AM-PRO-WWT-WWT 4.6 Activated Sludge-SEC3 Issue 1.1

THAMES WATER Asset Management
Internal Company and Partners Asset Standards

Technical Lead: Colin Pickersgill Issue 1.1
AM-PRO-WWT-WWT 4.6 Activated Sludge-SEC3 Page 1 of 26
UNCONTROLLED WHEN PRINTED

Asset Management
Asset Standard
Section 3 of 5
Operating Standard

Wastewater Non Infrastructure
WWT 4.6 Activated Sludge

Document Reference AM-PRO-WWT-WWT 4.6 Activated Sludge-SEC3
Version Issue 1.1
Data Owner Sarah Shipsey
Data Steward Kevin Kelleher
Technical Lead Colin Pickersgill
Document Author Tim Wheatley
Authorised by Asset Standards
Document Location AM Lotus Notes Best Practice Database on LNAPP01
Date of Issue December 2012
Reason for Issue Conversion and validation of old BOP into new Standard format
Next Review December 2014



3.0 Operating Standard..................................................................................................................... 3
3.1 Activated Sludge Performance Measures............................................................................... 3
3.2 Operator Activities ................................................................................................................... 6
3.2.1 Process Checklist Diffused Air...................................................................................... 6
3.2.2 Process Checklist Surface Aeration.............................................................................. 7
3.2.3 Process Checklist Package Plant ASP ......................................................................... 8
3.2.3 Process Checklist KEY.................................................................................................. 9
3.2.4 Process Checklist Notes .................................................................................................. 9
3.3 Troubleshooting Guide.......................................................................................................... 10
Appendices .......................................................................................................................................... 13
3.4 Notes for Operation and Control............................................................................................ 13
3.4.1 Activated Sludge Process Efficiency.............................................................................. 13
3.4.2 Impact of Poor Operation of Activated Sludge Process................................................. 14
3.4.3 Settlement Problems...................................................................................................... 15
3.4.4 Filamentous Outbreaks .................................................................................................. 15
3.4.5 Activated Sludge Process Control.................................................................................. 17
3.4.6 Contingency Planning.................................................................................................... 18
3.4.7 Plant Release / Taking out of and Bringing into service ................................................ 19
3.5 Performance Factors............................................................................................................. 22
3.5.1 Calculations.................................................................................................................... 22
3.6 Health and Safety.................................................................................................................. 26
Glossary of Terms................................................................................................................................ 26



3.0 Operating Standard

This document defines the Performance Measures for the Activated Sludge Process together with
key operator activities, and a troubleshooting guide. Background information on the Activated Sludge
process with types of plant together details of the Waiver and Asset Risk Certificates (ARCs),
processes is detailed in Section 1.

3.1 Activated Sludge Performance Measures

Measure Why Frequency Method of
Collection
Aeration
Plant Feed
Sewage

Determination of the aeration plant feed sewage
BOD, allowing calculation of organic loading and
the F:M ratio. This provides an understanding of
current plant performance.
Works PE
<1000
>1000
<5000
5,000 - 25,000
25,000-100,000
100,000-250,000
250,000-1,000,000
>1,000,000

6 monthly
Quarterly
Quarterly
Quarterly
Monthly
Monthly
Weekly
Weekly

Sampling /
Laboratory
Analysis
Aeration
Plant Feed
Sewage
Flow
Settled Sewage Flow required for Process
Calculations.
Continuous SCADA,
Onsite flow
reading, Daily
log
MLSS
MLSS must be maintained within the
recommended range for the site to ensure BOD
and ammonia compliance and to avoid excessive
costs in the aeration of unnecessarily high MLSS
concentrations.
<1000
>1000

1 x week
3 x week
Fixed or
Portable
Meter, On site
workstation,
Laboratory
RASS To ensure sufficient concentration of biomass is
returned to the aeration lane(s) to maintain
treatment. It is also required to calculate SSVI to
optimise performance.
<1000 -1 x week
>1000 -3 x week
Fixed or
Portable
Meter, On site
workstation,
Laboratory
SSVI To quantify the settling characteristics of the
activated sludge. The SSVI gives an indication of
the ease with which the mixed liquors will settle in
the final settlement tank, (FST), so that
performance of the FSTs can be optimised.
<1000 - 1 x
week
>1000 -
3 x week
On site
workstation


Collection
F:M Ratio This is the ratio between the feed sewage BOD
and the concentration of the mixed liquor
suspended solids (MLSS). This ratio is key in
setting the optimal conditions for treatment. Both
too high and too low an F:M ratio will result in loss
of treatment and the growth of filamentous micro-
organisms affecting performance and compliance.
Annually Process
Calculation
Off Gas
Test
To measure efficiency of aeration and
performance of domes. Used to highlight
deterioration in performance of domes.
Process Test
and
Calculation
Sludge
Age
Sludge age provides an indication of whether or
not effective nitrification is likely to occur in the
aeration lanes. Too long a sludge age will result in
excessive oxygen requirements (high MLSS),
increased power usage and the growth of
filamentous micro-organisms affecting sludge
settlement in the FSTs.
Too low a sludge age will result in poor nitrification
rates.
Quarterly Process
Calculation
Dissolved
Oxygen
Control of Dissolved Oxygen (DO) concentration
in the aeration lanes is necessary to ensure that
over-aeration (incurring increased costs), or
under-aeration (loss of nitrification, loss of
treatment and compliance failure), does not take
place.
Package Plant PE
<1000
>1000
Continuous

1 x week
5 x week (Note 1,
Note 2)
SCADA, Fixed
or Portable
Probe(s)
Hydraulic
Retention
Time
The hydraulic retention time is the length of time
that the mixed liquor actually spends in the
aeration lane. Typically it should be above 4 hours
but the ideal figure varies for different tank
configurations. A reduction in the retention period
occurs for example during periods of peak flow of
when RAS rates are increased. Retention times
within process design limits will ensure robust
plant performance and compliance.
Annually Process
Calculation
Filamento
us ID
To provide an understanding of the level and
types of filamentous micro-organisms present in
the mixed liquor. Evidence of high levels will result
in poor settlement in the FSTs and ultimately
sludge blanket loss resulting in compliance failure.
Monthly Laboratory
Analysis


Collection
RAS Rate Control of RAS rate to ensure sufficient
concentration of biomass in the aeration tanks to
provide robust treatment and compliance.
Adequate return rates will cater for appropriate
levels of thickening in the Final Settlement Tanks
ensuring optimum performance.
Package Plant PE
<1000
>1000
Continuous

1 x week
5 x week (Note 1)
RAS Pump
Control.
SCADA,
MLSS / RASS
concentration.
SAS Rate Control of Surplus Activated Sludge Rates: The
amount of solids wasted from the system will
determine the amount of solids retained in the
system and therefore the sludge age. Sludge age
is an important factor in optimising treatment and
costs, controlling nitrification (low sludge age),
and the growth of filamentous micro-organisms.
Package Plant PE
<1000
>1000
Continuous

1 x week
5 x week (Note 1)
SAS Pump
Control.
SCADA
FST
Blanket
Level
Control of Sludge Blanket levels ensures that
gross solids are not lost or discharged in the final
effluent.
Package Plant PE
<1000
>1000
Daily or
Continuous

1 x week
5 x week (Note 1)
SCADA, Fixed
or Portable
Blanket
Detectors.
Energy Control of aeration costs.

Package Plant Log kW Hours
PE <1000
PE >1000
Continuous

1 x week
5 x week (Note 1)
SCADA, Sub-
metering

Note 1: Performance measure may be completed per visit where site visit frequencies are less than 5
times per week,
Note 2: DO concentration is likely to be continuously measured for all plants.
rs Asset Standards

Internal Company and Partne

3.2 Operator Activities
3.2.1 Process Checklist Diffused Air
Any of the following checks that result in faulty operation needs to be logged and reported for maintenance / repair
Task Low PE
(10-1000)
Med PE
(1000-20,000)
High PE
(20,000-350,000)
Manned
(350,000+)
Activated Sludge - Diffused Air - Check and record Sludge Return From The Final Settlement Tanks N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check and record Bubble Pattern And Size Of The Bubbles N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check and The Blowers For Normal Operation N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check Air Filters Indicators For Normal Readings N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check Flow Distribution To Aeration Lanes If More Than One Lane
Present
N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check and record Rate And Frequency Of SAS Removal N/A OP/1W/2D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Check Mixers For Rotation in Anoxic (Un-Aerated) Zones N/A OP/1W OP/1W OP/1W
Activated Sludge - Diffused Air - Check Recycle Pumps Are Running, As Required (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Diffused Air - Check VFA / Liquor Return (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Diffused Air - Sample And Check Calibration Of MLSS Meter, If Fitted N/A OP/1M OP/1M OP/1M
Activated Sludge - Diffused Air - Check and record Dissolved Oxygen (DO) Readings, Where Probes Are
Installed
Activated Sludge - Diffused Air - Check DO Probe And/Or Timers Are Carrying Out The Correct Control
Functions
Activated Sludge - Diffused Air - Check Redox Monitor Is Operating Correctly (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Diffused Air - Withdraw The DO Probe From The Tank And Remove Clean N/A OP/1W OP/1W OP/1W
Activated Sludge - Diffused Air - Vent Condensate From Air Lines N/A OP/1W OP/1W OP/1W
Activated Sludge - Diffused Air - Sample, Measure And Record MLSS/RASS Concentration And Sludge
Settle Ability (SSVI)
N/A OP/1W OP/1W/3D OP/1W/3D
Activated Sludge - Diffused Air - Log KWh N/A OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Log Flows (Where Meters Are Fitted) N/A OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Log SAS Rate N/A OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Diffused Air - Log Changes To RAS Rate N/A OP/1W/5D OP/1W/5D OP/1W/7D


3.2.2

Process Checklist Surface Aeration
Task Low Pe
(10-1000)
Med Pe
(1000-20,000)
High Pe
(20,000-350,000)
Manned
(350,000+)
Activated Sludge - Surface Aeration - Check and record Sludge Return From The Final Settlement Tanks OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check Visually That Aerator(s) are Running OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check Aerators Are Operating Correctly And Automatic Switching
(where applicable)
OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check Outlet Weir Is Operating Correctly (where applicable) OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check Flow Distribution To Aeration Lanes Is Correct If More Than
One Lane Present
Activated Sludge - Surface Aeration - Check and record Rate And Frequency Of SAS Removal OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check Recycle Pumps Are Running (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Surface Aeration - Check VFA / Liquor Return (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Surface Aeration - Sample And Check Calibration Of MLSS Meter
OP/1M OP/1M OP/1M OP/1M
Activated Sludge - Surface Aeration - Check and record Dissolved Oxygen (DO) Readings OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Check DO Probe and/or Timers Are Carrying Out The Correct
Control Functions
Activated Sludge - Surface Aeration - Check Redox Monitor Is Operating Correctly (BNR Plants) N/A N/A OP/1W OP/1W
Activated Sludge - Surface Aeration - Check Mixers For Rotation in anoxic (Unaerated) Zones OP/1W OP/1W OP/1W OP/1W
Activated Sludge - Diffused Air - Withdraw The DO Probe From The Tank And Remove Clean
OP/1W OP/1W OP/1W OP/1W
Activated Sludge - Surface Aeration - Sample, Measure And Record MLSS/RASS Concentration And
Sludge Settle Ability
OP/1W OP/1W OP/1W/3D OP/1W/3D
Activated Sludge - Surface Aeration - Log KWh OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Log Flows (Where Meters Are Fitted) OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Log SAS Rate OP/1W OP/1W/5D OP/1W/5D OP/1W/7D
Activated Sludge - Surface Aeration - Log Changes To RAS Rate OP/1W OP/1W/5D OP/1W/5D OP/1W/7D


3.2.3

Process Checklist Package Plant ASP
Task Low Pe
(10-1000)
Med Pe
(1000-20,000)
High Pe
(20,000-350,000)
Manned
(350,000+)
Activated Sludge - Package Plants - Check Sludge Is Being Returned From The Final Settlement Tanks OP/1W OP/1W/2D OP/1W/5D N/A
Activated Sludge - Package Plants - Check The Bubble Pattern And Size Of The Bubbles OP/1W OP/1W/2D OP/1W/5D N/A
Activated Sludge - Package Plants - Check That Sufficient Blowers Are Operational And At The Right
Rate OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Check Air Filter Indicators For Normal Readings OP/1W OP/1W/2D OP/1W/5D N/A
Activated Sludge - Package Plants - Check Dissolved Oxygen (Do) Readings OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Check Do Probe And/Or Timers Are Carrying Out The Correct
Control Functions OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Check Distribution Of Flows To Aeration Tanks If More Than One
Tank Is Present OP/1W OP/1W/2D OP/1W/5D N/A
Activated Sludge - Package Plants - Check Settlement Zone For Blanket Level, And Adjust RAS Rate
As Necessary OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - As Required, Arrange For Tanker Collection Of SAS OP/1W OP/1W/2D OP/1W/2D N/A
Activated Sludge - Package Plants - Withdraw The Do Probe From The Tank And Remove Any
Attached Debris OP/1W OP/1W OP/1W N/A
Activated Sludge - Package Plants - Vent Condensate From Air Lines OP/1W OP/1W OP/1W N/A
Activated Sludge - Package Plants - Sample, Measure And Record MLSS/RAS Concentration And
Sludge Settle Ability OP/1W OP/1W OP/1W/3D N/A
Activated Sludge - Package Plants - Log Kwh OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Log Sewage Flows (Where Meters Are Fitted) OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Log SAS Rate OP/1W OP/1W/5D OP/1W/5D N/A
Activated Sludge - Package Plants - Log Changes To RAS Rate OP/1W OP/1W/5D OP/1W/5D N/A


3.2.3 Process Checklist KEY

OP =OPERATOR

1W/2D =2 TIMES PER WEEK 1W =1 TIME PER WEEK
1W/3D =3 TIMES PER WEEK 1M =1 TIME EVERY MONTH
1W/5D =5 TIMES PER WEEK (EVERY WEEKDAY)
1W/7D =7 TIMES PER WEEK (EVERYDAY)

3.2.4 Process Checklist Notes

What to check Action / What to check for on deviation.
Bubble pattern and size of
bubbles
Check for uneven patterns / bubble size as a symptom of broken or
badly fitted diffusers.
Blowers are operating
correctly (where used)
Check discharge flow and pressure. Align with that required by
aeration system
Check drawn current and confirm this is consistent with
manufacturers data
The air volumes from the blowers are usually controlled by means of
dissolved oxygen probes and/or timers to ensure that the optimum
volume of air is supplied.
Surface aerators are running
(where used)
Check that the aerators are operating.
Check that surface aerators
and automatic switching (if
applicable), are operating
correctly.
Check for excessive noise, heat, vibration etc..
Check that automatic switching (where appropriate), is operating
correctly.
Dissolved oxygen (DO)
reading (where probes are
installed)
Check operation of actuated valves in aeration system
Check for changes in the strength of the incoming sewage
Check for specific operations impacting load to ASP, liquors return,
tanker discharge, etc.
Check the DO probe for fouling and clean if necessary.
Check calibration of DO probe.
Check that mixers in anoxic
(unaerated) zones are
operating.
Arrange for repair if not operational or inactive.
The activated sludge plant may or may not have anoxic zones which
utilise the oxygen from the nitrates present in the returned activated
sludge (RAS), and thus reduce oxygen requirements. They tend to
produce a more stable sludge with a lower SSVI.
Calibration of MLSS meter if
required
On-line MLSS monitors should be regularly checked and calibrated
against a sample of mixed liquor sent to the Laboratory for
gravimetric determination of MLSS concentration.
If the correct equipment is available, a gravimetric determination of
MLSS concentration may be carried out on site.
Cockpit Data Collection MLSS, RAS suspended solids, dissolved oxygen, SSVI, power and f
low readings should be logged and captured on the Site Cockpit /
Dashboard.


3.3 Troubleshooting Guide

WWT 4.6 Troubleshooting Guide Activated Sludge Process
Symptom Possible Cause Action Risk / Consequence
MLSS
concentration
changes
(Increase or
decrease)
SAS rate not sufficient
to keep pace with the
sludge growth rate (or
SAS rate too high)

Changes in settled
sewage make-up.

Insufficient air to keep
solids in suspension

Solids lost from
settlement tank
Change the SAS rate
little by little to recover
from the
increase/decrease

Check quality of
sewage/settled sewage
feed
Adjust rate of aeration
Solids loading too
high for the final tanks
or insufficient
biomass to treat
sewage
Increased costs
Insufficient air to
sustain sludge
growth.
Deterioration in
effluent
quality/possible
consent failure
Blanket spillages
Poor
distribution of
sewage and/or
RAS
Distribution channel/
pipework wholly or
partially blocked
Investigate distribution
channels & pipework
and clear any blockages

Check RAS return rate
Plant not correctly
utilised with
overloading of
process
Inferior quality
effluent,
Possible consent
failure
Poor bubble
pattern
Foam or mousse on
surface of aeration
lane.

Pipe fracture or
blockage
Condensate in air
main
Sample foam and send
to the laboratory for
filamentous
identification.
Investigate airflows and
pressures
Repair fractures
Check air control valves
Drain condensate traps
Poor effluent quality
Possible consent
failure


Poorly settling
sludge (high
SSVI)
Over aeration
Under aeration
Retention time
inadequate
Flows too high
Changes in settled
sewage make-up
Build-up of filamentous
organisms in the
sludge
Check blower/surface
aerator control system. If
not controlled by DO,
consider installation of
probes or timers

Check quality of feed
sewage

Take a Filamentous ID
sample. Send to the
Laboratory for
identification.
Consider dosing to
control filamentous
Solids lost from final
settlement tank into
effluent
Inferior quality effluent
Possible consent
failure
Pin Floc in
Effluent
Mechanically thrashed
MLSS

High RAS rate
High Flow
Filaments in Mixed
Liquor
Sudden loss of normal
chemical dose
If DO is high enough,
reduce surface
disturbance by lowering
aeration
.Reduce RAS rate if
possible
Seek advice about
Filaments
Clear still boxes in the
Final Settlement Tanks
Risk to final effluent
consent including
Phosphorus (P)
Clumps of
Rising Sludge
RAS rate too low
Low DO at outlet end
of aeration lane
Check RAS pumps
delivering correct RAS
flow to aeration lanes.
Use blanket detector to
find sludge level in FST.
Solids lost from final
settlement tank into
effluent
Possible consent
failure.


Turbid &
Cloudy
effluent and/or
High ammonia
in FE
Very Low MLSS

High DO / dead MLSS

Low DO / high MLSS

Strong incoming flow
or liquors. (Low DO /
normal MLSS)

Problems with
chemical dosing
Check RAS pumps in
working order and
delivering correct flow
from the FSTs..
Reduce SAS rate to
increase MLSS
Potential toxic discharge
.to the site
Check DO probes are
operating correctly.
Consider re-seeding
MLSS
Check DO probes are
operating and clean.
Increase aeration if
possible. DO NOT
overpressure aeration
pipework or domes.
Increase SAS rate to
reduce MLSS.
Visually check incoming
sewage.
Check DO probes are
operating and clean.
Increase aeration if
possible. DO NOT
overpressure aeration
pipework or domes.
Process check of sludge
stream

Check that the pump is
operating correctly and
for chemical overdose.
.
Loss of nitrification.

Loss of treatment
(ammonia and BOD)
Probable consent
failure

quality.

Possible consent
failure

Possible consent
failure

Internal Company and Partners Asset Strategy & Standards


Appendices
3.4 Notes for Operation and Control

3.4.1 Activated Sludge Process Efficiency
To maintain high levels of treatment performance over a wide range of operating conditions it is
fundamental to apply adequate control of the Activated Sludge Process. Sludge Age and MLSS are
the most commonly used parameters for ASP control. The main strategies for the management of
ASP systems are:
Control of Dissolved Oxygen concentration in the aeration lanes: Oxygen is used by micro-organisms
during the breakdown of organic matter and the oxidation of ammonia. Oxygen levels in the aeration
lanes are therefore an indication of the microbial activity taking place. In feeding, micro-organisms
use more air so if we dont supply sufficient air the DO concentrations in the lane will decrease. On
the other hand, sharp increases in DO levels could reflect inhibition of the microbial activity or even its
destruction due to a toxic feed.
DO levels are frequently used for aeration control. Probes are attached to SCADA and have
operational set points assigned to them. The aeration system will pump more or less air as required
to maintain a minimum DO concentration, guaranteeing enough air is available to support waste
degradation. There is little benefit, in terms of ammonia removal, in going beyond DO concentrations
higher than 2.5mg/l. DO levels in aeration lanes are usually maintained in the 0.5 to 2 mg/l range.
Control of Returned Activated Sludge rates: The purpose of the RAS is to maintain a sufficient
concentration of biomass in the aeration tanks to provide adequate degradation of the waste in the
water. Adequate return rates will cater for appropriate levels of thickening in the Final Settlement
Tanks. As the retention times in the settlement tanks will be reduced during peak flows and the
thickness of the sludge will therefore be reduced, RAS pumping systems must be sized to guarantee
that enough solids are returned to maintain stable MLSS levels.
Control of Surplus Activated Sludge Rates: The amount of solids wasted from the system will
determine the amount of solids retained in the system and therefore the sludge age.

Sludge Age: Is an indication of whether efficient nitrification is likely to be taking place.

MLSS must be maintained within the recommended range for the site so as to guarantee BOD and
ammonia compliance and to avoid excessive costs in the aeration of unnecessary high solids
concentrations.


3.4.2 Impact of Poor Operation of Activated Sludge Process
As the activated sludge process is the means by which contaminants are biodegraded/oxidised and
therefore removed from the wastewater, poor performance of the process has a direct impact on the
works ability to meet its consent. Inadequate aeration would risk BOD and/or ammonia breaches
while poor operation of the Final Settlement Tanks, usually as a consequence of poor control of the
overall process will jeopardise solids removal and therefore Suspended Solids compliance.
Symptom Consequence
High MLSS
concentration
High MLSS may result in low dissolved oxygen levels and consequently, rising
ammonia levels in the final effluent. If the Mixed Liquor Suspended Solids (MLSS) rise
even further, then (depending upon the specific plant), then there may be problems
removing enough Activated Sludge from the final settlement tanks, leading to increased
solids within the final effluent and even sludge blanket loss.
Low MLSS
concentration
Low MLSS result in shorter sludge ages that are potentially insufficient to carry out
effective nitrification, increasing the risk of ammonia breakthrough in the final effluent.
If the Mixed Liquor Suspended Solids (MLSS) are lower than target levels, the amount
of biomass available for BOD removal may also be insufficient risking, a breach of the
BOD consent.
Excessively low
F:M levels
The relationship between the Biochemical Oxygen Demand (BOD) loading and the
amount of biomass (or Mixed Liquor Suspended Solids), (MLSS), within aeration plant
is quantified as the food to mass ratio (F: M).
Excessively low F: M levels will reduce the food available to the organisms to
metabolise, which will result in reduced growth which in extreme cases can lead to the
mortality rate exceeding the reproductive rate, resulting in a loss of treatment.
High or low F:M
ratio
Further problems with either high or low F: M ratio is the increased potential to cause a
filamentous bloom, which can detrimentally affect the treatment process and settlement
in the FSTs, especially when combined with high MLSS and high flows.
High DO
Concentration
Causes pin flocs and poor settlement. Inefficient operation leading to high power costs.
Low DO
Concentration
Poor performance including possible loss of nitrification and high ammonia levels in the
final effluent.
Potential for formation of filamentous micro-organisms resulting in high SSVI values and
loss of solids from the FSTs especially when combined with high MLSS and high
flows.
Too Long a
Sludge Age
This may be a result of supplying high organic loads to the aeration lanes. It is also a
consequence of operating with too low a surplus activated sludge (SAS) rate. Long
sludge ages will be reflected in high MLSS, excessive oxygen requirements, power
usage and growth of filamentous micro-organisms
Too Low a Sludge
Age
This may be due to operating higher than required surplus sludge (SAS) wastage rates
leading to low MLSS in the plant. Low sludge ages result in inadequate nitrification
and the potential for high ammonias in the final effluent.
Too high RAS
rates
A reasonably clear effluent might be produced but It would affect the ability of the Final
Settlement Tanks to adequately thicken the sludge, as a result of no sludge blankets
fine solids will be noticed in the final effluent.
The level of MLSS in the aeration basins will rise due to the low Suspended Solids
concentration of the SAS.
Too low RAS
rates
Not enough nitrifiers returned to aeration lanes for ammonia removal, risk of ammonia
breakthrough, denitrification in the FSTs and blanket spills.
Too short
hydraulic
retention time
Treatment may be inadequate. An increase in ammonia, Suspended Solids and BOD
would be likely.


3.4.3 Settlement Problems
Floc Shear: This effect is caused by the breaking of flocs by mechanical means, mostly due
to over aeration and the use of surface aerators. During a SSVI jar pin flocs have a powdery
appearance. They sink to the bottom of the jar but no clear water/sludge interface is formed.
Dispersed Growth: Tension active substances in the sewage (i.e. certain detergents) can
prevent the flocs from aggregating and therefore gaining the size and weight required for their
settlement. One indication is high SSVI however there are other causes of high SSVI which
would need to be considered.
Non-Filamentous Bulking: This phenomenon is caused by food imbalances in the biological
reactor. When fed purely with BOD and COD, but with insufficient nutrients such as
Phosphorus (P) or Nitrogen (N), bacteria tend to generate only waste as they are unable to
synthesise new cells. This waste is sticky, it doesnt compact and because it is highly water-
retentive it does not settle either. The condition is exacerbated by very old sludge. It results in
foaming on aeration tanks and Final Settlement Tanks and could lead to blanket spills.
Bubbles of gas in Final Settlement Tanks: The presence of gas bubbles in the Final
Settlement Tanks is problematic because in their upward movement to escape to the
atmosphere the bubbles lift bits of flocs. Bubbles in the settlement tanks can be either air or
nitrogen
.
The former are caused by over aeration. The latter by anoxic conditions developing
in the Final Settlement Tanks sludge when bacteria reduce nitrate to nitrogen gas. The
condition is promoted by the lack of an anoxic zone in the aeration tanks and by holding
sludge for too long in the Final Settlement Tanks. It results in small sludge flocs in the final
effluent and on bubbles visible on the surface of the Final Settlement Tanks and in the SSVI
test jar.
Filamentous Bulking: This condition is caused by the growth of filamentous organisms or
organisms that can grow in a filamentous form. Although filaments can help to prevent floc
shear by providing a stronger structure to the floc, when growing in excess the filaments of
single-cell organism attach end-to-end forming a floc with a large surface area to mass ratio
with poor settling characteristics. This type of bulking results in the formation of a mousse-
type foam on the aeration lanes and increased risk of blanket spilling from the Final
Settlement Tanks and the return of activated sludge with very low suspended solids.

3.4.4 Filamentous Outbreaks
Each organism within the Mixed Liquor has its own preferential set of conditions. Under those
conditions, that particular organism will multiply fastest than the others and be dominant. In sufficient
numbers filamentous bacteria render the flocs hydrophobic (not liking water) and attach to the gas
bubbles in the aeration lane, which then floats to the surface.

Filamentous growth


Filamentous outbreaks occur when certain types of bacteria predominate in the aeration basin due to
favourable influent temperature, F: M ratio, nutrient levels and DO concentrations. It is fundamental
to act fast once symptoms of filamentous bulking have been observed in the aeration lanes, the Final
Settlement Tanks or during the SSVI or MLSS microscopy tests.

Since the outbreak is caused by the predominance of a specific type of bacteria it is necessary to
identify it, to understand the conditions which are favourable for their development and to alter such
conditions.
A Filamentous ID will include the filament identification, filament index (how much of that species is in
the MLSS), floc size, shape and strength.
By knowing the filament and what conditions it prefers, decisions can be made on how to control the
organism in the long term. Sometimes it is necessary to increase the MLSS concentrations (not
often), sometimes to decrease it. Sometimes it is necessary to increase the DO, other times to
reduce it or change the air balance. In extreme cases chemical dosing may be required.

The two main bacteria responsible for filamentous outbreak are:

Nocardia

Microthrix Parvicella
Favourable conditions:
Septic conditions
pH 6.5
Lives on fats
Tolerates most sludge ages
Low F:M ratio
Uniform DO
Encouraged by foam created by
detergents in sewage
Favourable conditions:
Low F:M ratio
High Sludge Age (>10days)
Low DO
Grows on broken solids
Crude sewage mixed with RAS prior to
aeration

Response:
Remove fats from system
Physical removal of foam
Ensure anoxic conditions in anoxic zones
Response:
Reduce sludge age
Maintain uniform DO in aeration pockets
Ensure Primary Settlement Tanks are not
holding sludge


In addition, chemical dosing has been successfully used in controlling filamentous bacteria in
activated sludge systems. This should only be carried out under advice from Process Scientists.
Further details of this methodology are detailed below:

Hypochlorite: usually to be begun when SSVI between 95 and 120ml/g. Improvements noticeable
after 3 to 5 days. Dosing must be performed with care as overdosing would result in the destruction of
the biota in the system, loss of treatment capacity and breaching of consent. Dosing must be turned
once clear.
Polyelectrolyte: Typically Magnasol and aluminium based polymers (PAC). These act by binding to
floc and making it settle out. Effectiveness depends upon adequate mixing.

Control of Nocardia has been investigated over the years. The most effective method has been to
physically remove the scum and foam either by tankering away from the FST surface or by sinking
the foam with spray poly or chlorine and removing it with the SAS, chlorinate the RAS for a short time
(or spray the surface foam) and reduce the sludge age to below 9 days. All 3 of these techniques
have to be done concurrently to be effective.

3.4.5 Activated Sludge Process Control
As biological treatment relies on the availability of an active biomass for degradation of the waste in
the water, maintaining an adequate amount of micro-organisms in the aeration lanes is crucial to
guarantee that effective treatment is achieved.
For each plant an ideal band of MLSS concentrations exists which should be maintained at all times.
In case of deviations the following are the recommended actions:

Low MLSS
Reduce SAS (increase F:M ratio)
Ensure enough air is supplied for the new, higher MLSS levels.

High MLSS
Increase SAS

As nitrifiers take a longer time to develop, sludge must be maintained within the system for a period of
time long enough to allow their development. This is why sludge age must be monitored and
adequately controlled to prevent ammonia breakthroughs. Excessive sludge ages on the other hand
can lead to deterioration of the settling characteristics of the sludge flocs and ultimately lead to the
aeration of unnecessarily high quantities of biomass. In case of deviations from the prescribed sludge
age for the site the following are the recommended actions:

Too long a sludge age
Increase SAS by:
Increasing the number of SAS thickeners operating hours.
Increase the rate of the SAS pumps
In extreme cases, take one lane out of service

Too short a Sludge Age
Reduce SAS



SAS must always be increased carefully as a too abrupt change could result in the wasting of
too big a portion of nitrifying bacteria species (nitrifiers).

Nitrifiers are very vulnerable to changing conditions in the aeration lanes and as such to shock loads.
Primary Settlement Tanks should be controlled to minimise BOD load to the biological treatment
stage.
Some plants might need to run at high MLSS levels particularly during cold weather.
BOD shock loads are detrimental both to BOD and ammonia compliance. As the organic load to the
aeration lanes increase, heterotrophic bacteria predominate over a longer section of the lane, leaving
potentially insufficient volume for nitrification. Young or immature activated sludge can reach the Final
Settlement Tanks. These are small and with poor settling characteristics, also risking BOD and TSS
compliance.
The main cost associated with biological treatment is due to electric power for aeration. It is
fundamental to maintain MLSS levels within the prescribed band to guarantee adequate treatment
without incurring the excessive cost of unnecessary aeration.

Minimising Aeration Costs
Maintain blowers, diffusers and air pipework in good working order
Adequately manage Primary Settlement Tanks to maximise BOD removal and minimise load
to aerobic treatment.
Avoid BOD sludge loading to aeration plant (shock load)
Manage liquors return times to prevent shock loads.
Avoid excessive MLSS levels
Properly locate, calibrate and maintain DO probes

3.4.6 Contingency Planning

BOD shock load
Shock BOD loads to the aeration lanes can be caused by:

Return Liquors (sludge dewatering, tanker discharges, cesspool waste, etc)
Poor quality settled sewage
Accidental discharges from industry of effluents with a high organic load, (dairy, brewery,
abattoir, cattle markets, food processing, etc)

In the case of an unplanned increase in the BOD load to the plant caused by internal events such as
high strength liquors (digester liquor, septic sludge etc.), then the flow should be diverted if possible
to a spare tank or tankered from site and the source identified and stopped.
The increased microbial activity in the aeration lanes triggered by the surge of food will cause a sharp
decrease in DO levels. It is fundamental to monitor these closely and increase aeration levels where
possible, either by raising blowers speed / vane position or by increasing the immersion depth of
surface aerators.
To maintain enough active biomass in the reactor, sludge withdrawal rates from Final Settlement
Tanks should be increased and SAS rates decreased. MLSS levels must be closely monitored.



Toxic Discharge
Whenever possible the toxic discharge must be prevented from entering the biological reactor. Follow
the Procedure for unknown substance entering STW (below).

Procedure for an Unknown Substance Entering an STW

Control Options Action to take
Notify appropriate personnel Inform line management and or the department controlling
effluent discharges from industry. This may be a site emergency
requiring immediate action.
Prevent any further toxic
discharge from entering the
works
- divert flow to storm tanks
- undertake over-pumping or pumping station tankering
- take samples
Keep the surplus activated
sludge separate from other
sludges
Divert surplus sludge to a separate holding tank. The sludge is
probably toxic and must not receive further treatment (digestion,
pressing, return to works inlet, land disposal). Special disposal
methods must be considered
Mixed liquor suspended solids
level and sludge settlement
Monitor regularly, recovery may take several days
Reseed the plant with
uncontaminated activated
sludge from another works
Balance surplusing the toxic sludge with the reseeding operation.
Final effluent and river
monitoring (upstream and
downstream)
Monitor (ammonia, turbidity) closely for several days. Further
g maybe required.

If this is not possible, flows should be reduced and MLSS increased in the aeration lanes (by
decreasing SAS rates). Final effluent must be closely monitored and intensive sampling performed.
As Activated Sludge is probably toxic it should be kept separate form other sludge on site and not
receive further treatment (digestion, pressing, return to works inlet, land disposal). Special disposal
methods must be considered.
Should the toxic materials consist of matter not suitable for standard treatment and disposal, the
activated sludge will need to be removed and replaced with uncontaminated activated sludge from
other works. The reseeding operation should be balanced with purging of the toxic sludge.

Rising SSVI
As the settling properties of the mixed liquor start to deteriorate and SSVI values to increase, RAS
rates should be raised to prevent sludge blanket in the FST from spilling. The causes of increasing
SSVI should be addressed using the Troubleshooting Guide section 3.5.3.

3.4.7 Plant Release / Taking out of and Bringing into service

Taking out of service Planned
When activated sludge process units are being taken out of service the Plant Release procedure
needs to be followed together with site process risk assessment and plant availability. If an ASP unit
cannot be taken out of service due to process risk then this needs to be highlighted in the Risk
Register for potential investment/capital delivery purposes.


The frequency for removing ASP units from service must be set at a level that ensures the
performance of the plant is maintained and inspection of the aeration grids (where used) can be
made prior to any damage occurring. As a guide it should be initially set at four years.
Draining of ASP units for inspection is normally carried out in summer months or during periods of low
inlet flow to the works when plenty of time needs to be allowed for draining. Avoid draining back
upstream of Primary Settlement Tanks (PSTs) as this will cause additional problems.
Mixed liquors (MLSS) will be returned to the ASP distribution chamber by the RAS pumps to be
evenly distributed between the remaining ASP units. The MLSS concentration will have to be
carefully managed across the lanes to ensure that the plant can cope with the normal sewage load
with less aeration capacity. (This may mean increasing MLSS).
Ensure that the lane in question can be emptied safely on its own without putting the concrete
structure at risk from floating or internal walls collapsing

Taking out of service - Unplanned
The procedure for an unplanned event to take an ASP unit out of service will be similar to that of a
planned event, however contact with the Environment Agency will be required for an unplanned
event. The following points must be taken into account when taking an Activated Sludge Process unit
out of service to maintain site operation, maintenance and compliance.
Always protect effluent quality;
Ensure that adequate treatment capacity is available for flows and loads when plant is shut
down;
Ensure that air is passed through the diffusers at all times while liquid level is such that all or
parts of the diffusers are submerged (if using blowers and diffused aeration). Adjust the air
volumes to suit the new plant configuration;
Shut off inlet flow. Isolate tank;
Shut off aerator and weir (if surface aeration);
Protect dissolved oxygen probes from damage during the shut down. Ensure the control
system does not react to this probe if there is more than one lane on the plant.
Drain down the lane as required ensuring that other processes can accommodate the solids
load;
Normally mixed liquors will be pumped over to the next adjacent lane during an unplanned
event. Take care to maintain the correct solids balance within the lanes;
Wash down tank if required to prevent odour nuisance;
Health & Safety;
Inspections required;
Monitor downstream processes;
Alarms that could lead to needless Call Outs, i.e. not temporarily disabled during outage;
Inform the Waste Control Centre

This is not an exhaustive list and a site specific process risk assessment and method
statement must be drawn up.

Bringing Aeration Lanes into service
Check ASP alarms before leaving site. Check that all ASP units have equal flow distribution to
ensure optimal operation.



More than one Aeration Lane on site
If the aeration tank was not emptied the following procedure should be followed:
Turn on aerators
Check Mixed Liquor supernatant for compliance against final effluent consent
Check for correct operational control systems DO probes working and alarms
Turn on flow
Monitor Mixed Liquor supernatant for compliance against final effluent consent and final
effluent quality at regular intervals over a minimum of 12 hours

If the aeration tank was emptied the following procedure should be followed:
Fill lane with final effluent above diffusers
Turn on air at start of operation to fill lane. For surface aerators turn on when immersed.
Introduce RAS and sewage/settled sewage to lane
Increase flow and air supply as the lane fills to capacity.
Build up MLSS concentrations to a minimum of 70% of design
Introduce sewage to tank
Monitor Mixed Liquor supernatant for compliance against final effluent consent (AmmN)
Monitor effluent quality, blend or re-circulate as required
Alarms, inform the Waste Control Centre.

One tank only on site
As above but activated sludge will have to be imported to the site from another activated sludge plant
nearby. This needs to be fresh SAS (not thickened) from a good site with no (low) filamentous micro-
organisms.

General
It is advisable that an inspection of the Activated Sludge Process units and associated equipment
should be carried out within a few days of being put back in service.

Asset Standards

Internal Company and Partners

3.5 Performance Factors

3.5.1 Calculations

Hydraulic Retention Time in Aeration Tank:

The hydraulic retention time is the length of time that the mixed liquors actually spend in the aeration tank. Typically it should be above 4 hours but the ideal figure varies for
different tank configurations. A reduction in the retention period occurs for example during periods of peak flow of when RAS rates are increased. The data required to calculate it
can be obtained:
(A) Aeration volume: Design information SOM
(B) Daily Sewage Flow: Onsite flow reading, Daily log
(E) RAS flow: Onsite flow reading, Daily Log, SCADA

A B C D E F G

Vol of aeration
tank (m
3
)
Sewage
flow (l/s)
Sewage flow
(m
3
/hr)
Sewage RT
in aeration
(hrs)
RAS flow
(l/s)
RAS flow
(m
3
/hr)
Total flow to
aeration (m
3
/hr)
Total RT in aeration
tank (hrs)

B x 3.6 A / C E x 3.6 C + F A / G


Food:Mass Ratio

This is the ratio between the substrate available to the microorganisms and their concentration. The data required to calculate it can be obtained:
(A) Daily Sewage Flow: Onsite flow reading, Daily log
(B) Sewage BOD: Laboratory
(D) MLSS: On site test, Laboratory, Solids Meter
(E) Aeration volume: Design information SOM

A B C D E F

Daily sewage
flow (m
3
/d)
Sewage
BOD (mg/l)
BOD load
(kg/d)
MLSS
(mg/l)
Volume of
aeration tank
(m
3
)
ML Mass (kg)
F:M
(kgML/kgBOD/d)

A x B / 1000 D x E / 1000 C / F



Sludge Age

This parameter gives an indication of whether effective nitrification is likely to occur in the aeration lanes. The data required to calculate it can be obtained:
(A) MLSS: On site test, Laboratory, Solids Meter
(B) Aeration volume: Design information SOM
(D) RAS SS: On site test, Laboratory
(E)/(F) SAS rate: Current settings, logbook, SCADA
(K) FE SS: On site test, Laboratory
(L) Sewage Flow: Onsite flow reading, Daily log

A B C D E F H J K L M N

MLSS
(mg/l)
Aeration
tank
volume
(m
3
)
Total
MLSS
mass
(kg)
RASS
(mg/l)
SAS flow
(l/s)
SAS hrs
run/d
Daily
SAS
volume
(m
3
)
ML lost to
SAS (kg/d)
FE sus
solids
(mg/l)
Sewage
flow (l/s)
ML lost
in FE
(kg/d)
Total ML
lost (kg/d)
Sludge
Age (d)

A x B /
1000

E x 3.6 x
F
H x D / 1000
K x L /
1000
J + M C / N




SSVI (Stirred Specific Volume Index)

The Stirred Specific Volume Index (SSVI) is the volume in ml occupied by 1g of sludge after a period
of 30 minutes of settling whilst being slowly stirred. This measure was developed to quantify the
settling characteristics of the activated sludge. It gives an indication of the ease with which the mixed
liquor will settle in the final settlement tanks. Because solids concentration is related to settleability,
SSVI figures are usually quoted at a MLSS of 3500 mg/l. The SSVI is then designated as SSVI
3.5
.
SSVI tests are commonly performed by local operators and the parameters value can be obtained
from the collected data using the calculations below:

MLSS

A B C D

MLSS
(mg/l)
Height of
sludge in
cylinder
Settlement
%
MLSS SSVI (ml/g)

B x 2 C x 10,000 / MLSS
RAS

E F G H

RAS Susp.
Solids (mg/l)
Height of
sludge in
cylinder
Settlement
%
RAS SSVI (ml/g)

F x 2 G x 10,000 / MLSS

If RAS SSVI is GREATER than the MLSS SSVI

J
Sludge Settlement
Reduction
SSVI
3.5
(ml/g)
(H-D) x (E-3500) / (E-A) H J

If RAS SSVI is LESS than the MLSS SSVI

J
Sludge Settlement
Reduction
SSVI
3.5
(ml/g)
(D-H) x (E-3500) / (E-A) H + J


3.6 Health and Safety

The Thames Water H&S management system has been designed to ensure effective risk control, and
a key aspect of this system is risk assessment and the safe undertaking of activities conducted by the
business.

External suppliers using this Operational Standard must utilise an H&S process that is equal to the
Thames Water approach to managing risk

Thames Water managers must identify via the completion of the SHE 1 document activities to be
undertaken and how they are to be controlled via the adoption and implementation of relevant key
procedures (HSPs) and risk assessment guidelines (RAGs).

Thames Water employees must be provided with the necessary information, resources and training to
perform these tasks, and prior to completion they must confirm that they can comply with these
procedures and guidelines. However, if an employee believes that compliance will require additional
resource, the task should be reviewed using the SHE 5 form and if necessary curtailed.

Thames Water managers must be trained in this system, and be in receipt of a controlled copy of an
H&S manual which is supported by information posted on the company portal.

Glossary of Terms

TERM DESCRIPTION
ASP Activated Sludge Process
DO Bulk Dissolved Oxygen
F:M Food : Mass ratio
MLSS Mixed Liquor Suspended Solids
SSVI
3.5
Stirred Sludge Volume Index at 3500 mg/l MLSS
RAS Returned Activated Sludge
SAS Surplus Activated Sludge
FST Final Settlement Tank

---- End of section 3 ----

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