Water Safety Plan Guide

Treatment Processes
– Iron and Manganese Removal
Version 1, Ref P8.2

January 2014
 Citation: Ministry of Health. 2014. Water Safety Plan Guide: Treatment
Processes – Iron and Manganese Removal, Version 1, ref p8.2. Wellington:
Ministry of Health.

Published in January 2014

by the Ministry of Health
PO Box 5013, Wellington, New Zealand

ISBN: 978-0-478-42750-9 (print)

ISBN: 978-0-478-42751-6 (online)

Previously published in 2002 as Public Health Risk Management Plan

Guide: Treatment Processes – Iron and Manganese Removal, Version 1, ref
p8.2. This publication’s title and any reference within the text to ‘public
health risk management plan’ were changed in January 2014 to reflect the
December 2013 legislation change of the term ‘public health risk
management plan’ to ‘water safety plan’. No other changes have been made
to this document.

This document is available at: www.health.govt.nz

This work is licensed under the Creative Commons Attribution 4.0 International licence. In
essence, you are free to: share ie, copy and redistribute the material in any medium or format; adapt ie, remix,
transform and build upon the material. You must give appropriate credit, provide a link to the licence and indicate
if changes were made.
Contents

Introduction

Risk Summary

Risk Information Table

Contingency Plans

Water Safety Plan Performance Assessment

Ref P8.2 Water Safety Plan Guide: Treatment iii

Version 1, January 2014 Processes – Iron and Manganese Removal
Introduction
Iron and manganese are undesirable in water because of their effect on the appearance and
taste of the water, their ability to cause staining, and the health effects of manganese. They
can be removed by:
 oxidising them to form particles in the water, then letting the particles settle, or
filtering them out of the water
 adsorbing them onto ion-exchange resins.

Oxidation can be carried out by:

 aeration
– blowing air through the water
– spraying the water in the air
 using dissolved chemical oxidants
– chlorine (see Guide P7.1)
– chlorine dioxide (see Guide P7.2)
– ozone (see Guide P7.3)
– potassium permanganate (KMnO4)
 adsorbing the metals onto greensand.1

This Guide is mainly concerned with removal using potassium permanganate, aeration,
greensand and ion-exchange resins.

If an event occurs during the removal of these metals (ie, the process doesn’t work
properly), the following could happen:
 if there is incomplete removal of manganese, the manganese may cause sickness
 if too much oxidant is added, sickness may result from the oxidants themselves
 if germs get into the water during aeration, these germs may cause sickness
 if germs grow in the ion-exchange resin, these germs may cause sickness.

The use of chemicals during the removal process can present risks to the health of treatment
plant staff. These are acknowledged, but are not discussed further as such risks are the
subject of health and safety in employment legislation.

The success of removal by oxidation depends on:

 the oxidant used – stronger oxidants, and higher oxidant concentrations give better
oxidation (see Guides P7.1, P7.2, P7.3)
 pH – oxidation is faster at higher pH values (see Guide P8.1)
 organic matter attached to the metal – this makes oxidation difficult.

1
A naturally-occurring mineral treated with manganese which assists in the oxidation of the metals.

Ref P8.2 Water Safety Plan Guide: Treatment 1

Version 1, January 2014 Processes – Iron and Manganese Removal
After oxidation, the process used to remove the insoluble metal compounds will affect how
well the metal is removed (see the appropriate Guides in the P5 series for
coagulation/flocculation and sedimentation, and in the P6 series for filtration).

Greensand filters can oxidise and filter the metals in one step. These filter beds need to be
treated with potassium permanganate either continuously or periodically, when the filter
stops removing the metals properly. The risk information contained in Guide P6.1 is also
helpful for operating greensand filters.

For the ion-exchange process to work, the metals must be in a dissolved form. Air and
other oxidants must therefore be kept out of the water until after it passes through the ion-
exchange unit.

2 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
Risk Summary
The two events creating the greatest risk involved in the removal of iron and manganese
from water are adding too much oxidant to the water (see P8.2.2) and germs getting into the
water during aeration (see P8.2.1).

The most important preventive measures are:

 monitor the process to be sure the right dose is used, regardless of how the quality of
the incoming water may change (see P8.2.2, P7.1.2.4 (chlorine) and P7.2.2.4
(chlorine dioxide))
 regularly maintain the dosing equipment (P8.2.2.3, P7.1.2.1 (chlorine) and P7.2.2.1
(chlorine dioxide))
 place netting over aerator grills to stop entry of larger animals (P8.2.3.1).

(References in parentheses are to the Risk Information Table.)

Ref P8.2 Water Safety Plan Guide: Treatment 3

Version 1, January 2014 Processes – Iron and Manganese Removal
Risk Information Table
Reliable information about water quality is essential for the proper management of a water
supply. Knowledgeable and skilled staff are also essential for minimising the public health
risks associated with water supplies. Please read the staff training (Guide G1) and the
monitoring guides (Guide G2). While we haven’t pointed out every detail of how these
documents are linked with the present document, the links are many and are important.

Abbreviations: DWSNZ – Drinking-Water Standards for New Zealand; MAV – Maximum acceptable value – see
DWSNZ:2000

Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

Removal by oxidation

Event: NOT ALL THE MANGANESE REMOVED

Possible hazards: Manganese
Level of risk: Low

P8.2.1.1  Before designing the  Manganese.  Manganese  Carry out tests to

Treatment option treatment plant, use concentration is identify a more
not right for the bench-scale and pilot- more than 50% of appropriate
water chemistry. scale tests to select the the MAV. treatment for the
best treatment for the water.
 No sign of insoluble
water chemistry.
manganese
formation directly
after oxidation
(metals must be
insoluble to be
removed).

P8.2.1.2  Before designing the  Manganese.  Manganese  Monitor the

pH level is treatment plant, use concentration is manganese
unsatisfactory for bench-scale and pilot- more than 50% of concentration
the water scale tests to determine the the MAV. while adjusting
chemistry. best pH level for the the pH to
 No sign of insoluble
treatment option in use. determine the
manganese
best pH level.
formation directly
after oxidation
(metals must be
insoluble to be
removed).

P8.2.1.3
A number of oxidants can be used for the precipitation of iron and manganese. In addition to the causes of incomplete
oxidation noted in P8.2.1.1 and P8.2.1.2, another possible cause is that the oxidant concentration is too low. For oxidation
by chlorine, chlorine dioxide or ozone, refer to the event of oxidant concentration too low in Guides P7.1 (chlorine), P7.2
(chlorine dioxide) or P7.3 (ozone). In all cases, manganese should be added to the list of determinands to monitor,
especially when determining the correct dosing set-point (dose rate), and the indicators noted above should also be
included.

4 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

Event: NOT ALL THE MANGANESE REMOVED cont’d

The possible causes and preventive measures etc., of incomplete oxidation by potassium permanganate (KMnO 4),
aeration and greensand filtration are covered below.

P8.2.1.4  Use bench-scale and pilot-  Manganese.  Manganese  Carry out manual
KMnO4/air dose scale tests to determine the concentration is checks on
set-point best KMnO4 dose or more than 50% of manganese
incorrect/ dose aeration rate. the MAV. removal and
calculation adjust oxidant
 Use a dose controller (eg,  No sign of insoluble
incorrect. dose accordingly.
reduction-oxidation manganese
controller) that will take formation directly  Start calculation
account of changes in after oxidation checks.
water chemistry, or (metals must be
monitor the manganese insoluble to be
concentration often removed).
enough so that changes in
water chemistry can be
matched.
 From time to time have a
second person check the
dose calculations.

P8.2.1.5  Regular manual checks on  Manganese.  Manganese  Recalibrate

Dosing controller controller calibration. concentration is controller.
incorrectly more than 50% of
 Increase oxidant
calibrated. the MAV.
dose rate until
 No sign of insoluble recalibration can
manganese be undertaken.
formation directly
after oxidation
(metals must be
insoluble to be
removed).
 Calibration
schedule not signed
off.

P8.2.1.6  Install an alarm to warn  Manganese.  Manganese  Install alarm

KMnO4/air when the KMnO4 supply concentration is system.
 Maintenance
supply exhausted. is running low. more than 50% of
log.  Urgently order
the MAV.
 Ensure a reserve supply of replacement
KMnO4 is kept on site.  No sign of insoluble chemicals.
manganese
 Keep records of oxidant  Start log of
formation directly
use to provide a guide to oxidant use.
after oxidation
the length of time the
(metals must be  Initiate pump
chemical supply is likely
insoluble to be maintenance
to last.
removed). programme.
 Schedule a preventive
maintenance programme
for air pumps.

Ref P8.2 Water Safety Plan Guide: Treatment 5

Version 1, January 2014 Processes – Iron and Manganese Removal
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

Event: NOT ALL THE MANGANESE REMOVED cont’d

P8.2.1.7  Routine maintenance of  Manganese.  Manganese  Identify cause of

KMnO4 supply dosing pumps and concentration is fault and rectify.
 Maintenance
adequate, but feedlines to ensure they more than 50% of
log.  Determine what
KMnO4 is not are not blocked (see Guide the MAV.
steps can be taken
being dosed into P10).
 No sign of insoluble to stop it
the water: manganese happening again.
– Dosing pump formation directly
failure after oxidation
(metals must be
– Feedlines insoluble to be
blocked. removed).
 Maintenance log
shows ongoing
problems with
pump or line
blockage.

P8.2.1.8  Do routine controller  Manganese.  Manganese  Identify cause of

Dose controller maintenance. concentration is fault and rectify.
 Maintenance
malfunction. more than 50% of
 Replace controller with a log.  Replace
the MAV.
reliable unit if the present controller with a
unit is suspect.  No sign of insoluble new unit.
manganese
formation directly
after oxidation
(metals must be
insoluble to be
removed).
 Maintenance log
shows frequent
maintenance
needed.

Event: NOT ALL THE MANGANESE REMOVED cont’d

P8.2.1.9  From time to time have a  Manganese.  Manganese  Re-calculate

KMnO4 dosing second person check concentration is chemical
 Permangan-ate
solution calculations used for more than 50% of quantities
concentration
concentration preparation of KMnO4 the MAV. required for the
in dosing
incorrect, or dosing solution. dosing solution,
solution.  No sign of insoluble
prepared with and prepare a
 Check KMnO4 manganese
incorrect  Supplier’s new solution.
concentration in each new formation directly
chemical. certification of
batch of dosing solution after oxidation  Provide for staff
analysis.
prepared. (metals must be additional
insoluble to be training in
 Ensure that chemicals are
removed). calculations for
delivered to the correct
solution
bin, that bins are labelled,  Checks show
preparation.
and that an operator is frequent incorrect
there to supervise calculations.  Ensure that
chemical delivery. chemical supplier
is aware of the
 Check quality of KMnO4
need for the
delivered.
operator to be
present when
chemicals are
delivered.
 Obtain a new
batch of chemical
from the supplier,
if quality
unsatisfactory.

6 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

P8.2.1.10  Do calculations and tests  Manganese.  Manganese  If aerator relies

Poor air during design to ensure air concentration is on natural draft,
circulation for circulation will allow more than 50% of consider
droplet, or thin- enough oxygen to dissolve the MAV. installation of
film, aerator. in the water. blowers to
 No sign of insoluble
provide forced
manganese
draft.
formation directly
after oxidation  Modify the
(metals must be aerator to
insoluble to be minimise
removed). obstructions to air
flow.
 Calculations show
air circulation too
low.

P8.2.1.11  Design to ensure droplets  Manganese.  Manganese  Replace nozzles.

Poor nozzle are given longest possible concentration is
 Modify spray
design in spray time in the air to allow more than 50% of
trajectory.
aerator. oxygen exchange (nozzle the MAV.
design and trajectory are
 No sign of insoluble
important).
manganese
formation directly
after oxidation
(metals must be
insoluble to be
removed).

Event: NOT ALL THE MANGANESE REMOVED cont’d

P8.2.1.12  During design do pilot  Manganese.  Manganese  Replace or

Poor design of trials to check that the type concentration is modify the
aerator. of aerator chosen, and its more than 50% of aerator.
design, will provide the MAV.
adequate oxidation of the
 No sign of insoluble
metals.
manganese
formation directly
after oxidation
(metals must be
insoluble to be
removed).
 Trials/calculations
show design is
unsatisfactory.

P8.2.1.13 See P6 Guide series for a discussion of events, causes, preventive measures etc. associated with the use
Poor removal of of standard filters, and those using greensand for combined oxidation and filtration.
precipitated metal
by filtration.

Ref P8.2 Water Safety Plan Guide: Treatment 7

Version 1, January 2014 Processes – Iron and Manganese Removal
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

P8.2.1.14  Ensure KMnO4 dose (in  Manganese.  Manganese  Adjust dose rate.
Greensand the influent, or in off-line concentration is
 Undertake a more
performance regeneration) is adequate more than 50% of
complete check
inadequate. to maintain the oxidising the MAV.
on the water
capacity of the bed.
 No sign of insoluble chemistry and
 Ensure that concentrations manganese reconsider this
of other chemically formation directly treatment option
reduced determinands in after oxidation if reduced
the water (eg, organic (metals must be determinand
matter, nitrite, ammonia insoluble to be concentrations
and hydrogen sulphide) removed). are high.
are not so high that they
 Modify
exhaust the bed’s
operational
oxidising capacity.
procedure.
 Provide sufficient time for
 Start a filter
the bed to “ripen” after
maintenance
bringing it back on-line.
programme.
 Schedule routine filter
maintenance. This should
check for channelling for
example (see also Guide
P6.1).

P8.2.1.15  Provide stand-by  Continuity of  Loss of power.  Refuel generator,

Power failure. generator to ensure power. if appropriate.
continuity of power.

Event: OXIDANT DOSE TOO HIGH

Possible hazards: Manganese (if KMnO4 used as an oxidant), chlorine, chlorine dioxide or KMnO4.
Level of risk: Moderate

P8.2.2.1
Possible causes of overdosing with chlorine and chlorine dioxide are discussed in the relevant Guides for the individual
oxidants. See Guides P7.1 (chlorine) and P7.2 (chlorine dioxide). Overdosing with ozone will not create a public health
risk because of the rapid decay of this oxidant. The causes and preventive measures etc. associated with the use of KMnO 4
as an oxidant are noted below.

P8.2.2.2  Do bench-scale and pilot-  Manganese.  Manganese  Carry out manual

KMnO4 dose rate scale testing to determine concentration more checks on
 KMnO4 dose.
set incorrectly or the best KMnO4 dose or than 50% of its manganese
incorrect dose aeration rate. MAV. concentration and
calculation. adjust the oxidant
 Use a controller (oxidation  Pink water.
dose accordingly.
–reduction potential) that
will automatically adjust  Start checks on
the dose rate to ensure the the dose
right oxidant dose is used, calculations.
or monitor often enough
that the oxidant dose can
be adjusted to match
changes in water
chemistry.
 From time to time get a
second person to checks
on the dose calculation.

8 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

P8.2.2.3  Routine controller  KMnO4 dose.  Manganese  Identify cause of

Dosing controller maintenance. concentration more fault and rectify.
 Maintenance
malfunction. than 50% of its
 Replacement of a suspect log.  Replace
MAV.
controller with a reliable controller with
unit.  Pink water. new unit.
 Maintenance log
shows frequent
maintenance
needed.
 Maintenance log
not signed off.

P8.2.2.4  Regular manual checks on  KMnO4 dose.  Manganese  Recalibrate

Dosing controller the controller’s concentration more controller.
incorrectly calibration. than 50% of its
 Decrease dose
calibrated. MAV.
rate until
 Pink water. recalibration.
 Calibration
schedule not signed
off.

Event: OXIDANT DOSE TOO HIGH cont’d

P8.2.2.5  Check the concentration of  KMnO4 dose.  Manganese  Determine the

KMnO4 dosing the KMnO4 dosing concentration more cause of the high
 KMnO4
solution solution when it is first than 50% of its KMnO4
concentration
concentration too prepared. MAV. concentration and
in the dosing
high. rectify.
 Separate chemical storage solution.  Pink water.
from dosing solution  Provide training
 KMnO4
preparation tanks to in the preparation
concentration in the
reduce the likelihood of of oxidant
dosing solution
chemical spillage into the solutions
above the level
tanks. (including
expected.
calculations).
 Identify the
reasons for any
spillage and
rectify if possible.

Event: GERMS INTRODUCED DURING AERATION

Possible hazards: Germs.
Level of risk: Moderate1

P8.2.3.1  Place netting over aerator  Microbiological  E. coli or  Disinfection of

Micro-organisms grills to stop entry of water quality. coliforms the water
introduced into larger animals (eg, birds, detected in a 100 following
the water during rats, etc). ml sample taken aeration.
aeration, either in  after the aerator.
Provide disinfection
the airstream or following aeration to
through animals inactivate germs that get
entering the into the water.
aerator.

1 The consequences of the event, and therefore the level of risk, will be influenced by how well following disinfection
processes works.

Ref P8.2 Water Safety Plan Guide: Treatment 9

Version 1, January 2014 Processes – Iron and Manganese Removal
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

Removal by ion exchange

Event: INCOMPLETE REMOVAL OF MANGANESE

Possible hazards: Manganese.
Level of risk: Low

P8.2.4.1  Check water chemistry before  Manganese.  Manganese  Consider a

Ion-exchange selecting the treatment option concentration different
resin to determine the concentrations more than 50% treatment
exhausted. of ions that will be adsorbed of its MAV. process.
by the resin (commonly iron,
manganese, calcium and
magnesium). This will allow
an estimate of operational time
before regeneration will be
required, and how much the
hardness of the water will
interfere with the iron and
manganese removal.
 Monitor changes in treated
water chemistry (eg, calcium,
manganese) to determine when
the resin is exhausted and
regeneration is required.

P8.2.4.2  Check water chemistry before  Manganese.  Manganese  Pretreat the water
Ion-exchange selecting the treatment option concentration to remove
 Turbidity.
resin is fouled. to determine whether the water more than 50% organic matter.
contains organic material of its MAV.
 Consider a
which will foul the resin, or
 Turbid water different
whether the water contains
entering the treatment
insoluble iron or manganese
ion-exchange process.
which foul the resin.
unit.
 Locate and seal
 Ensure that air cannot come
 Exchange unit paths by which
into contact with the water
rapidly fouled. air may enter the
before it enters the ion-
system before the
exchange unit to avoid
ion-exchange
oxidation of iron and
unit.
manganese.
 Install
 Provide pre-treatment (eg,
appropriate pre-
filters) to remove particulate
treatment, or
matter from the water.
improve the
performance of
the treatment
already in use.

P8.2.4.3  Check when the exchanger is  Manganese.  Manganese  Repack the

Channels in the first installed that it has been concentration exchanger or
ion-exchange properly packed. more than 50% return to the
resin bed. of its MAV. manufacturer.

10 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
 Causes Preventive measures Checking preventive measures Corrective action

What to check Signs that action is

needed

Event: BUILD-UP OF GERMS IN THE RESIN BED

Possible hazards: Germs.
Level of risk: Low1

P8.2.5.1  Regeneration of the resin at the  Microbiological  High counts of  Regenerate and
Organic matter frequency recommended by quality. total bacteria. back-flush.
and micro- the manufacturer. This will
 Calcium.  Hardness not  Clean resin to
organisms also back-flush the bed and
being reduced. remove bead
trapped in the remove organic material.  Magnesium.
fouling.
resin bed.  Iron and/or
 Regularly clean (de-foul) the  Iron.
manganese not  Disinfect the
resin beads with the
 Manganese. being removed. water after the
recommended cleaning agent if
ion-exchanger.
iron or manganese are present  Odour.
in the water.
 Carry out treatment to remove
organic matter from the water
before the softener.

1 The consequences of the event, and therefore the level of risk, will be influenced by how well subsequent disinfection
processes work.

Ref P8.2 Water Safety Plan Guide: Treatment 11

Version 1, January 2014 Processes – Iron and Manganese Removal
Contingency Plans
If an event happens despite preventive and corrective actions you have taken, you may need
to consult with the Medical Officer of Health to assess how serious a problem is.

Event – Faecal matter gets into the water through the aerator

Indicators:  Faecal indicator organisms or pathogens are continually detected

in the water leaving the plant.
 Knowledge of an animal having entered the aerator.
 Widespread sickness in the community linked to the water
supply.

Required  Follow the actions given in Figure 3.2 of the DWSNZ:2000.

actions:
 Identify the reason for the failure and rectify.
 Record cause of system failure and steps taken to correct.
 Modify your water safety plan if necessary.

Responsibility: Manager designated responsible for the water supply.

12 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014
 Event – Very high oxidant concentration

Indicators:  Knowledge of a major spillage or overdose of oxidant into the

water.
 Pink colour of the water (KMnO4 overdose).
 Inability to obtain pink colour from DPD chlorine indicator
despite high chlorine dose rates (NB this indicates chlorine
levels well in excess of the MAV – very high chlorine or chlorine
dioxide levels bleach the pink colour that normally develops in
their presence).
 Water develops a strongly chlorinous odour.
 Widespread complaints of taste and odour, or black particles in
the water or staining (KMnO4 overdose), or illness in the
community.

Required  Close down the plant. Provide another source of potable water
actions: until water of acceptable quality can again be supplied.
 Inform the MOH of the situation.
 Identify the cause of the problem and rectify.
 Dump the reservoir water, or add chemicals to neutralise the
oxidant if more appropriate (neutralisation may be required
before any water is dumped anyway).
 Flush the distribution system, if excessive levels of chlorine are
also present in the distribution system, and monitor water quality
until chlorine concentrations are again back to normal operating
levels.
 Warn consumers to thoroughly flush their taps before drawing
water for use (if they are likely to have been affected).
 Record cause of system failure and steps taken to correct.
 Modify your water safety plan if necessary.

Responsibility: Manager designated responsible for the water supply.

Ref P8.2 Water Safety Plan Guide: Treatment 13

Version 1, January 2014 Processes – Iron and Manganese Removal
Water Safety Plan Performance
Assessment
To make sure that your supply’s water safety plan (formerly known as a Public Health Risk
Management Plan, PHRMP) is working properly, periodic checks are needed. The
overview document outlines what needs to be done. The following table provides the
detailed information for checking this particular supply element.

What to measure or  Chlorine, chlorine dioxide or KMnO4 residuals.

observe:
 Faecal indicators (E. coli).
 Manganese concentrations greater than 50% of the MAV
in the treated water.
Follow the protocols set out in DWSNZ:2000.
Note that the presence of faecal indicators may be influenced by
factors other than the operation of the aerator.

How often:  For the monitoring frequencies for FAC and E. coli
measurements see DWSNZ:2000 Section 3.3.2.
 Manganese should be monitored at least once a month if
not in transgression of the MAV.

What to do with the  Record results to meet legislative requirements or to allow

results: water safety plan performance assessment. The WINZ
database is good for this.
 The collected data need to be periodically reviewed to see
whether problems with this supply element are
developing. This should be done as frequently as the
manager responsible considers necessary to minimise risk
to public health arising from this supply element.
 Should this review show any unusual incidents, indicate
that proper procedures are not being carried out, highlight
poor laboratory results or indicate that poor water quality
is reaching customers, then review the procedures for
managing iron and manganese removal.
 Evaluate the monitoring results, and any actions taken as
the result of having to implement a contingency plan, to
see if the water safety plan needs modification – eg,
preventive measures are up to date; the contingency plan
steps are still adequate; and changes to the iron and
manganese removal process are recognised in the plan.

Responsibility: Manager designated responsible for the water supply.

14 Water Safety Plan Guide: Treatment Ref P8.2

Processes – Iron and Manganese Removal Version 1, January 2014