Facility 71 O and M 2018-08

WASTEWATER TREATMENT PLANT
(FACILITY 71)
OPERATIONS AND
MAINTENANCE MANUAL
Millennium Bulk Terminals – Longview, LLC

4029 Industrial Way
Longview, Washington 98632
August 2018
Facility 71 Wastewater Treatment Plant
Operations and Maintenance Manual
TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................. I
LIST OF TABLES .................................................................................................................... IV
LIST OF FIGURES .................................................................................................................... V
LIST OF APPENDICES ............................................................................................................. V
LIST OF ACRONYMS AND ABBREVIATIONS .................................................................... VI
PREFACE ............................................................................................................................... VII
TREATMENT SYSTEM OPERATING PLAN (TSOP).......................................................... VIII
1 GENERAL INFORMATION ................................................................................................ 1

1.1 Background ................................................................................................................1
1.2 Introduction ...............................................................................................................1
1.3 Purpose of Plant .........................................................................................................2
1.4 Names and Telephone Numbers ...............................................................................3
2 TREATMENT PROCESS DESCRIPTIONS .......................................................................... 3

2.1 Wastewater Source Management Process ................................................................5
2.2 Influent Batching Process..........................................................................................7
2.3 pH Adjustment Process .............................................................................................9
2.4 Reaction/Precipitation Process ...............................................................................13
2.5 Flocculation Process ................................................................................................17
2.6 Primary Clarification Process..................................................................................20
2.7 Treated Effluent Management Process ...................................................................22
2.8 Sludge Management Process ...................................................................................24
2.9 Programmable Logic Controller System.................................................................27
2.9.1 Human Machine Interface ................................................................................27
2.9.2 Alarms.................................................................................................................28
2.9.3 Data Logging by the PLC and HMI ..................................................................30
2.9.4 Logged Data Acquisition ...................................................................................32
2.9.5 SCADA Alarm Notifications .............................................................................32
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3 NORMAL OPERATIONS .................................................................................................. 32

3.1 Introduction .............................................................................................................32
3.2 Facility 71 Operational Limitations ........................................................................32
3.3 Treatment Efficiency ...............................................................................................32
3.4 Overview of Operational Activities ........................................................................33
3.4.1 Best Management Practices ...............................................................................33
3.4.2 Operational Tasks ..............................................................................................34
3.4.3 Equipment Inspections ......................................................................................34
3.4.4 Equipment Maintenance ...................................................................................35
3.4.5 Materials Management ......................................................................................36
3.5 Pumps .......................................................................................................................36
3.5.1 Pump Inventory .................................................................................................36
3.5.2 Pump Spare Parts and Units ..............................................................................37
3.5.3 Auxiliary Pumps Operations .............................................................................38
3.5.4 Process Transfer Pump Operations ...................................................................38
3.5.5 pH Loop Pump Operations ................................................................................38
3.5.6 Reagent and Polymer Feed Pump Operations .................................................39
Feed Pump Operations during Bulk Tote/Drum Exchange ...........................................39
3.6 Treatment Reagents and Polymers .........................................................................40
3.6.1 Reagent and Polymer Inventory Management ................................................40
3.6.2 Exchange of Reagent Bulk Totes and Polymer Bulk Drums ...........................42
3.7 Equipment Maintenance .........................................................................................42
3.7.1 Cleaning the pH Sensors....................................................................................44
3.7.2 Storing the pH Sensors When Not in Use ........................................................46
3.7.3 Maintenance of the Mix Mate Device ..............................................................46
3.7.4 Maintenance of the Reagent and Polymer Feed Pumps ..................................47
3.7.5 Maintenance of the Process Transfer Pumps ...................................................47
3.7.6 Maintenance of the pH Sampling Pumps .........................................................47
3.8 Equipment Calibration ............................................................................................48
3.8.1 Calibration of the Electromagnetic Flow Meters .............................................48
3.8.2 Calibration of the pH Sensors ...........................................................................49
3.8.3 Feed Pump Calibration ......................................................................................50
3.9 Facility 71 Normal Operational Parameters ...........................................................50
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3.9.1 Sulfuric Acid Feed System .................................................................................50

3.9.2 Reaction Tank Reagent Feed Systems ..............................................................52
3.9.3 Polymer Feed System ........................................................................................54
3.9.4 Sludge Management...........................................................................................55
3.10 Calculations for Operating Parameters...................................................................55
3.10.1 Polymer Feed Control .......................................................................................55
4 STARTUP PROCEDURES ................................................................................................. 56

4.1 Facility 71 Raw Influent Characterization .............................................................56
4.2 Startup Preparation – Inspection of Equipment and Piping .................................57
4.3 Effluent Flow Control..............................................................................................59
4.4 Supplies Inventory ...................................................................................................59
4.5 Pumping Overview ..................................................................................................59
4.6 Operational Parameters ...........................................................................................60
4.7 Sulfuric Acid Addition.............................................................................................60
4.8 Calcium Chloride and Ferrous Chloride Addition.................................................61
4.9 Polymer Addition ....................................................................................................62
4.10 Influent and Effluent Sampling Overview .............................................................63
4.11 Initialize Startup ......................................................................................................63
4.12 Monitor Process Displays ........................................................................................63
4.13 Inspect Processes ......................................................................................................63
4.14 Sludge Handling System ..........................................................................................63
4.15 Final Inspection and Sampling Prior to Discharge ................................................64
4.16 Discharge of Effluent from Facility 71 ...................................................................64
5 NORMAL SHUTDOWN PROCEDURES .......................................................................... 64

5.1 Documentation ........................................................................................................65
5.2 Influent Flow Management.....................................................................................65
5.3 Facility 71 in Normal Operating Conditions Prior to Shutdown ..........................65
5.4 Evacuation of the Process Tanks .............................................................................66
5.4.1 Evacuation of the Influent Batch Tank ............................................................66
5.4.2 Evacuation of the pH Tank or Reaction Tank..................................................67
5.4.3 Evacuation of the Polymer Addition Tank ......................................................67
5.4.4 Evacuation of the Lamella Clarifier ..................................................................68
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5.4.5 Evacuation of the Sludge Tank..........................................................................68

5.4.6 Evacuation of the Effluent Tank .......................................................................68
5.5 Purge Reagent Feed Lines .......................................................................................68
5.6 Manage Sludge .........................................................................................................69
5.7 Disable Equipment ...................................................................................................69
5.8 Extended Shutdowns ...............................................................................................69
6 EMERGENCY SHUTDOWN PROCEDURES ................................................................... 70
7 SAFETY .............................................................................................................................. 73
8 EMERGENCY PLANS AND PROCEDURES ..................................................................... 74

8.1 Spill Plan...................................................................................................................74
8.2 Emergency Eyewash and Shower Stations .............................................................75
8.3 Fire Protection .........................................................................................................75
8.4 Communications ......................................................................................................75
8.5 Alarms.......................................................................................................................75
9 LABORATORY PROCEDURES AND RECORDS ............................................................. 75

9.1 Influent Sample Collection......................................................................................75
9.2 Treated Effluent Sample Collection ........................................................................76
9.3 Sample Analysis .......................................................................................................77
9.4 Records of Analysis ..................................................................................................77
9.5 State Reporting Requirements ................................................................................78
9.6 Plant Operating Data and Reports ..........................................................................78
9.7 Procedure for Jar Testing Process Changes ............................................................78
List of Tables
Table 1 Influent Batching Process Equipment ................................................................. 6
Table 2 Influent Batching Process Equipment ................................................................. 7
Table 3 pH Adjustment Process Equipment ..................................................................... 9
Table 4 Reaction/Precipitation Process Equipment ....................................................... 14
Table 5 Flocculation Process Equipment ........................................................................ 17
Table 6 Primary Clarification Process Equipment ......................................................... 20
Table 7 Treated Effluent Management Process Equipment .......................................... 22
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Table 8 Sludge Management Process Equipment ........................................................... 25

Table 9 Color Designation on HMI EZ Touch Display .................................................. 28
Table 10 Alarms Summary ................................................................................................ 29
Table 11 Summary of Data Logged by PLC/HMI ............................................................. 31
Table 12 Facility 71 Pump Inventory ............................................................................... 37
Table 13 Calculated Consumption Rates .......................................................................... 41
Table 14 Equipment Maintenance Schedule .................................................................... 43
Table 15 Equipment Calibration Schedule ....................................................................... 48
Table 16 Monitored Analytes ............................................................................................ 77
List of Figures
Figure DWG-1 Vicinity Map and Project Location Map
Figure DWG-2 Temporary Treatment System Process Diagram
Figure DWG-3 Temporary Treatment Plan
Figure DWG-4 Detailed Temporary Treatment Plan
Figure DWG-5 Temporary Treatment Plant Details
List of Appendices
FIGURES
Appendix A Treatment Process and Equipment ID Schedule
Appendix B System Startup Procedures/Checklist
Appendix C Shutdown Procedures/Checklist
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List of Acronyms and Abbreviations

B(a)P benzo(a)pyrene
BMP Black Mud Pond
CaCl2 calcium chloride
CFR Code of Federal Regulations
CP control panel
CSV comma separated value
Ecology Washington State Department of Ecology
Facility 71 Industrial Wastewater Treatment Plant
Facility 73 Retention Basin and Filter Plant
Facility 77 Outfall Sump/Pump Station
FeCl2 ferrous chloride
gal. gallon
gpd gallons per day
gpm gallon per minute
H2SO4 sulfuric acid
H high (level switch)
HH high-high (level switch)
HDPE high-density polyethylene
HMI human machine interface
ID identifier or identification
L low (level switch)
LL low-low (level switch)
MBT-Longview Millennium Bulk Terminals–Longview, LLC
MCR main control room
mg/L milligram per liter
MGD million gallons per day
NPDES National Pollutant Discharge Elimination System
PLC programmable logic controller
PPE personal protective equipment
SDS Safety Data Sheet
SM Standard Method
TSS total suspended solid
UPS uninterrupted power supply
USEPA U.S. Environmental Protection Agency
WAD weak acid dissociable
WWTP wastewater treatment plant
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Preface
This manual is intended to be a reference source for operation and maintenance of the
reconstructed Wastewater Treatment Plant (WWTP; Facility 71) at the Millennium Bulk
Terminals – Longview, LLC (MBT-Longview) facility in Longview, Washington. The goal of
this manual is to provide a basis for the operation and maintenance of Facility 71 in order to
maximize operational efficiency.
As an operations and maintenance manual, it is anticipated that some changes in the

operating procedures may occur over time as conditions change. This manual shall be
reviewed annually and updated as needed.
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Treatment System Operating Plan (TSOP)

for
Facility 71 Wastewater Treatment Plant (WWTP)
1. Baseline Operating Conditions
Facility 71 is a fully contained batch treatment system that operates seasonally as needed.
Current influent sources to the WWTP include waters from the former leachate ditch and
the former cryolite ditches. Ditch waters from the former cryolite plant area and former
leachate ditch consist of infiltrated groundwater and stormwater that have accumulated in
the ditches. These waters are accumulated seasonally (i.e., during the rainy season) and are
managed through batch treatment in the WWTP. Waters from the ditch areas are pumped
and stored in the old clarifier tanks at Facility 77 (Tanks 1, 2, and 3). The WWTP is designed
to remove fluoride, cyanide, and PAHs [including B(a)P] from wastewaters. Waters
generated during site remediation and redevelopment activities will be evaluated for fluoride
and will be treated in Facility 71 if necessary.
The plant consists of a sequenced treatment process occurring in six interconnected tanks.
Treatment is accomplished through, influent batching, pH adjustment, reaction/
precipitation, flocculation, primary clarification, treated effluent management, and sludge
management. Facility 71 discharges into the Outfall Sump/Pump Station (Facility 77)
collection sump where it is combined with site stormwater. The combined effluent
undergoes further treatment through the Retention Basin and Filter Plant (Facility 73) prior
to its discharge into the Columbia River through Outfall 002A. Additional treatment
provided by Facility 73 includes settling and multimedia filtration.
The plant was formerly used to treat the aluminum reduction plant’s wet air emission control
system bleed stream, but this influent stream ended when aluminum reduction operations
ceased in 2001. Facility 71 operating parameters were originally set to remove cyanide and
fluoride down to 2 ppm and 300 ppm, respectively. Current influent concentrations are
much lower with WAD cyanide ranging from 0.010 to 0.023 ppb and fluoride ranging from
26 to 34 ppm. When Facility 71 is operating, the average discharge is 0.08 MGD.
2. Operating Procedures to Mitigate Upset Conditions

Since current operations at Facility 71 are seasonal and batched, the system can easily be shut
down. Major maintenance activities are scheduled during times when the treatment plant is
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down. During severe storm events, the system has plenty of storage and operation could be
shut down if upset conditions are noted. During startup, the system is designed to recirculate
until it is determined the effluent is ready for discharge. The automated operations at
Facility 71 use a programmable logic controller (PLC) for process management and
monitoring. Process tank levels, pump operations, and chemical pump operations are
monitored continuously, and the control system will set off an alarm if a malfunction or
operational error occurs. The alarm system will send a text and an email notification to
MBT-Longview staff available to respond, which includes a 24-hour guard.
The PLC logs flow, pH, chemical pump operation, and process tank levels. Critical
information is transferred to a Supervisory Control and Data Acquisition (SCADA) system
for remote monitoring, trend analysis, alarm monitoring, and data processing. In addition to
the automatic logging, manual inspections and recordings of key operational parameters (e.g.,
flow rates totalizers, pH) are logged daily during regular environmental staff business hours
(Monday-Friday, 8:00 am to 5:00 pm).
3. Maintenance and Repairs

Major maintenance activities are scheduled during times when the treatment plant is down
and therefore does not affect the volume or character of the wastewater being treated and
discharged from Facility 71. All cleaning/washing of equipment is done while the system is
down and any residual discharge is recirculated to the storage tanks and reintroduced into
the system when it is operating. No solvents, degreasers, or cleaners are used during the
wash down procedures.
The WWTP is designed to remove fluoride, cyanide, and PAHs [including B(a)P] from
wastewaters. Any small changes in influent concentrations for these parameters does not
cause upset conditions due to the fact that the system was designed to treat much higher
level concentrations.
For more detailed descriptions of the above processes please refer to the Facility 71 operating
and maintenance manual.
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1 GENERAL INFORMATION
1.1 Background
The original Facility 71 was built by Reynolds Metals Company in the 1980s to treat on-site
wastewater generated by the former aluminum reduction facility. The former aluminum
reduction facility was permanently closed in 2001, and the equipment necessary for the
aluminum reduction processes was subsequently removed through decommissioning.
Consequently, the majority of the wastewater, for which the original Facility 71 was
constructed, is no longer generated. The remaining principal water sources include
stormwater from the Closed Black Mud Pond (BMP) leachate ditch and the cryolite ditches
and remediation water or water generated during construction dewatering activities.
Facility 71 was reconstructed during late 2011 and early 2012, following the destruction of
the original wastewater treatment plant by a fire that occurred in June 2011. The facility
was constructed with new parts and materials. Nothing from the original wastewater
treatment plant was included in the replacement facility.
1.2 Introduction
Facility 71 is a fully contained batch treatment plant that consists of sequenced treatment
processes occurring in six interconnected portable tanks. A high-density polyethylene
(HDPE) containment membrane underlies Facility 71 and extends vertically along the
perimeter walls of Facility 71. The treatment efficiency of the facility is intended to match
the treatment efficiency of the original Facility 71 (see Figures DWG-1 through DWG-5).
In-use bulk totes of wastewater treatment chemicals and reagents are stored within the
Facility 71 containment structure, while bulk totes of chemicals and reagent held as
inventory are stored within the original Facility 71 containment structure. The original
containment structure was not damaged by the fire and still acts as a fully functioning
containment floor. The process tanks are connected in series by force main (pumped) piping
and gravity-flow piping. Within the various process tanks are equipment controls, tank
mixers, and circulation lines necessary for monitoring and addition of chemicals and
reagents.
Facility 71 includes a main control facility that contains many of the controls and operations’
equipment. The main control facility is a container unit that is divided into the following
three subunits:
 Main Control Room (MCR). A majority of the operations and controls for Facility 71
processes are located in the MCR at the control panel.
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 Mechanical Room. WWTP pumps (transfer pumps, sample pumps, and chemical,
reagent, and polymer feed pumps) used in Facility 71 are located in the
mechanical room.
 Ancillary Storage Room. General WWTP supplies, spare parts, and electrical service
panels are located in the ancillary storage room.
The WWTP treats benzo(a)pyrene (B[a]P), total cyanide, and fluoride. The monitoring point
for Facility 71 is Outfall 002B, an internal outfall that discharges into the Outfall Sump/Pump
Station (Facility 77) collection sump where it is combined with site stormwater. The Outfall
002B discharge and site stormwater is then transferred by pumping to the Retention Basin
and Filter Plant (Facility 73). The Retention Basin provides treatment through the settling of
solids and by mechanical skimmer removal of oil and grease components that rise to the
surface. The Filter Plant provides filtration treatment by further removal of solids, associated
metals and oil and grease, as necessary, when treatment through the Retention Basin is
insufficient. Discharging water from Facility 73 is then conveyed to the Columbia River
through Outfall 002A.
Treated effluent is monitored and sampled at Outfall 002B in accordance with the NPDES
Wastewater Discharge Permit WA000008-6. Currently the permit requires monitoring and
sampling when remediation water as defined in Section S1.E of the permit is processed.
Samples collected at Outfall 002B are analyzed by in-house and contracted off-site
laboratories. Influent flow rates, water level in process tanks, pH in two process tanks, and
reagent addition rates are continually monitored and displayed at the human machine
interface (HMI).
Facility 71 is capable of automatic operation using level switches located within the various
process tanks, failsafe controls, and built-in alarms that are annunciated locally at the control
panel and a call out to operators (either text or email notification).
1.3 Purpose of Plant

The purpose of Facility 71 is to improve the quality of wastewater effluent generated within
the MBT-Longview property prior to its discharge into the Columbia River through a
permitted outfall. This is accomplished by treating the various waste streams generated on
site, including, though not limited to, water from the BMP leachate ditch and cryolite
ditches, waters generated during remediation activities and future development, where
appropriate. Facility 71 removes pollutants from the collective wastewater before
discharging the treated effluent through Outfall 002B. The treated effluent discharged
through Outfall 002B is then mixed with on-site stormwater, and the commingled flows are

further treated through the on-site stormwater treatment processes and eventually pumped
into the Columbia River from Facility 73 through Outfall 002A. This train of treatment has
occurred since operation of the Retention Basin and Filter Plant began in the 1990s.
1.4 Names and Telephone Numbers

For questions and issues relating to the management and operation of Facility 71, refer to the
following list of names and telephone numbers for key contacts:
Position Name Telephone Number

Environmental Officer Cheryl Vezzani (503) 502-8925
Operator Lori Black (360)-562-7963
Operator Brandon Keith (360)751-6803
Operator Richie Allison (360)751-2636
Site Safety Officer Heather Sievers (360) 904-4321
Security Officer (Guards) (360)-749-1652
2 TREATMENT PROCESS DESCRIPTIONS

Influent wastewater undergoes the following treatment sequence through Facility 71:
wastewater source management, influent batching, pH adjustment, reaction/precipitation,
flocculation, primary clarification, treated effluent management, treated effluent sampling,
and sludge management. Each of the processes is generally described in the following
subsections. Additional information pertaining to system processes is included in Figures
DWG-2 to DWG-5.
The operational objective of Facility 71 is to efficiently remove B(a)P, fluoride, and cyanide
from the influent wastewater sources for which Facility 71 is designed. Specific processes are
included in Facility 71 for the removal of each listed influent constituent. B(a)P removal is
achieved in the flocculation process and sludge handling process. Fluoride and cyanide
removal is achieved through multiple processes, such as the pH adjustment and reaction
process, precipitation process, flocculation process, and ultimately the sludge handling
process.
The treated effluent from Facility 71 at Outfall 002B undergoes further treatment through
the Retention Basin and Filter Plant (Facility 73) prior to its discharge into the Columbia
River through Outfall 002A. Additional treatment provided by Facility 73 includes settling
and multimedia filtration.

ID Assignments
Assigning unique IDs to processes and equipment follows a format described in the list
below. In general, the format is focused on individual treatment processes in ascending ID
number, which follows treatment flow sequence. For a complete list, see Appendix A.
The treatment processes have been assigned the following ID sequences:

 100-level: Wastewater source management
 200-level: Influent batching process
 300-level: pH adjustment process
 400-level: Reaction/precipitation process
 500-level: Flocculation process
 600-level: Primary clarification process
 700-level: Treated effluent management process
 800-level: Sludge management process
 900-level: Operations and programmable logic controller (PLC)
General ID Assignment Format for Processes
ID Description Notes
X00 Treatment Process 100-level sequence for processes
X05 Process Influent Pump Typically a transformer pump for delivery of process water into a process tank
X19 Primary Inlet Typically an inlet to a process tank from a pump or a gravity-flow pipe
X20 Process Tank Tanks where processes occur
X21 HH Level Switch High-high-level switches (equipment control); typically installed in tanks
X22 H Level Switch High-level switches (equipment control); typically installed in tanks
X23 L Level Switch Low-level switches (equipment control); typically installed in tanks
X24 LL Level Switch Low-low-level switches (equipment control); typically installed in tanks
X25 Tank Mixer Typically for mechanical tank misers
X28 Bulk Totes/Drums1 Bulk totes and/or drums containing reagents, chemicals, or polymers
X29 Bulk Level Sensors1 Level sensors for bulk totes and/or drums to indicate product level
1
X30 Feed Pumps Feed pumps that draw product from bulk totes/drums
X40 Ancillary Pump Typically for circulation pumps
X50 Sensor/Device Typically for sensors/devices on circulation pump circuits
X52 Feed Pump Discharge Discharge point for feed pumps that draw product from bulk totes/drums
Point2
X55 Pump Discharge Point3 Discharge point for various pumps except for feed pumps; typically into a
process tank
X60 Tank Outlets X60 through X64 for tank outlets; X60 for primary tank outlet

ID Description Notes
X65 Tank Outlet Valves/ X65 through X69 for valves and other equipment attached (downstream) of
Equipment tank outlets; X65 for direct connection to outlet
X75 Process Effluent Pump Typically a transfer pump for delivery of process water into a subsequent
process tank
1 - Add five to the ID number of the primary process to generate the ID number of the additional chemical/reagent
process. For example, a primary feed pump would have the ID of X30, and the secondary feed pump would
have an ID of X35 (X30 + 5).
2 - Add one to the ID number of the primary process to generate the ID number of the additional chemical/reagent
process. For example, a primary feed pump discharge point would have the ID number of X52, and the
secondary feed pump discharge point would have an ID of X53 (X52 + 1).
3 - Add one to the ID number of the primary pump discharge point to generate the ID number of the additional
pump discharge point. For example, a primary pump discharge point would have the ID number of X55, and the
secondary pump discharge point would have an ID of X56 (X55 + 1).
2.1 Wastewater Source Management Process

2.1.1 Process Purpose
The purpose of the wastewater source management process is to independently manage each
wastewater source through a batch process if desired.
2.1.2 Process Inflow

Currently the two principle sources of wastewater treated by Facility 71 are water from the
BMP leachate ditch and cryolite ditches. Other potential sources for water treated at Facility
71 may include waters generated during remediation activities and future development.
Water from the leachate ditch area is pumped to Tank 3. Tank 3 is located in Facility 77 and
is one of three aboveground cylindrical tanks with an approximate volume of 600,000
gallons. Wastewater sources have, in the past, been pumped into Tanks 1 and 2 (also in
Facility 77) and then pumped from Tanks 1 and 2 into Tank 3. When possible, Tank 3 level
will be managed to avoid overflow to the surge tank by transferring water to designated
alternate storage vessels. Any incidental overflows to the Facility 77 surge tank or water
transferred to alternate storage vessels will be transferred back to Tank 3 for treatment when
capacity is available.
Water from the cryolite ditch area is pumped to Tank 1 and/or Tank 2 storage and then
pumped to Tank 3.
2.1.3 Process Equipment

Equipment used in the wastewater source management process is listed in Table 1.

Table 1
Influent Batching Process Equipment
Equipment System No(s).

BMP Leachate Ditch Pump 105
Cryolite Ditches Pump 110
Tank 3 (Facility 77) 120
Tank 3 Water Level Sensor 122,123
CP/HMI 925, 926
Tank 3 is equipped with a water level sensor that continuously measures the water level in
the tank. The measured level is displayed on the HMI in the MCR and on the sensor
controller near Tank 3 in Facility 77 in terms of percent full. The sensor measures the
percentage of volume capacity between the top of the tank cone and bottom of the overflow
trough near the top of the tank. If used for storage, levels in Tank 1 and Tank 2 will be
manually gauged by the system Operator. Both Tank 1 and Tank 2 have high level indicator
lights.
2.1.4 Process Controls

Pumps and controls operate the leachate ditch pump and the cryolite ditch pump
automatically based on relative water level elevations in the ditches and enable remote
operation of the leachate ditch pump from the control panel programmable logic controller
(PLC) system (925) located within the Facility 71 MCR. The cryolite ditch pump will
operate automatically based on ditch water level height but cannot be controlled from the
PLC control panel.
2.1.5 Process Operations

Process operations include manual operation of the cryolite ditch pump. The Operator must
manage the water levels in the BMP ditch, the cryolite ditches, and in Tanks 1, 2, and 3 of
Facility 77. In the event that Tanks 1 and 2 are used for storage, water will be transferred by
pump to Tank 3 and then batched as influent to Facility 71.
2.1.6 Process Outflow

Stored influent wastewater in Facility 77 is pumped to Facility 71, as described in the
following process.

2.2 Influent Batching Process

The purpose of the influent batching process is to commingle the various wastewater
streams, promote pre-settling, and accumulate a volume of water for batch treatment
through Facility 71.

The batch pump conveys wastewater from Tank 3 into the influent batch tank. The
containment pump, located beside the effluent tank, conveys precipitation collected within
the containment area into the influent batch tank.

Equipment used in the influent batching process is listed in Table 2.
Table 2
Influent Batching Process Equipment

Tank 3 (Facility 77)1 120
Batch Pump 175
Influent Air/Vacuum Release Valve4 190
Influent Batch Tank 220
Influent Batch Tank HH-level Switch 221
Influent Batch Tank H-level Switch 222
Influent Batch Tank L-level Switch 223
Containment Pump2 240
Containment Level Switch 241
Influent Batch Tank Discharge Valve3 265
Influent Batch Tank Discharge Wye-Strainer and Valve4 266
CP/HMI 925, 926
Notes:
1 = Equipment described in the previous process.
2 = Containment pump is not a process pump; it manages precipitation collected within the containment area.
3 = Valve is NORMALLY OPEN.
4 = Valve is NORMALLY CLOSED.
The batch pump is a 3-inch-diameter submersible pump located in Tank 3 (Facility 77). The
discharge line from the batch pump runs over the top of Tank 3, down along the outside wall
of Tank 3, and continues on-grade and below gratings between Tank 3 and Facility 71.

The influent air/vacuum release valve is installed on the batch pump discharge line at the top
of Tank 3 in Facility 77.
The influent batch tank is 40 feet long, 8 feet wide, 10 feet high, and it is located opposite the
main control facility. The pH tank and reaction tank are located atop the influent batch
tank. The influent batch tank volume between the batch pump normal operating cycles is
approximately 12,600 gallons. A wye-strainer and valve is attached to the influent batch
tank discharge valve; the wye-strainer valve is NORMALLY CLOSED and the wye-strainer
allows for the removal of accumulated sediment near the outlet of the influent batch tank.
The influent batch tank discharge valve is NORMALLY OPEN.
The containment pump is a common float-activated pump located near the effluent tank.

Process controls consist of three level switches in the influent batch tank, one level switch in
the containment area, and two level switches in the process tanks that affect the operation of
the batch pump under normal operations.
Under normal operations, the batch pump control switch at the control panel is in the
“Auto” position, and pump operations are controlled by level switches. When the water
level in the influent batch tank decreases below the influent batch tank low- (L-) level
switch, the batch pump will turn on and will continue to run until the water level in the
influent batch tank rises above the influent batch tank high- (H-) level switch, at which
point the batch pump will shut off.
A failsafe control will shut off the batch pump if the water level in the influent batch tank
rises above the influent batch tank high-high- (HH-) level switch. A second failsafe control
will shut off the batch pump if the water level in the containment area rises above the
containment level switch. The former may be engaged if the high-level switch fails, and the
latter may be engaged if any of Facility 71 process tanks are breached. Water level switches
are annunciated on the HMI with colored letter icons when an alarm condition occurs (e.g.,
HH, H, L, and LL) and a call out to operators.
When the water level within the containment area rises above the float switch on the
containment pump, the containment pump will run until water level falls below the float
switch.


Process operations in the influent batching process include periodic removal of debris and
solids that may accumulate inside the influent batch tank. Accumulated solids removal may
require draining the influent batch tank and the use of additional equipment (see Section
5.4.1).

The influent pump conveys wastewater from the influent batch tank into the pH tank.
2.3 pH Adjustment Process

The purpose of the pH adjustment process is to lower the pH of the influent wastewater to
enhance the removal of cyanide in later processes. Liquid sulfuric acid (H2SO4), at
93-percent concentration, is added to the wastewater in the pH tank which is thoroughly
mixed to reduce the pH of the wastewater. The pH of the influent wastewater ranges
between 6 and 9, and the target pH for enhanced cyanide removal ranges between 4 and 6.5.

The influent pump conveys wastewater from the influent batch tank into the pH tank.

Equipment used in the pH adjustment process is listed in Table 3.
Table 3
pH Adjustment Process Equipment

Influent Batch Tank1 220
Influent Batch Tank HH-level Switch1 221
Influent Batch Tank H-level Switch1 222
Influent Batch Tank L-level Switch1 223
Influent Batch Tank Discharge Valve1, 2 265
Influent Pump Suction Line Drain Valve3 274
Influent Pump 275
Influent Pump Isolation Valve2 277
Influent Pump Discharge Line Drain Valve3 278
Influent Flow Control Valve2 309


Influent Flow Meter4 310
pH Tank 320
pH Tank HH-level Switch 321
pH Tank LL-level Switch 324
pH Tank Mixer 325
Acid Bulk Tote 4 328
Acid Bulk Tote Level Sensor4 329
Acid Feed Pump4 330
Acid Feed Pump Containment Drum4 331
pH Sample Pump 1 Suction Line Valve2, 4 338
pH Sample Pump 1 Suction Line Drain Valve3, 5 339
pH Sample Pump 15 340
pH Sample Pump 1 Isolation Valve, Discharge2, 5 342
pH Sensor 1 Isolation Valve, Upstream2, 5 349
pH Sensor 15 350
pH Sensor 1 Isolation Valve, Downstream2, 5 351
pH Sensor 26 450
CP/HMI 925, 926
pH Controller4, 5 935
Notes:
1 = Equipment is described in the previous process.
4 = Equipment is used in multiple processes.
5 = Included equipment is referred to as the acid feed system.
6 = Equipment monitors pH in the reaction/precipitation process.
The influent pump is a centrifugal pump located in the mechanical room of the main control
facility. The influent pump suction line is connected to the influent batch tank discharge
valve located at the bottom of the tank and runs underneath and into the mechanical room
to the influent pump. The influent batch tank discharge valve on the suction line is
NORMALLY OPEN. The influent pump discharge line runs underneath the mechanical
room and along the outside wall of the influent batch tank, over the side and into the pH
tank. Drain valves on both the influent pump suction and discharge lines are located below
the mechanical room; the drains are NORMALLY CLOSED and may be used for freeze
protection during extended periods of freezing temperatures.

The influent flow meter is a magnetic flow meter located on the influent pump discharge
line between the mechanical room and the influent batch tank. It continuously measures
the flow rate between the influent batch tank and pH tank and displays the measured flow
rate on the instrument and also on the HMI in the MCR. The flow rate is used as an
operations parameter in various processes to control reagent addition, mixing, operation of
the sample pumps, and overall process control logic. The influent flow control valve is
located upstream of the influent flow meter and is NORMALLY OPEN; it may be closed to
circulate water between the effluent tank and pH tank.
The pH tank is 18 feet long, 7 feet wide, 5 feet high, and it is located on top of the influent
batch tank. There is an approximate volume of 2,200 gallons below the outlet invert
elevation of the pH tank.
The acid feed system includes the pH Sample Pump 1, pH Sensor 1, the pH controller, and
the acid feed pump, which are located in the mechanical room. Water is circulated by pH
Sample Pump 1 from the pH tank to the mechanical room past pH Sensor 1 and back to the
pH tank. The pH of the wastewater in the pH tank is continually measured by pH Sensor 1.
The pH controller compares the measured pH against the pH set-point and modulates the
speed of the acid feed pump to maintain the pH set-point entered into the pH controller.
The acid feed pump delivers the sulfuric acid into the pH Sample Pump 1 discharge pipe
below the floor of the mechanical room. The pH Sample Pump 1 suction line drain valve,
which is NORMALLY CLOSED, is located below the mechanical room and may be used for
freeze protection during extended periods of freezing temperatures. Sulfuric acid is stored in
the acid bulk tote located outside and adjacent to the mechanical room. Containment tubing
is installed on pressure line tubing connected to the acid feed pump. The containment
tubing is larger in diameter than the pressure line tubing and drains into the acid feed pump
containment bucket located below the mechanical room.
The suction line of pH Sample Pump 1 is located on the downstream end of the pH tank, at a
NORMALLY OPEN valve on the outside wall of the pH tank. The discharge line of pH
Sample Pump 1 empties into the pH tank over the rim of the tank. Isolation valves are
located downstream of Sample Pump 1 and on either side of pH Sensor 1; the isolation valves
are NORMALLY OPEN.
The pH of the wastewater in the reaction tank is monitored by pH Sample Pump 2 and
pH Sensor 2 as part of the reaction/precipitation process, described in Section 2.4. The
measurement of pH in the reaction/precipitation process is displayed on the pH controller
and HMI; this measured pH is displayed for informational purposes and may be helpful in

fine-tuning the feed rate set-points for acid addition and the other reagents used in
Facility 71.
The pH tank mixer is a constant speed mixer that operates continuously unless shut off by
controls described subsequently.

Process controls include level switches and adjustable variable inputs into the HMI. Two
level switches in the influent batch tank and one level switch in the pH tank control the
operation of the influent pump under normal operations. The variable inputs to the HMI
include the pH set-point, described previously, and a delay timer.
Under normal operations, the influent pump control switch at the control panel is in the
“Auto” position, and pump operations are controlled by level switches. When the water
level in the influent batch tank rises above the influent batch tank H-level switch, the
influent pump will turn on and will continue to run until the water level remains below the
influent batch tank L-level switch for a period of 20 minutes1, at which point the influent
pump will shut off. Failsafe controls will shut off the influent pump if the water level in the
pH tank rises above the pH tank HH-level switch; similar HH-level switches in the reaction
tank, polymer addition tank, lamella clarifier, and effluent tank will also shut off the influent
pump, as will a LL-level switch in the lamella clarifier. Water level switches are annunciated
on the HMI with colored letter icons when an alarm condition occurs (e.g., HH, H, L, and
LL) and a call out to operators.
The acid feed system will operate continuously unless the pH tank mixer is off. The pH tank
mixer will shut off if the influent flow meter measures a flow rate of fewer than 5 gallons per
minute (gpm) and a delay timer elapses or if the water level within the pH tank decreases
below the pH tank LL-level switch. An adjustable delay timer enables input into the HMI
that will allow the pH tank mixer to continue to run after the influent flow meter measures a
flow of fewer than 5 gpm.

Process operations include the following: 1) maintaining a sufficient supply of sulfuric acid
for the process; 2) adjusting the pH set-point in the pH controller, as necessary, for optimum
treatment efficiency; 3) periodic cleaning and calibration of pH Sensor 1; 4) periodic
1 The 20-minute timer delay allows the batch pump to begin replenishing the water level in the influent batch
tank. The timer delay is input into the HMI and can be adjusted; a value of zero will bypass the timer delay.

calibration of the acid feed pump; and 5) periodic removal of debris and solids that may
accumulate inside the pH tank.
The pH set-point, entered into the pH controller, may be adjusted using the pH controller—
not the HMI. Refer to the pH controller user manual to adjust the pH set-point.
A level sensor on the acid bulk tote is used to annunciate a warning on the HMI that the acid
level is low and needs to be replenished. The placement of the acid bulk tote level sensor
can be adjusted to provide adequate warning based on variable acid usage rates. Replacement
of the acid bulk tote requires the use of a forklift. Refer to Section 3.6.2 for procedures to
replace empty bulk totes.
The pH Sensor 1 should be cleaned and calibrated each time pH Sensor 2 (in the reaction/
precipitation process) is cleaned and calibrated. Refer to Section 3.7.1 for procedures to clean
the pH sensors, and refer to Section 3.8.2 for procedures to calibrate the pH sensors.
The acid feed pump should be periodically calibrated, as described in Section 3.7.
Accumulated solids removal may require draining the pH tank and the use of additional
equipment (see Section 5.4.2).

Wastewater in the pH tank flows by gravity into the reaction tank.
2.4 Reaction/Precipitation Process

The purpose of the reaction/precipitation process is to chemically alter the wastewater in the
reaction tank for the removal of fluoride and cyanide present in the wastewater.
Ferrous chloride (FeCl2) and calcium chloride (CaCl2) reagents (liquid solutions) are added to
the wastewater and are thoroughly mixed to promote the formation of solids (precipitates)
containing cyanide and fluoride, respectively. The solids can then settle out of the
wastewater in later processes.

Wastewater in the pH tank flows by gravity into the reaction tank.


Equipment used in the reaction/precipitation process is listed in Table 4.
Table 4
Reaction/Precipitation Process Equipment

Influent Pump1, 2 275
Influent Flow Meter 1, 2 310
pH Tank1 320
Reaction Tank 420
Reaction Tank HH-level Switch 421
Reaction Tank LL-level Switch 424
Reaction Tank Mixer 425
Calcium Chloride Bulk Tote3 428
Calcium Chloride Bulk Tote Level Sensor3 429
Calcium Chloride Feed Pump3 430
Calcium Chloride Feed Pump Containment Drum3 431
Ferrous Chloride Bulk Tote3 433
Ferrous Chloride Bulk Tote Level Sensor3 434
Ferrous Chloride Feed Pump3 435
Ferrous Chloride Feed Pump Containment Drum3 436
pH Sample Pump 2 Suction Line Valve3, 4 438
pH Sample Pump 2 Suction Line Drain Valve3, 5 439
pH Sample Pump 2 Isolation Valve, Discharge3, 4 442
pH Sensor 2 Isolation Valve, Upstream3, 4 449
pH Sensor 21, 3 450
pH Sensor 2 Isolation Valve, Downstream3, 4 451
CP/HMI 2 925, 926
pH Controller2, 3 935
Notes:
3 = Included equipment is referred to as the calcium chloride and ferrous chloride feed systems.

Similar to the pH tank, the reaction tank is 18 feet long, 7 feet wide, 5 feet high, and it is
located on top of the influent batch tank, downstream of the pH tank. The pH tank is
elevated about 6 inches higher than the reaction tank to provide for gravity flow from one
tank to the other. There is an approximate volume of 1,800 gallons below the outlet invert
elevation of the reaction tank.
The reagent feed system includes pH Sample Pump 2, the HMI, the calcium chloride feed
pump, and the ferrous chloride feed pump, which are located in the mechanical room. The
pH Sample Pump 2 circulates water from the reaction tank to the mechanical room past the
pH Sensor 22 and back to the reaction tank. The HMI uses the measured influent flow rate
from the influent flow meter to modulate the speed of the calcium chloride and ferrous
chloride feed pumps and maintain the calcium chloride and ferrous chloride feed rate set
points. The calcium chloride and ferrous chloride feed pumps deliver the reagents into the
discharge pipe of pH Sample Pump 2 below the floor of the mechanical room. The calcium
chloride bulk tote and ferrous chloride bulk tote are stored outside and adjacent to the
mechanical room. Containment tubing is installed on the pressure line tubing connected to
the calcium chloride and ferrous chloride feed pumps; the containment tubing are larger in
diameter than the pressure line tubing and drains into the calcium chloride and ferrous
chloride feed pump containment drums, respectively, located below the mechanical room.
The suction line of pH Sample Pump 2 is located on the upstream end of the reaction tank at
a NORMALLY OPEN valve on the outside wall of the reaction tank. The pH Sample Pump 2
suction line drain valve is located below the mechanical room and is NORMALLY CLOSED.
The pH Sample Pump 2 suction line drain valve may be opened for freeze protection during
extended periods of freezing temperatures. The discharge line of the pH Sample Pump 2
empties into the reaction tank over the rim of the tank. Isolation valves are located
downstream of Sample Pump 2 and on either side of pH Sensor 2; the isolation valves are
NORMALLY OPEN.
The reaction tank mixer is a constant speed mixer that operates continuously unless shut off
by controls described subsequently.

Process controls include level switches and adjustable variable inputs to the HMI; the
variable inputs to the HMI include the reagent feed rate set-points described previously and
a delay timer.
2 The pH Sensor 2 measures the pH of the wastewater in the reaction tank for process informational purposes
only. It does not affect the operation of the reaction/precipitation process.

Two level switches are located in the reaction tank—the reaction tank LL-level switch and
the reaction tank HH-level switch; each is annunciated on the HMI with colored letter icons
when an alarm condition occurs (e.g., HH and LL). If the water level in the reaction tank
decreases below the LL switch, the reagent feed systems and reaction tank mixer will shut off
after an adjustable delay timer elapses. If the water level in the reaction tank rises above the
reaction tank HH-level switch, the influent pump will shut off.
The calcium chloride and ferrous chloride feed systems operate continuously (at their input
set-points in the HMI) unless the reaction tank mixer is off. The reaction tank mixer
operates continuously, while the influent flow meter measures a flow rate of at least 5 gpm,
and the water level within the reaction tank is above the LL-level switch. An adjustable
delay timer input to the HMI allows the reaction tank mixer to continue to run after the
influent flow meter measures a flow of fewer than 5 gpm.

Process operations include the following: 1) maintaining a sufficient supply of ferrous
chloride and calcium chloride reagents for the process; 2) adjusting the ferrous chloride and
calcium chloride feed rate set-points in the HMI; 3) periodic cleaning and calibration of pH
Sensor 2; 4) periodic calibration of the calcium chloride and ferrous chloride feed pumps; and
5) periodic removal of debris and solids that may accumulate inside the reaction tank.
The calcium chloride and ferrous chloride feed rate set-points entered into the HMI may be
adjusted using the HMI. Refer to Section 3.9.2 to adjust the calcium chloride and ferrous
chloride feed rate set-points.
Level sensors on the calcium chloride bulk tote and ferrous chloride bulk tote are used to
annunciate a warning on the HMI if the reagent levels are low and need to be replenished.
The placement of the calcium chloride bulk tote level sensor and ferrous chloride bulk tote
level sensor can be adjusted to provide adequate warning based on variable reagent usage
rates. Replacement of the calcium chloride bulk tote and ferrous chloride bulk tote requires
the use of a forklift. Refer to Section 3.6.2 for procedures to replace empty bulk totes.
Cleaning of pH Sensor 2 should be conducted each time the pH Sensor 1 (in the pH
adjustment process) is cleaned and calibrated. Refer to Section 3.7.1 for procedures to clean
the pH sensors, and refer to Section 3.8.2 for procedures to calibrate the pH sensors.
The calcium chloride and ferrous chloride feed pumps should be periodically calibrated, as
described in Section 3.8.4.

Accumulated solids removal may require draining the reaction tank and the use of additional
equipment (see Section 5.4.2).

Wastewater flows by gravity from the reaction tank into the polymer addition tank.
2.5 Flocculation Process

The purpose of the flocculation process is to enhance the settling potential of the B(a)P and
fluoride and cyanide solids formed during the pH adjustment process and reaction/
precipitation process.
Diluted liquid polymer is added to the wastewater and gently mixed to create flocculants that
adhere to compounds present in the wastewater. The flocculants have a greater settling
potential, thereby enhancing the removal of B(a)P and the cyanide and fluoride compounds
in the primary clarification process, described in Section 2.6. Typical polymer addition to
the polymer addition tank is 1 to 2 gpd and must be determined and adjusted based on the
wastewater influent.

Wastewater from the reaction tank flows by gravity into the polymer addition tank.
Additionally, filtrate water from the sludge tank is pumped into the polymer addition tank
by the filtrate pump; the sludge tank and filtrate pump are described in Section 2.8.

Equipment used in the flocculation process is listed in Table 5.
Table 5
Flocculation Process Equipment

Influent Pump1, 2 275
Influent Flow Meter1 310
Reaction Tank1 420
Polymer Addition Tank Inlet Drain/Valve3 518
Polymer Addition Tank 520


Polymer Addition Tank HH-level Switch 521
Polymer Addition Tank LL-level Switch 524
Polymer Addition Tank Mixer 525
Polymer Bulk Drum4 528
Polymer Bulk Drum Level Sensor 4 529
Polymer Feed Pump 4 530
Polymer Feed Pump Containment Drum4 531
Water Input Rotameter/Control Valve, Upstream4,5 544
Water Input Rotameter/Control Valve, Downstream4,5 546
Mix Mate Device4 550
Diluted Polymer Sampling Valve3,4 551
CP/HMI 1, 2 925, 926
Notes:
4 = Included equipment is referred to as the diluted polymer feed system.
The polymer addition tank is the head unit of the lamella clarifier and includes the polymer
addition tank mixer, which is a constant speed mixer that operates continuously unless
disabled by controls described in the following subsection. The polymer addition tank inlet
drain/valve is located at the bottom of the 6-inch-diameter steel pipe connecting the reaction
tank to the polymer addition tank; the valve is NORMALLY CLOSED and may be used to
remove solids that accumulate in the bottom of the inlet pipe.
The diluted polymer feed system is located in the mechanical room and includes the polymer
feed pump, the Mix Mate device, and the polymer bulk container. The Mix Mate device has
three liquid inputs and a single outlet. The polymer feed pump delivers diluted polymer
(through the Mix Mate device) directly into the polymer addition tank. The Mix Mate
device has two water inputs—one located upstream and the other located downstream of the
liquid polymer input; the liquid polymer is diluted with the water and thoroughly mixed
through the Mix Mate device to the desired concentration. The water input rate may be
adjusted by manipulating the valves on the water lines, and the rate of water input is
displayed on the rotameters. A sampling valve is located downstream of the Mix Mate device
where diluted polymer may be collected or for maintenance purposes as discussed later in
this manual. The speed of the polymer feed pump is modulated based on the flow rate
measured by the influent flow meter and the feed rate set-point or max speed set-point input

to the HMI for polymer addition. See Section 3.9.3 for directions to input the polymer feed
rate set-points. The polymer bulk container is located in the mechanical room, near the
polymer feed pump. Containment tubing is installed on the pressure line tubing connected
to the polymer feed pump; the containment tubing is larger in diameter than the pressure
line tubing and drains into the polymer feed pump containment drum located below the
mechanical room.

Process controls include level switches and adjustable variable inputs to the HMI. The
adjustable variable inputs into the HMI are the polymer feed rate set-point and a delay timer.
Two level switches are located in the polymer addition tank—the polymer addition tank
LL-level switch and the polymer addition tank HH-level switch; each is annunciated on the
HMI with colored letter icons when an alarm condition occurs (e.g., HH and LL) and call out
to operators.
If the water level in the polymer addition tank decreases below the polymer addition tank
LL-level switch, the polymer feed pump and polymer addition tank mixer will be disabled.
If the water level in the polymer addition tank rises above the polymer addition tank
HH-level switch, the influent pump will be disabled.

Process operations include the following: 1) maintaining a sufficient supply of liquid polymer
for the process; 2) adjusting the polymer feed rate set-point in the HMI for optimum
treatment operations; 3) occasional cleaning of the Mix Mate device; 4) occasional calibration
of the polymer feed pump; and 5) periodic removal of debris and solids that may accumulate
inside the polymer addition tank.
Accumulated solids removal from the polymer addition tank may require partially or fully
draining the lamella clarifier (see Section 5.4.3).

Wastewater flows by gravity from the polymer addition tank into the lamella clarifier.

2.6 Primary Clarification Process

The purpose of the primary clarification process is to allow for settling of flocculants
containing B(a)P and fluoride and cyanide solids produced in previous processes through the
addition of polymer. Solids settle to the cone at the bottom of the lamella clarifier, while the
clarified (treated) water gravity drains to the effluent tank. Solids management is described
in Section 2.8.

Wastewater in the polymer addition tank flows by gravity into the lamella clarifier.

Equipment used in the primary clarification process is listed in Table 6.
Table 6
Primary Clarification Process Equipment

Influent Pump1, 2, 3 275
Influent Flow Meter1, 2 310
Polymer Addition Tank1 520
Lamella Clarifier 620
Lamella Clarifier HH-level Switch 621
Lamella Clarifier LL-level Switch 624
Lamella Clarifier Cone Sight Tubes/Valves4 650
Sludge Control Valve4 665
Effluent Tank5 720
Filtrate Pump5 875
Sludge Tank5 820
CP/HMI 2 925, 926
Notes:
3 = Equipment is described in the pH adjustment process.
5 = Equipment is described in the following process.

The lamella clarifier is an elevated clarifier with a conical shaped bottom and contains
inclined plates to promote settling of solids. The plates contained in the lamella clarifier
have an excess of 600 square feet of treatment surface area. Three sight tubes are installed on
the cone of the lamella clarifier; these sight tubes attach to the cone at individual ball valves.
The sight tubes may be used to determine the level of sludge accumulated in the cone. The
sludge control valve is located at the bottom of the cone and is NORMALLY CLOSED; this is
described in greater detail in the following processes.

Process controls include two level switches located in the lamella clarifier—the lamella
clarifier LL-level switch and the lamella clarifier HH-level switch; each is displayed on the
HMI with colored letter icons when an alarm condition occurs (e.g., HH and LL) and call out
to operators.
If the water level in the lamella clarifier decreases below the lamella clarifier LL-level switch
or rises above the lamella clarifier HH-level switch, the influent pump will be disabled, as
will the filtrate pump. The filtrate pump is described in greater detail in the following
processes.

Process operations include occasional cleaning of the inclined plates within the lamella
clarifier. The lamella clarifier needs to be drained down, depending on the level of cleaning
necessary (see Section 5.4.4).
In order to clean the plates, Facility 71 needs to be shut down, and the lamella clarifier needs
to be drained into the sludge tank. The plates may be cleaned using a pressure washer.
Solids and debris accumulated on the plates will fall into the lamella clarifier cone.
After the plates have been cleaned, Facility 71 should be started up and adequate time must
be allowed to refill the lamella clarifier.

Treated effluent flows by gravity from the lamella clarifier over a weir and into the effluent
tank. Accumulated solids must be pumped into the sludge tank, described in Section 2.8.

2.7 Treated Effluent Management Process

The purpose of the treated effluent handling process is to: 1) batch treated wastewater
effluent for sampling and monitoring at Outfall 002B when required; and 2) allow discharge
of the treated effluent from Facility 71.

Wastewater effluent flows by gravity from the lamella clarifier to the effluent tank.

Equipment used in the treated effluent management process is listed in Table 7.
Table 7
Treated Effluent Management Process Equipment

Influent Pump1, 2, 3 275
Lamella Clarifier1 620
Effluent Tank 720
Effluent Tank HH-level Switch 721
Effluent Tank H-level Switch 722
Effluent Tank L-level Switch 723
ISCO Auto Sampler4 740
ISCO Sample Inlet4 741
Effluent Tank Discharge Valve5 765
Effluent Tank Discharge Wye-Strainer/Valve6 766
Effluent Pump Suction Line Drain Valve6 774
Effluent Pump 775
Effluent Pump Discharge Line Drain Valve6 777
Effluent Bypass Flow Control Valve6 781
Effluent Flow Control Valve5 782
Effluent Flow Meter 785
Effluent Air/Vacuum Release Valve6 790
CP/HMI 1, 2 925, 926
Notes:
1 = Equipment is described in the previous process. 4 = Equipment is used in sampling processes.
2 = Equipment is used in multiple processes. 5 = Valve is NORMALLY OPEN.
3 = Equipment is described in the pH adjustment process. 6 = Valve is NORMALLY CLOSED.

The effluent tank, similar to the influent batch tank, is 40 feet long, 8 feet wide, and 10 feet
high. The effluent tank is located opposite the sludge tank. An approximate volume of
12,600 gallons is available between the pumping cycles.
An automated ISCO sampler, model 4700 (740), is configured to obtain composite samples of
the treated wastewater effluent in the effluent tank. The ISCO sampler includes the
equipment and controls necessary for the collection of composite samples; a refrigerator
keeps the samples at 4 degrees Celsius in accordance with the NPDES permit sample
collection requirements. The sampler draws water from the effluent tank from an inlet on
top of the effluent tank. (See Outfall Field Equipment SOP for ISCO operations.)
The effluent pump, a centrifugal pump, is located in the mechanical room with controls on
the control panel. In normal operations, the effluent pump switch on the control panel is in
the “Auto” position and is controlled by the level switches in the effluent tank, described in
the following subsection. The effluent pump is used to pump treated wastewater effluent
from the effluent tank into the sump in Facility 77. Drain valves on both the suction and
discharge lines connected to the effluent pump are located below the mechanical room; the
drains are NORMALLY CLOSED and may be used for freeze protection during extended
periods of freezing temperatures.
The effluent flow meter is an inline globe valve located upstream of the effluent flow meter;
the valve is NORMALLY OPEN. The effluent flow meter allows for circulation of water
from the effluent tank to the pH tank, which may be necessary to avoid damage to
equipment during freezing temperatures.
The effluent flow meter, similar to the influent flow meter, is a magnetic flow meter located
between the main control facility and the influent batch tank. The flow meter has a digital
display, and the measured flow rate is also displayed on the HMI in the MCR. The flow rate
between the effluent tank and Facility 77 is continuously measured and recorded. Flows are
totalized daily and monthly by the PLC; the flow is reset daily at 12:05 am, and the flow is
reset on the first day of each month at 12:05 am.
The effluent air/vacuum release valve is installed on the effluent pump discharge line at the
top of the containment wall.

Process controls include three level switches in the effluent tank, which control the
operation of the effluent pump in normal operations.

The effluent pump will turn on when the water level in the effluent tank rises above the
effluent tank H-level switch and will continue to run until the water level decreases below
the effluent tank L-level switch, at which point the effluent pump will shut off.
Similar to the HH-level switches in the pH tank, reaction tank, polymer addition tank,
lamella clarifier, and the LL-level switch in the lamella clarifier, once the water level in the
effluent tank rises above the effluent tank HH-level switch, the influent pump will
be disabled.
Each level switch is annunciated on the HMI with colored letter icons when an alarm
condition occurs (e.g., HH, H, and L).

Process operations in the treated effluent management process include the following:
1) sampling the treated effluent; and 2) periodic removal of debris and solids that may
accumulate inside the effluent tank. Accumulated solids removal may require draining the
effluent tank and the use of additional equipment (see Section 5.4.6).
Operation of the ISCO sampler is handled using the on-board controller. In preparation for
sample collection, the Operator (or sampling personnel) places a clean 20-liter jar in the
sampler unit to collect the composite samples and initiates the sampling session. The sampler
is programmed to automatically take samples over a 24-hour period. Once a sample session is
completed, the Operator (or sampling personnel) will turn off the ISCO sampler and prepare
the sample jar for transport to the laboratory for analysis. The ISCO sampler should be
cleaned and maintained according to the manufacturer recommendations. Refer to MBT-
Longview’s Laboratory QA/QC manual for sampling handling and sample subcontracting.

Treated wastewater effluent is pumped from the effluent tank to Facility 77.
2.8 Sludge Management Process

The purpose of the sludge management process is to: 1) remove accumulated sludge from the
cone of the lamella clarifier; 2) dewater the sludge to separate solids from filtrate; 3) remove
and properly dispose of the solids; and 4) circulate the filtrate back into Facility 71 for
further treatment.


Accumulated sludge from the lamella clarifier cone is pumped into the sludge tank by the
sludge pump.

Equipment used in the sludge management process is listed in Table 8.
Table 8
Sludge Management Process Equipment

Polymer Addition Tank1 520
Lamella Clarifier1 620
Sludge Control Valve4 665
Sludge Pump 805
Sludge Pump Air Valve4 810
Sludge Tank 820
Sludge Tank H-level Switch 822
Sludge Tank Hatch for Solids Removal 861
Sludge Tank Discharge Valve3 865
Filtrate Line Wye/Control Valve4 866
Filtrate Pump Suction Line Drain Valve4 874
Filtrate Pump 875
Filtrate Pump Discharge Line Drain Valve4 877
CP/HMI 2 925, 926
Notes:
1 = Equipment is described in a previous process.
The sludge pump, a pneumatic diaphragm pump located beneath the lamella clarifier, is used
to pump accumulated sludge from the cone of the lamella clarifier to the sludge tank. The
sludge pump air valve, located on the pressurized airline connected to the sludge pump,
supplies air to operate the sludge pump; the valve is NORMALLY CLOSED. The suction line
of the sludge pump is connected to the cone of the lamella clarifier at the sludge control
valve, which is NORMALLY CLOSED.

The sludge tank is an enclosed phase separation tank measuring approximately 22 feet long,
8 feet wide, and 5 feet tall. The sludge tank has a false bottom with a filter membrane that
allows the sludge to decant; liquid phase filtrate is collected below the false bottom and solid
phase filtrate is retained above the filter membrane.
The filtrate pump is a centrifugal pump located in the mechanical room with controls located
on the control panel. In normal operations, the filtrate pump control switch at the control
panel is in the “Auto” position and is controlled by the filtrate level sensor in the sludge tank,
described in the following subsection. The suction line of the filtrate pump is connected to
the end of the sludge tank at the filtrate control valve, which is NORMALLY OPEN. The
discharge line of the filtrate pump runs below the mechanical room, along the pavement, and
up into the polymer addition tank. Drain valves on both the suction and discharge lines
connected to the filtrate pump are located below the mechanical room; the drains are
NORMALLY CLOSED and may be used for freeze protection during extended periods of
freezing temperatures.

Process controls include the manual operation of the sludge pump and the filtrate level
sensor in the sludge tank.
The sludge pump controls are located at the pump and are “On”/“Off.”
The filtrate pump will turn on when the filtrate water level in the sludge tank rises
approximately 6 inches above the sludge tank H-level switch and will continue to run
approximately 5 minutes after the water level in the sludge tank decreases below the level
switch. The level switch is displayed on the HMI with a colored letter icon (e.g., H).

Process operations include manually operating the sludge pump and periodically removing
the accumulated sludge from the sludge tank, in accordance with MBT-Longview’s Solid
Waste Control Plan.
Prior to operating the sludge pump, the sludge control valve at the bottom of the lamella
clarifier cone, which is NORMALLY CLOSED, must be opened. The sludge pump is
manually operated at the pump by switching the pump on; the pump runs on compressed air
supplied by other on-site facilities. The sludge pump should be operated for a short duration
every day during treatment. Three drain tubes are installed on the side of the lamella
clarifier cone; each may be opened to determine the level of sludge accumulated in the cone.
Each drain tube is attached to a ball valve, which is NORMALLY CLOSED. To drain the

accumulation cones, turn off the sludge pump and close any valves opened during the
operation of the sludge pump. Open the site tube(s) and collect the sludge and water that
drains out into a bucket and dispose of the bucket contents into the sludge tank.
Removal of solids from the sludge tank is done by a contractor using a vactor truck. The
Operator must monitor the accumulation of solids within the sludge tank and coordinate the
solids removal by the contractor, as necessary. Occasional replacement of the sludge tank
filter membrane is necessary and should be done to maximize dewatering of sludge.
To evacuate the sludge tank, refer to Section 5.4.5.

Filtrate is pumped from the sludge tank into the polymer addition tank. Solids are removed
from the sludge tank and properly disposed of in accordance with the Solid Waste
Control Plan.
2.9 Programmable Logic Controller System

A programmable logic controller (PLC) system is used to measure, monitor, and record
various characteristics of the wastewater, monitor and record operational activities, and also
to control equipment operations during the treatment processes. Data collected are used to
adjust process conditions, as necessary, to optimize the efficiency of Facility 71.
2.9.1 Human Machine Interface

The PLC system display, referred to as a human machine interface (HMI), is located in the
mechanical room on the control panel. The HMI is used for system status display,
operational values entry, and range checking of the values entered. The HMI communicates
with the PLC via RS232 serial DF1 protocol.
The HMI includes an interface using a single EZ Touch 8-inch display. The screen saver
mode is enabled after 15 minutes of inactivity; the screen saver mode is stopped by touching
the screen. Colors used in the EZ Touch display are summarized in Table 9.

Table 9
Color Designation on HMI EZ Touch Display
Color HMI Screen Component

White Screen background
Black Text, borders, and icon outlines
Equipment or function is not available
or
Grey Equipment or device is de-energized or in the “Off” position
or
Alarm is not active
Equipment or device is in alarm
Yellow or
Alarm is active
Red Equipment or device is energized or in the “On” position
The HMI system includes the following display screens:
2.9.2 Alarms
The PLC is programmed to display and annunciate alarms that develop during operation of
Facility 71. Certain alarms are displayed on the HMI. Table 10 summarizes the various

alarms programmed into the PLC. Photograph 1 illustrates the Alarms Status screen on the
HMI.
Level switch-controlled alarms (triggered by water level in process tanks or by product level
in bulk totes/drum) will automatically reset after the alarm condition has cleared and
5 minutes have elapsed. The treatment system will resume operations afterwards.
When an alarm is triggered, a corresponding message is displayed in the PLC/HMI with a

time stamp. The alarm button text changes from “Alarm OK” to “Alarm Active,” and the
button color changes to red. Alarm occurrences can be reviewed on the HMI by navigating
to the Alarm History screen.
Table 10
Alarms Summary
Equipment/ Alarm Device

Alarm
Component (System No.)
Batch Tank Level High Influent Batch Tank HH-level Switch 1
Batch Pump Fail to Run1 Motor Control Relay M1 (176)
Influent Pump Fail to Run1 Motor Control Relay M2 (276)
pH Tank Level High pH Tank HH-level Switch (321)
pH Tank Level Low pH Tank LL-level Switch (324)
pH Tank Mixer Fail to Run1 Motor Control Relay M5 (326)
Reaction Tank Level High Reaction Tank HH-level Switch (421)
Reaction Tank Level Low Reaction Tank LL-level Switch (424)
Reaction Tank Mixer Fail to Run1 Motor Control Relay M6 (426)
Polymer Tank Level High Polymer Addition Tank HH-level Switch (521)
Polymer Tank Level Low Polymer Addition Tank LL-level Switch (524)
Polymer Tank Mixer Fail to Run1 Motor Control Relay M7 (526)
Clarifier Level High Lamella Clarifier HH-level Switch (621)
Clarifier Level Low Lamella Clarifier LL-level Switch (624)
Filtrate Pump Fail to Run1 Motor Control Relay M4 (876)
Effluent Tank Level High Effluent Tank HH-level Switch (721)
Effluent Pump Fail to Run1 Motor Control Relay M3 (776)
Acid Tank Level Low Warning Acid Bulk Tote L-level Switch (329)
Calcium Chloride Tank Level Low Warning Calcium Chloride Bulk Tote L-level Switch (429)
Ferrous Chloride Tank Level Low Warning Ferrous Chloride Bulk Tote L-level Switch (434)
Polymer Supply Tank Level Low Warning Polymer Bulk Drum L-level Switch (529)

Equipment/ Alarm Device

Alarm
Component (System No.)
pH Sample Pump 1 Fail to Run2 Motor Control Relay M8 (341)
2
pH Sample Pump 2 Fail to Run Motor Control Relay M9 (441)
Notes:
1 = Motor failure alarms “Fail to Run” require pressing the “Alarm Reset” button on the HMI panel after the alarm
condition is clear. Turn the equipment switch on CP from “Auto” or “Hand” to “Off” when resetting the motor
failure alarms.
2 = Motor failure alarms “Fail to Run” require pressing the “Alarm Reset” button on the HMI panel after the alarm
condition is clear. Turn the equipment switch, on pH sampler/controller panel from “Auto” or “Hand” to “Off”
when resetting the motor failure alarms.
Photograph 1. Alarms Status screen on HMI
2.9.3 Data Logging by the PLC and HMI

Data logging is handled by the PLC and HMI. Data are collected in 1-minute intervals and
are stored in a comma separated value (CSV) file format on a SD-card in the HMI. Data in
the CSV file may be imported into a spreadsheet program (e.g., Microsoft Excel) for further
evaluation. Logged data are listed in Table 11.

The PLC/HMI in Facility 71 receives operational signals and logs data from Facility 71 and
from other facilities onsite including Outfalls 002A, 006, and leachate ditch. Data logged by
the HMI for Outfall 002A occurs independent of the operation of Facility 71. Outfall 002A
monitoring data logged in the HMI include flow, pH, and temperature. This manual is
limited to the operation of Facility 71. Information relating to Facility 73 Operations and
Maintenance and Outfall 002A may be found in other reference documents related to those
operations.
Table 11
Summary of Data Logged by PLC/HMI
PLC Tag Description
Date mm/dd/yyyy
Time hh:mm:ss
FIT_002A_LO 002A Low Flow Rate1, 3
FIT_002A_LO_DAY 002A Low Flow Daily Totalizer
FIT_002A_LO_MON 002A Low Flow Monthly Total
FIT_002A_LO_DAY_AVG 002A Low Flow Daily Average
FIT_002A_HI 002A High Flow Rate1, 3
FIT_002A_HI_DAY 002A High Flow Daily Totalizer
FIT_002A_HI_MON 002A High Flow Monthly Total
FIT_002A_HI_DAY_AVG 002A High Flow Daily Average
AIT_003 002A pH3
TIT_004 002A Temperature Fahrenheit 2, 3
TIT_004_Celsius 002A Temperature Celsius
LIT_077 Tank 3 Level
FIT_080 71 Influent Flow
FIT_080 day 71 Influent Daily Flow Totalizer
DIT _080_mon 71 Influent Flow Monthly Totalizer
PH_SCALED 002A pH Scaled for Trend Display
FIT_980 002B Effluent Flow Rate
FIT _980_DAY 002B Effluent Flow Daily Totalizer
FIT_980_mon 002B Effluent Flow Monthly Total
FIT_006 Outfall 006 Flow
FIT_006_day Outfall 006 Daily Flow Totalizer
FIT_006_mon Outfall 006 Flow Monthly Total
Rainfall Total Daily Rainfall
Notes:
1 = Outfall 002A includes two flow meters—a High Flow meter and a Low Flow meter.
2 = Outfall 002A temperature is displayed and logged in degrees Fahrenheit.
3 = instantaneous measurement

2.9.4 Logged Data Acquisition

In addition to data collected and stored at the HMI, the data is also collected by a Supervisory
Control and Data Acquisition (SCADA) system that runs as a virtual machine on the main
MBT-Longview server. The SCADA software provides a historical database, real time data
trending, alarm notifications, and report generation.
2.9.5 SCADA Alarm Notifications

Alarms notifications, as described in Table 10, are sent to personnel via text messaging and
email.
3 NORMAL OPERATIONS
3.1 Introduction
This section expands upon Section 2, Treatment Process Descriptions, and provides guidance
to the Facility 71 Operator when making the necessary adjustments to the operational
parameters. Therefore, these two sections should be looked at jointly. Where details are not
clear, refer to the other sections, Figures DWG-2 to DWG-5, and manufacturer-supplied
equipment user manuals.
3.2 Facility 71 Operational Limitations

Facility 71 is a batch treatment plant and may not operate for extended periods depending on
wastewater source generation and storage capacity within Facility 77. Facility 71 operation
is seasonal and continuous operation is not critical; therefore, it is not equipped with a
backup power generator. However, the PLC/HMI does have a UPS battery backup. While
power outages occur infrequently, MBT-Longview has implemented an overall site plan to
mitigate power outages. The plan includes mobilizing, if necessary, a contractor-supplied
portable power generator.
3.3 Treatment Efficiency

The treatment efficiency of Facility 71 is primarily dependent on treatability of influent
contaminant concentrations, chemical addition rates, and resonance time within the reaction
tank. Variability in the contaminant concentrations and flow quantity of wastewater
influent to Facility 71 may be attributed to seasonal and weather variability and variations in
on-site operations.

Facility 71 is a batch treatment system, and flow rate throughput is constant when the
volume of stored wastewater is not limited. It is capable of continuous operations but may
be operated intermittently to treat batches of wastewater. The ability to batch treat
wastewater improves efficiency of the facility and allows for seasonal use of the plant (i.e.,
during periods of rain). Variability in contaminant concentrations in the influent
wastewater may require adjustment of the chemical and reagent feed rates. These feed rates
must be adjusted by the Facility 71 Operator when significant changes to influent
wastewater contaminant concentrations occur in order to optimize treatment efficiency.
3.4 Overview of Operational Activities

There are several activities that need to be performed on a regular basis for Facility 71 to
operate in a safe, reliable, and efficient manner. A summary of regularly required activities is
described briefly in the following subsection and in more detail in Section 3.9. In addition,
there will be many activities performed on an irregular basis; these activities include special
maintenance, process modifications, and resolving other irregular operational conditions.
3.4.1 Best Management Practices

The following items are best management practices that will be implemented to optimize
operations of Facility 71:
 Perform “good housekeeping” measures site-wide to minimize variability in flow and
minimize contaminants entering the various influent waste streams.
 Document staff interaction with Facility 71, such as:
 System inspections
 Equipment maintenance
 Daily operational parameters and modification of these parameters
 Modification of operations and individual systems
 Changes to the system, whether changes are temporary or permanent, regardless
of scope of change
 Changes to procedures, when different from those described herein
 Usage of consumables (i.e., chemicals, polymers, calibration solutions, and
personal protective equipment [PPE])
 Frequently inspect sources, systems, and equipment
 Maintain sufficient quantities of consumables
 Tag-out and/or lock-out equipment if operated in a condition other than
normal operations

3.4.2 Operational Tasks

The Facility 71 Operator must complete the following tasks as part of WWTP operation in
order to maintain process efficiency:
 Determine appropriate chemical, reagent, and polymer feed rate set-points
 Acid feed: pH set-point in pH controller (935); adjustment not normally required
 Ferrous chloride feed: Ferrous chloride set-point in HMI (926)
 Calcium chloride feed rate: Calcium chloride set-point in HMI
 Polymer feed rate: Polymer set-point in HMI
 Facility 71 Influent and Outfall 002B discharge are monitored and sampled in
accordance with the NPDES permit. When treating remediation waters as defined in
Special Condition S1.E, the operator:
 Obtains samples of Facility 71 influent and effluent using ISCO sampler
 Coordinates delivery of samples to off-site laboratory for analysis
 Obtains analysis results from off-site laboratory; record and report data on
monthly discharge monitoring reports
 Determines operational changes necessary to improve Facility 71 efficiency
 Operate the sludge pump (805) for a short period weekly during treatment based on
manual sludge level checks
 Resolve and report any problems or abnormalities
 Respond to alarms
3.4.3 Equipment Inspections

The following inspection items are necessary for proper operation of Facility 71:
 Inspect control panel (925) in the MCR and the pH controller (935) in the mechanical
room for the following:
 Look for alarms or abnormal operations
 Equipment controlled at the control panel and pH controller panel should
normally operate in “Auto” position
 Visually inspect Facility 71 for:
 Spills and leaking piping or equipment
 Valve positions (NORMALLY CLOSED and NORMALLY OPEN valves)
 Listen for abnormal operation of equipment, such as:
 Knocking, spraying, or grinding
 Excessive noise or no sound (indicating a failure or equipment is off)
 Check mechanical operation of equipment in Facility 71 for the following:

 Process transfer pumps (175, 275, 775, and 875)

 Chemical, reagent, and polymer feed pumps (330, 430, 435, and 530)
 pH sample pumps (340 and 440)
 Containment pump (240)
 ISCO sampler (740): Refrigerator and sample pump
 Tank mixers (325, 425, and 525)
 Mix Mate device (550)
 Valves
 Flow meters (310 and 785)
 pH sensors (350 and 450)
 Eye wash and shower station (950)
 Fire suppression equipment
 Check security and safety of bulk totes and drums
 Low-level switch position on the totes and drum
 Feed pump suction line in tote should be in the proper tote below the product
level in the tote
 Monitor sludge accumulation in the sludge tank; coordinate disposal of dewatered
solids, as necessary
3.4.4 Equipment Maintenance

Maintenance of equipment is discussed in greater detail in Section 3.7, and calibration of
equipment is discussed in Section 3.7. Equipment in Facility 71 shall be maintained in
accordance with the equipment manufacturer’s recommendations and in accordance with
the NPDES permit requirements, where applicable. The following maintenance is required
on a regular interval:
 Process transfer pumps

 Lubrication
 Reagent and polymer feed pumps
 Replacement of wearing parts (except for the acid feed pump)
 Scheduled replacement of pump unit (for acid feed pump, only)
 pH sampling pumps
 Lubrication
 pH sensors
 Cleanings
 Calibration

 Flow meters
 Calibration
 Mix Mate device
 Cleaning
 Mechanical tank mixers
 Valve exercising
 Eye wash and shower station
 ISCO sampler
3.4.5 Materials Management

Materials are consumed during operation of Facility 71 and must be replenished.
Furthermore, solids generated during treatment must be managed, accordingly. Materials
management includes:
 Visually inspect level of product in bulk totes and drums
 Replace empty totes and drums, as necessary
 Order and schedule delivery for proper inventory of supplies
 Bulk totes and polymer buckets (5 gals)
 pH sensor calibration solutions
 PPE: Gloves, masks, boots, aprons, and earplugs
 Arrange for removal and disposal of solids accumulation in the sludge tank, as necessary
3.5 Pumps
3.5.1 Pump Inventory
Not including the pump within the composite sampler or the containment sump pump, there
are 11 pumps of various types in use within Facility 71; five are used to transfer the
wastewater (and solids) between processes, two are used to circulate water for monitoring of
wastewater pH, and four are used to add chemical reagents and polymer as part of the
treatment processes. An inventory of the pumps used in Facility 71 is listed in Table 12.

Table 12
Facility 71 Pump Inventory
Pump Name System Manufacturer Pumps From

Pump Type Purpose
Location1 No. Model Pumps To
Batch Pump 175 Submersible, Process Tank 3 (Facility 77)
---
Tank 3 (Facility 77) Centrifugal Transfer Influent Batch Tank
Influent Pump 275 Viking Process Influent Batch Tank
Centrifugal
Mechanical Room AK4195 Transfer pH Tank
pH Sample Pump 1 340 Goulds Circulation, pH pH Tank
Mechanical Room MCS Centrifugal Monitoring pH Tank
Positive
Acid Feed Pump LMI Milton Roy Reagent Acid Bulk Tote
330 Displacement
Mechanical Room C781-36 Addition pH Tank
Diaphragm
pH Sample Pump 2 Goulds Circulation, pH Reaction Tank
440
Mechanical Room MCS Centrifugal Monitoring Reaction Tank
Calcium Chloride Positive
LMI Milton Roy Reagent Calcium Chloride Bulk Tote
Feed Pump 430 Displacement
C781-36 Addition Reaction Tank
Mechanical Room Diaphragm
Ferrous Chloride Positive
LMI Milton Roy Reagent Ferrous Chloride Bulk Tote
Feed Pump 435 Displacement
AA941-458SI Addition Reaction Tank
Mechanical Room Diaphragm
Positive
Polymer Feed Pump LMI Milton Roy Polymer Polymer Bulk Drum
530 Displacement
Mechanical Room AA941-458SI Addition Polymer Addition Tank
Diaphragm
Sludge Pump WasteCorp Mud Pneumatic Sludge Lamella Clarifier
805
Clarifier Outlet Sucker 3FA-Ap Diaphragm Transfer Sludge Tank
Filtrate Pump Blackmer Process Sludge Tank
875 Centrifugal
Mechanical Room SNP2 Transfer Polymer Addition Tank
Effluent Pump Gorman Rupp Process Effluent Tank
775 Centrifugal
Mechanical Room AK4195 Transfer Facility 772
Notes:
1 = Table does not include Facility 71 containment sump pump or the pump within the composite sampler.
2 = By manipulating the three-valve cluster near the influent and effluent flow meters, water from the effluent
tank may be circulated into the pH tank; this is an uncommon practice that may be necessary during extended
periods of freezing temperatures to avoid freeze damage of equipment.
3.5.2 Pump Spare Parts and Units

Facility 71 is a batch treatment plant and may not be required to operate for extended
periods depending on wastewater source generation and live storage capacity within

Facility 77. Most pumps in Facility 71 are typically available from local suppliers and can be
sourced and replaced quickly in the event of failure if they cannot be repaired.
The acid feed pump is the only pump in Facility 71 that handles the concentrated sulfuric
acid, and maintenance or repair of the acid feed pump is not recommended. A replacement
acid feed pump should be stored within the ancillary storage area of the main control facility
if pump failure occurs. See Section 3.7.4 for more information on maintenance.
3.5.3 Auxiliary Pumps Operations

There are two auxiliary pumps within Facility 71—a containment sump pump and a pump
within the composite sampler. These auxiliary pumps are not included in Table 12.
The containment pump is a common float switch activated pump located near the outlet of
the effluent tank. This pump dewaters precipitation and potential wastewater spills collected
within the containment area of Facility 71. The pump operates on an integrated float switch
and discharges to the influent batch tank (220). This pump requires minimal maintenance,
which should be done according to the manufacturer recommendations. See Section 3.7 for
more information on maintenance.
3.5.4 Process Transfer Pump Operations

Transfer pumps, except for the sludge pump (805), are normally run in the “Auto” position
on the control panel (925) in the MCR. These pumps are controlled with the use of level
switches located in the various process tanks and will run continuously at a constant speed
while engaged by the level switches. The sludge pump, located between the lamella clarifier
and sludge tank, is manually controlled at the pump and should be run daily for a short time,
as described Section 2.8.
The transfer pumps will be maintained according to the manufacturer recommendations.

See Section 3.7 for more information on recommended maintenance.
3.5.5 pH Loop Pump Operations

Control switches for both pH loop pumps (circulation pumps) are normally operated in the
“Auto” position on the pH sampler/controller (935) panel in the mechanical room. These
pumps will run continuously at a constant speed so long as: 1) the influent flow meter (310)
measures a flow rate greater than 5 gpm and an adjustable time delay has elapsed (if not
bypassed by entering a value of 0 minutes for the delay timers); or 2) the water level in the
pH tank and/or the reaction tank is maintained above their respective LL-level switches.

The pH sample pumps will be maintained according to the manufacturer recommendations.

See Section 3.7 for more information on recommended maintenance.
3.5.6 Reagent and Polymer Feed Pump Operations

The acid feed pump (330) is operated based on the pH set-point input into the pH controller
(935) and the measured pH of the wastewater in the pH tank (320). The speed of the acid
feed pump is modulated, as needed, to adjust the wastewater pH to the pH set-point.
The ferrous chloride, calcium chloride, and polymer feed pumps are operated based on the
feed rate set-points input into the HM (926); see Table 1 for consumption rates of ferrous
chloride and calcium chloride. The speed of the feed pumps is modulated based on the feed
rate set-point in the HMI and the flow measured by the influent flow meter. The feed
pumps will run continuously if the following conditions are met: 1) a feed rate set-point (for
that particular feed pump) is entered into the HMI; 2) the flow rate into Facility 71 is above 5
gpm (measured by the influent flow meter); and 3) other equipment interlocks are not
engaged (e.g., tank mixers are off and LL-level switches are not engaged).
Each feed pump has a single suction line and single discharge line. Each suction and
discharge line is equipped with outer containment tubing that will divert leaks that may
develop in the suction and discharge line tubing to a reagent-specific bucket located beneath
the mechanical room.
Maintenance of the feed pumps will be conducted according to the manufacturer

recommendations. See Section 3.7 for more information on maintenance.
Feed Pump Operations during Bulk Tote/Drum Exchange

The following discussion focuses on the operation of the feed pump during tote or drum
exchange. Refer to Section 3.6.2 for a more detailed description on bulk tote/drum exchange
operations.
To exchange totes/drums, Operators must use the PPE required by the Safety Data Sheets
(SDS). SDSs for the chemicals currently in use within Facility 71 are located in the main
control room. Prior to exchange, the appropriate feed pump must be unplugged from the
electrical receptacle. The Operator shall then remove the suction line and L-level switch
from the empty tote/drum and reinstall on the full exchanged tote/drum.

The Operator shall then plug in the feed pump to the electrical receptacle, and return the
feed pump to the normal operating function at the HMI and inspect the system
for abnormalities.
3.6 Treatment Reagents and Polymers

Facility 71 consumes reagents and polymers as part of the pH adjustment process, the
reaction/precipitation process, and the flocculation process, described earlier in this
manual. At present, the reagents used at Facility 71 are sulfuric acid, calcium chloride,
ferrous chloride, and polymer.
Sulfuric acid is added to the pH Sample Pump 1 discharge pipe, which discharges into the
pH tank. The calcium chloride and ferrous chloride are added to the pH Sample Pump 2
discharge pipe, which discharges into the reaction tank. Polymer is pumped into the
Mix Mate device located in the mechanical room, where the polymer is diluted and mixed
with water. The Mix Mate discharge line discharges directly into the polymer addition tank.
The reagents are liquid concentrates that are stored in portable bulk totes, which are located
outside the mechanical room on an elevated platform. Polymer is a liquid concentrate stored
in 5-gallon drums positioned in the mechanical room next to the polymer feed pump.
Reagent and polymer is withdrawn from their respective bulk tote/drum with a dedicated
single feed pump suction line. The feed pumps are located in the mechanical room and are
automatically controlled, independently of one another, by the HMI and pH controller
respective to each unique feed set-point.
3.6.1 Reagent and Polymer Inventory Management

An additional inventory of full bulk containers of reagent and polymer and empty containers
resulting from consumed reagent and polymer are stored in the containment structure of the
original Facility 71. A forklift is necessary to move the totes between the containment
structure of the original Facility 71 and the operational Facility 71.
The Operator shall manage the inventory and coordinate the purchase and delivery of
reagent and polymer from the supplier. Sufficient numbers of additional totes of the
reagents and drums of polymer shall be kept in inventory at all times. Empty totes shall be
exchanged with the oldest tote in the inventory, and no tote shall be used that has an expired
“use-by” date.
Expected rates of consumption of calcium chloride and ferrous chloride are listed in
Table 13. Consumption rates shown in the table are based on observations made during

continuous operation of the plant at approximately 50 gallons per minute. The consumption
rates are not design values and changes in influent chemistry or changes to a process or plant
operation will produce different rates of consumption. In the event of an operational or
process change, design calculations should be used to estimate product consumption.
Table 13
Calculated Consumption Rates
Ferrous Chloride Dosing (30 percent FeCl2)

Influent Cyanide Influent Flow Rate Feed Rate 30% FeCl2
Concentration (ppb) (gpm) (gpd) FeCl2 Ratio
50 60 0.14 1.57E-06
100 60 0.27 3.14E-06
200 60 0.54 6.29E-06
300 60 0.82 9.43E-06
500 60 1.36 1.57E-05
1,000 60 2.72 3.14E-05
Calcium Chloride Dosing (35 percent CaCl2)
Influent Fluoride Influent Flow Rate Feed Rate 35% CaCl2
Concentration (ppb) (gpm) (gpd) CaCl2 Ratio
15,000 60 16.00 1.85E-04
25,000 60 26.67 3.09E-04
35,000 60 37.33 4.32E-04
50,000 60 53.33 6.17E-04
75,000 60 80.00 9.26E-04
100,000 60 106.67 1.23E-03
Sulfuric Acid Dosing (93 percent H2SO4)
pH Set-point Influent Flow Rate Feed Rate
(SU) (gpm) (gpd)
Consumption is dependent on dosage required to
6.41 60
achieve set-point
Polymer Dosing
Influent Influent Flow Rate Feed Rate
Concentration (gpm) (gpd) Polymer Ratio
N/A 60 1.73 2.00E-05
Notes:
1 = pH ranges from 4 to 6.5 per recommendations identified in Proposed Temporary Wastewater Treatment System for Facility
71 (November 15, 2011)
CaCl2 = calcium chloride gpm = gallon per minute ppb = parts per billion
FeCl2 = ferrous chloride H2SO4 = sulfuric acid SU = standard unit
gpd = gallon per day N/A = does not apply

3.6.2 Exchange of Reagent Bulk Totes and Polymer Bulk Drums

A normal part of operations is to exchange the bulk totes and drums when empty. Each bulk
tote and drum in use has a single feed pump suction line inserted inside the tote/drum, and
each tote/drum in use has a dedicated removable L-level switch that will annunciate an
alarm on the HMI that notifies the Operator that the tote or container requires exchange.
Each suction line will be labeled to assist in identification.
A forklift is necessary to exchange an empty bulk tote. The in-use bulk totes are stored in
two rows on the elevated platform within Facility 71 containment, which requires moving
the front tote in order to service the tote behind the front tote. The polymer container in
use is positioned in the mechanical room.
Totes shall not be moved or exchanged without first properly disabling the feed pump that
sources the tote/drum to be moved or exchanged. Refer to Section 3.5.6 for details required
for the feed pump operations during a tote/drum exchange.
Recovery of residual product in a polymer bulk container shall be done by manually draining
the near-empty container into a clean, 5-gallon bucket and transferring the residual polymer
into a full or partially full container.
Recovery of residual sulfuric acid, calcium chloride, or ferrous chloride shall be done by:
1) donning appropriate PPE; and 2) taking necessary safety measures and draining residual
product from the near-empty reagent bulk totes into a full reagent bulk tote. To drain a
near-empty reagent bulk tote, personnel may need to use a forklift to tip the near-empty
reagent bulk tote and use the bottom drain on the bulk tote to transfer residual product into
another bulk tote. To minimize exposure of residual product, tubing should be used between
the drain of the near-empty bulk tote and the top inlet of the full bulk tote.
Caution: Do not overfill a full bulk tote.
3.7 Equipment Maintenance

Equipment maintenance is an ongoing task that can extend the service life of equipment and
typically leads to a system that is more safe, efficient, and reliable. Since Facility 71
operation is seasonal and operation is intermittent most maintenance is done while the
system is not operating. The seasonal operation also extends the life of many of the
components. A summary of equipment maintenance recommendations are is included in
Table 14.

With many of the system components in Facility 71 operated by the PLC, there is little day-
to-day interaction between the Operator and the equipment in Facility 71. For this reason,
frequent visual inspections are necessary to monitor the condition of the equipment.
Table 14
Equipment Maintenance Schedule
Maintenance
Equipment System No. Purpose Frequency
Necessary
Maintain
Clean sensors in a Monthly or more frequently as
pH Sensors1 350, 450 accuracy of pH
soap solution needed
measurements
Disassembly of
Maintain Annually or more frequently as
Mix Mate Device 550 device and cleaning
proper function needed
components
Replace pump with Once per 5 years or more
Acid Feed Pump2 330 Replacement
a new unit frequently as needed
Calcium Chloride
Calcium Chloride,
(430) Replace
Ferrous Chloride, Replacement of Once every 2 years or more
Ferrous Chloride combination valve
and Polymer Feed wearing parts frequently as needed
(435) seat-seal ring
Pumps Polymer (530)
Replace suction and
Replace
Feed Pump discharge line Annually or more frequently as
--- degraded
Tubing tubing and needed
material
containment tubing
Process Transfer
Pumps (not 175, 275, 775, Maintain See manufacturer
Lubrication
including Sludge 875 proper function recommendation
Pump)
pH Sampling Maintain See manufacturer
340, 440 Lubrication
Pumps proper function recommendation
Replace flexible
Maintain piping (suction and Inspect piping monthly; replace
Sludge Pump 805
proper function discharge piping, as conditions warrant
plant air supply line)
Replace as Inspect for proper Inspect monthly; replace upon
Tank Mixers 325, 425, 525
necessary function failure
Maintain
Process Valves Numerous Exercise valves Annually
proper function
Emergency Operate eyewash
Maintain Monthly or more frequently as
Eyewash and 950 and shower to flush
proper function needed
Shower water

Maintenance
Equipment System No. Purpose Frequency
Necessary
Lift float to check
Containment Maintain Once per week during
240 that pump is
Pump proper function precipitation events
functioning properly
Cleaning and
Maintain Four times per year or more
ISCO Sampler 740 replacement of
proper function frequently as needed
wearing parts
Evacuate tanks;
Evacuate and
220, 320, 420, remove Annually during period of low
inspect tanks;
Process Tanks 520, 620, accumulated solids precipitation
clean as
720, 820 and debris; inspect (see Section 5.4)
necessary
tank interior
Draw down the
Inspect clarifier Lamella Clarifier and Weekly inspections; clean as
Lamella Clarifier 620 holes and weirs clean as needed; needed
on top of unit cleaning requires (Section 0)
pressure washer
Close outlet valve,
Prevent
clean wye-strainer3, Weekly or more frequently as
Wye-Strainers 266, 766, 866 clogging of tank
reassemble, and needed
outlets
open outlet valve
Remove
Polymer Addition Open the valve and Monthly or more frequently as
accumulated
Tank Inlet 518 drain solids into a needed; may include in
solids from
Drain/Valve container3 cleanout of Lamella Clarifier
inlet pipe
Test fire system
components
950, 955, 956,
Maintain including
Fire System 957, 960, Monthly
proper function extinguishers;
965, 970
replace batteries in
fire detector
Notes:
1 = Equipment calibration to follow maintenance activity.
2 = Maintenance shall not be done on the acid feed pump without supervisory approval. The acid feed pump will
be replaced at a regular interval.
3 = Drain contents into a bucket or other portable container and dispose of collected contents into the Sludge Tank.
3.7.1 Cleaning the pH Sensors

There are two pH sensors (350 and 450) used in Facility 71, located on the discharge line of
the pH Sample Pump 1, which circulates water from the pH tank, and on pH Sample
Pump 2, which circulates water from the reaction tank.

Cleaning of the pH sensors is required to remove accumulated biofilm and debris from the
sensor, which may interrupt and affect the accuracy and response of the pH measurement.
Cleaning the sensors usually takes less than 10 minutes. Cleaning of the pH sensors shall be
done prior to calibration of the pH sensors. The sensors are removed from their respective
sample pump line to facilitate sensor cleaning.
pH Sensor Cleaning Procedures (Refer to the manufacturer’s documentation as necessary)

1. A sufficient quantity of standard buffer storage solution of pH 7 shall be kept in
on-site inventory; expired solutions shall not be used.
2. Prepare a mild soap solution with a non-abrasive dishwashing detergent that does not
contain lanolin.
3. Manually switch Sample Pump 1 and/or Sample Pump 2 switch at the pH
sampler/controller panel from “Auto” to “Off.”
4. Once the sample pump(s) is shut off, unplug the acid feed pump, the calcium chloride
feed pump, and the ferrous chloride feed pump from their respective electrical
receptacles.
5. Close the respective isolation hand valves on either side of the respective pH sensor.
6. Personnel performing maintenance should be equipped with PPE in accordance with
the SDS for the appropriate chemical exposure and in accordance with the required
site safety practices applying to wastewater influent with added sulfuric acid, calcium
chloride, or ferrous chloride.
a. Consult the SDS for details.
b. Consult the Site Safety Officer for additional details.
7. Remove the sensors from the sample pump lines and examine the sensor for debris
and deposits.
8. Use a clean, soft cloth to remove loose debris from the end of the sensor. Rinse the
sensor with clean, warm water.
9. Use a soft bristle brush to scrub the entire measuring end of the sensor.
10. If debris remains, soak the measuring end of the sensor in a dilute acid solution, such
as less than 5-percent hydrochloric acid for a maximum of 5 minutes.
11. Rinse the sensor with water and then return to the soap solution for 2 to 3 minutes.
12. Rinse the sensor with clean water.
13. Calibrate the sensors following cleaning.
14. Return the sensors into their respective sample pump discharge lines.

15. Open the respective isolation hand valves on either side of the respective pH sensor.
16. Plug in the feed pumps to the electrical receptacles.
17. Return the control manually shut off in Step 3 to normal automatic operations.
18. Monitor the feed pumps to determine that the reagent feed is normal. If needed, the
feed pumps may be operated in the “Jog” mode to prime the pumps.
3.7.2 Storing the pH Sensors When Not in Use

When the sensor(s) are not in constant use, or when the sensor(s) are removed from the
sample pump lines for more than 1 hour, fill a beaker with pH storage solution and place
probe in beaker. Repeat every 2 weeks for extended storage. See the manufacturer’s
documentation for further details.
3.7.3 Maintenance of the Mix Mate Device

The Mix Mate device (550) is used to dilute the liquid polymer solution before it is added to
the polymer addition tank. The liquid polymer is diluted with water from the plant through
two separate lines that enter the Mix Mate device upstream and downstream of the liquid
polymer feed. Dilution is controlled by the inflow rate of water and may be adjusted using
the inline valves; a rotameter is located on each of the two dilution lines and displays the
water inflow rate. Insufficient and improper dilution rates are the primary cause for
problems with the Mix Mate device, which primarily results in clogging when the dilution is
too low. See the manufacturer documentation for further details.
Clogging of the Mix Mate device can usually be observed in the tubing or sight tube
downstream of the second dilution line. Additionally, if clogging is occurring, the polymer
feed pump may be working harder than normal; the pump may sound labored.
Mix Mate Device Maintenance Procedures

1. Change the control of the influent pump at the control panel (925) from the “Auto”
position to the “Off” position. After a timed delay (when entered into the HMI), the
polymer feed pump will shut off.
2. Once the polymer feed pump has shut off, unplug the polymer feed pump from the
electrical receptacle.
3. Observe and record the position (setting) of the rotameters on the dilution lines.
4. Shut off the dilution lines by closing the inline valves located below the rotameters.
5. The Mix Mate device can now be disassembled for cleaning or other maintenance.

6. Reassemble the Mix Mate device.

7. Turn on the dilution line by adjusting the inline valves to match the previously
recorded setting or to a new setting calculated for dilution of the liquid polymer.
8. Plug in the polymer feed pump to the electrical receptacle.
9. Return the control of the influent pump at the control panel from the “Off” position
to the “Auto” position.
10. Monitor the polymer feed pump to determine that the polymer feed is normal. If
needed, the feed pump may be operated in the “Jog” mode to prime the pump.
3.7.4 Maintenance of the Reagent and Polymer Feed Pumps

Maintenance on the acid feed pump (330) will not be done without supervisory approval and
will be replaced at a regular interval, as identified in Table 14 or more frequently, as needed.
Maintenance on the calcium chloride (430), ferrous chloride (435), and polymer (530) feed
pumps includes replacing the combination valve seat and seal ring, which is a wearable part
in the pumps. Replacement parts shall be manufactured for use in the feed pumps, and
replacement of the pump parts shall follow the manufacturer recommendations.
Prior to servicing feed pumps, Facility 71 should be shut down, and the feed pumps should
be unplugged from their electrical receptacles. Personnel performing maintenance on the
feed pumps should be equipped with PPE in accordance with the SDS for the appropriate
chemical exposure and in accordance with the required site safety practices. Follow the
procedures outlined in Sections 2.4.6 and 2.5.2.
Other maintenance may include replacement of the feed pump tubing, as necessary, to allow
for visual observation of product flow through the tubing.
3.7.5 Maintenance of the Process Transfer Pumps

The process transfer pumps shall be maintained, as recommended by the manufacturer or
supplier. Maintenance may include replacement of wearable parts.
3.7.6 Maintenance of the pH Sampling Pumps

The pH sampling pumps shall be maintained, as recommended by the manufacturer and
supplier. Maintenance may include replacement of wearable parts.

3.8 Equipment Calibration

While calibration of equipment may be considered a part of equipment maintenance,
calibration is an important activity and is discussed separately in this section.
Equipment requiring calibration is listed in Table 15. Calibration shall be performed

according to the equipment manufacturer and to maintain compliance with the NPDES
permit requirements. Where applicable, calibration of equipment identified in Table 15 shall
be recorded with the name of the personnel conducting the calibration and the date and time
of calibration. Records of calibration shall be maintained on-site.
Table 15
Equipment Calibration Schedule
Equipment
Purpose Calibration Necessary Frequency
(System No.)
Influent Flow Meter Certified testing by
Check signal of meter At least once per year
(310) manufacturer or vendor
Effluent Flow Meter Certified testing by
Check signal of meter At least once per year
(785) manufacturer or vendor
Following sensor
pH Sensor 1 (350) and Calibrate sensors to
2-point calibration method cleaning; at least once
pH Sensor 2 (450) maintain accuracy
per month
3.8.1 Calibration of the Electromagnetic Flow Meters

Facility 71 has two electromagnetic flow meters—the influent flow meter (310) and the
effluent flow meter (785).
The NPDES permit requires that the influent and effluent flow meters be calibrated
according to the manufacturer recommendations or at a minimum frequency of once per
year.
The two flow meters are calibrated by a certified and authorized technician. The calibrations
are documented and retained in accordance with the NPDES permit. The calibration
documentation shall include, at a minimum, the name of the technician that conducts the
calibration and the date and time of calibration.

3.8.2 Calibration of the pH Sensors

There are two pH sensors (350 and 450) used in Facility 71, one each located in the pH
Sample Pump 1 and pH Sample Pump 2 lines. Calibration of the pH sensors shall be done
using a 1-point method, which includes the use of one standard buffer of pH 7.
Calibration of the pH sensors usually takes 10 minutes or less; however, calibration is

temperature-dependent. If the process water (that the pH sensor is monitoring) and standard
buffer solutions vary in temperature, then calibration cannot be properly conducted until the
temperature of the sensor and the standard buffer have equilibrated. See the manufacturer
documentation for further details.
Calibration of the pH Sensors by the 1-Point Method
1. The flow to the sensors must be turned off as described in Section 3.7.1
2. Check that there is sufficient quantity of standard buffer solution of pH 7; expired
solutions shall not be used.
3. Prior to calibration of the sensors, the sensors shall be thoroughly cleaned; refer to
Section 3.7.1.
4. Put the sensor(s) in the reference solution. Check that the sensor portion of the probe
is fully immersed in the liquid.
5. Wait for the sensor and solution temperature to equalize. This can take 30 minutes or
more if the temperature difference between the process water and reference solution
is significant.
6. On the pH controller, push the “Menu” key and select Sensor Setup, [Select Sensor],
Calibrate.
7. Select the type of calibration: 1-Point Buffer or 1-Point Sample.
8. If the passcode is enabled in the security menu for the controller, enter the passcode.
9. Select the option for the output signal during calibration: “Active”.
10. With the sensor in the first reference solution, push <ENTER>. The measured value
is shown.
11. Wait for the value to stabilize and push <ENTER>.
12. Review the calibration result
a. Passed – the sensor is calibrated and ready for use. The slope and/or offset
values are shown.

b. Failed – the calibration slope or offset is outside of accepted limits. Repeat the
calibration with fresh reference solutions. Refer to the manufacturer
documentation for further detail.
13. If the calibration passed, push <ENTER> to continue.
14. On the New Sensor screen, select whether the sensor is new:
a. Select no, unless the sensor is new.
b. Select yes if the sensor is new and is replacing the old during this calibration.
15. Return the sensor(s) to the sample pump lines and push <ENTER>. The output signal
returns to the active state and the measured sample value is shown on the
measure screen.
16. . Calibrate the second probe as described above.
3.8.3 Feed Pump Calibration

The four feed pumps may develop dosing inaccuracies over time. Inaccuracies may be caused
from wear on the feed pump, wear on the tubing, or other factors. For this reason,
calibration of the feed pumps should be done, as described in Table 14. Monitoring the usage
rate of reagents and polymer and comparing the monitored usage against the feed rate
set-points is one method to calibrate the feed pumps. More accurate calibration solutions are
available from the manufacturer or suppliers of the feed pumps.
3.9 Facility 71 Normal Operational Parameters

Under normal operations Facility 71 is mostly automated but needs to be monitored
frequently, and settings need to be adjusted based on observations and results of influent and
effluent sampling analyses.
Operational parameters for Facility 71 are values that the PLC uses to control the processes
and related process equipment. Sludge management is manually controlled.
3.9.1 Sulfuric Acid Feed System

Under normal operations, the acid feed system is entirely automated based on two
operational parameters or input values as follows:
 pH Set-point: Entered into the pH controller
 pH Tank Equipment Off Delay: Entered into the HMI

Normal operations include replenishing the sulfuric acid bulk tote. The acid feed pump has a
“Hand” function that allows for testing of the feed pump and is also used to purge and prime
the feed pump suction line. This “Hand” function will be used for the following:
 When troubleshooting interruptions in the feed stream

 To purge the feed pump suction line before exchanging a bulk tote
 To prime the feed pump suction line, such as is necessary after exchanging a bulk tote
pH Set-point
The acid feed rate in the pH tank is controlled by an adjustable pH value entered into the
pH controller. The value displayed in the pH controller as “pH SET-POINT” is entered as a
value between 0.0 and 14.0. The target treatment pH value ranges between 4.0 and 6.5.
The value for pH set-point may require adjustment if it is determined that the removal
efficiency of fluoride or cyanide can be improved to the benefit of adding less calcium
chloride or ferrous chloride, respectively.
Should the value require adjusting, the Operator shall refer to the pH controller user manual,
Vendor Installation, Operations and Maintenance Manuals for details; modification of the
pH set-point is not normally required.
pH Tank Equipment Off Delay
The pH tank equipment off delay timer is an adjustable value entered into the HMI to
control the operation of the pH tank mixer, pH Sample Pump 1, and the acid feed pump.
The value displayed in the HMI as “pH TANK EQUIPMENT OFF DELAY,” has an entry
range between 0 and 9,999 minutes. A value of 0 entered into the HMI will disable the
delay timer.
The delay timer extends the operation of the pH tank mixer, pH Sample Pump 1, and the
acid feed pump to the entered timer value when the influent flow meter measures a flow rate
less than 5 gpm. The purpose of the delay timer is to avoid equipment shutdown caused by
short pump cycle times.
Note that if the water level in the pH tank decreases below the LL-level switch in the pH
tank, the equipment will also be disabled.

Acid Feed Pump Manual Operation

To manually operate the acid feed pump, use the HMI “Jog” function on the acid feed pump.
This is not recommended for long-term use but is available to purge or prime the acid feed
pump suction line.
3.9.2 Reaction Tank Reagent Feed Systems

Under normal operations, the reaction tank reagent feed systems are entirely automated
based on three operational parameters, which are as follows:
 Calcium Chloride Ratio: Entered into the HMI
 Ferrous Chloride Ratio: Entered into the HMI
 Reaction Tank Equipment Off Delay: Entered into the HMI
Normal operations include replenishing the calcium chloride and ferrous chloride bulk totes.
The calcium chloride and ferrous chloride feed pumps have a “Jog” function that allows for
testing of the feed pumps and is also used to purge and prime the feed pump suction lines.
This “Jog” function will be used for the following:
 When troubleshooting interruptions in the feed stream
 To purge the feed pump suction line before exchanging a bulk tote
 To prime the feed pump suction line, as necessary, after exchanging a bulk tote
Additional reaction tank reagent feed system parameters described in this subsection include
the following:
 Calcium Chloride Jog Speed: Entered into the HMI
 Ferrous Chloride Jog Speed: Entered into the HMI
Calcium Chloride Ratio

Adjustment of the calcium chloride feed rate should be evaluated based on a comparison of
recent laboratory analytical results of influent and effluent sampling within Facility 71. The
feed rate is displayed in the HMI as “CALCIUM CHLORIDE RATIO.” The Operator shall
enter the lab-reported influent concentration of fluoride into the HMI in milligrams per liter
(mg/L).
It is important to note that the removal efficiency of fluoride in the wastewater when adding
calcium chloride is pH-sensitive; therefore, a change in the pH set-point should be
considered when adjusting the feed rate of calcium chloride.

To adjust the calcium chloride ratio, use the touch-screen navigation on the HMI to enter
the Set-points screen. Select the button “CALCIUM CHLORIDE RATIO” and enter the lab
reported value. Return the HMI to the Home screen.
Ferrous Chloride Ratio

Adjustment of the ferrous chloride feed rate should be evaluated based on a comparison of
recent laboratory analytical results of influent and effluent sampling within Facility 71. The
feed rate is displayed in the HMI as “FERROUS CHLORIDE RATIO.” The Operator shall
enter the lab-reported influent concentration of cyanide into the HMI in mg/L.
It is important to note that the removal efficiency of cyanide in the wastewater when adding
ferrous chloride is pH-sensitive; therefore, a change in the pH set-point should be considered
when adjusting the feed rate of ferrous chloride.
To adjust the ferrous chloride ratio, use the touch-screen navigation on the HMI to enter the
Set-points screen. Select the button “FERROUS CHLORIDE RATIO” and enter the lab
reported value. Return the HMI to the Home screen.
Reaction Tank Equipment Off Delay

The reaction tank equipment off delay timer is an adjustable value entered into the HMI to
control the operation of the reaction tank mixer, the pH Sample Pump 2, the calcium
chloride feed pump, and the ferrous chloride feed pump. The value, displayed in the HMI as
“REACTION TANK EQUIPMENT OFF DELAY,” has an entry range between 0 and 9,999
minutes. A value of 0 entered into the HMI will disable the delay timer.
The delay timer extends the operation of the reaction tank mixer, pH Sample Pump 2, and
the calcium chloride and ferrous chloride feed pumps to the entered timer value after the
influent flow meter measures a flow rate less than 5 gpm. The purpose of the delay timer is
to avoid a shutdown of these equipment caused by short pump cycle times.
Note that if the water level in the reaction tank decreases below the LL-level switch in the
reaction tank, the equipment will also be disabled.
Calcium Chloride and Ferrous Chloride Feed Pump Jog Speed
To manually operate the calcium chloride or ferrous chloride feed pumps in the “Jog” mode,
navigate the HMI to the Calcium Pump Calibration screen and select “CALCIUM
CHLORIDE JOG” or “FERROUS CHLORIDE JOG” to toggle the operation of the feed pump

to “Jog.” Next, select “CALCIUM CHLORIDE JOG SPEED” or “FERROUS CHLORIDE JOG
SPEED” and enter a value between 0 and 100 percent.
To return the calcium chloride or ferrous chloride feed pumps to normal operations, select
“CALCIUM CHLORIDE JOG” or “FERROUS CHLORIDE JOG” to toggle the operation out of
the “Jog” operation.
3.9.3 Polymer Feed System

Under normal operations, the diluted polymer feed system is entirely automated based on
two operational parameters, which are as follows:
 Polymer Pump Ratio: Entered into the HMI
 Polymer Tank Off Delay: Entered into the HMI
Polymer Pump Ratio

Adjustment of the polymer feed rate should be evaluated based on a comparison of recent
laboratory analytical results of influent and effluent sampling within Facility 71.
Alternatively, the polymer feed rate can be determined by preparing a series of jar tests to
compare performance of different feed rates. It may also be necessary to adjust the
determined polymer feed rate, as needed, to avoid overloading the system with residual
polymer.
The feed rate must be determined and used to calculate the polymer pump ratio value to be
entered into the HMI; the value is the ratio of the calculated feed rate to the influent flow
rate. The rate is based on a combination of factors, such as determination of performance
and the polymer manufacturer’s recommendations.
To adjust the feed rate set-point, use the touch-screen navigation on the HMI to enter the
Set-points screen. Select the button “POLYMER PUMP RATIO” and enter the calculated
value; range of entry is between 0.000000 and 1.000000. Return the HMI to the
“Home” screen.
Polymer Addition Tank Equipment Off Delay

The polymer addition tank equipment off delay timer is an adjustable value entered into the
HMI to control the operation of the polymer addition tank mixer and the polymer feed
pump. The value, displayed in the HMI as “POLYMER TANK OFF DELAY” has an entry
range between 0 and 9,999 minutes. A value of 0 entered into the HMI will disable the
delay timer.

The delay timer extends the operation of the polymer addition tank mixer and polymer feed
pump to the entered timer value after the influent flow meter measures a flow rate less than
5 gpm. The purpose of the delay timer is to avoid a shutdown of these equipment caused by
short pump cycle times.
Note that if the water level in the polymer addition tank decreases below the LL-level switch
in the reaction tank, the equipment will also be disabled.
Polymer Feed Pump Jog Speed

To manually operate the polymer feed pump in the “Jog” mode, navigate the HMI to the
chemical pump calibration screen and select “POLYMER PUMP JOG” to toggle the
operation of the feed pump to “Jog.” Next, select “POLYMER JOG SPEED” and enter a value
between 0 and 100 percent.
To return the polymer feed pump to normal operations, select “POLYMER PUMP JOG” to
toggle the operation out of the “Jog” operation.
3.9.4 Sludge Management

The Operator should operate the sludge pump weekly during treatment and must monitor
the collection of sludge solids and coordinate proper removal and disposal of the sludge at an
approved off-site facility, in accordance with the solid waste control plan.
3.10 Calculations for Operating Parameters

Facility 71 is mostly automated, based on a number of measured values and the results of
laboratory analysis of the influent wastewater characterization. One parameter, polymer
addition rate, requires calculation for initial startup, as described subsequently.
3.10.1 Polymer Feed Control

Diluted liquid polymer is added to the polymer addition tank to develop flocculants to
promote the settling of B(a)P and the fluoride and cyanide compounds formed in the
reaction tank.
The polymer feed system includes pumping the liquid polymer from the polymer bulk drum
to the Mix Mate device, located in the mechanical room, which dilutes the liquid polymer
prior to its addition to the polymer addition tank.

Provided that the feed rates of calcium chloride and ferrous chloride are sufficient to produce
the desired fluoride and cyanide compounds, respectively, the effectiveness of polymer
addition can be determined by comparing the sampling analyses of the influent and effluent,
with respect to fluoride and cyanide concentrations.
To determine the appropriate amount of polymer to add, follow the polymer manufacturer
recommendations; jar testing may be necessary to determine the appropriate polymer dosage.
Optimization of the polymer feed rate is often necessary depending on process variables such
as influent wastewater characterization, solids generation, and fouling of equipment.
4 STARTUP PROCEDURES
Startup is not an immediate and instantaneous task. Startup of Facility 71 requires planning,
requisition of supplies, inspection of equipment and supplies, laboratory analyses, and
process optimization before discharging treated wastewater effluent through Outfall 002B.
During a normal (planned) shutdown, the water levels in the influent batch tank and
effluent tank may be manually drawn down to minimize the amount of water remaining in
Facility 71 during the shutdown period. For this reason, discharge from Facility 71, upon a
startup, may not occur for quite some time, depending on the volume of raw influent
wastewater collected in Tank 3 of Facility 77.
The general procedures for starting Facility 71 are summarized in the following subsections.
A startup event should be thoroughly documented to include operational parameters,
procedures taken, observations made, and modification of equipment and systems.
Documentation will provide valuable information to aid in troubleshooting problems that
may arise during startup.
4.1 Facility 71 Raw Influent Characterization

If Facility 71 has been shut down for an extended period of time (more than 2 weeks) or if
there is a reason to believe that the character of the wastewater sources has changed since
the previous operation of Facility 71 (new sources of wastewater), samples of the influent
shall be taken from Tank 3 in Facility 77 to characterize wastewaters.
The results of the characterization should be considered before starting up Facility 71, and
adjustments to the processes shall be made, as necessary, usually through determination of
the operational parameters.

4.2 Startup Preparation – Inspection of Equipment and Piping

The following items are a list of tasks and inspections to be completed prior to startup of
Facility 71. Check the physical condition of equipment, tanks, and piping. For a complete
list of tasks in checklist format, refer to the Facility 71 System Startup Procedures Checklist
in Appendix B.
Inspections include the following:

 Inventory supplies—check for sufficient quantities of the following are available:
 Chemicals/reagents
o Sulfuric acid
o Calcium chloride
o Ferrous chloride
o Liquid polymer
o pH 7 sensor calibration solutions (check expiration date)
 PPE – Appropriate for WWTP chemicals based on SDSs and site safety procedures
 Order additional supplies as necessary
 Additional chemical totes on hand
 Initial inspection of the system: Inspect equipment; begin at water sources and end at
Facility 77. Visually inspect each process in sequence to determine that equipment
and piping are physically connected and that there are no observed problems with the
equipment (broken pipes or missing equipment/hardware).
 Equipment controls; note inconsistencies
o Displays: HMI, pH controller, flow meters, and Tank 3 level sensor (926, 935,
310, 785, and 150, respectively)
o Equipment switches should be in the “Off” position at the control panel (925)
and HMI (926) and the pH Controller (935)
o Feed pumps in the Equipment Room (930) should be unplugged from the
electrical receptacle
 Note equipment tagged out by location and/or System ID
 Inspect visible lines (pipes, hoses, tubing) for damage or missing pieces; note all
inconsistencies
 Inspect visible connections between equipment and lines for damage or
disjointing; note inconsistencies

 Inspect stand-alone equipment for damage or available power source (where

applicable); note inconsistencies
o ISCO auto sampler (740): Plugged in, internal temperature of refrigerator set
in accordance with NPDES permit
o Containment pump (240): Plugged in and operates when float is lifted
o Sludge pump: Air supply line pressurized
 Inspect inactive tank outlets (these should be closed and secured); note
inconsistencies
 Inspect tanks for damage, leaks, or irregular piping; note inconsistencies
 Inspect NORMALLY CLOSED valves; note those that are open (open valves that
are NORMALLY CLOSED should be tagged out)
 Inspect NORMALLY OPEN valves; note those that are closed (closed valves that
are NORMALLY OPEN should be tagged out)
 Inspect feed pump suction lines, discharge lines, and containment tubing; note
presence of reagent in containment tubing
 Inspect feed pump containment drums (drums should be empty); note presence of
reagent
 Inspect emergency eyewash and shower station in accordance with site
safety procedures
 Inspect containment area
o Holes, damage or cuts in the membrane; note location
o Spills, leaks, and/or accumulation of precipitation; note location
o Excessive debris; note location
 Check that equipment controlled by the HMI is in the normal operating condition;
switches should normally be in the “Auto” position, except as otherwise noted in this
document.
 The sludge pump should be in the “Off” position.
 Check the sludge tank (450). If solids box is full, make preparations to remove and
dispose of solids in accordance with the solid waste plan, preferably prior to startup.
 Check the composite sampler; the sampler should be plugged in to the electrical
receptacle, and the refrigerator should be at a regulated constant temperature.

4.3 Effluent Flow Control

Check that the main operation switch labeled “Control Power” on the control panel (925) is
in the “Off” position. All other controls on the control panel should be in the
“Auto” position.
There is a three-valve cluster near the influent and effluent flow meters. Manually close the
effluent flow control valve (782), located upstream of the effluent flow meter (785) and
manually open the effluent bypass flow control valve (781). The influent flow control valve
(309) should remain open. This modification will circulate water from the effluent tank into
the pH tank, while allowing water from the influent batch tank to pump water into the
pH tank.
4.4 Supplies Inventory

Check the reagent bulk totes and polymer drum to determine if there is an adequate amount
of each product. Exchange empty bulk totes/drum, as necessary—this includes the three
liquid chemical solutions: sulfuric acid (328), calcium chloride (428), ferrous chloride (433),
and liquid polymer (528). Manage the inventory of reagent bulk totes and polymer bulk
drums; order more bulk totes and drums, as necessary, to maintain a minimum of one full
backup bulk tote/drum each.
Check that there is the proper type and quantity of PPE for use in Facility 71. Consult with
the Site Safety Officer and refer to the SDS and equipment manufacturer recommendations
for the proper types of PPE. Determine if the proper equipment is available prior to start up
and select the proper equipment for use prior to startup.
Check that there are the proper types, sufficient quantities, and non-expired solutions
necessary for calibration of the pH sensors.
4.5 Pumping Overview

With the exception of the sludge pump (805), the process transfer pumps are controlled at
the control panel (925) and should be in the “Auto” position. The sludge pump, located
between the lamella clarifier outlet and the sludge tank, should be in the “Off” position at
the pump.
The pH sample pumps (340 and 440) are controlled at the pH sampler/controller control
panel; the two pumps should be in the “Auto” position.

The reagent and polymer feed pumps should be plugged in to electrical receptacles and their
suction lines should be properly located in the bottom of their respective reagent bulk tote
and polymer drum; check suction lines to avoid cross-connections between the feed pumps
and the bulk totes/drum. Each tote/drum should have a properly located low-level switch on
the exterior of the tote/drum; check that the correct L-level switch is placed on the
appropriate tote/drum.
The containment pump (240) should be plugged in to the electrical receptacle and properly
connected to its discharge line to the influent batch tank.
4.6 Operational Parameters

Determine the appropriate operational parameters and input the values into the HMI.
Settings include the following: (see Section 3.9)
 pH Set-point
 pH Tank Equipment Off Delay
 Reaction Tank Equipment Off Delay
 Calcium Chloride Ratio
 Calcium Chloride Pump Jog Speed; this is used to purge pump lines and/or prime the
pump
 Ferrous Chloride Ratio
 Ferrous Chloride Pump Jog Speed; this is used to purge pump lines and/or prime the
pump
 Polymer Addition Tank Off Delay
 Polymer Pump Ratio
 Polymer Feed Pump Jog Speed; this is used to purge pump lines and/or prime the
pump
In startups following brief shutdowns (less than 24 hours) or where the wastewater influent
characterization has not changed, changes to the operating parameters may not be necessary.
In all other circumstances, the operational parameters should be evaluated and reviewed for
approval by supervisory personnel prior to inputting the parameters into the HMI and
pH controller.
4.7 Sulfuric Acid Addition

Sulfuric acid addition to the wastewater influent is usually necessary. Determine the target
pH value for treatment of the influent and enter the “pH SET-POINT” value into the pH

controller in the mechanical room. Check that the acid feed equipment and operational
parameters are correctly positioned and entered, respectively, as follows:
 Visually inspect the sulfuric acid product level in the acid bulk tote (328) and check
that the L-level switch is in its proper position on the tote exterior.
Caution—do not attempt to open the tote and look inside
without taking the necessary precautions. Precautions include
following applicable plant safety protocols and regulations,
including plant protocols specific to work with or around
chemicals.
 Check that the acid feed pump suction line is in the bottom of the acid bulk tote.
 Plug in the acid feed pump (330) to the electrical receptacle.
 At the HMI, run the acid feed pump in “Jog” to check that that the pump is primed
and working correctly.
 Visually inspect the clear tubing lines to check that the pump is primed and
drawing product.
4.8 Calcium Chloride and Ferrous Chloride Addition

Calcium chloride and ferrous chloride reagent addition to the wastewater influent is usually
necessary. Determine the correct feed rates for calcium chloride and ferrous chloride and
enter the calcium chloride ratio and ferrous chloride ratio into the HMI. Check that the
polymer addition equipment and operational parameters are correctly positioned and
entered, respectively, as follows:
 Visually inspect the calcium chloride (428) and ferrous chloride (433) product levels
in the calcium chloride bulk tote and ferrous chloride bulk tote, respectively, and
check that the L-level switches are in their proper position on the proper
tote exterior.
Caution—do not attempt to open the totes and look inside without taking the
necessary precautions. Precautions include following applicable plant safety
protocols and regulations including plant protocols specific to work with or
around chemicals.
 Check that the calcium chloride feed pump suction line is in the bottom of the
calcium chloride bulk tote.
 Check that the ferrous chloride feed pump suction line is in the bottom of the ferrous
chloride bulk tote.

 Plug in the calcium chloride (430) and ferrous chloride (435) feed pumps to the
electrical receptacles.
 At the HMI (926), run the feed pumps in “Jog” to check that the pumps are primed
and working correctly.
 Visually inspect the clear tubing lines to check that the pumps are primed and
drawing product.
4.9 Polymer Addition

If polymer addition is necessary, determine the correct polymer feed rate and enter the
polymer addition ratio into the HMI. Check that the polymer feed equipment and
operational parameters are correctly positioned and entered, respectively, as follows:
 Check the polymer product level in the polymer bulk container (528) and that the L-
level switch is in its proper position on the tote exterior.
 The polymer feed pump suction line must be in the bottom of the polymer bulk
container.
 Plug in the polymer feed pump (530) to the electrical receptacle.
 Check that the dilution water line valves (544 and 546) on the Mix Mate device (550)
are open and at the correct feed rate (in gpm).
 At the HMI (926), run the polymer feed pump in “Jog” to determine that the pump is
primed and working correctly.
 Once the polymer feed pump begins running under the “Jog” function, use the visual
indication of “milkiness” in the glass tubing of the static mixer of the Mix Mate device
to determine if the polymer dilution is working correctly. Properly mixed polymer
addition will appear a milky white coloration.
 Visually inspect the clear tubing lines to determine that the pump is primed and
drawing product.
If polymer addition is not necessary for an extended period (about 1 year), carefully remove
the polymer feed pump suction line from the polymer bulk drum and purge the suction line
by running the polymer feed pump in the “Jog” function, controlled by the HMI. Turn off
the dilution water lines with their respective valves located upstream of the Mix Mate
device, and check that the polymer feed pump is unplugged from the electrical receptacle.

4.10 Influent and Effluent Sampling Overview

When treating remediation waters as defined in the NPDES permit Special Condition S1.E,
prepare the ISCO sampler (740) to obtain influent and effluent samples. Sampling should not
begin until Facility 71 discharges treated effluent from Facility 71; the influent and effluent
flow rates are measured by the respective flow meters and recorded by the PLC in the HMI.
Prior to obtaining influent and effluent samples, the ISCO samplers should be plugged in to
the designated electrical receptacle, should be kept at a constant temperature, and a clean
glass jar should be placed in each sampler refrigerator.
Prior to startup, review the treatment process descriptions as a final check that the systems
are in order.
4.11 Initialize Startup

At the control panel (925), turn the “Control Power” switch to the “On” position. Water
within Facility 71 will circulate from the effluent tank to the pH tank. Do not open the
effluent flow valve, which allows for discharge from Facility 71 to Facility 77.
4.12 Monitor Process Displays

Observe and confirm that the flow rate, chemical feed rates, mixer settings, and other
displays on the HMI are at the correct settings.
4.13 Inspect Processes

Inspect and observe the processes by walking through Facility 71 to check for problems. The
inspection should begin at the source(s) of wastewater influent (Tank 3 in Facility 77) and
progress through Facility 71 to the eventual effluent discharge (Facility 77 sump).
Report any observed leaks, equipment failures, or other system upsets and take action, as
necessary, to correct issues.
4.14 Sludge Handling System

Open the sludge control valve at the bottom of the lamella clarifier cone and turn on the
sludge pump (805). Run the pump for 5 minutes. Manually turn off the sludge pump and
close the sludge control valve at the bottom of the lamella clarifier (665).

4.15 Final Inspection and Sampling Prior to Discharge

After operating for a period of time, and if the procedures were followed as described in
Effluent Flow Control (see Section 4.3), the influent pump and batch pump will be disabled
once the water level in the influent batch tank rises above its H-level-switch. Facility 71
will continue to operate, and batch and influent pumps will cycle based on demand. Operate
Facility 71 in this manner for a time sufficient to exchange the volume of water present in
the effluent tank prior to startup. Once the effluent tank has turned over, the operator may
collect a grab sample of the treated effluent for laboratory analysis (this step is only necessary
if the influent concentrations have changed). Conduct a final inspection of the treatment
processes and continue to make necessary adjustments to the processes until Facility 71 is
working properly.
4.16 Discharge of Effluent from Facility 71

Once the operator has determined that 71 effluent is ready for discharge, manually open the
effluent flow control valve (782) and close the effluent bypass flow control valve (781); this
will begin discharging the treated effluent from the effluent tank, registering flow through
the effluent flow meter and into the Facility 77 sump.
5 NORMAL SHUTDOWN PROCEDURES

A shutdown of Facility 71 is a planned event and should be carefully evaluated prior to
implementation. A planned shutdown may be necessary for major maintenance activities,
modifications to Facility 71, or seasonal shut-down.
The shutdown should be carefully planned, in terms of timing—both in terms of planned

shutdown time and in terms of seasonal influence; extended period shutdowns are best
planned for the dry season. Provisions for storage of wastewater should be made prior to a
planned shutdown. It may be prudent to maximize the available storage for wastewater prior
to a planned shutdown; this may take time to draw down Tanks 1, 2 and 3 to their lowest
levels. Note that management of the wastewater sources (the leachate ditches) should
remain in normal operation during a planned shutdown. These sources should continue to
pump collected leachate wastewaters to Tank 3 in Facility 77, provided there is ample storage
capacity in Tank 3.
Depending on the purpose of the planned shutdown, it may be necessary to evacuate the
process tanks. For an extended period, it may be prudent to evacuate the process tanks to
avoid fouling of the equipment.

In general, the procedure for shutdown of Facility 71 is the reverse order as described in
startup; and modified as described subsequently. For a complete list of tasks in checklist
format relating to an extended shutdown, refer to the Facility 71 Extended Shutdown
Procedures Checklist in Appendix C.
5.1 Documentation
Documentation can provide the Operator valuable information if problems occur during
startup after the planned shutdown. In general, and at a minimum, documentation should
include a list of sequential events provided with a date, time, and initials of the personnel
involved in the shutdown. Other critical information includes documenting observations
made during the shutdown; observations should include date, time, and initials of those
making the observations.
5.2 Influent Flow Management

Manage the wastewater sources, as necessary, throughout the planned shutdown. This may
include manual operation of the source wastewater pumps. Monitor the water level in
Tank 3 of Facility 77. If Tank 3 is nearly full, make preparations to startup Facility 71, if
possible, or make other arrangements to store wastewater on site.
At the control panel (925), manually switch the batch pump control from “Auto” to “Off.”
This will cease the inflow of wastewater from Tank 3 into the influent batch tank (220). The
influent batch tank L-level switch (223) will shut off the influent pump once the water level
in the influent batch tank decreases below the L-level switch and 20 minutes’ elapse.
5.3 Facility 71 in Normal Operating Conditions Prior to Shutdown

If Facility 71 is operating under normal conditions after shutdown of the batch pump (175),
the influent pump (275) will continue to pump water from the influent batch tank (220) into
the pH tank (320) until the water level in the influent batch tank decreases below the L-level
switch (223) in the influent batch tank and a delay timer has elapsed. Once the influent
pump shuts off, all other equipment in the processes will shut off after delay timer elapses.
Multiple alarms will be triggered as equipment turns off; the alarms will be displayed on the
HMI (926).
Note that the effluent pump (775) may continue to pump depending on the level switches in
the effluent tank (720); discharge from the effluent tank may continue even if the effluent
pump is not operating. To stop gravity flow of effluent from the effluent tank, manually
close the effluent flow control valve (782) located upstream of the effluent flow meter (785).

Manual Operating Conditions Prior to Shutdown

If Facility 71 (or individual processes) is operating under manual conditions, equipment
controls will be overridden, where applicable. The shutdown procedures will need to be
tailored according to how processes operating in manual conditions relate with
other processes.
Alarms will be triggered as equipment turns off; the alarms will be displayed on the HMI.
5.4 Evacuation of the Process Tanks

If it is desirable or necessary to evacuate the various process tanks, manual control of
equipment is necessary and is described subsequently. Use of additional (external)
equipment may be necessary to evacuate some of the process tanks.
Tanks in the WWTP area are confined spaces and should be considered inherently
dangerous. A confined space entry permit is required to enter any tank in the WWTP.
Operators and personnel are required to abide by company safety policies and procedures
and relevant state safety regulations in order to work in a confined space.
CONSULT THE SITE SAFETY OFFICER BEFORE ENTRY OR WORK IN A CONFINED SPACE.
If evacuation of the process tanks is not needed, continue to Section 5.5. It should be noted
that the system is designed such that evacuation water is routed back to Facility 71, Tanks 1
and 2.
5.4.1 Evacuation of the Influent Batch Tank

To evacuate the influent batch tank (220) to a minimum level, manually turn the selector
switch for the batch pump (175) from the “Auto” position to the “Off’ position and manually
turn the selector switch for the influent pump from the “Auto” position to the “Hand”
position and leave the other processes running under normal operating conditions. Carefully
monitor the water level in the influent batch tank to prevent cavitation of the influent pump
(275). Drawdown of the tank may require a significant amount of time and may require
multiple iterations of manually operating the influent pump to achieve the desired water
level in the tank. Manually turn the selector switch for the influent pump from the “Hand”
position to the “Off” position when the desired water level has been achieved.

5.4.2 Evacuation of the pH Tank or Reaction Tank

External piping configurations are necessary to fully evacuate the pH and reaction tanks (320
and 420, respectively). An outlet and NORMALLY CLOSED valve is located on each tank;
piping would need to be connected to these outlets and discharged into the influent batch
tank (220) or to another tank.
To evacuate the pH and reaction tank, open the ball valves at the end of the tanks and turn
off the batch pump (175) and leave Facility 71 running in normal operations. The influent
batch tank (220) will draw down to its L-level switch (223) and will shut off the influent
pump after 20 minutes’ elapse, which will in turn shut down all other equipment except for
the effluent pump (775). Once piping configurations are completed on the outlets of the pH
tank or reaction tank, open the necessary outlet valve and drain the water remaining in the
pH tank or reaction tank into the influent batch tank. Close the outlet valves once the tanks
are evacuated.
5.4.3 Evacuation of the Polymer Addition Tank

To evacuate the polymer addition tank (520), water from the pH tank (320), and reaction
tank (420), the polymer addition tank will be drained into the sludge tank (820). Since the
filtrate pump (875) circulates water back into the polymer addition tank, the filtrate pump
must be shut down. Check that the filtrate water level in the sludge tank is sufficiently low.
Manually operate the following:

 At the control panel (925):
 Batch pump (175) from the “Auto” position to the “Off’ position
 Influent pump (275) from the “Auto” position to the “Off” position
 Filtrate pump (875) from the “Auto” position to the “Off” position
 Open the sludge control valve (665) at the bottom of the lamella clarifier cone
 Manually run the sludge pump (805) until the water level in the polymer addition
tank has been evacuated.
Note, once the water level in the polymer addition tank decreases below its LL-level switch
(524) or the influent flow meter (310) measures a flow fewer than 5 gpm and a delay timer
has elapsed, the polymer addition tank mixer (525) will shut off.

5.4.4 Evacuation of the Lamella Clarifier

Evacuation of the lamella clarifier is the same as described for the evacuation of the polymer
addition tank, except that the entire lamella clarifier (620) volume needs to drain into the
sludge tank. Refer to Section 5.4.3.
5.4.5 Evacuation of the Sludge Tank

The filtrate pump (875), under normal conditions, will pump down the level of the liquid-
phase filtrate to a minimum depth. To fully evacuate the liquid-phase filtrate from the
sludge tank (820) will require additional equipment. One solution is to manually turn the
selector switch for the filtrate pump (875) from the “Auto” position to the “Off” position, and
open the drain valve (866) located upstream of the filtrate level sensor (822) and drain the
remaining filtrate water into a container that may be disposed of into the influent
batch tank.
5.4.6 Evacuation of the Effluent Tank

To evacuate the effluent tank (720) to a minimum level, manually turn the selector switch
for the batch pump (175) from the “Auto” position to the “Off” position, and leave the other
processes running under normal operating conditions at the control panel (925). The
influent batch tank (220) will draw down below its L-level switch (223) and will shut off the
influent pump (275) after 20 minutes’ elapse, which will, in turn, shut down all other
equipment except for the effluent pump (775). At the control panel, manually turn the
selector switch for the effluent pump from the “Auto” position to the “Hand” position and
carefully monitor the water level in the effluent tank to prevent cavitation of the effluent
pump. Drawdown of the tank may require a significant amount of time and may require
multiple iterations of manually operating the effluent pump to achieve the desired water
level in the tank. Manually turn the selector switch for the effluent pump from the “Hand”
position to the “Off” position when the desired water level has been achieved.
External equipment and piping re-configurations may be used to fully evacuate the effluent
tank. One solution is to pump water from the effluent tank back to the influent batch tank
or other on-site tanks. This would include reconfiguration of the piping connected to the
outlet of the effluent tank. A pump of sufficient lift would be necessary to pump water from
the effluent tank into other tanks on site.
5.5 Purge Reagent Feed Lines

Reagent feed lines should be purged during extended shutdowns.

The calcium chloride, ferrous chloride, and polymer feed pumps (430, 435, and 530,
respectively) have a “Jog” operation that can be enabled to purge the feed lines.
Through the HMI (925), select “CALCIUM CHLORIDE PUMP JOG,” “FERROUS
CHLORIDE PUMP JOG,” or “POLYMER PUMP JOG,” and enter speed for the selected
parameter; entry range is between 0.0 and 100.0 percent.
Once the lines are purged, repeat the process above and enter a speed of 0.0 percent for
each parameter.
5.6 Manage Sludge

Solids accumulated in the sludge tank (820) should be removed during extended shutdowns.
5.7 Disable Equipment

Manually turn the selector switches for all equipment within Facility 71 to the “Off”
position; this includes the reagent feed pumps, tank mixers, and process transfer pumps.
Leave the main power on to continue recording and logging field data from Outfall 002A,
006, leachate ditch levels as well as other field parameters such as site rainfall. Check the
HMI (926) for notifications of equipment status—no 71 process treatment equipment should
be operating.
Note that the pumps in the leachate ditches (105 and 110) should remain in operation during
a planned shutdown; these pumps may need to be manually operated to continue to pump
stormwater wastewaters to Tank 3 in Facility 77.
Manually close the effluent flow control valve (782).
5.8 Extended Shutdowns

An extended shutdown of Facility 71 may occur due to seasonal conditions. The following is
a brief description of tasks for an extended shutdown. Evacuation of tanks is described in
more detail previously.
 Turn off the influent pump (275) at the control panel (925).
 Manually pump down system tanks as far as possible.
 Clean wye-strainers:
 Influent pump suction line (266) at influent batch tank discharge outlet
 Effluent pump suction line (766) at effluent tank discharge outlet
 Filtrate pump suction line (866) at sludge tank discharge outlet

 Drain or pump down, clean, and rinse process tanks (except for sludge tank). Note:
Solid materials from the process tanks are transferred into the sludge tank (820).
Waters are sent back to Facility 71, Tanks 1 and 2.
 pH and reaction tanks (320 and 420, respectively)
 Influent batch tank (220)
 Polymer addition tank (520)
 Lamella clarifier (620): Run sludge pump to empty clarifier
 Effluent tank (720)
 Fill process tanks and components with clean well water.
 Use well water supply from the water services connection in Facility 71.
 Set valves for recirculation within the treatment system.
 Close the effluent flow control valve (782)
 Close the influent flow control valve (309)
 Open the effluent bypass flow control valve (781)
 Pump down and clean sludge dewatering box in the sludge tank (820).
 Replace filter fabric if damaged or clogged
 Stabilize and dispose of residual solids in accordance with Solid Waste Control Plan
6 EMERGENCY SHUTDOWN PROCEDURES

Emergency shutdown may occur due to a power failure or an unplanned condition that
requires immediate shutdown of Facility 71.
The Operator should manually turn off all equipment switches on the control panel (925),
starting with the batch pump and working down the line (1-7). If it is necessary to cease
discharge from Facility 71, manually close the effluent flow control valve (782)3, located
upstream of the effluent flow meter (785) between the main control facility and the influent
batch tank (see Photograph 3). The main control power switch should always be on so the
HMI/PLC can continue to collect continuous monitoring field data.
3 The effluent pump is a centrifugal pump that allows for gravity flow even when not in operation (powered
on). The effluent pump will allow gravity flow as long as the water level in the effluent tank is above the
effluent pump, located in the MCR.

Photograph 2. Control Power Switch on Control Panel - Turn Off in emergency shutdown
1 2 3 4
5 6 7

Photograph 3. Effluent Flow Control Valve (NORMALLY OPEN) –

Close valve to cease discharge from Facility 71
Effluent Flow
Control Valve (782)
(Normally Open)
Note: The effluent flow control valve is NORMALLY OPEN and, if closed, the valve should
have a tag-out or lock-out according to site safety procedures.
The Operator shall document the time of the emergency shutdown, the reason for the
shutdown (if known), and the time when startup occurs following resolution of the
emergency shutdown.
Following resolution of the emergency shutdown, the Operator shall follow the normal
startup procedures.

7 SAFETY
Facility 71 contains and uses materials that are potentially dangerous. Additionally,
mechanical equipment used in the treatment process can be dangerous. The MBT-Longview
standard safety protocol regarding PPE apply to Facility 71, and additional special protective
clothing and gear should be worn when there is potential for contact with the influent and
various chemical additives. Special attention is drawn to the following conditions:
 Sulfuric acid may cause severe burns on contact with skin.
 Sulfuric acid is potentially explosive. Never add water to sulfuric acid. There must be
adequate ventilation when sulfuric acid fumes may be generated.
 The wastewater influent, when in contact with skin, may cause irritation.
 Many pieces of equipment will start automatically without warning. Always keep
clear of moving equipment and follow the lock-out/tag-out procedure when working
on any piece of equipment. Moving equipment, in general, poses a potential safety
hazard.
 Gases and fumes produced in process tanks are potentially dangerous. While
Facility 71 is open to atmospheric conditions, equipment and enclosed spaces should
be regularly checked for correct ventilation and operation. Take necessary precaution
before opening closed tanks and totes.
 Dust masks shall be worn when handling dry materials that may become airborne
when disturbed or handled.
 The open top process tanks constitute fall hazards and tanks shall be considered
confined spaces; precautions related to these hazards shall be taken when working in
or near the process tanks.
 Operations of Facility 71 may require heavy lifting to replenish and stockpile supplies.
Personnel should seek help in lifting heavy items and/or use dollies or carts to move
heavy items. Heavy items shall not be stockpiled in a manner that poses a
falling hazard.
 Walkway gratings have been installed within Facility 71 and should be used unless it
is necessary to inspect or operate elements of Facility 71 that are inaccessible from
the walkways.
 Walkways and platforms shall be free of trip hazards and storage of items that impede
easy ingress or egress from Facility 71.
 Feed pump line containment tubing is installed on the suction and discharge lines for
each feed pump. This larger diameter tubing will contain leaks that may develop in
the suction and discharge line tubing. The containment tubing on each feed pump is

discharged into a separate drum positioned underneath the mechanical room.

 An emergency eyewash and shower station (950) is located adjacent to the main
control facility; this station shall be inspected on a regular basis to ensure
proper function.
Chemical product data and SDSs can be found in the main control room. Other related
safety information may be covered in the subsequent Section 8 – Emergency Plans and
Procedures.
8 EMERGENCY PLANS AND PROCEDURES

Employees are trained in emergency response procedures. In the event of a medical
emergency, contact 911. For plant related issues, contact Bob Stewart (360) 957-2836 or the
24-Hour Guard Office at (360) 749-1652. SDSs are kept on file in the plant's Safety
Department office and copies are available at the Treatment Plant.
There are several features of Facility 71 that aid in responding to emergencies. These are
listed in the following subsections:
8.1 Spill Plan

The Facility 71 footprint is lined with an HDPE containment membrane, so spills are
contained to the immediate area. A large spill within Facility 71 will drain to the low-point
in the containment membrane, where the containment pump (240) is located; a float-
controlled pump will convey liquids accumulated in the containment membrane to the
influent batch tank (220).
Toxic and hazardous solutions used in Facility 71 include sulfuric acid, ferrous chloride, and
calcium chloride. Personnel that observe the spill should take extra precautions before
attempting to respond to the spill; precautions should always follow site safety procedures.
Spills may need to be cleaned up by hand, depending on the volume of the spill, whether or
not rainfall has collected within Facility 71, and the spill location. Spills originating from
influent and reagents used within Facility 71 may be routed into Facility 71 for treatment;
these spills should be characterized and evaluated for proper processing through Facility 71
to avoid system upsets. Spills originating from sources other than those present in Facility 71
process shall be properly handled and disposed of in accordance with applicable SDS and the
Solid Waste Control Plan.

Small releases that can be readily contained and do not involve fire, explosion, injuries or
storm drains and cannot escape containment, may be cleaned by area employees.
A release of hazardous materials that cannot be readily contained and/or involve fire,
explosion, injury, storm drains, could escape offsite, and threaten human health or the
environment, trigger the guard to implement emergency response.
8.2 Emergency Eyewash and Shower Stations

An emergency eye wash and shower station is present in Facility 71, within the containment
area. The station is located between the main control facility and the influent batch tank.
8.3 Fire Protection

A fire hydrant is located across the nearby access road from Facility 71. The Operator and
site safety personnel maintain operational status of fire protection systems to comply with
site and local fire protection requirements.
8.4 Communications
There are no phones located in Facility 71. The Operator and personnel involved with the
operations or maintenance will be equipped with radios and/or mobile telephones in
accordance with MBT-Longview policies.
8.5 Alarms
There are many operational conditions that will cause an alarm condition, as described in
Section 2.9.2.
9 LABORATORY PROCEDURES AND RECORDS

The monitoring requirements are contained in the NPDES Wastewater Discharge Permit
WA 000008-6. The following is offered as a summary and documentation for use in
operating the Treatment Plant:
9.1 Influent Sample Collection

Influent 24-hour composite samples are collected at the same time treated effluent 24-hour
composite samples are collected. Influent samples are collected at a port in the influent line
near the influent tank/batch tank. The sampling equipment is positioned on the asphalt slab
just outside of containment. The sampler equipment is not controlled by the PLC (925).

Sampling shall be done by the Operator or other personnel trained for sample collection.
The influent sampling schedule is included in Table 16.
9.2 Treated Effluent Sample Collection

Samples are collected from the effluent tank with the use of an ISCO sampler. The sampling
equipment is located on top of the effluent tank and includes a refrigerator and sampling
pump; the refrigerator needs to maintain a temperature of 4 degrees Celsius. The equipment
needs to be plugged in to the electrical receptacle on the side of the effluent tank, below the
sampler. The sampler equipment is not controlled by the PLC. Sampling shall be done by
the Operator or other personnel trained for sample collection. The effluent sampling
schedule is included in Table 16.
Procedures for Composite Sampling

1. Check that the refrigerator is maintaining an internal temperature of 4 degrees
Celsius.
2. Place a clean “pickle” jar, priority pollutant approved glass container, in the sampler
refrigerator and check that the sampling tube will discharge into the container.
3. Turn on the sampler equipment using the control panel.
4. For instruction on operation of the ISCO sampler, refer to MBT-Longview’s SOP for
Outfall Field Equipment.
5. Monitor the startup of the sampler for proper operation.
a. The sampler will cleanse and purge the suction line prior to discharging
treated effluent into the sample container.
b. Observe (visually and audibly) the equipment for abnormal conditions.
c. The sampler will discharge a subsample of treated effluent into the sampling
container resulting in a total composite sample volume of approximately 3
liters over a 24-hour period.
6. Turn off the sampler equipment using the control panel once the sampling event
is complete. Note that the refrigerator will continue to run whether or not the
sampling is occurring.
7. Sample removal and delivery to the laboratory:
a. Remove the sampling container, cap the container, and transport to the onsite
laboratory. Sub-divide the sample for in-house and contract laboratory
analyses.
b. Fill out the chain-of-custody form and other required paperwork
and documentation.

8. Refer to the Lab Quality Assurance Manual for NPDES Wastewater Analysis for
complete instruction of sampling protocols.
9.3 Sample Analysis

Analysis for the monitored constituents is performed according to the methods listed in
Table 16. MBT-Longview contracts with an off-site laboratory to conduct the requested
analyses. Fluoride is analyzed in the on-site laboratory.
The current primary contract laboratory is as follows:
Specialty Analytical
9011 SE Jannsen Road
Clackamas, OR 97015 (503) 607-1331
info@specialtyanalytical.com
In the event that the primary contract laboratory cannot perform the analyses, the secondary
contract laboratory is as follows:
Apex Laboratories, LLC

12232 SW Garden Place
Tigard, Oregon 97223
(503) 718-2323
DThomas@Apex-Labs.com
Table 16
Monitored Analytes
Constituent Reference Method

Cyanide - Free
SM 4500-CN(I/)
- Weak and Dissociable (WAD)
Fluoride SM 4500 F-C
Residual Non-filterable TSS SM 2540-D
Benzo(a)pyrene USEPA Method 625
9.4 Records of Analysis

Records of the analyses, including appropriate analytical worksheets, are kept on file in the
MBT-Longview laboratory and Environmental Program Managers office.

9.5 State Reporting Requirements

Monitoring and reporting requirements are described in the NPDES permit. Analytical
testing must be conducted by state-accredited laboratories.
9.6 Plant Operating Data and Reports

Continuous monitoring data (i.e., flow, temperature, and pH) are collected and stored at the
HMI. The data is also collected by a Supervisory Control and Data Acquisition (SCADA)
system that runs as a virtual machine on the main MBT-Longview server. The SCADA
software provides a historical database, real time data trending, alarm notifications, and
report generation. Laboratory analyses are summarized and maintained by the
Environmental Compliance Officer.
9.7 Procedure for Jar Testing Process Changes

The wastewater treated in Facility 71 may vary in source, quantity, and/or quality over time.
New wastewater sources and significant changes to the quantity or quality of existing
wastewater sources shall be evaluated by simulation in jar tests.

FIGURES
INDUSTRIAL WASTEWATER TREATMENT PLANT (WWTP) TEMPORARY REPLACEMENT
MILLENNIUM BULK TERMINALS - LONGVIEW, LLC RECORD DRAWING
THESE RECORD DOCUMENTS HAVE BEEN PREPARED BASED ON INFORMATION

PROVIDED BY OTHERS AND VISUALLY VERIFIED IN THE FIELD BY ANCHOR QEA, LLC.
ANCHOR QEA, LLC HAS NOT VERIFIED THE ACCURACY OF THIS INFORMATION IN ITS
ENTIRETY AND SHALL NOT BE RESPONSIBLE FOR ANY ERRORS OR OMISSIONS WHICH
VICINITY MAP LOCATION MAP

MAY BE INCORPORATED HEREIN AS A RESULT.
E
ENU
AV
TH
WEST LONGVIEW
38
SEATTLE
WASHINGTON
IN
DU
ST
LONGVIEW RI
AL
W
AY
CO
LU
M MILLENNIUM BULK
BI
A TERMINALS - LONGVIEW
RI
DWG-1
V ER
FACILITY 71, INDUSTRIAL
LONGVIEW
L:\Projects\Millennium_Bulk_Terminals-Longview_LLC\Matters_Subject_To_Holdback_Agreement_(110730-01.05)\WWTP Redesign\CAD\RECORD DRAWINGS\11073001-PL-002.dwg
WASTEWATER TREATMENT PLANT

(WWTP)
LORD ISLAND
AERIAL SOURCE: GOOGLE EARTH PRO 2010.

0 1/2 1
SCALE IN MILES
CO
L UM
PROJECT DATA BIA
RIV
ER
PROJECT LOCATION OWNER REPRESENTATIVE PROJECT ENGINEER
MILLENNIUM BULK TERMINALS - LONGVIEW, LLC TREVOR SIMMONS DAVID RICE, P.E.
4029 INDUSTRIAL WAY (PARCELS 61953 & 6195302) MILLENNIUM BULK TERMINALS - LONGVIEW, LLC ANCHOR QEA, LLC
LONGVIEW, WA 98632 LONGVIEW, WA 98632 720 OLIVE WAY, SUITE 1900 DRAWING INDEX: 0 200 400
36 & 38 SECTION T8N/R3W (360) 636-8340 SEATTLE, WA 98101 SHEET NUMBER DRAWING NUMBER DESCRIPTION
INCH SCALE ACCORDINGLY

SCALE IN FEET
AT FULL SIZE, IF NOT ONE

(206) 287-9130
PROJECT OWNER PROJECT CONTRACTOR 1 DWG-1 VICINITY MAP AND PROJECT LOCATION MAP
ONE INCH
2 DWG-2 TEMPORARY TREATMENT SYSTEM PROCESS DIAGRAM
MILLENNIUM BULK TERMINALS - LONGVIEW, LLC DENNIS CAUDELL 3 DWG-3 TEMPORARY TREATMENT PLAN
TERRA HYDR INC.
P.O. BOX 3616 4 DWG-4 DETAILED TEMPORARY TREATMENT PLAN
PORTLAND, OREGON 97208 5 DWG-5 TEMPORARY TREATMENT PLANT DETAILS
(503) 710-1227
REVISIONS
MILLENNIUM BULK TERMINALS - LONGVIEW, LLC
REV DATE BY APP'D DESCRIPTION DESIGNED BY: D. RICE
WASTEWATER TREATMENT PLANT DWG-1
Aug 01, 2012 12:30pm drice
01 08-01-12 DWR NL RECORD DRAWINGS DRAWN BY: D. RICE

CHECKED BY: N. LAFRANCHISE TEMPORARY REPLACEMENT
APPROVED BY: N. LAFRANCHISE
VICINITY MAP AND PROJECT LOCATION MAP

SCALE: AS NOTED
DATE: JULY 2012 SHEET NO. 1 OF 5
720 OLIVE WAY, SUITE 1900 | SEATTLE, WA 98101 | (206) 287-9130
RECORD DRAWING

SULFURIC ACID TOTE CALCIUM CHLORIDE TOTE FERROUS CHLORIDE TOTE POLYMER DRUM PROVIDED BY OTHERS AND VISUALLY VERIFIED IN THE FIELD BY ANCHOR QEA, LLC.
(328) (428) (433) (528) ANCHOR QEA, LLC HAS NOT VERIFIED THE ACCURACY OF THIS INFORMATION IN ITS
MAY BE INCORPORATED HEREIN AS A RESULT.
ACID FEED PUMP CACL2 FEED PUMP FECL2 FEED PUMP POLYMER FEED PUMP
(330) (430) (435) (530)
(CONTROLLED BY pH (CONTROLLED BY (CONTROLLED BY (CONTROLLED BY

CONTROLLER (935)) INFLUENT FLOW METER) INFLUENT FLOW METER) INFLUENT FLOW METER)
pH SENSOR 1 pH SENSOR 2 RECIRCULATION TO INFLUENT

(350) (450) WATER INPUT (544 AND 546)
pH SAMPLE PUMP 1 pH SAMPLE PUMP 2 PUMP DISCHARGE LINE WITH
(340) (440) MIXMATE DEVICE (550) CLOSURE OF EFFLUENT FLOW
CONTROL VALVE
pH TANK REACTION TANK
POLYMER ADDITION
MIXER (325) MIXER (425) EFFLUENT PUMP
TANK MIXER (525)
(775)
EFFLUENT, OUTFALL 002B
SAMPLING TAP
M TO FACILITY 77
EFFLUENT FLOW CONTROL STORMWATER SUMP
OVERFLOW
LEVEL SWITCHES, LEVEL SWITCHES, LEVEL SWITCHES, VALVE (782) AND EFFLUENT FLOW
HIGH-HIGH (321) HIGH-HIGH (421) (520) HIGH-HIGH (521) ISCO AUTO SAMPLER (740), METER (785)
DWG-2
LOW-LOW (324) LOW-LOW (424) POLYMER LOW-LOW (524) OUTFALL 002B POINT OF
(320) (420) COMPLIANCE
ADDITION TANK
LEVEL SWITCHES, (720)
pH TANK REACTION TANK (FLOCCULATION) LEVEL SWITCHES,

HIGH-HIGH (621) HIGH-HIGH (721)
(PRECIPITATION) LOW-LOW (624) EFFLUENT TANK HIGH (722)
LOW (723)
LAMELLA CLARIFIER (620) SLUDGE PUMP
M (805)
INFLUENT FLOW CONTROL SLUDGE
VALVE (309) AND INFLUENT FLOW
METER (310)
FILTRATE
INFLUENT PUMP
(275)
INFLUENT
LEVEL SWITCHES,
LEVEL SENSOR/SWITCHES,
HIGH-HIGH (221)
HIGH (122)
HIGH (222)
LOW (123)
LOW (223)
LEVEL SWITCHES,
RAW INFLUENT HIGH (822)
STREAM
SOLIDS DISPOSAL
(120) BATCH PUMP (220)
(175)
THICKENER TANK 3, FACILITY 77 INFLUENT BATCH TANK FILTRATE PUMP (820)
(875)
SYSTEM NO. SYSTEM
SLUDGE TANK
100 WASTEWATER SOURCE MANAGEMENT
200 INFLUENT BATCHING PROCESS
300 pH ADJUSTMENT PROCESS CONTAINMENT
PUMP
400 REACTION/PRECIPITATION PROCESS

(240)

500 FLOCCULATION PROCESS
ONE INCH
600 PRIMARY CLARIFICATION PROCESS
700 TREATMENT EFFLUENT MANAGEMENT PROCESS
800 SLUDGE MANAGEMENT PROCESS
900 OPERATIONS AND PLC
REVISIONS
Aug 01, 2012 12:31pm drice

SCALE: NOT TO SCALE TEMPORARY TREATMENT SYSTEM PROCESS
DATE: JULY 2012 DIAGRAM SHEET NO. 2 OF 5
NOTES: RECORD DRAWING
1. DRAWING IS SCHEMATIC. BUILDINGS, TANKS AND OTHER THESE RECORD DOCUMENTS HAVE BEEN PREPARED BASED ON INFORMATION
EQUIPMENT MAY NOT BE SHOWN TO THE EXACT SCALE, PROVIDED BY OTHERS AND VISUALLY VERIFIED IN THE FIELD BY ANCHOR QEA, LLC.
DIMENSIONS, OR LOCATION. ANCHOR QEA, LLC HAS NOT VERIFIED THE ACCURACY OF THIS INFORMATION IN ITS
2. PROCESS PIPING IS SOLID WALL, BUTT-FUSED HDPE PIPE, MAY BE INCORPORATED HEREIN AS A RESULT.
SIZED AS FOLLOWS:
2.1. PROCESS FORCE MAIN - 3" DIAM.
2.2. WATER, COMPRESSED AIR, CONTAINMENT - 1" DIAM. SYSTEM/EQUIPMENT LEGEND:
SYSTEM NO. ITEM NO. DESCRIPTION
100 WASTEWATER SOURCE MANAGEMENT

175 BATCH PUMP
200 INFLUENT BATCHING PROCESS
220 INFLUENT BATCH TANK; 21,000 GALLONS
240 CONTAINMENT PUMP
275 INFLUENT PUMP
300 pH ADJUSTMENT PROCESS
309 INFLUENT FLOW CONTROL VALVE
310 INFLUENT FLOW METER; MAG METER
320 pH TANK; 3,000 GALLONS
328 ACID BULK TOTE
330 ACID FEED PUMP
340 pH SAMPLE PUMP 1
400 REACTION/PRECIPITATION PROCESS
420 REACTION TANK; 3,000 GALLONS
428 CACL2 BULK TOTE
430 CACL2 FEED PUMP
DWG-3
433 FECL2 BULK TOTE

435 FECL2 FEED PUMP
440 pH SAMPLE PUMP 2

500 FLOCCULATION PROCESS
520 POLYMER ADDITION TANK (FOREBAY OF CLARIFIER)
528 POLYMER BULK DRUM
530 POLYMER FEED PUMP
600 PRIMARY CLARIFICATION PROCESS
620 LAMELLA CLARIFIER; 615-SF TREATMENT AREA
700 TREATED EFFLUENT MANAGEMENT PROCESS
720 EFFLUENT TANK; 21,000 GALLONS
740 ISCO AUTO SAMPLER (OUTFALL 002B POC)
775 EFFLUENT PUMP
782 EFFLUENT FLOW CONTROL VALVE
785 EFFLUENT FLOW METER; MAG METER
800 SLUDGE MANAGEMENT PROCESS
805 SLUDGE PUMP
820 SLUDGE TANK
875 FILTRATE PUMP
900 OPERATIONS AND PLC
901 MAIN CONTROL FACILITY; 40-FOOT CONEX CONTAINER
System Drain Valve (307)
(Upside Down Valve) LEGEND:
PROCESS PRESSURE LINE, SUCTION
PROCESS PRESSURE LINE, DISCHARGE
PROCESS GRAVITY LINE

Influent Flow Control Valve (308) CHEMICAL FEED LINE, SUCTION
(Blue Valve)
CHEMICAL FEED LINE, DISCHARGE

COMPRESSED AIR LINE

Tank 2 Clarifier POTABLE WATER LINE
ONE INCH
0 8 16
M FLOW METER
SCALE IN FEET
P PUMP
FLOW DIRECTION
REVISIONS
Aug 01, 2012 12:31pm drice

SCALE: AS NOTED
DATE: JULY 2012
TEMPORARY TREATMENT PLAN SHEET NO. 3 OF 5
FACILITY 71 NOTES: SYSTEM/EQUIPMENT LEGEND:
RECORD DRAWING
SYSTEM ITEM SYSTEM ITEM SYSTEM ITEM
1. THE INTENT OF THIS DRAWING IS TO DESCRIPTION DESCRIPTION DESCRIPTION
NO. NO. NO. NO. NO. NO. THESE RECORD DOCUMENTS HAVE BEEN PREPARED BASED ON INFORMATION
PROVIDE THE LAYOUT OF THE WWTP AND
SHOW KEY ELEMENTS. NOT ALL EQUIPMENT, 100 WASTEWATER SOURCE MANAGEMENT 428 CACL2 BULK TOTE 782 EFFLUENT FLOW CONTROL VALVE PROVIDED BY OTHERS AND VISUALLY VERIFIED IN THE FIELD BY ANCHOR QEA, LLC.
PIPING, CONDUIT, AND APPURTENANCES 120 THICKENER TANK 3, FACILITY 77 430 CACL2 FEED PUMP 785 EFFLUENT FLOW METER; MAG METER ANCHOR QEA, LLC HAS NOT VERIFIED THE ACCURACY OF THIS INFORMATION IN ITS
ARE SHOWN. ENTIRETY AND SHALL NOT BE RESPONSIBLE FOR ANY ERRORS OR OMISSIONS WHICH
175 BATCH PUMP 433 FECL2 BULK TOTE 800 SLUDGE MANAGEMENT PROCESS MAY BE INCORPORATED HEREIN AS A RESULT.
2. DRAWING IS SCHEMATIC. BUILDINGS, TANKS 200 INFLUENT BATCHING PROCESS 435 FECL2 FEED PUMP 805 SLUDGE PUMP
AND OTHER EQUIPMENT MAY NOT BE 220 INFLUENT BATCH TANK; 21,000 GALLONS 438 pH SAMPLE PUMP 2 SUCTION LINE VALVE LEGEND:
820 SLUDGE TANK
SHOWN TO THE EXACT SCALE, DIMENSIONS,
OR LOCATION. 240 CONTAINMENT PUMP 440 pH SAMPLE PUMP 2 865 SLUDGE TANK DISCHARGE VALVE PROCESS PRESSURE LINE, SUCTION
265 INFLUENT BATCH TANK DISCHARGE VALVE 450 pH SENSOR 2 866 FILTRATE LINE WYE/CONTROL VALVE
3. INFLUENT WASTEWATER IS PUMPED FROM PROCESS PRESSURE LINE, DISCHARGE
266 INFLUENT TANK DISCHARGE WYE-STRAINER 500 FLOCCULATION PROCESS 875 FILTRATE PUMP
THICKENER TANK 3 (AT FACILITY 77) INTO
FACILITY 71. 275 INFLUENT PUMP 520 POLYMER ADDITION TANK (FOREBAY OF CLARIFIER) 900 OPERATIONS AND PLC PROCESS GRAVITY LINE
300 pH ADJUSTMENT PROCESS 525 POLYMER ADDITION TANK MIXER 901 MAIN CONTROL FACILITY; 40-FOOT CONEX CONTAINER
4. OUTFALL 002B MONITORING AND SAMPLING CHEMICAL FEED LINE, SUCTION
IS CONDUCTED WITHIN FACILITY 71. 309 INFLUENT FLOW CONTROL VALVE 528 POLYMER BULK DRUM 910 ANCILLARY STORAGE ROOM
310 INFLUENT FLOW METER; MAG METER 530 POLYMER FEED PUMP 920 MAIN CONTROL ROOM CHEMICAL FEED LINE, DISCHARGE
5. EFFLUENT (TREATED WASTEWATER) IS 320 pH TANK; 3,000 GALLONS 600 PRIMARY CLARIFICATION PROCESS 925 MAIN CONTROL PANEL COMPRESSED AIR LINE
PUMPED FROM FACILITY 71 TO THE
STORMWATER SUMP AT FACILITY 77. 325 pH TANK MIXER 620 LAMELLA CLARIFIER; 615-SF TREATMENT AREA 930 EQUIPMENT ROOM
328 ACID BULK TOTE 665 SLUDGE CONTROL VALVE pH CONTROLLER POTABLE WATER LINE
935
6. THE TREATMENT RATE FOR THE TEMPORARY 700 TREATMENT EFFLUENT MANAGEMENT PROCESS
330 ACID FEED PUMP 950 EMERGENCY EYEWASH/SHOWER M FLOW METER
WASTEWATER TREATMENT PLANT IS
APPROXIMATELY 60 GALLONS PER MINUTE. 338 PH SAMPLE PUMP 1 SUCTION LINE VALVE 720 EFFLUENT TANK; 21,000 GALLONS
pH SAMPLE PUMP 1 ISCO AUTO SAMPLER (OUTFALL 002B POC) P PUMP
340 740
7. CONTAINMENT GROSS VOLUME: APPROX.
12,000 CF OR APPROX. 90,000 GAL. 350 pH SENSOR 1 765 EFFLUENT TANK DISCHARGE VALVE FLOW DIRECTION
400 REACTION/PRECIPITATION PROCESS 766 EFFLUENT TANK DISCHARGE WYE-STRAINER
8. THE TEMPORARY TREATMENT FACILITIES 420 REACTION TANK; 3,000 GALLONS 775 EFFLUENT PUMP
INCLUDE FIVE PROCESS TANKS (NOT
INCLUDING THICKENER TANK 3 AT FACILITY 425 REACTION TANK MIXER 781 EFFLUENT BYPASS FLOW CONTROL VALVE
77) AND ONE CONEX CONTAINER BOX (MAIN
CONTROL FACILITY) THAT HOUSES CONTROLS
DWG-4
AND EQUIPMENT.
9. PROCESS CHEMICAL AND/OR REAGENT FEEDS

INCLUDE SULFURIC ACID, CALCIUM

CHLORIDE, FERROUS CHLORIDE, AND LIQUID
POLYMER.
REACTION TANK MIXER (425) 3" HDPE
10. TREATMENT PLANT OPERATION REQUIRES
THE FOLLOWING UTILITIES: COMPRESSED INFLUENT BATCH TANK (220) POLYMER ADDITION TANK (520)
AIR, PROCESS (WELL) WATER, AND VALVE (438) POLYMER ADDITION TANK MIXER (525)
ELECTRICITY. UTILITIES HAVE BEEN
VALVE (338) LAMELLA CLARIFIER (620)
EXTENDED TO THE WWTP FROM FACILITY 77. SLUDGE TANK (820)
pH TANK MIXER (325) SE
HO SLUDGE DISPOSAL
INFLUENT BATCH TANK DISCHARGE 4"
VALVE (265), 3" BALL VALVE, AND
WYE-STRAINER (266)
2'-0" pH TANK 6" SLUDGE TANK DISCHARGE VALVE
INFLUENT FLOW METER (310) (320) REACTION TANK P (865), 4" BALL VALVE, AND
(420) FILTRATE LINE WYE (866)
INFLUENT FLOW CONTROL VALVE (309) SLUDGE PUMP (805) GRATING EFFLUENT TANK DISCHARGE
3" HDPE
(NORMALLY OPEN) (TYP)

B
VALVE (765), 4" BALL VALVE, AND
WYE-STRAINER (766) DWG-5
3" HDPE
3" HDPE
EFFLUENT FLOW CONTROL VALVE (782)
3" HDPE
(NORMALLY OPEN)
3" HDPE
3'-0"
EFFLUENT FLOW METER (785)
3" HDPE
3" HDPE
EMERGENCY 3" HDPE

M EFFLUENT BYPASS FLOW EYEWASH/SHOWER STAIRS
CONTROL VALVE (781) STATION (950) BULK TOTE
(TYP)
MAIN CONTROL FACILITY (901) (NORMALLY CLOSED) STORAGE
(40-FOOT CONEX CONTAINER, HOUSES M
PUMPS AND CONTROL EQUIPMENT) MAIN CONTROL
3" HDPE ROOM (920)
P P P P P P
EFFLUENT TANK (720)
3" HDPE
Influent Control Valve (308) ANCILLARY P P P
MAIN CONTROL
(Blue Valve) STORAGE ROOM PANEL (925) EQUIPMENT
(910) FERROUS CHLORIDE BULK TOTE (433)
ROOM (930)
Tank 2 Clarifier ACID BULK TOTE (328) 3" HDPE
1" HDPE
INFLUENT A
3" HDPE
EFFLUENT PUMP (775) CALCIUM CHLORIDE BULK TOTE (428) DWG-5
FROM BATCH PUMP (175) AT pH SAMPLE PUMP 1 (340) ISCO AUTOMATIC SAMPLER (740),
EFFLUENT
SUMP, FACILITY 77

TO STORMWATER

THICKENER TANK 3, FACILITY 77 INFLUENT PUMP (275) POLYMER FEED PUMP (530) OUTFALL 002B POINT OF COMPLIANCE
pH SAMPLE PUMP 2 (440) CONTAIMENT COMPRISED OF
(120) CALCIUM CHLORIDE FEED PUMP (430)
TACK-WELDED HEAVY DUTY HDPE
ONE INCH
COMPRESSED AIR System Drain Valve (307) FERROUS CHLORIDE FEED PUMP (435) CONTAINMENT PUMP (240)
FILTRATE PUMP (875) LINER UNDER EQUIPMENT AND
(FROM FACILITY 77) ACID FEED PUMP (330) ALONG INTERIOR OF PRE-CAST
(Upside Down Valve) POLYMER BULK DRUM (528)
PROCESS WATER CONCRETE BARRIER WALL PLACED 0 5 10
(FROM FACILITY 77) AROUND PERIMETER
DETAILED PLAN SCALE IN FEET
REVISIONS
Aug 01, 2012 12:32pm drice

SCALE: AS NOTED
DATE: JULY 2012
DETAILED TEMPORARY TREATMENT PLAN SHEET NO. 4 OF 5
RECORD DRAWING

PROVIDED BY OTHERS AND VISUALLY VERIFIED IN THE FIELD BY ANCHOR QEA, LLC.
ACID FEED PUMP (330) ANCHOR QEA, LLC HAS NOT VERIFIED THE ACCURACY OF THIS INFORMATION IN ITS
FEROUS CHLORIDE FEED PUMP (435) MAY BE INCORPORATED HEREIN AS A RESULT.
CALCIUM CHLORIDE FEED PUMP (430)
POLYMER FEED PUMP (530)
MAIN CONTROL FACILITY (901) OVERHEAD
MIXMATE DEVICE (550) ROLL-UP DOOR ISCO AUTOMATIC SAMPLER (740),
(40-FOOT CONEX CONTAINER, HOUSES
PUMPS AND CONTROL EQUIPMENT) OUTFALL 002B POINT OF COMPLIANCE
pH CONTROLLER (935) SAFETY RAIL (TYP)
OVERHEAD pH SENSOR 2 (450) FERROUS CHLORIDE BULK TOTE (433) (BEHIND)
ROLL-UP DOOR pH SENSOR 1 (350)
CALCIUM CHLORIDE BULK TOTE (428) (IN FRONT) EFFLUENT TANK DISCHARGE
MAIN CONTROL VALVE (765), 4" BALL VALVE,
PANEL (925) ACID BULK TOTE (328) (BEHIND)
(NORMALLY OPEN)
EQUIPMENT CONTAINMENT COMPRISED
TOP OF CONTAINMENT ROOM (930) OF TACK-WELDED HEAVY
DUTY HDPE LINER UNDER
3" HDPE EFFLUENT ANCILLARY EFFLUENT TANK (720) EQUIPMENT AND ALONG
STORAGE ROOM MAIN CONTROL INTERIOR OF PRE-CAST
3" HDPE INFLUENT (910) ROOM (920) 775
CONCRETE BARRIER WALL

PLACED AROUND PERIMETER
3" HDPE (EFFLUENT)

NOTES: MAIN ENTRY DOOR
MAIN ENTRY STAIRS STAIRS EFFLUENT TANK DISCHARGE
1. THE INTENT OF THIS DRAWING IS TO pH SAMPLE PUMP 1 (340) (TYP)
PROVIDE THE LAYOUT OF THE WWTP AND WYE-STRAINER W/ BALL VALVE
SHOW KEY ELEMENTS. NOT ALL EQUIPMENT, pH SAMPLE PUMP 2 (440) (766) (NORMALLY CLOSED)
DWG-5
PIPING, CONDUIT, AND APPURTENANCES EFFLUENT PUMP (775) SEE PLAN VIEW FOR PIPING BELOW FLOOR
ARE SHOWN. INFLUENT PUMP (275)
2. DRAWING IS SCHEMATIC. BUILDINGS, TANKS FILTRATE PUMP (875)

AND OTHER EQUIPMENT MAY NOT BE ELEVATION ELEVATION
SHOWN TO THE EXACT SCALE, DIMENSIONS, MAIN CONTROL FACILITY EFFLUENT TANK
OR LOCATION.
A ELEVATION - MAIN CONTROL AND EFFLUENT TANK
3. SEE DWG-4 FOR ADDITIONAL NOTES AND DWG-4 HORIZ. SCALE: 1"=5'
VERT. SCALE: 1"=5'
EQUIPMENT LEGEND.
HIGH-HIGH WSEL
HIGH-HIGH WSEL pH SAMPLE PUMP 2 LOW-LOW WSEL
LOW-LOW WSEL DISCHARGE LINE 3" HDPE HIGH-HIGH WSEL
STEEL SUPPORT BEAMS (TYP)
SAFETY RAIL (TYP) pH SAMPLE PUMP 1 LOW-LOW WSEL
ACCESS STEPS DISCHARGE LINE 3" HDPE REACTION TANK MIXER POLYMER ADDITION TANK MIXER (525)
3" HDPE INFLUENT pH TANK MIXER (SYSTEM 425) POLYMER ADDITION TANK (520)
FROM BATCH PUMP (SYSTEM 325)
LAMELLA CLARIFIER (620)
BATCH PUMP (175) BATCH PUMP AIR/VAC
INSTALLED IN TANK RELEASE VALVE HIGH-HIGH WSEL POROUS MEMBRANE ON FALSE
pH TANK (320) REACTION TANK (420) LOW-LOW WSEL BOTTOM FRAME, SOLID PHASE SLUDGE
TOP OF TANK 0.50
RETAINED ABOVE, LIQUID PHASE

8" STEEL PIPE (TO EFFLUENT TANK) ACCESS FILTRATE RETAINED BELOW
pH SAMPLE PUMP 1
SUCTION LINE 3" HDPE SLUDGE PUMP DISCHARGE LADDER HIGH WSEL
PH SAMPLE PUMP 2
SUCTION LINE
3" HDPE LINE 4" HOSE
INFLUENT BATCH TANK PH SAMPLE PUMP 1
SUCTION LINE
3" HDPE
BATCH PUMP (220)

DISCHARGE HIGH WSEL SLUDGE HOLDING TANK
LINE 3" HDPE pH SAMPLE PUMP 1 (820)
FILTRATE PUMP
9'-3" DISCHARGE LINE 3" HDPE DISCHARGE LINE 3" HDPE
LOW WSEL SLUDGE TANK DISCHARGE
TO INFLUENT
TANK VALVE (865), 4" BALL VALVE
3.00
(NORMALLY OPEN)
BOTTOM OF TANK/ INFLUENT PUMP pH SAMPLE PUMP 2 FILTRATE LINE WYE (866)
TOP OF FOUNDATION DISCHARGE LINE 3" HDPE SLUDGE PUMP (805) FILTRATE PUMP
SUCTION LINE 3" HDPE
INFLUENT PUMP CONTAINMENT PUMP SLUDGE PUMP SUCTION SUCTION LINE 3" HDPE
FILTRATE PUMP
SUCTION LINE, 3" HDPE DISCHARGE LINE 1" HDPE DISCHARGE LINE 3" HDPE LINE 4" HOSE PRE-CAST CONCRETE
pH SAMPLE PUMP 2 SUPPORT AND TIMBER
INFLUENT BATCH TANK INFLUENT BATCH TANK DISCHARGE FILTRATE PUMP CRIBBING (TYP)
DISCHARGE LINE 3" HDPE SLUDGE CONTROL VALVE (665)
VALVE (265), 3" BALL VALVE

DISCHARGE WYE- STRAINER (266) SUCTION LINE 3" HDPE

PARTIAL ELEVATION ELEVATION ELEVATION ELEVATION
ONE INCH
FACILITY 77, THICKENER TANK 3 INFLUENT BATCH TANK LAMELLA CLARIFIER SLUDGE TANK
B ELEVATION - INFLUENT TANK, CLARIFIER, AND SLUDGE TANK

DWG-4 HORIZ. SCALE: 1"=5'
VERT. SCALE: 1"=5'
REVISIONS
Aug 01, 2012 12:32pm drice

SCALE: AS NOTED
DATE: JULY 2012
TEMPORARY TREATMENT PLANT DETAILS SHEET NO. 5 OF 5
APPENDIX A
TREATMENT PROCESS AND EQUIPMENT
ID SCHEDULE
Appendix A
Treatment Process and Equipment ID Schedule
x00 Process 200 Influent Batching Process 340 pH Sample Pump 1
x05 Primary Source 219 Batch Pump Discharge Point 341 pH Sample Pump 1 Motor Relay
x06 Pump Motor Relays 220 Influent Batch Tank 342 pH Sample Pump 1 Isolation Valve, Discharge
x10 Flow Meter 221 Influent Batch Tank HH Level Switch 349 pH Sensor 1 Isolation Valve, Upstream
x19 Primary Inlet 222 Influent Batch Tank H Level Switch 350 pH Sensor 1
x20 Tank 223 Influent Batch Tank L Level Switch 351 pH Sensor 1 Isolation Valve, Downstream
x21 HH Level Switch 240 Containment Pump 352 Acid Feed Pump Discharge Point
x22 H Level Switch 241 Containment Level Switch 355 pH Sample Pump 1 Discharge Point
x23 L Level Switch 255 Containment Pump Discharge Point 360 pH Tank Outlet to Reaction Tank
x24 LL Level Switch 260 Influent Batch Tank Outlet to Influent Pump 361 pH Tank Outlet/Valve (Inactive 1)
x25 Mixer 261 Influent Batch Tank Outlet/Valve (Inactive 1) 362 pH Tank Outlet/Valve (Inactive 2)
x30 Reagent 1 265 Influent Batch Tank Discharge Valve
x31 Containment Drums 266 Influent Batch Tank Discharge Wye-Strainer w/ Valve 400 Reaction/Precipitation Process
x35 Reagent 2 274 Influent Pump Suction Line Drain Valve 419 Reaction Tank Inlet from pH Tank
x40 Sample Pump 275 Influent Pump 420 Reaction Tank
x50 pH Sensor 276 Influent Pump Motor Relay 421 Reaction Tank HH Level Switch
x52 Feed Pump Disch Point 277 Influent Pump Isolation Valve 424 Reaction Tank LL Level Switch
x55 Pump Discharge Point 278 Influent Pump Discharge Line Drain Valve 425 Reaction Tank Mixer
x60 Tank Outlets 426 Reaction Tank Mixer Motor Relay
x65 Outlet Valves/Equip 300 pH Adjustment Process 428 CaCl2 Bulk Tote
x75 Effluent Pump 307 System Drain Valve ("Upside-down" Valve) 429 CaCl2 Bulk Tote Level Sensor
x85 Effluent Flow Meter 308 Influent Flow Control Valve 430 CaCl2 Feed Pump
309 Influent Flow Control Valve 431 CaCl2 Feed Pump Containment Drum
100 Wastewater Source Management 310 Influent Flow Meter 433 FeCl2 Bulk Tote
105 BMP Leachate Ditch Pump 311 Influent Flow Transmitter 434 FeCl2 Bulk Tote Level Sensor
106 Closed BMP Pump Controls 319 Influent Pump Discharge Point 435 FeCl2 Feed Pump
110 Cryolite Ditches Pump 320 pH Tank 436 FeCl2 Feed Pump Containment Drum
111 Cryolite Ditches Pump Controls 321 pH Tank HH Level Switch 437 Reaction Tank Outlet to pH Sample Pump 2
118 Closed BMP Pump Discharge Point 324 pH Tank LL Level Switch 438 pH Sample Pump 2 Suction Line Valve
119 Cryolite Ditches Pump Discharge Point 325 pH Tank Mixer 439 pH Sample Pump 2 Suction Line Drain Valve
120 Tank 3; Facility 77 326 pH Tank Mixer Motor Relay 440 pH Sample Pump 2
122 Tank 3 Water Level Sensor: H Switch 327 441 pH Sample Pump 2 Motor Relay
123 Tank 3 Water Level Sensor: L Switch 328 Acid Bulk Tote 442 pH Sample Pump 2 Isolation Valve, Discharge
150 Tank 3 Water Level Sensor Display 329 Acid Bulk Tote Level Sensor 449 pH Sensor 2 Isolation Valve, Upstream
175 Batch Pump 330 Acid Feed Pump 450 pH Sensor 2
176 Batch Pump Motor Relay 331 Acid Feed Pump Containment Drum 451 pH Sensor 2 Isolation Valve, Downstream
190 Influent Air/Vac Release Valve 337 pH Tank Outlet to pH Sample Pump 1 452 CaCl2 Feed Pump Discharge Point
338 pH Sample Pump 1 Suction Line Valve
339 pH Sample Pump 1 Suction Line Drain Valve Page 1 of 2
Appendix A
Treatment Process and Equipment ID Schedule
453 FeCl2 Feed Pump Discharge Point 700 Treated Effluent Management Process 900 Operations and PLC
455 pH Sample Pump 2 Discharge Point 719 Effluent Tank Inlet from Lamella Clarifier 901 Main Control Facility
460 Reaction Tank Outlet to Polymer Addition Tank 720 Effluent Tank 910 Ancillary Storage Room
461 Reaction Tank Outlet/Valve (Inactive 1) 721 Effluent Tank HH Level Switch 920 Main Control Room
462 Reaction Tank Outlet/Valve (Inactive 2) 722 Effluent Tank H Level Switch 925 Main Control Panel (MCP)
465 Reaction Tank Discharge Pipe Drain/Valve 723 Effluent Tank L Level Switch 926 Human-Machine-Interface (HMI)
739 Electrical Receptacle 927 Sensaphone
500 Flocculation Process 740 ISCO Auto Sampler 930 Equipment Room
518 Polymer Addition Tank Inlet Drain/Valve 741 ISCO Sample Inlet 935 pH Controller
519 Polymer Addition Tank Inlet from Reaction Tank 760 Effluent Tank Outlet to Facility 77 950 Emergency Eyewash/Shower Station
520 Polymer Addition Tank 765 Effluent Tank Discharge Valve 955 Fire Extinguisher 1
521 Polymer Addition Tank HH Level Switch 766 Effluent Tank Discharge Wye-Strainer w/ Valve 956 Fire Extinguisher 2
524 Polymer Addition Tank LL Level Switch 774 Effluent Pump Suction Line Drain Valve 957 Fire Extinguisher 3
525 Polymer Addition Tank Mixer 775 Effluent Pump 960 Smoke Detector 1
526 Polymer Addition Tank Mixer Motor Relay 776 Effluent Pump Motor Relay 965 Fire Hydrant & Hose House
528 Polymer Bulk Drum 777 Effluent Pump Discharge Line Drain Valve 970 Plant Water Control Valve
529 Polymer Bulk Drum Level Sensor 781 Effluent Bypass Flow Control Valve 975 Plant Air Control Valve
530 Polymer Feed Pump 782 Effluent Flow Control Valve 980 Electrical Panels
531 Polymer Feed Pump Containment Drum 785 Effluent Flow Meter
544 Water Input Rotameter/Control Valve, Upstream 786 Effluent Flow Transmitter
545 Polymer Feed Pump Discharge Point 790 Effluent Air/Vac Release Valve
546 Water Input Rotameter/Control Valve, Downstream
550 MixMate Device 800 Sludge Management Process
551 Diluted Polymer Sampling Valve 805 Sludge Pump
555 Filtrate Pump Discharge Point 810 Sludge Pump Air Valve
556 Diluted Polymer Discharge Point 819 Sludge Pump Discharge Point
560 Polymer Addition Tank Outlet to Lamella Clarifier 820 Sludge Tank
822 Sludge Tank H Level Switch
600 Primary Clarification Process 860 Sludge Tank Outlet to Filtrate Pump
620 Lamella Clarifier 861 Sludge Tank Hatch for Solids Removal
621 Lamella Clarifier HH Level Switch 865 Sludge Tank Discharge Valve
624 Lamella Clarifier LL Level Switch 866 Filtrate Line Wye/Control Valve
650 Lamella Clarifier Cone Sight Tubes 874 Filtrate Pump Suction Line Drain Valve
660 Lamella Clarifier Outlet to Effluent Tank 875 Filtrate Pump
661 Lamella Clarifier Outlet to Sludge Tank 876 Filtrate Pump Motor Relay
665 Sludge Control Valve 877 Filtrate Pump Discharge Line Drain Valve
Page 2 of 2
APPENDIX B
SYSTEM STARTUP
PROCEDURES/CHECKLIST
Updated: May 2018 Page 1 of 1
Facility 71: System Startup Procedures

A system startup is a planned event that requires coordination prior to operation of the system.
Refer to the Operations and Maintenance Manual for additional information.
Wear personal protective equipment when working in Facility 71. Confer with Site Safety Officer and review SDS if you have
questions about appropriate personal protective equipment.
Supplies Inventory: Check current supplies and order additional supplies as necessary.
Chemicals/Reagents Qty. On-hand Reorder Qty. Personal Protective Equipment Reorder Qty.
o Sulfuric Acid o Face Shield
o Calcium Chloride o Chemical Resistant Suit
o Ferrous Chloride o Chemical Resistant Gloves
o Liquid Polymer
o pH 7, Standard Solution
– Properly dispose of expired solutions or solutions that are not properly labeled; see SDS for more information
Initial Inspection of System: Inspect all equipment; begin at wastewater sources and end at Facility 77.
– Figures 2 through 5 may be used for reference during inspection.

o Equipment controls; note inconsistencies
Displays: Human machine interface (HMI), pH controller, flow meters, and Tank 3 level sensor (Systems 926, 935, 310, 785, and 150,
o respectively)
All equipment switches should be in the "Off" position at the main control panel (MCP)/HMI (925/926) and the pH controller (System
o 935).
o All feed pumps in the Equipment Room (System 930) should be unplugged from the electrical receptacle.
o Note all equipment tagged out by location and/or system ID.
o Inspect all visible lines (pipes, hoses, tubing) for damage, missing pieces, etc.; note all inconsistencies
o Inspect all visible connections between equipment and lines for damage, disjointing, etc.; note all inconsistencies
o Inspect stand-alone equipment for damage, available power source (where applicable), etc.; note all inconsistencies
o ISCO Auto Sampler (System 740): Plugged in, internal temperature of refrigerator set in accordance with NPDES permit
o Containment pump (System 240): Plugged in and operates when float is lifted
o Inspect all inactive tank outlets (these should be closed and secured); note all inconsistencies
o Inspect all tanks for damage, leaks, irregular piping, etc.; note all inconsistencies
o Inspect all "normally closed" valves; note those that are open (open valves that are "normally closed" should be tagged out)
o Inspect all "normally open" valves; note those that are closed (closed valves that are "normally open" should be tagged out)
o Inspect feed pump suction lines, discharge lines, and containment tubing; note presence of reagent in containment tubing
o Inspect feed pump containment drums (drums should be empty); note presence of reagent
o Inspect emergency eyewash and shower station; operate to determine if working correctly
o Inspect containment area:
o Holes or cuts in the membrane; note location(s)
o Spills, leaks, and/or accumulation of precipitation; note location(s)
o Excessive debris; note location(s)
See the Operations and Maintenance Manual for further details regarding a System Startup
Startup Procedure of Facility 71
1. Check all chemical totes and suction lines to pumps from chemical totes. Be sure
there is enough chemicals onsite for startup—at least 4 totes of calcium and 2
totes of sulfuric.
2. Turn “upside down valve” in front of Conex box off and disconnect the black hose
going to #2 tank at Facility 77.
3. Turn on batch pump to “auto” and start filling up the influent tank. Be sure there
is enough process water in #3, #2, and #1 for startup.
4. Close ball valves on the ends of pH and reaction tanks (two grey tanks).
5. Be sure blue valve is open and recirculation valve is closed. Check to make sure the
influent valve is open and the wye strainer has been cleaned.
6. Turn on the influent pump on the control panel inside the Conex box. Fill up pH
tank and reaction tank. Gravity flow starts to fill up reaction tank, polymer tank,
and clarifier then goes to effluent tank. Fill up effluent tank about half-full
according to arrow on end of tank.
7. Turn all switches on control panel to “auto” (except effluent pump).
8. Calibrate pH probes. Replace pH probes in holders. Open red ball valve under
Conex box for acid.
9. Plug in all chemical pumps (except polymer pump). Turn on switch in electrical
panel labeled “chemical pumps”. Turn pH and reaction pumps in auto (located by
pH probes).
10. Start recirculation process for a couple hours.
11. Fill polymer container with polymer. Hook up tubing to bottom of container.
Open container and let polymer gravity flow to pump head. Disconnect the tubing
at the pump head to allow the polymer to gravity fill the tubing in order to prime
the pump. Put in prime mode and leave discharge side off until polymer is to the
mix chamber. Screw tubing on. Turn on poly feed water valves to #1 and #2.
12. After system has been recirculating for a couple hours, open effluent control valve
by the readout meter and close effluent sample line ball valve.
Recirculation Process:
 Influent valve off
 Open up recirculation valve
 Turn on effluent
Updated: August 2018

APPENDIX C
SHUTDOWN PROCEDURES/CHECKLIST
Updated: May 2018 Page 1 of 1
Facility 71: System Shutdown Procedures

An extended shutdown of the Plant may occur due to seasonal conditions. The following tasks shall be followed during an
extended shutdown. Refer to the Operations and Maintenance Manual for additional information.
Wear personal protective equipment when working in Facility 71. Confer with Site Safety Officer and review SDS if you
have questions about appropriate personal protective equipment.
Temporary Shutdown (normally 2-4 weeks)

Item Procedure
1 o Switch the batch pump (System 175) to "Off" at the main control panel (MCP; System 925).
Manually pump down system tanks; operate process pumps in "Hand" position at the MCP (925) human machine interface
2 o (HMI; 926).
– Includes influent pump, effluent pump, and filtrate pump.
– Maintain visual monitoring of water level in tanks to avoid pump cavitation during manual operation of pumps.
3 o On the backside and underneath the Conex box close the red ball valve for the sulfuric acid line.
4 o Equipment controls
Switch the Influent Pump, Effluent Pump, Filtrate pump and pH tank, Reaction Tank, and Ploymer Tank mixers to "Off" at
a o the MCP/HMI.
5 o Conex Box Pump Room
a o Switch the pH sample loop and Reaction loop pumps to "Off" at the pH Controller (System 935).
b o Close the red handled vertical ball valves for the pH loop and Reaction loop
c o Turn chemical pumps off in the electrical control panel (Systems 330, 430, 435, and 530).
Turn off water to polymer mixing chamber by closing the two red ball valves labed Poly feed water 1 isolation and Poly
d o feed water 2.
Extended/Seasonal Shutdown
6 o Begin extended shutdown when water levels in Tank 3 (System 120), clarifiers 1 & 2 and ditch levels are low.
7 o Perform steps 1-5 of temporary shutdown.
8 o Drain and/or pump down, clean, and rinse process tanks, except for sludge tank (System 820).
– Process tank contents transferred into sludge tank; filtrate and effluent pumps in "Auto" position at MCP/HMI
a o pH tank (System 320) and reaction tank (System 420)
b o Influent batch tank (System 220);
c o Polymer addition tank (System 520)
d o Lamella clarifier (System 620); run sludge pump (System 805) to empty clarifier
e o Effluent tank (System 720);
9 o Clean wye-strainers at pump connections to tanks.
10 o Pump down and clean sludge dewatering box in sludge tank (System 820).
a o Replace filter fabric if damaged or clogged; As needed
Inspect level of solids in sludge tank. Stabilize and dispose of residual solids in accordance with Solid Waste Control Plan.
b o As needed.
11 o Set valving for recirculation within the treatment system.
a o Close the effluent flow control valve (System 782) located behind Conex box near flow meter.
b o Close the influent flow control valve (System 309). Blue valve near influent flow meter
Open the effluent bypass flow control valve (System 781). After effluent tank is drained, open effluent sample line ball
c o valve located againt the back barrier under effluent line leading to Fac 77. This valve can be left open till start-up.
See the Operations and Maintenance Manual for further details regarding a System Shutdown
Note: The reagent bulk totes and polymer bulk drums may remain in-place. If it is desirable to remove the bulk totes and
drums from the plant, refer to the Operations and Maintenance Manual for information on how to purge the feed
pumps. Storage of bulk totes and drums shall have adequate containment measures.
Temporary Shutdown Procedure of Facility 71
(Maximum Two Weeks)
1. In Facility 71’s back storage room, turn off the chemical pumps at the
electrical panel located on the wall by flipping the circuit breaker labeled
Chemical Pumps. In the pump room, unplug each chemical pump at their
wall outlets.
2. On the back side of the Conex box, along the walkway halfway down
underneath the box, close the red ball valve to stop the flow of acid.
3. On the PLC in the main control room, turn the following equipment switches
from “auto” to “off”:
 Batch pump
 pH tank
 Reaction tank
 Polymer tank
 Effluent pump
 Influent pump
 Filtrate pump
4. In the pump room, turn pumps from auto to off (labeled pH Loop and
Reaction Loop). Turn the red-handled vertical ball valves (labeled pH Loop
and Reaction Loop) to the off position. Remove pH probes, rinse and clean
with DI water, and then place in pH buffer (potassium chloride).
5. In the pump room, turn water off to the polymer mixing chamber by using
the two red ball valves labeled with green tags (Poly Feed Water 1 Isolation
and Poly Feed Water 2 Isolation).
6. Polymer Container Supply Tank:

 If the polymer is below the discharge valve of the container, dispose of
the polymer in a disposable bucket.
 If the polymer is not below the discharge valve, put the rest of the
polymer back into an empty 5-gallon bucket and seal it.
Using a garden hose attachment, flush water through the lines with the
pump on prime. It will take 10-12 times of priming to get water flow through
the other end.
Extended/Seasonal Shutdown Procedure
of Facility 71
1. Follow the steps as outlined in the Temporary Shutdown Procedure of

Facility 71.
2. After the effluent tank is drained (check the level indicator at the end of the
tank), open the effluent sample line ball valve which is located against the
back barrier under the effluent line to Facility 77. This valve can be left open
until startup.
3. Close the effluent control valve located back of the Conex box, next to the
readout meter, labeled Effluent Flow Valve.
4. Close the blue valve on the influent flow meter. Open the recirculation
valve. Hook up the black hose to Clarifier Tank 2 at Facility 77.
5. In the front of the Conex building, left of the front door, open the blue valve
(upside-down) going into Clarifier Tank 2 through the black hose.
6. Check to make sure the influent valve is open at the end of the influent Baker
tank. Inside the Conex box, turn the influent pump to auto at the control
panel. Do not let the influent tank go empty—a few feet of water can be
left in the tank.
7. Open the ball valves on both the pH tank and reaction tank (two gray tanks
on top of the influent tank). This will allow them to drain into the influent
tank.
8. Check the flow from the black hose on the top of Clarifier Tank 2.
9. After the pH and reaction tanks have been drained, use a garden hose to
wash the inside of the tanks.
10. Using the butterfly valve on the bottom of the filtrate tank, drain the water
until it has dropped at least 1 foot. Use a garden hose to wash the louvers
inside the tank.
11. After a few hours (or at the end of the day) turn the filtrate pump and
influent pump to the off position.

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WASTEWATER TREATMENT PLANT

Millennium Bulk Terminals – Longview, LLC

TABLE OF CONTENTS ............................................................................................................. I

LIST OF TABLES .................................................................................................................... IV

LIST OF FIGURES .................................................................................................................... V

LIST OF APPENDICES ............................................................................................................. V

LIST OF ACRONYMS AND ABBREVIATIONS .................................................................... VI

PREFACE ............................................................................................................................... VII

TREATMENT SYSTEM OPERATING PLAN (TSOP).......................................................... VIII

1 GENERAL INFORMATION ................................................................................................ 1

2 TREATMENT PROCESS DESCRIPTIONS .......................................................................... 3

Millennium Bulk Terminals – Longview, LLC i August 2018

3 NORMAL OPERATIONS .................................................................................................. 32

Millennium Bulk Terminals – Longview, LLC ii August 2018

3.9.1 Sulfuric Acid Feed System .................................................................................50

4 STARTUP PROCEDURES ................................................................................................. 56

5 NORMAL SHUTDOWN PROCEDURES .......................................................................... 64

Millennium Bulk Terminals – Longview, LLC iii August 2018

5.4.5 Evacuation of the Sludge Tank..........................................................................68

6 EMERGENCY SHUTDOWN PROCEDURES ................................................................... 70

8 EMERGENCY PLANS AND PROCEDURES ..................................................................... 74

9 LABORATORY PROCEDURES AND RECORDS ............................................................. 75

Millennium Bulk Terminals – Longview, LLC iv August 2018

Table 8 Sludge Management Process Equipment ........................................................... 25

Millennium Bulk Terminals – Longview, LLC v August 2018

List of Acronyms and Abbreviations

Millennium Bulk Terminals – Longview, LLC vi August 2018

As an operations and maintenance manual, it is anticipated that some changes in the

Millennium Bulk Terminals – Longview, LLC vii August 2018

Treatment System Operating Plan (TSOP)

1. Baseline Operating Conditions

2. Operating Procedures to Mitigate Upset Conditions

Millennium Bulk Terminals – Longview, LLC viii August 2018

3. Maintenance and Repairs

Millennium Bulk Terminals – Longview, LLC ix August 2018

Millennium Bulk Terminals – Longview, LLC 1 August 2018

1.3 Purpose of Plant

Millennium Bulk Terminals – Longview, LLC 2 August 2018

1.4 Names and Telephone Numbers

Position Name Telephone Number

2 TREATMENT PROCESS DESCRIPTIONS

Millennium Bulk Terminals – Longview, LLC 3 August 2018

The treatment processes have been assigned the following ID sequences:

General ID Assignment Format for Processes

Millennium Bulk Terminals – Longview, LLC 4 August 2018

2.1 Wastewater Source Management Process

2.1.2 Process Inflow

2.1.3 Process Equipment

Millennium Bulk Terminals – Longview, LLC 5 August 2018

Equipment System No(s).

2.1.4 Process Controls

2.1.5 Process Operations

2.1.6 Process Outflow

Millennium Bulk Terminals – Longview, LLC 6 August 2018

2.2 Influent Batching Process

2.2.2 Process Inflow

2.2.3 Process Equipment

Equipment System No(s).

Millennium Bulk Terminals – Longview, LLC 7 August 2018

2.2.4 Process Controls

Millennium Bulk Terminals – Longview, LLC 8 August 2018

2.2.5 Process Operations

2.2.6 Process Outflow

2.3 pH Adjustment Process