PLANT COMMISSIONING AND

OPERATION & MAINTENACE

MANUAL
FOR

SEWAGE TREATMENT
PLANT

MBBR TECHNOLOGY

BY

Office No.1, Shastri Complex, Mukundnagar, Swargate, Pune-411037

E-Mail - [email protected]; Contact No. – 774 496 8378/ 721 978 8892
CONTENTS
A. INTRODUCTION: .................................................................................................................................... 3

B. ABOUT THE OEM: ................................................................................................................................. 5

C. GENERIC BLOCK DIAGRAM: ............................................................................................................. 6

D. NOMENCLATURE: ................................................................................................................................. 7

E. ITEMS SUPPLIED WITH THE PLANT: ........................................................................................... 8

F. PLANT START UP: ............................................................................................................................... 10

G. PREPARATION OF CULTURE:......................................................................................................... 12

H. OBSERVE & PRECAUTIONS: ............................................................................................................ 13

I. COMMISSIONING & TESTING OF TREATED WATER: ........................................................... 15

J. STP OPERATOR RESPONSIBILITIES:........................................................................................... 19

K. DAILY PLANT OPERATION: ............................................................................................................ 20

L. BLOWER OBSERVATION AND MAINTENANCE: ..................................................................... 21

M. PUMP OBSERVATION AND MAINTENANCE: ........................................................................... 23

N. GENERAL OPERATION AND MAINTENANCE CONSIDERATIONS: .................................. 25

O. DATA RECORDING AND SAFETY: ................................................................................................. 29

P. PROCESS TROUBLESHOOTING: .................................................................................................... 32

Q. GALLARY: ............................................................................................................................................... 35

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 A. INTRODUCTION:

The ownership and operation of a sewage system is a large responsibility. Through

proper operation, the local ecology of the area will be safe-guarded and the health and
welfare of the residents in the area will be protected. This Modular Sewage Treatment
Plant has been approved and permitted by most of the environmental authorities and
consultants.

When operated properly and maintained as provided by the manufacturer, the plant is
designed by the “Engineer of Record” to fit specific rule and permitting requirements.
Proper operation of the Sewage Treatment Plant assures the sanitary health and welfare
of the area you serve. This will remain true when properly operated and maintained and
if the plant is used for the design treatment loading. No other contributing wastewater
flows should be introduced into the plant for treatment, nor should plant modifications
be made to its design and operation without approval and authorization by the Owner.

This manual contains guidelines for operation and maintenance of Sewage Treatment
Plant (STP). The main role of Sewage treatment plant is to treat the domestic wastewater
generating from the residential / commercial complex before discharge. The instruction
given should be followed as per the site requirement, but the principal of treatment will
remain same. As per the site condition, plant operation may change to suit the site
condition at the time of operation.

PURPOSE & GENERAL INFORMATION

This Operational Guide is intended to describe Sewage Treatment Operation and

Operation Testing and Maintenance to enable you to adequately provide sewage
treatment for a long period of time with minimum operation and maintenance problems.

Sewage or waste water is a combination of bodily waste and the domestic waste from
park residences, business buildings, institutions, and establishments with ground surface
and or storm water as may find its way into the Sewage Collecting System. Sewage

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contents are generally a combination of liquids and solids. Usually, the solids are less than
0.1% and are made up of inorganic and organic matter. The solids themselves are also
classified as dissolved and suspended solids. Approximately 1/3 of the solids are in a
suspended state and the remaining 2/3 are in solution.

Several bacteria types are commonly found in sewage. These includes:

1. Pathogenic bacteria cause or can cause disease-- such as typhoid fever,
dysentery, diarrhea, etc. Those bacteria may spread disease and contaminate
the areathrough underground and surface water supply sources.
2. Anaerobic bacteria are a microorganism that thrives where oxygen is not
available. They perform functions in thedigestion and reduction of sewage.
3. Aerobic bacteria require free oxygen and isnecessary for the nitrification and
oxidation processes in the treatment of sewage. Bacteria is responsible for the
decomposition processes; when properly used andcontrolled, they produce the
desired results in the treatment of sewage.

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 B. ABOUT THE OEM:
OEM: Agile Ventures (AV), Pune
OEM Address: Office No.1, First Floor, Shastri Commercial Complex, Opposite Comet Super
mart, Mukundnagar, near Swargate, Pune – 411 037
OEM Contact details:
a. Mr. Sanket Kasat/COO
Mobile – +91 7744968378
Email – [email protected]
b. Mr. Kunal Todi/CEO
Mobile – +91 9011897676
Email – [email protected]
c. Mr. Deepak Mehta/CFO
Mobile – +91 7219788892
Email – [email protected]
Type of Plant: Sewage Treatment Plant (STP)
What the STP can treat: Bathing Water, Drinking Water, Toilet Water
What the STP can not treat: Common laundry water, common kitchen waste including used
thrown up Oil and food
Plant Design Basis: Plant is designed to operate for 24hrs, out of which 20hrs operational
and 4 hours cool down, maintenance, backwash operation etc.
Example: if plant capacity is 20KLD that means it can treat 20KLD/20Hrs = 1KL/hr
Always Remember:
- Plant commissioning should be done with FRESH sewage Only, any stored sewage should
be pumped out/thrown off
- Never Turn Off blowers
- Never empty MBBR tank
- Never allow overflow of tanks
- Everyday Backwash Sand & Carbon Filters
- Maintain plant neat and clean, use proper fittings

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 C. GENERIC BLOCK DIAGRAM:

RAW SEWAGE INCOMING

LINE

BAR SCREEN CHAMBER

OIL AND GREASE CHAMBER

EQUALIZATION / RAW
SEWAGE TANK

Return Activated Sludge

Overflow
MBBR TANK

AIR BLOWER
TUBE SETTLER TANK SLUDGE
AERATION
HOLDING
TANK

FILTER FEED TANK

Disposal by Client

PRESSURE SAND FILTER

ACTIVATED CARBON FILTER

CHLORINATION / OZONE
SYSTEM

TREATED WATER TANK

TREATED WATER FOR USE

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 D. NOMENCLATURE:
TYPE /
S/N ABB. FULL FORM MOC ELECTRIC CONNECTION
LOCATION
Bar Screen Chamber, Screen Plant Incoming Load
1 BSC RCC Under Ground
MOC - MS Required
2 O&G C Oil & Grease Chamber RCC Under Ground 1. 10KLD - 5kVA
Equalization Tank / Raw 2. 20KLD - 7kVA
3 EQT / RST RCC Under Ground 3. 25KLD - 7kVA
Sewage Tank
4. 50KLD - 10kVA
4 SHT Sludge Holding tank RCC Under Ground
5. 62.5KLD - 12kVA
5 MBBR TANK Moving Bio Bed Reactor TankMSEP Above Ground
6 TST Tube Settler Tank MSEP Above Ground
7 FFT Filter Feed Tank MSEP Above Ground
8 TWT Treated Water Tank MSEP Above Ground
9 PSF Pressure Sand Filter FRP Plant Room
10 ACF Activated Carbon Filter FRP Plant Room
11 RSP 1/2 Raw Sewage Pump 1/2 CI Plant Room 3 Phase
12 SP Sludge Pump CI Plant Room 3 Phase
13 FFP 1/2 Filter Feed Pump 1/2 CI Plant Room 3 Phase
14 AB 1/2 Air Blower 1/2 CI Plant Room 3 Phase
15 ECP Electrical Control Panel NA Plant Room
16 CDS Chlorine Dosing System NA Plant Room
17 CDP Chlorine Dosing Pump PP Plant Room Single Phase
18 CDT Chlorine Dosing Tank HDPE Plant Room
19 ODS Ozone Dosing System NA Plant Room
20 TL Tube light Plant Room Single Phase
21 EF Expeller Fan Plant Room Single Phase
22 PR Plant Room Above Ground

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 E. ITEMS SUPPLIED WITH THE PLANT:

S/N ITEM UOM QTY PURPOSE REMARKS

1 Bar Screen Nos 1 To Filter dirt above 10mm inside the BSC
To install inside EQT & SHT to diffuse air
2 Air Grid - CPVC Unit 1
from blower
Raw Sewage To lift raw sewage from EQT/RST to MBBR 1 Working +
3 Nos 2
Pump Tank 1 Stand by
Round cylindrical media is poured inside
4 MBBR Media LS 1 MBBR tank which helps to grow bacteria
colony
Supplied as per plant size, already installed
5 Air Diffuser Unit 1
at the bottom of the MBBR tank to diffuse air
It is wire mesh type cover, provided at the
MBBR Tank
outlet of MBBR tank, Drain and Overflow, to
6 protection Unit 1
avoid passing of MBBR media in the line or
cover
to the next tank
The blower/s are provided for aeration in
1 Working +
7 Air Blower Nos 2 EQT/RST, MBBR Tank and Sludge Holding
1 Stand by
Tank
Depending upon size of the TST tank, TS
Tube Settler media is fitted inside, the 45-degree slanting
8 Block 1
Media media helps to remove big size particles in
the filtrate
Filter Feed Connected with filter feed tank to suck water 1 Working +
9 Nos 2
Pump from FFT and pass to PSF, ACF 1 Stand by
Installed either at the inlet line to PSF or at
the Outlet line of ACF to control the plant
10 Rotameter Nos 1
capacity hourly flow which is passing
through PSF and ACF
Pressure Provided on lines to check pressure in the
11 Nos 5
Gauges system and control accordingly
A FRP vessel with graded sand filled inside is
Pressure Sand
12 Nos 1 provided to remove the dirt/debris in the FRP Material
Filter
water flowing from FFT
A FRP vessel with graded sand and activated
Activated carbon on the top layer is provided to
13 Nos 1 FRP Material
Carbon Filter remove the color and odor in the filtrate
water before going to treated water tank

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 1 Each installed on PSF & ACF. The MPV has
3 ports - Service, Backwash and Rinse
Service mode - when the plant is running
UPVC
14 Multi Port Valve Nos 2 Backwash mode - when the vessels needs to
material
be backwashed
Rinse Mode - after backwash vessel should
be rinsed once before entering Service Mode
The system comprises of Chlorine Dosing
Pump and Chlorine Dosing Tank
Chlorine Dosing
15 Unit 1 interconnected with each. The outlet from
System
the CDP is attached at the outlet of the ACF
before entering to Treated Water Tank
The system comprises of Oxygen
Ozone Dosing Concentrator and Ozone Generator Machine
16 Unit 1
System with a venturi to feed Ozone in the outlet
line from ACF to Treated Water Tank
It is connected to the TST to remove
deposited sludge in the tank and recirculate
17 Sludge Pump Nos 1 1 Working
(10%) to MBBR tank and waste (90%) to the
Sludge Holding Tank
Installed inside the plant room to make all
Electric Control equipment connections, it is PLC based panel
18 Nos 1
Panel which automatically runs the plant if auto
mode is selected
The level switches are provided to
Float/Level
19 Nos 2 maintain/auto cut-off the pumps when the
Switch
respective tanks are full/empty

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 F. PLANT START UP:
1) Place the Sewage treatment Plant unit on an absolutely plain PCC/RCC surface.
Make sure that there is no slope on either side where plant is to be placed.
2) Hook up incoming 3 phase connection load to the Panel MCB and carry out dry run
once. Connect the Control Panel to your main connection by using 16sqmm-4 core
copper armored/shielded cable. Connect 63AMP MCB Switch before cable enters in
to STP Control Panel. Also provide earthing to control panel too
3) Firstly you have to install the raw sewage pump (1 working + 1 standby) on
collection tank slab. The pumps are provided with discharge assembly. Foot valves
for these pumps are kept in dosing tank.
a. Piping (1.5” UPVC) from raw sewage pump to collection tank for suction &
from raw sewage pump to MBBR tank for discharge line is to be connected.
b. Sludge pumps and filter feed pumps with their respective suction and
discharges assembly is already fitted with the unit.
4) Close the drain plugs with the UPVC flanges that are given in the dosing tank. The
drain plugs are at bottom of a) Filter feed tank, b) MBBR tank, c) Treated water
tank.
5) Connect the PSF’s & ACF’s backwash line to collection tank.
6) Make sure all the pipeline connections are done and checked for tightness
7) All the drain points should be connected with a valve and a union for easy connection
and removal, one single drain line take it till collection tank
8) Make sure you have overflow line as well connecting FFT to EQT/RST so that overflow
can be avoided from MBBR Tank, Tube Settler Tank and Filter Feed Tank
9) Now you have to do the electrical connection of Raw Sewage pump, first connect
raw sewage pump with control panel by using 1.5sqmm-4 core cable provided to
you (50 mtrs) & also connect float switch to control panel by using 0.75sqmm-2
core cable and put the float switch in collection tank
10)Connect the float switch in filter feed with the help of 0.75sqmm-2 core cable
laying in the tank and put the float switch in the filter feed tank. Put float switch in
the tank at the level 200-300 mm from the bottom, so that as it reaches above the
float level, the filter feed pump will start and transfer the water to treated water
tank through PSF, ACF & with Chlorine dosing.
11)For more clarification, please refer the attached P&ID inside plant room

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 12)The Raw sewage pumps (RSP 1 & 2) shall be installed on the top of EQT / RST on the
provided skid and bolt it
a. The suction pipe from the RSCT to the pump suction should be with foot valve
at the bottom so that it can safeguard the pump by not sucking things which
can choke the impeller
b. The pump motors are not weather proof so a weather proof canopy should be
provided to safeguard against rain
c. The pumps should be connected to the provided control panel in the plant
room with a 2.5mm2 4 core pure copper cable
d. The pumps should also be connected to Low Leve switch in RSCT and with a
High-Level Switch inside FFT
e. The combined raw sewage outlet line should be connected to the MBBR
Tank ONLY. The raw sewage should flow from EQT/RST to MBBR Tank
f. There should be a return/loop line to return the excess flow back to the EQT
13)The supplied Air Distribution System (in CPVC Grid) should be installed at the bottom
of the EQT and SHT when the tank is empty and it should be bolted to the bottom of
the tank for air diffusion, this line should be connected to Air Blower Outlet at the
pump room side.
14)The raw sewage going inside the MBBR tank should be monitored, it should be fresh
and it should reach to the level at which MBBR tank overflows to Tube Settler Tank,
once the level is attained, turn off the raw sewage pumps
15)Now for the next 10-12 days, no fresh sewage to be pumped to the MBBR tank, as the
bacteria growth starts in the MBBR tank. All the sewage in coming 10-12 days should
be bypassed or stored as it is inside EQT/RST
16)Make sure the MBBR media provided with the plant (black color, cylindrical type) is
available inside MBR tank as this media is the home for bacteria to grow and cultivate,
bacteria form its colony on this media and helps to digest the COD & BOD load in the
water to purify the water
17)Aeration inside the MBBR tank should be ON 24hrs, no shut off if the plant is running
18)After all this, we shall prepare culture to add to the MBBR tank

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 G. PREPARATION OF CULTURE:

STEP 1: Take a bucket of fresh water (20 liters), and add 50 grams of Urea, 50 Grams of
DAP (Di-ammonium Phosphate), 50 Grams of Jaggery and 50 grams of readymade
culture (if available).

OR if the above items are not available then take 200grams of fresh cow dung and 200
grams of jaggery for a 20KLD plant;

thumb rule is 10-gram cow dung and 10-gram jaggery for 1 KLD capacity

STEP 2: Mix this mixture thoroughly in a bucket unless it becomes homogenous

STEP 3: Your air blower should be ON, aeration in the MBBR tank should be continuously
ON, then pour this mixture (prepared at STEP 2) in your MBBR Tank at once. Air blower
should be continuously working

REMEMBER: Blowers should be in automatic mode (so that both blowers can
toggle between them), make sure the blowers are not turned off at any time,
should be UP and RUNNING 24hrs.

STEP 4: Repeat STEP 1 & STEP 2 every 3rd day – Day 3, Day 6 and Day 9 unless the MBBR
media have fully grown bacterial culture developed on top of it and the color of MBBR
media changes to greyish/whitish/pale yellow. After Day 9 do not add anything to MBBR
tank, and observe for bacterial growth

PRECAUTIONS:

1. Blower should be ON and running throughout the life cycle of STP plant
2. The mixture should be added to MBBR tank every alternate day for 20 days
3. Once the MBBR tank is full and you started STEP 1, DO NOT TAKE FRESH
SEWAGE NOW IN MBBR TANK, STOP THE SEWAGE LIFTING PUMPS.
4. After 8-10 days of first mixture added to MBBR tank, start adding new sewage and
slowly water should pass to Tube Settler Tank (TST) / Secondary Tube Settler
Tank (STST) under gravity
5. NEVER take fresh sewage in TST, fresh sewage should be pumped from
Equalization tank (EQT)/ septic tank to MBBR tank only

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 H. OBSERVE & PRECAUTIONS:
1. After 10/12 days the MBBR media should be turning to grey/brown showcasing that
the bacteria is forming its colony on the media and you are on right track. If this is not
happening then pls add 1 more dose of cow dung and jaggery to observe the desired
result.
2. To confirm if the desired bacterial growth is attained or not, pls follow trailing
procedure:

a. You should Measure Mixed Liquor Suspended Solids (MLSS) in liquid in MBBR
tank.

What is MLSS (Mixed Liquor Suspended Solids) in wastewater treatment?

Mixed Liquor Suspended Solids, or MLSS, is a measure of the total concentration of

solids in an aeration tank, used in the wastewater treatment process. It is made up
of bacteria, organic substances, and suspended non-biodegradable materials.

Moreover, MLSS is thought to be a mixture of suspended particles and influent

wastewater, which acts as a barometer for the system's biomass.

b. How to check if you are having correct MLSS (3000-5000ppm):

i) Get 1000 ml sample from MBBR tank in 1000ml measuring cylinder.
ii) Leave it for 30 min
iii) Now you will have Sludge Volume Index.

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 c. Use below formula to calculate SVI:

Where,
SVI = Sludge Volume Index, mL/g
SV = Volume of settled solids in one-liter graduated transparent measuring
cylinder after 30 minutes settling period, mL/L
MLSS = Mixed liquor Suspended Solids, ppm, USE 0.3 in above eq.
d. Typically, a healthy sludge aeration MBBR Tank should have the value
registered within 80 to 150 mL/g
Looking at the characteristics of different samples will give you some clues as to
what you can expect from your own system.
- If the SVI is 80 mL/g or less, the sludge will be very dense and will settle rapidly.
- If the SVI is between 100 and 200 mL/g, the sludge will settle a little more slowly,
trapping more particulate matter during the settling process.
- If the SVI is above 250 ml/g, the sludge is very, very slow to settle, and does not
compact well. The result is a light and fluffy texture to the sludge.
3. Once your SVI reaches to 100-120 mL/g, your STP is well set to start regular
operations. If not, continue adding culture and increase quantity of cow dung and
jaggery by 100%.

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 I. COMMISSIONING & TESTING OF TREATED WATER:

1. At section G, as you have attained desired MLSS level, now you can start taking fresh
sewage to the STP system.

2. Remember that MBBR Tank – Tube Setter Tank (TST) – Filter Feed tank (FFT) is
under gravity flow, no pumping system installed for them, so when you start taking
fresh sewage in the MBBR tank, the overflow from MBBR tank shall go to TST and
from TST it will pass to FFT.

3. When your FFT tank is Full, due to High level switch linked with Raw Sewage Pumps,
the pump will cut off, so you need to now ON FILTER FEED PUMPS so that process
can be in continuous operation

4. The FFP 1 / 2 shall suck water from FFT and with pressure it will send to Pressure
Sand Filter, From PSF it will pass to Activated Carbon Filter (ACF) and from ACF the
outlet will be connected to Treated Water tank
REMEMBER: The position of both multiport valves (MPV) installed on PSF and
ACF should be at SERVICE mode, if not rotate handle accordingly and bring it to
SERIVCE
5. When the filter water is passing through PSF and ACF, always monitor Rotameter and
Pressure Gauges
a. The rotameter is the devise installed either at the start of PSF or at then end of
ACF, rotameter helps you to measure and control the plant flow per hour
Example: if the plant is of 20KLD i.e. 1KL/hr then your rotameter should read
1000lit/hr on its transparent reading marking
REMEMBER: When the rotameter turns black/green due to deposition from
inside then remove it through its union connections, clean it and replace
b. The pressure gauge installed at the start of PSF, at the outlet of PSF and at the
outlet of the ACF should have reading between 1 to 2 kg/cm2. This is an
indication that the pressure inside the vessels is correct.
REMEMBER: When the pressure goes aboe 2kg/cm2 that means the media
inside PSF and ACF are choked and requires backwash, even after backwash if

©Agile Venture Page 15 of 35

 the pressure is not coming down that means it requires maintenance or change
of media to avoid vessel cracking/bursting
c. BACKWASH OPERATION:
i. Turn the knob of multiport valve of Pressure Sand Filter (PSF) to
BACKWASH position.
ii. Turn ON Filter Feed Pump and start backwashing PSF.
iii. Once water coming out from PSF is clear, turn the knob to RINSE
position.
iv. Rinse the PSF for 10 min. This will help to settle the media which might
have lifted/shifted during backwash mode.
v. Tun the knob of the MPV of PSF to Service Mode now
vi. Turn the knob of multiport valve of Activated Carbon Filter (ACF) to
BACKWASH position. Water from PSF will flow to ACF from downside
vii. Since ACF is already in backwash mode, water will start coming out
from drain. (Mostly blackish color.)
viii. Once water coming out from ACF is clear, turn the knob to RINSE
position to settle the media level.
ix. After 10 min turn the knob on ACF to SERVICE mode. Water will start
flowing in treated water tank.
REMEMBER: At a time Only 1 vessel should be backwashed.
REMEMBER: Before you operate MPV knob from SERVICE mode to
BACKWASH mode or from BACKWASH mod to RINSE mode, ALWAYS turn-
off Filter Feed Pumps, if the pumps are on and liquid is flowing then it can
damage the MPV to the tune of replacement

6. There is dosing system provided at the outlet line from the ACF, the dosing system
can be chlorine dosing or ozone dosing
a. For Chlorine dosing:
i. Chlorine Dosing system comprised of:
1. Chlorine Dosing Tank (CDT)
2. Chlorine Dosing Pump (CDP)
ii. Mix 1lit pure chlorine in a 100lit water and prepare diluted solution
iii. Add this to CDT till its full, close the lid

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 iv. The CDP installed on the CDT lid is connected to the single phase in
control panel, should be on, this pump will stroke the chlorine dose in
the outlet line from ACF, to mix chlorine in the Treated Water
v. The CDP knob should be set at 50%
vi. Once the tank is empty, the CDP will cut off as its connected with a float
switch, now refill the tank and let the dosing continues
b. For Ozone Dosing:
i. Ozone Dosing system comprised of:
1. Oxygen Concentrator (OC)
2. Ozone Generation Machine (OGM)
3. Venturi
ii. The Ozone system is connected to a single-phase board which is in-turn
connected to the ECP
iii. Once you switch on the OC shall suck oxygen from the air and provide
it to the OGM, and OGM while using O2 convert it to Ozone (O3) and
through venturi it will dose in the outlet water line from ACF.
REMEMBER: Never store treated water for more than 24hrs in the
treated water tank, else foul smelling or bacteria development can start,
including mosquitoes, so always discharge within 24hrs from generation.

7. Once the plant is operation and you are achieving clear water in the treated water
tank, then check the outlet water parameters in a lab, as per CPCB norms the treated
water should have trailing characteristics
Input Output
S/N Parameters Unit
Parameters Parameters
1 pH - 6.0 - 7.0 6.5 – 8.5
2 COD ppm 400 - 500 <100
3 BOD ppm 200 - 300 < 30
4 TSS ppm 200 < 30
5 Oil & Grease ppm 20-30 <5

8. If the above parameters are achieved in the outlet water, then STP is on right track, if
not then one should look into the MLSS level and start from that step

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 9. Water gets collected in the treated water tank which can be used for desired
purposes. (e.g. Gardening, toilet flushing & other non-potable purposes.)

10. Disposal of treated water from the treated water tank is in the scope of client

11. SLUDGE MANAGEMENT:

a. We have provided Sludge Pump/s (SP) with the plant connected to suck sludge
deposited in the drain line of the Tube Settler Tank (TST)
b. The delivery line of sludge pumps are connected to Sludge holding Tank (SHT)
and MBBR Tank for activated sludge recirculation. The line going to MBBR
tank should be only 10% valve open and line going to SHT tank should be 90%
open (there is no indication on the valve, do it as per your acumen)
c. Ideally the sludge pumps should be run for 10-15 mins in 24hrs. In case there
is only liquid flowing to SHT and no much sludge then do not operate the
pump, only operate when you have thick sludge to lift
d. The overflow from the SHT should return to EQT/RST
e. When the SHT is completely filled, evacuate the same with vacuum truck, this
can be used as the best manure in the garden
f. The sludge retuning to MBBR tank is actually acting as food to the activated
bacteria in the MBBR Tank
REMEMBER: Do not flood the sludge inside MBBR tank, it can damage the
developed MLSS, so carefully operate the sludge recirculation valve

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 J. STP OPERATOR RESPONSIBILITIES:
The sewage treatment plant shall be operated by competent, reliable and experienced
personnel who have been trained in the operation of Sewage Treatment Plant.

1. Monitors the operation of the sewage treatment plant process, including

mechanical equipment such as pumps, air blowers, and other equipment;
2. Adjusts controls on sewage treatment plant equipment and machinery such as
valves, motors, pumps and clarifiers to ensure efficient operation of plant
equipment.
3. Assists in training personnel in the proper operation and maintenance of the plant.
4. Makes recommendations on the types and kinds of equipment needed for sewage
water maintenance and repair.
5. Recommends proper sludge handling, maintenance and safety procedures.
6. Reads gauges and other instruments and records data.
7. Cleans equipment, Cleans & adjusts valves & pumps
8. Collects samples and performs laboratory tests
9. Makes necessary calculations to obtain and record accurate test results
10. Preparation of Chlorine, adjustment of dosages.
11. Inspects and make mechanical repairs to plant and pumping & electrical
equipment;
12. Keeps records of plant operations and laboratory tests.
13. Operation of Pressure Sand Filter and Pressure Activated Carbon Filter.
14. Operation and troubleshooting of MBBR Tank

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 K. DAILY PLANT OPERATION:

1. Clean bar screen chamber and oil & grease trap once in a day
2. Give back wash to PSF & ACF at least once in a day. Second backwash should be
given if working pressure raises by 1 kg/cm2 to normal working pressure
3. Check & prepare dosing chemicals if required
4. Maintain MLSS (Mixed Liquor Suspended Solids) level to 3000-5000 ppm for
optimum results
5. Check blower pressure. Needs to be maintained below or equal to 0.4 kg/cm2
6. If the rotating equipments are tripping then check for the correct fault and phase
neutral if getting short
7. In case of emergency, shut down the plant from ECP with its main MCB before
switching off the main power supply

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 L. BLOWER OBSERVATION AND MAINTENANCE:

1. Air Blower: Check oil level in gear box & grease level in bearing side of each air
blower
2. Weekly check & top up oil & grease (with the help of grease gun) if reaches below
required range. Initial oil change: After 15 days (200 hours) of working
3. Regular Oil Change: Oil Should Change in Every Month, oil grade must be 90/320
and top up when oil level blew from the mark
4. Grease should change at every 15 days
5. Blower Noise: Keep check if unusual noise in air blower, which indicates
breakdown of bearing
6. Air Filter Should be clean in every month and replace before 6 months
7. V-Belt Alignment should check every 15 days
8. Prevent from direct sun light and raining water
9. Blower running pressure should be as per mention on name plate
10. Clean air blower’s silencer once in two months

BLOWER TROUBLE SHOOTING

Problem Reason
High Back Pressure ➢ NRV not open properly and its flap is not getting open to
release air.
➢ Bands should be check in pipeline.
➢ Gate valves are not open or partially open.
➢ No of diffusers should be according to air supply.
Blower Choked/Jam ➢ After Commissioning, If blower not run
/used for some months, due to moisture and air, it gets
jam because gap between rotors is in microns.
➢ Suck water from water tank due to incorrect rotation of
the blower. Instead of throwing air it suck water.
➢ Blower runs at very high pressure then it generate heat
and gets jammed.
➢ Filter Should clean
➢ Rusted rotor.

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Abnormal Sounds ➢ The sound can be of motor (all four bolts of foot are not
well tighten, rubbing cover with blades/fan, bearing got
broken)
➢ Belt Guard is not mounted properly and vibrating.
➢ Base frame is not grounded with anchor bolts.
➢ It can be gear sound because running gears without
lubrication.
➢ It can be polythene rapped on Air Filter.
➢ Less lubrication
➢ Quality of oil and grease.
➢ Motor reverse rotation
➢ PRV leakage.
Belt ➢ High Pressure on blower and getting heated
Melting/Slipping/Breakin ➢ Continuous duty without interval (1 working + 1
g
standby)
➢ Week/old belts
➢ Using cracked pulleys
➢ Using out standard/wrong grove/grade v-belts (like
using A grade instead of B)
➢ Using other pulley instead using supplied pulley with
blower
➢ Belt tension is not done properly slipping or too much
tighten
➢ Less no of belts are being used ( like 4 grove pulley but
3 belts)
➢ Belt alignment
➢ Filter choked
Motor Heating/ Tripping ➢ High Pressure on blower
➢ 2 phase supply instead of 3, if motor is of 3 phase
➢ Low voltage
➢ Running on high RPM cause using old/ existing pulley
instead of supplied pulley with blower.
➢ Either belt tension is to much tight or loose
➢ Relay set on below AMP

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 M. PUMP OBSERVATION AND MAINTENANCE:
Daily Check:
➢ Check the pump exterior for any leaks
➢ Clean the pump and nearby region to remove any debris
➢ Check for excessive pump vibration or unusual noises
➢ Check for foaming or oil discoloration
➢ Check the bearing temperature for overheating
➢ Inspect all gaskets to ensure there are no oil leaks
➢ Inspect self-flush pumps if applicable
➢ Clean bearing covers if needed
➢ Check pump cooling system
Monthly Check:
➢ Top up oil to bearing reservoirs if needed
➢ Clean oil bulbs and level windows
➢ Check the pump guards and replace them if needed
➢ Clear out dirt and debris from bearings and grease them
➢ If applicable, check that the hydraulic governors are working properly
➢ Check overall pump systems for leaks and clean the pumping system
surroundings
Quarterly Check:
➢ Check pump and motor for any vibration damage
➢ Grease bearings as per need
➢ Change the oil in bearing systems
➢ Check suction, discharge, and head pressure
➢ Check all hold-down bolts for tightness to reduce vibration
➢ If needed, inspect the shaft pump alignment
➢ Apply rust preventive coat to prevent corrosion
Annual Check:
➢ Check the axial float of the pump along with the driver shaft
➢ Remove the mechanical cover and inspect the entire pump arrangement
➢ Check disc couplings for damage
➢ Inspect coupling alignment
➢ Perform the Overspeed test for the pump

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 ➢ Inspect the seal chamber for scoring and pitting
➢ Check oil levels and refill as needed
➢ Inspect the impeller for erosion and replace it if needed

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 N. GENERAL OPERATION AND MAINTENANCE CONSIDERATIONS:

RAW SEWAGE LIFT PUMPS:

➢ Switch between main and standby pump every 2 hours (Approximately).

➢ Check oil in the pump every day; top up if necessary.
➢ Check motor-to-pump alignment after every dismantling operation.
➢ Check condition of coupling and replace damaged parts immediately.
➢ Check for vibrations and tighten the anchor bolts and other fasteners.
➢ Check conditions of bearings, oil seals, mechanical seal and replace if necessary.
➢ Completely drain out oil and replace afresh as per manufacturer’s
recommendation.
➢ Always keep safety guard in its proper position.
➢ Follow the LOTO (Log Out/Tag Out) safety principles while performing
maintenance activities.
➢ Ensure discharge of raw sewage into the aeration tank is visible and can be
monitored.
➢ Maintain the flow rate at designed level (no tampering with the bypass valve).

SLUDGE RECIRCULATION PUMP:

➢ Considerations here are identical to those specified for the raw sewage lift pumps.
➢ The manufacturer’s O&M manual must be followed with diligence.
➢ Ensure discharge of sludge recirculation into the aeration tank is visible and can
be monitored.
➢ In addition, if an advisable to force-flush the sludge line of the clarifier at frequent
intervals, so that the pipe remains clear at all times and incidence of chocking is
minimized.

FILTER FEED PUMPS (FFP):

➢ Switch between the main and standby pump every 4 hours.

➢ Check oil in the pump every day; top up if necessary.
➢ Check motor-to-pump alignment after every dismantling operation.

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 ➢ Check condition of coupling and replace damaged parts immediately.
➢ Check for vibrations and tighten the anchor bolts and other fasteners.
➢ Check condition of bearings, oil seals, mechanical seal and replace if necessary.
➢ Completely drain out oil and replace afresh as per manufacture’s
recommendation.
➢ Always keep safety guard in its proper position.
➢ Follow the LOTO safety principles while performing maintenance activities.
➢ Ensure discharge of raw sewage into the aeration tank is visible and can be
monitored.
➢ Maintain the flow rate at designed level (no tampering with the bypass valve).
➢ Follow the manufacture’s O&M manual diligently.

PRESSURE SAND FILTER (PSF):

➢ The operations essentially consist of a long filtration run, followed by a short

backwash sequence.
➢ The filter needs backwash when the pressure drop across the filter exceeds 0.5
kg/cm2
➢ However, it is a good practice to backwash once in a shift, irrespective of the actual
amount of pressure loss. A 15 minutes backwash will typically rid the filter of all
accumulated muck.

ACTIVATED CARBON FILTER (ACF):

➢ Just as the PSF, the ACF also needs to be backwashed, albeit at a lesser frequency
to dislodge any solid particles trapped by simple filtration action.
➢ When the carbon gets exhausted (indicated by no improvement in water quality
across the ACF), fresh carbon needs to be filled into the filter.

BAR SCREEN CHAMBER:

➢ Check and clean the bar screen at frequent intervals.

➢ Do not allow solids to overflow/ escape from the screen.
➢ Ensure no large gaps are formed due to corrosion of the screen.
➢ Replace corroded/ unserviceable bar screen immediately.

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OIL AND GREASE/ GRIT TRAP:

➢ Check and clean the bar screen at frequent intervals.

➢ Remove both settled solids (at bottom) and the floating grease.
➢ Do not allow solids to get washed out of the trap.
➢ Do not allow oil and grease to escape the trap.
➢ Redesign the trap if solids and grease escape on a regular basis, despite good
cleaning practices.

EQUILIZATION/RAW SEWAGE TANK:

➢ Keep air mixing on at all times.

➢ Ensure that the air flow/ mixing is uniform over the entire floor of the tank. Adjust
the placement of diffusers and the air-flow rate as needed.
➢ Keep the equalization tank nearly empty before the expected peak load hours
(otherwise it will overflow).
➢ Check and clean clogged diffusers at regular intervals.
➢ Manually evacuate settled muck/ sediments at least once in year.

MBBR TANK:

➢ Operation considerations include maintaining the correct design level of MLSS in

the aeration tank. Problems arise both in the case of excess or shortage of biomass,
causing an imbalance, leading to failure of the process. The next chapter shows
how to maintain the correct design level of MLSS the aeration tank.
➢ Visual observation will indicate if there is uniform aeration and mixing over the
entire area of the tank. Local violent boiling / bubbling is indicative of ruptured
membranes. Dead zone on the sewage surface indicate that membranes are
blocked from the air side or the liquid side. Both conditions call for immediate
attention, by cleaning or replacing the membranes.
➢ Cleaning of membranes is generally carried out by lifting out the defective units
and scouring out the adhering materials by high- pressure hosing. Scrubbing with
mild acid solution may also be resorted to in case of stubborn encrustation.
➢ Foaming in the aeration tank may be caused by excessive inflow of detergent like
substances in a great majority of cases, the cause may be traced to an imbalance

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 in the tank recipe (Food: Microorganisms: Air: Nutrients), and corrective
measures may be taken as indicated.

TUBE SETTLER TANK:

➢ If properly designed, engineered and constructed, clarifiers call for the very little
attention in terms unmechanized (hopper – bottom) settling tanks may be said to
be zero- maintenance units. Some parts of the mechanical rake (such as the motor,
gearbox etc.) call for only routine maintenance.
➢ The sacrificial rubber squeegees sweeping the floor of the clarifier need to be
checked and replaced, possibly once in two years.

DISINFECTION OF TREATED WATER:

➢ FOR CHLORINATION
o Prepare fresh Hypo solutions every day in the day tank.
o Shelf life of over 2 months is not recommended, especially during summer.
o Store Hypo in a cool place.
o Study material safety data sheets of Hypo and follow instructions.
o Periodically check available Chlorine strength of Hypo.
o Check and record Residual Chlorine concentration every day.
➢ FOR OZONE
o Maintain the continuous injection in the line after ACF.
o No need to do any other thing than monitoring if its working ok or not.

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 O. DATA RECORDING AND SAFETY:

DATA RECORDING & SAFETY

The regular recording to operating parameters and other information serves many
purposes. Records are needed for the following reasons;
1. Efficiency of Plant and its treatment units
2. Process malfunction
3. The success of plant process adjustments
4. Necessary adjustments to the treatment processes required because of raw
water changes due to the treatment processes required because of raw water
changesdue to seasonal or environmental conditions, and past problems.
OPERATION LOGS:
They are divided into the following groups:
1. Daily routine jobs & Checklist.
2. Daily, weekly or Monthly data record sheets.
3. Plant data information.
DATA RECORD SHEETS:
These are used for recording of process parameters such as flows, running hours,
tank levels, test data, etc. Daily, weekly or monthly analysis (both from field tests
and laboratory tests) shall be recorded.
Readings of instrument data (both panel and field mounted) shall not be recorded
on the same sheets as data from laboratory analysis (tests).
SAFETY
The plant personnel may be exposed to the following hazardous conditions:
1) Physical Injuries- Injury can be caused by rotating equipment such as
pumps, blowers and fans. Falling from or into tanks and elevated platforms.
These can be avoided by use of ladders, handrails, hard hats etc.
2) Chemical Burns- An emergency shower and eye wash should be located at
the plant for washing out hazardous chemicals of the skin and eyes.
Neutralizing solutions, proper equipment and clothing should be available
for safety reasons.
1) Oxygen Deficiency- Oxygen deficiency may occur in closed unventilated

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 vessels. Make sure fans or blowers are on when you inspect the vessel.
2) Toxic or suffocating Gases or Vapors – These come from chemicals used
in treatment processes and chlorine is particularly a hazardous gas and all
personnelshould be trained in ways to handle it and should be trained in the
use of self- contained breathing apparatus.
3) Fire- Burns from fire can cause very serious injury. Avoid accumulation of
flammable material and store any material of this type in approved
containers at proper locations. Note the location of fire fighting equipment.
4) Electrical Shock- Electrical shock causes serious injury. Do not attempt to
repair electrical equipment. Call an electrical repair technician.
5) Noise- Loud noise from blowers can cause permanent ear damage.
Personnel needto wear proper ear protecting devices whenever working in
noisy area
6) Specific Hazards-
a) Pressure Tanks and Piping: Always wear a hard-hat when working in areas
with low overhead piping to minimize injuries like bumps and bruises
resulting from into and tripping over valves and piping. While repairing and
inspecting inside the filter there is always hazard of insufficient oxygen.
Therefore, ventilate the filter with air before going into work and continue
ventilating the filter until you left it.
b) Chlorine: As chlorine is extensively used and is very active gas it can cause
potential harm to Eyes, Skin throat etc. In case the chemical is splashed into
eyes the patient should be laid down and his eyes should be flushed with
water or boricsaline solution. If chlorine pours down on the skin the patient
should be placed under shower after removing his clothes and skin should
be washed with larger amount of soap & water. In case it is inhaled the
patient should be allowed to lay down in comfortable position and his body
should be kept warm. Artificial respiration can also be given if necessary.
Drinking milk will comfort the patient incase there is throat irritation.
c) Atmospheric Tank Atmospheric Tank: The biggest hazard involved in
working in Atmospheric tank is the danger of slipping. Therefore, maintain
a good non-skid surface on all stairs, ladders & platforms. Railing should be
installed along the tank side of all stairways and platforms. Be cautious

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 while working inside it.
d) Pumps and Blowers: Always turn off, lock out, and tag pumps and blowers
beforeworking on them. Always be aware while working.

PRECAUTIONS
1) Never operate Multi-port valve while the pump is in operation. This will
damage the valve permanently.
2) Filters must be regularly back washed preferably once in a shift. The
period can be adjusted by experience after few weeks of operation
depending upon the suspendedmatter deposited. Regular backwash will
optimize the life of filter media
3) Aeration must not be stopped as a rule. Irregular aeration will affect the
biological process.
4) Preventive Maintenance for Motors: Motor should be kept clean and free
from oil, dust and moisture. Care should be taken to see that ventilation
passages are not blocked. The earthing conductor should be regularly
inspected and checked forcontinuity. The insulation resistance of stator
and rotor windings should be checked regularly between respective
terminals and the frame.

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 P. PROCESS TROUBLESHOOTING:
The process troubleshooting includes trailing thins:

Aeration Problem
A. Low DO and /or septic odors in mixed liquor
S/N Possible Causes Necessary Checks & possible corrective actions
1 Under Aeration - Check DO, should be in range 1.0 to 2.0 mg/L throughout in
the tank.
2. MLSS too high - Check Return Sludge Rate, Adjust MLSS by decreasing sludge
recycle rate to lower MLSS.
- MLSS to be maintained between the range of 3500-4000.

B) Excessive aeration needed although no apparent change in organic or hydraulic loading.

Difficult to maintain adequate DO-Level.
S/N Possible Causes Necessary Checks & possible corrective actions
1 Insufficient or inadequate Check air distribution uniformity of air distribution by air
oxygen transfer. blowers through air diffusers in aeration tank.
2 High organic loadings Check if organic loading in flows contributes significantly to
(BOD,COD, suspended overall process loading.
matter Internal
overloading)

Note:
Sewage water normally contains soap, detergents and other surfactants that produce foam when
the wastewater is being aerated. Large quantities of foam may be produced during startup of the
process when surfactants are present in the wastewater. The foaming action produces a froth that
contains sludge solids, grease, and large numbers of Sewage water bacteria. The froth might be
unsightly and is slippery and a hazard for plant personnel.
It is important to control froth formation. It can be done by spraying water on it through spray
nozzles to break it up or add a small quantity of antifoaming chemical into inlet of aeration tank or
into spray water.

Low oxygen uptake in Aeration Tank

S/N Possible Causes Necessary Checks & possible corrective actions

1 Cold Temperature -Decrease Process temperature can result in decreased
oxygen utilization.
-Increase MLSS to maintain organic removal.
2 pH out of Range -Eliminate source of pH upset
-Adjust pH in Aeration Tank to between 6.5 & 8.5
3. Spill -Eliminate source of spill
4 Low Organic Loading Check effluent quality. Adjust MLSS to maintain F/M ratio if
Effluent quality has decreased.

Floating Sludge in Secondary Settling Tank.

S/N Possible Causes Necessary Checks & possible corrective actions

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 1 Anaerobic Activity -Increase Dissolved oxygen level in Aeration Tank.
-Increase sludge return rate to lower sludge retention time in
settlement Tank.
2 Foam Floatation -Apply antifoam Chemicals to SAFF Reactor.

Bulking Sludge
A bulking sludge is one that has poor settling characteristics and poor compactability. Two
principal types of sludge-bulking problems have been identified. One is caused by growth of
filamentous organisms or organisms that can grow under adverse conditions.
This is a predominant form of bulking. The other is caused by bound water, in which bacterial cells
composing the flock swell through addition of water to the extent that their density is reduced and
will not settle. The causes of sludge –bulking that are most commonly known are-
1. The physical and chemical characteristics of the wastewater
2. Plant operation.
S/N Possible Causes Necessary Checks & possible corrective actions
1 Nutrient Check the nutrient ratio. BOD: N:P (100:5:1)
Deficiencies, Low Chlorination to return sludge 1-2 ppm/2-3 Kg/1000 kg MLSS
DO, pH Variation Add settling aid (Polyelectrolyte 2 – 5 ppm)
Maintain DO 1 – 2 mg/lit
Maintain pH 6.5 – 8.0 if low pH add alkaline agent & high Ph
add acidic agent.
Check if process is nitrifying due to high wastewater
temperature or low F/M
If nitrification is not required, increase sludge wasting rate by
not more than 20 % per day to stop nitrification.
If nitrification is not required, raise pH by adding an alkaline
agent to the MBBR reactor.

Operational Problems
S/N DEFECT CAUSE REMEDY
1 Treated water quality not a) Filter not backwashed Regularly backwash the filter.
up to the Standard b) Inlet s.s increased Check raw water quality
c) Excessive flow rate Check & ensure pressure
d) Channeling Check & ensure proper
Segregated media layers.
e) Disturbed media
2 Backwash frequency a) Inlet suspended solids load Check raw water quality
required is high increased
3 Unit Rinse takes long time a) Low flow rate Adjust the flow to normal
b) Improper backwash Give proper backwash
4 Pressure drop across bed is a) Insufficient Backwash filter properly
increasing backwash Check raw water quality
Backwash filter frequently

E.6. Precautions
S/N Unit Name Precautions Period

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1 Tube Settler 1. Sludge should be pumped As Required
out
2 Filer Feed Tank 1. Cleaning of the whole tank Half yearly
(Tube Settler Tank,
Supernatant Tank) Or as per requirement.
3 Pressure Sand Filter (PSF) 1. Backwashing of PSF. 1. Daily
2. Replacing the filter media 2. After one Year
or as per requirement
4 Activated Carbon Filter 1. Backwashing of ACF. 1. Daily
(ACF) 2. Replacing the filter media 2. After Six Months.
or as per requirement.
5 Pumps Pumps should not be run dry. Daily
Check the water level in the
tanks before starting the
pump.
6 Panel Board While shutting down the Daily
plant, all the MCB’s and the
power switch
should be switched OFF

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 Q. GALLARY:
Pls refer few photos as attached below:

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