SEWAGE TREATMENT PLANT

ADVANCE OXIDATION PROCESS

OPERATION MANUAL

MADANG PUBLIC MARKET

SEWAGE TREATMENT PLANT
 CONTENTS

◆ AIR BLOWER COMPONENTS AND MAINTENANCE

◆ OZONE GENERATOR COMPONENTS AND MAINTENANCE

◆ SUBMERSIBLE PUMP COMPONENTS AND MAINTENANCE

◆ PROCESS FLOW DIAGRAM

◆ OPERATION INSTRUCTION

◆ EQUIPMENT OPERATION

◆ APPENDIX A TROUBLESHOOTING MATRIX

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 BLOWER
Inspection and Troubleshooting:
Elements that may influence the service time of the blowers are though. Regular maintenance and
inspection of the blowers will ensure performance and lengthen the service time of the blowers.
Following are the criteria table on inspection and troubleshooting table:

1. Inspection:

Before
Inspection Cycle Test Every
Daily 3months Remarks
Inspection Items Running

Clean sundries from ○ No residents should be inside the

pipes
pipelines.
Make sure joints are ○ ○ Where the joints that the blower and
firmly fixed pipe are connected.

Open all valves ○ ○ Fully opened

Make sure Check

○ Make sure that the valve body can
Valve is in good
be smoothly moved.
condition
Check the wiring ○ ○ Wires must be tightly connected.
connections

Check Gear Oil Level ○ ○ On the middle of the level gauge.

Check Safety Valve ○ ○ Confirm with discharge side

operation valve operation.
Check Power Voltage ○ ○ Voltage: within ±10% of rated voltage.
and Current Current: below rated current.
Sound of motor and ○ ○ There should be no strange noises.
blower

Check V-belt tension ○ ○ Re-tension if sagging.

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Supply Bearing Grease ○ With specified Grease.

Replace Gear Oil ○ Replace all.

○ ○ Will extend initially, re-tensioning will be

Check V-belt
necessary. Replace all every year.
Clean insides of ○ Clean it every year.
Suction Silencer

ESSO Beacon Q2、MOBIL Mobiltemp 78、CALTEX Molytex ZP2

Recommended Bearing Grease
…or equivalent.
ESSO Spartan EP 220、SHELL Omala 220、
Recommended Gear Oil
MOBIL Mobil Gear 630 … or equivalent.

2. Belt Tension Adjustments:

1. Pulley Alignment:

1. Loosen the motor side pulley fixing bolt and using a metal scale or another similar tool, attach it
to both walls of motor pulley and the blower pulley, adjust to make both pulleys more parallel
and make them to the correct alignment.

II. Belt Tensioning:

3-Lobe Roots Blower Operation Manual

3-Lobe Roots Blower Operation Manual

1. Find out the center of “l”, depress vertically with under listed tension forces “W” (measured by a
tension meter), you will find the flexibility “δ” (belt shifting in mm). If the measured valves are
according to the following relationship, the belt tension will be good for operation.
δ = 0.016 x l
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OPERATION MANUAL
 Tension Force “W” (kg)

Belt Type A 3V 5V

Min. Value 1.0 1.5 3.5

Max. Value 3.0 3.0 5.0

2. Recheck the belt tension after 7 ~ 10 days of first operation. Owing to initial extension, the belts
should be re-tensioned after some period of operation time.
Spare Parts List:

PARTS Bearings for

SHAFTS V-Ring V-Belts Oil seal Remarks
MODE (Front/Rear
)
Rear : 6306Z x 28*45*10
RSS/V-40 3V500*2
2 Front: 6207Z VA-40
x2
Rear : 6306Z x 2 28*45*10
RSS/V-50 3V500*2
Front: 6207Z x 2 VA-40
Rear : 6306Z x 28*45*10
RSS/V-65 3V500*2
2 Front: 6207Z VA-40
x2
6309Z x 4 40*62*10
RSS/V-80 SPZ1537x3
VA-55
6309Z x 4 40*62*10
RSS/V- SPA1600x3
100 VA-55
RSS/V-125 6312Z x 4 70*85*10
SPB2000x3
RSS/V- VA-70
125A
6312Z x 4 70*85*10
RSS/V- SPB2000x3
150 VA-70
RSS/V-200 6315Z x 4 89*115*13
SPB2750x5
RSS/V- VA-95
200A
6315Z x 4 89*115*13
SPB2750x6
VA-95
RSS/V-
250
RSS/V- 6320Z x 4 VA-120 SPC4250*4 150*120*12
300

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 3-Lobe Roots Blower Operation Manual

OZONE GENERATOR
Spare Parts List:
High-tension Cooling water
Air/oxygen inlet cable connection outlet
Ozone outlet

Cooling Water
inlet

Hi-pot
grounding

220V Power connection

Adjustable potentiometer:

Adjust the power

Change the concentration and yield

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OPERATION MANUAL
 Product Manual

Technical Specifications:
--------------------------------------
Product: Ozone generator kit (high voltage control power supply + high voltage package + corona discharge
chamber)

Model: QL-50G

Voltage: AC220V/60Hz

Power: 0~ 300W

Cooling water: water flow: 1~2 T/Hr, temperature ≤30℃, pressure ＜0.4Mpa。

Source: Dry and clean oxygen or air dew point≤ 0℃, pressure ＜0.15Mpa。

Air flow rate: 58 LPM

Oxygen flow rate: 10-15 LPM

Ozone output：50 G/Hr

Temperature：-10～40℃ The best working environment temperature-10～25℃

Humidity：≤80%RH Relative humidity （Smooth surface without condensation）

Size: Discharge chamber: Length: 670mm, Diameter: 100mm （diameter of Stainless steel tube 80mm）

Power source: 200*140*90mm L*W*H

High pressure pack：100*50*70mm L*W*H

（There should be more than 15 cm from the metal plate to the edge around the high pressure pack when
install）

G.W：（ozone discharge chamber 4.3KG，power source+high pressure pack 1.4KG）

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 SUBMERSIBLE PUMPS
SECTION: A - PUMP SPECIFICATIONS

Inches
(mm)

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 SEWAGE TREATMENT PLANT

OPERATION INSTRUCTION

I. MANUAL SETTING
STEP 1. SWITCH ON ALL CIRCUIT BREAKERS INSIDE OF THE CONTROL PANEL.

ON

OFF

STP CONTROL PANEL

STEP 2. Set the Selector switch of Blower – 1 or 2, Ozone – 1 or 2, Transfer pump – 1 or 2, and Effluent pump – 1 or 2 to HAND
(H) position.

TRIP

STOP (LIGHT INDICATOR)

START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

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STEP 3. Check all Valves ( open/ close ) before running of the system.

STEP 4. PUSH START BUTTON of Blower – 1 or 2 and Ozone – 1 or 2 for primary and last treatment. ( 3 hours interval per
equipment )

TRIP

STOP (LIGHT INDICATOR)

START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

STEP 5. PUSH STOP BUTTON of Blower – 1 or 2 and Ozone – 1 or 2 for primary and last treatment. ( after 3hrs and repeat step
4. )

TRIP

STOP (LIGHT INDICATOR)

START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

STEP 6. PUSH START BUTTON of Transfer pump – 1 or 2 and Effluent pump– 1 or 2 for primary and last water transfer. ( Will
run based on the float switch installed on the chamber and it will automatically open the circuit when the water in the chamber
reached the maximum level to minimum level )

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 TRIP

STOP (LIGHT INDICATOR)

START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

STEP 7. PUSH the START BUTTON of the Recirculation pump for 10 mins every day after that PUSH STOP BUTTON .

TRIP

STOP (LIGHT INDICATOR)

START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

STEP 8. For the BACKWASHING SYSTEM OF MULTI-MEDIA and ACTIVATED CARBON FILTER turn the lever 180 deg.
counterclockwise one at a time for 10mins. This procedure must be done twice or thrice a week.

BACKWASH WASH- RINSE FILTER

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STEP 9. After of BACKWASHING of MULTI-MEDIA and ACTIVATED CARBON FILTER turn the lever 180 deg. clock-wise
one at a time. BACKWASH WASH- RINSE FILTER

II. AUTOMATIC SETTING

STEP 1. SWITCH ON ALL CIRCUIT BREAKERS INSIDE OF CONTROL PANEL

ON

OFF

STEP 2. Set the Selector switch of Blower – 1 or 2, Ozone – 1 or 2, Transfer pump – 1 or 2, and Effluent pump – 1 or 2
to AUTOMATIC (A) position

TRIP
STOP (LIGHT INDICATOR)
START (LIGHT INDICATOR)

STOP (PUSH BUTTON)

START (PUSH BUTTON)

SELECTOR SWITCH 3 POSITION ( H O A )

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STEP 3. For the BACKWASHING system please refer to steps 8 and step 9 of the manual setting for the procedure.

NOTE:

In the AUTOMATIC setting the BLOWER – 1 and 2, OZONE – 1 and 2, and Re-circulation pump will run based on the
timer installed inside of the STP control panel.

In the AUTOMATIC / MANUAL setting the TRANSFER PUMP – 1 and 2, and EFFLUENT PUMP – 1 and 2 will run based
on the installed float switch in the chamber.

For TROUBLESHOOTING please refer to the troubleshooting appendix of per equipment or contact us for immediate
assistance.

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 TROUBLESHOOTING

APPENDIX A
BLOWER
Abnormality Cause Antidote
The blower Rotate by hand, and perform an inching
Rotor sticking.
cannot rotate operation.
Indraft foreign objects in the casing. Remove the foreign objects
V-belt sagged or slipped. Re-tensioning the belt or replacing it.
Strange noise or Insufficient grease or grease transmuted, or
Replace (add) assign grease.
vibration grease is inferior.
Indraft foreign objects in the casing. Remove the foreign objects
Contact between rotors. Re-align the rotor position.
Abnormal pressure rising. Remove the sources that cause it.
The safety valve was ejected. Inspect the safety valve.
Bur or protrusion on pulley surface. Remove them.
Belt is too tight. Re-tensioning it.
Re-tensioning the belt, or adjust the belt
Contact between belt cover and belt.
cover.
Bad blower foundation, causes to
Strengthen the foundation.
Vibration.
Looseness in the fixing area. Tighten the loose joints.
Piping bent. Replace the bent segment.
Co-vibration occurred from the piping.
Insufficient gear oil or gear oil transmuted, or
Replace (add) assigned gear oil.
gear oil is inferior.
Abnormal heat Discharge pressure increased. Remove sources that cause it.
emission Increase ventilation to lower room
Insufficient room ventilation.
temperature.
Clogging of the suction pipeline. Cleaning silencer and the piping.
Oil leakage Too much Grease was supplied. Reduce the Grease volume.
Adjust to the middle level of the level gauge.
Too much Gear Oil was added.

Looseness in the fixing area. Tighten the loose area.

Gasket damage. Replace gasket.
Insufficient air or no air Leaking from the piping. Make up the leakage.
The safety valve was ejected. Inspect the safety valve.
Clogging of the suction pipeline. Cleaning silencer and the piping.
Discharge pressure increased. Remove sources that cause it.

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 V-belt sagged or slipped. Re-tensioning the belt or replacing it.
Insufficient motor RPM Increase the RPM.
Discharge pressure Valve closed or not fully opened. Fully open the valve.
increased The water level of the pond ascended.
Sludge density or sedimentation
Remove the sludge sedimentation.
increased.
RPM too high cause to high air volume
Reduce RPM.
supply.
Clogging of the diffusers. Clean the diffusers.
Check valve malfunctioned, or is connected in the Replace, or adjust the direction of the
wrong direction check valve.

SUBMERSIBLE PUMP
TROUBLESHOOTING
CAUTION! Always disconnect the pump from the electrical power source before handling.
If the system fails to operate properly, carefully read instructions and perform maintenance recommendations. If
operating problems persist, the following chart may be of assistance in identifying and correcting them: MATCH
“CAUSE” NUMBER WITH CORRELATING “CORRECTION” NUMBER.

NOTE: Not all problems and corrections will apply to each pump model.
PROBLEM
The pump will not run
The pump will not turn off
The pump hums but does not run
The pump delivers insufficient capacity
CAUSE
1. Poor electrical connection, blown fuse, tripped
breaker or other interruption of power, improper
power supply.
2. Motor or switch inoperative (to isolate
the cause, go to manual operation of the
pump). 2a. Float movement restricted.
2b. Switch will not activate the pump or is defective.
2c. Defective motor
3. Insufficient liquid level.
2a. Float movement restricted.
2b. Switch will not activate the pump or is defective.
4. Excessive inflow or pump not properly sized for
the application.
9. Pump may be airlocked
14. H-O-A switch on the panel is in the “HAND”
position
1. Incorrect voltage
8. Impeller jammed or loose on the shaft, worn or
damaged, impeller cavity or inlet plugged.
1. Incorrect voltage.
4. Excessive inflow or pump not properly sized for
the application.
5. Discharge restricted.
6. Check valve is stuck closed or installed backward.
7. Shut-off valve closed.
8. Impeller jammed or loose on the shaft, worn or
damaged, impeller cavity or inlet plugged.
9. Pump may be airlocked.
10. Pump running backward
CORRECTION
1. Check all electrical connections for security.
Have the electrician measure the current in
motor leads, if the current is within ±20%
of locked rotor Amps, the impeller is probably
locked. If the current is 0, overload may be tripped.
Remove power, allow the pump to cool, then
recheck current.
2a. Reposition the pump or clean basin as
required to provide adequate clearance for float.
2b. Disconnect level control. Set the ohmmeter for
a low range, such as 100 ohms full scale, and
connect to level control leads. Actuate level
control manually and check to see that ohmmeter
shows zero ohms for the closed switch and full
scale for the open switch. (Float Switch). 2c.
Check winding insulation (Megger Test) and
winding resistance. If a check is outside
of the range, dry and recheck. If still defective,
replace it per service instructions.
3. Make sure the liquid level is at least equal to
the suggested turn-on point.
4. Recheck all sizing calculations to
determine the proper pump size.
5. Check the discharge line for restrictions,
including ice if the line passes through or
into cold areas.
6. Remove and examine the check valve for
proper installation and freedom of operation.
7. Open valve.

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OPERATION MANUAL
Pump cycles too frequently or runs 6. Check valve is stuck closed or installed
periodically when fixtures are not in use backward.
11. Fixtures are leaking.
15. Ground water entering the basin.
The pump shuts off and turns on independent 1. Incorrect voltage.
of a switch, (trips thermal overload protector). 4. Excessive inflow or pump not properly sized for
CAUTION! A pump may start unexpectedly. the application.
Disconnect the power supply. 8. Impeller jammed, loose on the shaft, worn or
damaged, impeller cavity or inlet plugged.
12. Excessive water temperature.
(internal protection only)
The pump operates noisily or 2c. Worn bearings, motor shaft bent.
vibrates excessively 5. Debris in the impeller cavity or broken impeller
10. Pump running backward
13. Piping attachments to building structures are too flexible connector.
rigid or too loose.
8. Check the impeller for freedom of
operation, security, and condition. Clean the
impeller and inlet of any obstruction.
9. Loosen the union slightly to allow trapped
air to escape. Verify that the turn-off level of
the switch is set so that the suction is always
flooded. Clean vent hole.
10. Check rotation. If the power supply is three-
phase, reverse any two of the three power supply
leads to ensure proper impeller rotation.
11. Repair fixtures as required to eliminate
leakage.
12. Check pump temperature limits & fluid
temperature.
13. Replace a portion of discharge pipe with
14. Turn to automatic position.
15. Check for leaks around basin inlet and
outlets.

EQUIPMENT OPERATION

EQUIPMENT QTY DESCRIPTION POWER OPERATION DUTY

SUPPLY

TRI-LOBE 2 ROTARY TRI-LOBE 220V/440V, 60Hz,

3 HOURS INTERVALS ON/OFF
BLOWER UNIT BLOWER 3PHASE
5.5Kw
OZONE 2 220V, 60Hz, 3 HOURS INTERVALS ON/OFF
50g/L, 1.4Kw
GENERATOR UNIT SINGLE PHASE
WATER SUBMERSIBLE
2 220V, 60Hz, SYNCHRONIZED IN OZONE
OZONATOR VORTEX
UNIT SINGLE PHASE GENERATOR
PUMP IMPELLER, .75Kw

SUBMERSIBLE
EFFLUENT 2 220V, 60Hz,
VORTEX ONE DUTY & ONE BACK-UP
PUMP UNIT 3PHASE
IMPELLER, 3.7Kw

RE- SUBMERSIBLE
2 220V, 60Hz, MANUAL OPERATION EVERY
CIRCULATION VORTEX
UNIT SINGLE PHASE 6:00 PM, RUN FOR 10 mins.
PUMP IMPELLER, .75Kw

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