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HISTRY OF DOCUMENT REVISION

Doc. Type: Standard Operating Procedure

Document No. Effective Details of Revision Remarks

Date
OP/01/73 28-02-2025 Change of Format Approved
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OPERATION & MAINTENANCE

MANUAL
FOR

EFFLUENT TREATMENT PLANT

(Capacity 12 M3 PER DAY)

M/s. Dyna Glycols Pvt. Ltd.,

Sector No. IV, Plot No. 268-B
KASEZ, Kandla, Gandhidham
Kuchchh, Gujarat( India)

SR. NO. CONTENTS PAGE NOS.

GLOSSARY OF TERMS………………………………. 3-5

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1. INTRODUCTION ……………………………………… 6–7

2. BASICS OF EFFLUENT TREATMENT……………… 8

3. BASIS OF THE PLANT DESIGN ……………………… 9

4. TREATMENT PHILOSOPHY ………………………… 10 - 11

5. PROCESS FLOW CHART ……………………………. 12

6. OPERATIONAL PROCESS……………………………. 13 – 18

7. OPERATIONAL PROCEDURE………………………. 19 – 23

8. ESTIMATION OF VARIOUS CHEMICALS…………. 24 - 25

9. COMMISSIONING OF THE PLANT…………………. 26 – 27

10. PLANT SHUTDOWN……………………………………. 28

11. MAINTENANCE OF THE PLANT……………………. 29 – 31

12. TECHNICAL SPECIFICATION FOR ETP…………… 32 - 36

13. SCHEMATIC OF EFFLUENT TREATMENT PLANT 37

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GLOSSARY OF TERMS
Biochemical Oxygen demand (BOD): The strength of the wastewater is often determined by measuring the
amount of oxygen consumed by microorganism like bacteria in biodegrading the organic matter. The
measurement is known as the Biochemical Oxygen Demand (BOD). Microorganisms such as bacteria are
responsible for decomposing organic waste. When organic matter such as dead plants, leaves, grass
clippings, cellulose components, manure, sewage, organic waste like dyes, fats and oils, or even food waste
is present in a water supply, the bacteria will begin the process of breaking down this waste. When this
happens, bacteria in aerobic processes, robbing other aquatic organisms of the oxygen they need to live,
consume much of the available dissolved oxygen. If there is a large quantity of organic waste in the water
supply, there will also be a lot of bacteria present working to decompose this waste. In this case, the demand
for oxygen will be high (due to all the bacteria) so the BOD level will be high. As the waste is consumed or
dispersed through the water, BOD levels will begin to decline.

Chemical Oxygen Demand (COD): This is a means of measuring the ability of wastewater to sustain
aquatic life, essential for the preservation of the environment. It also enables proper assessment of treatment
plant performance. Aquatic organisms and animals require dissolved oxygen to flourish. The Chemical
Oxygen Demand (COD) test gives an indication of the impact of discharge waters on aquatic life by
measuring the oxygen depleting nature of the discharge water. COD is since nearly all-organic compounds
can be fully oxidized to carbon dioxide with a strong oxidizing agent under acidic conditions. COD is another
common measure of water-borne organic substances — the process of measuring COD causes the
conversion of all organic matter into carbon dioxide. For this reason, one limitation of COD is that it cannot
differentiate between biologically active and those which are biologically inactive. One major advantage of
COD over BOD is that COD can be measured in just three hours whereas BOD measurement takes at least
five days. The value of COD is always higher than BOD, this is because BOD accounts for only
biodegradable organic compounds while COD accounts for all organic compounds e.g. biodegradable as
well as no biodegradable but chemically oxidizable.
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Total suspended Solids (TSS): TSS is mainly organic in nature, are visible and can be removed from the
wastewater by physical/ mechanical means e.g. screening and sedimentation. TSS is measured by filtering a
certain quantity of effluent and then drying the filtration at certain temperature e.g. 105 0C followed by
weighing. TSS is expressed as parts per million or in milligram/liter. The pore size of the filter paper is very
important in estimating the TSS, the nominal pore size 1.58 micrometer.

Total Dissolved Solids (TDS): Dissolved solids generally pass through the unaffected system. TDS is the
sum of all of the dissolved matter in a given body of water. It is everything in the water that's not actually
water. It includes hardness, alkalinity, cyanuric acid, chlorides, bromides, sulfates, silicates, and all manners
of organic compounds. Every time we add anything to the water; we are increasing its TDS. This includes not
only sanitizing and pH adjusting chemicals, but also conditioner, algaecides, and tile and surface cleaners.
TDS also includes airborne pollutants and bather waste as well as dissolved minerals in the fill water. TDS is
referred to as the total amount of mobile charged ions, including minerals, salts or metals dissolved in a
given volume of water, and is expressed in units of mg per unit volume of water (mg/L), or as parts per
million (ppm).TDS is directly related to the purity of water and the quality of water purification systems and
affects everything that consumes, lives in, or uses water, whether organic or inorganic, whether for better or
for worse.

Microorganisms - Microscopic living objects, which require energy, carbon and small amounts of inorganic
elements to grow and multiply. They get these requirements from the wastewater and the sun, and in doing
so help to remove the pollutants.

pH – A term used to express the intensity of the acid or alkalinity source. pH represents the effective
concentration (activity) of hydrogen ions (H+) in water. This concentration could be expressed in the same
kind of units as other dissolved species, but H+ concentrations are much smaller than other species in most
waters. The activity of hydrogen ions can be expressed most conveniently in logarithmic units. pH is defined
as the negative logarithm of the activity of H+ ions: pH = -log [H+]

Where [H+] is the concentration of H+ ions in moles per liter (a mole is a unit of measurement, equal to 6.022
x 1023 atoms). Because H+ ions are associated with water molecules to form hydronium (H 3O+) ions, pH is
often expressed in terms of the concentration of hydronium ions. In pure water at 22 O C (72O F), H3O+ and
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hydroxyl (OH-) ions exist in equal quantities; each concentration is 1.0 x 10 -7 moles per liter (mol/L).
Therefore, pH of pure water = -log (1.0 x 10 -7) = -(-7.00) = 7.00. Because pH is defined as –log [H +], pH
decreases as [H+] increases (which will happen if acid is added to the water). Since pH is a log scale based
on 10, the pH changes by 1 for every power of 10 change in [H +]. A solution of pH 3 has an H + concentration
10 times that of a solution of pH 4. The pH scale ranges from 0 to 14. However, pH values less than 0 and
greater than 14 have been observed in very rare, concentrated solutions.

Sludge-The settle able solids separated from the liquid during sedimentation (clarification). The sludge being
chemical in nature is toxic and needs to be dealt with very carefully. Under no circumstances it should be mix
with the environment again.
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Chapter 1: Introduction
M/s. Dyna Glycols Pvt. Ltd,, At Plot No. 288-B, sector no IV designing the Effluent Treatment Plant. The
scope of work for effluent treatment plant is tret the raw effluent.

Every effluent treatment plant is unique with respect to its process flow sheet. This is because the treatment
scheme is adopted on the basis of design and input characteristics of the effluent as well as the stipulated
pollution level of the treatment. This in turn depends on the type of process, type of generated waste,
whether the treated waste will be discharged or recycled, the nature of water receiving body where the
treated waste will be discharged (if any) and the pollution laws of the concerned pollution authority.

The current effluent generation of the industry is in the range of 15-20 KL per day . The operating manual
serves as an important guideline for the operating personnel responsible for the start- up and maintenance of
the equipment and facilities provided in the plant. The instruction presents in this manual are based on the
experience in operation of such plants. However, due to variable nature of the effluents encountered in plant,
certain modification of process operation may be necessary depending on the degree of variation in the raw
effluent quality and quantity. This manual includes a brief description of the basis of design of the ETP, the
adopted treatment philosophy and the principles of treatment involved.
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Chapter 2: Basics of Effluent Treatment

Environmental problems of the industry are mainly caused by discharges of wastewater. In Pharmaceuticals
industry discharge waste water is depending on the nature of the raw chemicals/ material. Industrial
processes generate wastewater containing contaminants like pH, COD, BOD, TSS & Oil & Grease etc.
These end products, their concentrations must be reduced to acceptable levels before discharging them into
the environment.

The fate of the above mentioned pollutant vary, ranging from 100% retention to 100% discharge with the
effluent. Generally, Chemical industry generates wastewater possessing various level of toxicity. Such
industry uses fair amounts of water, mainly because of process, and domestic operations. If these
wastewaters are discharged into the environment they will cause serious and harmful impact not only on
under ground and surface water bodies and land in the surrounding area but also will have an adverse effect
on the aquatic ecological system. The effluents having the colour, which increases the turbidity of water
body.

The pollution level of wastewater is expressed in terms of pH, BOD, COD, TSS & oil & grease of the
discharging effluent. Temperature of stream is also important parameter because at higher temperature the
rate of transfer of gaseous oxygen into dissolved oxygen is reduced. Effluents generated from the
Pharmaceuticals industry are highly polluted. The ETP is designed in such a way so that if the factory need
to expansion in production without change in processing nature, even then the Effluent Treatment Plant will
be able to handle the treatment efficiency without any problem.

Chapter 3: Basis of the Plant Design

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3.1 Source

The raw effluent shall be discharge to the effluent treatment plant from the industry of the M/s. Dyna
Glycols Pvt. Ltd, At Plot No. 268-B, sector No. IVth , KASEZ, KANDLA, GANDHIDHAM.

3.2 Quantity
Though the plant is designed to treat 15 KL per Day load, the quantity of effluent to be treated
shall be of the order of 12000 to 20 KL per Day

3.3 Capacity of the Effluent Treatment Plant (ETP).

The effluent treatment plant has been designed on the basis of the following

 Operated continuously for 24 hours a day.

 Flow rate of treatment envisaged is 15 KL per Day.

3.4 General Characteristics of Inlet Effluent

Sr. No. Effluent Water Quality Unit Raw Effluent (mg/L) Treated Effluent
parameters (mg/L)
1 pH …….. 5-8 5.5 – 9.0
2 Total Suspended Solids (TSS) mg/L 300 <100
3 Total Dissolved Solids (TDS) mg/L 3,500 <2100
4 B.O.D., 20 0C, 5 days mg/L 1,800 <100
5 C.O.D. mg/L 5,000 <250
6 Oil & Grease mg/L 15 <10

3.5 Outlet Effluent Characteristics- Indian Standard (G.P.C.B)

Sr. No. Effluent Water Quality Parameters Units MPCB Standards

1. pH -- 6.5 – 8.5
2. Total Suspended Solids(TSS) mg/L <100
3. Total Dissolved Solids (TDS) mg/L <2100
4. B.O.D., 27 0C, 3 days mg/L <30
5. C.O.D. mg/L <250
6. Oil & Grease mg/L <10

Chapter 4: Treatment Philosophy

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As was mentioned the method of treatment of wastewater varies a lot. It mainly depends on the
characteristics of effluent, volume of effluent, level of toxicity to be removed and the type of environment to
receive the effluent. The treatment process that has been adopted for the Effluent Treatment Plant installed
at the M/s. DYNA Glycols Pvt Ltd, At Plot No 268-B, Sector No. IV th , is known as physic-chemical and
followed by biological and Tertiary treatment
The physical chemical process removes a substantial part of all the parameters shown in table 3.4. The
various stages of the plant treatment procedure are elaborated as follows. Biological process reduce
Maximum amount of COD, BOD. After biological treatment the effluent is collected in Clar settler which
separates solids & liquids by settling & passed through sand it filters suspended partials in effluent and finally
though the activated carbon filters. The activated carbon filter is highly successful in removing color & odor
content of the effluent.

4.1. PRIMARY TREATMENT

4.1.1 Oil & Grease trap – To separate out the oil, grease & other floating material.

4.1.1 Collection cum Neutralization - to adjust the pH between 6.5- 8.5

4.1.2 Settling Tank – to precipitate settle-able solid

All the above processes contribute to reducing of substantial amount of all the polluting parameters.

4. 2. SECONDARY TREATMENT

The biological treatment is responsible for reducing of the rest of the BOD and COD as well. The biological
treatment is carried out by in the biological tank.

4.2.1 Biological treatment (Bio reactor) - to reduce BOD and COD & decompose organic matter.
4.2.2 Clarifier - to remove the solids generated during biological treatment.

4. 3. TERTIARY TREATMENT
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4.3.1 Polishing Tank – To collect the effluent from clarifier.

4.3.2. Pressure Sand Filter -To remove TSS and any other pollutants in the form of
particle. This filter is also useful to protect the Activated Carbon Filter (ACF) from
overloading by pollutants such as particulates and organics.

4.3.3 Activated Carbon Filter- It is one of the many processes used in advanced treatment
of wastewater. The ACF is used to remove a considerable amount of odor & colour
also, relatively small quantities of refractory organics, as well as inorganic such as
sulfides and heavy metals, if any remain in well-treated wastewater.

4. 4. SLUDGE MANAGEMENT & DISPOSAL

4.4.1 Sludge Drying Bed – Sludge from primary settling tank & excess sludge from Clarifier collected
at sludge drying bed where water gets separated. Water separated from sludge back to
aeration tank & dried sludge for disposal.

4.4.2 Sludge Disposal – to separate the sludge from the thick slurry and then dispose of the sludge to
SEPPL, Bhachau

5. Process Flow Chart

Sample Analysis
pH- 5.0 – 8.0
Raw Effluent TSS – 200- 300
TDS – 2500 - 3500
COD – 4500- 5500
Oil & Grease trap BOD – 1000- 1800
Oil & Grease – 11-15

Dosing of
Lime/caustic, Alum, Collection cum
Neutralization Tank
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Dosing of Poly

Settling Tank Settling Tank

Sewage Effluent

Bio Reactor/ Aeration Bio Reactor/ Aeration

Secondary Settling Tank

Collection Tank

Clarifier

Polishing Tank
Sample Analysis
pH – 7.0 - 7.5
O & G - < 10
PSF & ASF COD - < 250
BOD - < 100
TSS - < 100
TDS - < 2100
Gardening
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Chapter 6: Operational Processes

6.1. PRIMARY-TREATMENT :-
6.1.1 Collection cum Neutralization Tank :-
The collection tanks are two in numbers to facilitate fill & draw operation. For equalization and mixing
purpose air has been provided to the tank with the help of air blower, which helps to mix the effluent.
Besides, the air mixing accomplishes a proper equalization of both varying loading and fluctuating pH values.
The following benefits are derived from the flow equalization process;
1. Biological treatment is enhanced, as the shock loadings are eliminated or minimized, inhibiting substances
diluted, and pH stabilized.
2. Chemical treatment is improved if chemical dosing is controlled to provide consistent performance.
3. The effluent quality and thickening performance of secondary sedimentation units are improved through
constant solids loading.
4. Effluent surface area requirements are reduced, filter performance is better, and more uniform filter-
backwash cycles are possible.

6.1.2 pH Correction (To adjust the inlet pH) :-

The effluent from tank is then checked for its pH and taken for the pH neutralization; where alum is dosed for
neutralizing the pH value around 7 to 7.5. The pH correction channel/neutralization tank is also supplied with
air for thoroughly mixing of waste with alum to maintained pH value.

6.1.3 Chemical Dosing (To remove color and effluent suspended) :-

To the homogenized neutral effluent, chemicals like lime (Calcium Hydroxide) and flocculants like ferric alum
are dosed. This is done for coagulation and removal of the particles. The basic idea of adding coagulant is to
bring together all the suspended and dye particles so that they can be precipitated out in tank by coagulation
and flocculation mechanism. The chemical reaction that occurs in the coagulation and flocculation process is
shown below;
CaO + H2O Ca (OH) 2
In the above reaction lime reacts with water and we get calcium hydroxide solution. This solution reacts with
the ferric alum solution.
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Adequate quantity of polyelectrolyte polymer solution is dosed in the effluent via dosing system to enhance
the process of color removal by the flocculation process. A substantial amount BOD and COD etc. are
removed in the coagulation and flocculation process.

6.1.4 Primary Settling Tank. (To remove the flocs materials) :-

Effluent enters in settling tank and then overflows from the launder to collection tank. The flocs and
suspended particles formed get settle down/precipitated in the hopper bottom of the settling tank due to
gravity which is further drained down to sludge tanks, whereas supernatant is allowed to overflow to the
launder of the Bio-reactor for biological treatment.

6.2 SECONDARY-TREATMENT :-

6.2.1 Biological Treatment (To reduce the remaining BOD / COD aerobically) :-

Bio reactor unit is biological treatment in which available organic matter degrades aerobically to reduce the
remaining BOD and COD aerobically. The biological treatment is designed on aeration principle. It enables
the bacteria to act upon the biodegradable matter in the effluent and reduce the BOD & COD content while
the rapid and turbulent movement of the effluent in the presence of oxygen. Diffused aeration system is
provided for the same. The chemical reactions that take place aeration tank can be defined according to the
following three processes;

A. Oxidation process :-

COHNS + O2 + Bacteria + DAP & UREA CO2 + NH3 + Energy

+ Other end Products

DAP and Urea is used as food for the microorganism.

B. Synthesis Process :-

COHNS + O2 + Bacteria C5H7NO2 (New bacteria)

C. Endogenous Respiration :-

C5H7NO2 + 5O2 5CO2 + NH3 + 2H2O

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Apart from the above basics reaction there are some other reactions that take place in the aeration tanks.
During aeration the oxygen reacts with C, S and N which is shown below.

C + O2 CO2

S + O2 SO2

N + O2 NO2

The biological degradation process in enhanced by addition some Di-ammonium Phosphate (DAP) and
UREA. It acts as food for the microorganism. Therefore it will be necessary to supply food for the bacteria.
Thus a combined solution of Urea and DAP are dosed in the biological tank to feed the bacteria.

6.2.2 Secondary Settling Tank - (To remove the biological solids generation.) :-

From the aeration tank effluent overflows to the Secondary Settling Tank, to remove the settle-able solids
generated Secondary Settling Tank. The effluent with activated biological sludge enters the Secondary
Settling Tank through a pipe to the launder, where it flows downwards and then outwards to launder. The
activated sludge settles at the bottom of the Secondary Settling Tank , where it collected in the center cone
of Secondary Settling Tank by gravity. The settled sludge continuously recirculated into the Aeration tank for
further degradation and excess sludge is pumped to the sludge drying beds. The supernatant of Secondary
Settling Tank overflow Collection tank.

6.2.3 Collection Tank :-

From the Secondary settling tank effluent overflows to the Collection Tank, to collect the supernatant effluent
from Secondary settling tank. The collected effluent of Collection Tank pumps into Clarifier tank

6.2.4 Clarifier Tank :-

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From the Collection tank effluent pumps to the Clarifier Tank through a pipe to the Center feed well, where it
flows downwards and then outwards to launder. The Lime & Alum dosing is carried out at centre feed well
which also helps to reduce General Parameters of the effluent. The lime & Alum dosing system are placed
above the clarifier. The excess sludge is pumped to the sludge drying beds. Then effluent overflow into the
polishing tank for tertiary treatment.

6.2.5 Polishing Tank :-

The treated clear effluent from Clarifier Tank is collected in the polishing tank. From the polishing tank
effluent is pumped to the pressure sand filter at first and then through activated carbon filter.

6.2.6 Pressure Sand Filter (To remove suspended matter) :-

The effluent from polishing tank is pumped to the pressure sand filter. The filtration takes place in the
downward mode. The filter is filled with a layer of graded sand media supported by a layer of graded gravel.
The suspended matters in the effluent are filtered out in this unit; the effluent is then flown into the activated
carbon filter. It is necessary to backwash the sand filter when required.

6.2.7 Activated Carbon Filter (To absorb the dissolved organic matter) :-

The treated and filtered effluent from the pressure sand filter flows into the activated carbon filter. In this unit
too, the feed flow is downward through a layer of granular activated carbon filter in which absorption of color
& odor also organics & inorganic element of the effluent are take place. It is necessary to backwash the
carbon filter when required.

6.2.8 Treated Effluent (Ready for disposed off) :-

The treated effluent samples emerging from the ACF are collected for analysis and after satisfactory analysis
report the treated effluent reuse for toilet flushing & floor washing also for gardening purpose.

6.2.9 Sludge Treatment and Handling:-

The sludge generated in the Primary settling tanks and excess sludge from secondary settling tanks is taken
to a sludge drying bed. The water that has been separated from the sludge will be flown back to collection
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cum neutralization tank for treatment. The sludge is then disposed in safe & secures way so that it will not
affect the environment. It is generally sent for disposal to CHWTSDF.
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UNITS OF EFFLUENT TREATMENT PLANT

Of
M/S. Dyna Glycols Pvt. Ltd.

Sr. No. Name Capacity No. of Unit

1. Oil & Grease Trap 5.88 M 3
1
2. Collection Tank 64.95 M3 1
3. Chemical Neutralization Tank 20 M3 2
4. poly-dosing system - -
5. Coras Bubble Aeration System For Neutralization - -
Tank
6. Primary Settling Tank 18 M3 1
7. Effluent transfer pump 9 M3 / hr 02
8. Sewage Effluent transfer pump 9 M3 /hr 02
9. Bio-Reactor 128.82 M3 01
10. Secondary Settling Tank 14.898 M3 01
11. Clarifier 13.59 M3 01
12. Polishing Tank 19.72 M3 01
13. Pressure Sand Filter 0.398 M3 01
14. Activated Carbon Filter 0.398 M3 01
15. Air Blowers 350.80 M3 / hr 02
16. Fine Bubble Diffused aeration system for Bioreactor - -
17. Return Sludge Pumps
18. Filter Feed Pumps
19. Sludge Drying Bed 38.732 M3
20. Garden Tank 61.226 M3

Chapter 7: Operational Procedure

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7.1 PREPARATION OF THE CHEMICAL DOSING

Before starting the operation it will be necessary prepare all the necessary chemical solutions. The
procedures of preparing the solutions are described below.

7.1.1 Preparation of the Lime solution

The daily requirement of the lime solution is calculated and shown in section 8.1. During preparing the dosing
solution of lime a 10 % solution is prepared. In this regard the dosing tank is at first filled with 100 litres of
water. After those 10 kgs of lime is added stir the solution. The stirring should be continuous. After that the
solution is ready for dosing in the neutralization tank.

7.1.2 Preparation of the Ferric alum solution

The daily requirement of the ferric alum is calculated and shown in section 8.2. During preparing the dosing
solution of ferric alum 10% solution is prepared. In this regard the dosing tank, which is fitted with a motor
and stirrer, is at first filled with 100 litres of water. Now 10 kgs of ferric alum is added and stir the solution.
The stirring is continued for nearly 1 hour. After that the solution is ready for dosing in the neutralisation tank.

7.1.3 Preparation of the Poly Electrolyte (PE) solution

The daily requirement of the PE solution is calculated and show PE dosing tank is at first filled with 100 litres
of water. After that 25-30 gms of PE is added and the solution is stirred manually. The stirring should be
continuous. Poly electrolyte solution is ready for dosing in settling tank.

7.1.4 Preparation of the Di-ammonium Phosphate (DAP) and Urea solution

The requirement of the DAP and Urea is calculated. During preparing the dosing solution of DAP and Urea a
5% mixed solution is prepared for dosing. In this regard 100 litres of water. After that 5 kgs of DAP and stir
the solution. The stirring should be continued for half of an hour. After that the solution is ready for dosing in
the biological tank. Same procedure followed for the preparation of Urea solution.
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7.2 Method of seeding bacteria

The following steps are to be followed during start up.

1. Check any leakage in the civil structure.

2. After completing the civil work, assemble air pipes. Fill the water tank. Take trial for air diffusion.
Aeration has to be uniform and there should not be any leakages in the air grid.
3. If aeration is o.k. fill the tank up to the water level.
4. Add filtered cow dung. Ensure that cow dung is free of foreign material and fibres. Make 5-10%
slurry. Filter it through 2-3 mm opening mesh. During the addition of slurry in FAB keep the blowers
on. Cow dung should be fresh. We can also have aerobic culture in place of cow dung. Add this
slurry. Aerate the dilute slurry continuously for about 25-30 days.
5. Dilute effluent can be loaded after this gradually; (Starting with 10% of design BOD load, for initially
7-8 days there after the load can be increased after every 4-5 days by 10% provided BOD reduction
is continuously 70-75% is observed at the increased BOD load.
6. Bio culture of named “Bactus” water solution of 45 liter fresh water with 5 liter influent and 150 gm. of
Bactus culture and aerated the solution at least 4 hrs., then pour in bioreactor.

If, in case, the bacteria of the reactor die for any reason like wrong acidity or alkalinity, nor aeration shock
load etc, in that case it will be necessary to seed the bacteria again. This has to be done by means of adding
5-10 tons of fresh cow dung as mentioned above. It is not very easy to detect the presence of bacteria in the
biological tank. By means of using a microscope it will only be possible to test the presence of bacteria in the
effluent. Apart from this by testing the BOD of the effluent before and after the biological reactor treatment it
will be possible to say whether there is any bacteria in the reactor or not. If the quantity of BOD is same
before and after the biological reaction then we can say that there are no bacteria to reduce the BOD. But, if
the BOD is getting reduced, after, treatment in the biological reactor then we can prove the presence of
bacteria in the biological tanks.

7.3 Important processing tips

1. Drain the sludge settled at the bottom of the settler at periodic interval to avoid carry overflow of
sludge.
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2. Changeover from operating to stand by equipment every 4 hours.

3. Regularly follow the lubrication and maintenance schedule for all mechanical moving items.
4. Take samples from the locations specified. Analyze them and maintain logbook regularly to ensure
better control over operation of the plant.
5. Do not let effluent –having pollutants more than specified range in the plant.
6. Do not handle chemicals, dosing system without taking precautions.
7. Do not allow acidic pH < 6 or alkaline pH > 8.5 or hot (temp > 400C
8. The Urea and DAP solutions are required for bacteria i.e. they works as nutrient for the
microorganisms. If, for any reason, the plant is kept shut down due to closure of the factory or any
reason, even then it will be necessary to run the biological reactor along with dosing DAP and Urea
solutions. This is because if the biological reactors are shutdown the bacteria will die and then again
it will be necessary to seed the bacteria according to the procedure.

7.4 Trouble Shooting Guide

7.4.1 Smell Problem

Septic odor in Collection/Equalization tank

Possible Cause Necessary Check And Possible Corrective Actions

Less aeration 1. Check the valves of blower and adjust accordingly.
2. Check the air quality delivered by blower, in case the
quantity is less than design; check the blower for any
mechanical problem. In case of any mechanical problem refer
the blower manual for the maintenance.
3. Check for adequate mixing in equalization tank.
Blower operation not continuous The blower should be in continuous operation
Grid are damaged In case the grid is damaged, this will result in excessive
turbulence but low oxygen transfer. The corrective action
should be taken for repairing the diffuser/grid.
High inlet Organic i.e. BOD/COD load 1. In case the BOD/COD load is higher than design, the same
to be controlled prior to E.T.P. If the increase is for a small
period the flow to the plant to be reduced to decrease the kg
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BOD/COD loading.
2. Solid level in the reactor very high, the settled solids (if any)
to be drained. The draining frequency can be ascertained
based on the site condition.

7.4.2 Foaming Problem

Possible cause Necessary check and possible corrective actions

Over aeration Check organic loading (kg/d), in case the level is much lower
than the design basis. Adjust the air quantity to the bio reactor
and maintain minimum D.O level as 2.0 mg/l.

Low bacterial level in the reactor Seeding should be done preferably by using activated sludge
from an well-operated plant.

Note- The foaming problem usually occurs during start-up and is only temporary. If you are under starting up
do not be alarmed by it. To avoid the foaming problem deformers shall be used.
7.4.3 Low oxygen uptake in Bio-reactor

Possible cause Necessary check & possible corrective actions

High Temperature At high temperature there will be decreased oxygen utilization.
Maintain the inlet effluent temperature between 250C to 350C
maintain organic removal
pH out of range Eliminate source of pH upset
Adjust pH in between 6.5 and 8.5
Spill Eliminate source of spill
Evaluate effect of spill on active Bio Mass.
Low organic loading Adjust the air supply according to the inlet BOD load,
simultaneously maintain the DO level >2.0 mg/l.

7.4.4 Low Bio Growth in the Bio-reactor

Possible Cause Necessary Check & Possible Corrective Actions

High Temperature High process temperature can result in decreased oxygen
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utilization and as a result low bacterial growth. Apart from this at

high temperature there is possibility that microorganisms may die

Maintain the inlet effluent temperature between 25 0C to 350C to

maintain organic removal
pH out of range Eliminate source of pH upset as it will adversely affect the
Biological process.
Insufficient aeration Insufficient aeration may lead to decrease in bacterial population.
The aeration should be continuously carried. Even if the effluent is
not available for a short span in a day blowers should not be
stopped.
Shock loading The effluent having pollutant level very high should be segregated
and stored separately.
The effluent having toxic pollutant should be prevented from
entering the ETP.

7.4.5 High suspended solids level in the Settling Tank outlet effluent

Possible cause Necessary Check & Possible Corrective Actions

Media position Withdraw samples for observations and adjust the dosing of
chemicals accordingly.
Excessive storage of sludge in the tube settler. The sludge needs to be drained periodically from the settler. In
case the sludge level increases in the settler the same will
result in sludge carry over.
Trough are not cleaned The trough should be cleaned manually periodically.

7.4.6 High COD (or BOD) level in Settling Tank outlet effluent

Possible cause Necessary Check & Possible Corrective Actions

Low Bio mass Seeding may be required.
High organic loading and/or excessive flow Increase in the inlet BOD/COD load in comparison to Design.
If the increase is for a short time decrease the flow to maintain
the kg BOD loading as far design.
High effluent suspended solid (SS) If COD increase is attributable to high effluent suspended
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solids, refer to corrective actions for “high effluent suspended

solids”
Inadequate DO Check organic loading by measuring COD. Increased oxygen
utilization can result from increased organic loading. Refer to
corrective actions for “low oxygen level”
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Chapter 8: Estimation of Various Chemicals

The requirements of various chemicals must be determined by means of jar test. It is strongly recommended
to conduct the jar test whenever any major changes occurs either in selection of process, dyes, or raw
material characteristics. Different process condition due to change of raw materials or change of brand of
dyes will lead to different types of effluent characteristics.

8.1 Estimation of quantity of lime (Calcium Hydroxide):-

From our experience of running plants and jar tests, the quantity of required lime can be estimated as
follows;

If the flow of effluent is “” M3/Hr.

Dose optimized by jar test = “y” mg / l.

Therefore,
“” M3 /hr. X “y” mg /l X 24 hrs.
CaO required = --------------------------------------------- = “A” Kg / day. = “B” kg/hr
1000

8.2 Estimation of quantity of Ferric alum/Ferrous Sulfate FeSO4.

Based on experience or by jar tests findings the dosages can be stabilized. e.g.
If flow of effluent is “” Cu.m / Hr.
Dose optimized by jar test = “y” mg / l.

Therefore
“”M3 /hr. X “y” mg /l X 24 hrs.
Ferric alum required = ------------------------------------------------- = A Kg / day. =B kg /hr
1000
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8.3 Estimation of quantity of Polyelectrolyte.

Based on experience or by jar tests findings the dosages can be stabilized. e.g.
If flow of effluent is “”Cum / Hr.
Dose optimized by jar test = ‘y’ mg / l.

Therefore,
“”M3/hr X ‘y’ mg / l X 24 hrs
Polyelectrolyte required = -------------------------------------------- =A kg / day = B kg / hr
1000

(This amount will be required for dosing in the flash mixing as well as centrifuge feed pump)
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Chapter 9: Commissioning of the Plant

1. Effluent allow in the Oil & Grease trap which helps to separate oil & grease from effluent.

2. Than Allow to fill the Collection Cum Neutralization tank up to the level.
3. The effluent is then allowed in the collection tank. 2 Nos. tanks to facilitate method of fill and draw
operation. With help air blower air introduced into the collection cum neutralization tank for the
homogenous mixing of the effluent which helps to coagulate the settle-able solids.
4. The pH of the effluent is adjusted in the collection cum neutralization tank. It is necessary to check
the pH of the effluent at this stage and if the pH is above 7 then alum solution is dosed to bring down
the pH within a range of 6.5 to 9.5. Also dosing of lime, ferric alum is done.
5. The effluent is pumped to the inlet launder of settling tank. During this, polyelectrolyte and some
amount of alum is dosed in the effluent. Soon after dosing, the color of the effluent will be changed.
6. Samples are withdrawn for lab analysis and the chemical dosing is adjusted accordingly.
7. After neutralization tank the dissolved matters will form small flocks. Under this condition a
substantial amount of sludge will be accumulated at the bottom of this settler tank. Settling tank
equipped with tube media for the settlement of sludge. Accumulated sludge is drained from the
hopper bottom of settling tank.
8. The overflow of the effluent from the settling tank is connected to the launder of Bio reactor tank for
biological treatment. Sewage generated is pumped via the sewage transfer pumps to the aeration
tank for treatment.
9. The effluent is in the Biological reaction tank is acted upon by microorganisms like bacteria which
are seeded in Biological reaction tank. Nutrients (DAP & Urea) are dosed in for nursing
microorganisms like bacteria. Aeration is provided with help of diffused aeration system. At this stage
the remaining BOD/COD will be reduced. From the Biological reaction tank, the effluent enters into
the Secondary Settling Tank. This happens due to overflow.
10. As the effluent flows through the Secondary Settling Tank, the sludge generated during bio treatment
is settled at the hopper bottom of the tank.
11. The effluent with activated biological sludge enters the Secondary Settling Tank through a pipe to
launder, where it flows downwards and then outwards to launder.
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12. The activated sludge settles at the bottom of the Secondary Settling tank, where it collected in the
center cone of Secondary Settling Tank by gravity.
13. The sludge recirculation line goes to the aeration tank and the overflow of effluent goes to Collection
tank. From collection tank effluent pumps through a pipe to the Center feed well of clarifier for further
treatment. The Lime & Alum dosing is carried out at center feed well which helps to reduce General
Parameters. Then effluent overflow into the polishing tank for tertiary treatment.
14. The effluent is then pumped to the pressure sand filter or Granular Media Filtration-to remove
carbonaceous BOD and nitrogenous and residual in solubilized phosphorous. This filter is also
useful to protect the downstream Activated Carbon Filter (ACF) from overloading by pollutants such
as particulates, organics.
15. The effluent is then pumped through the Activated Carbon Filter. Carbon adsorption is a proven
process in tertiary treatment for the processing biologically treated wastewaters, and is one of the
many processes used in the advanced treatment of wastewaters. The ACF is used to remove
relatively small quantities of refractory organics, as well as inorganic such as phenols, sulfides and
heavy metals remaining in an otherwise well-treated wastewater.
16. Samples are withdrawn periodically for lab analysis and checked for the parameters before
discharging to be under the MPCB limits.
17. The water at this stage is safe to be released into the environment and can be used for gardening,
flushing.
18. The sludge generated after drying in sludge beds is disposed off safely to CHWSTDF.
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Chapter 10: Plant Shutdown

In cases when the factory is kept shut down for a short period of time then there will not be any effluent, in
that case it will be necessary to continue aeration and nutrient dosing in the Biological reaction tank
otherwise the bacteria will die. If the bacteria die then it will be necessary to seed bacteria again. Also the
ETP/ units of ETP should be cleaned properly approximately once in two months or as on when required.
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Chapter 11: Maintenance of the plant

11.1 Equalization pump:
The valve should be checked before starting the pump. The valve of the suction line and discharge should be
opened and cleaned once every seven days.
11.2 Air Blower:
Check the lube oil level before starting the air blower. If there is no lube oil then fill lube oil and start the
blower. The lube oil pump should check frequently.
11.3 Sludge transfer pump and feed pump:
After starting the sludge transfer pump and feed pump it should be observed for a short period of time. If no
sludge is found then stop the pump and open and clean the delivery line.
11.4 Agitators of all the dosing tanks:
Check the lube oil every seven-day. Apply lube oil if finishes.
11.5 Settling tank:
The tanks should be cleaned very well in every month.
11.6 Sand Filter:
[

It is necessary to backwash the sand filter every four hours or as and when required.
11.7 Carbon filter:
It is necessary to backwash the carbon filter every four hours or as and when required.
11.8 Painting the plant:
All the pipes and M.S tanks should be painted every year.

Operation of Pressure Sand Filter & Activated Carbon Filter

The filtration section mainly comprises of following equipment

1. Pressure Sand Filter (PSF)

2. Activated Carbon Filter (ACF)
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Water from Polishing tank is pumped/ passed through the pressure sand filter (PSF) and then Activated
Carbon Filter (ACF).

Operation:
The Plant is designed to provide trouble free service. Each of the above filter units needs to be backwashed
once in 4 hour or whenever pressure drop across PSF and ACF whichever is earlier.
The Pressure Sand Filter & Activated Carbon Filters are backwashed in staggered fashion which is
described below.

A. Backwash of PSF
The following steps to be followed
Open backwash inlet valve and backwash outlet valve. Continue backwash of the filter for 8-10 minutes.
Water during backwash flows in the upward direction thereby cleaning the filter off dirt accumulated at the top
of the filter media. Backwash water comes out of backwash out let and same shall be drained. Flow rate for
filter backwash shall be maintained.
Valve position
Open- backwash inlet & outlet valve.
Close- service inlet & outlet valve rinse out let valve.

Step-3 Rinsing of PSF

Close backwash inlet & out let and open service inlet valve and rinse out let valve. Rinse water comes out of
backwash outlet and the same shall be drained. Continue rinsing for 5 minutes. Rinse flow rate shall be
same as service flow rate.
Valve position
Open- service inlet & outlet valve, rinse outlet valve.
Close- backwash inlet & outlet valve
Precaution:
Replacement of filter media is required to be done every 12 months.

B. Backwash of ACF
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Step-1 Backwashing of ACF

Close rinse outlet valve of PSF, service inlet and outlet valve of ACF. Open backwash inlet and outlet valve
of ACF. Backwash water flows in upward direction in ACF thereby backwashing the media. Continue
backwashing for about 10-15 minutes. Backwash water comes out from backwash outlet and the same shall
be drained .Flow rate for ACF backwash 1 m3/hr.

Valve position
Open ACF backwash inlet & outlet valve.
Close ACF service inlet & outlet valve, rinse backwash valve
PSF All the valve of sand filter close

Step-2 Rinsing of ACF.

Now close the backwash inlet & outlet valve of the ACF. Open service inlet valve of ACF and service inlet &
outlet valve of ACF rinse outlet valve. Continue rinsing for about 3-5 minutes. Rinse water comes out from
backwash outlet and the same shall be drained. Flow rate for ACF rinsing should be maintained.

Precaution:
It is necessary to replacement of Activated carbon media shall be every 12 months.
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TECHNICAL SPECIFICATION FOR ETP

AT
M/S. Dyna Glycols Pvt Ltd.,
1. OIL & GREASE TRAP: (CIVIL)

 Qty. : 1 No.
 Size : 2.4 M x 2.8 M x 1.3 M.
 M.O.C. : R.C.C.

2. COLLECTION CUM (CIVIL)

 Qty. : 2 Nos.
 Size : 6.4 M x 2.8 M x 3.6 M.
 M.O.C. : R.C.C.

3. CHEMICAL PREPARATION AND DOSING SYSTEM: (MECHANICAL)

 Qty : 3 Nos.
 Cap : 200 Lit each
 MOC : HDPE

4. ONLINE POLY DOSING SYSTEM: (MECHANICAL)

 Qty : 2 Nos.
 Cap : 10 Lit/hr
 MOC : PP

5. EFFLUENT TRANSFER PUMP: (MECHANICAL)

 Qty. : 2 Nos.
 Capacity : 9 M3 / hr.
 Head : 5 mtrs
 MOC : C.I.

7. CORAS BUBBLE AERATION SYSTEM : (MECHANICAL)

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 Qty. : 2 System.
 Size : 150 mm
 MOC : EPDM/HDPE
 Supports : Concrete block

8. SETTLING TANK: (CIVIL)

 Qty : 2 Nos
 Size :
 M.O.C. : MS Inner Rubber lined

9. AIR GRID FOR SETTLERS: (MECHANICAL)

 Qty : 2 Nos
 Cap : Ø1½"
 M.O.C : S.S. 3.4

10. AIR BLOWERS: (MECHANICAL)

 Qty : 2 Nos
 Cap : 350 M3/hr.
 Pressure : 0.6 kg/cm2
 Fittings : Suction filter, silencer, safety relief valve, etc

11. BIO-REACTOR: (CIVIL)

 Qty : 2 Nos
 Size : 7.5 M X 4.5 M X 3.7 M
 M.O.C : R.C.C
 O.S : Inside launders & working plate form

12. FINE BUBBLE DIFFUSE AERATION SYSTEM: (MECHANICAL)

 Qty : 1 system
 Size of diffusers : Ø 63mm & 2000 mm long
 M.O.C : ceramic/EPDM
 Fittings : SS clamps, bolts, etc.

13. SECONDARY SETTLING TANK: (CIVIL)

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Qty : 1 No
Size : 3.0M x 3.0M x 2.5M
M.O.C. : R.C.C
O. S : Hopper bottom, inside launders

14. EQUILIZATION TANK: (CIVIL)

 Qty : 2 No
 Size : 5.4 M x 2.7 M x 2.7 M
 M.O.C. : R.C.C

15. TRANSFER PUMPS: (MECHANICAL)

 Qty : 1 Nos
 Cap : 4m3 /hr
 M.O.C. : C.I
 Head : 12 mtr
 Make : Kirloskar

16. CLARIFIER TANK WITH F.M. (CIVIL)

 Qty : 1 No
 Size : Ø 3.0M & 3.0M ht
 MOC : R.C.C
 O.S : Hopper bottom , outlet Launder

17. CLARIFIER MECHANISM WITH F.M. AGITATOR: (MECHANICAL)

 Qty : 1 No
 Size : Ø 3.0 & 3.0 M ht
 MOC : MSEP
 Gear box : Heavy duty warm reduction
 RPM : 5 rph
 O.S : MS bridge with safety railing

F.M. Agitator : 1 No

 M.O.C. : SS 304
 RPM : 100
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 O.C. : Supports & Channel

18. RETURN SLUDGE PUMPS: (MECHANICAL)

 Qty : 2 Nos
 Cap : 9 m3 /hr
 M.O.C. : C.I
 Head : 13.5
 Type : heavy duty slurry pumps

19. SLUDGE DRYING BEDS: (CIVIL)

 Qty : 5 Nos
 Size : 2.5.0M x 2.50M x 1.0M
 MOC : B.M
 O.S : filter media

20. SEWAGE EFFLUENT TRANSFER PUMPS: (MECHANICAL)

 Qty : 1 Nos
 Cap : 3 M3 /hr
 M.O.C. : C.I
 Make : Kirloskar
 O.S : Level switch with Auto cut

21. POLISHING TANK: (CIVIL)

 Qty : 1 No
 Size : 3.9 M x 2.6 M x 1.9 M
 MOC : R.C.C

22. FILTER FEED PUMPS: (MECHANICAL)

 Qty : 2 Nos.
 Cap : 9 m3/ hr
 Head : 13.5 mtrs
 M.O.C. : C.I
 Type : High pressure pumps

23. PRESSURE SAND FILTER: (MECHANICAL)

 Qty : 1 No
 Cap : 4m3 /hr
 MOC : MSEP
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 O.S : Backwash Arrangement, Inside Multigrade Filter Media

 Filter Media Specification : Quartz Pebbles (Size: 1" x 1 ½”)
Quartz Pebbles (Size: 1 ½” x 1")
Quartz Pebbles (Size: ¼ " x ½”)
Quartz Pebbles (Size: 1/10" x ¼”)
Quartz Pebbles (Size: 16 x 30 mesh)

24. ACTIVATED CARBON FILTER: (MECHANICAL)

 Qty : 1 No
 Cap : 4m3 /hr
 O.S : MSEP
 O.S. : Back wash arrangement,
Inside high Graded Activated Carbon Layer
 Media Specification : Grade : GVC special
M.O.C. : Granular made of coconut shell charcoal
Iodine value : 1100 to 1200
Bulk density : 0.5  0.01gm/cc
Ash percentage: Maximum – 5%
PH : 9 to 10
Moisture : Maximum 5%
Mesh size : 8 x 16 (2mm x 1mm)
Reference Document: -

1. Influent and effluent record register

2. Chemical Consumption register
3. Parameter Monitoring Register

Prepared By Verified By Reviewed By Authorized By

Signature:

Date:
Name:
Designation: