O & M Manual for macoil 240 KLD
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Transcript of O & M Manual for macoil 240 KLD
OPERATION & MAINTENANCE MANUAL
FOR 240 KLD
EFFLUENT TREATMENT PLANT
Prepared To
M/S. MAC OIL PALM LIMITED
AMPAPURAM
Prepared By
SAI ENVIRO ENGINEERS PVT. LTD.
Flat No. 210, Challa Estate, Main Road, Erragadda,
Hyderabad – 500 018.
Phone No.: 040-65501128 TeleFax No.: 040-23801420
E-mail – [email protected]
1
INDEX
1. PREAMBLE
2. DESIGN BASIS
3. PROCESS DESCRIPTION
4. TECHNICAL SPECIFICATIONS
5. PROCESS START- UP & CONTROL
6. PREVENTIVE MAINTENANCE
7. EQUIPMENT MANUALS
8. DRAWINGS
2
PREAMBLE
3
PREAMBLE
The Effluent Treatment Plant has been designed to treat 240 KLD Effluent.
Salient features of treatment plant:
1. The treatment plant consists of Physical and biological processes. The biological process
consists of double stage anaerobic & aerobic systems.
2. For aeration, Diffused Aeration System with imported Diffusers and Air Purging Grids are
provided. Air is supplied through a twin lobe Air Blower of required capacity. This system
ensures fine bubble dispersion and better Oxygen transfer efficiency.
4
DESIGN BASIS
5
I) FLOW : 240 M3/DAY
II) RAW EFFLUENT CHARACTERISTICS:
Parameter Unit Effluent
Inlet
Flow m3/hr 10
PH - 3.0 to 4.0
TSS mg / lt. 10000
TDS mg / lt. 15000
COD mg /lt. 60000
BOD (3 days@ 27 ˚ C) mg /lt. 25000
Oil & Grease mg /lt. 4000
III) TREATED EFFLUENT CHARACTERISTICS:
Parameter UNIT Effluent
Outlet
PH - 7.0 – 8.0
TSS mg /lt. < 100
COD mg /lt. < 250
BOD (3 days @ 27deg C ) mg /lt. < 30
Oil & Grease mg /lt. < 10
6
PROCESS DESCRIPTION
7
ETP PROCESS DESCRIPTION
Effluent coming from the plant shall be collected in oil & fat removal tank. With the help of
mechanical scraper, oil & fat shall be removed and collected in a collection tank. From this unit
effluent flows to the collection cum equalisation tank. Mixing arrangement shall be provided in
equalisation tank. From equalisation tank, effluent shall be transferred by pumping to the flash
mixer unit. Chemical solutions are mixed in the tank which facilitates neutralisation of pH and for
coagulation of suspended solids. Effluent flows to the primary clarifier, where suspended solids get
removed. Sludge settled in the primary clarifier is pumped to the sludge drying beds. Overflow
from primary clarifier goes to Dissolved Air Flotation (DAF) system for separation of suspended
solids and oil & fat if any. Outlet from DAF unit collected in Anaerobic Reactor (AR) feed tank
from where the effluent is fed to biological system. Sludge from the DAF system is taken to the
sludge drying beds.
BIOLOGICAL TREATMENT
Oil & fat free effluent shall be pumped to anaerobic fixed film digester from feed tank. Major part
of organic load shall be removed here. The anaerobic organisms will degrade the high concentrated
organic matter present in the effluent. In this digester plastic media is used as a medium for
attachment of microorganisms, which will in turn convert the complex organic matter into simple
compounds like methane gas, CO2 & H2O. Overflow from this unit is treated at second stage
aerobic system. Aerobic treatment system comprises of two stage activated sludge process (ASP).
Outlet from anaerobic digester shall be further treated aerobically.
Necessary safety devices shall be provided to anaerobic digester to handle biogas generated from
the system. One number of Biogas flare system shall be provided to flare the gas generated from
the digester.
ASP SYSTEM-TWO SATGE -SERIES
8
Activated sludge process system comprises of aeration tank followed by secondary clarifier. In
aeration tank organic load as BOD shall be degraded by the help of cultivated microbial culture.
Constant mixed liquor suspended solids (MLSS) will be maintained in aeration tank in definite
proportions by recycling the bio sludge trapped by the secondary clarifier. At aeration tank air shall
be supplied from air blower to the diffused aeration system. Floating type aerators are also provided
at lagoons for the supply oxygen to microorganisms.
From dosing tank, nutrients like nitrogen & phosphorous shall be added to the effluent at aeration
tank in the ratio of BOD: N: P as 100: 5: 1
Recycling of bio-sludge from secondary clarifier shall be done by non-clog, centrifugal, semi open
type continuous duty & suitable capacity sludge re circulation pump. The overflow from secondary
clarifier –II shall be collected in supernatant tank where chlorine solution shall be added to kill
pathogenic micro-organisms. From here effluent shall be fed to Duel Media Filter with the help of
pressure pumps to trap suspended solids and the treated effluent flows to Activated Carbon Filter
where odour, residual chlorine etc. shall be removed. Outlet from carbon filter shall be collected in
polishing pond. Treated water meets the norms prescribed by the pollution control board for safe
disposal for on land Irrigation / Green Belt Development.
The excess sludge from the DAF, primary & secondary clarifiers shall be withdrawn by gravity to
sludge drying beds for dewatering. Dewatered and dried sludge cakes shall be used as good
manure.
9
TECHNICAL
SPECIFICATIONS
10
1.0. UNITS & EQUIPMENTS OF E.T.P.
1.1. CIVIL UNITS
SR.NO PARTICULARS QUANTITY
1. Oil & Fat Removal Tank and Collection Tank One No.
2. Equalization & Collection Tank Existing
3. Flash Mixer Tank One No.
4. Primary Clarifier Existing
5. Feed Tank Existing
6. Anaerobic Digester One No.
7. Anaerobic Lagoon Existing
8. Aeration Tank – I Existing
9. Secondary Clarifier - I Existing
10. Aeration Tank – II One No.
11. Secondary Clarifier - II One No.
12. Supernant Tank One No.
13. Polishing Pond Existing
14. Sludge Drying Beds Four Nos.
15. Pumps & Mechanical unit Foundations Lot.
16. MCC Room One No.
1.2. MECHANICAL UNITS / EQUIPMENTS
SR.NO. PARTICULARS QUANTITY
1. Oil & Grease Removal Mechanism One No.
2. Effluent Transfer Pump (1 W+1 Sb) Two Nos.
3. Flash Mixer Existing
4. Chemical Dosing Systems Three Nos.
5. Primary Clarifier Mechanism Existing
6. PC Sludge Pumps (1 W+1 Sb) Existing
7. DAF System One No.
8. Air Compressor One No.
9. Pressure Pump One No.
11
10. AR Feed Pump (1 W+ 1 Sb) Two Nos.
11. Bio-fills 1200 M3
12. AD Recycling Pump (1 W+1 Sb) Two Nos.
13. Floating Aerators Four Nos.
14. Secondary Clarifier Mechanism – I One No.
15. SC Recycling Pump (1 W+1 Sb) - I Two Nos.
16. Nutrient Dosing Systems Four Nos.
17. Air Blowers (1 W+1 Sb) Two Nos.
18. Air Diffuser 47 Nos.
19. Secondary Clarifier Mechanism One No.
20. SC Recycling Pump (1 W+1 Sb) Two Nos.
21. Chlorine Dosing System One No.
22. Pressure Pump (1 W+1 Sb) Two Nos.
23. Pressure Sand Filter One No.
24. Activated Carbon Filter One No.
1.3. INSTRUMENTATION
SR. NO. PARTICULARS QUANTITY
1. Liquid Flow Meter One No.
2. Moisture Trap One No.
3. Gas Flare Stack One No.
4. Flame Arrester One No.
5. Pressure Relief Valve One No.
12
2.0. TECHNICAL SPECIFICATIONS FOR UNITS & EQUIPMENTS
A. CIVIL UNITS
1. OIL & FAT SEPERATION & COLLECTION TANK
Type : Rectangular
Volume : Separation Tank – 13.5 M3
Collection Tank – 4.5 M3
Size : 1500mm x 7500mm x 1200mm SWD + 300 mm FB
1500 mm x 1500 mm x 2000 mm SWD + 300 mm FB
Construction : R.C.C. M20 & MS EP
Quantity : One No.
2. EQUALISATION & COLLECTION TANK
Type : Rectangular
Volume : 170 M3
Size : 9450 mm x 6000mm x 3000mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.
3. FLASH MIXER TANK
Type : Square
Volume : 10 M3
Size : 2000 mm x 2000mm x 2500mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.
4. PRIMARY CLARIFIER
Type : Circular
Volume : 37 M3
13
Size : 4000 mm dia. x 3000mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.
5. FEED TANK
Type : Square
Volume : 179 M3
Size : 8000 mm x 8000mm x 2800mm SWD + 300 mm FB
Construction : RCC M 20
Quantity : One No.
6. ANAEROBIC REACTOR
Type : Circular, Closed
Volume : 1800 M3
Size : 16000 mm x 9000 mm SWD + 1000 mm FB.
Construction : R.C.C M 20
Quantity : One No.
7. ANANEROBIC LAGOON
Type : Rectangular
Volume : 3500M3
Surface Area : 26000 x 51800
Construction : R.C.C M 20
Quantity : One No.
8. AERATION TANK - I
Type : Rectangular
Volume : 2400 M3
Surface Area : 20000 x 50000
Construction : R.C.C M 20
14
Quantity : One No.
9. SECONDARY CLARIFIER - I
Type : Circular
Volume : 34 M3
Size : 4000 mm dia. x 2700mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.
10. AERATION TANK - II
Type : Rectangular
Volume : 500 M3
Size : 12000 x 12000 x 3500mm SWD + 300 FB
Construction : RCC M 20
Quantity : One No.
11. SECONDARY CLARIFIER - II
Type : Circular
Volume : 51 M3
Size : 5100 mm dia. x 2500mm SWD + 300 mm FB
Construction : RCC M 20
Quantity : One No.
12. SUPERNATANT TANK
Type : Square/Rectangular
Construction : R.C.C M 20
Capacity : 11 M3
Size : 2100 x 2100 x 2500mm SWD + 300FB
Quantity : One No.
15
13. SLUDGE DRYING BEDS
Type : Square/Rectangular
Total Area : 25M2
Size : 5000 x 5000 mm
Construction : BBM
Quantity : 10 Nos.
14. POLISHING POND
Type : Rectangular
Volume : 2750 M3
Surface Area : 22000 x 51000
Construction : R.C.C M 20
Quantity : One No.
B. MECHANICAL UNITS
I) OIL & FAT REMOVAL MECHANISM
Application : To scrap the floatable Scum, Oil & Fat etc.
Location : Oil & Fat Removal Tank
Type : Semi automatic & scraping type.
Gear / Motor : Elicon & Siemens
Rated power : 0.5 HP
Make : EEC
Quantity : One No.
Motorized trolley with four wheels anti friction bearing, travel too & fro on MS rails,
16
having electrical limit switches on either side. Neoprene rubber lined skimmer plate is
provided. Control panel consist of air break reversing contractors, timer etc. Push button ,
flexible cable and drive system with geared motor.
II) EFFLUENT TRANSFER PUMP
Application : Effluent Transfer to Flash Mixer Tank
Location : At Equalization tank
Capacity : 10 M3 /Hr.
Drive : 2.0 HP
Motor Make : Siemens
Pump Make : Johnson
MOC : Internal SS
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : Two Nos. (1W+1Sb)
III) FLASH MIXER
Application : Effluent & Chemicals Mixing at Flash Mixer
Tank
Location : At Flash Mixer Tank
Type : Slow Speed
Drive : 2.0 HP
Motor Make : Siemens
Agitator Make : EEC
MOC : SS
Quantity : One No.
IV) CHEMICAL DOSING SYSTEM
Application : Dosing of Chemical Solutions (Lime /Alum
/Polyelectrolyte)
17
Location : Near Flash Mixer Tank
MOC : HDPE
Capacity : 1000Lit (1No.) / 500 Lit.(2 Nos.)
Pump Capacity : 0 to 100 LPH (1No) / 0 to 50 LPH (2 Nos.)
Drive : 0.5 HP
Make : SR Metering
Quantity : Three Nos.
V) PC MECHANISM
Application : To scrap the settled sludge at the bottom of
clarifier
Location : At Primary Clarifier.
Size : Suitable to Clarifier
Access Bridge : Diametric bridge with 5 mm thick chequered
plates up to centre with hand railing.
Drive : Centre drive gear through chain & sprocket
with motor coupled with gearbox.
Motor : 1 HP , Crompton / Equivalent make, TEFC ,
squirrel cage AC electrical weather proof
motor 3 phase, 415 V, 50 Hz, AC supply, IP
55 protection, class F insulation, rated for
continuous duty.
Gear : Elicon /Shanti make gear box.
Chain & Sprocket The suitable pitch of chain having TI
diamond make with cast steel sprocket
Scraping : MS - epoxy painted scrapper shaft, heavy-
pipe construction, coupled to the drive
housing. MS- epoxy painted scraper arms
of structural frame work complete with
blades to sweep the tank bottom twice
per revolution provided with neoprene
rubber squeezes to collect the sludge at the
centre point.
18
Feed well : MS-epoxy painted feed well, Supported
from the bridge ,with baffle plate.
Painting : MS with under water parts epoxy painted
with two coats whereas parts above
water synthetic enamel painted.
Quantity : One No.
VI) PC SLUDGE PUMP
Application : Sludge removal from PC
Location : At PC
Type : Self priming , Centrifugal, non-clog,
Semi - open impeller
Capacity : 10 M3 / Hr x 10 M. Head
Drive : 2.0 HP ( each ) motor , 3 phase , 2900
rpm, TEFC class ‘F’ insulation with
IPP 55 protection, weather proof.
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling
guard, foundation bolts etc.
Quantity : Two Nos.(1W+1Sb)
VII) DAF SYSTEM
Capacity : 10 M3 /Hr.
Drive : 0.5 HP geared motor
Recirculation Pump : 4.0 M3/Hr., 65 mtr. Head. @ 2 HP
MOC : MS
Air Mixing : Air mixing Tube
Air Compressor & Drive : 1.0M3/Hr. @ 6.5 kg/cm2 pressure , 1HP
Dosing Tank : One No. 100 ltrs HDPE
Dosing Pumps : One No. 0.25 HP
19
Quantity : One No.
VIII) ANAEROBIC REACTOR FEED PUMP
Application : Effluent Feed to Anaerobic Reactor
Location : At Feed Tank
Type : Self priming , Centrifugal, non-clog, Semi-
open impeller
Capacity : 10 M3 / Hr x 15 M. Head
Drive : 3.0 HP (each ) motor , 3 phase , 2900 rpm,
TEFC class ‘F’ insulation with IPP 55
protection, weather proof.
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : Two Nos.(1W+1Sb)
IX) AR RECYCLING PUMP
Application : Effluent recirculation at Anaerobic
Reactor
Location : Anaerobic Reactor
Type : Self priming , Centrifugal, non-clog, Semi-
open impeller
Capacity : 10 M3 / Hr x 15 M. Head
Drive : 3.0 HP ( each ) motor , 3 phase,
2900 rpm, TEFC class ‘F’
insulation with IPP 55
protection, weather proof.
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
20
foundation bolts etc.
Quantity : Two Nos.(1W+1Sb)
X)
BIO-FILLS
Application : Medium for Bacterial growth
Location : Anaerobic Digester
MOC : PVC
Make : Cooldek
Voidage : 97%
Size : 1200 x 600 x 600 mm
Quantity : 1200 cu.mt.
C. INSTRUMENTAION
1) PRESSURE GAUGE
Type : Diaphragm
Size : 100 NB
2) MOISTURE TRAP
Quantity : One No.
Application : To trap the moisture
Location : Gas pipeline
MOC : MS epoxy
Size : 80 NB
3) FLAME ARRESTOR
Quantity : Two Nos.
21
Application : To arrest flames
Location : Gas pipeline / Top of the Digester
Size : 80 NB
MOC : SS
4) PRESSURE RELIEF VALVE
Quantity : Two Nos.
Application : To relieve pressure
Location : Top of the Digester
Size : 80 NB
MOC : CI
5) GAS FLARE STACK
Quantity : One No.
Application : To flare the biogas
Location : At one corner of ETP plant
MOC : MS & SS
Size : 80 NB
6) LIQUID FLOW METRE
Quantity : One No.
Application : Flow measurement
Location : Feed line
Capacity : 0 TO 15 CU.MT./HR.
Type : ELECTROMAGNETIC
Make : E & H
XI) FLOATING AERATORS
22
Application : Mixing & Aeration
Make : EEC
Air Flow : 1800 M3/Hr.
Delivery Pressure : 0.40 kg/cm2
Type : Floating
MOC : MS-FRP
Motor HP : 15 HP (2 Nos.) & 30 HP (2 Nos.)
RPM : 75
Location : At Aeration Tank-I
Quantity : Four Nos.
XII)
SC MECHANISM - I
Application : To scrap the settled sludge at the bottom of
clarifier
Location : At Secondary Clarifier-I.
Size : Suitable to Clarifier
Access Bridge : Diametric bridge with 5 mm thick chequered
plates up to centre with hand railing.
Drive : Centre drive gear through chain & sprocket
with motor coupled with gearbox.
Motor : 1 HP , Crompton / Equivalent make, TEFC ,
squirrel cage AC electrical weather proof
motor 3 phase, 415 V, 50 Hz, AC supply, IP
55 protection, class F insulation, rated for
continuous duty.
Gear : Elicon /Shanti make gear box.
Chain & Sprocket The suitable pitch of chain having TI
diamond make with cast steel sprocket
Scraping : MS - epoxy painted scrapper shaft, heavy-
pipe construction, coupled to the drive
housing. MS- epoxy painted scraper arms of
structural frame work complete with
23
blades to sweep the tank bottom twice
per revolution provided with neoprene
rubber squeezes to collect the sludge at the
centre point.
Feed well : MS-epoxy painted feed well, supported from
the bridge with baffle plate.
Painting : MS with under water parts epoxy painted with
two coats whereas parts above water synthetic
enamel painted.
Quantity : One No.
XIII)
SC BIO - SLUDGE RECYCLING PUMP- I
Application : Sludge recycling from SC-I to AT-I
Location : At SC-I
Type : Self priming , Centrifugal, non-clog, Semi-
open impeller
Capacity : 10 M3 / Hr x 10 M. Head
Drive : 2.0 HP (each) motor, 3 phase, 2900 rpm,
TEFC class ‘F’ insulation with IPP 55
protection, weather proof.
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : Two Nos.(1W+1Sb)
XIV) AIR BLOWER
Medium Handled : Air
Make : Everest
Air Flow : 750 M3/Hr.
24
Delivery Pressure : 0.40 kg/cm2
Duty : Continuous
Cooling : Air Cooled
Drive : 20 HP
Motor Make : Siemens
Accessories : All accessories as per requirement
Location : Near Aeration Tank-II
Quantity : Two Nos. (1 W +1Sb)
XV) DIFFUSERS & AIR PURGING GRID
Type : Membrane type air diffuser
Make : Rehau, Germany
Size : 63 mm OD x 2000 mm length
Capacity : 16 M3/Hr.
Distribution : Air distribution channel extending over
the effective length guarantees an even
distribution of air.
Quantity : 47 Nos.
XVI) SC MECHANISM – II
Application : To scrap the settled sludge at the bottom of
clarifier
Location : At Secondary Clarifier-II
Size : Suitable to Clarifier
Access Bridge : Diametric bridge with 5 mm thick chequered
plates up to centre with hand railing.
Drive : Centre drive gear through chain & sprocket with
motor coupled with gearbox.
Motor : 1 hp , Crompton make, TEFC , squirrel cage AC
electrical weather proof motor 3 phase,
415 V, 50 Hz, AC supply, IP 55 protection,
25
class F insulation, rated for continuous duty.
Gear : Elicon /Shanti make gear box.
Chain & Sprocket The suitable pitch of chain having TI
diamond make with cast steel sprocket
Scraping : MS - epoxy painted scrapper shaft, heavy-
pipe construction, coupled to the drive housing.
MS- epoxy painted scraper arms of
structural frame work complete with blades to
sweep the tank bottom twice per
revolution provided with neoprene rubber
squeezes to collect the sludge at the centre
point.
Feed well : MS-epoxy painted feed well, supported from the
bridge, with baffle plate.
Painting : MS with under water parts epoxy painted with
two coats whereas parts above water synthetic
enamel painted.
Quantity : One No.
XVII) SC BIO- SLUDGE RECYCLING PUMP- II
Application : Sludge recycling from SC-II to AT-II
Location : At SC-II
Type : Self priming , Centrifugal, non-clog, Semi-
open impeller
Capacity : 10 M3 / Hr x 10 M. Head
Drive : 2.0 HP (each) motor, 3 phase, 2900 rpm,
TEFC class ‘F’ insulation with IPP 55
protection, weather proof.
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : Two Nos.(1W+1Sb)
26
XVII) NUTRIENT DOSING SYSTEM
Application : Dosing of Nutrients
Location : Aeration Tank-I & II
Capacity : 500 Lit.( each )
Dosing : by pumping.
Make : SR Metering
Pump Capacity : 0 to 20 LPH
Type of pump : Electronically Actuated
Quantity : Four Nos.
XIX) CHLORINE DOSING SYSTEM
Application : Dosing of Chlorine
Location : Supernatant Tank
MOC : HDPE
Capacity : 500 Lit.( each )
Pump Capacity : 0 to 30 LPH
Type of pump : Electronically actuated
Make : SR Metering
Quantity : One No.
XX) PRESSURE PUMP
Application : Feed to Pressure Filter
Type : Monoblock
Capacity : 11 M3 /Hr Head 30 mtr.
Drive : 5.0 HP
Pump Make : CI
Quantity : Two Nos. (1W+1Sb)
XXI) DUEL MEDIA SAND FILTER
27
Application : For removing Residual solids
Type : Cylindrical, Vertical
Capacity : 11 M 3 /Hr
MOC : MS epoxy
Media : Sand, Pebbles, Anthracite .
Make : SAI
Quantity : One No.
XXII) ACTIVATED CARBON FILTER
Application : For removing Residual Organic Matter
Type : Cylindrical, Vertical
Capacity : 11 M3 /Hr
MOC : MS epoxy
Media : Activated Carbon
I.V of Carbon : > 800
Make : SAI
Quantity : One No.
28
3.0 ELECTRICAL LOAD LIST
Sl. No. PARTICULARS Quantity Each
Load as HP
Total
Load as HP
1. Oil & Grease Removal Mechanism 1 0.5 0.5
2. Effluent Transfer Pump (1 W+1 Sb) 2 2.0 4.0
3. Flash Mixer 1 2.0 2.0
4. Chemical Dosing Systems 3 0.5 1.5
5. Primary Clarifier Mechanism 1 1.0 1.0
6. PC Sludge Pumps (1 W+1 Sb) 2 2.0 4.0
7. DAF System 1 0.5 0.5
8. Air Compressor 1 1.0 1.0
9. Pressure Pump 1 2.0 2.0
10. AR Feed Pump (1 W+ 1 Sb) 2 3.0 6.0
11. AD Recycling Pump (1 W+1 Sb) 2 3.0 6.0
12. Floating Aerators 4 15 HP &
30 HP
30.0
60.0
13. Secondary Clarifier Mechanism – I 1 1.0 1.0
14. SC Recycling Pump (1 W+1 Sb) - I 2 2.0 4.0
15. Nutrient Dosing Systems 4 220 volts
16. Air Blowers (1 W+1 Sb) 2 20.0 40.0
17. Secondary Clarifier Mechanism 1 1.0 1.0
18. SC Recycling Pump (1 W+1 Sb) 2 2.0 4.0
19. Chlorine Dosing System 1 220 volts
20. Pressure Pump (1 W+1 Sb) 2 5.0 10.0
Working Load : 83.0 H.P (62.25 KW)
Total Load : 178.5 H.P (133.5 KW)
(There are standby pumps & blowers
29
PROCESS START-UP
&
CONTROL
30
PROCESS START-UP and CONTROL
As the effluent does not contain organisms to stabilize the Organics present in the effluent it is
necessary to develop sufficient microbial mass or activated sludge in the aeration tank.
PRE-COMMISSIONING TESTS
The process is to be started with properly prepared cow dung solution for the microbial growth. Addition of
sewage directly also help for the growth of bacteria.
Before a new plant is commissioned it is necessary that all operational and maintenance personnel should
understand the function and location of each process unit, mechanical equipment and rooting of the
pipelines. Following checks should be made before the commissioning of the plant.
All the mechanical equipments are to be tested for good working condition, properly lubricated.
All the tanks and piping are to be clean to ensure from any chocking.
All the process units and mechanical Equipments should be tested with water for any leakages and
load testing of equipments including motor directions.
Check all the instruments for normal operation.
Check all the interlocks if any for proper tripping.
ROUTINE INSPECTION
Remove accumulation of foreign material from the inlet channel and outlet overflow weirs
regularly.
All the vertical walls and channels should be cleaned regularly.
All the mechanical equipment should be inspected regularly for oil levels in the gearboxes and for
any abnormal sound and vibrations. Foundation bolts and coupling bolts are to be checked.
Inspect sludge collection and other equipments annually for the induction of corrosion.
Check the alignment of equipments incase of any noise or foul operation.
Check oil & grease for equipments
EMERGENCY INSPECTION
31
In case of serious problem with any unit, feeding should be stopped immediately to that unit. Remove all the
waste water from the unit and inspect carefully the structure, unusual deposition if any and all moving parts
of the equipments. Once the inspection is completed run the equipment in idle condition and check for any
abnormalities. Once it is clear the equipment can be taken back in to operation.
PLANT START UP
Before starting the plant, it is essential that performance of the equipments shall be checked for proper
functioning and for any equipment abnormalities.
a. No Load Run of Motors
This is required to be carried out to ensure that the motors are running smoothly without any problems. To
carry out the inspection of motors, disconnect the coupling/belts. Then the motors shall be kick started and
stopped to observe their direction of rotation. If the direction is anti-clock wise the terminal box shall be
opened to change the phase connections. The motors shall run for about 30 min on no load to check for any
abnormality. During this run, one shall observe no load current of motors, vibrations, noise and bearing
temperature for signs of any defects. If no abnormality is observed, then motors shall be coupled with
equipments for testing on onload. If any defect is observed immediately inform to the supplier/manufacturer
for repair/replacement of the motor.
b. On Load Trail
All the equipments shall be tested onload with normal water before admitting effluent in to the system. If
any abnormality is observed, it shall be taken care before admitting the effluent. During trial runs with
water, motor load and temperature, bearing conditions and vibrations shall be observed.
c. Plant Shut Down
In case plant needs to be shut down for a considerable period of time, following should be observed.
Effluent feed shall be stopped to ETP and divert the flow to stand by storage tanks as per requirement. All
the effluent from the system shall be pumped out/drained and all the tanks shall be cleaned/washed.
PROCESS
The following procedure shall be followed for starting up the biological system:
32
Aerobic System
Aerobic reactor shall be filled with reactor. Sufficient culture (Sludge or cow dung solution) shall be added.
Aeration shall be started with blowers to provide oxygen to the attached microorganisms. Initially feed shall
be started with 2% and wait for 3 days. The condition shall be observed for a positive response then increase
the feed to 5%. Then wait for another 3 days and gradually increase the feed rate@10% for every 3 days.
During this process bacterial growth should be checked regularly and if any abnormalities are observed
immediately feed shall be stopped for some time and observe the conditions if conditions get stabilized
admit the effluent. MLSS and SVI shall be monitored regularly. Air blowers should run continuously. Once
the growth is observed feed the nutrient as per required.
Anaerobic System
Anaerobic reactor shall be filled with reactor. Sufficient culture (Sludge or cow dung solution) shall be
added. Aeration shall be started with blowers to provide oxygen to the attached microorganisms. Initially
feed shall be started with 2% and wait for 3 days. The condition shall be observed for a positive response
then increase the feed to 5%. Then wait for another 3 days and gradually increase the feed rate@10% for
every 3 days. During this process bacterial growth should be checked regularly and if any abnormalities are
observed immediately feed shall be stopped for some time and observe the conditions if conditions get
stabilized admit the effluent. MLSS and SVI shall be monitored regularly. Air blowers should run
continuously. Once the growth is observed feed the nutrient as per required.
Asp Process Control
Activated Sludge Process comprises of Aeration tank followed by Secondary Clarifier, which shall be
proposed to meet the requirements. In aeration tank organic load as BOD will be degraded by the help of
cultivated microbial culture. Constant Mixed Liquor Suspended Solids (MLSS) shall be maintained in
aeration tank in definite proportions by recycling the bio sludge trapped by the secondary clarifier. At
aeration tank air supplied from air blower/diffused aeration and also floating type aerators shall be provided
to supply oxygen to microorganisms.
From dosing tank, nutrients as Nitrogen & Phosphorous shall be added to effluent at Aeration Tank at the
ratio of BOD: N: P as 100: 5: 1
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Recycling of bio-sludge from secondary clarifier shall be done by non-clog, centrifugal, semi open type
continuous duty & suitable capacity sludge re circulation pump. The overflow from secondary clarifier –II
shall be collected in supernatant tank where chlorine solution shall be added to kill pathogenic micro-
organisms. From here effluent fed to Duel media pressure filter with the help of pressure pumps to trap
suspended solids and connected to Activated Carbon Filter to remove odour, residual chlorine etc. Outlet
from carbon filter shall be treated water & collected in polishing pond. Treated water meets the norms
prescribed by the pollution control board for safe disposal for on land irrigation / green development.
The excess sludge from DAF, Primary & Secondary Clarifiers shall be withdrawn by gravity to sludge
drying beds for dewatering. Dewatered and dried sludge cakes shall be used as good manure.
Constant Solids or MLSS
MLSS should be determined by taking a representative sample at three or more locations in the aeration
tank, so that it represents the mixed liquor in the tank.
F/M ratio
Load is measured by BOD or COD tests. COD test needs shorter time than that of BOD test. Once in the
laboratory COD/BOD ratio is established by a series of daily experiments for a period of one month or so,
BOD can also be calculated by the ratio of COD/BOD.
Micro organisms are measured as MLVSS (Mixed Liquor volatile suspended solids). However MLSS can
also be used.
Measuring MLSS is an even cruder approximation of the living organic matter than measuring MLVSS
MLVSS is normally 70-80% of the MLSS. The following data is required to calculate F/M ratio.
BOD concentration, mg/l in waste water flowing to the aeration tank
Q, flow rate, m3 /day
MLVSS in mg/l
The following formula is used to calculate F/M ratio
F/M ratio = (BOD, mg/l) * (Q, m3/day)
(MLVSS, mg/l) * V, m3
Where, V = aeration tank volume, m3
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Sludge Volume Index (SVI)
Settled sludge volume reading
SVI = on 1 liter graduated cylinder
After 30 minutes X 1000
MLSS concentration
SVI range usually 100 to 150: although higher values may provide good plant operation
Any changes in SVI reading are more important than the reading itself.
If the SVI increases, this means slower settling and it could indicate
- A decreasing sludge age
- Presence of filamentous organisms
- Or changing whether conditions.
SVI can be decreased by reducing by draining of the sludge.
If the SVI decreased (less than 100), there will be pin point flock in the supernatant. This is small flow that
is left behind the rest of sludge settled too fast. It is called stragger floc.
Settling Tank – Sludge Return
Settling tank serves a dual purpose in the activated sludge process; viz. it provides a clarified effluent and it
also concentrates the MLSS for its return to aeration tank.
To ensure that settling tank is working effectively.
Check F/M ratio. BOD and COD test results from samples taken over several days should be used
for calculation.
Compare the F/M ratio with obtained in the past and watch for changes.
Check oxygen uptake rate. If it is increasing or decreasing, change RAS (Return Activated Sludge).
Changes in RAS must be gradual.
Return of Activated Sludge
RAS is determined using solid balance equation.
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RAS = Plant flow X MLVSS
Return solids – MLVSS consent
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PREVENTIVE
MAINTENANCE
37
PREVENTIVE MAINTENANCE
EMERGENCY INSPECTION
In case of serious problem with any unit, feeding should be stopped immediately to that unit. Drain all the
waste water from the unit and inspect carefully the structure, unusual deposition, each and every part,
mechanical equipment attached to that unit, etc. All the mechanical equipment should be made in good
working condition. The unit should be cleaned properly before making the same operational again.
PREVENTIVE MAINTENANCE
The main purpose of preventive maintenance is to avoid break-downs of equipments so as to minimize the
shut down timings. The preventive maintenance shall help in reducing the cost of break-downs and
operational time.
Preventive maintenance of equipment supplied is to be carried out as per the manufacturer’s operation
manuals for this equipment. Specific guidelines for preventive maintenance for major equipment are
suggested in the table below. These guidelines should be adhered wherever applicable.
PREVENTIVE MAINTENANCE SCHEDULE
Sr.
No
Equipment Maintenance Frequency
01. Centrifugal
Pumps
a. Alignment Check
b. Oil Check / Refill
c. Gland Tightening/ Replacement
d. Chocking Clearance
At Commissioning Stage /
Quarterly
Weekly
Weekly
Quarterly / Monthly / As Required
02. Air Blowers a. Alignment Check
b. Oil Check / Refill
c. V–Belt Tightening/Replacement
d. Suction Filter Cleaning
At Commissioning Stage / Monthly
Weekly
Weekly
Monthly / As Required
03. Dosing Tanks Emptying and Cleaning Quarterly
04. Electrical
Connections
Routine Check Half Yearly
All butterfly valves shall be lubricated and operated regularly for easy operation.
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In case of any abnormal sound, vibrations, temperatures in rotating equipment, the same shall be
stopped immediately and check for gear box oil level, bed and foundation bolts, coupling bolts and
Impeller/rotors conditions.
Plant operator shall monitor the amperage/low voltage regularly and motors may be stopped in case
voltage falls below 380.
Spare parts for the equipment that are recommended by the manufacturer shall be kept in stock for
ready use.
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DRAWINGS
40
LIST OF DRAWINGS ENCLOSED
1. ETP Process Flow Diagram
2. ETP Layout Diagram
3. P & I Diagram
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