KAWERAU WTP FLUORIDATION OPERATING AND
MAINTENANCE MANUAL
S-0273-G-MAN-001

KDC
S-0273 Kawerau Fluoridation Project

Revision history
Date
Rev.  Author
Checked
Approved
Description
30/08/24
0  K Brooks

Issued for Use
12/11/24
1  K Brooks
J Brosnan
J Brosnan
Issued for Use (As Built)

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Kawerau WTP Fluoridation Operating and Maintenance Manual
S-0273 Kawerau Fluoridation Project
APPENDIX C—STANDARD OPERATING PROCEDURES ............................................................... 38
APPENDIX D—VENDOR EQUIPMENT DATA SHEETS AND OPERATION AND MAINTENANCE
MANUALS ........................................................................................................................... 39

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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ACRONYMS AND DEFINITIONS
Term
Definition
CDR
Lutra – Kawerau Fluoridation Assessment - Fluoride Assessment and Concept Design
Report , KDC001-R01-1 Fluoride Assessment and Concept Design Report , KDC001-
R01-1
FSA
Fluorosilicic acid, also known as HFA (hydrofluosilicic acid)
GA
General Arrangement
GPG or Good Practice  Water New Zealand, Good Practice Guide: Fluoridation of Drinking-Water Supplies in
Guide
New Zealand, February 2023 , Volume 1 & 2.
HSNO
Hazardous Substances and New Organisms (HSNO) Act.
IBC
Intermediate bulk container
MAV
Maximum Allowable Value
May
Indicates a possible course of action.
MoH
New Zealand Ministry of Health
PE
Polyethylene
Peer Review Report
Warren Mackenzie Consulting  - Kawerau Water Treatment Plant – Fluoridation System
Peer Review, dated 28/3/23
Shall
Indicates a mandatory requirement.
Should
Indicates a preferred course of action.
Taumata Arowai
The water services regulator for Aotearoa, New Zealand

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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1
INTRODUCTION

Purpose and Scope of the Fluoridation Project
Kawerau DC are required by the MoH to incorporate fluoride dosing into the existing Kawerau WTP,
hence TRILITY was engaged to design and build a fluoridation system at the plant on behalf of the
Kawerau District Council. The fluoridation system has been constructed in the existing WTP building
and it has four main aspects: chemical unloading, storage, dosing and analysis of the treated water
for fluoride. Fluoride is supplied and dosed as fluorosilicic acid (FSA). The fluoridation system is
described in Section 2.

Legal and Regulatory requirements
Concentrated FSA as supplied at 20-23% concentration is both a corrosive and toxic substance. It is
a Class 8 Dangerous Good and is also classed as a Hazardous substance. Operators should be aware
of the relevant requirements of NZ Health and Safety at Work (Hazardous Substances) Regulations
2017 and HSNO. Operators and contractors who are required to work at Kawerau WTP should be
trained in the precautions, handling, PPE, first aid, emergency management and regulatory
requirements for FSA.
Fluoride dosing into drinking water is regulated and monitored by the MoH, refer to the most recent
copy of the Good Practice Guide (GPG) (Volume 1 and 2)  for the requirements that must be met.
Fluoridation must be incorporated into KDC’ s Drinking Water Safety Plan.
This O&M manual refers to the requirements of the GPG from the February 2023 issue, this manual
should be reviewed and updated when these guidelines are updated.

Overview of the water supply system
The Kawerau water supply system serves around 2,900 properties, including residential households,
businesses, and industrial entities. The system caters to a resident population of approximately
8,000 people. The water is sourced from two springs and three bores. The treated water is stored in
two concrete reservoirs located on Monika Lanham Reserve, with a combined capacity of 6,700 m3,
and a third reservoir on Beattie Road Reserve with a capacity of 4,500 m3. The reticulation network
includes 75 kilometres of pipes, 700 valves, and 880 fire hydrants, efficiently distributing water to all
connected properties.
The water treatment process starts with screening to remove large debris, followed by UV
disinfection to kill harmful microorganisms. Chlorine is added to maintain a safe level of disinfectant,
and fluoride is added as part of the MoH directive to improve dental health. Finally, caustic soda is
used to adjust the pH and ensure effective disinfection.
The Pumphouse Treatment Plant is designed to handle a maximum flow rate of 725 m3/hr, with
continuous monitoring to maintain water quality. Reservoir levels are kept above 75% to ensure a
steady supply and prevent pressure fluctuations. Regular checks are conducted to keep the water
clear and free from sediment, and security measures are in place to prevent contamination. Regular
water quality sampling at the Pumphouse Treatment Plant and across the District to ensure the
reliability and water safety of the watery supply.

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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2
FLUORIDATION PLANT DESCRIPTION

Summary
Fluoride is delivered to the plant as fluorosilicic acid (FSA), in a 1,000L IBC. The operator will use
the forklift to load the FSA IBC onto the FSA IBC bund in the fluoride room.
When FSA Storage Tank filling is required, the operator will don PPE and use the removable drum
pump to load FSA into the 2, 000L storage tank, he/ she will place the drum pump into the top of
the IBC and turn the pump on at the local GPO on/ off switch. The operator will stop the pump once
the unloading is complete. As a safeguard, the control system will cut power to the pump on
reaching the safe fill level. Once the drum pump has been stopped, the delivery pipework will self-
drain both to the bulk tank and back to the IBC (through the drum pump), prior to the operator
removing the pump from the IBC and placing it back on its stand.
Fluoride is not dosed from the bulk storage directly into the water supply, instead, it is metered into
a day tank, which hold 1 days’ worth of FSA (at maximum plant flowrates), this is required (by NZ
regulations) in order to reduce the risk of overdosing of the water supply. The FSA is metered into
the day tank via air driven diaphragm pumps (operating as duty/ standby).
Once in the day tank, the FSA is dosed into the water supply via dosing pumps (operating as duty/
standby). Backpressure valves in the dosing system prevent the risk of siphoning from the day tank
to the water supply. The pumps are each fitted with a pressure relief valve, which relieves back to
the day tank, should a blockage occur in the dosing line. The dosed FSA enters the water supply via
(duty/standby) dosing lines with injection spears into the mains water.
To confirm that the fluoride dosing is at the correct dosage rate, duty/ standby fluoride analysers
analyse a sample from the water sample point, located a suitable distance downstream from the
dosing point to allow for mixing. The fluoride dosing system will automatically stop should the
analysed concentration be above the maximum allowable value, or if the analyser low flow switch
activates, indicating that the sample water is not running through the sample.
Special provisions have been made in the plant design to enable operating and maintenance without
risk of contact with the FSA, which is toxic and corrosive, and also to ensure fluoride is never dosed
if the water supply is not running, and to ensure that the fluoride dose does not exceed the guideline
concentration.

Plant Design Parameters
Table 1—Plant Design Parameters
Parameter
Value
Average Water Demand
4,000 m3/day

Peak Daily Demand
13,500 m3/day
Max Plant Capacity
14,000 m3/day
Background level of fluoride in water supply
0-0.1 mg/L
Fluoride Dose Requirement
0.75 mg/L
Fluoride Residual Setpoint
0.85 mg/L
Maximum Fluoride Dose Rate
1.00 mg/L
Supplied FSA concentration
22%

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Parameter
Value
Supplied FSA SG
1.22
FSA bulk storage tank nominal volume
2,000 L
FSA Day tank nominal volume
58 L
FSA instantaneous transfer rate to Day tank
10 L/min

Fluoridation Plant Equipment
2.3.1  IBC Bund
The FSA is supplied in 1,000L IBCs. An HPDE Bund is provided in the fluoride room for the supplied
Fluoride IBC to be placed on, the purpose of this bund is to contain leaks/ splashes from the IBC or
the Drum Pump. The bund has a drain valve which will normally be kept closed.

Figure 1 -IBC Bund
2.3.2  IBC Drum Pump and Load In Panel
A portable drum pump is provided for the operator to place into the top of the IBC to load FSA into
the storage tank. The drum pump has a dedicated GPO point. The operator connects the drum
discharge hose to the load in line, turns on the GPO and then switches on the hand switch on the
drum pump.  Refer to procedure S-0273-G-WI-001 Filling the FSA Tank from an IBC.
There is a Load-In panel on the building wall, visible to the operator at the drum pump, which
displays the following information:

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•  2x level indicator readings reading in litres, one from each level transmitter in the FSA Storage
Tank The load in panel has a label that reads “Safe Fill level = 1,800 L ; Maximum Fill Level =
2,000L”
•  An audible/ visual alarm which activates at the Safe Fill Level and at the Maximum fill level from
EITHER level instrument
•  A Safe Fill Level Override button which cancels the Safe Fill Level audible/ visual alarm AND the
Safe Fill level GPO interlock for a period of 2 minutes
•  A Maximum Fill Level Alarm silence button (Reset Lamp Test), which silences the maximum fill
level audible alarm.
•  A lamp indicating FSA tank bund high level.
•  A System Emergency stop button - activation of this will cut power to the Drum Pump GPO,
deactivate the transfer pumps’ solenoid valves and stop the dosing pump.

Figure 2 – FSA Load -In Panel
The operator will run the pump until the IBC is nearly empty, or the FSA tank is full. The drum pump
should not be run dry. The operator will switch off the pump either at the pump hand switch or the
GPO.
If the FSA Storage tank level (level instrument) reaches Maximum fill level, then the PLC will cut
power to the drum pump GPO, until BOTH instruments read below Maximum Fill Level. The Operator

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can press the “Maximum Fill Level Alarm Silence (Reset Lamp Test)” button which will de-activate
the audible alarm but will have no effect in the GPO interlock.
If the FSA Storage tank bund high level switch is activated, then the PLC will cut power to the drum
pump GPO and activate the lamp indicating FSA tank bund high level .  There will be no override for
this alarm.
2.3.3  FSA Storage Tank
FSA is stored in the FSA Storage Tank which is a 2,000 litre self-bunded PE Tank in the fluoride
room. The volume of the tank is monitored by two radar level transmitters. The level on these two
transmitters is also be displayed on the Load In Panel beside the IBC bund and on the OIP.
If FSA leaks/ overflows into the tank bund, this is indicated by a level switch
The FSA Storage tank overflow pipe terminates in a lute seal , or water trap,  to prevent odours
from the tank from entering the fluoride room. A low level switch indicates that the level on this
water trap is low, requiring that the operator manually opens the water fill valve and refills it (until it
overflows, and then re-closes the water supply.
The FSA tank is vented outside the WTP building.


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2.3.4  Transfer Pumps and Transfer line
As a protection from overdosing of fluoride into the water,  the dosing system must be supplied via a
Day Tank (refer to section 2.3.5)  which is limited to filling only once per day. The role of the
transfer pumps (2 , which operate duty / standby) is to fill this Day Tank. The Transfer pumps are
air-operated double diaphragm pump which use air power, rather than an electric motor, as the
motive force for pumping.
The nominal pump capacity of each pump is 15 L/min, however by manually limiting the air pressure
to 4 bar and providing back pressure to the delivery line via a manual valve diaphragm valve, this
will be capped at around 5-10 L /min. The pumps are started by the PLC opening the air solenoid
valve of the duty pump.  The control system will limit the running time of the pump to 1 minute at a
time to limit the fill rate of the day tank, prior to a 10 second interval to allow the level instrument
to stabilise. Hence the duty pump would be expected to run for up to 12 minutes over a period of 36
minutes each 24 hours. This transfer operation will start at 12:00am each evening, once the transfer
is complete, it will not run again until the same time the next evening. The day tank fills to the same
level each time, to the “Transfer Stop Level in FSA Day Tank”, set at 51 litres.
Two (fail closed) air actuated valves before and after the transfer pumps, are normally closed to
prevent siphoning when the pump is not operating. Line strainers trap foreign materials before the
day tank. A flow switch on the transfer pump discharge line indicates a no-flow fault situation.
Activation of the day tank/ dosing panel bund high level switch or the transfer pump bund high level
switch will immediately stop the FSA transfer pumps.

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2.3.5  FSA Day Tank
The Day Tank stores a maximum of 24 hours (at maximum plant flow) of expected fluoride usage in
a 58 litre PE tank. The overflow pipe terminates in a water trap to prevent odours from the tank
from entering the fluoride room. The tank vent joins a common vent line for the fluoride system
which vents outside of the building.
The day tank is fitted with a radar level transmitter and separate high and low level switches. The
level of the tank is monitored continuously and each fill cycle the daily use is recorded by SCADA.
The day tank overflow lute seal is fitted with a low level switch, once this switch is activated,
indicating the seal pot level is low, a solenoid valve opens and allows water refilling of the seal pot,
for 10 seconds, after switching off.

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2.3.6 Dosing Pumps and Lines
There are two fluoride dosing pumps (operating duty / standby) which dose the neat FSA from the
Day Tank into the mains water. These are Grundfos DDA 7.5 16 pumps, which are each capable of
dosing a maximum flow of 7.5 Lph of FSA into the water, during commissioning, this flowrate will be
limited to 2.4 Lph to prevent overdosing.

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The dosing sequence is as follows:
The call to run (for the dosing system) is initiated when the plant water flow is above the PLC coded
minimum value of 125 m3/hour AND the low water flow switch is not activated.
To prevent accidental overdosing, neither pump will run in auto if one pump’s selector switch (on the
panel) is in manual, in this case dosing shall stop and an urgent alarm will be raised “Dosing Pump
in Manual – Auto dosing stopped”.
There are two dosing lines, but only one is required to be in operation. The duty dose line is selected
by the operator and the appropriate manual valves are positioned to isolate the standby dose line by
the plant operator. Once Dosing is called to run, the dosing pumps suction and discharge lines’
actuated valves will open and the duty dosing pump will start.
The duty dose pumps speed signal is calculated from the water flow. The required dose rate is based
on the FSA concentration, the calculated total water flow and the required fluoride dose. The duty
dose pumps speed is trimmed based on the deviation of actual dose and the analysed fluoride
concentration downstream of the dose point.
The actual dose rate (i.e., referred to as Dose Verification in the Good Practice Guide) is calculated
from the measured FSA flow, the plant flow, and the FSA specific gravity.

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2.3.7  Fluoride Analysers
The potable water is sampled and analysed for fluoride concentration via two analysers located in
the fluoride room. The two analysers operate in parallel and at least one must be operational for
dosing to operate.

The flow to the analysers is manually controlled and is typically set up during commissioning. Each
analyser requires a flow of between 30 to 60 L/hr at a maximum pressure of 1 bar. The analysers
each have a low flow switch to indicate if sample flow has stopped.  The operator will be able to
select one of the two analysers to be out of service (but never both) , in which case the reading and
alarm/s from this analyser will be ignored by the control system.
2.3.8  Ancillary Equipment
Air Compressor
The actuated valves and FSA transfer pumps are driven by compressed air. An air compressor and
pressure vessel are installed behind the FSA room to supply this air. The compressor power is
permanently on, and its onboard control system will turn the compressor on and off as required to
maintain plant air pressure.
A low-pressure switch on the air line to the plant is installed to indicate a problem with the plant air
supply. Activation of this switch will stop the transfer and dosing systems, if they are in operation.
Note that although air pressure is required to allow fluoride dosing, loss of air pressure will cause
the air operated valves to fail in the closed position – effectively stopping dosing or day tank transfer
without operator action.

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Ventilation Fan
A ventilation fan is permanently on, drawing air through the louvres above the roller door and out
through the fan cowling to be discharged above the roof.
Safety Shower and Wash Down Hose
A safety shower has been installed in front of the Fluoridation room, for use in the event of a
chemical splash. The shower is fitted with a flow switch to indicate that it has been operated. Correct
operation of this shower should be checked regularly.

A wash down hose is included inside the building, near the IBC bund, for washing down any
chemical splashes.

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Reference Drawings
Table 2—Plant Reference Drawings
Drawing or Document
Number
Title
S-0273-E-503-01-001
Single Line Diagram
S-0273-E-503-02-001
Control Panel Schematic 1
S-0273-E-503-02-002
Control Panel Schematic 2
S-0273-E-503-02-003
Control Panel Schematic 3
S-0273-E-503-02-004
Control Panel Schematic 4
S-0273-E-503-02-005
Control Panel Schematic 5
S-0273-E-503-02-006
Control Panel Schematic 6
S-0273-E-503-03-001
Wiring Diagram 1
S-0273-E-503-03-002
Wiring Diagram 2
S-0273-E-503-03-003
Wiring Diagram 3
S-0273-E-503-03-004
Wiring Diagram 4
S-0273-E-503-03-005
Wiring Diagram 5
S-0273-E-503-03-006
Wiring Diagram 6
S-0273-E-503-03-007
Wiring Diagram 7
S-0273-E-503-04-001
Panel GA
S-0273-E-503-04-002
Panel Label List
S-0273-E-503-05-001
Dual Tank Control Panel – General Arrgt
S-0273-E-503-05-002
Dual Tank Unloading Panel – General Arrgt
S-0273-E-503-05-003
Dual Tank Control Panel – Electrical Schematic 1
S-0273-E-503-05-004
Dual Tank Control Panel – Electrical Schematic 2
S-0273-E-503-05-005
Dual Tank Control Panel – Electrical Schematic 3
S-0273-E-503-05-006
Dual Tank Control Panel – Electrical Schematic 4
S-0237-M-503-02-004
Bulk Storage Tank GA
S-0237-M-503-03-001
Day Tank And Dosing Panel GA
S-0237-M-503-04-001
Day Tank Transfer Pump Skid
S-0237-M-605-01-001
Fluoride Analyser Panel GA
S-0237-M-700-01-001
FSA Room GA
S-0237-P-001
P&ID Standard Symbols – Sheet 1 of 5
S-0237-P-002
P&ID Standard Symbols – Sheet 2 of 5
S-0237-P-003
P&ID Standard Symbols – Sheet 3 of 5
S-0237-P-004
P&ID Standard Symbols – Sheet 4 of 5
S-0237-P-005
P&ID Standard Symbols – Sheet 5 of 5
S-0237-P-503-001
P&ID – FSA Storage Tank

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Drawing or Document
Number
Title
S-0237-P-503-002
P&ID- Dosing Pump
S-0237-P-503-003
P&ID – Fluoride Dosing & Analysers
3
FLUORIDATION PLANT PROCESS OPERATION
In normal operation, fluoride dosing and FSA transfer to the day tank runs automatically via the
control system, and Operator intervention is not required unless an alarm has been raised or the
system has faulted. On first start up, or after the plant has been isolated for maintenance, the
Operator may be required to line up the plant valves in their correct positions prior to automatic
running of the plant. The correct line up of valves is described in SOPs S-0273-G-WI-002 Transfer
Pump Set-Up, S-0273-G-WI-003 Fluoride Start Up and S-0273-G-WI-007 Setting back pressure and
pressure relief valves for the dosing system.
Loading of FSA from the IBC to the FSA Storage Tank is a manual task, and this described in in SOP
S-0273-G-WI-001 FSA Unloading from an IBC.
4
FLUORIDATION PLANT PROCESS CONTROL
A detailed description of the fluoridation plant control is provided in S-0273-P-FUD-001, the plant
functional description. A copy of this document is included in Appendix A. This document should be
frequently reviewed and updated when changes occur.
5
EQUIPMENT MANUALS
For detailed descriptions of individual items of equipment, refer to the equipment vendors’ O&M
Manuals, copies of these are included in Appendix D.
6
OPERATING PROCEDURES
Plant operators must familiarise themselves with the plant equipment and operating procedures, a
list of the standard operating procedures is included below:
Table 3—Kawerau WTP Fluoridation System Standard Operating Procedures
Document Number
Document Title
S-0273-G-WI-001
FSA Unloading from an IBC
S-0273-G-WI-002
Transfer Pump Set Up
S-0273-G-WI-003
Fluoride Start Up
S-0273-G-WI-004
Dosing Pump Calibration
S-0273-G-WI-005
Fluoride Analyser Calibration & Filter Cartridge Change
S-0273-G-WI-006
Manual Sampling for Fluoride
S-0273-G-WI-007
Setting back pressure and pressure relief valves for the dosing system
S-0273-G-WI-008
Draining the bunds

WTP Emergency Response plan
Copies of these procedures are included in Appendix C.

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7
PLANT MAINTENANCE REQUIREMENTS:
For detailed descriptions of the maintenance requirements of each item of equipment, refer to the equipment vendors’ O&M Manuals, copies of these
are included in Appendix D. A brief summary of the recommended plant maintenance schedule is included below, this is not intended as a substitute
for fully reviewing and understanding the manufacturers’ recommendations.  This information has been provided prior to commissioning and should
be reviewed periodically and updated as necessary based on plant / equipment performance:
Table 4— Maintenance Schedule Recommendations
Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
EQUIPMENT:
TNK001
FSA IBC BUND
Periodic – visual inspection for damage/ monthly

PMP001
IBC DRUM PUMP
At each use – visual inspection for leaks or damage

FSA STORAGE TANK
Periodic – visual inspection for leaks or damage/ monthly

TNK101
FSA STORAGE TANK –
Periodic – visual inspection for leaks or damage/ monthly

OVERFLOW LUTE SEAL
Vendor recommendations

•  carry out periodic inspections (2-30 days in accordance
with the fluid pumped) on the filter element of the suction
strainer (if any) and remove any trapped filtrate when
PMP101,PMP102
FSA TRANSFER PUMP #1/#2
pumping fluids with solids;
TO FSA DAY TANK
•  carry out periodic inspections (3-5 months in accordance
with the fluid pumped and the environment conditions);
•  ensure correct operation of the system start/stop units;

FAN103
FSA ROOM BUILDING
None recommended

VENTILATION FAN
Periodic – visual inspection for leaks or damage/ monthly
Contact Ashair  0800 808 486
CPR104
PLANT AIR COMPESSOR
Annual service required

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Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
Periodic – visual inspection for leaks or damage/ monthly

Annual service required
FSA INLINE STRAINER, FSA  Periodic-  visual inspection for leaks / monthly

STN138, STN309
DOSING PUMP SUCTION
If flow restriction occurs flush system with water, then remove
STRAINER
strainer basket and clear
TNK301
FSA DAY TANK
Periodic – visual inspection for leaks / damage/ monthly

TNK302
FSA DAY TANK OVERFLOW
Periodic – visual inspection for leaks / damage/ monthly

LUTE SEAL
Periodic – visual inspection for leaks / damage/ monthly

CAL303
FSA DOSING PUMP
CALIBRATION COLUMN

Daily:
Vendor recommendation
Check, if liquid leaks from the drain opening (see manual) and if
the drain opening is blocked or soiled. If so, follow the instructions
given inspection 7.6 Diaphragm breakage ( of manual)
Check, if liquid leaks from the dosing
head or valves. If necessary, tighten dosing headscrews with a
torque wrench at 4 Nm. If necessary, tighten valves and cap nuts,
or perform service (see 7.4 Perform service, of manual).
Check, if a service requirement is present at the pump display. If
PMP301 , PMP302
FSA DOSING PUMP 1/ 2
so, follow the instructions given instructions given in
section 7.3 Service system (of manual).

Weekly -Clean all pump surfaces with a dry
Vendor recommendation
and clean cloth.
Monthly – Recalibrate and record results
Monthly flow calibration is required by GPG
24 Monthly ( or 8000 service hours)  - Service as per Pump manual  Vendor recommendation
section 7.4

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
Test operation on entry to the room – on each occasion

SSR424
SAFETY SHOWER AND
Periodic – inspect shower head / eyewash sprays for build-up ,
EYEWASH
debris or damage - Weekly
Periodic – complete flow test / annually
Periodic – visual inspection for leaks / damage/ 6 monthly

HOS426
Retractable Washdown Hose
(Indoor dosing panel area)

STN703, STN710
ANALYSER 1, 2  SAMPLE
Visual inspection to confirm that flow is not restricted / no algal

STRAINERS
growth in filter
Periodic – visual inspection for leaks / damage/ monthly

ME440, ME441
INJECTION QUILLS

Periodic – visual inspection for leaks / damage/ 6 monthly

ME719
SAMPLE SINK

ME720
PORTABLE STEP LADDER
Periodic – visual inspection for damage/ 6 monthly

INSTRUIMENTS:
AE/AIT7O6, 708
Carry out regular visual inspections of the fluoride measuring
Vendor advice
system, particularly the fluoride probe, the in-line probe housing
and the flow meter.
Look for:
• air bubbles in the sample water
• air bubbles in front of the LaF3 crystal of the fluoride probe
• leaks
• correct flow through the cell
Check that the limit value sensor is seated firmly on the flow
meter.
Check that the float can move freely inside the flow meter.
FLUORIDE ANALYSERS 1,2
If you need to alter the flow: the float should move. If necessary,
clean the flow meter and then test its function again (change flow).

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Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
Recalibration  - record results
At least monthly, or more frequently if

accuracy requirement is not being exceeded
FI 402,716, 706B,
None recommended

708B
ROTAMETERS - VARIOUS
FIT312
FSA DOSING FLOW
None recommended

TRANSMITTER
FS126,403,425,427
None recommended

706B,708B

FLOWSWITCHES - VARIOUS
LIT103 A, B, 301
LEVEL TRANSMITTERS
None recommended

LAH 107, 138
PANEL INDICATOR LAMPS
Test schedule  - Suggest 6 monthly lamp test

LSH124, 332
BUND LEVEL SWITCHES
None recommended

LSH107, 129, 307,
LEVEL SWITHCES –
None recommended

308, 330, 411, 429  VARIOUS
PI123,326, 404, 14,
None recommended

430
PRESSURE GAUGES -

VARIOUS
PSL137
COMPRESSED AIR
None recommended

PRESSURE SWITCH
VALVES:
BLL110,122,303,
Actuator:

331
- Check air quality / pressure periodically.
- Check for leaks of the device. If necessary, replace the o-rings

Ball Valve:
ACTUATED BALL VALVES -
1. Visual and function check (every three months): – Normal
VARIOUS
operating conditions unchanged – No leaks – No unusual operating

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Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
noises or vibrations
2. Ensure that fitting functions properly (opening, closing)
3. Clean fitting with a moist cloth if necessary

SOL124,125
Low frequency operation: Switch valves at least once every 30

days to prevent malfunction. Also, in order to use it under
SOLENOID VALVES – AIR
optimum state, conduct a regular inspection once every 6 months.
SOL329
SOLENOID VALVE – WATER  No specific recommendations

MANUAL BALL
Periodic – visual inspection for leaks / test for operation - 6

VALVES & V-PORT
MANUAL BALL VALVES & V-
monthly
BALL VALVES
PORT BALL VALVES

VARIOUS
VARIOUS
CHECK VALVES -
Periodic – visual inspection for leaks / test for operation - 6

VARIOUS
monthly
CHECK VALVES - VARIOUS

Diaphragm valves -  Diaphragm valves -
Periodic – visual inspection for leaks / damage/ monthly

VARIOUS
VARIOUS

RPZD416
DOSING SYSTEM WATER
Annual re-test/ re- certification by licenced plumber
Required by regulations ( tbc)
RPZD
SR320, 321
1. Visual and function check (every three months): – Normal

operating conditions unchanged – No leaks – No unusual operating
noises or vibrations
2. Check tightening torque of screws (12) (Manual → 9.2.3
DOSING PUMP PRESSURE
Tightening torques, Page 12).
RELIEF VALVES
3. Clean fitting with a moist cloth if necessary.
PRV123
AIR SUPPLY REGULATING
No specific recommendations

VALVE
PG328, PG414,
DOSING LINE BACK
1. Visual and function check (every three months): – Normal

PG431
PRESSURE VALVE
operating conditions unchanged – No leaks – No unusual operating

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Tag
Equipment/Instrument/valve
Name
Recommended Maintenance/ Maintenance Interval
Notes
noises or vibrations
2. Check tightening torque of screws (12) (Manual → 9.2.3
Tightening torques, Page 12).
3. Clean fitting with a moist cloth if necessary.

Table 5—Spare Parts Recommendations
The following table includes TRILITY’s initial recommendations for the installed equipment:

Tag
Equipment/Instrument/valve
Name
Recommended Spare parts
Notes
EQUIPMENT:
TNK001
FSA IBC BUND
No recommendations

PMP001
IBC DRUM PUMP
No recommendations

TNK101
FSA STORAGE TANK
No recommendations

FSA STORAGE TANK –
No recommendations

OVERFLOW LUTE SEAL
PMP101,PMP102
FSA TRANSFER PUMP #1/#2  4mm tubing and one-touch fittings

TO FSA DAY TANK
FAN103
FSA ROOM BUILDING
No recommendations

VENTILATION FAN
CPR104
PLANT AIR COMPESSOR
6mm & 10mm tubing and one-touch fittings

VE104
PLANT AIR COMPESSOR
10mm tubing and one-touch fittings

VESSEL

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Tag
Equipment/Instrument/valve
Name
Recommended Spare parts
Notes
FSA INLINE STRAINER, FSA  Replacement strainer basket / o-rings for each , or 1 complete

STN138, STN309
DOSING PUMP SUCTION
spare for each
STRAINER
TNK301
FSA DAY TANK
No recommendations

TNK302
FSA DAY TANK OVERFLOW
No recommendations

LUTE SEAL
CAL303
FSA DOSING PUMP
No recommendations

CALIBRATION COLUMN
Grundfos service kit, valve/diaphragm. SD-S-PV/T/C-1
Vendor recommendation
PMP301 , PMP302
FSA DOSING PUMP 1/ 2
Product Code: 97751539
SSR424
SAFETY SHOWER AND
Spare eyewash covers

EYEWASH
HOS426
Retractable Washdown Hose  No recommendations

(Indoor dosing panel area)
STN703, STN710
ANALYSER 1, 2  SAMPLE
Replacement 5micron 5” filter cartridge (usu. 1 spare supplied with  TRILITY recommendation , replacement
STRAINERS
unit )
frequency will depend on om water quality
ME440, ME441
INJECTION QUILLS
No recommendations ( these are duty /standby)

ME719
SAMPLE SINK
No recommendations

ME720
PORTABLE STEP LADDER
No recommendations

INSTRUIMENTS:
AE/AIT7O6, AND FI  FLUROIDE ANALYSERS 1,2
Item/Part #
This is the vendor recommended list,
70806B, 708B
and ROTAMETERS
•  Flow cellDGMA300T000
TRILITY advises that the items in bold are
the most likely to be needed - suggest
•  Transmitter FP V11028280
holding 1 set of spares per 2 analysers
•  Fluoride probe FELP 010 SE1028279
•  Reference electrode REFR1083790
•  Pt 100 sensor305063

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Tag
Equipment/Instrument/valve
Name
Recommended Spare parts
Notes
•  Polishing Paste559810
•  KCl solution 3M 250 ml791440
•  Magnetic Stirrer3671000l
•  Magnetic Stirrer Rod 001.215C
•  Magnetic Rod Retriever 004.250.C
•  Connection Set 8x5mm 1 pair 817053
•  Ball Valve –DGMA1010380
FI 402,716,
ROTAMETERS - VAROUS
None recommended

FIT312
FSA DOSING FLOW
None recommended

TRANSMITTER
FS126,403,425,427  FLOWSWITCHES - VARIOUS  None recommended

706B,708B
LIT103 A, B, 301
LEVEL TRANSMITTERS
No vendor recommendations – consider holding 1 complete spare
instrument
LAH 107, 138
PANEL INDICATOR LAMPS
Suggest keeping 1 spare of each colour

LSH124, 332
BUND LEVEL SWITCHES
Suggest keeping - 1 spare

LSH107, 129, 307,
LEVEL SWITHCES –
Suggest keeping - 1 spare

308, 330, 411, 429  VARIOUS
PI123,326, 404, 14,  PRESSURE GAUGES -
None recommended

430
VARIOUS
PSL137
COMPRESSED AIR
None recommended

PRESSURE SWITCH
VALVES:
BLL110,122,303,
ACTUATED BALL VALVES -
Actuators:
May be easier to keep 1 spare valve body of
331
VARIOUS
Spare kit available. Every kit includes:
each size ( DN15, DN20) & 1 spare actuator
o O-rings set
for ease of replacement

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Kawerau WTP Fluoridation Operating and Maintenance Manual
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Tag
Equipment/Instrument/valve
Name
Recommended Spare parts
Notes
o Pistons friction bands

o Pinions (models from PP10 to PP20)
o Shaft washer.
o Shaft safety ring

Ball Valve:
No specific recommendations
SOL124,125
SOLENOID VALVES – AIR
No specific recommendations – consider keeping 1 complete spare
valve or spare coil
SOL329
SOLENOID VALVE – WATER    Can get coil set , plunger tube set or wearing parts set, or keep 1
complete spare valve
MANUAL BALL
MANUAL BALL VALVES & V-
Suggest keeping:

VALVES & V-PORT
PORT BALL VALVES
•  1 x ½” (Ball Valve, 546 Pro, PVC-U, SCS, 1/2”, EPDM (p/n
BALL VALVES
VARIOUS
161546242)), &
VARIOUS
•  1 x 1” (Ball Valve, 546 Pro, PVC-U, SCS, 1”, EPDM (p/n
161546244)),
CHECK VALVES -
Check VALVES - VARIOUS
Suggest keeping 1 x ½” & 1 x 1” in stock

VARIOUS
Diaphragm valves -  Diaphragm valves -
Suggest keep 1 x ½” on hand (p/n 161 514 512)

VARIOUS
VARIOUS
RPZD416
DOSING SYSTEM WATER
Vendor recommend a repair kit consists of: relief valve repair kit,

RPZD
first check repair kit, second check repair kit, retainer (if plastic)
(p/n tba)
SR320, 321 AND
DOSING PUMP PRESSURE
Vendor advises the diaphragm & seals can be renewed as required
PG328, 414, 431
RELIEF VALVES AND
, however it may be easier to keep 1 x ½” spare complete valve in
DOSING LINE BACK
stock
PRESSURE VALVE

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Tag
Equipment/Instrument/valve
Name
Recommended Spare parts
Notes
PRV123
AIR SUPPLY REGULATING
No specific recommendations

VALVE
PIPING:
General note
Consider keeping small amount of DN15 pipe, fittings ,primer &

glue onsite

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link to page 30 link to page 30

Kawerau WTP Fluoridation Operating and Maintenance Manual
S-0273 Kawerau Fluoridation Project

8
MONITORING AND TESTING

Fluoride Levels
Fluoride dosing must be controlled within the following limits ( refer to GPG , Vol1, Sect 4.3):
Total fluoride ion
Parameter
concentration
Response to process limits
(mg/L)
Operating target (to be achieved for  0.85

≥95%of the time that the treatment
plant is producing water)
Operating range (≥95% of the time  Within ± 0.15 of

that the fluoridation plant is in
operating target.
operation)
Upper action process limit
1.3
Immediate fluoride plant shut down
(safeguards interlocked with the
dosing system.)
Emergency limit ( Maximum
1.5
Immediate fluoride plant shut down.
Allowable Value, MAV)
(Safeguards interlocked with the
dosing system.) Notify Taumata Arowai,
investigate the cause of the exceedance and
take appropriate action.

Plant Testing and Monitoring
In addition to the automated fluoride dosing control, online monitoring and automated subsequent
shutdown actions, the GPG requires that the items listed in Table 6— Record keeping requirements
are also monitored.
Refer to S-0273-G-WI-006 for a procedure for taking a manual sample for fluoride analysis.
Refer to Table 6— Record keeping requirements for details of how results are to be recorded.
9
SAFETY AND EMERGENCY PROCEDURES
FSA is a toxic and corrosive liquid, operators should review and understand the SDS and receive
specific training in the precautions, first aid procedures and safe handling for this product, and
records of this training should be kept.
A current SDS for FSA should be available to the operators (refer to Appendix B of this manual).

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Emergency Procedures
For Emergency Procedures, refer to Kawerau District Council’s document:  WTP – Emergency
Response Procedure in Appendix  .

Contact Information
Contact information for emergency services and regulatory authorities is as follows:
Contact
Contact details
Emergency Response – Fire / Police / Ambulance
Tel 111
Plant Designer – TRILITY solutions
TRILITY
Unit 4, 23 Tukorako Drive
Spare Parts - TRILITY Sales/ Service
Mount Maunganui NZ 3116
Tel: +64 7577 9988

Chemical supplier
IXOM
166 Totara Street
Mount Maunganui 3116
Tel: 0800 222 277
On call WTP Operator
Glen Penny
Tel: +64 27 292 0703
NZ Ministry of Health
Ministry of Health
133 Molesworth Street
Thorndon, Wellington 6011
Tel: 0800 400 569
Eg. Taumata Arowai, NZ Drinking Water Regulator
Taumata Arowai
Level 2/10 Brandon Street
Wellington Central, Wellington 6011
Tel: 04 889 8350
10
QUALITY CONTROL:
To ensure that fluoride dosing / analysis always operates within guidelines and in a safe and
effective manner,  there are three main aims of plant quality control, these are:
•  to ensure the accuracy and reliability of fluoride dosing and monitoring.
•  to verify and validate equipment performance.
•  To implement corrective actions for addressing deviations from target fluoride levels.
In the fluoridation plant these aims should be achieved by:
•  Monitoring, recording and reviewing plant dosing data based on the verification calculations in
the FUD.
•  Regular calibration and maintenance of the dosing pumps

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•  Regular calibration of the fluoride analysers
•  Regular laboratory testing of the fluoride level in the raw and treated water
•  Logging and recording incidences of deviation of plant control outside of guideline values
•  Obtaining and recording FSA concentration and analysis certificates from the vendor
•  Maintaining plant equipment regularly and holding stock of essential plant spares
•  Regular operator/ maintainer training / re- training.

11
RECORD KEEPING:
The Water New Zealand Good Practice Guide - Fluoridation of Drinking Water Supplies outlines
specific record-keeping requirements for drinking water suppliers. This section summarises those
requirements:
Table 6—Record Keeping Requirements
Records to be kept:
Suggested means of recording this:
Fluoride Dosing Records:
•  Record the amount of fluoride added to the water.  •  Data logging records ( Continuous data (minimum 5
minute interval records) as/where required by the
Drinking Water Quality Assurance Rules) of:
•  Water Flow
•  Online fluoride concentration
•  FSA flow
•  Manual records of FSA IBC receipts

•  Maintain records of the fluoride compound used,
•  Manual records of FSA IBC receipts
including batch numbers and suppliers. Supplier to

provide chemical analysis
•  The drinking-water supplier must, at a minimum,  •  Data logs
also record the following parameters at the
frequencies indicated:
•  The volume of water treated
•  The quantity of fluoride added to the water (based
on day tank or hopper and dose flow meter,
where monitored)
•  The stock of fluoride on hand
•  The results of fluoride analysis of the samples of
water taken from the treated water at the
intervals required – on site and IANZ accredited
samples
•  Average fluoride concentration each day on the
basis of the online analyser records
•  Average fluoride concentration each day on the
basis of the loss of mass or volume in the dosing

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Records to be kept:
Suggested means of recording this:
tank
•  A reconciliation of each of the independent checks
(refer Safeguard D and Section 4.7.6)
•  Note the date and time of fluoride addition.
•  Data logging of control system data for fluoride
pump operation
Water Quality Monitoring:
•  Regularly measure and record the fluoride
•  Data logging on analyser results
concentration in the treated water.
•  Regular laboratory analyses
•  Incorporate the Fluoride dosing into the suppliers’  •
Drinking Water Safety Plan ( Ref GPG Vol 1 , Sect
3.3)
•  Document the frequency of monitoring and the
•  Continuous monitoring for Fluoride levels at the
methods used for testing.
Fluoride Plant
•  Daily testing for fluoride levels at 3 different sites
across the district using a fluoride meter. Results
are recorded in the Daily Monitoring Sheet and
reported to Taumata Arowai monthly.
Equipment Maintenance Logs:
•  Keep detailed records of the maintenance and
•  Fluoride analyser log sheet (example tba)
calibration of equipment used for fluoride dosing
•  Fluoride dosing pump calibration log sheet (example
and monitoring. Include dates of inspections,
tba)
servicing, and any repairs carried out
•  Fluoride Inspection log sheet (example tba)
•  Fluoride Maintenance Logs – calibrations to be done
monthly
Operational Records:
•  Record any deviations from standard operating

procedures, including reasons and corrective
actions taken.
Refer to Fluoride Operational Logs
•  Document any incidents or issues related to
Refer to Fluoride Operational Logs
fluoride dosing, including equipment malfunctions
and quality control failures
•  The operation of shutdown systems must be fully  Refer to Fluoride Operational Logs
tested at least annually and the outcome of these
tests recorded ( Ref GPG Vol 1 , Sect 4.7.7)
•  Routine testing of critical alarms and corrective
Fluoride Maintenance Logs – routine testing to be done
actions and outcomes of the system shutdown
monthly
tests
•  Surveillance monitoring and audits records
Surveillance monitoring to be logged on the Fluoride
Operational Logs
Audit records to be kept in the KDC Shared Drive
•  Log any control overrides ( Ref GPG Vol 1 , Sect
Fluoride Operational Logs
4.7.7)
•  The drinking-water supplier should keep records
Operational and Maintenance Logs are to be updated

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Records to be kept:
Suggested means of recording this:
verifying that the fluoride plant is managed and
accordingly.
operation accordance with the GPG ( Ref GPG Vol
1 , Sect 6.5)
The printed copy is to be verified and scanned monthly,
to be kept in the KDC Shared Drive.
Compliance Documentation:
•  Maintain records of compliance with regulatory
Compliance records are kept digitally in the KDC Shared
requirements and guidelines.
Drive, readily available for compliance officers and
regulatory bodies.
•  Include any communications with regulatory
All communications with regulatory bodies, inspection
bodies, inspection reports, and audit findings
reports, and audit findings are found in the KDC
Internal Shared Drive.
Training Records:
•  Keep records of training provided to staff involved  Records of FSA training
in fluoride dosing and monitoring. Include dates,
training content, and names of attendees
Records of plant familiarisation and specific SOP
training
Public Communication:
Document any public notices or communications  Copy of correspondence records are found in the KDC
related to fluoride levels in drinking water
Internal Shared Drive
Keep a record of public inquiries and responses  Public enquiries can be lodged via email, phone or
provided
Antenno. Records of public enquiries and
responses (as well as status, service request type,
contact person and contact number, etc.) can be
found on the KDC Datascape CRM.
Annual reporting requirements:
Refer to the GPG (Ref GPG Vol 1, Sect 7)
Monthly reporting to Taumata Arowai are kept on the
KDC Internal Shared Drive and submitted on the
Hinekorako Website within the first ten days of the
month.
A copy of the reports is also provided to the water
compliance auditors as part of the Annual Water Quality
Audit.

By adhering to these record-keeping practices, drinking water suppliers can ensure the safe and
effective fluoridation of drinking water, while also maintaining compliance with regulatory standards
and providing transparency to the public.

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12
STAFF TRAINING
  Staff Qualifications
The GPG recommends that “National Certificate in Water Treatment (Site Operator) - Level 4 (or
equivalent), or preferably a National Diploma in Drinking Water - Water Treatment (Site Technician)
- Level 5 (or equivalent) is recommended as a minimum qualification for operators of fluoridation
plants” (refer to Vol 1 section 5.4).

  Staff Training
Staff must be trained in handling, precautions and emergency management for FSA, as well as the
associated regulatory requirements for chemical handling.
NZ GPG (Vol 1 section 5.4) requires that:
“The drinking-water supplier must ensure that operational personnel (employees or contractors) are
appropriately skilled and trained in the management and operation of the fluoridation plant, and that
these competencies are maintained (and that this is documented in the Water Safety Plan).
Operational personnel must have an adequate knowledge of the principles of fluoridation (including
the risks), the type of plant or equipment and its operation and maintenance.” and
“Operational personnel must have a sound knowledge base from which to make effective operational
decisions. This requires training in the methods and skills required to perform tasks efficiently and
competently. Operational personnel should be aware of the potential consequences of system
failures, and how decisions made can affect the safety of the scheme.”
  Procedure for Documenting Staff Training
Staff training are to be logged on the Staff Training Log Sheet – noting any expiration date of the
training so the staff can be booked for a refresher training

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Figure 3 – Example KDC Staff Training Log Sheet
13
REVIEW AND UPDATE PROCEDURES FOR THIS MANUAL
The NZ GPG recommends that this operating and maintenance manual is regularly reviewed, it is
the responsibility of KDC to see that this is implemented. TRILITY recommend that it is reviewed
after commissioning, and at regular intervals thereafter (eg. annually), or more frequently if it is
apparent that it is not suitable for facilitating meeting the objectives of KDC’ obligation to maintain
consistent and effective operation of the fluoridation systems, maintain compliance with regulatory
standards, and safeguard public health.
This manual should also be reviewed if the relevant legislation or guidelines are updated, OR if new
items of equipment are incorporated into the plant.
The latest version of the FSA SDS should also be kept with this manual.

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Kawerau WTP Fluoridation Operating and Maintenance Manual
S-0273 Kawerau Fluoridation Project
APPENDIX A—FLUORIDATION PLANT FUNCTIONAL CONTROL DESCRIPTION

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APPENDIX B—IXOM FLUOROSILIC ACID SAFETY DATA SHEET

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APPENDIX C—STANDARD OPERATING PROCEDURES

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APPENDIX D—VENDOR EQUIPMENT DATA SHEETS AND OPERATION AND
MAINTENANCE MANUALS

-

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