YADEN LABORATORIES (PVT) LTD.

KATUNAYAKE
EFFLUENT TREATMENT PLANT
HANDING OVER DOCUMENT

DESIGNED, CONSTRUCTED, SUPPLIED & INSTALLED BY

Enviro Tritech (PVT) LTD.

NO.87, Makola South, Makola,.

Sri Lanka.

Tel: + 94 11 5544399, 5544322, 2906517

Fax : + 94 11 4815201
E-mail : [email protected]
 CONTENTS

CHAPTER 01 - INTRODUCTION

CHAPTER 02 - TECHNICAL APPROACH

CHAPTER 03 - PROCESS DESCRIPTION

CHAPTER 04 - PROCESS FLOW DIAGRAM

CHAPTER 05 - INSPECTION SHEETS

CHAPTER 06 - INVENTORY

CHAPTER 07 - TECHNICAL DATA SHEET OF EQUIPMENT

CHAPTER 08 - WATER ANALYSIS REPORT

CHAPTER 09 - OPERATION

CHAPTER 10 - MAINTENANCE INSTRUCTION

CHAPTER 11 - OPERATOR’S ROLE

CHAPTER 12 - WARRANTY CERTIFICATION

CHAPTER 01 –

INTRODUCTION
CHAPTER 01 – INTRODUCTION

This manual describes the operation and control of the equipments of waste water treatment plant at
Yaden Laboratories (PVT) Ltd. – Katunayake

This manual has been prepared as a guideline to the plant personnel responsible for start-up, operation
and maintaining the equipments and facilities provided in such a manner as to achieve optimum results.

These instructions are based on experience, but in many cases, it may be necessary to vary the operating
variables and operating conditions to accommodate specific conditions that may arise. A brief description
of the theory and general principles are included. This will give the operating personnel a better insight
to the equipment and process they will be handling.

The treatment system includes following steps

1. Equalization tank
2. Coagulation And Flocculation
3. Primary P/P Clarifier tank
4. Aeration tank
5. Secondary circular clarifier
6. Intermediate tank
7. Pressure sand filter
8. Activated Carbon filter
9. Drying bed
 CHAPTER 02 –

TECHNICAL APPROACH
CHAPTER 02 – TECHNICAL APPROACH

Design is based on the wastewater characteristics provided by the client.

A. Waste water released from production process

Design Capacity of the plant = 45 m3/hr.

Operating hours = 24 h

TREATED WATER QUALITY (BOI STANDARDS)

Treated water quality

BOD <200
COD <600

WASTE WATER TREATMENT PLANT TANK CAPASITY

Tank Volume or
area
Equalization tank (Underground Closed Tank) 23.00m3

Coagulation & flocculation Chamber (Above ground open Tank) 1.50 m3

Primary PP Clarifier (Above ground open Tank) 3.80 m3
Aeration Tank (Above ground open Tank) 26.00m3
Secondary circular Clarifier (Above ground open Tank-Steel) 5.70 m3
Intermediate Tank (Above ground open Tank) 5.00 m3
Treated water collection tank (Underground Closed Tank) 6.00 m3
 CHAPTER 03 –
Process Description
CHAPTER 03 - Process Description
Waste water generated from the production process of Yaden Laboratories (PVT) Ltd. is directed to the
effluent treatment plant by trench system. At first step, waste water filtered through bar screen.

Screen chamber with bar screener

Wastewater containing rags and debris is sent through the bar screen to remove large particles and other
debris witch cause for clogging problems of pumps & pipe fittings. The screen chamber include bar
screener for this purpose. This facilitates to remove clogging problems in piping network and send to
waste water to next treatment process.

Equalization tank

After removing larger solids wastewater enters to an equalization tank. Equalization tank acts to buffer
the concentration and flow variations into the secondary treatment system.

Coagulation, Flocculation and pH adjustment

Colour of the waste water has to be removed by coagulation, flocculation. This unit consists controller
for dosing pumps. Necessary chemicals will be added at the appropriate sequence and mixed well in the
coagulation and flocculation to enhance the coagulation and flocculation process.

Parallel plate clarifier

After chemical adding, it flows to clarifier tank. In this clarifier tank, arrangements are made to flow the
liquid with least turbulence and ensure higher setting efficiency of chemical sludge. Settled sludge is
required to be removed to sludge drying bed by operator periodically. Cleared water will be transferred
in to next step intermediate tank
Aerobic reactor tank
The Treatment system next step is a natural biological degradation process designed to work on an
extended aeration principle of activated sludge process. The waste water that Pumps at a controlled rate
flows in to a new treatment step, named as aeration tank. The flow rate will be controlled with a Valve.
The aeration tank is provided with submerged array of diffuser including external root blowers. The
natural aerobic biomass will grow in this tank. This Aerator will provide Oxygen necessary for the
growth of aerobic biomass in the Aeration tank. The waste matter (mostly organic in nature) in the
wastewater will be a food for the biomass. Therefore with the presence of mainly oxygen & food matter
the biomass (Aerobic- Bacteria) will degrade waste matter come along with waste water. With the cell
synthesis the weight of the biomass will increase and would be able to settle in un-hindered water. The
digested sewage, which is at complete mix condition at the aeration tank, will flow under gravity to the
clarifier tank.

Secondary circular clarifier

Circular center feed clarifier operates with the effluent entering through a center stilling well with the
flow being forced downward. This ensures the proper residence time of the water in the clarifier to
allow for the settling of the solids. The water then rises and exits through a wall mounted weir through
that is placed on the inner circumference of the clarifier. A scraper arm assembly passes over the
bottom of the clarifier to dansify and condition the settled solids prior to being drawn off for additional
processing.

Intermediate Tank
Effluent from the clarifier gets collected to an intermediate tank. This functions as temporary holding
tank.
Pressure Sand Filter (PSF)
There is one pressure sand filter for further treatment. Dirt is collected in the filter by the sand bed as
water flows through the filter. Water enters the filter through the valve on top of the filter and is
distributed evenly downward across the sand bed. The dirt is removed by the sand and the clean water
flows through the piping (laterals) at the bottom of the filter, up through the standpipe, back to the valve
on top of the filter, where the clean water is returned to the carbon filter through the piping or hoses.
After a period of time, dirt will accumulate in the filter causing a resistance to the flow of water through
the filter. This resistance results in a diminished flow of water and a rise in the pressure of the filter.
Eventually the filter sand will have removed so much dirt and the filter pressure risen to such a point
that it will be necessary to clean (backwash) your filter. By setting the valve on top of the filter to the
backwash position, the flow of water is automatically reversed through the filter so that the flow of
water is directed to the bottom of the filter, up through the sand bed flushing, the dirt and debris out
through the waste line. Once the backwash procedure is complete, the valve is manually returned to its
filter position to resume normal filtration. The filter’s function is to remove suspended matter from the
water.

Activated Carbon Filter

Activated carbon filters are useful to reduce bad taste, odor, color and excess chlorine in the water. The
operation of the activated carbon filter removes contaminants through adsorption, primarily a physical
process in which dissolved contaminants adhere to porous surface of the carbon particles. This process
can be reversed and relatively easy.

Chlorine dosing system

The chlorine dosing systems installed within the plant one is used for secondary treatment and other is
used for tertiary treatment. Both operate automatically. Calcium hypochlorite Ca (OCL) 2 is needed to
be added to the chlorine dosing system. Dosing pump should be always in automatic mode unless for
maintenance. Adequate supply of chlorine will ensure proper disinfection.

Drying bed
Sludge from clarifier will be sent to the sludge drying beds. Dried sludge will be removed on top of the
sand beds. The dried cake to be disposed- off at a sanitary land fill approved by CEA or send to Holcim
for high temperature incineration.

Treated water collection tank

Final treated water and sewerage water generated in factory premises is collected to treated water
collection tank. Collected water is pumped to BOI manhole as directed to BOI central treatment plant.
 CHAPTER 04 –
PROCESS FLOW DIAGRAM
CHAPTER 04 – PROCESS FLOW DIAGRAM
Waste
Water In

Screen Coagulation &

Mechanism Flocculation Tank

Equalization Primary PP Clarifier Aeration Tnak

Tank

Dosing System
Geared motor

Treted
water Out

Chlorine dosing Secondary Circular

Treated Water Tank Sand Filter Sand Filter Filter Feed Intermediate Tank
system Clarifer
pump

Dried Sludge
Removed by client Diaphragm sludge
pump
Drying Bed
 CHAPTER 05 –
INSPECTION SHEET
CHAPTER 05 – INSPECTION SHEET

1) Equalization pump- 01

Pump Model – Tsurumi 50C2.75/0.75KW/ 400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

2) Equalization pump- 01

Pump Model – Tsurumi 50C2.75/0.75KW/ 400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

3) Dosing Pump-1 –PAC

Pump Model –SEKO AML 200

Dosing Pumps Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Pulse Correct Incorrect
Rated Current
Starting Current
Serial No of Pump

4) Dosing Pump- 2 – PE

Pump Model – SEKO AML 200

Dosing Pumps Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Pulse Correct Incorrect
Rated Current
Starting Current
Serial No of Pump
 5) Sludge pump

Pump Model – Tsurumi 50PU2.4/ 0.4KW/400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

6) Root blower – 01

Pump Model – Tsurumi TSR 2-50/ 1.8KW/400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

7) Root blower – 02

Pump Model – Tsurumi TSR 2-50/ 1.8KW/400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump
 8) Filter feed pump – 01

Pump Model – SOLEX SXD 144/1.5T /0.75KW /400V/3Ph/50Hz

Filter feed Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

9) Filter feed pump – 02

Pump Model – SOLEX SXD 144/1.5T /0.75KW /400V/3Ph/50Hz

Filter feed Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

10) Treated water pump - 01

Pump Model – Tsurumi 50C2.75/0.75KW/ 400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump
 11) Treated water pump -02

Pump Model – Tsurumi 50C2.75/0.75KW/ 400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

12) Dosing Pump –Chlorine

Pump Model – SEKO AML 200

Dosing Pumps Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Pulse Correct Incorrect
Rated Current
Starting Current
Serial No of Pump

13) Drive head

Drive Head Model – INDOFAB A-450/0.37KW/ 400V/3Ph/50Hz

Submersible Pump Items / Description Status Remarks
Motor KW/HP Three phase Single phase
Motor Speed
Rotation Correct Incorrect
Rated Current
Starting Current
Floater Switch for OFF, Low level
Floater Switch for ON, Desired Level
Serial No of Pump

……………………………… ...............................................

Contractor Client

Enviro Tritech (Pvt) Ltd Yaden Laboratories (Pvt) Ltd.

CHAPTER 06–
INVENTORY
 CHAPTER 06– INVENTORY

Description Qty
Submersible Pumps, Control Panel & Accessories
Equalization Transfer pumps - Tsurumi 50C2.75/0.75KW/ 400V/3Ph/50Hz 2
Dosing Pumps PE- SEKO AML 200 2
Dosing Pumps PAC- SEKO AML 200 2
Rapid mixing agitator 1
Sludge pump – Tsurumi 50PU2.4/ 0.4KW/400V/3Ph/50Hz 2
Root blower – Tsurumi TSR 2-50/ 1.8KW/400V/3Ph/50Hz 2
Filter feed pump - SOLEX SXD 144/1.5T /0.75KW /400V/3Ph/50Hz 2
Dosing Pumps Cl- SEKO AML 200 2
Sand Filter – 21” x 65 “ FRP Vessel 1
Activated carbon filter – 21” x 65 “ FRP Vessel 1
Clarifier drive head - INDOFAB A-450 /0.37KW /400V/3Ph/50Hz 1

Electrical Work
Control Panel 1
All electrical accessories & wiring 1

……………………………… .............................….

Contractor - Representative Client - Representative

Tritech Engineers (Pvt) Ltd Yaden Laboratories (Pvt.) Ltd.

CHAPTER 07 – TECHNICAL DATA SHEET OF
EQUIPMENT
 CHAPTER 08 –
WATER ANALYSIS REPORT
CHAPTER 09 –
OPERATION
CHAPTER 10 – OPERATION

SAND FILTER UNIT

 Check whether the sand filter gives an adequate flow rate through itself by comparing
the normal average flow rate.

 Backwashing time & rinsing time and the duration of opening position of each stage
are given as below.

 Back wash and rinse the sand filter regularly.

In
Sand
Out
Backwash Filter

& Rinsing

DURATION

SERVICING 24 hrs

BACKWASING 10 -20 min

RINSING 2 -5 min

Warning:

 Switch off the pump when you change the operation of sand/carbon filter.
 ABOUT VALVE SYSTEM

 To control the filter operation.

 Have six locating positions on the top of the valve, selectable by turning the valves
manually.

THE VALVE POSITIONS ARE

Used to get filtered water from filter.

FILTER

Used for cleaning the filter media by reversing the flow.

BACKWASH

Used after backwashing to flush any remaining dirt from the valve
RINSE and settle the media bed or use in regeneration.

Bypasses filter. Used for pumping water to waste.

WASTE

Bypasses filter. Used for water circulation or transfer.

RECIRCULATE

Shuts off all flow to filter

CLOSED
 CHAPTER 10 –
MAINTENANCE INSTRUCTION
CHAPTER 11– MAINTENANCE INSTRUCTION

The following precautions have to be always taken to avoid unnecessary breakdowns.

 Always make sure the process tanks are not polluted with foreign matters such
as plant leaves, branches and so on.

 Make sure you have switched on all relevant pumps and equipments.
 Make sure you are draining those clarifiers as per the given instructions.
 Do not run the plant if any one of the pump does not work properly or blocked
before repairing that particular unit.

Periodic Maintenance Inspection

Screen chamber with bar screener
 Debris or rags trap in bar screen yes / no
 Clean bar screen regularly yes / no

Chemical treatment (Coagulation)

 System in operation yes / no
 Check influent- / effluent piping ok / clogged
 Colour of the clarifier normal
 Impurities (big) yes / no
 Maintenance service every 3 months
Clarifier Tanks
 Sludge content in the effluent water yes / no
 Swimming sludge in the clarifier yes / no
 Smell yes / no
 Clean clarifier completely yes/ no
 Check time sludge removal Same / more / less
Sand filtration

 Operation of pressure filtration smooth / not smooth

 Pressure gauge reading _______
Electrical installation
* Check all functions and connections of the electrical control panel
Sample Analysis
* Sample Analysis Results ..............................
Coagulation
Coagulation dosage is one of the most important factors that have been considered to determine the
optimum condition for the performance of coagulants in coagulation. Essentially, insufficient dosage or
overdosing would result in the poor performance in flocculation. Therefore, it is significant to
determine the optimum dosage to minimize the dosing cost and sludge formation and also to obtain the
optimum performance in treatment.

The best performance of alum in removing turbidity from water was obtained at pH 8

Clarifiers
This waste water treatment process includes both inclined plate (lamella) clarifier and circular clarifier.

Inclined plate clarifier

The Inclined plate clarifier consists of a series of closely spaced flat plates inclined at an angle of from
45 to 60 degrees from horizontal. Preconditioned water with entrained solids enters the plate pack and
flows between the plates. The path length, plate spacing, and angle of the plate are the usual
engineering variables. As the water flows between pairs of plates, the heavy solids with a specific
gravity higher than the surrounding water will settle onto the top surface of the lower plate, and slide
down the inclined surface to be collected in the sludge hopper. Clear, near solids-free water then exits
the top of the plate area and flows over an adjustable weir.

Advantage

 Increased settling efficiency due to increased surface area

 Smaller Area Needed for Installation
 Mostly Industrial Applications
Circular clarifier

 Influent typically enters the basin from the center rather than from one end.
 A Circular Baffle Directs Flow
 Solids Settle scraped to sump removed by gravity
 Bottom drive Mechanism keep continues slow rotation as not to condense settled sludge.
 The Water Flows to the Effluent Weir around the Circumference of the Clarifier.
 Require to remove settled sludge at least three times per week.
Troubleshooting and solutions

Observation Possible causes Monitor Possible solutions

EQ pump not Flow / Indicator 1. Check the working
working bulbs condition of EQ tank’s
floater switch. If not work
properly, replace the
relevant floater switch
2. If “Trip” indicator bulb
light up,
Press relevant “reset”
button.
3. If “Trip” indicator bulb
light up frequently, pump
Overflowing the
need to be checked by
equalization tank
skilled person
EQ pump work, but Flow 1. Take out the pump from
water flow low/ zero EQ tank & inspect by
skilled person. Impeller
may be damaged.
EQ pump work, but Flow 1. Take out the pump from
Pump is clogged EQ tank & remove/ clear
clogged impurities.
Actual waste water Flow 1. Re-design the plant
flow rate exceed
design flow rate
Hydraulic overload Flow 4. Use all available tanks;
choke bake flows to
increase detention time.
5. Consider adding chemical
coagulations.
Sludge build up in Sludge removing Monitor sludge levels
tanks reduces duration & establish a more frequent and
volume and allows sludge level consistent sludge removing
solids to scour out schedule.
Poor suspended solid
tank
removal
Strong recycle flows Quality & Recycle at low flow periods or
quantity of re-route recycle flows to an
recycle alternate process.
Industrial waste Influent sampling Identify and restrict any
contribution industrial contaminant that
may be adversely affecting
primary settling.
Temperature currents Wastewater Monitor temperature and
temperature eliminate storm flows.
Pump cycling, flow Pump cycling 1. Modify pumping
surge strategies.
2. Increase tank volume or
Sludge washout from tank use equalization basin
Uneven weir settings Weir settings 1. Level weirs
2. Repair, replace or install
baffles
 Unusual amount of Industrial Remove material manually, if
floatable material has contribution possible.
entered plant
A foaming substance Industrial 1. Identify & restrict this
Foaming has entered plant contribution material from entering the
plant, if it interferes with
plant operation.
2. Use spray water or foam
reducing chemicals to keep
foam down
Velocity too low velocity 1. Increase the flow velocity.
Sludge settling in influent 2. Agitator with air or water
lines to keep the material in
suspension
Sludge becoming Tank surface for Remove sludge more &
septic in tank black sludge frequently or at a higher
Damaged or worn Inspect collection Repair or replace as necessary
collection equipment equipment

Sludge with drawl Sludge removal Clean line

Floating sludge line plugged output
Return of well Effluent nitrates Vary the age returned sludge,
nitrified waste or recycle waste sludge to an
activated sludge alternate process
Too few tanks in Retention time Place tanks into service
service
Damaged or missing Baffles Repair, replace or install
baffles baffles.
Clog the Sand filter Pressure Gauge 1. Backwash the PSF
reading before 2. Check the intermediate
PSF increase tank water quality (sludge
contain or not), If sludge
Clogging Pressure Sand contain clean the
Filter (PSF) & Pressure intermediate tank.
carbon filter(PCF) 3. If PSF clog frequently,
replace the filter media
Clog the Activated Pressure Gauge 1. Backwash the PCF.
carbon filter reading before 2. If PCF clog frequently,
PCF increase replace the filter media
Clog the pump “Trip” indicator 1. Press relevant “reset”
bulb button.
2. If pump trip frequently,
“Trip” indicator bulb light
take out the pump from EQ
up of relevant pump
tank & remove/ clear
clogged impurities.
3. Contact OM for further
actions
 CHAPTER 11 –
OPERATOR’S ROLE
CHAPTER 12 – OPERATOR’S ROLE

Wastewater treatment plant operators have an important responsibility in water quality

control. Their job is day by day control which cannot be neglected without doing harm
to someone else downstream from their collection. Because the stream receives an
effluent that still has organic materials, chemicals & organisms even with the best
treatment available today, the stream must be considered as a portion of Sewage
treatment plant. Odors must be kept to an absolute minimum. Appearance of both plant
and personnel are vital to good operation.

Operator

o Wastewater treatment plants only work satisfactorily, if they are serviced and
checked periodically.
o The operator must check the functioning of the unit and the values of the effluent
parameters on a regular basis.
o The operator shall be responsible for daily operation and routine maintenance of
the collection, treatment and disposal systems.
o The certified operator shall spend at the plant a minimum of two hours per day.
o The certified operator shall report any plant malfunction.
o The operator shall also be responsible for maintaining daily ,weekly and monthly
check lists with required records regularly for inspection and shall submit copies of
the results to the to the company under commissioning period.
 CHAPTER 13 –
WARRANTY CERTIFICATION
Equalization pumps/ Treated
water pumps
Tsurumi 50C2.75
 Sludge Pump
Tsurumi 50PU2.4
 Root Blower
Tsurumi TSR 2-50
Dosing pump
SEKO, AML-200
 Filer feed pump
SOLEX, SXD144/1.5T
 FRP Vessel
MARTIN, 21 x 65
 Disc Diffusers
SHOWFU, SUPER - M
 Drive Head
INDOFAB, A-450