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SKIKDA, ALGERIA
OPERATING MANUAL VOLUME IV, SECTION 6-2
UNIT 64 SANITARY TREATMENT PACKAGE
KBR
JOB NO.: J6404
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running ................................................................................................................6
3.1.1 Sanitary Treatment Package 64-ML01 ..........................................................................6
3.1.2 New Control Room Sanitary Lift Station 64-ML04 .........................................................8
3.1.3 Existing Control Room Sanitary Lift Station 64-ML03 ....................................................9
3.2 Typical Operating Parameters ..........................................................................................9
3.3 Temporary Operation ......................................................................................................10
4.0 START – UP ....................................................................................................... 11
4.1 Sewage Treatment Unit ..................................................................................................11
4.2 Air Blowers ......................................................................................................................11
4.3 Chlorine Unit ...................................................................................................................12
5.0 SHUT DOWN ...................................................................................................... 13
5.1 Normal Shutdown ...........................................................................................................13
5.2 Temporary Shutdown......................................................................................................13
5.3 Extended Shutdown ........................................................................................................13
5.4 Process Upsets and Production Loss .............................................................................14
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 15
6.1 Safety Critical Shutdown Systems ..................................................................................15
6.1.1 64-ML01-MJ10/10A Effluent Pumps Trip .....................................................................15
6.1.2 64-ML01-MJ11/11A & 64-ML01-MJ12/12A Lift Station Sump Pumps Trip .................15
6.2 Pressure Safety Valve Summary ....................................................................................15
6.3 Special Precautions ........................................................................................................15
7.0 ATTACHMENTS ................................................................................................. 16
7.1 Attachment I: Equipment List ..........................................................................................17
7.2 Attachment II: Utility Consumption .................................................................................18
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
1.0 INTRODUCTION
This operating manual relates to the facilities indicated on the following KBR Process
Flow Diagrams and P&IDs:
PR-64-PR32-001
PR-64-SYPI-001
PR-64-SYPI-004
PR-64-SYPI-004A
Vendor’s P&ID drawings associated with this operating manual include S&D
Worldwide Enterprises drawing:
0912-PID-2
0913B-PID
0913A-PID
The Sanitary Treatment Package, Item 64-ML01 is an extended aeration biological
treatment system with equalization, aeration, clarification, chlorination and sludge
storage. The package consists of two 100% capacity units (64-ML01-ML01/A, one
operating and one spare unit).
Sanitary waste is collected from the new control room, old control room, the
laboratory and unit #10 change rooms to sanitary lift stations where the effluent is
pumped to a Sanitary Treatment Package for reduction in suspended solids and
BOD (Biological Oxygen Demand) in the waste. The treated effluent is chlorinated
and pumped through clean water storm water basin to the outfall canal.
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F
A
B
E
C
D
H
8
8
7
7
Signal from
SKIKDA, ALGERIA
DCS
SANITARY
64-ML03-MJ11/A TREATMENT UNIT LY- 64-MJ17-A/B
1021 POLE 2
LC OUTFALL
M LC M CANAL
6
6
EXISTING
CONTROL ROOM 64-ML01-ML01
& LABORATORY
(SANITARY
SEWAGE) TREATED SANITARY
64-ML03-CV03 WASTEWATER
5
5
64-ML01
SANITARY TREATMENT
64-ML01-ML01A PACKAGE
4
4
64-ML04-MJ12/A
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LC M
NEW CONTROL
ROOM &
LABORATORY
(SANITARY
SEWAGE) 64-ML04-CV04
3
3
64-ML04
2
2
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
DOCUMENT NO.
PP-AAA-PP1-152
1
1
A
B
E
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D
H
KBR
NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
Page 5 of 18 KBR
NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Sanitary
Treatment Package. Refer to Section 3.2 for a list of typical operating variables for
this system.
3.1.1 Sanitary Treatment Package 64-ML01
Sanitary wastewater (sewage) from the new control building is collected in Control
Room Sanitary Sump, 64-ML04-CV04, and then pumped via the Control Room
Sanitary Pumps, 64-ML04-MJ12/A to Sanitary Treatment Package 64-ML01-ML01/A.
The treatment package is an extended aeration biological treatment system with
equalization, aeration, clarification, chlorination and sludge storage. It consists of two
units (one operating and one spare), each with its own level transmitter 64-LT-1021
and 64-LT-1022. Only one Sewage Treatment Unit is used at any given time. The
manual valves on the inlet and outlet of the Sanitary Treatment Package (STP) not in
service should be kept closed.
There are four separate operations that are involved in the sewage treatment
process as follows:
1. Screening process - as the influent enters the sewage treatment unit, a bar
screen will catch any large trash such as rags, plastic bags, etc., and prevent it
from entering the system.
2. Aeration – when the sewage passes through the bar screen, it flows into the
aeration chamber which provides a 24-hour retention time for the daily average
flow volume of sewage. In the aeration chamber, the sewage is mixed with
water that contains a large concentration of very active aerobic bacteria that
consume the organic waste material in the sewage. Air flowing up through the
liquid from the diffusers keeps the bacteria in suspension and provides the
necessary amount of oxygen required by the bacteria for their respiration and
digestion process. The airflow through the liquid also provides the agitation
necessary to keep solids from settling on the bottom and helps break up solid
waste material in the sewage.
3. Clarification and Settling - After 24-hour average retention time in the aeration
chamber, the displaced liquid flows into a separate chamber called the clarifier.
The liquid in the clarifier is kept as still to allow the sludge to settle to the
bottom. This settling process creates a zone of clear liquid at the top of the
clarifier which is displaced over a weir, disinfected and then discharged to clean
water storm water basin and from there pumped to outfall canal. The sludge that
has settled to the bottom of the clarifier is continuously drawn up by the airlift
sludge return line, and discharged back into the aeration chamber. The floating
material is then discharged back into the aeration chamber.
Each unit has two aeration blowers which are supplied with this package. The
operating unit must have one on at all times (other blower on standby). They
can be manually started and stopped from the DCS or operated by the logic.
When the blowers are both in Remote mode, DCS logic K-6402 alternates
operation every twelve hours.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
Inadequate air supply to the aeration chamber diffusers will also result in the
growth of anaerobic bacteria that will release odor-causing gases.
Blowers in operation: For the Sewage Treatment Unit and Blowers that are in
operation, the blowers should be alternated every 12 hours. It is critical that one
blower be in operation at all times when the Sewage Treatment unit is in
service.
Both blowers should never be operating at the same time or damage to the air
piping and diffusers could occur.
Blowers not in operation: For the Sewage Treatment Unit and Blowers that
are not in operation, refer to the IOM manual for instructions on storing,
preserving and maintaining the Blowers while not in service.
4. Disinfection of the clear liquid flowing from the clarifier.
The liquid discharged from the clarifier is chlorinated by flowing through a
“Sanuril” tablet-type chlorinator. As the treated liquid accumulates in the chlorine
contact chamber, it is discharged by effluent pumps (64-ML01-MJ10/10A, 13.4
m3/hr @ 20.9 M TDH). Each chamber of the sewage treatment unit has drain
connections provided to permit draining for maintenance and inspection.
Treated effluent is pumped out by pumps 64-ML01-MJ10 and 64-ML01-MJ10-A,
which are supplied with this package, to the existing seawater discharge canal.
The pumps can be manually started and stopped from the DCS as long as the
level is above 21%.
When the both pumps are in Remote mode DCS logic K-6401 starts and stops
them based on level. The operator selects the level transmitter to use with DCS
selector switch 64HS1021, based on which unit is in operation.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
4.0 START – UP
This section outlines the steps necessary to place the Sewage Treatment Package in
service. For the purpose of this section of the operating manual, it is assumed that
the necessary electric power is available and all piping, blowers and pumps skids are
ready for start-up. For a more detailed start up of the unit, refer to the latest revision
of Sanitary Treatment System Start up Manual PP-AAA-PP1-252.
4.1 Sewage Treatment Unit
1. Check to make sure the diffuser air valve(s) are open.
2. Check to make sure the sludge return and skimmer air valves are open. These
valves are located next to the clarifier chamber.
3. Fill the unit with water having the same characteristics as that used in the
sanitary system. Do not fill the unit with untreated sewage!! The unit may be
filled by using a hose placed in the bar screen.
4.2 Air Blowers
1. Follow the blower manufacturer start up instruction in IMOI manual.
2. Introduce air into the unit.
3. With the unit completely full of water (i.e. water has exited out of the discharge).
Check the adjustable top skimmers in the clarifier. Note these skimmers were
set at the factory but may have moved in shipping.
The skimmer is set by adjusting the bolts on the end of the skimmer. The level
of the skimmer is set in conjunction with the air flow to the recirculation line. The
valves are located on the side of the clarifier.
Note: The amount of air lift from the skimmer back to the aeration
chamber is a site specific setting. Follow manufacturer’s start up
instruction as described in IMOI manual. The smallest amount of return
skimming giving the required discharge effluent is the objective.
Operate the unit initially with the return line operating at up to one third full (from
the end view at the aeration chamber).
If this does not adequately remove floating debris, turn the central return line off
and operate the two outside return lines. If this does not adequately remove
floating debris operate all three return lines at low return rate.
4. Adjust the air to the air lift pumps at the bottom of the clarifier hoppers per
manufacturer start up instruction in IMOI manual.
Note: The amount of air lift from the clarification hoppers back to the
aeration chamber is a site specific setting. The smallest amount of return
flow giving the required discharge effluent quality is the objective. View
the return lines as they spill into the aeration chamber to ascertain flow
level. Adjust flow to the hoppers as necessary to obtain the required
effluent quality
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
Set Pressure
Valve Number Description/Location (barg)
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-152
OPERATING MANUAL VOLUME IV SECTION 6-2: REVISION 1
SANITARY TREATMENT PACKAGE 24-July-13
Utility
Equipment No. Description Consumption
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