Schedule 9 Part 1 Practical Completion Part 1 ... - Wakefield

Schedule 9 – Part 1 Practical Completion

07/01/2013 Part 1

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Part 1 – Practical Completion

1 For the purposes of this Schedule 9 only, the South Kirkby Main RCV Facility shall be deemed to be a Non-Acceptance Test Facility and references to New Waste Management Facilities shall exclude the Carrwood Road TLS.

2 Where applicable each New Waste Management Facility and the South Kirkby Main Site shall for the purposes of Practical Completion satisfy the following requirements in accordance with the Works Delivery Plan and all Necessary Consents:-

a) has been designed and constructed on the relevant Site;

b) has had any relevant landscaped areas completed;

c) has had any other facilities shown on the appropriate drawings completed;

d) all external fencing, gates, security equipment, vehicular and pedestrian accesses have been completed;

e) is secure from intrusion and uncontrolled public access;

f) all buildings are weatherproof and watertight as appropriate;

g) all building services, drains, fire and any security related equipment have been completed;

h) all surface water drainage connections have been completed in accordance with the requirements of the land drainage authority and any damage has been made good;

i) any foul sewer diversion has been completed;

j) all buildings, and the relevant parts of each Site are clean and tidy and all debris and rubbish have been removed;

k) all mechanical and electrical installations, plant and equipment have been installed, tested, certified and are safe for use;

l) all weighbridges have been calibrated and are operational;

m) is entitled to operate lawfully and accept Contract Waste;

n) all health and safety systems are operational; and

o) all roads and hard-standings required for the delivery of Contract Waste have been constructed and completed including surface dressings, kerbs, drainage and road markings.

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Part 2 – Acceptance Tests

Acceptance Tests will be carried out using Contract Waste only and no Non-Contract

Waste will be processed during the conduct of these Acceptance Tests.

The Acceptance Tests shall be carried out in accordance with the agreed Acceptance

Test Programme.

The Acceptance Tests shall be supervised by the Independent Certifier and the

Contractor.

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1. South Kirkby Main Composting Facility

1.1 The Acceptance Test

1.1.1 The Acceptance Test will demonstrate that the South Kirkby Main Composting Facility can process the Composting Input without breaching the Environmental Permit and produce Composted Material in accordance with test 1.1 of Table 1 below.

1.1.2 In order to complete the test in a reasonable period of time the Acceptance Test will be restricted to the processing of four (4) composting tunnels worth of Composting Input over a complete composting cycle using the normal operational Composting procedure as set out in section 2.10.4.1 of the Works Delivery Plan and the Operating Manuals.

1.1.3 Four (4) of the first stage composting tunnels will be filled to their design operating capacities so that the required composting conditions are achieved and maintained throughout the period of the Acceptance Test. The time taken to fill the four (4) tunnels will depend on the delivery rate of Composting Input.

1.1.4 The criteria being monitored or measured are defined in Table 1 below.

1.1.5 The Acceptance Test of the South Kirkby Main Composting Facility shall be deemed passed provided the pass criteria defined in Table 1 below are achieved

1.1.6 Should the pass criteria in test 1.1 of Table 1 below not be achieved then, following modification to the South Kirkby Main Composting Facility, test 1.1 shall be repeated with a duration that shall be agreed with the Independent Certifier.

1.1.7 Should the pass criteria in tests 1.3, 1.4, or 1.5 of Table 1 below not be achieved then, following modification to the South Kirkby Main Composting Facility, that test shall be repeated within the remaining period of the Acceptance Test or the period of the Acceptance Test shall be increased to accommodate the retest as agreed with the Independent Certifier.

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Table 1 South Kirkby Main Composting Facility Parameters

Test Feature being

tested

Any specific conditions for

the facility to ensure that the

feature being tested is

subject of a valid test

Test Process and parameters measured Pass Criteria

1.1 Throughput of

the South

Kirkby Main

Composting

Facility

Throughout the period of the

Acceptance Test the South

Kirkby Main Composting

Facility shall be operated in

accordance with the relevant

Operating Manuals.

The South Kirkby Main

Composting Facility will be

staffed with the number of Staff

as set out in the relevant

Operating Manuals. Staff will

have completed the appropriate

induction and training process

prior to the commencement of

the Acceptance Test.

The time taken to reach maturity will depend on a number

of parameters and it is the role of the Contractor’s

composting operator to determine when the composting

process has finished. When the Contractor’s composting

operator deems that, after maturation, the material has

reached a suitable condition, the composted material for

each of the four batches shall be sampled using the

guidance in BS EN 12579 and the samples shall be tested

to demonstrate that the South Kirkby Main Composting

Facility can produce Composted Material to achieve:

a Composted Material compliant for agricultural or horticultural use in accordance with the standards defined in Table 1 of the Materials and Energy Marketing Plan.

and after further maturation and screening a Composted Material that meets the product quality aspects of PAS 100:2005 standard and is in accordance with Quality Protocol - Compost (the Quality protocol for the production and use of quality compost from source-segregated biodegradable waste” published by WRAP and the Environment Agency, July 2010).

1.2 Contribution of

the facility to

Contract

Targets

Throughout the period of the

Acceptance Test the South

Kirkby Main Composting

Facility shall be operated in

accordance with the relevant

Tonnage of Composting Input will be recorded and a mass

balance will be compiled detailing the input and output

streams across the South Kirkby Main Composting Facility.

Although there is no specific figure for the South Kirkby

Main Composting Facility the mass balance will be used to

determine the contribution of the South Kirkby Main

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Operating Manuals.

The South Kirkby Main

Composting Facility will be

staffed with the number of Staff

as set out in the relevant

Operating Manuals. Staff will

have completed the appropriate

induction and training process

prior to the commencement of

the Acceptance Test.

Composting Facility towards:

the Household Waste Recycling Target; and

the BMW to Landfill Target

1.3 Noise levels The peak noise levels will be

recorded at the test points

identified in the South Kirkby

Acceptance Testing

Measurements Points SK-EXT-

9201 during normal operating

conditions whilst the following

activities are being conducted:

while Composting Input is being delivered;

while the waste shredder is operating at near operating capacity; and

while the loading shovel is filling a tunnel

The level of noise generated by the South Kirkby Main

Composting Facility will be measured in accordance with

the detailed procedure set out in the Acceptance Test

Programme.

The level of generated noise will be measured on one

occasion at each of the test points on the boundary of the

South Kirkby Main Site. The measurements taken at these

points, as may be determined by the Environmental Permit,

are to ensure that noise levels comply with the

requirements of the Environmental Permit.

1.4 Odour Levels This test will be performed

towards the end of the test

period for the South Kirkby

Main Composting Facility.

The biofilter operation will be

adjusted to take into account

The odour shall be monitored at a number of points on the

boundary of the South Kirkby Main Site as may be

determined by the Environmental Permit and in accordance

with the detailed procedure set out in the Acceptance Test

Programme to ensure that odour levels comply with the

requirements of the Environmental Permit.

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the number of tunnels being

tested using suitable means,

such as temporary baffles, to

maintain the residence time at

the design levels. The

ventilation fans in the unused

tunnels shall be configured so

as to maintain the expected

efflux velocity at the discharge

point. If the efflux velocity varies

from the predicted velocity no

correction factor shall be

applied.

The odour output from the biofilters will be measured to

ensure compliance with the levels of odour set out in the

Environmental Permit.

Should the measured odour level from either biofilter be

more than above the defined level in the air quality

model (in OUe/m3); the potential impact on overall site

odour release will be evaluated using the air quality model

once all odour measurements required as part of the

Acceptance Tests have been completed.

1.5 Bioaerosol

Levels

The bioaerosol tests shall not

be undertaken before the

biofilters have been

acclimatised and optimised.

The biofilter operation will be

adjusted to take into account

the number of tunnels being

tested using suitable means,

such as temporary baffles, to

maintain the residence time at

the design levels. The

ventilation fans in the unused

tunnels shall be configured so

as to maintain the expected

efflux velocity at the discharge

If required by the Environment Agency as part of the

Environmental Permit, bioaerosol levels will be measured

at a number of points on the boundary of the South Kirkby

Main Site in accordance with the detailed procedure set out

in the Acceptance Test Programme.

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point.

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2. South Kirkby Main MRF

2.1 The Acceptance Test

2.1.1 The period for the Acceptance Test for the South Kirkby Main MRF shall be two (2) weeks.

2.1.2 The Acceptance Test will demonstrate that the South Kirkby Main MRF can process the MRF Input without breaching the Environmental Permit and produce Reclaimed Materials and Waste Derived Products in accordance with test 2.2 of Table 2 below.

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Table 2 South Kirkby Main MRF Parameters

Test Feature being tested Any specific conditions for

the facility to ensure that the

feature being tested is subject

of a valid test

Test Process and parameters measured Pass Criteria

2.1 Average Throughput

of the South Kirkby

Main MRF

The South Kirkby Main MRF

shall be operated in accordance

with the relevant Operating

Manuals with adjustments to

take into account the quantity of

MRF Input delivered for the

purposes of the Acceptance

Test.

The South Kirkby Main MRF will

be staffed with the number of

Staff as set out in the relevant

Operating Manuals. Staff will

have completed the appropriate

induction and training prior to

the commencement of the

Acceptance Test.

Each week of the testing period shall comprise the following categories of time.

Planned Operating Time (POT) shall be 45 hours/week. This is the time when the plant would normally be expected to be in operation including: preparation, startups, shutdowns and daily maintenance and cleaning. The exact start and finish times which make up POT each week shall be set by the Sub Contractor and written into the detailed testing procedures prior to starting the test.

Planned Weekend Maintenance Time (PWMT) shall be 48 hours/week. The exact start and finish times for PWMT each week shall be set by the Sub Contractor and written into the detailed testing procedures prior to starting the test.

Planned Idle Time (PIT) shall be the remaining periods in the week which are not covered by POT or PWMT.

The throughput over the testing period shall be calculated as follows.

AT = TTP/(POT-UIT+EXT)

AT = Average Throughput (expressed in tonnes/hours input waste)

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TTP = Total Tonnes Processed as measured using weighbridge data, with appropriate adjustments for inventory levels at the start and end of the testing period.

UIT = Unplanned Idle Time is any time within the specified POT periods when the plant cannot operate solely due to lack of waste in the reception area. For any time to count towards UIT, the plant shall not be cleaned, maintained, prepared, worked on in any manner or awaiting repairs.

EXT = Extra Time is any time within the PIT

periods when the plant is being operated

cleaned, maintained, prepared or worked on in

any manner

2.2 Contribution of the

South Kirkby Main

MRF to Contract

Targets

The South Kirkby Main MRF

shall be operated in accordance

with the relevant Operating

Manuals with adjustments to

take into account the quantity of

MRF Input delivered for the

purposes of Acceptance Test.

The South Kirkby Main MRF will

be staffed with the number of

Staff as set out in the relevant

Operating Manuals. Staff will

have completed the appropriate

induction and training prior to

the commencement of the

Acceptance Test.

The tonnage of MRF Input and both Waste

Derived Products and Reclaimed Materials

delivered to market will be recorded and a mass

balance will be compiled detailing the input and

output streams across the South Kirkby Main

MRF to determine the contribution of the South

Kirkby Main MRF towards:

the Household Waste Recycling Target; and

the BMW to Landfill Target

Reclaimed Materials and Waste Derived

Products shall be produced to a standard that

can be delivered to the markets identified in

Table 1 of the Materials and Energy Marketing

Plan.

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2.3 Noise levels The peak noise levels will be

recorded at the test points

identified in the South Kirkby

Acceptance Testing

Measurements Points SK-EXT-

9201 during the test operating

hours and under normal

operating conditions whilst the

following activities are being

conducted:

while MRF Input is being delivered;

while the loading shovel is in operation; and

while the trommel screen is handling MRF Input.

The level of noise generated by the South Kirkby

Main MRF will be measured and in accordance

with the detailed procedure set out in the

Acceptance Test Programme.

The level of generated noise will be measured on

one occasion at each of the test points on the

boundary of the South Kirkby Main Site. The

measurements taken at these points, as may be

determined by the Environmental Permit, are to

ensure that noise levels comply with the

requirements of the Environmental Permit.

2.4 Odour Levels The odour test shall not be

undertaken unless the South

Kirkby Main MRF ventilation

fans are operating.

The odour shall be monitored at a number of

points on the boundary of the South Kirkby Main

Site as may be determined by the Environmental

Permit and in accordance with the detailed

procedure set out in the Acceptance Test

Programme to ensure that odour levels comply

with the requirements of the Environmental

Permit.

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2.5 Dust Levels The dust test shall not be

undertaken unless the South

Kirkby Main MRF ventilation

fans are operating.

A test shall be conducted to monitor dust levels

emitted from the facility if required by the

Environmental Permit.

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3. South Kirkby Main Residual Waste Treatment Facility

3.1 The Acceptance Test

3.1.1 For the purpose of this Section 3 reference to the South Kirkby Main Residual Waste Treatment Facility includes all stages in the process from reception hall up to and including the pasteurisation process and shall exclude the anaerobic digestion system which includes; the intermediate storage tanks, anaerobic digestion tanks, digestate dewatering system, gas handling systems, effluent treatment system and combined heat and power facilities.

3.1.2 The period for the Acceptance Test for the South Kirkby Main Residual Waste Treatment Facility shall be four (4) weeks

3.1.3 The Acceptance Test will demonstrate that the South Kirkby Main Residual Waste Treatment Facility can process the Residual Waste Treatment Input without breaching the Environmental Permit and produce Reclaimed Materials and Waste Derived Products and AD feedstock/cooked organic fraction in accordance with test 3.1 of Table 3 below.

3.1.4 The South Kirkby Main Residual Waste Treatment Facility shall be tested to demonstrate its compliance with the overall design capacity requirements as set out in section 2.2 of the Works Delivery Plan by operating the facility for a period of time required to process the tonnage of Residual Waste Treatment Input available.

3.1.5 The average hourly throughput rate is calculated in accordance with the following formula:

Average hourly throughput rate =

∑(daily tonnage of Residual

Waste Treatment Input)

∑(daily operating hours)

Where

Daily operating hours The daily operating period (hours) taken as the period from the recorded start time until the recorded end time as defined in test 3.1 of Table 3.

3.1.6 Unless agreed with the Independent Certifier, during the period of the Acceptance Test planned maintenance and defect rectification can only be carried out during:

the daily operating hours;

during the planned daily maintenance and cleaning period (4.5 hours);

the weekend non operating periods.

3.1.7 Plant preparation activities such as the preparation of the boiler can be completed outside of the daily operating hours.

3.1.8 The criteria being monitored or measured are defined in Table 3 below.

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3.1.9 The Acceptance Test of the South Kirkby Main Residual Waste Treatment Facility shall be deemed passed provided the pass criteria defined in Table 3 below are achieved.

3.1.10 Should the pass criteria in test 3.1 of Table 3 below not be achieved then following modification to the South Kirkby Main Residual Waste Treatment Facility, test 3.1 of the Acceptance Test shall be repeated with a duration that shall be agreed with the Independent Certifier.

3.1.11 Should the pass criteria in tests 3.2, 3.3, 3.5, or 3.6 of Table 3 below not be achieved then following modification to the South Kirkby Main Residual Waste Treatment Facility that test shall be repeated within the remaining period of the Acceptance Test or the period of the Acceptance Test shall be increased to accommodate the retest as agreed with the Independent Certifier.

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Table 3 South Kirkby Main Residual Waste Treatment Facility Parameters

Test Feature being

tested

Any specific conditions for

the facility to ensure that the

feature being tested is

subject of a valid test

Test process and parameters measured Pass Criteria

3.1 Throughput of

the South

Kirkby Main

Residual

Waste

Treatment

Facility

The South Kirkby Main

Residual Waste Treatment

Facility shall be operated in

accordance with the relevant

Operating Manuals.

The South Kirkby Main

Residual Waste Treatment

Facility will be staffed with the

number of Staff as set out in

the relevant Operating

Manuals. Staff will have

completed the appropriate

induction and training process

prior to the commencement of

the Acceptance Test.

The tonnage of Residual Waste Treatment Input to the

South Kirkby Main Residual Waste Treatment Facility

will be taken from weighbridge records with appropriate

adjustments for waste inventory levels at the start and

end of the test period.

The start time for processing of waste on each day shall

be recorded as the time the first load of waste is

collected by the front end loading shovel for depositing in

the waste loading hopper.

The end time for processing of waste on each day shall

be recorded as the time the last load of waste is

collected by the front end loading shovel for depositing in

the waste loading hopper.

3.2 AD feedstock

preparation

using the

autoclave

The entire South Kirkby Main

Residual Waste Treatment

Facility including the autoclave

shall be operational

At some stage during the Acceptance Test the AD

feedstock produced by the autoclave process will be

tested in accordance with the detailed procedure set out

in the Acceptance Test Programme to ensure that it is a

suitable feedstock for Anaerobic Digestion. The following

criteria will be measured:

The level of pathogens as defined by the Animal By- Products Regulations.

Plastics content is within the specification for Digestate defined in Table 1 of the Materials and Energy

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Marketing Plan

Glass content is within the specification for Digestate defined in Table 1 of the Materials and Energy Marketing Plan

3.3 AD feedstock

preparation

using the

autoclave

bypass line

The entire South Kirkby Main

Residual Waste Treatment

Facility shall be operational

excluding the autoclave which

shall be bypassed and the

autoclave bypass line shall be

operational

At some stage during the Acceptance Test the autoclave

bypass line shall be operated and the suitability of the

AD feedstock for Anaerobic Digestion established in

accordance with the detailed procedure set out in the

Acceptance Test Programme. The following criteria will

be measured:

The level of pathogens as defined by the Animal By- Products Regulations.

Plastics content is within the specification for Digestate defined in Table 1 of the Materials and Energy Marketing Plan

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Glass content is within the specification for Digestate defined in Table 1 of the Materials and Energy Marketing Plan

3.4 RDF quality The South Kirkby Main

Residual Waste Treatment

Facility shall be operated in

accordance with the relevant

Operating Manuals.

The RDF output shall be sampled and tested in

accordance with Schedule 2 of the Ferrybridge Off-Take

Contract.

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3.5 Contribution of

the South

Kirkby Main

Residual

Waste

Treatment

Facility to

Contract

Targets

The South Kirkby Main

Residual Waste Treatment

Facility shall be operated in

accordance with the relevant

Operating Manuals.

The South Kirkby Main

Residual Waste Treatment

Facility will be staffed with

the number of Staff as set

out in the relevant Operating

Manuals. Staff will have

completed the appropriate

induction and training

process prior to the

commencement of the

Acceptance Test.

The tonnage of Residual Waste Treatment Input and

both Waste Derived Products and Reclaimed Materials

delivered to market will be recorded and a mass

balance will be compiled detailing the input and output

streams across the South Kirkby Main Residual Waste

Treatment Facility to determine the contribution of the

South Kirkby Main Residual Waste Treatment Facility

towards.

the Household Waste Recycling Target; and

the BMW to Landfill Target

Reclaimed Materials and Waste Derived Products shall

be produced to a standard that can be delivered to the

markets identified in Table 1 of the Materials and

Energy Marketing Plan.

The quantity of AD feedstock sent to Anaerobic

Digestion shall be estimated.

There is no requirement to measure the water vapour

and exhaust gases given off as a by-product of the

autoclave process

3.6 Noise levels The peak noise levels will be

recorded at the test points

identified in the South Kirkby

Acceptance Testing

Measurements Points SK-

EXT-9201 during normal

operating conditions whilst the

following activities are being

conducted

while Residual Waste Treatment Input is being

The level of noise generated by the South Kirkby Main

Residual Waste Treatment Facility will be measured

and in accordance with the detailed procedure set out

in the Acceptance Test Programme.

The level of generated noise will be measured on one

occasion at each of the test points on the boundary of

the South Kirkby Main Site. The measurements taken

at these points, as may be determined by the

Environmental Permit, are to ensure that noise levels

comply with the requirements of the Environmental

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delivered,

while the pre-sort MRF and autoclave are in operation,

while the loading shovel is in operation.

Permit.

3.7 Odour Levels -

Residual

Waste

Treatment

Facility

In order to ensure that the bio-

scrubbers have achieved

stable operation this test shall

not be commenced until after

the first week of the

throughput test has been

completed.

The ventilation fans shall be

operating normally during the

conduct of the odour test.

whilst Residual Waste Treatment input is being stored on the floor of the reception hall

the bag opener shall be operating normally.

The level of odour shall be assessed whilst the autoclave

is venting into the condenser with the remainder of the

South Kirkby Main Residual Waste Treatment Facility

processing Residual Waste Treatment Input.

The odour shall be monitored at a number of points on

the boundary of the South Kirkby Main Site as may be

determined by the Environmental Permit and in

accordance with the detailed procedure set out in the

Acceptance Test Programme to ensure that odour levels

comply with the requirements of the Environmental

Permit.

Should the monitoring at all points not be completed on a

single autoclave vent cycle then the test shall cover

additional autoclave cycles as necessary.

Odour Levels -

Autoclave

Building

The ventilation fans shall be

operating normally during the

conduct of the odour test.

In order to ensure that the bio-

scrubbers have achieved

stable operation this test shall

not be commenced until after

the first week of the

The level of odour release shall be measured at two

stages of the autoclave cycle:

1. Whilst the autoclave is venting into the condenser

with the remainder of the South Kirkby Main

Residual Waste Treatment Facility processing

Residual Waste Treatment Input.

2. During the autoclave cook phase with the

remainder of the South Kirkby Main Residual

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throughput test has been

completed.

Waste Treatment Facility processing waste

The odour output from the AD and autoclave

bioscrubbers and the pre-sort MRF carbon filter will be

measured individually to ensure compliance with the

levels of odour set out in the Environmental Permit.

Should the measured odour level from any of the

bioscrubbers/carbon filters be more than above the

defined level in the air quality model (in OUe/m3); the

potential impact on overall site odour release will be

evaluated using the air quality model once all odour

measurements required as part of the Acceptance Tests

have been completed.

Odour Levels

– Reception

Hall

The ventilation fans shall be

operating normally during the

conduct of the odour test. The

measurements will be taken

whilst at least 50% of the

Residual Waste Treatment

Input expected during that day

is on the floor in the Reception

Hall.

the bag opener shall be

operating normally.

The odour output from the carbon filter will be measured

to ensure compliance with the levels of odour set out in

the Environmental Permit.

Should the measured odour level from any of the carbon

filters be more than above the defined level in the

air quality model (in OUe/m3); the potential impact on

overall site odour release will be evaluated using the air

quality model once all odour measurements required as

part of the Acceptance Tests have been completed.

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Part 3 - Post Anaerobic Digestion Test

1. Introduction

1.1 The Anaerobic Digestion system will take several months to commission and establish

steady state operations. The Parties agree and acknowledge that this test does not

form part of the Acceptance Tests required for the South Kirkby Main Residual Waste

Treatment Facility to receive a Completion Certificate (and this test does not need to

be undertaken for the Contractor to achieve the Full Service Commencement Date and

the step up to the Unitary Charge). The Contractor shall undertake this test at an

appropriate time during the Full Service Period and the results passed to the Council.

1.2 This test will be conducted to demonstrate that the Anaerobic Digestion system is

performing as expected by generating Digestate that meets the market requirement

defined in the Materials and Energy Marketing Plan.

1.3 Once the Anaerobic Digestion system has achieved a steady state, the Digestate

produced over a 24 hour period will be sampled and tested. The test results will be

compared with the market requirements defined in the Materials and Energy Marketing

Plan. The sampling methodology and the detailed tests to be carried out will be

defined in the Acceptance Test Programme.