DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.

2020

OPERATION MANUAL

FOR

EFFLUENT & SEWAGE TREATMENT PLANT

110 KLD

SUBMITTED TO

M/s. HPCL

Bangalore
SUBMITTED BY

Enviro Care India Pvt. Ltd.,

Plot No. 43, Second Street
Harvey Nagar, Madurai – 625 016
Tel 91 452 4355103, 4355203

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

PROCESS DESCRIPTION:

ETP & STP:

 The raw effluent will be received at the inlet of collection tank after passing through the scree
chamber for the removal floating impurities in the raw effluent.

 Since the BOD &COD load is high in our raw effluent, the raw effluent from collection tank will
transfer to Flash Mixer tank for chemical treatment. Where Acid & Alkali dosed to the water for
Neutralization.

 The overflow from the Flash Mixer tank is passed to Primary Settling tank through Flocculator.
Here the settled chemical sludge will be pumped to the sludge Holding Tank at regular intervals.
The overflow from the Settling Tank will be passed to the SBR I. The Sequential Batch Reactor
will be provided with adequate detention time. A Blower will be provided to supply oxygen in
the form of fine air droplets into the Aeration Tank for reducing BOD and Total Suspended
Solids.

 The Clear water from the SBR I will be Pumped by decantation pumps to SBR II where Domestic
Sewage to be added for its Biological Treatment. The Sequential Batch Reactor will be provided
with adequate detention time. A Blower will be provided to supply oxygen in the form of fine air
droplets into the Aeration Tank for reducing BOD and Total Suspended Solids. Here the settled
bio sludge will be pumped to the sludge Holding Tank at regular intervals. Dried sludge from
filter press will be packed, weighed and stored inside the premises.

 The clear water after the settling phase in SBR II overflow will be collected by Filter Feed tank.
From this Filter Feed tank, the effluent will be pumped to Pressure Sand Filter followed by
Activated Carbon Filter for removal of very fine suspended solids, odour and turbidity.

 The dewatered sludge will be periodically disposed.

 The treated water will be stored in a treated water storage tank.

OPERATION MANUAL
 DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

OPERATION OF THE PLANT:

All the units should be clean from debris, waste material, bolts, nuts, wires or any extraneous material
otherwise they would spoil the pump & ensure that all the pumps are in 3 phase & 430V.

1. MECHANICAL,CHEMICAL & ELECTRICAL CHECK UP

 The self-priming pump should be filled with water to ensure self-priming.
 Measure the No load current of all the motors and check if it is within limits.
 All valve and lines should be checked and cleaned before start up.
 The fresh water is passed through the various units and all the tanks are filled up to the overflow
levels .This also helps to check the leakages if any. All the valves, pumps and other mechanical
items are checked. The overflow levels in the weirs are checked to see that they are uniform
throughout.

Startup Procedure for ETP :

1.Initial Startup for Plant:

 Ensure that all electrical equipments, mechanical equipments and instruments functional checks
are completed. Also checks for all consumables are available at store.
 Ensure the incoming power supply should be 415V, 3 Phase & 50Hz.

2.Normal Startup:

The sequence of the operation to be done as follows.

1. Allow effluent to be collected in collection tank after passing on screen.

2. Now switch on Raw Effluent transfer pump to transfer the effluent to Flash Mixer tank.
3. Control the flow rate of the pump to desired flow rate.
4. Now switch on Agitators of Flash Mixer & Flocculator.
5. Now add Acid or Alkali as per Jar test taken at the site to the Flash Mixer tank by means of Dosing
Pump.
6. Allow the water pass through the Flocculator for the formation of the flocs.

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

7. Sludge gets settled at the bottom of the Primary settling tank and the clear water filled to the SBR
Tank I
8. Sludge from Primary Settling tank to be transferred to Sludge Holding tank for further Sludge
Dewatering.
3. REGULAR OPERATION

1. Clean the bar screen as and when accumulation of floating particles and debris blocks it.
2. Pump room area equipments should be cleaned every day.
3. Ensure the incoming power supply is being 415V, 3 Phase.
4. Maintain the Feed Flow Rate 1 m3/hr.
5. Dosing the chemicals as per prescribed doses. Check the pH of ETP outlet at regular interval with
help of pH paper record in logbook.

DO’S AND DONT’S

 Always, check inlet water or Oil & Gaseous content. Don’t allow such water to pass
through the filter.
 Do periodical Maintenance as described in the manual.
 Do annual media Checkup and replacement as required.
 Backwash the filter regularly as per manual.
 Always use genuine spare parts.

OPERATION MANUAL
 DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

OPERATION OF THE SBR SYSTEM (I & II) :

Startup Procedure for Plant:

1. Ensure that all electrical equipments, mechanical equipments and instruments functional checks
are completed. Also checks for all consumables are available at store.
2. Ensure the incoming power supply should be 415V, 3 Phase & 50Hz.
3. PSF & ACF to be backwashed before put into service.

Initial Startup Procedure for SBR Tank:

1. Fill 25% of the SBR Tank with Fresh water.

2. Start aeration and maintain dissolved oxygen level in the Aeration Tank around 2 – 3ppm
(minimum 2ppm).
3. Dose culture/Biomass.
4. Fill 25% of the aeration Tank with raw sewage effluent.
5. Continue the aeration and maintain dissolved oxygen level in the Aeration Tank around 2 –
3ppm (minimum 2ppm).
6. Aerate for 2 days by running the air blower continuously.
7. Ideal pH value for culture growth is 7 to 7.5.
8. PH value less than 7 should not be allowed to the Aeration Tank. Low pH will kill the bacteria’s
and micro-organisms. It will tend to septic the sewage water in the bio-aeration.
9. Check the MLSS Value of the SBR Tank and proceed for commissioning of the system after the
growth exceeds 150 ml per 1000 ml.
Normal Startup:

At normal startup, the plant has to be operated for 25% output. All the respected valves have to be opened
for 25% of flow. The sequence of the operation to be done as follows.

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

1. Allow the Effluent water from the Primary settling tank to SBR Tank I ( Fill Decant water of SBR I
or Sewage water for SBR II) to
2. Continue the Aeration for about 4 Hrs and then switch off the Blowers.
3. On completion of Settling phase of an hour decant the clear water from SBR I to SBR II (Decant
the clear water from SBR II to Decanter Tank for SBR II Operation)
4. Open the suction and discharge valve of filter feed pump based on selected Filter Feed pump.
Also open the inlet and outlet valve. Now start the filter feed pump.
5. Control the Flow rate of Filter Feed Pump to 2.2 Cum/Hr
6. Backwash the PSF & ACF and put into service.
7. Duration Time:-
a. Backwash – 15mins
b. (b) Rinse - 10mins.
8. Operate the Sludge Transfer Pump to transfer the Sludge to Sludge Holding tank for Sludge
Dewatering purpose.
9. Flow to be monitored at regular intervals. It should be filled in the log sheet.
10. Refer respective manuals for the operation of mechanical equipments for pumps and blowers.

MANUAL START UP OPERATION OF Filter

a) BACK WASHING
- Check whether the Back wash pump has been switched off

- Open Backwash inlet and outlet valve accordingly.

- Now Switch on the pump for Backwash

- After 15 minutes or when the water is clearly switch off the pump

- This completes backwash operation.

b) RINSING

- Check whether the Back wash pump has been switched off

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

- Open Service inlet and Rinse valve accordingly.

- Now Switch on the pump for Rinsing

- After 10 minutes (approx.) check the clarity of water.

Do’s:

1. Clean the bar screen as and when accumulation of floating particles and debris blocks it.
2. In collection tank the water level must be maintain minimum 30% capacity.
3. Ensure the incoming power supply is being 415V, 3 Phase.
4. Blower must be operated continuously (24 x7 basis).
5. Raw water and Filter feed pumps should be changed every 8hours.
6. The sewage pumped to the aeration Tank should not exceed the Designed flow rate.
7. Feed should be given continuously to Aeration tank.
8. Sludge has to be removed from clarifier by Sludge transfer pump 2 days once to Sludge Drying
Beds.
9. Flow to be monitored at regular intervals. It should be filled in the log sheet.
10. Backwashing of the DMF filter should be done once in 8hrs
Back wash duration – 15minutes

Rinse duration – 10minutes.

11. Check MLSS level, it should not be below 30%.

12. Ensure the PH level should be 7-7.5
13. If any abnormal sound noted from any equipments and leakage from any pipe line should be
checked and informed to appropriate person.
14. Log sheet has to be maintained regularly.
Don’t ’s:

1. Do not run the pumps in dry condition.

2. Solid or cloggy materials should not be allowed nearby the pump suction.
3. The maintenance work should not be carried out while running of equipments.
4. Do not start the pumps without priming.

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

Plant/Mechanical Equipments Shut Down Procedure:

Emergency Shutdown Procedure:

1. Stop the plant inlet.

2. Stop the sewage transfer pump and close the discharge valves
3. Stop the filter feed pump and close the discharge valves.
4. Remove the PSF & ACF filter from operation
5. Close the clarified water tank outlet valves.

Normal Shut down Procedure for More than 15 days:

This shutdown procedure is applicable only at the time of annual maintenance / total maintenance and
painting to the total plant.

1. Stop the plant inlet.

2. Transfer all the sewage effluents to the Aeration tank.
3. Stop the sewage transfer pump and close the discharge valves.
4. After providing sufficient retention time to the sewage in the Aeration tank, transfer the sewage
to the secondary settling tank.
5. Keep running the air blower to maintain the DO in the Aeration tank.
6. Now send the sludge to the sludge digester through the sludge outlet valve.
7. Transfer the clarified sewage to the clarified water tank.
8. Feed the available water to the Filter.
9. Now total plant is free of sewage water.

Normal Shutdown for Less Than 15 Days:

1. Fill the sewage collection sump to the maximum level with the sewage effluent.
2. Stop the plant input.
3. Fill the bio-aeration..

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

4. Now stop the sewage transfer pump. Drain the water and pressure gauge and Pump.
5. Remove the sludge out.
6. Close the clarified water tank outlet valves.

Filter Press Operation

1. Assure that the filter plates are arranged in the plate stack properly before filtering to maximize
filtration performance.

2. Confirm that optional manual hydraulic isolation valve is open prior to operating manual
hydraulic pump.

3. Switch the selector switch on the hydraulic pump to the close position.

4. Pressurize the hydraulic pump to the recommended pressure as indicated in the filter press
specifications and close manual hydraulic isolation valve, if provided.

5. Slowly open all of the discharge valves on the manifold.

6. Slowly open the center-feed valve.

7. Introduce 25-psi air pressure to the feed pump. The feed pump cycling will slow as the filter
press becomes filled. Steadily increase in 25-psi increments, when the pump stalls, until 100-psi
maximum feed pressure is attained and the pump stalls.

8. Turn off the air supply to pump.

9. Close center-feed assembly valve.

10. Close all of the discharge valves on the manifold and slowly open the air supply valve on the
upper left hand corner, introducing 30 psi of air to the manifold. This will evacuate all excess
water that is trapped between the cloths and plates. Continue the air blow down procedure for
30 minutes. There should be very little liquid exiting from the lower right hand filtrate pipe.

11. After the air blow down procedure is complete, turn off the air valve slowly and open the
discharge valves slowly and let the filter press gravity drain for 5 minutes.

12. Open manual hydraulic isolation valve, if provided.

13. Slowly change the selector switch on the hydraulic pump to the open position.

OPERATION MANUAL
DOCUMENT NO: HPCL/VKBS/ECI/OMM/14/R1 DATE: 23.07.2020

14. The hydraulic ram will automatically return the operator should then rotate the cylinder ram up
and pull the tail plate back. This will allow the operator to separate the plates and use the
nonabrasive edge on the nylon paddles to aid in the cake removal.

OPERATION MANUAL