Professional Documents
Culture Documents
FOR
ALEMBIC LIMITED,
BADDI, DIST. SOLAN
Date:
Page 1 of 32
Client :
Project:
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.
Date:
1-Nov-04
Page 2 of 32
Project:
DESIGN CRITERIA
&
PROCESS DESCRIPTION
Rev:
Date:
1-Nov-04
Page 3 of 32
Project:
1. DESIGN CRITERIA:
Units
M3/day
25.0
M3/day
50.0
pH
6.5 to 8.5
Mg/L
2,500.0
Mg/L
1,500.0
Mg/L
250.0
Mg/L
200.0
1.2.
Value
The plant is designed to deliver, after final treatment, effluent as per following parameters:
Rev:
Parameter
Units
pH
Mg/L
Mg/L
Mg/L
Date:
1-Nov-04
Value
6.5 to 8.5
Page 4 of 32
Project:
2. PROCESS DESCRIPTION
The treatment scheme can be divided into the following sections:
2.1.
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.
Rev:
Date:
1-Nov-04
Page 5 of 32
Project:
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
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.
Rev:
Date:
1-Nov-04
Page 6 of 32
Project:
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.
Rev:
Date:
1-Nov-04
Page 7 of 32
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Rev:
Date:
1-Nov-04
Page 8 of 32
Rev:
1-Nov-04
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
10
11
13
12
13
14
15
Date:
Flow Meter
P 02
Secondary Clarifier
Flash Mixer
Air Blower 2
Air Blower 1
P 01 B
Item
P 01 A
Tag No.
Sr.
Digital
800 mm Dia
800 mm Dia
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
10
11
Tag No.
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
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.
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
Secondary Clarifier
Aeration Tank
Tube Settler
Flash Mixer
Equalization Tank
O & M Manual for Effluent Treatment Plant for Ispat Industries Ltd.
BBM
BBM
RCC
RCC
RCC
RCC
MS
RCC
RCC
RCC
MOC
No. of
Compart.
Length
Width
SWD
Free Board
Depth
Total
Total
Working
Volume
Project:
DRAWINGS
Rev:
Date:
1-Nov-04
Page 12 of 32
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Acid Dosing
Tank
Effluent
Channel
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
Rev:
Date:
Treated water
Tank
1-Nov-04
Activated Carbon
Filter
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Date:
1-Nov-04
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Date:
1-Nov-04
Page 17 of 32
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Rev:
Date:
1-Nov-04
Page 18 of 32
Client :
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Once one of the tank is full, stop the flow into that tank and start flow into the second
tank.
2.6.
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.
Rev:
Date:
1-Nov-04
Page 19 of 32
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Rev:
Date:
1-Nov-04
Page 20 of 32
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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.
4.5.
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.
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.
Rev:
Date:
1-Nov-04
Page 21 of 32
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4.6.5. ENSURE THAT NO LUMPS OF POLYELECTROLYTE ARE FORMED & THAT THE
POLYELECTROLYTE IS COMPLETELY DISSOLVED IN THE WATER.
4.7.
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.
Rev:
Date:
1-Nov-04
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5.2.
The only operation is to check the sludge levels periodically and remove the waste
sludge.
5.3.
Rev:
Date:
1-Nov-04
Page 23 of 32
Project:
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.
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.
Rev:
Date:
1-Nov-04
Page 24 of 32
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7.7.
Rev:
Date:
1-Nov-04
Page 25 of 32
Client :
Project:
7.7.6. Allow the MLSS to flow into the sludge drying bed as per the following calculation.
3500 mg/l
48.0 M3
192 Kg 168 Kg = 24 Kg
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
Rev:
Date:
1-Nov-04
Page 26 of 32
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Pumping of Treated Effluent from Treated Water Tank to Sand & Carbon Filter
8.1.
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.
8.6.
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.
Date:
1-Nov-04
Page 27 of 32
Client :
Project:
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
28
23
27
24
25
33
32
29
22
31
26
Rev:
Date:
1-Nov-04
30
34
Page 28 of 32
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Rev:
10.1.
The clean water after carbon filter is collected in the clean water tank.
10.2.
Date:
1-Nov-04
Page 29 of 32
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Rev:
Date:
1-Nov-04
Page 30 of 32
Synergie ecoSolutions
Pvt. Ltd.
Date:
A/B/C
Shift:
Operator:
Tag No.
Description
P - 01 A
P - 01 B
P - 02 A
P - 02 B
P - 03 A
P - 03 B
P - 04 A
P - 04 B
P - 05
Polyelectrolyte Pump
10
P - 06
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
Total Running
T - 02 A
Equalization Tank 1
T - 02 B
Equalization Tank 2
T - 02 A
Equalization Tank 1
T - 02 B
Equalization Tank 2
T - 05
T - 06
T - 10
T - 11
T - 12
T - 13
Tag No.
FI - 01
Description
Hours
1
E. POWER CONSUMPTION
Reading at Beginning of the Shift
Total
Synergie ecoSolutions
Pvt. Ltd.
Date:
A/B/C
Shift:
Operator:
F. pH Data
Sr.
Tag No.
Description
T - 04 A
Equalization Tank 1
T - 04 B
Equalization Tank 2
T - 05
Aeration Tank
T - 07
T - 08
Hours
1
Total
G. CHEMICAL CONSUMPTION
Sr.
Tag No.
Description
Alkali
Acid
Alum
Polyelectrolyte
Urea
DAP
Hours
1
Total Cons.
H. SAMPLING RECORDS
1
ETP Inlet
I. ANALYSIS RESULTS
1
pH
ETP Inlet
Final Outlet
HPCB Std.
J. REMARKS
Operator
ETP Incharge
Maintenance Incharge
Project:
ANALYSIS SCHEDULE
Rev:
Date:
1-Nov-04
Page 31 of 32
Project:
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
O&G
TSS
TDS
BOD
COD
Daily
2. Equalization Tank
Per Shift
Daily
Daily
3. Aeration Tank
Daily
Daily$
Daily
Daily
Daily*
Daily*
Daily
Daily*
Daily
Daily
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:
Date:
1-Nov-04
Page 32 of 32