Manual for

operators

Effluent Treatment Plant

Written by Faye Milroy, Prior Training.

Technical assistance was provided by John Karounos, Brian Jeffrey, Tad Plata and
Paul Pedretti from Geelong Wool Combing Ltd.

April 2003
Contents

Section 1: Introduction 1
1.1 The training program 1
1.2 The top-making process at GWC 2
1.3 Overview of the ETP process 3
1.4 Operator tasks 7
1.5 The Environmental Management System 8
1.6 Word list 9

Section 2: Occupational Health and Safety 10

2.1 General safety procedures 10
2.2 Safety in the ETP 12

Section 3: ETP equipment and functions 14

Section 4: Operating procedures 18

4.1 Suggested shift routine 18
4.2 Wool wax recovery 21
4.3 Operating the Alfa-Laval FVSX-510X (Separators) 24
4.4 Operating the Alfa-Laval FUVPX-407 (Concentrators) 27
4.5 Operating the Alfa-Laval FUVPX-407 (Purifier) 29
4.6 Operating the scour liquor decanters 31
4.7 Preparation of the polymer solution 33
4.8 Operating the bio-decanter 34
4.9 Sampling and testing procedures 37

Section 5: Documentation 39

Section 6: Maintenance and troubleshooting 41

6.1 Normal operating conditions 41
6.2 Using the SCADA as a diagnostic tool 42
6.3 Troubleshooting the Alfa-Laval separators 44
6.4 Regular maintenance and cleaning 45

Section 7: Assessment 46
7.1 The assessment procedure 46
7.2 Checklist of operator tasks 47
7.3 Oral questions – ETP operator 49
 ETP Operator Manual

Section 1: Introduction
1.1 The training program

The purpose:

To train you to operate and monitor the Effluent Treatment Plant (ETP) efficiently and
safely, with little supervision in accordance with company enterprise agreements.

Training objectives:

At the end of this training the operator will be able to:

1. explain the function of the ETP
2. explain and demonstrate the major duties of the ETP operator, including
a. materials handling
b. documentation and communication
c. monitoring ETP functions
d. monitoring quality and taking samples
e. operating and adjusting ETP equipment
f. labelling and preparing drums
g. chemicals handling
h. following safety procedures
i. performing basic maintenance

Assessment methods:

1. practical demonstration of competency on the ETP equipment, according to the

checklist at the back of this manual
2. satisfactory answers to oral test questions relating to ETP operations and the
monitoring of ETP functions

Note that an ETP operator needs to have:

• a dogman’s licence
• a forklift licence
• a basic boiler operation certificate

April 2003 1

1.2
1. Receivals/Wool Store
• Bale specifications are checked.
• Bale lots stacked together.
6. Gilling (3 stages)
• Blends a number of slivers together.
• Makes the fibres parallel.
• Forms a sliver of even thickness.
• Forms a sliver of desired weight.
7. Combing
• Removes short fibres and small tangles
(neps).
• Removes remaining vegetable matter.
• Blends many slivers into one.
• Makes fibres parallel.
ETP Operator Manual
The top-making process at GWC
2. Opening and blending 3. Scouring
• Compacted bales are opened. • Wool is washed in detergent to remove
• Wool bales are blended into lots. grease, sweat and dirt.
• Wool is rinsed and dried.
• Wool blended and anti-static oil added
5. Carding
• A machine with a series of rollers
covered with metal pins.
• 4. Effluent treatment
Untangles clumps of wool into
individual fibres. • Wool grease is extracted for lanolin.
• Sludge is removed for compost.
• Removes vegetable matter and dust.
• Begins to make fibres parallel. • Cleaner effluent is released to sewer.
• Forms wool into a continuous sliver.
8. Finishing (2 stages)
• Completes process of blending and 9. Pressing
making fibres parallel. • The tops are compressed into bales for
• Forms sliver of desired weight and despatch.
evenness. • Waste by-products are also pressed into
• bales for sale.
Winds sliver into a top or bump.
10. Despatch to customers
April 2003 2
 ETP Operator Manual

1.3 Overview of the ETP process

A typical bale of greasy wool might contain:

wool fibre 55-65%

moisture 5-10%
wool grease 12-15%

suint 5-8%

dirt, soil 10%

vegetable matter 2-5%

Most of the dirt, suint (pronounced ‘swint’) and grease are removed during the scouring
process. The scouring line has seven bowls through which the wool passes.

Two liquor streams are created at the scour:

• Stream 1 is the 'heavy phase' containing heavy contaminants such as dirt and sand.
• Stream 2 is an emulsion (water and oil mix), rich in woolgrease.

Bowl 1 is the de-suint bowl where the heavy contaminants are removed from the wool, and
combined with the underflow liquors of wash bowl 4 and the rinse bowls 5, 6, & 7.

It is important that bowl 1 temperature is maintained between 220C - 250C. If it is below

220C the wool mat will cool down and lower the effectiveness of wash bowl 2. If the
temperature is above 250C it will melt the woolgrease and result in low recovery rates in
the ETP.

Bowls 2,3 & 4 are wash bowls which are heated to 650C, with detergent added to bowls 3
& 4. This provides ideal conditions for removal of the woolgrease, creating a grease
enriched emulsion.

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 ETP Operator Manual

The two scour streams follow a separate path through the ETP and are subsequently treated
differently due to their makeup. First the liquor from each stream is run through a
noggerath. This is a rotating drum strainer/filter that removes wool fibres and some
vegetable matter. The greasy stream then goes into the South pit while the heavy stream
goes into the North pit.

WOOL

Flow chart of the scour liquor streams

From the North pit the heavy stream passes through the primary and secondary sand traps,
causing the heavy particles to settle before being removed to the compost plant. The liquor,
with unrecoverable woolgrease and small particles that will not settle readily is then fed
into the aerated biological tanks for further treatment before being discharged to the sewer.

Heavy stream flow chart

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 ETP Operator Manual

Wool wax recovery

From the South pit the greasy liquor is pumped into a 100m3 buffer tank, before being
pumped to the wool wash decanter where the dirt and sand is removed, resulting in a
sludge that is directed to the compost plant.
The resulting clean liquor or ‘centrate’ gravitates into the centrate sump. This is the first
step in the separation and concentration of the wool wax.
The Alfa Laval separators use centrifugal force to progressively remove water and increase
the grease concentration from less than 10% to more than 99%. The water is separated off
and directed to the aeration tanks. The wool wax is fed into a drum for storage.

Flow chart of the grease recovery process

The aeration tanks therefore contain the balance of the effluent from the rinse and grease
streams. This liquid contains detergent, fibres and plant matter that provide food for the
bacteria, called the biological load. These bacteria require oxygen, which is circulated into
the aeration tanks via the turbine blowers.

The treated liquor then passes to the settling tank or clarifier. Here the sludge, sand and
bacteria sink to the bottom while the clarified water is discharged into the sewer.

The sludge passes to the thickener where the material settles further. The upper liquid layer
is then redirected back to the aeration tanks. The settled sludge goes to the bio-decanter for
dewatering, where some of it is recycled back to the aeration tanks to replenish the
bacteria. The rest of the sludge is directed to the compost plant.

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 ETP Operator Manual
Flow chart of the ETP process

April 2003 6
 ETP Operator Manual

1.4 Operator tasks

The duties for the ETP operator include:

1. Conducting materials handling

• use a forklift and overhead crane
• fill, change and move grease drums
• handle bulk chemicals

2. Working with documentation

• read and maintain ETP records
• read and apply MSDS requirements
• ISO 14001 and EMS

3. Communicating with others

• explain ETP functions and operations
• ETP/topsoil operators, other GWC personnel and visitors

4. Working without supervision

• plan and prioritise own work

5. Interpreting and monitoring ETP technology

• control panels and Mimic boards in ETP office
• SCADA computer program

6. Operating and adjusting ETP equipment

• noggerath
• sand trap
• decanters
• separators
• Floc tank
• aeration tanks and blowers
• clarifier
• thickener
• heat exchanger
• boiler room
• water softener room

7. Conducting basic maintenance

• regular cleaning and lubrication
• fixing basic problems

8. Monitoring ETP quality

• regular sampling and testing of liquor, sludge and grease

9. Following safe work practices

• use appropriate personal protective equipment
• observe GWC safety procedures

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 ETP Operator Manual

1.5 The Environmental Management System

GWC was the first wool processor in the world to obtain certification to the Environmental
Standard ISO 14001 on the 22nd January 1998. Why is GWC concerned about
environmental management?

• Legal Requirements
There are various agreements and regulations relating to the environment which
have to be followed so that GWC can lawfully carry on its activities at Lara.

• Marketing Demands
Certain clients require GWC to offer proof that our operations are carried out in a
manner that does not harm the environment.

• Cost Savings
Reduction in waste and recycling should deliver cash savings.

• Neighbourhood Relations
GWC can have an effect on neighbours from the emission of noise, dust or
odours. We have procedures in place to monitor each of these impacts.

Several environmental procedures and work instructions cover the ETP. Your trainer will
take you through the procedures and work instructions related to your job.

It is your responsibility to follow these procedures, and to report any environmental

accident or incident.

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 ETP Operator Manual

1.6 Word list

Pumping air into liquors to maintain healthy bacterial activity

Aeration
and aerobic conditions

The resulting sludge from biological treatment of scouring

Bio-Sludge
liquors

m³ Abbreviation for cubic metre

Centrifugal Rotating force usually relating to pumps or separators

Centrate A liquor which has had solids removed

Effluent A treated stream which is released to sewer

Emulsion A mixture of woolgrease, water and detergent

Floc A settled particle after biological or chemical treatment

A process by which suspended solids are treated to encourage

Flocculation
settling

A process diagram engraved onto a laminated panel with

Mimic Panel
status indication of various treatment processes

MSDS Material Safety Data Sheets

Polyelectrolyte A chemical used to assist in separation or settling

Polymer Refer Polyelectrolyte

SCADA Supervisory Control and Data Acquisition

Sediment The resulting sludge when scour liquors are allowed to stand

Settle-ability A measure of the effectiveness of Bio-activity

A chemical used to settle out calcium and magnesium salts

Water softener found in mains water, thereby increasing the effectiveness of
scour detergent

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 ETP Operator Manual

Section 2: Occupational health and safety

2.1 General safety procedures
Personal protective equipment
Hearing protection must be worn in the production areas, to protect
your ears from machinery noise.
Sound can damage your ears if it is too loud, too high, or you are
exposed too often.
With some noise your ears will hurt straight away, with other noise
the damage to your ears will happen over time.

You will not "get used to the noise."

You will get used to your loss of hearing!

Remember, once your ears are damaged they never get better.

Rigger's gloves are provided where required for manual work.

Rubber safety gloves are provided when handling certain chemicals

and harmful substances.

Certain tasks require eye protection or breathing protection, or both.

For example, eye and breathing protection must be worn while

performing any cleaning task that causes fibres or dust to circulate in
the air.

Face protection may also be necessary when handling certain

chemicals, to prevent being splashed or breathing in fumes.

Safety boots must be worn in all production areas.

In certain work areas such as the boiler room and when handling
chemicals, long trousers must be worn - not shorts.

Long hair should be tied back or covered when working near

machinery.

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 ETP Operator Manual

Heavy lifting
• Keep your back straight and let your legs do the lifting

Hot surfaces
• Beware of burns from hot equipment, pipes and liquids.

Slips, falls
• Take care when moving around the plant. Wet floors and
steps can be slippery.

Emergency stops
• Know where the on/off and emergency stop buttons are
located, in case of emergency.

Lock out/tag out procedure

• Make sure all equipment is locked out/isolated before any
cleaning or maintenance work
• Do not start up any equipment that is locked out.

Chemicals
• Know the hazards associated with the chemicals you use
in the ETP
• Refer to the MSDS for each chemical for safe handling
procedures

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 ETP Operator Manual

2.2 Safety in the ETP

ETP spills and leaks (Refer to work instruction ETP-WI-009)

Polyelectrolyte spill
Dry Powder: Collect the powder and reuse it. The residual must be hosed down to
the sand trap pit. Do not throw it in a bin.

Solution: Hose down to sand trap using a squeegee if required.

Be careful as it is extremely slippery when wet.

Emulsion Spill From Overhead Tank

Stop the feed to the tank immediately. Close water and steam to the tank. When the tank
stops overflowing, hose it down to the sand trap pit using the hot water hose. Use a
squeegee if required. For large quantities collect the spill in a bucket using a shovel and
pour into the centrate sump. Hose down the residual to the sand trap.

Wool Wax Drum Overflow

If a small amount of wax has overflowed hose it down to the sand trap. For large quantities
collect the spill in a bucket using a shovel and pour into the centrate sump. Hose down the
residual to the sand trap. Remove the lid of the weighing scale and clean the pit using the
hot water hose.

Wool Wax Drum Leak

If a damaged drum is identified before filling commences store the drum separately. These
are then returned to the supplier for exchange.
If filling has started or completed before identifying the damage then proceed as follows:
• If the damage is identified while the wax is in the molten state then use the drum
holder and crane to tilt the drum and transfer the wax to the concentrator, using a
small plastic container or bucket. Turn the SX machine to cleaning mode and shut
the feed valve of the concentrator during this period. The grease drum should be
oriented above the drain channel to divert any leakage to the sand trap.
• If the wax has already solidified apply the electrical drum heater until the wax is
molten and then empty as above. The empty drum can then be sent back to the
drum supplier for exchange.

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 ETP Operator Manual

ETP emergency procedures (Refer to work instruction ETP-WI-010)

The following procedures outline what to do in the case of emergencies such as power
failure and fire. These procedures are only to be followed if it is safe to do so.
Do not put yourself at risk to carry out these procedures.

Power failure
• Stop the feed into the PX machines.
• Open the drain valve of emulsion phase to drain in SX and PX machines.
• Close steam valve to SX heat exchanger.
• Do not apply brakes on SX and PX machines. (Let the machine stop)
• Proceed to the assembly area.

Resumption of power
• Reset the plant.
• Inspect the condition of the sand trap.
• Start the boiler.
• Start the blower and circulation pumps for the aeration tanks.
• Start all of the pumps for the ETP and ensure their operation on the SCADA
monitor.
• Reset decanters and start as required.
• Start the scraper in the clarifier.
• Start the scraper in the thickener tank.
• Start the water treatment room.
• Start Monopump.

Fire
• In case of fire hazard hit the group emergency switch.
• If time permits follow the steps under power failure, do not put yourself at risk.
• Proceed to the assembly area.

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 ETP Operator Manual

Section 3: ETP equipment and functions

Noggerath Filters out fibres from scour liquor to prevent pipe blockages.
Fibres are disposed of as rubbish.

100m³ wool wash tank Storage tank for scour liquor

Sandtrap Catchment area for sand to prevent it going into bio-tank

where it can damage the pumps.

Wool wash decanter Removes heavy suspended material. (See following diagram)

Centrate sump Storage tank for feeding liquor to separators.

Alfa Laval separators There are 3 stages to progressively separate the grease and
remove the water. (See diagrams on next pages)
In the primary separator the emulsion reaches 70%.
In the concentrator the emulsion reaches 90-95%.
The purifier produces >99.0% pure wool grease.

Aeration tanks Contain bacteria to destroy organic material before release

of effluent to sewer.

Blowers Blows air into aeration tank for bacteria (1-5 pp million)

Clarifier Allows sediment to drop to bottom. The effluent from the

top is released to the sewer.

Thickener Allows the sediment from the clarifier to settle further. The
top material is redirected to the aeration tank to replenish the
bacteria content.

Bio-decanter De-waters the sediment from the thickener up to 20% Total

Solids.

Boiler Supplies steam for operation of the whole plant

Softener Treats the water for use in the scour and boiler.

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 ETP Operator Manual

The Alfa Laval separators

Operating principles
The separators use centrifugal force to separate the wool grease from the water, and
remove any solids at the same time. As the machine rotates rapidly, the liquor is fed into
the top of the machine and out towards the discs. The separation takes place in the space
between the discs.
The lighter liquid (grease) is directed to the centre of the bowl and up to the light phase
outlet. The heavier liquid (water) moves to the outside of the discs and up to the paring
chamber, where it is pumped out by the paring disc.
The separated solid particles are forced towards the edges of the bowl and out through the
nozzles together with some water.

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 ETP Operator Manual

The purifier

The purifier bowl has two outlets. The

emulsion flows through the distributor to
the spaces between the discs, where the
liquid phases are separated from each
other by centrifugal force.
The heavy phase (water) and any solids
move along the underside of the discs
towards the edges of the bowl, where the
solids settle on the bowl wall. The water
proceeds along the upper side of the top
disc towards the neck of the bowl hood
where it is discharged.
The light phase (grease) moves along the
upper side of the discs towards the bowl
centre, and discharges via the hole in the
top disc.

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 ETP Operator Manual

The wool wash decanter

The sludge is pumped through the feed pipe (1) into the inlet chamber (2).
Under centrifugal force it leaves the chamber through ports (3) and flows into the
centrifugal bowl (4).
Sedimentation begins just outside the feed ports and continues for the length of the bowl.
The solids and the liquid travel in the same direction, with the heavy solids settling on the
inside wall of the bowl due to the centrifugal force.
The screw (5) transports the solids towards the discharge ports (7), where it is ejected into
the housing and then via a pipe to the compost plant.
The bowl and the screw turn in the same direction but at slightly different speeds,
controlled by the gearbox (6).
The centrate flows through the return channels (11) on the screw hub, in the opposite
direction to the solids, back to the feed end.
The centrate is discharged over weir plates (12) which can be adjusted to control the depth
of overflow and the volume inside the centrifuge.
The centrate passes into the housing and through the discharge pipe to the centrate sump.

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 ETP Operator Manual

Section 4: Operating procedures

4.1 Suggested shift routine
A large part of the ETP operator’s job is monitoring, that is checking that the equipment is
running correctly and that the effluent and wool wax is up to quality standards. To do this
efficiently you will need to work to a routine so that problems can be quickly identified.

An effective routine would include:

• regular visual inspection of the equipment and tanks
• regular checking of the main control panels, Mimic boards and SCADA screens
• conducting tests and samples at specified times
• accurately completing ETP records as required

At the start of your shift:

1. Check the logbook to see if there are any issues from the previous shift
2. Check the main control panels and SCADA for anything that needs attention
3. Take a sample beaker of grease to the laboratory
4. Climb up to the aeration tanks, taking a probe with you
a. measure the temperature and oxygen levels with the probe
b. take a water sample from each tank, leave to settle for ½ hour then
measure the solids
5. Take all the required tests to the lab before 0800:
• aeration tanks 1 & 2 overflow
• clarifier underflow
• effluent discharge to sewer
• auto sampler test (sand trap)
• bio-decanter feed (thickener underflow)
6. Complete the aeration tank check-sheet
7. Complete a visual inspection of all equipment

A suggested route to follow is:

Control room Grease plant Sand traps

Scour line Noggerath pits Aeration tanks

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 ETP Operator Manual

What to check at each location on your route

Control room: Record data in log book.

Check control panels and Mimic boards.
Monitor operations on the SCADA screens.

Grease plant: Check flow of grease/liquor.

Check back pressures.
Check water temperature.
Maintain supply of empty drums.
Tighten closures on cooled drums.
Remove full pallet of filled drums.
Complete paperwork.

Sand traps: Clean and change filter (twice per day).

Check flow through pump, change filter if less than 17 l/hr.
Check heat exchange temperature is 26º-32º (SCADA).

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 ETP Operator Manual

Aeration tanks: Check 2 to 3 times per shift.

Check temperature and 0² level.
Check condition (if excessive foaming there may be a problem,
contact team leader).
Check settle-ability by filling glass cylinder, leave for ½ hour to
settle. (Indicator of bio-activity).
Complete aeration tank check sheet.

Top view of aeration tank

Noggerath pits: Check baskets at least once per shift, clean as required.

Scour line: Check recycle flow between 4 - 6.0m³/hour (SCADA).

Check flow into scour, no excess water lost via overflow, running
taps, etc. (SCADA).

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 ETP Operator Manual

4.2 Wool wax recovery (Refer to work instruction ETP-WI-002)

4.2.1 Drum labelling

1. Bring empty drums from the drum storage area.

2. Stencil the side of the drum with the following information:

2.1 GWC Logo
2.2 Gross Kg (Weight including drum)
2.3 Nett Kg (Weight of grease)
2.4 Drum No.
2.5 Extra labelling if required by the customer

Tare (Wt of drum)

GWC GWC
Drum number
Drum No. Gross…..kg
Nett…..kg

Gross
Nett

Figure 1. Labelling of Drums

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 ETP Operator Manual

4.2.2 Filling of wool wax drums

1. Zero the scale. The weighing scale must be reset to zero.

2. Record the drum Record the drum number (sequential) in the Wool
number Wax Log, GWC-263.
3. Put empty drum on Place the empty drum on the weighing scale platform.
scale Record the tare weight (drum weight) on the top of the
drum, using a permanent marker pen, and in the Wool
Wax Log, GWC-263.
4. Position drum Align the opening of the drum under the transfer pipe
outlet and insert the funnel in the drum opening for
collecting the wool wax.
5. Zero the scale Tare the scale. (return to zero)
6. Record start time Record the time at the start of drum filling in the Wool
Wax Log, GWC-263.
7. Listen for alarm An alarm will sound when the drum is almost full.
Remain at the drum to complete the filling and drum
changing process.
8. Record nett weight When the drum is full record the nett weight on the
side of the drum and in the Wool Wax Log, GWC-
263.
9. Record gross weight Calculate the gross weight by adding the tare weight
to the net weight and write on the side of the drum.
10. Change drum Replace the full drum with an empty drum.
11. Complete records Initial the ‘filled by’ column in the Wool Wax Log,
GWC-263.
Use one page of the Wool Wax Log, GWC-263, per
day listing all wool wax drums from 6:00 am
onwards.

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 ETP Operator Manual

4.2.3 Storage of wool wax drums

1. Allow wax to cool To prevent the drum from collapsing as the wax cools,
engage and turn the drum closure a maximum of one
turn, so that air can enter the drum as the wax
contracts.

2. Put drum on pallet Place the full drum on a pallet.

3. Close cooled drum Only when the drums have cooled, tighten the drum
closures to prevent moisture contaminating the wax.
Initial the appropriate ‘SEALED BY’ cells in the
Wool Wax Log, GWC-263.

4. Move pallet to storage When the pallet is full, transfer it to the wool wax
storage area using a forklift.

5. Complete records At the end of the day, place the original Wool Wax
Log GWC-263 sheet in the tray to be collected.

4.2.4 Shipment of wool wax drums

1. Check shipping advice The ETP Operator will receive the Shipping Advice,
GWC-028, (1 original and 3 copies) at least three
working days before scheduled pickup.

2. Assemble drums The ETP Operator will assemble the drums indicated
in the Shipping Advice, GWC-028, with a forklift at
least 24 hours before due pickup, on pallets near the
truck loading bay north of the ETP.

3. Check drums The forklift driver will check each drum closure and
drum number prior to loading and sign all four
Shipping Advices, GWC-028, in the ‘Checked By’
column when satisfied that all drum closures are tight
and all drum numbers are correct.

4. Sign shipping advice The driver must sign the original Shipping Advice,
GWC-028 and the three copies.

5. File records After loading the wool wax drums onto the truck the
original Shipping Advice, GWC-028, and one copy
will be handed to the truck driver and two copies will
be placed in the office tray.

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 ETP Operator Manual

4.3 Operating the Alfa-Laval FVSX-510X (Separators)

(Refer to work instruction ETP-WI-003)

Initial plant set-up

1. Check the pressure Ensure a pressure of 0.9 bar in the saturation tank. The
same pressure should be indicated on the steam
pressure controller on the Control Panel

2. Open steam valves Open steam supply hand valves (AV-27 and AV-28)
to the heat exchanger. Open slowly to avoid
hammering in the piping

3. Open air supply The air supply hand valve, located on the left side of
SX 8.1, should be open.

4. Open sludge valve Open sludge valve (A-V6-1) from the machine to the
drain pipe.

5. Check water line open The hand valve (AV-13) in the start-up water line,
located behind SX machines, should be open.

6. Open water valve Open cleaning water valve (A-V-23)

7. Release the brake Release the brake on SX machine.

8. Open the drain valve Open the drain valve (V-X-4) to divert the light phase
to the drain.

9. Start Separator Press the SX-separator start button, located on Control

Panel.

10. Press cleaning button When the machine reaches its full speed, indicated by
a green light ON, press the ‘Cleaning’ button to light
the ‘cleaning’ indicator on the Control Panel.

11.Check temperature Check that the water temperature is 80oC. If it is not,

check heating system set point on controller.

12. Transfer emulsion Open hand valves (A-CV-23-1 and A-CV-23-2) for
transferring emulsion from SX-8.1 to PX-3.1
overhead tank.

13. Check the nozzles Check the nozzles and the vibration monitor.

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To start production

1. Check sump level Check that the centrate sump level is above 30%.

2. Press standby button.

3. Check pump Check that the emulsion pump is running.

4. Start production and Press the ‘Production’ button. Adjust the feed rate
adjust feed rate using the ‘feed adjust’ potentiometer on the Decanter
Control Panel.

5. Adjust back-pressure Adjust the back-pressure to ensure the right quantity

and quality of emulsion (2.5 bar can be a good starting
point).

6. Close drain valve, open Divert the emulsion to the emulsion pump by closing
pump valve the hand valve (V-X-4) to the drain and opening the
hand valve (V-X-3) to the pump.

7. Adjust the feed Adjust the feed to maintain a level of about 30% in the
centrate sump

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To stop production

1. Press standby button Press the ‘Stand By’ push button on control panel, the
‘Stand By’ light will flash and becomes steady.

2. Press cleaning button Press the ‘Cleaning’ button. The emulsion pump will
stop after a short delay.

3. Open hand valve Open the hand valve to divert the emulsion phase to
drain.

4. Press standby button Continue cleaning for at least 20 minutes, or until the
light phase going to funnel is clear. Press the ‘Stand
by’ button.

5. Complete records Record the date and any comments on the Alfa-Laval
Separator Cleaning form, GWC-245.

6. Close steam valves Close steam supply hand valves (AV-27 & AV-28)

7. Press standby button

8. Press stop button and Press the ‘Stop’ button. Check that the current in the
apply brake current meter drops to zero. Immediately go to the
machine and apply the brake.

9. Close all valves When the machine has stopped:

9.1 Close cleaning water hand valve (AV-23).
9.2 Close start up water valve (AV-13).
9.3 Close the sludge valve (A-V6-1)
9.4 Close the drain valve (V-X-4).
9.5 If both SX machines are stopped close air supply
valve.

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4.4 Operating the Alfa-Laval FUVPX407 (Concentrator)

(Refer to work instruction ETP-WI-004)

System start up

1. Check tank level and If the overhead emulsion storage tank is at least ¼ full, open the
temperature steam valves for the heating system for piping and overhead
If tank ¼ full - open tank (B-V5 and B-V6) (located under the tank at the north-east
steam valves corner).
The temperature of overhead tank should be between 88 - 92oC.

If tank empty do not If the overhead emulsion tank is empty, do not open the steam
open valves. valve at this stage.

3. Open sludge valve Open the sludge valve (B-V6-1) located at back of the machine.

4. Open heavy phase Open heavy phase valve (B-V5-1) located at back of machine.
valve

5. Release brake Release the brake on the machine.

6. Open drain valve Open hand valve between the light phase funnel and the drain.

7. Open valves to Open the hand valves between the emulsion pump and the
purifier tank purifier overhead tank (B-V4-1 and C-V4-3).

8. Turn rotary switches Turn all rotary switches on the Alfa-Laval Control Panel to the
to Auto Auto position.

9. Press start button Press the ‘Start’ button on the Alfa-Laval Control Panel.

10. Open water valves Open bowl operating water valves (B-V16-1 and B-V15-1).

11. Open gravity disc When machine reaches full speed, the stirrer & emulsion pump
sealing water valve will start. Open gravity disc sealing water valve (B-V14). An
extension rod is used to control the opening of the valve.

12. Open heating valve When overhead tank is at least ¼ full of emulsion start heating
the tank by opening the valve located under the tank (middle).

13. Check heating Check all heating systems for normal operation. The
systems temperature of overhead tank should be between 88 - 92oC.

14. Open feed valve When there is enough emulsion in the overhead tank, open the
feed valve to the machine.

15. Close drain valve, When the light phase starts emerging into the funnel, close the
open pump valve valve between the funnel and the drain and open the valve
between the funnel and the emulsion pump. The emulsion will
then go to the purifier overhead tank

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Machine shut down

1. Stop feed Stop the feed to the machine.

2. Open sealing water Open the sealing water valve (B-V14) about ¾ full.
valve

3. Open light phase valve Open the hand valve from the light phase funnel to the
drain.

4. Close sealing water When clean water starts to come out of the heavy
valve phase outlet, close the sealing water valve (B-V14)

5. Stop machine Press the ‘Stop’ button on the Control Panel

6. Complete records Record the date and any comments on the Alfa-Laval
Separator Cleaning form, GWC-245.

7. Apply brake When the current in the meter drops to zero, go to the
machine and apply the brake.

8. Close water, sludge and When the machine stops:

heavy phase valves Close the two bowl operating water valves (B-V15-1)
and B-V16-1)
Close the butterfly sludge valve (B-V6-1) from the
machine to the drain
Close the heavy phase valve (B-V5-1).

9. Drain overhead tank Drain the overhead tank completely and clean it if
machine is to stop for a long time. This should be
done during machine change over.
9.1 Open hand valve (B-V17) to flush tank with hot
water.
9.2 Open drain valve (B-V9).
9.3 Close hand valve (B-V17).
9.4 When tank is empty close drain valve (B-V9)

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4.5 Operating the Alfa-Laval FUVPX407 (Purifier)
(Refer to work instruction ETP-WI-005)
System start up
1. Check tank level and
temperature
If tank ¼ full - open steam
valves
If tank empty do not open
valves.
2. Open sludge valve
3. Open heavy phase valve
4. Release brake
5. Open light phase valve
6. Turn rotary switches to
Auto
7. Press start button
8. Open water valves
9. Open sealing water
10. Start tank heating
system
11. Check grease line
heating
12. Open feed valve
13. Close drain valve, open
drum valve
ETP Operator Manual
If the overhead emulsion storage tank is at least ¼ full
open the steam valves for the heating system for
piping and overhead tank (C-V5 and C-V6), located
under the tank at the north-east corner.
The tank temperature should be between 90-95oC
If the overhead emulsion tank is empty, do not open
the steam valve at this stage.
Open the sludge valve (C-V6-1) located at the back of
the machine.
Open the heavy phase valve (C-V5-1) located at the
back of the machine.
Release the brake on the machine.
Open the hand valve between the light phase funnel
and the drain.
Turn all rotary switches on the α-Laval Control Panel
to the Auto position.
Press the ‘Start’ button on the α-Laval Control Panel.
Open the two bowl operating water valves (CV-16-1
and CV-15-1).
Open the sealing water to the gravity disc after the
machine has attained full speed.
When the overhead tank is at least ¼ full, start the
heating system for the tank. The temperature of the
tank should be between 90-95oC.
Check the heating system for the grease transport line
to the drums.
When there is enough emulsion in the overhead tank,
open the feed valve to the machine and adjust as
required.
When grease starts to flow into the jacketed transfer
line, close the valve from the transfer line to the drain
and open from transfer line to drum for storing grease.
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 ETP Operator Manual

Shut down

1. Stop feed Stop the feed to the machine.

2. Open sealing water Open the sealing water about ¾ full.

3. Open drain valve, close Open hand valve from the transport pipe to the drain
drum valve and close the valve from the transport line to the
drum.

4. Close cleaning water, When clean water starts to come out of the heavy
press stop phase outlet, close the cleaning water and press the
‘Stop’ button on the Control Panel.

5. Complete records Record the date and any comments on the Alfa-Laval
Separator Cleaning form, GWC-245.

6. Apply brake When the current in the meter drops to zero, go to the
machine and apply the brake

7. Close valves When the machine stops

Close the two bowl operating valves
Close the butterfly valve from the machine to the
drain.
Close heavy phase valve (C-V5-1).

8. Drain overhead tank Drain the overhead tank completely and clean it if
machine is to stop for a long time. This should be
done during machine change over.
8.1 Open hand valve (C-V17) to flush tank with hot
water.
8.2 Open drain valve (C-V9).
8.3 Close hand valve (C-V17).
8.4 When tank is empty close drain valve (C-V9)

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4.6 Operating the scour liquor decanters

(Refer to work instruction ETP-WI-006)

Prestart checks

1. Check tank level Make sure that the 100m3 scour liquor storage tank
level is above 30%. (35-40% is a good starting range).

2. Check scour Check that the scour is running before proceeding

System startup

1. Open water valve Open the cooling water valve for the hydraulic
system, located near the hydraulic oil tank.

2. Start hydraulic pump Press the “hydraulic pump 1B start” button.

3. Start decanter After 5 minutes press the “decanter start 2B” button.

4. Open cleaning water if If decanter has been stopped for some time, open
required cleaning water located in front of decanter. Continue
flushing until clear water appears in the funnel.

5. Reverse conveyor lattice Press the conveyer lattice 5B “reverse” button.

6. Stop conveyor then When the decanter reaches full speed press the “stop”
select forward button 5B and start “forward”.

7. Open diverter gates if If the sludge is to be run into bins open the diverter
required gates for the conveyors:

8. Open feed valves Open the hand valves in the feed line.

9. Open motorised valve Press the motorised valve “MV2 open” button. A
green light will come on.

10. Turn feed pump on Press the feed pump drive “3C ON” button.

11. Open steam line Open hand valve in steam line to decanter.

12. Adjust feed rate Adjust the feed rate to synchronise with the
Alfa-Laval centrifuge feed and 100m3 tank level.

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 ETP Operator Manual

System shutdown

1. Stop the feed pump.

2. Close feed valve Close the feed valve (MV2).

3. Open cleaning water Keep running the system for 10 minutes and then open
the hand valve for cleaning water located in front of
the decanter.

4. Continue flushing Continue flushing until clear water appears in the

funnel. Keep water running until decanter has
completely stopped.

5. Stop decanter Press the “decanter stop” button.

6. Stop conveyor and select Run water for another 10 minutes, then press the
reverse Discharge “conveyor stop” button and the Discharge
“conveyer reverse” button.

7. Stop conveyor When the decanter stops completely, stop the

discharge conveyor 5B

8. Close cleaning water Close the cleaning water hand valve.

9. Complete records Complete Decanter Centrifuge Return Tube Cleaning

Form, GWC-244.

10. Stop pump after 45 Keep the hydraulic pump running for 45 minutes and
minutes then stop it by pressing the “hydraulic pump stop”
button.

11. Close feed valves Close the hand valves in the feed line.

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 ETP Operator Manual

4.7 Preparation of polymer solution

(Refer to work instruction ETP-WI-007)

1. Select tank Select the tank to be filled. (An alarm will sound as
one tank empties)

2. Select Auto Turn the “Floc Tank Automatic Control” toggle

switch to the Auto position.

3. Start water and stirrer Press the start buttons for filling the tank with water
and starting the stirrer, these are located on the pillar
near the floc tank. (Ground level)
The stirrer will start when the level in the tank
exceeds 25%.

4. Add poly powder To mix the polyelectrolyte powder:

4.1 Insert the end of the eductor hose into the
appropriate feed pipe
4.2 Open the air hand valve located on the platform
above the mix tank.
4.3 Open the water hand valve.
4.4 Insert the suction end of eductor into the
polyelectrolyte bag. Pierce the top of the bag to
allow air to pass through.
4.5 Add 8kg of polyelectrolyte, read off the scales

5. Stop water then air Turn the water hand valve off.
Turn the air valve off.
The stirrer will continue for 25 minutes after the tank
is full and will then stop automatically.

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4.8 Operating the Bio-decanter
(Refer to work instruction ETP-WI-008)
Machine start-up
1. Check poly mix
2. Check water is on
3. Start hydraulic pump,
select reverse then start
decanter
4. Select forward, open poly
feed valve then start floc
pump
5. If required, direct sludge
to bins
6. Start decanter feed
7. Establish mud seal
8. Stop when silo full
ETP Operator Manual
Make sure that the poly mix is ready.
Ensure that the cooling water valve for the hydraulic
system located near the oil tank is on.
On the main control panel:
Press the “hydraulic pump drive 1A start” button.
Press the conveyor lattice 5A “Reverse” button.
After 5 minutes press the “Decanter 2A start”
button.
When the decanter attains full speed:
Press the “forward” button.
Open the poly feed motorised valve,MV3 or
MV4, depending on which tank is selected.
Press the “Floc pump drive start” button.
If the sludge is to be run into bins do the following:
Start conveyors 9, 10 and 11 and open the
diverter gates.
Open the hand valves in the feed line.
Press the motorised valve MV1 “open” button. A
green light will come on.
To start feeding the decanter press the “feed pump
drive 3A start” button.
Optimise the system to establish a mud seal by
adjusting:
Feed rate of the sludge.
Internal conveyor speed.
Feed rate of the polymer
Stop Bio-sludge when sludge silo is 23T full. In
case of emergency use tippler bin and inform shift
manager of the situation.
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 ETP Operator Manual

Machine shut down

1. Stop feed pump

2. Close feed valve Close feed valve MV1

3. Stop Floc pump

4. Close floc valve Close floc motorised valve MV3 or MV4

5. Clean the machine To clean the machine:

Keep running for 10 minutes.
Open the cleaning water using a toggle switch
mounted on the pillar near the floc pump.
Continue flushing until clean water appears in the
funnel, and then for another 10 minutes after
clean water appears.

6. Stop the decanter Press the “decanter stop” button.

Press the “discharge conveyor 5A stop” button.
Press the “discharge conveyor 5A reverse” button.
If the sludge is to be run into bins stop conveyors 9,
10 and 11.

7. Switch off conveyor When the decanter stops completely, switch off
conveyor 5A.

8. Run pump for 45 minutes Keep the hydraulic pump running for 45 minutes
and then stop it by pressing the “hydraulic pump
stop” button.

9. Close feed line valve Close the hand valve in the feed line.

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 ETP Operator Manual

Running bio-sludge through wool wash decanter

1. Check valve position Open valve V-41, then close V-42. If this is not
done the biosludge will go to the centrate pump.

2. Start wool wash decanter Start wool wash decanter. Refer to Operating
Procedures for Scour Liquor Decanters ETP-WI-006
and proceed up to step 7

3. Open valves to divert Go to feed pumps area and open hand valves to
sludge divert sludge through spare feed pump 3B, and wool
wash flow meter FM2.

4. Open motorised valve Open motorised valve MV2.

5. Start feed pump Start feed pump 3B.

6. Open feed valve Open polyelectrolyte feed motorised valve MV3 or

MV4.

7. Start feed pump Start polyelectrolyte feed pump drive.

8. Adjust feed rates Adjust feed rates for sludge and polyelectrolyte.

Machine shut down

1. See machine shut down for bio-decanter.

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 ETP Operator Manual

4.9 Sampling and testing procedures

4.9.1 Daily samples for laboratory testing

Sample or test Purpose What to do

Wool wax Ash and colour Take sample first thing in
the morning at start of shift.
Hold beaker under flow
from purifier.
Send to lab in labelled
100ml beaker.

Scour recycle from Check oil and grease % Take sample from 5l bottle,
Autosampler (Sandtrap) then empty and clean it.
Reset auto sampler.
Send sample to lab before
0800 in labelled 2l bottle.

Effluent to drain Measure suspended solids Hold sample bottle under

(SS mg/l) effluent flow from clarifier.
Send to lab before 0800 in
labelled 2l bottle.

Aeration tank 1 & 2 Measure mixture liquid Fill sample bottle from
suspended solids. overflow at top of tank.
(MLSS g/l) Send to lab before 0800 in
Also measure pH labelled 2l bottle.

Clarifier underflow Total solids (TS g/l) Open tap, let run for 10 secs,
then take sample.
Send to lab before 0800 in
labelled 2l bottle.

Thickener underflow Total solids (TS %) Take sample from tap before
bio-decanter pump.
Send to lab before 0800 in
labelled 2l bottle.

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 ETP Operator Manual

4.9.2 Daily operator checks

Check or test Purpose What to do

Wool wax Water content Take sample for every new drum.
Hold beaker under flow from
purifier.
Check for water content.

Aeration tanks - Measure level of Fill glass cylinder from overflow

settle-ability test bioactivity. at top of tank.
Allow to settle for 30 minutes.
Record result on Aeration Tank
Check Sheet GWC-248

Testing for settle-ability

Refer to the Documentation section of this manual for other checks that the ETP operator
is expected to do.

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 ETP Operator Manual

Section 5: Documentation
The ETP operator is required to keep accurate records of ETP production and equipment
operational performance. This requires the completion of a number of forms that record
daily and/or weekly measurements.

Document Purpose

ETP log book Record problems, incidents, significant issues as

they occur. This is valuable information for
operators on other shifts.
Always refer to at start of shift.

Aeration tank check sheet Record data each morning to monitor bio-activity
(GWC-248) and tank conditions (temperature, oxygen probe,
settle-ability, etc).

Decanter Check Sheet - Bio-sludge Completed at end of shift.

(EMSF-005) Measurements are taken from SCADA, main
control panel and local equipment controls.

Plant water consumption record Completed each morning. (0600-0700)

GWC-243 Measurements are taken from SCADA and local
equipment controls.

Scour liquor decanter form Completed at end of each shift. (Day and night)
(GWC-241) Bottom section is completed weekly.
Measurements are taken from SCADA and main
control panel.

SX machine record sheet Record shift data at end of shift (bottom of sheet)
(GWC-246) Record weekly data at top of sheet.
Measurements are taken from SCADA and local
equipment controls.

PX machine record sheet Record shift data at end of shift (bottom of sheet)
(GWC-247) Record weekly data at top of sheet.
Measurements are taken from SCADA and local
equipment controls.

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 ETP Operator Manual

Document Purpose

Water treatment checklist Completed daily.

(GWC-250)

Boiler water analysis Completed daily.

Maintenance shift log Record details of any maintenance job.

Wool wax log (GWC-263) Record data on number and weight of drums.
(Kept at drums) One page is completed for each 24 hours

Decanter centrifuge return tube Completed at weekly cleaning when tank levels
cleaning form (GWC-244) are low.

Alfa-Laval separator cleaning form Completed when maintenance or cleaning is done

(GWC-245) on the separators.

Shipping advice (GWC-028) Contains details for despatch of filled drums.

One original and 3 copies to be completed.
Operator to check information and sign.

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 ETP Operator Manual

Section 6 Maintenance and troubleshooting

6.1 Normal operating conditions
As a competent ETP operator you should know the optimum operating conditions for the
ETP equipment, so that you can recognise abnormal conditions and respond quickly with
the appropriate action. Remember that the ETP operates as a process, and that any action
or adjustment you make could have consequences either up or down the line.

Function/Parameter Normal range Corrective action

Saturation tank Alarm sounds if low.
• inlet steam pressure 750-800 kPa Check pressure of boiler.
• reduction 0.9 kPa
100m³ buffer tank level 35-70% Tank level must be sufficient to act
as buffer in the event of a grease
plant stoppage.
If too high, reduce loop system.
If too low, set separators on clean
mode (scour stops)
Centrate sump tank level 35-40% The feed rates must be synchronised
to maintain a stable level in the
centrate sump.
Don’t go below 20%
Aeration tanks oxygen levels 1 ppm If too low increase back pressure in
blower.
SX separators
• water temperature 80°C If low, viscosity increases (Auto)
• back pressure 2.5 bar Adjust pressure to maintain grease
• vibration 3 mm/sec concentration

PX overhead tank temperature

• concentrator 88-92°C If the temperature is too low the
• purifier 90-95°C pipes and tanks might block.

Alfa-Laval heat exchanger 80ºC Automatic

Bio-decanter (sludge quality)
• sludge feed rate 5-8m³/hr Adjust at control panel
• internal conveyor speed 15 rev/min Adjust at decanter. If too fast the
• polymer feed rate sludge becomes sloppier.
Drum nett 192-200kg

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 ETP Operator Manual

6.2 Using the SCADA as a diagnostic tool

SCADA = Supervisory Control and Data Acquisition

The SCADA screens can be used to:

• display current production data (Mimics)
• display graphs of equipment operation over time (Trends)
• provide data on past production events/alarms. (Historical alarms)

These functions are selected from the main menu screen:

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 ETP Operator Manual

The Mimic screens display the current operating values and settings for the selected
process. Below is the mimic screen for the wool grease process.

The trend screens give a graphical display of how various functions are running, using
different coloured lines. The screen below displays the trends for the noggerath and sandpit
levels. Notice the peak in the pink line, indicating a problem in the heat exchanger.

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 ETP Operator Manual

6.3 Troubleshooting the Alfa-Laval separators

Problem Cause Remedy

Excessive vibration Bowl out of balance. Stop immediately.

Disc pressure too low. Notify team leader.
Vibration dampers worn.
Incorrect assembly.

Speed too high Motor fault Notify team leader

Speed too low Brake applied Release brake

Light phase (grease) too Throughput too high Adjust feed

watery

Grease from purifier Bowl clogged with sludge. Actuate sludge discharge,
contains water Liquid seal broken. and reduce interval between
discharges.
Stop and clean bowl.

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 ETP Operator Manual

6.4 Regular maintenance and cleaning

Equipment / Task What to do

Gravity separator discs Change every 7 days or when grease quality

is poor.

Decanter return tubes Clean weekly

Noggerath Empty baskets daily.

Hose out once per shift

Sand trap Clean filters when flow less than 17m³/hr

Hose out once per shift (day only)

Housekeeping Keep main office neat and tidy. File all

paperwork in designated location.
Keep floors and general work area clean and
free of obstacles.

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 ETP Operator Manual

Section 7: Assessment
7.1 The assessment procedure
There are two parts to the assessment of a trainee:

• a checklist to monitor the progress of the trainee and assess their competence
in all areas of operation.

• a set of oral questions related to quality maintenance, workplace

communication, and occupational health and safety.

The checklist
The checklist sets out all major areas of ETP operation and the related sub-tasks.

The trainer will check off each task:

• as it is explained to the trainee.

• as the trainee is observed in the task during normal operation (practice

without assessment).

• as the trainee demonstrates the task while observed by the assessor for
assessment.

• when the trainee has mastered all the sub-tasks and is therefore competent in
the major area of operation.

• when the trainee answers the oral questions to the satisfaction of the assessor.

Note: The checklist does not set out the tasks in order of teaching.
The training program will determine in what order to teach the tasks, and trainers should
also take advantage of situations that occur in normal daily operations
(e.g. occurrence of problems and faults).

Oral test
This will take place in the training room and in the workplace during the training period.

Sample questions are included in section 7.3 of this manual.

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 ETP Operator Manual

7.2 Checklist of operator tasks

Your trainer will initial each item on the checklist as you go

through your training program. You can then keep track of what
you know, and what you still have to learn.
(Note that you will not necessarily learn things in this order).

Trainee observed by

Trainee can perform

Trainee assessed
Task explained by
Effluent Treatment Plant

task under normal

trainer in practice

as competent
conditions
Major tasks/areas of operation

trainer
Individual skills/sub-tasks

Explain effluent treatment and grease recovery process

Identify plant equipment and describe function

Explain general safety procedures and PPE

Identify hazards within the ETP

Demonstrate procedures for spills and leaks

Fill and label wool grease drums

Operate the Alfa Laval primary separators

Operate the Alfa Laval concentrators

Operate the Alfa Laval purifiers

Operate the scour liquor decanter

Prepare the polymer solution

Operate the bio-decanter

Collect lab samples for:

• Autosampler

• Effluent to drain

• Aeration tanks

• Clarifier underflow

• Thickener underflow

• Wool grease

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 ETP Operator Manual

Trainee observed by

Trainee can perform

Trainee assessed
Task explained by
Effluent Treatment Plant

task under normal

trainer in practice

as competent
conditions
Major tasks/areas of operation

trainer
Individual skills/sub-tasks

Interpret SCADA screens

Interpret and operate main control panel

Respond to alarms

Change gravity discs in separators

Clean decanter return tubes

Empty and clean noggerath baskets

Clean sandtrap filters

Complete documentation for:

• ETP log book

• Aeration tank check

• Bio-sludge decanter

• Plant water consumption

• Scour liquor decanter

• SX machine record

• PX machine record

• Wool wax log

• Shipping advice

• Centrifuge return tube cleaning

• Alfa Laval cleaning

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 ETP Operator Manual

7.3 Oral questions – ETP operator

These are questions that a workplace assessor might ask you in order to assess your
competence as an Effluent Treatment Plant (ETP) operator.

Explain the function of the E.T.P. by answering questions 1 to 3.

1. What goes into the E.T.P., and what part of the plant does it come from?
2. What are the major elements of waste that go into the E.T.P.?
3. What are the outputs of the E.T.P.?

Explain the major duties of the E.T.P. operator by answering questions 4 – 14.
4. Materials handling is an important aspect of E.T.P. operation. What materials
handling does the operator have to perform? What are some of the potential
problems the operator has to avoid?
5. List each item of documentation the operator has to complete and its purpose.
6. List the position titles of the people with whom the E.T.P. operator has to
communicate, and the nature of the information communicated.
7. Operating the E.T.P. means that a lot of work has to be performed without much
contact with other people. What are some of the issues that can arise for the E.T.P.
operator because of this factor?
8. Describe the main operator duties involved in:
8.1 Monitoring and controlling E.T.P. tank functions
8.2 Monitoring and controlling overhead tank temperatures
8.3 Monitoring and controlling separator hot water supply
8.4 Operating air pressure supply
8.5 Operating and adjusting turbo blowers
8.6 Operating and adjusting SX and PX machines
8.7 Labelling and preparing empty drums for filling
8.8 Adjusting decanter parameters
8.9 Adjusting polymer addition rates to biosludge decanters
9. Why does and E.T.P. operator require….
9.1 A Basic Boiler Operation Certificate
9.2 A Dogman’s Licence
10. Describe at least sic basic maintenance functions carried out by the E.T.P. Operator.
11. Name at least ten regular checks and samples carried out by the E.T.P. operator and
briefly describe their purpose.
12. Name the hazardous chemicals used in E.T.P. and the type of hazard each can cause.
13. List at least five safety issues (other than hazardous chemicals) in the E.T.P. area.
14. Name the five common reasons why the E.T.P. operator may need assistance from
another tradesperson.

April 2003 49