Sample OM Manual
Sample OM Manual
PLANT HERE
ADDRESS
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1.0 Emergency / Vendor Contact Information
E-mail : info@ecosystem-sbr.com
Website : www.ecosystem-sbr.com
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2.0 System Description
The Sequencing Batch Reactor (SBR) System provided in this project is designed to operate
as a fill and draw system wherein a predetermined batch volume of wastewater is fed to the
reactor for treatment prior to discharge. Organic loading removal, “biomass” separation and
effluent withdrawal is carried out sequentially in one single basin, through a cyclic operation of
the process equipment.
The SBR System operates on the principle that the microorganism contained in the
wastewater agglomerate to form a biomass, which feeds on particulate and soluble substrates.
The substrates consisting primarily of carbonaceous BOD, phosphorus and ammonia,
represent an energy source for biomass. The use of these substrates by the biomass allows
the treated sewage water to meet government regulation on effluent standards.
The new sewage treatment system consists of One (1) Manual Bar Screen; One (1)
Equalization tank; Two (2) Sequencing Batch Reactor; One (1) Aerobic Sludge Digester Tank,
One (1) Chlorine Contact Tank/Effluent well
BAR SCREEN
Raw sewage which contains large objects over than ½ inch will be removed by screening. A
rake shall be provided for cleaning purposes. The bar screen shall be made of stainless steel
materials.
EQUALIZATION TANK
The sewage will flow by gravity from the screen to the equalization tank. The equalization tank
is also provided with two (2) transfer pumps, acting on duty and standby, to pump sewage to
the next tank, the sequencing batch reactor.
The ESTI – sequence bio reactor process is the most advanced and most effective biological
process today. It is a waste treatment system that operates by “TRUE” batch and allows large
number of suspended microorganisms to biodegrade the organic matter and converts them to
useful and stable gasses such as carbon dioxide, nitrogen and water under various conditions
i.e. aerobic, anoxic and anaerobic. It combined carbon oxidation, nitrification and denitrification
processes in the same reactor ensuring complete biological treatment of waste water and
preventing odor problem.
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The different modes of operation in the “true batch” sequencing batch reactor are FILL,
REACT, SETTLE, DECANT and IDLE. No influent is allowed to flow into the reactor during the
settle and decant stage. The automated operation of the biological process allows organic
pollutants to undergo a complete reaction cycle, from aerobic oxidation to anaerobic
degradation. The SBR uses less equipment and minimal operator’s supervision.
The SBR reactors shall be installed to provide the biological treatment carbonaceous
substances of the waste. The aeration to the SBR shall be by air diffusion using positive
displacement air blower(s) and stainless steel 304 AIREOMIX non clog stainless steel cyclone
diffusers.
Biologically treated sewage from the SBR will be disinfected using sodium hypochlorite
solution before being pumped out in the effluent wet well to nearby drainage line. Sodium
hypochlorite solution will feed using chlorine dosing pump.
The waste sludge is pumped from each SBR to the aerobic sludge digester. The digester is
provided with aeration system attached to air diffusers. After digestion, the volume of volatile
suspended solids (digested sludge) is expected to be reduced/oxidized to stable forms by
about 40 to 50%. Stabilized sludge shall be disposed offsite as soil conditioner
The operation of the equipment as well as sequence control will be carried out by
programmable logic controller (PLC) placed in NEMA enclosure control panel. This PLC will
detect and signal any equipment operation and failure, and will automatically take action, so
that the system may resume operation using the remaining basins/equipment as programmed
in the PLC. The unit control of each equipment is also provided with independent auto/manual
controller.
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1.1 Process Design Control Parameters and Specifications
The sewage treatment plant, SBR system is designed to treat raw sewage generated from the
operation and various uses of the AMETTA PLACE Building. The system is designed on the
basis of the following parameters as stated in the bid documents.
ESTI guarantees that the STP effluent quality will meet DENR standards.
Parameter Unit DENR Set standards for “Class C”
Inland Water
Biochemical Oxygen Demand, BOD5 mg/L Less than 50
pH 6.5 – 8.5
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3.0 System Operation
The Sequencing Batch Reactor (SBR) Process Technology operates on the following stages:
1 – Filling
2 - React Fill
3 – React / Mixing
4 – Sludge Withdrawal
5 – Settle
6 – Decant
At the beginning of the process cycle, the SBR is at minimum bottom water level (BWL) and
influent transfer pump(s) will start to transfer raw sewage water from influent tank to SBR as
“Static Fill” stage start. During “static fill” stage only the influent pump is in operation. The next
stage is the “React fill” where the final filling of the SBR is completed. During this “React Fill”
stage, the blower(s) designated to the SBR starts to operate and supply oxygen to the SBR.
Oxygen in air is diffused through air diffuser at the bottom of the tank. The influent transfer
pump stops when the water level reaches predetermined top water level (TWL) and or “React
Fill” period elapsed. “React” period commences after “React Fill” is completed. As sludge level
starts to increase or has exceeded desired level, “Sludge Withdrawal” or “Sludge Wasting” is
initiated manually during later part of “React” period. The time of wasting is adjusted according
to desired sludge volume. The operation of sludge wasting is dependent on the biomass
condition, incoming wastewater characteristics and flows. Thus, operation of waste sludge
pump is undertaken manually.
Waste activated sludge is pumped to the aerobic digester tank for final digestion and
stabilization. The waste activated sludge from aerobic digester is intermittently supplied with
air automatically coming from the digester blower through the air diffuser located at the bottom
of the digester tank. This process is used to stabilize waste sludge from the reactor.
When “React” period is over, aeration and mixing is terminated and the SBR aeration blower
shuts off signaling the start of the “Settling” stage. During Settling period, “quiescent”
separation of biomass and treated sewage water takes place. No internal movement or
continuous entry of raw sewage into the reactor take place and the biomass settles at the
bottom of SBR basin leaving clear supernatant on top. After the Settling period, “Decant”
stage is initiated. During “decant” period, the supernatant (treated water/effluent) is withdrawn
from suspension and discharge to the Chlorine contact tank. The decant period will stops
when the water level at SBR tank reaches the bottom water level (BWL) and the reactor is now
ready to receive another batch of wastewater and the process stages is repeated.
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and characteristics and set during the commissioning stage. This provides disinfection of the
effluent wastewater prior to the discharge of the effluent to the main sewer line.
START – UP PROCEDURE
Once all the equipment has been installed and checked according to Manufacturers
instructions, the STP plant is ready for start-up and shall be operated on the procedures:
MANUAL OPERATION
4. Put the influent transfer pump 1 circuit breaker into “ON” position and start by switching
their selector switch to “HAND” position to start filling the SBR Tank with wastewater.
5. Wait until the wastewater level reaches approximately one (1) meter from the bottom of
the tank and put the SBR Blower circuit Blower to “ON” position and start the SBR blower
by switching the selector blower to “HAND” position.
6. Observe the volume of incoming wastewater from the influent tank and switch the pump
selector to “OFF” and “HAND” position occasionally.
7. After the react fill period (Top Water Level is reached) switch the influent transfer pump to
“OFF” position. Allow the system to complete the treatment until react period elapsed. The
TWL is set at 4.50 to 5.0 m from bottom of tank. The final setting is dependent on
incoming flow.
8. After the react period switch the blower selector to “OFF”. Settling period starts at this point.
Allow complete separation of biomass and treated wastewater.
9. After the settling period switch the decanter selector switch to “HAND” position to discharge
treated wastewater and switch “OFF” after one (1) minute.
10. Check the Settleable “biomass” solids concentration after one to two weeks of operation. A
1000 ml graduated cylinder is provided to monitor sludge level in the reactor.
To check the biomass concentration in the reactor, a sample volume is taken out of the reactor, and
poured in the graduated cylinder. Allow the biomass to settle for 30 mins. Read from graduated cylinder
the sludge level and record.
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11. When the Settleable Solids reaches the 400 to 500 ml as observed from a graduated
cylinder, switch the waste activated sludge pump selector to “HAND” position during react
Period. Suggested time for wasting of sludge is 10 min. per day until desired sludge level
is achieved. Continuously monitor settleable solids using the graduated cylinder.
AUTOMATIC OPERATION
3. Put the Influent pump, SBR Blowers, Decanter, Effluent Pump, Chlorine Dosing Pump,
selector switch to “AUTO” position.
4. Switch on the PLC to start the automatic operation of the system. The influent transfer
pump will start filling the SBR Tank with wastewater.
5. Check the Settleable “biomass” solids concentration after one to two weeks of operation.
A 1000 ml graduated cylinder is provided to monitor sludge level in the reactor.
To check the biomass concentration in the reactor, a sample volume is taken out of the reactor, and
poured in the graduated cylinder. Allow the biomass to settle for 30 mins. Read from graduated cylinder
the sludge level and record.
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4.0 System Maintenance
4.1 Process Control Measure
The STP is a treatment process and not a depository of any or minute amount of unwanted
impurities that could alter the chemical and biological processes.
All design parameters of the incoming wastewater must be strictly followed at all times.
To maintain an effective treatment process the following suggested maintenance task must be
part of the daily routine of the person in-charge of the facility.
The assigned Pollution Control Officer shall be responsible for the elimination of possible
excessive sources of oil and grease or excessive use of chemicals (HCL Acid, Chlorine)
arising from the building maintenance activities.
Check and removed all floating solids and oil and grease in the surface
Equalization tank of the tank.
Check operation daily and conduct quarterly cleaning of transfer
pumps.
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Suggested Process Trouble Shooting Guide
Sludge bulking Toxic chemicals present Check for sources of toxic chemicals
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4.2 Process Equipment Maintenance
3. Conduct daily, weekly and monthly monitoring report on the status of all equipment.
4. Authorized and trained operators only shall have access to the plant room and to operate
the STP.
6. All equipment repair activities shall be recorded and shall have the following information:
All equipment installed should be periodically checked and maintained to ensure efficient
system operation and to prolong the service life of the equipment.
Repairs and periodic maintenance, replacement of sensitive parts for blowers, pumps and
other equipment that would require the dismantling of entire assemblies must be carried out by
supplier and or manufacturer authorized personnel within the warranty period of the
equipment. At the end of the warranty period, only competent and or trained personnel shall
conduct major repairs on all the equipment.
1. Piping
Check open valves and make sure that no pressure is being lost from them.
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Be sure that all discharge side valves are fully open during equipment operation.
2. Power Supply
Check all electrical connection for any loose connection from motor to control
Conduct daily monitoring of all equipment in service for voltage and current.
Caution:
Do not operate any voltage other than the regulation voltage.
Operation at incorrect voltages can lead to fires or electric shocks.
Put the selector switch to “OFF” position and the power supply must be cut when carrying
out a manual operation check. Take care that fingers etc. are not caught up in the V-belt or
pulley.
Rotate the blower pulley by hand and confirm that there are no problems with any internal
components.
If foreign objects have somehow entered the machine, the pulley will not rotate, there will
be resistance to motion or there may be sensation of grinding.
In any of these cases, disconnect piping, inspect and clean the internals.
The rotation should be counter clockwise when viewed from the pulley side. Make sure it is
in the direction of the arrow.
Check and inspect the air vents on the motor. Remove any obstruction or dirt accumulation.
Always make sure that this air vents are always clean every time the blower operates.
Warning
A belt cover must be in place when operating this machinery.
Failure to do so will expose a risk of objects being pulled in
by rotating components, and this is in return could possibly result in injury.
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4. Setting the Safety Valve
Caution:
The safety valve should be adjusted before carrying out regular operations.
Gradually tighten the discharge side valve and increase pressure to about 10% above the
set level.
Next, loosen the lock nut and loosen the adjusting bolt until air starts to be blown out from
the safety valve.
Re-tighten the lock nut. Use a spanner or another similar tool while tightening the lock nut
to hold the adjusting bolt in its new set position.
Once again, start to gradually tighten the discharge side valve to confirm the safety valve
actually operates.
When this setting has been completed, fully open the discharge side valve.
Caution
The purpose of the safety valve is to protect the blower, and it must not be used to adjust
the air volume. If air is allowed to be discharged from this valve during a regular operation,
it may possibly be damaged. Also, because air discharge from the air valve may be very
hot, do not use hands or fingers to check whether it is leaking air.
5. Lubrication
While the blower is stopped, confirm the oil level line on the gear cover is in the middle of
the oil level gauge. Change oil should be carried out every three months.
Gear oil change Procedure:
The bearing grease employed must be heat-resisting grease. The specified grease should
be added at least once every three months.
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6. Noise
It is possible that there will be a generation of noise immediately after start up due to the viscosity of the
lubrication oil. However, this should disappear after 10 to 20 seconds. Also, different pipe sizes can
cause small differences in sound levels even in blowers of the same type.
Pay attention to any abnormalities (in sound, pressure, current, temperature etc.) that occur during
operation. If such an abnormality should occur, immediately stop the machine and investigate its cause.
Failure to do so could result in serous damage being done.
Check whether discharge pressure and current levels are below those noted on the face plate.
Make sure that the cock on the pressure gauge is closed when it is not actually being
used to perform a pressure measurement.
If the current level exceeds the motor’s rated current level, possible causes could be a
restriction at the suction/discharge ends or reverse rotation. Stop the machine and confirm where
the problem lies.
Always conduct current and voltage reading daily. If there is any change in current reading, check the
suction side of the pump by lifting pumps and perform necessary inspection for any solid material i.e.,
plastics etc., clean the suction side by spraying clean water.
The chemical dosing pump for this project requires very little maintenance. However, the pump and all
accessories should be checked regularly.
Check suction and discharge tubing for any signs of cracking, discoloration.
Replace worn out or damaged tubing immediately.
Clean suction strainer weekly.
Check and clean air vents located at the back of the motor compartment and under the pump head.
Clean and removed any obstruction.
Maintain sufficient Chemical Solution level in the chemical tank.
Do not operate pump when there is no sufficient chlorine solution.
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4.2.2 Summary of Maintenance, Inspection, Lubrication Schedule
Inspection
Cycle
D Q Y T F
a u e w o
i a a o u
l r r r
Inspection Parameters y t l y y Remarks
e y e e
r a a
l r r
y s s
A. Blower With Electric Motor
Drive
Valve condition Fully open
Gear oil Level Middle of Level gauge(while stopped),cleanliness
Pressure Below face plate value
Current Below rated current
Noise There should be no strange noise
Vibration There should be no abnormal vibration
Temperature There should be no abnormalities in suction air, blower
surface or motor surface temperature.
Safety Valve Confirm with discharge side vale operation
Motor Insulation Resistance At least above 2 Mega Ohms
Tightness of all connection points Blower, piping etc.
V-Belt Tension-Condition Re-tension if sagging
V-Belt Replacement As required
Bearing Grease supply Replenishment of specified grease
Gear Bearing Smoothness Check looseness by manual operation
Gear Oil Change Complete oil change or as required
Cleaning of Suction filter As required
Bearing oil seal replacement
B. Submersible Pumps
Current
Voltage
Flow
Insulation Resistance At least above 2 Mega Ohms
Noise
C. Chemical Dosing Pump
Suction Tubing
Suction tubing replacement
Discharge tubing
Discharge tubing replacement
Flow
Noise
Strange noise or Contact between internal components Carry out inspection of internal components
vibrations
Pressure abnormality Removed source of pressure abnormality
Too much oil added Adjust to the middle of the level gauge while
blower is stopped
Oil Leakage Looseness in the fixing area Tighten the loose component
B. Submersible Pump
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Trouble Cause Remedies
Circuit open Check circuit line voltage
Locked impeller or clogged with rags Clean up & remove trapped materials
or other material
Insufficient water Pipe broken or leakage Repair
flow
Low power voltage Check power voltage, wires and cable
condition
Reverse running Change one phase with the phase of the
power line
Bearing worn out Replace new one
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C. Dosing Pumps
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5.0 Equipment Schedule