Etp Manual

Rev: 0Date: 1-Nov-04 Page 1 of 32 OPERATION & MAINTENANCE MANUAL FOR THE EFFLUENT TREATMENT PLANT FORALEMBIC LIMITED,BADDI, DIST. SOLAN Synergie ecoSolutions Pvt. Ltd.1, Mi tal iApt, Pl ot # 45, Bhusari Colony, Paud Road,Kothrud,Pune 411038 Maharashtra India Phone- (91 20) 5285026 Fax -(91 20) 5285426 Email [email protected] OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 2 of 32 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 ETPH.Pro-forma for Log Sheet I.Analysis Schedule J.Copies of catalogues and manuals of various equipment OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 3 of 32 DESIGN CRITERIA&PROCESS DESCRIPTION OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 4 of 32 1.DESIGN CRITERIA: 1.1. Inlet Effluent Characteristics ThefollowingdesigndatahasbeenconsideredfordesignoftheETP,basedonthedatagiven by M/S. Ispat Industries Ltd. ParameterUnits Value Average Flow Rate (Present)M3/day25.0 Average Daily Flow Rate (Future)M3/day50.0 pH -6.5 to 8.5 Chemical Oxygen Demand (COD)Mg/L2,500.0 Bio-Chemical Oxygen Demand (BOD)Mg/L1,500.0 Total Suspended SolidsMg/L 250.0 Oil & GreaseMg/L 200.0 1.2.Treated Effluent Characteristics The plant is designed to deliver, after final treatment, effluent as per following parameters: ParameterUnits Value pH -6.5 to 8.5 Bio-Chemical Oxygen Demand (BOD)Mg/LLess than 100.0 Total Suspended SolidsMg/LLess than 50.0 Oil & GreaseMg/LLess than 10.0 OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 5 of 32 2.PROCESS DESCRIPTION The treatment scheme can be divided into the following sections: 2.1.Effluent Collection & Equalization The effluent fromtheplantis conveyedtotheETPthrough closedpipelines.NeartheETP,all thepipelinesareconnectedtoacommonchamber.Fromthiscommonchamber,theeffluent flows by gravity into the Oil and Grease Trap (T 01).Theoilandgreasetrapwillbedividedintothreecompartments,connectedbyanH-Pipe mechanism.InthesecondcompartmentoftheOil&GreaseTrap, theanyfree floatingoiland grease present will float to the top, under quiescent condition and will be skimmed off manually atregularintervals.Theeffluentthatisessentiallyoffreefloatableoilandgreasewillbe collected in the last compartment.Fromtheoilandgreasetrap,theeffluentflowsbygravityintotheNeutralizationCum 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 therequirement.OncethepHisadjusted,theeffluentpumpingisstartedfromthistankand thefreshincomingeffluentiscollectedinthesecondcompartment.Anaciddosingtankand 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 Non-clog 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 theeffluentwillbemixedwithalumandpolyelectrolyte,inordertocoagulate,flocculateand thereby increase the settling of the suspended solids present in the waste water. The flash mixer hasbeendesignedtogivearetentiontimeofapprox.30minutesatfinalflow.Themixingof alum and polyelectrolyte will be carried out by means of a mechanical mixer. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 6 of 32 The alum and polyelectrolyte will be dosed into the effluent at a desired rate using the alum and polyelectrolytedosingpumpsrespectively.Twonumbersofelectronicdosingpumpsare provided for the purpose. From the flash mixer, the effluent will flows into the Tube Settler (T 04). Thetube settler has beenprovidedinordertoconservethespaceandpromoteeffectivesettlingofthesuspended solids.APVCtubepackhasbeeninstalledintheTubeSettlertoincreasethesurfacearea availableforsettling.Thesludgewhichcollectsinthehopperoftheprimaryclarifierwillbe drained periodically into the sludge drying beds. The clarified effluent will then flow into the aeration tank for further treatment. 2.3.Secondary Treatment Thesecondarytreatmenthasbeenprovidedtoremovetheorganicmatterpresentinthe effluent,bybiologicalaction.Theclarifiedwastewaterflowsbygravitytotheinletlaunderof the Aeration Tank (T 05).Thepurposeoftheaerationtankistoprovidesuitableconditionsforthegrowthofmicrobial mass,calledasthe ActivatedSludge &measuredbyparametercalledas MLSS.Theactivated biomassorMLSS in theaeration tank willdegradestheorganicmatter (whichismeasured as BOD/COD),inpresenceofoxygenandconvertsthemtoharmlesscarbondioxideandwater, thus leading to reduction in BOD/COD. This process can be represented as: Organic Matter + O2 +BacteriaCO2+H2O+More Bacteria (Waste Sludge) TheoxygenrequiredfortheAerobicBiologicalActionisprovidedbymeansofaDiffused Aeration System, consisting of Membrane Diffusers & Air Blower.TheMLSSintheaerationtanksettlesintheSecondaryClarifier(T06)andtheclarified treatedeffluentflowsintotheTreatedWaterTank(T07).InordertomaintaintheMLSS 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 7 of 32 If the quantity of MLSS in the aeration tank increases beyond a certain level, a part of the sludge isdischargedtotheSludgeDryingBeds(T09)fordewateringanddrying.Thefiltrateof 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 smallquantityoforganicspresentinthetreatedwastewatercanberemoved.Forthis,the treatedeffluentfromthetreatedwatertankispumpedbytheTreatedWaterPumps(P03 A/B)throughthePressureSandFilterandActivatedCarbonFilterandcollectedinClean WaterTank (T08). 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 Thesolidwastegeneratedduringtheprimarytreatmentandthebiologicaltreatmentwillbe dewateredintheSludgeDryingBedsandthensundried.Thedriedsludgewillthenbe transported periodically to the authorized solid waste disposal facility. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 8 of 32 LIST OF MECHANICAL EQUIPMENT AND CIVIL STRUCTURES Rev: 0 Date: 1-Nov-04 Page 9 of 32 1. List of Mechanical Equipment Sr. Tag No. Item Specifications Make Model Sr. No. 1 P 01 A Raw Effluent Pump 1 3 M3/Hr @ 12 MWC Johnson Pumps KGEN 11 3 2 P 01 B Raw Effluent Pump 2 3 M3/Hr @ 12 MWC Johnson Pumps KGEN 11 3 3 P 02 Sludge Recycle Pump 3 M3/Hr @ 12 MWC Johnson Pumps KGEN 11 3 4 P 03 A Treated Water Pump 1 3 M3/Hr @ 30 MWC Johnson Pumps KGEN 16 3 5 P 03 B Treated Water Pump 2 3 M3/Hr @ 30 MWC Johnson Pumps KGEN 16 3 6 P 04 A Clean Water Pump 1 3 M3/Hr @ 30 MWC Johnson Pumps KGEN 16 3 7 P 04 B Clean Water Pump 2 3 M3/Hr @ 30 MWC Johnson Pumps KGEN 16 3 8 P 05 Alum Dosing Pump 0-5 LPH @ 25 M WC E -Dose 9 P 06 Poly. Dosing Pump 0-10 LPH @ 25 M WC E Dose 10 B 01 A Air Blower 1 200 M3/Hr @ 5 M WC Usha Compressor UGRK 11 B 01 B Air Blower 2 200 M3/Hr @ 5 M WC Usha Compressor UGRK 13 A - 01 Flash Mixer 100 rpm Kumar Process 12 A 02 Secondary Clarifier 3.0 M Dia x 3.0 M SWD Environ Engg. Central Drive 13 F 01 Pressure Sand Filter 800 mm Dia Synergie ecoSolutions 14 F 02 Activated Carbon Filter 800 mm Dia Synergie ecoSolutions 15 FI 01 Flow Meter Digital Vaturkar

O & M Manual for Effluent Treatment Plant for Ispat Industries Ltd. Synergie ecoSolutions Pvt. Ltd.2. List of Motors Sr. Tag No. Equip Tag Power RPM Phase Make Volts Current Frame Size Sr. No. 1 M - 01 P 01 A 1 HP 2900 3 Crompton 415 2 M 02 P 01 B 1 HP 2900 3 Crompton 415 3 M 03 P 02 A 1 HP 2900 3 Crompton 415 4 M 04 P 03 A 3 HP 2900 3 Crompton 415 5 M 05 P 03 B 3 HP 2900 3 Crompton 415 6 M 06 P 04 A 3 HP 2900 3 Crompton 415 7 M 07 P 04 B 3 HP 2900 3 Crompton 415 8 M 08 B 01 A 5 HP 2900 3 Crompton 415 9 M 09 B 01 B 5 HP 2900 3 Crompton 415 10 M 10 A 01 0.5 HP 1450 3 Crompton 415 11 M 11 A 02 0.5 HP 1450 3 Crompton 415

O & M Manual for Effluent Treatment Plant for Ispat Industries Ltd. Synergie ecoSolutions Pvt. Ltd.3. List of Civil Structures Depth Volume Sr. Tag No. Title MOC No. of Compart. LengthWidth SWD Free Board Total Total Working 1. T 01 Oil & Grease Trap RCC 3 2. T 02 Equalization Tank RCC 2 3. T 03 Flash Mixer RCC 1 4. T 04 Tube Settler MS 1 5. T 05 Aeration Tank RCC 1 6. T 06 Secondary Clarifier RCC 1 7. T 07 Treated Water Tank RCC 1 8. T 08 Clean Water Tank RCC 1 9. T 09 Sludge Drying Beds BBM 2 10. R - 01 Control Room BBM

OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 12 of 32 DRAWINGS OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 13 of 32 Process Flow Diagram Collection Chamber Alum Dosing Tank Raw Effluent Pumps EffluentChannel Oil & Grease Trap Equalization Tank Flash Mixer Tube SettlerPoly Dosing Tank Aeration Tank Sludge Drying Beds Sec.Clarifier Central Drive Treated water Tank Pressure Sand Filter Activated Carbon Filter Disposal to Gardens Alkali Dosing Tank Acid Dosing Tank Waste SludgeWasteRecycle T 09 A/B Air Blowers Dosing PumpsSludge Recycle PumpsTreated Water Pumps Treated water Tank Clean Water Pumps OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 16 of 32 SINGLE LINE & WIRING DIAGRAM FOR CONTROL PANEL OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 17 of 32 STANDARD OPERATING PROCEDURES OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 18 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 19 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 20 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 21 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 22 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 23 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 24 of 32 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 rates- Urea:2.0 Kg/day (for flow rate of 25 M3/day) DAP:0.4 Kg/day (for flow rate of 25 M3/day) 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.Donotwasteanysecondarysludge(MLSS)intothesludgetank,untilthe design value is reached.6.8.2.Add bio-products at the given dosage in the aeration tank, by dissolving them in water. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 25 of 32 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 26 of 32 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. 4.0Kg/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: 48.0 M3x 3.5 Kg/M3

as per design ( B) = 168.0 Kg,Actual weight of MLSS in Aeration Tank: 48.0 M3 x4.0 Kg/M3

= 192.0 Kg Excess MLSS in aeration tank( C- B): 192 Kg 168 Kg =24 Kg Amount of Return sludge to be : 24.00 Kg Wasted ------------ =3.0 M3 8 Kg /M3

Theactualsludgetobewastedcanbecalculatedasabove,basedontheactualfiguresfor MLSS & Return Sludge concentrations. Theexcesssludgeshouldbedischargedtothesludgedryingbedsdistributedin3equal volumes , i. e. in above case 1.0 M3 every 8 hours OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 27 of 32 8.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. 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 28 of 32 9.Operation of Sand & Carbon Filter9.1.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 OperationValves to be openedValves to be closed Normal ModeSand Filter Inlet V 23 Sand Filter Outlet V 25 Carbon Filter Inlet V 29 Carbon Filter Outlet V - 30 All Other Valves Sand Filter Backwash Mode Sand Filter Backwash V 27 Sand Filter Backwash V 24 Sand Filter Inlet V 23 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 Sand Filter Backwash V 31Carbon Filter Inlet V 29 Carbon Filter Outlet V 30 Carbon Filter Vent V 33 Carbon Filter Bypass V - 34 30 23 2431 29 25 32 33 34 28 27 26 22 OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 29 of 32 10. Collection of Water in Clean Water Tank 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. OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 30 of 32 PROFORMA OF LOG SHEET FOR THE ETP A. EQUIPMENT OPERATIONAL STATUS1 2 3 4 5 6 7 81 P - 01 A2 P - 01 B3 P - 02 A4 P - 02 B5 P - 03 A6 P - 03 B7 P - 04 A8 P - 04 B9 P - 05 10 P - 0611 B - 01 A12 B - 01 B13 A - 0114 A - 02B. EQUALIZATION TANK UNDER PUMPING1 T - 02 A2 T - 02 BC. WATER LEVEL IN TANKS (in meters)1 T - 02 A Equalization Tank 12 T - 02 B Equalization Tank 23 T - 05 Treated Water Tank4 T - 065 T - 106 T - 117 T - 128 T - 13D. FLOW METER READING1 2 3 4 5 6 7 81 FI - 01E. POWER CONSUMPTIONReading at End of ShiftTotal power consumption in Shift Total Daily Power Cons.Reading at Beginning of the ShiftHours Equalization Tank OutletTotalPoly. Dosing TankSr. Tag No. DescriptionAlkali Dosing TankAcid Dosing TankAlum Dosing TankClean Water TankFlash MixerSecondary Clarifier Clean Water Pump 1Equalization Tank 1Equalization Tank 2Air Blower 1Air Blower 2Tag No. Sr.Polyelectrolyte PumpAlum Dosing PumpSludge Recycle Pump 1Sludge Recycle Pump 2Treated Water Pump 1Treated Water Pump 2Raw Effluent Pump 1Raw Effluent Pump 2A / B / CClean Water Pump 2Hours Total Running DescriptionSynergie ecoSolutions Pvt. Ltd.EFFLUENT TREATMENT PLANT LOGSHEETDate:Shift:Operator:F. pH Data1 2 3 4 5 6 7 81 T - 04 A2 T - 04 B3 T - 054 T - 075 T - 08G. CHEMICAL CONSUMPTION1 2 3 4 5 6 7 8123456H. SAMPLING RECORDS123I. ANALYSIS RESULTS HPCB Std.12345J. REMARKSAlumPolyelectrolyteETP Incharge Maintenance InchargepHOil & GreaseTotal Suspended Solids / MLSSChemical Oxygen DemandAeration Tank Sec. Cl. O/L Final OutletSr.Synergie ecoSolutions Pvt. Ltd.EFFLUENT TREATMENT PLANT LOGSHEETDate:Shift:Operator:A / B / CDescriptionHours TotalHours Total Cons. DescriptionAeration TankTreated Water TankClean Water TankTag No. Sr.Tag No.Urea DAPAlkaliAcidEqualization Tank 1Equalization Tank 2Biochemical Oxygen DemandOperatorETP InletSecondary Clarifier OutletFinal ETP OutletETP Inlet OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 31 of 32 ANALYSIS SCHEDULE OPERATION & MAINTENANCE MANUAL Client :Alembic Limited, BaddiProject:Effluent Treatment Plant Rev: 0Date: 1-Nov-04 Page 32 of 32 The following is the suggested schedule of analysis for the ETP. The same may be modified depending on the local requirements and constraints. ItempHO & GTSSTDSBODCOD 1.Oil & Grease Trap Inlet Daily 2.Equalization TankPer ShiftDailyDaily Daily*Daily*Daily 3.Aeration TankDaily Daily$ 4.Secondary Clarifier OutletDaily DailyDaily*Daily 5.Recycle Sludge Line 6.Treated Water TankDailyDaily 7.Clean Water Tank DailyDailyDaily*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