Functional Design Report

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Industrial Wastewater Tre

Industrial Wastewater Treatment Facility

atment Facility

Springhill Farms, LP and

Town of Neepawa, MB

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1998 West Judith Lane 1998 West Judith Lane

Boise, Boise, ID ID 8370583705 208-433-1900 208-433-1900 NEW NEW IWWTF IWWTF SITE SITE

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TOC Page 1

TABLE OF CONTENTS TABLE OF CONTENTS SECTIONS SECTIONS SECTION 1 – INTRODUCTION SECTION 1 – INTRODUCTION SECTION 2 – DESIGN BASIS SECTION 2 – DESIGN BASIS SECTION 3 – PROCESS

SECTION 3 – PROCESS FUNCTIONAL DESIGNFUNCTIONAL DESIGN SECTION 4 – FACILITY DESIGN CRITERIA SECTION 4 – FACILITY DESIGN CRITERIA SECTION 5 – SCHEDULE

SECTION 5 – SCHEDULE SECTION 6 – COST OPINION SECTION 6 – COST OPINION

TABLES

TABLES PAGESPAGES

2-1:

2-1: Estimated Estimated Unit Unit Wastewater Wastewater Production Production 2-12-1 2-2:

2-2: Estimated Estimated Unit Unit Wastewater Wastewater Facility Facility Influent Influent 2-22-2 2-3:

2-3: Effluent Effluent Discharge Discharge Criteria Criteria 2-22-2 3-1:

3-1: Activated Activated Sludge Sludge / / MBR MBR Process Process Sizing Sizing 3-33-3 3-2:

3-2: Equipment Equipment List List 3-63-6 5-1:

5-1: Project Project Schedule Schedule 5-25-2 6-1:

6-1: Project Project Capital Capital Cost Cost Opinion Opinion 6-26-2 6-2:

6-2: Project Project Operation Operation and and Maintenance Maintenance Cost Cost Opinion Opinion 6-36-3

DRAWINGS DRAWINGS

General: General: G-0

G-0 COVER COVER SHEET SHEET & & DRAWING DRAWING INDEXINDEX G-1

G-1 HYDRAULIC HYDRAULIC PROFILEPROFILE Civil

Civil C1.0

C1.0 FACILITY FACILITY LOCATION LOCATION PLANPLAN C2.0

C2.0 SITE SITE PLANPLAN C3.0

C3.0 SITE SITE YARD YARD PIPING PIPING PLANPLAN Mechanical:

Mechanical: M1.0

M1.0 TREATMENT BUILDING TREATMENT BUILDING PLANPLAN M1.1

M1.1 TREATMENT BUILDING TREATMENT BUILDING SECTIONSSECTIONS M2.0

M2.0 SCREENING / SCREENING / PUMPING PUMPING BUILDING BUILDING PLANPLAN M2.1

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TOC Page 2

DRAWINGS (cont)

Process &

Process & InstrumentatioInstrumentation Diagrams:n Diagrams: N0.0

N0.0 PROCESS PROCESS FLOW FLOW DIAGRAMDIAGRAM N0.1

N0.1 PROCESS PROCESS AND AND INSTRUMENTATION INSTRUMENTATION LEGENDLEGEND N0.2

N0.2 PROCESS PROCESS AND AND INSTRUMENTATION INSTRUMENTATION LEGENDLEGEND N1.0

N1.0 NEW NEW RAW RAW INFLUENT INFLUENT PUMP PUMP STATIONSTATION N2.0

N2.0 INFLUENT INFLUENT SCREEN SCREEN P&IDP&ID N3.0

N3.0 FLOW FLOW ATTENUATION ATTENUATION P&IDP&ID N3.0

N3.0 DAF DAF P&IDP&ID N4.0

N4.0 BASIN BASIN P&IDP&ID N5.0

N5.0 MEMBRANE MEMBRANE P&IDP&ID N6.0

N6.0 AERATION AERATION BASIN BASIN BLOWER BLOWER / / AERATION AERATION P&IDP&ID N7.0

N7.0 MBR MBR / / BLOWERBLOWER N8.0

N8.0 UV UV DISINFECTION DISINFECTION P&IDP&ID N9.0

N9.0 CHEMICAL CHEMICAL FEED FEED P&IDP&ID N10.0

N10.0 FERRIC FERRIC SYSTEMS SYSTEMS P&IDP&ID N11.0

N11.0 DAF DAF PRETREATMENTPRETREATMENT

APPENDICES APPENDICES

A

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Section 1 – Page 1 Section 1 – Page 1

Section 1

Section 1 Introduction

Introduction

The Springhill Farms pork processing facility located in Neepawa, Manitoba has been operating with an The Springhill Farms pork processing facility located in Neepawa, Manitoba has been operating with an industrial wastewater treatment facility (IWWTF) that has not be able to meet the provincial discharge industrial wastewater treatment facility (IWWTF) that has not be able to meet the provincial discharge requirements.

requirements. As a result the ToAs a result the Town of Neepawa muwn of Neepawa municipal wastewater treatmnicipal wastewater treatment facility has beenent facility has been accepting industrial wastewater treatment plant effluent where the water is further stabilized and accepting industrial wastewater treatment plant effluent where the water is further stabilized and discharged on a seasonal basis.

discharged on a seasonal basis.

Hytek Ltd, recently purchased the Springhill Farms processing facility and plans on expanding the plant Hytek Ltd, recently purchased the Springhill Farms processing facility and plans on expanding the plant to its licensed capacity.

to its licensed capacity. As part of the acquisition and expansiAs part of the acquisition and expansion, a new industrial wastewater treatmenton, a new industrial wastewater treatment facility will be constructed to meet the Provincial regulatory requirements.

facility will be constructed to meet the Provincial regulatory requirements.

New provincial discharge requirements were put in-place to provide additional protection for surface New provincial discharge requirements were put in-place to provide additional protection for surface water quality.

water quality. New limits on nitroNew limits on nitrogen and phosphorus, chemigen and phosphorus, chemicals that function as fertilizers in surfacecals that function as fertilizers in surface waters, will effectively reduce in-stream algae growth and provide subsequent higher dissolved oxygen, waters, will effectively reduce in-stream algae growth and provide subsequent higher dissolved oxygen, thereby improvin

thereby improving conditions for aqug conditions for aquatic life. atic life. The new IWWTF at NeepawThe new IWWTF at Neepawa will be one of the firsta will be one of the first industrial facilities to comply with the new provincial requirements, producing some of the cleanest industrial facilities to comply with the new provincial requirements, producing some of the cleanest wastewater effluent possible.

wastewater effluent possible.

This report develops the IWWTF with innovative treatment processes in order to meet the new provincial This report develops the IWWTF with innovative treatment processes in order to meet the new provincial requirements.

requirements. The design basis relies on wasThe design basis relies on wastewater treatment technolotewater treatment technology knowledge of the progy knowledge of the project teamject team along with indust

along with industry experience with other processing faciry experience with other processing facilities. lities. The process has been developed to mThe process has been developed to meet aeet a 15 mg/L total n

15 mg/L total nitrogen and 1 mg/itrogen and 1 mg/L total phosphoruL total phosphorus discharge requirems discharge requirement. ent. Functional design Functional design levellevel drawings are developed to define the project in

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Section 2

Section 2 Design Basis

Design Basis

The new IWWTF will treat wastewater flows from the Springhill Farms LP pork processing facility at The new IWWTF will treat wastewater flows from the Springhill Farms LP pork processing facility at Neepawa, Manitoba.

Neepawa, Manitoba. Process wastewater will be combinProcess wastewater will be combined with truck wash and holdied with truck wash and holding area wastes priorng area wastes prior to initial screening and

to initial screening and pumping.pumping. Influent Criteria

Influent Criteria

Operation at Springhill Farms had included 18,250 head per week killed and 8,250 head per week cut. Operation at Springhill Farms had included 18,250 head per week killed and 8,250 head per week cut. Future operation is planned to includ

Future operation is planned to include 27,550 head killed and cut on a weekly basis. e 27,550 head killed and cut on a weekly basis. Future water use isFuture water use is expected to increase on a per ho

expected to increase on a per hog basis. g basis. Table 2-1 listTable 2-1 lists the unit wastewats the unit wastewater production on a per hoer production on a per hog basisg basis for the 5-day production week.

for the 5-day production week.

Table 2-1 Table 2-1

Estimated Unit Wastewater Production Estimated Unit Wastewater Production

Weekly Production Basis Weekly Production Basis

Springhill Farms LP Pork Processing Facility Springhill Farms LP Pork Processing Facility

Description

Description Units Units CriteriaCriteria Raw Raw Influent Influent UNIT PRODUCTION UNIT PRODUCTION Head

Head Killed Killed Week Week 27,55027,550 Flow

Flow per per head head L/h L/h 386386 BOD

BOD55per per head head kg/head kg/head 0.550.55

COD

COD per per head head kg/head kg/head 1.211.21 TKN

TKN per per head head kg/head kg/head 0.130.13 TP

TP per per head head kg/head kg/head 0.0120.012

5-DAY WASTEWATER PRODUCTION 5-DAY WASTEWATER PRODUCTION

Flow Flow m3/d m3/d 2,1282,128 BOD BOD55 mg/L mg/L 1,4401,440 kg/d 3,057 kg/d 3,057 COD COD mg/L mg/L 3,1353,135 kg/d 6,655 kg/d 6,655 TSS TSS mg/L mg/L 820820 kg/d 1,741 kg/d 1,741 TKN TKN mg/L mg/L 338338 kg/d 718 kg/d 718 TP TP mg/L mg/L 3030 kg/d 64 kg/d 64

The treatment facility will be designed to treat the weekly production flow, with typically five or six days The treatment facility will be designed to treat the weekly production flow, with typically five or six days of operation, in a 7-day period.

of operation, in a 7-day period. Raw influent will be screened and then pRaw influent will be screened and then pumped to a flow-attenuatioumped to a flow-attenuationn tank.

tank. The attenuation tanThe attenuation tank will fill durink will fill during the week and wilg the week and will drain over the course ol drain over the course of the weekend. f the weekend. TableTable 2-2 lists the 7-day average treatment criteria which will serve

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Table 2-2 Table 2-2

Estimated Wastewater Treatment Facility Influent Estimated Wastewater Treatment Facility Influent 7-Day Wastewater Treatment Basis - Post Attenuation 7-Day Wastewater Treatment Basis - Post Attenuation

Springhill Farms LP Pork Processing Facility Springhill Farms LP Pork Processing Facility

Description

Description Units Units CriteriaCriteria Raw Pretreat Raw Pretreat Removal Removal Pretreat Pretreat Effluent Effluent 7-DAY WASTEWATER PRODUCTION

7-DAY WASTEWATER PRODUCTION Flow FlowAA m3/d m3/d 1,520 1,520 1,5201,520 BOD BOD55 mg/L mg/L 1,440 1,440 55% 55% 648648 kg/d kg/d 2,184 2,184 983983 COD COD mg/L mg/L 3,135 3,135 55% 55% 1,4111,411 kg/d kg/d 4,754 4,754 2,1392,139 TSS TSS mg/L mg/L 820 820 77% 77% 190190 kg/d kg/d 1,243 1,243 288288 TKN TKN mg/L mg/L 338 338 56% 56% 150150 kg/d kg/d 513 513 227227 TP TP mg/L mg/L 30 30 25% 25% 2323 kg/d kg/d 45 45 3434 A.

A. Pre-attenuation Pre-attenuation flows (raw flows (raw pumping anpumping and screening) d screening) estimated at estimated at max of max of 4,540 lps 4,540 lps whichwhich translates to a

translates to a peaking factor of 3.0 during the 5-peaking factor of 3.0 during the 5-day production periodday production period

Effluent Discharge Criteria Effluent Discharge Criteria

The Springhill Farms LP IWWTP is going through the permitting process and this functional design is The Springhill Farms LP IWWTP is going through the permitting process and this functional design is part of that licensing process.

part of that licensing process. Manitoba ConservatiManitoba Conservation will require nitrogen and phon will require nitrogen and phosphorus removal forosphorus removal for new wastewater treatment facilities in Manit

new wastewater treatment facilities in Manitoba. oba. Table 2-3 lists the permit limitsTable 2-3 lists the permit limits..

A minimum of 90% total nitrogen removal efficiency will be accomplished by sufficient recycle rates, A minimum of 90% total nitrogen removal efficiency will be accomplished by sufficient recycle rates, proper operation, and the modern day equipment included in this design package.

proper operation, and the modern day equipment included in this design package. Table 2-3

Table 2-3

Effluent Discharge Criteria Effluent Discharge Criteria Springhill Farms LP IWWTF Springhill Farms LP IWWTF

Parameter Value

Carbonaceous 5-day Biological Oxygen Demand

Carbonaceous 5-day Biological Oxygen Demand <30 mg/L (based on 30 day rolling avg.)<30 mg/L (based on 30 day rolling avg.) Total

Total Suspended Suspended Solids Solids <30 <30 mg/L mg/L (based (based on on 30 30 day day rollinrolling g avg.)avg.) Total

Total Nitrogen Nitrogen <15 <15 mg/L mg/L (based (based on on 30 30 day day rolling rolling avg.)avg.) Total

Total Phosphorus Phosphorus <1 <1 mg/L mg/L (based (based on on 30 30 day day rolling rolling avg.)avg.) Fecal

Fecal Coliform Coliform <200/100 <200/100 mL mL based based on on 30 30 day day geometric geometric meanmean

Escherichia col

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Section 3 - Page 1 Section 3 - Page 1

Section 3

Section 3 Process Functional Design

Process Functional Design

This section presents the treatment processes in the industrial wastewater treatment facility serving the This section presents the treatment processes in the industrial wastewater treatment facility serving the Springhill Farm

Springhill Farms wastewater. s wastewater. The narratives The narratives below discuss below discuss the proposed the proposed treatment systtreatment system and refer em and refer toto the drawings that appear at the

the drawings that appear at the end of this report.end of this report.

Current Operation

Currently, raw influent from the facility drains to a sump in the dissolved air flotation (DAF) treatment Currently, raw influent from the facility drains to a sump in the dissolved air flotation (DAF) treatment room.

room. There it is pumThere it is pumped to the DAped to the DAF. F. DAF effluent flows DAF effluent flows to a manhole thto a manhole that also receives sanat also receives sanitary sewer,itary sewer, hog receiving facility wa

hog receiving facility water, and truck wash water. ter, and truck wash water. From the manholFrom the manhole, the combined flows are delie, the combined flows are deliveredvered to the existing treatment facility.

to the existing treatment facility.

Proposed Facility Process Description

The discu

The discussion belssion below followow follows sheet s sheet N0.0, the N0.0, the Process FloProcess Flow Diagram, w Diagram, in the in the drawing sdrawing set. et. ProcessProcess mechanical and civil d

mechanical and civil drawings are also noted. rawings are also noted. Drawings can be found at tDrawings can be found at the back of the report, after thehe back of the report, after the cost opinion section

cost opinion section

Raw Influent and Screening.

Raw Influent and Screening. Future raw influent Future raw influent will be modwill be modified from the current ified from the current operation. operation. ProcessProcess flows, sanitary sewer, barn waste and truck was flows will be combined just outside the processing flows, sanitary sewer, barn waste and truck was flows will be combined just outside the processing facility.

facility. A new pump station wA new pump station will lift water into a forcemill lift water into a forcemain and convey flows to the primain and convey flows to the primary treatmentary treatment building at the new treatment site.

building at the new treatment site.

The raw influent pumping and screening facilities need to be sized to process all flows that occur during The raw influent pumping and screening facilities need to be sized to process all flows that occur during the product

the production schedion schedule. ule. Flows vary Flows vary widely duwidely during a ring a production production day. day. Most of Most of the wastewatthe wastewater flowser flows occur during the 8-hour work day with additional wastewater coming as a result of cleaning flows after occur during the 8-hour work day with additional wastewater coming as a result of cleaning flows after the productio

the production day. n day. The raw The raw influent puminfluent pumping and ping and screening facilitscreening facilities are sized ies are sized for 4,540 for 4,540 lpm. lpm. On aOn a seven day period, this equat

seven day period, this equates to a peaking factor of 4.3 on a seven day week. es to a peaking factor of 4.3 on a seven day week. Production may occur,Production may occur, however, in a five day week and so the raw influent side of the IWWTF needs to be sized to however, in a five day week and so the raw influent side of the IWWTF needs to be sized to accommodate those flow

accommodate those flows. s. If 4,540 lpm is applied tIf 4,540 lpm is applied to a five day production scho a five day production schedule, the associated dailyedule, the associated daily peaking factor is 3.0.

peaking factor is 3.0. As each hog processing facility is uniqAs each hog processing facility is unique, pumping capabilitue, pumping capabilities will be sized withies will be sized with flexible capacities to be able to

flexible capacities to be able to provide for a certain level of provide for a certain level of uncertainty.uncertainty. Influent screen

Influent screen size will be size will be 0.76 mm t0.76 mm to 1.0mm. o 1.0mm. Vendor data on Vendor data on the screen (IPEC 5the screen (IPEC 5496) is prov496) is provided inided in the appendices.

the appendices.

Instrumentation schematics N1.0 and N2.0 show the raw pumping/screening and pumping to the flow Instrumentation schematics N1.0 and N2.0 show the raw pumping/screening and pumping to the flow attenuation tank.

attenuation tank. Mechanical sheet M2.0 and MMechanical sheet M2.0 and M2.1 show the facility l2.1 show the facility layout and a section.ayout and a section. Primary Treatment – First Stage DAF.

Primary Treatment – First Stage DAF. Out of the screen, water will drain to the new first stage DAFOut of the screen, water will drain to the new first stage DAF unit, sized to

unit, sized to treat flows form treat flows form the raw influent the raw influent pump statipump station. on. The purpose of The purpose of the primary the primary DAF unit is DAF unit is toto remove fats/oils and gritty

remove fats/oils and gritty material that would presenmaterial that would present operational issues in tht operational issues in the flow attenuation tank. e flow attenuation tank. ItIt will remove 70% to 80

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Section 3 - Page 2 Section 3 - Page 2 with a tricanter centri

with a tricanter centrifuge that will sepfuge that will separate the fat from the water anarate the fat from the water and from the solidsd from the solids. . The tricanterThe tricanter technology includ

technology includes a heat treatment step with steam addites a heat treatment step with steam addition prior to addition to thion prior to addition to the centrifuge. e centrifuge. The fatThe fat fat stream will be pump

fat stream will be pumped to a fat storage tank and then used foed to a fat storage tank and then used for boiler heating. r boiler heating. The sludge and centratThe sludge and centratee are recombined to the main sludge hopper that is

are recombined to the main sludge hopper that is pumped to the sludge stabilization and storage pond.pumped to the sludge stabilization and storage pond. Effluent from the first stage DAF unit d

Effluent from the first stage DAF unit drains to a sump. rains to a sump. That water is subsequently pumThat water is subsequently pumped to the flowped to the flow attenuation tank.

attenuation tank. Flow Attenuation.

Flow Attenuation. The tank will be covered and insulated to reduce heat loss during winter timeThe tank will be covered and insulated to reduce heat loss during winter time conditions.

conditions. It will be eqIt will be equipped with uipped with a mixing sa mixing system to ensystem to ensure no solid seture no solid settling occurs. tling occurs. The attenuationThe attenuation tank will provide 2.5 days of storage.

tank will provide 2.5 days of storage. It will fill throughout the work week and will draiIt will fill throughout the work week and will drain throughout then throughout the two day weeken

two day weekend. d. The remaininThe remaining 0.5 days g 0.5 days of storage wof storage will be usill be used as a mied as a minimum watnimum water level to er level to ensureensure the tank can be mixed and the wastewater quality out o

the tank can be mixed and the wastewater quality out of the tank remains consistentf the tank remains consistent. . This will allow theThis will allow the main treatment process to be designed for average flows, reducing the overall capital cost as well as the main treatment process to be designed for average flows, reducing the overall capital cost as well as the variability in wastewater quality.

variability in wastewater quality.

The attenuation tank will be sized for 2.5 days of storage, translating to 3,800 M

The attenuation tank will be sized for 2.5 days of storage, translating to 3,800 M33. . It It will will be be a epoa epoxyxy coated bolted steel structure with a cover and spray on insulation that is protected with a spray on coated bolted steel structure with a cover and spray on insulation that is protected with a spray on membrane.

membrane.

Primary Treatment - Second Stage DAF.

Primary Treatment - Second Stage DAF. The second stage DAF unit includes a flocculantion andThe second stage DAF unit includes a flocculantion and coagulation step wit

coagulation step with metal salt (likely ferric chloride) and poh metal salt (likely ferric chloride) and polymer. lymer. Flows from the attenuation tank areFlows from the attenuation tank are regulated to the DAF unit.

regulated to the DAF unit. Metal salt and polymer is inMetal salt and polymer is introduced upstream of a plug flow troduced upstream of a plug flow reactor prior toreactor prior to entering the DAF unit.

entering the DAF unit. The metal salt and polymThe metal salt and polymer will be key in achieving suffier will be key in achieving sufficient nitrogen removcient nitrogen removalal so that the activated sludge system can meet

so that the activated sludge system can meet permit limits.permit limits.

Effluent from the second stage DAF unit drains to a large standpipe/wetwell and is subsequently pumped Effluent from the second stage DAF unit drains to a large standpipe/wetwell and is subsequently pumped to the anoxic basin in the

to the anoxic basin in the activated sludge process.activated sludge process.

Sludge from the second stage DAF will flow to the main sludge hopper where it is combined with Sludge from the second stage DAF will flow to the main sludge hopper where it is combined with tricanter sludge and thickened waste activated sludge prior and then is pumped to the sludge stabilization tricanter sludge and thickened waste activated sludge prior and then is pumped to the sludge stabilization and storage ponds.

and storage ponds.

Activated Sludge / MBR.

Activated Sludge / MBR. The membrane bioreactor (MBR) is an activated sludge process that usesThe membrane bioreactor (MBR) is an activated sludge process that uses membranes in lieu of clarifiers as the solids/liqu

membranes in lieu of clarifiers as the solids/liquids separation step. ids separation step. The activated sludge system relies onThe activated sludge system relies on suspended

suspended bacteria in bacteria in solution solution that cothat consume nsume organic morganic material. aterial. They coThey convert thnvert the organic e organic material,material, expressed as chemical oxygen demand (COD) or biological oxygen demand (BOD

expressed as chemical oxygen demand (COD) or biological oxygen demand (BOD55), and produce more), and produce more

bacterial biomass.

bacterial biomass. In doing so, nitrogIn doing so, nitrogen and phosphorus en and phosphorus are taken up to support groare taken up to support growth of the bacteria.wth of the bacteria. Metal salts will be added to the treatment process to further reduce soluble phosphorus in the liquid Metal salts will be added to the treatment process to further reduce soluble phosphorus in the liquid stream.

stream. The system uses an aerated reactoThe system uses an aerated reactor to oxidize ammor to oxidize ammonia to nitrate (nitrificatnia to nitrate (nitrification) and a primaryion) and a primary non-aerated bi

non-aerated biological ological reactor to reactor to transform transform nitrate to nitrate to nitrogen nitrogen gas (denitrigas (denitrification). fication). A secondarA secondary non-y non-aerated reactor is provided that will be dosed with an external carbon sources (sugar) to polish additional aerated reactor is provided that will be dosed with an external carbon sources (sugar) to polish additional nitrate out

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Section 3 - Page 3 Section 3 - Page 3 The general pro

The general process configuration cess configuration is illustrated is illustrated on instrumon instrumentation sheet entation sheet N0.0. N0.0. The liquid The liquid processprocess component is further illus

component is further illustrated in sheets N4.0 and N5.0. trated in sheets N4.0 and N5.0. The aeration systems are illusThe aeration systems are illustrated in sheetstrated in sheets N7.0 and N8.0.

N7.0 and N8.0.

Civil drawing sheet C2.0 and C3.0 show the layout of the anoxic and aeration ta

Civil drawing sheet C2.0 and C3.0 show the layout of the anoxic and aeration tanks. nks. Mechanical drawingMechanical drawing sheets M1.0 and M1.1 show the layout of

sheets M1.0 and M1.1 show the layout of the MBR equipment within the treatment building.the MBR equipment within the treatment building.

There are a number of MBR manufacturers in the market today, but one in particular stands out in the There are a number of MBR manufacturers in the market today, but one in particular stands out in the industrial treatme

industrial treatment market. nt market. Zenon/GE EnvironmZenon/GE Environmental was the first large scale mental was the first large scale manufacturer of MBRsanufacturer of MBRs and today remains

and today remains the leader related to desithe leader related to design and build gn and build work. work. Vendor data for the ZenVendor data for the Zenon equipment andon equipment and other ancillary equipm

other ancillary equipment is provided in the appendices. ent is provided in the appendices. The Zenon proposal has equipThe Zenon proposal has equipment that has ament that has a firm capacity of 1,520 M

firm capacity of 1,520 M33 /day. /day. One One membrane membrane tank tank can can process process the the design design flow flow during during periods periods of of maintenance, provi

maintenance, providing the ding the necessary level onecessary level of redundancy. f redundancy. The system hThe system has an expandabas an expandability of ility of approximately 10% for future growth

approximately 10% for future growth or additional flows.or additional flows.

Table 3-1 Table 3-1

Activated Sludge / MBR Process Sizing Activated Sludge / MBR Process Sizing Springhill Farms LP Pork Processing Facility Springhill Farms LP Pork Processing Facility

Parameter Value Parameter Value Anoxic Tank Anoxic Tank Volume Volume

HRT for forward flow HRT for forward flow MLSS MLSS Anoxic Recycle Anoxic Recycle 950 M 950 M33 15.0 hrs 15.0 hrs 10,000 mg/L 10,000 mg/L 14 times Q 14 times Q Aeration Tanks Aeration Tanks Number and Volume Number and Volume Total Volume Total Volume HRT HRT MLSS MLSS 2 @ 760 M 2 @ 760 M33 1520 M 1520 M33 24 hrs 24 hrs 10,000 mg/L 10,000 mg/L Membrane Separation (ZeeWeed

Membrane Separation (ZeeWeed®®)) Number of Units

Number of Units Cassettes per Unit Cassettes per Unit

No. Modules per Cassette No. Modules per Cassette Type:

Type:

Size of Each Unit Size of Each Unit Effluent TSS Effluent TSS 2 2 2 2 48 48 Zenon ZW500D Zenon ZW500D 12.2 m x 2.4 m x 3.4 m high 12.2 m x 2.4 m x 3.4 m high < 2 mg/L < 2 mg/L SRT SRT

WAS (with metal salt addition) WAS (with metal salt addition)

25 days 25 days 816 kg/day 816 kg/day

Disinfection.

Disinfection. The MBR effluent has low effluent suspended solids and turbidity and as such is relativelyThe MBR effluent has low effluent suspended solids and turbidity and as such is relatively easy to disinfect.

easy to disinfect. A closed conduit ultravioA closed conduit ultraviolet disinfection system let disinfection system is proposed for use and will be lois proposed for use and will be locatedcated inside the treatmen

inside the treatment building. t building. The units will be a loThe units will be a low pressure high intensitw pressure high intensity system by Wedeco or equaly system by Wedeco or equal.. Two units are propo

Two units are proposed, each that can disinfect 10sed, each that can disinfect 100% of the design 0% of the design flow. flow. The units have been The units have been sized for asized for a disinfection of 120% of the design flow (1,825 M

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Section 3 - Page 4 Section 3 - Page 4 backup

backup capacity. capacity. The The 100 100 mJ/cmmJ/cm22 dose will produce effluent easily dose will produce effluent easily meeting the coliform values listed inmeeting the coliform values listed in Table 2-3.

Table 2-3.

Vendor data on the UV

Vendor data on the UV equipment is provided in the appendices.equipment is provided in the appendices.

The UV system is illustrated in instrumentation drawing N8.0 and shown on mechanical sheet M1.0 and The UV system is illustrated in instrumentation drawing N8.0 and shown on mechanical sheet M1.0 and M1.1.

M1.1.

Effluent Cooling.

Effluent Cooling. A cooling tower process will be installed to provide effluent at winter ambient (4oC)A cooling tower process will be installed to provide effluent at winter ambient (4oC) conditions.

conditions. The process will The process will have the ability for have the ability for recirculation and autorecirculation and automatic bypass to matic bypass to regulate theregulate the effluent temperature.

effluent temperature. Biosolids Handling.

Biosolids Handling. Several sludge streams will be produced between primary treatment and theSeveral sludge streams will be produced between primary treatment and the activated sludge system

activated sludge system. . The sludge flow from thThe sludge flow from the first DAF will be high in fat that must be separate first DAF will be high in fat that must be separateded from the sludge flow.

from the sludge flow. Sludge will be pumped Sludge will be pumped to a tricanter process that heats tto a tricanter process that heats the sludge and thenhe sludge and then processes through a special cent

processes through a special centrifuge that fractionates the fat from trifuge that fractionates the fat from the solids and water. he solids and water. The fat is thenThe fat is then pumped to a heated s

pumped to a heated storage vessel and then used in torage vessel and then used in the boiler system as fuelthe boiler system as fuel. . The primary DAF isThe primary DAF is expected to produce appro

expected to produce approximately 300 lbs oximately 300 lbs of fat per day. f fat per day. The fat from the DAF unit The fat from the DAF unit is expected to fullyis expected to fully fuel the steam boi

fuel the steam boiler on an average basis. ler on an average basis. The boiler will bThe boiler will be installed with due installed with dual burners, however, as aal burners, however, as a backup system

backup system. . l. l. The sludge The sludge and water wiand water will be recomll be recombined in bined in a common a common hopper with hopper with sludge from sludge from thethe second stage DAF.

second stage DAF. That combined sludge stream will be pumThat combined sludge stream will be pumped to the sludge storage ponds.ped to the sludge storage ponds.

Sludge flow from the MBR/activated sludge process is be thickened in a dedicated dissolved air flotation Sludge flow from the MBR/activated sludge process is be thickened in a dedicated dissolved air flotation thickener (DA

thickener (DAFT) unit. FT) unit. The DAFT The DAFT is sized is sized sufficiently lsufficiently large so arge so that polymthat polymer is er is not necessary. not necessary. FloatFloat sludge from this unit is comb

sludge from this unit is combined in a common hopper with the sludge from thined in a common hopper with the sludge from the pretreatment DAFs e pretreatment DAFs TheThe two DAF units are expected to produce approximately 1,200 kg/d total solids, including metal salt two DAF units are expected to produce approximately 1,200 kg/d total solids, including metal salt complexes, with the sec

complexes, with the second stage DAF producinond stage DAF producing the most sludgg the most sludge. e. The activated sludge sysThe activated sludge system istem is expected to produce 840 kg/d total solids

expected to produce 840 kg/d total solids, including metal salt complexes, including metal salt complexes. . ..

The 12 million gallon polishing cell in the existing treatment process will be retrofitted and to store and The 12 million gallon polishing cell in the existing treatment process will be retrofitted and to store and stabilize sludge.

stabilize sludge. The existing cell will be drained, cleaned out and a new divider berm will be installed inThe existing cell will be drained, cleaned out and a new divider berm will be installed in the middle of

the middle of the pond. the pond. The inside slThe inside slopes will be graded opes will be graded to 3:1. to 3:1. A new double HA new double HDPE liner system DPE liner system willwill be installed to provi

be installed to provide primary and secondary code primary and secondary containment. ntainment. The new sludge ponds wThe new sludge ponds will have aeration,ill have aeration, mixing, and sludge lo

mixing, and sludge loadout. adout. Each compartment wiEach compartment will be approximately 18ll be approximately 18,500 cubic meters and will be,500 cubic meters and will be sufficient to provide 400 days of hold time so that each will be fed on alternate years to provide ‘batch’ sufficient to provide 400 days of hold time so that each will be fed on alternate years to provide ‘batch’ treatment

treatment

The liner system

The liner system will consist owill consist of the following: f the following: HDPE geocompoHDPE geocomposite media with site media with single sided nsingle sided non-wovenon-woven geotextile on the soil side for gas venting, 80 mil HDPE conductive containment liner plumbed to a geotextile on the soil side for gas venting, 80 mil HDPE conductive containment liner plumbed to a monitoring sump, HDPE geocomposite media to convey leakage flow between the liners, and a final monitoring sump, HDPE geocomposite media to convey leakage flow between the liners, and a final primary layer of 80 mil HDPE conductive liner. The primary liner leakage will be monitored for leakage primary layer of 80 mil HDPE conductive liner. The primary liner leakage will be monitored for leakage by using the

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Equipment List

Table 3.2 lists the major equipm

Table 3.2 lists the major equipment identified for this projectent identified for this project. . The list generally follows tThe list generally follows the discussionhe discussion above.

above.

Operational Requirements

The wastewater treatment facility wil

The wastewater treatment facility will run 24 hours per day seven days per week. l run 24 hours per day seven days per week. It will be staffed duringIt will be staffed during one shift per

one shift per day, seven days peday, seven days per week. r week. Three full timThree full time staff have been e staff have been assumed for opeassumed for operations.rations.

Control System

Because the plant will run

Because the plant will run unattended much of the time, automatic control of the unattended much of the time, automatic control of the unit processes is critical.unit processes is critical. A central programmable logic controller (PLC)

A central programmable logic controller (PLC) will provide the automatic control and will provide the automatic control and data acquisition fordata acquisition for the various unit processes

the various unit processes. . Some of the unit processes wiSome of the unit processes will be supported by vendll be supported by vendor PLCs, such as withor PLCs, such as with the MBR, centrifuges, and UV disinfecti

the MBR, centrifuges, and UV disinfection equipment. on equipment. In those instances, the vendor PLCs wilIn those instances, the vendor PLCs will providel provide data to the central PLC.

data to the central PLC. In the event of a critical alarmIn the event of a critical alarm, the central PLC will produce an al, the central PLC will produce an alarm call toarm call to plant staff telephones.

plant staff telephones.

Odors

Wastewater treatment facili

Wastewater treatment facilities generate odors. ties generate odors. Some are minor and some are major, but alSome are minor and some are major, but all treatmentl treatment facilities produce

facilities produce some type of off-gsome type of off-gas with an aroma. as with an aroma. Such odors can be mSuch odors can be managed or minimanaged or minimized byized by containment,

containment, ventilation, ventilation, facility cifacility citing, anting, and odod odor contror control equil equipment pment when nwhen necessary. ecessary. The exThe existingisting industrial wastewater treatment facility generates odors due to the DAF pretreatment facility and industrial wastewater treatment facility generates odors due to the DAF pretreatment facility and treatment ponds

treatment ponds. . The plant lThe plant location, on the ocation, on the downwind sidownwind side of the Tode of the Town of Neepawa, aswn of Neepawa, assists in keepsists in keepinging wastewater and hog processing odors out of town.

wastewater and hog processing odors out of town. The new IWWTF will contain consi

The new IWWTF will contain considerably less open water surface than the exiderably less open water surface than the existing facilities. sting facilities. The unitThe unit processes contain a hig

processes contain a higher level of control than her level of control than the existing facilitthe existing facilities. ies. Therefore, the new IWWTF willTherefore, the new IWWTF will produce less odors than the existing facilities.

produce less odors than the existing facilities.

Traffic

The wastewater treatment facility wil

The wastewater treatment facility will be staffed one shift per day. l be staffed one shift per day. Chemical deliveries of polymChemical deliveries of polymer, metaler, metal salt (ferric chloride or alum), magnesium hydroxide, and carbon source (sugar) will be brought in on a salt (ferric chloride or alum), magnesium hydroxide, and carbon source (sugar) will be brought in on a monthly

monthly basis. basis. Truck traffic Truck traffic to the to the IWWTF wiIWWTF will average ll average about twabout two trucks o trucks per day per day during during normalnormal conditions.

conditions. Under non-biosolidUnder non-biosolids application periods, the traffic to and from the IWWTF will be minimal.s application periods, the traffic to and from the IWWTF will be minimal. Once per year, there will be a liquid biosolids handling campaign where stored biosolids will be pumped Once per year, there will be a liquid biosolids handling campaign where stored biosolids will be pumped out and applied to land.

out and applied to land. During those campDuring those campaigns, there will be approximaigns, there will be approximately 800 (5,000 gallon) truately 800 (5,000 gallon) truck ck loads over a two week period.

loads over a two week period. Trucks will be routed throTrucks will be routed through the a new plant access road in ugh the a new plant access road in the existingthe existing plant access right of way.

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Section 3 - Page 6 Section 3 - Page 6 Table 3-2 Table 3-2 Equipment List Equipment List

IITTEEM M AANND D FFUUNNCCTTIIOONN NNOO.. TTYYPPEE CCAAPPAACCIITTYY HPHP LLOOCCAATTIIOONN SSPPEECCIIFFIICCAATTIIOONNS S / / CCOOMMMMEENNTTSS

HEADWORKS FACILITY HEADWORKS FACILITY

R

RAAW W LLIIFFT T PPUUMMPP 1+1+((11)) SSEELLF F PPRRIIMMIINNGG TRASH PUMP TRASH PUMP 3024 LPM @ 12.2 m (800 3024 LPM @ 12.2 m (800 gpm @ 40 feet) gpm @ 40 feet) 15 kW (20 15 kW (20 HP) HP) HW

HW BLBLDGDG T-T-SESERIRIES ES GOGORMRMAN AN RURUPPPP, B, BACACKUKUP SP SHAHAREREDD WITH RAW LIFT PUMP, Z-BELT

WITH RAW LIFT PUMP, Z-BELT CONFIGURATION CONFIGURATION F FIINNE E SSCCRREEEENN 11 IINNTTEERRNNAALLLLY Y FFEEDD DRUM DRUM 45 4530 30 LPLPM (M (1,1,20200 G0 GPMPM)) 1.1.1 k1 kWW (1.5 HP) (1.5 HP) HW

HW BBLDLDGG IPIPEC EC 545496 96 WIWITH TH 0.0.0202" W" WEDEDGEGEWIWIRERE SC

SCREREENENED ED LILIFT FT PUPUMPMP 1+1+(1)(1) SESELF LF PRPRIMIMININGG TRASH PUMP TRASH PUMP 3024 LPM @ 12.2 m (800 3024 LPM @ 12.2 m (800 gpm @ 40 feet) gpm @ 40 feet) 15 kW (20 15 kW (20 HP) HP) HW

HW BLBLDGDG T-T-SESERIRIES ES GOGORMRMAN AN RURUPPPP, B, BACACKUKUP SP SHAHAREREDD WITH RAW LIFT PUMP, Z-BELT

WITH RAW LIFT PUMP, Z-BELT CONFIGURATION

CONFIGURATION

FLOW ATTENUATION TANK FLOW ATTENUATION TANK

FLOW ATTENUATION FLOW ATTENUATION TANK TANK 1 1 PPAAIINNTTEED BD BOOLLTTEEDD STEEL STEEL 3787M3 (1.0 MG), 24.4 M 3787M3 (1.0 MG), 24.4 M (80FT) DIA. X 9.1 M (30 (80FT) DIA. X 9.1 M (30 FT) SWD FT) SWD N

NAA OOUUTTSSIIDDEE WWIITTH H CCOOVVEERR, , WWIITTH H 33" " FFOOAAM M IINNSSUULLAATTIIOONN AND SPRAY ON MEMBRANE

AND SPRAY ON MEMBRANE T

TAANNK K MMIIX X PPUUMMPP 11 SSEELLF F PPRRIIMMIINNGG TRASH PUMP TRASH PUMP 4540 LPM @ 17 m (1200 4540 LPM @ 17 m (1200 gpm @ 45 feet) gpm @ 45 feet) 25 kW (40 25 kW (40 HP) HP) HW

HW BLBLDGDG T-T-SSERERIEIES GS GORORMAMAN RN RUPUPP, P, Z-Z-BEBELTLT CONFIGURATION CONFIGURATION D DAAF F FFEEEED D PPUUMMPP 11 SSEELLF F PPRRIIMMIINNGG TRASH PUMP TRASH PUMP 1500 LPM @ 3 m (400 1500 LPM @ 3 m (400 gpm @ 10 feet) gpm @ 10 feet) 1.9 kW 1.9 kW (2.5 HP) (2.5 HP) HW

HW BLBLDGDG T-T-SSERERIEIES GS GORORMAMAN RN RUPUPP, P, Z-Z-BEBELTLT CONFIGURATION

CONFIGURATION

ACTIVATED SLUDGE TANKAGE ACTIVATED SLUDGE TANKAGE

A ANNOOXXIIC C TTAANNKK 11 PAPAIINNTTEED D BBOOLLTTEEDD STEEL STEEL 950M3 (0.25 MG), 14.3 M 950M3 (0.25 MG), 14.3 M (47FT) DIA. X 6.4 M (21 (47FT) DIA. X 6.4 M (21 FT) SWD FT) SWD N

NAA OOUUTTSSIIDDEE NNO CO COOVVEERR, , WWIITTH 3H 3" " FFOOAAM M IINNSSUULLAATTIIOON N AANNDD SPRAY ON MEMBRANE

SPRAY ON MEMBRANE A

ANNOOXXIIC C TTAANNK K MMIIXXEERR 11 FFLLOOAATTIINNG G MMIIXXEERR NNAA 330 0 kkW W ((4400 HP) HP)

ANOX

ANOXIC TANKIC TANK AQUA AEAQUA AEROBIROBICS DDMCS DDM A AEERRAATTIIOON N TTAANNKK 22 PPAAIINNTTEED D BBOOLLTTEEDD STEEL STEEL 760M3 (0.20 MG), 12.5 M 760M3 (0.20 MG), 12.5 M (41FT) DIA. X 6.4 M (21 (41FT) DIA. X 6.4 M (21 FT) SWD FT) SWD N

NAA OOUUTTSSIIDDEE NNO CO COOVVEERR, , WWIITTH 3H 3" " FFOOAAM M IINNSSUULLAATTIIOON N AANNDD SPRAY ON MEMBRANE SPRAY ON MEMBRANE A AEERRAATTIIOON N SSYYSSTTEEMMSS 22 99" " MMEEMMBBRRAANNEE DIFFUSER DIFFUSER 450 DIFFUSERS, 650 450 DIFFUSERS, 650 SCFM EACH SYSTEM SCFM EACH SYSTEM N NAA AAEERRAATTIIOONN TANKS TANKS

ITT / SANITAIRE SILVER SERIES ITT / SANITAIRE SILVER SERIES P POOSST T AANNOOXXIIC C TTAANNKKSS 22 PPAAIINNTTEED D BBOOLLTTEEDD STEEL STEEL 169M3 (0.05 MG), 6 M 169M3 (0.05 MG), 6 M (20FT) DIA. X 6 M (20 FT) (20FT) DIA. X 6 M (20 FT) SWD SWD N

NAA OOUUTTSSIIDDEE CCOOVVEERREEDD, , WWIITTH 3H 3" " FFOOAAM M IINNSSUULLAATTIIOON N AANNDD SPRAY ON MEMBRANE

SPRAY ON MEMBRANE POST ANOXIC MIX

POST ANOXIC MIX PUMPS PUMPS 2 2 EENND D SSUUCCTTIIOONN HORIZONTAL, FRAME HORIZONTAL, FRAME MOUNTED MOUNTED 750 LPM @ 15.2 m (200 750 LPM @ 15.2 m (200 gpm @ 50 feet) gpm @ 50 feet) 4.7 kW 4.7 kW (6.5 HP) (6.5 HP) PROCESS PROCESS BUILDING BUILDING

BELL AND GOSSETT OR EQUAL BELL AND GOSSETT OR EQUAL

MBR AND ANCILLARIES MBR AND ANCILLARIES MEMBRANE UNITS, MEMBRANE UNITS, PREASSEMBLED PREASSEMBLED 2 2 PPRREE--AASSSSEEMMBBLLEEDD 11,,55220 0 MM33//D D ((00..4 4 MMGGDD)) FIRM FIRM N NAA PPRROOCCEESSSS BUILDING BUILDING

EPOXY COATED RECTANGULAR TANK WITH EPOXY COATED RECTANGULAR TANK WITH 96 ZW500D MEMBRANE ELEMENTS IN TWO 96 ZW500D MEMBRANE ELEMENTS IN TWO CASSETTES, PART OF MBR SUPPLIER CASSETTES, PART OF MBR SUPPLIER PACKAGE PACKAGE MBR RECIRCULATION MBR RECIRCULATION PUMP RACK PUMP RACK PR

PRE-E-ASASSESEMBMBLELEDD 262625 25 LPLPM @ M @ 7.7.6 m 6 m (7(70000 gpm @ 25 feet) gpm @ 25 feet) T TBBDD PPRROOCCEESSSS BUILDING BUILDING

PART OF MBR SUPPLIER PACKAGE PART OF MBR SUPPLIER PACKAGE P PEERRMMEEAATTE E PPUUMMP P R AR ACCKK PPRREE--AASSSSEEMMBBLLEEDD 55225 5 LLPPM M @ @ X X m m ((22880 0 ggppmm @ X feet) @ X feet) T TBBDD PPRROOCCEESSSS BUILDING BUILDING

PART OF MBR SUPPLIER PACKAGE PART OF MBR SUPPLIER PACKAGE MEMBRANE SCOUR MEMBRANE SCOUR BLOWERS BLOWERS 2 2 PPOOSSIITTIIVVEE DISPLACEMENT WITH DISPLACEMENT WITH SOUND SOUND ENCLOSURES ENCLOSURES T TBBDD 3300kkWW((4400 HP) HP) PROCESS PROCESS BUILDING BUILDING

KAESER MODEL XXX, SOUND ENCLOSURE KAESER MODEL XXX, SOUND ENCLOSURE TO MEET 75 DbA at 1m,

TO MEET 75 DbA at 1m, PART OF MBRPART OF MBR SUPPLIER PACKAGE

SUPPLIER PACKAGE AERATION / AIR LIFT

AERATION / AIR LIFT PUMP BLOWERS PUMP BLOWERS 3 3 PPOOSSIITTIIVVEE DISPLACEMENT WITH DISPLACEMENT WITH SOUND SOUND ENCLOSURES ENCLOSURES 1,200 SCFM AT MAX 1,200 SCFM AT MAX 12PSIG BLOWOFF 12PSIG BLOWOFF 75KW 75KW (100 HP) (100 HP) PROCESS PROCESS BUILDING BUILDING

KAESER FB 620C, SOUND ENCLOSURE TO KAESER FB 620C, SOUND ENCLOSURE TO MEET 75 DbA at 1m. MEET 75 DbA at 1m. F FEERRRRIIC C TTAANNKK 11 PPOOLLYYEETTHHLLEENNEE 223 3 MM3 3 ((66,,00000 0 GGAALL)) NNAA F FEERRRRIIC C FFEEEEDDEERR 11 HHOOSSE E PPUUMMPP MMAAX X 33..5 5 LLPPM M ((556 6 GGPPHH)) <<00..3 3 KKWW (<0.5 HP) (<0.5 HP) PROCESS PROCESS BUILDING BUILDING

WATSON MARLOW DU520REL HOSE PUMP, WATSON MARLOW DU520REL HOSE PUMP, WILL KEEP ONE ON-SHELF SPARE INSTEAD WILL KEEP ONE ON-SHELF SPARE INSTEAD OF REDUNDANT UNITS OF REDUNDANT UNITS MAGNESIUM MAGNESIUM HYDROXIDE TANK HYDROXIDE TANK 1 1 PPAAIINNTTEED D SSTTEEEELL 223 3 MM3 3 ((66,,00000 0 GGAALL)) 1 1 KKW W ((11..55 HP) HP) PROCESS PROCESS BUILDING BUILDING

TOP MOUNTED MIXER 7.5 HP MIXER TOP MOUNTED MIXER 7.5 HP MIXER MAGNESIUM MAGNESIUM HYDROXIDE FEEDER HYDROXIDE FEEDER 1 1 HHOOSSE E PPUUMMPP MMAAX X 33..5 5 LLPPM M ((556 6 GGPPHH)) <<00..3 3 KKWW (<0.5 HP) (<0.5 HP) PROCESS PROCESS BUILDING BUILDING

WATSON MARLOW DU520REL HOSE PUMP, WATSON MARLOW DU520REL HOSE PUMP, WILL KEEP ONE ON-SHELF SPARE INSTEAD WILL KEEP ONE ON-SHELF SPARE INSTEAD OF REDUNDANT UNITS OF REDUNDANT UNITS S SUUGGAAR R BBUULLK K SSYYSSTTEEMM 11 S SUUGGAAR R SSTTOOCCK K TTAANNKK 11 PPOOLLYYEETTHHLLEENNEE 223 3 MM3 3 ((66,,00000 0 GGAALL)) NNAA MAGNESIUM MAGNESIUM HYDROXIDE FEEDER HYDROXIDE FEEDER 1 1 HHOOSSE E PPUUMMPP MMAAX X 33..5 5 LLPPM M ((556 6 GGPPHH)) <<00..3 3 KKWW (<0.5 HP) (<0.5 HP) PROCESS PROCESS BUILDING BUILDING

WATSON MARLOW DU520REL HOSE PUMP, WATSON MARLOW DU520REL HOSE PUMP, WILL KEEP ONE ON-SHELF SPARE INSTEAD WILL KEEP ONE ON-SHELF SPARE INSTEAD OF REDUNDANT UNITS OF REDUNDANT UNITS DAF Units DAF Units P PRRIIMMAARRY Y DDAAFF 11 44,,55440 0 LLPPM M ((11,,22000 0 GGPPM M--US) US) IPL090E BY NIJHUIS IPL090E BY NIJHUIS S

SEECCOONNDDAARRY Y DDAAFF 11 11,,33220 0 LLPPM M ((33550 0 GPGPMM--UUSS)) IIFFPP009900E E BBY Y NNIIJJHHUUIIS S WWIITTH H PPFFRR T

THHIICCKKEENNIINNG G DDAAFF 11 662 2 LLPPM M ((1166..5 5 GGPPMM--UUSS)) GGDDS S BBY Y NNIIJJHHUUIISS S SLLUUDDGGE E PPUUMMPPSS 11 LAGOON SYSTEM LAGOON SYSTEM SLUDGE AERATION SLUDGE AERATION BLOWER BLOWER 1 1 110000 KKAAEESSEERR M MIIXXIINNGGLLOOAADDOOUUTT 11 TTBBDD

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Contingency Planning

The Neepawa IWWTF, as layed out, has redundancy in-place in each unit process and has multiple The Neepawa IWWTF, as layed out, has redundancy in-place in each unit process and has multiple barriers.

barriers. The combined reduThe combined redundancy with mndancy with multiple barriers leaves ultiple barriers leaves the facility far less sthe facility far less susceptible tousceptible to catastrophic failure as a result of process and process equipment.

catastrophic failure as a result of process and process equipment. The following are provisions availabThe following are provisions available:le: •

• Influent Pumping.Influent Pumping. One duty and one standby pumpsOne duty and one standby pumps •

• Screen.Screen. One screen provided tOne screen provided that is highly reliabhat is highly reliable from a mechanical standple from a mechanical standpoint. oint. If for someIf for some reason, the screen could no

reason, the screen could no longer function, the system can run without screening.longer function, the system can run without screening. •

• Flow attenuation lift pumps.Flow attenuation lift pumps. One duty lift pump with a One duty lift pump with a standby pump.standby pump. •

• Two Stage DAF System.Two Stage DAF System. The first DAF is fed by gravity from the flow attenuation tank andThe first DAF is fed by gravity from the flow attenuation tank and does

does not not rely rely on on chemical chemical dosing. dosing. The The second second stage stage DAF DAF does does have have chemical chemical dosing. dosing. TheThe system can be run with on

system can be run with one unit down for a period fe unit down for a period for servicing. or servicing. The DAF equipmenThe DAF equipment is highlyt is highly reliable, however, and not subject to

reliable, however, and not subject to break downs with proper maintenance.break downs with proper maintenance. •

• Process Feed Pumps.Process Feed Pumps. DAF effluent will be fed to the anoxic tank using process feed pumps.DAF effluent will be fed to the anoxic tank using process feed pumps. One duty and one standby pump are

One duty and one standby pump are provided.provided. •

• Anoxic Recycle PumpingAnoxic Recycle Pumping is accomplished with is accomplished with air lift pumps tair lift pumps that are not subject that are not subject to failure. o failure. OneOne blower is dedicat

blower is dedicated to air lift ed to air lift pumping and pumping and is same size as is same size as the aeration blothe aeration blowers. wers. A standbyA standby blower is provided for backup.

blower is provided for backup. •

• MBR Recycle PumpingMBR Recycle Pumping is accomplished wis accomplished with end suction ith end suction pumps in pumps in the treatment builthe treatment building. ding. AA spare pump is provided for backup.

spare pump is provided for backup. •

• Two MBRTwo MBRtanks with assoctanks with associated membrane cassettes are proiated membrane cassettes are provided. vided. The system is sized sThe system is sized such thatuch that all the flow can

all the flow can be processed through one membrane tank when necessary.be processed through one membrane tank when necessary. •

• Post Anoxic Treatment.Post Anoxic Treatment. The pretreatment and activated sludge system is designed to meet theThe pretreatment and activated sludge system is designed to meet the required effluent conditions related to total nitrogen removal assuming a certain set of required effluent conditions related to total nitrogen removal assuming a certain set of assumptions

assumptions related trelated to wastewo wastewater compoater composition. sition. Because Because there is there is an ever an ever small small chance thechance the wastewater could be organically limited, a post anoxic system is provided that includes post wastewater could be organically limited, a post anoxic system is provided that includes post anoxic tanks ahead of the MBR tanks.

anoxic tanks ahead of the MBR tanks. A supplementary carbon source feed systA supplementary carbon source feed system is provided toem is provided to ‘trim’ nitrate out of the

‘trim’ nitrate out of the system to meet required permit levels.system to meet required permit levels. •

• Chemical Feed SystemsChemical Feed Systems are provided that include ferric chloride, alkalinity, polymer, and sugarare provided that include ferric chloride, alkalinity, polymer, and sugar (carbon source) dosing.

(carbon source) dosing. There is a single model of delivThere is a single model of delivery pumps (variable speed perisery pumps (variable speed peristaltics)taltics) that are highly reliable an

that are highly reliable and unlikely subject d unlikely subject to failure. to failure. Because of this, an on the shelBecause of this, an on the shelf sparef spare pump is provided in the even that

pump is provided in the even that one does malfunction.one does malfunction. •

• Chemical Containment.Chemical Containment. Each chemical feed system has its own associated containmentEach chemical feed system has its own associated containment volume, equal to 1.5 times the maximum storage volume.

volume, equal to 1.5 times the maximum storage volume. •

• Ultraviolet Disinfection.Ultraviolet Disinfection. Two UV disinfection units in a one (duty) and one (standby)Two UV disinfection units in a one (duty) and one (standby) arrangement.

arrangement. •

• Effluent Cooling.Effluent Cooling. The cooling system relies on a The cooling system relies on a cooling system that is mechanically simple andcooling system that is mechanically simple and relies on recirculation pumps and an automatic diversion valve linked to a temperature relies on recirculation pumps and an automatic diversion valve linked to a temperature transmitter.

transmitter. Spare recycle Spare recycle pumps pumps are proviare provided. ded. The systThe system is em is designed designed so that so that as freezingas freezing occurs, water is bypassed to

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Section 3 - Page 8 Section 3 - Page 8 •

• Backup Power.Backup Power. Backup power will be provided to ensure the system will continue to conveyBackup power will be provided to ensure the system will continue to convey flow.

flow. A small A small engine generator will engine generator will be installed at be installed at the treatment facility the treatment facility and will power and will power allall necessary elements

necessary elements to convey flow. to convey flow. If a If a large scale large scale power outage occurred, power outage occurred, the processingthe processing facility will also lose power which will subsequently stop wastewater production.

facility will also lose power which will subsequently stop wastewater production. The redundancy at each

The redundancy at each unit process is unit process is the main approach to the main approach to contingency planning. contingency planning. Structural elementsStructural elements will be designed to withstand design winds, earthquakes, and snow loads.

will be designed to withstand design winds, earthquakes, and snow loads.

Groundwater Protection

New facilities are

New facilities are designed with little designed with little or no or no leakage. leakage. Process tanks Process tanks will have will have concrete foundations. concrete foundations. TheThe liner system on

liner system on the retrofitted lagoon will the retrofitted lagoon will meet lagoon seepage meet lagoon seepage requirements. requirements. The double liner The double liner systemsystem will provide continuous seepage monitoring.

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Section 4

Section 4 Facility Design Criteria

Facility Design Criteria

The following elements will be used for detailed design of

The following elements will be used for detailed design of the industrial wastewater treatment facility.the industrial wastewater treatment facility.

Structural

A geotechnical engineering report was prepared for the site that will be available during detailed design. A geotechnical engineering report was prepared for the site that will be available during detailed design. That report found groundwater at 2 to 2.5 meters in depth and native sand soils that were considered That report found groundwater at 2 to 2.5 meters in depth and native sand soils that were considered acceptable for typical foundations no

acceptable for typical foundations not requiring piles. t requiring piles. Soil bearing for structures was recommenSoil bearing for structures was recommended notded not to exceed 11

to exceed 110 kPa which 0 kPa which will be mwill be met by all net by all new facilities. ew facilities. Slab work wiSlab work will include ll include a layer of cleaa layer of cleann crushed gravel.

crushed gravel. Native soil was considNative soil was considered appropriate for sub-gered appropriate for sub-grade structure backfill.rade structure backfill. The site is classified as Seismic Site

The site is classified as Seismic Site Response - Site Class D.Response - Site Class D.

The treatment building and screening building are currently planned as pre-engineered steel buildings. The treatment building and screening building are currently planned as pre-engineered steel buildings. Outdoor tanks will be constructed as epoxy coated bolted steel, either with bolted steel floors or cast in Outdoor tanks will be constructed as epoxy coated bolted steel, either with bolted steel floors or cast in place concrete floors.

place concrete floors.

Facilities will be designed in accordance with the following codes: Facilities will be designed in accordance with the following codes:

•

• Manitoba Building CodeManitoba Building Code •

• National Building Code of Canada (NBC) National Building Code of Canada (NBC) 19951995 •

• NBC Structural Commentaries (Part 4)NBC Structural Commentaries (Part 4) •

• ACI 350ACI 350M-01 M-01 Code Code Requirements Requirements for Enfor Environmental vironmental Engineering Engineering Concrete Concrete StructuresStructures •

• Any other provincial or municipal codes or ordinancesAny other provincial or municipal codes or ordinances

Fire Protection

Where appropriate NFPA 820 will be used as a guideline for design associated with ventilation and Where appropriate NFPA 820 will be used as a guideline for design associated with ventilation and electrical requirements.

electrical requirements. Currently, there is a fire hydrant system Currently, there is a fire hydrant system at the facility on a 150 mm diamat the facility on a 150 mm diametereter pipe.

pipe.

HVAC

Screening Building.

Screening Building. The screening buildiThe screening building will be somewhng will be somewhat humid and odorouat humid and odorous. s. It will be designedIt will be designed with a two rate ventilation system; 6 air changes per hour when not occupied and 12 air changes per hour with a two rate ventilation system; 6 air changes per hour when not occupied and 12 air changes per hour when occupied.

when occupied.

Treatment Building.

Treatment Building. There are three rooms in the treatment building and each will have differentThere are three rooms in the treatment building and each will have different characteristics.

characteristics. 1.

1. Pretreatment Pretreatment Building.Building. This room will contain a raw influent screen, a first stage DAF unit,This room will contain a raw influent screen, a first stage DAF unit, a second stage DAF unit with a steam injected sludge treatment tricanter technology, and a waste a second stage DAF unit with a steam injected sludge treatment tricanter technology, and a waste activated slud

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Section 4 – Page 2 Section 4 – Page 2 change per hour s

change per hour system. ystem. Heating equipmHeating equipment will be dent will be designed to maiesigned to maintain 10ntain 10ooC conditions with theC conditions with the maximum 6 air changes per hour.

maximum 6 air changes per hour. 2.

2. MBR MBR Process Process Area.Area. This area contains the MBR equipment (mixed liquor suspended solidsThis area contains the MBR equipment (mixed liquor suspended solids with 1% solids content), non-classified chemicals (magnesium hydroxide, ferric chloride, sugar, and weak with 1% solids content), non-classified chemicals (magnesium hydroxide, ferric chloride, sugar, and weak acids for membrane cl

acids for membrane cleaning), and electric motorseaning), and electric motors. . MBR tankage will be covMBR tankage will be covered and vented to outsidered and vented to outsidee in an effort to reduce moi

in an effort to reduce moisture. sture. A maximum ventiA maximum ventilation rate of 2 air changes per hlation rate of 2 air changes per hour is suggested forour is suggested for this space in order to co

this space in order to control moisture. ntrol moisture. Heating equipment wHeating equipment will be designed to mainill be designed to maintain 10tain 10ooC conditionsC conditions with the maximum 6 air changes per

with the maximum 6 air changes per hour.hour. 3.

3. Breakroom/Lab/Electrical Breakroom/Lab/Electrical Room Room Space.Space. This area is furred in from the MBR process area.This area is furred in from the MBR process area. Air will be handled separately in this space, maintained with a positive pressure, and vented to the MBR Air will be handled separately in this space, maintained with a positive pressure, and vented to the MBR process area.

process area. This space will be designed with a miThis space will be designed with a minimum air exchange for an occupied space and heatednimum air exchange for an occupied space and heated to 22

to 22ooC in winter C in winter conditions.conditions.

Electrical

The site currently runs on a 3-phase, 600 volt

The site currently runs on a 3-phase, 600 volt power system and has a 1,000 amp capacity. power system and has a 1,000 amp capacity. This systemThis system will be continued.

will be continued. Initial work at the site suggesInitial work at the site suggests that the existing power trants that the existing power transformer is large enough tosformer is large enough to power the new site.

power the new site. This will be confirmThis will be confirmed during detailed designed during detailed design..

The screening facility will be treated as a classified space with regards to electrical.

The screening facility will be treated as a classified space with regards to electrical. Motors will all be 3-Motors will all be 3-phase TEFC, lights will meet Class I Division II requirements

phase TEFC, lights will meet Class I Division II requirements. . HVAC equipment will meet nonHVAC equipment will meet non-sparking-sparking requirements.

requirements.

The treatment buildin

The treatment building is not considered clg is not considered classified. assified. All equipment mAll equipment motors, however, will be 3-phaseotors, however, will be 3-phase TEFC.

TEFC. Control panels that are suControl panels that are subject to any water will be Nembject to any water will be Nema 4 or Nema 4x.a 4 or Nema 4x.

Civil

The site for the new treatment facilities are on the north side of the hog processing buildings and south of The site for the new treatment facilities are on the north side of the hog processing buildings and south of the existing was

the existing wastewater treatment facilitiestewater treatment facilities. . An effort is being madAn effort is being made to keep the new IWWTF sie to keep the new IWWTF site aste as compact as possible whi

compact as possible while still serving functile still serving functional requirements. onal requirements. Sheet C1.0, C2.0, and C3.0 provide aSheet C1.0, C2.0, and C3.0 provide a preliminary civil perspective on the site.

preliminary civil perspective on the site. Currently, there is no

Currently, there is no asphalt on the asphalt on the north side of the north side of the facility. facility. In an effort to reduIn an effort to reduce dirt traffic intoce dirt traffic into buildings, the current strategy is to have

buildings, the current strategy is to have 10 meters of asphalt approach on 10 meters of asphalt approach on all garage doors, sidewalks andall garage doors, sidewalks and personal doors.

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Section 5

Section 5 Schedule

Schedule

Implementation of the new IWWTF includes the functional design step, a permitting or environmental Implementation of the new IWWTF includes the functional design step, a permitting or environmental review step, detailed design

review step, detailed design, design review, equipmen, design review, equipment procurement and finally cot procurement and finally construction. nstruction. Table 5-1Table 5-1 lists the schedul

lists the schedule. e. It assumes two desIt assumes two design packages. ign packages. In Phase 1, the process mIn Phase 1, the process mechanical and electrical wechanical and electrical willill be suitably developed so that piping, electrical, and instrumentation stubs can be located in the building be suitably developed so that piping, electrical, and instrumentation stubs can be located in the building slab.

slab. This will This will also be the palso be the point where thoint where the MBR equipme MBR equipment vendor negoent vendor negotiation is fitiation is finalized. nalized. Then theThen the treatment build

treatment building and associing and associated foundation ated foundation will be will be designed. designed. When environmWhen environmental licensing ental licensing isis complete, the site will be cleared and the building construction will proceed with the goal of completing complete, the site will be cleared and the building construction will proceed with the goal of completing the slab work prior to wi

the slab work prior to winter. nter. The steel erection will tThe steel erection will then be completed over the winhen be completed over the winter.ter.

Phase 2 will include the full civil, process mechan

Phase 2 will include the full civil, process mechanical, structural, electrical and instrumenical, structural, electrical and instrumentation design. tation design. ItIt will proceed after licensing and continue in the fall/winter with a final design review step in January will proceed after licensing and continue in the fall/winter with a final design review step in January 2009.

2009. Equipment Equipment procurement will procurement will be started in be started in the late fall the late fall 2008 and con2008 and continue through tinue through winter,winter, completing in February 2009.

completing in February 2009. Civil work will begin on ApriCivil work will begin on April 1, 2009 with simultaneoul 1, 2009 with simultaneous work inside thes work inside the treatment building wit

treatment building with mechanical and electrical disciplinh mechanical and electrical disciplines. es. Table 5-1 shows treatment process startuTable 5-1 shows treatment process startupp beginning in mid-August and

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Table 5-1 Table 5-1

Springhill Farms IWWTF Springhill Farms IWWTF Project Development Schedule Project Development Schedule

Element

Element CalendarCalendar Start Start FinishFinish Days

Days Duration Duration Permitting / Licensing

Permitting / Licensing 150 150 Apr Apr 2, 2, 2008 2008 Aug Aug 30, 30, 20082008 Detailed Design

Detailed Design 150 150 May May 1, 1, 2008 2008 Dec Dec 18, 18, 20082008 Construction

Construction

Treatment building subgrade with stubs for Treatment building subgrade with stubs for process piping, water,

process piping, water, electricalelectrical

35

35 Sep Sep 13, 13, 2008 2008 Oct Oct 18, 18, 20082008 Treatment

Treatment building building foundation foundation 28 28 Oct Oct 19, 19, 2008 2008 Nov Nov 16, 16, 20082008 Metal

Metal building building erection erection 90 90 Dec Dec 16, 16, 2008 2008 Mar Mar 16, 16, 20092009 Fur

Fur in in electrical/lelectrical/lab/break ab/break room room 21 21 Mar Mar 17, 17, 2009 2009 Apr Apr 7, 7, 20092009 Site

Site grading grading and and civil civil piping piping 35 35 Apr Apr 1, 1, 2009 2009 May May 6, 6, 20092009 Tank

Tank foundations foundations 35 35 May May 7, 7, 2009 2009 Jun Jun 11, 11, 20092009 Tank

Tank erection erection 42 42 Jun Jun 12, 12, 2009 2009 Jul Jul 24, 24, 20092009 Tank

Tank Testing Testing 14 14 Jul Jul 25, 25, 2009 2009 Aug Aug 8, 8, 20092009 Process

Process mechanical mechanical in in buildings buildings 63 63 Apr 14, Apr 14, 2009 2009 Jun Jun 16, 16, 20092009 Electrical

Electrical 60 60 May May 14, 14, 2009 2009 Jul Jul 13, 13, 20092009 Instrumentation

Instrumentation - - integration integration 35 35 Jul Jul 14, 14, 2009 2009 Aug Aug 18, 18, 20092009 Seeding

Seeding / / landscaping landscaping 21 21 Sep Sep 1, 1, 2009 2009 Sep Sep 22, 22, 20092009 Asphalt

Asphalt 14 14 Aug Aug 24, 24, 2009 2009 Sep Sep 7, 7, 20092009 Startup

Startup 21 21 Aug Aug 19, 19, 2009 2009 Sep Sep 9, 9, 20092009 Tuning

Tuning 60 60 Sep Sep 10, 10, 2009 2009 Nov Nov 9, 9, 20092009 Performance Testing