Ardagh - Operation of Wastewater Treatment System

ARDAGH METAL BEVERAGE USA INC.
BASIC TRAINING MATERIAL FOR

OPERATION OF
WASTEWATER TREATMENT SYSTEM
AUGUST 1, 2001
Revised on: 3/26/2010, 6/9/2011, 7/14/2016
one brandone vision 1

TABLE OF CONTENTS
Page
CHAPTER 1 REGULATORY REQUIREMENT 3
CHAPTER 2 DESCRIPTION OF WASTEWATER TREATMENT SYSTEM 9
CHAPTER 3 QUALITY CONTROL CHECKS 45
CHAPTER 4 TROUBLE SHOOTING PROCEDURE 58
CHAPTER 5 INSTRUCTIONS FOR WASTEWATER MONITORING 67
CHAPTER 6 STARTUP AND SHUTDOWN PROCEDURES 72
CHAPTER 7 PREVENTIVE MAINTENANCE 77

CHAPTER 1
REGULATORY REQUIREMENT

CHAPTER 1
REGULATORY REQUIREMENT
(THE STANDARDS)
On November 17, 1983, US EPA promulgated wastewater treatment standards for 2-pc
canmakers. The applicable standards for an existing facility (PSES) discharging to a Publicly
Owned Treatment Works (POTW) are as follows:
ALLOWABLE MASS OF POLLUTANTS THAT

CAN BE DISCHARGED TO THE SEWER
POLLUTANT DAILY MAXIUMUM MAXIMUM MONTHLY

AVERAGE
Milligrams/1000 Pounds/1,000,000 Milligrams/1000 Pounds/1,000,000
Cans Manufactured Cans Manufactured Cans Manufactured Cans Manufactured
(mg/M Cans)* (lbs/MM Cans) (mg/M Cans)* (lbs/MM Cans)
mg/M Cans lbs/MM Cans mg/M Cans lbs/MM Cans

Chromium (Cr) 36.92 0.081 15.10 0.033
Copper (Cu) 159.41 0.351 83.90 0.185
Zinc (Zn) 122.49 0.270 51.18 0.113
Fluoride (F) 4992.05 11.001 2214.96 4.883
Phosphorus (P) 1401.13 3.089 573.04 1.263
Manganese (Mn) 57.05 0.126 24.33 0.053
Total Toxic Organics** 26.85 0.059 12.59 0.028
Oil & Grease (O&G) 1678.00 3.699 1006.80 2.220
Effluent samples are to be taken a minimum of once each month or more frequently as
required by the control authority to verify compliance.
PSES Pretreatment Standard Existing Source
* Milligrams/1000 cans manufactured (mg/M cans) equals grams/1,000,000 cans

manufactured (g/MM cans) where M = 1000 and MM = 1,000,000

** Total Toxic Organics (TTO) optional
The applicable standards for a new facility (PSNS) discharging to a Publicly Owned
Treatment Works (POTW) are as follows:
ALLOWABLE MASS OF POLUTANTS THAT

CAN BE DISCHARGED TO THE SEWER
POLLUTANT DAILY MAXIMUM MAXIMUM MONTLY

AVERAGE
Milligrams/1000 Pounds/1,000,000 Milligrams/1000 Pounds/1,000,000
Cans Manufactured Cans Manufactured Cans Manufactured Cans Manufactured
(mg/M Cans)* (lbs/MM Cans) (mg/M Cans)* (lbs/MM Cans)
mg/M Cans lbs/MM Cans mg/M Cans lbs/MM Cans
Chromium (Cr) 27.98 0.0617 11.45 0.025

Copper (Cu) 120.84 0.2767 63.60 0.140
Zinc (Zn) 92.86 0.205 38.80 0.086
Fluoride (F) 3784.20 8.3435 1679.04 3.702
Phosphorous (P) 1062.12 2.342 434.39 0.958
Manganese (Mn) 43.25 0.095 18.44 0.041
Total Toxic Organics** 20.35 0.045 9.54 0.021
Oil & Grease (O&G) 1272.00 2.804 763.20 1.683
To verify compliance, effluent samples are to be taken a minimum of once each month, or
more frequently as required by the control authority.
PSNS Pretreatment Standard New Source
* Milligrams/1000 cans manufactured (mg/M Cans) equals grams/1,000,000 cans

manufactured (g/MM Cans) where M = 1000 and MM = 1,000,000
** Total Toxic Organics (TTO) optional

CALCULATIONS TO MEET THE STANDARDS
MASS OF POLLUTANT = CONCENTRATION OF x RATE OF FLOW

DISCHARGED POLLUTANT IN EFFLUENT
(mg/M cans) = (mg/l) x (L/M Cans)
OBTAINED FROM ANALYSIS TOTAL FLOW IN

OF SAMPLE COLLECTED LITERS DURING
(LABORATORY RESULTS) THE 24-HOUR
SAMPLING
PERIOD
TOTAL (M) CANS

MANUFACTURED
DURING THE 24-
HOUR SAMPLING
PERIOD
NOTE:
mg/M Cans = g/MM Cans
lbs/MM Cans = g/MM Cans / 454 g/lb
M = 1000
EXAMPLE:
1. A 24-Hour Composite Sample of the effluent is collected. (Composite Sample means
a sample that is composited or formed by mixing together various smaller samples taken
at regular time intervals of half hour or one hour each during the full 24-hour period.)
Also, on grab sample is collected randomly during the 24-hour sampling period. The 24-
Hour Composite Sample is for the analysis of Cr, Cu, Zn, F, P and Mn. The Grab
Sample is for the analysis of O&G by Method E.
2. The 24-Hour Composite Sample and the Grab Sample are then sent to a local
laboratory for analysis. Plastic and/or glass jars that have been thoroughly cleaned and

rinsed at least three times should be used. Only glass jars are to be used for O&G
Method E.
3. The laboratory submits the results in terms of concentration (mg/l) of the pollutants in the
sample submitted for analysis.
As an example say the analysis of the sample is:
(mg/l)
Cr - 0.032
Cu - 0.200
Zn - 0.100
F - 12.000
P - 1.000
Mn - 0.050
O&G - 2.000
4. During the 24-hour sampling period Total Flow going through to the sanitary sewer is
also measured. Say it was found to be 132,100 gallons. Then: 132,100 gallons x 3.785
liters/gallon = 500,000 liters.
5. Also the Total Can Production during the 24-hour sampling period is obtained. Say it
was found to be 2000 M cans.
6. Therefore, the Rate of Flow during the sampling period is 250 L/M cans (500,000
Liters/2000 M cans).
7. The MASS OF POLLUTANTS discharged during the sampling period is calculated by
multiplying the concentration of the pollutants supplied by the laboratory by the Rate of
Flow.

CONCENTRATION OF x RATE OF = MASS OF POLLUTANTS
POLLUTANTS IN FLOW DISCHARGED
EFFLUENT (mg/l) (L/M Cans) (mg/ M Cans)
Cr 0.032 x 250 = 8.00
Cu 0.200 x 250 = 50.00
Zn 0.100 x 250 = 25.00
F 12.000 x 250 = 3000.00
P 1.000 x 250 = 250.00
Mn 0.050 x 250 = 12.50
O&G 2.000 x 250 = 500.00
8. Compare the MASS OF POLLUTANTS discharged (mg/M cans values) with the
Standards (DAILY MAXIMUM AND MAXIMUM FOR MONTHLY AVERAGE).
9. For the example under consideration, all pollutants are within both standards except
FLUORIDE, which is within DAILY MAXIMUM standard but out of standard for
MAXIMUM MONTHLY AVERAGE. In this example, corrective action for reduction of
Fluoride was initiated: Lime addition was increased to reduce Fluoride concentration in
the wastestream.
It will be noted that both the Concentration of Pollutants in the Effluent and the Rate of
Flow have an effect on the Mass of Pollutants discharged. The Concentration of
Pollutants in the Effluent is a function of the effectiveness of the Treatment System whereas
the rate of Flow is governed by the water usage at the washer. In order that the Standard is
met the Treatment System is to be operated efficiently and the flow through the washer has
to be kept as low as possible.

CHAPTER 2
DESCRIPTION OF WASTEWATER
TREATMENT SYSTEM

CHAPTER TWO
DESCRIPTION OF WASTEWATER TREATMENT SYSTEM
The wastewater treatment system is comprised of 5 sub-systems working in unison with each other.
The 5 sub-systems are:
1. TREATMENT OF WASHER EFFLUENT

2. TREATMENT CHEMICAL ADDITION
3. PHYSICAL TREATMENT PROCESS
4. ACIDWASH SYSTEM
5. USED OIL TREATMENT
1. TREATMENT OF WASHER EFFLUENT
The treatment of washer effluent consists of 2 steps:
STEP 1 Waste Chemical Collection
Washer effluent from the washer tanks containing the cleaner and treatment chemicals (counter
flows from washer stages), the D.I. wastes, washer trench wastes and the waste from the
trenches around the treatment system enter Waste Chemical Holding Tank. Hydrated lime
powder stored in the lime silo is mixed in a mixing tank located under the lime silo to form a light
Lime Slurry. The Lime Slurry is pumped or flows by gravity from the mixing tank directly into
the Waste Chemical Holding Tank where a mixer mixes the Lime Slurry with the contents of the
tank. The primary purpose of addition of lime slurry into wastewater effluent is to remove fluoride
and miscellaneous metals. The secondary purpose is to control the condition of sludge developed
at the end of process treatment. The pH in the Waste Chemical Holding Tank can range from 9.5
to 9.8 or higher up to 10.5 if required, to a chemical reaction between the contents of the Waste
Chemical Holding Tank and the Lime Slurry. Lime neutralization and precipitation is also
commonly used for the treatment of wastewaters containing heavy metals. The reactions involve
the removal of metals as Metal Hydroxide precipitants. The contents of the Waste Chemical
Holding Tank carrying the lime slurry with it overflow into the pH Neutralization Tank Stage #1.

WASTE CHEMICAL HOLDING TANK

TREATMENT CHEMICALS
1. Lime Ca(OH)2
Precipitation agent for fluoride and heavy metals (Cr, Cu, Zn, Mn, etc.)
2. Phosphoric Acid H3PO4- optional use if required.
Precipitation agent for fluoride. Works in combination with Lime.
3. Cationic Polymer Coagulant
Destabilizes soluble synthetic oil/water emulsions

Particulizes synthetic oil
4. Sulfuric Acid, 66 Baume (93% H2SO4)
pH adjustment
5. Caustic Soda (50% NaOH)
pH adjustment
Precipitation agent for heavy metals (Cr, Cu, Zn, Mn)
6. Anionic Polymer Flocculent
Accentuates solid particle size in an effort to increase the efficiency of the Lamella
Clarifier solid removal system.

WASTE CHEMICAL HOLDING TANK
(BASIC REACTIONS)
Fluoride Removal
1. Ca(OH)2 = 2F- = CaF2 + 20H-
Heavy Metals Removal
Cu+2 + 2 OH- Cu (OH) 2 pH 8.2 8.6
Zn+2 + 2 OH- Zn (OH) 2 pH 8.0
Mn+2 + 2 OH- Mn (OH) 2 pH 9.0
NOTE: If further fluoride reduction is needed, phosphoric acid is added to pH Neutralization
Tank stage #1.
pH NEUTRALIZATION TANK STAGE #1

(BASIC REACTIONS)
Further Fluoride Removal
1. H3PO4 3H + PO4-3
2. 5Ca(OH)2 + 3PO4-3 Ca5(OH)(PO4)3 + 9OH

Calcium Hydroxyapatite if formed.
3. Ca5(OH)(PO4)3 + F Ca5(F)(PO4)3 + OH-

Calcium Fluorapatite is formed.

INSERT DIAGRAM:
EFFECT OF PH ON FLUORIDE AFTER LIME
TREATMENT

INSERT DIAGRAM:
EFFECT OF PH EFFICIENCY OF MANGANESE
REMOVAL USING LIME

INSERT DIAGRAM:
TYPICAL EFFECT OF PH ON PHOSPHOUROUS
REMOVAL

STEP 2 pH Neutralization
The contents of the Chemical Waste Holding Tank after mixing with lime slurry,
overflows or is pumped into the pH Neutralization Tank Stage #1. Cationic polymer
(coagulant) and/or Phosphoric Acid (H3PO4) are added to the pH Neutralization Tank:
Stage #1. Cationic polymer (coagulant) and/or H3PO4 act as a coagulant aid, assist in
the removal of oil and grease and further removal of the fluoride from the wastestream.
Cationic polymer (coagulant) is a demulsifier that is added for the removal of petroleum
based oil and grease. It destroys the emulsifying properties of oil by neutralizing the
charged oil particles.
Since calcium fluoride solubility is pH dependent, pH adjustment is done in the pH
Neutralization Tank Stage #1. This is the most important step in the wastewater treatment
system.
Caustic or sulfuric acid is added to pH Neutralization Tank Stage #1 as required to adjust
the pH of the pH Neutralization Tank to the optimum pH around 8.0 8.2. The addition of
the acid and caustic is accomplished by the Beckman or equivalent pH Control System.
Returned sludge for the Lamella Clarifier can be added to Stage #1 to assist in sludge
formation prior to being pumped to the Lamella Clarifier. All contents in this tank are mixed
thoroughly to form a uniform chemistry. The effluent overflows from the pH Neutralization
Tank Stage #1 to Stage #2. This stage is also called the Lift station Stage #2.

INSERT DIAGRAM:
STAGES 1,2 TREATMENT SYSTEMS

2. TREATMENT CHEMICAL ADDITION
Treatment chemicals are added to the effluent at various points in the system. The treatment
chemicals are added for adjusting pH, sludge conditioning or precipitation of the pollutants.
There are four (4) modes of addition of the chemicals:
MODE 1 Treatment Chemical Additions Using Chemical Metering Injection Pumps pH
adjustment with an Equivalent pH Control Systems:
The chemicals used for pH adjustment are sulfuric acid and caustic. Sulfuric acid and caustic
normally purchased in regular tote tanks from which the chemicals are dispensed using
metering injection pumps which dispense either caustic or acid as required by the pH control
set point in this stage. The pH probe in the effluent stream senses the pH of the effluent
entering Stage #1 pH Neutralization Tank and sends a signal back to the pH Controller.
The Controller then sends a signal to the metering injection pumps which dispense sufficient
quantities of either sulfuric acid or caustic to adjust the pH to the desired set point. The
normal desired set point for this tank is 8.2. If the pH of the effluent stream is below the set
point, the probe will call for addition of caustic. If the pH of the effluent stream is above the
set point, the probe will call for sulfuric acid. The system is completely automatic except for
maintaining a supply of acid and caustic in the tote tanks, cleaning the pH probes once or
twice a shift as required and periodically calibrating the pH probes.
CAUTION
EXTREME CARE SHALL BE TAKEN IN PLACING THE SULFURIC ACID AND CAUSTIC
TOTE TANKS TO INSURE THAT THE PROPER CHEMICAL IS PUMPED THROUGH THE
CORRECT METERING INJECTION PUMPS.

CAUTION
ENSURE METERING INJECTION PUMPS ARE PROPERLY PRIMED TO OBTAIN THE
CORRECT CHEMICAL DOSAGES. THERE SHOULD BE NO AIR BUBBLES IN THE INLET
AND DISCHARGE SIDES OF PUMPS. TO PRIME THE PUMPS, TURN THE BLACK
ADJUSTMENT SCREW COUNTER CLOCKWISE OF ANTI-SIPHON PRIMING VALVE
LOCATED ON THE DISCHARGE SIDE OF THE PUMPS. RUN WITH VALVE OPEN UNTIL
SOLID STREAM OF FLUID COMES OUT OF BYPASS TUBING. TURN THE SCREW
CLOCKWISE TO CLOSE ANTI-SIPHON VALVE.
CAUTION
DO NOT ADD WATER TO SULFURIC ACID OR CAUSTIC TANKS, DRUMS OR TOTES.
CAUTION
DO NOT MIX CAUSTIC WITH SULFURIC ACID.
CAUTION
USE GLOVES, SAFTY GLASSES AND/OR SAFTEY SHIELD AND CHEMICAL RESISTANT
APRON WHEN HANDLING CAUSTIC, SULFURIC ACID AND ANY OTHER DANGEROUS
CHEMICALS. EXTREME CARE MUST BE TAKEN TO AVOID PERSONAL INJURY.
MODE 2 Treatment Chemicals Metered Metering Injection Pumps:
The treatment chemicals are directly discharged into the effluent stream by metering pumps
that meter the addition of the treatment chemicals at a predetermined rate.
To vary the feed rate of the metering pumps, there are 2 controls available: one regulates the
speed of the pump (0-100% speed) and the other regulates the stroke of the piston (0-100%
stroke). The maximum rating of the metering pump used for this is 60 gpd or any other
capacity. If, however, the speed is set at 50% and the stroke is also set at 50% the pump will

deliver (.5 x .5) of the maximum 60 gpd or 15 gpd. In other words, the adjusted feed rate of
the pump is the product of (% stroke) X (% speed) X (pump max rating) or in the above case
15 gpd.
The metering pumps are used to dispense Cationic Polymer (Coagulant) and/or Phosphoric
Acid to the pH Neutralization Tank Stage #1. To ensure proper chemical injection feed,
maintain a sufficient supply of cationic polymer (coagulant) and phosphoric acid in the tote
tanks or drums.
CAUTION
USE GLOVES, SAFETY GLASSES, FACE SHIELDS AND APRON WHEN HANDLING
PHOSPHOIC ACID. EXTREME CARE MUST BE TAKEN TO AVOID PERSONAL INJURY.
CAUTION
ENSURE METERING INJECTION PUMPS ARE PROPERLY PRIMED TO OBTAIN THE
CORRECT CHEMICAL DOSAGES. THERE SHOULD BE NO AIR BUBBLES IN THE INLET
AND DISCHARGE SIDES OF PUMPS. TO PRIME THE PUMPS, TURN THE BLACK
ADJUSTMENT SCREW COUNTER CLOCKWISE OF ANTI-SIPHON PRIMING VALVE
LOCATED ON THE DISCHARGE SIDE OF THE PUMPS. RUN WITH VALVE OPEN UNTIL
SOLID STREAM OF FLUID COMES OUT OF BYPASS TUBING. TURN THE SCREW
CLOCKWISE TO CLOSE ANTI-SIPHON VALVE.

INSERT DIAGRAM:
CHEMICAL INJECTION SYSTEM

INSERT DIAGRAM:
METERING INJECTION PUMP

MODE 3 Anionic Polymer Delivered in Solution by Polyblend Mixing System:
The anionic polymer is injected into the system via the flash mix tank. The polymer must be
added in a diluted form at a predetermined rate. The Polyblend Mixing System is utilized to
achieve the desired mix of water to polymer and dosage rate.
BASIC FUNCTIONAL DESCRIPTION OF POLYBLEND MIXING SYSTEM:
Please refer to Schematic A. Liquid polymer in solution or emulsion form is drawn from the
drum (1) by an adjustable metering pump (2). Depending on the output rating of the model,
either a diaphragm-type or gear pump may be supplied.
At the same time, the inflow of water from a supply source (3) is regulated by a solenoid
valve (4) and the rate-adjusting valve/rotameter (5). In some models, a differential pressure
regulator is installed between the solenoid valve and rate-adjusting valve.
The polymer and water are injected near the bottom of the mixing chamber (6). The impeller
(7) blends polymer and water in high-energy, low-shear, completely back-mixed environment
to assure complete polymer activation. The blended and activated polymer then exits at the
top of the mixing chamber through the discharge port (8) and is piped to the flash mix tank of
the lamella clarifier.
The polyblend PB-50 or PB-100 series units have a current-to-frequency converter box
mounted and are connected internally to the electronics of the diaphragm metering pump
(LMI). The box has the following features:
LCD digital display in strokes per minute/hour.
Internal/External mode selector switch with SPM or SPH.
Stroke indicator light.
Output increase knob.

The current to frequency converter box is also called the Remote Output Controller and
Signal Converter. To activate this box, the speed control knob is set to EXTERNAL and
the stroke control knob is set to any desired value (e.g. 60%) on the metering pump of the
polyblend unit. The unit can be operated manually when the mode selector witch is in the
INTERNAL position on SPM or SPH. To increase or decrease the injection rate in strokes
per minute/hour, simply turn the OUTPUT knob clockwise to increase the polymer solution
dosage rate or counterclockwise to decrease the polymer solution dosage rate.
A well-planned polymer injection system is an important step in liquid/solid separation in the
flocculation tank of a clarifier. If floc particles are too small and take a very long time to settle,
an insufficient amount of polymer is being added to the flash-mixing tank. This may mean the
polyblend-metering pump has lost its prime or that the polymer drum is empty. When the
motor/pump switch is in the ON position, the impeller inside the mixing chamber, which is
filled with water starts rotating. The pump should begin to make a clicking sound with a
blinking stroke indicator light upon injecting small amounts of polymer into the mixing
chamber. The water in the mixing chamber will rapidly turn milky or cloudy as the polymer
is injected. If the water in the mixing chamber is clear, the metering pump may have lost its
prime due to a large air bubble in the suction line or the polymer drum may be empty.

INSERT DIAGRAM:
POLYBLEND MIXING SYSTEMS

Procedure for Priming a Polyblend Unit
To prime a polyblend unit, the procedure described below should be followed: (Refer to
Schematic B.)
The Primary Accessory Kit contains the following parts:
1. Plastic labcock valve

2. Barbed fitting
3. Syringe
1. Disconnect or turn off power to Polyblend unit.
2. Locate and remove the PVC pipe plug in the clear plastic pump head. Wrap Teflon
tape over the threads of the labcock valve. Hand tighten the valve into place (open
valve).
3. Wrap Teflon tape over threads of the barbed fitting. Hand tighten the fitting into the
labcock valve.
4. Close syringe, push tip of syringe into barbed fitting.
5. Hold tip in the fitting while opening syringe (pull back on plunger).
6. Repeat procedure until polymer enters syringe and the suction tube completely filled with
polymer solution with no air pockets or bubbles. The pump is now primed.
7. Close labcock valve after priming, and remove syringe.
8. Clean syringe and keep it near the unit for future use.
9. Reconnect power to the Polyblend unit.
10. Inspect mixing chamber for polymer injection (milky color).
11. If necessary, repeat steps 1 through 10.

INSERT DIAGRAM:
POLYBLEND PRIMING ACCESSORY KIT

MODE 4 Treatment Chemicals Delivered in Slurry as by the Lime Slurry System:
Hydrated lime in powder form is stored in the lime silo and is fed by an accurate feeder into a
lime slurry mixing tank. The accurate feeder is driven by an independent pH control system
programmed to dispense hydrated lime into a lime slurry mixing tank. The pH probe in the
effluent stream senses the pH of the effluent entering in to the Waste Chemical Holding
Tank and sends a signal back to the pH Controller. The Controller then sends a signal to the
accurate feeder which dispenses required quantities of hydrated lime until the desired set
point is reached. The accurate feeder speed will vary based on the effluent pH entering in to
this tank. Fresh water and/or treated water is added to the lime slurry mixing tank, which
mixes the powdered hydrated lime and fresh water to form a light lime slurry. Lime slurry is
then overflowed in to the Waste Chemical Holding Tank. The primary purpose of addition of
lime is to control the amount of Fluoride and miscellaneous metals in the wastestream and
secondary conditioning of the sludge.
3. PHYSICAL TREATMENT PROCESS
The purpose of the physical treatment process is to separate the solids generated by the
chemical treatment process from the wastewater effluent prior to discharge. This process is
carried out in two (2) steps:
A. Flocculation and Clarification
B. Sludge Dewatering
A. Flocculation and Clarification
The effluent from the lift station Stage #2 first enters the flash mix tank attached to the
Lamella Clarifier. An anionic polymer is added to the flash mix tank to assist in the
formation of a good settable floc.

The polymer is properly mixed in the flash mix tank by an agitator and the effluent then
overflows into the flocculation tank. In the flocculation tank, a secondary gate mixer provides
additional time for the reaction to take place. The flocculation tank discharges into the
clarifier where the solids are settled by gravity and separated from the effluent stream as it
flows out of the clarifier. A portion of the treated effluent from the clarifier is diverted to the
lime slurry mix tank in the lime silo and remaining treated effluent then discharges to the
sanitary sewer. The sludge from the Lamella Clarifier is drawn off from the bottom at a rate
of approximately 5 to 10 gpm and discharged to the Sludge Holding Tank, and/or back to
the pH Neutralization Tank Stage #1 as required.
Refer to the following page for a schematic of a typical Lamella Clarifier.

INSERT DIAGRAM:
LAMELLA CLARIFIER

B. Sludge Dewatering
The solids that settle to the bottom of the Lamella Clarifier are drawn off by the air operated
Lamella sludge pump from the bottom of the Lamella Clarifier. The liquid sludge, at this
point, is mostly all water and is pumped to the sludge holding tank and/or to Stage #1 (i.e.,
pH Neutralization Tank). The treated water generated by the Used oil Treatment System is
pumped directly to the waste chemical holding tank where it becomes part of the process.
Air-operated sludge delivery pumps transfer the liquid sludge from the Sludge Holding Tank
for dewatering the sludge in the Filter Press. The liquid sludge passes through the
polypropylene filter media in the Filter Press allowing the water to pass through while
retaining the solids to form a filter cake. When the Filter Press is full (i.e., when the sludge
delivery pump stops pumping), compressed air is forced at 30 35 P.S.I. through the filter to
increase the dryness of the cake. This process is called BLOWING DOWN of filer press
medias. Compressed air for drying the cake is turned off, the press is opened and the filter
press residue is dropped into a dumpster for disposal at a landfill. The filtered water (filtrate)
is returned to the Waste Chemical Holding Tank for further treatment. (See following page
for schematic.)

INSERT DIAGRAM:
SLUDGE DEWATERING & ACID WASH SYSTEM
4. ACID WASH SYSTEM

During the filtration cycle, the filter cloth media is the initial barrier that separates the solids
from the liquid; therefore, the filter cloth must remain porous to provide high filtration rate.
During the normal operation, the filter cloth may gradually become plugged with minute
particles, such as those from metal hydroxide sludge. The particles enter the cloth and
become lodged in the depth of the weave, which leads to decreased filtering action. These
particles must be removed periodically to maintain high filtration rates and drier cakes.
Filter cloth washing is required when one of the following factors indicate plugging has
occurred:
1. Initial high filtration pressure.
2. Long filtration cycles.
3. Wet filter cakes.
The most commonly used method with metal hydroxide sludge particles is the Acid Wash
System. The acid wash system is designed to pump a solution of 30% muriatic acid through
the filter press and return to a storage tank. The acid wash system consists of an air
operated acid pump, a 300-gallon acid wash holding tank and all associated piping. To
conduct an acid wash of a filter press you must remove the press from operation and remove
all solids. When press is clean close valve (to drain) open valve (from acid wash holding
tank) and open valve (return line from filter press to acid wash holding tank). Run acid
through press for a minimum of 30 minutes and a maximum of 60 minutes. Upon completion
of wash allow press to drain by gravity and use only air blow down (max 15 psi) to remove
the final traces of the acid. To place press back into service reverse procedure outlined
above.

OPENING PROCEDURE:
(Refer to Schematic C.)
1. Turn the hydraulic pump switch to the OFF position.
2. Next, turn the SELECTOR switch to the OPEN position. The hydraulic cylinder will
retract, opening the press.
! NOTE: The air supply switch must be in the ON position.
3. When the press is completely open, turn the air supply to the OFF position.
You are now ready to clean the plates. Position the collection dumpsters under the filter
press to be cleaned.
Separate the plates. When the plates are separated, the filter cake will fall to your collection
drums or dumpsters. Refer to the diagram at the top of the next page for proper cleaning
techniques.
! NOTE: Make sure the gasket sealing surfaces are free of filter cake.
When the plates are thoroughly clean, you can close the J-Press and repeat the filtration
process. Follow the instructions under CLOSING PROCEDURE.

INSERT DIAGRAM:
FILTER PRESS OPENING SYSTEM

CLOSING PROCEDURE:
(Refer to Schematic D.)
If your air supply is properly connected to the press, the line pressure will register on the
LINE AIR PRESSURE GAUGE as shown below on the standard control panel. Refer to
YOUR J-PRESS SPECIFICATIONS for the required air pressure for your press.
1. Turn the AIR SUPPLY switch to the ON position.
2. Now turn the SELECTOR switch to the CLOSE position. The hydraulic cylinder will
extend and move the follower, along with the plate stack, toward the head end of the
press.
3. Once the hydraulic cylinder is fully extended, turn on the HYDRAULIC PUMP switch.
You will hear the air-oil pump cycling and see the HYDRAULIC PRESSURE rise. The
pumps cycling rate will slow as it reaches the preset closing pressure. Finally, the pump
will stall.
! CAUTION: The HYDRAULIC PUMP switch must be left ON during the

complete process cycle and only turned OFF once the press is ready for opening.

INSERT DIAGRAM:
FILTER PRESS CLOSING PROCEDURE
5. USED OIL TREATMENT SYSTEM

The used oil from the various can manufacturing process sources is collected in the Used oil Holding
Tank.
The used oil from the used oil holding tank is transferred to the Used oil Treatment Tank for batch
processing where an estimated 2,800 gallons of used oil can be treated at a time.
The batch processing of the used oil treatment system involves the addition of oil breaking cationic
polymer and a little amount caustic, if necessary, in a continuous mixing operation.
After treatment with the oil breaking cationic polymer and caustic addition, the used oil is mixed for a
period of time after which the mixer is turned off and the contents of the tank are allowed to stand idle
for a period of time.
During this idle period, all the oily particles from oil-in-water emulsions, which are separated during
demulsifier (oil breaking polymer) addition, will float to the top of the tank leaving water at the bottom
portion of the tank. This Used oil Treatment Tank is equipped with an optical sensor with adjustable
sensitivity to detect top layer of demulsified oil from the treated water.
The bottom portion of treated water is discharged into the Waste Chemical Holding Tank via trench
where it becomes part of the continuous process wastewater for final treatment. As soon as the top
layer of demulsified oil comes in contact with the optical sensor, the valve shuts off so that the
demulsified used oil does not discharge into the Waste Chemical Holding Tank.
The top portion of the demulsified used oil is discharged to the Treated Used oil Holding Tank from
which a tanker truck hauls away the treated used oil for final disposal.
The used oil treatment is a physical-chemical separation of oil from water. The physical-chemical
separation consists of the two major steps as follows:
A. PH adjustment with caustic and addition of oil breaking cationic polymer.
B. Physical separation of oil from water.

INSERT DIGRAM:
USED OIL TREATMENT SYSTEM
Operating Instructions
Used oil Treatment
(Oil De-watering Only)

Step 1 Push the red cycle start button on the used oil control panel to begin the
transfer of the used oil treatment tank.
Step 2 When level in used oil treatment tank reaches working level (6 below
overflow pipe), turn on tank mixer.
Step 3 Follow dosage determination procedure to determine the amount of

polymer needed to treat the batch.
Step 4 Add amount of cationic polymer as determined from Step 3.
Step 5 Upon completion of adding polymer, continue tank mixing for one hour.
Step 6 After 1 hour of mixing, sample tank to ensure that oil particulization has
taken place.
Step 7 Discontinue mix. Allow treatment tank to stand idle for at least one hour
so the oil/water separation can occur.
Step 8 Discharge the water portion from the oil/water separation by opening the
inch drain line at the bottom of the used oil treatment tank.
Step 9 Adjust the drain valve to maintain a flow rate of 2 5 gpm into the
treatment system.
Step 10 Close the inch discharge line when water draining is completed. Care
must be taken not to allow the oil portion from the oil/water separation
from entering the WWT system. This is normally controlled by the optical
sensor with the adjustable sensitivity installed at the bottom of the tank.
Transfer oil layer to used oil-holding tank.

Step 11
System ready for another batch.
Step 12
Cationic Polymer Used oil Treatment

Dosage Determination
Material Needed

1 600 ml Beaker
1 5 ml Syringe
1 Magnetic Stirrer and Stirring Bar
Procedure
1. Fill used oil treatment tank to capacity.
2. Turn on mixers.
3. From the top of the used oil tank, pull a representative sample. Decant 500 ml of
the used oil into the 600-ml beaker.
4. Using the magnetic stirrer, slowly mix sample.
5. Check pH. Adjust to 7 9, if necessary, with caustic. Please refer to the pH
adjustment chart for proper treatment dosage.
6. Using the 5-ml syringe, add cationic polymer into the used oil sample at 0.5-ml
intervals.
7. After each addition, visually check for a discernable break in the used oil. The
break is characterized by a solution color change from gray to black. At this pint,
oil particulization will be evident.
8. Discontinue mix.
9. By using the attached chart, determine the amount of gallons of cationic polymer
needed to treat 2750-gallon batch by noting the amount of milliliters needed to
successfully treat the sample.
Cationic Polymer Dosage Ratio

vs.
Milliliters in Beaker

No. of Gallons of Cationic Polymer to Treat
Milliliters 2750 Gallon Batch
0.25 1.4
0.50 2.8
0.75 4.1
1.00 5.5
1.25 6.9
1.50 8.3
1.75 9.6
2.00 11.0
2.25 12.4
2.50 13.8
2.75 15.1
3.00 16.5
3.25 17.9
3.50 19.3
3.75 20.6
4.00 22.0
4.25 23.4
4.50 24.8
4.75 26.1
5.00 27.5
Please Note:
If a successful oil/water separation is not achieved with 5 milliliters or less, the used oil batch
contains too much oil for a polymer treatment and should be pumped directly into the final
used oil tank.
PH Adjustment Chart

Caustic Soda Dosage Ratio
vs.
Milliliters in Beaker
No. of Milliliters of Caustic

Milliliters Required to Raise pH to 8.5 9.0
0.1 160 mls

0.2 320 mls
0.3 480 mls
0.4 640 mls
0.5 800 mls
0.6 960 mls
0.7 1120 mls
0.8 1280 mls
0.9 1440 mls
1.0 1600 mls
1.1 1760 mls
1.2 1920 mls
1.3 2080 mls
1.4 2240 mls
1.5 2400 mls
1.6 2560 mls
1.7 2720 mls
1.8 2880 mls
1.9 3040 mls
2.0 3200 mls
Please Note:
1. For caustic soda addition, use a 1.0 milliliter capacity syringe.
2. The caustic dosage addition is based on a final pH range of 7.0 9.0.

CHAPTER 3

QUALITY CONTROL CHECKS REQUIRED
To ensure correct operation of the treatment system, certain quality control checks must be
conducted. All quality control observations shall be recorded on the plants computer
terminal. The following should be a representation of the screen for entering the wastewater
treatment system observations in the computer each shift, however the computer screen
varies from facility to facility under QCII program.
1. Clarify of Discharge :XXXXXX (Cloudy/Clear)

2. Waste Chemical Holding Tank pH :XX.XX (pH Units)
3. Neutralization Tank (Stage 1) pH :XX.XX (pH Units)
4. Sanitary Sewer Discharge pH :XX.XX (pH Units)
5. pH Controller Set Point :XX.XX (pH Units)
6. Fluoride :XX.XX (mg/l of Fluoride)
7. Sludge Settleability (1000 250 ml) :XX:XX (time in minutes & seconds)
8. Process Discharge Flow Rate :XXX (gallons per minute)
9. Coagulant Injection: :XX.XX (ml/min)
10. Phosphoric Acid Injection: :XX.XX (ml/min)
11. Anionic Injection: Polymer :XX.XX (Speed%/Stroke%/RotometerGPH)
12. Caustic Tank Level :XXXXXXX (Full/1/2 Full/1/4 Full/Empty)
13. Acid Tank Level :XXXXXXX (Full/1/2 Full/1/4 Full/Empty)
14. Lime Feed :XX.XX (pounds/hour)
The frequency of observation per shift, required for each category of data entry, is stated in
the itemized instructions. However, only the most representative observation per shift is to
be entered on the screen for each category. The itemized instructions follow:
1. Clarity of Discharge
The effluent from the clarifier shall be checked as to clarity (i.e., free of suspended solids,
color, etc.). Observations should be recorded in the plant's computer. The frequency of
this check shall be twice each shift.
2. Waste Chemical Holding Tank pH
Samples are to be collected from the Waste Chemical Holding Tank. At the time the
samples for analysis are collected, the reading on the pH Control System Display should
be noted. The samples are to be analyzed on the laboratory pH meter. The results
obtained on the laboratory meter should be compared against the readings noted on the
pH Control System Display. The frequency of the check is twice per shift with results to
be recorded in plants computer.
Neutralization Tank (Stage #1) pH
Samples are to be collected from the pH Neutralization Tank Stage #1 for analysis. At
the time the samples for analysis are collected, the reading on the pH Control System
Display should be noted. The samples are to be analyzed on the laboratory pH meter.
The results obtained on the laboratory meter should be compared against the readings
noted on the pH Control System Display. The frequency of the check is twice per shift
with results to be recorded in plants computer.
3. Sanitary Sewer Discharge pH
Samples are to be collected from the flume. The samples are to be analyzed on the
laboratory pH meter and recorded twice per shift.
4. pH Controller Set Point
The pH Controller set point is to be noted on the panel and recorded in the plants
computer twice per shift.
5. Fluoride Measurement
See Procedure for Measurement of Fluoride in Appendix A. Frequency of recording is
twice per shift.
6. Sludge Settleability
Collect a sample twice per shift from the flocculation tank of the Lamella Clarifier and
check the settling rate of the sludge. To check the settling rate of the sludge, the following
procedure shall be used:
A. Sample of liquid from flocculation tank shall be collected into a 1,000 ml graduated
cylinder.

B. The time required for sludge to settle from 1000 ml to 250 ml shall be recorded.
Based on the above check, the polymer shall be either increased or decreased.
Results in minutes and seconds to be recorded in plants computer.
7. Process Discharge Flow Rate
The instantaneous flow rate shall be read from the process discharge flow meter at the
flume and recorded twice each shift in plants computer.
8. Coagulant Injection
Collect a sample of coagulant twice per shift from the discharge point of coagulant
metering injection pump into a 25 ml graduated cylinder for one (1) minute. Results to be
recorded in ml/min in plants computer.
9. Phosphoric Acid Injection (optional)
Collect a sample of phosphoric acid twice per shift from the discharge point of phosphoric
acid metering injection pump into a 25 ml graduated cylinder for one (1) minute. Results
to be recorded in ml/min in plants computer.
10. Anionic Polymer Injection (Flocculent)
Stroke per minute from the polyblend display shall be checked and recorded twice per
shift in plants computer.
11. Caustic Tote Tank Level
The level of the caustic in the Tote tank shall be checked as required. Replace tote tank
immediately when this tank becomes empty. The frequency of this check is twice per shift
and observations shall be recorded in plants computer.
12. Sulfuric Acid Tote Tank Level

The level of the sulfuric acid in the Tote tank shall be checked as required. Replace tote
tank immediately when this tank becomes empty. The frequency of this check is twice per
shift and observations shall be recorded in plants computer.
13. Lime Feed
Collect a sample of powdered lime from the lime feeder into a 1000-ml plastic pre-
weighted beaker for one (1) minute. Obtain the net weight of the powdered lime placing
the pre-weighted beaker (taking the empty beaker weight into account to zero the scale)
onto weighing scale. Convert the net weight powdered lime obtained in ounces into
pounds (divide by 16, I lb = 16 ounces) and multiply the pound numbers by 60 to obtain
pounds of dry powdered lime feed. Results to be recorded twice per shift in pounds per
hour in plants computer.
720A METER
pH DETERMINATION
1. Push 2nd button and then channel button to get to #2 channel for pH probe.
2. Push mode button until pH is displayed.

3. Push 1st button.
4. Push calibrate button.
5. Enter number of buffers used, 3 then push yes. (use buffers: 4.0 and 7.0 and 10.0)
6. Immerse pH probe in 4.0 buffer. When meter displays ready enter 4.0 and push yes.
7. Meter will advance to buffer 2. Rinse the probe with D.I. water and immerse into the 7.0
buffer.
8. When meter displays ready enter 7.0 and push yes.
9. Meter will advance to buffer 3. Rinse the probe with D.I. water and immerse into the
10.0 buffer.
10. When meter displays ready enter 10.0 and push yes.
11. Meter will calibrate slope. Push stand-by button.
12. Remove probe, rinse with D.I. water and immerse probe into sample. Push measure
button to get reading.
13. After calibration immerse probe in each buffer and record reading of each. Rinse probe
with D.I. water between each reading.
NOTE: Follow the Operation and Maintenance manual for more detailed instructions.
APPENDIX A

720 METER
PROCEDURE FOR MEASUREMENT OF FLOURIDE
PROCEDURE
1. Use channel #1. Push 2nd button and then channel button until channel #1 is
displayed.
2. Push mode button until you get to CON.
3. Push 1st button.
4. Push calibrate button. Number of standards will be 2.
5. Enter 2 and push yes.
6. Immerse probe in 1 ppm standard. (green)
7. When ready is displayed enter 1.0 and push yes.
8. Rinse probe with D.I. water.
9. Meter will advance to number 2 standard.
10. Immerse probe in 10 ppm standard. (blue) When ready is displayed enter 10.0 and
push yes.
11. Next push stand-by button.
12. Prepare sample:
25 mls of waste water from clarifier discharge and 25 mls of Tisab. Mix well.
13. Rinse probe with D.I water and immerse in sample. Push measure button. Read
directly and record. (ppm = mg/l)
0 to 15 In compliance
16 to 20 Borderline
Above 21 Out of compliance
NOTE: To reset meter if you make a mistake just unplug the meter.
APPENDIX B

CHEMICAL DOSAGES
The effectiveness of the treatment system is dependent upon the correct dosage of
chemicals being added to the treatment system. The chemical concentrations must remain
the same regardless of the rate of effluent flow through the system.
Given this premise, the dosage of chemicals into the effluent stream shall be adjusted
dependent upon the flow. The method of adjusting the dosage is to adjust the chemical
metering pumps or to add or decrease the amount of lime added to the system through the
accurate feeder.
To assist in the operation, attached to this chapter are two graphs showing the relationships
between pump settings, lime dosage and flow. These graphs are developed for your plant at
the time of startup of the treatment system.
Graph A is the dosage for the phosphoric Acid (H3PO4) addition.
Graph B is the dosage for the lime addition.
To change chemical dosage using Graphs A and B the following steps must be followed
before any changes to chemical dosages are made:
STEP 1: Collect sample from Stage 2 of can washer and check for F using standard
procedure except dilute 50 to 1.
STEP 2: When F is determined, check discharge volume through flume.
STEP 3: Using appropriate chart select flow closest to flow through the flume select
proper flow rate and determine new settings.
The cationic polymer should be regulated by visual observation, i.e., keep increasing
discharge rate till effluent from lamella is clear. However, remember any change in dosages
takes 4 hours for the change to be noticed in the effluent.

The settings noted in Table 3 have been established from these graphs. These are optimum
settings at which the concentration of the treatment chemicals will result in the most efficient
operation of the treatment chemicals will result in the most efficient operation of the treatment
system for the removal of the pollutants in the effluent stream. In the event the flow
characteristics change due to process modifications, the settings will have to be changed as
well.

INSERT DIAGRAM:
GRAPH A
DOSAGE FOR PHOSPHORIC ACID

INSERT DIAGRAM:
GRAPH B
LIME ADDITION
TABLE 3
TREATMENT CHEMICAL ADDITION OPERATING PARAMETERS SETTINGS
The following are the operational settings for the Treatment Chemical Addition Systems,
which will produce the most consistent results:
SETTING DATE OF COMMENT SETTING DATE OF REASON FOR

SETTING CHANGED TO CHANGE CHANGE
MODE 1 Treatment Chemicals Using Metering Injection Pumps

pH adjustment with an Equivalent pH Control
pH Control System
1. Buffer Low
2. Buffer High
3. Slope calibration
4. Slope recall
5. Set pH value
6. Output 0/4 MA
7. Simulate pH
8. Temperature
9. ALM. Pt 1
10. ALM. Pt 2
11. Max on time
12. % Control output
13. Control output
14. Gain
15. Reset
MODE 2 Treatment Chemicals Metered

LMI Metering Pumps:
A. Cationic Polymer
1. Speed %
2. Stroke %
3. ML/MIN
B. Phosphoric Acid Feed Pump

1. Speed %
2. Stroke %
3. ML/MIN
SETTING DATE OF COMMENT SETTING DATE OF REASON FOR

SETTING CHANGED TO CHANGE CHANGE

MODE 3 Treatment Chemicals Delivered in Solution
as by Polyblend Mixing Systems:
A. Polyblend Polymer System
1. Speed %
2. Stroke %
3. Rotometer
GPH
4. SELECTOR
MODE SWITCH
EXT/INT
SPM/SPH
5. STROKES PER
MINUTE/HOUR
MODE 4 Treatment Chemicals Delivered in a Slurry

as by the Lime Slurry System:
A. Lime Slurry System
1. Lime Feed lbs/hr

CHAPTER 4
TROUBLE SHOOTING PROCEDURE

CHAPTER 4
TROUBLESHOOTING PROCEDURE
PROBLEM CAUSE CORRECTIVE ACTION
No Flow through System. Can lines down. No flow All chemical feeds should be
from washer. turned off for semi-automatic
system. Remember to turn
them on when washer
comes back on line.
Lift pumps in operative. Check to see if lift pumps

have been turned off by low
level. If so, no corrective
action if required.
Flow proportional valve not Check to see if low level

operating. slows the lift pump due to
wastewater frequency drive.
If so, no action is required.
Lift pump cavitating due to Put a spare lift pump in

plugged strainer at the base service. Disconnect the
of the pump. discharge pipe at the ball
valve. Flush the pipe with
fresh water at high pressure
to unplug the strainer at the
base of the pump. If flow
from pump is still not
sufficient, arrange for
maintenance personnel to
unplug the strainer.
Ball and/or check valves at Put spare lift pump into

the discharge line are service. Arrange for
clogged with sludge build- maintenance person to
up. remove and clean the valve,
if necessary.

TROUBLESHOOTING PROCEDURE (cont.)
High liquid level in Stage #2. Lift pumps not operating. Verify that pumps are turned
ON. If not, turn them on. If
ON, but not operating,
contact plant maintenance
for corrective action.
Excessive flow into system. Adjust discharge valves on

lift pumps to restabilize flow
through system. Also check
valves on washer treatment
tanks. Balance the flow by
adjusting the discharge
valves on the washer to stop
excessive flow into the
wastewater treatment
system.
Discharge volume from lift Open discharge valve all the

pumps reduced. way. If flow from pumps is
still weak, switch to spare
pump and request
maintenance to evaluate and
repair.
Discharge volume reduced Bring into service the spare

due to cavitation of lift pump. lift pump. Disconnect the
discharge pipe at the ball
valve and flush the pipe with
high-pressure fresh water to
unplug the strainer at the
base of the pump. If flow
from pump is still
inadequate, request
maintenance to evaluate and
repair.
Excessive flow due to D.I. Collect waste coming from

regeneration waste coming the D.I. regeneration
into system. process into D.I. Columns
Waste Regeneration Tank,
which can be pumped and/or
overflowed slowly into the
system to re-stabilize the
system.

High liquid level in Stage #2. Ball and/or check valves at Put the spare lift pump in
(cont.) discharge line clogged with service and arrange for
sludge buildup. maintenance to remove and
clean valves.
Low pH Stage #1. No caustic in caustic storage Pump caustic into storage
(i.e., pH<6.0) tank. tank.
Caustic lines control valves Clean and reinstall control

clogged due to buildup of valves.
caustic crystals.
Faulty pH reading. Clean and recalibrate pH

probe. If broken, replace pH
probe.
Metering pump not Check to verify that switch is

responding to signal. turned ON at the pump and
that Selector switch is in
AUTO position. If problem
still exists, notify electrical
maintenance.
High pH Stage #1. No sulfuric acid in sulfuric Pump sulfuric acid into
(i.e., pH>10.0) acid storage tank. storage tank.
Control valves for sulfuric Clean and reinstall control

acid feed lines clogged due valves.
to material buildup.
Metering pump not Check to see that switch is

responding to signal. turned ON at the pump and
that Selector switch is in
AUTO position. If problem
still exists, notify electrical
maintenance.
Faulty pH reading. Clean and recalibrate pH

probe. If broken, replace pH
probe.
Excessive lime slurry. If feasible, reduce feed rate

of lime slurry to waste
chemical holding tank.

Excessive caustic usage. Metering pump for sulfuric Using a repair kit, rebuild the
acid is siphoning due to pump. Refer to pump
pump diaphragm failure. manual for correct rebuilding
procedure.
Selector switch left in Set Selector switch to the

Manual position using Auto position.
constant amount of caustic.
Large swing in pH range due Fine-tune the pH PID loop

to pumps running against on pH control system to
each other. narrow the pH range swing.
Excessive usage of sulfuric Metering pump for caustic is Using a repair kit, rebuild the
acid. siphoning due to pump pump. Refer to pump
diaphragm failure. manual for correct rebuilding
procedure.
Selector switch left in Set Selector switch to the

Manual position using Auto position.
constant amount of sulfuric
acid.
Large swing in pH range due Fine-tune the pH PID on pH

to pumps running against control system loop to
each other. narrow the pH range swing.
Insufficient floc formation. No polymer feed to flash Polymer drum empty.

mix. Replace and reprime
Polyblend feed unit.
Polyblend unit lost prime. Reprime Polyblend unit. If

problem continues, reduce
length of suction tube to a
minimum.
Polymer feed rate is Adjust Polyblend system to

insufficient. increase polymer feed rate.
Check that the suction side
of Polyblend pump is clog-
free. Refer to Polyblend
manual for procedure.
Insufficient coagulant. Increase coagulant.
High or low pH reading. Take corrective action as

necessary.
Excessive flock formation. Excess lime. Reduce lime slurry to

optimum level.
Excess solids. Increase coagulant.
Floc floating in Lamella. Excess polymer. Reduce polymer feed to

flock mix tank.
Lamella full. If polymer feed is fine,

proceed to next section.
High sludge level in Lamella. Failure of sludge transfer. Switch to Standby pump.
Arrange repair of failed
pump.
Sludge draw-off rate too low. Increase discharge rate of

pump by increasing air
pressure to pump. If pump
cycles too fast, wash out
suction line and restart
pump.
Lamella plugged with solids. Turn lift pumps off. Increase

rate of sludge transfer
pumps. Empty and clean
lamella.
Sludge cake not dry. Insufficient air blow-down. Increase air blow-down cycle
until dry cake is achieved.
Press opened before it is Increase cycle time.

filled with solids.
Insufficient lime in system. Increase lime slurry to

optimum point.
Filter cloths blinded. Acid wash system needs to

be operated.

High F reading. Insufficient lime. Increase lime feed rate by

adjusting accurate feeder 50
units at a time, a maximum
increase of 250 units.
NOTE: After each correction,
wait four hours to check
effectiveness before
proceeding.
Incorrect pH. Correct problem with pH.

NOTE: Clean all pH probes
thoroughly before
recalibration or correction.
Insufficient phosphoric acid. Increase phosphoric acid

feed pump by 5 per cent.
Wait four hours to determine
effectiveness. If required,
repeat cycle no more than
five times.
Excessive F discharge from If possible, correct washer

washer. problem. If not, contact
Process Engineering.
High Manganese reading. Incorrect pH. Correct pH problem.
Solids carry over lamella. Correct solids settling

problem.
Excess oil. Increase coagulant.

(cationic polymer)
Excessive discharge from Correct washer discharge. If

washer. still high, contact shift
supervisor.

Excessive solids carry-over High oil and grease. Correct solids settling
Lamella. problem.
Discharge milky. High oil and grease. Increase coagulant, until

discharge clears. If problem
persists, contact shift
supervisor.
Calcium carbonate buildup Excessive lime slurry. If feasible, reduce feed rate
(hard scale). of lime slurry to waste
chemical holding tank.
Filtrate from filter press is Torn filter cloth. Replace torn filter cloth(s).
dirty (cloudy).
Filter cloth is not in groove. Check to see if cloths are in
grooves.
Filter press is Service the Filter press.

malfunctioning.

WATEWATER TREATMENT SYSTEM UPSET
TURBID (CLOUDY) WATER AT FLUME CLEAR WATER, BUT SIGNIFICANT

NO FLOC PRESENT AMOUNTS OF SOLIDS PRESENT AT FLUME
YES YES
NO NO
VERIFY SYSTEM pHS CHECK THE VERIFY SYSTEM pHS
ARE CORRECT FUNCTION OF pH ARE CORRECT
CONTROLLER;
ACID/CAUSTIC FEED
OPERATIONAL, pH
PROBES
YES CALIBRATIONS, YES
REPLACE
BROKEN/WORN OUT
PROBES ETC.
VERIFY FLOCULANT STRANCO VERIFY FLOCCULENT

(ANIONIC POLYMER) NO POLYBLEND NO (ANIONIC POLYMER)
IS FEEDING OPERATIONAL, IS FEEDING
CORRECTLY EMPTY DRUM, FEED CORRECTLY
RATE AT STANDARD
SETTING, PRIME
YES POLYBLEND UNIT. YES
NO
NO
VERIFY LIME FEED IS SLURRY SLUDGE VERIFY
OPERATIONAL. MECHANISM REMOVAL PUMP LAMELLA
OPERATIONAL, FEED OPERATIONAL, CLARIFIER
RATE AT STANDARD CLARIFIER OPERATION.
SETTING. SATURATED
WITH SLUDGE,
YES FILTER PRESSES
ARE FULL AND YES
NO
SLUDGE BUILDS-
UP IN THE
SYSTEM ETC.
VERIFY COAGULANT NO CHEMICAL FEED VERIFY LIME FEED IS

(CATIONIC POLYMER) PUMP OPERATIONAL, CORRECT.
FEED IS CORRECT. EMPTY DRUM, FEED
RATE AT STANDARD
SETTING, ETC. YES
YES
NO NO
INCREASE CONTACT SHIFT INCREASE
COAGULANT FEED SUPERVISOR. FLOCCULENT AT
RATE TO IMPROVE INTERVALS OF 5%
CLARITY. OUTPUT FEED RATE
TO IMPROVE CLARITY.

CHAPTER 5
INSTRUCTIONS FOR WASTEWATER MONITORING

ARDAGH BCA SAMPLING INFORMATION
WASTEWATER SAMPLE KIT INFORMATION
Sample kits will contain:
Proper sample containers, with preservatives, to perform the necessary routine analysis
at your facility. The CHAIN OF CUSTODY RECORD for your facility, included with each
kit, indicates the permit requirements. Please review this for accuracy. If you know of
discrepancies, please contact Diana Mockler at TEST AMERICA Laboratories
immediately. If you require extra analysis and are unsure of sample container needs,
please contact TEST AMERICA Laboratories.
One (1) Wastewater Pretreatment Self-Monitoring Report page in plastic envelope

(make copy for your files after completion)
One TEST AMERICA Laboratories Chain of Custody Record. Chain of custody forms
will eventually all be preprinted, meaning that all you need to do is fill in the sample
date/time/etc. and sign the form. Again, if you see discrepancies, please contact TEST
AMERICA Laboratories. If you are requesting additional analysis, please complete a
separate Chain of Custody record for the additional parameters.
Complete the self-monitoring report page. If the monitoring report page is not complete,
sampling must be repeated. This monitoring report, in addition to all required paperwork,
must be placed in the plastic bag inside the sample kit return cooler.
Cooler and Bottle Packing:

Coolers will have proper labels included. A temperature blank will be included with each
cooler. You do not have to do anything to this bottle; simply leave it in the cooler. When the
cooler is received at the lab, the temperature of the water in this bottle will be documented.
The sole purpose of the temperature blank is to ensure that the cooling practices being
employed during shipping are sufficient as to not affect the integrity of the sample. Sampling
guidelines in the Code of Federal Regulations indicate that samples should be stored at 4C
+ 2C.
Pack glass containers in a matter to ensure that they will not break in shipping. Bubble wrap
will be included with each cooler shipped after September 30, 1996. TEST AMERICA
Laboratories recommends that you utilize this bubble wrap by wrapping each individual glass
container at least twice with the bubble wrap.
Finally, each cooler must be packed in ice, not only ice packs. Place ice in large Zip Lock
Bags, clearly labeled ICE PACK. Two bags per cooler should be utilized if space permits.
The cooling demands change, obviously with the weather, so common sense and feedback
from the receiving lab will control the final amount of ice required. As previously mentioned,
sample temperature upon receipt at the laboratory should be 4C + 2C.

WASTEWATER SAMPLING GUIDELINES
SAMPLING PROCEDURE:
1. Read the Wastewater Pretreatment Self-Monitoring Report form and be prepared to
complete this report.
2. Be certain the composite sample container, located in the plant sampler, is clean. The
bottle should be thoroughly cleaned at the end of each sampling period.
3. Enter the information on the Wastewater Pretreatment Self-Monitoring Report form
required for the start of the sampling (time sampling started, flow meter reading, etc.).
4. Commence sampling.
5. Twenty-four (24) hours later, turn the sampler to the OFF position.
6. It is recommended that disposable gloves be worn at all time when handling samples and
sample containers.
7. Mix the composite sample thoroughly.
8. Open each bottle in the kit identified as a COMPOSITE sample. Be certain to stand up
wind since the sample bottles contain preservatives, which can create fumes and cause
skin irritation. Do not spill the preservatives.
9. Again, mix the composite sample thoroughly and quickly fill each bottle identified as a
COMPOSITE sample.
10. Replace caps quickly after filling the containers.
11. Grab samples for Fats, Oil, and Grease (FOG) should be collected directly in the glass
bottle or bottles. BE SURE TO WEAR LATEX/RUBBER GLOVES WHEN COLLECTING
THE FOG SAMPLE. The bottles should be placed into the stream and filled completely,
allowing as little rinsing effect as possible in the bottle. The FOG bottles should not be
filled using another container unless it is necessary (i.e., you cannot get the glass bottle
into the stream to allow it to fill completely). If you have a problem with this, please
contact TEST AMERICA Laboratories at 219-464-2389. They will be happy to discuss a
procedure with you. TEST AMERICA Laboratories provides sample containers with
preservative already in place. If you are concerned that it may not be feasible to obtain a
sample and keep the acid in the bottle, check the pH following collection. The pH must be
below 2.0. If you cannot achieve this, please contact TEST AMERICA Laboratories.
12. Place sample containers in coolers.
13. Take another grab sample from the flume and measure the pH of the grab. Enter the
value of pH on the Self-Monitoring report form.
14. Complete the Wastewater Pretreatment Self-Monitoring Report and make one (1) copy
for your records.
15. Place the original Wastewater Pretreatment Self-Monitoring Report in the plastic
envelope provided and place it in the mailing pack.
16. Clean your composite sample container thoroughly between sample events. Be sure to
place it where it will not be used for any other purpose until the next sampling.
17. Wash hands.
18. Pack coolers in ice, taking necessary precautions with the glass bottles. All paperwork
should be placed in a large zip-lock bag. Return address labels will be in each cooler.
19. Seal the cooler using shipping or duct tape and ship to the designated TEST AMERICA
Laboratories facility via next day air service (Federal Express, UPS, or equivalent).

INSERT:
ARDAGH BCA WASTEWATER PRETREATMENT
SELF MONITORING REPORT

INSERT:
EXAMPLE FORM TO INCLUDE WITH CHAIN-OF-
CUSTODY

CHAPTER 6
STARTUP AND SHUTDOWN PROCEDURES

CHAPTER 6
STARTUP WASTEWATER TREATMENT SYSTEM
SECTION 1: Initial Startup of a Wastewater Pre-treatment System:
The initial startup of the wastewater pre-treatment system requires that the following
steps be followed in the order listed:
Step 1: Check all valves and piping to ensure that flow from all components is
directed to proper location (i.e., lift pump to inlet of the lamella, lamella
sludge transfer pumps to sludge holding tank, filter press feed pumps to
filter press, used oil delivery pumps to used oil tank, used oil sludge
pump to sludge holding tank, and discharge from lamella to sanitary
sewer through flow monitoring device, etc.).
Step 2: Fill all oilers for air operated diagram pumps and set pump regulators at
initially 30 psi to start.
Step 3: Calibrate the metering injection pumps, the polyblend units, and the
accurate lime feeder. Generate the dosage charts relating output of
metering equipment to concentration and flow through the system. For
general procedure, see attachment.
Step 4: Adjust set point on Beckman or equivalent pH control unit to 8.0 allow
system to stabilize. To set the Beckman or equivalent pH control unit,
see the manual.
Step 5: Energize the Swaby lift pumps, thereby starting the process effluent
through the wastewater pre-treatment system.

Step 6: Start lime slurry system initial accurate setting 300 indicated on digital
counter on side of accurate feeder.
Step 7: Start lamella sludge transfer pump. The lamella transfer pump pumps
sludge from lamella to the sludge holding tank regulator. The pump
should be set at 30 psi.
Step 8: Start chemical injection metering feed pump at setting to give 50 ppm in
stage #1 Check dosage chart prepared in Step 3 for proper setting. The
flow is obtained from the flow monitoring system.
Step 9: Start polyblend feed system at a setting to give 25-ppm polymer in
wastestream. Check dosage chart prepared in Step 3 for proper
setting. The flow is obtained from the flow monitoring system.
Step 10: When the sludge holding tank is full and overflowing to the trench, start
filter feed pumps to the filter press (start-up instructions for filter press, as
per manual).
Step 11: Start up flow monitoring system by turning power on to the flow monitor.
For start-up of sampler, see instructions in manual.
Upon completion of above, the system is ready to be fine-tuned and operated.
SECTION 2: Fine-tuning of Wastewater Treatment System
Fine-tuning of the wastewater treatment system requires that all components operate
as a single unit, which will generate a treated effluent of a quality, which will meet the
discharge limitations. To assist in the fine-tuning of the system, the following is
provided:
A. To fine-tune the coagulant concentration in the wastewater, the metering injection
pump should be set at 75% rated capacity. After system has reached equilibrium

(approx. 6 hours), the dosage rate should be reduced till the effluent from lamella
clouds: once cloudiness is observed, note settling and increase 15%.
B. To fine-tune the lime slurry feed rate, determine the quantity of fluoride
concentration limit on a monthly average basis required for the discharge into
sanitary sewer. To determine the quantity of fluoride in discharge of lamella, see
procedure outline in Chapter 3. Start optimizing the lime feed rate until the fluoride
concentration is below the monthly average concentration limit mentioned in the
wastewater permit. Leave the lime feeder running about 10%-15% higher than the
optimum value.
To adjust the lime slurry feed; you increase or decrease the amount of lime
delivered to the lime slurry tank through the accurate feeder, which is
accomplished by changing the digital setting on the lime feeder.
C. Fine-tuning of the polymer dosage requires that the settling rate of the floc in the
flocculation tank of the lamella be determined. The optimum settling rate is 300
ml/min. in the flocculation tank. To determine the settling rate, follow procedures
outlined in Chapter 3 of this manual. Adjustments to the polymer are made by
adjusting the polymer feed to the Polyblend unit; the feed is adjusted by varying
the speed and stroke of the LMI pump associated with the unit.
Adjustments to the feed rate shall be made until the desired settling rate is
determined (i.e., 300 ml/min. once the desired settling rate is determined).
D. pH: To determine optimum pH, samples are to be collected and analyzed by the
lab with the results reviewed and optimum pH for treatment selected.
E. Sludge Draw-off Rate: The sludge draw-off rate from the lamella is related to the
state at which the sludge is formed. The optimum sludge draw-off rate is a rate

that will maintain the sludge level in the lamella between the bottom sample drain
and top sample drain.
Upon completion of fine-tuning of the wastewater pretreatment system, a report will be
attached to this manual which will show settings, operating parameters, sludge settling
rate, etc. If a problem develops, the system should be returned to original settings and
Environmental Health & Safety Department should be notified.
SECTION 3: Normal Shutdown and Startup Procedure
The procedure which is to be followed to shut down and restart the wastewater treatment
system, is as follows:
Step 1: Shut off all chemical feed systems.
Step 2: Shut manual valves just prior to acid and caustic Fox Boro valves.
Step 3: When filter press is full, empty solids from the press and do not put back
into service (this needs to be done only if plant will be down more than
48 hours).
Step 4: Turn off all air pumps, i.e., Lamella sludge transfer pumps, filter press
feed pumps and acid or caustic feed pumps.
Step 5: Turn off flash mixer on Lamella.
Step 6: Turn off flocculating mixer on Lamella.
Step 7: Turn off all automatic monitoring equipment.
Step 8: System down.
As will be noted from above Steps, we have not turned off the lift pumps, mixers and pH
Control System. These three are left on as a safety precaution in case the washer develops
any problem. When you get ready to start-up the wastewater treatment system just reverse
steps 1 through 7.

CHAPTER 7
PREVENTIVE MAINTENANCE

CHAPTER 7
PREVENTATIVE MAINTENANCE
To insure continuous and trouble free operation of the wastewater treatment system the
following preventive maintenance needs to be done.
ITEM FREQUENCY ACTION REQUIRED
1. Check oil level in the 1/month If low, fill to correct level

flash mixer. with recommended oil.
2. Check oil level in 1/month If low, fill to correct level

flocculating mixer. with recommended oil.
3. Check oil level in oilers 1/day Fill with recommended oil.

for all air operated
pumps.
4. Clean all pH probes. 2/shift Immerse in 10% solution

muriatic for 30 seconds,
then reinstall.
5. Acid wash filter press. 1/month Press to be taken out of

service and an acid wash
cycle conducted.
6. Calibrate all pH 1/week Follow the calibration

probes. procedure from the
manual.
7. Lamella cleaning. 1/week Pump system down to

minimum. Turn Lamella
sludge transfer pumps up
to maximum discharge
rate when Lamella is
draining. Wash down all
plates. When Lamella is
fully drained, restart
system.
8. Grease Lift pumps. 1/month Grease to manufacturers

recommendation.

9. Mixer vibration. 1/week If mixer has excessive
vibration check mounting
bolts. Tighten if required.
If still vibrates, pull shaft
and clean chemical build
up off the blades.
10. Lime silofilter bags. 1/nine months Replace all filter bags: 4
1/year required.
11. Filter press cloths. 1/quarter Replace all cloths that

show sign of wear and
tear.
12. Filter press plates O 1/year Replace all worn o rings.

rings.

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ARDAGH METAL BEVERAGE USA INC.

BASIC TRAINING MATERIAL FOR

Revised on: 3/26/2010, 6/9/2011, 7/14/2016

one brandone vision 1

CHAPTER 1 REGULATORY REQUIREMENT 3

CHAPTER 2 DESCRIPTION OF WASTEWATER TREATMENT SYSTEM 9

CHAPTER 3 QUALITY CONTROL CHECKS 45

CHAPTER 4 TROUBLE SHOOTING PROCEDURE 58

CHAPTER 5 INSTRUCTIONS FOR WASTEWATER MONITORING 67

CHAPTER 6 STARTUP AND SHUTDOWN PROCEDURES 72

CHAPTER 7 PREVENTIVE MAINTENANCE 77

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Owned Treatment Works (POTW) are as follows:

ALLOWABLE MASS OF POLLUTANTS THAT

POLLUTANT DAILY MAXIUMUM MAXIMUM MONTHLY

mg/M Cans lbs/MM Cans mg/M Cans lbs/MM Cans

required by the control authority to verify compliance.

PSES Pretreatment Standard Existing Source

* Milligrams/1000 cans manufactured (mg/M cans) equals grams/1,000,000 cans

one brandone vision 4

Treatment Works (POTW) are as follows:

ALLOWABLE MASS OF POLUTANTS THAT

POLLUTANT DAILY MAXIMUM MAXIMUM MONTLY

mg/M Cans lbs/MM Cans mg/M Cans lbs/MM Cans

Chromium (Cr) 27.98 0.0617 11.45 0.025

more frequently as required by the control authority.

PSNS Pretreatment Standard New Source

* Milligrams/1000 cans manufactured (mg/M Cans) equals grams/1,000,000 cans

** Total Toxic Organics (TTO) optional

one brandone vision 5

MASS OF POLLUTANT = CONCENTRATION OF x RATE OF FLOW

(mg/M cans) = (mg/l) x (L/M Cans)

OBTAINED FROM ANALYSIS TOTAL FLOW IN

TOTAL (M) CANS

mg/M Cans = g/MM Cans

lbs/MM Cans = g/MM Cans / 454 g/lb

1. A 24-Hour Composite Sample of the effluent is collected. (Composite Sample means

Sample is for the analysis of O&G by Method E.

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sample submitted for analysis.

As an example say the analysis of the sample is:

liters/gallon = 500,000 liters.

was found to be 2000 M cans.

7. The MASS OF POLLUTANTS discharged during the sampling period is calculated by

one brandone vision 7

Cr 0.032 x 250 = 8.00

Cu 0.200 x 250 = 50.00

Zn 0.100 x 250 = 25.00

F 12.000 x 250 = 3000.00

P 1.000 x 250 = 250.00

Mn 0.050 x 250 = 12.50

O&G 2.000 x 250 = 500.00

Standards (DAILY MAXIMUM AND MAXIMUM FOR MONTHLY AVERAGE).

MAXIMUM MONTHLY AVERAGE. In this example, corrective action for reduction of

Flow have an effect on the Mass of Pollutants discharged. The Concentration of

to be kept as low as possible.

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DESCRIPTION OF WASTEWATER TREATMENT SYSTEM

1. TREATMENT OF WASHER EFFLUENT

1. TREATMENT OF WASHER EFFLUENT

The treatment of washer effluent consists of 2 steps: