Operation and Maintenance Manual For

Effluent Treatment Plant

40 KLD
Client
M/s. PIDILITE INDUSTRIES LTD KALAMB
Supplied by

WTE INFRA PROJECTS PVT LTD

 PAP-S-77 , Near Bridgestone Company , MIDC Phase II, Chakan Road,
Sawardari, Maharashtra 410501

E - MAIL: contact@watertreatmentindia.net

1
 INDEX

SR.NO. CHAPTER NAME PAGE NO.

1 INTRODUCTION 03

2 PROCESS DESCRIPTION 05

3 EQUIPMENT DETAILS 11

4 SCHEMATIC FLOW CHART 21

5 PRE COMMISSIONING 25

6 PLANT START UP 32

7 MAINTAINENCE 38

8 SAFETY 47

2
CHAPTER I
INTRODUCTION
Overview
The main reason that we developed the water recycle system is to protect human
health. The technology available to do this has become more efficient and
effective over the years and new methods are still being found today.
We treat Raw Effluent to-
 Avoid drinking water contamination
 Avoid food contamination
 Avoid ecological damage via eutrophication
This manual provides guidelines for operation and maintenance of Effluent
Treatment plant. It provides starting operation and maintenance of equipment
supplied for the plant. Do read through the guidelines in this manual prior to
actual start of the plant.

Nature of Waste Water Effluent

Flow 40 m3 /day / Average
Operating Period 16hrs /day

Design Parameters
A. INLET PARAMETERS

Sr. No. Parameters Unit Results

1 pH - 4-9
2 TSS mg/lit <50
3 Turbidity mg/lit < 50
4 TDS mg/lit < 8000
5 Hardness mg/lit < 3000

3
 B. OUTLET WATER QUALITY

Sr. No. Parameters Unit Results

1 pH - 6.5-7.5
2 TSS mg/lit <5
3 Turbidity mg/lit <5
4 TDS mg/lit <8000

ASSUMPTIONS
1. The plant is designed to operate at +/- 10 % variation in raw wastewater
parameter.
2. No other parameters other than mentioned above is present in the raw
waste water which is beyond Pollution Control Norms and hazardous to
microorganisms.
3. Treated water quality will be achieved if the inlet raw water quality is as
per the raw water quality mentioned as well as no other pollutant than the
mentioned, is present or exceeds the limits or which is hazardous in
nature, which otherwise may affect the biological treatment process.

4
CHAPTER II
PROCESS DESCRIPTION
To have eco-friendly & natural treatment, this plant is designed based on the
biological treatment concept. This means naturally occurring microbes (which
are present in sewage water itself) removes or degrade the organic matter
present in the sewage & at the end clean water is available for the non-potable
usage or to dispose safely in the drainage or river bodies as per the norms.

1. Pre – Treatment

Screening: This is the first units of the plant in which large or floating
materials in the sewage gets arrested and blockage or choking of the
downstream equipment’s can be avoided. This arrested material will be
removed manually and then will be disposed off suitably.

Equalization: To absorb variation in quantity and quality of grey water and to

provide uniform flow at the downstream treatment process, a collection or
equalization tank is provided. This will avoid shock loading and process upsets
of the treatment plant. To avoid settling of suspended solids in this tank,
continues air agitation is provided.

If at site, septic tank is provided then collection tank as well as air agitation is
not required.

Transfer Pumps transfer the wastewater from equalization tank or lift station to
the process tank. The transfer pumps are automatically activated by the Level
Switch in a lead/lag arrangement according to the level in the tank.

Neutralization: Neutralization system is provided to neutralize the effluent

using lime slurry (10 %) or soda ash.

5
 2. Secondary Treatment

Flash Mixer:
A flash mixer is a chamber that contains mechanical stirrers, which is designed
to assure fast, thorough, mixing of lime and alum for the purpose of creating
floc.
After screening out debris and testing the raw water, water treatment really
begins at the flash mix chamber. Here, chemicals are added to the water,
primarily to aid in coagulation and flocculation. In the flash mixer, the water is
agitated violently for a short period of time before being released into the
flocculation basin.

Flocculator:
Flocculation requires gentle mixing and the use of a high molecular weight
polymeric flocculant. The flocculant adsorbs to the submicron flocs and
facilitates bridging of gaps between flocs. Bringing particles closer together
creates the effective range for Van Der Waals attraction forces to reduce the
energy barrier for flocculation and loosely packed flocs form. Aggregation,
binding, and strengthening of flocs occurs until visibly suspended macroflocs
form. At the right weight, size, and strength sedimentation occurs. Macroflocs
are very sensitive to mixing and once torn apart by strong shear it is difficult or
impossible for them to reform.

Flocculation happens naturally during the formation of snowflakes or subsea

sediments but it is also deliberately applied in the biotechnology, petroleum,
pulp and paper, and mining industries.

Tube Setteler:
Tube settlers use multiple tubular channels sloped at an angle of 60° and adjacent
to each other, which combine to form an increased effective settling area. This

6
provides for a particle settling depth that is significantly less than the settling
depth of a conventional clarifier, reducing settling times.

Tube settlers capture the settleable fine floc that escapes the clarification zone
beneath the tube settlers and allows the larger floc to travel to the tank bottom in a
more settleable form. The tube settler’s channel collects solids into a compact
mass which promotes the solids to slide down the tube channel.

Advantages of Tube Settlers

The advantages of tube settlers can be applied to new or existing clarifiers/basins

of any size:

 Clarifiers/basins equipped with tube settlers can operate at 2 to 4 times the

normal rate of clarifiers/basins without tube settlers.
 It is possible to cut coagulant dosage by up to half while maintaining a
lower influent turbidity to the treatment plant filters.
 Less filter backwashing equates to significant operating cost savings for
both water and electricity.
 New installations using tube settlers can be designed smaller because of
increased flow capability.
 Flow of existing water treatment plants can be increased through the
addition of tube settlers.
 Tube settlers increase allowable flow capacity by expanding settling
capacity and increasing the solids removal rate in settling tanks.

7
 3. TERTIARY TREATMENT

A. COARSE FILTRATION
The raw water is first passed through a Multigrade sand filter to reduce the
suspended solids present in the raw water. The filter will have to be washed with
the help of raw water for 10 to 15 mins daily. This filter is provided to keep a
check on the suspended solids.
B. ACTIVATED CARBON FILTER
Activated Carbon Filter shall be used for De-chlorination of filtered water,
where the excess chlorine will be removed along with undesired color & odor
Advantages of treatment scheme

 This plant will produce the treated water which can be recycled back.
 This plant is based on biological principle hence no need uses of any
excessive hazardous chemicals for the main degradation process.
 Being an attached growth process there is no need of Return sludge
recycling.
 Due to media technology, foot print area required for the plant is very less.
 Due to smaller unit sizes, civil construction cost & overall project cost is
very less
 Due to efficient system, electrical power requirement is very low.
 Due to user friendly equipment, plant maintenance is very less.
 Due to inbuilt automation, plant machinery life is high & ensures trouble
free operation.
 All process rotating electromechanical equipment is provided with standby
equipment to ensure the uninterrupted operation.
 Due to effective after sales service from our qualified staff, maintenance
issues to the owner are less.
 This plant is based on biological principle hence no need uses of any
excessive hazardous chemicals for the main degradation process.

8
CHAPTER III
EQUIPMENTS DETAILS
BAR SCREEN

No. of units 1 Nos

MOC SS304
Type Bar
Bar spacing 5 mm
Make WTE

ACID DOSING SYSTEM

Quantity Of Pump 01 No
Chemical Acid
Dosing Pump Electronic Diaphragm
Capacity 0-10LPH @2kg/cm2
Solution Tank 01 No
Capacity 100 Lit
MOC LDPE

ALKALI DOSING SYSTEM

Quantity Of Pump 01 No
Chemical Alkali
Dosing Pump Electronic Diaphragm
Capacity 0-10LPH @2kg/cm2
Solution Tank 01 No
Capacity 100 Lit
MOC LDPE

9
EFFLUENT TRANSFER PUMP
Type Self-Priming,Non-Clog
Capacity 25 m3 / hr @ 12 m head
Duty To pump sewage
MOC CI
Make Wilo
Quantity 2 No. (1W + 1SB)

10
 Type Submersible
Capacity 25 m3 / hr @ 12 m head
Duty To pump sewage
MOC CI
Make Wilo
Quantity 2 No. (1W + 1SB)

Quantity 2 Nos
Type Circular
MOC MSFRP – 3 MM FRP – 3 mm FRP
Capacity 50 KL each
Accessories 1 lot
COARSE BUBBLE DIFFUSERS FOR ET 1 & 2
Type Tubular, retrievable, Coarse bubble
11
MOC EPDM
Make Scogen/Rahau/Jaegers/Equiv.
Duty For mixing
Quantity of diffusers 1 Lot

- AIR BLOWER WITH MOTOR FOR AREATION TANK

Air Blower Type Twin Lobe
Capacity 100 m3/hr air flow @ 0.4 Kg/cm2
Duty Air supply to ET
MOC CI
Quantity 2 No (1W+1SB)
Motor IE 3

- BIOREACTOR FEED PUMP

Type Self-Priming, non-clog, Centrifugal
Capacity 1.25 m3/hr @ 10 m head
Duty To pump Effluent
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 2 Nos (1W+1SB)

- BIOREACTOR TANK 1 & 2 WITH AGITATOR

Tank 2 Nos
Capacity 5 m3
MOC MSFRP – 3 MM FRP
Mixer 1 no.
MOC of skid MSEP
MOC of agitator SS 316
RPM 20 to 100
Motor 2 Nos
Gear Box 2 Nos
VFD 2 Nos

- FLASH MIXER FEED PUMP

Type Self-Priming, non-clog, Centrifugal
Capacity 1.25 m3/hr @ 10 m head
12
Duty To pump Effluent
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 2 Nos (1W+1SB)

- DOSING SYSTEM – 6 NOS

Quantity of pumps 1 No
Dosing pump Electronic diaphragm operated
Capacity 0 – 10 LPH @ 2 kg/cm2
MOC PP
Solution tank 1 no.
Capacity 200 liter
MOC LDPE
Agitator 1 No
MOC SS 316
RPM 100 to 200
Motor 1 no.
Gear Box 1 no.

- FLASH MIXER WITH TANK

Tank 1 No
Capacity 0.2 m3
MOC MSFRP – 3 MM FRP
Mixer 1 no.
MOC SS 304
RPM 100
Motor 1 no.
Gear Box 1 no.

- FLOCCULATOR AGITATOR WITH TANK

Tank 1 No
Capacity 0.6 m3
MOC MSFRP – 3 MM FRP
Mixer 1 no.
MOC SS 304
RPM 10 to 20
Motor 1 no.
Gear Box 1 no.

- PRIMARY TUBE SETTLER WITH TANK

Qty 1 No
13
MOC MSEP
Capacity 3.75 m3
Shape of Tube Hexagonal chevron
Angle of Tube 60 Deg.
Thickness 1.0 To 1.2 mm
Height 750 mm
Working Temp 50 Deg. C.
MOC PVC
Quantity 1 lot

- PRIMARY SLUDGE TRANSFER PUMP

Type Self-Priming, non-clog, Centrifugal
Capacity 1 m3/hr @ 10 m head
Duty To pump Effluent
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 2 Nos (1W+1SB)

- AERATION TANK I & II

Qty 2 Nos
Flow Rate 1.25 m3/hr
Capacity 30 KL each
MOC MSEP

- DIFFUSER MEMBRANE FOR AT I & II

Type Tubular, retrievable, fine bubble
MOC EPDM
Make Scogen/Rahau/Jaegers/Equiv.
Duty Uniform air distribution & oxygen
Transfer
Quantity of diffusers 1 Lot
- AIR GRID WITH AIR BLOWER PIPING
Quantity 1 set
Location For AT
MOC UPVC
Type Sch 40
Size As per requirement
Air Blower piping 1 set
Outside water MSEP
Type B class
14
Inside Water UPVC
Valves 1 set
Type Butterfly valves

- AIR BLOWER WITH MOTOR FOR AREATION TANK

Air Blower Type Twin Lobe
Capacity 150 m3/hr air flow @ 0.5 Kg/cm2
Duty Air supply to AT
MOC CI
Quantity 2 No (1W+1SB)
Motor IE 3
- DOSING SYSTEM – 2 NOS
Quantity of pumps 1 No
Dosing pump Electronic diaphragm operated
Capacity 0 – 10 LPH @ 2 kg/cm2
MOC PP
Solution tank 1 no.
Capacity 200 liter
MOC LDPE
Agitator 1 No
MOC SS 316
RPM 20 to 100
Motor 1 no.
Gear Box 1 no.
- SECONDARY TUBE SETTLER WITH TANK
Qty 1 No
MOC MSEP
Capacity 4.5 m3 effective
Shape of Tube Hexagonal chevron
Angle of Tube 60 Deg.
Thickness 1.0 To 1.2 mm
Height 750 mm
Working Temp 50 Deg. C.
MOC PVC
Quantity 1 lot
- SECONDARY SLUDGE TRANSFER PUMP
Type Self-Priming, non-clog, Centrifugal
Capacity 1 m3/hr @ 10 m head
Duty To pump Effluent
Accessories Standard Base Frame, NRV and
15
 Valves
MOC CI
Quantity 2 Nos (1W+1SB)
- FILTERED WATER TANK
Qty 1 No
Capacity 2 KL
MOC HDPE Sintex / MSEP
- FILTER FEED PUMP
Type Centrifugal, Mono-Block
Capacity 1.25 m3/hr @ 28 m head
Duty To pump water
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 2 No. (1W+1SB)

- MULTI GRADE SAND FILTER

No. of Units 1 No
Capacity 1.25 m3/hr
Material of Construction FRP
Diameter 16”
Height on straight 65”
Pipe line size 25 NB
Operating/Working Pressure 2.5 Kg/cm2
Filter media Fine sand, gravels &
Media Quantity 1 lot
Valve Type Manual Multiport Valve
Valve size 25 NB
Operation Manual

- ACTIVATED CARBON FILTER

No. of Units 1 No
Capacity 1.25 m3/hr
Material of Construction FRP
16
Diameter 16”
Height on straight 65”
Pipe line size 25 NB
Operating/Working Pressure 2.5 Kg/cm2
Filter media Fine sand, gravels & pebbles +
carbon
Media Quantity 1 lot
Valve Type Manual Multiport Valve
Valve size 25 NB
Operation Manual

- HYPO DOSING SYSTEM AFTER ACF

Quantity of pumps 1 No
Chemical Hypo
Dosing pump Electronic diaphragm operated
MOC PP
Capacity 0 - 10 LPH @ 2 kg/cm2
Solution tank 1 no.
Capacity 200 liter
MOC LDPE

SLUDGE THICKENING TREATMENT

- FILTER BACKWASH PUMP
Type Centrifugal, Mono-Block
Capacity 3 m3/hr @ 28 m head
Duty To pump water
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 2 No. (1W+1SB)

- SLUDGE HOLDING TANK WITH AGITATOR

17
Quantity 1 No
Capacity 1 KL
MOC MSEP
Nozzle 1 Set
Agitator 1 No
MOC MSEP
RPM 6 To 10
Motor 1 no.
Gear Box 1 no.
- POLYMER DOSING SYSTEM
Quantity of pumps 1 No
Chemical Poly
Dosing pump Electronic diaphragm operated
Capacity 0 - 10 LPH @ 2 kg/cm2
Solution tank 1 no.
Capacity 100 liter
MOC LDPE
Agitator 1 No
MOC SS 316
RPM 20 to 100
Motor 1 no.
Gear Box 1 no.
- SETTLING TANK
Qty 1 No
MOC MSEP
Capacity 2.5 m3
Shape of Tube Hexagonal Chevron
Angle of Tube 60 Deg.
Thickness 1.0 To 1.2 mm
Height 520 mm
Working Temp 50 Deg. C.
Make WTE
Quantity 1 lot

18
- SCREW PUMPS .
Type Screw
Capacity 1 m3/hr @ 10 m head
Accessories Standard Base Frame, NRV and
Valves
MOC CI Body, Stator – rubber, Rotor – SS
410
Quantity 2 No. (1W+1SB)

- VOLUTE FEED TANK

Quantity 1 No
Capacity 2 KL
MOC MSEP
Nozzle 1 Set
Agitator 1 No
MOC MSEP
RPM 6 to 10
Motor 1 no.
Gear Box 1 no.
- INTERCONNECTING PIPING & FITTINGS
MOC UPVC/ MS
Quantity 1 lot within the Battery Limit
Piping Supports 1 lot
MOC MSEP
Fittings & valves 1 set
Flange Table D
- INSTRUMENTS
Pressure Gauge 1 lot as per requirement
Sampling Valve 1 lot
Flow meter 1 No
Type Electromagnetic
Level Switch 1 lot
PH meter 2 Nos
Location Equalization tank 1 & 2
Low Level switch All dosing tank – 1 No each
19
- ELECTRICAL & EQUIPMENTS
No. of Unit 1 no
Protection IP 54
Panel Make WTE
MOC MS Powder coated
Type Compartmentalized
Loto Switch 1 Set
PLC & HMI 10” 1 No
Make of contactors L&T/ABB/Siemens/Schneider
and relays
On/Off/Trip Indication 1 lot as per requirement
Cabling 1 lot – within the battery limit
Type Armored
Entry Bottom
Make Polycab/Finolex/KEI/CALTER
Energy Hour Meter 1 no
Earthing 1 Set
Type Patti Fitting
LPBS 1 Lot
Hooter 1 No
Operation Semi –Automatic level based
- LEACHATE PUMP
Type Self-Priming, non-clog, Centrifugal
Capacity 1.5 m3/hr @ 10 m head
Duty To pump Effluent
Accessories Standard Base Frame, NRV and
Valves
MOC CI
Quantity 1 No

STORE STANDBY PUMPS

- DOSING PUMP

20
 Quantity of pumps 1 No
Dosing pump Electronic diaphragm operated
MOC PP
Capacity 0 - 10 LPH @ 2 kg/cm2

 NOTE :
1. Earthing Pit shall be supplied by client. Earthing material will be
provided by WTE. Earthing material for instrumentation will be
provided by WTE.
2. Panel will be non-Draw-out fixed Type.
3. We have considered STD specifications for piping, Valves, electrical
and instrumentation as per above. Any deviation in the same will be
having cost impact.
4. All Piping and fittings are considered as per ERW pertaining to WTE
STD.
5. All drawings shall be provided only in Auto Cad Latest version. 3D
Modeling is excluded from our scope of supply.
6. All pumps are Non-API with Two Pole, IE2 motor.
7. We have considered our STD HSE requirement. Any additional HSE
requirement will have cost impact.
8. All TPI (Third Party Inspection) are excluded from our scope of
supply.
9. We have considered our STD painting specifications. For additional
requirement will have cost impact.
10. QAP will be done as per WTE standards for any additional
requirement will cost extra.
11. We have considered Standard electrical specifications as per WTE
standard, for any additional requirement will cost extra.
12. Our Scope of supply will be strictly as above.

21
CHAPTER IV

PRECOMMISSIONING

1. Direction of the flow is marked clearly on the pipes.

2. All the mechanical equipment is tested and are in good working condition
properly lubricated.
3. All the tanks and piping are clean and free of debris.
4. All the process units and mechanical equipment should be tested with water
for the normal operation of each unit and hydraulic system. Only after this,
wastewater should be introduced to the system.
5. All the lights, meters, indicators, etc. are operational.
6. Check all lines for leaks. Any repairs needed are easier to make before
wastewater is added.
7. Operation and maintenance manual have been read by the operators and
stored in one location for ready reference.
8. No load runs of motors
9. This is carried out to ensure that the motors are running smoothly without any
problems either in their bearings or in stator - rotor combination. To carry out
this activity, disconnect the coupling pins/valves from the driven equipment.
Then the motors are kick started and stopped to observe their direction of
rotation.
10.If the direction is not as required by the driven equipment, then reverse the
phase connections.
22
11.The motors are once again kick started to ensure the required direction of
rotation. After ensuring the direction of rotation, no load run shall be carried
out for 4 to 8 hours depending on their ratings.
12.If the motors capacities are of smaller size, then there is no need of going for
no load test. During the no-load run, current drawn by motor, vibration, noise
and bearing temperature shall be observed and noted. If all these readings are
within limits, then motors are coupled with driven equipment for further step.
Otherwise, possible causes for defects should be found out and rectified as
given in Motor Manuals.
13.On Load Trial (With Clear Water).

PLANT START UP

MECHANICAL START-UP
Before starting the plant trials on full load, it is essential that mechanical
performance of the equipment have to be established to ensure their proper
functioning when sewage is taken in. To achieve these following steps should be
observed –

No load runs of motors

This is carried out to ensure that the motors are running smoothly without any
problems either in their bearings or in stator - rotor combination. To carry out this
activity, disconnect the coupling pins/valves from the driven equipment. Then the
motors are kick started and stopped to observe their direction of rotation. If the
direction is not as required by the driven equipment, then reverse the phase
connections. The motors are once again kick started to ensure the required
direction of rotation. After ensuring the direction of rotation, no load run shall be
carried out for 4 to 8 hours depending on their ratings. If the motors capacities are
of smaller size, then there is no need of going for no load test. During the no load
run, current drawn by motor, vibration, noise and bearing temperature shall be
observed and noted. If all these readings are within limits, then motors are
coupled with driven equipment for further step. Otherwise, possible causes for
defects should be found out and rectified as given in Motor Manual

On Load Trial (With Clear Water)

23
The sewage normally has density equal to density of water. It, thus, suffices to run
these on clear water for sufficient time to prove the adequacy of mechanical
equipment. This is done as follows: -

All tanks in which equipment is supposed to run on load are filled up with clear
water. Lines are flushed with water. Then the respective equipment are run as
mentioned below:

PUMPS
Open suction valves in pump suction. Start the pump with delivery valve closed.
Open the valve slowly observing the pressure gauge so as to set the delivery
pressure to design limit. The pump will thus be running at designed duty point.
Allow the pump to run. It will run for the duration, which will be determined by
capacity of holding tank and pump for rate, unless fresh water is fed into holding
tank. During this period observe motors temperature; pump bearing temperature,
vibration, noise, etc. In case of any problems, study/follow the equipment manual
enclosed.

BLOWERS
Close the discharge valve.
Open vent valve fully.
Start the Blower
Open the discharge valve gradually.
Close the vent valve gradually.

DAF
Close the discharge/ drain valve.
Open inlet line valve fully.
Start the Feed Pump, and fill the DAF tank.
Start the recirculation pump and DAF system.
Open the drain valve as per the cycle operation.
24
DECANTER
Open the feed line valve.
Start the decanter motor.
Connect the sludge disposal to the collecting tray.

PRESSURE SAND Filter

Check the vessels is filled with media and check Multi port valve operation and
ensure that the all operating valves is fitted with as per water flow direction.
Check for proper installation of Dosing pump with dosing tank to the PSF inlet
line.

Activated Carbon Filter

Check the vessels is filled with media and check Multi port valve operation and
ensure that the MPV is fitted with as per water flow direction. Check for proper
installation of Dosing pump with dosing tank to the PSF inlet line.

PLANT SHUTDOWN
- In case plant needs to be shut down for a considerable period of time,
following should be observed.
- Close inlet valve to plant and open bye-pass valve if any.
- Pump out sewage from intermediate sump.
- Open drain valves of tank and drain out the contents.
- Backwash the vessels before shutdown by using fresh water.
- The equipment then should be flushed with clear water.
- Follow instructions for short & long shutdown for membranes as per
membranes manufacturer.

25
 CHAPTER V

 COMMISSIONING & OPERATION

Solution for Sodium Hypo chloride should be prepared and kept ready before
start-up of the plant. Actual dosage will be decided as per instructions given by
us.

1) BAR SCREEN:

Objective:
- TO stop the large particles to enter in the process.
Normal Operation
- Bar screen comes up with 6-10 mm gap.
- The larger particles from the gap arrested prior to enter in the process.

2) EUQALIZATION TANK:

Objective:
- To equalize the incoming Raw Sewage
26
 Process:
- Raw water generated in various locations of the plant flows into the
Equalization Septic tank.
- This raw water has different individual characteristics, which are
continuously mixed and homogenized in the tank.
- This prevents shock loading on the downstream biological units.
- Level switch is provided in the tank for tripping the pumps if the level in
the tank is low.
- Also aeration is provided for continuous mixing.

3) NEUTRALIZATION TANK:

Objective
- To neutralize the pH level in tank.

4) DAF FEED PUMP:

Objective
- To transfer the neutralized water to DAF system
Process
- Working & 1 Stand-By pump to pump Raw water to the DAF system.
Normal Operation
- Ensure that tank holds desired liquid level.
- Care must be taken to ensure that entrapped air if any is released through
air release cock before starting the motor.
- This pump is to be used in suitable rotation during normal flow to restrict
wear and tear of the pumps as well as to ensure regular maintenance.
Routine checks before commissioning are to be followed as indicated in the
manufacturer’s operation manual.

5) SLUDGE HOLDING TANK:

Objective:
- To collect the plant heavy sludge into the tank.
27
 Normal Operation
- The heavy untreated sludge used to transfer form sludge pump.
- Only transfers the sludge to the sludge holding tank.

6) DAF SYSTEM:
Objective:
- To clarifies wastewater by removing suspended matter.
Process:
- Removes the suspended matters by using an scrapper blade with motor
driven.
Normal Operation
- The neutralized water firstly enters in pipe flocculator where it mixes with
the chemical.
- The Coagulant Flocculent dosing helps to separate the solid matters from
water.
- This water directly enters into the DAF where solid particles floats on the
top of water with the oil.
- The motor driven scraper wipes out the floating particles and clear water
passes out by outlet line.
- The recirculation pump keeps recirculate the water to keep sludge play with
the help of air.
.

7) UASBR:
Objective:
- To separate the treatment useful water from the heavy sludge.
Process:
- The separated water flows to the aeration tank by using gutter.
- The left sludge deals with the bio-logical reaction and generates an gas.
- Which burnt burnt using flare stack.
Normal Operation
28
 - The wastewater enters the reactors from the bottom and flows upward.
- The sludge left behind the UASBR tank.
- Due to the biological treatment flammable gas generate inside the UASBR
tank.
- Then the gas burnt by flare stack.

8) AERATION TANK
Objective:
- To reduce organic load (COD, BOD) from raw sewage using biological
treatment
Normal Operation
- After proper acclimatization with the raw sewage, the normal flow of
sewage is fed to the aeration tank continuously.
- Run the air blowers continuously for 24 hours.
- Fine bubble diffusers are placed in the bottom of aeration tank which
diffuse atmospheric oxygen into the aeration tank which is consumed by
the biomass developed in aeration tank (bacterial culture) during aerobic
oxidation of organic matter present in the sewage.

9) TUBE SETTLER

Objective:
- This provides for a particle settling depth that is significantly less than the
settling depth of a conventional clarifier, reducing settling times.
Normal Operation
- The settlers use multiple tubular channels sloped at an angle of 60° and
adjacent to each other.

29
 - Tube settlers capture the settle able fine floc that escapes the clarification
zone beneath the tube settlers and allows the larger floc to travel to the tank
bottom in a more settle able form.
- The settler's channel collects solids into a compact mass which promotes
the solids to slide down the tube channel.

10) SETTLING TANK

Objective
- To settle excess Bio-Sludge.

Process
- It contains Tube settler media.
- This media prevents the sludge from rising up.
- Thus, it separates clear water and the sludge remains at the bottom.
- Settled Bio-Sludge to be fed to the filter press for dewatering of sludge.
Normal Operation
- Sludge Settling & overflow to supernatant tank.

11) SLUDGE PUMP

Objective:
- To pump the Sludge from Tube Settler to the sludge drying bed.
Process
- One pump is provided to pump sludge to sludge drying bed. It should be
manually operated twice in a day.
Normal Operation
- Ensure that tank holds desired sludge level.
- Open suction and discharge valve of pump.

30
 - This pump is to be used in suitable rotation during normal flow to restrict
wear and tear of the pumps as well as to ensure regular maintenance.
Routine checks before commissioning are to be followed as indicated in the
manufacturer’s operation manual.

12) CHLORINE DOSING TANK

Objective
- To disinfect the bacteria, present in treated sewage.
Process:
- Sodium Hypochlorite (NaOCl) is added to the overflow from settling tank
for Disinfection. Water is collected in the tank. It has a level switch for
starting and tripping of the Filter feed pump.
Normal Operation
- Level should be maintained for proper pump functioning.

13) FILTER FEED PUMP

Objective
- To pump the treated Effluent water to Sand Filter.
Process
- One working centrifugal type pump is provided to pump sewage to the sand
Filter.

Normal Operation
- Ensure that tank holds desired liquid level.
- Always keep open the suction and discharge valve of pump. Care must
be taken to ensure that entrapped air if any is released through air release
cock before starting the motor.
- This pump is to be used in suitable rotation during normal flow to restrict
wear and tear of the pumps as well as to ensure regular maintenance.
Routine checks before commissioning are to be followed as indicated in the
manufacturer’s operation manual.
31
14) MULTIGRADE FILTER

Objective:
- To remove the suspended solids from treated sewage
Process
- Butterfly valves are provided for Rinse, Backwash & Service Cycle of the
filter.
Normal Operation
- Keep valve position on service for regular filtration process.
- Filtration removes balance suspended solids, odor and color from treated
sewage.
- Once in 24 hrs. carry the backwash operation of the filter.
- This should be done for 10-15 minutes.
- Then rinse the filter for 5-10 minutes.
- Again place the service line valve in open position

ACTIVATED CARBON FILTER

Objective:
- To remove the Color and odor from treated sewage
Process
- Butterfly valves are provided for Rinse, Backwash & Service Cycle of the
filter.
Normal Operation
- Keep valve position on service for regular filtration process.
- Filtration removes balance suspended solids, odor and color from treated
sewage.
- Once in 24 hrs. carry the backwash operation of the filter.
- This should be done for 10-15 minutes.
- Then rinse the filter for 5-10 minutes.
- Again place the service line valve in open position.
32
15) TREATED WATER TANK

Objective:
- To collect and store the treated water.

CHAPTER VI

MAINTEINANCE

1. The Effluent Treatment plant should be inspected every three months and any
damaged paint work or vessels, pipe work and valves renewed.

2. An internal inspection of tanks and vessels is also recommended every six

months, although this period could be extended if service experience indicates
that a longer period would not jeopardize the performance.

3. In addition to the items specifically mentioned in the MAINTENANCE

section, rectify leaking valves and joints immediately by loosened nuts and
bolts or changing sealing joints (gasket). Replace gland packing when
required.

33
4. If it is necessary for maintenance personnel to enter any of the treatment units,
rubber or soft solved shoes must be worn and great care taken to avoid damage
to any rubber lining and internal lateral systems.

5. Entry into the vessels or tanks should be avoided unless required in case of
emergency but if unavoidable, must be carried out under the supervision of our
supervisor.

6. Valves should be inspected regularly and gland packing where used should be
replaced regularly.

7. Refer to the auxiliary manuals for maintenance instructions on other

equipment that may be supplied such as pumps, blowers, diffusers, and
instrumentation etc.

Duties of Plant Operator:

The duties of Plant Operator may be classed under the following general outline:

 To ensure that the plant consistently produces a sewage of no lower quality than
it was designed to produce.

 To see that all operating details are performed promptly and efficiently. This is
best accomplished by establishing a routine schedule of operation

 To systematically monitor and record different process parameters including

chemical consumption.

 To carry out or arrange for all required laboratory analysis and tests of the
sewage passing through the plant as to maintain proper efficiency in operation

34
 To maintain all equipment and structures of the plant in good order and
condition

 To keep proper records of operation & maintenance jobs including spare part
costs and consumed man hours.

 To ensure that all precautions necessary for the safety of personnel and property
are observed.

 To bring the notice of the engineer any alteration work, or facilities which may
be necessary to place or maintain the plant in efficient operation

 To place and maintain the surroundings of the plant in a condition as attractive

as possible.

GUIDELINES FOR DATA RECORDING

General

By keeping records of observations, tests result and services / repairs jobs, an

Operator can often readily recognize imminent problems which are developing
and affect remedial operating measures to ensure that treatment process is
maintained and equipment restored in good working condition.

Reference to old records of Plant conditions and performance can be of great

assistance when deciding a course of action to be taken with a particular plant-
operating problem.
35
A] Purpose of Record Keeping

The regular recording of operating parameters and other information serves many
purposes.

Records are needed for the following reasons:

 Plant Operation
Review of operating records can indicate:

- Efficiency of Plant and its treatment units

- Process malfunctions

- The success of plant process adjustments

- Necessary adjustments to the treatment processes required because of raw water

changes due to seasonal or environmental conditions, and past problems

 Plant Maintenance
Records are needed to show type and frequency of maintenance of operating
Units and evaluation of effectiveness of maintenance programs

 Evaluations & Process Adjustments

Records of past performance and operational procedures are invaluable tools
for the engineer in the evaluation of present performance and serve as a basis
for the design of future treatment units

 Budgets
Records are used to support budget requests for personnel, additional facilities, or
equipment

 Accidents

36
 Records may be needed in damage suits. They can be especially helpful to the
Operator if an accident occurs. As soon as possible after an accident someone
should record the chain of events leading to the accident, exactly what happened,
and any preventive or corrective action

 Reporting

Records provide the actual data for the preparation of monthly or annual reports.

B] Operation Logs

There are commonly two main classifications:

- Record Logs/Sheets
- Monthly Report

The content of the above categories are shortly described below:

A) A DIALY LOG shall be a wide variety of factual information on matters

such as progress of construction or maintenance work equipment failures,
accidents, time spent on the Plant, bypassing of a unit, complaints and
visitors. This information is valuable for later references

B) The DAILY ROUTINE JOBS & CHECKLIST shall verify that the
Operator has carried out necessary inspection and observations

By using monthly average figures, calculations of parameters that are helpful in

process control are made to reflect consistency or changing conditions.

The Monthly Report also contains a summary of Influent and Final Sewage quality
parameters and "Trend Curves" for Laboratory tests.

C] Maintenance Jobs:

1) All mechanical and electrical work tasks on equipment that needs to be carried
out on a weekly, monthly or yearly basis to maintain the equipment in a

37
satisfactory working condition. This will include repair jobs as well as regular
servicing such as lubrication/oil changes, etc.

2) All physical repairs or servicing work on equipment that needs to be carried out
immediately to restore process control (or which may be carried out at a later stage
if not critical for the operation of the Plant)

3) All routine testing of physical instruments and equipment.

TABLE No. 1
TESTS SCHEDULE
JOB DESCRIPTION REMARKS/REFERENCES

1.RAW SEWAGE (INFLUENT)

 pH Once a Month)

 TSS & COD Once a Month)

 BOD5 (Once a Month)

38
 TABLE No. 1
TESTS SCHEDULE
JOB DESCRIPTION REMARKS/REFERENCES

2.TREATED WATER
 pH (Once a week)
 TSS & COD (Once a Month)
 Free Residual Chlorine (Once a Month)
 BOD5 (Monthly)

Note:
TSS : Total Suspended Solids
DO : Dissolved Oxygen
COD : Chemical Oxygen Demand
BOD : 5 days Biochemical Oxygen
Demand

CHAPTER VII

SAFETY

7.1 Objectives

39
The primary objective of safety measures is to reduce the chance of injury to plant
personnel or visitors. The design of this plant incorporates a number of safety
features for the purpose of providing a safe place to work.

The Operator has the responsibility for the Plant and must see to it that it is
maintained in such a manner that a safe place to work is continuously provided.
This can only be done by constantly acting and thinking safety.

The Operator has the responsibility of protecting himself and other plant personnel
or visitors by seeing that proper safety procedures are followed.

All operation personnel should train themselves to analyze jobs, work areas and
procedures from a safety standpoint. Potentially hazardous actions or conditions
shall be recognized.

If a hazard is recognized, take immediate steps to eliminate it by corrective action.

If corrective action is not possible, guard against the hazard by proper use of
warning signs and devices.

Accidents can be prevented by using good common sense, following established

safety procedures, and particularly by acquiring a good knowledge of the hazards
peculiar to specific jobs.

Behind every accident there was a chain of events, which led to an unsafe act,
unsafe condition, or a combination of both.

7.2 Kinds of Hazards

The type of equipment and structures required by a Sewage Treatment Plant can be
very hazardous. For this reason, the design of the plant has included a number of
safety features to help minimize the risk of injury to the plant personnel. But even
the best of safety measures are of no value if established safety procedures are not

40
followed. If an accident occurs, it is equally necessary to know what steps to take to
minimize further injury and damage.

This section describes potential safety hazards of the Plant and recommends ways to
avoid or minimize these hazards. However, you should not rely upon the
information presented here exclusively, because work habits and method of
operation and maintenance that develop over the life of the plant may introduce
additional hazards. As conditions will change continually, it is extremely important
that all personnel always be on the lookout for potentially hazardous actions or
conditions.

Plant personnel may be exposed to the following hazardous conditions:

 Physical Injuries

 Chemical Burns

 Toxic or Suffocating Gases or Vapors

 Fire

 Electrical Shock

 Noise

7.2.1 Physical Injuries

The most common physical injuries to which plant personnel are exposed are cuts,
bruises, burns, and crushed or broken bones. Injuries can be caused by rotating
41
equipment such as pumps, blowers and fans. Falls from or into tanks and elevated
platforms can be extremely hazardous. Most of these hazards can be avoided by the
proper use and maintenance of ladders, handrails, hand tools, and safety equipment
and by following established safety procedures.

7.2.2 Chemical Burns

Plant operators handle potentially hazardous chemicals on a daily basis.

Chemicals to which the Operator will be exposed include coagulants of various
types, acids and bases. Chemical safety data for most chemicals anticipated to be
used on the plant site including first aid measure and recommended methods of
cleaning up spills are presented.

As contact with or ingestion of all of these chemicals can be extremely hazardous or

lethal, it is very important for all plant personnel to be familiar with the
recommended first aid procedures to be administered in case of accident.

Emergency eyewash is located at the Plant for washing hazardous chemicals off the
skin and out of the eyes. All plant personnel should know where the emergency
eyewash is located.

7.2.3 Oxygen Deficiency

Oxygen deficiency may exist in any enclosed, unventilated structure. Plant
structures that may present this hazard include filters that have been taken out of
service for inspection or maintenance and manholes.

Ventilation may be provided by fans or blowers. It is important to use a blower to

blow air into any vessel before you go to inspect or work on it, and to keep air
flowing until you have left the vessel.

7.2.4 Toxic or Suffocating Gases and Vapors

42
Toxic or suffocating gases or vapors may come from any of the chemicals used in
the treatment process. You are especially subject to this hazard when chemicals are
in contact with water or when working with chemicals in enclosed and unventilated
areas.

Because toxic gases and vapors can rapidly disable a person, it is important to
constantly be alert to conditions of unusually strong vapors and fumes or situations
where you might be subject to hazardous concentrations of toxic vapors or fumes.
Take immediate actions to correct any unusual situation.

Chlorine is a particularly hazardous gas. All personnel should know the proper ways
to handle chlorine and should be trained in the use of self-contained breathing
apparatus.

7.2.5 Fire
Burns from fire can cause very serious injury. Avoid the accumulation of flammable
material and store any material of this type in approved containers at proper
locations. Note the location of firefighting equipment and the proper use of the
equipment.

7.2.6 Electrical Shock

Electrical shock frequently causes serious injury. Do not attempt to repair electrical
equipment. Call an electrical repair technician.

7.2.7 Noise
Loud noise from Air Blowers can cause permanent ear damage. Personnel need to
wear proper ear protecting devices whenever working in noisy areas.

7.3 Specific Hazards

Potential safety hazards specific to the plant systems and equipment are described
below. The hazards described below may not comprise all the potential hazards
43
since changes in operation of the Plant over a period of time may introduce
additional hazards.
7.3.1 Pressure Tanks and Piping
On a day-to-day basis, the most common hazards associated with pressure tanks and
piping will be bumps and bruises resulting from running into and tripping over
valves and piping. To minimize such injuries, always watch where you are walking.
Watch out for low overhead piping. Always wear a hard-hat when working in areas
with low overhead piping.

When working with the filter, you must be particularly careful not to bump, scrape,
or cut yourself on the internal water distribution and collection piping and piping
supports.

7.3.2 Chemical Addition Systems

As an Operator you will be handling a variety of chemicals in conjunction with
batch mixing and will be performing maintenance on pumps, valves, and piping.
You will also come in contact with various types of toxic chemicals. All these
chemicals can cause serious injuries, if they come in contact with your skin, if they
are ingested, or if their vapors are inhaled.

Other hazards associated with the chemical addition systems include cuts, bruises,
broken bones and head injuries due to tripping over or bumping into piping systems.
Always be careful of where you walk and be aware of the location of overhead
piping. Always wear a hard-hat when working around overhead piping.

Some chemicals may come bagged as a dry powder that must be loaded in the top of
a mixing tank. Never attempt to carry bags of chemicals up a ladder. Never attempt
to lift a bag that seems too heavy. If a bag seems too heavy to lift, it probably is. Get
assistance.

Whenever adding dry chemicals to a mixing tank, you are particularly subject to
coming into contact with the chemical or inhaling its dust. Always wear protective
clothing and a dust mask when handling dry chemicals.

44
Whenever working on chemical tank platforms, you are at risk of falling to the
ground or into a tank. Such falls may cause serious injuries or drowning. Whenever
working on raised platforms, stairways or ladders, be certain that you have a clean,
firm surface to stand on. Remove all slimes, rags, greases, or other material that may
cause you to slip. Good housekeeping in these areas is mandatory.

Railings should be installed along the tank side of all walkways. Railings should
also be installed on all stairways. Do not work outside of these railings, they are
there to help prevent you from falling. Keep all railings and walking surfaces in
good repair.

7.3.2.1 Chlorine
As chlorine is extensively used, some aspects with this chemical is dealt with in
particular.

Chlorine is a very active chemical that reacts readily with most forms of living
tissue as other organic and inorganic materials, metals and non-metals. This
reactivity also allows its use in oxidizing objectionable chemicals in waste.
However, because of its reactivity, chlorine is difficult to handle, while its toxicity
makes it hazardous if it is not properly handled and controlled.

If exposed to this chemical in a hazardous way, the patient shall in all cases be
removed immediately from the contaminated area, a physician called and
appropriate first aid must begin immediately. A brief outline of first aid measures
for exposure to chlorine is as follows:

Eyes
In case chemical is splashed into the eye (no matter the quantity), quick action is
vital. The patient should be laid down, using force if necessary, the eyelids should
be held apart and the eyes flushed copiously with running water (a boric saline
solution may also be used). The flushing should be continued for about 15 minutes
and repeated if necessary. The patient should be encouraged to roll his eyes during

45
the operation. No medication should be attempted except under specific instruction
from a physician.

Skin
The patient should be placed under a shower immediately, clothes and all. Clothing
should be removed while the shower is running and the skin washed with larger
quantities of soap and water. Neutralization of chlorine with chemicals should not
be attempted. Salves or ointments should not be applied, except as directed by a
physician.

Inhalation
If the patient is breathing, he should be placed in a comfortable position, and kept
warm and rest until a physician arrives. If breathing seems to have stopped, artificial
respiration should begin immediately. Mouth to mouth resuscitation or any
approved method may be used.
Oxygen should be administered if equipment and trained personnel are available.
Automatic artificial respiration is considered preferable to manual, but only when
administered by an experienced Operator. Some rest is recommended after severe
chlorine exposure.

Throat Irritation
Drinking milk will relieve the discomforts of throat irritation from chlorine
exposure. Emergency rules given by a physician should be followed. In the absence
of such rules, the first aid steps above are suggested.

7.3.3 Pumps and Blowers (Jet Aerator)

Always turn off, lock out, and tag pumps and blowers before working on them.
Stay clear of any situation where your body or the tools you are using may get
caught in the machinery. Keep the guards in place whenever the unit is in
operation.
46
7.3.4 Sampling
Because you may be required to collect water samples and conduct certain
laboratory tests, you must be aware of the specific hazards involved in this type of
work.

Collecting Samples
Rubber gloves must be worn when your hands may come in contact with sewage
and/or chemicals. When you have finished sampling, always wash the gloves
thoroughly before removing them. After removing the gloves, wash your hands
thoroughly.
7.4 Fire Prevention
Fires are a serious threat to the health and safety of the Operator and to the
buildings and equipment in the Treatment Plant. Fires may injure or cause the
death of a person. Equipment damaged by fire may no longer work properly and
the Plant may have difficulty to function.
Know where fire extinguishers and hoses are kept and know where possible yard
hydrants are located. Find out what each is for and how to use them. You can
prevent fires by:

 Maintaining a neat and clean work area and preventing accumulation of

rubbish.
 Putting oil and paint-soaked rags in covered metal containers
 Observing all "No Smoking" signs
 Keeping exits, stairs, and firefighting equipment clear of obstruction
 Reporting any fire hazards, you see that are beyond your control, especially
electrical hazards, which are the source of many fires

7.5 Safety Equipment

It is the responsibility of the operating personnel to know the location and types of
safety equipment available at the Plant (breathing apparatus etc.)
All operating personnel should be thoroughly familiar with the operation and
maintenance of each piece of equipment. They should review these periodically to
47
be certain that they can safely use the piece of equipment as well as to be sure that it
is in operating condition.

7.6 Housekeeping
Good housekeeping can and has prevented many accidents. When tools and
equipment are not being used, see that they are kept in their proper place. Clean
up all spills of oil, grease, and other substances. Keep walkways and work areas
clean. Provide proper containers for waste, oily rags, papers, etc. and empty these
frequently.

CHAPTER VIII
TROUBLESHOOTING POINTS IN ETP

48
SR.
NO PROBLEMS CAUSE REMEDIES
.

49
A BAR SCREEN
1. Clogged with
A.1 Clean bar screen regularly.
Inlet flow debris.
reduced. 2. Damaged bar Check bar screen regularly and repair if
A.2
screen necessary.
B OIL & GREASE CHAMBER
1. Provision for oil removal.
Non proper
1. Oil enters in 2. Oil trap should be as per desired level.
B.1 growth of
aeration system 3. Clean the O&G chamber and check
Bacteria
for and damages.
C. AIR BLOWER
Check belt condition and replace it if
1. Loose belt
necessary.
2. Loose foundation
Tighten the foundation bolts.
C.1 Noisy operation bolts
3. Air filter damages. Replace air filter.
4. Damaged exhaust Check for exhaust system and repairs if
system necessary.
Check belt condition and replace it if
1. Loos belt
necessary.
2. Faulty motor Check for motor and repair if necessary.
3. Worn out air Check and all wear-tear parts and
C.2 Reduced air flow blower/ motor parts. repair/replace if necessary.
4. Leakages in air
Check for leakages arrest them.
blower/line.
5. Air filter
Replace air filter.
damaged.
D CENTRIFUGAL PUMPS
1. Improper pump
Make it proper
selection
Loss in outlet 2. Damaged pump
D.1 Check and repair/replace if necessary.
flow impeller.
3. Leakages in Check and repair/replace if necessary.
50
 casing
4. Improper line size Make it proper
1. Loose foundation
Check and tighten the foundation bolts.
bolts
D.2 Noisy operation 2. Motor issue Check for motor and repair if necessary.
3. Bearing Check for bearing condition and replace
maintenance. if necessary.
E DAF SYSTEM
1. DAF pump running Check DAF pump operation and repair
issue pump if necessary.
Micro Bubbles 2. DAF pump getting Check airline and check for air
E.1 air or not. pressure.
formation
3. Pressure on the Check for desired backpressure. Or
DAF pump refer the manual.
1. Scrapper blade
Check and repair/replace if necessary.
damages
2. Scrapper motor not
Check and repair/replace if necessary.
Not wiping out working
E.2
the particles 3. Chain mechanism
Check and repair/replace if necessary.
not working.
4. Particles settles Check for air compressor and air line at
down the DAF
1. Damaged Scrapper
Check and repair/replace if necessary.
mechanism.
No clear water at
E.3
outlet of DAF
2. No air at DAF Check for air at DAF.

51