Manimed Pharma: Effluent Treatment Plant Installation

By Mechwat
April 8, 2019
Blog

By Mechwat
April 8, 2019
Blog

Project : Effluent Treatment Plant Installation

Client : Manimed PharmaCeutical

Plant Location : Ahmedabad, Gujarat.

Design Concept :

Plant Capacity	2 M³/hr
Flow Rate	0.334 M³/hr
Service Cycle	6 hrs
Plant Capacity

Inlet Parameter of Effluent Waste Water :

Sr. No.	Parameter	Unit	Averages
1.	pH……………………………..	-…………………………………	6-8
2.	TDS…………………………….	ppm……………………………	1200-2000
3.	TSS……………………………..	ppm……………………………	200-400
4.	Color…………………………..	ppm……………………………	40-100
5.	BOD……………………………	ppm……………………………	190-300
6.	COD……………………………	ppm……………………………	450-5000
7.	Oil & Grease……………….	ppm……………………………	2
8.	Sulphate……………………..	ppm……………………………	99-200
9.	Chloride………………………	ppm……………………………	400-600
10.	Ammonical Nitrogen…..	ppm……………………………	39-100
11.	Sodium………………………	ppm……………………………	520-600
Inlet Effluent Parameter

Outlet Parameter of Treated Effluent :

Sr. No.	Parameter	Unit	Averages
1.	pH……………………………..	-…………………………………	6.5 to 7.8
2.	TDS…………………………….	ppm……………………………	1200
3.	TSS……………………………..	ppm……………………………	100
4.	Color…………………………..	ppm……………………………	100
5.	BOD……………………………	ppm……………………………	30
6.	COD……………………………	ppm……………………………	100
7.	Oil & Grease……………….	ppm……………………………	2
8.	Sulphate……………………..	ppm……………………………	1000
9.	Chloride………………………	ppm……………………………	600
10.	Ammonical Nitrogen…..	ppm……………………………	50
11.	Sodium………………………	ppm……………………………	520
Outlet Effluent Parameter

Effluent Treatment Process :

Sr No.	ETP Process Unit	Size(LxBxH) in M	Capacity (Liter)
0	Effluent Inlet	–	–
1	Oil & Grease Chamber	0.5 x 0.5 x 1	500
2	Collection cum neutralization tank	2 x 1.5 x 2	6000
3	Settling Tank	2 x 2x 2	8000
4	Sludge Drying Bed	1.2 x 1.2 x 2	2880
5	Pressure Sand Filter	0.2 x 1.2	100
6	Activated Carbon Filter	0.2 x 1.2	100
7	Water Supply for Gardening Propose	–	–
8	Water Evaporation System	500 Liter/Day	500 Liter/Day
ETP Process Unit Detail

Effluent Treatment Process Description :

Sr.No.	Process Unit	Process Description
1.	Oil & Grease Chamber	Washing water from Tablet, Ointment unit transfer to Oil & Grease Tank to trap the Oil Content. Oil and water will be separate through density difference. Water having more density forms the lower layer and oil having less density forms the upper layer.
2.	Collection cum Neutralization Tank	Effluent from oil & grease tank transfer to collection cum neutralization tank by gravity base. Initially pH of effluent water set up at 8.5 by chemical dosing of direct flocculants. Sub sequently pH raise to 10.5-11.5 by lime dosing. Chemical mixing is done by Agitator having 1 HP Gear Motor & SS Impeller Shaft. Initially chemical dosing will help to maximum sludge separation. Coagulation-Flocculation Separation : The use chemical re-agent to destabilize and increase the size of the particles ; mixing; increasing of flog size pH of effluent will be maintain at 7.8 settled for 3 hrs then supernant transfer to settling tank and residual sludge transfer to sludge drying bed through 1 HP mud pump.
3.	Settling Tank	Treated effluent from collection cum neutralization tank transfer to settling tank by water transfer pump. Flocculated water will be settled to remove the turbidity of water.
4.	Pressure Sand Filter	Settled water will be treasnfer to pressure sand filter by water transfer pump. Pressure sand filter remove suspened solids.
5.	Activated Carbon Filter	Filtered water from pressure sand filter will be filter out in activated carbon filter to remove the chlorine content and residual.
6.	Water supply for gardening	Filter out water of carbon filter utilize for gardening purpose
7.	Evaporation System	If area is not enough to avaible for gardening then water will be evaporate in Water Evaporator.
ETP Process Description

Technical Specification :

Oil & Grease Chamber
1	Quantity	1 Nos
2	Type	Manual Batch- Density Difference
3	Size	500 Liter
4	MOC	Civil Work- 225mm Brick Plaster
Collection Cum Neutralization Tank
1	Quantity	1 Nos
2	Capacity	6000 Liter
3	Design	As per drawing
4	MOC	Civil Work-225mm Brick Plaster
Alum Dosing System
1	Dosing Tank capacity	100 Liter
2	MOC	HDPE
3	Operation	Manual Valve Type
4	Chemical	Alum
5	Make	Suntex
Poly Electrolyte Dosing System
1	Dosing Tank Capacity	100 Liter
2	MOC	HDPE
3	Operation	Manual Valve Type
4	Chemical	Anion/Cation Polyelectorlyte
5	Make	Suntex
pH Maintenance Dosing System
1	Dosing Tank Capacity	100 Liter
2	MOC	HDPE
3	Operation	Manual Valve Type
4	Chemical	HCL / NaOH
5	Make	Suntex
Settling Tank
1	Quantity	1 Nos
2	Capacity	8000 Liter
3	Design	AS per drawing
4	MOC	Civil Work- 225mm brick plaster
Pressure Sand Filter
1	Quantity	1 Nos
2	Capacity	0.5 m³/hr
3	Design Data	Min. & Max. Press. (2.4 -3.5 kg/cm²)
4	MOC	FRP
5	Make	Pentair
6	Mode of Operation	Manual Multiport Valve
7	Media Type	Filtration graded sand & pebbles
8	Design Velocity	6 M/hr
Activated Carbon Filter
1	Quantity	1 Nos
2	Capacity	0.5 m³/hr
3	Design Data	Min. & Max. Press. (2.4 -3.5 kg/cm²)
4	MOC	FRP
5	Make	Pentair
6	Mode of Operation	Manual Multiport Valve
7	Media Type	Filtration graded sand & pebbles
8	Design Velocity	6 M/hr
Sludge Drying Bed
1	Quantity	1 Nos
2	Capacity	2880 Liter
3	Design	AS per drawing
4	MOC	Civil Work- 225mm brick plaster
Water Evaporation System
1	Evaporator Type	Electric Heated
2	Evaporator	500 Litres/day
3	Size	2 Ft [Dia.] x 2.75 Ft [ Height]
4	MOC	MS IS 2062
5	Thickness	6 MM Flat Bottom
6	Heating Media	Electric
7	Quantity of Heater	3 Nos.
8	Heater Capacity	3 KW Each
9	Total load of heaters	9 KW
10	Insulation	With outer side insulation 40 mm with glass wool and coated by 26 gauge aluminium sheet with other required connection inlet and outlet
11	Electric.
		Dial Type Thermocouple “J” Type
		Contactor – Schneider Make
		MCB-Schneider Make
		Liquid level controller – shut off heater when water level low
		RYB Light
		On/OFF Push Button – L&T Make
Interconnecting Piping & Valves
1	Quantity Offered	One Lot.
2	Type	UPVC /HDPE/GI As applicable Complete Interconnecting Piping Within The Battery Limits
3	Valves	Ball Valve and manual valves as required
4	Supports	Pipe Supports for interconnecting piping
Instrumentation
1	Pressure Gauges	At Feed of carbon filter & pressure sand filter
2	Flow meter	Discharge of Activated Carbon Filter & Pressure Sand Filter
3	Energy Meter	HPL Make; Analoge Type KWH Meter 3Ph Four Wire 10-60 Amps
Technical Specification

Civil Work Specification :

Sr. No.	ETP Process Unit	Size [ L x B X H ]	Capacity [ Liter]	Civil Work Type	Work Scope
1	Oil & Grease Chamber	[ 0.5 x 0.5 x 1] M	500	250 mm brick work	Client
2	Collection Cum Neutralization Tank	[ 2 x 1.5 x 2 ] M	6000	250 mm brick work	Client
3	Settling Tank	[ 2 x 2 x 2] M	8000	250 mm brick work	Client
4	Sludge Drying Bed	[ 1.2 x 1.2 x 2] M	2880	250 mm brick work	Client
Civil Work Specification

Installed Plant Process Unit Layout :

Sr No.	ETP Process Unit	Size(LxBxH) in M	Capacity (Liter)
0	Effluent Inlet	–	–
1	Oil & Grease Chamber	0.5 x 0.5 x 1	500
2	Collection cum neutralization tank	2 x 1.5 x 2	6000
3	Settling Tank	2 x 2x 2	8000
4	Sludge Drying Bed	1.2 x 1.2 x 1	2880
5	Pressure Sand Filter	0.2 x 1.2	100
6	Activated Carbon Filter	0.2 x 1.2	100
7	Water Supply for Gardening Propose	–	–
8	Alum Dosing System	–	100
9	Poly Electrolyte Dosing System	–	100
10	pH Control System	–	100
11	Water Evaporation System	–	500
ETP Process Unit Detail

Installation Qualification :

Sr. No.	Item Name	Specification	Checked By	Status
Oil & Grease Chamber
1	Quantity	1 Nos	MTPL	Ok
2	Type	Manual Batch- Density Difference	MTPL	Ok
3	Size	500 Liter	MTPL	Ok
4	MOC	Civil Work- 225mm Brick Plaster	MTPL	Ok
Collection Cum Neutralization Tank
1	Quantity	1 Nos	MTPL	Ok
2	Capacity	6000 Liter	MTPL	Ok
3	Design	As per drawing	MTPL	Ok
4	MOC	Civil Work-225mm Brick Plaster	MTPL	Ok
Alum Dosing System
1	Dosing Tank capacity	100 Liter	MTPL	Ok
2	MOC	HDPE	MTPL	Ok
3	Operation	Manual Valve Type	MTPL	Ok
4	Chemical	Alum	MTPL	Ok
5	Make	Suntex	MTPL	Ok
Poly Electrolyte Dosing System
1	Dosing Tank Capacity	100 Liter	MTPL	Ok
2	MOC	HDPE	MTPL	Ok
3	Operation	Manual Valve Type	MTPL	Ok
4	Chemical	Anion/Cation Polyelectorlyte	MTPL	Ok
5	Make	Suntex	MTPL	Ok
pH Maintenance Dosing System
1	Dosing Tank Capacity	100 Liter	MTPL	Ok
2	MOC	HDPE	MTPL	Ok
3	Operation	Manual Valve Type	MTPL	Ok
4	Chemical	HCL / NaOH	MTPL	Ok
5	Make	Suntex	MTPL	Ok
Settling Tank
1	Quantity	1 Nos	MTPL	Ok
2	Capacity	8000 Liter	MTPL	Ok
3	Design	AS per drawing	MTPL	Ok
4	MOC	Civil Work- 225mm brick plaster	MTPL	Ok
Pressure Sand Filter
1	Quantity	1 Nos	MTPL	Ok
2	Capacity	0.5 m³/hr	MTPL	Ok
3	Design Data	Min. & Max. Press. (2.4 -3.5 kg/cm²)	MTPL	Ok
4	MOC	FRP	MTPL	Ok
5	Make	Pentair	MTPL	Ok
6	Mode of Operation	Manual Multiport Valve	MTPL	Ok
7	Media Type	Filtration graded sand & pebbles	MTPL	Ok
8	Design Velocity	6 M/hr	MTPL	Ok
Activated Carbon Filter
1	Quantity	1 Nos	MTPL	Ok
2	Capacity	0.5 m³/hr	MTPL	Ok
3	Design Data	Min. & Max. Press. (2.4 -3.5 kg/cm²)	MTPL	Ok
4	MOC	FRP	MTPL	Ok
5	Make	Pentair	MTPL	Ok
6	Mode of Operation	Manual Multiport Valve	MTPL	Ok
7	Media Type	Filtration graded sand & pebbles	MTPL	Ok
8	Design Velocity	6 M/hr	MTPL	Ok
Sludge Drying Bed
1	Quantity	1 Nos	MTPL	Ok
2	Capacity	2400 Liter	MTPL	Ok
3	Design	AS per drawing	MTPL	Ok
4	MOC	Civil Work- 225mm brick plaster	MTPL	Ok
Water Evaporation System
1	Evaporator Type	Electric Heated	MTPL	Ok
2	Evaporator	500 Litres/day	MTPL	Ok
3	Size	2 Ft [Dia.] x 2.75 Ft [ Height]	MTPL	Ok
4	MOC	MS IS 2062	MTPL	Ok
5	Thickness	6 MM Flat Bottom	MTPL	Ok
6	Heating Media	Electric	MTPL	Ok
7	Quantity of Heater	3 Nos.	MTPL	Ok
8	Heater Capacity	3 KW Each	MTPL	Ok
9	Total load of heaters	9 KW	MTPL	Ok
10	Insulation	With outer side insulation 40 mm with glass wool and coated by 26 gauge aluminium sheet with other required connection inlet and outlet	MTPL	Ok
11	Electric.		MTPL	Ok
		Dial Type Thermocouple “J” Type
		Contactor – Schneider Make
		MCB-Schneider Make
		Liquid level controller – shut off heater when water level low
		RYB Light
		On/OFF Push Button – L&T Make
Interconnecting Piping & Valves
1	Quantity Offered	One Lot.	MTPL	Ok
2	Type	UPVC /HDPE/GI As applicable Complete Interconnecting Piping Within The Battery Limits	MTPL	Ok
3	Valves	Ball Valve and manual valves as required	MTPL	Ok
4	Supports	Pipe Supports for interconnecting piping	MTPL	Ok
Instrumentation
1	Pressure Gauges	At Feed of carbon filter & pressure sand filter	MTPL	Ok
2	Flow meter	Discharge of Activated Carbon Filter & Pressure Sand Filter;	MTPL	Ok
3	Energy Meter	HPL Make; Analoge Type KWH Meter 3Ph Four Wire 10-60 Amps	MTPL	Ok
Installation Qualification

Operation specification :

Sr. No.	ETP Process Unit Segment	Action Required	Frequency
1	Energy Meter	To note down energy meter reading in ETP Manual before starting the electricity in ETP Plant	Daily
2	Water Flow Meter	To note down the energy meter reading of activated carbon discharge point and water evaporation inlet unit	Daily
3	pH Check	To Check the pH of effluent Inlet	Daily
4	ETP Inlet Point	To Check the flow of effluent from process unit to ETP is proper	Weekly
		To remove the plastic and other non- treatable waste from inlet	Weekly
5	Oil & Grease Unit	To check the whether Oil is collect in first part of unit or not.	Daily
		To collect the excessive oil from past of oil & grease unit through manual operation	Weekly
		If there is excessive emulsion type sludge then manually required to extract and dry in sludge drying bed.	Weekly
6	Collection cum Neutralization Tank	To Take the dosing operation of Non- ferric Alum as per given SOP Calculation	Daily
		To Start the Agitator for mixing propose	Daily
		To Take the dosing operation of Poly Electrolyte as per SOP Calculation	Daily
		To Maintain the pH@7.0 by dosing of pH Control	Daily
		To check the chemical mixing performance through natural circulation by visual observation.	Daily
		If mixing is not proper than ETP Operator will require to recirculation of water through Water Pump	Daily
		If there is excessive sludge found in tank then manual operation for sludge removal required	Monthly
7	Alum Dosing Dosing Tank	To fill up the alum dosing solution in tank whenever required. Dosing process will be follow the SOP Calculation	Daily
8	Poly-Electrolyte Dosing Tank	To fill up the poly electrolyte dosing solution tank whenever required.	Daily
9	pH Control Unit	To fill up the acid/base whatever required for pH Control	Weekly
10	Effluent Transfer	To transfer the effluent from collection cum neutralization tank to settling tank	Daily
11	Effluent Settling Tank	To maintain the minimum 4 Hrs. retention time for water settling tank	Daily
		To Drain out sludge in sludge drying bed	Weekly
12	Effluent Transfer	To Transfer the settled effluent from settling tank to pressure sand Filter by water transfer pump	Daily
13	Pressure Sand Filter	To Transfer the effluent from settling tank to pressure sand filter by water transfer pump	Daily
		To rinse water in pressure sand filter using manual multiport valve operation for 10 minute for 3 times continue.	Daily
		To backwash the water in pressure sand filter using manual multiport valve operation for 10 minute for 3 times continue.	Daily
14	Activated Carbon Filter	To Transfer the effluent from settling tank to Activated carbon filter by water transfer pump	Daily
		To rinse water in Activated Carbon filter using manual multiport valve operation for 10 minute for 3 times continue.	Daily
		To backwash the water in Activate Carbon filter using manual multiport valve operation for 10 minute for 3 times continue.	Daily
15	Water Evaporation System	To start the water evaporation if gardening area is not enough for treated water ETP	Daily
16	Treated Water Supply for Gardening	To utilize the activated carbon filter water for gardening purpose	Daily
Operation Specification

Standard Operation Process for ETP :

Oil & Grease Tank :

To check the supernatant liquid of oil & grease tank
If Oil & grease residual found then manually extract by bucket.
Check the pH of Effluent

Collection cum Neutralization Tank

Start the Water Transfer pump.
To Start the agitator for chemical mixing in effluent water.
If pH is acidic or neutral then Raise the pH of effluent up to 9 by dosing of lime [150 Gram in 2000 Liter]
After raising the pH upto 9, Start the dosing of alum [200 gram in 2000 Liter ] or maintain the pH 7 by dosing of Alum.
Once the pH maintain at 7 Start the Cationic polymer dosing [56 gram in 2000 Liter]
Maintain water mixing at least 20 minute after the dosing of cationic polymer.
[If color residual found in final treated water then also add the bleaching powder in 5 ppm concentration]
Stop the water mixing and start the Water Transfer in Settling Tank

Settling Tank

Maintain the water settling for 6 Hrs.
Transfer the supernatant water for filtration of Evaporation propose.
Transfer the settled solid of settling tank to sludge drying bed [Operation is once a week]

Filtration

Start the water transfer pump of filtration unit.
Operate the activated carbon filter in Rinse & Back Wash mode for 15 minute.
Operate the pressure sand filter in Rinse & Back Wash mode for 10 minute.
Transfer the treated water for gardening propose.

Evaporation.

Feed the water from settling tank to Evaporator and operate evaporator till water completely evaporated.

Sludge Discharge

Dried sludge required to supply for GPCB Authorize landfill site

Chemical Requirement in Daily Operation

Sr. No.	Chemical Detail	Dosing Required for 2000 Liter Effluent	Chemical requirement for 100 liter dosing tank for daily operation of 2000 Liter Effluent Treatment
1	Lime	150 Gram /Day	150 Gram /Day
2	Alum	200 Gram / Day	200 Gram /Day
3	Cation polymer	56 Gram /Day	56 Gram /Day
4	Bleaching Powder	37 Gram /Day	37 Gram /Day

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