SOPs on Operation & Maintainance of CETP

1. SOPs on Operation & Maintainance of CETP

2. Staff Requirement Plant Manager : individual with environmental engineering or science background with experience of at least three years on similar plant(s). He must have thorough understanding of unit operations and application of microbiology and environmental chemistry in the effluent/ sewage treatment. He should be well versed in working out dosages of chemicals and nutrients based on the raw effluent quality and change it as the treatment progresses and results start forthcoming. As CETP Manager, he should prepare a weekly roster of duties for each individual and broadly lay down in writing the duties and responsibilities of each category of staff. He should understand and be able to plan a forecast and use of chemicals / nutrients for the plant operations and the laboratory. He should be able to take decisions to divert/bypass/distribute the flow in the event of breakdown of electrical or mechanical equipments until repairs/replacements are successfully carried out.

3. Plant Operators : A team of qualified / trained operators who work in shifts in operating and maintaining screens, grit removal devices, pumps, aerators, valves etc. in directing the effluent and settled sludge to various units for / after treatment. They should also assist the electrical/mechanical maintainance technicians in carrying out the preventive and breakdown maintainance tasks. They should be able to sense troubles. Electrical/Mechanical Technicians : A team of qualified maintainance technicians with the ability and experience of diagnosing health of equipments & motors. Their main aim is preventive maintainance, assigning causes and reasons of faults and ultimate failure. Able to quickly carrying out minor repairs/replacements by reaching, removing, repairing, assembling of routine electrical and mechanical machines/equipments including piping and valves.

4. Laboratory Analyst (s) : A qualified individual who has knowledge of water and wastewater chemistry. Must be trained in preparing laboratory chemicals, use of laboratory instruments. Collection and preservation of wastewater samples and analysis of various environmental parameters like pH, SS, BOD, COD, TDS etc. Should be able to draw an Analyzer program for collection & analysis of daily, weekly, monthly samples and report results as per time schedule. Able to undertake performance studies from time to time. Be responsive and prepared to undertake additional responsibility of the plant manager. Report deficiencies in treatment as shown by effluent quality analysed at the laboratory. Labours/Helpers : These persons are required to assist the operators/technicians/analysts for maintainance of various units, structures, areas, floors, rooms, equipments etc. They are used for good housekeeping, loading & unloading of chemical dosing, Filter press operations, removal, loading, carriages of wastes.

5. Operational Aspects Designing of CETPs: Basis of designing depends on treatability studies of incoming effluents, type of industries, no. of industries, exact quantity of effluent generation by industries, raw material used by industries for their production Performance: Performance of CETP mainly depends on quality of incoming effluent. To control the incoming quality of effluent, separate sampling points of each industry is very necessary. Every industries strictly follow the consent conditions of SPCBs. Special Treatment Section : If majority of industries are chemical based or steel producing, then there is a necessity of STS plant to deal with the toxic elements in the effluent. Treatability studies : Plant manager conduct the treatability studies by directing lab analyst on routine basis. After conducting these studies, plant manager fix the shift wise chemical dosing. One lab analyst in each shift is the basic requirement.

6. Unit wise monitoring : Unit wise routine sampling and analysis is very necessary to improve the performance of CETP. This is important to minimize the operational gaps and find out the solutions for better and better treatment and smooth running of the CETPs. Laboratory set up: Well equipped laboratory facilities having sophisticated instruments and trained analysts to carry out the treatability studies on incoming effluent is a basic requirement of every CETP for examine the input and finding out the better solution for treatment. Primary Treatment: After fixing shift wise dosing, it is duty of the shift operators, that dosing should not be stopped at any instance. Drain of Chemical sludge as and when possible is very important factor to avoid the disturbance to biological system. The chemical slurry feed to Filter press must be regular practice. Regular cleaning and replacement of filter press cloths are also important aspects.

7. Biological System: To maintain the requisite level of MLSS, MLVSS & DO is the prime responsibility of every CETP operators. Plant manager should arrange the required nutrient dosing depending on F/M ratio, cow dung, biomass, jaggary etc. Tertiary Treatment: Shift wise regular back wash of the Filters are very important, to control the outlet parameters specified by SPCBs. If this does not happens, all the efforts made at primary and secondary stages of treatment are wastage. Replacement of filter media in regular interval is most important factor. Hazardous Waste Disposal: Proper handling, storage and transportation of hazardous sludge/waste generated are also the major issues of concern. Care must be taken to avoid any type of spillage or leakage of the Hazardous waste leachate during handling and transportation to TSDF. Personnel safety: Every technician, operator, labour must have safety measures like hand gloves, nose masks, safety goggles, gum boots, safety shoes during handling of industrial effluent as well as hazardous wastes

8. MaintainanceAspects Pumps and motors: Routine check up of every pumps and motors installed in plant in terms of oiling/greasing, pump alignment, checking current is major responsibility of every technician and operators of the plant. Calibration of Instruments: Quarterly/half yearly/yearly calibration of every instrument in laboratory or plant depending on their type and usage to improve the performance is major maintainance aspect. Tank Cleaning: Tank cleaning in every six months is very important, to remove the settled sludge at the bottom of the tanks which ultimately disturbs the performance of the CETP. Maintaining the Power Factor: Power factor with in the range of 0.9 to 1.0 must be maintained by the operators. To do so every mechanical operator must be communicate with electrical operator after start/stop of any pump or machinery.

9. Cleaning/ replacement of diffusers: Proper attention towards the working of diffusers is very important. Quarterly cleaning and replacement as and when required is necessary to improve the performance. Replacement of Filter Media: Filter media must be replaced after checking the Iodine value of Activated carbon twice in a year, if it reduce below 150 mg/gm of carbon. As the replacement of filter media is a time consuming process, other media like Silica Quartz Sand (SQS), gravels, pebbles may also be replaced with Activated Carbon. Records Keeping: Keeping the records of each and every activity with in the plant is most important including laboratory reports, flow data, maintainance history cards, purchasing of any products, oil & grease checklist, tank cleaning record, diffusers cleaning/replacement record, filter media replacement records etc. Training & Health Check up: Yearly training to staff members on each aspects of plant is very necessary. Yearly check up of staff members is also necessary.

10. Dos and Don'ts in CETP O&M • Obey all safety instructions regarding storage, transport, handling or pouring of chemicals • Wear personal protective equipment and chemical resistant clothing to avoid exposure of skin or eyes to corrosive and/or polluted solids, liquids, gases or vapours. • Check electrical equipment for safety before use, verify that all electrical cables are properly insulated. • Learn and use safe lifting and moving techniques for heavy loads such as containers of chemicals, use mechanical aids to assist in lifting. • Do not smoke, eat or drink in areas where chemical or biological contamination may be expected. • All workers should undergo periodic examination by occupational physician to reveal early symptoms of possible chronic effects or allergies.

11. THANK …. YOU ….