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



Quantity : One No.

4. PRIMARY CLARIFIER

Type : Circular

Volume : 37 M3

13

Size : 4000 mm dia. x 3000mm SWD + 300 mm FB


Quantity : One No.

5. FEED TANK

Type : Square

Volume : 179 M3


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


Quantity : One No.

8. AERATION TANK - I

Type : Rectangular

Volume : 2400 M3



14

Quantity : One No.

9. SECONDARY CLARIFIER - I

Type : Circular

Volume : 34 M3



Quantity : One No.

10. AERATION TANK - II

Type : Rectangular

Volume : 500 M3

Size : 12000 x 12000 x 3500mm SWD + 300 FB


Quantity : One No.

11. SECONDARY CLARIFIER - II

Type : Circular

Volume : 51 M3



Quantity : One No.

12. SUPERNATANT TANK

Type : Square/Rectangular


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



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


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.


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


Drive : 3.0 HP (each ) motor , 3 phase , 2900 rpm,

TEFC class ‘F’ insulation with IPP 55

protection, weather proof.


Pump Make : Johnson




IX) AR RECYCLING PUMP

Application : Effluent recirculation at Anaerobic

Reactor

Location : Anaerobic Reactor


open impeller


Drive : 3.0 HP ( each ) motor , 3 phase,

2900 rpm, TEFC class ‘F’

insulation with IPP 55



Pump Make : Johnson


20



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


clarifier

Location : At Secondary Clarifier-I.




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.





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


open impeller


Drive : 2.0 HP (each) motor, 3 phase, 2900 rpm,




Pump Make : Johnson




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


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


clarifier

Location : At Secondary Clarifier-II




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.





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


open impeller


Drive : 2.0 HP (each) motor, 3 phase, 2900 rpm,




Pump Make : Johnson




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

33

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

34

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.

35

RAS = Plant flow X MLVSS

Return solids – MLVSS consent

36

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.

38

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.

39

DRAWINGS

40

LIST OF DRAWINGS ENCLOSED

1. ETP Process Flow Diagram

2. ETP Layout Diagram

3. P & I Diagram

41

Date post:	23-Nov-2014
Category:	Documents
Upload:	bathalapalli
View:	123 times
Download:	0 times

O & M Manual for macoil 240 KLD

Documents