Standard O&m Manual- Banganga.pptx

NAIK ENVIRO OPERATION & MAINTANANCE MANUAL FOR PACKAGE SEWAGE TREATMENT PLANT (STP) 1.5 mld, banganga.

Designed , Manufactured, Installed , Tested and Commissioned by

NAIK ENVIRONMENTAL ENGINEERS PVT LTD Address : A-686, Naikenviro House, TTC Industrial Area, Pawan, Navi Mumbai- 400705. Tel: 022-27780811/2154 email : [email protected] Website: www.naikenviro.com Patent No. 234990

PATENT CERTIFICATE

Project specifications Objective of Work: To treat and reuse the waste water for purpose like gardening, toilet flushing, car washing, road & sewer cleaning to reduce the demand of fresh water in the city area.

Scope of the work: •To design STP of 3 MLD capacity in two symmetrical modules of 1.5 MLD each. •To construct one module of 1.5 MLD. •To carry out O &M of 1.5 MLD STP for 15 years. Automation & Control System •Micrologix 1400 Programmable Controllers (SCADA) to control all pumps, valves, switches & probes etc. •Programmable Logic Control System. •Online Flow measuring arrangements like DO meter, Temperature meter, pH & Flow meter. Space Requirement: Space given for Construction of two 1.5 MLD STP : 1274m2 Footprint used for Construction of one unit of 1.5 MLD: 225 m2 (75% space saved) Energy Consumption: Power Consumption will be less than or equal to 1849 units/day (inclusive of all the pumps, illumination, Ozonation system)

PRODUCT INFORMATION •Cuts Wastewater treatment costs by using the intensified package concept.

•Drastically reduces space requirements. •Runs with a very low power input. •Produces a sparkling, clear treated effluent free from any trace of odour.

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THE OPERATING PRINCIPLE OF STP 3 2

4

1

Conceptually, the process is extremely simple: A small amount of microorganisms 1 converts a large mass of polluted water 2 into clean water 3. This process also produces a co-product: A vastly reduced, compact solid biomass 4 (the excess microorganisms produced by growth and multiplication of the original population of microorganisms).

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FEATURES OF DESIGN Treated effluent quality: Treated effluent meets the most stringent of standards (BOD: <10 ppm, TSS: <10 ppm). Compact and elegant: The system is elegantly designed with particular emphasis on compactness, aesthetics and ergonomics. Custom designed Geometry: Geometry of the unit has been tailored to suit the site geometry. The system requires far less space than that earmarked for the plant. Odour free environment: The system design ensures an odour free environment unlike competing systems. Low process power input: Less than 30% of that for a conventional activated sludge systems. Corrosion free materials: The plant is manufactured from mild steel plates and structural with resin epoxy coating on all surfaces for superior protection against corrosion. Minimal moving parts: Geared motors, pumps and support bearings for the RMBR constitute the moving parts requiring lubrication and servicing. The easy accessibility of these makes maintenance very convenient. Modular design: As the design is modular, expandability of the plant is convenient. Installation: Installation is very easy as the plant is entirely prefabricated and is merely to be mounted at the site. NAIKENVIRO

Dismantling and relocation: The entire plant can be conveniently shifted to a new location in future. Automated operation: The plant is designed for automated operation therefore manpower operation is minimal. Technology: The entire system can be remotely operated through a SCADA system and this is the first such Sewage Treatment Plant in India. Complete drying of sludge: Wedge-wire Stainless Steel trolleys with heating coils ensures complete drying of sludge, destruction of pathogens and deodorization, and drastic reduction in volume of sludge for disposal Cleaner environment: The fully enclosed design ensures a clean environment unlike competing systems.

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DESIGN CRITERIA RAW

TREATED

•

PH

6.9 Mg/l

•

PH

6.5-9.0

•

TSS

840 Mg/L

•

TSS

< 10 Mg/L

•

COD

•

DO

< 4 Mg/L

•

BOD

•

BOD

< 5 Mg/L

•

O&G

•

Nitrogen as Ammonia < 5 Mg/L

•

DO

•

Fecal Coli Forms < 200 Nos./100 Ml

•

FREE AMONIA

21 Mg/L

•

Color

Colorless

•

CHLORIDES

132 Mg/L

•

Odor

Odorless

•

TEMPERATURE

630 Mg/L 272 Mg/L Below Detection Level Below Detection Level

29 C

PROCESS FLOW DIAGRAM Screen

Raw waste water pump

Settling Tank

Flocculation Channel

Sludge Dewatering System

RMBR

Sludge

Meters: 1] Flow meter 2] pH meter 3] Temperature meter 4] DO meter Treated Water Tank

Activated Carbon Filter

Treated Water Tank

Ozone Dosing System

Pressure Sand Filter

Backwash/Rinse

Filter Feed Tank

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PLANT LAYOUT

3-D DRAWING OF 1.5 MLD STP RAW SEWAGE TANK

RMBR1,2,3

SETTLING TANK- 1,2,3

BEFORE

AFTER

Plant parts

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1. Raw sewage tank- It collects the incoming sewage. 2. Raw sewage pumps- These can be submersible/horizontal/ centrifugal in arrangement and are used to pump the water from Raw sewage tank to the RMBR after primary treatment i.e., removal of floatable plastics or solids using different types of screens. 3. RMBR- The RMBR brings about an intimate contact between the substrate in the wastewater and the active micro-organisms, in the presence of air. Here, organic matter in the wastewater comes into contact with a very large area of a biofilm residing on polypropylene media placed in the drum. 4. RMBR media- The media is of material polypropylene which is typically 12 cm in diameter, available surface area is greater thus larger bacterial population for the digestive process is available. The media is forty per cent (40%) immersed in wastewater. As the tank rotates, bacteria present in the wastewater, adhere to that plastic media as a film of slime. 5. RMBR tank- The tank provides the environment in which the digestion process occurs. It constricts the path of the wastewater stream to allow maximum exposure of organic waste in the water stream with the media.

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6. Settling Tank- Insoluble’s are separated from the water. The settler is based on the widely used principle of shallow depth sedimentation. After the retention time of 4hrs the Sludge settles into the hopper under the effect of gravity.

7. Filter Feed Sump- Clarified water from settler is collected in a filter feed sump, from where it is pumped for filter treatment. Here, the water is retained for 10 min for aeration. 8. Filtration unit- The pressure sand filter contains specially designed bed of graded quartz sand which removes residual colloids while the activated carbon column removes the residual dissolved trace organic compounds thereby rendering water free of organic contamination. The activated carbon also removes excess chlorine residuals resulting from hypochlorite dosing. 9. Valves- Filter , Backwash , Rinse , Recirculation , Closed. 10. Rotameter- The flow of the incoming treated water is measured with the help of Rotameter. 11.Treated water tank- The water after primary, secondary as well tertiary treatment render into the treated water tank from where is supplied for different purposes like gardening, toilet flushing etc. NAIKENVIRO

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STANDARD OPERATING PROCEDURE

1. Raw wastewater passes through a bar screen, which separates floatable solids from the incoming tank, and is collected in a Raw Sewage tank and pumped at a steady rate into the ECO-BIO-PACK.

2. The wastewater flows through the rotating media bioreactor where organic matter in the wastewater comes into intimate contact with a very large area of a rotating bio-film residing on synthetic media. 3. Aeration is achieved by rapid surface renewal of thin films of wastewater. As the film grows in thickness it sloughs off and a new film takes its place. This is a far superior and energy efficient system compared with bubbled aeration processes. 4. The effluent from RMBR flows through a settler in which sloughed biological solids settle to the bottom of the tank in quiescent conditions while clarified water flows out on a continuous basis. 5. Settled sludge is discharged on a periodic basis into a suspended bag sludge dewatering system. Dewatered humus is an excellent soil conditioner and is therefore a valuable byproduct of the system.

8. Clear water is then polished by pumping it through a Dual Media Filter containing Activated Carbon.

9. Filtered water is disinfected using an Ozone Dosing System before utilization for toilet flushing or gardening or any other designated use subject to our acceptance. 10. A bypass Orifice type Rotameter is provided to measure the flow rate. 11. The entire operation is extremely simple and the system once stabilized, can be left to itself with very little human intervention. A Control panel takes care of the operation of the plant.

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Unit operation

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SCREEN

Major unit operations in STP

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RMBR

1. Raw Sewage Pumping Arrangement 2. Inlet Chamber Unit 3. Screen Chamber Unit 4. Secondary & Tertiary Treatment Unit 5. Disinfection Unit

SETTLING TANK

6. Sludge Collection & Treatment Unit 7. Treated Water Tanks

FILTERATION UNIT

8. Automation & Control System CONTROL PANEL

OZONATER

LABORATORY/ CONTROL ROOM

SCREENING The function of the bar screen is to prevent entry of solid particles/ articles above a certain size; such as plastic cups, paper dishes, polythene bags into the STP. (If these items are allowed to enter the STP, they clog and damage the STP pumps, and cause stoppage of the plant.)

1

Inlet pipe for the STP

2

Debris (plastic bags, paper cups, paper dishes, etc.) gets trapped here.

3

Muck (sediment in sewage)accumulates and blocks the grill (if not cleaned regularly)

4

Grill. Must be cleaned regularly to avoid build-up of debris (2) and muck (3).

5

Screened sewage. If the screen (4) is maintained well, this would be free of any large articles.

6

Outlet pipe (goes to the Equalization Tank)

7

Platform. The STP operator stands here to take out the debris (2).

RAW SEWAGE PUMPING If we use gravity to move the sewage through the units of STP, the units would have to be placed progressively deeper below the ground level. To avoid deep excavations, a pumping stage is introduced to lift sewage to the next unit in the STP. Two raw sewage pumps are provided with level control system and provision for pump selector and auto/manual operating mode. 1

There are two identical pumps. Controls ensure that only one pump can run at a time.

2

Both pumps have independent suction pipes. The inlet pipes extend almost to the bottom of the tank, and must not have foot-valves. The delivery pipes from both pumps are combined in a Tshaped header. A delivery pipe takes sewage from this header to the RMBR tank. The bypass pipeline returns the excess sewage back to the tank Valves fitted on all three pipelines serve different purposes: The valve on the bypass line is adjusted to “waste” the excess capacity of the working pump. The delivery pipeline (3) always carries sewage at the designed flow rate. The valve on the delivery pipe is closed off when the corresponding pump is removed for repairs. This prevents sewage delivered by the other pump from coming out.

3

4

5

ROTATING MEDIA BIO-REACTOR In rotating media bioreactor degradation of organic matter present in raw sewage takes place. RMBR rotates at speed of 2 – 3 rpm with the help of gear drive provided. 40% of RMBR is submerged into the wastewater at any instant and 60% is open to air. Raw sewage is discharged in to RMBR @ 62.5 cum/hr. 1

RMBR Drum. It is in continuous rotation at 2-3 rpm. While rotating it is 40% submerged in water and 60% exposed to air. The microbial growth takes place on its surface, inside it is fully packed with media.

2

Inside the RMBR drum, is the polypropylene media with a high surface area to support maximum growth of beneficial micro-organisms. RMBR tank receives sewage from raw sewage tank and has a retention time of 30 mins where the digestion by the biofilm takes place. The RMBR is rotated with the help of a motor, chain sprocket system. The treated water from the RMBR tank then flows to the Flocculation channel where alum dosing is done and flocculation of the organic treated matter takes place.

1 2

3

4 5

3

4 5

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ALUM DOSING • • •

Alum dosing system is provided for floc formation and settling of biologically treated sewage. Keep the brick alum at the at flocculation channel provided. Solids formed in RMBR are then settled and remove in settling tank.

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SETTLING TANK The purpose and function of the secondary clarifier is twofold:  Allow settling of biomass solids in the Mixed Liquor (biomass slurry) coming out of the RMBR tank, to the bottom of the clarifier.  To thicken the settled biomass, in order to produce a thick underflow.

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1

The sewage inlet pipe brings sewage from the flocculation tank.

2

The incoming sewage enters from the end of the inlet pipe and gently releases it in the settling tank, without causing any disturbance or turbulence.

3

The sludge is only slightly heavier than water; so it takes time to sink. It slides down the steeply sloped walls of the tank toward the centre of the bottom. (collects in hopper)

4

The bacterial flocs collect here in high concentration.

5

The sludge flows out under the effect of gravity to the sludge dewatering system

6

The clear water rises to the top of the tank.

7

The clarified water pipe takes the decanted water to the clarified water sump.

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FILTER FEED PUMP • • • • •

Two filter feed pumps are provided in the filter feed sump with level controller and auto/manual operation. Treated water from intermediate tank is discharged into the filter feed sump. Once the water level in filter feed sump reaches at pre-determined top level one of pump starts automatically if auto operation is selected. This pumps steadily deliver the water at the top of pressure dual media filter Filter feed pumps are also used for backwashing of filter columns.

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PRESSURE SAND FILTERATION • • • • • •

FRP sand filter with multiport valve is provided for pressure sand filtration. Keep the valve in normal filter mode Start the filter feed pump. Water is discharged at top of filter. Solid particle are trapped on sand and clarified water from sand filter is discharged to drain or used for gardening. Sand filter needed to be backwashed for removing the trapped solids.

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ACTIVATED CARBON COLUMN

• • • • • • •

FRP activated filter with multiport valve is provided. Keep the valve in normal filter mode Start the filter feed pump Water from sand filter is discharged at top of carbon filter. Odour if any, other organic matter and excess hypo from sand filter is adsorbed on the activated carbon. Treated water from carbon column is discharged into treated water storage tank. Carbon filter needed to be backwashed for removing the organic matter trapped on it.

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BACKWASH OF FILTER • When pressure over comes to 2 kg/cm2 backwash should be needed. • Stop the pump. Adjust the multiport valve in backwash mode. • Start the pump. • Backwash water is discharged to the raw sewage tank. • Backwash should be performed for 5 to 10 minutes after every 8 hours operation. • Once backwash is completed, stop the pump. • Adjust the multiport valve in normal filter mode. • Start the pump.

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OZONATION OF TREATED water • • •

Ozone is injected into Treated Sewage Water with the help of ozonator provided. Ozone generated in Ozonater is injected at treated water tank. Ozonation of treated sewage ensure that minimum 2mg/L of Dissolved oxygen is maintained

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SLUDGE HANDLING Biological treatment of wastewater perforce produces excess biological solids due to the growth and multiplication of bacteria and other microorganisms in the system. The excess biomass thus produced needs to be bled out of the system, and disposed off efficiently. This is a FOUR-step process: sludge removal, storage, dewatering and disposal. 1

The stainless steel table allows splashing of water without getting rusted.

2

The openings have a collar beneath, where the bags can be clamped

3

The sludge pipeline brings sludge from the settling tank. The valves can be used to regulate the flow rate, and also to turn off if there is no bag beneath.

4 5

The laminated poly bags capture the floc, but allow the water to run.

6

The stainless steel collection tray collects the water (and fine sediments) The stainless steel grill supports the bags and allows the water to fall through.

7 8

The collection pipe takes the filtrate back to the Raw water tank. NAIKENVIRO

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LUBRICATION • • •

Use gear oil no.320 ( Castrol make) for RMBR gear drive Recommended oil change : once every three month RMBR bearing grease : once in every three month.

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SCADA •The operating system at site is SCADA, which stands for supervisory control and data acquisition. It is an industrial control system where a computer system monitors and controls the ongoing operation/process. •The software gives various information's like details of pump operation, breakdown details, energy consumption, treated water quality parameters, historical trends etc.

Main Screen

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SCADA –Home Screen

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Daily reports

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Daily reports

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Daily reports

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Daily reports

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TROUBLE SHOOTING POSSIBLE FAULTS

CAUSE

REMEDIES

PUMP FAILS TO PRIME

SOLID PARTICLE MAY GOT STUCK UP IN IMPELLOR

OPEN THE CASING AT BOTTOM AND REMOVE THE SOLID PARTICLES

PUMP NOISY

BEARING

APPLY GREASE TO BEARINGS

RMBR BEARING NOISY

IMPROPER LUBRICATION

FREQUENTLY APPLY GREASE TO BEARINGS

RMBR GEAR MOTOR HEATS UP

LESS OIL LEVEL

FILL UP WITH GEAR OIL 150

RMBR OVERFLOWS

PUMPING RATE HIGH THAN CAPACITY

ADJUST THE VALVE OF RAW SEWAGE PUMP

SETTLING TANK EFFLUENT TURBID

INSUFFICIENT SLUDGE REMOVAL FROM SETTLING TANK

FREQUENTLY PUMP THE SLUDGE FROM SETTLING TANK IN TO TROLLEY

SLUDGE FLOATS ON TOP OF INTERMEDIATE TANK

SAME AS ABOVE

SAME AS ABOVE

TREATED EFFLUENT FROM DUAL MEDIA FILTER COLUMN TURBID

IN SUFFICIENT BACKWASH

INCREASE THE BACKWASH DURATION

ODOUR TO TREATED WATER/PARAMETER NOT WITHIN LIMIT

PUMPING RATE HIGH THUS NO REQUIRED DETENTION TIME FOR SEWAGE IN PLANT AVAILABLE

CHECK THE FLOW RATE FLOW RATE . SHOULD BE <=62.5 CUM/HR. MEASURE FLOW BY STOPWATCH METHOD AT OUTLET OF INTERMEDIATE SUMP

INSUFFICIENT CHLORINE DOSING

INCREASE THE CHLORINE PERCENTAGE IN CHLORINE SOLUTION

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METERING PUMP NOT FUNCTIONING

FUSE BLOWN OUT

REPLACE FUSE

FM1

Digital Flow meter shows erratic readings

Chokage /flow meter fault

check as per causes and rectify.replace as per vendor manual.

FM2

Digital Flow meter broken

Accidental impact or load

Replace .

pHM 1

If the ph reading of the incoming Alum added is in excess, the treated water is less than 6 water is acidic

Reduce the dose of alum in the process.

pHM 2

If the ph reading of the incoming Alum added is insufficient, the treated water is more than 9 water is alkaline

Increase the dose of alum. Maintain the pH between 6-9.

Ozone not coming

Problem with electrodes

Check & Rectify as per manual.

Dissolved Oxygen is less than 2mg/l

Ozonater not working

Check & Rectify as per manual.

Temperature is not monitered & recorded

Problem with Probe

Ozonater

DO M TEMP M

Check & Rectify as per manual.

Refer O&M manuals pump/gear motors/dosing pumps.

maintenance A]BAR SCREEN •Check and clean the bar screen at frequent intervals. •Do not allow solids to overflow/ escape from the screen. •Ensure no large gaps are formed due to corrosion of the screen. •Replace corroded/ unserviceable bar screen immediately.

B] GREASE TRAP •Check and clean trap at frequent intervals. Remove both settled solids (at bottom) and the floating grease. •Do not allow solids to get washed out of the trap. •Do not allow oil and grease to escape the trap. •Redesign the trap if solids and grease escape on a regular basis, despite good cleaning practices.

D] PUMPS •Pumps do not start

1) Check the power supply. 2) Check the float switch. 3) Check the water level for operating Float switch.

•Pump getting over-heated:

1) Pump running dry 2) Delivery line/ pump casing blocked remove the pump and clean 3) check for proper supply of voltage.

•Pump give less discharge

1) Inlet of pump blocked, Remove and clean 2) Discharge head is beyond Pump capacity, select proper pumps

•Pump is noisy:

1) Impellor clogged/ damaged. 2) Delivery flow too high. 3) Obstruction in delivery line.

E ] MOTOR •Motor will not start:

1) Replace fuse 2) Check bearing and lubrication 3) Reduce load 4)Look for broken parts

•Motor runs & dies down:

1) Check for loose connections.

•Motor does not come to speed:

1) Use higher voltage 2) Look for cracks near the rings, New rotor is required.

•Motor gets hot/ burns out:

1) Decrease belt tension. 2) Alignment of coupling faulty/ loose. 3) Move pulley closer to motor.

Noisy operation:

1) Remove interference. 2) Tighten holding bolts. 3) Check & correct bearing.

•Motor vibrates:

1) Realign. 2) Strengthen base. 3) Balance coupling/ bearings.

F] CHEMICALS: •Prepare fresh solutions every day in the tank. •Shelf life of over 2 months is not recommended, especially during summer. •Store chemicals in a cool place. •Study Material Safety Data Sheets of the chemicals and follow instructions. •Periodically check available strength of chemicals by mock tests. •Check and record concentration every day. G] SLUDGE HANDLING •Fresh sludge (not more than a day old), kept fully aerated and mixed (agitated), dewaters easily in the filter press. Hence, sludge must not be stored in the holding tank for longer durations. •After every dewatering operation, the filter cloths must be thoroughly cleaned, so that clogging in the pores of the woven polypropylene filter fabric is avoided. •Periodic cleaning of filter cloth with Hypo solution will also prolong the life of cloth. •When the filtration process becomes excessively slow, it is time to replace the filter cloth with a fresh set.

SOME PRECAUTIONS TO BE TAKEN •Never stop the RMBR even if there is no raw sewage inflow. •Never quit the backwash operation provides necessary backwash. •De-sludge at recommended frequencies. •Always apply sufficient grease to RMBR bearings. •Refer vendor manual for equipment maintenance. •Before starting the pressure filters ensure that valve at outlet of filter is open. •Ensure proper lubrication for all equipment. •Backup power to run the entire STP in case the mains electricity line fails. •Design and engineer the STP to be operator friendly.

•Design and engineer the STP for the operator’s safety, health and hygiene. •Adequate illumination in STP if in a room, or basement. •Adequate exhaust and ventilation system to be provided for operator comfort, health and hygiene. NAIKENVIRO

•Provide safe and comfortable access to all units in STP for monitoring, operation, and maintenance. •Prepare and maintain a Standard Operating Procedure for the STP and train all operators to follow those procedures.

•Prepare and maintain a mechanical checklist for routine preventive maintenance. •Prepare and maintain a History Sheet for critical equipment in the STP. •Provide a Water meter at the outlet of the ACF to monitor average daily throughput of the STP.

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