WCS WCSEE T300 Instruction manual

WCSEE T300 + (T3HP FOR HIRE)
INSTALLATION, OPERATION &
MAINTENANCE MANUAL

WCSEE- T300 INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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TABLE OF CONTENTS
1. SAFETY .................................................................................................................... 4
Health and safety at work act 1974........................................................................4
General health and safety........................................................................................4
Leptospirosis...............................................................................................................4
Sensible Precautions.................................................................................................5
Vaccinations...............................................................................................................5
2. Warranty ................................................................................................................. 5
T300 tank enclosures................................................................................................5
WCSEE Ltd will provide a 12 month warranty period for the external & internal
structure of the tank. ...........................................................................................................5
M&E installation .........................................................................................................6
Warranty limitations and exemptions ....................................................................6
Chargeable non warranty work...............................................................................6
3. Risk assessment..................................................................................................... 7
Introduction.................................................................................................................7
3.1.1 Installation Design Considerations .................................................................7
3.1.2 Installation and positioning ..............................................................................8
3.1.3 Maintenance........................................................................................................8
4. Introduction............................................................................................................ 9
T300 SAF Tank –Showing Top Level Access.....................................................10
T3HP SAF Tank –For Hire......................................................................................11
5. PLANT OPERATION.............................................................................................. 12
TIMER (applicable to 2023 models tanks) ...........................................................13
5.1.1. Timer Set Up .....................................................................................................13
5.1.2. General Requirements.........................................................................................15
5.1.3. Electrical Connections..........................................................................................15
6. ROUTINE MAINTENANCE.................................................................................... 16
Weekly.......................................................................................................................16
Six Monthly................................................................................................................16
Annually ....................................................................................................................16
7. PROBLEM SOLVING ............................................................................................. 17
Poor Effluent.............................................................................................................17

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Blower not Running .................................................................................................17
Power cut........................................................................................................................17
Power supply fault ........................................................................................................17
Blower overload has tripped ......................................................................................17
Blower runs intermittently...........................................................................................17
No air bubbles showing on the surface of the filter section .............................17
Blower not running .......................................................................................................17
Blower running...............................................................................................................17
Blockages .................................................................................................................17
Level in sections is higher than normal ....................................................................17
Smell..........................................................................................................................18
Smell escaping from the covers on the plant.........................................................18
Smell escaping from the kiosk ...................................................................................18
Plant smells ....................................................................................................................18
POOR AIR DISTRIBUTION OVER THE FILTER SECTION....................................18
Blocked air Diffusers.....................................................................................................18
Filter media partially blocked by excessive biomass............................................18
Filter media partially blocked with sludge ..............................................................18
8. PLANT START UP ................................................................................................. 19
Introduction...............................................................................................................19
Start Up .....................................................................................................................20
Procedure..................................................................................................................20
9. Decommissioning and transportation .............................................................. 21
Revision table:
Date
Change description
Owner
Checked
Rev
25/04/2017
First issue
TC
A
29/11/2018
Updated Issue
TC
B
07/05/2019
Updated
TC
RT
C
20/05/2019
Hire Tank Added
TC
OH
D
19/05/2020
Hire Tank –Lid Added
TC
AB
E
18/12/2020
New blower specs
RT
TC
F
21/06/2021
Revised border
TC
RT
G
20/09/2022
Maintenance section revised
TC
BD
H
30/11/2022
Revised manual layout with timers
TC
BD
I

WCSEE- T300 INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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WCSEE LTD T300 SAF TANKS
1. SAFETY
It is extremely important that maintenance procedures in this document are
followed. Any deviation from this could cause serious injury or have a detrimental
effect on its operation.
Health and safety at work act 1974
Section 6a of the act requires manufacturers to advise their customers on safety
and handling precautions to be observed when operating, maintaining and
servicing their products.
The user’s attention should be drawn to the following:
•All sections of this manual should be read before undertaking work on the
equipment.
•Suitably trained personnel must carry out the installation.
•Normal Health and safety precautions must be taken and appropriate
procedures observed to avoid accidents.
•Refer to WCSEE Ltd for further technical advice or product information.
General health and safety
The layout of the WCSEE LTD T300 tanks have been laid out to ensure that
health and safety on site is optimised in line with designer duties specified by the
CDM regulations 2015. It will be safe manner, and agrees with comments from
the principal designer. Lone working in, and around the plant should be
prohibited.
Leptospirosis
The following is extracted from a health warning card issued to WCSEE LTD staff.
It is the client’s responsibility to ensure that the relevant Personal Protective
Equipment (PPE) is available and used.
There are two types of Leptospirosis that effect people in the UK and they are as
follows:
•Weil’s disease, which is a serious infection transmitted to humans by
contact with soil, water or sewage that has become contaminated with
urine from infected rats.
•Hardjo-type Leptospirosis, which is transmitted from cattle to humans.
The typical symptoms for both diseases start with a flu like illness, with a
persistent and severe headache, muscle pains and vomiting. Jaundice generally
appears on the fourth day of the illness.
The bacteria can enter your body through cuts and scratches or through the
lining of the mouth, throat and eyes.

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Sensible Precautions
After working with contaminated fluid or other materials it is important that hands
and forearms are washed thoroughly with soap and water. If your clothing or
boots become contaminated, then they should also be washed immediately after
use.
Immediate action should be taken, so that any cuts scratches or abrasions are
washed thoroughly with clean water, prior to applying any protective covering
(plaster or bandage).
Do not handle food, drink or smoking material without first washing your hands. If
you display any of the symptoms described after coming in to contact with
sewage; report to your doctor immediately advising them of the circumstances.
Vaccinations
To avoid the possibility of illness it is recommended that all site personnel have
the following vaccinations. WCSEE Ltd also recommends that you that you
consult your doctor for any additional vaccinations that you may require. The
general vaccinations WCSEE use for all personnel are as follows:
•Hepatitis A
•Hepatitis B
•Polio
•Tetanus
•Typhoid/cholera –probably carried out as a child.
2. Warranty
WCSEE Ltd will provide the following warranty to the items listed below:
Note: warranty period will be active from the day, from which the tanks are
positioned on the base slab, or passes on to the customer’s
premises/construction site.
T300 tank enclosures
WCSEE Ltd will provide a 12 month warranty period for the external & internal
structure of the tank.

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M&E installation
WCSEE LTD takes no responsibility for improper storage, or bad
installation/maintenance performed by unqualified personnel. This also covers
the overloading of the plates, above that of normal conditions, and any other
accidental cause, or disregard for the information in this document.
Warranty limitations and exemptions
WCSEE Ltd shall not be liable for any labor involved for the removal or
replacement of its equipment or the subsequent transportation, handling or
packaging of any part or parts thereof. In no case will WCSEE Ltd be liable for
loss incurred because of interruption of service or for consequential damages,
labor or expense required to repair defective units, nor shall this constitute a
cause for the cancellation of the contract of purchase and sale. Specifically
exempt from this warranty are limited life of consumable components subject to
normal wear and tear.
Chargeable non warranty work
Service charges will be incurred (including parts and labour), due to the
following:
•Unauthorized alteration.
•Accidental damage, caused by plant or movement on site outside of
WCSEE’s control.
•Improper use.
•Abuse.
•Tampering.
•Failure to follow installation instructions or failure to follow operating and
maintenance procedures.
The above will not be covered by this warranty. All service visits for non-warranty
work are chargeable at the standard engineer day rate plus mobilization. This
warranty gives specific additional benefits. Statutory rights are unaffected.
Note: WCSEE LTD will not uphold the guarantee on the purchased equipment if
the routine maintenance has not been performed and documented.
WCSEE LTD strongly recommends that the installation of the purchased product
is carried out by a qualified and experienced installer. Dependent on the site a
suitably qualified civil engineer may need to be consulted for the construction of
suitable base slab to support the imposed load.

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3. Risk assessment
Introduction
This section of the manual is intended as a guide and as such does not cater for
every situation encountered on site. WCSEE assumes that the necessary
permissions have been granted prior to the installation of the plant. It is also the
assumption that working methodology abides by the Health and Safety at work
act and that all civil engineering design is undertaken by a chartered Civil
Engineer.
Please ensure that due consideration is given to the following:
3.1.1 Installation Design Considerations
•Planning permissions & Building Regulations and other regulating or
interested parties.
•Environment Agency consent to discharge.
•The size of the plant relevant to the number and type of people that will be
using it, e.g. domestic, light industrial, etc.
•Costs, legal implications and siting in consideration to shared systems.
•The whereabouts of wells, boreholes and springs used as sources of
potable water; existing non-mains sewerage systems and soakaways; water
courses, ponds and lakes and designated protected areas.
•The whereabouts of other services, pipes, cables and ducting.
•Local ground conditions. Is specialist knowledge of civil engineering
required, catering for specific ground condition requirements?
•The water table at the time of installation - specialist knowledge is required
when installing in an excavation that allows water to enter.
•The water table in winter - Special consideration should be given to
installations that will be subject to high water table pressure or flood
conditions. The treatment plant will need to be installed so that it cannot
“float” out of the ground and provision made for continued discharge of
treated effluent, should the discharge pipework/soakaway be under water.

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3.1.2 Installation and positioning
•Siting - The plant must be sited within 30m of heavy vehicle access for
draining. The plant should, where possible, be sited above the high-water
table mark and above or beyond the flood plain. See items above and
accompanying note. The plant should be sited as far from the habitable
parts of the dwelling as possible. Many local authorities recommend 10m
as a minimum, but easements are possible for smaller sites.
•Electrical supply –If the plant has been equipped with a pumped de-
sludge option, a qualified electrician should only undertake electrical
installation. A safe and reliable power supply is required at all times, as the
pumps are required to de-sludge at intervals 24/7. Adequate means of
power failure indication should be provided. This can be an audible or
visual alarm or by regular manual checks.
Note: Due to the health risks associated with raw sewage, WCSEE recommend
that the SAF treatment plant is not used until the system is complete,
commissioned and is operating in a stable manner.
3.1.3 Maintenance
•The legal responsibility for the plant as far as operation and maintenance
and on-going discharge is concerned.
•Electrical supply: a qualified electrician should undertake the electrical
installation.
A reliable power supply will be required at all times, so an indication of
power failure will be required, which can be audible or visual.
•Any visiting personnel should report to the site office and acquaint
themselves with the specific site health and safety protocol.
•Before carrying out any maintenance or installation on the equipment it
should be electrically isolated, unless a trained electrician is carrying out
specific checks under controlled conditions. When performing works of
this nature, warning signs should be erected to alert others of the works in
progress.
•For all works, risk assessments and method statements will be required to
carry out work on site. These should identify the method of work and the
risks associated.
•Temporary barriers and warning signs should be erected around any open
covers or manholes as appropriate, in particular warning of deep water in
the tanks.
•See section 7 for routine maintenance.

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4. Introduction
The process used within the WCSEE SAF has been developed to meet the more
stringent discharge consents now being imposed by the Environment Agency,
particularly with reference to low ammonia levels. The HiPAF can achieve
ammonia standards better than 10mg/l.
The T300 and T3HP (for Hire Use) has been designed for above ground
installation only.
The T300 is equipped with an optional access ladder and handrails, where as the
T3HP does not require any top-level access. This is shown in more detail in the
next pages.
Blowers and controls to provide the air are housed in a separate standalone kiosk
adjacent to the plant. The tank and kiosk are manufactured in GRP for corrosion
resistance and long life.
*As these units are above ground and generally receiving pumped flows, it is
therefore necessary to provide suitable flow control before the effluent is received
by the unit.
The plant should receive Dry Weather Flow as stated in the relevant quotation or
design documentation; ensuring adequate hydraulic retention time for the relevant
biological processes to take place.
WCSEE advises the following for lifting practices for the T300 & T3HP tanks:
Checks:
•Inspect all lifting points and tension if required with a suitable tool.
•The unit must be hoisted empty of all material and fluids.
Test lift the unit to check that the centre of gravity of the unit is in the correct
location (See drawing supplied by WCSEE LTD), and that all of the chains are
taut. It is critical to ensure a balanced lift, but if in doubt don’t lift the tank.

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T300 SAF Tank –Showing Top Level Access
Drawing above shows a T300 with top level access.
(This can be supplied without top level access).
10m of 2” High temperature air hose is provided to connect the blower process
air to the tank.
Connecting the air hose to the Kiosk
•2” hosetail connection mounted on the manifold within the Kiosk
enclosure. Use Mega clamps which are provided.
Connecting the air hose to the Tank
•2” hosetail high level connection mounted to the top side of the SAF tank.
Use Mega clamps which are provided.

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T3HP SAF Tank –For Hire
Drawing above shows the Hire Asset T3HP with low level 4” Bauer connections to
both the Inlet & Outlet. No top-level access is required with this arrangement
and the unit comes equipped with a lid for access by WCSEE only.
10m of 2” High air temperature hose is provided to connect the blower process
air to the tank.
Connecting the air hose to the Kiosk
•2” hosetail connection mounted on the outside of the Kiosk. Use Mega
clamps which are provided.
Connecting the air hose to the Tank
•2” hosetail low level connection mounted to the side of the SAF tank. Use
Mega clamps which are provided.

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5. PLANT OPERATION
The plant is designed to operate continuously with the minimum of maintenance
after it has been commissioned. The plant will provide effluent within the
designed discharge consent standard after an initial start-up period, of 4 to 10
weeks depending on the water temperature and site conditions.
*It is important that the sewage-input conditions are kept within the plant
design criteria. Refer to section 8. Start Up Procedure.
Both the T300 Tank and the Hire T3HP come with duty/standby blowers (Elmo
Rietschle 3.45Kw, 3 phase 2BH1510). The blower operates continuously to provide
air for the biological process in the filter section.
Note:- The T3HP Hire Kiosk comes equipped with an external 3ph, 32A 5-pin
socket, mounted to the outside of the Kiosk. This allows for an easy and fast
installation.

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TIMER (applicable to 2023 models tanks)
There is a timer positioned inside the control panel on the back side of the door. It
is to reduce the power consumption by turning off and on the blower(s) in 15min
intervals, during normal operation. (Note:- the Blowers should be running 24/7 for
the first 6-8 weeks or until the plant is fully seeded).
Only the site operator should adjust the settings.
5.1.1. Timer Set Up
To set up the timer, follow the below steps:
-Selecting the “A” letter on the bottom left of the timer, means the timer is in
the “Auto” position. (As indicated in Picture 1 below). This set-up will allow the
timer to be in operation.
-When the main switch (located on the front of the control panel) is in the
“Auto” position, the low air pressure switch will be automatically inhibited to
OFF for a certain period of time when the blower stops, so the beacon will
not flash showing a fault.
Picture 1
-On the Timer, Once the “Auto” mode is selected, select the cycles required
for the blower ON/OFF times. This will be done by moving the switches from
the circle of yellow tabs to the outwards position for ON and the inwards
position for OFF (see Picture 2 below).
-The Initial set-up is for 15min OFF and 15min ON. If the quality of effluent is
deteriorating, increase the blower ON time by moving more yellow tabs to
the outwards position.

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Picture 2
-On the Timer, selecting the letter “I” on the bottom left of the timer mode will
run the blower in manual setting, (as indicated in Picture 3 below). It is
advisable that once a week to run the blower(s) in manual mode for 4 hours,
to scour the media.
Picture 3
-On the Timer, selecting the letter “O” on the bottom left of the timer, will
switch the blower OFF and no air will go to the plant, (as indicated in Picture 4
below).
Picture 4

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5.1.2. General Requirements
All timers retrofitted in existing panels must be installed by WCS EE, or the process of
the sewerage treatment plant will not be guaranteed by WCS EE.
On factory fitted timers, a visit is required after 2 months in operation to check the D.O.
(Dissolved Oxygen Levels) and to visually inspect the effluent.
5.1.3. Electrical Connections
Below shows the electrical details of the timer controls.

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6. ROUTINE MAINTENANCE
Weekly
•Check that there is noise coming from the kiosk indicating that the blowers
are operational.
•If a warning alarm beacon is fitted it will flash to indicate a lack of air to the
plant.
Six Monthly
Carry out the weekly check plus:
•Open the Kiosk and check the extract fan, if fitted, is operating and that the
blower and control panel are dry and in good working order.
•(If the tank is supplied with top level access) open the Lid on the main unit
and check that there is an even distribution of air around the filter indicated
by an even distribution of bubbles on the surface of the filter sections.
•Check that the blower air filters are clear and knock off any collected dust
or replace if necessary.
•On the T3HP Hire Unit, the air diffusers for the biozone are split into two
zones. In normal operation the air feeds both zones, but both can be
isolated (not at the same time). Every 6 months, 1 zone can be isolated for 1
hour followed by the second zone for a further hour so to ensure there it is
no build-up of unwanted biomass on the media.
Annually
Carry out the monthly checks plus:
•Thoroughly check all the plant. If there is any scum or grease build up on
the sides of the tanks or fittings this should be removed by pressure
washing or removed with a wood or plastic scraper. DO NOT USE A
METAL SCRAPER.
•Check the control panel, fan inlet filters and blower(s) for correct operation
and service or replace as required.
•Check the air distribution over the filter surface (if required). Safe
temporary access will need to be erected.

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7. PROBLEM SOLVING
Poor Effluent
Blower not running
Refer to 7.2
No Air bubbles in
filter chamber
Refer to 7.3
Poor air distribution
Refer to 7.6
Poor flow control
Refer to site
Blower not Running
Symptoms
Corrections
Power cut
If temporary (24/48 Hours) do nothing. If extended, obtain
alternative source of power or tanker sewage away.
Important: on power being returned to three phase supplies check
for correct rotation of blowers
Power supply fault
Switch off blowers check fuses and any RCD breakers, on 3-phase
supplies check for correct rotation. Switch blowers to on and the
blowers should start. If not switch off and call electrician.
Blower overload has
tripped
Check for any obvious causes, reset overload and switch to on.
Blowers should start, if not switch off and call an electrician.
Blower runs
intermittently
Check that the cooling fan is running and the air ducts are clear, as
overheating in the cabinet will cause the high temperature trip to
switch off the power to all but the fan and beacon if fitted. Replace
fan if it has failed. Temporary solutions if the weather is fine: leave
the kiosk door open but ensure that no one can gain access to
electrical or rotating mechanisms.
No air bubbles showing on the surface of the filter section
Symptom
Corrections
Blower not running
Refer to 7.2
Blower running
Check all valves are open in the kiosk and main unit. Check that the
airlines are not broken or leaking. Find where the air is escaping
from pipe work and repair. Check inlet filter(s).
Blockages
Symptom
Correction
Level in sections is
higher than normal
If the plant has been flooded due to high water level or other
cause the 'V' notches may have become blocked these should be
cleared of any debris the material should be returned to the
primary settlement tank.

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Smell
Symptoms
Corrections
Smell escaping from
the covers on the
plant
If venting is via the inlet pipework, ensure that the outlet T-
vent is closed and the inlet T-vent is open. If venting is via
the outlet pipework, ensure that the inlet T-vent is closed
and the outlet T-vent is open. Also check the seals around
the covers and reposition as necessary.
Smell escaping from
the kiosk
Check that any ducts to the plant (holding tank or pump
chamber if installed) are sealed with expanding foam.
Plant smells
Check that grease has not entered the treatment plant. Do
all the 'Annual Checks'.
POOR AIR DISTRIBUTION OVER THE FILTER SECTION
Cause
Correction
Blocked air Diffusers
(NOT relevant to
the T3HP Hire
Unit)
VALVE
TOP
UNION
TO
DIFFUSER
LEG
Turn off all but one of the air diffusers at the valves. Then
proceed to check the one that is on for the position of bubbles.
The increased pressure should clear any blockage in the
diffuser. If not the diffuser can be removed by switching the air
supply (blower) off and disconnecting the diffuser tube at the
top of valve, turning through 90oand lifting up through the
diffuser access slot. On early units the diffuser is screwed into
the fitting on the end of the tube and can be removed for
cleaning or replacement. Later units have a cap with a 5mm
hole in the end. In addition there are also some cross holes on
some of the horizontal pipe. Clear all holes.
UNSCREW
DIFFUSER LEG
Repeat as required for any other suspect blocked diffusers, and
then move the air diffusers by angling the tube as required to
improve air distribution.
Filter media partially
blocked by excessive
biomass
This indicates that the plant is overloaded, check design
loading and contact WCSEE for advice.
Filter media partially
blocked with sludge
This indicates carry over from primary tank, check sludge
levels and de-sludge if required. Also check for excessive flow
possibly due to ground water ingress into foul sewer.

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8. PLANT START UP
For commissioning, carry out the six checks as stated in this manual. The plant
should then be left running as normal. It takes time, depending on the
temperature, for the plant to grow a stable biomass when it is first started up.
This is 3 to 6 weeks for the process to start reducing the BOD. It then takes
another 4 weeks for the process to start reducing the ammonia.
Introduction
The bacteria necessary to provide the biological oxidation are present in
normal sewage and will rapidly multiply if given the right conditions. The
process breaks down most of the sewage into carbon dioxide and water.
There are two main types of bacteria:-
a) Carbonaceous bacteria which, as the name suggests will break down
the carbon based solids.
b) Nitrifying bacteria which break down the ammonia to nitrogen, and this
will be partially converted to nitrogen gas before being discharged.
The carbonaceous bacteria are more prolific and also less prone to damage by
chemicals (cleaning agents) than the nitrifying bacteria. Both are adversely
affected by low temperatures or low pH which may be found in soft water
areas. The nitrifyers are more critical and cease to be effective in
temperatures below 100C or pH below 7. Low temperatures are not normally
found in domestic sewage, this will rarely drop below 150C unless the pipe
runs are very long or the flow very small.
The right conditions to grow bacteria are to have both oxygen and food
available and these conditions are found in the Submerged bed aerated filter
section of the HIPAF
The effluent quality is defined by a group of two or three figures as BOD:SS:
NH3 (Biological Oxygen Demand: Suspended Solids: Ammonia) All figures
represent the concentration in ppm( parts per million) and the most usual
requirement is 20:30 with no Ammonia standard. If the discharge point is very
sensitive the standard may be as tight as 10:10:5

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Start Up
It is very important that the air blowers are switched on BEFORE any sewage is
allowed to flow into the Aerated filter section.
As soon as sewage is introduced into the tank to provide flow, the bacterial
action will commence. The carbonaceous break down will start almost
immediately which will produce large quantities of foam. Although the
process will have started the initial quality of the effluent will initially be poor
with little treatment.
In order to reduce the time to full treatment the plant can be seeded with
activated sludge and / or proprietary bacteria, BUT a quantity of normal
sewage will also be required.
Procedure
1. Switch on Blower(s) and check that air distribution is correct are working.
IMPORTANT:- on blowers with 3 phase motors check for correct rotation
BEFORE CONNECTING THE HOSES TO THE BLOWER(S)
2. Introduce sewage into the tank at the design rate.
3. Check after 12 to 24 hours that:-
I. Blower(s) are running correctly and not overheating
II. Air distribution in the Filter section is correct and that foam is being
produced
There is no further intervention required once the plant is in operation.