P-OM-001-011 Gravity Belt Thickener

DOHA WEST SEWAGE TREATMENT WORKS
EXTENSION NO. 5
CIVIL PROJECT CP807
PROJECT CODE IA 14/15 C077G
CLIENT
ASHGHAL
PO Box 22188,
Doha, State of QATAR.
O&M JV CONTRACTOR's
DOHA WEST O&M – Degremont Marubeni JV
DOHA WEST Sewage Treatment Plant
PO BOX 24 038
DOHA QATAR
TEL +974 4476 5333
http://www.degremont.com
5 12-04-2018 Final version LBO SGO JPI

4 19-10-2017 Review the file LBO SGO JPI
3 27-07-2017 Add Extension 5 LBO SGO JPI
2 29-11-2015 Change logo, Add template SSE SPO DWR
1 16-05-2013 Review the file,Add extension 4 PLU CRO TCH
0 08-11-2011 First emission SPA RBU OMA
Rev Date Modification Issued by Checked Approved
GRAVITY BELT THICKENER
COMPANY DOCUMENT NUMBER REV: D.STATUS

SUEZ MRB P-OM-001-011 5 FA
DOHA WEST SEWAGE TREATMENT WORKS Doc No.
EXTENSION N°5 P-OM-001-011
Rev: Date:
05 12-04-2018
OPERATOR MANUAL
Drawn by Checked by: Approved by:

L.BOURGEOIS S.GONNOT J.PIENS
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1. Introduction
The aim of this manual is to provide a standard reference to Thickening Unit equipment and their operation.
It will address the following subjects,
What are the targets of Thickening Unit?
Which physical and chemical principles are included in this treatment?
What is the configuration of this unit?
What are the main adjustments, instructions and maintenance activities to be implemented?

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1. INTRODUCTION 3
2. GENERAL PRESENTATION 6
2.1. Objectives 6
2.2. Localization 7
2.3. P&ID’s Reference 8
2.4. Risks 9
2.4.1. Biological risks on Human Health 9
2.4.2. Effects of chemicals used on Human Health 10
3. PHYSICAL AND BIO-CHEMICAL PRINCIPLES 12
4. TECHNICAL DESCRIPTION 13
4.1. General description 13
4.2. Surplus Activated Sludge Balancing Tanks 14
4.3. Thickening by GBT 16
4.3.1. General description 16
4.3.2. Progressive cavity pumps – Feeding & Diluting pumps 17
4.3.3. Polyelectrolyte Powder and Emulsion – Preparation & Dosing Units 19
4.3.4. Gravity Belt Thickeners 23
4.3.5. Compressed air production for GBT 25
4.3.6. Progressive cavity pumps – GBT outlet forced pumps 26
4.4. Site drainage pumping stations 28
5. ADJUSTMENTS 30
5.1. Process Control Philosophy 31
5.1.1. Sludge Building 600 – GBT sequence 31
5.1.2. Sludge Building 600B – GBT sequence 32
5.2. Sludge building 600 33
5.2.1. Sludge Balancing Tank 33
5.2.2. Gravity Belt Thickening 36
5.2.3. Polymer Preparation Unit 38
5.3. Sludge Building 600B 40
5.3.1. Liquid sludge storage and pumping 40
5.3.2. Gravity Belt Thickening 49
5.3.3. Polymer Preparation & Dosing Units 53
5.3.4. Compressed air production for GBT 56
5.3.5. GBT site drainage 57
6. ROUTINE TASKS AND FIRST LEVEL MAINTENANCE 59

6.1. Sludge Balancing Tanks 59
6.2. Polyelectrolyte Powder & Emulsion Units 62
6.3. Thickening by Drainage 64
6.4. MCC Rooms and Sub-Stations 68
7. OPERATION PROCEDURES 71
7.1. P-OM-001-000 Resetting of One Equipment Tripped 71
7.2. P-OM-016-600 Manually Start of Gravity Belt Thickener 73
7.3. P-OM-017-600 Manually Stop of Gravity Belt Thickener 77
7.4. P-OM-000-488C Manual Extraction of Surplus Activated Sludge 80
7.5. P-OM-000-610 Isolation for one compartment 610B 81

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7.6. P-OM-045-600 Polymer Dosing Calculation for GBT 83

7.7. P-OM-046-600 Sludge Dilution Calculation for GBT 84
8. TROUBLESHOOTING AND REPAIR 85

8.1. Operating Problem for GBT 86
8.2. Booster Pump Stop or not Starting 87
8.3. GBT Stop or not Starting 87
8.4. Sludge Pump Stop or not Starting 88
8.5. Polymer Pump Stop or not Starting 88
8.6. No Sludge coming from 488 but Extraction Pump Running 89
8.7. Flocculation and polymer preparation 89
9. APPENDIX 90
9.1. Details Supplier 90
9.2. Acronyms 92

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2. General Presentation
2.1. Objectives
} The objective is to get an average concentration of 20 g/l to feed the aerobic digester with sludge from Surplus
Activated Sludge (SAS) balancing tanks (610 & 610B).
} A part of the excess sludge is thickened on Gravity Belt Thickeners (GBT) to a concentration of about 45 g/l.
} The other part of the excess sludge at 5 to 7 g/l by-pass the GBT.
} Thickened and liquid sludge is mixed together prior to feed digesters.

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2.2. Localization
Localization of the Gravity Belt thickener Units

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2.3. P&ID’s Reference
CP807 DGT M DS 610 001 Z Sludge Balancing Tank
CP807 DGT M DS 600 001 Z Thickening by Drainage A B C
CP807 DGT M DS 600 011 Z Thickening by Drainage D
CP807 DGT M DS 600 002 Z Powder and Emulsion Polyelectrolyte - Dosing
CP807 DGT M DS 600 012 Z Powder and Emulsion Polyelectrolyte Preparation
CP807 DGT M DS 600 050 H 600B - Thickening by drainage - Gravity Belt A, B, C
CP807 DGT M DS 600 051 H 600B - Thickening by drainage - Gravity Belt D, E
CP807 DGT M DS 600 060 F 600 B - Powder and Emulsion Polyelectrolyte Preparation
CP807 DGT M DS 600 061 F 600 B - Polyelectrolyte Powder and Emulsion Dosing to Thickening
CP807 DGT M DS 600 090 F 600 B - Compressed Air Production for Gravity Belt
CP807 DGT M DS 610 050 E Storage of Liquid Sludge

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2.4. Risks
2.4.1. Biological risks on Human Health
} Wastewater constitutes a vector for many bacteria likely to cause man diseases. In the water treatment plant,
the risk is important and there are many possibilities for contact with sludge or wastewater:
o All contacts with sludge or water whatever their state
o Breathing the bacteria in suspension in the air close to the aerators
Symptoms
} When the symptoms mentioned below are detected, the concerned person should be
immediately transported to the hospital:
o Digestive problem;
o Diarrhea;
o Gastro-enteritis;
o Viral Maladies.
Precaution
} Avoid any contact with sludge, water, Screening Risk of

microbiological
} Use gloves and clean overalls and adapted boots if necessary. contamination
} Respect elementary hygiene rules (wash the hands before eating, taking a shower after
work...).
} Check that you are vaccinated against the most current diseases.
First Aid Measures
} When contact with a risky product occurs: wash with soap immediately.
} After a fall in a tank: wash immediately yourself AND consult a doctor.
} If you have the symptoms in a chronic way, prevent your hierarchy, AND consult a doctor

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2.4.2. Effects of chemicals used on Human Health
} Appropriate chemical PPE must be worn during any intervention.
} Refer to SAFETY DATA SHEET for more information.
} Polymer Zetag® 8165

o Work areas need to be regularly maintained to avoid slippery floors and any fall risks;
o Signs must be installed during operation of polymer.
Use for: Flocculation agent for Thickening and Dewatering units
Characteristics: Polyacrylamide, cationic

White and odourless powder
Personal Protection:
Potential health effects: Slippery - Non-irritant
First Aid Measures: If inhaled, remove to fresh air and seek medical attention. On
ingestion, rinse mouth and then drink plenty of water.
SAVING RULES
Do not handle chemicals products without appropriate protection.

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3. Physical and Bio-Chemical Principles

Flocculation
} Sludge contains settleable material and also very small compounds that have a tendency to stay suspended in
water. These small compounds are colloidal particles.
} In order to treat these particles in the GBT, it is necessary to agglomerate them in grosser particles. This process
is the flocculation.
} To perform this flocculation, a chemical reagent named polymer is injected at the entry of the GBT.
} The polymer sticks to the side of particles and links them together. It is called “gating agglomeration”.

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4. Technical Description
4.1. General description
} The process of thickening is the same for each sludge building 600 & 600B and detailed in the scheme hereunder.
} Surplus activated sludge from biological treatment is stored in a SAS Balancing Tank. One pump feed the GBT with
SAS to be thickened until 45 g/l. An injection of polymer is foreseen to allow a good thickening of the sludge.
Another pump feed the outlet of GBT to dilute the thickened sludge to 20 g/L which is sent through a forced pump
to aerobic digestion.
} The filtrate and wash water is evacuated to a drainage pumping station.

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4.2. Surplus Activated Sludge Balancing Tanks
SAS Balancing tank 610
} Hydro-jets
TAG NUMBER: 610_PO101A/B/C
Three Hydro-jets have been provided to keep a homogeneous sludge
concentration in the sludge balancing tanks. An air system is also
present in order to prevent the sludge fermentation.
There is one hydro-jet per sludge tanks.
SAS Balancing tank 610B
} The SAS from 488C is aerated and mixed in the SAS Balancing tank 610B where the sludge is divided in two
compartment interconnected by a manual penstock (610__VH450_). One compartment can be isolated in case
of maintenance.
Tank Per compartment
Volume 505 m 3
Number of coarse air bubble diffusers 324
} Two aeration air blowers (610__KI153A/B), 1 on duty, 1 in stand-by, produce air for Sludge Balancing Tank. This
air injection avoid anoxic condition or fermentation. Each compartment of the SAS Balancing Tank is aerated by
means of coarse air bubble diffusers (Vibrair© type) in floor configuration to keep a homogeneity and maintain
a minimum of 1.0 mg/L of dissolved oxygen through the full depth of the sludge.
} The air diffusers network is fed through motorized valves (610B1/2VM477A/B). There are open when their
corresponding compartment (A or B) are in operation and the SAS level is above low threshold. They will be close
by operator in case of maintenance.
} Manuals valves equipped with limit switches allowed to drain the compartments. Sludge Balancing Tank drain
flows with drain from Odour Control Unit to the pumping station 921C.
} Each compartment is equipped with a dissolved oxygen analyser (610B1/2AIT350_), a temperature measurement
(610B1/2TIT350_), a level measurement (610B1/2LIT350_) and very high (610B1/2LSHH352_) and very low
(610B1/2LSLL351_) level switches. Level measurements are considered as redundant measurement if the
corresponding inlet valve (488CVH452A/B) is opened. The average DO level to maintain is around 1 mg/L.
} Air blower’s characteristics:

TAG NUMBER: 610__CS153A/B
The two aeration blowers are on VFD. Motors are equipped with high temperature
switch.
- Air blower unit capacity: 2,000 Nm 3 /h.
Blowers runs on:

- Frequency/Duration cycles according to an adjustable timer
- Or continuously depending on the operator demand regarding the SAS LAB TEST.
The aim is to reach the suitable dissolved [O 2 ] in the Sludge Balancing Tank.
In case of very high or very low dissolved Oxygen and very high temperature in the
Sludge Balancing Tank, an alarm is reach on the SCADA.

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} Equipement and instrument included in this section

Equipment / instrument TAG Number Equipment’s supplier
SLUDGE BALANCING TANK
Manual Isolation penstock 610__VH450_ 1 KWT
Sludge Balancing tank level measurement 610B1/2LIT350_ 2 E+H
Sludge Balancing tank very high level switch 610B1/2LSHH352_ 2
BAMO
Sludge Balancing tank very low level switch 610B1/2LSLL351_ 2
Dissolved oxygen measurement 610B1/2AIT350_ 2
HACH
Temperature measurement 610B1/2TIT350_ 2
AIR PRODUCTION
SAS Balancing tank 610B aeration blowers 610__CS153A/B 2
Aeration blower acoustic hood fan 610__CV153A/B 2
In Line Strainer Filter 610__XH250A/B 2 AERZEN
Silencer 610__XQ251A/B 2
Differential pressure indicator 610__PDI250A/B 2
610B1VM477A/B
Air to 610B SAS Balancing Tank - Isolating motorized valve 4 EBRO ARMATUREN
610B2VM477A/B
610B1AA251[A-I]
610B1AA252[A-I]
Air mixing Vibrair© 36 AMGI
610B2AA251[A-I]
610B2AA252[A-I]

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4.3. Thickening by GBT
4.3.1. General description
} For both of the buildings, the thickening system is as followed:

Composition of a thickening line Building 600 Building 600B
4 lines (A to D) 5 lines (A to E)
3 on duty, 1 on stand-by 4 on duty, 1 on stand-by
One GBT feeding pump 610__PO102A/B/C/D 610__PO160A/B/C/D/E
One GBT dilution pump 610__PO103A/B/C/D 610__PO161A/B/C/D/E
One Gravity Belt Thickener (GBT) 623__SP101A/B/C/D 623__SP151A/B/C/D/E
One polymer dosing pump to thickening 813__PO106A/B/C/D 813__PO156A/B/C/D/E
One wash water solenoid valve 922__VY429A/B/C/D 929__VY468A/B/C/D/E
One GBT outlet forced pump 623__PO102A/B/C/D 623__PO152A/B/C/D/E
} There is also two air compressors per building to control the opening of solenoid valves.
} The polymer preparation unit is common for thickening and dewatering workshops.

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4.3.2. Progressive cavity pumps – Feeding & Diluting pumps
} Progressive cavity pumps are provide for transportation of sludge to different treatment units.
Positive displacement pump
The feeding pumps: are used to convey excess sludge from sludge balancing tank 610 (respectively 610B)
directly to Gravity Belt Thickeners, in sludge building 600 (respectively 600B).
The by-pass GBT - Dilution are used to send SAS liquid sludge at 5 to 7 g/l to dilute thickened sludge at 35 to 60
pumps: g/l with in the sludge hopper at the outlet of GBT.
Sludge Building 600
} Eight progressive cavity pumps:

o Four Feeding pumps (3 on duties, 1 on standby);
o Four Dilution pumps (3 on duties, 1 on standby).
Each feeding and diluting pipe (6 pipes) is equipped with an electromagnetic flow meter (610__FIT307A/C/D and
610__FIT306A/C/D) to measure and control the volume of sludge for thickening and the volume of sludge for
dilution.
Sludge Building 600B
} There is ten progressive cavity pumps. Each pump is equipped

with VSD and two high temperature detectors: high temperature
switch and dry running protection.
o Five Feeding pumps (4 on duties, 1 on standby)
- Minimum Unit Flow: 60 m3/h
- Maximum Unit Flow: 170 m3/h
o Five Dilution pumps (4 on duties, 1 on standby)
- Minimum Unit Flow: 20 m3/h
- Maximum Unit Flow: 60 m3/h
The pumps runs continuously according to the GBT sequences.

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} Each feeding pipe (5 pipes) is equipped with an electromagnetic flow meter (610__FIT360A/B/C/D/E) which
control the pumps feeding the GBT in order to maintain the flow set point to reach the sludge concentration at
the outlet around 45 g/l.
} Each dilution pipe (5 pipes) is equipped with an electromagnetic flow meter (610__FIT361A/B/C/D/E) which
control the pumps diluting the sludge at the GBT outlet in order to maintain the flow set point to reach the sludge
concentration around 20 g/l.

x = A, B, C, D, or E
GBT feeding pump suction pressure transmitter 610__PIT362x 5 E+H
GBT feeding pump 610__PO160x 5 SEEPEX
GBT feeding pump discharge flow measurement 610__FIT360x 5 E+H
GBT feeding pump discharge pressure transmitter 610__PIT360x 5
BAUMER
GBT feeding pump motor high pressure switch 610__PSH360x 5
By-pass GBT - Dilution pump suction pressure transmitter 610__PIT363x 5 E+H
By-pass GBT - Dilution pump 610__PO161x 5 SEEPEX
By-pass GBT - Dilution pump discharge flow measurement 610__FIT361x 5 E+H
By-pass GBT - Dilution pump discharge pressure transmitter 610__PIT361x 5
BAUMER
By-pass GBT - Dilution pump motor high pressure switch 610__PSH361x 5

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4.3.3. Polyelectrolyte Powder and Emulsion – Preparation & Dosing Units
} The polymer preparation concentration rate is 3 g/L. From this preparation, the polymer will be diluted with
industrial water in order to decrease his concentration. Then it is conveyed at the inlet of GBT in order to improve
the thickening process.
Preparation Unit Description
} The three compartments of the Polymer Unit (preparation [1.1], maturing [1.2] and dosing [1.3]) are connected
together by baffles to ensure an appropriate retention time in each compartment and obtain a homogenous
preparation.
} The equipment is automatically controlled by the level detector [5] (through the electrics box [6]) installed in the
dosing compartment.
} When the pumps (located downstream from the dosing connections [7]) are in service and the solution reaches
the «low» levels, polymer production is started.
} The «low level» detector [5.2] triggers the solenoid valve [4.4] and triggers the start-up of the dry feeder [3].
} When the solution reaches the «high» level [5.3], polymer production is stopped. The level controller [5] enables
to stop the dry feeder [3] and closes the water intake solenoid valve [4.4].
} If the solution reaches the «very high» level [5.4], polymer production is halted and the «General fault» button
lights up on the control unit.
} If the solution reaches the «very low» level [5.1], the process is halted (the dosing feed pumps stop) and the
«Fault» button lights up on the control unit. To compensate for failure of the «low» level detector [5.2], polymer
production is re-started.
} The agitators [2.1] and [2.2] operate in continuous mode at all stages of the cycle.
Note: Depending on the polymer concentration, the polymer solution will lose its properties after 24 to 48 hours
if not used within this period.
1 Three compartment tank

1.1 Preparation compartment
1.2 Maturation compartment
1.3 Dosage compartment
2.1 Agitator for preparation
2.2 Agitator for maturation
3 Dry feeder
4 Water intake
4.3 Flow meter
4.4 Solenoid valve
5.1 Very low level sensor
5.2 Low level sensor
5.3 High level
5.4 Very high level sensor
6 Control panel
7 Dosing connections
Polymer Preparation Unit: Operating principles

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Sludge building 600

TAG NUMBER: 813A/B/C/D_KI101
} Four polymer preparation units are provided. They do supply polymer to GBT and centrifuges. They can accept
either liquid or powder polymer.
Sludge building 600B
TAG NUMBER: 813A/B/C/D_KI151
Polymer preparation…………………………………………………………………………………………………………………….……………………………….3g/L
} Four polymer preparation units are provided. They do supply polymer to GBT and centrifuges and can accept
either liquid or powder polymer.
o 2 preparation units for thickening treatment: 1 on duty, 1 on stand-by;
o 2 preparation units for dewatering: 2 on duty, in parallel.
Polymer preparation units
} The preparation unit tanks feed two sets of progressive cavity pumps:
o One set dedicated to thickening treatment (813__PO156A/B/C/D/E);
o One set dedicated to dewatering (813__PO157A/B/C/D).
} The preparation unit tanks A or B dedicated to the thickening treatment feed a set of 5 progressive cavity pumps
(813__PO156A/B/C/D/E – Refer to scheme Positive Displacement Pump in §4.3.2). Preparation tank B’s isolating
pneumatic valve (813B_VA450_) is fed with air from compressors (923__CP181A/B).
} The dosing pump discharge pipes to GBT are equipped with a flow measurement (813__FIT351A/B/C/D/E) and a
high pressure indicator and switch (813__PISH350/A/B/C/D/E). When a low flow or high pressure is reached, an
alarm is generated.
} The pumps runs according to their associated belt thickener sequence and the flow is proportional to GBT inlet
sludge feed flow (610FIT360A/B/C/D/E).
} Each discharge polymer pump is equipped with a dilution panel where an injection of industrial water decrease
the polymer concentration. The industrial water is injected only when the associated pump starts. The water
injection is constant and controlled by the opening and closing of the solenoid valve (813__VY454A/B/C/D/E). A
low flow detector (813__FSL353A/B/C/D/E) generate an alarm if the solenoid valve is in position OPEN. An
intervention of the operator is then needed.
} Pipe arrangement is foreseen in order to have at least one stand-by pump per pump (a set of manual valves
equipped with low and high limit switch allowed the different configurations – refer to the scheme below):
o The Pump 813__PO156A can be used as 813__PO156B stand-by pump and vice-versa;
o The Pump 813__PO156B can be used as 813__PO156C stand-by pump and vice-versa;
o The Pump 813__PO156D can be used as 813__PO156E stand-by pump and vice-versa.

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Polymer dosing installation to thickening
Dilution Panel
} Dosing pumps for GBT characteristics

TAG NUMBER: 813__PO156A/B/C/D/E
5 pumps are dedicated to thickening treatment, 4 on duty,
1 on stand-by. All of them are equipped with manual
stroke, VSD and 2 TSH and 1 dry running protection.
- Unit flow rate: 1,500 l/h

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x = A, B, C, D or E
PREPARATION UNIT
Polymer preparation unit tank 813A/B_RF251_
Polymer preparation unit powder polymer hopper 813A/B_RF252_
Polymer preparation unit level measurement 813A/B_LIT251_
Polymer preparation unit tank high level switch 813A/B_LSH251_
Polymer preparation unit tank very high level switch 813A/B_LSHH251_
Polymer preparation unit tank low level switch 813A/B_LSL251_
Polymer preparation unit tank very low level switch 813A/B_LSLL251_
2 TMI
Rapid mixer on Polymer preparation unit - 1 st compartment 813A/B_AG151A*
nd
Rapid mixer on Polymer preparation unit - 2 compartment 813A/B_AG151B*
Dosing pump for emulsion transfer 813A/B_PO155_*
Screw conveyor for powder transfer 813A/B_QD152_*
Screw conveyor for powder transfer hopper low level switch 813A/B_LSL152_
Industrial water to polymer preparation unit - Solenoid valve 813A/B_VY452_
Industrial water to polymer preparation unit - Low flow switch 813A/B_FSL350_
Polymer outlet - Isolating pneumatic valve 813B_VA450_ 1
GF
Polymer outlet - Solenoid valve for isolating pneumatic valve 813B_VY450_ 1
DOSING TO GBT UNIT
Polymer dosing pump for GBT 813__PO156x 5 SEEPEX
Polymer dosing pump for GBT flow measurement 813__FIT351x 5 E+H
Polymer dosing pump for GBT high pressure switch 813__PISH350x 5 BAUMER
DILUTION PANEL
Industrial water to polymer dilution panel - Solenoid valve 813__VY454x
Industrial water to dilution panel low flow switch 813__FSL353x 5 TMI
Polymer dilution panel static mixer 813__QG250x
*Those agitators & screw conveyor are equippe d with high tempe rature switch.

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4.3.4. Gravity Belt Thickeners
General description
} The Gravity Belt Thickeners consists in a drainage table where the sludge is drained by gravity action on a moving
filtering belt. It is mounted on rollers and moves forward at a rather high speed (up to 15 m/min). A mechanical
and pneumatic device guides the belt.
} The sludge is first flocculated in the feed pipe and then goes through a static flocculator (1) placed ahead of the
table, which improves formation of flocs.
} The gravity separation occurs in the gravity zone (3), where most of the liquid between the suspended solids
flow off.
} The first part (2) of the gravity thickening zone serves as sludge feed and allows a uniform distribution over the
entire working width of the belt filter by a spreader plate.
} The gravity belt thickener is equipped with four rows of baffles (12) which compact, rearrange and deflect the
sludge.
} The thickened cake is lifted off (4) from the belt and evacuated by an abrasion resistant scrapper.
} A maintenance system - that can quickly be dismantled - allows an access for cleaning.
} The filtrate is collected in a closed tray mounted inside the frame. Then the filtrate is discharged on the drive
side (11).
} The belt is cleaned by a spray system (8), equipped with flat jet nozzles removing remaining particles from the
belt.
Gravity Belt Thic kener: Operating principles

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1 Static Flocculator 7 Belt tracking roller

2 Sludge Spreading 8 Belt cleaning System
3 Gravity Zone 9 Machine drive
4 Cake discharge 10 Belt
5 Belt tightening Roller 11 Filtrate outlet
6 Belt tightening System 12 Rows of baffles
Sludge building 600

TAG NUMBER: 623__KE101A/B/C/D

623__KE151A/B/C/D/E
} This building houses 5 GBT. 4 GBT are on duty and 1 in stand-by.

GBT Characteristics Values
Maximum inlet flow 180 m3/h at 5 g/l
Design flow 90 to 150 m3/h
Maximum output rate 1260 kg DS/h at 30 g/l
Design flow output rate 600 to 1150 kg DS/h
Nominal output concentration 40 to 60 g/l
Wash water supply 9 m 3 /h – 8 bars
Compressed air supply 0.5 Nm 3 /h – 6 bars
} Equipment and instruments included in this section

x = A, B, C, D or E
Venturi mixer for polymer & sludge in-line mixing 813__QG251x
Gravity belt thickener 623__SP151x*
GBT high level switch 623__LSH151x
5 ANDRITZ
GBT low pressure switches 623__PSL151x-1
GBT air low pressure switches 623__PSL151x-2
GBT belt position sensor 623__ZSH151x
GBT wash water - Solenoid valve 929__VY468x 5 GF
*The GBT’s motor is equipped with high temperature switch.

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4.3.5. Compressed air production for GBT
Balancing tank 600B
} Two air compressors (923__CP181A/B) are provide for the 5 thickening lines. They are used for compressed air
supply to GBTs, pneumatic valves at polymer preparation and pneumatic valves for OCU chemicals unloading.
} A compressed air low pressure switch (923__PISL381_) generate an alarm in case of compressed air low pressure
and stop the GBT sequence.

Air compressor for GBT and polymer valves 923__CP181A/B 2
Enclosure hood fan 923__CV182A/B 2
Dryer 923__EF283_ 1
KAESER
Air compressor - receiver 923__RF281_ 1
Compressor inlet filter 923__XH281A/B 2
Air filter 923__XH283_ 1
Compressed air low pressure switch 923__PISL381_ 1 BAUMER

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4.3.6. Progressive cavity pumps – GBT outlet forced pumps
The scheme of the pump is the same as it is in §4.3.2 – Progressive cavity pumps – Feeding & Diluting pumps.
Sludge Building 600

TAG NUMBER: 623__PO102A/B/C/D
} Four progressive cavity pumps: Four GBT outlet forced pumps (all in duty).
Sludge Building 600B
} The thickened sludge is sent to the digesters by means of the outlet forced pumps. These pumps receive together
the thickened sludge from the GBTs – 45g/L – and the diluted sludge from the dilution pumps – 5 to 7 g/L –. The
thickened sludge and the diluted sludge are mixed in the pump inlet hopper. At the outlet, the average sludge
concentration is about 20 g/l.
} The GBT outlet forced pumps operate according to their dedicated GBT sequence and the level in the hopper.
TAG NUMBER: 623__PO152A/B/C/D/E
} Five GBT outlet forced pumps (progressive cavity pumps - all in

duty). The pumps are equipped with VFD, TSH, dry running
protection and pressure switch at the discharge.
- Minimum Unit Flow: 30 m 3 /h
- Maximum Unit Flow: 60 m 3 /h

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} A flow measurement (623__FIT350_) record the thickened sludge going to the digesters. It is located on the
common pipe.
} A suspended solids measurement (623__AIT350_) is provide on the same common pipe measure the sludge
concentration and generate alarms in case of very low or very high sludge concentration.

x = A, B, C, D or E
GBT outlet forced pump hopper very high level switch 623__LSHH352x
GBT outlet forced pump hopper high level switch 623__LSH352x
GBT outlet forced pump hopper medium level switch 623__LSM352x
5 BAUMER
GBT outlet forced pump hopper low level switch 623__LSL352x
GBT outlet forced pump hopper very low level switch 623__LSLL352x
GBT outlet forced pump high pressure switch 623__PSH352x
Gravity belt thickener outlet forced pump hopper 623__RF252x 5 PELOSI
GBT outlet forced pump 623__PO152x 5 SEEPEX
Thickened sludge suspended solids measurement 623__AIT350_ 1 HACH
Thickened sludge flow measurement 623__FIT350_ 1 E+H

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4.4. Site drainage pumping stations
} Each building 600 and 600B is equipped with a site drainage pumping station equipped with submersible pumps.
The submersible pump motor causes to spin the

impeller which creates a vortex similar to that found
in a toilet bowl when it is flushed or a tornado. Since
the impeller is not in the flow path of the volute, the
pump is ideal for handling liquids that contain long
stringy solids, large diameter solids, slurries or a
combination of all of these without plugging up.
Schematic of a v ortex type pum p

Sludge Building 600
TAG NUMBER: 921B_PO101A/B/C/D
} Four submersible pumps are used in order to convey return Liquors (wash water discharge, excess water and
centrate from centrifuge) to inlet works.
- Unit flow rate: 210 m 3 /h
} All returns liquors from both GBT and Centrifuges within the building 600B and Chemical Odour Control Unit
730B are collected to a drainage pumping station (921C). A set of 3 submersibles pumps (two in duty, one in
standby) send waste water to inlet works.
} The Pumping station is equipped with level measurement and level switches. The pumps run using the levels
thresholds on the measurement (921C_LIT352_).
} The flow discharge line to the inlet work is equipped with a flow measurement (921C_FIT351_). This data are
used for the operator as information for the mass balance.
} Submersibles pumps characteristics

TAG NUMBER: 921C_PO151A/B/C
Each pump is equipped with high moisture and temperature switches.

- Unit flow rate: 400 m 3 /h

Drainage pumps 921C_PO151A/B/C 3 SULZER
Anti-hammer vessel 921C_RF201_ 1 MASSAL

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Flow rate indicator transmitter 921C_FIT351_ 1

Anti-hammer vessel differential pressure 921C_PDI305_ 1 E+H
Drainage pumping station level measurement 921C_LIT352_ 1
Drainage pumping station very high level switch 921C_LSHH353_ 1
Drainage pumping station low level switch 921C_LSL354_ 1 BAMO
Drainage pumping station very low level switch 921C_LSLL354_ 1

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5. Adjustments
} This part includes 2 main parts as described below:
o SCADA View Presentation
o SCADA Using and Adjustments
} Main parameters adjustments to ensure a good quality parameters monitoring using of Gravity Belt Thickener
unit by SCADA.

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5.1. Process Control Philosophy
5.1.1. Sludge Building 600 – GBT sequence
Note that comparatively to Ext 4, the sequence has been changed in order to avoid clogging of the belt with the
polymer.

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5.1.2. Sludge Building 600B – GBT sequence

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5.2. Sludge building 600
5.2.1. Sludge Balancing Tank
5.2.1.1. SCADA Presentation
Hydrojet Air Fan
LEL sensor
Blower
Level
Meter
H2 S sensor
Sludge Progressive
cavity pump
Flow Meter

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5.2.1.2. Belt Thickener Sludge Feed Pump Control
Gravity Belt Thickener sludge feed pump is controlled by the pop-up:
With this virtual switch, the operator can

choose which pump the standby pump will
replace.
The sludge flow is controlled by

- the settings Qs,
- or by Manual set point for each
pump
qmin and qmax are defined as per the

specification of the pump; these values shall
not be changed.
Number of pumps in operation is controlled

by the number of GBT in operation.
The sludge feed pump 610_PO102D installed for the 2050 stage feeds either the new belt thickener 623_KE101D,
or the existing standby belt thickener 623_KE101B.

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5.2.1.3. Belt Thickener Sludge Dilution Pump Control
Thickened Sludge Dilution Pump Control is controlled by the pop-up:

replace.
MODE 1
not be changed.
The flow control Q is proportional to the

sludge feed flow (610_FIT306A/C/D). The
proportion can be entered under “X_SP”.
To ensure a good concentration of sludge at the

inlet of the digester (20 g/l), refer to
procedure:P-OM-046-600 Sludge Dilution
Calculation for GBT.
MODE 2
The sludge dilution flow Set-point (Qdil) is
either manually entered by the operator on
the relevant SCADA screen or it is calculated
by the PLC using the equation.
The sludge concentration at the outlet of GBT
(Diluted Sludge + thickened Sludge) is controlled
by the outlet TSS Concentration.
→ The ﬂ ow of sludge dilu on will be adapted.
The sludge dilution pump 610_PO103D feeds either the new belt thicker 623_KE101D, or the existing standby belt
thickener 623_KE101B

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5.2.2. Gravity Belt Thickening
Air C ompr essors

to move clea ning
trolleys
Gas detectors
Gravity B elt Thickener
Booster Pumps

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5.2.2.2. Belt Thickener and booster pump Control
Thickening process is controlled by the pop-up:
Starting and stopping of GBT are hourly set.
The feed pump flow is chosen according to the

Sludge Production.
If you change the feed pump flow, sludge
dilution flow (mode 1) and polymer dosing flow
shall be adapted.
Refer to Procedure P-OM-045-600 Polymer
Dosing Calculation for GBT and P-OM-046-600
Sludge Dilution Calculation for GBT

replace.
Booster pumps are controlled by the pop-up
Minimum and maximum speed of the booster

pump can be set.
Status of the pumps and their outlet valve can

also be reviewed on this faceplate.

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5.2.3. Polymer Preparation Unit
Polym er pr eparation
skid
Polymer pump to GB T Polym er pump to

centrifuge
Flowmeter
5.2.3.2. Polymer preparation units

If two polymer preparation units are in service, only one feds the collector at a time. At the beginning of the
operating sequence, the two preparations units are put in service together. However, the automatic valve
813B/C/D_VA401 associated to the first unit feeding the polymer line is opened as long as low level switch in that
unit is not reached.
When the low level is reached, a new preparation polymer is launched.

When the control bow signal is detected meaning that this preparation is started, then the automatic valve of the
second polymer preparation unit opens and then the automatic valve of the first polymer preparation unit feeding
the collector closes.
All four preparation units are connected to the main polymer feeding line.
The unit 813A_KI101 and the standby unit 813B_KI101 are used for the needs of thickening (GBT).
The units 813C_KI101 and 813D_KI101 as well as the standby unit 813B_KI101 are used for the needs of dewatering
(centrifuges).
The standby unit can be used for the needs of polymer thickening by opening the manual valve onsite 813_VH403
and closing the manual valve 813_VH404. By closing the valve 813_VH403 and opening the valve 813_VH404, the
standby unit can be used for dewatering.

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5.2.3.3. Polymer dosing pump settings
Belt Thickener polymer dosing pump control is controlled by the pop-up:
qmin and qmax are defined as per the specification

of the pump; these values shall not be changed.
The polymer flow is proportional to the associated

GBT sludge feed flow 638A/B/C/D/EFIT304. The
proportion can be entered under “d”.
A manual set point can also be entered (MAN_SP)
With this virtual switch, the operator can choose

which pump the standby pump will replace.
For a best setting, be informed of the Procedure P-

OM-045-600 Polymer Dosing Calculation for GBT.
Example of calculation according to these settings:
Qs = 180.4 m 3 /h
Sludge Concentration (g/l) = 6 g/l
Sludge Flow (Kg/hr) = 180.4 x 6 = 1080 Kg
Polymer Flow (Kg/hr) = Qs x d /1000 = 180.4 x 25 / 1000 = 4.5 Kg/hr
Polymer Rate ( Kg pol / Ton of Sludg e ) = Polymer Flow / Sludge Flow x 1000 = 4.5 x 1000 / 1080 = 4.1 Kg

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5.3. Sludge Building 600B
5.3.1. Liquid sludge storage and pumping
5.3.1.1. SCADA view presentation

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5.3.1.2. Parameters
a) Belt thickener feed pump control
v Accessibility
Gravity Belt Thickener sludge feed pump is controlled by the pop-up:

enable or disable the calculation mode.
qmin and qmax are defined as per the tests

on the pump; these values shall not be
changed.
Calculation according to these settings:
The sludge flow setpoint (600B_QS) in m3/h is either manually entered by the operator (600B_QS_x when 600B_Qs_Enable=0) on
the Scada or it is calculated (600B_Qs_Enable=1) using the equation here below:
Equation 1
600 _ − 600 _ ∗ 600 _ ∗ 600 _ ∗ 600 _

600 _ =
600 _ ∗ 600 _ ∗ 600 _ ∗ 600 _
Where:
600B_Qmass Total mass flow to be sent to digestion (from daily mass balance) kgDS/d
600B_NGBT Number of GBT in service (Calculated by PLC) -
600B_HGBT Number of hour of operation per day h/d
600B_CDgt Expected concentration to digestion kg/m3
600B_Cin SAS concentration (to be updated daily from lab results) kg/m3
600B_TGBT Recovery rate at GBT %
600B_QDil Sludge flow rate for the thickened sludge dilution pump m3/h

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The set point speed sent to the speed inverter is calculated according to the table below:
600B_Qs < 610PO160x_QMin
610PO160x_SPEED:= 610PO160x_VMin %
610PO160x_QMin < 600B_Qs < 610PO160x_QMax
600 _ − 610 160 _

∗ 610 160 _ − 610 160 _ + 610 160 _ %
610 160 _ − 610 160 _
600B_Qs > 610PO160x_QMax
610PO160x_SPEED:= 610PO160x_VMax %
v Control Action
D EFAU LT
P ARAMETER U NIT R ANGE F UNCTION /U TILI TY
VALUE
610FIT360A_HH 180 m3/h 0-250 -
610FIT360A_H 130 m3/h 0-250 -
610FIT360A_M 100 m3/h 0-250 -
610FIT360A_L 30 m3/h 0-250 -
610FIT360A_LL 20 m3/h 0-250 Stop the associated pump
610FIT360B_HH 180 m3/h 0-250 -
610FIT360B_H 130 m3/h 0-250 -
610FIT360B_M 100 m3/h 0-250 -
610FIT360B_L 30 m3/h 0-250 -
610FIT360B_LL 20 m3/h 0-250 Stop the associated pump
610FIT360C_HH 180 m3/h 0-250 -
610FIT360C_H 130 m3/h 0-250 -
610FIT360C_M 100 m3/h 0-250 -
610FIT360C_L 30 m3/h 0-250 -
610FIT360C_LL 20 m3/h 0-250 Stop the associated pump
610FIT360D_HH 180 m3/h 0-250 -
610FIT360D_H 130 m3/h 0-250 -
610FIT360D_M 100 m3/h 0-250 -
610FIT360D_L 30 m3/h 0-250 -
610FIT360D_LL 20 m3/h 0-250 Stop the associated pump
610FIT360E_HH 180 m3/h 0-250 -
610FIT360E_H 130 m3/h 0-250 -
610FIT360E_M 100 m3/h 0-250 -
610FIT360E_L 30 m3/h 0-250 -
610FIT360E_LL 20 m3/h 0-250 Stop the associated pump
610PIT360A_HH 2 bar 0-4 Alarm very high pressure at the pump discharge
610PIT360A_H 1 bar 0-4 -
610PIT360A_M 0.8 bar 0-4 -
610PIT360A_L 0.5 bar 0-4 -
610PIT360A_LL 0.2 bar 0-4 -
610PIT360B_HH 2 bar 0-4 Alarm very high pressure at the pump discharge
610PIT360B_H 1 bar 0-4 -
610PIT360B_M 0.8 bar 0-4 -
610PIT360B_L 0.5 bar 0-4 -
610PIT360B_LL 0.2 bar 0-4 -

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610PIT360C_HH 2 bar 0-4 Alarm very high pressure at the pump discharge
610PIT360C_H 1 bar 0-4 -
610PIT360C_M 0.8 bar 0-4 -
610PIT360C_L 0.5 bar 0-4 -
610PIT360C_LL 0.2 bar 0-4 -
610PIT360D_HH 2 bar 0-4 Alarm very high pressure at the pump discharge
610PIT360D_H 1 bar 0-4 -
610PIT360D_M 0.8 bar 0-4 -
610PIT360D_L 0.5 bar 0-4 -
610PIT360D_LL 0.2 bar 0-4 -
610PIT360E_HH 2 bar 0-4 Alarm very high pressure at the pump discharge
610PIT360E_H 1 bar 0-4 -
610PIT360E_M 0.8 bar 0-4 -
610PIT360E_L 0.5 bar 0-4 -
610PIT360E_LL 0.2 bar 0-4 -
610PIT362A_HH 0.5 bar 0-2 -
610PIT362A_H 0.4 bar 0-2 -
610PIT362A_M 0.3 bar 0-2 -
610PIT362A_L 0.1 bar 0-2 -
610PIT362A_LL 0.05 bar 0-2 Stop the associated pump
610PIT362B_HH 0.5 bar 0-2 -
610PIT362B_H 0.4 bar 0-2 -
610PIT362B_M 0.3 bar 0-2 -
610PIT362B_L 0.1 bar 0-2 -
610PIT362B_LL 0.05 bar 0-2 Stop the associated pump
610PIT362C_HH 0.5 bar 0-2 -
610PIT362C_H 0.4 bar 0-2 -
610PIT362C_M 0.3 bar 0-2 -
610PIT362C_L 0.1 bar 0-2 -
610PIT362C_LL 0.05 bar 0-2 Stop the associated pump
610PIT362D_HH 0.5 bar 0-2 -
610PIT362D_H 0.4 bar 0-2 -
610PIT362D_M 0.3 bar 0-2 -
610PIT362D_L 0.1 bar 0-2 -
610PIT362D_LL 0.05 bar 0-2 Stop the associated pump
610PIT362E_HH 0.5 bar 0-2 -
610PIT362E_H 0.4 bar 0-2 -
610PIT362E_M 0.3 bar 0-2 -
610PIT362E_L 0.1 bar 0-2 -
610PIT362E_LL 0.05 bar 0-2 Stop the associated pump
600B_TGBT 95 % 0-100 Recovery rate at GBT
600B_CDgt 20 kg/m3 0-30 Expected concentration to digestion
610PO160A/B/C/D/E_QMax 170 m3/h 0-250 Feeding pump maximum flow at Vmax speed
610PO160A/B/C/D/E_QMin 60 m3/h 0-250 Feeding pump minimum flow at Vmin speed

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b) Belt thickener dilution pump control
v Accessibility
Thickened Sludge Dilution Pump Control is controlled by the pop-up:

enable or disable the calculation mode.

choose mode auto 1 or 2 for each GBT.
MODE 1
not be changed.
The dilution flow rate is proportional to the

sludge feed flow (610FIT360A/B/C/D/E). The
proportion can be entered under “GBTx flow
percentage”.
To ensure a good concentration of sludge at

the inlet of the digester (20 g/l), refer to
procedure:P-OM-046-600 Sludge Dilution
Calculation for GBT.
MODE 2
The GBT dilution pump flow rate
(610PO161y_Q) equals the dilution pump flow
set-point 600B_QDil. It is either manually
entered by the operator on the SCADA
(600B_QDil_Enable=0) or it is calculated using
the equation here below
(600B_QDil_Enable=1):
600 _
600 _ − ∗ 600 _
600 _
610 161 _ = 600 _ =
600 _ − 600 _ ∗ 600 _ ∗ 600 _
The following Set-points are entered by the operator on the SCADA:
600B_Qmass Total mass flow to be sent to digestion from workshop 600B (from daily kgDS/d
mass balance) –
600B_NGBT Number of GBT in service (Calculated by PLC) -
600B_HGBT Number of hour of operation per day h/d
600B_CGBT Estimated concentration at GBT outlet kg/m3
600B_CDgt Expected concentration to digestion kg/m3
600B_Cin SAS concentration kg/m3
600B_TGBT Recovery rate at GBT %

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610PO161y_Q < 610PO161x_QMin
610PO161x_QMin < 610PO161y_Q < 610PO161x_QMax

610PO161y_ − 610 161 _
∗ 610 161 _ − 610 161 _ + 610 161 _ %
610 161 _ − 610 161 _
610PO161y_Q > 610PO161x_QMax
v Control Action
PARAMETER D EFAU LT VALUE U NIT R ANGE F UNCTION/U TILI TY

610FIT361A_HH 70 m3/h 0-250 -
610FIT361A_H 60 m3/h 0-250 -
610FIT361A_M 30 m3/h 0-250 -
610FIT361A_L 10 m3/h 0-250 -
610FIT361A_LL 5 m3/h 0-250 Stop the associated pump
610FIT361B_HH 70 m3/h 0-250 -
610FIT361B_H 60 m3/h 0-250 -
610FIT361B_M 30 m3/h 0-250 -
610FIT361B_L 10 m3/h 0-250 -
610FIT361B_LL 5 m3/h 0-250 Stop the associated pump
610FIT361C_HH 70 m3/h 0-250 -
610FIT361C_H 60 m3/h 0-250 -
610FIT361C_M 30 m3/h 0-250 -
610FIT361C_L 10 m3/h 0-250 -
610FIT361C_LL 5 m3/h 0-250 Stop the associated pump
610FIT361D_HH 70 m3/h 0-250 -
610FIT361D_H 60 m3/h 0-250 -
610FIT361D_M 30 m3/h 0-250 -
610FIT361D_L 10 m3/h 0-250 -
610FIT361D_LL 5 m3/h 0-250 Stop the associated pump
610FIT361E_HH 70 m3/h 0-250 -
610FIT361E_H 60 m3/h 0-250 -
610FIT361E_M 30 m3/h 0-250 -
610FIT361E_L 10 m3/h 0-250 -
610FIT361E_LL 5 m3/h 0-250 Stop the associated pump
610PIT363A_HH 0.5 bar 0-2 -
610PIT363A_H 0.4 bar 0-2 -
610PIT363A_M 0.3 bar 0-2 -
610PIT363A_L 0.1 bar 0-2 -
610PIT363A_LL 0.05 bar 0-2 Stop the associated pump

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P ARAM ETER D EFAULT V ALUE U NIT RAN GE F UNCTION /U TILITY

610PIT363B_HH 0.5 bar 0-2 -
610PIT363B_H 0.4 bar 0-2 -
610PIT363B_M 0.3 bar 0-2 -
610PIT363B_L 0.1 bar 0-2 -
610PIT363B_LL 0.05 bar 0-2 Stop the associated pump
610PIT363C_HH 0.5 bar 0-2 -
610PIT363C_H 0.4 bar 0-2 -
610PIT363C_M 0.3 bar 0-2 -
610PIT363C_L 0.1 bar 0-2 -
610PIT363C_LL 0.05 bar 0-2 Stop the associated pump
610PIT363D_HH 0.5 bar 0-2 -
610PIT363D_H 0.4 bar 0-2 -
610PIT363D_M 0.3 bar 0-2 -
610PIT363D_L 0.1 bar 0-2 -
610PIT363D_LL 0.05 bar 0-2 Stop the associated pump
610PIT363E_HH 0.5 bar 0-2 -
610PIT363E_H 0.4 bar 0-2 -
610PIT363E_M 0.3 bar 0-2 -
610PIT363E_L 0.1 bar 0-2 -
610PIT363E_LL 0.05 bar 0-2 Stop the associated pump
Alarm very high pressure at the
610PIT361A_HH 2 bar 0-4
pump discharge
610PIT361A_H 2 bar 0-4 -
610PIT361A_M 2 bar 0-4 -
610PIT361A_L 2 bar 0-4 -
610PIT361A_LL 2 bar 0-4 -
610PIT361B_HH 2 bar 0-4
pump discharge
610PIT361B_H 2 bar 0-4 -
610PIT361B_M 2 bar 0-4 -
610PIT361B_L 2 bar 0-4 -
610PIT361B_LL 2 bar 0-4 -
610PIT361C_HH 2 bar 0-4
pump discharge
610PIT361C_H 2 bar 0-4 -
610PIT361C_M 2 bar 0-4 -
610PIT361C_L 2 bar 0-4 -
610PIT361C_LL 2 bar 0-4 -
610PIT361D_HH 2 bar 0-4
pump discharge
610PIT361D_H 2 bar 0-4 -
610PIT361D_M 2 bar 0-4 -
610PIT361D_L 2 bar 0-4 -
610PIT361D_LL 2 bar 0-4 -
610PIT361E_HH 2 bar 0-4
pump discharge
610PIT361E_H 2 bar 0-4 -
610PIT361E_M 2 bar 0-4 -
610PIT361E_L 2 bar 0-4 -
610PIT361E_LL 2 bar 0-4 -
GBT dilution pump flow rate set
600B_QDil 30 m3/h 0-100
point
Estimated concentration at GBT
600B_CGBT 40 kg/m3 0-50
outlet
Dilution pump maximum flow at
610PO160A/B/C/D/E_QMax 60 m3/h 0-75
Vmax speed

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P ARAM ETER D EFAULT V ALUE U NIT RAN GE F UNCTION /U TILITY

Dilution pump minimum flow at Vmin
610PO160A/B/C/D/E_QMin 20 m3/h 0-75
speed
GBT A/B/C/D/E (600B_QDil) flow
GBTA/B/C/D/E_XDil 13 % 0-100
percentage set point
c) Blower control
v Accessibility
Blowers are controlled by the pop-up:
Blower speed set point can be set. They enable to

reach the suitable dissolved oxygen
concentration in the SAS Balancing tank:
Ø 610CS153AB_SP2 when 2 compartments
are in operation (both compartments
are activated & level is above low
threshold in each compartment).
Ø 610CS153AB_SP1 when 1 compartment
is in operation (one compartment is
activated and/or level is above low
threshold only in one compartment).
Ø No aeration when 2 compartments are
not in operation (both compartments
are not activated and/or level is below
low threshold in each compartment).
Period and duration timer can be set. SAS Balancing tank aeration blower A or B (one in duty and one in standby) are
operated discontinuously (610CS153AB_T4 period / 610CS153AB_T3 duration). The operation of the blower can also
be continuous if the operator sets up a duration value longer than the period.

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v Control Action
PARAMETER D EFAU LT V ALUE U NIT RAN GE F UNCTION/U TILI TY

610B1AIT350_HH 2 mg/l 0-20 Alarm dissolved oxygen very high concentration
610B1AIT350_H 2 mg/l 0-20 -
610B1AIT350_M 2 mg/l 0-20 -
610B1AIT350_L 2 mg/l 0-20 -
610B1AIT350_LL 2 mg/l 0-20 Alarm DO very low concentration
610B2AIT350_HH 2 mg/l 0-20 Alarm dissolved oxygen very high concentration
610B2AIT350_H 2 mg/l 0-20 -
610B2AIT350_M 2 mg/l 0-20 -
610B2AIT350_L 2 mg/l 0-20 -
610B2AIT350_LL 2 mg/l 0-20 Alarm DO very low concentration
610B1TIT350_HH 40 °C 0 - 50 Alarm very high temperature compartment 1
610B1TIT350_H 30 °C 0 - 50 -
610B1TIT350_M 20 °C 0 - 50 -
610B1TIT350_L 10 °C 0 - 50 -
610B1TIT350_LL 0 °C 0 - 50 -
610B2TIT350_HH 40 °C 0 - 50 Alarm very high temperature compartment 2
610B2TIT350_H 30 °C 0 - 50 -
610B2TIT350_M 20 °C 0 - 50 -
610B2TIT350_L 10 °C 0 - 50 -
610B2TIT350_LL 0 °C 0 - 50 -
610CS153AB_SP1 40 % 0-100 Aeration blower VFD setpoint for 1 compartment
Aeration blower VFD setpoint for 2
610CS153AB_SP2 80 % 0-100
compartments
610CS153AB_T3 25 min 0-120 Aeration blower duration setpoint
610CS153AB_T4 30 min 0-120 Aeration blower period setpoint

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5.3.2. Gravity Belt Thickening

Page 49 of 92
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5.3.2.2. Parameters
a) Belt thickener
v Accessibility
Thickening process is controlled by the pop-up:
Starting and stopping of GBT are hourly set.
The feed pump flow is chosen according to the

Sludge Production.
If you change the feed pump flow, sludge
dilution flow (auto 1) shall be adapted.
Refer to Procedure P-OM-045-600 Polymer
Dosing Calculation for GBT and P-OM-046-600
Sludge Dilution Calculation for GBT
Belt thickeners step sequence are

controlled by the pop-up
Step timer of the belt thickener can be

set.
With this virtual switch the operator

can choose to start or stop the GBT.

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v Control Action
P ARAMETER D EFAU LT VALUE U NIT RAN GE F UNCTION /U TILITY

Total mass flow to be sent to
600B_Qmass 14850 kgDS/d 0-60000 digestion Thickening workshop 600B
(from daily mass balance)
GBT A/B/C/D/E, daily chart preset
600B_MINS_A/B/C/D/E[1/2/3/4] 1000 m3 0-4000
(Volume to treat)
GBT A/B/C/D/E, daily chart preset
600B_QS_A/B/C/D/E[1/2/3/4] 110 m3/h 0-200
(Feed pump flow)
600B_T2_A/B/C/D/E 30 sec 0-120 Starting belt drive delay timer
Opening wash water solenoid valve
600B_T3_A/B/C/D/E 30 sec 0-120
delay timer
Starting polymer dosing pump
600B_T4_A/B/C/D/E 30 sec 0-120
delay timer
Starting GBT feeding pump delay
600B_T5_A/B/C/D/E 30 sec 0-120
timer
600B_T7_A/B/C/D/E 30 sec 0-120 Stop GBT feeding pump delay timer
Waiting timer after high level
600B_T8_A/B/C/D/E 30 sec 0-120
detection
600B_T9_A/B/C/D/E 30 sec 0-120 Washing timer of the GBT
b) Booster pump
v Accessibility
Booster pumps are controlled by the pop-up
Minimum and maximum speed of the booster

pump can be set.

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v Control Action
P ARAMETER D EFAU LT V AL UE U NIT R AN GE F UNCTION /U TILITY

Alarm Suspended solids very high
623AIT350_HH 30 g/l 0-50
concentration
623AIT350_H 26 g/l 0-50 -
623AIT350_M 22 g/l 0-50 -
623AIT350_L 18 g/l 0-50 -
623AIT350_LL 15 g/l 0-50 Alarm SS very low concentration
623FIT350_HH 250 m3/h 0-250 -
623FIT350_H 200 m3/h 0-250 -
623FIT350_M 150 m3/h 0-250 -
623FIT350_L 100 m3/h 0-250 -
623FIT350_LL 50 m3/h 0-250 -
Gravity belt thickener outlet
623PO152A/B/C/D_LowSpeed 0 % 0 - 100 forced pump A/B/C/D - Low speed
preset
Gravity belt thickener outlet
623PO152A/B/C/D_HighSpeed 50 % 0 - 100 forced pump A/B/C/D - High speed
preset

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5.3.3. Polymer Preparation & Dosing Units
5.3.3.2. Parameters
a) Polymer preparation units
The four preparation units are connected to the main collector polymer feeding line. This line can be isolated in a
way to allow using two different kinds of polymer: one for thickening and one for dewatering. If two different
polymers are used then the valves 813AVH458 and 813VH459 are closed. If the polymer used for thickening and
dewatering is the same, at least one of the isolating valves should be closed in order to separate the main collector
in two sections, one for thickening and one for dewatering.
The automatic valve 813B/C/D_VA450 associated to the first unit feeding the polymer line is opened as long as low
level switch in that unit is not reached.
When the low level is reached, operator has to launch a new preparation polymer.
When the control low signal is detected meaning that this preparation is started, then the automatic valve of the
second polymer preparation unit (B, C & D) opens and then the automatic valve of the first polymer preparation
unit (B, C & D) feeding the collector closes. Regarding the unit A, when the low signal is detected operator has to
close the manual drain valve in order to isolate the unit A.
All four preparation units are connected to the main polymer feeding line. The needs for polymer thickening are
covered with one preparation unit although for dewatering two units are necessary.
The unit A and the standby unit B are used for the needs of thickening (GBT).
The units C and D as well as the standby unit B are used for the needs of dewatering (centrifuges).

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The standby unit can be used for the needs of polymer thickening by opening the manual valve on site 813_VH458
and closing the manual valve 813_VH459. By closing the valve 813_VH458 and opening the valve 813_VH459, the
standby unit can be used for dewatering.
v Control Action
P ARAM ETER D EFAU LT V AL UE U NIT R AN GE F UNCTION /U TILITY

Permutation from one polymer
813A/B/C/DLSLL251_Timer 30 sec 0-180
preparation unit to another
b) Polymer dosing pump settings
v Accessibility
Belt Thickener polymer dosing pump control is controlled by the pop-up:
qmin and qmax are defined as per the tests on the

pump; these values shall not be changed.
The polymer flow is proportional to the associated

GBT sludge feed flow 610FIT360A/B/C/D/E.
For a best setting, be informed of the Procedure P-

OM-045-600 Polymer Dosing Calculation for GBT.
Calculation according to these settings:
The polymer flow Set-point 600B_Qp_x is calculated using the equation here below :
Equation 2
600 _ × 610 360 × 600 _
600 _ _ =
600 _
Where:
600B_Qp_x Polymer flow rate x calculated l/h

600B_D Polymer rate Kg/ton DS
610FIT360y GBT y sludge feed flow m3/h
600B_CPol Polymer Concentration adjustable from Scada g/l
600B_Cin SAS concentration adjustable from Scada g/l

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600B_Qp_x < 813PO156x_QMin
813PO156x_QMin < 600B_Qp_x < 813PO156x_QMax
600 _ _ − 813PO156x_
∗ 813PO156 _ − 813PO156 _ + 813PO156 _ %
813PO156 _ − 813PO156 _
600B_Qp_x > 813PO156x_QMax
v Control Action
P ARAMETER D EFAULT V ALUE U NIT RAN GE F UNCTION /U TILI TY

813FIT351A_HH 1500 l/h 0-2000 -
813FIT351A_H 1400 l/h 0-2000 -
813FIT351A_M 900 l/h 0-2000 -
813FIT351A_L 700 l/h 0-2000 Stop the pump
813FIT351A_LL 100 l/h 0-2000 -
813FIT351B_HH 1500 l/h 0-2000 -
813FIT351B_H 1400 l/h 0-2000 -
813FIT351B_M 900 l/h 0-2000 -
813FIT351B_L 700 l/h 0-2000 Stop the pump
813FIT351B_LL 100 l/h 0-2000 -
813FIT351C_HH 1500 l/h 0-2000 -
813FIT351C_H 1400 l/h 0-2000 -
813FIT351C_M 900 l/h 0-2000 -
813FIT351C_L 700 l/h 0-2000 Stop the pump
813FIT351C_LL 100 l/h 0-2000 -
813FIT351D_HH 1500 l/h 0-2000 -
813FIT351D_H 1400 l/h 0-2000 -
813FIT351D_M 900 l/h 0-2000 -
813FIT351D_L 700 l/h 0-2000 Stop the pump
813FIT351D_LL 100 l/h 0-2000 -
813FIT351E_HH 1500 l/h 0-2000 -
813FIT351E_H 1400 l/h 0-2000 -
813FIT351E_M 900 l/h 0-2000 -
813FIT351E_L 700 l/h 0-2000 Stop the pump
813FIT351E_LL 100 l/h 0-2000 -
600B_Cpol 3.5 g/l 0-10 Polymer Concentration
600B_D 3.6 Kg/Ton DS 0-10 Polymer rate
Gravity belt thickener polymer pump
813PO156A/B/C/D_QMin 715 l/h 0-2000 A/B/C/D – minimum flow at VMin
speed
Gravity belt thickener polymer pump
813PO156A/B/C/D_QMax 1500 l/h 0-2000 A/B/C/D – minimum flow at VMax
speed

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5.3.4. Compressed air production for GBT
5.3.4.2. Parameters
The compressor air package is autonomous. The air compressors are controlled locally (by the control panel
923IA181) with redundant capabilities and with internal pressure control system.
Using the selected control mode, the controller switches the machine between its various operational states in
order to compensate for air being drawn by consumers, and to maintain the system pressure between the set
minimum and maximum values. The control mode also rules the degree of energy efficiency of the machine.
The machine-dependant venting phase between the LOAD and READY operating modes ensures load changes at
minimum material stresses.
The controller SIGMA CONTROL 2 was set to work with the QUADRO mode. Refer to supplier documentation for
more details about the design and function of the skid.
The “Operation authorization” digital output (TS_923IA181_ON) is triggered by the PLC when there is no
interlock/fault and when the normal start conditions are true (equipment in remote position and virtual selector
on SCADA is put in position ON by the operator).
v Control Action
P ARAMETER D EFAU LT VALUE U NIT R AN GE F UNCTION /U TILITY

923PISL381 3.5 bar - GBT immediate stop condition

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5.3.5. GBT site drainage
5.3.5.2. Parameters
Note: The small ‘x’ in tag name represents the letter ‘A’, ‘B’, ‘C’ according to the drainage pump.
In normal operation:
The level measurement 921CLIT352 is used for operating the drainage pumps 921CPO151x (2 pumps on duty, 1 pump
on stand-by, during normal operation) according to adjustable level thresholds.
When the level is above the medium threshold, the first pump 921CPO151x starts.
When the level is above the high threshold, the second pump 921CPO151x starts.
When the level is below the medium threshold, the second pump 921CPO151x stops.
When the level is below the low threshold, all the pumps 921CPO151x stop.
There is a cyclic permutation of the pump on each stop and on fault of the running pump.
In degraded operation:
If the level measurement 921CLIT352 is unavailable, the pumps will be operated by the level switches:
When the low level switch is not triggered (level is above the low level), two timers 921CLSL354_T1/T2 are launched
until the low level switch is triggered.
At the end of 921CLSL354_T1 timer, first pump 921CPO151x starts.

At the end of 921CLSL354_T2 timer (level is always above the low level), second pump 921CPO151x starts.

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When low level switch is triggered, a pump stops.

When the very low level switch is triggered, all pumps stop.
In case of loss of communication with PLC#1, the pumps will be stopped.
v Control Action
P ARAMETER D EFAU LT VALUE U NIT R AN GE F UNCTION /U TILITY

921CLIT352_HH 4.5 m 0-10 Alarm very high level
921CLIT352_H 3.3 m 0-10 Start the second pump
Above this value : first pump starts
921CLIT352_M 2.7 m 0-10
Below this value: second pump stops
921CLIT352_L 1.5 m 0-10 Stop all the pumps
921CLIT352_LL 1 m 0-10 Alarm very low level
921CLSL354_T1 120 sec 0-900 First pump starts
921CLSL354_T2 240 sec 0-900 Second pump starts
If 2 pumps running, stop all the
921CFSL351 400 m3/h 0-1200
pumps
If 1 pump running, stop the running
921CFSLL351 200 m3/h 0-1200
pump and permutation

Page 58 of 92
6. Routine Tasks and First Level Maintenance
The purpose of the operator ’s preventive maintenance schedule is both to keep the equipment ready and to detect any signs of equipment malfunction during operation
and scheduled maintenance checks
6.1. Sludge Balancing Tanks
Sludge Balancing Tank 610
EQUIPMENT FIRST MAINTENANCE ROU TINE TASK PICTURES
HYDROJET Ensure that hydro jets are running

610_PO101A/B/C properly
Ensure absence of leakage

PROGRESSIVE CAVITY PUMPS
610_PO102A/B/C/D Clean the motor (dust)
610_PO103A/B/C/D
Check temperature, noise, vibration
Record the Flow at 6 am

610_FIT_306A
FLOW METER 610_FIT_306B
610_FIT_306A/C/D Clean the Flow meter (dust) 610_FIT_306C
610_FIT_307A/C/D 610_FIT_307A
610_FIT_307B
610_FIT_307C
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Sludge Balancing Tank – 610B
EQUIPMENT FIRST MAINTENANCE FREQUENCY ROU TINE TASK FREQUENCY PICTURES

Check Vibration, Noise &
Daily
Temperature
Ensure air fan(s) is running Daily
Clean the motor Weekly
AIR BLOWER Check oil level Daily

610__CS153A/B
Check Absence of leakage Daily
Clean the area Weekly Check the pressure at the outlet

Daily
See manometer
SLU DGE BALANCING TANK Ensure homogeneous aeration

Daily
610B in the two compartments
Clean the motor (dust) Weekly Ensure absence of leakage Daily

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PROGRESSIVE CAVITY
PUMPS Check temperature, noise,
Daily
610_PO160A/B/C/D/E vibration
610_PO161A/B/C/D/E
Record the Flow at 6 am

610_FIT_360A
610_FIT_360B
610_FIT_360C
FLOW METER 610_FIT_360D
610_FIT_360A/B/C/D/E Clean the Flow meter (dust) Weekly 610_FIT_360E Daily
610_FIT_361A/B/C/D/E 610_FIT_361A
610_FIT_361B
610_FIT_361C
610_FIT_361D
610_FIT_361E

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6.2. Polyelectrolyte Powder & Emulsion Units
Polymer preparation A/B/C/D – 600

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES
Clean the Polymer Dosing Screw Ensure that Polymer is flowing properly
Clean the area Check polymer dilution efficiency

Dosing Screw Polym er
DOSING POLYMER UNIT

813A/B/C/D_KI101_ 1
Clean the Motors Ensure that Mixers are running (1)
Motors
Ensure presence of polymer (more than half)
Clean Hoover filter (once a month) in the feeding hoper
with a air compressor Ensure that powder polymer is not humid in
order to avoid clogging hover filter
Clean Dosing Polymer Dosing Pump
DOSING POLYMER UNIT Ensure for each diluted pump that Water
813_PO106A/B/C/D Dilution Flow = 2.5 m 3/h
Clean Area
Dosing pum p a nd Diluted Water
Pump

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Polymer preparation A/B/C/D – 600B
EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

Clean the Polymer Dosing
Every shift Ensure there is no leakage in the area Every shift
Screw
At least
Clean the area Ensure that Polymer is flowing properly Every shift
weekly
Clean the mixer motors Weekly Ensure that Mixers are running Every shift
DOSING POLYMER Clean the polymer tank for
Ensure presence of polymer (more than
UNIT removal of any rust, dirt, Weekly Daily
half) in feeding hoper
813A/B/C/D_KI151_ polymer spillage
Ensure that powder polymer is not humid Daily
During Ensure that service water dilution flow is
Check the condition of mixer polymer proper to get required polymer
blades tank concentration: Daily
cleaning - To GBT
- To Centrifuges
Ensure absence of leakage Daily
DOSING POLYMER
Clean Polymer Dosing Pump Weekly
UNIT
Check Noise, temperature and vibration Daily
To GBT
813_PO156A/B/C/D/E Ensure that the required polymer is flowing
Daily
properly
To Centrifuges At least Ensure for each diluted pump that Water
813_PO157A/B/C/D Clean Area
weekly Dilution Flow = 2.5 m 3/h
Daily
- To GBT
- To Centrifuges

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6.3. Thickening by Drainage
Gravity Belt Thickeners – 600
Clean the GBT at the inlet Check good Flocs
Clean Area Check belt is visible
GRAVITY BELT THICKENER Inlet GBT

623_KE101A/B/C/D
Ensure dry and compact Sludge
Ensure distance between scrapper and belt

Clean the GBT at the outlet is not > 1 mm
Ensure that belt is clean after GBT running

Outlet G BT

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Open the valve to clean spray nozzle,

turn valve (several times) in order to
623_KE101A/B/C/D
brush spray nozzle
Belt C leaning Wat er Va lve
AIR COMPRESSOR
Drain the compressor twice a day Check Pressure > 6 bars
623_KI101A/B
Air Compressor for Air Valve

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Gravity Belt Thickeners – 600B
FREQU
EQUIPMENT FIRST MAINTENANCE FREQUENCY ROU TINE TASK PICTURES
ENCY
Check the good sludge repartition at the

Clean the GBT at the inlet A least weekly Daily
inlet
Every
Check good Flocs
shift
Clean Area At least weekly

Check belt is visible and ensure absence of Every
foreign object on it shift
Clean the GBT at the outlet At least weekly
Every
Ensure dry and compact Sludge
GRAVITY BELT shift
Clean the bottom tank and rollers During belt
THICKENER
by opening the inspection Hatches cleaning activity
623_KE151A/B/C/D/E Ensure distance between scrapper and belt Every
is not > 1 mm shift
Clean the wash water spray During belt Every

Ensure that belt is clean after GBT running
nozzles cleaning activity shift
Check the lubrification of the During belt

sliding rods and swivel bearing cleaning activity Open the valve to clean spray nozzle, turn
Every
valve (several times) in order to brush spray
shift
Check and ensure pressure on the During belt nozzle
deflector blade is 15 mm cleaning activity
Remove the belt tracking device
During belt
and check the surface for cracks Check the tensioning of the belt setting Daily
cleaning activity
and clean it

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Clean level sensors of the Hopper Weekly
GRAVITY BELT Check temperature, noise, vibration Daily

THICKENER OUTLET
Clean the motor (dust) Weekly
FORECD PUMP
623__PO152A/B/C/D/E Ensure absence of leakage Daily
Record
- the flow: 623__FIT350_ Daily
- the suspended solids 623__AIT350
GRAVITY BELT Check there is no trip conditions

THICKENER LOCAL Press Lamp test button, warn the Daily
PANEL CONTROL maintenance in case of lamp failure
Check Pressure ~ 8 bars Daily
Check the compressed air filter for

AIR COMPRESSOR
condensate Weekly Ensure absence of leakage Daily
923__KI181
Drain the compressor
Check the oil level Daily
Ensure no leakag e on the discharge pipes Daily

DRAINAGE PUMPING
Clean the area Weekly
STATION - 921C
When pumps ar e running, check a ny a bnorm al
Daily
noise.

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6.4. MCC Rooms and Sub-Stations
MCC ROOM C4 & C1
Ensure absence of trip condition

Clean Area
(orange Light)
Push the test lamp button once a week and warn the
Check A/C is running
maintenance team to replace burn light
MCC ROOM C4 and C1 MCC Room
Check if filter are clogged by hating

Clean Filters Every Week
(carefully) on them.
M CC Filt er
MCC ROOM E2

Ensure absence of trip condition
Clean Area Weekly Daily
(orange Light)
Push the test lamp button and warn the
MCC ROOM E2 Weekly Check A/C is running Daily
maintenance team to replace burn light
Check if filter are clogged by hating
Clean Filters Weekly Daily
(carefully) on them.
Clean the system Twice a week Ensure there is no fire alarm Daily
FIRE ALARM SYSTEM
Check the alarm system power is ON Daily Ensure there is no false alarm Daily
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Sub Station 930 C
Level (more than half)
SU B STATION 930 C
Clean area Ensure absence of leakage
FUEL TANK FOR GENERATOR
Visual Inspection
Fuel Tank
To ensure absence of fuel, water
Clean area
leakage around the generator
SU B STATION 930 C Fuel circuit should be always opened

Oil Level Checking (once a
week)
Fuel quantity in daily tanks is > half Substation 930C

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Sub Station 930 E2

Fuel quantity in main tank is >
Twice a week
half, else warn hierarchy
Ensure absence of leakage Twice a week
SU B STATION 930 E2
Clean area Weekly
FUEL TANK FOR GENERATOR
Visual Inspection Twice a week
Fuel qua ntity in main tank is > half,

Twice a week
else warn hier archy
Clea ning Weekly
To check a bsence of leakage Twice a week
Visua l Inspection Twice a week
Check there is no leak of f uel, water
Clea ning Area Weekly Twice a week
around the generator
Oil Level C hecking Weekly Fuel circuit should be a lwa ys opened Twice a week
GENERATOR E2 Clea n Battery (dust) Weekly To check a bsence of acid leakage Twice a week
Check level of acid Weekly around the battery Twice a week
Fuel qua ntity in daily ta nks is > ha lf
Engine speed (=1500 rpm)
Inject. Qua ntity (%) Twice a week
(When it is working)
Running hours (h)
Ener gy (Kw)
Running hours of fuel pumps
Clean the system Twice a week Ensure there is no fire alarm Daily
FIRE ALARM SYSTEM Check the alarm
Daily Ensure there is no false alarm Daily
system power is ON

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7. Operation Procedures
7.1. P-OM-001-000 Resetting of One Equipment Tripped
SAFETY NEVER OPEN AN ELECTRICAL PANEL IF YOU ARE NOT AUTHORIZED

IF YOU ARE NOT SURE: WARN THE HIERARCHY OR AN ELECTRICIAN
PROBLEM: If you find an equipment failed (TRIP in the MCC room = Orange light)
FIRST CHECKS
1) Check that equipment is not locked-up (look for tag, safety lock…)
2) Have a visual inspection of the equipment on site (check there is no blockage, no debris in it, nobody
working in the area…)
3) Check that there is no emergency stop on site
4) Check that there is no emergency stop on the MCC
5) Record on log-book that equipment is failed and after resetting, informs the hierarchy that equipment
has been failed.

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HOW TO RESTART:
1) Push the “RESET” button (black)
- If the orange light doesn’t disappears then:

a. Shut down the panel (OFF)
b. Wait that all the displays are shut down (VFD,
current indicator…)
c. Restart the panel (ON) and wait that all the
displays are started
- If the orange light disappears then, push the “START” button (green)
- If the AUTO/0/LOCAL selection is on “LOCAL”, push the green button on the MCC for a local Start
- If the AUTO/0/LOCAL selection is on “AUTO”, restart the equipment from the SCADA
Equipment is restarted if green light is “ON”
IF RESTARTING IS NOT POSSIBLE,

DO NOT RETRY THIS PROCEDURE TWICE.
IF SAME EQUIPMENT FAILED 2 TIMES IN ONE DAY
WARN THE HIERARCHY OR AN ELECTRICIAN.

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7.2. P-OM-016-600 Manually Start of Gravity Belt Thickener
SLU DGE BUILDING 600
PROTECT YOU R SELF WITH GLOVES AND OVERALLS

WASH YOUR HANDS AFTER WORKING IN THE SLUDGE AREA
Check that:
No trip on booster pump;

No trip on GBT belt;
No trip on polymer pump;
1) Start the GBT;
2) Make sure the water is coming on the GBT (for spraying nozzle);
3) Open the drain valve;
4) Start the polymer pump A (overdosing the polymer at the beginning is better to start faster);
5) Open water dilution of polymer => Set the flow to 2.5 m3/h;
6) Start the 2 sludge feeding pumps:

- The sludge feeding pump of the GBT;
- The dilution pump;
Be careful: Push red button to start
7) Check the flocculation quality at the inlet of GBT:

- Good quality of the flocs;
- Sludge not too liquid;
8) If flocculation is good, close the drain valve;
9) Observe the sludge at the inlet of GBT:

- Flocs must be visible on the belt;
- Belt must be visible (white);

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VERY BAD
NOT ENOU GH SLUDGE OK (TOO MUCH SLUDGE or NOT
ENOUGH POLYMER)
ð Good flocs ð Good flocs ð No flocs
ð Belt visible (white) ð Belt is visible (white) ð Belt is not visible
=> Increase the quantity of polymer

injected
=> Check if the drain valve is closed
=> Check that the water dilution
=> Check if the 2 sludge pumps are
flow for polymer dilution is = 6
in operation
m3/h
10) Observe the quality of sludge in the middle and at the outlet of the GBT:
- No water;
- Sludge must be “dry” and compact;
VERY GOOD VERY BAD

ð Dry sludge
ð Sludge very liquid
ð Compact sludge
11) When the half of the hopper of the booster pump is filled with sludge, push reset button. The pump will
start automatically as soon as the high level is reached
12) When quality is good, call 488 operator to:

- START THE EXTRACTION PU MP C of the sludge tank 488
- Check level in the sludge tank 488

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SLUDGE BUILDING 600B
PROTECT YOUR SELF WITH GLOVES AND OVERALLS

X = GBT A/B/C/D or E
Preliminary Actions
TAG
1) Check that:
o No trip on Sludge Feeding pump 610__PO160x
o No trip on Sludge Dilution pump 610__PO161x
o No trip on Sludge Booster pump 623__PO152x
o No trip on GBT belt unit 623__KE151x
o No trip on polymer pump 813__PO156x
2) Check the level in the sludge balancing tank 610B 610B1/2LIT350
Dig A: 623__VA481A
Dig B: 623__VA481B
Dig C: 639__VA402C
3) Check the selected digester feed valve are in open condition. Dig D: 639__VA402D
Dig E: 639__VA402E
Dig G: 639__VA402G
Dig H: 639__VA402H
4) Check the polymer preparation unit. Liquid prepared polymer must
be half of the tank and concentration to be in 3 g/l (Polymer
Concentration calculation refer P-OM-600-003 Polymer Dosing
Calculation for GBT).
5) Check the sludge level in 610B sludge balancing tank, which is
coming from 488C.
Actions
6) Start the GBT manually:

- Button on LOCAL ( Local control panel- LCP/HMI)
- Start Order
7) Check that:
- polymer pump is running – set the flow at 2.5 m 3 /h
- sludge feeding and diluting pumps are running
- the flocculation quality at the inlet of GBT:
a. Floc must be good quality,
b. Sludge not too liquid on the surface of the belt.
- Make sure that water is coming on GBT (for spraying nozzle)
8) Observe the sludge at the inlet of GBT:
VERY BAD
NOT ENOU GH SLUDGE OK (TOO MUCH SLU DGE or NOT ENOUGH
POLYMER)

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ð Bad flocs
ð Good flocs
ð Bad repartition on ð No flocs
ð Belt is visible
the belt and belt to ð Belt is not visible
(white)
much visible
PI CTURE PICTURE PICTURE
=> Check if the drain valve is => Increase the quantity of polymer
closed injected
=> Check if the 2 sludge => Check that the water dilution flow
pumps are in operation for polymer dilution is = 6 m3/h
9) If flocculation is good, keep on continuous operation of GBT

10) Observe the quality in the middle and at the outlet of the GBT:
- no water
- sludge must be “dry” and compact
VERY GOOD VERY BAD
ð Dry sludge
ð Sludge very liquid
ð Compact sludge
PICTURE PICTURE
11) Check the GBT booster pump running properly based on Hopper level and
same time check the dilution pump MUST be run.
Key Points to be monitor after GBT Start up:
1) Maintain the 610B sludge balancing tank level.

2) Maintain the polymer tank level including Hopper.
3) Monitor the Centrate pit level and don’t maintain high level.
4) Maintain Sludge outlet concentration 18 g/l ( after dilution)
5) Maintain the level in digesters

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7.3. P-OM-017-600 Manually Stop of Gravity Belt Thickener
SLU DGE BUILDING 600

1) Call 488 operator to:

- STOP THE EXTRACTION PUMP C;
When Extraction Pump is stopped:
2) Stop the 2 sludge feeding pumps

- The sludge feeding pump of the GBT;
- The dilution pump;
Be careful: Push red button to start
3) Stop polymer pump;
4) Stop water dilution of polymer;
5) Clean the sprinklers (spray) by turning the cleaning valve;
6) Use a water hose to clean the outlet scrapper;
7) Use a water hose to clean the inlet hopper;
8) Drain the inlet hoper by opening the drain valve;

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9) Let the GBT running with industrial water to clean the belt (during at least 30 minutes);
10) When belt is cleaned, stop the GBT;
11) Clean the area;

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SLUDGE BUILDING 600B

Actions
Note: The GBT to stop x = A/B/C/D/ or E
TAG
1) Stop 488C Extraction pumps, to stop feed to the GBT. 482C_PO102A/B/C
2) Stop GBT in Local Panel Control 623__SP151x
3) Check that following pumps are stopped:
- sludge feeding pump 610__PO160x
- sludge dilution pump 610__PO161x
- booster pump 623__PO152x
- polymer pump 813__PO156x
4) Check that wash water valve is still open and drive belt motor is
929__VY468A/B/C/D/E
running for cleaning
5) During the cleaning use a water hose to clean
- the outlet scrapper
- the inlet hoper
6) When cleaning sequence is ended, check that wash water valve is
closed and drive belt motor stop
7) Clean the area.

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7.4. P-OM-000-488C Manual Extraction of Surplus Activated Sludge

Preliminary action
- Check no trip condition on extracted SAS pumps

- Check the level in Balancing TANK 610B
Actions
1) In SCADA the operator:

- enter the pump speed (on the VFD)
- enter the number of pump to run
2) Check the level is increasing in the balancing tank 610B
3) When the level required is reach, stop the pumps in SCADA
4) Check that balancing tank 610B aeration is correctly working, based
on the sequence and a value of 1.0 mg/l of dissolved oxygen is
maintained in the compartments

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7.5. P-OM-000-610 Isolation for one compartment 610B

Scope
An isolation of a compartment may be require for several operation :

- Inspection of the compartment
- Reparation on the submersible aeration system
HOW TO ISOLATE A COMPARTMENT

Actions
x = 1 or 2
y = A or B
TAG
1) On site, close the isolating penstock and apply a LOTO consignment 610_VH450
2) On site, close the SAS inlet manual and apply a LOTO consignment valve 488C_VH452y
3) Close the outlet discharge manual valve of the OTHER compartment
until the compartment to empty reach the low level
4) The level will decrease with the GBT running. When the low level is
reach, open the outlet discharge manual valve of the OTHER
compartment and close the outlet discharge manual valve of the
compartment to empty
5) Close the air injection motorized valves and apply a LOTO
610BxVM277A and B
consignment
6) Remove the DO probes. Store them in a bucket full of water. The
bucket has to be full of water at all time. Or remove it and keep it in
safe place
7) Totally empty the compartment by the opening of the drainage pipe
610BxVH480_
valve. Then close it when the tank is empty
8) Proceed to the operation
9) Check frequently the level in the other compartment

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HOW TO GATHER THE TWO COMPARTMENTS
Actions
x = 1 or 2
y = A or B
TAG
1) Ensure absence of any debris in the compartment
2) Remove the LOTO consignment on the SAS inlet manual valve and
488C_VH452y
open it
3) When half of the compartment is filled, Replace the DO probe
4) Remove the LOTO consignment on the air inlet valves and open them
610BxVM277A and B
The blower will run until reach a DO > 1 mg/l
5) Purge the air system by opening of the purged air manual valves 610BxVH478A
610BxVH479A
610BxVH478B
610BxVH479B
6) Remove the LOTO consignment on isolating penstock and open it
610_VH450
The two compartments will balance to reach the same level
7) Remove the LOTO consignment on the outlet discharge manual valve
610VH457y
610VH457y and open it

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7.6. P-OM-045-600 Polymer Dosing Calculation for GBT
Weight of Polymer (KgPol/T Dry Sludge) is chosen according the following formula:
Flow of Polymer (L/h) x Concentration of Polymer (g/L)
Total Suspended Solids (g/l) x Flow of Sludge (m 3 /h)
This weight has to be comprised between 2 and 4 kg of polymer per Ton of dried sludge.
Bearing in mind that:
The sludge concentration in the Sludge Balancing tank is approximately 5 g/L.
A GBT’s maximum flow rate is 180 m 3 /hour.
A GBT’s maximum load rate is 180 x 5 = 900 Kg/h = 0.9 Ton/h
The treatment rate is 3 kg polymer / Ton of Dry Sludge
The maximum polymer Consumption is 3 x 0.9 = 2.7 Kg/h
Polymer concentration is 3 g/L = 0.003 Kg/L
Flow of Polymer is 2.7 / 0.003 = 900 L/h
BE CARREFULL, A TOO HIGH CONCENTRATION WILL DECREASE SLUDGE QU ALITY AS DESCRIBED BY THE GRAPH
BELOW
Sludge Quality
Flow of Polymer
(for am identical
concentration)

Page 83 of 92
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7.7. P-OM-046-600 Sludge Dilution Calculation for GBT
The Sludge Flow dilution (m 3 ) is chosen according the following formula:
GBT Outlet Flow x (CST – Cf)
Sludge Diluted Flow x (Cf – Ci)
Where,
C ST = Outlet GBT Sludge Concentration

Cf = Sludge Final Concentration (Diluted Sludge + GBT Sludge)
Ci = Sludge Initial Concentration (in the sludge balancing tank)
Bearing in mind that:
The sludge concentration in the Sludge Balancing tank is approximately 5 g/L.
A GBT’s maximum inlet flow rate is 180 m3 /hour.
A GBT’s maximum outlet load rate is 180 x 5 x 90%= 810 Kg/h = 0.81 Ton/h
A GBT’s set point sludge concentration is 35 g/l.
A GBT’s maximum outlet flow rate is 0.81 / 35 = 23 m 3 /hour
The Dilution flow is equal to:
(35 x 23) + 5 x X = 20 x (23 + X)

(35 x 23) + 5X = (20 x 23) +20X
(35 x 23) – (20 x 23) = 20X – 5X
23 x (35 -20) = 15X
347 / 15 = X
X = 21 m 3 /hour

Page 84 of 92
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8. Troubleshooting and Repair
The following troubleshooting guide is provided for quick reference only. For detailed troubleshooting of system
components, consult the Vendor Data.
Be sure to consult all necessary safety information prior to troubleshooting.
Mechanical or electrical maintenance should only be performed by qualified personnel. In the event of any
differences between this manual and the supplied Vendor Data, the supplied Vendor Data should always take
precedence. It is up to the operator to follow the correct safety procedures when doing any type of
troubleshooting.

Page 85 of 92
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8.1. Operating Problem for GBT
TROU BLE POSSIBLE CAUSES CHECKING SOLUTIONS
1.1 Sludge application - Check sludge pumping - Adjust influent pumping

rate too high rate rate.
1.2 Belt speed too high - Check belt speed - Adjust belt speed
1. Low dryness in product
cake - If polymer dose is much
1.3 Incorrect polymer less or much greater than
- Check polymer mixing
dose (also see item 4 the ideal dose,
and dose
below ) performance will
decrease.
- Adjust the mechanical
stops of the adjustable
- Check tracking of belt to
2.1 Improper alignment of pressing jacks so that for
2. Excessive belt wear see if it creeps off to one
rollers a same roller both
side.
mechanical stops have the
same adjustment.
- Check polymer mixing - Use test to determine
3.1 Incorrect polymer and dose optimum dose.
dose -Check influent sludge - Reduce sludge pumping
pumping rate rate accordingly.
3. Solids in filtrate 3.2 Solids running off the - Adjust belt speed as
- Check belt speed
edge of the filter belt. required
3.3 Sludge application

- Check sludge feed rate. - Reduce sludge feed rate
rate too high
- Adjust powder polymer
4.1 Incorrect polymer - Check polymer feed rate
feed rate.
dosage - Check. sludge feed rate
- Adjust sludge feed rate.
4. Ponding in gravity - Prepare a batch of fresh
4.2 Polymer batch too old. - Check solution age.
drainage section solution.
4.3 Inadequate dilution
- Check dilution water flow - Increase dilution water
water flow into polymer
rotameter feed rate.
solution.
- Check belt wash water

- Increase belt wash water
flow
flow
5.1 Belt not cleaning - Check for wash water
- Clean spray nozzles.
properly nozzle.
- Clean strainer elements
- Check strainer device (if
(if exists)
exists)
5. Belt blinding
5.2 Overdose of polymer - Check polymer solution - Reduce polymer solution

solution feed rate. pumping rate.
5.3 Inadequate cake - Check belt/doctor blade - Reduce belt/doctor blade

removal. clearance.. clearance (1/10mm).

Page 86 of 92
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8.2. Booster Pump Stop or not Starting
8.3. GBT Stop or not Starting

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8.4. Sludge Pump Stop or not Starting
8.5. Polymer Pump Stop or not Starting

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8.6. No Sludge coming from 488 but Extraction Pump Running
8.7. Flocculation and polymer preparation

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9. Appendix
9.1. Details Supplier
Progressive Cavity Pump

Extension 3&4 Extension 5
Supplier: SEEPEX Supplier: SEEPEX
PETROFAC Qatar SEEPEX France

Blue Salon Building 1 rue Pelloutier
P.O. Box No. 4404, Doha 77183 Croissy Beaubourg – FRANCE
24H-Hotline: +49 2041 996 350 Phone: +33 (0) 6 01 64 11 44 50
Phone: +974 (447) 8800 Fax: +33 (0) 1 64 11 44 69
Fax: +974 (447) 8811 E-mail: info.fr@seepex.com
E-mail: saneesh@petrofac-qatar.com
www.petrofac-qatar.com
Hydrojet Air blowers

Supplier: GRUNFOS Supplier: AERZEN
United Arab Emirates ZI - 10 avenue Léon Harmel

GRUNDFOS Gulf Distribution F-92168 Antony – France
P.O. Box 16768 Contact: Jacky DIEMERT (Service & Spare Parts)
Jebel Ali Free Zone Phone +33 (0) 1 46 74 13 00
Dubai Fax +33 (0) 1 46 66 00 61
Phone: +971 48 815 166 E-mail: aerzen@aerzen.fr
Fax: +971 48 815 136
Website: www.grundfos.com/
Polymer Preparation Unit

Supplier: MILTON ROY EUROPE (DOSAPRO) Supplier: TMI
10 Grande rue 1 rue Gustave Eiffel - B.P 70305

27360 Pont Saint Pierre – France 42353 La Talaudiere CEDEX – France
Phone : +33 2 32 68 30 00 Contact: Fabien SAUSSAC
Fax : +33 2 32 68 30 93 Phone: + 33 (0) 4 77 53 28 72
E-mail: contact@miltonroy-europe.com Fax: + 33 (0) 4 77 53 30 78
Website: www.miltonroy-europe.com E-mail: tmi@tmi.fr

Page 90 of 92
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Gravity Belt Thickener

Supplier: Andritz Separation Technologies Supplier: ANDRITZ
France ANDRITZ SAS

Andritz S.A.S Allée de la Garenne
2-4 Avenue de l'Europe-Bât A Zone Industrielle du Buxérioux
78140 Vélizy-Villacoublay 36000 Châteauroux – France
Tel: +33 1 39 26 0550 Phone: +33 (0) 2 54 61 33 33
Fax: +33 1 39 26 0560 Fax: +33 (0) 2 54 61 33 01
Mail: environ.fr@andritz.com
India
Andritz Separation Private Limited
Plot No. 1961-B Asiad Colony
Anna Nagar Western Extensio
Chennai 600 101
Phone: +91 44 2615 3750/3751
Fax: +91 44 2615 4741
Mail: separation.in@andritz.com
Website: www.andritz.com/
Submersible pumps
Supplier: GRUNDFOS Supplier : SULZER
United Arab Emirates SULZER WASTEWATER France SAS

GRUNDFOS Gulf Distribution 26 Allée du plateau
P.O. Box 16768 93250 Villemomble – France
Jebel Ali Free Zone – Dubai Contact: Didier PARCHAP
Phone: +971 48 815 166 Phone: +33 (0) 1 49 35 24 55
Fax: +971 48 815 136 E-mail: Didier.parchap@sulzer.com
Website: www.grundfos.com/

Page 91 of 92
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9.2. Acronyms
BOD Biochemical Oxygen Demand

BP Back Pulse
BW Back Wash
CCT Chlorine Contact Tank
COD Chemical Oxygen Demand
DO Dissolved Oxygen
FM Flow Meter
GBT Gravity Belt Thickener
LCP Local Control Panel
MC Maintenance Cleaning
MCC Motor Control Center
ML Mixed Liquor
ND Nominal Diameter
OCU Odour Control Unit
ORP Oxygen Redox Potential
PLC Progammable Logic Controller
PS Pumping Station
RAS Recirculated Activated Sludge
RC Recovery Cleaning
SAS Surplus Activated Sludge
SCADA Supervisory Control and Data Acquisition
SP Set Point
TSE Treated Sewage Effluent
TSS Total Suspended Solids
TSH Temperature Switch High
UF Ultra-Filtration

Page 92 of 92

P-OM-001-011 Gravity Belt Thickener

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DOHA WEST SEWAGE TREATMENT WORKS

5 12-04-2018 Final version LBO SGO JPI

GRAVITY BELT THICKENER

COMPANY DOCUMENT NUMBER REV: D.STATUS

GRAVITY BELT THICKENER

Drawn by Checked by: Approved by:

It will address the following subjects,

What are the targets of Thickening Unit?

Which physical and chemical principles are included in this treatment?

What is the configuration of this unit?

Drawn by Checked by: Approved by:

3. PHYSICAL AND BIO-CHEMICAL PRINCIPLES 12

6. ROUTINE TASKS AND FIRST LEVEL MAINTENANCE 59

Drawn by Checked by: Approved by:

7.6. P-OM-045-600 Polymer Dosing Calculation for GBT 83

8. TROUBLESHOOTING AND REPAIR 85

Drawn by Checked by: Approved by:

Drawn by Checked by: Approved by:

Localization of the Gravity Belt thickener Units

Drawn by Checked by: Approved by:

2.3. P&ID’s Reference

CP807 DGT M DS 610 001 Z Sludge Balancing Tank

CP807 DGT M DS 600 001 Z Thickening by Drainage A B C

CP807 DGT M DS 600 011 Z Thickening by Drainage D

CP807 DGT M DS 600 002 Z Powder and Emulsion Polyelectrolyte - Dosing

CP807 DGT M DS 600 012 Z Powder and Emulsion Polyelectrolyte Preparation

CP807 DGT M DS 600 050 H 600B - Thickening by drainage - Gravity Belt A, B, C

CP807 DGT M DS 600 051 H 600B - Thickening by drainage - Gravity Belt D, E

CP807 DGT M DS 610 050 E Storage of Liquid Sludge

Drawn by Checked by: Approved by:

2.4.1. Biological risks on Human Health

} Avoid any contact with sludge, water, Screening Risk of

First Aid Measures

Drawn by Checked by: Approved by:

2.4.2. Effects of chemicals used on Human Health

} Appropriate chemical PPE must be worn during any intervention.

} Refer to SAFETY DATA SHEET for more information.

} Polymer Zetag® 8165

Use for: Flocculation agent for Thickening and Dewatering units

Characteristics: Polyacrylamide, cationic

Potential health effects: Slippery - Non-irritant

Do not handle chemicals products without appropriate protection.

Drawn by Checked by: Approved by:

Drawn by Checked by: Approved by:

3. Physical and Bio-Chemical Principles

Drawn by Checked by: Approved by:

} The filtrate and wash water is evacuated to a drainage pumping station.

Drawn by Checked by: Approved by:

4.2. Surplus Activated Sludge Balancing Tanks

SAS Balancing tank 610

SAS Balancing tank 610B

} Air blower’s characteristics:

Blowers runs on:

Drawn by Checked by: Approved by:

} Equipement and instrument included in this section

Drawn by Checked by: Approved by:

4.3. Thickening by GBT

4.3.1. General description

} For both of the buildings, the thickening system is as followed:

Drawn by Checked by: Approved by:

4.3.2. Progressive cavity pumps – Feeding & Diluting pumps

Positive displacement pump

Sludge Building 600

} Eight progressive cavity pumps: