Update Operation Manual

OPERATION MANUAL FOR ETP
LIBAS TEXTILES LTD.

BANGLADESH
TOTAL WATER SOLUTION

HOUSE NO#07, ROAD#11,
Kind Attn: Engr, MD. Shahadat Hussain SECTOR-11, UTTARA,

Executive Director DHAKA, BANGLADESH
Libas Textile Limited.
Jabbar Tower, 11th Floor
House#42, Gulshan Avenue
DHAKA-1212, BANGLADESH Version: 02
Revision Date: 25-Jun-2022
INSTRUCTION MANUAL
FOR
OPERATION & MAINTENANCE
OF
EFFLUENT TREATMENT
PLANT
BASED ON MBBR
KURARAY PVA GEL TECHNOLOGY

JAPAN
Manual for O&M of ETP

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1. TABLE OF CONTENTS
SL NO. Topics Page No.

01 Table of Contents 02
02 Introduction 03
03 Plant Compounds 04-05
04 List of Major Equipment 06-07
05 Design Philosophy 08
06 Block Diagram of ETP 09
07 Start up the plant 10-16
08 Operation & Maintenance for the tanks used in the 17-20
System
09 Description of PVA Gel (Kuraray, Japan) Media 22-23
10 Fluidization diagram of PVA Gel Tank & Aeration 24
tank A and B.
11 O&M Related ETP Components 25
12 O&M Requirement Identification 26
13 ETP O&M Staff Requirements 27-28
14 ETP Staff Competency 29-30
15 ETP Staff Training 31-33
16 Guidelines For Safety In ETP Operation 34-41
17 Plant Performance Monitoring 42-44
18 Guideline For Record Keeping 45-51
19 Emergency Response Plan 52-53
20 Dictionary of technical terms used in the waste water 54-59
treatment sector

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2. INTRODUCTION
LIBAS TEXTILES LIMITED, Dhaka Bangladesh, is a composite knitting, Dyeing and

Garments factory. The industry is equipped with modern state of art machinery and at the same
time complies with all Government, international laws & regulations and as well as it will be
considered to be a one of the best industries in Bangladesh. Industrial operations such as washing,
printing process & utilities produce some wastewater. A Wastewater Treatment Plant has been
established to treat the present industrial waste water stream prior to re-use into gardening, car
washing, toilet flashing & others non-contact applications, to achieve:
 Reduction of water drawn from the Earth to secure the coming future
 Generations against water scarcity.
 Securing the ground water against undesired contaminations.
 Making the premises & surroundings healthier through increased green area.
As the treatment plant is biological it is based on the use of bacteria and microorganism, which,
if kept in determinate environmental circumstances, are able to destroy polluting organic matter.
It is easy to understand that all contributing to environment forming in which bacteria develop
their action, must be rigorously balanced and related, to offer a greater opportunity of
development, in no way inhibiting any of the treatment phases.
So we understand that a biological plant is to be compared to a micro ambient with proper
chemical physical factors (temperature, pH, dissolved oxygen etc.) in which the microbial
biomass develop its proper vital cycle (reproduction included) and tends to establish its own
regime; by means of this equilibrium the best efficiency conditions of the plant will be achieved.
3. PLANT COMPOUNDS

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The waste water treatment plant consists of following:
SL. No. Name of tank

1.0 Collection Tank
2.0 Equalization Tank
3.0 PVA Gel Tank
4.0 Aerobic Tank A
5.0 Activated Sludge Tank/ Aerobic Tank B
6.0 Tube Settler Clarifier
7.0 Filter Feed Tank
8.0 Dual Media Filter
Collection Tank- After separating coarse and fine matter at the inlet of the plant by fine
screening, then effluent water stored in the collection tank.
Equalization Tank – Influent stream free from large physical contents & free Oil-grease
flows to main storage tank. The mass is kept in continuous movement by forced mixing,
which is obtained mechanically, and by micro-bubble oxygen injection; in this phase also a
pre-oxidation stage of the waste water is achieved.
PVA Gel Tank – The tank with PVA gel from Kuraray Japan capable of reducing the BOD
loading by ~90%. SS Screen is used to protect PVA Gel from floating away. Diffuser
arrangements are designed in retractable way, So that to change or check any diffuser, plant will
remain in operation, no need to shut down the plant.
Aerobic Tank A- To mix return sludge uniformly with treated water from PVA Gel tank, Air
diffuser are used to mix for enhance biodegradation.
Activated Sludge Tank/ Aerobic Tank B –The tank to manage the desired Bio-degradation and
conversion into activated Bio-sludge to separate the undesired of available organic
contamination. Biological Oxidation is carried out through the action affected by bacteria and
aerobic micro-organism on the polluting load. The necessary oxygen is supplied by blowers and
silicon diffusers are used for proper aeration.

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Clarifier Tank –To ensure the fast & efficient separation of flocks is to be needed conical bottom
tank. Bio-decomposed effluent gets separated into two streams as clear water over-flows from the
top of clarifier & sludge from the conical bottom.
Dual Media Filter – Biologically treated & Clarified water will pass through the unit for removal
of remaining suspended impurities, by the action of multi graded quartz stone media provided into
the unit. This filter media is back washable to re-clean the same for regular & long-term
performance.
4. LIST OF MAJOR EQUIPMENT
Equipment Specification Working Standby Remarks

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Automatic Drum Capacity 300 m3/hr,
1 N/A
Screen Auto Controlled
2 more
Capacity 66 m3/hr
Effluent Feed pumps(50m3/hr
@ 20 M, 7.5 KW, 2 1 each) installed by
Pump
Non Clog client with old ETP
Circular type
Cooling Tower & 2 N/A
Square type
Capacity 220 m3/hr
Circulation pump @ 20 M, 18.5 KW, 1 1
for Cooling tower End suction
Capacity 150 m3/hr

Filter feed pump 1 1
@ 24 M, 15 KW
Another blower
Capacity 2000
(1050 m3/hr)
Air Blower m3/hr, 700 mbar, 75 2 1
installed by client
KW
with old ETP
Capacity 66 m3/hr
Sludge Recycle
@ 20 M,7.5 KW, 3 1
Pump
Non Clog
Dual Media Filter Anthracite & Sand

2 N/A
unit filter
Sludge
Capacity 100 Kg /Hr 1 N/A
Dehydrator
MCC Control With PLC & touch

1 N/A
Panel screen monitor
Online Analyzer On line monitoring 1 N/A

system for BOD,
COD, TSS & pH.

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Auto pH Controller
Automatic pH
with Acid dosing 1 N/A
Controlling system
pump
Automatic D.O
Sensor with motor 1 N/A
DO Sensor
drive controller &
display.
Note: For operation & maintenance of the equipments, please follow the specific operation
manual for the related equipments.
5. DESIGN PHILOSOPHY
OBJECTIVE
Treatment of waste-water stream & water recovery:

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 To minimize the fresh water requirement by recovery of suitable quality water for
gardening.
 Protection of environment from water contamination
 To establish & practice a concept of maximum but effective utilization of natural
resources.
EFFLUENT
Waste-water consists of Suspended matters, Inorganic & Organic Contents.
EFFLUENT GENERATION
Maximum Feed Flow - 150 m3/hr
WASTE WATER PARAMETERS – FEED & TREATED
SL. No. Description Feed Treated

1 pH 09-11.00 <6-9>
2 TSS 450 PPM <50 PPM
3 BOD 450 PPM <30 PPM
4 COD 900 PPM <150 PPM
5 Temperature <65 C (maximum)
o
<35oC

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6. BLOCK DIAGRAM OF ETP
pH Control Nutrient
Activated Sludge/
Equalization Tank PVA Gel Tank Aeration Tank A
Aeration Tank B
Activeted
sludge
return
Collection PIT Filter Feed Tank Secondary Clarifire
Treated Effluent
Drum Screen Filter Sludge PIT
Outlet

Effluent intel
2
ETP Design

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7. START UP THE PLANT
Before start up of a PVA Gel based Biological plant it is necessary to check the following:
 To clean the tanks of all residue accumulated during build up;
 To check the perfect leveling of overflow on the top of the sedimentation tank;
 To check assemblage and functioning of all valves;
 With the diffuser aeration systems, to check the manifolds, the working of the air filter
and of the condense traps, the lubrication and the clearance in the blower, the alignment
between motor and blower, fixing of the motor and the blower, the performance of the
diffusers;
 To start the blower and to check the sense of rotation, vibration, noise or abnormal
overheating, to measure the power absorption;
 To run the system for four or five hours and repeat the controls more times.
The startup plant procedure is given bellow:

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8. Operation and Maintenance for the Tank Used in
the System
BIOLOGICAL TREATMENT
The overall objective of biological treatment is to:
1. Oxidize particulate and dissolved biodegradable constituents into acceptable end
products.
2. Capture and transform suspended and non-soluble colloidal solids into biological flock
or biofilm.
3. Removal of nutrients (nitrogen and phosphorus)
The objective of using biological treatment for industrial wastewater is to remove/reduce the
concentration of organic/inorganic compounds.
EQUALIZATION TANK
An equalization tank has been provided in the initial stage before the influent enters into the
biological system.
The objective of providing this tank is to act as a buffer as in:

1. Homogeneous mixing of the influent
2. Optimum dosage for the neutralization of influent
3. Reduce the peaking requirement
4. Reduce the process overload
5. Reduction against the toxic upsets
6. Potential reduction of operational problems

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The equalization tank is equipped with Air diffuser, Level Switch, Thermometer, pH meter and
Acid dosing pump.
For O&M of equalization tank it is to be ensured that:

1. Air mixing is on at all the times.
2. Air mixing is uniform over the entire floor of the tank.
3. The diffusers are free from clogging.
4. Manual evacuation of settled sludge at least once in a year.
PVA GEL TANK

The first tank in the biological treatment is the Media Tank (PVA Gel Tank). This technology
employs introduction of small biofilm carriers (Poly Vinyl Alcohol gel beads) suspended in the
tank capable of freely flowing in the wastewater with the help of aeration. The media is porous
in nature with micro tunneling structure which provides a huge surface area of ~2500 m2/m3 of
gel for the growth of bacteria/biofilm. It is this high density population of bacteria that achieves
high rate biodegradation within the system, while also offering process reliabilility and ease of
operation. The HRT of PVA gel tank is set at ~3 hours which is sufficient for >90% removal of
BOD.
This tank is equipped with 7-15% media packing (V/V), PVA gel screen (to ensure that PVA
gel beads retain in the tank only and do not get flown in next tank), Air Diffusers and online DO
meter.
The objective and advantages of using PVA Gel tank is to:

1. Achieve degradation of BOD (and soluble COD) for the organic removal.

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2. Simultaneous Nitrification which converts the ammonia present in the wastewater to
nitrite and nitrates.
3. Resist the shock load (toxic load)
4. No maintenance of F/M ratio or MLSS levels since the biomass retains inside the media
only.
5. Actively sloughed biofilm automatically responds to the load fluctuations.
6. Reduction of footprint as compared to the other conventional technologies.
7. No recycling required
8. Higher SRT which is favorable for nitrification
9. Very less sludge production (Removal of organic sludge)
O&M of PVA gel tank includes:

1. Ensure that the aerators are always on and the media is always in motion freely flowing
in the tank.
2. No need to maintain the F/M ratio or MLSS in the PVA gel tank.
3. Check that there is no clogging on the diffusers and there is no dead space in tank.
4. The sieves/screen used at the outflow of the tank should be clean and there should be no
choking so that the outlet can flow freely.
5. The size of the screen should be checked so that there is no overflow of media from the
tank. Typical screen should be with 2mm pore size.
6. Skilled labor required for monitoring and operations of pumps and blowers.
7. Maintain the packing ratio of PVA gel in tank for optimum treatment.
8. DO to be maintained in the tank in the over 2 mg/L.
AERATION TANK A

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After the treatment from the PVA Gel Tank, the wastewater enters into the aeration tank A. The
main purpose of using Aerobic tank A is cultivate thriving populations of microorganisms by
providing oxygen to the tank. DO is to be maintained in this tank in the range of 1-2 mg/L. The
HRT for this tank is kept at ~3 hours with a BOD loading of 0.32 kg/m3/day.
This tank is equipped with Mechanical submerged mixers, Return Sludge pump.
The objective or advantage of using Aeration Tank A/ AS Tank A is:

1. Act as polishing tank for the effluent.
2. Formation of settle able solids
3. Reduction of clarifier loading.
O&M of AS Tank A includes:
 Check that the diffusers are not clogged.
 DO must be maintained in the tank in the range of 1-2 mg/L
 There should be no dead space in the tank.
AERATION TANK B/ ACTIVATED SLUDGE TANK

The nitrified effluent is then passed into the Aeration Tank or Activated Sludge Tank which
basically acts as the polishing tank for the effluent. In this tank, the microorganisms responsible
for the treatment are kept in suspension and aerated. This tank forms the flocculent settle able
solids that can be removed by gravity settling in the sedimentation tanks. Diffusers are provided
in this tank to keep the wastewater aerated and in mixing condition. MLSS of this tank is an

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important factor which needs to be maintained. Generally 3-4 g/L MLSS is maintained in the
aeration tank. Also, F/M ratio is to be maintained in this tank. DO is to be maintained in this
tank in the range of 1-2 mg/L. The HRT for this tank is kept at ~4.5 hours with a BOD loading
of 0.23 kg/m3/day. This tank is equipped with Air diffusers, Return sludge pump, DO meter.
The objective or advantage of using Aeration/ AS Tank is:

1. Act as polishing tank for the effluent.
2. Formation of settle able solids
3. Reduction of clarifier loading.
O&M of AS Tank includes:

 Check that the diffusers are not clogged.
 DO must be maintained in the tank in the range of 1-2 mg/L
 There should be no dead space in the tank.
 MLSS should be maintained in the tank in the range of 3-4 g/L.
CLARIFIER
Clarifier has been installed after the AS Tank which collects the effluent with some settle able
solids from the AS Tank. This tank is designed keeping in consideration the surface overflow
rate and solids loading rate. 100% recycling from this tank is maintained so as to keep the
activated sludge in the system. In this case, Sludge loading rate has been calculated at 21.3
kgSS/m3/d. Surface Overflow Rate and Weir Overflow rate have been calculated at 23.87
m3/m2/day and 81.08 m3/m2/day respectively. The HRT for this tank is kept as ~3.4 hours for
effective settling of the sludge.

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This tank is equipped with blower to prevent the sludge from settling such that it can be
recycled to the system, sludge pump unit and return sludge pump.
The objective and advantage of using clarifier is:

1. To remove the settable suspended solids created in AS Tank.
2. To recycle the activated sludge to the system and remove the waste sludge forms the
system.
O&M of secondary clarifier includes:

 Check that there is no clogging at the bottom surface of the clarifier.
 The surface area should be sufficient for the proper settling of sludge.
 Cleaning of the weir wall so that there is no choking.
 No algal growth should be allowed on the surface of clarifier
9. Description of PVA Gel (Kuraray, Japan) Media

PVA-gel beads are used as the biomass retention matrix. They consist of 4-mm diameter
spheres with a solids content of about 10% and specific gravity of 1.025. They are
hydrophilic in nature and have a porous structure with a continuum of passages 10 to 20
μm in diameter tunneling through each bead. Treatment with PVA gel yields less excess
sludge as compared to conventional biological methods.

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It has very high water content due to its extensive porosity, thus allowing for favorable
permeability of oxygen and nutrients to the bacteria colonized inside the beads. One
PVA-gel bead can hold up to 1 billion microorganisms.
It is currently being used as a carrier for retention of biomass in over 250 wastewater
treatment applications. The Fig. shows the structure of PVA Gel and the growth of
microorganisms inside it.

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CHARACTERISTICS OF PVA GEL
1. Excellent fluidity in water requiring minimal energy for mixing.

2. PVA gel has a network of minute pores about 20 microns in diameter tunneling
throughout each bead.
a. Effective bacteria can be enriched in large numbers in the protective core of the
beads, thus greatly reducing sloughing of biomass while maintaining stable
treatment efficiencies.
b. Good oxygen permeability can support a high loading. Therefore even with a low
filling ratio PVA gel has high treatment power.
3. Treatment with PVA gel yields less excess sludge as compared to conventional biological
methods.
4. PVA gel has very high water content due to its extensive porosity, thus allowing for
favorable permeability of oxygen and nutrients to the bacteria colonized inside the beads.
5. Polymerized PVA gel is essentially insoluble in water and is not known to be
biodegradable.
6. Depending on the characteristics of the wastewater, treatment ability using PVA gel can
be enhanced up to 5 times over that of conventional activated sludge, thus allowing for
upgrading of existing overloaded systems or for design of new process units with greatly
reduced foot prints.
Characteristics of media Unit Value
Effective surface area m2/m3 ~2500

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Specific surface area m2/m3 1000
Shape - Spherical
Diameter mm 4
Specific gravity - 1.015±0.01
10. Fluidization Diagram of PVA Gel & Anoxic

Tank
Fluidization diagram of PVA Gel tank:
Fluidization diagram of Anoxic tank:

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Fundamentals Check points of plant operation:
Fundamental Parameters including, temperature, pH, BOD, COD, TSS, MLSS and nutrients
need to be checked on a regular interval from all the tanks in the system including equalization
tank, PVA gel tank, AS Tank and Clarifier.
11. O&M Related ETP Components
The components of ETP that need O & M are :

 Coarse & Fine Bar and automatic Screens
 Equalization basins / Raw Effluent Sump (Wet Well)
 Raw Effluent Pumping Station (Dry Well)
 Raw Effluent Pumps and Motors
 Cooling Tower Mechanism
 Grit Removing Channel
 Grit Removing Mechanism
 Aerobic Treatment Processes
• PVA Gel Tanks using Mechanical Diffused Air

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• Aeration Tanks using Mechanical Diffused Air.
 Tube Settling Tank (s)
 Secondary Sludge Sump (s) (Wet Well)
 Secondary Sludge Pumping Station (Dry Well)
 Secondary Sludge Handling Pumps
 Plant Laboratory for testing of Environmental Parameters of pollution
 Treated Effluent Channel to the outfall stream
12. O&M Requirement Identification
An ETP installation needs to equip itself with proper protocol for O & M. The first step in
preparation for O & M is preparing inventory of maintenance requirements. This inventory is
generally included in the Operation & Maintenance (O&M) Manual written down for the
installation by the contractor who designs and builds the installation. He on completion of the
work hands over this manual to the Principal for whom he builds the installation. The
following sections of the O & M Manual would lay down the maintenance requirements:
Maintenance of Equipment: This section provides schedules that list periodic maintenance
requirements for the various equipments and also includes record-keeping forms as necessary.
A list of equipment suppliers and service representatives along with telephones is also given
therein. Also, the manufacturer’s O&M requirement is provided in this section. The ETP

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maintenance staff / the Operation & Maintenance contractor should particularly review this
section of the O&M mannual.
Storeroom and Spare Parts Inventory: It includes a list of critical replacement parts that
may have long delivery times associated with them. Contact details of manufacturers or
dealers of various equipment used in the installation, who are located nearby is helpful in
seeking recommendations/ guidance. This section also indicates where the spares are to be
stored. To optimize spare parts inventory, the ETP Staff/ O&M Contractor can make/ procure
computerized maintenance software programs to help keep track of spares, supplies and
lubricants.
Manufacturer’s O&M Literature: In the O&M manual, cut-sheets and other manufacturer’s
literature are also contained. ETP staff/ O&M Contractor should familiarize itself with all
these documents to ensure proper planning and execution of O&M activities. In case these
documents are not available the same should be prepared based on study of the plant, process,
equipment’s, past experience, and interaction with manufacturers/suppliers.

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13. ETP O&M Staff Requirement
The manpower requirement for ETP O&M can broadly be listed as follows:
Plant Manager: is an individual with environmental engineering or science background with
experience of at least three years on similar plant(s). He must have thorough understanding of
unit operations and application of microbiology and environmental chemistry in the effluent/
sewage treatment. He should be able to take decisions to distribute the flow in the event of
disruptions of mechanical or electrical equipment until resumption is in place and
rreplacements are successfully carried out. He should understand and be able to plan a forecast
and use of chemicals for the plant operations and the laboratory. He should be well versed in
working out dosages of chemicals and nutrients based on the raw effluent quality and change
it as the treatment progresses and results start forthcoming. As ETP Manager, he should
prepare a weekly roster of duties for each individual and broadly lay down in writing the
duties and responsibilities of each category of staff. He should ensure that the staff on plant
should get rotated in various shifts during each month. It is needless to mention that he is the
backbone of ETP operation.
Plant Operator(s): comprise a team of qualified operators who work in shifts in operating
and maintaining screens, grit removal devices, pumps, aerators, valves, etc. in directing the
effluent and settled sludge to various units for after treatment. They should be able to sense
troubles and act as ears and eyes of the Plant manager. They should also assist the electrical /
mechanical maintenance technician(s) in carrying out the preventive and breakdown
maintenance tasks.

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Electrical / Mechanical Technician (s): form team of qualified maintenance technicians with
the ability and experience of diagnosing health of equipment and motors with the aim of
taking these on for preventive maintenance, assigning causes and reasons for faults and
ultimate failure, quickly carrying out minor replacements by reaching, removing, stripping,
repairing, assembling of routine electrical and mechanical machines / equipment including
piping and valves.
Laboratory Analyst: is a qualified individual who has knowledge of water and waste water
chemistry and is trained in preparation of laboratory chemicals, use of laboratory instruments,
collection and preservation of waste water samples and analysis for various environmental
parameters such as pH, SS, BOD, COD, TDS etc.
Labor/Helpers: In addition to the above trades, labor/helpers are required to assist the above
individuals and upkeep and maintenance of the various units, structures, areas, floors, rooms,
equipment, tanks, vessels, beds etc. and removal, loading, haulage/carriage of wastes,
screenings, stores and chemicals and other such material as the requirement.
It is essential that each ETP staff shall be well trained in related tasks and be equipped in
resources such as tools, spares and tackles. ETP O & M skills are acquired mostly through
onjob training. Trainees usually start as attendants or operators-in-training and learn their
skills on the job under the direction of an experienced operator. They learn by observing and
doing routine tasks such as recording meter readings, taking samples of liquid waste and
sludge, and performing simple maintenance and repair work on pumps, electric motors,
valves, and other plant equipment. ETP Operators need mechanical aptitude and should have
knowledge of basic mathematics, chemistry, and biology. They must have the ability to apply
data to formulas prescribing treatment requirements, flow levels, and concentration levels.

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ETP operation is a team work. It requires proper team selection, training need assessment,
training, on-job molding, laboratory and statistical analysis for ensuring desired performance,
trouble forecasting and trouble shooting. O & M staff profile should ad- dress all these
requirements. Since it is not feasible to position a Repair/Maintenance Shop at the si te to carry
out major overhauls/repairs to electrical and mechanical equipment, it is essential to identify
back-up workshop facilities. A good ETP operating contractor may have his own central
resources in place within workable co-ordinates which will help to carry out such heavy
repairs and maintenance or he may have agreement to move such resources, own or from
trade, to the site with matching capability to establish temporarily for completion of task. This
should be taken in to account if ETP operation is to be outsourced.
14. ETP STAFF COMPETENCY
Plant Manager:

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a) A Post -graduate in Environmental Sciences or a Graduate Environmental Engineer /
Chemical Engineer with one year experience or a Diploma in Environmental /
Chemical Engineering/ Graduate in Environmental Sciences
/Microbiology with three years’ experience in an in Maintenance or Design of ETP
b) Should be physically fit and mentally alert.

c) Should accept tasks allotted by higher offices and complete these without any further
guidance as also have own initiative to find, assign and super- vise tasks to his own
subordinates to achieve goals assigned to him by the organization.
d) Should have worked / trained on the operation of a Sewage / Effluent Treatment Plant for
at least one year.
e) Should have attended and participated in a training /refresher course in Effluent Treatment
Design/Operation..
Plant Operator (s):
a) Should be at least a High School Pass with sciences and be physically fit and
mentally alert.
b) Should accept assigned tasks willingly and complete these without any further
guidance as also have initiative to find work and willingly undertake it on his own,
for the betterment/ achievement of organizational goals.
c) Should have attended training / refresher course for personnel working on a Effluent
Treatment Plant operation.
d) Should have at-least one year experience in the operation of Pumps and Valves at a
Pumping Installation.
e) Or should have been a helper for five years and helped Electrical / Mechanical
maintenance teams for at least three years.
Electrical / Mechanical Technician (s):

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a) Should be at least an SSC Pass with Sciences and be physically fit and mentally
alert.
b) Should accept assigned tasks willingly and complete these without any further
guidance as also have initiative to find work and willingly undertake it on his
own, for the achievement of organizational goals.
c) Should have attended a training / refresher cadre for personnel working on Effluent
Treatment Plant.
d) Should have at least one year experience in the operation as well as maintenance of
Pumps, Motors, and Switch gears, Reduction Gears, Valves and Pipes at an
Effluent Treatment Plant or at a Water Supply Installation.
e) Or should have been a Plant operator for five years and helped Electrical/
Mechanical maintenance teams for at least three years Labor /Helper:
a) Should at least be Class VII pass and be physically fit and mentally alert.
b) Should accept assigned tasks willingly and complete these without supervision
and further guidance.
Laboratory Analyst:
a) Should be at least B.Sc. with Chemistry with three years analytical experience
or M.Sc. with Chemistry with one year analytical experience.
b) Should have attended a training / refresher cadre for Laboratory Analysts for
working on Effluent Treatment Plant laboratory.
c) Should be able to draw an Analysis Program for collection and analysis of

daily, weekly and monthly samples and follow it and report results as per time
schedule thus agreed upon.
d) Draw out a program to undertake performance studies from time to time and
have it approved from the higher offices through his plant manager before
execution.

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e) Be responsive and prepared to undertake additional responsibility of the Plant
Manager when the incumbent is away for short durations.
f) Be bold to report deficiencies in treatment as shown by effluent quality
analyzed at the Laboratory.

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15. ETP STAFF TRAINING
“Training Need Identification, Imparting Training, Training Effectiveness Evaluation, and

ReTraining” is the Mantra for ensuring reliable ETP operation. This is more so due to high
turnover of ETP staff.
Training can be imparted at ETP site by academic/research institutions, by in-house experts, or

by sending staff to courses offered by professional bodies. However, experience shows that
the best options is training by experienced ETP operating agency. Such training will be rich in
the terms of practical hints, case-studies, and participants will find it easier to communicate
with the faculty.
Training courses may be run for 6 to 10 working days at a stretch with residential facilities for
batches of 10 – 12 individuals at a time. Shorter courses may be arranged for senior engineers
from industry/municipal bodies.
The emphasis in training should be on the following aspects:

1. The Course should commence with a quick visit to the Effluent Treatment Plant where
the participants are made conversant with the units / processes that shall be dealt with
subsequently in the course syllabus.
2. Introduction of,
a) Various unit operations and processes (Separation by Screening, Floatation,
Settling / Sedimentation, Filtration, Neutralization, Coagulation, Flocculation,
Absorption, Adsorption, Chemical Reactions, Oxidation/Reduction,
Dissolution, Ion exchange, Chlorination)
b) Operation of Units such as Screens (Coarse / Fine Bar screens,

Manual/Mechanically operated), Sumps and Pumping Stations including
Pumps, Motors and Panels (Centrifugal Horizontal / Vertical Turbine), Valves
36 Manual for O&M of ETP

(Sluice gates, Non return, Reflux), Pipes/Specials and Pipe Joints, Grit
Removal Units. Primary Sedimentation / Settling tanks, Scraping Mechanisms,
Sludge withdrawal, Sludge Sumps, Sludge Pumps, Aeration tanks and
Aerators, Secondary Settling Tanks, Secondary Sludge Sumps, Pumps, Sludge
Thickeners, Sludge Digesters, Gas Production, Sludge handling and Drying.
c) Maintenance of Pumps and Motors, Electrical Panels (Starters, Meters (Energy,

Voltage, Amperage, Power factor), Manual or Electrically Operated
Trolley Gantry, Blow out Fuses, Valves, Gates, Scraping Bridge Trolley,
Aerators, Reduction Gears, Open Air Weather Casings for Motors, Sprocket
wheels and Chains for Mechanical Grit and Screen removing devices.
d) Introduction to Quality aspects of Raw and Treated Effluent and the
importance of each of the quality parameters and corresponding unit operation /
process that plays a part in influencing quality parameters.
3. Identification of flaws and troubles with treatment and its trouble shooting where it is
not due to inbuilt flaws in design / design criteria, such as bulking of sludge in the
lower layers and floating of sludge lumps in a settling tank, foul smelling in an
Aeration Tank, heading up in the Settling Tanks or Aeration tanks, passing of undue
flocks in the settled effluent from settling tanks, disruption of operation by failure of
main power supply and malfunctioning of scraping mechanism in the clarifiers.
4. Undertaking segregation of a motor and pump from the manifold at suction and
delivery, its disconnection from the panel, hauling up of both pump and motor to the
maintenance platform, dissembling of the pump, replacement of shaft, reassembly of
the pump, check motor for its characteristics, haul back to the mounting location,
couple up / connect the pump and motor and reconnect power and rejoin with suction
and delivery manifold.
5. Undertaking replacement of a mechanical surface aerator in an Aeration Tank and
undertake replacement of a Reduction Gear Assembly including its maintenance.
6. Removing and Replacing of a Sluice Gate Valve from a mains and undertaking
maintenance of the Sluice Gate Valve.
7. Maintaining a Power Factor, methodology and upkeep of the Power Factor Battery
Bank.
8. The role of each of the category of tradesmen on site in bringing the final effluent
quality better than the discharge standards.

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A separate laboratory training course should be run for only Laboratory Analysts for a period
of 6 Working days. It may include:
a) Introduction to items at Serials 1 & 2 above.
b) Importance of quality and plant performance parameters e.g. pH, TS, SS, TDS, BOD,
COD, DO, Temperature, MLSS, MLVSS and SVI including methods of
determination.
c) A three day regular analysis program in which the participants in pairs are given a
sample of effluent for analysis for pH, TS, SS, TDS, BOD, COD, DO, Tempera- true
and a sample of Aeration Tank discharge for determination of MLSS, MLVSS and
SVI. The results should be discussed and candidates should be encore- aged to express
their views as to how these can further be improved.
d) Preparing sampling schedule (locations, numbers, frequency, grab/continuous),
sample preservation methods, statistical tools.
Daily training must be followed by a Quiz Test for all cadres before the close of the day and
the participants be evaluated based on the outcome of the course results. The participants be
presented “Participation Certificates” at the end of the course. This serves as an excellent
incentive.

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16. GUIDELINES FOR SAFETY IN ETP
OPERATION
Hazard Identification
Effluent treatment plant operators work both indoors and outdoors and are exposed to noise
from machinery and to unpleasant odors. Operators’ work is physically demanding and work
is often is performed in unclean locations. Moreover, plants operate 24 hours a day, 7 days a
week; therefore, operators work one of three 8-hour shifts, including weekends and holidays,
on a rotational basis. Operators may be required to work overtime.
Also, ETP operators are exposed to a variety of hazardous chemical agents, contained in the
effluents and to the reagents used in the waste water processing, or generated during the
waste waters treatment. These chemical agents may cause acute poisoning, chemical
accidents (e.g., skin burns, injury to the eyes, etc.) damage to the respiratory system,
allergies, dermatitis, chronic diseases, etc.
Occupational safety and health (OSH) considerations are becoming integral part of modern
day operations. In view of this it is necessary to identify hazards and devise preventive and
remedial measures to mitigate OSH risks in ETP operation. The hazards in ETP O & M are
listed below:
 Slips and falls on floors made slippery by water, aqueous solutions or solvents.
 Blows and contusions caused by falling heavy articles, including containers of
chemical reagents, e.g., from overhead conveyers, or by contact with moving
machinery or vehicles.
 Falls into ponds, pits, clarifiers or tanks causing injuries or drowning.
 Hazards related to entry into confined spaces - suffocation due to oxygen deficiency,
poisoning (e.g. by hydrogen sulphide), etc.
 Burns, by steam or hot vapors, by splashes of hot plating baths, solvents and other
liquids, by contact with hot surfaces (e.g., annealing ovens), etc.
 Electric shock caused by contact with faulty electrical equipment, cables, etc.
 Injuries (especially of eyes) caused by flying particles, in particular from rotating
brush cleaning or wheel grinding.

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 Fire and explosions due to the formation and release of flammable gases during
processing (e.g., methane, hydrogen).
 Vigorous chemical reactions caused by uncontrolled mixing of chemicals (e.g., if
water is mixed with concentrated sulphuric acid) during the preparation of reagents
for wastewater treatment.
 Acute poisoning caused by various chemicals present in the wastes, used as reagents
(e.g., gaseous chlorine), or released during the treatment; a particular hazard is caused
by the possible release of a number of poisonous gases, e.g., hydrogen-cyanide (from
metal plating or heat treatment wastes upon acidification), hydrogen-sulphide, etc.
 Acute intoxication caused by erroneous drinking of untreated wastewater.
 Poisoning by phosgene, which may be formed if a worker smokes in the presence of
chlorinated-solvent vapors, or if welding or other flames or arcs are used.
 Chemical burns by corrosive liquids Damage to eyes by splashes of irritating or
corrosive liquids.
It is good use to prepare a good obligation and danger signaling system on the installation.
The most important signals are the following:
 Danger
 Parts with voltage
 Moving parts danger
 Corroding liquids danger
 Prohibition of removing the safety tools
 Prohibition of operating on moving parts
 Entrance forbidden to unauthorized people

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 Headset use: mandatory
 Protecting clothing use: mandatory
 Mask use: mandatory
 Protective gloves use: mandatory
ETP Operation for Safety Cases

1. Use safety shoes or boots with non-slip soles.
2. Wear personal protective equipment and chemical resistant clothing to avoid exposure
of skin or eyes to corrosive and/or polluted solids, liquids, gases or vapors.
3. Do not mix chemicals without the supervision of a qualified chemist or safety
professional.
4. Obey all safety-instructions regarding the storage, transport, handling or pouring of
chemicals.
5. Check electrical equipment for safety before use; verify that all electric cables are
properly insulated; take faulty or suspect electrical equipment to a qualified electricity
technician for testing and repair.
6. Wear safety goggles in all cases where the eyes may be exposed to dust, flying
particles, or splashes of harmful liquids.
7. Wear respirator, or gas mask, when exposed to harmful aerosols, dusts, vapors or
gases.
8. Take extreme care when handling highly corrosive agents such as liquid or gaseous
chlorine, concentrated acids or alkalis, or when toxic gases may be emitted from the
reagents, etc.
9. Obey all safety instructions concerning entry into confined spaces, e.g., check
atmosphere for oxygen or for poisonous gases, use respiratory protection equipment if
needed, have a co-worker stand guard in case of need for help, etc.

32
10. Do not smoke, eat or drink in areas where chemical or biological contamination may
be expected.
11. Use non-latex gloves if sensitivity to latex has been diagnosed.
12. All workers should undergo periodic examinations by occupational physician to reveal
early symptoms of possible chronic effects or allergies.
13. Learn and use safe lifting and moving techniques for heavy or awkward loads such as
containers of chemicals; use mechanical aids to assist in lifting.
14. If the tank depth is more than 1.5m when the worker down to the tank they must have
to use safety belt.
15. In every tank at least one tube must have for swim to get rid of any type of accident.
Personal Protective Equipment (PPE) for ETP O&M
While planning the list of PPE, the following types of situations should be faced:
 Impact / Penetration / Compression while doing maintenance tasks
 Chemical Handling
 Heat/cold and wetting
 Harmful dust
 Oxygen deficiency
 Obnoxious odors of decomposing matter
 Hydrogen sulphide presence
 Light (optical) radiation
 Biological exposure from raw / treated effluents and sludge handling
 Noise of machines and vibrations.
 Electric shock
 Rain / Storm
General List of PPE:
 Safety Boots with non-skid soles and Steel Toes.

32
 Electrical Hazard safety Toe shoes
 Gas Masks and Face Shields
 Oxygen meters for ascertaining type of atmosphere in a confined area.
 Single-use Ear Plugs / Ear-muffs
 Safety Goggles
 Helmets / Hard Hats
 Latex Rubber/ Butyl Rubber/ Fabric / Chemical Resistant Gloves
 Overall Clothing
 Aprons for laboratory Personnel
 Safety Belts
 First Aid Box
 Fire extinguishers
 Respiratory Protective mask with man pack cylinders
Safe Handling of Chemicals and Corrosive substances

Since handling of chlorine and corrosive chemicals form part of many ETPs, special attention
should be given to safe handling of these chemicals and ccorrosive substances such as Acids
(Sulphuric acid), Alkalines etc.
General Chemicals used in Effluent Treatment:
 Neutralization / pH correction: Hydrochloric acid.
 Coagulant / Settling Aids: Poly Electrolytes (Polymers).
 Nutrients: Urea
 Disinfectant: Sodium Hypo-chlorite
 Adsorption / Absorption: Activated Carbon

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General Characteristics of ETP Chemicals
1. Acids and Alkalis fall into the category of Corrosive chemicals. Corrosives are most
commonly acids and alkalis, but many other materials can be severely damaging to
living tissue.
2. Corrosives can cause visible destruction or irreversible alterations at the site of

contact. Inhalation of the vapor or mist can cause severe bronchial irritation.
Corrosives are particularly damaging to the skin and eyes.
3. Certain substances considered non-corrosive in their natural dry state are corrosive
when wet such as when in contact with moist skin or mucus membranes. Examples of
these materials are lithium chloride, halogen fluorides, and alkyl iodide.
4. Sulphuric acid is a very strong dehydrating agent and nitric acid is a strong oxidizing
agent. Dehydrating agents can cause severe burns to the eyes due to their affinity for
water.
Use and Storage of Corrosives
1. Always store acids separately from bases. Also, store acids in acid storage cabinets
away from flammables since many acids are also strong oxidizers.
2. Do not work with corrosives unless an emergency shower and continuous flow
eyewash are available.
3. Add acid to water, but never add water to acid. This is to prevent splashing from the
acid due to the generation of excessive heat as the two substances mix.
4. Never store corrosives above eye level. Store on a low shelf or cabinet.
5. It is a good practice to store corrosives in a tray or bucket to contain any leakage.
6. When possible, purchase corrosives in containers that are coated with a protective
plastic film that will minimize the danger to personnel if the container is dropped.
7. Store corrosives in a wooden cabinet or one that has a corrosion-resistant lining.
Corrosives stored in an ordinary metal cabinet will quickly damage it. If the cabinet supports
that hold up the shelves become corroded, the result could be serious. Acids should be stored
in acid storage cabinets specially designed to hold them and Nitric acid should be stored in a
separate cabinet or compartment.
Health Hazards Associated with Corrosives

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1. All corrosives possess the property of being severely damaging to living tissues and
also attack other materials such as metal.
2. Skin contact with alkali metal hydroxides, e.g., sodium hydroxide and potassium
hydroxide, is more dangerous than with strong acids. Contact with alkali metal
hydroxides normally causes deeper tissue damage because there is less pain than with
an acid exposure. The exposed person may not wash it off thoroughly enough or seek
prompt medical attention.
3. All hydrogen halides (HF, HCl, HBr and HI) are acids that are serious respiratory
irritants and also cause severe burns. Hydrofluoric acid is particularly dangerous. At
low concentrations, hydrofluoric acid does not immediately show any signs or
symptoms upon contact with skin. It may take several hours for the hydrofluoric acid
to penetrate the skin before you would notice a burning sensation. However, by this
time permanent damage, such as second and third-degree burns with scarring, can
result.
Acute Health Effects
Inhalation Irritation of mucus membranes, difficulty in breathing, fits of

coughing, pulmonary edema
Ingestion Irritation and burning sensation of lips, mouth, and throat; pain
in swallowing; swelling of the throat; painful abdominal
cramps; vomiting; shock; risk of perforation of the stomach
Skin Contact Burning, redness and swelling, painful blisters, profound

damage to tissues, and with alkalis; a slippery, soapy feeling
Eye Contact Stinging, watering of eyes, swelling of eyelids, intense pain,

ulceration of eyes, loss of eyes or eyesight
Chronic Health Effects
Symptoms associated with a chronic exposure vary greatly depending on the chemical. For example,
the chronic effect of hydrochloric acid is damage to the teeth; the chronic effects of hydrofluoric acid
are decreased bone density, fluorosis, and anemia; the chronic effects of sodium hydroxide are
unknown. First Aid:

32
Inhalation Remove person from source of contamination if safe to do so. Get
medical attention. Keep person warm and quiet and do not leave
unattended.
Ingestion Remove person from source of contamination if safe to do so. Get
medical attention. Keep person warm and quiet and do not leave
unattended.
Skin Contact Remove person from source of contamination and take immediately
to an emergency shower or source of water. Remove clothing, shoes,
socks, and jeweler from affected areas as quickly as possible, cutting
them off if necessary. Be careful not to get any chemical on your
skin or to inhale the vapors. Flush the affected area with water for a
minimum of 15 minutes. Get medical attention.
Eye Contact Areas as quickly as possible, cutting them off if necessary. Be

careful not to get any chemical on your skin or to inhale the vapors.
Flush the affected area with water for a minimum of 15 minutes. Get
medical attention.
Eye Contact Areas as quickly as possible, cutting them off if necessary. Be
careful not to get any chemical on your skin or to inhale the vapors.
Flush the affected area with water for a minimum of 15 minutes. Get
medical attention.
Personal Protective Equipment
Always wear the proper gloves when working with acids. Neoprene and rubber gloves are
effective against most acids and bases. Polyvinyl chloride (PVC) is also effective for most
acids. A rubber coated apron and goggles should also be worn. If splashing is likely to occur,
wear a face shield over the goggles. Always use corrosives in a chemical fume hood.

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17. PLANT PERFORMANCE MONITORING
The operation of the plant requires control of the index parameters and the regular maintenance
of the equipment. Control is carried out by means of simple tests ( pH, OD, VF) effected
directly on the plant as frequent as above indicated or with a frequency that may establish the
operator himself based on his experience and the plant's need. Periodically, more complete
analysis in specialized laboratories must be performed. Even very important are the
observations of the operator, who will be able to estimate the plant's running also based either
on the aspect, the smell and the color of the sludge or on other phenomena which may be
noticed by managing the plant.
 pH
 Suspended Solids (SS)
 Total Dissolved Solids (TDS)
 Biochemical Oxygen Demand (BOD)
 Chemical Oxygen Demand (COD)
 Dissolved Oxygen (DO)
 Temperature
 Mixed Liquor Suspended Solids (MLSS)
 Mixed Liquor Volatile Suspended Solids (MLVSS) and Sludge Volume Index (SVI)

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List of Laboratory Equipments Suggested
Testing Parameters Equipment Proposed
pH Online pH Meter
TSS, BOD, COD Online TSS / BOD / COD Analyzer
O&G Titration
T-P Titration
T-N Nitrate Sensors/ Titration
T-K-N Titration
DO DO Meter
MLSS Filters + Vacuum Pumps
MLVSS Filters + Vacuum Pumps
SVI Glassware
NH4-N Titration
Fecal Coli form Colony Counter
TDS TDS Meter
ORG ORG Meter
Color Photo-Spectrometer/ Colorimeters

Alkalinity Chemicals
Temperature Field Thermo-Meter
For All Titrations + Chemical Testing Set Of Glassware – Including
Funnels, Burettes, Jars, Cylinders,
Weighing Machine Etc. As Per
Annexure Below
Conductivity Conductivity Meter
Other general apparatus for the regular usage in Laboratory:

APPARATUS
• Brushes
• Clamps, Rings & Stands
• Crucibles
• Crucibles & Casseroles
• Dispensers & Droppers

32
• Grab Samplers
• Oil And Grease
• Other Apparatus
• Pipette Acids
• Pipettes
• Racks
• Stir Bars
• Tubing
• Weighing Accessories
GENERAL LAB CONSUMABLES
• Boiling Chips
• Desiccant
• Filters & Accessories
• Funnels, Pumps & Manifolds
• Stoppers
• Syringes
GLASSWARE/PLASTICWARE
• Beakers
• Bottles
• Burettes
• Carboys & Buckets
• Cylinders
• Flasks
• Test Tubes
• Wash Bottles
INSTRUMENTS
• Anemometers
• Balances
• Flock Testers/Jar Testers
• Hot Plates & Stirrers
• Metals Analyzers
• Microscopes
• Moisture Analyzers
• Other Instruments
• Ovens & Incubators
• Refract meters  Thermometers
• Timers
• Vacuum Pump
• Water Purification Systems
All the above listed equipment if required for the testing process can be purchased.

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18. GUIDELINES FOR RECORD KEEPING
Running Records are required to be kept for various operating machines such as Mechanical
Screens, Mechanical Grit Removers, Pumps, Motors, Scrapers, Chemical consumption, etc.
as maintained by the operators and kept at Control Room or duty room of the operators that is
closer to the location of the machines.
The records of effluent quality and other laboratory tests are kept in the laboratory as per daily
sample collection and testing schedules.
The record with respect to flow need to be maintained by operators as per Table below. The
daily log sheet is passed to the Plant Manager on the subsequent day duly signed by the
operator in the first shift. All operators shall be responsible to fill up their part of
observations and calculations. The Plant Manager shall verify the daily record as well as the
calculations and shall be responsible to generate further data using these.
It is pertinent to mention that there shall be a requirement of drawing site specific procedures
and formats / forms for keeping records. This shall be the responsibility of the Plant Manager.
Hourly record of Flow as measured / recorded through the Notch/ Weir/

Flow meter:
AVERAGE
HEAD OVER RATE OF RATE OF FLOW
Date / Time THE NOTCH / FLOW FLOW IN QUANTITY
WEIR PAST HOUR
/ / m3 3 3 m3
m / HOUR m / HOUR
08.00 am
09.00 am
10.00 am
11.00 am
12.00 am
13.00 pm

32
14.00 pm

32
HEAD OVER AVERAGE FLOW
THE RATE OF RATE OF QUANTITY
Date / Time NOTCH / FLOW FLOW IN
WEIR PAST
m3
/ / m 3 3
3 m / HOUR m / HOUR
15.00 pm
16.00 pm
17.00 pm
18.00 pm
19.00 pm
20.00 pm
21.00 pm
22.00 pm
23.00 pm
24.00 pm
01.00 am
02.00 am
03.00 am
04.00 am
05.00 am
06.00 am
07.00 am
08.00 am
∑
Total flow in the past 24 hour; =
Computations of daily figures for the System:
Daily Raw Treated SS

Flow Effluent Effluent Organic passed
load into
Date / Month removed outfall
BOD SS BOD SS
/ Year m3/day mg/L mg/L mg/L mg/L Kg/day Kg/day
Record of consumption of Electricity from the Energy meter:

Energy Energy Energy
Meter Consumed In Rate / Unit Expenses
Reading At Past 24 Hours Of Energy Per Day
Date 0800 Hours
Daily
KHW KHW BDT BDT
Total for the month Unit. = BDT =

48
47
Record of Chemicals / Spares Consumption:
This record has to be prepared using a page for each chemical.
NAME OF THE CHEMICAL / SPARES: Alum OR Bearing

Date Quantity Rate Quantity Balance in Cost of
Procured Procured Consumed Stock Consumption
Kg./Ltr. BDT/Kg./Ltr. Kg./Ltr. Kg./Ltr. BDT
Total for the month Unit. = BDT=
Record of monthly Expenses:
EXPENSES EXPENSES PROJECTIONS

HEAD ITEM DURING IN THE FOR THE
THE PAST NEXT
MONTH MONTH MONTH
BDT BDT BDT
STAFF
Salaries
Conveyance
Travel
Pf By Employer
Esis By
EMPLOYER
Arrears of Wages
TOTAL
VEHICLES /
TRUCKS Fuel
Repairs From
Trade
Maintenance
Spares
TOTAL
PLANT Spares For
MACHINES/ Repairs To
EQUIPMENT / Installation
PIPES / VALVES Maintenance Fuel
/ Oils / Greases/
Civil / Gardening
Renewals
From Trade
Hiring
Transportation
TOTAL
Stock Chemicals
EFFLUENT Chlorine
TREATMENT
TOTAL

48
48
Operational Control for PVA Gel Tank
PVA Gel technology is a compacted biological treatment process which usually does not require
any operational control. However, the bellow operational control is required-  Maximum
temperature allowed in PVA Gel tank is -37 degree Celsius
 Require DO in PVA gel tank is more than 2 mg/L
 Required Temperature in PVA gel tank is between 20o – 37o Celsius
 Mixing condition of PVA Gel is required such that all the PVA gel is in motion and
completely mixing.
 Required controlling pH is 6.5 ~8.5
Operational Control of Aeration tank A
At Aeration tank A, the bellow operational control is required.
 Required DO in Aeration tank A is between 0-1 mg/L

 Required Temperature in Aeration tank A is between 20o – 37o Celsius
 Mixing condition of Aeration tank, A is required such that it is completely mixing.
 Required controlling pH is 6.5 ~8.5
Operational Control of Aeration Tank B
 Required DO in aeration tank B is more than 1 mg/L

 Required Temperature in aeration tank B is between 20o – 37o Celsius
 Mixing condition of aeration tank B is required such that it is completely mixing and there is
no dead space in the tank.
 Required controlling pH is 6.5 ~8.5.

48
19. EMERGENCY RESPONSE PLAN
For a biological effluent treatment system, the following emergency can happen-
 Insufficient oxygen in the PVA Gel Tank and Aeration Tank
 Very low F/M ratio in aeration tank
 Highly acidic and alkaline waste water
 Microbial growth resistant or antibacterial agent are discharged in ETP
In case of above mentioned emergency, the effluent treatment plant operator should follow the
bellow recommendations:
 Inform the issue to the management immediately and stop of the production process for a
while until the issues are resolved
 As an instant step add enough amount of clean water to the PVA Gel tank and aeration tank
 For low F/M ratio- add Urea and DAP 150 gm/day for one week
 For every emergency condition communicate with the consultant immediately and inform
the issue.
 If the plant remain malfunctioned for longer period (more than 7 days), commissioning steps
need to start again from beginning to activate the Biological system.
Emergency Contact:
For any type of disruption to the plant emergency contact with factory internal & external teams for
crisis management.

48
Equipment related Emergency plan
Problem Problem Identity Corrective plan
Area/Equipment
All pump and • Motor Damage-  Emergency backup with standby

Blower related pump/blower and replace or repair asap.
Pump blockage-
problem- • Leakage or
physical damage- 
Belt damage
Gel strainer- • Blocking • Any blocking of strainer to be cleanup

• Damage to release asap.
PVA gel • For damage issue, need to repair that
part or replace it.
Diffuser damage  Damage diffuser in • In the running condition of plant

gel tank diffuser can be replaced, maintain
stock. And replace asap.
• Or block temporary damage area and
replace asap.
Most of the equipment having standby system, therefore if any problem happens severely apart from
above needs to shut down the production until resolves the problem.

48
20. Dictionary of Technical terms used in the Waste
Water Treatment Sector
Acids and basics, chemical substances which act respectively as donors and acceptors of protons.
More simply, are called acids the aqueous solutions in which predominate hydrogen ions, basic or
alkaline those in which predominate hydroxyl ions, neutral those with equal contents of both types
of ions.
Activated carbon, substance endowed with a remarkable absorbing power of vegetal or mineral
origin. When exhausted, it regenerates by means of water or steam backwashing, or by thermic
reactivation.
Activated sludge, aerobic purifying method of polluted water based on the fact that, when a liquid
is submitted to aeration, sludge, made up by colonies of aerobic micro-organisms which feed on
organic substances held in the very liquid, purifying it (biologic oxidation), forms.
Absorption, tendency of a substance in solution ( in liquid or gaseous state), to adhere to the
surfaces of a solid substance, in relation to the revealed tendency of diminishing of the free energy
of the said surface. As a consequence, the best absorbent materials are those porous (activated
carbon). The absorption increases at rising of the pressure and at decreasing of temperature; it
becomes stronger when the molecular weight of the absorbed substance is less high.
Aeration, introduction of air in an aqueous solution, with the goal to restore the saturation in
dissolved oxygen in it. Henry's Law regulates the solubility of oxygen in water to the balance,
which is achieved as sooner as the turbulence of water is greater.
Alkalinity, characteristic property of basics, contrary to acidity, which is typical of acids. Natural
water is alkaline when its pH is higher than 7 ("actual alkalinity"); its "stechiometric alkalinity "
instead is given from the total bicarbonate ion content, carbonate and hydrate, measured by methyl
orange titration with a titrated acid solution. It is expressed in ppm of CaCO3.
Bacteria, micro-organisms belonging, as algae, to the vegetable kingdom, but deprived of
chlorophyll. The pathogenic bacteria (agents of disease) must be eliminated from water for
alimentary use (chlorination, disinfection, ozonation, potabilization). Among non-pathogen bacteria
there are: nitrifying b., which transform ammonia into nitrite and nitrate, denitrifying b., which
reduce it in elementary nitrogen; sulphur reducing and sulphur oxidizing b., which transform
sulphured compounds respectively in hydrogen sulphide and in sulphuric acid; ferric b., which
transform the compounds of dissolved iron in ferric hydroxide. Bacteria can be aerobic or
anaerobic.

48
Biochemical oxygen demand or BOD, quantity of oxygen required for the aerobia decomposition
of the organic substances contained in water for 5 days at 20°C; it is expressed in ppm of oxygen.
BOD is one of the most usual systems which gives the measure of the organic pollution grade of
water, however, its determination is subject to various causes of mistake, which reduces its
reliability.
Biodegradability, property, which most of the organic substances and many of the inorganic ones
have, consisting in being attacked and destroyed completely by micro-organisms living in natural
water and in biological waste water plants.
Biological denitrification, process based on action of facultative aerobe bacteria which reduce
oxidized compounds of nitrogen to elementary nitrogen, which frees itself in gaseous form. It is
used in treatment of sewage bounded to still waters (lakes, coastal water), to avoid nutriment
saturation.
Biological filtration, aerobic purifying method, consisting in sludge spreading on a bed consisting
in a filtering mean of suitable size (gravel, coke, plastic, etc.). The sludge percolates through the
mean, finding air which rises by natural or forced draught, and this favors forming, on the surfaces
of these means, of a gelatinous film of aerobic micro-organisms, which cause the transformation of
the organic substances.
Biological oxidation, treatment consisting in satisfying BOD, or the biochemical oxygen demand,
of the polluted water (activated sludge, biological filtration, oxidation pits), in such a way that the
biological processes of demolishing of the organic substances evolve in aerobic sense, forming final
products relatively innocuous, such as: carbon dioxide, nitrate, sulphate, phosphate.
Carbon dioxide, odorless gas, formula CO2, heavier than air, moderately soluble in water, forming
carbonic acid H2CO3. It is produced by combustion of carbon and his organic compounds, in case of
oxygen excess.
Chemical Coagulation, thickening of the particles of a colloidal dispersion in flakes of bigger
dimensions, which thus can sediment (sedimentation). It is obtained by addition of bi- or trivalent
metal salts (calcium, magnesium, zinc, iron, aluminum) whose ions attenuate the electrostatic power
of repulsion between the particles; the latter combine in flakes thanks to the powers of Van der
Waals. Plays also the fact that the hydroxides of bi- and trivalent metals have a low product of
solubility and they precipitate in flakes, which drag the suspended particles with them by action, in
part mechanical, in part electrostatic. The c. depends mainly on: pH, temperature, reaction time,
reagent doses, and agitation speed. Normally it is followed by sedimentation, filtration or floatation.
Main coagulant reagents: aluminum sulphate (pH 5-7), ferrous chlorine (pH 4-10), ferrous sulphate

48
(pH 8-11). Substances as activated silica, polyelectrolyte and bentonite are said coagulation
auxiliaries which, added to coagulants, improve the results of the coagulation process.
Chemical oxygen demand or COD, quantity of oxygen, expressed in ppm, needed for oxidation of
oxidizable substances contained in water, carried out by reflux through a solution of potassium
dichromate in sulphuric acid. It is perfectly reproducible and thus it supplies a reliable measure of
pollution, even if conventional.
Chlorination, introduction of chlorine or its compounds in water, as chemical oxidant or for
disinfection. The bactericide power of chlorine, probably due to the formation of nascent oxygen,
depends mainly on the pH, on the temperature and on the chlorine concentration.
Corrosion, alienation or deterioration of material under chemical or electrochemical action of the
surrounding mean. The c. of metal in aqueous solutions is an electrochemical phenomenon. On the
exposed surface form anodic zones where metal melts and cationic zones where hydrogen (acid
solutions) develops or hyxodryl ions form (Neutral or alkaline sol.). The presence of carbonic
anhydride, rendering the mean more acid, quicken the development of hydrogen, while presence of
dissolved oxygen has a depolarizing effect, which means, it removes the obstacles which come
between the development of the corrosive phenomena; that's why both of these gasses (CO 2 e O2)
are fearful stimulators of corrosion.
Disinfection, elimination of micro-organisms, particularly of that pathogen. They are generally
affected by chlorination or ozonization, on water destined to civil use, on water of industrial use and
on effluents of various origins.
Enzymes, specific biologic catalysts made up by nitrated substances produced directly by the cells.
Each enzyme affects a substance, or a well individuated group of substances, called substratum. The
e. has a great importance in the biological waste water treatment process.
Eutrophication, natural evolutional phenomenon of lakes, consisting in progressive decrease, in the
course of time, of oxygen content from the deep strata of water (ipolimnio). The e. is a consequence
of increasing organic substances, produced by the biological living population in the lake, owing to
accumulation of nutritive substances in lake water. The e. which is very slow in nature is strongly
accelerated by discharge of all kinds; the only remedy consists in removal of the nutrient
substances, or at least of the phosphoric compounds, from all waters destined to immission in
lacustrine surroundings.
Fermentation, this name is given to particular biochemical reactions, operated by micro- organisms
which secrete enzymes, producing well defined chemical substances.
Filter pressing, discontinuous dehydration process of half-liquid sludge by means of a filter press,
consisting in a series of blades and frames, arranged alternatively on a bearing guide. The sludge is

48
pumped at a pressure of (04-87) atm in the filter press, and the liquid comes out of it; after 4-12
hours the equipment opens and the sludge panels are extracted holding 25-45% of humidity.
Floatation, separation of suspended solid substances, or substances in emulsion, from a liquid,
thanks to either their low specific weight, or by injection of a gaseous current, which induce them to
float. Floatation is particularly adapted to fat and oily substance removal.
Flocculation, term normally used as synonymous of chemical coagulation, actually it is only a
phase of coagulation, during which the single particles thicken and form flocks of major
dimensions, which settle faster. Flocculation is favored by agitation of the liquid, such to encourage
the encounter of the single particles, but not excessive, for not breaking the flocks already formed.
Hardness, contents of water in calcium and magnesium ions, which is determined by titration with
EDTA and expressed in mg/ltr, ppm CaCo3 o°F.
Inhabitants equivalent, number of inhabitants whose waste, discharged in a day, should adsorb a
quantity of oxygen, measured on base of BOD, equal to that adsorbed from the daily discharges of a
given industry. It is a parameter adopted to compare, approximately, the polluting power of an
industrial effluent to those of a "standard" sewerage system, supposing that the daily oxygen
consumption will be 54 g oxygen per inhabitant.
Inverse osmosis, treatment consisting in applying external pressure, higher than the osmotic
pressure, in a cell with two compartments containing respectively pure water and a concentrate
solution, and separated by an osmotic membrane. The normal osmotic process is inverted and the
water passes from the second compartment to the first one, leaving the solutes behind.
Mechanical filtration, passage of a suspension through a bed of particles of suited nature and
dimensions, in a way that the suspended substances are kept by the bed and on the contrary the fluid
can proceed beyond; the force which provokes filtration may be natural gravity or a gradient of
pressure. In the "immedium" filters the drainage system is immersed in the filtering layer. Very
important is periodical washing, which in gravity and pressure filters is carried out in counter
current and in that vacuum by means of water jets on the cloth.
Micro-organisms, mono-cellular living beings, visible only with help of the microscope (algae,
bacteria, fungus, protozoa).
Mineralization, transformation which organic substances undergo, till production of final inorganic
substances, or minerals.
Neutralization, treatment of an acid solution with an alkaline reagent, with the goal to increment
the pH, or of an alkaline solution with an e acid reagent, with the goal to decrease it.

48
Nitrification, transformation of ammonia in nitrite, operated by the nitrogen-bacteria
(Nitrosamines), or in nitrate, by the work of the nitrobacteria (Nitrobacter). It constitutes a very
important phase of the biological oxidation.
Nitrogen, gaseous element, symbol N, N 2 bi-atomic molecule, endowed with a great chemical
inertia. It is found in the atmosphere, of which it forms about 4/5 in volume, in organic substances
and as nitrite o nitrate, in rural ground, where it forms, as phosphorus, one of the fundamental
fertilizing principals.
Oil and grease separation, removal of oily or greasy substances from sewage by simple overflow
or through absorption, coagulation, floatation, biological oxidation.
Oxidation pit, aerobe method of purifying based on use of one or more pits which consists in two
parallel united channels at the opposite extremity of semi-circular connections. The sludge enters
the pit and passes the ring more times, pushed and simultaneously aerated by a mechanical system
(rotating brushes) or by a compressed air flow. The produced sludge is completely mineralized and
thus not putrescible.
Protozoa, unicellular animal micro-organisms, with rudimental locomotion organs, called ciliates,
flagellates and pseudopodes. The p. are having an important part in biological oxidation. Retention
time, meters the duration of permanence of sludge in a determined phase of the di purification
process. Its entity is very important, either to the treatment's efficacy effects, or to those economical.
Sand separation, separation of siliceous rubbish with diameter greater than 0.2 mm from sewage,
by means of passage with controlled speed through suitable channels where they settle. Screening,
removal of coarse solid substances from sludge, by means of passage through fix or mobile
screens.
Sedimentation, operation by means of which the suspended solid substances in a liquid have got to
settle on the bottom of a suitable tank, thanks to its force of gravity.
Sediments, deposit of organic or mineral insoluble substances, which form on the bottom of natural
water bodies.
Self-cleaning power, capacity of natural water to digest a polluting load imposed to it, thanks to the
work of the aerobic micro-organisms, which demolish the organic substances forming relatively
innocuous final products.
Solubility, property of a substance to form with another substance a physical mixture (i.e. a
miscellaneous whose compounds can be separated by bland physical means, such as distillation or
freezing). The solubility of a substance is limited by its saturation value in the given solvent,
exceeding which the substance does not melt any more or, if already melted to excess, precipitates.
Superficial tension, property determined by the molecular forces of the superficial pellicle of the

48
liquids, which tend to assume to the very same liquid the form which assures the minimum surface
for a given volume. Foam forming increases remarkably the surface of a liquid; that's why addition
of substances which diminish the superficial tension (synthetic detergents) makes foaming easier.
Suspension, mechanical mixture (i.e. a miscellaneous whose compound can be separated by
mechanical means) of solid particles dispersed uniformly in a liquid.
Synthetic detergents, organic substances generally surfactants which, unlike soap, clean well even
in hard water and they have more bathing, dispersing and emulsifying properties. They distinguish
in anionic (alkylbenzensulphonates or ABS) non-ionic and cationic; the first ones (ABS) are the
most used. They are noxious for their tendency of foam forming, and because they disturb aeration
and sedimentation. The ABS is not biodegradable because of ramification of their molecular chain,
so they are prohibited by the legislation of various countries; at their place LAS at linear chain,
biodegradable are used.

48
Table-1: Daily Log Sheet to be maintained for every operations of effluent treatment plant
No. Date Sludge Generation and

Testing Parameter in Inlet Testing Parameter in Outlet Chemical Consumption in Kg Disposal in Kg
Temp pH COD TSS BOD Temp pH COD DO TSS BOD Acid Poly decolour Urea/DAP Wet Dry Remarks
1
2
3
4
5
6
7
8
9
10
11
12

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OPERATION MANUAL FOR ETP

LIBAS TEXTILES LTD.

TOTAL WATER SOLUTION

Kind Attn: Engr, MD. Shahadat Hussain SECTOR-11, UTTARA,

KURARAY PVA GEL TECHNOLOGY

Manual for O&M of ETP

SL NO. Topics Page No.

Manual for O&M of ETP

LIBAS TEXTILES LIMITED, Dhaka Bangladesh, is a composite knitting, Dyeing and

Manual for O&M of ETP

SL. No. Name of tank

Manual for O&M of ETP

4. LIST OF MAJOR EQUIPMENT

Equipment Specification Working Standby Remarks

Manual for O&M of ETP

Capacity 150 m3/hr

Dual Media Filter Anthracite & Sand

MCC Control With PLC & touch

Online Analyzer On line monitoring 1 N/A

Manual for O&M of ETP

Manual for O&M of ETP

WASTE WATER PARAMETERS – FEED & TREATED

SL. No. Description Feed Treated

Manual for O&M of ETP

Manual for O&M of ETP

Manual for O&M of ETP

The startup plant procedure is given bellow:

Manual for O&M of ETP

The objective of providing this tank is to act as a buffer as in:

Manual for O&M of ETP

For O&M of equalization tank it is to be ensured that:

PVA GEL TANK

The objective and advantages of using PVA Gel tank is to:

Manual for O&M of ETP

O&M of PVA gel tank includes:

Manual for O&M of ETP

The objective or advantage of using Aeration Tank A/ AS Tank A is:

AERATION TANK B/ ACTIVATED SLUDGE TANK

Manual for O&M of ETP

The objective or advantage of using Aeration/ AS Tank is:

O&M of AS Tank includes:

Manual for O&M of ETP

The objective and advantage of using clarifier is:

O&M of secondary clarifier includes:

9. Description of PVA Gel (Kuraray, Japan) Media

Manual for O&M of ETP

Manual for O&M of ETP

1. Excellent fluidity in water requiring minimal energy for mixing.

Characteristics of media Unit Value

Effective surface area m2/m3 ~2500

Manual for O&M of ETP

Specific gravity - 1.015±0.01

10. Fluidization Diagram of PVA Gel & Anoxic

Fluidization diagram of PVA Gel tank:

Fluidization diagram of Anoxic tank:

Manual for O&M of ETP

11. O&M Related ETP Components

The components of ETP that need O & M are :

• PVA Gel Tanks using Mechanical Diffused Air

Manual for O&M of ETP