357 6,30/160 20,74/527 9,13/232 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 7.4/10
2,5"/65 1,57/40 6,571167 4/100 4,52/115 5,79/146 14,92/379 6,30/160 21,61/549 10,04/255 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 7.4/10
3"/80 1,96/50 7,16/182 4/100 4,88/124 6,37/162 15,90/404 6,30/160 22,59/574 12,20/310 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 7.4/10
4"/100 1,96/50 7,95/202 4/100 5,52/140 7,36/187 17,51/445 6,30/160 24,21/615 14,44/367 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 7.4/10
5"/125 1,96/50 8,50/216 4/100 6/150 8,30/211 18,85/479 6,30/160 25,55/649 17,00/432 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 11.1/15
6"/150 2,36/60 9,48/241 4/100 6,89/175 9,33/237 20,86/530 6,30/160 43,30/1100 19,56/497 10,43/265 9,80/249 2,44/62 9,37/238 0.79 x 0.16/20 x4 18.44/25
8"/200 2,36/60 11,57/294 4,80/122 8,07/205 12,16/309 24,88/632 6,30/160 49,29/1252 25/635 10,43/265 9,80/249 2,44/62 9,37/238 0.98 x 0.2/25x5 25.81/35
10"/250 2,75/70 14,01/356 4,80/122 9,64/245 14,33/364 29,09/739 7,87/200 51,93/1319 30,59/777 11,14/283 10/254 2,55/65 9,76/248 0.98 x 0.2/25 x5 44.25/60
12"/300 2,75/70 16,14/410 4,80/122 11,02/280 16,30/414 32,44/824 7,87/200 55,47/1409 35,62/905 11,14/283 10/254 2,55/65 9,76/248 0.98 x 0.2/25 x5 51.63/70
14"/350 3,78/96 18,62/473 7,75/197 12/300 20,07/510 37,00/940 7,87/200 60,04/1525 41,22/1047 11,14/283 10/254 2,55/65 9,76/248 1.38 x 0.24/35x6 73,75/100
16"/400 3,93/100 21,18/538 7,75/197 13,77/350 22,04/560 42,71/1085 12,40/315 65,74/1670 46,10/1171 15,31/389 13,22/336 3,58/91 11,25/286 1.38 x 0.24/35 x6 103.25/140
18"/450 4,17/106 23,15/588 10,63/270 16,53/420 23,94/608 47,36/1203 12,40/315 70,98/1803 51,22/1301 15,31/389 13,22/336 3,58/91 11,25/286 1.38 x 0.24/35 x6 132.77/180
20"/500 4,33/110 25,43/646 10,63/270 17,711450 26,30/668 50,90/1293 12,40/315 74,52/1893 57,52/1461 15,31/389 13,22/336 3,58/91 11,25/286 1.38 x 0.24/35x6 125.38/170
24"/600 4,33/110 25,43/754 10,63/270 20,86/530 31,33/796 59,25/1505 12,40/315 86,81/2205 67,36/1711 15,31/389 13,22/336 3,58/91 11,25/286 1.38 x 0,24/35x6 162.26/220
OBX 05/21
Reserves the right to change specifications without notice Rev.13
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A. TL (SER,30)_1 1
www.orbinox.com
COFTL SERIES 30
ANSI B16.5, class 150
42" 4 3/n" 5/8" - 11 UNC 7/16" 4 - 0
2 1/2" 51/2" 4 5/8" - 11 UNC 7/16" 4 - 0
3" 6" 4 5/8" - 11 UNC 9/16" 4 - 0
4" 71/2" 8 5/8" - 11 UNC 9/16" 4 - 4
5" 8 1/2" 8 3/4" - 10 UNC 9/16" 4 - 4
6" 91/2" 8 3/4" - 10 UNC 11 /16" 4 - 4
8" 11 3/a" 8 3/4" - 10 UNC 11 /16" 4 - 4
10" 141/4" 12 7/8" - 9 UNC 7/9" 8 4
12" 17" 12 7/8" - 9 UNC 7/9" 8 4
14" 18 3/4" 12 1" - 8 UNC 7/9" 8 4
16" 21 1/4" 16 1" - 8 UNC 1 1 /8" 12 4
18" 22 3/4" 16 1 1 /8" - 7 UNC 7/9" 12 4
20" 25" 20 1 1 /8" - 7 UNC 1 1 /4" 16 4
24" 291/2 " 20 1 1 /4" - 7 UNC 1 " 16 - 4
EN 1092-2 PN 10
50 125
a"
M-16 11 4 04
65 145 4 M-16 11 4 - 0
80 160 8 M-16 14 4 4
100 180 8 M-16 14 4 4
125 210 8 M-16 14 4 4
150 240 8 M-20 18 4 4
200 295 8 M-20 18 4 4
250 350 12 M-20 22 8 4
300 400 12 M-20 22 8 4
350 460 16 M-20 28 12 -4
400 515 16 M-24 28 12 -4
450 565 20 M-24 32 16 -4
500 620 20 M-24 32 16 -4
600 725 20 M-27 25 16 -4
Reserves the right to change specifications without notice
ON 2"-3"
CS
ON 1fi"-1 El"
T
Zd
ON 50-65
n o
ON 350-400
n o
ORBINOX
VALVE $OL1/rION$ IN MARE 1HAN 70 COUNWIE$
N C-S" ON 1C"-14"
ON 20"-24"
7
BLIND TAPPED HOLES
THROUGH HOLES
ON SO-90D
ono
ON 450-600
DIN 550-300
ono
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL, ORBINOX CHILE, ORBINOX PERU, ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
OBX 05/21
Rev.13
TL (SER.30)-12
www.orbinox.com
4d - ;Y ..
i _
C" "1
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