Maintenance Manual for 240 KLD Glass Fibre Industry

1

MAINTENANCE MANUAL

FOR 150 KLD

EFFLUENT TREATMENT PLANT

OF

AN GLASS FIBRE INDUSTRTY

2

INDEX

PAGE NOS.

1. TECHNICAL SPECIFICATIONS 3-23

2. PREVENTIVE MAINTENANCE 24-26

3. EQUIPMENT MANUALS

3

4

TECHNICALTECHNICALTECHNICALTECHNICAL

SPECIFICATIONSSPECIFICATIONSSPECIFICATIONSSPECIFICATIONS

5

1.0 UNITS & EQUIPMENT FOR ETP

1.1. CIVIL UNITS

Sr. No.

Particulars

Quantity

1 Bar Screen Chamber One No.

2 Surge Tank One No.

3 CSM Holding Tank One No.

4 Equalization Tank One No.

5 Flash Mixer Tank One No.

6 Primary Clarifier One No.

7 Bio-Tower One No.

8 Aeration Tank One No.

9 Secondary Clarifier One No.

10 Sludge Collection Tank One No.

11 Chlorine Contact Tank One No.

12 Electrical Control Panel Room & Laboratory Room One No.

13 Foundations for Mechanical Equipments Lot

6

1.2 MECHANICAL UNITS / EQUIPMENTS

Sr. No.

Particulars

Quantity

1. Screen ( 1W + 1Sb) Two Nos.

2. Surge Effluent Transfer Pump ( 1W + 1Sb) Two Nos.

3. Floating Agitators Two Nos.

4. CSM Effluent Transfer Pump ( 1W + 1Sb) Two Nos.

5. Raw Effluent Feed Pump ( 1W + 1Sb) Two Nos.

6. Flash Mixer One No.

7. Chemical Dosing Systems Seven Nos.

8. Primary Clarifier Mechanism One No.

9. Sludge Withdrawal Pump ( 1W + 1Sb) Two Nos.

10. Bio-fills 47 cu. mt.

11. Bio-Tower Distribution Sprinklers One Set

12. Bio-Tower Recirculation Pump ( 1W + 1Sb) Two Nos.

13. Air Blower ( 1W + 1Sb) Two Nos.

14. Air Diffusers 14 nos.

15. Secondary Clarifier Mechanism One No.

16. Bio-Sludge Recycling Pump ( 1W + 1Sb) Two Nos.

17. Filter Press One No.

18. Pressure Pump( 1W + 1Sb) Two Nos.

19. Duel Media Filter One No.

20. Activated Carbon Filter One No.

7

1.3 PIPING & FITTINGS

Sr. No.

Particulars

Quantity

1. Interconnecting Piping between ETP

units with all necessary Valves & other fittings.

Lot

1.4 ELECTRICAL WORKS

Sr. No.

Particulars

Quantity

1. Electrical Panel board One No.

2. Remote Push Button Stations supply Lot

3. Electrical cabling from control panel to

units of Effluent treatment plant

Lot

4. Earthing Lot

1.5 INSTRUMENTATION

Sr. No.

Particulars

Quantity

1. Liquid Flow Meter with Totaliser Two Nos.

2. pH Controller System One No.

3. Pressure Gauges Twelve Nos.

4. Level Switches Four Nos.

8

2.0 MECHANICAL UNITS

I) SCREEN

Application : Screening floatable solids

Location : At Screen Chamber

Type : Manual mesh screen

Size : 500 x 500 mm with 5 mm openings.

MOC : SS 304

Make : SAI

Quantity : Two Nos.(1W+1Sb)

II) SURGE EFFLUENT TRANSFER PUMP

Application : Effluent feed to Equalization Tank

Location : At Surge tank

Type : Centrifugal, non clog

Capacity : 10.5 M3 /Hr.

Head : 10 mtr.

MOC Internals

MOC externals

: SS

CI

Drive : 2.0 HP

Make : Jhonson

Quantity : 2Nos (1 W + 1 S )

III) FLOATING AGITATOR

Application : To mix the effluent with chemical solutions

MOC : MS-FRP lined

Type : Slow Speed floatable

Geared motor : Eliocn-Siemens

Impeller : World renowned simcar design –cone type

Shaft /impeller : MS-FRP lined

Floats : Three Nos. FRP lined

9

RPM : 100

Rated power : 5.0 HP

Accessories : Fabricated MS base-plate, foundation bolts

etc

Make : SAI

Quantity : Two Nos.

IV) CSM EFFLUENT TRANSFER PUMP

Application : Effluent feed to Equalization Tank

Location : At CSM Holding tank

Type : Centrifugal, nonclog


Head : 10 mtr.

Internals : SS/ PP

Externals : CI

Drive : 1.0 HP

Pump Make : Johnson


V) RAW EFFLUENT FEED PUMP

Application : Effluent feed to Flash Mixer Tank

Location : At Equalization tank

Type : Centrifugal, non clog


Head : 10 mtr.

Internals : SS

Drive : 2.0 HP

Pump Make : Johnson


10

VI) FLASH MIXER

Application : To mix the effluent with chemical solutions

Location : At Flash Mixer Tank

MOC : SS

Type of Mixer : Slow Speed

Geared motor : Bonfligliloli

RPM : 100


Make : SAI

Scope : Supply

Quantity : One No.

VII) CHEMICAL DOSING SYSTEM

Application : Storage & Dosing of Chemical Solutions

Type : Vertical, Cylindrical with close top

Capacity : 500 liters + 200 liters

MOC : HDPE

Make : Sintex

Dosing : By Pump

Capacity : 0 to 50 LPH / 0 to 20LPH

Make : SR Metering / Equivalent

Drive : 0.5 HP (two nos.) + Electronically actuated

Quantity : Seven Nos. (Two + Five Nos.)

VIII) PRIMARY CLARIFIER MECHANISM

Application : To scrap the settled sludge at the bottom of

clarifier & to collect sludge in center chamber.

Location : At Primary Clarifier.

Size : Suitable to civil unit

Access Bridge : The full span structural bridge 1000 mm width

support at center & 5 mm thick plate upto

center with hand railing.

11

Drive : Centre drive

Gear Box

Motor

: Elicon

Siemens

Scraping : MS – epoxy painted the center pipe having

two scraper arms with neoprene rubber

squeegees. The floor is scraped twice in

revaluation to collect sludge at the center.

Feed well

: MS-epoxy painted feed well, supported from

the bridge, with baffle plate.

Painting : All wetted parts will be one coat of epoxy

primer & two coats of epoxy paints & other s

parts are two cots of enamel paints.

The scraper arms lifting hand operated mechanism is provided so that incase over

loading the complete assembly can be lifted manually up to 300 mm


Quantity : One no.

IX) SLUDGE REMOVAL PUMP

Application : Sludge removal from PC

Location : At PC

Capacity : 10 M3 /Hr.

Head : 10 mtr.

MOC of pump : CI

Internals : SS

Drive : 2.0 HP

Motor Make : Siemens

Pump Make : Johnson

Accessories : Fabricated MS base-plate, coupling guard,

foundation bolts etc.

Quantity : Two Nos.(1W +1Sb)

12

X) BIO-FILLS

Application : Medium for Bacterial attached growth.

Location : Bio-tower

MOC : PVC UV stabilized sheets

Specific Surface Area : 93 M2 / M

3

Void Ratio ( M2 / M

3 ) : More than 97 %

Thickness : 0.3 mm

Standard Dimensions : 1200x 600 x 600 mm

Max. width of support : 100 / 150 mm

Dry weight : 20 kg / m3

Make

No. of blocks

: MM Aqua

108 nos.

Quantity : 47 cu. mt.

XI) BT RECYCLING PUMP

Application : Effluent recirculation at Bio-tower

Location : At Bio-tower

Type : Self priming ,centrifugal, non-clog, semi-open

impeller

Capacity : 26 M3 /Hr

Head : 8 mtr.

MOC of Pump : CI

Drive : 3.0 HP motor


Pump Make : Johnson



Quantity : 2 Nos. ( 1W + 1Sb)

13

XII) BT EFFLUENT DISTRIBUTION SPRINKLERS

Application : Effluent distribution at the top of Bio-tower

Location : At Bio-tower

MOC : PVC

Quantity : One Set

XIII) AIR BLOWER

Location : Near Aeration Tank

Application : Supply of Air for mixing –ET & HT and

aeration in Aeration Tank

Medium Handled : Air

Blower Make : Kay


Air Flow : 420 M3/hr.

Delivery Pressure : 0.45 kg/cm2

Duty : Continuous

Motor HP : 15

Accessories : All accessories as per requirement

Quantity : Two Nos.(1W+1Sb)

XIV) AIR DIFFUSERS

Type : Membrane Diffusers

MOC : Silicon membrane with PP Pipe

Make : Rehau, Germany

Size : 63mmOD x 2000 mm length

Type : Lift able with nylon ropes and accessories

Air Flow : 18 M3/Hr.

Location : Aeration Tank

Quantity : Fourteen Nos. (Including spares)

14

XV) SECONDARY CLARIFIER MECHANISM

Application : To scrap the settled sludge at the bottom of

clarifier & to collect sludge in center chamber.

Location : At Secondary Clarifier.

Size : Suitable to civil unit

Access Bridge : The full span structural bridge 1000 mm width

support at center & 5 mm thick plate upto

center to with hand railing.

Drive : Centre drive

Gear Box : Elicon

Motor : Siemens

Scraping : MS – epoxy painted the center pipe having

two scraper arms with neoprene rubber

squeegees. The floor is scraped twice in

revaluation to collect sludge at the center.

Feed well

: MS-epoxy painted feed well, supported from

the bridge ,with baffle plate .

Painting : All wetted parts will be one coat of epoxy

primer & two coats of epoxy paints & other s

parts are two cots of enamel paints.

The scraper arms lifting hand operated mechanism is provided so that incase over

loading the complete assembly can be lifted manually up to 300 mm


Quantity : One no.

XVI) BIO-SLUDGE RECYCLING PUMP

Application : Sludge Recycling To Aeration Tank & excess

sludge into sludge collection tank.

Location : At Secondary Clarifier

Type : Self Priming, centrifugal, non-clog, semi-open

impeller

15

Capacity : 6.5 M3 / Hr

Head : 10 mtr.

MOC of pumps : CI



Pump Make : Johnson



Quantity : 2 Nos. (1 W + 1 S )

XVII) FILTER PRESS

Application : For Dewatering of Sludge

Location : Near Sludge Collection Tank

Pump capacity : 5 M3

/ Hr.

Sludge Feed : 5 M3/ Hr.

Operation : Two batches per day

Capacity : 240 Liters /batch wet cake holding capacity

Type : Plate

MOC of Plates : PP

Size of Plates : 610 x 610mm

No .of Plates : 25

MOC of unit : CI



Make : Hydro Press

Quantity : 1 No.

XVIII) PRESSURE FEED PUMP

Application : Feed to Filters

Location : At Chlorine Contact Tank

Type : Monoblock

Capacity : 7 M3 / Hr

16

Head : 30 mtr.

MOC of pumps : CI


Make : Kirloskar

Quantity : 2 Nos. (1 W + 1 S )

XIX) DUEL MEDIA FILTER

Application : Removal of SS

Location : After Chlorine Contact Tank

Type : Vertical, Cylindrical


MOC : MS-EP

Valve : AUTO MPV*

Backwash : AUTO time setting

Thickness : 5mm

Pressure : 3.5 Kg/Cm2

Media : Sand & Anthracite

Make : SAI

Scope : Supply

Quantity : One No.

XX) ACTIAVTED CARBON FILTER

Application : Removal of odor/ chlorine

Location : After Duel Media filter

Type : Vertical, Cylindrical


MOC : MS-EP

Thickness : 5mm

Valve : AUTO MPV*

Backwash : AUTO time setting

Pressure : 3.5 Kg/Cm2

17

Media : Activated Carbon

Iodine Value : >800

Make : SAI

Scope : Supply

Quantity : One No.

*Note: PLC based control panel included.

C. PIPING & FITTINGS

Application : Interconnecting Piping between all ETP units

Location : ETP Plant Battery limits

Accessories : Valves, Flanges, Reducers, Joints, Bends etc.

MOC : CPVC

D. ELECTRICAL WORKS

I) CONTROL PANEL

Motor Control Centre (MCC) is to be fabricated in 16 swg CRCA sheet with

compartment, dust & vermin proof, floor mounting, cable entry at bottom with back

access. At the bottom ISMC channel will be provided for installation of panel. Suitable

painting should be done to the panel.

In this panel one incomer is to be provided which should have Ammeter, Voltmeter

indicating lamps & energy meter. Outgoing feeders are as per drives of mechanical

equipments.

All major components are Siemens Make.

Quantity : One No.

18

II)

REMOTE PSUH BUTTON STATIONS

Make : Technic

III)

CABLING

Electrical cabling from control panel to units of Effluent treatment plant.

The cables shall be Copper ( upto 2.5 sq.mm) aluminum

(above 2.5 sq.mm) conductor armored . The entire cable shall be supplied capacity

wise for all motors / units.

IV)

EARTHING

Earthing for Motors – Copper.

19

E. INSTRUMENTATION

I) LIQUID FLOW METER

Application : To measure the liquid flow

Location : FMT Feed line

Type : On line, Electromagnetic type with totalizer

and Indicator

Make : E & H ,Germany

Flow : 0 to 12.5 M3/Hr.

Quantity : Two Nos.

II) PH METER

Application : To measure the pH Online

PH Sensor : Innovative sensors –Two Nos.

PH Transmitter : Wavetec

PH Indicator : Wavetec

Make : Wavetec

Quantity : One No.

III)

PRESSURE GAUGES

Application : To measure the pressure

Location : Pipeline after Pumps/Blowers

Type : Dial

Make : H-Guru

Size : 4”

Quantity : 12 Nos.

20

IV) LEVEL SWITCHES

Application : Automatically on or off the pump at set points

Make : Techtrol

Quantity : Four Nos.

21

4.0 ELECTRICAL

Sr. No.

PARTICULARS

Quantity

Each

HP

Total

HP

1. Surge Effluent Transfer Pump

( 1W + 1Sb)

Two Nos. 2.0 4.0

2. CSM Effluent Transfer Pump

( 1W + 1Sb)

Two Nos. 1.0 2.0

3. Floating Agitator Two Nos. 5.0 10.0

4. Raw Effluent Feed Pump

( 1W + 1Sb)

Two Nos. 2.0 4.0

5. Flash Mixer One No. 2.0 2.0

6. Chemical Dosing System Two Nos. 0.5 1.0

7. Primary Clarifier Mechanism One No. 0.5 0.5

8. PC Sludge Pump ( 1W + 1Sb) Two Nos. 2.0 4.0

9. Secondary Clarifier Mechanism One No. 0.5 0.5

10. SC Sludge Pump ( 1W + 1Sb) Two Nos. 2.0 4.0

22

11. BT Recycling Pump ( 1W + 1Sb) Two Nos. 3.0 6.0

12. Air Blower ( 1W + 1Sb) Two Nos. 15.0 30.0

13. Sludge Dewatering System One No. 2.0 2.0

14. Pressure Feed Pump( 1W + 1Sb) Two Nos. 2.0 4.0

Total Working Load : 45 HP (33.75 KW)

(Some motors will work partially )

23

PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

24

PREVENTIVE MAINTENANCE

EMERGENCY INSPECTION

In case of any abnormality in primary and secondary clarifiers, drain the water from the

system and clear the accumulated sludge from the bottom. Check for fouling of any foreign

material with the racking mechanism . racking mechanism is to be checked thoroughly for

any damage of shaft , arms and supports. After thorough inspection and repairs as per

requirement take trail runs on no load and after satisfactory running fill the system with

water and restart the process.

If any abnormal sound / vibrations of pumps , aerators, and blowers observed , immediately

stop the equipment and check the equipments for any damage of bearings, oil seals ,

gearbox, coupling damages. After replacing /repair of the equipment proper alignment is to

be done and trail run is to be taken on no load then only take the equipment into operation.

PREVENTIVE MAINTENANCE

The main purpose of preventive maintenance schedule is to avoid break down maintenance

of the equipments. The preventive maintenance will avoid the damage to the equipment

and increases the equipment availability to the maximum possible extent and interns

increase the capacity utilization and help to increase the plant production .

The preventive electrical and mechanical maintenance allows to keep all the conditions

necessary to the equipments running and to maintain their performance at a level close to

their starting one.

Preventive maintenance of equipment supplied is to be carried out as per the manufacturer’s

operation manuals for this equipment. Specific guidelines for preventive maintenance for

major equipment are suggested in the table below. These guidelines should be adhered

wherever applicable.

25

PREVENTIVE MAINTENANCE SCHEDULE

S.No Equipment Maintenance Frequency

01. Centrifugal

Pumps

a. Alignment Check

b. Oil Check / Refill

c. Gland Tightening / Replacement

d. Chocking Clearance

At Commissioning Stage Quarterly

Weekly

Weekly

Quarterly / Monthly / As Required

02. Air Blowers a. Alignment Check

b. Oil Check / Refill

c. V–Belt Tightening / Replacement

d. Suction Filter Cleaning

At Commissioning Stage / Monthly

Weekly

Weekly

Monthly / As Required

03. Dosing

Tanks

Emptying and Cleaning Quarterly

04. Electrical

Connections

Routine Check Half Yearly

• All butterfly valves in fixed OPEN / CLOSE positions are to be operated weekly to prevent

jamming.

• In case of undue noise / vibration in rotating equipment, the same may be shut down

immediately and attend to.

• Plant operator is to monitor the voltage regularly and motors may be shut down when the

voltage falls below 380 V.

• Spare parts for the equipment that are recommended by the manufacturer are to be kept

under stock for ready use.

Maintenance Manual for 240 KLD Glass Fibre Industry

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