maintenance manual for 240 kld glass fibre industry
TRANSCRIPT
1
MAINTENANCE MANUAL
FOR 150 KLD
EFFLUENT TREATMENT PLANT
OF
AN GLASS FIBRE INDUSTRTY
2
INDEX
PAGE NOS.
1. TECHNICAL SPECIFICATIONS 3-23
2. PREVENTIVE MAINTENANCE 24-26
3. EQUIPMENT MANUALS
3
4
TECHNICALTECHNICALTECHNICALTECHNICAL
SPECIFICATIONSSPECIFICATIONSSPECIFICATIONSSPECIFICATIONS
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1.0 UNITS & EQUIPMENT FOR ETP
1.1. CIVIL UNITS
Sr. No.
Particulars
Quantity
1 Bar Screen Chamber One No.
2 Surge Tank One No.
3 CSM Holding Tank One No.
4 Equalization Tank One No.
5 Flash Mixer Tank One No.
6 Primary Clarifier One No.
7 Bio-Tower One No.
8 Aeration Tank One No.
9 Secondary Clarifier One No.
10 Sludge Collection Tank One No.
11 Chlorine Contact Tank One No.
12 Electrical Control Panel Room & Laboratory Room One No.
13 Foundations for Mechanical Equipments Lot
6
1.2 MECHANICAL UNITS / EQUIPMENTS
Sr. No.
Particulars
Quantity
1. Screen ( 1W + 1Sb) Two Nos.
2. Surge Effluent Transfer Pump ( 1W + 1Sb) Two Nos.
3. Floating Agitators Two Nos.
4. CSM Effluent Transfer Pump ( 1W + 1Sb) Two Nos.
5. Raw Effluent Feed Pump ( 1W + 1Sb) Two Nos.
6. Flash Mixer One No.
7. Chemical Dosing Systems Seven Nos.
8. Primary Clarifier Mechanism One No.
9. Sludge Withdrawal Pump ( 1W + 1Sb) Two Nos.
10. Bio-fills 47 cu. mt.
11. Bio-Tower Distribution Sprinklers One Set
12. Bio-Tower Recirculation Pump ( 1W + 1Sb) Two Nos.
13. Air Blower ( 1W + 1Sb) Two Nos.
14. Air Diffusers 14 nos.
15. Secondary Clarifier Mechanism One No.
16. Bio-Sludge Recycling Pump ( 1W + 1Sb) Two Nos.
17. Filter Press One No.
18. Pressure Pump( 1W + 1Sb) Two Nos.
19. Duel Media Filter One No.
20. Activated Carbon Filter One No.
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1.3 PIPING & FITTINGS
Sr. No.
Particulars
Quantity
1. Interconnecting Piping between ETP
units with all necessary Valves & other fittings.
Lot
1.4 ELECTRICAL WORKS
Sr. No.
Particulars
Quantity
1. Electrical Panel board One No.
2. Remote Push Button Stations supply Lot
3. Electrical cabling from control panel to
units of Effluent treatment plant
Lot
4. Earthing Lot
1.5 INSTRUMENTATION
Sr. No.
Particulars
Quantity
1. Liquid Flow Meter with Totaliser Two Nos.
2. pH Controller System One No.
3. Pressure Gauges Twelve Nos.
4. Level Switches Four Nos.
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2.0 MECHANICAL UNITS
I) SCREEN
Application : Screening floatable solids
Location : At Screen Chamber
Type : Manual mesh screen
Size : 500 x 500 mm with 5 mm openings.
MOC : SS 304
Make : SAI
Quantity : Two Nos.(1W+1Sb)
II) SURGE EFFLUENT TRANSFER PUMP
Application : Effluent feed to Equalization Tank
Location : At Surge tank
Type : Centrifugal, non clog
Capacity : 10.5 M3 /Hr.
Head : 10 mtr.
MOC Internals
MOC externals
: SS
CI
Drive : 2.0 HP
Make : Jhonson
Quantity : 2Nos (1 W + 1 S )
III) FLOATING AGITATOR
Application : To mix the effluent with chemical solutions
MOC : MS-FRP lined
Type : Slow Speed floatable
Geared motor : Eliocn-Siemens
Impeller : World renowned simcar design –cone type
Shaft /impeller : MS-FRP lined
Floats : Three Nos. FRP lined
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RPM : 100
Rated power : 5.0 HP
Accessories : Fabricated MS base-plate, foundation bolts
etc
Make : SAI
Quantity : Two Nos.
IV) CSM EFFLUENT TRANSFER PUMP
Application : Effluent feed to Equalization Tank
Location : At CSM Holding tank
Type : Centrifugal, nonclog
Capacity : 3.0 M3 /Hr.
Head : 10 mtr.
Internals : SS/ PP
Externals : CI
Drive : 1.0 HP
Pump Make : Johnson
Quantity : 2Nos (1 W + 1 S )
V) RAW EFFLUENT FEED PUMP
Application : Effluent feed to Flash Mixer Tank
Location : At Equalization tank
Type : Centrifugal, non clog
Capacity : 10.50 M3 /Hr.
Head : 10 mtr.
Internals : SS
Drive : 2.0 HP
Pump Make : Johnson
Quantity : 2Nos (1 W + 1 S )
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VI) FLASH MIXER
Application : To mix the effluent with chemical solutions
Location : At Flash Mixer Tank
MOC : SS
Type of Mixer : Slow Speed
Geared motor : Bonfligliloli
RPM : 100
Rated power : 2.0 HP
Make : SAI
Scope : Supply
Quantity : One No.
VII) CHEMICAL DOSING SYSTEM
Application : Storage & Dosing of Chemical Solutions
Type : Vertical, Cylindrical with close top
Capacity : 500 liters + 200 liters
MOC : HDPE
Make : Sintex
Dosing : By Pump
Capacity : 0 to 50 LPH / 0 to 20LPH
Make : SR Metering / Equivalent
Drive : 0.5 HP (two nos.) + Electronically actuated
Quantity : Seven Nos. (Two + Five Nos.)
VIII) PRIMARY CLARIFIER MECHANISM
Application : To scrap the settled sludge at the bottom of
clarifier & to collect sludge in center chamber.
Location : At Primary Clarifier.
Size : Suitable to civil unit
Access Bridge : The full span structural bridge 1000 mm width
support at center & 5 mm thick plate upto
center with hand railing.
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Drive : Centre drive
Gear Box
Motor
: Elicon
Siemens
Scraping : MS – epoxy painted the center pipe having
two scraper arms with neoprene rubber
squeegees. The floor is scraped twice in
revaluation to collect sludge at the center.
Feed well
: MS-epoxy painted feed well, supported from
the bridge, with baffle plate.
Painting : All wetted parts will be one coat of epoxy
primer & two coats of epoxy paints & other s
parts are two cots of enamel paints.
The scraper arms lifting hand operated mechanism is provided so that incase over
loading the complete assembly can be lifted manually up to 300 mm
Rated power : 0.5 HP
Quantity : One no.
IX) SLUDGE REMOVAL PUMP
Application : Sludge removal from PC
Location : At PC
Capacity : 10 M3 /Hr.
Head : 10 mtr.
MOC of pump : CI
Internals : SS
Drive : 2.0 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : Two Nos.(1W +1Sb)
12
X) BIO-FILLS
Application : Medium for Bacterial attached growth.
Location : Bio-tower
MOC : PVC UV stabilized sheets
Specific Surface Area : 93 M2 / M
3
Void Ratio ( M2 / M
3 ) : More than 97 %
Thickness : 0.3 mm
Standard Dimensions : 1200x 600 x 600 mm
Max. width of support : 100 / 150 mm
Dry weight : 20 kg / m3
Make
No. of blocks
: MM Aqua
108 nos.
Quantity : 47 cu. mt.
XI) BT RECYCLING PUMP
Application : Effluent recirculation at Bio-tower
Location : At Bio-tower
Type : Self priming ,centrifugal, non-clog, semi-open
impeller
Capacity : 26 M3 /Hr
Head : 8 mtr.
MOC of Pump : CI
Drive : 3.0 HP motor
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : 2 Nos. ( 1W + 1Sb)
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XII) BT EFFLUENT DISTRIBUTION SPRINKLERS
Application : Effluent distribution at the top of Bio-tower
Location : At Bio-tower
MOC : PVC
Quantity : One Set
XIII) AIR BLOWER
Location : Near Aeration Tank
Application : Supply of Air for mixing –ET & HT and
aeration in Aeration Tank
Medium Handled : Air
Blower Make : Kay
Motor Make : Siemens
Air Flow : 420 M3/hr.
Delivery Pressure : 0.45 kg/cm2
Duty : Continuous
Motor HP : 15
Accessories : All accessories as per requirement
Quantity : Two Nos.(1W+1Sb)
XIV) AIR DIFFUSERS
Type : Membrane Diffusers
MOC : Silicon membrane with PP Pipe
Make : Rehau, Germany
Size : 63mmOD x 2000 mm length
Type : Lift able with nylon ropes and accessories
Air Flow : 18 M3/Hr.
Location : Aeration Tank
Quantity : Fourteen Nos. (Including spares)
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XV) SECONDARY CLARIFIER MECHANISM
Application : To scrap the settled sludge at the bottom of
clarifier & to collect sludge in center chamber.
Location : At Secondary Clarifier.
Size : Suitable to civil unit
Access Bridge : The full span structural bridge 1000 mm width
support at center & 5 mm thick plate upto
center to with hand railing.
Drive : Centre drive
Gear Box : Elicon
Motor : Siemens
Scraping : MS – epoxy painted the center pipe having
two scraper arms with neoprene rubber
squeegees. The floor is scraped twice in
revaluation to collect sludge at the center.
Feed well
: MS-epoxy painted feed well, supported from
the bridge ,with baffle plate .
Painting : All wetted parts will be one coat of epoxy
primer & two coats of epoxy paints & other s
parts are two cots of enamel paints.
The scraper arms lifting hand operated mechanism is provided so that incase over
loading the complete assembly can be lifted manually up to 300 mm
Rated power : 0.5 HP
Quantity : One no.
XVI) BIO-SLUDGE RECYCLING PUMP
Application : Sludge Recycling To Aeration Tank & excess
sludge into sludge collection tank.
Location : At Secondary Clarifier
Type : Self Priming, centrifugal, non-clog, semi-open
impeller
15
Capacity : 6.5 M3 / Hr
Head : 10 mtr.
MOC of pumps : CI
Drive : 2.0 HP motor
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard,
foundation bolts etc.
Quantity : 2 Nos. (1 W + 1 S )
XVII) FILTER PRESS
Application : For Dewatering of Sludge
Location : Near Sludge Collection Tank
Pump capacity : 5 M3
/ Hr.
Sludge Feed : 5 M3/ Hr.
Operation : Two batches per day
Capacity : 240 Liters /batch wet cake holding capacity
Type : Plate
MOC of Plates : PP
Size of Plates : 610 x 610mm
No .of Plates : 25
MOC of unit : CI
Drive : 2.0 HP motor
Motor Make : Siemens
Make : Hydro Press
Quantity : 1 No.
XVIII) PRESSURE FEED PUMP
Application : Feed to Filters
Location : At Chlorine Contact Tank
Type : Monoblock
Capacity : 7 M3 / Hr
16
Head : 30 mtr.
MOC of pumps : CI
Drive : 2.0 HP motor
Make : Kirloskar
Quantity : 2 Nos. (1 W + 1 S )
XIX) DUEL MEDIA FILTER
Application : Removal of SS
Location : After Chlorine Contact Tank
Type : Vertical, Cylindrical
Capacity : 7.0 M3 / Hr
MOC : MS-EP
Valve : AUTO MPV*
Backwash : AUTO time setting
Thickness : 5mm
Pressure : 3.5 Kg/Cm2
Media : Sand & Anthracite
Make : SAI
Scope : Supply
Quantity : One No.
XX) ACTIAVTED CARBON FILTER
Application : Removal of odor/ chlorine
Location : After Duel Media filter
Type : Vertical, Cylindrical
Capacity : 7.0 M3 / Hr
MOC : MS-EP
Thickness : 5mm
Valve : AUTO MPV*
Backwash : AUTO time setting
Pressure : 3.5 Kg/Cm2
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Media : Activated Carbon
Iodine Value : >800
Make : SAI
Scope : Supply
Quantity : One No.
*Note: PLC based control panel included.
C. PIPING & FITTINGS
Application : Interconnecting Piping between all ETP units
Location : ETP Plant Battery limits
Accessories : Valves, Flanges, Reducers, Joints, Bends etc.
MOC : CPVC
D. ELECTRICAL WORKS
I) CONTROL PANEL
Motor Control Centre (MCC) is to be fabricated in 16 swg CRCA sheet with
compartment, dust & vermin proof, floor mounting, cable entry at bottom with back
access. At the bottom ISMC channel will be provided for installation of panel. Suitable
painting should be done to the panel.
In this panel one incomer is to be provided which should have Ammeter, Voltmeter
indicating lamps & energy meter. Outgoing feeders are as per drives of mechanical
equipments.
All major components are Siemens Make.
Quantity : One No.
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II)
REMOTE PSUH BUTTON STATIONS
Make : Technic
III)
CABLING
Electrical cabling from control panel to units of Effluent treatment plant.
The cables shall be Copper ( upto 2.5 sq.mm) aluminum
(above 2.5 sq.mm) conductor armored . The entire cable shall be supplied capacity
wise for all motors / units.
IV)
EARTHING
Earthing for Motors – Copper.
19
E. INSTRUMENTATION
I) LIQUID FLOW METER
Application : To measure the liquid flow
Location : FMT Feed line
Type : On line, Electromagnetic type with totalizer
and Indicator
Make : E & H ,Germany
Flow : 0 to 12.5 M3/Hr.
Quantity : Two Nos.
II) PH METER
Application : To measure the pH Online
PH Sensor : Innovative sensors –Two Nos.
PH Transmitter : Wavetec
PH Indicator : Wavetec
Make : Wavetec
Quantity : One No.
III)
PRESSURE GAUGES
Application : To measure the pressure
Location : Pipeline after Pumps/Blowers
Type : Dial
Make : H-Guru
Size : 4”
Quantity : 12 Nos.
20
IV) LEVEL SWITCHES
Application : Automatically on or off the pump at set points
Make : Techtrol
Quantity : Four Nos.
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4.0 ELECTRICAL
Sr. No.
PARTICULARS
Quantity
Each
HP
Total
HP
1. Surge Effluent Transfer Pump
( 1W + 1Sb)
Two Nos. 2.0 4.0
2. CSM Effluent Transfer Pump
( 1W + 1Sb)
Two Nos. 1.0 2.0
3. Floating Agitator Two Nos. 5.0 10.0
4. Raw Effluent Feed Pump
( 1W + 1Sb)
Two Nos. 2.0 4.0
5. Flash Mixer One No. 2.0 2.0
6. Chemical Dosing System Two Nos. 0.5 1.0
7. Primary Clarifier Mechanism One No. 0.5 0.5
8. PC Sludge Pump ( 1W + 1Sb) Two Nos. 2.0 4.0
9. Secondary Clarifier Mechanism One No. 0.5 0.5
10. SC Sludge Pump ( 1W + 1Sb) Two Nos. 2.0 4.0
22
11. BT Recycling Pump ( 1W + 1Sb) Two Nos. 3.0 6.0
12. Air Blower ( 1W + 1Sb) Two Nos. 15.0 30.0
13. Sludge Dewatering System One No. 2.0 2.0
14. Pressure Feed Pump( 1W + 1Sb) Two Nos. 2.0 4.0
Total Working Load : 45 HP (33.75 KW)
(Some motors will work partially )
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PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE
24
PREVENTIVE MAINTENANCE
EMERGENCY INSPECTION
In case of any abnormality in primary and secondary clarifiers, drain the water from the
system and clear the accumulated sludge from the bottom. Check for fouling of any foreign
material with the racking mechanism . racking mechanism is to be checked thoroughly for
any damage of shaft , arms and supports. After thorough inspection and repairs as per
requirement take trail runs on no load and after satisfactory running fill the system with
water and restart the process.
If any abnormal sound / vibrations of pumps , aerators, and blowers observed , immediately
stop the equipment and check the equipments for any damage of bearings, oil seals ,
gearbox, coupling damages. After replacing /repair of the equipment proper alignment is to
be done and trail run is to be taken on no load then only take the equipment into operation.
PREVENTIVE MAINTENANCE
The main purpose of preventive maintenance schedule is to avoid break down maintenance
of the equipments. The preventive maintenance will avoid the damage to the equipment
and increases the equipment availability to the maximum possible extent and interns
increase the capacity utilization and help to increase the plant production .
The preventive electrical and mechanical maintenance allows to keep all the conditions
necessary to the equipments running and to maintain their performance at a level close to
their starting one.
Preventive maintenance of equipment supplied is to be carried out as per the manufacturer’s
operation manuals for this equipment. Specific guidelines for preventive maintenance for
major equipment are suggested in the table below. These guidelines should be adhered
wherever applicable.
25
PREVENTIVE MAINTENANCE SCHEDULE
S.No Equipment Maintenance Frequency
01. Centrifugal
Pumps
a. Alignment Check
b. Oil Check / Refill
c. Gland Tightening / Replacement
d. Chocking Clearance
At Commissioning Stage Quarterly
Weekly
Weekly
Quarterly / Monthly / As Required
02. Air Blowers a. Alignment Check
b. Oil Check / Refill
c. V–Belt Tightening / Replacement
d. Suction Filter Cleaning
At Commissioning Stage / Monthly
Weekly
Weekly
Monthly / As Required
03. Dosing
Tanks
Emptying and Cleaning Quarterly
04. Electrical
Connections
Routine Check Half Yearly
• All butterfly valves in fixed OPEN / CLOSE positions are to be operated weekly to prevent
jamming.
• In case of undue noise / vibration in rotating equipment, the same may be shut down
immediately and attend to.
• Plant operator is to monitor the voltage regularly and motors may be shut down when the
voltage falls below 380 V.
• Spare parts for the equipment that are recommended by the manufacturer are to be kept
under stock for ready use.