Operation & maintenance manual

 Responsibilities:
 User Department / Area in-charge of STP:
 Ensure the operation done as per SOP for STP.
 Ensure effective control measures implemented and sustained.
 Head Environment Health and Safety (EHS):
 Provide training to all relevant Staff regarding the Operation activity & related
documentation of SOP for STP.
 To co-ordinate with relevant staff and support for the smooth operation as per SOP
for STP.
 Quality Assurance Department:
 Check the SOP and maintain the master copy of SOP for all departments.
 Issue controlled copy of SOP & maintain issuance copy record.
 Retrieve the control copy of superseded SOP.
 Monitor the review process of the SOP.
 Ensure implementation of SOP.
 Distribution:
 Environment, Health & Safety (EHS)
 Quality Assurance (QA)
 Information Technology (IT)

 Abbreviations and Definition of Terms:

 Abbreviations :
 SOP        :   Standard Operating Procedure
 ETP      :    Effluent Treatment Plant
 STP       :   Sewage Treatment Plant
 EHS      :   Environment Health Safety
 PPE         :   Personal Protective Equipment
 DAP       :   Di-ammonium Phosphate
 SAFF     :   Submerged Aerobic Fixed Film
 PSF      :   Pressure Sand Filter
 ACF       :    Activated Carbon Filter
 KL         :   Kilo Liter
 P            :Parts Per Million
 Definition of Terms:
 Waste Water: Used water after for domestic or industrial purposes.
 Effluent: Treated wastewater, flowing from a tank, treatment process, or
treatment plant.
  Sewage Treatment Plant (STP):
 It is the process of removing contaminants from waste water and
house hold / industrial sewage, both runoffs (effluents).
 Settling Tank:
 A vessel / tank in which solids settle out of water by gravity during
wastewater treatment processes.
 Sludge:
 Any solid, semisolid, or liquid waste that settles to the bottom of
settling tanks (Sewage Treatment Plants) or septic tanks.
 Procedure (SOP for ETP and STP):
 Operation of Sewage Treatment Plant (STP)
 Shall carry out by the operators / Technician’s in each shift round the clock
under the supervision of the area in-charge and above.
 Before operation any pump care should take that any valve properly
placed or not.
 Operation of Sewage Treatment Plant – SOP for STP :
 Effluent comes from the plant in to Effluent collection sump. Two Nos.( W+1S)
Pump provided with level sensor for automatic control of effluent level in
collection sump to avoid over flow and then effluent comes into bar screen
chamber of Inlet chamber .
 Then effluent enters in to inlet Chamber again over flows to Oil Grease. The
Debris Big particles will be removed from the screen chamber on daily basis.
 The oil obtained as a floating scum at the surface of the oil and grease tank and
this is skimmed off manually in to the oil collection drum.
 Then the over flow of oil free effluent enters in to Equalization Tank Equalization
tank is provided by diffused air grid system comprising of air blowers to avoid
any shock load and equalize both hydraulic and organic load to the system.
 Safety measures and Testing :
 Prepare dosing solutions as per instruction provided by the area in-charge.
 Use proper PPE’s like Hand Gloves, Mask, safety shoe etc. while Mixing the
DAP and Urea
 Performing jar test for raw effluent when chemical or effluent quality changes fix
the dosing rate.
 Tube settler is fixed in Primary settling tank (PST) which are inclined PVC
media for better settlement polyelectrolyte solution dosed in the
1st compartment of PST and care should take for the adjust effluent flow
rate for better settling conditions avoiding eddy currents and turbulence.
 Settled flocs in the primary settling tank are nothing but sludge drained off to
sludge collection sump (T – 13) on a regular interval (every 24 hours).
 Primary Settling Tank effluent overflows by gravity to SAFF Reactor Tank – I (T –
05 A) having capacity 60 KL.
 Oxygen is supplied the SAFF – I & also SAFF – II for aerobic biological treatment
by running of Air Blowers (AR – 01 A / B) and arrangement of diffused aeration
system to the uniform distribution of oxygen to this tank.
 Effluent overflows from SAFF – I launder to Secondary Settling Tank – I (T –
06A) having capacity 9 KL.
 The settled biomass on Secondary Settling Tank – I is recalculate by means of
two nos. pumps ( Sludge recirculation pump P – 02 A / B) & excess sludge will
be wasted to the Sludge Collection Sump T – 11 as when required or instruction
provided by the area in-charge.
 Secondary Settling Tank – I overflow to SAFF Reactor Tank – II (T – 06 B)
having capacity 60 KL.
 Secondary Settling Tank – II (T – 06 B) having capacity 60 KL. & the settled
biomass recalculate by means of two nos. pumps (Sludge re-circulation pump P
– 03 A / B) & excess sludge will be wasted to the Sludge Collection Sump T – 11
as when required or instruction provided by the area in-charge.
 Nutrients like Urea, DAP (Di Ammonium Phosphate) and Jiggery (Molasses Solid
form) added to SAFF – I & SAFF – II for proper growth of the biomass as
instruction provided by the area in-charge.
 Launder cleaning done as when required.
 Secondary Settling Tank – II overflows to Intermediate Collection Tank (T – 07 )
having capacity 11 KL.
 Hypo-chloride Dosing Solution:
 With Concentration 1 ppm, Do the  Hypo-chloride dosing in
HDPE tank (T – 16) having capacity 100 Liters.
 Prepare the solution with portable water supplied by the
designated area
 Hypochlorite solution dosing on the MS baffled inlet launder
before running the operation activity.
 The air grid system provided for proper mixing of
hypochlorite to the effluent & tank cleaning activity should
perform as when required.
 From this intermediate collection tank, the mixed effluent will
pump into Pressure Sand Filter (PSF) using pump P– 04 A /
B having capacity 5 m3 / hr. The retention time of the tank is
2.7 hr.
 Pressure Sand Filter (PSF) (T – 08) removes the suspended
particulate matter, proper backwashing required at the
pressure loss of 0.8 kg / cm2 observed in the inlet and outlet
pressure gauge.
 The raw effluent line is provided to pump suction line P– 04
A / B & Backwash duration will be 15 to 20 min. for both
Filters PSF & ACF, .
 The backwash effluent of this system taken into the inlet
chamber of ETP for retreatment.
 Before completion of backwash,
 Ensure that coming to the inlet chamber should clear.
 Before and after the backwash related valve should check
properly.
  Treated effluent from Pressure Sand Filter (PSF) then goes
to Activated Carbon Filter (ACF) (T – 09) which removes
odor and color present in the effluent.
 Proper backwashing required at the pressure loss of 0.8 kg /
cm2 observed in the inlet and outlet pressure gauge.
 After completion of filtration (PSF & ACF), effluent enters
into final collection tank (T – 10) having capacity 50.6 KL and
finally discharges through two number of the submersible
pump ( P – 07 A / B)
 Operation of Filter Press ( FP – 01) – SOP for ETP and STP
 Before plan to operate filter press equipment check the cleaning status i.e.
– with a clean cloth and fixed properly.
 Filter press operation should start when sludge collection sump (T – 11)
having capacity 9.6 KL at least 75 % full and the batch should be made
with adding polyelectrolyte.
 Depends upon sludge characteristic polyelectrolyte dosing quantity should
fix by performing jar test or instruction provided by the in-charge.
 Before feeding sludge in to filter press (FP – 01) line should flush by the
portable water line connected to the pump.
 After completion of the line flushing portable water valve should shut down
and the sludge feed valve should open.
 At the starting of sludge feeding to FP – 01 recirculation valve should
adjust.
 Never shut down the recirculation valve.
 Initially pressure not shown to the pressure gauge and after some time
pressure generated and
 it should maintain between 2.0 – 4.0 kg / cm 2
 The operator should ensure the pressure when goes to raise more,
recirculation valve should adjust and
 Backpressure increases due to the generation of sludge cake.
 Remember overpressure may damage the system.
 Ensure the filtrate continues through discharge cock/tap and indicates
sufficient soluble discharges,
 when no effluent discharges stop the filter pressure operation.
 Shut down the second feed valve and open the recirculation valve and
flush the running pump. After that stop the pump and plan to give
compressed air from the compressor to filter press for removing the
effluents/filtrates from the sludge cake.
 When Compressor is breakdown condition (SOP for ETP and
STP)
 Then compressed air should be provided from the plant main compressor
line and the operator inform the utility in-charge / area in-charge.
 Before cleaning the sludge cake ensure the airline valve shut down and
mobile trolley placed on proper place and used proper PPE’s.
  Operate the lever of the hydraulic system reverse direction and switch off
from the main panel to avoid any major accident and after completion of
the job again switch on from the main panel.
 Hydraulic system to operate safely when pressure gauge shows 200 –
230 kg / cm2
 Pull the slide head of the moving plates and remove the sludge cake from
sliding one by one plate & sludge cake fall down to the below mobile
trolley.
 Finally cleaned the filter press and removed sludge to pack in a bag and
shifted to the hazardous waste storage area.
 Handling of ETP sludge should perform with PPE’s.
 Then follow the above relevant steps, then the equipment is ready for the
next batch operation.
 Cleaning of discharge cock/tap and foot valve/check valve to perform
(when required).
 Overall operation time for a batch depends upon the concentration of the
effluent sludge and high concentrations of filter press feed sludge reduce
the batch completion time.
 Operation of Sewage Treatment Plant (STP) (SOP for ETP and
STP) :
 Raw effluent comes by gravity to STP inlet chamber A / B (both
compartment).
 Do Screening with a bar screen chamber to separate heavy and grit
particles from not entering our system.
 Effluents then enter into equalization tank A / B (both compartment) to the
lower cut out, where oil and grease separate and cleaned manually as
when required. Chemical dosing is done in an equalization tank for
primary treatment.
 Caustic soda Dosing Solution :
 Caustic Soda dosing is done in the HDPE tank having
capacity 100 Liters with Concentration 10 %.
 Solution preparation is done with portable water supplied by
the designated area before running the operation activity.
 Manually mixing of the chemical to be done & tank cleaning
activity should be performed (when required).
 Alum Dosing Solution :
 Do the Alum dosing with Concentration 10 %  in HDPE tank
having capacity 100 Liters.
 Prepare the solution preparation with portable water.
Supplied by the designated area.
 Manually mixing of the chemical to be done & tank cleaning
activity should perform.
 Poly Dosing Solution (SOP for ETP and STP):
  Poly dosing is done in HDPE tank. Having capacity 100
Liters with Concentration of 0.1 to 0.2 %.
 Solution preparation is done with portable water supplied by
the designated area before running the operation activity.
 Manually mixing of the chemical to be done & tank cleaning
activity should be performed as when required.
 The effluent then enters into the lower cut-out to aeration
tank A / B ( both compartment) and
 Dosed nutrients like Urea, DAP And Jiggery / Molasses
(solid form) to maintain the biomass of the system.
 Aeration tank effluent overflows into the Clarifier tank by
gravity on settling and recalculate the return biomass by
means of two Nos. sludge recirculation pump A / B.
 Excess sludge to waste into sludge drying bed / Sludge
Collection Sump ( T – 11).
 Clarifier overflows through launders to Chlorine contact tank
and hypochlorite is dosed into this tank.
 Hypochlorite Dosing Solution:
 Dosing of Hypochlorite in HDPE tank, Tank capacity should 100 Liters
with Concentration 1 to 2 ppm.
 Solution preparation is done with portable water supplied by the
designated area before running the operation activity.
 Manually mixing of the chemical to be done & tank cleaning activity should
be performed as when required.
 Then effluent overflows into Final treated tank or effluent transferred from
chlorine contact tank to final treated tank by means of to nos. pumps A / B
 Final treated effluent discharges for reuse purposes (gardening/toilet
flushing) by means of two nos. of pumps (FTD – 01 A / B)
 Final treated effluent transferred quantity should be measured by two no’s
flow meter F.M – 01 & F.M – 02 in each shift & documented as per
Annexure (2)
 Monthly ETP performance report is prepared by the ETP / STP in-charge /
Area in-charge & documented as per Annexure (3)
 Monthly STP performance report is prepared by the ETP / STP in-charge /
Area in-charge & documented as per Annexure (4)