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 TRAINING MATERIAL: OCCUPATIONAL CERTIFICATE - PROCESS CONTROLLER

The main focus of the learning in this knowledge module is to build an understanding of providing an overview of the chemistry and calculations that apply in the practice of water services process control. The knowledge acquired will enable the learner to demonstrate general understanding of treatment processes in water services, system international units and related calculations, basic chemistry, sampling and operational testing.


Overview of the treatment processes in water services

  • Overview and basic principles and practices of the treatment processes in water services
  •  Definition of terms
  • Characteristics and sources of water and factors influencing its quality
  • Characteristics and sources of wastewater and factors influencing its quality


System International (SI) Units, related water services calculations 

  • SI Units and conversions methods - p?? of link
  • Water treatment calculations


Basic Chemistry

  • Branches of chemistry
  • Elements and compounds
  • Matter and phases
  • Water services chemistry
  • Chemical analysis used for water services testing


Sampling and operational/ compliance tests

  • Basics of sampling
  • Operational/ Compliance tests


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The main focus of the learning in this knowledge module is to build an understanding of the chemical treatment processing of water services. in order to operate and control treatment processes. The knowledge acquired will enable the learner to demonstrate understanding of coagulations and flocculation, oxidation, stabilisation, taste and odor removal and pre-chlorination


Coagulation and flocculation

  • Principles of coagulation and flocculation
  • Primary and secondary flocculants
  • Coagulation and flocculation processes
  • Dosing calculations
  • Tests and performance evaluation and performance control


Oxidation

  • Principles and application of oxidation and related processes
  • Types of chemicals
  • Dosing calculations
  • Tests and performance evaluation and performance control


Disinfection

  • Principles and application of disinfection
  • Chemicals and methods
  • Disinfection processes
  • Dosing calculations
  • Tests and performance evaluation and performance control


Stabilization

  • Principles, processes and application of stabilization
  • Types of Chemicals
  • Dosing calculations
  • Tests and performance evaluation and performance control


Taste and odor removal and pre-chlorination

  • Principles, processes and application
  • Types of chemicals
  • Dosing calculations
  • Process optimisation

The main focus of the learning in this knowledge module is to build an understanding of the biological treatment processing of waste water. The knowledge acquired will enable the learner to demonstrate general understanding of activated sludge process, fixed film aerobic biological processes and ponds


Activated sludge process

  • Concepts and theory of activated sludge treatment process
  • Configurations of activated sludge processes
  • Methods and control of aeration processes
  • Process control systems in activated sludge plants
  • Sludge characteristics
  • Biological Nutrient Removal process
  • Operational tests and interpretation for activated sludge plants
  • Elementary microbiology


Fixed film biological processes

  • Concepts and theory of fixed film bio-filtration processes
  • Process control and operation of fixed film bio-filtration processes
  • Recirculation in fixed film bio-filtration processes
  • Elementary microbiology


Ponds

  • Concepts and types of ponds
  • Performance assessment and operation of ponds
  • Elementary microbiology

The main focus of the learning in this knowledge module is to build an understanding of the physical treatment processing of water services. The knowledge acquired will enable the learner to demonstrate understanding of the fundamentals of hydraulics, preliminary treatment, primary treatment, filtration process and membrane technology.


Fundamentals of Hydraulics

  • Conceptual understanding of the physical properties of water
  • Fundamentals of pumping unit processes
  • Fundamentals and calculation of Flow measurement in pipes, flumes, weirs and channels


Preliminary Treatment

  • Theory of sedimentation
  • Theory of clarification
  • Interpreting operational test result for primary treatment


Filtration Process

  • Types and components of filters
  • Filtration and cleaning cycles
  • Operation of filter wash-water recovery system
  • Operation and troubleshooting of filters


Membrane Technology

  • Principles of membrane treatment
  • Types of membranes and their related uses
  • Operation, operational maintenance and troubleshooting of membranes

The main focus of the learning in this knowledge module is to build an understanding of the sludge treatment / handling in order to operate a process. The knowledge acquired will enable the learner to demonstrate understanding of the dissolved air flotation, sludge gravity thickening, sludge digestion, sludge dewatering, sludge drying and sludge disposal.


Dissolved air flotation

  • Concepts, components, operation and process control of dissolved air flotation
  • Treatment requirements for dissolved air flotation unit processes


Sludge gravity thickening

  • Concepts, theory and components of the gravity thickening process
  • Operation, process control and performance requirements of gravity thickening


Sludge digestion

  • Concepts, theory and components of Anaerobic digestion
  • Concepts, theory and components of Aerobic digestion
  • Operation, process control and performance requirements of anaerobic digesters
  • Operation, process control and performance requirements of aerobic digesters


Sludge dewatering

  • Concepts, theory and components of sludge dewatering
  • Operation, process control and performance requirements of sludge dewatering unit processes


Sludge drying

  • Concepts, theory and components of sludge drying
  • Operation, process control and performance assessment of sludge drying systems


Sludge disposal

  • Concepts related to sludge utilisation and disposal
  • Classification of wastewater sludge
  • Sludge disposal options

The main focus of the learning in this knowledge module is to build an understanding of the relevant environmental and safety legislation and the contexts for application in water services treatment. The knowledge acquired will enable the learner to demonstrate understanding of the framework of environmental legislation affecting the water sector and health and safety in the workplace.


Framework of environmental legislation affecting the water sector

  • National Water Act, Water Services Act, National Environmental Management Act, SANS241 and General Authorisation and Special Standards
  • The concept of ‘the green economy


Health and Safety in the workplace

  • The Occupational Health and Safety Act
  • Safety, health and environment (SHE) principles and practice

The main focus of the learning in this knowledge module is to build an understanding of knowing different types of equipment and materials used at a waterworks. The knowledge acquired will enable the learner to demonstrate understanding of the mechanical and electrical equipment, instrumentation, process control systems and materials.


Mechanical Equipment

  • Pumps and drive units
  • Compressors, blowers and fans
  • Pipes, valves and fittings


      • Operating Principles of Pumps

        • The chances of a Water or Wastewater Treatment System existing without any need for pumping is quite slim – they are either required for conveying water / wastewater to or from the works (pump stations) or for moving liquid around between the various process units on a Water Services Works 

          In order to guide us through the types of pumps, how they operate and the application of each of these, we will be referring to “Booklet 6: O&M of Pumps, Drives and Pump Stations” (Water Treatment).



  •  This booklet is accompanied by “Booklet 6: O&M of Wastewater Pumps, Drives and Pump Stations”, so you are encouraged to refer to that resource when looking specifically at wastewater pumping.  Chapter 27 of the WISA “Handbook for the Operation of Wastewater Treatment Works” also has some very useful information when it comes to the operating principles of the various types of pumps.  


  • Our journey through the world of pumps will start by looking at ways in which pumps are powered – hand pumps, wind, solar power, engines and of course electrical pumps.  We will then look into how pumps are chosen (pump efficiency and pump curves) after which we will explore the different types of pumps.  This will be followed by a look into components that typically needs to be maintained and how this is to be done correctly and safely.


  • This booklet also contains information on compressors and blowers.

  • As the information contained in “Booklet 6: O&M of Pumps, Drives and Pump Stations” will not be repeated in our guidebook, you are encouraged to make your own notes for easy future reference.


 

 


Valves

 

  • Now that we have looked at how to pump liquid between various Process Units, we need to explore ways in which to control the flow of liquid - valves, pipes and fittings. 

  • When dealing with valves, we have a very comprehensive guide in the “Department of Energy Fundamentals Handbook – Mechanical Science: Valves”.  This handbook provides us with an overview of the components of a valve after which we delve into the different types of valves and their applications.




          Different Types of Valves

    • Numerous types of valves exist, each with specific advantages and disadvantages in terms of its operation and specific application. The most common ones are: Gate Valves: With a Gate Valve the disk moves up and down in the valve to create a solid “gate” that restricts flow.  This type of valve creates a tight seal when closed, but is not intended for throttling. Ball Valves:  This type of valve uses a ball-shaped disk to start or stop flow.  As the ball is rotated it either blocks the flow (solid side wall of ball) or flow is allowed through the center of the ball (there is a hole in the ball). Diaphragm Valves: As the name suggests, this valve consists of a diaphragm (flexible disk) that can be positioned quite precisely inside the valve body. Butterfly Valves: The disk in a butterfly valve rotates through 90o in the body.  When the disk is perpendicular to the flow, the valve is shut.  As moving parts are limited, maintenance costs are typically lower on these types of valves and they are typically better suited to applications where large amounts of solids are present in the water.



  •  


     Pipes & Fittings


  • Pipes and fittings are discussed in our “Introduction to Piping and Pipe Fittings” guidebook.  This deals with piping materials, sizes and ways in which pipes are connected.  Reference is also made to the first 10 pages of the “Material”-chapter (Chapter 2) of the “Vinidex PVC Pressure Pipe & Fittings Technical Manual” that deals specifically with PVC Pipes.


    Numerous pipe fittings are available to connect pipes to one another.  These include elbows - for making angle turns in piping, nipples - for making close connections. They are threaded on both ends with the close nipple threaded for its entire length, couplings - for connecting two pieces of pipe of the same size in a straight line. Unions - for providing an easy method for dismantling piping. Tees and Crosses - for making branch line connections at 90°.Y-bends - for making branch line connections at 45°. Return Bends - for reversing direction of a pipe run. Plugs and Caps - for closing off open pipe ends or fittings.




Electrical Equipment

  • Basic concepts of electricity
  • Types and uses of motors
  • Control and distribution Panels
  • Types and uses of Cables
  • Uses of transformers



Instrumentation (Electrical &Pneumatics &Hydraulics

  • Introduction to Instrumentation
  • Pressure measurement
  • Temperature measurement
  • Flow measurement
  • Level measurement
  • Analytical instruments


  • Process Control Systems
    Introduction to Process Automation Systems
  • Programmable Logic Control (PLC)


Materials

  • Properties and Application of Materials
  • Corrosion Control

TRAINING MATERIAL: OCCUPATIONAL CERTIFICATE - PROCESS CONTROLLER

page? in www.book

video on www.subsc

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TRAINING MATERIAL: OCCUPATIONAL CERTIFICATE - PROCESS CONTROLLER

page? in www.book

video on www.subsc

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TOOLS FOR PRACTICAL TRAINING

WHY NOT CONSIDER A FLOCCULATOR?

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WHAT ABOUT A DESKTOP SIZE WORKS?

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GUIDANCE ON PRACTICAL TRAINING REQUIREMENTS

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Useful External Links

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