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The Role of Critical ControlPoints in ControllingContaminants

2Role of Critical Control Points

• Systematic preventative approach to Food Safety.

• Common with TQM – focuses on process barriersrather than end of pipe quality.

• FDA/USDA mandatory for juice and meat.

• Applied to drinking water treatment.

• A number of examples for IPR and other recycledwater production

Hazard Analysis and Critical Control Points(HACCP)

Conceived in 1960s by Pillsbury for NASA

Defined in ISO 22000 – Food Safety


The 7 HACCP Principles

Conduct a HazardAnalysis

Determine CriticalControl Points

Establish CriticalLimits

Establish System toMonitor the Control of a

CCP

Establish Corrective Action to beTaken When Monitoring a CCP is

Not Under Control

Establish Procedures forVerification to Confirm that

HACCP System is workingeffectively

Establish DocumentationConcerning All Procedures andRecords Appropriate to These

Principles and Their Application

1

2

3

4

5

6

7


HACCP Approach Applied to Recycling

IdentifyHazardousContaminants

IdentifySource ofContaminants

IdentifyHazardousEvents

Determine andRank Risks

Identify CriticalControl Points

Identify WaterQuality Testing

Validation Develop CCPResponseProcedures

Verification OngoingAnalysis andAssessment

Hazard Analysis

Critical Control Points

Monitoring

Procedures &Corrective Actions

Identify CriticalControl Points

Identify WaterQuality Testing

Validation Develop CCPResponseProcedures

Verification OngoingAnalysis andAssessment

Critical Control Points

Monitoring

Procedures &Corrective ActionsIdentify

HazardousContaminants




Hazard Analysis


Select Critical Control Points – Control Hazards

Halliwell et al WRRF 09-03

Clear methodology forCritical Control PointSelection


Example – Western Corridor Recycled Water Plant

CCP 2

Microfiltration(Pressure Decay Integrity Test)

CCP 3

Reverse Osmosis(Permeate conductivity)

CCP 4

Advanced Oxidation(Peroxide Dose and UV Dose)

CCP 1

Activated Sludge Process(On Line Ammonia)

CCP 5

Chlorine Dose(CT)


Establish Critical Limits

The HACCP team establishes critical limits to assess whether aparticular control measure is effective.

If this critical limit is exceeded or not met, it triggers the need for acorrective action.

The critical limit can be either a numerical limit (e.g., chlorine residualconcentration, system pressure) or a yes/no type response on whethera particular control measure was completed .

Example limit – Western Corridor Qld Australia


Operational Response


• Western Corridor Recycled Water Project, Brisbane Australia (ISO 22000Certified).

• PUB, Singapore SS 444:998 (Singapore Standard)

• Orange County Water District – Groundwater Replenishment Scheme, CA

• Melbourne Water – Recycling System

• Gold Coast Seawater Desalination Plant

• Elements in the US, but current concern is additional requirements.

Where have Critical Control Points BeenUsed


Critical Control Point Assessment toQuantify Robustness and Reliability ofMultiple Treatment Barriers of a DPRScheme

WRRF-13-03:Can We Trust the

Technology?


Direct Potable Reuse - The Definition

Indirect Potable ReuseDirect Potable Reuse


DPR- Raising the Stakes

Can We Trust theTechnology?

Can We TrustOperations?

Trust but VerifyWRRF 13-03

Critical Control Point Assessment to Quantify Robustnessand Reliability of Multiple Treatment Barriers of a DPRScheme

WRRF 13-13

Development of Operation and Maintenance Planand Training and Certification Framework forDirect Potable Reuse (DPR) Systems

Convincing a skeptical public Convincing regulators


Utility and Other Partners

Water Campus


Conduct a hazard assessment to identify health risks, identifywater quality objectives and identify critical control points for 2treatment trains.

Goals for 13-03

Full Advanced Treatment(FAT)

Non MembraneTreatment


FAT - MF/UF – RO – UV/H2O2 – Cl2 – Engineered Storage


Non FAT - O3 – BAC – GAC – UV – Cl2 – Engineered Storage

UV REACTOR

WASTEWATERTREATMENT PLANT

GAC

BAC

CHLORINE

CHLORINECONTACTOR

OZONE

DRINKING WATER PLANTOR DISTRIBUTION

ENGINEEREDSTORAGE


• Identify hazards and hazardous events.

• Assess and quantify those risks.

• Describe how hazards and hazardous events are to bemanaged and which control measures need to beimplemented.

Conduct a Hazard Analysis

Source Water Analysis

IdentifyHazardousContaminants




Hazard Analysis


Began with a literature review

• Source concentrations inliterature.

• Reviewing data fromparticipating utilities.

Identify Source Water Hazards


Target water quality -EPA primary drinking water regulations andincluded California Drinking Water Regulations.

Used lower of the two values where applicable

Focus on action levels and notification levels.

The team agreed not to include secondary standards unless anargument can be made for specific individual constituents.

Determined our Treated Water QualityObjectives


Identify Hazardous Events

Accidentalcontamination of the

catchment

Disease outbreak –high pathogen load

Failure of biologicalprocesses

High rainfall event –bypassed treatment Catastrophic

membrane integritybreach

Formation of DBPs inthe process train

Overdosing,underdosing or

contamination ofchemicals


Semi Quantitative Risk AssessmentWe established a model source water basedon CA facilities

Contaminant Risk before treatment Risk post treatment


CCPs – FAT TrainNDMA Control

Micro-organisms

Micro-organismsChemicals of Concern

Micro-organismsChemicals of Concern

Lead/copper leaching indistribution system.

Micro-organisms


CCPs – Non FAT TrainCCP and Risk Assessment Highlight Need for Process Modification

Particle Removal

Treat as Combined

TOC, DBP, DBPPrecursors

Micro-organisms Micro-organisms

Micro-organisms

Micro-organismsTOC


How Reliable are these CCPs?

Monte Carlo Simulation from FullScale Operating Data

Quantify Reliability with Statistical Analysis

2 4 6 8

10

12

14

Fre

quency

0.0

0

0.0

5

0.1

0

0.1

5

0.2

0

0.2

5

0.3

0

Fre

quency

94

95

96

97

98

99

100

Fre

quency


TOC time series


TOC lognormal probability plot


TOC Rejection (%) by RO2 4 6 8

10

12

14

Fre

quency

0.0

0

0.0

5

0.1

0

0.1

5

0.2

0

0.2

5

0.3

0

Fre

quency

94

95

96

97

98

99

100

Fre

quency


RO rejection (%) by Monte Carlo simulation93

94

95

96

97

98

99

100

Fre

quency

50

55

60

65

70

75

80

85

90

95

100

Fre

quency

98.0

98.2

98.4

98.6

98.8

99.0

99.2

99.4

99.6

99.8

100.0

Fre

quency

92

93

94

95

96

97

98

99

Fre

quency


• Identify gaps following review of full scale plants.

• Planned full scale plant tests (Scottsdale Water Campus)

• Additional bench scale for gaps if required.

Where to From Here..

Conduct Bench/Pilot Level Challenge Test Studies


Develop Standard Design Approachesand Response Strategies

Alert limit is exceeded

Check analyser as perWI-GWA-WCB-2232.

Check SCADA reading isconsistent with analyser reading.Check presence of significant air

bubbles in the associatedde-bubbling column.

Alert limit is still exceeded?

Monitor RO feed turbidityanalysers (1A_AIT 2004-1 or

1B_AIT 1921)

Record

Critical limit is exceeded

Critical limit is stillexceeded?

Check analyser as perWI-GWA-WCB-2232.

Check SCADA reading isconsistent with analyser reading.Check presence of significant air

bubbles in the associatedde-bubbling column.

NO

NOYES

YES

Shut down the MF plant if ROturbidity analyser exceeds 0.2NTU for more than 15 minutes

Manually initiate a PDT

PDT and start pressure areacceptable?

Refer to CCP 5 / PDT

YES

NO

Notify Plant Supervisor

MF plant auto shut down

Check the common header andunit selectable turbidity analysers

trends. Look for failure ofindividual MF units.

Put back online the units that areproducing acceptable filtratequality. Leave others offline.


Summary

Can We Trust theTechnology?

Trust but Verify

CCP – ongoing verification of the technology.

Provides a framework to transparently demonstrate how risks are managed.

Provides reliability and safety of water quality.

Integrates well into operations and is practical.

YES

32The Role of Critical Control Points in Controlling Contaminants

Recycled Water

Controlling Contaminants

Contaminants fromPollution

Algae Outbreaks

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