March 14, 2017 | Author: Atul Sharma | Category: N/A
OPERATION & MAINTENANCE MANUAL FOR THE EFFLUENT TREATMENT PLANT
FOR ALEMBIC LIMITED, BADDI, DIST. SOLAN
Synergie ecoSolutions Pvt. Ltd.
1, Mitali Apt, Plot # 45, Bhusari Colony, Paud Road, Kothrud, Pune – 411038 Maharashtra India Rev:
0
Date:
Phone - (91 20) 5285026 Fax - (91 20) 5285426 1-Nov-04 Email –
[email protected]
Page 1 of 32
OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Project:
Effluent Treatment Plant
TABLE OF CONTENTS
A. Design Criteria B. Process Description C. List of Equipment, with their makes and serial numbers D. List of Motors, with their serial numbers E. List of Civil Structures with their sizes and capacities F. Drawings a. Process Flow Diagram b. Piping & Instrumentation Diagram c. Hydraulic Flow Diagram d. Single Line & Wiring Diagram for MCC Panel G. Standard Operating Procedures for the ETP H. Pro-forma for Log Sheet
Rev:
I.
Analysis Schedule
J.
Copies of catalogues and manuals of various equipment
0
Date:
1-Nov-04
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
DESIGN CRITERIA & PROCESS DESCRIPTION
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0
Date:
1-Nov-04
Page 3 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Effluent Treatment Plant
Project:
1. DESIGN CRITERIA:
1.1. Inlet Effluent Characteristics The following design data has been considered for design of the ETP, based on the data given by M/S. Ispat Industries Ltd. Parameter
Units
Average Flow Rate (Present)
M3/day
25.0
Average Daily Flow Rate (Future)
M3/day
50.0
pH
-
6.5 to 8.5
Chemical Oxygen Demand (COD)
Mg/L
2,500.0
Bio-Chemical Oxygen Demand (BOD)
Mg/L
1,500.0
Total Suspended Solids
Mg/L
250.0
Oil & Grease
Mg/L
200.0
1.2.
Value
Treated Effluent Characteristics
The plant is designed to deliver, after final treatment, effluent as per following parameters:
Rev:
Parameter
Units
pH
-
Bio-Chemical Oxygen Demand (BOD)
Mg/L
Less than 100.0
Total Suspended Solids
Mg/L
Less than 50.0
Oil & Grease
Mg/L
Less than 10.0
0
Date:
1-Nov-04
Value 6.5 to 8.5
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
2. PROCESS DESCRIPTION The treatment scheme can be divided into the following sections:
2.1.
Effluent Collection & Equalization
The effluent from the plant is conveyed to the ETP through closed pipelines. Near the ETP, all the pipelines are connected to a common chamber. From this common chamber, the effluent flows by gravity into the Oil and Grease Trap (T – 01). The oil and grease trap will be divided into three compartments, connected by an H-Pipe mechanism. In the second compartment of the Oil & Grease Trap, the any free floating oil and grease present will float to the top, under quiescent condition and will be skimmed off manually at regular intervals. The effluent that is essentially of free floatable oil and grease will be collected in the last compartment. From the oil and grease trap, the effluent flows by gravity into the Neutralization Cum Equalization Tank (T – 02 A/B). The equalization tank will be divided into two compartments – The effluent will be collected in one of the compartment, which is sufficient to collect one days effluent at present flow. Once one compartment is full, the contents of the tank will be mixed by blowing air through the pipe grid at bottom of the tank. The pH of the effluent will be checked and the effluent required by dosing acid or alkali as per the requirement. Once the pH is adjusted, the effluent pumping is started from this tank and the fresh incoming effluent is collected in the second compartment. An acid dosing tank and alkali dosing tank are kept near the equalization tank for the purpose. From the equalization tank, the effluent is pumped to the effluent treatment system by the Raw Effluent Pumps (P – 01 A/B). As a good engineering practice, 2 (Two) Nos. of Centrifugal Nonclog Type Pumps (1 Working + 1 Standby) have been installed.
2.2.
Primary Treatment
From the equalization tank, the raw effluent will be pumped to the Flash Mixer (T – 03), where the effluent will be mixed with alum and polyelectrolyte, in order to coagulate, flocculate and thereby increase the settling of the suspended solids present in the waste water. The flash mixer has been designed to give a retention time of approx. 30 minutes at final flow. The mixing of alum and polyelectrolyte will be carried out by means of a mechanical mixer.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
The alum and polyelectrolyte will be dosed into the effluent at a desired rate using the alum and polyelectrolyte dosing pumps respectively. Two numbers of electronic dosing pumps are provided for the purpose. From the flash mixer, the effluent will flows into the Tube Settler (T – 04). The tube settler has been provided in order to conserve the space and promote effective settling of the suspended solids. A PVC tube pack has been installed in the Tube Settler to increase the surface area available for settling. The sludge which collects in the hopper of the primary clarifier will be drained periodically into the sludge drying beds. The clarified effluent will then flow into the aeration tank for further treatment.
2.3.
Secondary Treatment
The secondary treatment has been provided to remove the organic matter present in the effluent, by biological action. The clarified wastewater flows by gravity to the inlet launder of the Aeration Tank (T – 05). The purpose of the aeration tank is to provide suitable conditions for the growth of microbial mass, called as the Activated Sludge & measured by parameter called as MLSS. The activated biomass or MLSS in the aeration tank will degrades the organic matter (which is measured as BOD/COD), in presence of oxygen and converts them to harmless carbon dioxide and water, thus leading to reduction in BOD/COD. This process can be represented as: Organic Matter + O2 +Bacteria
CO2 + H2O + More Bacteria (Waste Sludge)
The oxygen required for the Aerobic Biological Action is provided by means of a Diffused Aeration System, consisting of Membrane Diffusers & Air Blower. The MLSS in the aeration tank settles in the Secondary Clarifier (T – 06) and the clarified treated effluent flows into the Treated Water Tank (T – 07). In order to maintain the MLSS concentration at the desired level, the settled biomass is re-circulated back into the aeration tank by the Sludge Recycle Pump (P – 02) and the treated water is treated further, if required.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
If the quantity of MLSS in the aeration tank increases beyond a certain level, a part of the sludge is discharged to the Sludge Drying Beds (T – 09) for dewatering and drying. The filtrate of sludge drying beds is conveyed back to equalization tank.
2.4.
Tertiary Treatment
A sand filter and carbon filter can be provided, so that even the remaining suspended solids and small quantity of organics present in the treated wastewater can be removed. For this, the treated effluent from the treated water tank is pumped by the Treated Water Pumps (P – 03 A/B) through the Pressure Sand Filter and Activated Carbon Filter and collected in Clean Water Tank (T – 08). From the clean water tank, the effluent will be pumped for gardening by the Clean Water Pumps (P – 04 A/B).
2.5.
Sludge Disposal
The solid waste generated during the primary treatment and the biological treatment will be dewatered in the Sludge Drying Beds and then sun dried. The dried sludge will then be transported periodically to the authorized solid waste disposal facility.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
LIST OF MECHANICAL EQUIPMENT AND CIVIL STRUCTURES
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Date:
1-Nov-04
Page 8 of 32
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P – 03 A
P – 03 B
P – 04 A
P – 04 B
P – 05
P – 06
B – 01 A
B – 01 B
A - 01
A – 02
F – 01
F – 02
FI – 01
0
4
5
6
7
8
9
10
11
13
12
13
14
15
Date:
Flow Meter
P – 02
3
Activated Carbon Filter
Pressure Sand Filter
Secondary Clarifier
Flash Mixer
Air Blower – 2
Air Blower – 1
Poly. Dosing Pump
Alum Dosing Pump
Clean Water Pump 2
Clean Water Pump 1
Treated Water Pump 2
Treated Water Pump 1
Sludge Recycle Pump
Raw Effluent Pump 2
P – 01 B
2
Item
Raw Effluent Pump 1
P – 01 A
Tag No.
1
Sr.
1. List of Mechanical Equipment
Digital
800 mm Dia
800 mm Dia
3.0 M Dia x 3.0 M SWD
100 rpm
200 M3/Hr @ 5 M WC
200 M3/Hr @ 5 M WC
0-10 LPH @ 25 M WC
0-5 LPH @ 25 M WC
3 M3/Hr @ 30 MWC
3 M3/Hr @ 30 MWC
3 M3/Hr @ 30 MWC
3 M3/Hr @ 30 MWC
3 M3/Hr @ 12 MWC
3 M3/Hr @ 12 MWC
3 M3/Hr @ 12 MWC
Specifications
Vaturkar
Page 9 of 32
Synergie ecoSolutions
Synergie ecoSolutions
Environ Engg.
Kumar Process
Usha Compressor
Usha Compressor
E Dose
E -Dose
Johnson Pumps
Johnson Pumps
Johnson Pumps
Johnson Pumps
Johnson Pumps
Johnson Pumps
Johnson Pumps
Make
Central Drive
UGRK –
UGRK –
KGEN 16 – 3
KGEN 16 – 3
KGEN 16 – 3
KGEN 16 – 3
KGEN 11 – 3
KGEN 11 – 3
KGEN 11 – 3
Model
Sr. No.
M - 01
M – 02
M – 03
M – 04
M – 05
M – 06
M – 07
M – 08
M – 09
M – 10
M – 11
2
3
4
5
6
7
8
9
10
11
Tag No.
1
Sr.
2. List of Motors
A – 02
A – 01
B – 01 B
B – 01 A
P – 04 B
P – 04 A
P – 03 B
P – 03 A
P – 02 A
P – 01 B
P – 01 A
Equip Tag
0.5 HP
0.5 HP
5 HP
5 HP
3 HP
3 HP
3 HP
3 HP
1 HP
1 HP
1 HP
Power
O & M Manual for Effluent Treatment Plant for Ispat Industries Ltd.
1450
1450
2900
2900
2900
2900
2900
2900
2900
2900
2900
RPM
3
3
3
3
3
3
3
3
3
3
3
Phase
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Crompton
Make
415
415
415
415
415
415
415
415
415
415
415
Volts
Current
Frame Size
Sr. No.
Synergie ecoSolutions Pvt. Ltd.
T – 01
T – 02
T – 03
T – 04
T – 05
T – 06
T – 07
T – 08
T – 09
R - 01
2.
3.
4.
5.
6.
7.
8.
9.
10.
Tag No.
1.
Sr.
Title
Control Room
Sludge Drying Beds
Clean Water Tank
Treated Water Tank
Secondary Clarifier
Aeration Tank
Tube Settler
Flash Mixer
Equalization Tank
Oil & Grease Trap
3. List of Civil Structures
O & M Manual for Effluent Treatment Plant for Ispat Industries Ltd.
BBM
BBM
RCC
RCC
RCC
RCC
MS
RCC
RCC
RCC
MOC
2
1
1
1
1
1
1
2
3
No. of Compart.
Length
Width SWD
Free Board
Depth Total
Total
Working
Volume
Synergie ecoSolutions Pvt. Ltd.
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
DRAWINGS
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1-Nov-04
Page 12 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
Process Flow Diagram
Acid Dosing Tank
Effluent Channel
Oil & Grease Trap
Collection Chamber
Alkali Dosing Tank
Equalization Tank Alum Dosing Tank
Raw Effluent Pumps
Poly Dosing Tank
Dosing Pumps Flash Mixer
Air Blowers
Waste Sludge
Tube Settler
T – 09 A/B Aeration Tank
Waste Recycle
Sludge Drying Beds
Sec. Clarifier Central Drive Sludge Recycle Pumps
Treated water Tank
Treated Water Pumps
Pressure Sand Filter Clean Water Pumps
Disposal to Gardens
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Treated water Tank
1-Nov-04
Activated Carbon Filter
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
SINGLE LINE & WIRING DIAGRAM FOR CONTROL PANEL
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
STANDARD OPERATING PROCEDURES
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Page 17 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
1. Collection of Effluent in the Oil & Grease Trap 1.1. The effluent from the plant flows into the oil & grease trap by gravity through a closed pipeline.. 1.2. The free floating oil and grease in the effluent floats to the top in the second compartment of the oil & grease trap. 1.3. Check the oil & grease level daily 1.4. If the oil level in the second compartment is more than 1” in thickness, skim off the oil manually using a suitable vessel and collect it in an open drum, with valve at the bottom. 1.5. Once the collected oil is settled, open the bottom valve and remove any water that is collected with the oil.
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OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Project:
Effluent Treatment Plant
2. Operation of the Equalization Tank 2.1. The effluent free from oil and grease will flow into the equalization tank. 2.2. The equalization tank is divided into two compartments: Equalization Tank 1 & Equalization Tank 2
2.3. To collect the effluent in Equalization Tank 1: 2.3.1. Open the Valve V – 01 of Equalization Tank 1 2.3.2. Close the valve V – 02 of the Equalization Tank 2 2.3.3. Collect the effluent in Equalization tank 1, till the desired top water level of the tank is reached. 2.3.4. Check that there is sufficient air flow into the tank for mixing of the effluent, by adjusting the air valve AV – 03.
2.4. To collect the effluent in Collection Tank 2 2.4.1. Open the Valve V – 02 of Equalization Tank 2 2.4.2. Close the valve V – 01 of the Equalization Tank 1 2.4.3. Collect the effluent in Equalization tank 2, till the desired top water level of the tank is reached. 2.4.4. Check that there is sufficient air flow into the tank for mixing of the effluent, by adjusting the air valve AV – 04. 2.5.
Once one of the tank is full, stop the flow into that tank and start flow into the second
tank.
2.6.
Adjustment of pH in the Equalization Tank
2.6.1. Check pH of the effluent in the tank from which the effluent is to be pumped. 2.6.2. Start air flow in the equalization tank, under consideration. 2.6.3. Add Acid or Alkali, as per the requirement, till pH of effluent is in the range of 7.0 to 7.5.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
3. Pumping of Effluent from Equalization Tank 3.1. Once the pH is adjusted, stop the air flow. 3.2. Check that the MCB of the pumps is in an “On” position.
3.3. Operation of Pump P – 01 A in Equalization Tank T – 02 A 3.3.1. Check that the valve V-05 on the pump discharge line is open. 3.3.2. Check that the valve V – 06 on the pump discharge of Raw Effluent Pump P – 01 B is closed. 3.3.3. Switch on the pump, by pushing the green push button on the control panel. 3.3.4. Observe for a few minutes for any abnormal noise. 3.3.5. Check if there is a steady effluent flow in the flash mixer. 3.3.6. Periodically check that the footvalves of the pumps are not choked. 3.3.7. Stop the pump by pushing the red button for the respective pumps.
3.4. Operation of Pump P – 01 B in Equalization Tank T – 02 B 3.4.1. Check that the valve V-06 on the pump discharge line is open. 3.4.2. Check that the valve V – 05 on the pump discharge of Raw Effluent Pump P – 01 A is closed. 3.4.3. Switch on the pump, by pushing the green push button on the control panel. 3.4.4. Observe for a few minutes for any abnormal noise. 3.4.5. Check if there is a steady effluent flow in the flash mixer. 3.4.6. Periodically check that the footvalves of the pumps are not choked. 3.4.7. Stop the pump by pushing the red button for the respective pumps.
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OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Project:
Effluent Treatment Plant
4. Operation of the Flash Mixer 4.1.
Switch on the flash mixer by pressing the green button in the control panel.
4.2.
Check for direction of rotation of the flash mixer. The rotation should be in clockwise
direction. 4.3.
Start the dosing of alum and polyelectrolyte at the desired flow rate.
4.4.
Preparation of 10% Alum Solution
4.4.1. Weigh 10 Kgs of Alum. 4.4.2. Dissolve the alum in about 50 liters if water in a tank. 4.4.3. Allow the solution to settle. 4.4.4. Decant the supernatant and make up the volume to 100 Liters.
4.5.
Dosing of Alum Solution
4.5.1. Start the Alum Dosing Pump from the control panel. 4.5.2. Switch on the button located on the back panel of the pump. 4.5.3. Once the pump is operational, adjust the flow rate of the solution to approx. 50% of the full capacity by turning the knob on the back panel. 4.5.4. DO NOT ROTATE THE STROKE LENGTH KNOB OF THE PUMP, WHEN THE PUMP IS NOT IN OPERATION. THIS CAN DAMAGE THE PUMP. 4.5.5. Ensure that the flow rate of the alum is proper and in the desired range.
4.6.
Preparation of 0.1% Polyelectrolyte Solution
4.6.1. Measure and take 100 liters of water in the Polyelectrolyte dosing tank. 4.6.2. Weigh 100 grams of suitable polyelectrolyte. 4.6.3. Add slowly to the water in the poly. dosing tank, with constant mixing. 4.6.4. Mix continuously for about 20 minutes to ensure a uniform smooth, viscous solution.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
4.6.5. ENSURE THAT NO LUMPS OF POLYELECTROLYTE ARE FORMED & THAT THE POLYELECTROLYTE IS COMPLETELY DISSOLVED IN THE WATER.
4.7.
Dosing of Alum Solution
4.7.1. Start the Polyelectrolyte Dosing Pump from the control panel. 4.7.2. Switch on the button located on the back panel of the pump. 4.7.3. Once the pump is operational, adjust the flow rate of the solution to approx. 50% of the full capacity by turning the knob on the back panel. 4.7.4. DO NOT ROTATE THE STROKE LENGTH KNOB OF THE PUMP, WHEN THE PUMP IS NOT IN OPERATION. THIS CAN DAMAGE THE PUMP. 4.7.5. Ensure that the flow rate of the Polyelectrolyte is proper and in the desired range.
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OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Project:
Effluent Treatment Plant
5. Operation of the Tube Settler 5.1.
No operation is required normally in the tube settler.
5.2.
The only operation is to check the sludge levels periodically and remove the waste
sludge.
5.3.
To remove the waste Sludge
5.3.1. Close the secondary clarifier sludge withdrawal valve V – 8. 5.3.2. Close the Discharge Valve V – 10 on the aeration tank. 5.3.3. Open the discharge valve V – 07 at the bottom of the Tube Settler. 5.3.4. Open valve V – 11 or 12 on the sludge drying beds. 5.3.5. Start the pump by from the push button located on the control panel. 5.3.6. Allow the waste sludge to flow into the sludge drying bed, till clear water is seen. 5.3.7. When clear water is seen in the waste sludge line, Stop the Sludge Recycle Pump. 5.3.8. Close the discharge valve V – 07 at the bottom of the Tube Settler. 5.3.9. Close valve V – 11 or 12 on the sludge drying beds.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
6. Aeration of Effluent in Aeration Tank 6.1.
Maintain air supply in the aeration tank continuously for 24 hours.
6.2.
Check whether the air flow from the diffusers is approximately uniform and at the given flow rate, by adjusting Air Valve AV – 01.
6.3.
Add Urea & DAP solutions in the aeration tank, so as to get COD:N:P Ratio of 100:5:1 at the following ratesUrea
:
DAP 6.4.
2.0 Kg/day (for flow rate of 25 M3/day)
0.4 Kg/day (for flow rate of 25 M3/day)
:
The bacterial mass which develops in the aeration tank (called as MLSS) is normally brown in color and flocculent (settles easily).
6.5.
The MLSS should be maintained between 3,000 mg/l and 3,500 mg/l.
6.6.
Ensure that the sludge from the secondary clarifier is continuously recycled back to the aeration tank at a rate of 1 to 2 M3/Hr. The flow rate can be maintained by throttling the valve V – 09 on the delivery side of the sludge recycle line.
6.7.
If the MLSS increases above 3,000 mg/l, discharge a part of the MLSS from the recycle line into the sludge tank (“Sludge Wasting”). For calculations, see item no. 6.0 of the manual.
6.8.
During Commissioning : 6.8.1.
Do not waste any secondary sludge (MLSS) into the sludge tank, until the design value is reached.
6.8.2.
Add bio-products at the given dosage in the aeration tank, by dissolving them in water.
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OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
7. Clarification & Recycle of MLSS in Secondary Clarifier 7.1. The wastewater from the aeration tank will flow into the secondary clarifier, where the MLSS from the aeration tank will settle down and the clear supernatant will flow to the treated water tank. 7.2. Check the sludge levels twice per shift. 7.3. If the sludge levels appear to be too high, increase the sludge recycle rate. 7.4. If lot of microbial mass is seen floating on top of the water, 7.4.1. Check pH of the aeration tank. The pH should be in the range of 7.4 to 7.7. If the pH is not in the above range, adjust the pH by adding suitable quantity of lime in the aeration tank.
7.5. Recycling of MLSS into the Aeration Tank: 7.5.1. Open the secondary clarifier sludge withdrawal valve V – 8. 7.5.2. Open the Discharge Valve V – 10 on the aeration tank. 7.5.3. Check that the discharge valve V – 07 at the bottom of the Tube Settler is closed. 7.5.4. Check that the valves V – 11 & 12 on the sludge drying beds are closed. 7.5.5. Start the pump by from the push button located on the control panel. 7.5.6. Recycle the settled sludge from the secondary clarifier into the aeration tank at rate of 1 to 2 M3/Hr. 7.6. Adjust the flow rate by adjusting the discharge valves of the sludge recycle pumps
7.7.
Wastage of Sludge from Secondary Clarifier
7.7.1. Open the secondary clarifier sludge withdrawal valve V – 8. 7.7.2. Close the Discharge Valve V – 10 on the aeration tank. 7.7.3. Check that the discharge valve V – 07 at the bottom of the Tube Settler is closed. 7.7.4. Open valve V – 11 or 12 on the sludge drying beds are closed. 7.7.5. Start the pump by from the push button located on the control panel.
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OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Project:
Effluent Treatment Plant
7.7.6. Allow the MLSS to flow into the sludge drying bed as per the following calculation.
7.8. Sludge Wasting Calculations
Design MLSS Concentration
:
3500 mg/l
Measured MLSS Concentration
:
4000 mg/l ( i.e. 4.0 Kg/M3)
Actual Return Sludge Concentration (A)
:
8000 mg/l (i.e. 8.0 Kg/M3) Assumed
Volume of aeration Tank
:
48.0 M3
Req. Weight of MLSS in aeration tank as per design ( B)
:
48.0 M3 x 3.5 Kg/M3 = 168.0 Kg,
Actual weight of MLSS in Aeration Tank
:
48.0 M3 x 4.0 Kg/M3 = 192.0 Kg
Excess MLSS in aeration tank( C- B)
:
192 Kg – 168 Kg = 24 Kg
Amount of Return sludge to be Wasted
:
24.00 Kg ------------ = 3.0 M3 8 Kg /M3
The actual sludge to be wasted can be calculated as above, based on the actual figures for MLSS & Return Sludge concentrations. The excess sludge should be discharged to the sludge drying beds distributed in 3 equal volumes , i. e. in above case 1.0 M3 every 8 hours
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OPERATION & MAINTENANCE MANUAL Client : 8.
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
Pumping of Treated Effluent from Treated Water Tank to Sand & Carbon Filter
8.1.
Check that the MCB of the pumps is in an “On” position.
8.2.
To operate Treated Water Pump – 1, check that the valve V – 13 on the pump suction line and V-14 on the pump discharge line are open.
8.3.
To operate Treated Water Pump – 2, check that the valve V – 15 on the pump suction line and V-16 on the pump discharge line are open.
Rev:
8.4.
Switch on the pump, by pushing the green push button on the control panel
8.5.
Observe for a few minutes for any abnormal noise.
8.6.
Check if there is a steady effluent flow to the sand filter.
8.7.
Adjust the flow rate to the sand filter, by adjusting the position of valves V – 21 & V – 22.
8.8.
Periodically check that the footvalves of the pumps are not choked.
8.9.
Stop the pump by pushing the red button for the respective pumps.
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Page 27 of 32
OPERATION & MAINTENANCE MANUAL Alembic Limited, Baddi
Client :
Effluent Treatment Plant
Project:
9. Operation of Sand & Carbon Filter 9.1.
For operation of the sand filter and carbon filter, see Table 13.1 below:
Table 13.1: Position of Valves for operation of sand and carbon filter in various modes. Mode of Operation Normal Mode
Valves to be opened
Valves to be closed All Other Valves
Sand Filter Inlet V – 23 Sand Filter Outlet V – 25 Carbon Filter Inlet V – 29 Carbon Filter Outlet V - 30
Sand Filter Backwash Mode
Sand Filter Backwash V – 27
Sand Filter Inlet V – 23
Sand Filter Backwash V – 24
Sand Filter Outlet V – 25 Filter Bypass V – 26 Air Vent V – 28 All Carbon Filter Valves
Carbon Filter Backwash
Carbon Filter Backwash V – 32
Carbon Filter Inlet V – 29
Sand Filter Backwash V – 31
Carbon Filter Outlet V – 30 Carbon Filter Vent V – 33 Carbon Filter Bypass V - 34
28
23
27
24
25
33 32
29
22
31 26
Rev:
0
Date:
1-Nov-04
30
34
Page 28 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
10. Collection of Water in Clean Water Tank
Rev:
10.1.
The clean water after carbon filter is collected in the clean water tank.
10.2.
From the clean water tank, the water is drained out.
0
Date:
1-Nov-04
Page 29 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
PROFORMA OF LOG SHEET FOR THE ETP
Rev:
0
Date:
1-Nov-04
Page 30 of 32
Synergie ecoSolutions Pvt. Ltd.
Date:
EFFLUENT TREATMENT PLANT LOGSHEET
A/B/C
Shift: Operator:
A. EQUIPMENT OPERATIONAL STATUS Sr.
Tag No.
Description
1
P - 01 A
Raw Effluent Pump 1
2
P - 01 B
Raw Effluent Pump 2
3
P - 02 A
Sludge Recycle Pump 1
4
P - 02 B
Sludge Recycle Pump 2
5
P - 03 A
Treated Water Pump 1
6
P - 03 B
Treated Water Pump 2
7
P - 04 A
Clean Water Pump 1
8
P - 04 B
Clean Water Pump 2
9
P - 05
Polyelectrolyte Pump
10
P - 06
Alum Dosing Pump
11
B - 01 A
Air Blower 1
12
B - 01 B
Air Blower 2
13
A - 01
Flash Mixer
14
A - 02
Secondary Clarifier
Hours 1
2
3
4
5
6
7
8
5
6
7
8
Total Running
B. EQUALIZATION TANK UNDER PUMPING 1
T - 02 A
Equalization Tank 1
2
T - 02 B
Equalization Tank 2
C. WATER LEVEL IN TANKS (in meters) 1
T - 02 A
Equalization Tank 1
2
T - 02 B
Equalization Tank 2
3
T - 05
Treated Water Tank
4
T - 06
Clean Water Tank
5
T - 10
Alkali Dosing Tank
6
T - 11
Acid Dosing Tank
7
T - 12
Alum Dosing Tank
8
T - 13
Poly. Dosing Tank
D. FLOW METER READING Sr. 1
Tag No. FI - 01
Description
Hours 1
2
3
4
Equalization Tank Outlet
E. POWER CONSUMPTION Reading at Beginning of the Shift
Reading at End of Shift
Total power consumption in Shift
Total Daily Power Cons.
Total
Synergie ecoSolutions Pvt. Ltd.
Date:
EFFLUENT TREATMENT PLANT LOGSHEET
A/B/C
Shift: Operator:
F. pH Data Sr.
Tag No.
Description
1
T - 04 A
Equalization Tank 1
2
T - 04 B
Equalization Tank 2
3
T - 05
Aeration Tank
4
T - 07
Treated Water Tank
5
T - 08
Clean Water Tank
Hours 1
2
3
4
5
6
7
8
6
7
8
Total
G. CHEMICAL CONSUMPTION Sr.
Tag No.
Description
1
Alkali
2
Acid
3
Alum
4
Polyelectrolyte
5
Urea
6
DAP
Hours 1
2
3
4
5
Total Cons.
H. SAMPLING RECORDS 1
ETP Inlet
2
Secondary Clarifier Outlet
3
Final ETP Outlet
I. ANALYSIS RESULTS 1
pH
2
Oil & Grease
3
Total Suspended Solids / MLSS
4
Chemical Oxygen Demand
5
Biochemical Oxygen Demand
ETP Inlet
Aeration Tank Sec. Cl. O/L
Final Outlet
HPCB Std.
J. REMARKS
Operator
ETP Incharge
Maintenance Incharge
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
ANALYSIS SCHEDULE
Rev:
0
Date:
1-Nov-04
Page 31 of 32
OPERATION & MAINTENANCE MANUAL Client :
Alembic Limited, Baddi
Project:
Effluent Treatment Plant
The following is the suggested schedule of analysis for the ETP. The same may be modified depending on the local requirements and constraints.
Item
pH
1. Oil & Grease Trap Inlet
O&G
TSS
TDS
BOD
COD
Daily
2. Equalization Tank
Per Shift
Daily
Daily
3. Aeration Tank
Daily
Daily$
4. Secondary Clarifier Outlet
Daily
Daily
Daily*
Daily*
Daily
Daily*
Daily
5. Recycle Sludge Line 6. Treated Water Tank
Daily
7. Clean Water Tank
Daily
Daily Daily
Daily*
Daily*
Daily*
Daily*
* This is normally a statutory requirement. This is not essential for operation of the plant. $ TSS when measured for aeration tank is called MLSS
Rev:
0
Date:
1-Nov-04
Page 32 of 32
