OPERATION & MAINTENANCE

MANUAL

For

SEWAGE TREATMENT PLANT

Client: M/s. CAPGEMINI INDIA PRIVATE LIMITED

Hyderabad

Supplied by

AMAZON ENVIROTECH Pvt. Ltd

#19, Pottery Road, Cooke Town, Bangalore - 560 005.

Tel: 080-25495325/26. Fax: 080-25495324
E-mail: admin@amazonenviro.com
Website: www.amazonenviro.com
 CONTENTS

1. Introduction

2. Process Design Basis

3. Unit Details, Salient Features and Operation

4. Plant Start - Up Procedures

5. Safety and Standard Operating Procedures

6. Trouble Shooting Procedures

7. Instruction Manual for Bought out items

8. Drawings

2
CHAPTER - 1

INTRODUCTION

3
1.0 Introduction

1.1 Preamble

Amazon Envirotech Pvt Ltd. has supplied Sewage Treatment Plant for
M/s. Capgemini India Pvt Ltd, The plant is designed to treat up to 200
m3/day domestic sewage to the desired quality as being discharged as surface
discharge or being reused / recycled as water for irrigation / gardening.

1.2 Objectives of the Sewage Treatment Plant

The primary objectives are:

1. Single-stage biological treatment using ‘Moving Bed Bio-Reactor’.

Air is supplied by ‘Diffused Aeration System’.

4
 CHAPTER -2

PROCESS DESIGN BASIS

5
2.0 Process Design Basis

2.1 Waste Water Quantity

The wastewater quantity at present is of the order of 200 m3/day of

domestic sewage.

2.2 Influent Quality Parameters

2. 2.1 Raw and Treated Effluent Characteristics

-----------------------------------------------------------------------------------
Parameter Units Raw Effluent Treated Effluent
-----------------------------------------------------------------------------------
pH 6.5 - 7.5 7.0 - 8.5
BOD mg/l 200 - 250 < 20
COD mg/l 500 – 600 < 200
TSS mg/l 400 < 20
-----------------------------------------------------------------------------------

2.2.2 Service and Drinking Water

Service water at adequate pressure is to be available at the sewage

treatment plant, for preparation of nutrient/ chemical solutions, and other
miscellaneous purposes.

6
2.3 Design Basis for the Sewage Treatment Plant

2.3.1 Technical Write- Up

Raw sewage piped from various sources is taken by gravity through the Bar
Screen into the Equalisation Tank for homogenization. The sewage is then
constantly pumped to Moving Bed Bio reactor (MBBR). In the MBBR Tank,
sufficient detention time is provided to oxidize organics absorbed by the
bacterial biomass in the waste water. Required quantity of oxygen is
supplied and mixing done by the Diffused aeration system. Stoichiometric
quantity of air supply and increased hydraulic retention time ensures
complete oxidation of organics contributing to BOD/ COD.

The aerobic environment in the SBR is achieved by the use of ‘Diffused

Aeration’, which also serves to maintain the mixed liquor in a completely
mixed regime. Air application is uniform throughout the tank area. During
the aeration period, adsorption, flocculation, and oxidation of organic matter
occur. The conversion of organics by the bacteria is as follows:

Oxidation and Synthesis

COHNS + O2 + Nutrients – Bacteria  CO2 + NH3 + C5H7NO2 (Organics)

+ (New Bacterial Cells) + other end products.

Endogenous Respiration

C5H7NO2 + 5 O2 - Bacteria -----> 5 CO2 + 2 H2O + NH3 + Energy.

Diffused aeration is used for the supply of air. In this process, as the supply
of available substrate (food) is depleted, the micro-organisms, now in an
endogenous phase, begin to oxidize their own cell tissues to obtain energy
for cell maintenance reactions. The oxidation products are carbon dioxide,
water and ammonia, which in turn is subsequently oxidized to nitrate as
digestion proceeds.

The resulting overall reaction is given by the following equation:

C5H7NO2 + 7 O2  5 CO2 + NO3 ion + 3 H2O + H ion.

A section of the reaction tank acts as a settling zone, overflow from this
zone is clear liquid to which Stochiometric quantities of Hypo solution are
dosed for disinfection. The addition of hypo solution also oxidizes the
remaining organic traces present in the above treated sewage. The clarified

7
and disinfected water is then used for irrigation, flushing / discharged as per
the Pollution Control Board norms.

Sludge Dewatering / Handling

The excess Bio-sludge from the MBBR tank is pumped to the Sludge
holding tank where it is conditioned by adding requisite quantities of
Polymer and is pumped through a Filter Press for de-watering the sludge
using a positive displacement pump. The de-watered sludge is carted in a
trolley for land filling / soil conditioning and the filtrate will go back to the
system.

BRIEF DESCRIPTION OF DIFFUSED AERATION SYSTEM

The Diffused Aeration System (DAS) comprising of EPDM Membranes and

PVC Pipe Grid supported by RCC Supports is installed at the bottom of the
Aeration Tank. Air from the blowers at the desired rate and having the
required pressure is diffused through the DAS.

The diffuser consists of a porous membrane, 1.0 / 0.5 M in length made of

EPDM. Each membrane diffuser is supported over the full length and
circumference with a 90 mm PVC Membrane Support Frame. The diffuser is
retained in place by S.S Clips. Each diffuser is provided with a removable
End Cap to facilitate flushing of diffuser assembly, should cleaning become
necessary.

The diffuser is fitted to the pipe lateral by a Tee arrangement. Each diffuser
is connected to the Air Header by means of a Flexible Hose, to facilitate easy
removal of the unit for maintenance. The wetted parts of the system are
made of non-corrosive material.

During shut down condition, the membrane contracts and closes around the
PVC support frame, to prevent any back flow. The diffuser is designed to
ensure uniform permeability, and to produce a flow of fine air bubbles,
approximately 2 mm in diameter. The fine, uniform pore size ensures
minimal head loss across the diffuser.

Since the bubbles are of extremely small size, the total surface area that
interfaces with the liquid is large. The high contact area provided by the fine
bubbles and the high contact time provided by the slow rise rate of the
bubbles makes this system very efficient in terms of oxygen transfer
efficiency.

The slow upward movement of fine bubbles keeps the bottom of the tank
swept clears of any settling deposits, and also provides gentle mixing. The
gentle uniform diffusion of air also prevents floc shear, which means the

8
settling time of flocs are reduced. This results in increased efficiency of the
clarifier, and higher sludge concentrations. The air piping and air distribution
system shall be designed to allow easy regulation of airflow to the aeration
tank.

Air piping shall be metal from the blowers the through the air headers. The
metal lateral piping shall terminate at the water surface and convert to PVC
flexible hose. Metal piping is normally required above water line to avoid
thermal deterioration of plastic lateral and to avoid mechanical damage due
to thermal expansion / contraction.

9
 CHAPTER -3

UNIT DETAILS, SALIENT

FEATURES AND OPERATION

10
3.0 UNIT DETAILS AND SALIENT FEATURES

In this section the various units of the plant are listed, their objective
explained, salient features of the units given and the normal operational
procedure defined with precautions to be followed listed. The sections
have been organised in sequential manner with connected sub units being
placed under one section.

3.1 BAR SCREEN CHAMBER

OBJECTIVE

The main objective of the Bar Screen is to retain the floating matter.
Floating matter retained in the Bar Screen has to be manually cleaned. Bar
screens are made of MS angle frame with MS flats.
SCREEEN
Type : Manual
Screen Dimensions : 0.5 L x 0.5 W
Angle of Inclination : 60 Degree to Ground
M.O.C of Screen : MS

3.2 RAW SEWAGE TRANSFER PUMP

OBJECTIVE
The main Objective of this pump is to pump the raw sewage for the
treatment

Quantity : 1
Capacity : 10 m3/hr @ 10 m head
Make : Grundfos
Model : DAB-FEKA VS 1000 T NA

3.3 COARSE BUBBLE DIFFUSER SYSTEM

OBJECTIVE
The main purpose of Coarse Bubble Diffuser System is to mix the
wastewater for Sewage Treatment.

COARSE BUBBLE DIFFUSER SYSTEM

Type : Coarse Bubble Diffuser System
Number of Membranes : 16 Nos. (0.760 M Long)
M.O.C of Membranes : EPDM

11
 Air Source : Twin Lobe Air Blowers
Make : Amazon

3.4 AERATION SYSTEM

OBJECTIVE
The Reaction tank is used to remove oxygen consuming organic matter from
the sewage by Biological treatment. Diffused Aeration is used for supplying
air-containing oxygen. The bubbles produced from the diffusers are of
extremely small size. Thus the total surface area that interacts is large and
the contact time of bubbles is large due to slow rise rate of the bubbles. The
system is thus extremely efficient in terms of oxygen transfer efficiency. The
flow of fine bubbles provides a gentle mixing, which prevents floc shear.

The diffuser consists of a porous membrane, each made of EPDM rubber.

Each diffuser is fully supported over the length and circumference with a 90
mm PVC membrane support frame.

AERATION SYSTEM
Type : Diffused Aeration System
Number of Membranes : 16 Nos. (1.0 M Long)
M.O.C of Membranes : EPDM
Air Source : Twin Lobe Air Blowers
Make : AETPL – EDI. USA

OPERATION
The Reaction Tank operates on the overflow principle. Constant aeration and
mixing of the contents is required to ensure complete mix of the biomass and
the wastewater. Aeration also prevents septic conditions.

3.5 TWIN LOBE AIR BLOWERS

OBJECTIVE
The purpose of the Twin Lobe Air Blowers is to provide a source of
compressed air for the fine bubble Diffused Aeration / mixing system in
the Reaction tank. The Twin Lobe Air Blowers are complete with
accessories such as suction filter, suction and discharge silencer, vibration
pads, pressure gauge, pressure relief valve, non return valve, etc.

BLOWER I
Quantity : 1 No.
Make : USHA BLOWERS
Model : UGRK-140
Capacity : 200 cum/Hr @ 0.5 Kg/sq.cm

12
MOTOR I
Quantity : 1 No.
HP : 7.5
Speed : 1450 rpm
Make : ABB

BLOWER II
Quantity : 1 No.
Make : USHA BLOWERS
Model : UGRK-120
Capacity : 120 cum/Hr @ 0.5 Kg/sq.cm

MOTOR II
Quantity : 1 No.
HP : 7.5
Speed : 1450 rpm
Make : ABB

OPERATION
The Air Blowers need to be operated on a continuous basis. A minimum
of one Blower should be kept always in operation.

3.6 MBBR Media

OBJECTIVE
MBBR is primarily an attached growth process, treatment capacity is a
function of the specific surface area (SSA) of the reactor. The media has its
own characteristic SSA. The media SSA reflects the amount of surface area
available for biofilm development per unit volume of the media, on a bulk
volume basis. The carriers can occupy up to 70% of the reactor volume on a
bulk volume basis.

MEDIA
Volume of Media : 5 m3
M.O.C of Media : PVC
Surface Area : 400 m2/m3
Make : Cooldeck

OPERATION
The carriers are kept in constant circulation in an aerobic reactor. Circulation
is induced through the action of air bubbles injected into the tank by a fine
bubble diffuser system.

13
 CHAPTER – 4

PLANT START – UP
PROCEDURES

14
4.0 General
This section deals with the start-up of the plant for the first time. The pre
start-up and first time start-up checks have been delineated -major unit /
equipment / component wise.

4.1 Pre Start- Up checks - General

 Prior to start-up, all units of the plant need to be thoroughly cleaned

and removed of any construction debris, especially at all the discharge
points, drain sections, etc.

 All pipelines need to be flushed with clean water and cleaned of any
blockages.

 All rotating equipment’s has to be checked for pre-commissioning as

per the manufacturers’ recommendations/ instructions given in the
Equipment’s Operation and Maintenance Instruction Manual.

 All electrical equipments have to be tested on No-load and Full-load

conditions.

 All the process units need to be filled with service water.

4.2 Pre Start up Checks - Pumps & Tanks

Pumps

This Section covers the first time start-up procedures for pump
installations from which pumps are taking suction -

 Check the instruments, valves and piping for the direction of

installation, etc.

 Open the suction valve of the in-service pump, during which the
delivery end valve must be kept closed.

 Expel all air from the pump suction by priming the pump, using the
cock provided.

 Start the pump, check that the pump has attained full load and then
open the delivery valve.

15
Tanks

This Section covers the first time start-up procedures for all tank installations

 Clean the tanks of any construction debris.

 Fill the tanks which would normally hold wastewater / treated water
(i.e. equalisation tank, clarifier tank, aeration tank and post-aeration
tank) with service water.

 It is desirable to fill up the liquid / water holding structures up to the

SWD level and to check for uniform overflow. This test will ensure
that the tanks are free of leakage, and also that the overflow is uniform
in all launders.

4.3 Pre Start Up Checks - Mechanical Equipment's

Pumps

 Check the installation of pumps as recommended by the manufacturer.

 Check the direction of rotation of the pump drive in an uncoupled state.

 It should rotate in the direction as specified on the pump.

 Fill pump suction with service water, and start the pump.

 Centrifugal pumps should be started with the delivery valve closed

while Positive Displacement pumps should always be started with the
delivery valve in open condition.

 For Centrifugal pumps, check the current drawn by the pump and the
pressure developed - it should be as per the manufactures
recommendations. Open the delivery valve, note the pressure and if the
delivery point is viewable, check the flow visually.

 For Positive Displacement pumps, note the current drawn. The flow
should be measured / recorded especially in the case of a metering
pump / dosing pump.

16
4.4 Blowers

The following procedure is recommended when a compressor is started up

for the first time or when a machine is put to work again after major
repairs, which have necessitated its removal from its foundations.

 Inspect the interior of the compressor and all piping leading to and
from it to ensure that all foreign matter has been removed.

 Check for the level and alignment of drive. Check the belt tension and
alignment. Incorrect alignment and/or tension can cause excessive wear
on bearings, V-Belts or coupling bushes.

 Check for correct lubrication. It is essential that the oil level in the gear
case should be up to the specified mark when the compressor is not in
operation. Too much oil will cause overheating and excessive noise in
the gear case. Too little oil will result in the rapid failure of the gears
due to their running dry.

 Apply the recommended grease to both drive end bearings until grease
appears at the release vents. These vents must be kept clear.

 Rotate the impellers by hand to ensure that there are no tight spots.

 'Flick' the motor on two or three times by putting the starter on and off
in succession to check the direction of rotation, and also to ensure that
the impellers turn freely.

 Start the compressor and run for at least fifteen minutes under no-load
conditions. During this period keep checking at various points on the
compressor casing and the bearing housing for signs of heating. The
compressor should remain cool throughout this period.

 Apply the load gradually over a period of say, thirty minutes. Whilst
under full load, keep the machine under observation.

 Frequent checks should be carried out during the first day in service.

 In the event of suspected faulty operation, shut down the compressor

immediately and investigate for possible causes. If this is not done,
serious damage may result in a very short time.

17
4.4 Motors

 Check all the motors for proper connections, earthing and the direction
of rotation.
 Test under no – load conditions.

4.6 Clarifiers

 Activate all systems individually.

 Test under dry conditions for the direction of rotation, sweep arm
clearance, etc.
 When fully satisfied, fill the tanks with water for functional testing
(under load conditions).

4.7 Normal Operation of Solution Preparation & Dosing System

Preparation of Solutions

 Fill up about 2/3 of the tank effective volume with service water.
 Add one charge of the desired chemical to make one tank full of
solution of the strength required gradually.

Check List for Starting of Dosing Pumps and Withdrawal from

Solution Preparation / Dosing Tanks

 Check the level in the solution preparation tank connected to the pump.
If the tank is at low level, do not start the pumps.
 The quality of the prepared solution must be checked periodically by
the plant Process / Quality Control Operator and due authorization
given for starting of the pumps.

Procedure for Starting Individual Dosing Pumps

 Start the pump.

 Adjust the dosing rate.

Safety Guidelines

 Never operate the pump with the discharge valve closed. This is a
positive displacement pump and operating it with the discharge valve
closed can cause serious damage to the pump/system.
 Regularly check the Pressure Relief Valve for blockages if any.

18
  Replace glands and other wearing parts as recommended by the
manufacturer.
 DO NOT operate the pump dry - it will damage the pump.
 Capacity / Stroke length adjustment should be made while the pump is
in operation.

4.8 Operation and Maintenance Procedure for Filters

4.8.1 Normal Operation (Service)

Open the service inlet and outlet valves and regulate the flow by
means of the outlet valve. During initial start up operation, the dust / dirt
need to be cleaned from the filtering media. Hence it is recommended to
do a thorough backwash of the filtering media using fresh water. Once all
the dirt is removed then the service cycle shall be started. During the
service operation i.e. when the filter bed is free from dirt or suspended
impurities the pressure drop across the filter is generally 0.8 ksc which
shall be measured by finding the differential pressures of both inlet and
outlet pressure gauges. Once the media gets accumulated with the
suspended impurities, then the pressure drop across the pressure vessel
increases. The filter needs to be back washed depending on one of the
following conditions whichever occurs earlier.

 Once in a day

 When the pressure drop across the filter goes beyond 0.8 ksc.

4.8.2 Backwash

Back washing should be done periodically to maintain the quality of

treated water. Open the back wash outlet valve and then slowly open the
wash inlet valve. During this operation please ensure both service inlet
and outlet valves are closed. Take care to see that media, especially the
carbon media is not washed out. Continue back-washing the filter for 10 –
15 minutes or till the effluent (i.e. the filtered water) is clear.

Close the wash outlet valve and open the air release valve. When all the
air is expelled and water comes from the air release line, close the air
release valve and wash inlet valve.

Open inlet and drain valve, when the water in the drain sump is clear,
close drain valve and open service outlet valve. Adjust the outlet valve to
get the desired flow.

19
4.8.3 Maintenance

The routine maintenance on the filter is to be carried out as follows:

Valves

The valves on the filter should be opened at periodic intervals and do

necessary mechanical maintenance and check for leakage if any.

Extended Backwash

Once a week carry out the extended backwash operation for at least 45
minutes. This will ensure that accumulation of suspended solids on the
filtering bed (media) is minimized.

Internal Painting

Check the condition of the paint inside the filter once a year by removing
the media if necessary. Any area, which is found corroded, must be
cleaned and two coats of the appropriate paint applied.

20
 CHAPTER - 5

SAFETY AND STANDARD

OPERATING PROCEDURES

21
5.0 Operational Responsibilities

The effluent/ wastewater treatment plant should be operated by

competent, reliable and experienced personnel who have been trained in
the operation of sewage treatment plants. Operation of the plant by trained
and experienced personnel is recommended from the point of view of
safety and also for the plant to achieve the desired treatment objectives.

Proper management and control of equipment's and manpower has an

important bearing on the successful operation of the treatment plant.

5.1 Operator’s Responsibilities

The person responsible of the operation of the Treatment plant should

have a thorough knowledge of the functions of each and every unit of the
plant under his control. A resourceful operator should be in a position to
understand the normal problems arising during the course of operation
bring it to the notice of the concerned supervisor/manager and take
necessary corrective actions immediately.

Following are the major problems, which may be faced by operational

personnel:

 Change in the quality and quantity of the waste water/ effluent.

 Malfunctioning of certain Process Units of the plant.

 Mechanical and/or Electrical faults.

5.2. Operator Training

Training of the operating personnel is an important requirement in the

operation and maintenance of an effluent/ wastewater plant. The proposed
operators of the wastewater treatment plant should be deployed from the
pre-commissioning stage itself, so that they can grasp the importance of
preventive maintenance, control methods and troubleshooting operations.
While selecting the operator, due consideration must be given to his/ her
previous experience in the operating of similar plants.

5.3 Safety Measures

 Since the effluent is enriched with various groups of highly pathogenic

microbes, it must not be touched or inhaled as far as possible.

22
  The operator must not operate the valves with bare hands.

 The operator must use personal protective equipment’s like hand

gloves, gum-boots, mask, helmet and goggles.

 The topmost priority should be given for safety measures while

operating an effluent/ wastewater treatment plant, because of the
various types of toxic elements present in it.

5.3.1 Do’s and Don’ts (General)

Do’s

 Maintain a gap of at least two feet from the manhole of the collection
tank.

 Before climbing the aeration tanks, check that the shoelaces are tight,
and also that the helmet and belts are fastened, to prevent any
accidental falls.

 Be alert while standing on the aeration tank.

 Climb the ladder slowly.

 Close the concrete slabs of tanks after each operation.

Don’ts

 Do not peep into the collection tank manhole.

 Do not slide on the barrication of the aeration tanks.

5.3.2 Do’s and Don’ts (Mechanical)

Do’s

 After any maintenance job, check the alignment of the equipment.

 In case of any leakage, immediately inform the Supervisor In-charge &

enter it in the log book.

 Enter in the daily log book any abnormality you observe in any
equipment.

 Always use the correct type of lubricant.

 Check the oil level every week, in the case of blowers.

23
  Replace the oil every 20 days, in the case of blowers.

 Use the proper type of tools for all repair/ maintenance operations.
Don’ts

 Do not check the oil level in the case of blowers, when they are
running.

 Do not remove the blower- belt guard in running condition.

 Do not lubricate the pumps at the shaft.

5.3.3 Do’s and Don’ts (Electrical)

Do’s

 Follow the lock, tag; try procedure during maintenance operations of

any electrical equipment.

 If the pump trips on overload more than 2 times, inform the concerned
Electrical Supervisor.

 Use double tested lamp to check the presence of supply of power.

 Keep the area around the electrical panel clean and dry.

 Use the proper kind of tools for any kind of repair/ maintenance
operations.

 Check for the presence of cable route markers once in a week.

 Report any abnormality to the concerned In-charge/ supervisor.

Don’ts

 Do not remove the guard when the motor is running.

 Do not employ unqualified people to carry out any repair/ maintenance

work.

 Do not switch off the MCB / isolator before switching off the pumps
individually.

 Do not excavate without receiving a permit from the concerned

authorities/ In-charge.

24
5.4 Standard Maintenance Procedures for the Major Rotating
Equipment’s (Especially for Pumps and Blowers)

 Clean the equipment thoroughly before carrying out any maintenance

work.

 Remove the coupling or belt, as the case may be.

 Remove the base bolts.

 Shift the equipment to the maintenance area. ( If required )

 Dismantle the equipment for finding the probable causes of break-

down/ stoppage.

 Check the bearing condition & replace it, if necessary.

 Replace the lubricant. (Oil / Grease)

 Re - assemble the equipment.

 Shift it back to the original position.

 Fix the base bolts.

 Fix the coupling /belts.

 Align the equipment.

 Tighten the base bolts.

 Re-check the alignment.

 Inform the operator & enter it in the daily logbook & history sheet.

25
 CHAPTER - 6

TROUBLE SHOOTING
PROCEDURES

26
6.1 Trouble Shooting - Blower

6.1.1 Noisy Operation (Possible Causes)

Badly worn gears or bearings, Excessive wear and tear of gears will allow
the impellers to come into contact one another with the result that a
regular metallic knock will be heard from within the casing. The
compressor should not be allowed to run in this condition as it will rapidly
deteriorate, and will eventually result in complete failure. Replacement
gears or bearings should therefore be fitted immediately.

6.1.2. Excessive Heating (Possible Causes)

Gear case: Incorrect grade of oil or wrong oil level.

Bearing: Either too much or insufficient grease in the bearing housing.

In the case of drive shaft bearing, the cause may be misalignment of the
drive.

Casing:
 Build up of internal deposits, thereby reducing the clearance between
impellers and the casing to zero.
 Distortion of the casing due to incorrect alignment of pipe connection.
 Over pressurization of the compressor.

Head Plate:
 Impellers may be out of adjustment axially due to failure in the locating
bearing or a drive imposted end loading of the drive shaft.
 Over pressurisation of the compressor.

6.1.3. Excess Power Consumption (Possible Causes)

 Blockage of the air intake filter, or partially closed valve.

 Similar blockage in the delivery pipeline causing excessive pressure at
the outlet of the machine.
 Relief valve sticking, allowing the delivery pressure to rise above that,
which is normally required.
 Build up of internal deposits resulting in rubbing or contact between
impellers and the casing.

27
6.1.4 Loss of Capacity (Possible Causes)

As the compressor is of the positive displacement type, a reduction in

output can only be caused by either loss of speed or by increased internal
clearances allowing additional slip past the impellers. Reduced speed
may be caused by belt slip. Increased clearance may be due to passing of
abrasive material through the compressor over a long period of time. If
some other gas contaminates the air, corrosion may result which would
similarly affect the clearances.

6.1.5. Seizure (Possible Causes)

A seizure during the initial start-up may be the result of pressure overload,
misalignment of drive or of pipe connections. Should the seizure occur
after a prolonged period of running, this may be due to a build up of
foreign matter within the casing or by contact of one or other of the head
plates with the impellers as a result of defective locating bearings,
permitting excessive end float.

A rapid buildup of temperature at the point of contact between the

impellers and the casing, and at the same time a rapid increase in power
consumption are warnings of seizure, and the operator should shut down
the compressor immediately.

6.1.6 Drive Shaft Breakage (Possible Causes)

Drive shaft breakage may be caused by an excessive over-hanging load

such as a large V-Belt pulley having a wide face or by excessive belt
tension in the V-Belt drive.

6.2. Trouble Shooting - Clarifier

 Sludge must be removed from the clarifier several times daily to

prevent any accumulation of heavy rake loads. A regular schedule of
pumping should be made and strictly adhered to.
 The quantity of grit in the incoming flow is very important. If it is
present in appreciable quantities, more frequent intervals of pumping
will be necessary.
 Plugging could be caused by two reasons – either due to the excessive
thickening of the sludge, or due to particulate matter clogging the
pipeline. To correct this, turn on high-pressure water through the
underflow line until the line is cleared.

28
  There may be an accumulation of sludge in the tank, which has been
gradually building up due to the sludge being discharged at a rate less
than the rate of introduction of solids in the feed. To remedy this, by-
pass the feed line and open up the discharge line to eliminate the
accumulation of sludge, simultaneously allowing the mechanism to
continue running, if possible. If the overload is so heavy that the cut
off switch continues to stop the machine, it will be necessary to drain
the tank and sluice out the excess sludge.
 Some foreign objects such as tools, rocks, etc. may have dropped into
the tank accidentally. Stop the mechanism and see if the object can be
‘fished out’. If this is not possible within a short time, it will be
necessary to cut off the influent to prevent too great an accumulation of
sludge. If the object cannot be removed with the tank filled, it will be
necessary to drain the tank and remove it before operating the machine.
 All bolts and nuts should be screwed on tight and original alignments
maintained. Inspections should be made at regular intervals to confirm
the same.
 Wherever possible, examine gears and all wearing parts periodically to
determine whether excessive wear is taking place.
 If the power is shut-off, or if the mechanism is stopped for any reason
for longer than an hour, bypass the flow until the machine is again
started.
 Keep the machine and the surroundings clean and touch up all rust
spots with paint frequently.
 The entire mechanism above and below the water line should be
painted once every year, to prevent any corrosion effects.

6.3 Trouble Shooting - Diffuser Membranes

The AETPL Flex-Air unit is a fine pore aeration device that offers
maximum benefits for oxygen transfer and mixing. Proper operation and
maintenance of the Flex-Air diffuser can provide years of long term
performance with minimum energy and maintenance costs. For all fine
pore diffusers, it is necessary to follow preventive maintenance
procedures to sustain peak of optimum performance, prolong equipment
life, and avoid emergency situations or a system failure. Proper
maintenance procedures will also minimize the frequency of system
interruptions. The following guidelines should be referenced in
maintaining the Flex-Air diffuser system and diffuser media:

 The diffuser sleeves should be protected from excessive heat and

potential mechanical damage.

29
  The diffuser sleeves should be protected from petroleum products i.e.
mineral oils and aromatic hydrocarbons. Contact with such substances
will degrade the membrane.
 Good air filtration is required for all fine bubble diffusers including
Flex-Air units. The blower system should be equipped with inlet filters
having a performance efficiency of 95% removal of 5 micron sized
particles to prevent clogging of the diffuser media.
 The inlet filters of the blower system should be changed before the inlet
filter head-loss reaches 20 inches water column. This head-loss is
normally measured with a spring type gauge mounted on the filter
housing or a manometer. Improper maintenance of the air filtering
system may overload the blower system due to a high inlet loss or may
result in reduced filtration efficiency which could lead to diffuser
clogging.
 Some evidence of increased head-loss through the diffuser unit may be
experienced over a long period of operation. This pressure build-up is
often the result of biological and/or inorganic materials building up on
the media surface. The propensity for this condition is job specific and
is a function of the type of waste, and the specific operating
characteristics of the system.

6.3.1. Accessing the Flex-air Diffuser Assembly

AETPL recommends that the Flex-Air units be accessed on a fairly regular

basis (annually) to visually inspect the units. The aeration system is
designed to allow diffuser units to be accessed by lifting the PCC support
blocks with the diffuser assembly using the nylon rope provided. The air to
the basin through the membranes should be passed at a desired rate, to
prevent any settling of sludge at the bottom of the tank and on membrane.
Excessive airflows to the units may damage the membrane.

The following items may be helpful in servicing the Flex-Air diffuser

assemblies during periodic inspections or maintenance procedures:

1. Ladder to access the de-watered basin.

2. Protective gloves and clothing

3. Crimping tool

4. Long-handled bristle brush for cleaning diffuser assembly for

observations.

5. Spare Flex-Air diffuser membrane sleeves and S.S. Clamps.

30
6.3.2 In-situ Cleaning of the Diffuser Media

Typically, membrane diffuser units will require cleaning because of two

common types of surface build-up, namely biological and inorganic
scaling. The recommended cleaning procedure for both types of build-up
is detailed below:

1. Biological build-up is characterised by a moss like growth. The

recommended cleaning procedure is to physically dislodge the growth
either by gently brushing the substance off or using low or high
pressure hosing. The hosing method is effective in removing loose
surface deposits on the diffuser media. Maintain minimum air flow-
rate to the diffuser during hosing operation. The time required to
remove deposits is dependent on the type of surface foulant, water
pressure, etc.

2. Inorganic scaling is characterized by a granular mineral-like precipitate

that can form on the membrane surface. The recommended cleaning
procedure would be the application of acid, which dissolve the scales,
but leaves the membrane unaffected. The general procedure is outlined
below.
Acid Application - Maintain air rate to the Flex-Air unit at the
minimum. Use a water jet to remove sludge from the media surface.
Spray Muriatic acid (14%) evenly over the surface of the diffuser
media and gently brush the media with a soft bristled brush to remove
surface deposits and saturate the media pores.

3. Allow the media to soak for a minimum of 15 minutes to restore its

water porosity. This removes any solubilised and/ or dislodged
materials from the acid treatment.

6.3.3. Replacing Flex-air Diffuser Sleeves

If routine inspections reveal the need to replace a diffuser sleeve, the

following guidelines should be followed:

1. Lift the PCC support block for the diffuser sleeve using the nylon
rope provided. Keep the blower in running condition to pass the air
through the membrane at the desired rate.

2. Remove both the two S.S. clamps on either side of the membrane.
This is easily accomplished by bending back the small tab on the
clamp with a crimping tool. The operator should not attempt to ship
or cut the ear of the clamp. The SS material is very strong and
excessive force used could shear the material.

31
 3. Remove PVC threaded End cap.

4. Gently pull the rubber sleeve off the PVC support. Care should be
taken not to break or damage the PVC support during this removal
operation.

5. Installation of the new sleeve is done by reversing the above

procedure. The S.S. Clamps should be slid on the Membrane sleeve
ends and should be fully compressed with the help of the crimping
tool.

Note: The 1” non-perforated portion of the membrane sleeve should be installed at the
bottom of the diffuser and centered over the air discharge holes to provide check valve
action. The ¾” perforated zone is located at the top of the diffuser.

32
 Trouble Shooting - Pumps (Horizontal, Centrifugal)
Sl. No. Defects Causes Remedy

1 No priming or a) Insufficient quantity of a) Fill pump casing with clear

water/
Priming takes Water not filled in pump Water or liquid to be
casing. pumped.
too much time
b) Suction pipe and b) Clean suction branch and
strainer ( if
Any) clogged partially adjust
or fully.
c) Pump speed too low. c) Check up speed of prime
mover and adjust

d) Suction lift too high. d) Reduce Suction lift.

e) Leakage in suction pipe. e) Prevent leakage in suction

Pipe
f) Too warm liquid in f) Replace too warm liquid by
pump
Casing. cold liquid.

g) More clearance between g) Measure the clearance bet-

Impeller and Wearing ween Impeller & Wearing

plate
N.D.E. plate N.D.E. and adjust by
using proper packing.

h) Shaft sleeve & gland h) Replace shaft sleeve and

packing
worn ,and air leaks. gland packing with sleeve

gasket.
i) Recirculating ports in i) Clean recirculating ports of
Delivery
casing clogged partially delivery casing.
or

33
 Fully

2. Not enough a) Speed too low. a) Check up speed of prime

water
Delivery. mover and adjust.
b) Leakage in suction side b) Prevent leakage in suction
fitting and piping. pipe and fitting.

c) Discharge head too high c) Check up vertical head and

frictional losses.

d) Pump casing empty. d) Fill up the pump casing.

e) Rubber flap valve e) Check up rubber flap

clogged.
assembly & leakage from
pump casing.
f) Shaft sleeve/gland f) Replace the shaft sleeve/
packing
worn and air leaks. gland packing.

g) More clearance between g) Measure the clearance bet

Impeller and Wearing ween Impeller and Wearing

plate. plate and adjust by using
proper packings.
h) Suction lift too high or h) Avoid high suction and
suction
pipe too long suction piping.

3. Pump takes a) Speed too high. a) Check and correct the

more
power. speed.
b) Head less than specified b) Provide min. specified
head.
range.
c) Shaft bent. c) Check and replace the shaft.

34
 d) Misalignment of the set. d) Correct the alignment
between
pump and prime mover.

4. Not enough a) Prime mover not a) Check the speed of prime

pressure running
below rated speed. mover and correct it.
b) Leakage through gland b) Replace gland packing.
packing.
c) Too much clearance c) Measure the clearance bet-
between
impeller and wearing ween impeller and wearing
plate. Plate and adjust by using
proper packing.

5. Pump vibrates a) Pump Casing not filled a) Fill up the pump casing.
an noise.
Makes with
water/liquid (it is
possible

only during priming

time).
b) Suction lift too high. b) Reduce the suction lift or
install the foot valve.
c) Misalignment. c) Correct the alignment bet-
ween Pump and prime
mover
d) Foundation not rigid. d) Provide rigid foundation,
tighten the bolts.
e) Shaft bent. e) Replace the shaft.
f) Bearing worn out. f) Check and replace bearing.

g) Lack of lubrication. g) Lubricate the bearing

properly.
h) Pump operation at very h) Reduce total head.
low
Capacity.

6. Bearing have a) Misalignment a) Correct the alignment of

pump
Short life. and prime mover.

b) Shaft bent. b) Check the shaft condition

and

35
 replace, if necessary.
c) Excessive grease or lack c) Check up lubrication.

of grease

d) Dirty water getting into d) Protect bearing neatly.

bearings. Replace water deflector.

36
 Annexure - I

Maintenance Schedule:

______________________________________________________
DESCRIPTION PERIOD OIL GREASE
______________________________________________________

AIR BLOWER 20 DAYS YES YES

CLARIFIER DRIVE 6 MONTH YES ---

HEAD & GEAR
_______________________________________________________

Note :
1 .The maintenance schedules for all the equipment’s are also mentioned in
detail in the manuals supplied by the manufacturers which are enclosed
along with this operation and maintenance manual.

The various grades of oil/grease to be used for equipment are as

follows:

__________________________________________________________

DESCRIPTION OIL GREASE

AIR BLOWERS SAE – 320 HQBBG

CENTRIFUGAL PUMPS (ALL) SAE – 20 / 40 HQBBG

CLARIFIER DRIVE HEAD & GEAR SAE - 90 -

__________________________________________________________

Note:

HQBBG - High quality ball bearing grease

37
Chapter 8

DRAWINGS

38
 Chapter 7

INSTRUCTION MANUALS FOR

BOUGHT – OUT ITEMS

39