PART III
DESIGN STANDARDS FOR BOTTLED WATER,
BULK WATER HAULING, WATER VENDING MACHINES
AND RETAIL WATER FACILITIES
INTRODUCTION
DEP rules and regulations at 25!Pa. Code Chapter!109, Safe Drinking Water, includes definitions for
bottled water systems, bulk water hauling systems, vended water systems and retail water facilities.
Subchapter!J of Chapter!109 contains regulations which apply specifically to these systems. Because
many drinking water standards are established based on the consumption of two (2) liters of water
per day, the department intends to regulate as bottled water systems only those systems which
provide water in one>half gallon (1.9!liter) or larger containers. Smaller containers generally are used
to market beverages or pharmaceuticals and are regulated under other state and federal food and
drug laws. Vending machines are not exempt under this interpretation due to the lack of control
over the volume of drinking water obtained by the customer.
383>2126>303 / November 1, 1997 / Page III>1
PART III
CHAPTER 1 > APPLICATIONS FOR PERMITS
1.0
General
The purpose of this chapter is to outline the design requirements and permit application procedures
which are to be followed when applying for a bottled water system, bulk water hauling system,
vended water system or retail water facility permit. Design and construction standards which DEP
considers to be acceptable for these systems have been provided in the subsequent chapters of
Part!III. Other designs will be considered where the applicant can demonstrate to the satisfaction of
the department that the alternative design will be capable of providing drinking water that
consistently meets DEP standards.
1.1
Permit Requirements
Under the provisions of Subchapter J, Section 109.1005 of the Safe Drinking Water Regulations, a
person may not construct or operate a bottled water or vended water system, retail water facility or
bulk water hauling system without first obtaining a permit from DEP. Furthermore, no person may
substantially modify a bottled water or vended water system, retail water facility or bulk water
hauling system operated under a public water system permit without first obtaining a permit
amendment from DEP.
1.1.1 Coverage
The following projects must be submitted to DEP for review and approval:
a.
All facilities of any new bottled water or vended water system, retail water facility
or bulk water hauling system;
b.
Any addition to or modification of an existing bottled water or vended water
system, retail water facility or bulk water hauling system which will or may affect
the quality and/or quantity of the supply. The following major modifications
require the submission of a complete permit application as outlined in Section 1.4.
Minor modifications must be discussed with the appropriate regional water
supply engineer to determine the extent of the information which must be
submitted to obtain DEP approval;
Major Modifications
Minor Modifications
New sources
Changes in treatment chemicals
New types of product or product lines
Interconnections for bulk water
Additions or deletions of treatment
techniques or processes
Replacement of storage tank or reservoir
linings/coatings
Addition of vending machines not
certified by the National Automatic
Merchandising Association (NAMA)
Addition or modification of bulk
carrier vehicles and standpipes
Pumping stations
(except for well pumps)
Storage reservoirs
Construction of prefabricated
storage tanks
Transmission mains
Permit transfers
Repair of water vending machines and
addition of a new NAMA certified machine
383>2126>303 / November 1, 1997 / Page III>2
c.
Persons proposing to install National Automatic Merchandising Association
(NAMA) certified water vending machines on an existing community water system
source shall obtain a separate and distinct permit>by>rule for each DEP region in
which the water vending machines will be located.
1.1.2 Application Fees
Applications for a permit or for a major modification as outlined in Section 1.1.1 must be
accompanied by a check in the amount of §750, payable to the "Commonwealth of
Pennsylvania." A system purchasing finished water, as its only source of water, from an
approved community water system, shall submit a fee of §300. Out>of>state bottled
water systems submitting proof of out>of>state approval must submit a fee of §100.
1.1.3 Construction and Operation Permits
In administering the permit requirements of DEP Safe Drinking Water Regulations, the
Bureau of Water Supply Management has implemented a two>part approval process.
Upon approval of the plans, modules and other design documents, a construction permit
will be issued approving the construction or modification in accordance with the
approved plans. This approval will be valid for a period of two years unless substantial
work is initiated. Upon completion, the public water supplier is required to submit a
certificate of construction completion to DEP stating that construction or modification
was completed in accordance with approved plans. This statement must be signed by
the professional engineer or other person responsible for the work. Upon receipt of the
certification, DEP will inspect the facility and issue an operations permit when the
construction has been satisfactorily completed.
1.1.4 Revisions to Approved Plans
Any deviations from approved plans or specifications affecting the hydraulic capacity,
operation or the type of water treatment processes, or the quality of finished water,
must be approved by DEP before such changes are made. Revised plans or specifications
should be submitted in time to allow the review and approval of such plans or
specifications before any construction work which will be affected by such changes is
begun.
1.1.5 Department's Review and Permit Coordination
Under the requirements of the Safe Drinking Water Regulations, DEP must grant or deny
a permit within 120 days of receipt of a complete application. In order to comply with
this requirement DEP will not accept an application for review until the application is
determined to be complete. As other department, state or inter>state environmental
agencies may require approvals, applicants and their consultant engineers are advised to
hold a preliminary engineering conference with the regional water supply engineer to
identify and coordinate these approvals. Failure to satisfy any permit coordination
requirements could result in the refusal of an application or the denial of a permit.
1.1.6 Chemicals and Materials
Under the requirements of Section 109.606 of the Safe Drinking Water Regulations, all
chemicals or materials (i.e., paints, coatings, liners, etc.) which may come in contact with
the raw or finished drinking water must be acceptable to DEP. Chemicals used by a
public water supplier which may come in contact with or affect the quality of the water
and which are certified for conformance with ANSI/NSF Standard 60 (Drinking Water
Treatment Components, Health Effects, National Sanitation Foundation) are acceptable.
383>2126>303 / November 1, 1997 / Page III>3
Materials to be used in construction or modification of a public water system including
waterline extensions which may come in contact with or affect the quality of the water
and which are certified for conformance with ANSI/NSF Standard 61 (Drinking Water
System Components, Health Effects, National Sanitation Foundation) are acceptable.
1.2
Sources
It is DEP policy to require the use of the best available source(s) of supply taking into
consideration the current technology in water treatment needed to provide a safe and potable
water for human consumption. In selecting the source or sources of water to be used, the
designing engineer must prove to the satisfaction of DEP that the water which is to be
delivered to the consumers will consistently meet the drinking water standards of DEP.
1.2.1 Analyses of Proposed Sources
As a minimum, all new sources of drinking water must be sampled and tested for all DEP
Maximum Contaminant Levels (MCLs). Other parameters which a sanitary survey may
determine as having a potentially adverse impact on the quality of the raw water also
should be included in the analyses so that background information for future
comparison is available.
1.2.1.1
Laboratories
All physical, chemical, microbiological and radiological analyses must be
performed by a laboratory certified by DEP.
1.2.1.2
Surface Water Sources
At least three sets of samples so spaced that the high, average and low stream
flows will be sampled shall be taken to reflect the effects of various
meteorological, geological and hydrological conditions. Samples shall be
taken during a minimum time interval of six months and preferably one year.
1.2.1.3
Groundwater Sources
For all new drinking water sources, at least one set of samples shall be
collected at the termination of the 48>hour pump test and analyzed for DEP
MCLs. Applicants or their consulting engineer should notify the Bureau of
Water Supply Management regional Technical Services Section Chief (see
Table III>1.1) at least 48 hours prior to starting the pump test. Applicants are
further advised to contact their respective river basin commission to verify the
need to conduct a longer (i.e., 72>hour) pump test.
1.2.1.4
Finished Water Sources
At least one set of samples should be collected and tested for all DEP MCLs.
The results of analysis obtained from the source/selling water system may be
used to satisfy this requirement provided the samples were collected and
analyzed within the routine monitoring schedule for that category of
parameters. The results submitted should be from samples collected as close
to the proposed point of interconnection as possible, and preferably from the
exact location.
383>2126>303 / November 1, 1997 / Page III>4
1.2.2 Surface Water Sources
Surface water sources are defined as all water open to the atmosphere or subject to
surface runoff, or sources which are directly influenced by surface water, which may
include springs, infiltration galleries, cribs or wells. The term excludes finished water.
Whether there is direct influence by surface water may be determined on a case by case
basis. Direct influence may be indicated by:
a.
Significant and relatively rapid shifts in water characteristics such as turbidity,
temperature, conductivity, or pH (which also may change in groundwater but at a
much slower rate) which closely correlate to climatological or surface water
conditions;
b.
The presence of insects or other microorganisms, algae, organic debris, or large>
diameter pathogens such as Giardia lamblia.
Where surface>water sources are proposed to be used as a source of drinking
water, a water allocation permit must be obtained from DEP. Applicants are
advised to obtain the water allocation permit prior to preparation of plans and
specifications.
1.2.2.1 Source Quality
A sanitary survey and study shall be made of the factors, both natural and
man>made, which will affect the quality of the water at the source. The
results of the sanitary survey shall be submitted to DEP. Such survey and
study shall include, but not be limited to:
a. Obtaining samples over a sufficient period of time to assess the
bacteriological, physical, chemical and radiological characteristics of
the water;
b. Determining future uses and their effects on the stream or
impoundments;
c.
Determining the degree of control over the watershed that can be
exercised by the owner;
d. Assessing the degree of hazard or vulnerability to the supply by
accidental or deliberate spillage of materials that may be toxic,
harmful or detrimental to treatment processes.
1.2.2.2 Intakes
Where used, intake structures shall:
a. Be designed to handle the maximum anticipated daily demand with
due consideration to operation under minimum head conditions.
Intakes at pumping stations should be protected by at least two sets of
removable, stationary screens, or by a traveling screen. Screen open>
ings should be small enough to exclude all matter which will clog;
b. Have protection against clogging by sediment, debris or ice, and
against damage due to wave action and flotation;
383>2126>303 / November 1, 1997 / Page III>5
c.
Have a velocity of flow through the inlet structure such that frazil ice
will be held to a minimum, generally not to exceed 0.5 feet per
second;
d. Have inspection manholes every 100 feet for pipe sizes large enough
to have visual inspections;
e. Be able to withdraw water from more than one level if quality varies
with depth;
f.
Have separate facilities for release of less desirable water held in
storage;
g. Be accessible during adverse weather conditions.
1.2.2.3 Impoundments and Reservoirs
a. Site selection shall give consideration to:
(1) Topography and geology;
(2) Storage capacity required;
(3) Safety;
(4) Water rights;
(5) Raw water characteristics;
(6) Proximity to sources of pollution;
(7) Accessibility during adverse weather conditions.
b. Site preparation shall provide:
(1) Removal of brush and trees to a level of 10 feet above the
anticipated high water elevation;
(2) Protection from floods during construction.
c.
Site Construction
Where earth disturbance will occur, an Erosion Control Plan must be
developed and retained at the construction site for the duration of
the earth moving activities.
1.2.3 Groundwater Sources
Groundwater includes all water from dug, drilled, bored, jetted or driven wells
and infiltration galleries. Springs which emerge at the surface within the confines
of a springhouse also can be considered groundwater, but only after extensive
evaluations of the geological conditions and catchment area are conducted.
Groundwater sources subject to direct influence by surface water may be
classified as surface water sources and may require treatment as a surface water
383>2126>303 / November 1, 1997 / Page III>6
source. Water suppliers and their consultants are advised to consult with DEP to
establish the minimum level of treatment which will be required.
1.2.3.1 Quality
Sanitary surveys conducted for the selection of locations for wells, springs,
or infiltration galleries shall consider the following items:
a. Character of local geology, size and topography of catchment area,
and slope of ground surface and groundwater table;
b. Nature, and distance of local sources of pollution such as animal feed
lots, landfills, privies, sink holes, sewer lines and industrial facilities;
c.
Extent of drainage area likely to effect or contribute water to the
supply, population density, land use and waste disposal methods in
the drainage area;
d. Proximity to flood plain or impoundments which may cause flooding;
e. Proximity of other existing wells.
1.2.3.2 Location and Protection
Minimum distances from a well to possible sources of pollution shall be
great enough to provide assurances that subsurface flow of contaminated
water will not reach the well. Each proposed site should be field surveyed
to evaluate the character and location of possible sources of
contamination, types of geologic formations present, depth to the water
bearing aquifer, direction of groundwater flow and the effect on
groundwater movement by well pumping.
a. Location
DEP shall be consulted during the location of a proposed well to
determine the required separation between existing and potential
sources of contamination.
b. Protection
Protection of the proposed new well site should be provided through
ownership, easements or zoning. Water suppliers should control all
land within a radius of 100!feet of the source and any additional land
which a sanitary survey may deem affects the supply. It is strongly
recommended that the water supplier develop a wellhead protection
plan in accordance with Appendix A of Part II (Community System
Design Standards) of this manual and other guidance given by DEP.
1.2.3.3 Testing and Records
a. Yield and drawdown tests shall:
(1) Be performed on every well;
(2) Have the test method clearly indicated in the specifications;
383>2126>303 / November 1, 1997 / Page III>7
(3) Have a test pump capacity at least 1.5 times the yield anticipated;
(4) Provide for continuous pumping for at least 48 hours;
(5) Provide the following data:
(a)
Test pump capacity>>head characteristics,
(b)
Static water level,
(c)
Depth of test pump setting,
(d)
Time of starting and ending of test cycle;
(6) Provide recordings and graphic evaluations of the following:
(a)
Pumping rate(s),
(b)
Pumping water level,
(c)
Drawdown,
(d)
Water recovery rates and levels;
(7) Provide for samples of water to be collected for quality
determination at the end of the 48>hour test period.
b. Samples and Records
During drilling and completion of the well, a detailed log or comple>
tion form (available from the department©s Bureau of Topographic
and Geologic Survey) is to be completed and returned to the
department as required under Chapter!107 (Drilling Water Wells) of
the department©s rules and regulations. Formation samples should be
maintained and turned over to the water system owner. The log shall
contain information on: the reference elevation; depth, thickness
and type of formations penetrated; rates of penetration; drill hole
diameters and depths; water levels; depth and description of well
casing; well screen type, size and levels of placement where
appropriate; depth of grouting with type and quantity used; location
of any blast shots and the drawdown results of the 48>hour pump test.
c.
Plumbness and Alignment
Every well shall be tested for plumbness and alignment in accordance
with AWWA©s Standard A>100>90. The test method and allowable
tolerances shall be clearly stated in the specifications.
As a minimum, a 40>foot section of pipe or rigid dummy of the same
length, having an outside diameter of not more than one>half inch
less than the inside diameter of the well casing or hole being tested,
should move freely throughout the length of the well casing or hole
to the lowest anticipated pump setting.
383>2126>303 / November 1, 1997 / Page III>8
1.2.3.4 General Well Construction
a. Minimum Protected Depths
All drinking water supply wells and observation wells shall be
constructed in such a manner so as to be watertight to such depths as
may be necessary to exclude pollution from surface runoff and from
polluted aquifers above the aquifer being used as a source of supply.
b. Temporary Casings
Temporary casings used for construction shall be capable of
withstanding the structural load imposed during its installation and
removal.
c.
Well Casing Material
Protective casing of wrought iron or steel shall have minimum weights
and thickness as specified in AWWA©s Standard A>100>90. Well casing
material other than wrought iron or steel must be resistant to the
corrosiveness of the water and to the stresses to which it will be
subjected during installation, grouting and operation. Casing and
grouting materials must be compatible.
(1) Ferrous casings shall:
(a)
Be new pipe meeting ASTM or API specifications for water
well construction;
(b)
Have additional thickness and weight if minimum thickness is
not considered sufficient to assure reasonable life
expectancy of the well;
(c)
Be capable of withstanding forces to which it is subjected;
(d)
Be equipped with a drive shoe when driven;
(e)
Have full circumferential welds or threaded pipe joints.
(2) Nonferrous casing shall meet appropriate ANSI/ASTM or NSF
standards for well casing applications as outlined in AWWA©s
Standard A>100>90. Nonferrous casing materials shall not impart
any taste, odor or toxic substances to the well water. Nonferrous
casing, if used, shall not be driven. The casing shall be placed a
minimum of five (5) feet into the consolidated formation with a
minimum annular opening of three (3) inches larger than the
outside diameter of the casing so that grout can be placed in
accordance with Section!1.2.3.4g.
d. Packers
Packers shall be of materials that will not impart taste, odor, toxic
substances or bacterial contamination to the well water.
383>2126>303 / November 1, 1997 / Page III>9
e. Screens
Well screens, when used, shall:
(1) Provide the maximum amount of open area while still
maintaining structural strength;
(2) Have the size of openings in the screen based on a sieve analysis of
the material contained in the surrounding geological formation
or gravel pack;
(3) Be constructed of materials resistant to damage by chemical
action of groundwater or cleaning operations;
(4) Have sufficient diameter to provide adequate specific capacity and
low aperture velocity. Usually, the entrance velocity should not
exceed 0.1 feet per second;
(5) Be installed so that the pumping water level remains above the
screen under all operating conditions;
(6) Be designed and installed to permit removal or replacement
without adversely affecting water>tight construction of the well;
(7) Be provided with a bottom plate or wash down bottom fitting of
the same material as the screen.
f.
Blasting and Chemical Conditioning
In general, specifications covering the blasting or chemical
conditioning of wells shall be submitted to DEP for approval.
(1) Blasting procedures shall be included in the project specifications
and specify:
(a)
Depth, number, frequency and size of charges;
(b)
Cleaning procedures.
(2) Chemical conditioning procedures shall be included in the
specifications as to method, equipment, chemicals, testing for
residuals, disposal of wastes and inhibitors used.
g. Grouting Requirements
All permanent well casings shall be surrounded by a minimum of
1.5!inches of grout to a minimum depth of 20!feet from the ground
surface, or into the impervious subsurface formation which caps the
aquifer, whichever is deeper, or as otherwise specified in
Section!1.2.3.5.
383>2126>303 / November 1, 1997 / Page III>10
(1) Neat cement grout1
Grout shall consist of a mixture of API Spec.!10, Class G cement (or
Class!B similar to ASTM C150 Type!II) and water in the ratio of
five!gallons of water per 94!lb. sack of cement weighing approxi>
mately 118!lbs/cu. ft. A maximum of six!percent, by weight,
bentonite and two!percent, by weight, of calcium chloride may be
added.
(2) Pozmix>cement grout1
Grout shall consist of a mixture of 50!percent by volume of
Pozzolan!A (74!lbs/cu. ft) and 50!percent by volume of API
Spec.!10, Class!G cement with 5.8!gallons of water per 84!lbs. of
mixture.
To this mixture may be added a maximum of
two!percent, by weight, bentonite and a maximum of two
percent, by weight, of calcium chloride, at the discretion of the
contractor.
(3) Concrete grout1
Grout shall contain 5.3 sacks of portland cement (ASTM!C150
Type!II) per cubic yard of concrete and a maximum of seven
gallons of water per 94!lb. sack of cement. The maximum slump
shall be four!inches. The aggregate shall consist of 47!percent
sand and 53!percent coarse aggregate, conforming to ASTM
Designation C>33. The maximum size aggregate should be
0.75!inches. Concrete seal shall not be placed in an annulus of less
than three!inches.
(4) Sand cement grout1
Grout shall consist of a mixture of portland cement (ASTM!C150
Type!II), sand and water in the proportion of not more than two
parts, by weight, of sand to one part of cement with not more
than six gallons of water per 94!lb. sack of cement.
(5) Application
(a)
All grouting shall be performed by adding the mixture, from
the bottom of the annular opening upward, in one
continuous operation, until the annular opening is filled.
(b)
When the annular opening is less than four inches, grout
shall be installed under pressure by means of a grout pump
in one continuous operation.
(c)
After grouting is applied, work on the well shall be
discontinued until the grout has properly set.
1. From AWWA©s Standard for Water Wells A>100>90
383>2126>303 / November 1, 1997 / Page III>11
(6) Guides
The protective casing must be provided with sufficient guides
welded to the casing to permit unobstructed flow and uniform
thickness of grout.
h. Upper Terminal Well Construction
(1) Permanent casing for all groundwater sources shall project at least
12!inches above the pumphouse floor or concrete apron and at
least 18!inches above final ground surface.
(2) Where a well house is constructed, the floor surface shall be at
least six!inches above the final ground elevation.
(3) The top of the well casing at sites subject to flooding should
terminate at least three!feet above the highest known flood
elevation or as may be directed by DEP.
i.
Well Development
Every well shall be developed to remove the native silts and clays,
drilling mud and/or the finer fraction of the gravel pack.
Development should continue until the maximum specific capacity is
obtained from the completed well.
j.
Capping
A properly fitted, firmly driven, solid wooden plug shall be the
minimum acceptable method of capping a well until pumping
equipment is installed. A welded metal plate is preferred.
k. Well Abandonment
(1) Abandoned wells and test wells which are not to be used shall be
sealed by such methods as necessary to restore the controlling
geological conditions which existed prior to construction. The well
abandonment procedures outlined in AWWA©s Standard A>100>90
should be followed.
(2) Wells to be abandoned shall:
(a)
Be sealed to prevent undesirable exchange of water from
one aquifer to another;
(b)
Preferably filled with neat cement grout;
(c)
Have fill materials free from foreign or toxic materials.
1.2.3.5 Aquifer Types and Special Construction Methods
a. Gravel Pack Wells
(1) Gravel pack shall be well rounded particles, 95 percent siliceous
material, that are smooth and uniform, free of foreign material,
383>2126>303 / November 1, 1997 / Page III>12
properly sized, washed and disinfected immediately prior to or
during placement.
(2) Gravel pack shall be placed in one uniform continuous operation.
(3) Gravel refill pipes, when used, shall be Schedule!40 steel pipe
incorporated within the pump foundation and terminated with
screwed or welded caps at least 12!inches above the pump house
floor or concrete apron.
(4) Gravel refill pipes located in the grouted annular opening shall be
surrounded by a minimum of 1.5 inches of grout.
(5) Protection from leakage of grout into the gravel pack or screen
shall be provided.
b. Sand or Gravel Wells
(1) If clay or hard pan is encountered above the water bearing
formation, the permanent casing and grout shall extend through
such materials.
(2) If a sand or gravel aquifer is overlaid only by permeable soils, the
permanent casing and grout shall extend to at least 20 feet below
original or final ground elevation, whichever is lower.
(3) If a temporary outer casing is used, it shall be completely
withdrawn as grout is applied.
c.
Limestone or Sandstone wells
(1) Where the depth of mantle is more than 50 feet, the permanent
casing shall be firmly seated in uncreviced or unbroken rock.
(2) Where the depth of mantle is less than 50 feet, the depth of casing
and grout shall be at least 50!feet or as determined by DEP.
d. Naturally Flowing (Artesian) Wells
(1) Flow shall be controlled.
(2) Permanent casing and grout shall be provided.
(3) If erosion of the confining bed appears likely, an inner casing
joined watertight to the protective casing shall be provided.
e. Radial Water Collectors
(1) Locations of all caisson construction joints and porthole
assemblies shall be indicated.
(2) The caisson wall shall be reinforced to withstand the forces to
which it will be subjected.
383>2126>303 / November 1, 1997 / Page III>13
(3) Provisions shall be made to assure that radial collectors are
essentially horizontal.
(4) The top of the caisson shall be covered with a watertight floor.
(5) All openings in the floor shall be curbed and protected from
entrance of foreign material.
(6) The pump discharge pipe shall not be placed through the caisson
walls.
f.
Infiltration Lines
(1) Infiltration lines may be considered only where geological
conditions preclude the possibility of developing an acceptable
drilled well.
(2) The area around infiltration lines shall be under the control of the
water supplier for a distance acceptable to DEP.
(3) Flow in the lines shall be by gravity to the collecting well.
g. Dug Wells
(1) Dug wells may be considered only where geological conditions
preclude the possibility of developing an acceptable drilled well.
(2) A watertight cover shall be provided.
1.2.3.6 Well Pumps, Discharge Piping and Appurtenances
a. Line Shaft Pumps
Wells equipped with line shaft pumps shall:
(1) Have the pump structure effectively sealed to the well casing to
prevent entrance of surface water;
(2) Have the casing firmly connected to the pump structure or have
the casing inserted into a recess extending at least one>half inch
into the pump base;
(3) Have the pump foundation and base designed to prevent water
from coming into contact with the joint.
b. Submersible Pumps
Where a submersible pump is used:
(1) The top of the casing shall be effectively sealed against the
entrance of water under all conditions of vibration or movement
of conductors or cables;
(2) The electrical cable should be firmly attached to the riser pipe at
20!foot intervals.
383>2126>303 / November 1, 1997 / Page III>14
c.
Discharge Piping
(1) Discharge piping shall:
(a)
Have control valves and appurtenances located above the
pump house floor when an above ground discharge is
provided;
(b)
Be protected against the entrance of contamination;
(c)
Be equipped with a check valve, a shut off valve, a pressure
gauge, a means of measuring flow, and a sampling tap
located at a point where positive pressure is maintained;
(d)
Where applicable, be equipped with an air release>vacuum
relief valve located upstream from the check valve, with
exhaust/relief piping terminating in a downturned position
at least 18!inches above the floor and covered with a
24>mesh corrosion resistant screen;
(e)
Be valved to permit test pumping and control of each well;
(f)
Have all exposed piping, valves and appurtenances protected
against physical damage and freezing;
(g)
Be properly anchored to prevent movement;
(h)
Be protected against surge or water hammer.
(2) The discharge piping should be provided with a means of
pumping to waste, but shall not be directly connected to a sewer.
d. Pitless Well Units
(1) Pitless units shall:
(a)
Be shop>fabricated from the point of connection with the
well casing to the unit cap or cover with compression fittings
certified by the Water Systems Council under Recommended
Standards (PAS>1);
(b)
Be threaded or welded to the well casing;
(c)
Be of watertight construction throughout;
(d)
Be of materials and weight at least equivalent and
compatible to the casing;
(e)
Have field connection to the lateral discharge from the
pitless unit of threaded, flanged or mechanical joint
connection;
(f)
Terminate at least 18 inches above final ground elevation or
three feet above highest known flood elevation or as DEP
directs.
383>2126>303 / November 1, 1997 / Page III>15
(2) The design of the pitless unit shall make provision for:
(a)
Access to disinfect the well;
(b)
A properly constructed casing
requirements of Section!1.2.3.6e;
(c)
Facilities to measure water levels in the well;
(d)
A cover at the upper terminal of the well that will prevent
the entrance of contamination;
(e)
A contamination>proof entrance connection for electrical
cable.
vent
meeting
the
(3) If the connection to the casing is by field weld, the shop>
assembled unit must be designed specifically for field welding to
the casing. The only field welding permitted will be that needed
to connect a pitless unit to the casing.
(4) The grouting of wells using pitless units shall conform to the
applicable criteria of Sections 1.2.3.4g and 1.2.3.5 except that
grout only shall be placed to a level immediately below the point
where the adapter is connected to the well casing.
e. Casing Vent
Provisions shall be made for venting the well casing to the
atmosphere. The vent shall terminate in a downturned position, at or
above the top of the casing or pitless unit in a minimum one>inch
diameter opening covered with a 24>mesh, corrosion resistant screen.
The pipe connecting the casing to the vent shall be of adequate size to
provide rapid venting of the casing.
f.
Water Level Measurement
(1) Provisions shall be made for periodic measurement of water levels
in the completed well;
(2) Installation of permanent water level measuring equipment shall
be made using corrosion resistant materials attached firmly to the
drop pipe or pump column and in such a manner as to prevent
entrance of foreign materials.
g. Observation Wells
Observation wells shall be:
(1) Constructed in accordance with the requirements for permanent
wells if they are to remain in service after completion of a water
supply well;
(2) Protected at the upper terminal to preclude entrance of foreign
materials.
383>2126>303 / November 1, 1997 / Page III>16
1.3
Treatment
All treatment processes used in the manufacturing of bottled water or water from vending
machines or retail water facilities are subject to the approval of DEP. DEP recognizes that the
design standards and criteria specified in PART II, Chapter 4 of the Public Water Supply Manual
may not apply to bottled water and vended water systems or retail water facilities. However,
information on each unit process must be submitted in sufficient detail to allow DEP to
adequately evaluate each water treatment process proposed. DEP Public Water Supply
Modules (form 3800>FM>WSM0077) are to be used for that purpose.
1.3.1 Required Treatment
Section!109.605 of Chapter!109, Safe Drinking Water, has established the following
minimum treatment requirements for all new sources and for existing sources whenever
a modification increases available water supply.
1.3.1.1
Surface Water Sources
a. Public water systems shall provide conventional filtration designed and
operated in accordance with standards established in Chapter!4, Part!II of
the Public Water Supply Manual.
b. DEP may permit the use of direct filtration, slow sand filtration and
diatomaceous earth filtration, if studies, including studies where
appropriate are conducted and demonstrate that the minimum treatment
design standard of 99 percent removal of Giardia cysts and a 99!percent
removal of viruses can be achieved consistently, reliably and practically
under appropriate design and operating conditions.
c.
Other filtration technologies may be permitted after on>site studies,
including pilot studies where appropriate, demonstrate that the
technology can consistently achieve the minimum treatment design
standard.
d. The public water system shall provide disinfection capable of a total of
99.9!percent inactivation of Giardia cysts and a 99.99!percent inactivation
of viruses prior to the first user of the system. The CT factors and
measurement methods established by the EPA are the criteria to be used
in determining compliance with this minimum treatment design standard.
1.3.1.2
Ground Water Sources
Public water systems shall provide continuous disinfection.
1.4
Procedures for Obtaining a Permit
Applications for a bottled water, bulk water hauling, vended water system or retail water
facility permit shall be submitted in writing on forms provided by DEP and be accompanied by
plans, specifications, engineer's report, raw and finished water quality analyses and other data,
information or documentation reasonably necessary to enable DEP to adequately evaluate the
proposal.
1.4.1 Registered Engineer
The party desiring to construct, add to, or modify a water supply shall engage the
services of an engineer registered as a professional engineer and legally qualified to
383>2126>303 / November 1, 1997 / Page III>17
practice in Pennsylvania, who is competent in the design and construction of water
supply facilities. The plans, specifications, and engineer's report must be prepared by
him or under his supervision.
1.4.2 Preliminary Engineering Conference
A preliminary conference with the regional water supply engineer should be held for
projects which include new sources of supply or treatment facilities. This conference will
be helpful to the applicant in making the necessary contacts for other permits which
may be required.
1.4.2.1
Scope
Subjects appropriate to the project as covered in Section!1.4.3.1, Engineer's
Report, should be discussed in the preliminary engineering conference.
1.4.2.2
Preliminary Plans
Location maps, layout sketches and other illustrative material should be
included.
1.4.2.3
Preliminary Report
A report presenting the proposed design data should be included in the
material presented in the preliminary conference. If a conference is not held,
it is advisable to submit a preliminary report at least 30!days prior to
preparation of final plans.
1.4.2.4
Department Advice
Advice given by the regional water supply engineer or the engineering staff
of the appropriate county health department is not to be construed as
representing official approval by DEP. Favorable consideration of design data
submitted at a preliminary conference or in a preliminary report in no manner
waives the legal requirements for the submission of final plans, specifications,
and an engineer's report in support of the application for a permit, nor does it
waive the right of DEP to require modification of plans which in its judgment
do not conform to good engineering practice or its requirements.
1.4.3 Submission of Application
In>state bottled water, bulk water hauling, vended water systems and retail water
facilities must submit their applications, reports, final plans and specifications in
duplicate to the appropriate regional office listed in Table III>1.1. Applicants should
allow at least 90!days for processing of the application. In some regions, a third copy of
the application data may be necessary for submission to a county health department or
river basin commission.
Out>of>state bottled water and bulk water hauling applications shall be submitted to
the Bureau of Water Supply Management, P. O.!Box!8467, Harrisburg, PA!17105>8467 for
review.
Documents submitted for approval of a major modification shall include: (a)!application,
(b)!modules, (c)!engineer's report, (d)!detailed plans, (e)!specifications, (f)!water quality
analyses, (g)!permit fee and (h)!copies of labels where appropriate. The modules,
specifications and front cover or flyleaf of each set of plans, shall bear the signature and
383>2126>303 / November 1, 1997 / Page III>18
imprint of the seal of the registered engineer by or under whom prepared. In addition,
each plan submitted shall bear an imprint or a legible facsimile of such seal.
Applicants for a bottled water system permit also will be required to submit an analysis
of the quality of the manufactured water for each water product to be sold prior to final
approval. This analysis must be for all parameters as outlined in Section 1.4.3.4. A copy
of each label to be affixed to a bottled water product must also be submitted. This label
must meet the requirements of Section!109.1007 of the Safe Drinking Water
Regulations. Applicants also must submit proof that the system is in compliance with the
standards of the Food and Drug Administration contained in 21 CFR Part 129 (relating to
processing and bottling of bottled drinking water).
1.4.3.1
Engineer's Report
As a minimum, the engineer's report shall consist of completed copies of the
appropriate modules furnished by DEP. All modules pertaining to the project
must be included.
A comprehensive engineer's report, covering the following items, shall be
prepared where major construction or modification of a water system is
proposed.
a. General Information shall include:
(1) A description of the existing and proposed water system;
(2) A description of the area to be served;
(3) Where earth moving activities will be involved, an Erosion and
Sedimentation Control Plan which meets the requirements of
Chapter!102 of DEP rules and regulations must be submitted.
b. Sources of Water
Describe the proposed source or sources of water supply to be used, the
reasons for their selection, and provide information as follows:
(1) Surface>Water Sources:
(a) Summarized data on the quality of the raw water with special
reference to fluctuations in quality, changing meteorological
conditions, stream flow, etc.,
(b) Hydrological data, stream flow and weather records,
(c) Reliable yield, including all factors that may affect it,
(d) Maximum flood flow, together with approval for safety features
of the spillway and dam from the Bureau of Waterways
Engineering
(e) Description of the watershed, noting any existing or potential
sources of contamination (i.e., sewerage treatment plants,
industrial facilities, etc.) which may affect water quality;
383>2126>303 / November 1, 1997 / Page III>19
(2) Groundwater Sources:
(a) Sites considered and quality of raw water at each site,
(b) Advantages of the site selected,
(c) Elevations with respect to surroundings and flood plain,
(d) Probable character of formations through which the source is to
be developed,
(e) Geologic conditions affecting the site,
(f) Summary of any source exploration, test well depth, method of
construction, placement of liners or screen, test pumping rates
and their duration, water levels and specific yield,
(g) Sources of possible contamination such as sewerage facilities,
highways, railroads, landfills, outcroppings of consolidated water>
bearing formations, chemical facilities, waste disposal wells, etc.;
(3) Finished Water Sources:
Finished water obtained from an approved public water system is
considered to be raw water for purposes of an application. Applicants
proposing to use finished water as their source of supply must provide
information on the quality of the water. The results of analyses
submitted shall be from samples collected at the point closest to the
proposed point of interconnection.
c.
Proposed Treatment Processes
Summarize the adequacy of the proposed processes and the unit
hydraulics for each treatment process to be used.
d. Automation
Where appropriate, provide supporting data justifying automatic
equipment, including the servicing and operator training to be provided.
e. Waste Disposal
Discuss the various wastes from the water hauling, bottling or treatment
facilities, their volume, proposed treatment and methods of disposal.
1.4.3.2
Detailed Plans
Plans shall be legible and shall be drawn to a scale which will permit all
necessary information to be correctly shown. The size of the plans should not
be larger than 36 inches by 50 inches. The plans shall include topographic
maps, general layouts, plan views, elevations, sections and supplementary
views, which, together with the specifications, provide the information for
the contract and construction of the works. The topographic map shall
include the location of the existing and potential sources of pollution listed in
the engineer's report.
383>2126>303 / November 1, 1997 / Page III>20
The plans should include the datum used; the north point; boundaries of the
municipalities; water districts or specified areas to be served; land area owned
by the purveyor; topography of the drainage area and site, including wells,
springs, streams, lakes, dams and reservoirs; the location, dimensions and
elevations of structures and piping; the location and outline form of
equipment; flood levels; and the diameter and depth of well casings and
liners. Each plan shall bear a suitable title showing the name and address of
the company served, the scale in feet, a graphic scale, the date, and the name,
address and seal of the design engineer.
1.4.3.3
Specifications
Complete, detailed technical specifications shall be supplied for each major
modification, including:
a. All additional laboratory facilities and equipment;
b. The type and design of chemical feed systems and grades of chemicals to
be used;
c.
1.4.3.4
All paints, coatings or other materials which will come into contact with
drinking water during and after construction.
Water Quality Analyses
All bacteriological, inorganic, organic and radiological laboratory analyses
must be performed by laboratories certified by DEP in accordance with the
analytical techniques adopted by the United States Environmental Protection
Agency under the federal act or methods approved by the department.
Contact the Bureau of Water Supply Management, P.O. Box 8467, Harrisburg,
PA 17105>8467 or the regional offices (see Table III>1.1) for the current list of
DEP's Maximum Contaminant Levels.
383>2126>303 / November 1, 1997 / Page III>21
TABLE III>1.1
DEP REGIONAL OFFICES
Region
Region Headquarters
Counties Supervised
Southeast
Suite 6010 Lee Park
555 North Lane
Conshohocken, PA 19428
Phone: 610>832>6059
*Bucks, *Chester, Delaware,
Montgomery, Philadelphia
Northeast
2 Public Square
Wilkes>Barre, PA 18711>0790
Phone: 717>826>2511
Carbon, Lackawanna, Lehigh,
Luzerne, Monroe, Northampton,
Pike, Schuylkill, Susquehanna,
Wayne, Wyoming
Southcentral
One Ararat Blvd.
Room 101>103
Harrisburg, PA 17110
Phone: 717>657>4586
Adams, Bedford, Berks, Blair,
Cumberland, Dauphin, Franklin,
Fulton, Huntingdon, Juniata,
Lancaster, Lebanon, Mifflin, Perry,
York
Northcentral
208 West Third Street, Suite 101
Williamsport, PA 17701
Phone: 717>327>3675
Bradford, Cameron, Centre,
Clearfield, Clinton, Columbia,
Lycoming, Montour,
Northumberland, Potter, Snyder,
Sullivan, Tioga, Union
Southwest
400 Waterfront Drive
Pittsburgh, PA 15222>4745
Phone: 412>442>4217
*Allegheny, Armstrong, Beaver,
Cambria, Fayette, Greene, Indiana,
Somerset, Washington,
Westmoreland
Northwest
230 Chestnut Street
Meadville, PA 16335>3481
Phone: 814>332>6899
Butler, Clarion, Crawford, Elk,
*Erie, Forest, Jefferson, Lawrence,
McKean, Mercer, Venango, Warren
*County Health Departments
383>2126>303 / November 1, 1997 / Page III>22
PART III
CHAPTER 2 > BOTTLED WATER SYSTEMS
2.0
General
The purpose of this chapter is to provide minimum acceptable standards on the design of
bottled water systems. This information has been taken, in part, from standards established by
the Food and Drug Administration, 21 CFR Part 129 (Processing and Bottling of Bottled
Drinking Water) and from the technical manuals published by the International Bottled Water
Association. Other designs may be approved by DEP provided that the applicant can
demonstrate that the alternate design will be capable of providing a consistently reliable, safe
quality of drinking water to the public.
2.1
Sources of Supply
All water for bottling and operating a bottled water system shall be from a source approved by
DEP. Purchase of water from a permitted public water supply system also must be approved by
DEP.
2.2
Buildings and Facilities
2.2.1 Siting
The location of a bottled water plant shall be such that it is free from any conditions
which may result in the contamination of finished water, the equipment used in the
manufacturing process, or the primary containers.
2.2.2 Plant Design and Construction
2.2.2.1
General
Bottled Water Plants should:
a. Be designed and constructed to allow proper installation of equipment,
facilitate maintenance, and provide for the sanitary operation of the
bottle water operation;
b. Have floors which are smooth, impervious and properly drained. All drains
shall be equipped with traps and grills;
c.
Have joints between walls and floors which are tight and impervious;
d. Have walls and ceilings which are smooth, of a light color, and easily
cleaned;
e. Have no fixtures, ducts, or pipe suspended over work areas that may allow
condensate to contaminate the product or bottling equipment.
2.2.2.2
Bottling Room
The bottling room should be separated from other plant facilities or storage
areas by tight walls, ceilings, and self>closing doors to protect against
contamination. Conveyor openings shall not exceed the size required to
permit passage of containers. Joints between floors and walls should be
covered. Doors, windows, and all outside openings into bottling rooms shall
383>2126>303 / November 1, 1997 / Page III>23
be screened and/or otherwise protected against entry of insects, birds,
rodents, dust, and airborne contamination. Where air curtain blowers are
used, they should be located inside the bottling room so that cleaner air will
be moved through the filter and around the bottles.
2.2.2.3
Bottle Washing Area
A separate enclosed room should be provided for the washing and sanitizing
of containers for bottled drinking water. The washing and sanitizing
equipment should be positioned within the room to minimize any possible
post>sanitizing contamination of the containers before they enter the
bottling room.
2.2.2.4
Bottle Storage and Chemical Storage
a. Bottles
Adequate clean, dry storage areas or facilities shall be provided for
containers, closure materials, paper for wrapping, adhesives and other
production materials to provide protection from dust, insects, chemicals
or other sources of contamination. The materials should be stored on
pallets above the floor away from the wall to facilitate cleaning. Partially
used cartons of containers, caps or other closure materials shall be
resealed between uses.
b. Chemicals
Separate storage facilities shall be provided for chemicals used in
container sanitizing operations, equipment sanitizing and/or general
plant sanitation. Separate areas should be provided for each chemical,
properly labeled and ventilated where appropriate. Where toxic or
hazardous chemicals are used, the requirements in Part II, Section 5.2 of
this manual shall be followed.
2.2.2.5
Dressing and Locker Rooms
Adequate facilities shall be provided for the orderly storage of the clothing
and personal belongings of employees where employees routinely change
clothes within the establishment. Such designated areas should be provided
for each sex and shall be located outside the bottling room, bottling washing
room, bottle storage areas and utensil washing areas.
2.2.2.6
Ventilation
a. Adequate ventilation shall be provided to minimize condensation or the
accumulation of noxious fumes in processing rooms, bottling rooms, and
in container washing and sanitizing areas. This equipment shall not create
conditions that may contribute to product contamination. Positive
pressure ventilation in bottling rooms is recommended.
b. Ventilation systems for chlorine gas rooms shall comply with Part II,
Sections 5.4.3.2 and 5.4.3.3 of this manual.
2.2.2.7
Lighting
Adequate lighting, either natural or artificial, must be provided in all areas
where finished water is examined, processed, or stored, and where equipment
383>2126>303 / November 1, 1997 / Page III>24
and bottles are cleaned. A minimum of 50>foot candles must be provided in
any product inspection station. Light bulbs, fixtures, skylights, or other glass
suspended over exposed product in any step of preparation shall be of the
safety type or otherwise protected to prevent product contamination in case
of breakage.
2.2.2.8
Sanitary Facilities
a. Each bottled water manufacturing establishment shall have available,
conveniently located washroom facilities which are separate from any
room or rooms where bottled water is manufactured or packaged and
from areas where bottles are sanitized or stored.
b. Each washroom shall provide toilets, urinals and lavatories appropriate
for the number of employees. Handwashing facilities shall be equipped
with hot and cold running water under pressure, hand cleansing soap or
detergent, and approved sanitary towels or other approved hand>drying
devices. Washrooms shall have self>closing doors and windows or a
ventilation system to the outside.
c.
2.3
Wastewater disposal facilities must be acceptable to or approved by DEP.
Treatment
All treatment processes used in the manufacturing of water for bottling must be approved by
DEP. It is recognized that the design requirements specified in Part II, Chapter 4 of this manual
may not apply to bottled water systems; however, information on each unit process must be
submitted in sufficient detail to allow DEP to adequately evaluate the bottled water treatment
system. DEP's Public Water Supply Modules are to be used for this purpose.
Bottled water systems shall be designed to provide an adequate quality of water to the public.
The design shall ensure that the system will, upon completion, be capable of providing water
that complies with the primary and secondary MCLs and treatment techniques established in
Section 109.1002 of DEP's Safe Drinking Water Regulations (relating to MCLs and treatment
technique).
Bottled water systems shall provide continuous disinfection for groundwater sources. Refer to
Chapter!3 of Part!IV (Noncommunity System Design Standards) of this manual for design
standards on ultraviolet light systems.
2.4
Equipment
2.4.1 Materials of Construction
Contact surfaces of equipment used in the processing, storage, handling and
transportation of finished water shall be of a material which can be easily cleaned and
withstand the repeated application of sanitizing chemicals. Only safe, nontoxic
lubricants shall be used on equipment which may come into contact with the product
water and are required to receive periodic lubrication.
2.4.2 Storage Tanks
Storage tanks shall be of the type which can be securely closed to exclude foreign matter
and shall be adequately vented through inverted air filters. Any liner or coating used in a
raw or finished water storage tank must be acceptable to DEP.
383>2126>303 / November 1, 1997 / Page III>25
2.4.3 Sanitizing Systems
Sanitizing systems for equipment and bottles should be provided. Where temperature is
an important factor in the operation of the sanitizing operation, at least two
temperature gauges shall be provided in the system for monitoring purposes.
2.4.3.1
Steam in an Enclosed System
Steam sanitizing shall occur at a temperature of at least 170∞F for no less than
15 minutes or at least 200∞F for no less than five!minutes. Steam used in
contact with product water>contact surfaces shall be free from any materials
or additives other than those allowed in 21 CFR 173.310 or as otherwise
approved by DEP.
2.4.3.2
Hot Water in an Enclosed System
Hot water sanitizing shall occur at a temperature of at least 170∞F for no less
than 15 minutes or at least 200∞F for for no less than five!minutes.
2.4.3.3
Chemical Sanitizers
Chemical sanitizers shall conform with 21 CFR 178.1010 or otherwise be
acceptable to DEP.
a. The preferred method will be to clean by exposing all surfaces to not less
than 2Ω!percent caustic solution at a minimum temperature of 120∞F for
not less than one!minute where high velocity jets are used and for not less
than three!minutes where soaker type bottle washers are used, followed
by a thorough rinsing with operations water or product water.
b. Acceptable alternate procedures are to sanitize with 100 ppm chlorine
water solution at 75∞F for not less than 30 seconds, or sanitize with
200!ppm approved quaternary ammonium water solution at 75∞F for not
less than two!minutes.
2.4.4 Rinse Facilities
Finished water rinse facilities shall be provided to remove any traces of the chemicals
used in the chemical sanitizing process. The design shall be such that only disinfected
water shall be used for this purpose.
2.5
Containers and Closures
Containers and closures for bottled water shall comply with the requirements of 21 CFR
Parts!170 through!189.
2.5.1 Containers
All bottled water containers shall be made of a nontoxic material which is readily
cleanable and not subject to deterioration or leaching of injurious substances when
subjected to sanitizing operations.
2.5.1.1
Single Service
Single>service containers shall be stored in a manner to protect their sanitary
condition until used.
383>2126>303 / November 1, 1997 / Page III>26
2.5.1.2
Multiservice
Multiservice containers shall be adequately cleaned, sanitized and inspected
immediately prior to being filled.
2.5.2 Closures
All bottles shall be provided with nontoxic, tamper>proof seals or caps which are not
subject to deterioration or leaching of injurious substances. Only new screw, snap, or
crown caps may be used without sanitizing, and only when received clean and kept
protected from contamination.
2.6
Tanker Trucks
Tanker trucks used in transporting bulk water for bottling shall comply with the design
requirements in Chapter 3 of this part on Bulk Water Hauling Systems.
2.7
Laboratory Equipment
Sufficient laboratory equipment and testing facilities shall be provided to allow for the routine
testing necessary to assure proper operation. In addition to equipment for the routine testing
of the water for bottling, the appropriate equipment needed to test all cleansing and
sanitizing solutions used in the bottling operation shall be available. Laboratory equipment
should not be located in the bottling room or bottle washing area.
The laboratory equipment requirements specified in Part II, Section 2.4 of this manual should
be followed.
383>2126>303 / November 1, 1997 / Page III>27
PART III
CHAPTER 3 > BULK WATER HAULING SYSTEMS
3.0
General
The purpose of this chapter is to provide basic information on the design of water hauling tank
trucks which will be used to transport bulk water from a DEP approved source of supply to the
customers point of use or storage. This information has been taken, in part, from the "3>A
Sanitary Standards for Stainless Steel Automotive Milk and Milk Products Transportation Tanks
for Bulk Delivery and/or Farm Pick>Up Service.'' Though the use of milk trucks for water
hauling purposes is a generally accepted practice, each truck must have the interior of the tank
thoroughly cleaned and inspected with an ultraviolet lamp each time water is to be
transported. Tanks previously used to transport petroleum products, toxic materials or other
deleterious substances shall not be used to haul drinking water.
3.1
Sources
All sources of water used for bulk water shipment must be approved by DEP and are subject to
the quality and treatment requirements outlined in Chapter!109 of DEPπs rules and regulations
relating to Safe Drinking Water. Where new groundwater or surface water sources are
developed as part of a bulk water hauling system, the design standards outlined in Chapter!1
of this part shall apply.
3.2
Tank Trucks
3.2.1 Construction Materials
3.2.1.1
Tanks
All water contact surfaces should be of stainless steel of the American Iron and
Steel Institute (AISI) 300 series or corresponding Alloy Casting Institute (ACI)
types or stainless steel that is nontoxic and nonabsorbent and which under
conditions of intended use is equally resistant as stainless steel of the
American Iron and Steel Institute (AISI) 300 series or corresponding Alloy
Casting Institute (ACI) types.
3.2.1.2
Noncontact Surfaces
Noncontact surfaces should be of a waterproof, corrosion resistant material
which is nonabsorbent, durable and easily cleaned.
3.2.1.3
Gaskets and Seals
Plastic, rubber, and rubber>like materials may be used for water transfer
tubing, bearings, seals and gaskets provided that they comply with the food
additives and indirect food additives provisions of 21 CFR Parts 170 through
189.
3.2.2 Fabrication
3.2.2.1
Outer Shell
The outer shell should be smooth and effectively sealed except for a vent or
weep hole. The vent or weep hole shall be located in a position that will
provide drainage from the outer shell and shall be insect proof.
383>2126>303 / November 1, 1997 / Page III>28
3.2.2.2
Outlets
Each tank or compartment shall have a separate outlet. The outlet should be
of welded construction except that a rolled>on fitting may be used on the
terminal end. The outlets shall provide complete drainage of the tank or
compartments.
3.2.2.3
Manhole Opening and Covers
Manhole openings should be not less than 16 inches by 20 inches oval or 18
inches in diameter. Each manhole shall provide an effective seal to prevent
entrance of contaminants. Where air vents are installed, they shall be
designed so they are easily removable and readily cleaned. Manhole cover
gaskets shall be removable and cleanable.
3.2.2.4
Baffles
Where used, baffles shall not interfere with the free drainage of the tank.
They shall be permanently attached to the tank and have no sharp edges.
Baffles shall be designed that walk>through accessibility is provided to all
areas for inspection and cleaning.
3.2.2.5
Cabinets
Transfer tubing storage cabinets shall be dust tight and, doors should be
equipped with a compression type closing device. Gasket material for sealing
doors may be installed on the face of the cabinet except along a drainage
area, where it shall be attached to the doors. A roof overhang or suitable drip
molding should be provided over the cabinet doors. Where transfer tubing is
stored, a means should be provided to support the loose end of the tubing
above the cabinet floor to ensure proper sanitation.
3.3
Water Loading Stations
Filling stations should be designed in such a way as to prevent backflow that may contaminate
the feed water supply.
3.4
Transfer Tubing
Single lengths of transfer tubing should not exceed eight!feet except where adequate
provisions have been made to clean greater lengths. A sanitary closure shall be furnished for
the open ends of the tubing.
383>2126>303 / November 1, 1997 / Page III>29
PART III
CHAPTER 4 > VENDED WATER SYSTEMS
4.0
General
The purpose of this chapter is to provide minimum acceptable standards on the design of water
vending machines. This information has been taken, in part, from standards established by the
NSF International (NSF) (Standard 25 > Vending Machines for Food and Beverages) and the
National Automatic Merchandising Association's Vending Machine Evaluation Manual. Other
designs may be approved by DEP provided the applicant can demonstrate the alternate design
will be capable of providing a consistently reliable, safe quality of drinking water to the public.
4.1
Coverage
For the purposes of this chapter, the following definition of a water vending machine shall
apply:
Water Vending Machine > Any self>contained, self>service device which, upon insertion of a
coin, paper currency, token, card, key, or other similar means or through manual operation,
dispenses unit servings of water, either in bulk or in packages, without the necessity of
replenishing the device between each vending operation.
This definition is not meant to include machines which dispense carbonated soft drinks, coffee,
tea, soup, milk, chocolate drinks or fruit juices which are regulated by DEP under Title!7,
Chapter 80, Department of Agriculture (Food Vending Machines).
4.2
Sources
All sources of drinking water must be approved by DEP and sampled and tested for the
parameters specified by DEP's new>source sampling requirements. Vending machines which
will obtain their source water from the distribution system of an approved public water system
may submit the results of analyses obtained by the source/selling water system when
submitting an application for a permit. The analyses must have been conducted within the
appropriate routine monitoring schedule and conducted by a laboratory certified by DEP.
Source water analyses are not required from water vending machines which meet the special
permit>by>rule requirements.
4.3
Vending Machine Design
Vending machines shall comply with the following design and construction standards or their
equivalent.
A.
NSF Standard!25, Vending Machines for Food and Beverages.
B.
National Automatic Merchandising Association's Vending Machine Evaluation Manual.
4.3.1 Exterior
The exterior of the vending machine shall be designed to facilitate cleaning and to
prevent the entrance of dust, dirt, insects and rodents.
4.3.1.1
Materials
The materials of construction shall be durable, study, easily cleaned and
capable of withstanding the corrosive effects of cleaning chemicals. Paints or
383>2126>303 / November 1, 1997 / Page III>30
other materials used in fabrication shall not impart an odor, color, taste, or
toxic substance to the dispensed water.
4.3.1.2
Surfaces
External surfaces, including corners, joints and seams shall be sealed and
smooth to eliminate sharp edges which might cause accidents or interfere
with proper cleaning and drainage.
4.3.1.3
Doors and Covers
Doors and covers shall be tight fitting and, if necessary, gasketed to prevent
the entrance of dust, moisture, insects and rodents.
4.3.1.4
Ventilation Openings
All ventilation openings shall be effectively screened and accessible for
cleaning. Screening size shall not be less than 16>mesh per inch except for
motor compartments which shall not be larger than eight!mesh per inch.
4.3.1.5
Water Vending Openings
Customer service openings shall be designed to minimize the entrance of
contaminants, insects and rodents. Bulk water vending machines shall have a
self>closing door or panel to protect the water during the vending stage.
4.3.1.6
Service Connections
All service connections through an exterior wall (i.e., water, electrical, etc.)
shall be grommeted or sealed to prevent the entrance of insects or rodents.
4.3.2 Interior
All interior surfaces and component parts of the vending machine shall be designed and
constructed to permit easy cleaning.
4.3.2.1
Materials
All interior surfaces of the machine shall be of smooth, nontoxic, corrosion>
resistant and nonabsorbent material, and shall be capable of withstanding
repeated cleaning and sanitizing by normal procedures.
4.3.2.2
Accessibility
All containers, valves, pipes, tubes, fittings, faucets, discharge nozzles and
other water>contact components shall be accessible for cleaning and
inspection by disassembly with simple tools such as an open>end wrench or
screwdriver. When disassembled, all surfaces shall be visible for inspection
and cleaning.
4.3.2.3
Water Reservoirs
Water reservoirs, when installed as a separate internal component of the
vending machine, shall meet the following requirements:
a. Be removable from their in>use position;
383>2126>303 / November 1, 1997 / Page III>31
b. Have covers which are flanged to overlap the container opening;
c.
Have covers which are sloped to provide drainage whenever condensation
may form;
d. Have outlet tubing which can be easily removed from the basin;
e. Have floats and assemblies, where provided, which are smooth, nontoxic
and easily cleaned.
4.3.2.4
Water Supply System
The materials and method of installation of all water piping, connections and
fittings which, in field use, will be directly connected to a potable water
supply shall conform to local plumbing codes and the source water system
requirements.
4.3.2.5
Waste Containers
Containers shall be provided for the collection of drip, spillage, overflow or
other internal wastes. Waste containers shall be leak proof, readily
removable, easily cleanable and corrosion resistant.
4.3.2.6
Protection of Source Water Supply
The potable water supply to vending machines shall be protected from
backflow and back pressure from in>machine water by means of properly
installed cross>connection control and backflow prevention device.
4.3.2.7
Drains
Drains shall be effectively protected against the entrance of insects and
rodents by the use of a 16>mesh screen or an effective trap.
4.3.2.8
Drainage to Sewers
Wastewaters discharged to a sewer shall be through a minimum air gap of
two inches.
4.4
Treatment
4.4.1 Filters
Water treatment devices installed by the manufacturer should be of the disposable type
or of a type that can be readily disassembled with ordinary tools for cleaning, sanitizing
or replacement of the active elements.
4.4.2 Activated Carbon
Activated carbon if used should be virgin carbon. Carbon which complies with the NSF
Standard!61 or any other certification organization as stringent as NSF is acceptable.
4.4.3 Disinfection
Vended water shall be disinfected prior to delivery into the customer©s container.
Chlorine, chlorine compounds, ozone and ultraviolet (UV) light or other methods
acceptable to DEP may be used provided the appropriate contact times are provided.
383>2126>303 / November 1, 1997 / Page III>32
Water supplied by the source/selling water system is considered to be raw water and
must be disinfected prior to dispensing from the vending machine.
4.4.3.1
Ultraviolet Radiation
a. UV systems may be used provided they comply with the Food and Drug
Administration's requirements under 21 CFR 179.39 and the NSF
Standard!55. UV systems of the Class A type, as approved by NSF under
Standard 55, are acceptable to DEP.
b. Machines using UV shall be equipped with a sensor to shut off the
machine if the lamp burns out or the intensity of the effective radiation at
2,537 Angstrom units falls below 13,000 microwatt seconds per square
centimeter based on the manufacturer's recommended flow rate.
c.
4.4.3.2
UV lamp assemblies shall be designed to permit intensity testing with a
portable unit while avoiding direct eye exposure to radiation during the
test.
Ozone
Ozone may be used provided that its application complies with the Food and
Drug Administrations requirements under 21 CFR 184.1563.
4.5
Machine Location
Vending machines shall be located in a room, area or space which can be maintained in a clean
condition and which is protected from overhead leakage or condensation from water,
wastewater, or sewer piping. Each vending machine shall be located so that the space around
the machine and the space under the machine, unless effectively sealed to the floor, can be
readily cleaned and so that insect and rodent harborage is not created. The floor area on which
vending machines are located shall be reasonably smooth and be capable of withstanding
repeated washings and scrubbings. The space and immediate surroundings of each vending
machine shall be maintained in a clean condition.
4.6
Machine Markings
Water vending machines shall display, in a position clearly visible to customers, the following
information:
A.
The name of the owner/operator;
B.
The full address of the owner/operator;
C.
A telephone number that can be used to obtain further information, service, or register
complaints;
D.
A statement describing the treatment processes and chemicals used;
E.
A statement indicating the source of raw water.
383>2126>303 / November 1, 1997 / Page III>33
PART III
CHAPTER 5 > RETAIL WATER FACILITIES
5.0
General
The purpose of this chapter is to provide minimum standards acceptable to DEP on the design
of retail water facilities. This information has been taken, in part, from standards established
by the Food and Drug Administration, 21 CFR Part 129 (Processing and Bottling of Bottled
Drinking Water) and NSF (Standard 25 > Vending Machines for Food And Beverages). Other
designs capable of providing a consistently reliable, safe quality of drinking water to the public
also may be approved by DEP.
5.1
Coverage
For the purpose of this chapter, the following definition of a retail water facility shall apply:
Retail Water Facility > A public water system (PWS) which provides water for bottling without
the use of a water vending machine by dispensing unit servings of water in containers,
whether or not the container is provided by the customers.
5.2
Sources of Supply
All water for bottling at a retail water facility shall be from a source approved by DEP and
sampled and tested for the parameters outlined on DEPπs Maximum Contaminant Levels (MCL)
list.
Retail water facilities which will obtain their water from an approved public water system may
substitute for this testing the results of analyses obtained by the source/selling water system
when submitting an application for a permit. The analyses must have been conducted within
the appropriate routine monitoring schedule of the source water system by a laboratory
certified by DEP.
5.3
Buildings and Facilities
5.3.1 Siting
The location of a retail water facility shall be such that it is free from any conditions
which may result in the contamination of the finished water, the equipment used in the
manufacturing process, or the primary containers.
5.3.2 Facility Design and Construction
5.3.2.1
General
Retail Water Facilities should:
a. Be designed and constructed to allow proper installation of equipment,
facilitate maintenance, provide for sanitary operation, and prevent
contamination of the finished water, process equipment or containers;
b. Have floors which are smooth, impervious and properly drained, with
traps and grills as necessary;
c.
Have joints between walls which are tight and impervious;
383>2126>303 / November 1, 1997 / Page III>34
d. Have walls and ceilings which are smooth, of a light color and easily
cleaned;
e. Have no fixtures, ducts or pipe suspended over work areas that may allow
condensate to contaminate the product or bottling equipment.
5.3.2.2
Bottle Washing Area
A separate enclosed area should be provided for the washing and sanitizing
of containers for retail drinking water. The washing and sanitizing equipment
should be positioned within the room to minimize any possible post>
sanitizing contamination of the containers before they enter the bottling
area.
5.3.2.3
Container Storage and Chemical Storage
a. Retail Containers
If containers are provided for customers use, adequate, clean, dry storage
areas or facilities shall be provided for containers and container
preparation materials to assure protection from dust, insects, chemicals or
other sources of contamination. The materials should be stored on pallets
above the floor away from the walls to facilitate cleaning. Partially used
cartons or containers, caps or other closure materials shall be resealed
between uses.
b. Chemicals
Separate storage facilities shall be provided for chemicals used in
container sanitizing operations, equipment sanitizing and/or general
facility sanitation. Separate areas should be provided for each chemical,
properly labeled, and ventilated where appropriate. Where toxic or
hazardous chemicals are used, the requirements in Part II, Section 5.3 of
this manual shall be followed.
5.3.2.4
Ventilation
a. Adequate ventilation shall be provided to minimize condensation or the
accumulation of noxious fumes in processing or retail areas. Ventilation
equipment shall not create conditions that may contribute to product
contamination. Positive pressure ventilation in bottling rooms is
recommended.
b. Ventilation systems for chlorine gas rooms shall comply with Part II,
Section 5.4.3.3 and 5.3.2 of this manual.
5.3.2.5
Lighting
Adequate lighting, either natural or artificial, must be provided in all areas
where finished water is examined, processed, or sold, and where equipment
and bottles are cleaned. A minimum of 50>foot candles must be provided in
any product inspection station. Light bulbs, fixtures, skylights, or other glass
suspended over exposed products in any step of preparation shall be of the
safety type or otherwise protected to prevent product contamination in case
of breakage.
383>2126>303 / November 1, 1997 / Page III>35
5.3.2.6
Sanitary Facilities
a. If available, washroom facilities shall be separate from any room or rooms
where bottled water is manufactured or packaged and from areas where
bottles are sanitized or stored.
b. Wastewater disposal facilities must be acceptable to or approved by DEP.
5.4
Treatment
All treatment processes used in the purification of water at retail water facilities must be
approved by DEP. It is recognized that the design requirements specified in Part II, Chapter 4
may not apply to retail water facilities; however, information on each unit process must be
submitted in sufficient detail to allow DEP to adequately evaluate the retail water treatment
system. DEP's Public Water Supply Modules are to be used for this purpose.
For retail water facilities using pre>assembled treatment devices, those whose treatment
devices have been evaluated and certified by a third party organization such as NSF will be
considered acceptable. Equipment used in the treatment of drinking water should be
approved under the appropriate NSF standards: 42>Drinking Water Treatment Units: Aesthetic
Effects, 43>Chemical Feeding and Processing Equipment, 44>Cation Exchange Water Softeners,
53>Drinking Water Treatment Units: Health Effects, 55>Ultraviolet Water Treatment Systems,
58>Reverse Osmosis Drinking Water Treatment Systems and 62>Drinking Water Distillation
Systems.
Disinfection of the water must be provided immediately prior to filling the containers.
Chlorine, compounds, ozone and ultraviolet light or other methods acceptable to the
department may be used provided that the appropriate contact times are provided. Water
supplied by the source/selling water system is considered to be raw water and must be
disinfected prior to dispensing to the customer's containers.
5.5
Equipment
5.5.1 Materials of Construction
Contact surfaces of equipment used in the processing, storage, and handling of finished
water shall be of a material which can be easily cleaned and withstand the repeated
application of sanitizing chemicals. Only safe, nontoxic lubricants shall be used on
equipment which may come into contact with the product water and are required to
receive periodic lubrication.
5.5.2 Storage Tanks
Storage tanks shall be of the type which can be securely closed to exclude foreign matter
and shall be adequately vented through inverted air filters. Any liner or coating used in a
raw or finished water storage tank must be acceptable to DEP.
5.5.3 Sanitizing Systems
Sanitizing systems for equipment and bottles should be provided. Where temperature is
an important factor in the operation of the sanitizing operation, at least two
temperature gauges shall be provided in the system for monitoring purposes.
5.5.3.1
Steam in an Enclosed System
The minimum exposure temperature and duration shall be 170∞F for five
minutes. Steam used in contact with product water>contact surfaces shall be
383>2126>303 / November 1, 1997 / Page III>36
free from any materials or additives other than those allowed in 21!CFR
173.310 or as otherwise approved by DEP.
5.5.3.2
Hot Water in an Enclosed System
The minimum exposure temperature and duration shall be at least 170∞F for
no less than 15!minutes or at least 200∞F for no less than five minutes.
5.5.3.3
Chemical Sanitizers
Chemical sanitizers shall conform with 21 CFR 178.1010 or otherwise be
acceptable to DEP.
a. The preferred method will be to clean by exposing all surfaces to not less
than 2Ω percent of caustic solution at a minimum temperature of 120∞F for
not less than one minute where high velocity jets are used, and not less
than three minutes where soaker>type bottle washers are used, followed
by a thorough rinsing with operations water or product water, or
b. Acceptable alternative procedures are to sanitize with 100 ppm chlorine
water solution at 75∞F for not less than 30 seconds, or
c.
Sanitize with 200 ppm approved quaternary ammonium water solution at
75∞F for not less than two minutes.
5.5.4 Rinse Facilities
Finished water rinse facilities shall be provided to remove any traces of the chemicals
used in the chemical sanitizing process. The design shall be such that only disinfected
water shall be used for this purpose.
5.6
Containers and Closures
Containers and closures for retail water shall comply with the requirements of 21 CFR Parts 170
through 189.
5.6.1 Containers
All retail water containers shall be made of a nontoxic material which is readily
cleanable and not subject to deterioration or leaching of injurious substances when
subjected to sanitizing operations. Containers shall be stored in a manner to protect
their sanitary condition until used.
5.6.2 Closures
All containers shall be provided with nontoxic, tamper>proof seals or caps which are not
subject to deterioration or leaching of injurious substances. Only new screw, snap, or
crown caps may be used without sanitizing, and only when received clean and kept
protected from contamination.
5.7
Tanker Trucks
If tanker trucks are used in transporting bulk water to the facility, the truck shall comply with
the design requirements in Chapter 3 of this part on Bulk Water Hauling Systems.
383>2126>303 / November 1, 1997 / Page III>37
APPENDIX A
OPERATION AND MAINTENANCE STANDARDS
383>2126>303 / November 1, 1997 / Page III>38
PART III
APPENDIX A > CHAPTER 1
OPERATION AND MAINTENANCE STANDARDS FOR BOTTLED WATER
1.0
General
The purpose of this chapter is to provide basic guidelines on the operation and maintenance of
bottled water manufacturing facilities. This information has been taken in part, from standards
established by the Food and Drug Administration under 21!CFR Part!129 (processing and
bottling of bottled drinking water) and from technical manuals published by the International
Bottled Water Association. DEP's community water supply ™operation and maintenance∫
requirements, as they apply to bottled water systems, also have been incorporated into this
chapter.
1.1
Records
Properly kept records are a valuable tool for making adjustments in operation and
management of a bottled water system. Good records also serve as proof of performance for
justifying the expenditure of money and resolving disputes where there are concerns over
water quality. The following are the types of records that should be maintained at a bottled
water plant:
1.1.1 Plant and Equipment
All design drawings, specifications and all construction documents should be retained in
a safe location for the life of the facility regardless of any changes. Detailed records as to
the manufacturer, make, model and date installed for each piece of equipment and the
persons installing the equipment also should be retained. Repairs of any kind also should
be recorded.
1.1.2 Operation
Records should be maintained of all inspections, cleaning and sanitizing activities which
should include the names of the persons involved, date, time, and the results of the
inspection or activity. These records should be maintained for at least three years.
Sanitary surveys conducted on the source(s) of raw water should be retained for not less
than 10!years.
Water quality analysis data for each source, each product and any intermediate samples
are to be retained. Bacteriological and turbidity analysis data are to be retained for at
least five years; and chemical, radiological and organic analysis data are to be retained
for at least 10 years. All water quality analysis data should clearly indicate which tests
were done in>house and which were done by DEP approved laboratories. In addition to
identifying the person(s) conducting the tests, the laboratory procedure or the
technique used should be recorded.
1.1.3 Chemicals
Accurate records are to be kept on all types of chemicals used in the plant, when and
from whom purchased, and where and how they are stored. Where hazardous or toxic
chemicals are involved, it is recommended that access be restricted to essential personnel
and that detailed records be retained on their purchase and use. Daily records on the
amount of each chemical used should be kept and retained for at least two years.
383>2126>303 / November 1, 1997 / Page III>39
1.1.4 Personnel
Bottled water manufacturers should maintain up>to>date records for each of its
employees. Records should include the employee's name, address, telephone number,
emergency phone number, date hired, education, medical history, criminal record, and
information of any physical disabilities. These records should be retained for at least
five!years.
1.1.5 Emergency Response
A critical element in the operation of any drinking water system is the ability to respond
to an emergency situation. For that reason it is very important that the owners and
operators maintain accurate and up>to>date records on the names, addresses, telephone
numbers and responsibilities of each individual employed. Emergency response plans
should be updated at least annually and should provide specific information on the
responsible officials for each shift. Detailed instructions on how to implement a product
recall and initiate public notification should be provided in the emergency response
plan.
1.2
Buildings and Grounds
Buildings, fixtures, and other physical facilities of the plant must be kept in good repair and are
to be maintained in a sanitary condition. Cleaning operations should be conducted in such a
manner as to minimize the danger of contamination of product and product contact surfaces.
Only materials required for the proper operation and maintenance of the plant and equipment
are to be stored in the plant. These materials shall be properly identified and stored in a safe
manner.
1.2.1 Buildings
a.
Buildings must be vermin>proof and kept in good repair. Only pesticides approved
for use by the Food and Drug Administration and/or registered with the U.S.
Environmental Protection Agency shall be used for vermin control.
b.
Walls and ceilings in bottling areas must be kept clean. Overhead structures,
fixtures, and ducts in nonbottling areas are to be kept free from accumulations of
dust and other contaminants.
c.
Floors are to be kept clean and free of waste, litter, and extraneous material.
Floors in the bottling areas should be cleaned daily and sanitized with a 200 ppm
chlorine solution.
d.
Doors and windows must be kept clean and in good repair.
e.
Ventilation equipment should not create conditions that may contribute to
product contamination by airborne contaminants and must be kept free of
accumulation of dust and grease.
f.
Washrooms must not be utilized for storage of garments, food products, utensils,
or packaging and wrapping materials. Hot and cold running water; powdered,
liquid, or bar soap; and single>use sanitary towels are to be provided. The toilet
room and fixtures are to be maintained in a sanitary condition and kept in good
repair at all times. Signs informing employees to wash their hands after using the
washrooms must be posted in a visible location.
g.
Where employee locker and lunchrooms are provided, they are to be separated
from plant operations and/or storage areas and be equipped with self>closing
383>2126>303 / November 1, 1997 / Page III>40
doors. The rooms shall be maintained in a clean and sanitary condition with
refuse containers provided. Packaging or wrapping material or other processing
supplies must not be stored in locker or lunchrooms.
h.
Storage facilities must be kept clean and dry, and provide protection from splash,
insects, dust, and other contaminants.
i.
All refuse must be stored in properly identified, covered containers.
1.2.2 Grounds
The grounds about a bottled water plant under the control of the operator must be kept
free from conditions which may result in the contamination of the product water or
manufacturing facilities. This is to be achieved by:
1.3
a.
Prompt elimination of any litter, waste or refuse, within the immediate vicinity of
the plant buildings that may attract or provide a breeding place or harborage for
rodents, insects and other pests;
b.
The elimination or control of air pollutants (i.e., dust, engine exhaust) that may
contribute to the contamination of the product during its manufacture;
c.
Adequately draining areas that may cause contamination through seepage or by
providing a breeding place for insects or microorganisms;
d.
Where plant grounds are bordered by land not under the operator©s control of
the kind described in subparagraphs a, b, and c of this section, additional care
must be exercised by increased plant inspections, extermination, or other means
which will ensure exclusion of pests, dirt, and other contaminants.
Sanitary Operations
1.3.1 Whenever air under pressure is directed at product water or a product water>contact
surface, it must be free of oil, dust, rust, excessive moisture, and extraneous materials.
1.3.2 The product water>contact surfaces of all multiservice containers, utensils, pipes and
equipment used in the transportation, processing, handling and storage of bottled
water shall be clean and adequately sanitized. All product water>contact surfaces are to
be inspected by plant personnel as often as necessary to evaluate the sanitary condition
of such surfaces and to take appropriate action to assure they are kept free of scale,
evidence of oxidation, and other residue. The presence of any contaminants, scale,
residue, or oxidation will be sufficient reason to reject the container or utensil from
further use or until properly cleaned.
1.3.3 After cleaning, all multiservice containers, utensils and disassembled piping and
equipment must be stored in such a manner as to assure drainage and be protected from
contamination.
1.3.4 Single>service containers and caps or seals shall be stored in sanitary closures and kept
clean and dry until used. Prior to use they must be examined and as necessary, washed,
rinsed, and sanitized.
1.3.5 Filling, capping, closing, sealing, and packaging of containers shall be done in a sanitary
manner to preclude contamination of the bottled drinking water.
383>2126>303 / November 1, 1997 / Page III>41
1.4
Processes and Controls
1.4.1 Treatment of Product Water
The manufacture of bottled water by distillation, ion>exchange filtration, ultraviolet
treatment, reverse osmosis, or any other process shall be done in a manner to achieve
the optimum level of treatment. All facilities and treatment processes approved by
permit from DEP shall be operated and maintained in accordance with DEP's rules and
regulations. Chemicals approved under NSF Standard 60 are accepted. Product water
samples shall be taken after processing and prior to bottling, and analyzed as often as is
necessary to assure uniformity and effectiveness of the treatment processes. The
following recommendations are provided for each treatment process:
a.
Distillation
Feed water with a high hardness should be deionized prior to distillation to
preclude rapid and excessive scale buildup in the evaporator. Scale buildup
reduces evaporator efficiency. Sufficient boiler blow>down also should be
provided to reduce scale buildup.
To maintain the quality of the distilled water, a conductivity meter should be
installed in the product line. Conductivity should be recorded at start>up and then
regularly (e.g., hourly) during a production run. The conductivity of the finished
water should be less than 10 micromhos.
b.
Ion exchange
Prior to start>up, the ion exchange resins should be conditioned before putting
into service. Maintaining demineralization efficiency of a two>bed system is very
important. This could be carried out in the following manner:
(1) Cation Unit
(a) Backwash the unit using reverse flush (upward) to remove trapped solids
and prevent packing/channeling.
(b) Proceed with normal regeneration, by passing a strong acid solution
(sulfuric or hydrochloric acid) downward through the resin.
(c) Rinse by passing rinse water downward to flush out minerals and excess
acid.
(2) Anion Unit
(a) Backwash the unit using reverse flush to remove trapped solids and
prevent packing/channeling.
(b) Proceed with normal regeneration, by passing a strong base solution, such
as caustic soda (sodium hydroxide) or soda ash (sodium carbonate)
downward through resin. The type of base used depends on resin used.
(c) Rinse by passing rinsed water downward to flush out minerals and excess
base.
The operating, regeneration procedures and flow rates specified by the
manufacturers should be followed to ensure proper operation of the units.
383>2126>303 / November 1, 1997 / Page III>42
As a minimum the conductivity of the water from the deionizing units should be
checked at start>up and every hour. Preferably, automatic controls should be used
to shut off the system when a preset level of conductivity is exceeded. Records of
each regeneration should be kept and the number of gallons produced per cycle
recorded.
c.
Maintenance of Filters
The manufacturer's service and maintenance guidelines should be followed when
servicing filters. Particulate filters should be changed regularly (cartridge type) or
backflushed (sand, or mixed>media) to reduce particulate matter and ensure a
high clarity water. All backwash should be done with finished product water. A
turbidity of 0.1 NTU or less is highly desirable. When carbon filters are used for
taste and odor control, the bed must be backwashed regularly to dislodge
trapped particulates and reverse carbon compaction. Sanitation of carbon beds
with chlorine is not recommended. Such a procedure could result in possible
release of chlorinated organics into the product water. Backflushing regularly is
sufficient.
After performing maintenance on a particulate filter, test for filter performance
and measure the pressure drop across the filter. The quality of the product water
should be tested by measuring turbidity, total suspended solids (TSS), and
heterotrophic plate count.
d.
Maintenance of UV Systems
Only ultraviolet light systems of the class A type, as approved by NSF under
Standard 55, are acceptable to DEP. The operation, maintenance and installation
of these units must follow the recommendations outlined in that standard. The
ultraviolet lamps should warm up for at least five minutes before allowing their
use in treating water. The following routine maintenance is recommended for UV
disinfection systems:
(1) The quartz jacket of the lamp should be wiped at least once a month;
(2) Lamps should be replaced when the intensity meter indicates less than
50!percent of the rated lamp intensity;
(3) Check UV intensity of 253.7 nm daily;
(4) Check accuracy of intensity meter monthly.
e.
Maintenance of Reverse Osmosis (RO) Units
(1) Fouling of Membrane
RO units should be preceded by one micron particulate filters. For water from
municipal sources, a polishing filter usually is sufficient. Pretreatment of feed
water is essential to prevent membrane fouling. For cellulose acetate
membranes, an acid feed often is required to prevent the formation of
carbonate scale. For hard feed water, a water softener or a polyphosphate
feed which keeps the hardness minerals from precipitating out of the
membrane may be used. It is advisable to periodically flush the system with a
detergent solution to remove builtup solids.
383>2126>303 / November 1, 1997 / Page III>43
(2) Temperature of Feed Water
RO units are temperature>sensitive. Since membranes will degrade much
more quickly at elevated temperatures, water temperature must be kept at
2∞C to 35∞C for cellulose acetate and polyamide, 2∞C to 30∞C for cellulose
triacetate, and 2∞C to 45∞C for thin film composite. However, lowering feed
water temperature dramatically reduces the production rate of product
water. As a rule of thumb, a 2∞C reduction in water temperature reduces the
flow of product water by three percent.
(3) Pressures
RO units are very pressure sensitive. It is very important to maintain design
pressure drop because a reduction in this operating variable not only reduces
production but also allows more salt passage. Back pressure can build up as a
result of deliberate throttling, causing the same effect of increased salt
passage. Control of transmembrane pressure is critical to optimum
performance.
(4) Monitoring RO System
To maintain a consistent quality of product water, an RO system must be
carefully monitored. Records of hourly measurements are recommended for
pH, feed water temperature, feed water TDS, chlorine, product TDS, pump
pressure, product flow, brine flow, polyphosphate feed (if used), and softener
records (if used).
1.4.2 Equipment Maintenance
All tanks, pipelines, and equipment used to store, handle, and transport water must be
inspected, maintained, cleaned, and sanitized (see Section 3.3 for storage tanks).
1.4.3 Containers
a.
Multiservice containers (i.e.,!containers which are intended by the bottler for
more than one use) shall be adequately cleaned, sanitized, and inspected just
prior to being filled, capped and sealed. Containers found to be unsanitary or
defective by the inspection are to be reprocessed or discarded. All multiservice
containers shall be washed, rinsed, and sanitized by mechanical washers or by
other methods giving adequate sanitary results. Mechanical washers should be
inspected as often as is necessary to assure adequate performance. Records of
physical maintenance, inspections and conditions found, and performance of the
mechanical washer are to be maintained by the plant operators.
b.
Multiservice shipping cases (i.e.,!shipping cases which are intended by the bottler
for more than one use) should be maintained in such condition as to assure they
will not contaminate the primary container or the product water. Adequate dry or
wet cleaning procedures should be performed as often as necessary to maintain
the cases in satisfactory condition.
1.4.4 Cleaning and Sanitizing Solutions
Cleaning and sanitizing solutions utilized by the plant shall be sampled and tested by the
plant at least daily to assure adequate performance in the cleaning and sanitizing
operations. Records of these tests are to be maintained by the plant operators.
383>2126>303 / November 1, 1997 / Page III>44
1.4.5 Cleaning and Sanitizing Bottling Room
The bottling room must be thoroughly cleaned and sanitized daily. Upon completion
there should be no dust, grease, or oil film on the exterior of the processing equipment.
At the finish of each daily bottling run, bottle caps should be removed from the capper,
cap bowl, and bin and placed into a sealed container. Caps only should be handled by
persons wearing sterile gloves or with clean hands sanitized with a disinfectant.
At the end of each day's operation, the filling room should be cleaned as follows:
a.
Brush off dust and debris from conveyor;
b.
Sweep floor and remove all unnecessary items, such as unfilled bottles and bottle
crates;
c.
Use detergent solution to wash frames on fillers and capper. Rinse with product
water;
d.
Scrub floor (and walls if needed) with detergent solution and nylon brush. Hose
down entire floor and walls;
e.
Clean floor drain;
f.
Clean all windows and window sills inside and outside of the filling rooms;
g.
Carefully wipe off electrical panels, light fixtures, and other surfaces not directly
hoseable with a damp cloth. This includes top of filler, nozzle hoses, air hoses,!etc.,
because vibration of operating conveyor, filler or capper can knock loose dust into
product.
Before the start of bottling, the filler room should be sanitized each day. Bottling lines
and the interiors of filler nozzles should be sanitized with ozonated water of at least
0.1!ppm or preferably > 0.35 ppm, or chlorine solution of about 50 ppm.
1.4.6 Sanitizing Operations
a.
Sanitizing Bottles
Sanitizing operations must be adequate to effectively sanitize the product water>
contact surfaces and any other critical area. Plant operators are to maintain a
record of the strength of the sanitizing solution and the time the agent was in
contact with the surface being sanitized. The following times and strengths are
considered a minimum:
(1) Steam in enclosed system > At least 170∞F for no less than 15 minutes or at least
200∞F for no less than five minutes;
(2) Hot water in enclosed system > At least 170∞F for no less than 15 minutes or at
least 200∞F for no less than five minutes;
(3) Chemical sanitizers shall be equivalent in bactericidal action to a two>minute
exposure of 50!ppm of available chlorine at 57∞F when used as an immersion
or circulating solution. Chemical sanitizers applied as a spray or fog shall have
as a minimum 100!ppm of available chlorine at 57∞F or its equivalent in
bactericidal action;
383>2126>303 / November 1, 1997 / Page III>45
(4) 0.1 ppm ozone water solution in an enclosed system for at least five minutes.
b.
Sanitizing Capper, Bottle Shield and Filler Spout
Capper, chute, filler spouts, and bottle shields should be sanitized with 200!ppm
chlorine. The following procedures should be performed immediately before
bottling:
(1) Capper > Moisten sponge with sanitizing solution and apply to all surfaces of
the capper coming into contact with caps;
(2) Capper Chute > Moisten sponge in sanitizing solution and apply to inside
surfaces of chute;
(3) Filler Spouts > Moisten sponge with sanitizing solution and apply to all outside
surfaces of spouts;
(4) Bottled Shields > Moisten sponge with sanitizing solution and apply to
underside surfaces of shields. Remove corrosion or foreign material if found;
c.
Sanitizing Floor of Bottling Room
Bottling room should be sanitized every night as the last step in cleaning bottling
room. The following procedure is recommended:
(1) Materials > Tank>type sprayer with 200!ppm chlorine.
(2) Procedure > After normal cleaning, spray entire floor with fine mist of chlorine
spray. Do not rinse chlorine>sanitized floor.
1.4.7 Filling, Capping, or Sealing
During the process of filling, capping or sealing either single>service or multiservice
containers, the performance of the filler, capper or sealer is to be monitored. Filled
containers are to be visually or electronically inspected to assure that they are sound,
properly capped or sealed, coded and labeled. Containers which are not satisfactory
shall be reprocessed or rejected. Fillers must be kept free from scale, evidence of
oxidation and residue, and are to be sanitized on a daily basis using the cleaning and
sanitizing procedures specified in 3.3A.2 under Appendix!A of this part of the manual.
The filler reservoir shall be kept covered at all times.
In accordance with filler manufacturer's instructions, any parts which are not designed
to be cleaned in>place should be disassembled and removed. All of these parts are to be
cleansed and sanitized prior to reassembly using appropriate cleansing and sanitizing
procedures,as specified in 1.4.6a above.
All surfaces of the filler which do not contact water are to be cleaned manually so as to
render all surfaces clean and free of any residues.
The filler should be prepared and all appropriate connections made in accordance with
the filler manufacturer's instructions to place the filler in the clean>in>place mode. To
prepare the filler, the following procedures should be followed:
a.
An alkaline cleaning solution of appropriate strength should be recirculated
through the filler to provide effective cleaning of all product contact surfaces,
with minimum recirculation time of 20 minutes at a temperature between
140∞F!and 170∞ F;
383>2126>303 / November 1, 1997 / Page III>46
b.
The cleaning solution must be drained and followed with a product water rinse>
to>drain for the removal of all residual cleaner. This step may be preceded by the
application of an acidified rinse prior to the product water rinse in order to
neutralize any residual alkalinity on the water contact surfaces.
Following reassembly of all parts, the filler is to be sanitized in>place in
accordance with procedures specified in 1.4.6a.
1.4.8 Quality Assurance Procedures
To assure that the plants production of bottled drinking water is in compliance with
DEP's requirements, the plant should conduct the following tests. All tests must be
performed by laboratories certified by the DEP.
Test for microbiological contaminants weekly and for all other primary maximum
contaminant levels annually. Where a surface source is used, plants shall monitor for
turbidity every four hours. Source water from other than a public water system should
be analyzed for VOCs and unregulated contaminants annually. Systems which fluoridate
shall conduct operational monitoring for fluoride at least once each day. At least once
each three months, a bacteriological swab and/or rinse count should be made from no
less than four containers and closures selected just prior to filling and sealing. Three of
the four samples should not exceed more than one bacteria per milliliter of container
capacity and not over one colony per square centimeter of closure area, and should be
free of coliform organisms.
1.4.9 Packaging Processes
Packaging processes and materials shall not transmit contaminants or deleterious
substances to the bottled water and shall conform to the applicable food additive
regulations in CFR Title 21 and NSF Standard 61.
a.
Containers and closures for bottled water must be manufactured from approved
materials.
b.
Only sanitary, nontoxic lubricants shall be used on container contact surfaces.
1.4.10 Storage Facilities
Clean, dry storage facilities must be provided for containers, closure materials, paper for
wrapping, adhesives and other production materials to prevent contamination. The
materials are to be stored on pallets above the floor and away from any wall to facilitate
cleaning.
1.5
Personnel
The plant management shall take all reasonable measures and precautions to assure the
following:
A.
Cleanliness > All persons, while working on bottled water preparation facilities or
equipment which manufactures and packages bottled water should:
1.
Wear clean outer garments and maintain a high degree of personal cleanliness
while on duty;
2.
Wash their hands thoroughly in a proper hand>washing facility before starting
work, after each absence from the work station, and at any other time when the
383>2126>303 / November 1, 1997 / Page III>47
hands may have become soiled or contaminated. Hands are to be sanitized at
frequent intervals using a sponge saturated with an approved sanitizing solution
or by immersing the hands in the solution at capping, packing and faucet
installation stations;
3.
Remove all insecure jewelry and, during periods where the process is manipulated
by hand, remove from hands any jewelry that cannot be adequately sanitized;
4.
If gloves are used, maintain them in an intact, clean and sanitary condition. Such
gloves should be of an impermeable material except where their usage would be
inappropriate or incompatible with the work involved;
5.
Wear hair nets, headbands, caps, or other effective hair restraints;
6.
Not store clothing or other personal belongings, or drink beverages in areas
where the bottled water product is exposed or in areas used for washing
equipment or utensils;
7.
Consume food only in designated dining areas. Areas where product water
utensils or manufacturing equipment are stored shall not be designated as a
dining area;
8.
Not use tobacco in any form during production. Employees are to use tobacco
only in designated areas. An employee tobacco>use area shall not be designated
for that purpose if the use of tobacco may result in contamination of product
water, equipment utensils, or other items needing protection;
9.
Take any other necessary precautions to prevent contamination of the product
water with microorganisms or foreign substances including, but not limited to,
perspiration, cosmetics, chemicals or medicines.
B.
Disease Control > No person affected by disease of a communicable form, or while
affected with boils, sores, infected wounds, or other abnormal sources of
microbiological contamination, shall be permitted to work in a bottled water plant.
C.
Education and Training > Personnel responsible for identifying sanitation failures or
product contamination should have sufficient background education or experience, or
combination thereof, to provide a level of competency necessary for overseeing the
production of safe bottled drinking water. Workers and supervisors should receive
appropriate training in proper operating techniques and bottled water protection
principles. The international Bottled Water Association©s ™Technical Training Course™ or
its equivalent is an example of acceptable basic course for this requirement. This course
should be taken at least annually.
D.
Supervision > Responsibility for assuring compliance by all personnel with the
requirements of this part should be assigned to competent supervisory personnel. This
person should receive appropriate training for this purpose.
E.
Activities > Activities unrelated to the bottling process such as sleeping, eating, etc. are
prohibited in all working and storage areas.
F.
Sanitizing Hands > It is essential for workers to keep hands clean and sanitized when
working on the ™clean™ side of the bottling plant. Hand>washing facilities should be
conveniently located in the bottling area. If no hand>washing stations are convenient,
dip stations or sanitizers should be provided.
383>2126>303 / November 1, 1997 / Page III>48
PART III
APPENDIX A > CHAPTER 2
OPERATION AND MAINTENANCE STANDARDS FOR VENDED WATER SYSTEMS
2.0
General
The purpose of this chapter is to provide standards for the operation and maintenance of
drinking water vending machines. This information has been taken in part from standards
established by the National Automatic Merchandising Association (NAMA) and NSF. Readers
also are referred to Part V of DEP's Public Water Supply Manual for additional operation and
maintenance standards which may apply to their system.
2.1
2.2
Machine Location
A.
Drinking water vending machines are to be located in a room, area or space which can
be maintained in a clean condition. The immediate area in which the equipment is
located is to be well lighted and ventilated. In addition, the counter or floor where the
machines are located must be smooth, of cleanable construction, and be capable of
withstanding repeated washing and scrubbing.
B.
Each machine is to be located so that the space around and under the machine can be
easily cleaned and maintained.
Employee Training
The owners/operators of drinking water vending machines must provide competent and
properly>trained staff to oversee the operation and routine maintenance of the machines.
Personnel are to be trained in the specific types of processes and equipment used in their
machines. Those individuals operating reverse osmosis filters, deionization units, or where
chemicals are added to the water are to receive specific training on the operation of these
systems.
2.3
Operations and Maintenance Plan
Each vended water system must develop an Operations and Maintenance (O & M) Plan, which
includes a testing program covering the routine servicing of each water vending machine
(WVM). Copies of the service manuals containing cleaning and sanitization procedures, field
testing procedures, component replacement schedules and component servicing instructions
are to be included in the O & M Plan. In addition, the O & M Plan should contain at least the
following information:
A.
A description of the treatment processes used in each machine as identified by their
model number;
B.
A detailed explanation of the system's normal operation procedures;
C.
Information on the frequency and procedures for maintaining and cleaning the
machine;
D.
Staffing and training;
E.
Records and reporting system;
F.
Safety program and emergency response plan;
383>2126>303 / November 1, 1997 / Page III>49
G.
Manufacturer's manuals.
The O & M Plan should be reviewed and updated at least yearly and revised to reflect
changes in the operation and maintenance of the machines. The plan should be bound
and placed in locations which are readily accessible to the vending water system's
personnel, and must be presented upon request to DEP.
2.4
Service and Maintenance
At every service, inspect all interior parts and surfaces of the water vending machine in
accordance with the service manual. The vending stage and dispensing nozzle must be
thoroughly cleaned and sanitized each time the machine is serviced. All exterior surfaces are to
be well maintained and visibly clean. A record of all cleaning and maintenance operations shall
be kept by the operator for each water vending machine and is to be available for inspection
upon request. A copy of the cleaning and servicing records should be kept inside each machine.
A.
Maintenance Schedule
The following guidelines are recommended minimums. However, cleaning will vary
depending on local water conditions and the amount of water produced. Each water
vending machine must be maintained individually in accordance with its own particular
location requirements. At every service:
1.
General Internal Cleaning
a. Thoroughly inspect all inside surfaces of the machine to be sure they are clean.
b. Wash, rinse and sanitize the dispensing nozzle. Clean the vending stage
thoroughly; then wash, rinse and sanitize the stage.
2.
Check Operational Parameters
a. Check all lines for leaks.
b. Check dates of all replaceable components in conformation with change>out
schedule and replace outdated and/or used up components. These would
include the following items: coarse prefilter(s), carbon filter(s) or block(s), RO
and DI systems (if applicable), and UV light intensity. Follow the
manufacturerπs instructions to replace, as needed, indicated by but not
limited to change in vended water quality, flow rate, pressure or as scheduled
according to their individual rated capacities, etc.
c.
Check the finished product water storage tank, if applicable. Follow the
manufacturer's cleaning and servicing instruction.
d. Cycle the drinking and/or purified water and check volume and applicable
physical parameters. Record the reports on the operating report.
3.
General External Cleaning
a. Clean the outside surface of the machines with a safe, nontoxic industrial
cleaner. Follow the manufacturer's instructions.
383>2126>303 / November 1, 1997 / Page III>50
2.5
Sampling
NAMA approved machines connected to an approved community water system are eligible for
a permit>by>rule. For such permitted machines, the vended water from each machine shall be
monitored for total coliforms once every month. In addition, the vended water system shall
sample the vended water for lead, cadmium and total dissolved solids (TDS) annually.
For non>NAMA approved machines or machines connected to an unapproved community
water system, the vended water from each machine shall be monitored for total coliforms once
every week. In addition, each year the vended water system shall sample the vended water
from one>third of the system's water vending machines for all primary MCLs so that all
machines are sampled once every three years. All water analyses must be done by a laboratory
certified by DEP.
Any water vending machine having a water sample which exceeds an MCL for any parameter is
to be taken out of use until it is serviced and subsequent check samples indicate a level below
the MCL.
A more frequent analysis of the above should be done by the water vending machine system if
there is concern that the vended water is being affected by contaminants in the source water.
Samples for analysis should be collected by laboratory personnel or individuals who have been
trained in proper collection techniques. To simulate actual dispensing conditions, no
extraordinary flushing should be conducted prior to the collection of the samples. Any water
vending machine having a positive>coliform water sample shall be taken out of service until it is
completely serviced and all water contact parts are sanitized. An additional sample with
acceptable results is to be obtained prior to placing the machine in service.
Vending machines utilizing silver>impregnated carbon filters in the treatment process should
be tested for silver at least once every six months. Any water vending machine having a sample
which exceeds 0.05 mg/L of silver is to be taken out of use until it is serviced and subsequent
samples for silver are below this standard.
383>2126>303 / November 1, 1997 / Page III>51
PART III
APPENDIX A > CHAPTER 3
OPERATION AND MAINTENANCE STANDARDS FOR BULK WATER HAULERS
3.0
General
The purpose of this section is to provide basic information on the operation and maintenance
procedures for bulk water hauling systems. Information for this section has been taken in part
from the Pennsylvania Department of Agriculture standards. Readers also should refer to
Part!V of DEP's Public Water Supply Manual for additional information on the operation and
maintenance requirements that apply to public water supply systems.
3.1
Operations
Tank trucks, loading and unloading facilities, and other equipment used to transport bulk
water are to be maintained clean and sanitary at all times. Tanks previously used to transport
toxic materials, petroleum products, or other deleterious substances shall not be used to haul
drinking water.
3.2
3.3
Records
A.
Daily records are to be maintained for each vessel which include the number of gallons
delivered and all cleansing and sanitizing or sanitizing activities conducted on the tank
truck exterior, interior, risers, connections, pumps, hoses, etc.
B.
Such records shall include date, time and location of pickup or delivery, concentration of
residual disinfection, and the results of any other water quality analysis which are
conducted.
Storage Tanks
There should be ample room around a tank for inspection and maintenance. Bulk water
storage tanks used to transport and store water shall be inspected, maintained, cleaned and
sanitized according to the following guidelines:
A.
Storage Tanks
1.
Storage tanks should be inspected for cleanliness on a monthly basis and shall be
kept free of scale, evidence of oxidation, and residue.
2.
Storage tanks also should be cleaned on a monthly basis by sanitizing with one of
the following:
(a) Chlorine water solution of 200 ppm for a minimum of five minutes;
(b) Spray wet surface with 200 ppm chlorine water solution. This is to be used on
surfaces that are not reached by the above soaking treatment;
(c) 0.1 ppm ozone water solution for not less than 10!minutes contact time;
(d) Flushing with product water for at least 30 minutes.
383>2126>303 / November 1, 1997 / Page III>52
B.
Maintaining Tanks
Tanks for water transport or storage must be maintained in good repair and regularly
sanitized to prevent microbiological contamination of the water. Before entering a tank
to work on the interior surfaces, the following precautions are to be taken:
C.
1.
Notify a foreman or other responsible employee that tank is out>of>service and
work is being performed inside it;
2.
Lock all valves to the tank;
3.
Verify that tank is free of water, air pressure, and vacuum;
4.
When using an electrical cord with light, cord must be waterproof with no
insulation breaks, properly grounded and have a shielded bulb;
5.
Set up a small forced>draft blower outside the tank to blow air into the tank via a
flexible duct. The suction of blower should be placed so that exhausted air from
the tank will not be recirculated into the tank.
Cleaning/Sanitizing Tanks
The following steps are necessary for cleaning tanks:
1.
Isolate tank from other tanks and lines by closing valves. Inspect valves for
tightness and leaks;
2.
Carry out safety precautions as outlined in Section!B;
3.
Remove, clean, and re>install air filter and vent piping;
4.
Add approximately 50!gallons of 100 to 200!ppm chlorine solution on to the tank.
If done by spray, allow 15 to 20!minutes contact time;
5.
If wrench is used for removing spray heads, be careful not to drop the wrench.
Tank linings are thin, delicate coverings and are easily broken by a dropped
wrench;
6.
Rubber boots may be worn only after washing them in 200 to 400!ppm chlorine
solution. Be sure that no dirt is on the soles of the boots;
7.
Inspect linings and fittings;
8.
Remove and clean spray heads, if present;
9.
Sanitize sight glass or plastic tube by pumping chlorine solution upward through
it. If tube needs scrubbing, remove it for cleaning, sanitizing, and rinsing with
disinfected product water;
10.
In all tanks, always start at the highest point so that ™dirt'' doesn't fall on to areas
already scrubbed. For horizontal tanks, start scrubbing at the top of the inside end
panel, dipping the brush into the chlorine solution frequently. For vertical tanks,
start scrubbing at top;
11.
Scrub manhole cover and gasket (replace and seal, if spray system is used);
12.
Drain scrubbing solution from tank;
383>2126>303 / November 1, 1997 / Page III>53
13.
Rinse with 100 ppm chlorinated water followed by rinse with product water. Use
lightly chlorinated product water (0.2 to 0.5!ppm) if this water is to be stored in
the tank. Rinse until test shows the tank to be clean and free of impurities;
14.
Close all drains;
15.
Put tank into use, or alternatively for distilled water tanks, add about 1/6 tank of
water;
For purified water, frequency of tank cleaning may be reduced by ozonating at
night once each one to two days as long as tank is made of stainless steel or other
material resistant to ozone oxidation. In this way, bacteria growth may be
controlled in water storage tanks over long periods.
D.
Cleaning Tank Air Vent Filters
Storage tank air filters should be dismantled, cleaned, and sanitized, or the element
replaced each time the tank is scrubbed. Each time the filter is removed, clean filter
piping by dismantling.
3.4
Bulk Transport and Transfer Procedures
3.4.1 Sanitation
a.
Prior to filling, tank interior should be cleaned, flushed with potable water,
sanitized with not less than 100 ppm chlorine water solution for a contact period
of not less than 20 minutes, and rinsed with potable water. The dome cover shall
be closed immediately after cleaning.
b.
Tanks used for the transport of dairy products must have the interior of the tank
inspected with a black lamp (ultraviolet) after cleaning and flushing as outlined in
3.4.1a above. Tanks shall be rejected for use when odors or contaminants are
found or suspected.
c,
All hoses, connections, and fittings shall be sanitized with a concentrated solution
of chlorine (three ounces of 5>1/4!percent household bleach to two gallons of
water) by brushing solution on all exposed parts.
3.4.2 Fluid Transfer
a.
Tank trucks or tank trailers should be filled through the fitting on the inner dome
cover when the tail pipe cannot be used.
b.
Water quality in the tank, after 20 to 30!gallons have been delivered into the
tank, should be checked as follows:
(1) Stop filling;
(2) Open discharge valve;
(3) Inspect water as it discharges. If water has unpleasant odor and/or looks dirty,
it shall be rejected for use;
(4) Check disinfectant residual.
c.
When these checks indicate satisfactory water quality, proceed to fill the tank.
383>2126>303 / November 1, 1997 / Page III>54
d.
The dome cover shall be closed and sealed after filling to volume desired.
e.
The tank discharge valve cover shall be closed and sealed after filling.
383>2126>303 / November 1, 1997 / Page III>55
PART III
APPENDIX A > CHAPTER 4
OPERATION AND MAINTENANCE STANDARDS FOR RETAIL WATER FACILITIES
4.0
General
The purpose of this chapter is to provide basic guidelines on the operation and maintenance of
retail water facilities. This information has been taken in part, from standards established by
the Food and Drug Administration under 21 CFR Part!129 (processing and bottling of bottled
drinking water) and NSF International (NSF). Readers also are referred to Part V of DEP's Public
Water Supply Manual for additional operation and maintenance standards which may apply to
their system.
4.1
Records
The following are the types of records that should be maintained at a retail water facility.
4.1.1 Facility and Equipment
All design drawings, specifications and all construction documents should be retained in
a safe location for the life of the facility regardless of any changes. Detailed records as to
the manufacturer, make, model and date installed for each piece of equipment and the
persons installing the equipment also should be retained. Repairs of any kind also should
be recorded.
4.1.2 Operation
Records should be maintained of all inspections, cleaning and sanitizing activities which
should include the names of the persons involved, date, time, and the results of the
inspection or activity. These records should be maintained for at least three years.
Sanitary surveys conducted on the source(s) of raw water should be retained for not less
than 10 years.
Water quality analysis data for each source, each product and any intermediate samples
also are to be retained. Bacteriological and turbidity analysis data are to be retained for
at least five years; chemical, radiological and organic analysis data are to be retained for
at least 10!years. All water quality analyses data should clearly indicate which tests were
done in>house and which were done by DEP approved laboratories. In addition to
identifying the person(s) conducting the tests, the laboratory procedure or technique
used should be recorded.
4.1.3 Chemicals
Accurate records are to be kept on all types of chemicals used in the facility, when and
from whom purchased, and where and how stored. Where hazardous or toxic chemicals
are involved, it is recommended that access be restricted to essential personnel and that
detailed records be retained on their purchase and use. Daily records on the amount of
each chemical used should be kept and retained for at least two years.
4.1.4 Personnel
Retail water facilities should maintain up>to>date records for each of their employees.
Records should include the employeeπs name, address, telephone number and other
pertinent background information. These records should be retained for at least five
years.
383>2126>303 / November 1, 1997 / Page III>56
4.1.5 Emergency Response
A critical element in the operation of any drinking water system is the ability to respond
to an emergency situation. For that reason, it is very important that the owners and
operators maintain accurate and up>to>date records on the names, addresses, telephone
numbers and responsibilities of each individual employed. Emergency response plans
should be updated at least annually. Detailed instructions on how to implement a
product recall and initiate public notification should be provided in the emergency
response plan.
4.2
Buildings and Grounds
Buildings, fixtures, and other physical facilities must be kept in good repair and are to be
maintained in a sanitary condition. Cleaning operations should be conducted in such a manner
as to minimize the danger of contamination of product contact surfaces. Only materials
required for the proper operation and maintenance of the facility and equipment are to be
stored in the facility. These materials shall be properly identified and stored in a safe manner.
4.2.1 Buildings
a.
Buildings must be vermin>proof and kept in good repair. Only pesticides approved
for use by the Food and Drug Administration and/or registered with the U.S.
Environmental Protection Agency shall be used for vermin control.
b.
Walls and ceilings in the facility must be kept clean. Overhead structures, fixtures,
and ducts are to be kept free from accumulations of dust and other contaminants.
c.
Floors are to be kept clean and free of waste, litter, and extraneous material.
Floors in the filling areas should be cleaned daily and sanitized with a 200 ppm
chlorine solution.
d.
Doors and windows must be kept clean and in good repair.
e.
Ventilation equipment should not create conditions that may contribute to
product contamination by airborne contaminants and must be kept free of
accumulation of dust and grease.
f.
Storage facilities must be kept clean and dry, and provide protection from splash,
insects, dust, and other contaminants.
g.
All refuse must be stored in properly identified, covered containers.
4.2.2 Grounds
The grounds about a retail water facility under the control of the operator must be kept
free from conditions which may result in the contamination of the product water or
manufacturing facilities. This is to be achieved by:
a.
Prompt elimination from within the immediate vicinity of the facility buildings of
any litter, waste or refuse that may attract or provide a breeding place or
harborage for rodents, insects and other pests.
b.
Adequately draining areas that may otherwise cause contamination through
seepage or by providing a breeding place for insects or microorganisms.
383>2126>303 / November 1, 1997 / Page III>57
4.3
Sanitary Operations
4.3.1 Whenever air under pressure is directed at product water or a product water>contact
surface, it must be free of oil, dust, rust, excessive moisture, and extraneous materials.
4.3.2 Containers and caps or seals shall be stored in sanitary closures and kept clean and dry
until used. Prior to use they must be examined and as necessary, washed, rinsed, and
sanitized.
4.3.3 Filling, capping, closing, sealing, and packaging of containers shall be done in a sanitary
manner to preclude contamination of the retail drinking water.
4.4
Processes and Controls
4.4.1 Treatment of Product Water
The treatment of retail water by distillation, ion>exchange filtration, ultraviolet
treatment, reverse osmosis, or any other process shall be done in a manner to achieve
the optimum level of treatment. All facilities and treatment processes approved by
permit from DEP shall be operated and maintained in accordance with DEP©s rules and
regulations. Chemicals approved under NSFπs Standard!60 are accepted. Product water
samples shall be taken and analyzed as often as necessary to assure uniformity and
effectiveness of the treatment processes.
4.4.2 Equipment Maintenance
All tanks, pipelines, and equipment used to store and handle water must be inspected,
maintained, cleaned, and sanitized (see Section 3.3 for Storage Tanks).
4.4.3 Containers and Washing Equipment
Containers shall be adequately cleaned, sanitized, and inspected just prior to being
filled, capped and sealed. Containers found to be unsanitary or defective by the
inspection are to be reprocessed or discarded. All multiservice containers shall be
washed, rinsed, and sanitized by mechanical washers or by other methods giving
adequate sanitary results. Mechanical washers should be inspected as often as necessary
to assure adequate performance. Records of physical maintenance, inspections and
conditions found, and performance of the mechanical washers are to be maintained by
the plant operators.
4.4.4 Cleaning and Sanitizing Solutions
Cleaning and sanitizing solutions utilized by the facility shall be tested by the plant at
least daily to assure adequate performance in the cleaning and sanitizing operations.
Records of these tests are to be maintained by the facility operators.
4.4.5 Cleaning and Sanitizing Bottling Area
The bottling area must be thoroughly cleaned and sanitized daily. Upon completion
there should be no dust, grease, or oil film on the exterior of the processing equipment.
4.4.6 Sanitizing Operations
a.
Sanitizing Containers
Sanitizing operations must be adequate to effectively sanitize the product water>
contact surfaces and any other critical area. Facility operators are to maintain a
383>2126>303 / November 1, 1997 / Page III>58
record of the strength of the sanitizing solution and the time the agent was in
contact with the surface being sanitized. The following criteria are considered
minimums:
(1) Steam in enclosed system > At least 170∞F for no less than 15 minutes or at least
200∞F for no less than five minutes;
(2) Hot water in enclosed system > At least 170∞F for no less 15 minutes or at least
200∞F for no less than five minutes;
(3) Chemical sanitizers shall be equivalent in bactericidal action to a two>minute
exposure of 50!ppm of available chlorine at 57∞F when used as an immersion
or circulating solution. Chemical sanitizers applied as a spray or fog shall have
as a minimum 100!ppm of available chlorine at 57∞F or its equivalent in
bactericidal action;
(4) 0.1!ppm ozone water solution in an enclosed system for five minutes.
b.
Sanitizing Capper, Bottle Shield and Filler Spout
Capper, capper chute, filler spouts, and bottle shields should be sanitized with
200!ppm chlorine. The following procedures should be performed immediately
before bottling:
(1) Capper > Moisten sponge with sanitizing solution and apply to all surfaces of
the capper coming into contact with caps;
(2) Capper Chute > Moisten sponge in sanitizing solution and apply sponge to
inside surfaces of chute;
(3) Filler Spouts > Moisten sponge with sanitizing solution and apply to all outside
surfaces of spouts;
(4) Bottle Shields > Moisten sponge with sanitizing solution and apply to
underside surfaces of shields. Remove corrosion or foreign matter if found.
c.
Sanitizing Floor of Filling Area
Filling area should be sanitized every night as the last step in cleaning bottling
area. The following procedure is recommended:
(1) Materials > Tank>type sprayer with 200 ppm chlorine;
(2) Procedure > After normal cleaning, spray entire floor with fine mist of chlorine
spray. Do not rinse chlorine>sanitized floor.
4.4.7 Filling, Capping, or Sealing
During the process of filling, capping or sealing containers, the performance of the filler,
capper or sealer is to be monitored. Filled containers are to be visually or electronically
inspected to assure they are sound, properly capped or sealed, coded and labeled.
Containers which are not satisfactory shall be reprocessed or rejected. Fillers must be
kept free from scale and evidence of oxidation and residue, and are to be sanitized on a
daily basis using the cleaning and sanitizing procedures specified in Section!4.4.6a. The
filler reservoir shall be kept covered at all times.
383>2126>303 / November 1, 1997 / Page III>59
In accordance with filler manufacturer's instructions, any parts which are not designed
to be cleaned in>place should be disassembled and removed. All of these parts are to be
cleansed and sanitized prior to reassembly using appropriate cleansing and sanitizing
procedures, as specified in Section!4.4.6a.
All surfaces of the filler which do not contact water are to be cleaned manually to render
all surfaces clean and free of any residues.
The filler should be prepared and all appropriate connections made in accordance with
the filler manufacturer's instructions to place the filler in the clean>in>place mode. To
prepare the filler, the following procedures should be followed:
a.
An alkaline cleaning solution of appropriate strength should be recirculated
through the filler to provide effective cleaning of all product contact surfaces,
with minimum recirculation time of 20 minutes at a temperature between 140∞F
and 170∞F;
b.
The cleaning solution must be drained and followed with a product water rinse>
to>drain for the removal of all residual cleaner. This step may be preceded by the
application of an acidified rinse prior to the product water rinse in order to
neutralize any residual alkalinity on the water contact surfaces.
Following reassembly of all parts, the filler is to be sanitized in>place in accordance with
procedures specified in Section!4.4.6a.
4.4.8 Quality Assurance Procedures
To assure that the production of retail drinking water is in compliance with DEP's
requirements, the facility should conduct the following tests. All tests must be
performed by laboratories certified by the DEP.
a.
Test for microbiological contaminants weekly and for all other primary maximum
contaminant levels annually. Source water from other than a public water system
should be analyzed for VOCs and unregulated contaminants annually. Facilities
which fluoridate shall conduct operational monitoring for fluoride at least once
each day. At least once each three months, a bacteriological swab and/or rinse
count should be made from no less than four containers and closures selected just
prior to filling and sealing. Three of the four samples should not exceed more
than one bacteria per milliliter of container capacity and not over one colony per
square centimeter of closure area, and should be free of coliform organisms.
4.4.9 Packaging
Packaging processes and materials shall not transmit contaminants or deleterious
substances to the bottled water and shall conform to the applicable food additive
regulations in CFR Title 21 and NSF Standard 61.
a.
Containers and closures for retail water must be manufactured from approved
materials.
b.
Only sanitary, nontoxic lubricants shall be used on container contact surfaces.
4.4.10 Storage Facilities
Clean, dry storage facilities must be provided for containers, closure materials, paper for
wrapping, adhesives and other production materials to prevent contamination. The
383>2126>303 / November 1, 1997 / Page III>60
materials are to be stored on pallets above the floor and away from any wall to facilitate
cleaning.
4.5
Personnel
The facility management shall take all reasonable measures and precautions to assure the
following:
A.
Cleanliness > All persons while working on retail water preparation facilities or
equipment which manufactures and packages retail drinking water should:
1.
Wear clean outer garments and maintain a high degree of personal cleanliness
while on duty;
2.
Wash their hands thoroughly in a proper hand>washing facility before starting
work, after each absence from the work station, and at any other time when the
hands may have become soiled or contaminated;
3.
Remove all jewelry;
4.
Maintain gloves, if used, in an intact, clean and sanitary condition. Such gloves
should be of an impermeable material except where their usage would be
inappropriate or incompatible with the work involved;
5.
Wear hair nets, headbands, caps, or other effective hair restraints;
6.
Consume food only in designated dining areas. Areas where product water
utensils or manufacturing equipment are stored shall not be designated as a
dining area;
7.
Not use tobacco in any form during production. Employees are to use tobacco
only in designated areas. An employee tobacco>use area shall not be designated
for that purpose if the use of tobacco may result in contamination of product
water, equipment, utensils, or other items needing protection;
8.
Take any other necessary precautions to prevent contamination of the product
water with microorganisms or foreign substances including, but not limited to,
perspiration, cosmetics, chemicals or medicines.
B.
Disease Control > No person affected by disease of a communicable form, or while
affected with boils, sores, infected wounds, or other abnormal sources of
microbiological contamination, shall be permitted to work in a retail water facility.
C.
Education and Training > The owners/operators of retail water facilities must provide
competent and properly trained staff to oversee the operation and routine maintenance
of the facility. Personnel are to be trained in the specific types of processes and
equipment used in their facilities. Those individuals operating reverse osmosis filters,
deionization units, or where chemicals are added to the water are to receive specific
training on the operation of these systems.
D.
Sanitizing Hands > It is essential for workers to keep hands clean when working on
"clean'' side of the facility. Hand>washing facilities should be conveniently located in the
bottling area. If no hand>washing stations are convenient, dip stations or sanitizer
should be provided.
383>2126>303 / November 1, 1997 / Page III>61
4.6
Operations and Maintenance Plan
Each retail water facility must develop an Operations and Maintenance (O & M) Plan which
includes a testing program covering the routine servicing of each treatment unit. Copies of the
service manuals containing cleaning and sanitization procedures, field testing procedures,
component replacement schedules and component servicing instructions are to be included in
the 0&M Plan. In addition, the O&M Plan should contain at least the following information:
A.
A description of the treatment processes used;
B.
A detailed explanation of the facilities normal operation procedures;
C.
Information on the frequency and procedures for maintaining and cleaning unit
process;
D.
Staffing and training;
E.
Records and reporting system;
F.
Safety program and emergency response plan;
G.
Manufacturer's manuals.
The O & M Plan should be reviewed and updated at least yearly and revised as necessary to
reflect changes in the operation and maintenance of the facility. The plan must be bound and
placed in locations which are readily accessible to the facilityπs personnel, and must be
presented upon request to the department.
4.7
Service and Maintenance
Where water dispensing machines are used, each machine is to be serviced at intervals
specified by the manufacturer. At each service, all interior parts and surfaces of the machine
are to be cleaned and sanitized in accordance with the service manual. All exterior surfaces are
to be well>maintained and visibly clean. A record of all cleaning and maintenance operations
shall be kept by the operator for each machine and is to be available for inspection upon
request.
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Commonwealth of Pennsylvania
Department of Environmental Protection
An Equal Opportunity Employer