Operating Philosophy and Control Description for Saudi Aramco Bulk Plants Y00002 and Y00003

By Aaron Bergstreser 11/20/07 FOR INTERNAL USE ONLY

Table of Contents

List of Abbreviations CIP: DO: MC: MLSS: MOS: RAS: TMP: WAS: Clean-In-Place Dissolved Oxygen Maintenance Clean Mixed Liquor Suspended Solids Membrane Operating System Return Activated Sludge Trans Membrane Pressure Waste Activated Sludge

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Introduction Recent advances in membrane separation technology coupled with reduced membrane costs have made Membrane Bioreactors (MBRs) an economically viable wastewater treatment method. As the name implies, MBR technology marries a biological activated sludge process with downstream solids removal using membranes. This treatment method offers several advantages over traditional wastewater treatment system such as reduced footprint and higher effluent quality. In many cases, the effluent from a MBR is suitable for reuse with minimal downstream processing. The Rothschild, WI office of Siemens Water Technologies (SWT) has been contracted by two engineering firms (Saud Consult and Sofcon) to provide MBRs for sanitary wastewater treatment at six sites owned by Saudi Arabian Oil Company (Aramco). Each MBR system is comprised of two 75% treatment trains. Five of the sites have relatively significant lower average daily flows than the sixth site and have thus been termed Small Bulk Plants. These plants are located in Al Hasa, Duba, North Riyadh, Tabuk, and Turaif. The sixth plant is referred to as the Large Bulk Plant and is located in North Jeddah. In an effort to reduce overall project costs, the five Small Bulk Plants share a common system design. Furthermore, the feed concentrations of key contaminants (BOD, TSS, TKN, Ammonia) have been standardized across all of the MBR plants. Although the average daily flows vary from plant to plant and the design loadings vary between the Small Bulk Plants and the Large Bulk Plant, the overall plant design is universal (i.e. same style of equipment and same unit operations). Therefore, the following process description will be general and will apply to all six MBR plants. Process Description Feed System Sanitary wastewater will enter the MBR system battery limits and flow through a screening and grit removal system designed to remove debris and grit from the waste stream that can potentially damage the membranes. Solid material caught in the screen will be automatically conveyed to a dumpster through action of the supplied motor-driven screw conveyor. Grit that has settled in the grit basin will also be removed in a dumpster but will require the opening of a manual valve for grit drainage. De-gritted wastewater then flows to the Equalization/Emergency Sump where both flow and composition are stabilized. Mixing is accomplished by bubbling air through the liquid contents of the sump. Each MBR system is designed to handle four times its average daily flow for a period of one day through a combination of flow through the plant and storage capacity in the Equalization/Emergency Sump. For example, if the average daily flow of influent sanitary wastewater to the treatment plant is 24 m3/day and the total hydraulic capacity of the plant is 48 m3/day, the storage volume in the Equalization and Emergency Sump has to be 48 m3 (this example is taken from the common design basis of the Small Bulk Plants). This storage volume is provided in

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addition to the maximum accumulated volume in the sump due to the site diurnal flow pattern. MBR Feed Pumps transfer wastewater from the Equalization/Emergency Sump to a Splitter Box. Here, flow is divided equally into two streams by overflowing two equallength weirs. Each stream will be directed to separate treatment trains within the MBR treatment plant. A recycle line is also provided on the MBR Feed Pump discharge line for purposes of precise and accurate feed flow control given the common design for the Small Bulk Plants. The goal is to operate the MBR Feed Pumps on a controllable region of their pump curves given the comparatively significant differences in average daily flow rates between the Small Bulk Plants. See the Control Description below for a discussion of the considerations regarding the operation of the automatic recycle valve. Before wastewater is introduced to the biological reactors, it must be screened again to remove fine fibrous particles (i.e. hair) that could not be removed in the upstream screening and grit removal system (coarse vs. fine screen). Perforated plate drum screens are used for this purpose. Wastewater enters the drum screens via gravity flow from the splitter box. Since the splitter box and drum screens are located above the biological reactors, effluent from the drum screens also flows by gravity to downstream treatment equipment. Screened solids from the drum screens are collected in dumpsters for ease of removal. A common dumpster is used for both treatment trains. The drum screens also require a periodic washing to remove any solids that may have plugged the perforated plates. Biological Treatment The biological treatment portion of each train includes an anoxic zone followed by an aeration zone to facilitate both nitrogen removal via nitrification/denitrification and BOD removal. Nitrification is the process of producing nitrate from ammonia while denitrification generates nitrogen gas from nitrate. Both zones are housed in a single cylindrical Anoxic/Aeration Tank and are separated by an internal baffle. Mixed liquor from the anoxic zone flows over the baffle to the aeration zone. Heterotrophic bacteria in the aeration zone provide the bulk of the BOD removal through cellular respiration. Nitrification reactions also occur in the aeration zone through autotrophic bacteria. These processes require free oxygen (O2) which is supplied through the Aeration/MOS Blowers and an in-tank air distribution system. The supply of air through the mixed liquor in the aeration zone also provides mixing to the contents of that zone. Heterotrophic bacteria in the anoxic zone also remove BOD in conjunction with denitrification reactions. Since oxygen in the form of nitrate serves as the oxygen source for denitrification, nitrates that are formed in the aeration zone must be recycled back to the anoxic zone. MOS Feed/Recirculation Pumps are supplied for this purpose. Nitrate is reduced in the process and leaves as N2. The anoxic zone is located ahead of the aeration zone to ensure a sufficient carbon source (BOD) is available to support the

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denitrification reactions. Mixing in the anoxic zone is accomplished using motor driven Anoxic Mixers. Since biological activity and vitality is sensitive to pH, each MBR plant is provided with a pH control system. Sodium hydroxide (20 wt%) and dilute sulfuric acid (20 wt%) are utilized to control pH and are injected at the bottom of the anoxic zone in the Anoxic/Aeration Tank. Control of pH in the anoxic zone will produce a controlled pH in the aeration zone. The anoxic zone will operate between a pH range of 7.5-8.5 (typical). Once outside of this range, the appropriate type and quantity of chemical will be dosed until pH is again within the desired range. Since pH adjustment is a batch operation, pH swings within the desired operating range may be common, depending on the quality of the feed. Foaming is not an uncommon phenomenon in activated sludge processes and can lead to overflowing of the Anoxic/Aeration Tank if not properly managed. A spray nozzle is provided in each Anoxic/Aeration Tank for foam control purposes. The nozzle is fed from a side stream of the anoxic recirculation line, which itself is being fed from the MOS Feed/Recirculation Pumps. With this design, mixed liquor from the aeration zone is being used to control foaming and no additional foam control chemicals are required. Membrane Operating System (MOS) The purpose of the membranes in an MBR system is to separate the suspended solids, consisting of bacteria used for treatment, from the treated water. Membranes are physical barriers which only allow particles of a certain size to pass through. The size of such particles depends upon the nominal pore size of the membrane in use. The style of membranes used in both the Small and Large Bulk Plants are hollow fiber. The membranes are submerged in mixed liquor in atmospheric MOS Tanks, and filtrate passes from the outside of the membranes to the inside (lumens) over a pressure gradient. This pressure gradient is an important operating parameter and is known as TMP (transmembrane pressure). TMP must always be below 50 kPa to avoid membrane damage. Since the MOS Tank is atmospheric, the lumens of the membrane are under vacuum. The magnitude of the required vacuum is dependent upon the extent to which the membranes are fouled. Membrane fouling, therefore, is another important operating parameter and is qualitatively assessed through membrane permeability. Permeability is calculated as membrane flux (l/m2h or LMH) divided by TMP (overall units of l/m2hbar). Permeability varies with TMP and TMP varies with the viscosity of water. Since the viscosity of water varies with temperature, TMP and permeability also vary with temperature. Therefore, operating permeability is adjusted to a standard temperature from which conclusions regarding membrane fouling can be made. The MOS Tanks are fed from the MOS Feed/Recirculation Pumps. Filtrate is drawn through the membranes by means of filtrate pumps, and mixed liquor is returned to the aeration zone via an overflow on the MOS Tank.

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There are several design considerations and operating procedures focused on membrane fouling management. These include providing a reasonable membrane flux, control of solids concentration in the MOS Tank, membrane scouring, relaxation, maintenance clean, and clean-in-place (CIP). The first five devices are used continually in attempts to sustain membrane permeability while the last is used for permeability recovery. Flux is defined as a volume or mass flow rate divided by a unit area. Generally, a low membrane flux produces a longer run time between cleaning. Of course, the term low has to be assessed for the particular wastewater being treated, as different wastewaters have different fouling characteristics. It should also be mentioned that there are two different flux terms. The net flux (whether it be average daily net flux, peak daily net flux, etc.) is simply the net filtrate flow rate divided by membrane area. Conversely, the instantaneous flux is the actual flux of the MBR system due to downtime. In this context, downtime refers to any event causing the Filtrate Pumps to shut off or function at a flow rate lower than the average daily influent flow rate. An example of this is a cleaning procedure where the filtrate pumps are stopped, causing influent flow to accumulate somewhere in the system. Therefore, since the total accumulated flow in a given time period needs to be processed through the system, and since the system is not functional for that entire time period, the filtrate pumps need to operate at a flow rate slightly higher than the average influent flow rate. The instantaneous flux is always larger than the average daily net flux. However, the total supplied membrane area should always be determined by the highest allowable flux. For instance, if a plant has a hydraulic rating that is much larger than the average daily flow rate, the hydraulic flux may be larger than the instantaneous flux. More membrane area may be supplied, but the frequency of the hydraulic flow scenario must also be considered before deciding upon a reasonable membrane area. The Small Bulk Plants were designed with a design net flux of 10.0 l/m2h and the Large Bulk Plant was designed with a design net flux of 14.5 l/m2h. Solids concentration in the MOS Tank also affects the membrane fouling rate. An increase of the solids concentration in the aeration zone directly increases the solids concentration in the MOS Tank since mixed liquor is fed from the former to the latter. Therefore, solids concentration must be controlled in the aeration zone in order to control the solids concentration in the MOS Tank. Bacterial growth and reproduction occur as biological activity for wastewater treatment proceeds. In order for the solids concentration in the aeration zone to remain constant, solids must be wasted from the system. This is accomplished through a wasting line piped from the discharge of the MOS Feed/Recirculation Pumps to the Sludge Holding Tank for further processing. A second method of solids concentration control in the MOS Tank is through operation of the MOS Feed/Recirculation Pumps. The mixed liquor solids in the MOS Tank are continually concentrated as the Filtrate Pumps pull treated water through the membranes.

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Consequently, the MOS Feed/Recirculation Pumps must supply a sufficiently higher flow to the MOS Tanks than the filtrate flow from the MOS Tanks such that the mixed liquor concentration in the MOS Tanks does not exceed a certain value. Of course, this flow rate depends upon the solids concentration in the aeration zone. Typical solids concentrations are 10,000 mg/l in the aeration zone and 12,500 mg/l in the MOS Tank. This gives a typical MOS feed rate of 5 times the filtrate flow rate. The solids concentration in the MOS Tank is allowed to reach 14,500 mg/l during plant peak daily flow events. Another technique used to reduce fouling rates is membrane scouring. Air, supplied from the Aeration/MOS Blowers, is distributed through the membrane modules specifically for scouring purposes. Mixed liquor is also distributed through the modules, but for the specific reason of maintaining an equal flux across all membranes instead of scouring. Nonetheless, distribution of air and mixed liquor in this fashion provides a two phase scouring action. The scouring energy must be vigorous enough to remove bulk solids from membrane surfaces but sufficiently gentle to not damage the membranes. A third method for managing membrane fouling is relaxation. Relaxation is a procedure programmed in the logic controller which shuts down the Filtrate Pumps associated with the MOS Tank undergoing relaxation for one minute. Scouring air and mixed liquor flow to the MOS Tank continues during relaxation to dislodge solids from the membrane surface while the continual pull from the Filtrate Pumps is no longer present. Relaxation occurs once every twelve minutes. Cleaning procedures are performed as a final means of managing membrane fouling. Two types of cleaning procedures are employed for this purpose. A Maintenance Clean (MC) is recommended once or twice per week and utilizes a 300 ppm chlorine solution to remove organic fouling. Flow is directed through the lumens of the membranes and into the MOS Tank. There are two backwash steps during a MC with intermediate relaxation. A complete MC procedure lasts approximately 50 minutes. The second cleaning procedure is termed Clean-In-Place (CIP). Solutions of 1500 ppm chlorine and 2 wt% citric acid can both be used during a CIP, the former used to remove organic fouling while the latter is used to remove inorganic scale. A CIP lasts approximately 5-7 hours per chemical and can be thought of as a permeability recovery procedure rather than a fouling prevention mechanism like a MC. The cleaning solutions are prepared in the MOS Tank which requires initial draining of the mixed liquor in the tank. Valving is arranged such that the filtrate pumps draw the cleaning solution through the membranes and recirculate it back to the MOS Tank. There are a number of intermediate steps associated with a CIP which are detailed in other documents. A CIP is recommended whenever the permeability drops below a certain value or every 3 months, whichever comes first. An important clarification regarding the chlorine concentration specified for the cleaning solution should be made here. The hypochlorite ion (OCl-) actually provides disinfection power in liquid (the hypochlorite ion concentration will be referred to as disinfection

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power in the following discussion). Therefore, any chemical or solution that can provide hypochlorite ions in solution can be used instead of chlorine. It is common to use sodium hypochlorite solutions (bleach) instead of chlorine because of the risks associated with storing and using compressed chlorine gas. Since chlorine was commonly used in the past, a set of vocabulary related to chlorine disinfection has become the vernacular when discussing disinfection. This lexicon has been preserved in the age of hypochlorite solutions. Consequently, the specification of a 1500 ppm chlorine solution during CIP, for example, means that the disinfection power of the cleaning solution should be the same as a 1500 ppm chlorine solution, regardless of what ultimate form of hypochlorite ion is used to make the solution. Continuing with sodium hypochlorite as the common solution used for MBR systems, one mole of sodium hypochlorite has the same disinfecting power as one mole of chlorine. This analysis assumes sodium hypochlorite fully dissociates into the sodium and hypochlorite ions, and that chlorine fully dissociates to HOCl, hydrogen ion, and chlorine ion in water. The latter assumption is based on chlorine equilibrium in water at pH greater than 4, which should always be the case in MBR applications. Once in solution, HOCl establishes equilibrium with hydrogen ion and hypochlorite ion. Therefore, a 1500 ppm chlorine solution produces a specific concentration of hypochlorite ion for disinfection. This hypochlorite concentration is the same if equal molar amounts of chlorine or sodium hypochlorite are added to solution because of the equilibrium between HOCl, hydrogen ion, and hypochlorite ion. As a final point regarding the lexicon that has been established surrounding chlorine disinfection, the listed or advertised concentrations of sodium hypochlorite solutions often times reflect a trade percent available chlorine. For example, a twelve percent sodium hypochlorite solution may actually contain 120 grams per liter of chlorine equivalent disinfection power (120 gpl/1000 gpl [density of water] = 0.12). This solution, then, is approximately 10.76 per cent sodium hypochlorite by weight. This distinction, although technically accurate, has produced little difference in supplied CIP equipment thus far. The recommendation for sodium hypochlorite transfer pumps used during CIP is to dose the required chemical in the MOS Tank in 20-30 minutes. As a quick estimate, one can use the advertised sodium hypochlorite concentration as the weight per cent sodium hypochlorite and assume a 20 minute fill time to size these transfer pumps. In most cases, if not all, using this pump with the more accurate weight per cent sodium hypochlorite will produce a fill time of less than 30 minutes. However, the more accurate calculation should always be used to calculate the sodium hypochlorite metering pumps used during MC as this dosing rate must be matched with the continuous water flow rate used during the backwash (MC cleaning solution is made continuously in-line while CIP cleaning solution is made batch-wise in the MOS Tank before being used). The cleaning philosophy of the Small Bulk Plants and the Large Bulk Plants is that of CIP only. Since all of the plants are treating sanitary wastewater and the net flux rates

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are low, the membrane fouling rate is not anticipated to be high. Sodium Hypochlorite Chemical Feed Pumps are used in conjunction with the Filtrate Pump of the online treatment train to create the cleaning solution in the MOS Tank of the train to be cleaned. Effluent System As mentioned above, the Filtrate Pumps are charged with the task of pulling treated water through the membranes and pumping the filtrate to the final discharge location. Two main considerations when deciding upon a filtrate system are pump type and pump location. It may be that settling on one category dictates the other, but that is not always the case. Two common filtrate pump types used in MBR applications are centrifugal and rotary (gear or lobe). Centrifugal pumps offer an economical advantage over rotary pumps but are often times more restrictive in suction capabilities. Rotary pumps offer the additional advantage of reversing the flow through the pump. This significantly simplifies the piping required to accommodate various membrane cleaning operations. Wet suction lift is an important criterion for the filtrate pumps because these pumps must overcome membrane pressure losses (max 50 kPa), piping pressure losses, and, potentially, elevation lift on the suction side. This is where the physical location of the filtrate pumps becomes important. If the filtrate pump is located above the membranes, not only does a structure need to be provided to support and provide access to the pumps, but the pump must provide enough wet suction lift to overcome the aforementioned losses. A filtrate pump that is located on the ground, on the other hand, can take advantage of the siphon effect as the suction of the pump is at a lower elevation than the membrane filtrate header. Therefore, rotary pumps are a better choice of filtrate pump when located above the MOS Tank. As a further note, the location of the filtrate pump does not have a significant impact on the required total developed head (TDH) of the pump. If the final discharge point is at a lower elevation than the liquid contents of the MOS Tank, the siphon effect will occur on the suction side of the pump if elevated or the discharge side of the pump if at grade. In other words, it takes the same amount of energy to pump from one elevation to any other elevation (ignoring differences that may occur in pipe routing of course). Also, the dry suction lift capability of the chosen filtrate pump has little impact on the selection of the pump. The reason for this is there is an eductor located at the high point of the suction piping. The eductor is used to prime the pump any time it is stopped. A secondary function of the eductor is to provide a temporary solution to vacuum leaks in the filtrate pump suction piping. Such leaks will cause the filtrate pump to gas bind. Prolonged operation with a leaky vacuum system will cause a loss of production and operational headaches. It should be noted that the operation of a grade-located filtrate pump may require additional attention as the extra elbows in the piping act as potential collection points for gas or vapor which could break pump suction. However, leaking eductor isolation valves

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are expected to be more problematic. For this reason, solenoid valves, or any other valves that perform well under vacuum and frequent actuation, are used for this service. Rotary gear pumps were chosen as the Filtrate Pumps for the Small and Large Bulk Plants because the pumps are located above the MOS Tank. The design on the Bulk Plants, however, does not take advantage of the reduced complexity of the filtrate piping required for cleaning. The reason for this is that the original design utilized centrifugal pumps, and the change to rotary gear pumps did not come until the project was well along its schedule. Also, since MC is not provided on the Bulk Plant design, only one line could be removed for piping simplification if desired. A common means of system protection, when utilizing positive displacement pumps, is the supply of relief valves. Relief valves offer the advantages of overpressure protection and overheating protection by providing an open flow path at a given set pressure. Overpressure protection is not a concern for the Bulk Plants because the total pressure that can be developed by the chosen filtrate pumps is less than maximum allowable pressure of the piping and pump casing. Also, the pump motor is protected through the motor control center (MCC). The only failure mechanism associated with these pumps, therefore, is overheating and seizing. Overheating will occur if there is inadequate flow through the pump to carry heat away. A low-low filtrate flow trip function is provided for this purpose instead of relief valves. The reasons for providing a low-low flow trip function for pump protection instead of a relief valve for the Bulk Plants are numerous. The first reason is the failure mechanism of the Filtrate Pumps as discussed above. Second, a VFD is provided on the Filtrate Pumps to adjust pump speed to meet a desired filtrate flow rate. The only way for the pump to experience low flow, other than a mechanical failure of the pump, is through a closure of a downstream block valve. If this happens, the normal flow control scheme will increase pump speed. Given the selected motor horsepower for the Small Bulk Plants, the total differential pressure that can be developed by the pump is approximately 38 psi at the maximum speed (approximately the same for the Large Bulk Plant). This presents a difficulty in designing the inlet and discharge piping for a relief valve to comply with the 3% and 10% (of set pressure) pressure losses, respectively. Third, the suction losses have to be subtracted from 38 psi to determine a set point since this value is given as a developed pressure. This drives the relief valve set point even lower, especially when one considers the maximum pressure drop across the membrane. Finally, with such a low set point, the normal pump discharge pressure may exceed the relief valve set point or be close enough to cause excessive valve chatter. Often times, filtrate is disinfected before leaving the MBR system battery limits as final effluent. In the case of the Small and Large Bulk Plants, disinfection is accomplished through tablet chlorination. Filtrate flows through the Tablet Chlorinator and contacts calcium hypochlorite which dissolves in the liquid. The hypochlorite ion (OCl-) provides

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the disinfecting power. A static mixer is also supplied downstream of the Tablet Chlorinator to ensure proper mixing. The residual chlorine concentration can be varied by adjusting the cap of the Tablet Chlorinator. The initial cap setting will be determined in the field. The Tablet Chlorinators are provided as one operating and one spare to facilitate switch over when the tablet inventory is depleted in the online unit. Switch over will require operator attention as there is no automatic means of detecting when the tablets have been exhausted. Other disinfection methods include UV light and sodium hypochlorite. In the authors experience thus far, disinfection using sodium hypochlorite is by far the most common practice. This method involves the injection of a sodium hypochlorite solution into the filtrate stream. A static mixer is often placed downstream of the injection point but may be disregarded in some installations. This method offers the advantage of utilizing (or partially utilizing) existing equipment as sodium hypochlorite is often used to prepare the chlorinated membrane cleaning solutions described above. Waste Sludge Handling System The waste sludge handling system designed for the Bulk Plants consists of a sludge holding tank and drying beds. Waste activated sludge is directed to the Sludge Holding Tank from the MOS Feed/Recirculation Pumps. The Sludge Holding Tank is an aerated, atmospheric tank with a sludge retention time that satisfies the sludge stabilization requirements of project specification SAES-A-104 (USEPA Class B sludge requirements) prior to sludge dewatering and final disposal. The specific sludge retention time is country/project specific and other countries/projects may have different requirements. Aeration is provided to keep the contents of the tank well mixed and to prevent septic conditions. Essentially, the Sludge Holding Tank functions as an aerated sludge digester. Digested sludge flows by gravity from the Sludge Holding Tank to the Drying Beds for dewatering. To assure the aforementioned sludge stabilization requirements are achieved, discharge from the Sludge Holding Tank will only occur when the liquid level in the tank reaches the 20 + 10 days of wasted volume level and will continue until the 20 day level is reached (approximately 2.5m drained to 1.7m for the Small Bulk Plants and approximately 3.2m drained to 2.1m for the Large Bulk Plant). Draining the Sludge Holding Tank is a manual operation. Free water flows through the Drying Beds, is collected in an under drain, and is returned to the Equalization/Emergency Sump via gravity. The dried sludge is physically scooped from the drying beds and can be used for land application or sent to a landfill. Control Description Equalization/Emergency Sump and Feed Flow Control The purpose of the Equalization/Emergency Sump is to provide a buffering volume for the site diurnal flow patterns and a collection volume to accommodate an emergency

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flow volume, for one day, of four times the average daily flow less the hydraulic capacity of the MBR system. As the influent flow to the MBR system is pumped from the Equalization/Emergency Sump via the MBR Feed Pumps, the forward feed flow control is closely associated with the level control in this sump. The MBR Feed Pumps are supplied as one operating and one spare and will have a remote manual start function. Startup of the operating pump will require a level in the Equalization/Emergency Sump. If at any point the level in the Equalization/Emergency Sump drops below a low-low level, a shutdown signal will be sent to both pumps. Additionally, a fault signal from the operating pump will automatically enable the start of the spare pump, provided the aforementioned level condition is met. The stop function will be a manual operation and will be provided remotely through the DCS. The forward feed flow to the MBR system will be automatically controlled to a user defined set point through use of a flow meter and control valve. When both treatment trains are operating, the set point of the flow controller should be equal to the site average daily flow. The level in the Equalization and Emergency Sump will be allowed to vary between high and low levels, based on the site diurnal flow pattern. The level controller for the Equalization/Emergency Sump will provide a remote set point to the feed flow controller when level eclipses or falls below the level band established by the diurnal flow pattern. As level increases, the remote set point will gradually increase until the hydraulic capacity of the two treatment trains is reached. If level continues to rise, a high-high alarm will be given to alert the operators that system capacity has been reached. As level decreases, the remote set point will gradually decrease in an attempt to prevent a low-low level tripshutdown of the MBR Feed Pumps. If level continues to decrease, the forward flow set point will be set to zero, the automatic block valves upstream of the Drum Screens will close, and the recycle line will open. Forward flow will continue when the Equalization/Emergency Sump level reaches its normal high level. During an automatic shutdown of one treatment train, the forward flow set point will be automatically reduced to the design flow rate of one treatment train if the previous user defined set point exceeded this value. The only automatic shutdown of a treatment train occurs from a high-high level in the aeration zone of the Anoxic/Aeration Tank. Accordingly, the remote set point of the flow controller from the level controller in the Equalization/Emergency Sump will now becontinue to adjusted the remote set point of the flow controller based on the normal flow, design flow, andut will not be allowed to eclipse the hydraulic capacity of one treatment train. A flow recirculation line is also supplied on the MBR Feed Pump discharge line for purposes of accurate and precise forward feed flow control. Since the Small Bulk Plants share a common design and are supplied with the same equipment, and since the average daily flow variation between each plant is comparatively significant, the recycle line is provided so the MBR Feed Pumps will operate on a controllable portion of their pump curves. The normal position of the automatic valve on the recycle line will be site specific. The pump characteristics for the larger flow Small Bulk Plants may be such that

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recycle may not be needed for adequate flow control. For the plants that do require recycle, the valve should normally be open with closure on a low flow measuremently when the feed pump cannot produce the desired forward feed flow. This scheme should not be impacted by the Equalization/Emergency Sump level control of the forward flow set point because the entire flow control scheme will be set up to handle the range of flows from normal to hydraulic capacity. The feed flow and Equalization/Emergency Sump level control schemes should also be customized for each location such that the residence time in the Equalization/Emergency Sump does not cause an appreciable increase in water temperature (i.e. some plants may be run at a lower sump level). The feed flow controller is also active in the anoxic recirculation, MOS feed, and filtrate flow control loops. This interaction will be discussed in more detail during the description of those individual control schemes. Drum Screen Backwashing of the Drum Screens is required whenever the screen openings become plugged with solids. This is accomplished with a controller which opens a solenoid valve on the utility water flush line at regular intervals. Another control shuts the solenoid valve after a flush has occurred for pre-set duration. Automatic block valves are also supplied upstream of the Drum Screens. These valves are used to stop feed flow to the associated treatment train, and may be actuated manually through the DCS or automatically through a high-high aeration zone level trip function or a CIP procedure. Limit switches are also provided on these valves for indication of whether the valve is opened or closed. If one of the valves is closed and the forward feed flow exceeds the capacity of the online filtrate pump, level will build in the online aeration zone which may completely stop feed flow. Aeration/MOS Blowers Air is required to support the biological reactions occurring in the aeration zone and to provide scouring to the membranes to manage fouling. One positive displacement Aeration/MOS Blower is supplied per treatment train to provide air for both functions. A common in-line spare is also provided. The spare blower automatically starts on a fault signal from one of the normally operating blowers. The discharge of the spare blower is piped into the air distribution line of both treatment trains. Automatic block valves, normally used to isolate the spare blower from the air distribution lines of both trains, automatically open to the appropriate treatment train when the spare blower becomes operational. A VFD is supplied with each Aeration/MOS Blower to manage the total air demand for the MBR system. The two processes requiring air have different needs, and a unique air control scheme is in place to handle both requirements. The aeration zone in the Anoxic/Aeration Tank requires enough air for the biology to destroy BOD and nitrify. This air demand varies as the BOD and ammonia load to the system varies. To handle this variable air demand situation, dissolved oxygen (DO)

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control is utilized. The DO probe in the aeration zone measures the concentration of dissolved oxygen in the mixed liquor. A DO controller compares this measurement to a user-defined set point (2 mg/l DO is recommended) and manipulates the travel of the control valve to maintain the set point. Unlike the varying air demand of the aeration zone, the MOS Tank requires a constant scouring air flow rate. Since both services are the responsibility of one centrifugal blower, any fluctuation in air demand in the aeration zone affects the air flow rate to the MOS Tank. Therefore, a flow controller is utilized to maintain a constant air flow to the MOS Tanks. A flow meter in the air line to the MOS Tanks measures the air flow rate and communicates with the flow controller. The flow controller manipulates the VFD on the blowers to maintain flow. A low-low air flow interlock is also utilized to protect the membranes in the event that scouring air cannot be delivered to the MOS Tank. Under this scenario, the block valve on the mixed liquor feed line to the MOS Tank is automatically closed and the filtrate pumps are tripped for the individual train experiencing the condition. Certain steps in the CIP procedure requires air flow to the MOS Tank to be stopped. During these times, the block valve on the air line to the MOS Tank undergoing CIP is automatically closed. To maintain proper air flow to the associated aeration zone, the control valve is locked in a predetermined position through a DCS stopits last position and the signal from the DO controller manipulates the VFD on the associated blower. Operation in this manner will also prevent a blower relief event. Sludge Tank/Equalization Sump Blowers Air is supplied to the Sludge Holding Tank and Equalization/Emergency Sump for the purpose of mixing. Individual positive displacement blowers are provided for each service. A common spare blower is also provided. The automatic start of the spare blower and the operation of the automatic discharge block valves are enacted exactly the same as those for the spare Aeration/MOS Blower. In fact, the automatic start of any spare equipment follows the same philosophy. When the spare equipment is not connected to two lines, automatic block valves are not used. Rather, check valves are relied upon to prevent flow in the reverse direction. Since the purpose of these blowers is to provide mixing, no control logic is required. The blowers have been sized to provide adequate mixing for the maximum liquid volumes of the Sludge Holding Tank and Equalization/Emergency Sump. Manual motor speed adjustment will be required if less mixing air is desired. pH Control Sodium hydroxide and sulfuric acid chemical feed packages are supplied to control system pH. Each chemical feed package consists of a day tank and individual dosing pumps for each treatment train with a common spare. The day tanks will be equipped with level instruments and a low-low level trip of the dosing pumps for equipment protection.

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The pH probes in the anoxic zone of the Anoxic/Aeration Tanks continually monitor system pH. When the pH falls outside of a predetermined range, the pH controller will automatically start the Caustic Dosing Pump or Acid Dosing Pump associated with the treatment train experiencing a low or high pH, respectively. To avoid on/off cycling of the dosing pumps, chemical will be continually injected until the pH reaches the opposite limit of the initial fault (i.e. if the pH is low, caustic will be dosed until the pH reaches the high limit of the operating range). Anoxic/Aeration Tanks The biological processes used for wastewater treatment occur in the Anoxic/Aeration Tanks. Any measures not described above for controlling biological treatment will therefore be described here. This includes control of the anoxic recirculation rate, the MOS feed rate, and control of mixed liquor wasting. Equipment and instruments used in overall system control functions not directly associated with biological treatment but physically located near or on the Anoxic/Aeration Tanks are also described here. This includes the MOS feed rate, control of mixed liquor wasting, level control and trip functions, and temperature measurements for permeability alarms. Control of the recirculation rate from the aeration zone to the anoxic zone is important for nitrogen removal purposes. Control of the MOS feed flow is important for managing the fouling rate of the membranes. Both flows are produced from the MOS Feed/Recirc Pumps (supplied as one operating and one spare) and are controlled in a similar fashion. The operator defines a set point for each flow rate as a ratio to the influent flow rate. Flow meters are used in each line to measure actual flow and communicate with the associated flow controllers. The influent flow meter also communicates with each flow controller, which creates an actual set point in flow based on the user-defined input ratio. The position of the flow control valves is manipulated based on the deviation between the actual flow rate and the set point. The amount of waste activated sludge (WAS) is controlled to manage the MLSS concentration in the Anoxic/Aeration Tanks. If the biomass concentration is too low, the MBR system may not reach its treatment objectives. If the MLSS concentration is too high, the MOS Tanks will experience operational problems (see Process Description above for more details). The control scheme surrounding wasting is fairly simple and consists of an automatic valve and a flow totalizer. The operator will define how often the automatic wasting valve will open and the amount of flow to waste per event. The automatic valve opens at the start of each interval and will close when the defined volume, as measure by the flow totalizer, is wasted. A level transmitter and controller is also utilized on the Sludge Holding to prohibit the wasting valve from opening if the level in the Sludge Holding Tank is too high. Level in the Anoxic/Aeration Tank also plays a role in the operation of the filtrate pumps. If the total daily filtrate volume does not match the total daily influent volume, level in the Anoxic/Aeration Tank will increase or decrease. Tank level is, however, expected to

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slightly increase due to the fact that the filtrate pumps will not be operating during relaxation and during some steps in the CIP procedure. Therefore, level control of the filtrate pumps will be enabled when the level is outside a defined band. This band will be determined during startup. It should also be mentioned that level control of the filtrate pumps in this fashion is a secondary measure to control system volume. The primary measure is described below in the discussion concerning the filtrate pumps. A high-high level trip function is also utilized to prevent an overflow event. As described above, the high-high level trip function will act to shut the automatic block valves upstream of the Drum Screens. This will prevent flow from entering the treatment train experiencing the high-high level. Recall that the influent flow rate is also automatically adjusted to accommodate the unaffected treatment train. The remaining equipment associated with the affected train will continue to function and will thus require manual shutdown in the event that system repairs are required or maintenance of system volume is required. The VFD associated with the affected filtrate pumps will, however, eventually ramp motor speed to the minimum from the Anoxic/Aeration Tank level control function. If level continues to drop, the low-low level trip function will activate a trip of the MOS Feed/Recirc Pumps and Anoxic Mixer motor. Finally, temperature is measure in the Anoxic/Aeration Tank for the calculation of membrane permeability. The viscosity of water is dependent on temperature and the pressure drop across the membranes is dependent on mixed liquor viscosity. In order to account for these effects, the permeability calculation must be temperature corrected to a standard temperature (20 C) before a decision to perform a CIP is made. A further discussion of membrane permeability can be found below under the MOS Tank control description. MOS Tanks The two most important operating parameters for the membranes in an MBR system are trans-membrane pressure (TMP) and permeability. TMP is a measurement of the pressure drop across the membranes. If TMP becomes too high, membrane damage will occur. The maximum TMP allowed during filtration and backwashing is 50 kPa (7.25 psi) and 100 kPa (14.5 psi) respectively. Recall that backwashing only occurs during MC and the maximum TMP is only listed here for completeness. TMP is measured through a comparison between the pressure measurements of the pressure transmitter located at the bottom of the MOS Tank and the pressure transmitter located in the suction line of the filtrate pumps. A high-high TMP shutdown function is provided to trip the Filtrate Pumps for membrane protection. Membrane permeability is defined as the flux (volume flow per unit area, l/m2h or LMH) per unit TMP (permeability units are flux/P). Permeability is continually measured in the DCS as an indication of membrane fouling. As the membranes foul, either flux will be constant with a higher TMP or flux will be lower with the same TMP. A low permeability alarm is provided to alert operators of the need for a CIP procedure.

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Operator action is required to initiate the CIP procedure which proceeds completely automatically. The inputs to the permeability calculation are filtrate flow rate and temperature. Filtrate flow rate is measured by the flow meter downstream of the associated filtrate pump of a given MOS Tank. The temperature measurement from the aeration zone is used to correct the permeability measurement at the operating temperature to that at a standard temperature (typically 20 C). This is necessary because the pressure drop through the membranes decreases with increasing temperature due to a decrease in water viscosity. Therefore, the pressure drop through the membranes at 35 C may be low enough to produce an actual (uncorrected) permeability that does not alarm a CIP at face value. However, this may be a false representation of membrane fouling because the decrease in pressure drop due to the increased temperature may be masking any increases in pressure drop due to fouling. Since the clean membrane permeability criteria are defined at 20 C, a temperature adjustment of permeability is necessary. Clean-In-Place (CIP) Procedure Saudi Aramcos operating philosophy is complete automation. For this reason, several automatic valves are provided where manual valves would normally be used for a semiautomated CIP procedure. In an effort to facilitate a comprehensible discussion of the CIP procedure for both the Small Bulk Plants and the Large Bulk Plant, and for a CIP procedure in general, a list of definitions is given below. The description of which automatic valves open or close during the various steps of the CIP procedure will reference the following definitions. MOS Tank Fill Line: The line from the online filtrate pumps to the MOS Tank undergoing CIP. Sodium hypochlorite is also dosed in this line. MOS Tank Recirculation Line: The line from the filtrate pumps associated with the MOS Tank undergoing CIP through which the cleaning solution is recirculated. This line is piped into the MOS Tank fill line. Mixed Liquor Feed Line: The discharge line from the MOS Feed Pumps of the aeration zone associated with the MOS Tank in question. This line supplies mixed liquor from the aeration zone to the MOS Tank for solids separation. MOS Tank Air Line: The discharge line from the Aeration/MOS Blowers associated with the MOS Tank in question. This line provides scouring air to the membranes. MOS Tank Drain Line: The drain line for the MOS Tank in question. Operating Filtrate Pump: The filtrate pump associated with the treatment train that is not undergoing CIP. Normal Discharge Line: The discharge line of the filtrate pumps that directs filtrate towards the Tablet Chlorinators and the final discharge point.

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The following list describes the steps involved in the CIP procedure with explanation of the control functions required to enact each step. A CIP procedure is initiated through the DCS by operator action. The control system will cycle through the steps described below and the CIP procedure status will be displayed on the control screen. Chemical: Sodium Hypochlorite Chemical Concentration: 1500ppm chlorine Chemical Recirculation flowrate: 568L/hr (2.5 gpm) per module - a flux rate of 15 lmh or the lowest flow achievable by the pump. Frequency: 3 months Duration: 5-7 hours Procedure: 1. Stop the Filtrate Pump associated with the MOS Tank being cleaned. Drain Tank stop blower when 1/3 of the module is exposed. Upon operator initiation of the CIP sequence, the automatic valve upstream of the Drum Screen associated with the affected treatment train will close. This will cause the forward feed flow set point to automatically adjust to the design flow of the online treatment train (see description in Equalization/Emergency Sump and Feed Flow Control section above). Simultaneously, the Filtrate Pump associated with the MOS Tank being cleaned will automatically stop. Then, the automatic valves on the Normal Discharge Line of this filtrate pump and on the Mixed Liquor Feed Line will also close. The mixed liquor feed flow control set point will be automatically set to zero. The MOS Tank will then be drained by opening the automatic valve on the MOS Tank Drain Line. The level controller on the MOS Tank will shut the automatic block valve on the MOS Tank Air Line when 1/3 of the module is exposed. Recall that when the block valve on the MOS Tank Air Line is closed, the blower VFD is manipulated from the DO signal in the appropriate aeration zone instead of the flow meter in the MOS Tank Air Line. 2. Start ML feed pump with the membrane tank drain open. Run for 2 minutes to allow sludge on the bottom of the tank to be removed. The automatic valve on the Mixed Liquor Feed Line will open and the set point of the mixed liquor feed flow controller will reset to its previous value. A timer will close this automatic valve after two minutes and will again set the mixed liquor feed flow controller set point to zero. 3. Drain tank and close membrane tank drain. The automatic valve on the MOS Tank Drain line should still be open at this point and

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will close when the level controller on the MOS Tank indicates an empty tank. 4. Fill tank with filtrate, start blower when 1/3 of module is exposed. Fill to level of headers. Aerate for 30 mins. The MOS Tank will be filled with filtrate from the Operating Filtrate Pump. The automatic valve on the MOS Tank Fill Line will be opened as the automatic valve on the Normal Discharge Line of the Operating Filtrate Pump is closed. When 1/3 of the module is exposed, as determined by the level controller on the MOS Tank, the automatic valve on the MOS Tank Air Line will be opened. Similarly, the level controller on the MOS Tank will determine when the tank is filled to the level of the headers. At this point, the automatic valve on the MOS Tank Fill Line will be closed while the automatic valve on the Normal Discharge Line of the Operating Filtrate Pump is opened. 5. Drain tank stop blower when 1/3 of the module is exposed. After 30 minutes of aeration, a timer will open the automatic valve on the MOS Tank Drain Line. The level controller on the MOS Tank will again initiate the closure of the automatic valve on the MOS Tank Air Line when 1/3 of the membrane module is exposed. This controller will also close the automatic valve on the MOS Tank Drain Line when the tank is empty. 6. Fill with chemical solution to set point level just above the top of the module. After the MOS Tank is completely drained, the automatic valve on the MOS Tank Fill Line will open while the automatic valve on the Normal Discharge Line of the Operating Filtrate Pump closes. The Sodium Hypochlorite Chemical Feed Pumps will start after these valves are appropriately positioned and will operate for a pre-set period of time (determined during start up). The appropriate amount of chemical should be dosed in the MOS Tank before the tank is filled to the top of the membrane modules. Therefore, the level controller on the MOS Tank will open the automatic valve on the Normal Discharge Line of the Operating Filtrate Pump and close the automatic valve on the MOS Tank Fill Line when this level is reached. Ensuring that the Operating Filtrate Pump runs longer than the Sodium Hypochlorite Chemical Feed Pumps provides a flush to the MOS Tank Fill Line. 7. Filtrate Recirculation with filtrate pump - 568L/hr (2.5 gpm) per module or the lowest flow achievable by the pump for 20 minutes. After the level mentioned in the previous step is reached, the automatic valve on the MOS Tank Recirculation Line Internal Use Only Page 20 6/30/2011

will open and the Filtrate Pump associated with the MOS Tank undergoing CIP will be started. The flow rate of this filtrate pump will be controlled to the aforementioned flow rates through the filtrate pump flow controller (set point will be automatically adjusted to the above flow rate). After 20 minutes, the Filtrate Pump will again be stopped. 8. Soak for a. 3 hours if T > 10 C b. 5 hours if T < 10 C 9. Air Pulse during soak stage a. Chlorine CIP: 30 secs on / 15 mins off. The air pulse is achieved by opening and closing the automatic valve on the MOS Tank Air Line. A timer controls the opening and closing of this valve based on the previously mentioned schedule. During this step, the blower VFD will still be controlled by the DO signal in the aeration zone. b. Citric CIP (NOT USED FOR THIS APPLICATION): 15 mins on / 15 mins off: air pulse is achieved by opening the valve for that tank and having the blower run for the 15 min period. 10. Drain tank. After the last 15 minutes of the air-pulsed soaking step, the automatic valve on the MOS Tank Drain Line is opened. This valve will close when the level controller senses an empty MOS Tank. 11. Refill with mixed liquor start blower when 1/3 of the module is exposed. After the MOS Tank has been completely drained, the automatic valve on the Mixed Liquor Feed Line will open and the set point of the mixed liquor feed flow controller will be adjusted based on the feed flow to the online treatment train as if the treatment train undergoing CIP was the only online train. 12. Relaxation: 15 mins with aeration and mixed liquor feed pump running. The MOS Feed/Recirc Pump is now providing its normal feed flow the MOS Tank. During this step, the automatic valve on the MOS Tank Air Line will open to provide scouring air to the membranes. The Filtrate Pump remains off and the MOS Tank will operate in this relaxation mode for 15 minutes. 13. Prime filtrate suction line with priming eductor. After 15 minutes of relaxation, the CIP sequence will open the solenoid valves on the eductor suction line and the eductor motive fluid line. These valves will be closed when the level sensor in the eductor suction

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line senses a liquid level. This indicates that the Filtrate Pump suction line is primed. 14. Filtrate Recirculation: recirculation filtrate back to the membrane tank for 10 minutes for chemical flush and turbidity spikes (TURBIDIMETER NOT PROVIDED IN THIS APPLICATION). The automatic valve on the Normal Discharge Line of the Filtrate Pump undergoing CIP should already be closed from step 1. Similarly, the automatic valve on the MOS Tank Recirculation Line should already be open from step 7. After the level sensor in the eductor suction has measured a liquid level and closed the valves on the eductor lines, the Filtrate Pump of the MOS Tank undergoing cleaning will be started. Recirculation of filtrate back to the MOS Tank will occur for 10 minutes. The VFD on this Filtrate Pump will now be manipulated by the forward feed flow to the online treatment train as if the treatment train undergoing CIP was the only online train (now the Filtrate Pump flow rate should be in sync with the mixed liquor feed flow, much like in normal operation). 15. Open the isolation valve for turbidity meter (NOT IN THIS APPLICATION), start in normal filtration. After 10 minutes of filtrate recirculation, the automatic valve on the Normal Discharge Line of the Filtrate Pump associated with the MOS Tank undergoing cleaning will open. The automatic valve on the MOS Tank Recirculation Line will also shut at this point. This marks the end of the CIP sequence and the entire MBR system will operate as in normal filtration. The automatic valve upstream of the Drum Screen will open and forward feed flow controls will be adjusted for two online trains (feed flow set point will reset to the user-defined set point previously applied). The Filtrate Pumps of both trains will also operate in their normal ratio control to the total forward feed flow (flow per Filtrate Pump should be half of the total forward feed flow). Clean-in-Place Permeability - Warning for CIP at 100 lmh/bar (4.12 gfd/psi) - Shutdown at 60 lmh/bar. (2.47 gfd/psi) - Clean return at 200 lmh/bar. (8.24 gfd/psi) Maintenance Clean (MC) Procedure Even though MC is not provided on the Small Bulk Plants or the Large Bulk Plant (due to small size, low membrane flux, and the fact that the wastewater feed is sanitary waste), the procedures for a MC are outlined here for completeness. However, no control commentary is given as this procedure does not apply to this application. Internal Use Only Page 22 6/30/2011

Chemical: Sodium Hypochlorite Chemical Concentration: 300ppm Chemical Backwash flowrate: 568L/hr (2.5 gpm) per module - a flux rate of 15 lmh Frequency: 7 days Duration: 50 minutes total. Procedure 1. Stop Filtration: optional to have ML feed pump off, aeration continues. 2. First Backwash: a. 1 minute line prime: Chemical pump and filtrate pump operating b. 4 minutes chemical backwash: continue with pumps running at required flowrates. 3. Relaxation: 10 mins, optional to have ML feed pump off. 4. Second Backwash: a. 1 minute line prime: Chemical pump and filtrate pump operating b. 4 minutes chemical backwash: continue with pumps running at required flowrates c. minute line flush: chemical dosing pump stops and filtrate is allowed to flush out residual chlorine. 5. Relaxation: 10 mins, optional to have ML feed pump off. 6. Prime filtrate suction line with priming eductor. 7. Filtrate Recirculation: recirculation filtrate back to the membrane tank for 10 minutes for chemical flush and turbidity spikes. 8. Open the isolation valve for turbidity meter, start in normal filtration. Filtrate Pumps The Filtrate Pumps are supplied as one operating and one inline spare with automatic switchover to the spare pump on a fault signal from the operating pump. Filtrate flow rate is automatically controlled as a ratio to the MBR system feed flow through manipulation of a VFD. A signal from the downstream flow meter is also an input in the controller which manipulates the VFD in order to ensure the correct flow rate is achieved. The purpose of this ratio control is to actively manage liquid level in the system. Since Internal Use Only Page 23 6/30/2011

the Filtrate Pumps are routinely stopped for relaxation, CIP, etc., the time available for pumping filtrate from the system is less than the time over which wastewater enters the system. In other words, to prevent accumulation of water, the same volume must be pumped out during a shorter time period. The user-defined ratio used in this control scheme can only be changed by operator action. The overall control ratio, on the other hand, is automatically adjusted based on the number of online treatment trains. Recall that one treatment train is considered offline when the block valve upstream of the Drum Screen associated with that train is closed. For instance, during normal operation when two treatment trains are operating, the input control ratio is multiplied by one-half to determine the required flow rate for each filtrate pump. When one treatment train is operating, the input control ratio is not adjusted and only functions on one filtrate pump. Several scenarios which cause the block valve upstream of the Drum Screen to close have been addressed above. Another scenario causing the closure of this valve is the lack of a run signal from the Filtrate Pump. Valve closure cannot be immediate, however, because of the automatic switchover to the spare Filtrate Pump. The exact value of the user-defined ratio must be determined after a CIP frequency has been established. However, since the relaxation step accounts for the majority of system downtime, the ratio can initially be set at 13/12 (operate for 12 minutes, relax for 1 minute). In fact, the 13/12 ratio may be adequate given the other controls provided on this system. The ratio control described above is the primary means of controlling liquid level in the system. The secondary means is level control from the aeration zone described in the Anoxic/Aeration Tanks section above. This secondary control is used in the event the operator-defined ratio is not exactly correct, and to conform to Saudi Aramcos philosophy of fully automatic operation with little operator action. The range over which this level controller acts is relatively small. In all of the Bulk Plants, the normal liquid level in the aeration zone is one half foot lower than the overflow weir separating the anoxic zone from the aeration zone. Also, 3 feet of freeboard is provided in the anoxic zone. Therefore, the level control of the filtrate pumps will be enabled when the level in the aeration zone approaches the level of the overflow weir (operator input for exact height) and will continue over the remainder of the total tank height. Membrane relaxation, as mentioned above, is a regular maintenance procedure initiated by the control system for the purpose of managing membrane fouling. During relaxation, the Filtrate Pumps are shut off while mixed liquor and scouring air continue to flow past the membranes. Relaxation occurs once every twelve minutes for one minute. Since relaxation is a regular maintenance procedure initiated by the control system and lasting one minute, the block valve upstream of the Drum Screen will not close due to the lack of the Filtrate Pump run signal during relaxation.

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Since the filtrate piping is elevated above the normal liquid level in the MOS Tank, the Filtrate Pump suction piping is not necessarily flooded after pump shutoff. Therefore, a pump priming sequence must be initiated before the Filtrate Pumps are restarted. In some cases, such as after certain steps in the CIP or after relaxation, the Filtrate Pumps are automatically primed. In other instances, such as an operator-initiated shutdown of the Filtrate Pumps, the priming sequence must be started by an operator through the DCS. The priming sequence involves the opening of the automatic valve on the eductor suction line followed by the opening of the automatic valve on the eductor motive fluid line (instrument air in the case of the Bulk Plants). The eductor will pull filtrate through the membranes and into the suction piping of the Filtrate Pumps. A level sensor in the eductor suction line senses when the piping is liquid-filled. At this point, the block valves on the eductor suction and motive fluid lines are closed and the Filtrate Pumps are allowed to start. A number of Filtrate Pump trip functions are provided in order to protect equipment. One such function utilized for membrane protection is the high-high TMP trip discussed in the MOS Tanks Section above. Another Filtrate Pump trip function utilized for membrane protection is the low-low scouring air trip. Unlike the high-high TMP trip function which protects against physical fiber damage, the low-low scouring air trip protects against excessive (and possibly irreversible) fouling. Two additional trip functions, provided for Filtrate Pump protection, include a low-low MOS Tank level trip function and a low-low filtrate flow trip function. The low-low MOS Tank level trip offers protection against cavitation due to low net positive suction head whereas the low-low filtrate flow trip affords protection against overheating and seizing. The reasons for providing a low-low filtrate flow trip instead of a relief valve for pump protection are outlined in the Effluent System section of the Process Description above. The Filtrate Pumps will also be shutdown on the lack of a MBR Feed Pump run signal to prevent a low-low MOS Tank level and an excessive solids concentration in the MOS Tank. Sodium Hypochlorite Chemical Feed Package The Sodium Hypochlorite Chemical Feed Package consists of a 100 liter storage tank and two Chemical Feed Pumps (one operating, one spare). Automatic switchover to the spare pump is provided and occurs on a fault signal from the operating pump. A low-low Sodium Hypochlorite Chemical Feed Tank level trip of the Chemical Feed Pumps is also provided for pump protection. The Chemical Feed Pumps are used to supply chlorine to the MOS Tank during a CIP. Therefore, these pumps are automatically started and stopped through the CIP control sequence (as described in the CIP Procedure above). In the event that the MOS Tank is filled faster than expected, the level controller on the MOS Tank signals a shutdown of these pumps.

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