STP Guide Web (Med) (Repaired)

Design, Operation and Maintenance
Author Dr. Ananth S. Kodavasal

Editor Nagesh
Illustrator Nagesh
Publisher Karnataka State Pollution Control Board,
Bangalore, India
2 | The STP Guide – Design, Operation and | 3

Maintenance
Contents
The STP Guide – Design, Operation and Maintenance, First Edition
Author
Copyright © 2011 by Karnataka State Pollution Control Board (KSPCB), Dr. Ananth S Kodavasal
Bangalore, India.
All rights reserved. Foreword..................................................................................................................11
Editor
Preface.....................................................................................................................13
Nagesh
This book exists in two different forms: print and electronic (pdf file).
Acknowledgements.................................................................................................15
• An electronic copy of this book can be freely downloaded from the websites
authorized by KSPCB. How to Use This Book.............................................................................................17
Illustrator
• Printed copies of this book are available at a nominal price through all KSPCB
Nagesh
Background..............................................................................................................19
offices; and its head-office at the address provided below.
The Operating Principle of STPs................................................................................................. 21
Permission is granted to make copies of this book and re-distribute them; provided that
these copies are not sold for profit. Typical Process in an STP........................................................................................................... 23
DTP & Layout
Benefits of a well-run STP........................................................................................................... 24
Prasun Banerjee
Disclaimer:
Understanding the STP Stages...............................................................................27
No patent liability is assumed with respect to the use of the information contained herein.
Although every precaution has been taken in the preparation of this book, the publisher and author Bar Screen Chamber...............................................................................................28
assume no responsibility for errors or omissions; Nor is any liability assumed for damages resulting Publisher
from the use of the information contained herein. 1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
This book is meant to enlighten and guide the target audiences. The checklists and calculations in this
book are designed to provide a reference for assessing the STP. However, in case of a commercial/ 1.2 How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
regulatory dispute, further interpretation and analysis by professional expert may be required. This is
desired in light of alternative design approaches that achieve the same desired result, or the presence KSPCB
1.3 Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
of other factors that may mitigate an apparent deficiency.
The reader is cautioned that this book explains a typical STP design based on the “Extended Aeration 1.4 Construction And Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Activated Sludge Process”. The underlying principles and/or the calculations may not be fully
applicable to STPs of other types, including STPs that are based on a modified/hybrid approach. 1.5 Operation And Maintenance Considerations. . . . . . . . . . . . . . . . . . . . . . . 29
No warranty of fitness is implied: The information is being provided on an “as is” basis.
1.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wastewater treatment is a fast-developing field in India. At present, there is a lot of churn, as many of
the new entrant technologies are found to be unsuited to the existing constraints in Indian cities and Oil And Grease/Grit Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
apartments. Thus with passage of time, the state of technology is expected to be more advanced as
compared to the book. The author/editor assume no responsibility to keep the book current with the
fast-changing scenario. Although it is envisaged that subsequent revisions of this book will reflect the
2.1 Function........................................................................................................................... 30
changes in general, it would be impossible to characterize the vast variations possible in the basic
design at any given point of time.
2.2 How It Works................................................................................................................... 30
2.3 Design Criteria................................................................................................................. 31
Contact: 2.4 Construction And Engineering......................................................................................... 31
To obtain any kind of clarifications or permissions, please contact - 2.5 Operation And Maintenance Considerations...................................................................31
The PRO/PIO, Karnataka State Pollution Control Board,
2.6 Troubleshooting............................................................................................................... 31
“Parisara Bhavan”, #49, Church Street
Bangalore- 560 001, INDIA. Equalization Tank....................................................................................................32
email: ho@kspcb.gov.in
3.1 Function........................................................................................................................... 32
3.2 How It Works................................................................................................................... 32
3.3 Design Criteria................................................................................................................. 33
3.4 Construction And Engineering......................................................................................... 34
3.5 Operation And Maintenance Considerations...................................................................35
2 | The STP Guide – Design, Operation and Maintenance Content | 3

3.6 Troubleshooting............................................................................................................... 35 8.1
Raw Sewage Lift Pumps.........................................................................................36

4.1 Function........................................................................................................................... 36
4.2 How It Works................................................................................................................... 36
4.3 Design Criteria................................................................................................................. 37
4.4 Construction And Engineering.........................................................................................37
Aeration Tank..........................................................................................................40
5.1 Function........................................................................................................................... 40
5.2 How it works.................................................................................................................... 40
5.3 Design Criteria................................................................................................................. 41
Secondary Clarifier/Settling Tank...........................................................................46
6.1 Function........................................................................................................................... 46
6.2 How It Works................................................................................................................... 46
6.2.1 Settling tank with air-lift pump.......................................................................................... 46
6.2.2 Settling tank with direct-suction electric pump.................................................................48
6.2.3 Settling tank with buffer sump.........................................................................................50
6.2.4 Mechanized Clarifier Tank...............................................................................................52
6.3 Design Criteria................................................................................................................. 55
Sludge Recirculation...............................................................................................58
7.1 Function........................................................................................................................... 58
7.2 How It Works................................................................................................................... 58
7.3 Design Criteria................................................................................................................. 59
Clarified Water Sump..............................................................................................61

Function 61
8.2 Design Criteria................................................................................................................. 61
Filter Feed Pumps (FFP)..........................................................................................62
9.1 Function........................................................................................................................... 62
9.2 Design Criteria................................................................................................................. 62
Pressure Sand Filter (PSF)......................................................................................64
10.1 Function........................................................................................................................... 64
10.2 How It Works................................................................................................................... 64
10.3 Design Criteria................................................................................................................. 65
Activated Carbon Filter (ACF).................................................................................66
11.1 Function........................................................................................................................... 66
11.2 How It Works................................................................................................................... 66
11.3 Design Criteria................................................................................................................. 66
Disinfection Of Treated Water................................................................................69
12.1 Function........................................................................................................................... 69
12.2 Design Criteria................................................................................................................. 69
12.4 Operation And Maintenances Considerations.................................................................69
Excess Sludge Handling.........................................................................................70
13.1 Function........................................................................................................................... 70

13.2 Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Bar Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13.3 Construction And Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Equalization tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.3.1 Plate-and-Frame Filter press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
13.3.2 Bag-type dewatering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Aeration tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
13.4 Operation And Maintenance Considerations. . . . . . . . . . . . . . . . . . . . . . . 73 Secondary settling tank (Hopper-bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Secondary Clarifier tank (mechanized, with rake) . . . . . . . . . . . . . . . . . . . . . . . 106
Miscellaneous Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Sludge Recirculation pumps-Airlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Design and Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Sludge Recirculation pumps-Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
STP Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Sludge Recirculation system-Direct suction . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Design process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Sludge Recirculation system- With a buffer sump . . . . . . . . . . . . . . . . . . . . . . . 111
Design Criteria for STP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Clarified water tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Sewage Quantity (STP Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Filter feed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Bar Screen Chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Backwash pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Equalization Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Pressure Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Activated Carbon filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Aeration Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Disinfection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Clarifier Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Sludge-Handling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Airlift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Air Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electric Pumps for Return Sludge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 MISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Sludge-holding sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Operational checks for the STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Pressure Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Activated Carbon Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Bar Screen Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Sodium Hypo Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Equalization tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Sludge-Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Engineering checks for the STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Aeration tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Secondary settling tank (Hopper-bottom). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Secondary Clarifier tank (mechanized, with rake).....................................................................130
Sludge Recirculation pumps-Airlift.............................................................................................131
Sludge Recirculation pumps-Electric.........................................................................................131
Sludge Recirculation system-Direct suction..............................................................................132
Sludge Recirculation system- With a buffer sump.....................................................................132
Clarified water tank.................................................................................................................... 132
Filter feed Pumps...................................................................................................................... 133
Backwash pumps...................................................................................................................... 133
Pressure Sand Filter.................................................................................................................. 133
Activated Carbon filter............................................................................................................... 134
Disinfection system.................................................................................................................... 134
Sludge-Handling system............................................................................................................ 134
Air Blowers................................................................................................................................ 134
MISC......................................................................................................................................... 135
Appendices............................................................................................................137
Managing the Microbes............................................................................................................. 138

MLSS......................................................................................................................................... 139
Glossary.................................................................................................................................... 140
About the Author........................................................................................................................ 142

10 | The STP Guide – Design, Operation and Maintenance | 11
Preface
Over five years ago, the Karnataka State Pollution Control Board mandated that Sewage Treatment
Plants be built and operated in individual residential complexes having fifty or more dwellings, or
generating 50 m3/day or more of sewage. Additional conditions imposed among others were that the
treated water quality shall meet stringent “Urban Reuse Standards”, treated water shall be reused for
toilets flushing (thus requiring dual plumbing system in the residential complexes), for car washing, and
for irrigation use within the campus.
For a city like Bangalore, the action of the KSPCB as above comes as a blessing in disguise.
Let me elaborate my viewpoint:
Fresh water is getting scarcer by the day in every part of the Globe. Bangalore as a city finds itself in
a precarious position as far as availability of water is concerned, among other essentials for civilized
society. Planners and public utilities have abdicated their duty and responsibility to provide one of the
basic needs of the citizenry of good, clean water. In the years to come this scenario is only likely to
worsen.
More than fifteen years ago, I had recommended to the then Commissioner of the Mahadevapura
CMC that the water from Varthur lake could be renovated by employing suitable treatment schemes to
supply potable water to the then outlying areas of Bangalore city. This would be much more
economical and eminently feasible than the grandiose plans of multiple stages and phases of Cauvery
schemes that were being touted. My logic was simple: The river Cauvery, like a majority of all other
rivers in the world will continue to be a dwindling source of fresh water. The Varthur lake on the other
hand is a perennial source of water (albeit of a lesser quality), carrying the water discharged from
millions of homes in Bangalore. In a similar fashion, at other extremities of the city, other such
perennial sources of water may be tapped: The Vrishabhavati to the South and the Hebbal valley to
the North.
(I shall not go into the pros and cons of decentralized vs. centralized STPs, except to point out that
centralized plants will necessarily be under the aegis of the public utilities, and there I rest my case.)
A large residential complex, in its sewage generation potential, may then be viewed as a microcosm of
the city itself; with a ready and perennial source of water right at its doorstep. All that the complex
needs is to have a good, robust, well designed STP to produce water for all its secondary needs.
Kudos to the KSPCB for taking this initiative!
So, given this already grim and rapidly worsening scenario, it is important for the people living in
Bangalore and other mega cities in India to realize the importance of recycled water, and strive to set
up efficient water treatment plants within their complexes, so that they can themselves control the
quality of the water they use. At the same time, they will also be bringing down their own cost of living
substantially, by obviating the laying of huge pipelines that bring water from far-off places.
This book will help them achieve this all important goal.
It is my hope that all of us (legislators, experts, environmentalists and public at large) will make
concerted efforts to avert a water crisis of mega proportions.
Bangalore Dr. Ananth S Kodavasal

May 2011
12 | The STP Guide – Design, Operation and Maintenance Preface | 13

Acknowledgements
I owe a deep debt of gratitude to Mr. A.S Sadashivaiah, the Hon’ble Chairman of the KSPCB for
providing the impetus for this book, his further encouragement and support by undertaking to publish
the book under the aegis of the KSPCB for a worthy public cause.
I would like to thank Dr. D L Manjunath, for reviewing the book and giving his valuable inputs and
suggestions. Dr. Manjunath has been a respected academic at the Malnad College of Engineering,
Hassan, and the author of a textbook prescribed by the Visvesvaraya Technological University for its
degree courses in Environmental Engineering. He has served as Chairman of the Technical Advisory
committee of the KSPCB, and has been a member of the high powered State-Level Expert Appraisal
committee on environmental impacts of large projects. His achievements in this field are far too
numerous to be fully listed in this humble note of thanks.
Special thanks go to senior officers of the KSPCB M/s. M D N Simha, M N Jayaprakash, S Nanda
Kumar, K M Lingaraju, and H K Lokesh for their support at various stages in the making of the book.
Much of the credit for making this book a reality goes to my dear friend, Nagesh, who edited the book
and also provided illustrations. His keen intellect and a questioning mind ever probing to get to the
bottom of every issue big and small made him the perfect foil and indeed a sounding board for me to
keep this book simple to read yet convey the essentials of the subject in a comprehensible manner.
His illustrations in colour, done painstakingly, truly add value to the book, and break the monotony
of technical jargon, while giving flesh and blood and bringing to life otherwise inanimate objects in a
sewage treatment plant.
Dr. Ananth S Kodavasal

August 15, 2011
14 | The STP Guide – Design, Operation and Maintenance Acknowledgements | 15

How to Use This Book
This booklet is meant to be a primer on a Several variants of STP are in use, of which the
domestic STP (Sewage Treatment Plant). Extended Aeration Activated Sludge Process
The design, engineering, operation and model is most prevalent. Therefore this book is
maintenance aspects of the various units in the focused on this model.
STP are covered. The sections in this book are structured to follow
This book is for you if you belong to one of the the logical treatment process chain in a typical
following groups: STP, starting with the Bar Screen, and ending
with treated water for flush and drinking
• For large and small builders alike, who purposes. It also has a round up of the final
generally depend on plumbing consultants for chore: handling of the dewatered sludge.
STP designs, this book serves as a
reference. They can avoid a lot of costly For each unit of the STP, the following aspects
rework and delayed projects by following the are addressed:
design and engineering recommendations • The basic intended function of each unit
made in this book.
• How a typical unit looks like, and how it works
• For the Managing Committees (and Estate
• Design considerations
Managers) of an apartment complex, this
book provides both guidelines and checklists • Engineering considerations
for taking over from the builders. It also
• Operation and maintenance aspects
provides detailed guidance for day-to-day
operation and maintenance of STP. • Troubleshooting chart
• For the Facility Managers of factories The booklet is concise enough to give you a
and large office complexes, this book will bird’s eye view of an STP in a single sitting. But
serve as a guide for their daily operation and you may also wish to delve deeper into any
maintenance. section of this book to gain greater appreciation
of that particular unit of the STP. Take a moment
• For the officers of a Pollution Control
to ponder over the several statements made in
Board, who may be confronted with a myriad
each section, and to ask yourself the questions
options in design, served up by less-than-
what? how? why? when? You will be surprised to
competent agencies and individuals, this
find the answers for yourself with little application
book provides the core design and
of mind. Common sense is indeed the
engineering principles that must be met. It
cornerstone of Environmental Engineering!
also lists specific operational, maintenance,
safety and ergonomic considerations for Note that this book does not claim to be a
each stage of the STP. This should make it comprehensive design handbook for all forms of
easy for an officer to take a nonsubjective STPs, nor does it venture to compare the relative
decision about acceptability of any plant. merits of the various other schemes. Also note
that all the figures in this book are for illustrative
• For the students of Environmental purpose only; and many details are intentionally
Engineering, this booklet will bring a omitted to make them simple to understand.
welcome break from their differential Therefore please do not try to construct/modify
equations, and instead take them directly to any of the units based on these figures.
the end-result of these equations, tempered
with a large dose of practical know-how. If you would like to send any suggestions for
improvements, or any other feedback about
• For any lay person or environmentalist, this book, you can send a mail to the author at
this book provides general knowledge on the kodavaas@bgl.vsnl.net.in.
subject.
|
1
1
7
Background
A sewage treatment plant (“STP”) has to handle the designed quantity of sewage and deliver
satisfactory quality of treated water, on a consistent, sustained basis over typically 10-15 years.
This requires proper design and engineering; followed by proper operation and maintenance
throughout its life.
There are as many variations in the design and engineering of an STP as there are permutations and
combinations of Builders/ developers, architects, Utility Consultants, Vendors. It cannot be gainsaid
then that each of these agencies will have its own set of priorities and constraints which may adversely
impinge on the design and engineering of the STP, thereby diluting to various degrees the very
function and objective of the STP. Some of these constraints observed in the past on the part of these
agencies are:
• Lack of commitment to the environment
• Lack of appreciation of the enormous benefit of recycle and reuse
• Funding constraints
• Lack of necessary knowledge and skill on the part of the designer
• Lack of commitment for proper operation & maintenance
• External pressures, etc.
Certain basic minimum criteria must be followed in the design and engineering of an STP, irrespective
of any and all constraints, if the Plant is to deliver its stated objectives.
The following sections outline in brief these basic minimum requirements in terms of design and basic
engineering of the various units in the STP.
18 | The STP Guide – Design, Operation and Maintenance Background | 19

The Operating Principle of STPs
First of all, let us understand the underlying concept of a biological sewage treatment plant.
Conceptually, the process is extremely simple: A small amount of microorganisms 1 converts a large
mass of polluted water 2 into clean water 3. This process also produces a co-product: A vastly
reduced, compact solid biomass 4 (the excess microorganisms produced by growth and multiplication
of the original population of microorganisms).
However, translating this simple principle into a properly designed and engineered STP is a real
challenge: It requires sound knowledge of the biology of the microorganisms, chemical and mechanical
engineering principles, and an equally large dose of common sense.
We need an STP that-
• Achieves the desired results on a consistent and sustained basis.
• Is robust and reliable, and lasts for at least 10-15 years without major repairs.
• Needs minimum amounts of money, energy and chemicals to achieve the desired treated water
quality.
• Is easy to operate and maintain.
This manual provides tips on how to build and operate such an STP.
20 | The STP Guide – Design, Operation and Maintenance The Operating Principle of STPs | 21
Typical Process in an STP
The flow chart of a typical STP is shown below (optional units are shown in yellow).
Canteen drain Sewage
Oil, grease, grit trap Bar Screen Chamber
Extracted Water
Equalization Tank
Aeration Tank
Return Sludge Excess Sludge
Settling (Clarifier) Tank
Clarified Water Sump Conditioning
Sand Filter Dewatering System
Activated Carbon Filter Dewatered Sludge

(Cake/bags)
Treated Water Tank
Water Softener Micron Filter
Chlorination Ultra Filter
Water for reuse RO Filter

(Toilet flush, gardening, etc.)
Potable Water
22 | The STP Guide – Design, Operation and Maintenance Typical Process in an STP | 23
Benefits of a well-run STP The following table illustrates the quality of water obtainable from a well-designed, engineered and
Parameter
operated
pH
STP at In raw
very
6.5-7.5
sewage
affordable After
treatment costs 2 treatment What it means to you...
6.5-7.5
.
The acidity/alkalinity balance is not
• Assured availability of water for various secondary uses affected/altered.
The primary benefits of a well-run STP are- • BOD
Enormous savings 200-in250
fresh water costs < 10 mg/L
mg/L
1
Normally, the biodegradable material
• Lesser Environmental Degradation in the sewage consumes oxygen
when it degrades. If this sewage is
• Improved public Health released in lakes/rivers, it would draw
naturally dissolved oxygen from
water, depleting the oxygen in the
lake/river. This causes death of fish
and plants. But the STP provides
enough oxygen to digest the
biodegradable material in sewage.
The treated sewage does not need
oxygen any longer. Thus it does not
affect the aquatic life in lakes and
rivers.
1.Turbidity Not specified < 10 NTU 2. The outgoing treated specifies
sewage ahas low
2
The cost of treating water is about Rs. Although the KSPCB limit of
20~30 per kL (the capital cost of plant turbidity
2 NTU, we (suspended particles
believe this ought to be that
is not counted). This means a saving of cloud thetowater).
relaxed 10 NTU, which is the limit
50%-70% as compared to buying fresh specified by
In other words, BISwe10500 – Indianwater.
get “clear”
water. Drinking water Standards.
This prevents the pipelines from
getting clogged by settled sediments. |
2
If cloudy water is allowed to reach the
lakes and rivers, it blocks the sunlight2
from reaching the bottom of the water5
body. This stops the photosynthesis
process of the aquatic plants, killing
them. That in turns stops generation
of oxygen as a byproduct of the
photosynthesis process. Depletion
of dissolved oxygen in water kills all
fish.
Thus low turbidity in discharge water
ultimately sustains aquatic life in
lakes and rivers.
E. Coli Not specified NIL The STP removes the harmful
bacteria completely.
Understanding
the STP Stages
Maintenance
Bar Screen Chamber 5 Screened sewage. If the screen (4)
is maintained well, this would be free of
platform itself must be provided with weep holes,
so that the operator can leave the collected
any large articles. debris on the platform for some time to allow
unbound water and moisture from the screened
6 Outlet pipe (goes to the Equalization
1.1 Function • The gaps between the bars may vary
between 10 and 25 mm. Tank)
debris to drip back into the chamber. This not
only reduces the weight and volume of trash to
The function of the bar screen is to prevent entry • Larger STPs may have two screens: Acoarse 7 Platform with weep holes. The be finally disposed off, but also reduces the
of solid particles/ articles above a certain size; bar screen with larger gaps between bars, STP operator stands here to rake the nuisance of odor coming from the putrefying
such as plastic cups, paper dishes, polythene debris (2). He also uses the platform as
followed by a fine bar screen with smaller matter.
bags, condoms and sanitary napkins into the gaps between bars. a drip-tray for the collected debris.
STP. (If these items are allowed to enter the
STP, they clog and damage the STP pumps, and • In smaller STPs, a single fine bar screen
cause stoppage of the plant.) may be adequate. 1.5 Operation And
The S e If this
screenin cr (c unit is
g is e ut left
achieve e a unattend
d by n w ed for
placing C a long
a h y periods
screen a vi of time,
made m e it will
out of b w generate
vertical er ). a
bars, (a significa
placed ls nt
across o amount
the c of odor:
sewage al it will
flow. le also
d result in
a backing
“ of
B
1.2 H ar
sewage
in the
o S
cr
incomin
g
w e
e
pipelines
and
n chamber
I C s.
h
t a
n
W n
o el
”)
r is
s
k h
o
s w
A typical n
Bar h
er
Problem Cause
3 Muck (sediment in sewage)
accumulates and blocks the grill (if not Large articles pass Poor design / poor
through, and choke the operation / screen
1.3 D o
n
h
o
d by
the 4
Maintena
cleaned regularly) • Check and
Grill. Must be cleaned regularly
clean the to
bar
solids to
overflow/
formed due to
corrosion of the 1.4 C
B
pumps damaged
t
h
e al ur bars nce screen at
avoid a build-up of debris (2) and muck escape from screen C Upstream water level Poor operation T
o ly of (3). frequent the screen a is much higher than (inadequate cleaning)
s p fl the Consider intervals
• Ensure no
• Replace corroded/
unserviceable bar 2
downstream level
e o scre Excessive collection of Poor operation |
i ni w en ations • Do no allow large gaps are screen immediately
trash on screen
g n ra itself 2. Excessive odor Poor operation / trash 2
g te is not disposal practices 9
n ar
e
)
at
to be
coun 1.6
a
to
a
v
ted
in
Troublesho
C al el this oting
r lo
w
o
ci
calcu
lation
i p
a
ty
of
.) ge are visible.
t s 0. SL Remarks
s 8 1 Inlet pipe for the STP.
e a to
2 Debris (plastic bags, paper cups,
r g
e
1.
0
condoms, sanitary napkins, paper
dishes, etc.) gets trapped here.
i of m
s /s Note:
a e , O
w nly
The ( th
a
design T e
g
criteria h su
e
applies e rfa
at
more to c ce
p of
the r
e th
sizing o
a e
and s
k se
dimensi s
fl wa
ons of - ge
o
the s is
w
Screen e sh
ra
chambe c ow
te
r rather ti n,
(2 so
than the o
.5 th
screen n
to at
itself. a
3 ite
l
1. The ti m
a s
scre m
r su
en e
e b
cha s
a m
mber th
o er
must e ge
c
have a d
c
suffi v in
u
cient er th
p
cros a e
i
s- g se
e wa
secti e
Oil And Grease/Grit Trap The trapped material (both floating film of
grease/ fat and the grit settled at bottom) must
be collected frequently; otherwise the trap will fail
the contact time between solids and wastewater to serve its fundamental purpose. Therefore the
trap must be
2.1 a
Fun d
S
ctio
n
The
grease
and grit
trap is
placed
at the
discharg
e point
of the
canteen/
kitchen
area
itself to
arrest
solid
and fatty
matter
at
source.
The
wastew
ater
output
from this
unit is
taken to
the
equali
zation
tank.
The
solids
and fats
that are
separat
ed in
this unit
are
dispose
d off
along
with
other
biodegr
engineered to despite good cleaning
facilitate frequent o e practices
removal of these
two layers. For n 3. Resid
example, the C minut

covers must be
made of lightweight A o does not result in appreciable
improvement) 2.6
materials for easy
lifting. n n 4.
Tro
Large traps may be
provided with vent
d s uble
pipes to release
gases.
i sho
M
d
a 4 The heavier grit and solids sink to
otin
2.5 e the bottom of the tank (most of it lies
i below the inlet pipe, but some of the grit g
O r may be moved toward the outlet side
n due to the strong flow of the
p a wastewater). ,
t
e t This mass also needs to be removed
from the tank periodically. b
e Note:
u
r i 5 The baffle plate prevents the floating T t
n fat and scum (3) from drifting towards h
a o the outlet (7). e
i
a 6 Wastewater reaching the outlet side t
t n is free of fat, scum, grit and solids t
n 7 The outlet is through a T-joint pipe,

a
i
i s similar to the inlet (1).
n
k
s
c The upper part is capped off (opened n
• Check and clean only for maintenance). i
o
s
2.2 How It Works trap at frequent
intervals
t
A typical Oil and grease/grit trap is 2.3 Desig Remove both

f
i
s
shown below (the front side is removed h
to show internal structure). n settled solids (at l
l
o
bottom) and the
Criteri floating grease e
w
n
d
a Do not allow solids
• to get washed out of h
w
Typical design e
criteria used for the trap i
r
the grease trap t
e
include: h
s
1. • Do not allow oil w
o
and grease to a
escape the trap s
2. t t
• Redesign the e h
trap if solids w a
and grease a t
escape on a t
regular basis, e t
r h
Problem Cause
Oil and grease pass Poor design/ poor
e T through the trap operation t
2.4 C h An excessive amount Poor design/
. poor
o e of solids passes operation
t
h
o through the trap T
h
t Excessive odor Poor operation/
e
r
n a
e
waste disposal
n practices
i
s k
e
n
t
e t s
d
m h
s r o
o
f
u
a u l
t
r d
h
e c e
h
v
i
t a
i
v
n
s
i
i e
c
o
b
l o w
m
e a
i
. n t
n
e
g
SL Remarks 2 The tank is always filled till this level. r
1 The incoming liquid is released below 3 A
The fat and scum rise to the top and p
r
p
surface through a T-joint so that the float on the liquid. This needs to be i
falling water does not disturb (break up) n
removed periodically, otherwise it will o
o
p
the floating film of fat and scum (3). leach into the wastewater. e
d f
i
p
s
l
E a
k
s
n t
e
p
e
g r
t
i
i n
b
e
g
n l
o
i
e n
w
s
e i
t
h
d
r e
e
i a
w
a
n
n d
t
e
g o
r
u
l (
e a
v n
e d
l
, b
r
s e
o a
k
t
h u
a p
t )
t t
h h
e e
i u
n p
c p
o e
m r
i
n f
g l
o
w a
a t
t i
e n
r g
d l
o a
e y
s e
r
n
o o
t f
d g
i r
s e
t a
u s
r e
b .
3 |
Equalization Tank Notes:
1. The figure uses color-coding only to distinguish the
3 The raw sewage lift pumps
move the sewage to the aeration tank.
parts from each other: In real life the color-coding is
(These pumps are explained in the next
not followed.
3.1 Function 2. An air-compressor is required, but not shown
chapter.)
fluctuating rates, and pass it on to the rest of the 4 The delivery pipe takes the sewage
The sewage from the bar screen chamber because in most cases a single blower provides the
to the aeration tank.
STP at a steady (average) flow rate.
and oil, grease and grit trap comes to the compressed air needed at multiple places in the
equalization tank. During the peak hours, sewage comes at a high STP. 5 The coarse bubble diffusers are
rate. The equalization tank stores this sewage, short length of tubes that have holes
The equalization tank is the first collection tank 3. The figure shows only the surface of sewage (2),
and lets it out during the non-peak time when so that other items submerged in the sewage can
at regular spacing. They release large
in an STP. bubbles in the tank to lightly aerate the
there is no/little incoming sewage. be shown.
Its main function is to act as buffer: To collect sewage, and also to agitate the mix
Thanks to the constant outflow rate, it is easier continuously. The figure shows an array
the incoming raw sewage that comes at widely SL Remarks
to design the rest of the units of the STP. of eight diffusers, strapped to cement
1 The inlet pipe carries filtered sewage
blocks so that the assembly remains
from the Bar Screen Chamber.
firmly anchored in one place.
2 The sewage is collected in the tank.
Diffusers can also be used in separate
Flow Rate (m3/Hr)
The level fluctuates throughout the

day, because while the incoming rate pairs or even individually.
fluctuates widely, the outgoing rate is 6 Compressed air comes though this air-
constant. supply pipeline. This may be a rigid
Outflow (The level shown in the figure is almost pipe or a flexible hose. The figure
full. If there is a peak inflow now, the shows a single array of 8 diffusers.
Inflow tank will overflow.) However, it is more convenient to use
separate pairs of diffusers with their
0 Hours own air pipe (flexible hose).
0 4 8 12 16 20 24
3.3 Design Criteria complex, an equalization tank with a capacity

3.2 How It Works Since the diurnal variation in the quality of the
to hold 4-6 hours of average hourly flow
should be adequate (based on the diversity of
A typical equalization tank is shown here. sewage is not significant, the equalization tank is the population in the complex).
used only for buffering the daily fluctuations in
• In addition, the sewage generation may be
the sewage flow quantity.
heavier during the weekends. In such cases,
The equalization tank must be of sufficient the sewage volume generated on a weekend
capacity to hold the peak time inflow volumes. should be taken as reference.
Peak times and volumes are site-specific and • In the case of a commercial or software
variable: complex, peak flows commonly occur during
• In the case of residential complexes, there the lunch hour.
is a distinct morning major peak (when all
• In the case of manufacturing units, the shift
residents are using their kitchens, bathrooms
timings is a major factor. Peaks occur at
and toilets), followed by a minor peak in the
breakfast, lunch and dinner timings of the
late evening hours. In a typical residential
canteen.
32 | The STP Guide – Design, Operation and Maintenance Equalization Tank | 33

A fairly scientific method of calculating the
required capacity of the Equalization tank is by
The equalization tank should be large enough
to hold the maximum difference between the
As a rule of thumb, the higher of the following
two figures is taken as the air volume required
3.6 Troubleshooting
plotting a graph of the projected inflow and
inflow and the outflow. In our example, the per hour:
outflow over a Problem Cause
24-hour period, as shown below: maximum difference is 150-60=90 m3. Therefore,
• 1.2-1.5 times the volume of the Equalization Insufficient mixing/ Poor design,
the equalization tank must be larger than 90 m3
tank, or aeration engineering
(otherwise it will overflow).
• 2.5-3.0 m3/m2 of floor area. Excessive odor Poor design,
engineering
The number and placement of diffusers must be
Insufficient capacity to Poor design
200 adequate to dispense the calculated amount of
handle peak flows
air in the tank.
Usable capacity Poor maintenance
The capacity of the air blower must be adequate reduced due to solids
to deliver the required quantity of air to the
Cumulative Flow (m3)
150 accumulation
equalization tank as well as all other aerated
Max Difference tanks it serves.
This tank is most prone to odor generation, since
100 it contains raw (untreated) sewage. It may also
build up gas, which can be explosive. Therefore
it must have good ventilation.
50
3.5 Operation And

0 Hours Maintenance
0 4 8 12 16 20 24
Considerations
3.4 Construction And The tank may be of any shape, provided it
• Keep air mixing on at all times
• Ensure that the air flow/ mixing is uniform
permits placement of air diffusers for full floor
Engineering coverage and uniform mixing over the entire floor
over the entire floor of the tank. Adjust the
placement of diffusers and the air-flow rate as
The incoming sewer line is usually gravity-fed, area.
needed.
and is likely to be at considerable depth below The diffusers should be retrievable: Individual
the ground level. Therefore it is prudent not to • Keep the equalization tank nearly empty
diffusers (or sets of diffusers) may be lifted out
make the tanks of STP too deep, otherwise it before the expected peak load hours
and cleaned for routine maintenance. This will
requires very deep excavations and expensive (otherwise it will overflow)
reduce frequency of shut down of the
construction. It also makes the maintenance and Equalization tank for manual cleaning purposes. • Check and clean clogged diffusers at regular
cleaning processes very hazardous.
intervals
If membrane diffusers are used, they will
In it necessary to force compressed air in the fail frequently, due to the repeated cycles of • Manually evacuate settled muck/ sediments
sewage held in the tank. This is mandatory for expansion and contraction caused by fluctuating at least once in a year
water levels in the equalization tank. Therefore,
two reasons: only coarse bubble diffusers must be used
in the equalization tank.
• It keeps the raw sewage aerated, thereby
avoiding septicity and suppressing odor-
generation
• It keeps solids in suspension and prevents

settling of solids in the tank, thereby reducing
frequency of manual cleaning of the tank

Raw Sewage Lift Pumps SL
1
Remarks
There are two identical pumps.
The lifting capacity of the pumps (called ‘total
head’ or ‘total lifting height’) may be selected
based on the level difference between the sewage-
Controls ensure that only one pump can delivery level at the aeration tank and the floor
run at a time. level of the
Each pump delivers sewage at a rate 4.1 F t
that is slightly higher than the actual u
flow rate of the STP.
n
2 Both pumps
suction pipes.
have independent 4.2
c H
t A
The inlet pipes extend almost to the
bottom of the tank, and must not have
i
foot-valves. o
3 The delivery pipes from both pumps are n
combined in a !-shaped header. If we
use
A delivery pipe takes sewage from
gravity
this header to the aeration tank.
to move
4 The bypass pipeline returns the the
excess sewage back to the tank. sewage
5 Valves fitted on all three pipelines through
serve different purposes: the units
• The valve on the bypass line is of STP,
adjusted to “waste” the excess the units
capacity of the working pump. (The would
delivery pipeline (3) always carries have to
sewage at the designed flow rate) be
placed
• The valve on the delivery pipe is progres
closed off when the corresponding sively
pump is removed for repairs. This deeper
prevents sewage delivered by the below
other pump from coming out. the
ground
level.
To avoid
deep
excavati
ons, a
pumping
stage is
introduc
ed to lift
sewage
to the
next unit
in the
STP,
which is
36 | The STP Guide – Design, Operation and Maintenance Raw Sewage Lift Pumps | 37
equalizatio c e three
n tank. r
D o differen
1. Su
t types b
T
of
L m
pumps
4.4 C for this er
job:
o si
bl
n e
pu
s m
t ps
wit
r h
sm
u 4.3 Design alle
r
c Criteria flo
w
t The capacity
pa of the ra
capacityssa
of
i ge
s in
o the
ir
n im
pell
ers
are
A not
the
n cor
rec
d t
ap
plic
E ati
on
for
n this
dut
g y:
Th
i ey
are
n pro
ne
e to
fre
e qu
ent failures (either the impeller gets SH) , , 22 1. T
damaged, or the pumps stall and pum hours of h
then the winding burns). ps operatio 2.
n e
with o n in a N
2. Comminutor pumps with a open day may C
cutter/shredder option solve the impe
s be -
clogging issue by pulverizing the llers.
u consider S
obstacles, but they end up mixing There c ed). H
non- biodegradable material in the are other
sewage in such a way that h STPs p
valid and u
separating the material becomes are
practical c m
impossible. This is a threat to the usually
reasons o p
environment. designe
for this l is
d with a
3. Therefore, the correct choice would selection o r
duplicat
be horizontal, centrifugal, non- : r o
ed
clog, solids- handling (NC- - pumping b
r c system: u
a o In place s
t d of using t
Note: i i a single f
T o n pump, o
h n g two r
e pumps t
p i are fixed h
e u s in is
x r parallel, a
a p f but only p
m o o one p
p s l pump is li
l e l operate c
e s o d at a a
. w time. ti
e Such o
s
I d pumps n
h
n . can be ,
o
operate a
w
a d round n
s
c the d
t clock f
t
u (12 a
h
a hours il
e
l per u
pump). r
p e
i p
r
p r
a
e a
t
l c
e
i t
/
n i
fr
e c
e
s e
3. The NC-SH pumps are less expensive than
submersible pumps, but work at a lower
the equalization tank) with a control valve must
be provided, so that the sewage flow rate can be
4.6 Troubleshooting
efficiency due to open impeller design. precisely set to the designed value. In an STP, robust
• At
treatment
t
performance is of
h
prime importance
e
and of higher
priority than
savings in energy s
at the cost of a
treatment m
efficiency. e
4. Repair/ servicing t
costs for NC-SH i
pumps are m
negligible e
compared to ,
submersible
pumps p
r
o
v
i
d
e
f
o
r
l
o
c
k
i
n
g
t
h
i
s
v
a
l
v
e
,
s t s o n i
o i t r a v
n s n i
t g b c t
h s e a e i
a n e
t t a d a s
o l c .
t l t t
h i o e
5. T
e n w c
h
c e h
e
S r d n
T e i
a c N
P a C
s r i
o a -
o e S
p u n
n s H
e t
r h d
f p
a e u
t t o
h r m
o f p
r l e
r s
o
w p o
c m
u u
a a
m t
n r y
p i Problem Cause
n a
n
o t bExcessive noise Poor engineering/
f e
t e e maintenance
o
. Excessive vibration Poor engineering/
r o
t S p s maintenance
a u m e eOverheating Poor maintenance
m f o r r Loss in efficiency of
p Poor maintenance
f v a vpumping
e i e t i
r c m i c
i e o e
w e n n d
i n t
t t a a
h o n t
s f d
i p t
t a o m h
s c p a e
e e i
s r n
e m a t S
t u t e
T
P
facto
ry
these pumps are for use and
throw duty only)
4.5 o
for
7. Guarantees/ warranties on Operation n
any
s
repai
repaired units are available, And
i
t rs,
only if sent to the respective s
e and
factories. M •S
the 8. The NC-SH pumps are
i time equipped with a Non Return a w
i
requi Flap valve in the body itself, t
t
s red which functions as a normal foot i c
is valve: hence priming of these h
e
l typic pumps is not required at every n
ally start.
f
2
The raw sewage lift pump is a
t b
e
wee
w
i ks.
critical machinery, and so it must
have a standby unit. The electrical
e t
w
t
h
6. Onc
e a
control circuit must ensure that both
pumps cannot run at the same time
n e
e
i
n
sub
mers
(otherwise they will generate
excessive pressure and damage
a n
a
ible
pum
the plumbing. Also, a higher flow
rate means partially treated sewage
n t
h
f
p
goes
is passed out of STP.) c e
Separate suction piping for each of
e
w
for
repai
the two pumps is preferred, so that e m
a
a clogged inlet pipe can be cleaned
r, it i
while the other pump is operating.
neve n
h
o r The delivery header of the two C
reco pumps must conform to good piping a
u
r vers engineering practice with o n
100 necessary fittings for isolating the d
s
% pumps for maintenance, etc. n
effici
w
i ency s s
t
, and
t
h failur i a
n
es
r start d d
b
occu
e
a rring e y
perio
d
i dical r p
u
ly
l
y (As a m
p
per
avail
able
consumables.
our t e
On the other hand, the expe
spar
es submersible pumps have to be rienc i v
e
and sent to their service center/ e, r
y e g t e s
r n i l
4 y m o y a
e n n
•C
h d n d
h
o a t o e
u y f c o
r ; a k t
s f c h
t t o e
f
( o e u r
o
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p l f
p u e i a
v
r p v n s
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b
x i r e
r
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r m o
e p g w
d e e
r t r
•M
i a
a
n p t
i
g u e
n
m
t
w p a
a
i s n
i
n t d
h t
h h
t a
h t e
h t a
e
e d
p
f r
l b w
y o e
o v
p need. Therefore, a bypass branch line (back to
1 The inlet pipe brings sewage from 7 The fine bubble diffusers are
the raw sewage lift pump (sewage from actually rigid pipes with long slots,
the equalization tank). The pipe is bent which are then covered with tubular
downward, so that the sewage does not
Aeration Tank
synthetic rubber membranes. The
SL Remarks
get propelled toward the outlet pipe (6). compressed air is released in the form
2 The baffle wall does not let the of fine bubbles throughout the length of
the diffusers, through minute holes
5.1 Function maintain a high population level of microbes.
This mixture is called MLSS (Mixed Liquor
incoming sewage and sludge go across
the tank toward the outlet pipe (6). The punched in the rubber membrane. The
Suspended Solids). wall forces the mix toward the bottom figure shows an array of eight
The Aeration tank (together with the settling diffusers. The array is strapped to
of the tank; thus ensuring maximum
tank/ clarifier that follows) is at the heart of the The mixed liquor is passed on to the clarifier cement blocks (ballasts) to keep the
retention.
treatment system3. tank, where the microbes are made to settle at entire assembly anchored to the bottom
the bottom. The settled microbes are recycled 3 The tank is always filled till this level
The bulk of the treatment is provided here, (which is set by the top of the launder of the tank.
back to the aeration tank. Thus they are retained
employing microbes/bacteria for the process. (4). 8 In the case of fixed diffusers,
for a long period within the system (see compressed air is supplied through a
The main function of the Aeration tank is to Appendix So the remaining height of the tank header pipe at the bottom of the
- page 138). serves as freeboard (height margin tank, as shown.
to ensure that the tank does not
5.2 How It Works overflow immediately under moderate Some designs use flexible air hose
emergencies.) lines and pairs of diffusers to make
A typical Aeration tank is shown below. them easily retrievable. In this case
Design
4 The Criteria
Outlet Launder collects the
sewage and delivers it to the outlet pipe
each pair of diffusers is also provided
with a nylon rope to enable lifting out of
(6). When de
the aeration tank for maintenance.
u
Note that the outlet launder is located 9 The recirculated sludge pipeline r
farthest from the inlet pipe (1) to brings bacteria floc from the settling f
Notes: minimize short circuiting of flow from tank/secondary clarifier). It is always a
1. T the inlet to the outlet of the tank. located very close to the inlet pipe (1) c
h5 The net prevents entry of debris in the so that the raw sewage and bacteria e
e outlet pipe (6). get mixed thoroughly. (By design, both
pipes deliver roughly the same volume o
f The operator should remove debris
collected in the launder (4) periodically, f
i
g otherwise eventually the mesh will
be blocked with accumulated debris, t
u
resulting in a rise of water-level in the h
r
aeration tank. In the extreme case, this e
e
will cause overflow from the tank.
s
s6 The outlet pipe takes the sewage to
the settling tank/secondary clarifier. e
h
w
o
a
w
g
s
e
,
o
n
s
l
o
y
t
t
h
h
a
e
t
s
i
40 | The STP Guide – Design, Operation and Maintenance Aeration Tank | 41
t
e
2. A
3 Since both tanks work together, they cannot be

explained in isolation. 4 This approximation
is only to give you a rough idea: The actual ratio
depends on the design parameters.

The other factors are selected as follows: Operating platforms must be provided next to the • Gentle aeration (less breakage of the The microbes produce a large amount of Carbon
Treatment 90 to 98 %, as defined by tank, such that all the diffusers installed in the biomass floc) Dioxide, which must be handled by the exhaust
efficiency the Pollution Control Board. tank are easily accessible, and amenable to and ventilation system.
• Performance unaffected by foaming in tank
easy maintenance. In theory, the desired • Substantial reduction
Food/ For STPs with extended volume can be
Microorganisms aeration, required F/M is achieved in aerosol formation
ratio (F/M) 0.10 to 0.12 • In th heref
fa a ore,
ct n we
This , th can
gives th e simpl
the e a y
required a m calcu
size m o late
(volume o u the
) of the u nt air
aeration nt of requi
tank. of ai red
The ai r for
next r re micro
step is re q bes;
to q ui and it
calculat ui re will
e the re d serve
amount d to the
of air fo k other
to be r e purp
pumped re e ose
into the s p well.
aeration pi th
The
tank, to ra e
thumb
keep ti ta
rule is
the o n
50-60
microbe n k
m3/hr of
s alive of c
air for
and in th o
every kg
continuo e nt
of BOD
us m e
removed
suspens ic nt
(i.e., the
ion ro s
differenc
(they b c
e
must e o
between
mix well s m
BOD
with the is pl
readings
food, al et
of the
and not w el
incomin
settle at a y
g
the y m
sewage
bottom s ix
and
of the m e
treated
tank). or d.
sewage)
e T

. v pth of nts. m e ) nes, the ( c , without re ni The
w S
e the How a h lesser is c al having a ty outlet
That i So the a
r tank: ever, b e o tit to s of end may
conclu t depth is f
, ther o a u u empty o th be
des h • The fixed e
e is v v n d the n, e provided
the se first. w
i a e y t e aeration th s with a
desig m wa The o
n ge pena th di , tank. e e launder
n of u length r
dep lty to e ff t vi (Regular sl w at the
the l and k
p th be ta u h s cleaning u a desired
Aerati t width of i
r ma paid n s n e c extends d g water
on i the
a y in k, e g o the life g e level in
tank: p aeration
c be the fo rs c f si of the e in the tank
the l tank
t bet form r fr o o ty diffusers re le (which in
size e may be
i we of o o n l , ). ci t, fact
(volu compute
c en high p m d l f rc to
me), c d to suit It is
e 2.5 er e b it o o ul m
conce o the necessa
, - (and r ot i w ul at a
ntratio m diffuser ry to
4.0 mor at to o i in io xi
n of b membra n ensure
t m. e o m n g n m
micro i nes s that the
h Th diffic r , g , pi iz
bes to n selected ) incomin
e e ult) c y a p e
be a to g
gre main o o • Mixi f gi e th
maint t provide sewage
f ate tena m u n a n (fr e
ained, i the does not
o r nce, fo m g c g o c
and o required go to
l the cost rt a in t , m o
the n quantity exit
l wat s of a y d o e th nt
quanti s of air. directly.
o er a n n e r tc e a
ty of To
w de high d e It is best pt s . s ct
air to o minimiz
i pth er to e to use h : et ti
be f • Non- e this
n , pres al d the least tli m
suppli •D interr “short
g the sure lo to possible p n e
ed per t e uptiv circuitin
hig air w fi number r g of
hour. a s e g”, raw
f her blow m x of e ta m
n i main sewage
a the er, ai a membra s n ic
k g tena lift
c effi high nt p nes and s k) ro
n nce/ pumps
t cie er e ul therefor u m or
d repla must
o ncy air n le e use r u g
i c cem deliver
r of temp a y the e st a
m a ent the
s tra erat n s largest , d ni
e n is sewage
nsf ures c y of the el s
n poss at one
l er and e st availabl iv m
s t t ible end of
i of relat ( e e sizes: er s
i a e the tank,
m Ox ed e. m 90 Dia x The sl wi
o k m and the
i yg probl g. o 1000 diffusers u th
n e p outflow
t en ems. to n mm must be d ra
s e must be
to r th long. retrieva g w
. • Req r as far
t the et e The i ble, for e s
uire a away
h tan ri c lesser n regular in e
H ment t from this
e k e ei the t cleaning th w
o for u point.
co v li number o and e a
w head r
d nte e n of mainten For the vi g
e roo e
e th g membra a ance same ci e.
s SS S in t n es. tra
p
5.5 C (biom the h g Dead
by lifting out
the defective
m
at
by high-
pressure
Membra
ne
ta
in
an
ystr
en in the
event of
i ass aeratio e zones ay
O o n conc n tank. i on the
units and er hosing. diffusers
are the
e
d
tra
sh
fro
m
emergen
cies
scouring out ial en
c entrat t s sewage preferre (such as
p n l ion)
See
a surface
the adhering s
n aining d
ter
in
g blockag
e s u in the
appen
dix
n i indicate 5.4 e st structur equipme
th
e
se
co
e of pipe
d aerati k n that nt for nd between
r es as
r i e on
(page
139) to
. d membr C e u specifie aeration ar
y aeration
tank. L i anes in the se tank and
ct d in
a d m Probl
unders
tand
o c are o r io relevant aeration ttl settling
a ems c a blocked tank er tank,
n Indian
t e i arise
how
MLSS
a t from n i ( codes. over ta excessiv
n both l i the air other nk e
ratio is a The
i r t in the
measu
v v side or s n s
shape
the
is tank
not
of forms of . foaming
a case i e the very
critical, aeration S etc.)
red a
o a
i of
and
o liquid t g r
as long (low- uf overflow
n exces l o side. speed fi from the
controll e
n t
i s or
ed.
e f Both r T
h m surface ci aeration
n short n r conditio aerators e tank can
o
i
g age Visual t u ns call u e
A st / High- nt be
of observ b p for speed fr avoided
A t biom ation o t immedi c e ot
floating for some
o h ass, will i u ate r h
e aerators
e
e time.
n e causi indicat l r attentio t at / Note
n ng an e if i e n, by io r
ta submer
b
o that the
d c imbal there is n d cleanin i n ged freeboar
s o ance, unifor g g or ta n
k venturi
ar
d d only
n
O r leadi m / m replaci o k s aerators m gives
M p r ng to aeratio b e ng the
is in , etc.) u the STP
e e failur n and u m membr n g th for st operator
a r c
t
e of
the
mixing
over
b
b
b
r
anes.
Cleaning
e e several
reasons:
b some
addition
a of n S e
i t proce the l a membra
nes is e T • Ener pr al time
i d ss. entire i n generally
carried A r P gy o to react
n o e The area of out
al ), savin vi to an
n s next
the
fix
e
so
useful n ly d gs d
t i chapt
maintenance, s to fix a of e e
c g er
and the fewer
th
e coarse d w si
• Less d
e o n show
s how
the chances of w mesh at g
num
ber
in
n m at screen e n th
n s l to a er in the r e
of e
i e maint lf le
v launder E p d
rotati ta
a d v ain u el to r a
ng n
e e the n in
th n o s
mac k,
n r l corre c
e of w
hiner s
a ct ti
o
ta g R at
y to o
c t o desig
n
n
k) C e
be th
i f n
. . i C r-
oper at
e o level It c r
ated e
n M
L
of
MLS
is
al n o et
and
main
v

Scru w use • Stan e n r 5 The clarifier-- the
bbing a may dby m membranes next tank in the
A
with o be facilit t l are rated to chain).
mild f g trace y h e operate
acid r d to e s within
soluti d e an s certain
on e a imbal a range of air
may t t ance e c flux rates.
also e in the r o So power is
be r m aerati a m saved by
resor g a on t p turning
ted e j tank i a down
to in n o recip o r (reducing)
case t r e n e the air flow
of - i (Food d during
stubb l t : t certain
orn i y Micro a t times, such
encr k organ n o as night
ustati e o isms: k hours.
on. f Air: t
s Nutri a h
Foa
u c ents), f e
ming
b a and f
in the
s s corre e s
aerati
t e ctive c e
on
a s meas t t
tank
n , ures i t
may
c may n l
be
e t be g i
caus
s h taken n
ed by
: e as S g
exce
indica T
ssive
I c ted. P t
inflo
n a a
p n
as o e k
•T
adequ f r
u
ate f (
r
floor n o s
cover d r e
age o m c
and w a o
unifor n n n
m c d
mixing o e a
can p r
be t a y
achiev i r
ed by o e
proper n
place 5
f
ment a
5.6 Troubleshooting
Problem Cause
Inadequate mixing/ aeration Poor design/ engineering/ maintenance
Violent boiling in tank Ruptured membranes/ damaged pipeline
Black coloration Poor design/ engineering
(medium to dark brown color indicates good
health)
Foaming Poor design/ engineering/ operation
Note: Foaming during initial start-up of STP is
normal, due to the acclimatization period
of the bacteria in the growth phase.
Paucity of bacteria Poor design/ engineering/ operation

• Very light colored liquid in Aeration Tank
• MLSS below acceptable limits

Secondary Clarifier/ Settling Tank
6.1 Function There are three popular design variations in the
unmechanized clarifier tank.
The purpose and function of the secondary They differ in the manner in which the sludge is
clarifier is threefold: collected and returned to the Aeration tank.
• Allow settling of biomass solids in the Mixed
Liquor (biomass slurry) coming out of the Air-lift Sludge is collected with an air-lift
aeration tank, to the bottom of the clarifier pump pump. By varying the air pressure,
the flow rate of the sludge can
• To thicken the settled biomass, in order to be adjusted. This version is most
produce a thick underflow prevalent.
• To produce clear supernatant water, in the Electric Sludge is collected with an electric
overflow from the clarifier pump- pump. Since the flow rate of
The clarifier tank is only a passive device: All the Direct this pump cannot be varied, the
above actions occur due to gravity. suction pump is turned off periodically
to arrive at a lower net flow rate.
The thick biomass is recirculated back to the (For example, it is kept off for 10
aeration tank. minutes every hour.)
Electric Sludge is allowed to flow in a
pump and buffer sump (using gravity). From SL Remarks
6.2 How It Works buffer
sump
here, sludge is pumped back to
aeration tank using a pump. The
1 The sewage inlet pipe brings
sewage from the aeration tank.
net flow rate is adjusted using
The clarifier tanks can be classified in two 2 The center-feed well (also called
a bypass pipeline with a valve
groups: mechanized and unmechanized. “influent well”) takes this incoming
(exactly like the raw sewage lift
• In an unmechanized clarifier, the bottom of sewage and gently releases it in the
pumps).
the tank is shaped like a funnel, with a steep settling tank, without causing any
slope. The sludge slowly settles towards The unmechanized and mechanical varieties of disturbance or turbulence. Note that the
bottom, and slides down the slope to collect clarifiers are explained next. well is always filled with water because
at the lowest point of the funnel-shaped of its position. So the incoming sewage
bottom. does not drop from a height and disturb
6.2.1 Settling tank with air-lift the sludge that is already settling
• In a mechanical clarifier, the bottom of the toward the bottom of the tank.
tank has only a gentle slope toward the pump
center. The sludge settles uniformly across Also note that the top of the well is
A typical settling tank with air-lift pump is shown positioned above the water surface, so
the floor of the tank. A set of slowly rotating
on the next page.. (The front side is removed to that the incoming water cannot find a
rubber blades sweep the sludge into a
show internal parts.) path of least resistance, straightway
hopper at the center of the tank6.
rise to the top and exit to the launder. (If
that is allowed to happen, then the
solids will never be able to settle.)
6 This is just like how the windshield wipers in your car sweep water.
46 | The STP Guide – Design, Operation and Maintenance Secondary Clarifier/ Settling Tank | 47
3 The sludge is only slightly heavier than
water; so it takes time to sink. It slides
down the steeply sloped walls
7 Each floc is loosely aggregated mass of bacteria. It is a brownish of the tank toward the center of the
tiny ball of 2-3 mm dia, with a soft, spongy and slimy texture. bottom.
8 This simplified diagram shows a separate layer of flocs at bottom. 4 The bacterial flocs7 collect here in
In reality, at any given moment, the newly arriving flocs are high concentration8. Even when the
gradually sinking, and clear water is rising upward. This creates a flocs settle at bottom, they actually
gradual increase of floc- density toward the bottom of the tank, but remain suspended in water, rather than
there are no distinct layers. forming a solid sediment.
Note: This figures shows it as
semitransparent only to show
the suction pump mechanism.
In real life, the mix would be a
dense opaque mass.
The upper part of the tank, till
the surface, holds clear water
(the figure shows only its
surface 8).
electric pump is shown below. (The front side is
The compressed air pipe (5) feeds removed to show its internal parts.)
compressed air to the airlift pump. As
this air is released near the bottom, it
expands suddenly in bubble form and
rises to the top through the delivery
pipe (7). The Venturi effect at the joint
of 5 and 7 creates a partial vacuum,
and sucks in the bacterial flocs through
the inverted funnel (6). The
compressed air propels this mass up
through the delivery pipe (7).
8 The clear water rises to the top of the
tank.
9 Typically the tank has launders on all
four sides. (The launder on the front is
not shown, so that the other parts can
be shown clearly.)
If the water overflowed over the weir at
fast velocity, it will pull up the solids
from the bottom of the tank. This is
prevented by providing weir of sufficient
length.
In small plants, launder on a single side
is adequate.
10 The clarified water pipe takes the
decanted water to the clarified water
sump.
6.2.2 Settling tank with direct-

suction electric pump
A typical settling tank with a direct-suction
SL Remarks 5 The sludge delivery pipe delivers11
the slurry (a mix of flocs and water) to
1 The sewage inlet pipe brings
the pumps (6). The pipe is split
sewage from the aeration tank.
between the two pumps (they do not
2 The center-feed well (also known have separate inlet pipes).
as “influent well”) takes this
incoming sewage and gently releases it The valve on the main pipe is used
in the settling tank, without causing any to close it during maintenance. The
valves near the pumps regulate the
disturbance or turbulence. Note that the
flow, and also close the pipe when the
well is always filled with water because
corresponding pump is removed for
of its position. So the incoming sewage
repairs.
does not drop from a height and disturb
the sludge that is already settling 6 There are two identical pumps.
toward the bottom of the tank. Controls ensure that only one pump can
run at a time.
Also note that the top of the well is
positioned above the water surface, so Each pump delivers sludge at a rate
that the incoming water cannot find a that is slightly higher than the required
path of least resistance, straightway flow rate. Since the flow rate of these
rise to the top and exit to the launder. (If pumps is fixed, they need to be turned
that is allowed to happen, then the off periodically to bring down the net
solids will never be able to settle.) flow rate to achieve the desired MLSS
ratio.
3 The sludge is only slightly heavier than
water; so it takes time to sink. It slides This is a critical operation, because if
down the steeply sloped walls flocs remain in the settling tank for more
of the tank toward the center of the than 30 minutes, the microorganisms
bottom. die due to lack of oxygen. Therefore the
4 The bacterial flocs9 collect here in on/off cycles have to be small.
high concentration10. Even when the Since this is a round-the-clock
flocs settle at bottom, they actually operation, and a critical task, this is
remain suspended in water, rather than done using a timer circuit that turns
forming a solid sediment. the pump on/ off automatically. The
Note: This figures shows it as operator has to monitor the MLSS
semitransparent only to show ratio, and keep adjusting the timer’s
the suction pump mechanism. duty cycle (the on/ off periods) as
In real life, the mix would be a required.
dense opaque mass. 7 The !-shaped header assembly
joins the outlet pipes of both pumps,
and delivers the sludge to the aeration
tank.
surface (8).
9 Each floc is loosely aggregated mass of bacteria. It is a brownish tiny ball of 2-3 mm dia, with a soft,
spongy and slimy texture.
10 This simplified diagram shows a separate layer of flocs at bottom. In reality, at any given moment, the
newly arriving flocs are gradually sinking, and clear water is rising upward. This creates a gradual
increase of floc- density toward the bottom of the tank, but there are no distinct layers.
11 Because of the water column above, the slurry is delivered with pressure. Thus the pumps do not need
to apply suction: They work only to lift the slurry to the top of the aeration tank.
9 Typically the tank has launders on all 6.2.3 Settling tank with buffer 2 The center-feed well (also known 5 The sludge delivery pipe delivers14
four sides. (The launder on the front sump as “influent well”) takes this the slurry (a mix of flocs and water) to
side is not shown, so that the other incoming sewage and gently releases it the buffer sump (6).
parts can be shown clearly.) This design overcomes the critical deficiencies in in the settling tank, without causing any
the direct-suction electric pump version. Note that the pipe is located below the
disturbance or turbulence. Note that the
If the water overflowed over the weir at water surface, therefore the slurry is
The settling tank is built just like the direct-suction well is always filled with water because delivered with pressure.
fast velocity, it will pull up the solids
electric pump version, but two critical external of its position. So the incoming sewage
from the bottom of the tank. This is
components are added: An intermediate tank with does not drop from a height and disturb The valve on the pipe is used to
prevented by providing weir of sufficient
aeration, and a bypass pipeline. These additional the sludge that is already settling regulate the slurry flow rate and also to
length.
components keep the bacteria flocs alive, and also toward the bottom of the tank. close the pipe during maintenance.
In small plants, launder on a single side allow the operator to adjust the sludge flow rate to The slurry remains in the sump (6) only
is adequate. Also note that the top of the well is
get the desired MLSS ratio. positioned above the water surface, so for a short time.
A typical settling tank with buffer sump is shown that the incoming water cannot find a The compressed air pipeline
decanted water to the clarified water
below. (The front side is removed to show its path of least resistance, straightway (7) provides air to the coarse air
sump. rise to the top and exit to the launder. (If
internal parts.) bubble diffusers (8), which release
Because of the requirement to switch the pump of an operator mistake), this method that is allowed to happen, then the large bubbles in the slurry. This not only
on/off round the clock (and the consequences is not recommended. SL Remarks solids will never be able to settle.) provides oxygen to the bacteria, but
The next variant overcomes the 1 The sewage inlet3pipe The sludge is only slightly heavier than
brings also continuously agitates the slurry to
sewage from the aeration water; so it takes time to sink. It slides
tank. prevent settling of the flocs to the
design limitations mentioned above.
down the steeply sloped walls bottom of the sump15.
of the tank toward the center of the 9 There are two identical pumps which
bottom. pass the slurry to the Aeration tank.
4 The bacterial flocs12 collect here Controls ensure that only one pump can
in high concentration13. Even when run at a time.
the flocs settle at bottom, they actually
remain suspended in water, rather than Each pump delivers sludge at a rate
forming a solid sediment. that is slightly higher than the required
flow rate. The extra flow is diverted
Note: This figures shows it as back to the sump through the bypass
semitransparent only to show pipeline (10). The returning slurry is
the suction pump mechanism. released at a height, thus agitating the
In real life, the mix would be a
contents of the sump.
dense opaque mass.
The valve on the bypass line is adjusted
to achieve the desired net flow rate.
surface 8).
12 Each floc is loosely aggregated mass of bacteria. It is a brownish tiny ball of 2-
3 mm dia, with a soft, spongy and slimy texture.
13 This simplified diagram shows a separate layer of flocs at bottom. In reality, at
any given moment, the newly arriving flocs are gradually sinking, and clear
water is rising upward. This creates a gradual increase of floc- density toward
the bottom of the tank, but there are no distinct layers.
14 Because of the water column above, the slurry is delivered with pressure. Thus
the pumps do not need to apply suction: They work only to lift the slurry to the
top of the aeration tank.
15 If any flocs settle to bottom, they will not be recirculated to the aeration tank,
and they will die because of lack of food. Just oxygen is not sufficient to keep
the
m
aliv
e.
11 The !-shaped header assembly 14 Typically the tank has launders on all The sewage inlet pipe (1) brings sewage So the remaining height of the tank above the
joins the outlet pipes of both pumps, from the aeration tank. weir serves as freeboard (height margin to
four sides. (The launder on the front
ensure that the tank does not overflow
and delivers the sludge to the aeration side is not shown, so that the other The center-feed well (also known as
immediately under moderate emergencies.)
tank via the delivery pipe (12). parts can be shown clearly.) “influent well”) (2) takes this incoming
13 The clear water rises to the top of If the water overflowed over the weir at sewage and gently releases it in the settling The bacterial flocs settled at the bottom have to
the tank. fast velocity, it will pull up the solids tank, without causing any disturbance or be quickly collected and sent back to aeration
from the bottom of the tank. This is turbulence. Note that the well is always filled with tank, otherwise they would die because of lack of
(This figure shows only the surface, but oxygen and food.
prevented by providing weir of sufficient water because of its position. So the incoming
the upper part of the tank is filled with
length. sewage does not drop from a height and disturb This is done with a set of rubber blades (called
clear water).
the sludge that is already settling toward the “squeegees”) (7): The squeegees sweep the
In small plants, launder on a single side bottom of the tank.
is adequate. floor in circular movement, and propel the sludge
Also note that the top of the well is positioned toward a collection-pit (8) at the center of
above the water surface, so that the incoming the tank. From here, a pump takes the sludge to
decanted water to the clarified water aeration tank.
water cannot find a path of least resistance,
sump
straightway rise to the top and exit to the launder. The squeegees work just like how a windshield
(If that is allowed to happen, then no settling of wiper works in your car.
6.2.4 Mechanized Clarifier Tank solids will occur.)
This design is used for large STPs only. Note how each squeegee is set at an angle.
The three types of clarifier tanks described so far The sludge is only slightly heavier than water; so When a squeegee sweeps through the layer of
were not mechanized: In those tanks, the sludge A typical tank is shown below. it takes time to sink. accumulated sludge, the sludge slides towards
settles and moves to the deepest part of the tank As shown, the tank is cylindrical, with bottom that The bacterial flocs16 collect at the bottom in its trailing edge. The squeegee leaves a
due to gravity, from where a pump takes it to the slopes toward the center, with very little slope. high concentration17. Even when the flocs settle continuous ridge of sludge at the trailing edge.
aeration tank. at bottom, they actually remain suspended in (The five squeegees on each arm leave five
The figure does not show the clarified water
In a mechanized clarifier tank, the sludge settles and sludge, so that the submerged parts can be water, rather than forming a solid sediment. ridges of sludge behind.)
at the bottom over a wide area, and a few rubber shown clearly, Since the bottom (3) has very little slope, the
wiper blades (called “squeegees”) sweep it to a flocs do not move from their settling spot.
pit at the center of the tank, from where a pump
The clear water rises to the top. Most of the tank 16 Each
takes it to the aeration tank.
Remarks is filled with clear water (not shown here), As we of 2-
go down, we find the sludge in progressively 17 At an
higher concentration. clear
The tank has a launder (5) around its towa
periphery.
The clear water flows over its top edge (4)
(called “weir”) into the launder, and is collected
by the outlet pipe (6) and taken to the filter
units (pressure sand filter and activated carbon
filter).
Note that the position of the launder determines
the depth of water in the tank: Under normal
running condition, the water level never rises
beyond the weir. It rises only when the outlet
pipe is blocked for some reason.
Each ridge is then collected by the next
squeegee in the opposite arm of the rake (after
Some critical details of the sludge-collection pit
are shown below:
squeegees strike the floor violently, and get
damaged. Such torn squeegees cannot sweep
6.4 Construction And
the rake turns by half a turn), and again pushed
toward the center.
the sludge properly. Again, this leaves a lot of
sludge unswept on the floor. Bacteria that cannot
Engineering
be collected within one hour from the clarifier Proper construction and engineering of a
Thus each pass of the squeegees moves the
tank die, and turn septic. clarifier/ settling tank is of utmost importance,
sludge toward the center by one blade length.
and several factors need to be considered and
The last squeegees (nearest the center) drop the Thus the bottom bush plays a vital role.
executed with great precision. Any deficiency in
sludge into the collection pit.
In some designs, a sludge-concentrator even one of these aspects can make or mar an
Thus, if each arm has five squeegees, the sludge (not shown here) is fitted on the central shaft (7) STP. Some of the more critical factors are listed
below:
w k q
i e u
l e
l t e
o g
t e
a r e
k e s
e a
c a
u h r
p e
t
t h a
o e r
r
f p a
i i n
v t g
e . e
d
A
r
l
o t
s
t o
o
a
t c
n
i o
o
o v
t
n e
e
s r
t
o t
h
f h
a
e
t
t
h e
t
e n
h
t
e
r i
a r
s
e u “bridg c out
The ng Radial
T b • St g
• entry of e”, ol through
concentrator is tank the
f h a e h mixed because T le
like a large (>
l i c e • h c outlet
o s t
screw. It
rotates with the
p
450)
t 6. liquor
into the
it spans
across
e ti port (3)
o
r i
e
r
rake, and
s
l
• Weir
at
h
e
3 feed well the tank
fi
g o and
n
s i
pushes/squeez
es the flocs
o unifor D Minimu
in most
de-
ur
e pi
outlet
pipe (4)
o
f a
a
l
down the pit.
p
e
m
level
f
o
e m
differenc
signs)18 s
h
t
In the
At the bottom
of the pit, the
i • Influ l si e in
allows
mountin
o
(
2)
center of
the pit,
w
t
h
c
r
f
l
floc
n
t
ent l
o
g water
level in
g of the s c
ol an RCC
driver
e i o
concentration
is the highest.
h
feed
well w n aeration motor,
o
nl le pillar
ct (5) is
t
t
i
c
s
This increases
e
h
to i
n
C tank and
clarifier
and also y
s s provided
allows
a c
the density of
the slurry that
o
kill
turb g rit (not the STP
o
m
th
e
.
bush
A
n
k
a
l
d
o
is returned to
p
p
ulen
m
er more
than 0.2
operator
to
e sl
u housin
p
;
the
tank
aeration
e
ce
of e ia m) observe ar d
g
g (6) is
mounted
r n r c the tank t
inco of e on this
e e o - min h from th pillar.
s q t b a th
g above. e at
p u o n It is The
mix t s
e i r tt i always housing
ed a w contains
c r e o s has
liqu n e a bush,
i e m m or m safety pt
k which
a m a from : hand- b
fl provides
l e i s the
A g s a very rails y
l n n e motor e o th a
aera at slow (not
y t tt (9) e it speed in o e frictionle
tion shown
: i li drives a s s the tank. in the r s ss
tank speed- ( q support
t n ( n This figure to u
the Clarifier t e reduct 1 to the
h I 7 or slow reduce e
tank for i s ion ). rotatin
e t ). m speed complex e
extended o gear A
period and die. n i T al ensures ity.) b g g rake
o e box s that the u e
s h e (7). This
u n T (10), p sludge c
o u s. ensures
t s h The e settled k
f a gear s et that the
e u e e at the Th rotating
c box w -
r r drives a d, bottom e rake
t h h s
e c shaft th of the co remains
h i e h
p s i e tank is a lle
e e (11). n steadily
r p ct
e v The th fr not centered
c shaft is e ed
r t s e e a stirred in the
u attache d sl
i h m m up. tank;
l q d d to the sl ud
p a frame ot e ge and
a u The u
h t or ro is more
r e t (12) platfor d importan
e e h that ro ta pu
r t m (13) g tly, the
g r carries ta te m
y h m all the s (also e pe squeege
e o te -
. e o squee at called d es
remain e e depth mean. a t len e e • If e t
T • Mi
in cl of the r swe gth v the s h
h It is n
contact a clarifier e pt of a e slud i e
e customa i
with the rif has no t by rak r n ge- g
fu ry to m
floor as ie role to a the e m t with n c
n specify u
they r play in n blad bla o dra l
d depth of m
rotate. is the k es) des i s wal c a
a clarifier f
If a th “clarifica between i mus on n c pipe o r
m o
bush is e tion” 2.5 to s t the il is n i
e o
not cr function: 3.0 m. fi hav rak l l buri s f
nt t
provide o Increasi tt e e a a ed i i
al In order p
d, the s ng e stee arm r t ben d e
d to ri
rake s- depth of d p g i eath e r
e restrict n • Spee
would s the w slop e o the r
si localize t d of
be e clarifier it e. n floor a -
g d high o the
danglin ct only h rake c in a t
n upflow f • Unif
g from io helps in a arm l o mec i i
cr velocitie t orm
the n the m a f hani o .
it s, h slop • Bott
platform al “thickeni e r t cal n e
e clarifiers e e in om
. As it a ng” c i h clari .
ri have to c floor “ste
rotates r function. h f e fier, i k
o be e , ady
in the e a i it s g
n Clarifier provided n with bus
thick a n e r shal
fo cross- with t out h”
slurry, it of i r a l be t s
r sectiona sufficien r maj for
meets th c s k mini h o
cl l area is t length a or the
uneven e a e mu e l
a typically of “weir” l und vert
resistan cl l t m i
rif compute over s ulati ical
ce and a r o a 4” “ d
ic d at which l ons sha
currents rif a r dia S s
at between overflow u ft of
; ie k • Rub p m met o /
io 12 – 18 occurs. d rak
r. e ber r s er. l m
n m3/hr/m2 In small g
In , squ and starts swinging.Circular i 2
of of clarifiers e clarifiers
th it eeg d /
th through , the - As a result, thein squeegees
most
e s ees s H
e put flow c caseswith the
cannot remain in touch
st “Weir c of are built r
m of o floor, and their sweeping
ri Overflo o the with anaction L .
ix sewage, w Rate” ll is not uniform. Thatall-round
leaves a lot
ct r mec o
e dependi does not e of sludge unswept weir,
on
e n hani a I
d ng on assume c A which
st e cal d n
li various critical ti rubber again is
th r rake i
q other significa o adequat
e s to n t
u factors. nce, and n e.
o ( swe g y
o For in a h
r w ep A p
r small square o
et h the n R i
c domesti tank, a p
ic i floor o a c
o c STPs, weir on p
al c t t a
m a figure a single e • Nu
s h h e l
in of 16 side of r mbe
e a e ”
g may be the tank • If a r,
n r r d
in taken as will be angl
s s e i o
to the sufficien e
e, q n d n m
th golden t. and
th u o e
s
t n
i o
c t
S o
T f
P
s g
, r
e
t a
h t
i
s s
i
p g
a n
r i
a f
m i
e c
t a
e n
r c
e
i .
s
18 This figure shows only half of the bridge, so that
the items located under it can be shown clearly.
6.5 Operation And 6.6 Troubleshooting
Maintenance Problem
Solids are
Cause
Poor design/ engineering/
Considerations carried over with
decanted water
operation/ maintenance
If properly designed, engineered and constructed,

Mushroom cloud Poor engineering/
clarifiers call for very little attention in terms of
of solids maintenance
Poor settlement of Poor design/ engineering
solids
Thin slurry in Poor design/ engineering
underflow
Excessive Poor engineering
turbulence in
clarifier
Rotational flow of Poor engineering
solids in upper
layers19
operation and maintenance. Indeed, the
unmechanized (hopper-bottom) settling tanks may 19 In fact, any movement of water in the clarifier
be said to be zero- maintenance units. Some parts should not be noticeable at all, except near the
of the mechanical rake (such as the motor, overflow weirs, where the velocities are high
gearbox etc.) call for only routine maintenance.
The sacrificial rubber squeegees sweeping the
floor of the clarifier need to be checked and
replaced, possibly once in two years.
Sludge Recirculation SL
1
Remarks
There are two identical pumps.
7.3 Design Criteria
Sludge recirculation rates are typically between
Controls ensure that only one pump can 50 % to 100 % of the throughput rate of sewage
7.1 Function needs to maintain a high level of microbes in the
aeration tank. Both these objectives are
run at a time. in the STP. Hence, in a majority of cases, the
The sludge from the sludge hopper of capacity and specifications of the raw sewage lift
The indivisible combination of the aeration tank, achieved by recirculating the sludge from the the clarifier is taken by gravity into a pumps are replicated for this duty as well.
settling tank and sludge recirculation constitutes settling tank, and also bleeding out of excess sludge sump, from where the pumps
an “activated sludge biological treatment microbes from the system at regular intervals. return the sludge to the aeration tank.
system”. All three must be fine-tuned to act in
To illustrate by a simple example: if the total
unison to produce the desired high level of
treatment. biomass inventory in the system is 100 kg, and
2 Both pumps have independent suction
pipes
7.4 Construction
daily bleed/ wasting rate is 4 kg, then the
The optimum desired age of the microbes is average age of biomass in the system is 25 • It is not desirable to have a common And Engineering
between 25 to 30 days. At the same time, an days. suction pipeline, because if it fouls
The engineering principles prescribed for the raw
STP up, both pumps will have to be shut
sewage lift pumps (see section 4.3) apply to the
down.
sludge recirculation pumps as well.
• The pipes must not have foot-
7.2 How It Works valves, because the foot-valves
Providing an intermediate sludge sump (between
the clarifier and the recirculation pumps) to
A typical pair of pumps (working and standby) is would get jammed frequently.
collect sludge from the bottom of the clarifier
shown below: • The inlet pipes extend almost to the tank is preferable to directly connecting the
bottom of the tank pump to the sludge pipe of the clarifier: This
3 The delivery pipes from both pumps are strategy enables control of the recirculation
combined in a !-shaped header. sludge rate, without having to throttle the pump,
thereby reducing pump-maintenance costs and
A delivery pipe takes sludge from this extending life of the pumps.
header to the aeration tank.
Typically in small plants (say up to 150 m3/day)
4 The bypass pipeline returns some 5-10 m3/hr of air is sufficient to lift sludge in a 2”-
sludge back to the sludge-holding tank. 3” dia sludge pipe, and deliver it back to the
5 Valves fitted on all three pipelines aeration tank. Note that air-lift pumps work well
serve different purposes: only when the submergence is high (i.e., when
• The valve on the bypass line is the mouth of the airlift pump is deep inside the
adjusted to “waste” the excess sewage) and the delivery head is small (i.e.,
capacity of the working pump. (The when the Aeration tank’s top is not much above
delivery pipeline (3) always carries the top level of the settling tank). In other words,
sludge at the designed flow rate, the water level difference between the Aeration
to achieve the desired MLSS in the Tank and Settling Tank must not be excessive;
aeration tank.) otherwise the pump will not be able to lift the
sludge, and thus the recirculation will stop.
• The valve on the delivery pipe is
closed off when the corresponding
pump is removed for repairs. This
prevents sludge coming from the
other pump from coming out.
Note:
T
h
e
e
x
a
m
p l c
l u o
e s d
t i
s r n
h a g
o t
w i i
s o s
n
t f
h p o
e u l
r l
p p o
i o w
p s e
e e d
l s .
i .
n 5
I |
e
s n
5
i a 9
n c
t
d u
i a
f l
f
e p
r r
e a
n c
t t
i
c c
o e
l ,
o
r n
s o
o s
n u
l c
y h
f c
o o
r l
o
i r
l -
7.5 Operation And 7.6 Troubleshooting Clarified Water
Maintenance Problem Cause
Sump
Excessive noise Poor engineering/
Considerations maintenance 8.3 Construction And
Considerations here are identical to those
specified for the raw sewage lift pumps (see
Excessive
vibration
Poor engineering/
maintenance 8.1 Function Engineering
Section 4.4). Overheating Poor maintenance Overflow water from the clarifier is collected in The tank should be able to properly feed the
an intermediate clarified water sump, This suction pipeline of the filter feed pumps.
The manufacturer’s O&M manual must be Loss in efficiency Poor maintenance sump acts as a buffer tank between the Minimum aeration with coarse bubble diffusers is
followed with diligence. of pumping secondary and the tertiary treatment stages in an recommended in this tank to prevent settling of
Ensure discharge of sludge recirculation into the STP. the trace amounts of suspended solids slipping
aeration tank is visible and can be monitored In a well-run STP, the treated water quality at this through the settling tank.
In addition, if an intermediate sludge sump is stage is good enough for reuse on lawns and It should be possible to clean and maintain the
provided, it is advisable to force-flush the sludge gardens with sufficient disinfection, and water for diffusers with ease.
line of the clarifier at frequent intervals, so that garden use may be directly taken from this p t
the sump, without having to overload the tertiary ic iw
units. a
Also, during lean inflow periods to the STP,
backwashing of the filters is carried out. At this
8.2 Design M
Criteria a
Any sump tank that s
minutes, soithat only
the pump may run
In addition, n
the tank
t
prudent to provide a r
Despite best design,
e pre
tank. This means
aerate this tank, in ord
n also
The air bubbles
in continuous suspen
from settlingaat the b
eventually starve and
n conten
would turn the
c
e
C
o
n
s
i
Troubl
deratio eshoot
ing in
ns this
There are no special unit of
requirements, as this tank plays a the
passive role in STP functioning. STP is
not
In general, look after aeration, called
and inspect the tank periodically for
for sediments. Remove due to
sediments as required. its
passiv
e role.
8.5
Troubleshooting
.
6 |
6
1
Filter Feed Pumps (FFP) 9.5 Troubleshooting
9.1 9.4
Function
Filter feed pumps
O
are used to take the
water from the
p
clarified water sump
and pass it through
e
the pressure sand
filter and activated
r
carbon filter installed
in series.
a
t
i
o
n
A
n
d
M
a
i
n
t
e
n
a
n
62 | The STP Guide – Design, Operation and Maintenance Filter Feed Pumps (FFP) | 63
Problem Cause
Excessive noise Poor engineering/
maintenance
c e 9.3 Co
Excessive Poor• engineering/
Check oil in the
vibration pump every day;
maintenance
e r nst
Overheating
top up if
Poor maintenance
necessary
a ru
Loss in efficiency Poor
C maintenance
C of pumping h
t cti e
o c
i on k
n
o An m
s o
n d t
i o
s En r
d -
•
gin t
o
between the main and standby pump
Switch eer -
p
ev
er
ing u
y The filter feed m
4 pumps may be p
ho selected either to be
ur of the open impeller a
s type (more efficient) l
(a or, we may fall back i
pp upon the trusted g
ro non-clog, solids- n
xi handling (NC-SH) m
m type of pump e
at selected for raw n
el sewage lifting (see t
y). Section 4.4).
Capacity of the filter feed pumps may be
9.2 D chosen keeping in view the desired
The option is left
a
f
entirely to the
e number of hours of operation of filters (if
not the standard 20-22 hours of operation).
designer/ engineer,
t
e
provided the rest of
si In this case, the capacity of the
the STP has been
r
intermediate clarified water sump also
g needs to be enhanced accordingly.
designed
e
n The discharge head of the filters may be v
e
specified at 1.5 - 2 kg/cm2, to overcome the
C pressure differential across the two filters r
y
under the worst condition (which is just
rit before backwashing or backflushing the
d
er filters).
i
s
ia m
a p h
n l a e
t a n c
l c d k
i e
n t c
g d i o
a g n
o m h d
p a t i
e g e t
r e n i
a d o
t t n
i p h
o a e o
n r f
•C t a
h s n b
e c e
c i h a
k m o r
m r i
c e n
o d b g
n i o s
d a l ,
i t t
t e s o
i l i
o y a l
n •C n
h d s
o e e
f c o a
k t l
c h s
o f e ,
u o r
p r m
l f e
i v a c
n i s h
g b t a
r e n
a a n i
n t e c
d i r a
o s l
r n •C
e s s
e l d n
a a
•F
l a t
o
n i
l
a d o
l
n n
o
d r • Al w
e w
r p a t
e l y h
p a s e
l c
a e k L
c e O
e a e T
f p O
i r
f e s s
s a a
n h f f
e e e
c a t t
e s y y
s
s p g p
a e u r
r r a i
y r n
•C m d c
o a i
m n i p
p u n l
l f e
e a i s
t c t
2
e t s
0
l u
y r w
p
e h
r
d r i
o
r ’ l
p
a s e
e
i r
n r p
e e
p
o c r
o
u o f
s
t m o
i
m r
t
e m
o i
n i
i o
n w o o
g a n
g i t
m e t a
a o m
i i r p
n n e e
t t d r
e o •M i
n a n
a t i g
n h n
c e t w
e a i
a i t
a e n h
c r
t a t t
i t h h
v i e e
i o
t n b
f
i y
l
e t p
o
s a a
w
•E n s
n k r s
s a
u i t v
r s e a
e l
v a v
d i t e
i s )
s i d •F
c b e o
h l s l
a e i l
r g o
g a n w
e n e
d d t
o h
f c l e
a e
r n v m
a e a
w b l n
e u
s ( f
e m n a
c n
t u
u a
r l
e
r d
’ i
s l
i
O g
& e
M n
t
m l
a y
.
and engineered to the satisfaction of a purist.
20 See http://en.wikipedia.org/wiki/Lock-out_tag-out
Pressure Sand Filter (PSF) 10.3 Design Criteria the filter will be restricted to the center line; and
the media placed near the wall of the tank will
A good average design filtration rate is not contribute to the filtering action.)
12 m3/ m2/hr of filter cross-sectional area, and These good engineering practices ensure
optimum
10.1 T
hi
m
filtration
Fun s
un
os
t
efficienc
ctio it filt
y by
n is
es er
avoiding
short
The se s
pressure nti us circuitin
sand all g of flow
filter y ed
(PSF) is in inside
used as a
pr S the filter,
a and also
es T
su minimizi
re P
ve ap ng
ss pli pressure
el
th ca
at tio
is ns
fill ar
ed e
wi de
th si
gr gn
ad ed
ed on
m thi
ed s
ia
ba
(s
si
an
s.
d
an
d
gr
av
el)
.
tertiary typically The
water
treatme filtered
nt unit to with PSF
trap the is
passed
trace on to the
amounts
of solids next
which stage in
escape the STP
the chain:
clarifier, the
and can Activated
64 | The STP Guide – Design, Operation and Maintenance Pressure Sand Filter (PSF) | 65
Carbon loss in the filter due to sudden fittings. A set of pipes, sh when the p A five to
expansion/ constrictions in the valves, bypass 10.5O pressure drop r ten
F
handle up
to 50 mg/l
i 10.4 Co line, backwash
waste line etc. p C across the
filter exceeds
e
s
minute
backwa
of solids in nst are also
o 0.5 kg/cm2. s sh will
an
ruc provided to e However, it is
u typically
facilitate r rid the
economical
manner. tio r n a good
e filter of
practice to
l all
n a s backwash
o accumu
once in a shift,
An i s lated
d t irrespective of
the actual
s muck.
.
E welded to
ends i d amount of
spaces between theoperations
sand particles.
n the top and o e such
Gradually, the space
particle
as sand
between
filtration,
10.2 How It gi bottom). A
r
typical
n vessel is n bypass
Works (during
The upper layers of theesand

designed to a servicing),
backwash etc.
withstand a
function.
e
perform the actual filtration
pressure of A t Pressure
gauges are
merely ri 5 kg/cm . 2
i
support to the upper nsand In small n gets filled with incoming
th solids. This
provided
blocks the passagee of water
at through
the
layers. diameter
g vessels, it is d o the sand layer. As fil a inlet
result,
and the
The sand used in the PSF is te drops
pressure at the outlet rapidly
outlet, to
The
not ordinary construction
customary
to provide a
n r
and wastes the pumping power, and
monitor
It has particle Filter ri ofthe
reduces the throughput the filter.
vess sieved
range, and is specially
bolted dish
at the top M s se pressure
When the pressures drops beyond a
for this purpose. el is drop
for ease of The limit, the sand shis cleaned by
Think of a sand filter
desig
ned as a maintenanc
3D a operati backwashing ofar
across
the
the filter.
filter
(“in depth”) filter, as compared e. In large ons (backflushing)
as a
a tea bag filters,
to planar filters likepress or a i essenti water is
pl
y The shell
tea strainer. Here, ure manhole of
the filtration ally direction (from outlet toheight
inlet). This
vessdepth >of0.6 m dia
occurs along the entire n consist process agitates, fluidizestypically and
the sand is provided of a expands the sand bed. varies
particles in the consi
el (it
water get at the top. A t long water carries between
entrapped and enmeshed hand-hole
in filtration pollutant solid particles as
1.2backwash
m to
the
sts of
a of > 200 e run, waste. 1.5 m in
mm dia is followe small
straig
ht provided at n d by a plants.
the bottom short Graded
cylind
rical of the a backwa pebbles
cylinder, to sh ranging
shell,
with facilitate n sequen from 0.5”
removal of ce. to 1” are
conv
ex media from c The 21 Stated filled as
dish- the vessel differently, bottom
shap at the time e filter
needs the pressure- layers in
ed of servicing. drop across the filter,
backwa
up to a depth of nearly
0.5 -0.6 m. The top
10.6Tro
layers consist of the ubl
filtering sand media
(Coarse and fine es
sand) to a depth of
0.6 – 0.7 m. A
ho
freeboard of nearly oti
0.3 m above the level
of sand may be
ng
provided (to allow for Problem
expansion of sand
Excessive
during backwash).
pressure drop
A great majority of across filter
filters operate in the Progressively
downflow mode poor filtration
(water flowing in top- efficiency
to-bottom direction).
Very low pressure
Necessary
drop across filter
appurtenances are
provided at the top for
distributing the inflow
uniformly across the
cross-sectional area
of the filter: similarly,
a pipe manifold with
laterals is fitted at the
bottom as the
underdrain system.
(Without these
structures, the water
flow inside
Activated Carbon Filter (ACF) 11.4 Construction And
Engineering
11.1 Funct water that is
already filtered
structure of the activated carbon. Granular
activated carbon is typically used for this
ion by the Pressure purpose.
Sand Filter and The water filtered by the Pressure Sand
An activated carbon
improves Filter enters the Activated Carbon Filter.
filter, like the
multiple quality
Pressure Sand Unlike in the case of the sand filter,
parameters of
Filter, is a tertiary trapped molecules in the carbon cannot
the water: BOD,
treatment unit. It be backwashed and got rid of. Hence,
COD, clarity
receives the activated carbon in the filter has a finite
(turbidity), color
and odor. capacity to adsorb and hold the pollutants,
after which the carbon is said to be
exhausted. The exhausted material is
removed from the filter and disposed off:
11.2 Ho Fresh activated carbon is charged in the
filter.
w It
Wo
rks 11.3 Design Criteria
This filter uses Very precise design criteria are available
the adsorption for design of activated carbon columns
action of (adsorption isotherms, kinetics of mass
activated transfer between the liquid and solid
carbon. phase, breakthrough curves etc.). For
everyday applications, however, the
Activated simplified rules used for the sand filter
carbon is have been found to be adequate.
typically
manufactured However, we recommend that the
from coconut diameter of the activated carbon filter be
shell or selected to be 25% larger than the sand
charcoal, the filter (SPF) to reduce the frequency of
“activation” servicing.
process
creating a highly
porous material
with a very large
surface area.
Organic
pollutant
molecules are
physically
adsorbed and
held fast within
the catacomb-
like porous
66 | The STP Guide – Design, Operation and Maintenance Activated Carbon Filter (ACF) | 67
C n d
o F s e A a
n i i d c
s l d t i
t t e d i
r e u v n
u r o e a
c f t t
t i t e
i s t o d e
o h
n s e b C n
i o a
a m f t r a
n i i h b
d l l o n
a t t n
e r e h . c
n r e
g t , a e
i o b
n e r 11.5 O
e t p a
e h o s p C
r e x i
i y v e o
n P e
g S p r n
F a a
o . i n a s
f n d
I t t i
t n c
h c o i d
e a o r
d a r o e
A d t o
c i i s n r
t t n i
i i g v a
v o e
a n i A t
t , s n
e a n i
d o r t
n e u d o
C c r
a t o e n
r h m
b e m o M s
o e f J
n i n
u p t e n
s a a h n e
t l r e t e
b t d
a e i c i s
s i c a n
t l r t
t e b w o
h a s o a
e t n t b
t e e
P a r g r
S a e f
F l p t q i
, e p s u l
s e a l
t s d e l e
h e x i d
e r b h t
y a y i
A f u n
C r s s a t
F e i t c o
q m e r
a u p d o t
l e l s h
s n e ( s e
o c i
y f n t f
n i d h i
e t l i e l
e o t c t
d r a A e
s d a t C r
i t e F .
t s i d )
o l o ,
o n
b d
b
y f
11.6 Troubleshooting
e g a r Problem Cause
e c n e
b t Excessive Poor operation/
o s pressure drop maintenance
a a i h
c n o across filter
i
k y n m c Treated water Carbon life exhausted
w . p a smells, or has a (change)
a s r r color
W
s o o b Poor BOD/COD Carbon life exhausted
h
h l v o (change)
e
e i e n
n Black carbon Poor quality of granular
d d m particles in outlet carbon
,
Disinfection Of Treated Water
12.1 Function 12.4 Operation And
The treated water is disinfected to destroy and
render harmless disease-causing organisms, Maintenance
such as bacteria, viruses, etc.
The most common methods of disinfection
Considerations
include Chlorination, Ozonation and UV • Prepare fresh Hypo solutions every day in the
radiation. day tank
Of these, Chlorine finds widespread application. • Shelf life of over 2 months is not
The primary action of the chemical involves recommended, especially during summer
damaging the cell wall, resulting in cell lysis and • Store Hypo in a cool place
death.
• Study Material Safety Data Sheets of Hypo
In most STPs, the common form of Chlorine and follow instructions
used is Sodium Hypochlorite (Hypo) available
commercially at 10-12 % strength, being safe, • Periodically check available Chlorine strength
easy to handle and having a reasonable shelf of Hypo
life. • Check and record Residual Chlorine
concentration every day
12.2 Design Criteria

Efficiency of disinfection is dependent both on 12.5 Troubleshooting
the residual concentration of the chemical used,
as well as the contact time, a factor measured as Problem Cause
R x T. Generally, a contact time of 20-30 minutes Inadequate Poor operation/ poor
is recommended to achieve over 99 % Chlorine residual quality chemical
germicidal efficiencies. in treated water
Fishy smell in Excessive chlorination
treated water
12.3 Construction
And Engineering
The Chlorine disinfection system consists of
a Hypo-holding tank (its size depends on the
flow rate of the STP) and an electronically
metered dosing pump. Hypo solution of desired
concentration is prepared in the tank. The dosing
rate is set in the metering pump as per the
desired Chlorine dose rate, typically 3-5 PPM.
Hypo solution is dosed at the outlet of the ACF,
online, so that adequate mixing of Hypo with the
treated water is achieved.
68 | The STP Guide – Design, Operation and Maintenance Disinfection Of Treated Water | 69
Excess Sludge Handling
13.1 Function gives the quantity of excess sludge to be handled
Biological treatment of wastewater perforce per day in m3/day.
produces excess biological solids due to the
growth and multiplication of bacteria and other
microorganisms in the system. The excess
biomass thus produced needs to be bled out of
13.3 Construction And
the system, and disposed off efficiently. Engineering
This is a five-step process: sludge removal, We will discuss two different methods of handling
storage, conditioning, dewatering and disposal. the dewatering system:
Sludge is removed (“bled”) from the system • Plate-and-Frame Filter press
from the sludge recirculation pipeline (through a
branch). • Bag-type dewatering
The sludge is in the form of a thick slurry. It is
taken into a sludge-holding tank, and kept under
aeration (to prevent the living organisms from 13.3.1 Plate-and-Frame Filter
putrefying) until dewatering operations can be press
carried out.
The Plate-and-Frame Filter press is the most
Before dewatering, polymer or other chemicals
commonly used method of dewatering the sludge.
may be added for conditioning the sludge, to
It consists of three to four parts:
facilitate the process. Sludge is then dewatered
in a filter press/ Sludge bag/ centrifuge. • Sludge-holding tank with aeration/ mixing SL Remarks The figure shows a hydraulic jack
(4) that extends and retracts the
• Polymer solution-preparation tank and dosing 1 The press makes use of multiple filter
plunger (5).
(for conditioning the sludge) plates.
The job of the plunger is to tightly press
• High-pressure filter-press feed pump Each plate has indentations and
the filter plates (1) against each other,
13.2 Design Criteria • Plate-and-frame filter press
recesses on the sides, such that when
two plates are pressed together, a so that the slurry (which is injected in
The quantity of excess sludge generated in the the press under high pressure) does not
The polymer solution tank must be of sufficient hollow chamber is formed between the
STP is dependent on various factors including leak from the joints between the filter
capacity to hold 0.1 % solution of polymer to plates. The dewatered sludge settles
the BOD concentration, MLSS levels, plates.
condition one batch of excess sludge: Typically, in this hollow part to form a brick (also
temperature etc. The F/M loading rate is called “cake”). In smaller filter presses, the electric jack
polymer requirement is between 1-2 % of the
however is the factor which chiefly determines and plunger are replaced with a large
excess sludge on dry weight basis. 2 The end-plate is a solid plate used to
the amount of excess solids produced. Sufficient screw that is turned manually with a
press the filter plates (1) together.
data are available in literature in graphical form The sludge-holding tank must be of sufficient large wheel.
for determination of this number. A typical figure capacity to accommodate the combined volume of 3 All the filter plates and the end-plate
have “wings”, which rest on these two 6 The inlet pipe brings the excess
for use in India is between 0.20 to 0.25 times (on (a) the excess sludge to be dewatered in a single sludge slurry from the screw pump (not
dry mass basis), kg of BOD removed in the batch, and (b) the polymer solution that is added. rails.
shown in the figure).
aeration tank, in extended aeration systems with All the plates hang on the rails, and they
The high-pressure filter press-feed pump (4 – 5 The slurry travels the path of least
low F/M. are designed to easily slide along the
kg/cm2 pressure) must be selected to dewater a resistance and fills up the cavities
Since the excess sludge is available in slurry single batch of excess sludge within 3-4 hours of rail when pushed.
between the filter plates (1).
form from the sludge recirculation line, the slurry filter press operation.
consistency may be taken to be between 0.8 to All cavities are lined with a filter cloth.
A typical press is shown on the next page.
1.0 %.
Simple arithmetic using the above two numbers
70 | The STP Guide – Design, Operation and Maintenance Excess Sludge Handling | 71
13.3.2
7 Bag-type dewatering
The liquid in the slurry (called “filtrate”)
can pass
This contraption through
actually the cloth,
is an imitation while
of our daily tea-strainer! In fact, once the sludge is strained, it
the thicker paste-like sludge (mainly
does look remarkably like used tea powder (not the CTC or whole tea leaves, but the lowly tea dust.)
bacterial flocs and some solids) cannot
pass through the cloth. The key factor that allows this method is that
the flocs of bacteria are globular with 2-3 mm
The filtrate travels to the outlet ports diameter. These flocs can be easily trapped with
at the top and bottom of the plate, and a laminated poly bag. These bags are used to
from there it is discharged through the transport sugar, fertilizer and other foodstuff, and
filtrate discharge pipe. at the end of the cycle, they are discarded.
The solids remain in the cavity between These used bags are available in secondary
the plates. Typical thickness of cake in market at very cheap rates.
the chamber is 2 to 5 cm, The equipment is very simple, as shown on
A freshly produced cake has a moisture facing page: A rustproof Stainless Steel table is
content of between 70 – 75 %. Note manufactured with provision to hang 2-4 bags.
that it is impossible to achieve a bone- The sludge is poured in each bag, and just like
dry cake even after prolonged air- tea-strainer, the water drains out.
drying: The moisture content would not
drop below 50%.
In any case, the main use of the cake is SL Remarks
used for making compost, in which case 1 The stainless steel table allows However, because the sludge is not squeezed the filter press. Hence, sludge must not be
the sludge has to be moistened once splashing of water without getting (as in the frame-and-plate press), the bag stored in the holding tank for longer durations.
again. Therefore the cake is usually not rusted. remains wet. So, after the water stops dripping,
dried further. The desired quantity of polymer needs to be
2 The openings have a collar beneath, the operator has to close the bag and place it on
Once the filtrate stops coming out of where the bags can be clamped added 15 - 30 minutes before the dewatering
airing racks to let it dry for several days.
the discharge pipe (7), the jack (4) is operation. Filter press operation is carried out
3 The excess sludge pipeline brings In fact, if the dewatered sludge is to be used as over 3 - 4 hours, or when filtration ceases.
deactivated, which retracts the plunger sludge from the settling tank.
(5). Now the filter plates (1) are slid compost, then it need not be dewatered further:
4 The valves can be used to regulate After every dewatering operation, the filter cloths
The moist sludge can be directly used as an
apart on the rails (3). must be thoroughly cleaned, so that clogging in
the flow rate, and also to turn off if there ingredient!
is no bag beneath. the pores of the woven polypropylene filter fabric
As soon as the plates separate, the
is avoided. Periodic cleaning of filter cloth with
cakes fall down in a basket placed
Hypo solution will also prolong the life of cloth. 5 The laminated poly bags capture
below the press. the floc, but allow the water to run.
Now the press is ready for another 6 The stainless steel collection 13.4 Operation And When the filtration process becomes excessively
slow, it is time to replace the filter cloth with a
tray
cycle.
collects the water (and fine sediments)
Maintenance fresh set.
8 The work-bench is simply a support
structure for the parts described above. 7 The stainless steel grill supports
the bags and allows the water to fall
Considerations Normal maintenance as prescribed by the
manufacturer may be practiced for the high
through Typically, in small plants, the filter press may be pressure helical screw pump. Care must be
sized for a single batch operation per day. In taken not to damage the rubber stator of the
8 The collection pipe takes the filtrate
back to the Equalization tank. large plants, three batches per day, one per shift, screw pump by dry running of the pump. It is
is the norm. generally preferable to locate the pumps such
(Sump and pump required for this that positive suction is enabled.
Fresh sludge (not more than a day old), kept
purpose are not shown).
fully
aerated and mixed (agitated), dewaters easily in
72 | The STP Guide – Design, Operation and Maintenance Excess Sludge Handling | 73
13.5 Troubleshooting Miscellaneous Considerations
Problem Cause
Filter press does Poor design/ engineering • • Prepare and
not dewater the maintain a
slurry sufficiently mechanical
quickly • Design and engineer the STP to be operator- friendly checklist for
Dewatering is very • Oily / slimy sludge, routine
•
slow preventive
• Filter cloth is clogged, maintenance
• Improper conditioning • • Prepare and
• Incorrect filter cloth maintain a
fabric • History Sheet
for each critical
Insufficient • Rubber stator of screw
equipment in
pressure pump worn out
the STP
developed •
• Steel rotor damaged
• Prepare and
maintain a
chemicals/
• consumables
stock register
• Periodically
check and
validate all log
books,
checklists etc.
•
• Provide a Water
meter at the
outlet of the
• ACF to monitor
average daily
throughput of
the STP
• • Ventilation
system:
Generally 10-12
air changes per
hour should
give good
ventilation22.
The air change
is calculated
based on the
open/ vacant
head space of
the
underground/
basement room.
There must be a
fresh air fan
(forced draft)
and an exhaust
fan (induced draft), with e
two separate ducting m
systems. i
s
• If the induced draft fan
s
is designed for a
i
slightly higher capacity
o
than the fresh air fan,
n
then the room will
s
always be under a
.
slight negative
pressure, and gases
will not escape the
room as fugitive
22 For example, if the STP room has 5 m3

tanks), then the circulation system should have minimum handling capacity of 50
m3/Hr.
|
7
7
5
Design and
Engineering
Maintenance
STP Design Process The designer has to consider the following main influencing factors:
Parameter Typical range Remarks

F/M ratio 0.05 to 0.30 In Extended Aeration-type STP, this range is 0.10 to
In the previous chapters, the STP units were introduced one by one. This chapter provides the 0.12.
complete design process (calculations) for all units of a typical STP.
Oxygen 1.0 to 1.8 kg/kg BOD Providing oxygen consumes energy. Lower is better.
In the subsequent two chapters, we will see the engineering and operational aspects of the STP in requirement
detail. Excess sludge 0.1 to 0.25 kg/ kg BOD How much sludge is to be disposed off. Lower is
better.
Design process overview Efficiency 70 % to 95 % The percentage of biodegradable matter broken
Before starting design, let us review how an extended aeration type STP functions. down in the STP. Higher is better.
1. Domestic sewage is typically pure water that is laden with a small amount of biodegradable
pollutants. The STP uses bacteria in the aeration tank 23 to digest this biodegradable material. The F/M ratio is the main choice available to the STP designer. However, he has to keep in mind that
Therefore the incoming sewage must remain in the aeration tank long enough to let the bacteria any ratio he chooses will have a major effect on the STP, as shown below:
complete the digestion process.
So the first task before the designer is to retain the sewage long enough in the aeration tank.
Effects of F/M ratio
2. The bacterial population needs Oxygen to survive.
Effect
So the second task before the designer is to provide adequate Oxygen.
Oxygen Excess sludge Treatment Aeration Tank
3. The bacterial mass (called “activated sludge”) is recycled and retained in the aeration tank, while F/M Requirement Production Efficiency (% ) volume
the treated water overflows from the clarifier tank. This clarified water is further filtered, disinfected
and reused for non-potable purposes (toilet-flushing, washing cars, gardening, etc.). A sizable LO HI LO HI HI
fraction of treated water remains unused, which is released in nature. MED MED MED MED MED
So the third task before the designer is to clarify, filter and disinfect the water. HI LO HI LO LO
4. The bacteria breed in the aeration tank, which increases the sludge volume constantly. Secondly, Note:
the bacterial population is the most vigorous when average age of the bacteria in the tank is The fonts show whether this is a good, neutral or bad outcome
maintained at 25 days. Both these purposes are achieved by bleeding off the excess sludge
periodically. (The discarded sludge is used as organic manure).
The first row of the table is explained below as an example:
So the fourth task before the designer is to provide a system for disposal of excess sludge.
If the chooses a low F/M ratio (a higher amount of bacteria in the aeration tank), the following things
The designer starts by estimating the amount of sewage generated. This is the basis for calculating all happen:
physical properties of the STP (tank volume, pump capacity, etc.)
1. The higher amount of bacteria need more oxygen (which is bad , because providing more
Then the designer estimates the amount of nutrition (carbohydrates, proteins, etc) present in the compressed air requires more energy)
sewage. This is called “food” (which the bacteria have to digest). For a given type of use (residential/
2. A lower amount of excess sludge is produced (which is good: It saves energy needed to dewater
office/factory) and scale of operation, the amount of food can be estimated with a fair accuracy (using
the sludge; and saves the expenses of disposing the excess sludge).
empirical data).
3. More bacteria are able to digest a larger percentage of the sewage (which means that a lesser
The next step is to find the amount of bacteria needed to digest this amount of food. Based on this amount of biodegradable matter remains in the treated sewage. When this sewage is released to
figure, the subsystems needed to handle the bacteria are designed (amount of oxygen needed,
nature, it would demand lesser amount of Oxygen from lakes and rivers, which is good.)
amount of excess sludge to be handled, etc.).
4. More bacteria means the aeration tank has to accommodate more bacterial flocs (apart from the
incoming sewage). This is bad , because it requires a larger tank size.
23 T
h
e
78 | The STP Guide – Design, Operation and Maintenance STP Design Process | 79
b
c a
l c
a t
r e
i r
f i
i a
e l
r
f
t l
a o
n c
k s
i a
s n
d
j
u r
s e
t t
u
a r
n
m
e t
c h
h e
a m
n
i t
s o
m
t
t h
o e
r a
e e
c r
o a
v t
e i
r o
n
t
h t
e a
n
k
w
i
t
h
i
n
o
n
e
h
o
u
r
.
Y
o
u
c
a
n
t
h
i
n
k
o
f
i
t
a
s
s
t
r
a
i
n
e
The following table shows the consequences of imbalance in food, microorganisms and oxygen. In each Aeration tank 1. Design BOD : 250 mg/L (equalized sewage)
case, only one factor is shown out of balance: the other two are assumed to be as per design.
2. Aeration time: 16 Hrs minimum (desirable: 18 hrs)
Parameter Too low Too high
3. F/M ratio : 0.12 (to achieve over 95 % BOD removal)
Microorganisms 1. The STP is overloaded 1. The STP is underloaded
4. MLSS : 3500 mg/L
(Bacteria) 2. Sewage is treated only 2. Filamentous growth
partially 5. Air : 50 - 60 m3/Hr/ kg BOD
3. Gradual failure of plant
6. Diffusers : Flux rate 8 – 12 m3/ Running meter /Hr (for 90 OD
Oxygen 1. Underaeration 1. Overaeration
diffuser)
2. Partial treatment of sewage 2. Pinpoint flocs Secondary Clarifier • Overflow rate : 12-18 m3/m2/Day
3. Filamentous growth 3. Poor settling (chokes the filters) • Detention time : 2.5-3.5 hours
4. Gradual failure of plant 4. Gradual failure of plant • Solids loading : 2-3 kg/m2/Hr
Food 1. Filamentous growth 1. The STP is overloaded
• Weir loading : Less than 50 m3/Running meter/day
2. Gradual failure of plant 2. Partial treatment of sewage Pressure sand filter Loading rate : Less than 12 m3/m2/Hr
3. Filamentous growth Activated Carbon filter Loading rate : Less than 10 m3/m2/Hr
4. Gradual failure of plant Carbon charge : For 6- 8 months replacement
Such unbalanced conditions cannot be sustained over long periods of time: It will lead to eventual Softener Design hardness removal from 300 mg/L down to 100-120 mg/L
failure of STP. Hypo dosing 5 PPM dosing, to leave 0.5-2 PPM residual
Therefore the designer also has to do a fine balancing act between these factors. Excess Sludge 0.20 – 0.25 kg excess solids per kg BOD removed (dry basis)
Sludge conditioning 0.8-1.2 kg lime per kg dry activated sludge
Note: 1 – 2 % polymer to sludge on dry weight basis

That developing a new culture of bacteria in the required large quantities takes time. So, if an STP Filter press Sufficient wet cake holding capacity based on excess sludge
fails, it may take several days to recover. Till the STP recovers, the users have to make alternative production, as calculated above (For STP size of 400 m3/day and
arrangements to treat the sewage (such as pumping the raw sewage out and ferrying it to a public above, design for 2 cycles per day)
STP.) This operation is extremely expensive. Therefore a failed STP can be devastating in monetary
and environmental terms.
We will be using three different types of values for the calculations:
1. The design criteria (see the table above).
Design Criteria for STP 2. Fact-based figures for the given complex (e.g. number and type of apartments)
Item Design Criteria Used 3. Assumptions (e.g. water consumption per person per day)
Bar screen • Flow velocity thru screen Max. 0.3 m/sec

Based on these values, the dimensions for all
• Solids units
to be of the STP
captured : 12 are
mmderived.
or more
• To calculate a parameter, we may use one orofmore
• Placement values
a coarse calculated
screen beforebeforethe
thatfine
point.
screen will be
beneficial • In the following calculations, the units KLD (kiloliters per day) and m3/day are used interchangeably.
Equalization tank • Minimum detention time: 4-6 hours (to handle peak flow)
We will take an example of a typical apartment complex with 200 3-bedroom apartments, and see how
• Air for mixing and avoid settling and septicity its STP is designed.
• Air flow: 1 m3/ m3 of tank volume OR 2 m3/m2 of tank floor
(whichever is greater)
Raw sewage lift pumps Capacity calculated based on 20-hour/day working of STP, to leave
sufficient margin for change over, maintenance, rest period, etc.
Sewage Quantity (STP Capacity) Bar Screen Chamber
The STP must be able to treat all the sewage generated in the complex. That is why we start by The bar screen chamber is the first unit in the STP, so all the incoming sewage passes through its grill.
calculating how much sewage is actually likely to be generated in the complex. Therefore it should be able to handle the sewage (especially the peak flows) without overflowing.
In general, almost all the water that is used in the kitchens, bathrooms and toilets of the apartments There are two major factors to be considered:
reaches STP as sewage. Only some of the consumed water is lost (e.g. evaporation); and therefore
1. Adequacy of the cross-sectional area of the chamber itself
does not get converted in to sewage24.
2. Obstruction posed by the bars of the screen.
Parameter Value/Calculation Remarks
The net opening should be adequate to allow proper flow of the sewage (especially during peak
Dwelling type Residential apartment Commercial and office complexes would inflow).
complex have different basis for calculating the water
consumption. Parameter Value/Calculation Remarks
Grade “Superior” Although such formal profiles do not exist, Average daily 120 KLD26 Quantity of sewage to be handled by the STP on daily
it helps in assuming certain lifestyle for the flow basis (ref. page 82)
residents; which in turn helps in assuming certain
Average hourly = 120 / 24
parameters (such as daily water consumption
flow
rate). = 5 m3/Hr
No. of dwellings 200 x 3-bedroom Apt Figure taken for this example. = 5 / 3600 m3/sec
Total population 1000 Population assumed at 5 persons per apartment
= 0.0014 m3/sec
Diversity factor 90 % To account for reduction of population due to
Peak hourly = 3 x Avg. hourly flow The peak is assumed to be three times the average.
a few vacant apartments, lesser number of
flow
residents in some apartments, etc. = 3 x 5 m /Hr
3
Per capita water 150 LPD This figure is assumed for “superior” grade = 15 m3/Hr
consumption apartments25
Design flow 0.30 m/sec This is the optimal velocity:
(LPD=Liters per day) velocity
• Sewage flowing at a higher velocity will forcibly
push the debris through the screen.
Total water = 1000 x 90 /100 x 150 = (Population) x (diversity factor) x (per Capita • Sewage flowing at a lower velocity will leave an
consumption consumption) excessive amount of sedimentation on the floor of
= 135,000 LPD
the screen chamber.
Cross-sectional = 0.0014 / 0.3 Volume/Hr = Cross-sectional area x flow velocity.
Sewage generated 120,000 LPD The consumptive usage and losses are area of screen
approximately 10%. The result is rounded off. = 0.005 m2
channel
Sewage quantity 120 KLD This figure is the basis for designing all stages of Adjust for = 0.005 m2 x 1.5 Cross-sectional area is increased by 50% to
the STP. the flow-area compensate for the obstruction posed by the bars of
= 0.0075 m2
Note: blocked by the the grill.
This 120 KLD is a reference figure, which will be used for designing all stages of the STP. bars
In general, the multiplication factor is (1+ W/G)
Where-
G = Gap between two bars of the screen (here, 10
mm)
W = Width of a bar (here, 5 mm)
24 If the apartment has a swimming pool, it does not contribute to the sewage.
25 The consumption is more in “Super luxury” and “luxury” grade apartments; and lesser in “mid-level” and
“economy” grade apartments. Select this figure carefully; otherwise the STP would be unable to handle the
actual quantum of sewage. 26 KLD=Kiloliter per day.
Required 0.1 m x 0.1 m This is a comfortable target: Actually it is easier to bypass pipeline.
minimum build larger channels. Also, a larger chamber is easier The following table shows the calculations for selecting the correct pumps for our STP.
dimensions27 for the STP operator to clean. These larger chambers
can handle much larger peaks in the inflow. Parameter Value/Calculation Remarks
STP quantity 120 KLD Quantity of sewage to be handled by the STP on
daily basis (ref. page 82)
=120 m3/day
Equalization Tank Pump capacity = 120/20 Select a pump that has a little higher capacity, so
The equalization tank must be able to provide the necessary buffer for the fluctuating inflow and that a little quantity can be bypassed to achieve
= 6 m3/Hr
provide a steady outflow. It must also keep the sewage agitated and provide sufficient aeration to the desired net flow rate.
prevent odor problem. • If the pump capacity is too high, a lot of
The following calculations show what type of equalization tank would be required for out STP. sewage will have to be bypassed, resulting in
waste of energy.
Parameter Value/Calculation Remarks Suction head (m) Difference in floor level of The sewage level in the equalization tank
STP quantity 120 KLD Quantity of sewage to be handled by the STP on the equalization tank and fluctuates throughout the day. The worst-case
daily basis (ref. page 82) suction level of pump suction condition exists at late night/ dawn, when
=120 m /day
3
the equalization tank is almost empty just before
Hourly average = 120/24 m3/Hr the peak morning inflow starts. That is why the
sewage inflow pump must be selected to take care of this
= 5 m3/Hr
suction head.
Equalization tank = 5 x 6 m3 Tank is designed to hold six hours of average flow.
volume Delivery head (m) The difference in top Select a pump that has the rated capacity at this
= 30 m 3
Note that this is the usable volume, and does not level of aeration tank and delivery head.
include the freeboard. delivery level of pump
Freeboard 0.3 to 0.5 m Selected by convention. Total head (m) = Suction Head + Delivery Select a pump that has the rated capacity at this
Water depth in tank 2.0 to 2.5 m The incoming sewage line is already below ground Head delivery head.
level, and the entire equalization tank has to be
(excluding
located below this pipe. This puts a constraint on
freeboard)
the depth.
Tank area = 30/2 m2 Area = Volume / Depth
Aeration Tank
The aeration system should be able to retain the incoming sewage for a certain time, and also provide
=15 m2 Select length and width to suit the site conditions sufficient amount of bacteria and oxygen needed to digest the sewage.
Diffusers required Select size and number Typically, a pair of diffusers must fit within the width
to suit the dimensions of of the tank. If the tank is not wide enough, the pair The following calculations establish what kind of aeration tank would be needed for our STP.
the tank may be placed at an angle.
Several such pairs of diffusers are placed along the STP quantity 120 KLD Quantity of sewage to be handled by the STP on
length of the tank. daily basis (ref. page 82)
Air quantity No. of diffusers x 5 Maximum air flux rate per coarse bubble diffuser of BOD in sewage28 250 mg/L Empirical value, for typical Indian domestic
required m3/Hr 90 OD x 800 L may be taken as 5 m3/Hr. sewage. BOD may range form 200-250 mg/L. We
=0.000250 kg/L
have taken the highest (the worst-case) value in
the range; so that the STP can deal with lighter
loads also.
Raw Sewage Lift Pumps

The raw sewage lift pumps have to handle the entire daily quantity of the sewage. The pumps must be
selected to have a little higher capacity, so that we can adjust the flow rate precisely by adjusting the 28 How to interpret this BOD figure: It means if this sewage is released in nature, it would demand (absorb)
250 mg of Oxygen from the surrounding air/water for every liter of sewage. The idea is to provide that much
27 Note how a tiny bar screen chamber (just 10 cmx10cm) can comfortably serve a 200-apartment complex! Oxygen inside the aeration tank, so that the treated sewage would become inert, and when the treated
sewage is released in nature, it would not demand any Oxygen from its surroundings.
BOD load/day = (120 x 1000) x 0.000250 This means the aeration tank has to supply 30 kg Aeration tank volume = 250 300 / 3.5 = Biomass / MLSS
of Oxygen every day. (This is the “Food” in the
= 30 kg/day = 72 86 m 3
Selecting lowest MLSS yields the highest-
F/M ratio.)
possible size for the aeration tank. This size will
F/M ratio 0.12 This value is taken from the available range of
be able to handle higher values of MLSS.
0.10 to 0.12. The higher limit represents the worst-
case scenario (more food in the sewage for the Average retention time = 72 86/ 120 x 24 Hrs Think of this as =(24/120) x 86.
bacteria existing in the aeration tank). = 14.4 17.2 Hrs The first term is the time taken by a unit volume
M (Biomass) = 30 / 0.12 This means that we need 250 kg of bacterial flocs of sewage to exit the aeration tank.
to digest the sewage, Multiplying this with the volume of the tank gives
= 250 kg
Note that this is the biomass needed in the us average time taken by the present contents of
aeration tank at any point of time. This figure does the tank to exit the tank (=average retention time)
not include the mass of bacteria that is in the
clarifier tank.
Now our retention
Design MLSS time3500
in themg/L
aeration tank is within the
Thelimits; and weMLSS
acceptable can proceed
range iswith the rest of the design.
3500-4500.
level
(= 3.5 kg/ m3) But we chose the lowest MLSS in the range in the
range, because it gives us the most conservative Parameter Value/Calculation Remarks
size for the aeration tank (see the row below). Depth of aeration = 3.0 m Select 3 m water depth29 as a good practical
Aeration tank = 250 / 3.5 = Biomass / MLSS tank working depth (considering the typical ceiling
volume height available in an STP).
= 72 m3 Selecting lowest MLSS yields the highest-possible
size for the aeration tank. This size will be able to If area is severely constrained, the depth may be
handle higher values of MLSS. increased up to 4.0 m.
Average = 72/ 120 x 24 Hrs Think of this as =(24/120) x 72. Area of aeration tank = 86/3 Area = Volume / Depth.
retention time
= 14.4 Hrs The first term is the time taken by a unit volume of = 29 m2
sewage to exit the aeration tank. Width of aeration 3.6 m This width is ideal to accommodate set of 1m long
Multiplying this with the volume of the tank gives tank diffusers
us average time taken by the present contents of Length of aeration = 29 / 3.6 Length = Area/width
the tank to exit the tank (=average retention time) tank
=8m
BOD load per hour = 30 / 22 = (BOD load per day) / (no. of aeration hours).
We will have to pause here, because we got a retention time of 14.4 hours; compared to our target of = 1.36 kg/Hr Assuming 22 hrs of aeration.
16 hours minimum (preferred: 18 hours). We will have to go back and change a factor till we achieve
16 hours of aeration. Air requirement for = 1.36 x 60 60 m3/Hr of air per kg BOD is a good, generous
BOD figure, resulting from an involved equation, which
This is a perfect example of an iterative design, which also reinforces the fact that the designer has to = 82 m3/Hr
accounts for a number of variables such as
make a considered decision based on several site-specific conditions. density of air, Oxygen content in air, kinetics of
So let us examine which of the independent factors can be altered to achieve the desired retention Oxygen transfer from the gas phase to the liquid
time (Note that the value of that factor must be tweaked within its acceptable range; so as not to upset phase, correction for impurities present in
the delicate balance). wastewater, etc.
Air requirement for = 86 x 1.1 This requirement is @1.0-1.2 m3/m3 of tank
Fortunately, we have found a quick solution: Maintaining a higher population of biomass in the system
mixing volume
is a desirable feature, in order to overcome a temporary hiccups in the aeration tank performance = 95 m3/Hr
(which may be caused by loss of power, equipment malfunction/breakdown, and even a huge surge of
sewage).
Therefore, we will choose to introduce a 20 % safety margin, and increase the biomass from 250 kg to
300 kg.
Now we will re-calculate the last two rows of the preceding table with this new value: 29 Water depth is measured from bottom of the tank to the top-edge of the weir. The freeboard is the height of
the top of the tank from the water surface (=the top edge of the weir).
Air requirement for = 2 x 29 This requirement is @ 2 m3/hr / m2 floor area
mixing Design throughput 120 m /day
3
Quantity of sewage to be handled by the STP on
= 58 m3/Hr flow daily basis (ref. page 82)
Air to be supplied 95 m3/hr The highest quantity of the three iterations above. Max. hourly =120 m3/ 20 hours Assuming 20 hours of pumping in small plants.
(In this case, the volume-based requirement is the throughput The 4 hours of down time is a worst-case
= 6 m3/Hr
highest, so that figure overrides the others.) scenario: In practice, pumping will be done for
more than 20 hours. Thus the actual hourly
Select size of 90 OD30 x 1000 Length Selected to suit the geometry of the tank, and
throughput rate will be always less than this.
diffusers to minimize the number of diffusers used for the
same quality of air dispensed. Design overflow rate 16 m3/m2/day This is a proven figure for extended aeration
No. of diffusers = 95 /8 = (Air to be supplied) / (minimum air flux rating) biological processes.
= 0.67 m3/m2/Hr
= 11.8 Nos The data sheets for the diffusers show a desirable Cross-sectional area = 6 / 0.67 m2 = (Hourly throughput) / (hourly loading rate)
range of air flux rate of 8 – 12 m3/Hr. (The diffuser of tank
= 12 Nos = 9 m2
will work properly only if compressed air is
Dimensions For a square tank- Area of a square = Side2
(nearest whole number) supplied in excess of this rate.)
Placement of 12 diffusers (6 pairs) are Rows are distributed evenly along the length of =3x3m
diffusers arranged in a row, set the tank. For a circular tank- Area of a circle = !/4 x Dia2
apart by 8 / 6 = 1.3 m
= 3.4 m Dia
Diffuser Each pair is separate, We should be able to easily retrieve each pair Depth of tank 2.5 m to 3.0 m Selected by convention
configuration with its own air hose, of diffusers from sewage. If all diffusers are
nylon tie rope and interconnected as a single array, it would be too Solids load = 6 m3/hr x 3.5 kg/ m3 = Hourly throughput x MLSS
ballast. heavy for a single person to lift. It would also = 21 kg/Hr This is the volume of bacteria that gets added to
make it difficult to isolate a faulty diffuser. the tank. MLSS value of 3.5 kg/m3 is taken from
Tip: the Design Criteria table (see page 81).
The tank volume can be linearly extrapolated based on design quantity of sewage. Solids loading rate = 21 / 9 = (Solids load) / (Cross-sectional area of tank)
= 2.33 kg/m2/Hr The calculated value is within the limit of 3.0.31
Weir length in clarifier = 2 x 3 for a square Length of launder = 2 x Side
Clarifier Tank tank
For a square tank with launder on two sides,
The design of the clarifier tank caters to two separate flow paths: = 6 RM
= 3.14 x 3.4 for a Length of launder = ! x Dia
1. The flow of clarified sewage that flows over the weir (the top edge of the launder)
circular tank
For a circular tank with launder around the
This decanted sewage is taken to the filters.
= 10 RM periphery
2. The flow of solids that settle toward the bottom of the tank. Weir loading rate = 120/6 The calculated value is within the limit of 50.32
This bacterial mass is taken back to the aeration tank. = 20 m3/RM/day = (Sewage flow rate) / (length of weir)
The first is called “hydraulic” and the second is called “solid”. For square tank, the weir is 6 RM long.
= 120/10 = (Sewage flow rate) / (length of weir)
Note: = 12 m3/RM/day For circular tank, the weir is 10 RM long.
The hydraulic design criteria for a clarifier/ secondary settling tank are developed based on throughput
flow only: The recycle sludge flow is not counted.
31 Only in thickener tanks, if the solids loading rate exceeds 3.0, then the area of the thickener will have to be
increased.
32 Only in very large clarifiers, the loading rate may exceed 50, in which case additional launders are provided.
In fact, the cross-sectional area of the clarifier can be linearly extrapolated based on the design quantity of
30 OD = Outer Diameter sewage
Sludge slump capacity = 120 / 24 x 0.5 The sump should be capable of buffering the
Volume of tank =9 x 2.5 Volume = Area x depth return flow for 30 minutes.
= 2.5 m (Minimum)
3
= 22.5 m3
Hydraulic detention = 22.5 / 120 x 24 = (Tank Volume) / (throughput rate) x 24 hours
time33
= 4.5 Hrs Compared to ideal range of 2.5 – 3 hours, this
result is slightly on high side. This cannot be
avoided in small plants due to minimum depth
Pressure Sand Filter
requirement The filter should be able to treat all the water that is decanted from the Secondary Clarifier tank.
The following calculations show the filter capacity required for our STP.

Airlift Pump Design throughput flow 120 m /day
3
Quantity of sewage to be handled by the STP on
The airlift pump returns the active sludge to the aeration pump. daily basis (ref. page 82)
Design filtration hours 20 Hrs (per day) Allow 4 hours for rest, backwash, etc.
The airlift pumps require 5-10 m3/Hr to work.
Filtration rate = 120 / 20 The filter must be able to handle the clarified
• The air-flow is adjusted till we achieve the exact sludge flow rate water at this rate.
= 6 m3/Hr
Loading rate on filter 12 m3/m2 / Hr Empirically taken optimum value, to achieve
only 1 hour (if bacteria are detained for longer, they filtration
will start efficiency
dying). at minimum size of filter
Electric Pumps for Return Sludge Filter cross-sectional = 6 / 12 = (Filtration rate) / (Loading rate)
These pumps are a less-preferred alternative to airlift pumps (see above). However, if the prevailing area required (min)
= 0.5 m 2
conditions do not allow use of airlift pumps, or if the designer opts for this design option, these pumps
Diameter of filter (min) = (0.5 x 4/ !)1/2 Area of a circle= !/4 x Dia2
are necessary.
= 0.8 m
The design requirements for these pumps are same as those for the raw sewage lift pumps. Therefore
the same pump models can be selected for the return sludge application as well. Height of filter 1.5 – 1.8 m Selected by convention
Depth of sand layer 0.6 – 0.75 m Selected by convention
Therefore, refer to the raw sludge lift pump section (see page 85).
Sludge-holding sump
This tank is needed if the designer does not prefer the airlift pumps or the direct-suction sludge-return
methods.
The following calculations show the tank capacity and the aeration requirements for this tank.

Design throughput flow 120 m /day
3
Quantity of sewage to be handled by the STP
on daily basis (ref. page 82)
Maximum rate of sludge- 100 % of throughput Typically Recirculation rate varies from 60
recirculation sewage flow – 100 % of throughput flow to maintain
desired MLSS levels.
Therefore the pump must be capable of
handling the highest flow rate (=sewage
throughput rate).
33 Note that the detention time for solids (bacterial flocs) is a separate parameter, which has a typical value of
Tip:
Cross-sectional area of the filter can be linearly extrapolated based on design quantity of sewage
Activated Carbon Filter Sodium Hypo Dosing System
The filter should be able to treat all the water that is filtered by the sand filter. The filtered water has to be disinfected before it can be used for flushing, gardening, etc..
The following calculations show the filter capacity required for our STP. The following calculations show the required capacity of this disinfection system.
Parameter Value/Calculation Remarks Parameter Value/Calculation Remarks

Design throughput 120 m /day
3
Quantity of sewage to be handled by the STP on Design throughput flow 120 m /day
3
Quantity of sewage to be handled by the STP
flow daily basis (ref. page 82) on daily basis (ref. page 82)
Design filtration hours 20 Hrs (per day) Allow 4 hours for rest, backwash, etc. Design Max. Chlorine 5 PPM PPM = Parts per Million = mg/L
Filtration rate = 120 / 20 = (water quantity to be filtered) / (operation dose
= 5 mg/L 1 kg =106 mg, 1 m3 = 1000 L.
hours)
= 6 m3/Hr = 0.005 kg/m3
Loading rate on filter 34
10 m3/m2 / Hr Empirically taken optimum value, to achieve Chlorine dose per day = 120 x 0.005
filtration efficiency at minimum size of filter.
= 0.6 kg
Filter cross-sectional = 6 / 10 Filter cross-sectional area = (Flow rate) / (loading
area required (min) rate) Hypo dose per day = 0.6 / 0.1 Hypo is available at 10 % strength.
= 0.6 m2
= 6 kg/day
Diameter of filter (min) = (0.6 x 4/ !)1/2 Area of a circle= !/4 x Dia2
Select Hypo tank 50 L Mix 6 kg Hypo in 44 L of water
= 0.9 m capacity
(Approx. 6 L + 44 L= 50 L)
Height of filter 1.5 – 1.8 m Selected by convention
Dosing pump rating35 0-4 L/Hr This rate is adequate to dispense 50 L of Hypo
Depth of carbon layer 0.6 – 0.75 m Selected by convention
in 20 hours
Tip:
The cross-sectional area of the filter can be linearly extrapolated based on design quantity of sewage Note:
Controls must ensure that the chlorine pump is run only when the filters are in operation.
34 Notice that the loading rate for ACF is diameter.

smaller than the loading rate for PSF. As
a result, the ACF has a marginally larger
35 The dosing pump is adjustable.
Therefore its rating should be chosen
such that our required value lies
between 50-75% of its maximum rated
flow rate.
Sludge Dewatering System Cake-holding capacity of 30 L This is the minimum required capacity: Select
the filter press a press with larger capacity. (You can always
Wet sludge coming out of the bottom of the clarifier is in slurry form. This slurry is dewatered to create remove some plates if the quantity of sludge is
“cakes” (small bricks). less.)
The following calculations show what kind of filter press would be needed for our STP.
Parameter Value/Calculation Remarks Select filter press size 470 x 470 Standard plate size, easy to handle in small
plants
Design throughput flow 120 KLD Quantity of sewage to be handled by the STP on
daily basis (ref. page 82) Cake thickness in 20-25 mm This is the practically achievable cake thickness,
chamber after which the filtration rate drops dramatically.
Design BOD removal 30 kg/day = 120 KLD x 250 mg/L
Volume of each chamber = 0.42 x 0.42 x 0.02 Figures taken from the catalog of the filter press.
= 120000 L/day x 0.000250 kg/L
= 3.5 L (The plate edges do not contribute to chamber
= 30 kg/day volume)
Excess Sludge produced = 30 x 0.25 Dry weight basis, 0.25 kg of excess sludge per Required No. of 10 To give 35 L total cake-holing capacity
kg of BOD) chambers
= 7.5 kg/day (a little above the minimum requirement)
Slurry consistency36 0.8 – 1.0 % Typical thickening achieved in a clarifier with 2.5
Tip:
– 3.0 water depth.
The number of plates in the filter press can be linearly extrapolated.
Slurry volume = 7.5 / 0.8 x 100 In words, the 7.5 kg of excess sludge is
contained in 750 L of liquid mix that settles at
= 950 L
the bottom of the clarifier tank.
Note: That this volume of excess sludge builds
gradually over a 24-hour period: It does
NOT mean that at any given moment this
quantity is present at the bottom of the
clarifier tank, waiting to be pumped off.
The sludge would have to be pumped out
as it builds.
Filter press operation 1 batch per day. A free choice by the designer.
Each batch takes 4
Hrs
Filter press feed pump 0.5 m3/Hr at 5 kg Capable of delivering up to 2 m3 in 4 hours of
delivery pressure operation, which is adequate
Proportion of solids in = 25 % Sludge cake has 75% moisture.
the cake
=0.25 (as a fraction)
Sludge cake volume =7.5 / 0.25 = (Excess sludge produced) / (Proportion of
solids).
= 30 L
36 In other words, at the bottom of the clarifier tank, the density of the sludge is 0.8 to 1.0% (by weight). The
remaining 99 to 99.2% (by weight) content is water. Thus even a 3 m deep tank does not achieve solid
dense sediment at all.
96
| Engineering checks for the STP
Th
e The following tables show how to check for important engineering aspects of the STP. Each table describes checks for a particular
ST stage of STP.
P The methods of checking are as follows:
Gui
de
–
Code Method How to check-
De V Visual Check for presence (or absence) of the indicated feature
sig
n, Note: Olfactory checks are also clubbed with visual checks
Op
era M Measurement Measure the indicated dimensions and compare against specified limits.
tio T Performance test Conduct a test and compare the results against the specified limits.
n
an D Documentation check Check in drawings and calculations
d
Ma (typically for aspects that cannot be checked by visual inspection or other testing methods)
int
ena Note: Some of the units have alternative designs. For example, the clarifier tank may be either hopper-bottom (purely gravity-aided) or
nce mechanized (with rotating rake). Separate tables are provided for each alternative design. Please select the correct table.
Preparation
Sl. Item Check Acceptance Criteria Method Category Rationale
1 Design Verify • All dimensions must be as per M Mandatory Before scanning the STP for
verification against the design engineering aspects, the entire
design process-chain must be verified
(See the solved example for
against the design, so that we do not
step-by-step calculation)
end up wasting energy only to realize
• All deviations must be reviewed that it is inadequate in the first place.
and approved
2 DG backup Sufficient Minimum required backup power = M Mandatory This is a continuous process. If
DG backup Combined power for all units +20% aeration breaks down for over an
margin. hour, all bacteria may die. If pumping
stops, the tanks may overflow. Thus
• For a duplicated pair of pumps,
uninterrupted power is essential.
count only one pump as load.
Bar Screen
Sl. Check Acceptance Criteria Method Category Rationale
1 Chamber The manhole (or the opening from V Mandatory Must allow safe and hygienic way of
location where the debris is removed) must not collecting and disposing off the debris.
lie in a public area. The debris removed from the STP is
coated with sewage. It must not soil public
areas.
2 Accessibility The top of the screen must not be more V Mandatory If access is not easy, the chamber will not
than two feet below the operating floor be cleaned as frequently as needed.
level.
• Best efficiency can be achieved if
waist-level access is provided to the
chamber.
3 Screen The screen must be inclined V Mandatory The bar screen has to be cleaned several
inclination times in a day. Therefore this operation
(Recommended inclination: 45º to 60º)
must not be difficult and tiring. An
En
gin
inclined screen is far easier to clean. This
eer prevents operator fatigue.
ing
che On the other hand, vertical screens are
cks difficult to clean.
for
the
ST
P
97
98 4 Robustness Bars are robust to withstand abuse and M Recommended The operator may use heavy-handed
| of bars corrosion. methods to remove the trapped debris.
The bars must be robust enough not
(Typically, MS flats of 20x5 mm are to
Th to bend (-and allow enlarged gaps-)
e be used)
ST
under such abuse. Further, the bars
P must withstand moderate corrosion with
Gui passing time without weakening.
de
– 5 Coarse • Coarse screen (with 15 mm M Mandatory This screen traps larger items and
De screen used opening) fixed. reduces the load on the fine screen.
sig
n, • The screen is inclined at 40º to 60º.
Op
era • The coarse screen is fixed BEFORE
tio the fine screen.
n
an Note: Mandatory for large STPs (>500
d
Ma
KLD) only.
int 6 Platform • Minimum width= 2 ft V Mandatory The operator must be able to work safely
ena without falling off the platform by accident.
nce • Must carry 120 kg weight without
The platform must be able to carry the
sagging
operator’s weight.
• Must be rust-proof (e.g. made of
It must be able to hold the screened
RCC)
debris for drip-drying. The construction
must be corrosion-proof so that it does not
weaken with time.
7 Hand-rake Rake must be capable of picking T Mandatory If the rake cannot remove the debris from
for operator trapped debris from the screen, and the floor and grill, it will remain in the
also picking up debris from any corner chamber and block the flow.
of the floor.
8 Epoxy The bars should be painted with epoxy- V Recommended For longer life of the grill
coating coat.
(Not required for Stainless Steel bars)
9 Stainless • Bars are made of Stainless Steel. V Optional For longer life of the grill
Steel bars
Equalization tank
1 Easily The tank must be easily accessible. V Mandatory For periodic cleaning with safety and comfort
accessible for a gang of cleaners to carry out the task
2 Safe entry The following features must be V Mandatory The operator has to access the inside of the
present, at minimum: tank for periodic cleaning and to maintain the
diffusers.
• Ventilation to dispel the gases/
odor The tank has relatively low oxygen level and
the raw sewage emits hazardous gases and
• Good lighting that reaches inside
strong odor. So the operator must be provided
the tank
with safety equipments such as mask, gloves,
• Platform that allows easy reach full body harness, gum boots.
inside the tank
3 Aeration • Diffusers in sufficient number to V, T Mandatory To prevent the solids from settling in dead
and mixing cover the entire floor zones (which in turn avoids the necessity to
clean the tank frequently)
• Uniform placement of diffusers
• The aeration is uniform across the
surface.
(Test practically with a dummy load.)
4 Diffuser type • Coarse bubble diffusers are used V Mandatory Unlike the fine bubble diffusers, the coarse
(not fine-bubble diffusers) bubble diffusers are not affected by fluctuating
water level
En 5 Floor slope Floor slope towards suction pit for V Mandatory For complete evacuation of contents by pump.
gin
eer towards pumps
Floor slope is given so that during tank
ing suction pit
che cleaning, all the water is collected in the
for pumps
cks suction pit of the pumps and the equalization
for tank is evacuated by pumps alone, with
the
ST
minimum manual cleaning required.
P
99
10 6 Openness The tank must be open to the extent V Recommended To prevent accumulation of gases , easy
0 of tank of being able to disperse the gases, access to diffusers for maintenance purposes,
Th
e
access all the diffusers placed in the and safe and secure entry for periodic
ST tank, and for safe entry of operators cleaning
P during cleaning operations.
Gui
de 7 Diffusers in The PCC ballast block holding down V Recommended For periodic maintenance of membranes
– retrievable the diffusers must be provided with a without shutting down the aeration tank
De execution Nylon rope which extends to the top
sig
n, of the tank and tied to a convenient
Op post.
era
tio
n
an
d
Ma
Raw Sewage Lift Pumps
int
ena Sl. Check Acceptance Criteria Method Category Rationale
nce 1 Pump rating The pump must have around Since pumps are available with a few discrete
110% of the STP flow rate operating points (head vs volume), it is difficult
(reference: page 81). to get a pump that exactly meets the
requirement. Thus it is necessary to select a
pump that rated only a little higher than the
ideal. Too high a rating would waste energy. Too
little a rating would mean the STP would not be
able to handle the daily volumes.
2 Redundancy • Both pumps must be of same V Mandatory This is a critical unit; so it must have a standby
rating. to avoid stoppage of the pumping.
• Control circuits must prevent
both pumps from running
simultaneously
3 Easily Minimum clearance of 1 ft on all V Mandatory Space must be available for regular
accessible sides maintenance, since these pumps are prone to
frequent choking.
4 Proper • The pipe size must match with V Mandatory 1. Mismatching pipes would lower the efficiency
suction the pump’s suction port or one of the pumps.
piping size higher only.
2. Foot valves get choked frequently; therefore
• The suction pipes must NOT must be avoided.
be fitted with foot valves
Separate suction pipes are V Recommended If a single pipe is provided, the operator has to
provided for each pump shut off both pumps to clean it.
5 Proper • Control valves are provided in V Mandatory In order to maintain pump efficiency
delivery the outlet to shut off any
header branch (for pump repair, etc.)
• Elbows are used for corners
instead of tee-joints,
necessary fittings such as
unions/ flanges are provided
for easy dismantling and
maintenance of the piping
system, etc.
6 Bypass • The pipeline must be V Mandatory To maintain the rate of sewage flow (to the
pipeline terminated above the highest aeration tank) at the desired value.
sewage level;
• The delivery end must be
easily observable by the
operator at all times without
lifting any manhole covers,
En etc.
gin
eer 7 Pump type Centrifugal, solids handling, V Recommended The SH-NC type pump has several inherent
ing non clog pumps instead of advantages (Ref: page 37.)
che
cks
submersible pumps
for
the
ST
P |
10
1
10 Aeration tank
2
Th Sl. Check Acceptance Criteria Method Category Rationale
e
ST 1 Head room • Minimum headroom = 3 ft V,M Mandatory Required to let the gases escape and
P also for regular
Gui • Not obstructed by pipes, or ventilation
maintenance/cleaning of diffusers
de ducts etc.
–
De 2 Work-platform • Must provide waist-level access to tank V Mandatory Required for MLSS check, and
sig maintenance of the diffusers
n, • Must have safety railings,
Op
era • Minimum width=3 ft
tio
n • Must have anti-skid surface
an
d • If made from MS, must be painted to
Ma prevent corrosion
int
ena 3 Shape of tank • The shape of the tank must not obstruct V,T Mandatory The shape of tank must allow
nce placement of diffusers. uniform aeration, and also thorough
mixing of sewage and sludge for
• Test the uniformity and full coverage of
vigorous and healthy growth of
bubbles with a dummy load.
bacteria.
4 Inlet pipe Elbow/T joint at the end to deliver the V Mandatory The pipe must not propel the sewage
sewage downward; toward the outlet.
5 Inlet pipe The raw sewage and sludge inlet pipes are V Mandatory Discharge of both raw sewage and
placement above the sewage level (i.e., above the sludge into aeration tank should be
weir of the outlet-side launder) visible for monitoring purposes, and
not immersed inside water.
6 Baffle wall A baffle wall is provided V Recommended To prevent short-circuiting of

(Mandatory in sewage: The incoming sewage
STPs below 50 must not head straight toward the
KLD) exit without adequate retention
(digestion) in the tank.
The height of the baffle wall above the V Mandatory To ensure that the incoming sludge
water surface must be equal to the other does not “boil” over the baffle wall
walls of the tank (no overflow).
The depth of the baffle wall under the V Mandatory To prevent possibility of creating a
water surface must be between 0.25D and dead zone immediately behind the
0.30D. baffle wall.
• Where D = Depth of water in the tank.
7 RAS inlet Maximum distance between the sewage V Mandatory Recirculated sludge must be
and sewage inlet pipe and return sludge inlet pipe= 2 ft. delivered in close vicinity of the raw
inlet pipe sewage inlet, to ensure maximum,
placement intimate contact between sewage
and bacteria.
8 Inlet-outlet The inlet is positioned to give maximum V Mandatory The inlet and outlet must be placed
separation possible linear distance from the outlet farthest from each other; to ensure
maximum possible retention time of
sewage (and thus treatment) in the
tank.
9 Launder for It is easy to reach the mesh on the outlet V Mandatory If the mesh is not cleaned regularly, it
outlet port, for cleaning purposes. would lead to blocking of outlet, and
En overflow of the tank.
gin 10 Freeboard The freeboard must be 0.3 to 0.5 m. M Mandatory To prevent emergency situations.
eer
ing A recommended practice should be
che
cks
level-monitoring and warning system
for (float switch in the tank connected to
the an alarm annunciator).
ST
11 Air hose The hose must be rated for high V Mandatory To be able to handle the compressed
P |
temperatures. air, which becomes hot. This avoids
softening of the hose and rupture.
10
3
10 Retrievability Check for maintenance features: V Mandatory To avoid messy shut down of aeration
12
4 of diffusers tank.
Th • The headroom and horizontal
e clearance between pillars must be Add checks for structural features
ST
P adequate to allow easy removal of the that allow this.
Gui diffuser assemblies.
de
– • Nylon rope must be of sufficient size to
De lift the diffuser assembly
sig
n, 13 Air-control Each set of diffusers must have individual V Mandatory Required for pulling out of individual
Op valves air control valve sets of diffusers for maintenance.
era
tio 14 Membrane Makeshift diffusers, such as PVC/ HDPE V Mandatory The aeration tanks need to transfer
n type diffuser pipe with drilled holes or Coarse bubble oxygen to sewage with high
an
diffusers must not be used. efficiency. Only fine bubble diffusers
d
Ma are suitable for this purpose.
int V Optional Enables temporary shut down of one
15 Number of Tank is divided in two compartments, each
ena
nce compartments with diffusers. aeration tank while the other tank
Mandatory for
continues to work.
STPs > 500 KLD
Secondary settling tank (Hopper-bottom)

Note: Select this table if the settling tank is non-mechanized. Select the next table if the STP uses a mechanized clarifier tank.

1 Inlet pipe • The inlet pipe from aeration tank M Mandatory The inlet pipe handles almost double the
size to clarifier must be large enough to average hourly flow of the STP, because
handle recirculation flow also of almost equal amount of sludge that is
recirculated.
2 Feed well • Inlet to the clarifier must be through V Mandatory To kill kinetic energy of the incoming flow
a feed well and present calm conditions for settling, and
(Influent
prevent short circuiting
well) • The feed well is of sufficient size
typically 300 dia in small tanks to
800 mm Dia in larger tanks
• The well is located at the center of
the tank
• An inlet baffle wall can be used in
place of a feedwell, but only if
there is a single launder at the
opposite side (i.e., the outlet end) of
the settling tank.
3 Inlet flow Inlet flow must not drop down vertically V Mandatory Vertical flow will transfer kinetic energy
direction into the feed well, but must enter downwards, disturbing bacteria that has
radially. already settled.
4 Overflow • Weir is provided all round in case of V Mandatory The longest-possible weir should be
weir a circular tank. provided to reduce the localized high upflow
velocities that can pull up the solids from the
• Weir is provided on at least two
depth of the tank.
sides in case of square tanks up to
200 KLD
• Weir is provided on all four sides
in case of square tanks above 200
KLD
En
gin 5 Weir level The weir is at a uniform level all round T Mandatory If weir is uneven, the overflow will occur
eer only in some sections of the weir, resulting
ing (check with tube level gauge)
in high localized upflow velocities; which in
che
cks
turn will pull up the flocs, overloading the
for filters that follow
the
ST
6 Total water The water depth at the center of the M Mandatory To achieve sufficient clarification in the
P |
depth tank must be 2.5 m or more. supernatant overflow and thickening of
solids in the underflow
10
5
10
7 Depth of The depth of hopper at the center must M Mandatory To provide for the minimum 100 mm dia
6
Th central be 200 mm or more. sludge withdrawal pipe
e sludge
ST hopper
P
Gui 8 Straight Minimum straight depth must be 1.2 m M Mandatory To achieve sufficient clarification in
de depth supernatant water and thickening of sludge
–
De
in the underflow
sig 9 Hopper Sloping hopper must have minimum 45º M Mandatory To enable rolling down of settled sludge on
n, slope slope the sloping walls to a central pit.
Op
era 10 Dia of If sludge pipe is buried beneath the V Mandatory To prevent clogging of buried pipe
tio sludge pipe tank floor, its dia must be 100 (nominal)
n
an or more. This minimum Diameter
d ensures that smaller articles do not
Ma choke the pipe frequently.
int
ena 11 Bottom pit The square bottom floor pit must not be V Mandatory If the pit is too large, the suction pipe cannot
nce more than 300x300mm remove the bacteria settled at the periphery
of the pit.
12 Air lift pump Air lift sludge recirculation suction-head V Mandatory If the suction-head is placed too high/low,
must be placed about 0.5 m from the pipe will not be able to collect all the
bottom of tank bacteria settled at bottom.
Secondary Clarifier tank (mechanized, with Rotating Rake)

Note: Select this table if the STP uses a mechanized clarifier tank. If the settling tank is non-mechanized, select the previous table.

1 Provision of rake Rotating rake with a set of squeegees V Recommended In larger tanks, the sludge does not
is provided for STPs move to the center by gravity. Raking of
between the settled sludge is needed to push the
150-200 KLD. sludge to a central sludge-collection pit.
Mandatory for
STPs above
200 KLD.
2 Drive mechanism Bridge is required to mount the motor, V Mandatory Required to support the motor and gear
support bridge gearbox at the centre of the tank, and box.
also for maintenance purposes
3 Handrail on • Hand-rails cover entire length of V Mandatory The clarifier is a large tank, with moving
bridge the bridge. parts and possibly wet area. Thus the
rails are essential to prevent the
• Hand-rails are of adequate height.
operator from falling in.
4 Mechanism • The shaft of the rake mechanism V,M,T Mandatory If any area of the floor remains
located in exact must be located in exact center of unswept, the flocs will not be collected
center of tank the clarifier tank. and returned to the aeration tank.
• The tank must be perfect square/
perfect circle (not oblong)
• The rake blades must reach close
to walls of the tank
5 Rubber blades • Rake blades must be provided with V Mandatory To prevent bacteria from remaining on
bottom wearable rubber squeegees the floor of the tank
to sweep the tank floor
6 Blade overlap • In a double-winged rake, blades on V,M Mandatory To ensure that all the settled bacterial
opposite arms of the mechanism mass is swept to the central collection
must overlap pit in minimum time
• In a single-winged rake, all the
blades must overlap within the
single set.
En
7 Rotational speed Rotational speed of the mechanism T Mandatory If the rake rotates at higher speeds, its
gin must be 4 to 6 rounds per hour. wake will disturb the settled bacteria;
eer and at lower speeds, the bacteria will
ing remain for too long a period on the
che
cks floor, and start dying due to lack of
for oxygen and food.
the
ST
P |
10
7
10 8 Uniform floor • The tank floor must have uniform V,T Mandatory To prevent pockets of stationary sludge
8 slope slope. on the floor.
Th
e • The surface must not be uneven
ST (no pits, depressed areas or
P bumps).
Gui
de • The surface must not be rough (it
– will damage OR wear out the
De
sig rubber squeegees)
n, 9 Slope of corners In square tanks, the four corners that V,M Mandatory The four corners of a square are not
Op
era in a square tank are not swept by the blades must have swept by the rotating blades; so they
tio steep 45º slope will accumulate sludge, which will die
n and putrefy.
an
d 10 Inlet pipe size The inlet pipe from aeration tank to M Mandatory The inlet pipe handles almost double
Ma clarifier must be large enough to the average hourly flow of the STP,
int handle recirculation flow also because of almost equal amount of
ena
nce sludge that is recirculated.
11 Feed well • Inlet to the clarifier must be through V Mandatory To kill kinetic energy of the incoming
(Influent well) a feed well flow and present calm conditions for
settling, and prevent short circuiting
• The feed well is of sufficient size
typically 300 dia in small tanks to
800 mm Dia in larger tanks
• The well is located at the center of
the tank
12 Inlet flow Inlet flow must not drop down vertically V Mandatory Vertical flow will transfer kinetic energy
direction into the feed well, but must enter downwards, disturbing settled bacteria
radially
13 Overflow weir • Weir is provided all round in case V Mandatory The longest-possible weir should be
of a circular tank. provided to reduce the localized high
upflow velocities that can pull up the
• Weir is provided on at least two
solids from the depth of the tank.
sides in case of square tanks up to
200 KLD
• Weir is provided on all four sides in
case of square tanks above 200
KLD
14 Weir level The weir is at a uniform level all round T Mandatory If weir is uneven, the overflow will occur
only in some sections of the weir,
(check with tube level gauge)
resulting in high localized upflow
velocities; which in turn will pull up the
flocs, overloading the filters that follow
15 Floor slope Floor slope between 1:8 and 1:10 M Mandatory A gentle slope helps in movement of
sludge toward the central pit.
16 Water depth The water depth at the periphery of the M Mandatory To achieve sufficient clarification in the
tank is 2.5 m or more. supernatant overflow and thickening of
solids in the underflow
17 Depth of central The depth of pit at the center is 200 M Mandatory To provide for the minimum 100 mm dia
sludge pit mm or more sludge withdrawal pipe
18 Dia of sludge If sludge pipe is buried beneath the V Mandatory A buried pipe is very difficult to clean,
pipe tank floor, its dia must be 100 NB or So, a large pipe is used, to ensure that
more. small articles don’t choke the pipe
frequently.
19 Circular clarifier The clarifier tank is circular. V Recommended Easier to maintain
tank
20 Squeegees The squeegees may be of hard rubber V Recommended The squeegees should be able to
or Brass. sweep the floor of the tank thoroughly,
without wearing out fast.
21 Bottom steady A bottom steady bush supports the V Recommended Without a support at bottom, the rake
Bush central rotary shaft of the rake. assembly will swing around. As a
result, the blades cannot sweep the
En floor uniformly. They will also strike the
gin
eer floor violently and get damaged.
ing 22 Blade for pit A rake blade is provided inside the V Optional To prevent solidification of thick sludge
che
cks
central sludge pit to sweep it in large in the large pit
for tanks
the
ST
P |
10
9
11 Sludge Recirculation pumps - Airlift
0
Th Notes:
e 1. Use this table if the STP design uses an airlift pump.
ST
P 2. Use the next table if the STP design uses electric pumps (either in direct-suction mode or with a buffer sump)
Gui
de
– Sl. Check Acceptance Method Category Rationale
De Criteria
sig
n, 1 Pump Use an air-lift V Recommended There are multiple reasons for preferring an air-lift pump: It saves energy
Op type pump and space, allows the operator to vary the flow rate of sludge (to control the
era MLSS), without needing an extra buffer tank; clogs rarely (and much easier
tio
n
to clean).
an
d
Ma
int
ena Sludge Recirculation pumps - Electric
nce
Notes:
1. Use the previous table if the STP design uses an airlift pump.
2. Use this table if the STP design uses electric pumps (either in direct-suction mode or with a buffer sump)

1 Pump type Centrifugal, non clog, solids handling pumps V Mandatory Ref: page 37
2 Standby For electrical pumps only (for direct suction or V Mandatory This is a critical unit: Stoppage
buffer sump) of recirculation for about an
hour may kill all bacteria and
• Both pumps must be of same rate.
also cause overflow of tank.
• Control circuits must prevent both pumps from
running simultaneously.
3 Bypass branch • Must be terminated above the highest sludge V Mandatory Bypass branch line back to
line level (not immersed in sewage); sludge sump ( if provided) for
flow control
• Placed so that the operator can observe the
flow at all times without lifting any manhole
covers, etc..
4 Delivery header Proper delivery header V Mandatory In order to maintain pump
efficiency
5 Accessibility Easily accessible V Mandatory For ease of maintenance
Sludge Recirculation system - Direct suction

Note:
Use this table in conjunction with the Sludge Recirculation pumps-Electric table.

1 Suction pipeline from clarifier Proper suction piping V Mandatory In order to maintain pump efficiency
tank
Sludge Recirculation system - With a buffer sump

En Note:
gin
eer Use this table in conjunction with the Sludge Recirculation pumps-Electric table.
ing
che
cks
for 1 Sump size 30 - 60 minutes retention M Recommended To provide for recirculation of sludge to Aeration
the
ST
capacity, calculated based on tank Although this is an optional unit, it has the
P the average hourly flow capability to kill the bacteria if it is not designed
| well.
2 Depth of the Should be between 1.5-2.5 m M Recommended To accommodate the Coarse Bubble diffusers
11 sump
1
11 3 Diffusers type Coarse Bubble diffusers must be V Mandatory This tank is small and shallow; where the fine
2 used (not fine bubble diffusers) bubble diffusers are not suitable.
Th
e Since this tank has a flat bottom the sludge
ST
needs to be agitated. This can be achieved with
P
Gui coarse bubble diffuser
de 4 Diffuser • The diffusers must cover the V,T Mandatory To ensure that there are no dead zones in the
–
De coverage entire floor of the tank tank, where the bacteria stagnate and die
sig because of lack of food.
n, • Check bubbles across the
Op floor area with dummy load.
era
tio
n
an
d
Ma
Clarified water tank
int
ena
nce 1 Aeration 0.5 m3/hr of air per m3 of tank volume V Mandatory To prevent solids accumulation
2 Tank • Sufficient holding capacity to match filter sizes M Mandatory To provide sufficient stock of water to
capacity and hours of filtration cover the rest period of pumps and for
backwash water requirement
• 2-3 hours of average hourly flow in large plants
if the filters are run continuously over 24 hours
• 8-10 hours if the filter operation is for only 16
hours in a day, as in smaller STPs
Filter feed Pumps

1 Standby • Standby pump is provided V Mandatory The filter is a critical unit
Pump
• Both pumps must be of same rating
• Control circuits must prevent both pumps
from running simultaneously.
2 Pump type Centrifugal, non clog, solids handling pumps V Mandatory Choice available depending on
OR soundness of STP
3 Accessibility Easily accessible for maintenance purposes V Mandatory For ease of maintenance
4 Suction Proper suction piping V Mandatory In order to maintain pump efficiency

pipe
5 Delivery Proper delivery header with pressure gauge V Mandatory In order to maintain pump efficiency
header
6 Bypass line Bypass branch line back to Clarified water V Mandatory To control the flow rate to filters
tank for flow control with a control valve
7 Backwash Separate set of suction piping for backwash V Recommended Backwash with filtered water is more
pipe from filtered water tank efficient
8 Plumbing Non-return valves as required if the same V Mandatory To prevent water from clarified water
pumps take suction both from clarified water tank and filtered tank from mixing up
tank and filtered water tank
9 Backwash Separate backwash pumps V Optional Allows better engineering. Allows full
pumps isolation of clarified and filtered water
tank
En
gin
eer
ing
che
cks
for
the
ST
P |
11
3
11 Backwash pumps
4
Th Note: This table is applicable only when the design uses a separate set of pumps for backwash (not by reversing the flow of the filter-
e feed pumps)
ST
P
Gui
de 1 Standby • Standby pump is V Mandatory If the single backwash pump fails, the plumbing
– provided will not allow reversing the flow using the filter
De
sig feed pump. Thus the choked filter will become a
• Both pumps must be of
n, bottleneck.
Op same rating.
era
tio
• Control circuits must
n prevent both pumps from
an running simultaneously.
d
Ma 2 Interlock between Interlock between filter feed T Mandatory To prevent a filter feed pump and a backwash
int pumps pump and backwash pump pump operating at the same time.
ena
nce
Pressure Sand Filter

1 Pressure test 5 kg/cm pressure test certificate
2
D Mandatory Safety requirement
2 Manhole Big enough manhole on top dish OR V Mandatory Safety requirement, ease of maintenance
Entire top dish is bolted to the tank
(up to 800 dia)
3 Pressure-relief Pressure relief valve on top V Mandatory Safety feature
valve
4 Backwash Separate backwash waste line V Mandatory To avoid sudden surge flows into aeration
pipeline tank or settling tank, the pipeline must be
The backwash waste must be piped
connected only to the equalization tank.
to Equalization tank; not to any other
tank.
5 Inlet distributor Proper inlet distributor for uniform D Mandatory Uniform distribution, better filtration
dispersal of incoming flow over the
entire area of the filter – like a
splash pad : A distributor gridwork of
pipe may also be used
6 Frontal piping MS frontal piping V Mandatory To carry out various filter operations,
without frequent outages.
Normally pipelines in an STP are made of
PVC.
However, the frontal piping is subject
to frequent stresses and strains due to
operation of valves, and hence it is prone
to failure at joints.
Therefore MS pipeline is recommended
here.
7 MPV Multi-port valve V Recommended MPV is convenient, and provides
ONLY for small interlocking
(Multi-Port
filters, up to
Valve)
500 mm dia.
8 Valves Individual Butterfly control valves in V Recommended In large filters, a plastic PMV is prone to
place of plastic MPV damage.
Therefor separate valves must be used in
place of MPV.
En 9 Valves • Valves easily operable V Mandatory Operator comfort, ergonomics
gin
eer • Located for easy access for the
ing operator without stretching or
che
cks
bending
for • Butterfly valves are preferable to
the
ST ball valves, for quick open/ shut
P | operations
11
5
11 10 Pressure Inlet and outlet pressure gauges V Mandatory To monitor condition of filter.
gauges
6 If the filter is choked, a lot of energy is
Th wasted, and throughput is reduced
e
ST drastically
P
Gui
0.5 kg/cm2 pressure drop across a filter is
de an indication of choked filter and to
– commence backwash
De
sig 11 Media Proper media filling, with graded D Mandatory If the successive layers of media are not
n, gravel/ pebbles and sand filled with graded material (increasing
Op diameter of particles), the layers will break
era
tio
up and the media will mix up; thus affecting
n the 3D- filtering, which is essentially
an provided by the sand layer (at the top) only.
d
Ma 12 Hand-hole Hand-hole provided at the bottom of V Mandatory To remove media from the bottom, avoiding
int the tank for easy maintenance manual entry into the filter vessel
ena
nce 13 Collection Proper manifold and pipe grid as Mandatory If sewage passes through a narrow local
mechanism underdrain collector channel, the entire cross-section of the
sand media would not be efficiently used.
14 Backwash line Backwash waste line to be diverted Mandatory To avoid sudden surge flows into aeration
routing to equalization tank and not Aeration tank or settling tank, the pipeline must be
tank connected only to the equalization tank.
Activated Carbon filter

1 Pressure test 5 kg/cm pressure test certificate
2
D Mandatory Safety requirement
2 Manhole Sufficiently large manhole on the V Mandatory Safety requirement, ease of maintenance
top dish, OR
Entire top dish is bolted to the
tank (up to 800 Dia)
3 Pressure-relief Pressure relief valve on top V Mandatory Safety feature
valve
4 Backwash Separate backwash waste line V Mandatory To avoid sudden surge flows into aeration
pipeline tank or settling tank, the pipeline must be
The backwash waste must be
connected only to the equalization tank.
piped to Equalization tank; not to
any other tank.
5 Inlet distributor Proper inlet distributor for D Mandatory Uniform distribution, better filtration
uniform dispersal of incoming
flow over the entire area of the
filter – like a splash pad : A
distributor gridwork of pipe may
also be used
6 Frontal piping MS frontal piping V Mandatory To carry out various filter operations, without
frequent outages.
Normally pipelines in an STP are made of
PVC.
However, the frontal piping is subject
to frequent stresses and strains due to
operation of valves, and hence it is prone to
failure at joints.
Therefore MS pipeline is recommended
here.
7 MPV Multi-port valve V Recommended Plastic MPV prone to damage
(Multi-Port Valve) ONLY for small
En filters, up to
gin 500 mm dia.
eer
ing 8 Valves Individual Butterfly control valves V Recommended In large filters, a plastic PMV is prone to
che in place of plastic MPV damage.
cks
for Therefor separate valves must be used in
the place of MPV.
ST
P |
11
7
11 9 Valves • Valves easily operable V Mandatory Operator comfort, ergonomics
8
Th • Located for easy access for
e the operator without
ST stretching or bending
P
Gui • Butterfly valves are
de preferable to ball valves, for
–
De quick open/ shut operations
sig 10 Pressure gauges Inlet and outlet pressure gauges V Mandatory To monitor condition of filter.
n,
Op If the filter is choked, a lot of energy is
era
tio wasted, and throughput is reduced
n drastically
an
d 0.5 kg/cm2 pressure drop across a filter is an
Ma indication of choked filter and to commence
int
backwash
ena
nce 11 Media Proper media filling, with graded D Mandatory If the successive layers of media are not
gravel/ pebbles and sand filled with graded material (increasing
diameter of particles), the layers will break
up and the media will mix up; thus affecting
the 3D- filtering, which is essentially provided
by the sand layer (at the top) only.
12 Hand-hole Hand-hole provided at the bottom V Mandatory To remove media from the bottom, avoiding
of the tank for easy maintenance manual entry into the filter vessel
13 Collection Proper manifold and pipe grid as D Mandatory

mechanism underdrain collector
14 Backwash line Backwash waste line to be V Mandatory To avoid sudden surge flows into aeration
routing diverted to equalization tank and tank or settling tank, the pipeline must be
not Aeration tank connected only to the equalization tank.
15 Epoxy coating Epoxy coating on the inside of Specs Mandatory Carbon is corrosive and abrasive
the vessel
Disinfection system
1 Hypo dosing Hypo dosing at the outlet of V Mandatory For proper disinfection, and to meet PCB norms
the Activated Carbon filter
Sludge-Handling system
1 Sludge-holding As per CFE M Mandatory To hold the day’s excess sludge until
tank dewatering operations start
2 Diffusers Sufficient coarse bubble diffusers V Mandatory To ensure adequate aeration and mixing in
are used, calculated at the rate of the sludge-holding tank, to prevent septicity in
2 m3 air/Hr/ m3 of tank volume sludge, and to maintain dewaterability.
3 Supernatant Supernatant water is drawn off V Recommended Ensures that only thick slurry is fed to the filter
drain pipe from the sludge-holding tank by press, to reduce the volume of sludge to be
tap offs at 2 or 3 levels, so that dewatered, and enhance dewatering rate
water is removed and only thicker
sludge is left in the tank
4 Suction line Positive suction for the helical V Mandatory Dry run causes serious damage
En filter feed pump
gin 5 Bypass branch Bypass branch line in pump V Mandatory • To control feed rate to filter press
eer
ing line discharge line to control flow to
• For varying sludge conditions, condition
che Filter press
cks
of cloth, condition of the pump itself, the
for operator may need to control the feed rate
the to the filter press.
ST
P |
11
9
12
6 Mixer Proper low speed (300 RPM) T Mandatory Polymer is viscous. Low speeds to prevent
0
Th mechanized mixing arrangement degradation of long chain polymer
e for polymer solution tank
ST Large tank is required since 0.1 to 0.5 %
P For a typical Medium size STP, a polymer solution is recommended due to
Gui tank of 200 L should be sufficient extremely high viscosity
de
– 7 Closing device Manual Hydraulic closing device V Mandatory To close the plates together under high
De for press for filter press pressure, leaving no gaps between plates, thus
sig avoiding leakages during the high-pressure
n,
Op filtration cycle
era 8 Closing device Motorized hydraulic closing V Recommended To save manual labor
tio
n for press device recommended in STPs
an above 1000 KLD
d
Ma 9 Drain tray Drain tray for filter press V Mandatory To avoid spillages on floor
int 10 Air pipe (drier) A compressed air pipeline with V Mandatory To aid in faster dewatering
ena
nce control valve is provided
11 Sheet cover sheet cover over filter press, if V Mandatory To prevent degradation of Filter cloth under
placed in the open direct sunlight
Air Blowers
1 Standby • Standby blower is provided V Mandatory Critical unit: The blowers supply
compressed air to all diffusers (coarse
• Both blowers must be of same rating.
and fine) in the multiple tanks. They also
• Control circuits must prevent both run the air-lift pump. Thus if this unit fails,
blowers from running simultaneously the entire STP would come to grinding
halt.
2 Air header • Large air header (like an air-receiver V Mandatory Larger air header prevents overheating of
tank) is provided. air, and lessens the pipeline’s resistance.
It also lessens the back-pressure on the
blower; especially when a remote valve is
opened/closed swiftly.
3 Noise Check for the following: V Mandatory Since this unit is the noisiest in the STP,
attenuation noise-reduction measures are necessary.
• Not mounted on a tank (tanks amplify
If noise is not suppressed, it can reach
the noise)
unacceptable levels
• Mounted with anti-vibration mountings
• Padding around pipes to reduce
vibrations.
4 Air pipelines Air piping of adequate size as per good V. M Mandatory Selection of proper cross-sections
engineering practice. prevents excessive heating, and back
pressure on blowers ( < 12 m/sec)
Maximum air velocity around
10-12 m/sec.
5 Air vent Provide for an air vent line for V Mandatory To relieve excess air and overloading of
emergencies, so that when some tanks diffusers in other tanks
are under maintenance, excess air is not
passed on to other tanks
6 Noise- Proper acoustic enclosures V Recommended The air blowers create very high noise,
reduction which can affect the working efficiency
and even the health of the operator.
Therefore noise-attenuation is required.
En
gin
eer
ing
che
cks
for
the
ST
P |
12
1
12 MISC
2
Th Sl. Check Acceptance Criteria Method Category Rationale
e
ST 1 Pressure At air blower, filter press, filters inlet and V Mandatory To monitor pressure levels at these
P Gauges outlet points
Gui
de 2 Piping system Good engineering practice are followed V Mandatory 1. Minimum bends
–
De 2. Proper anchoring to wall/ floor
sig
n, 3. Fittings such as flanges, unions at
Op appropriate locations for easy
era opening of sections of pipelines
tio
n 4. All frequently opened joints have
an
d
adequate clearance to allow fast
Ma opening.
int
ena
3 Electrical • ELCB must be used (not MCB) V Mandatory To avoid frequent down time, safety
nce System etc.
• Use of power factor capacitor banks
to balance the load In general compliance with the National
Electric Code is a must.
• Use of Bus bar to distribute the load
evenly
• Use of interlocks to prevent use of
working and standby pumps
4 Exhaust/ Fresh air fan with fresh air ducting for at V Mandatory Operator comfort, prevents
Ventilation least 12 air changes per hour accumulation of gases
System if in
basement
room
5 Exhaust/ • Exhaust air fan with exhaust air V Mandatory Operator comfort, prevents
Ventilation ducting accumulation of gases, and fugitive
System if in emissions out of the STP room
• The exhaust fan must have a slightly
basement
higher capacity than the Fresh air
room
fan, to maintain a small negative air
pressure inside the STP
6 Flooring of the The National Building Code is followed in V Mandatory Compliance with a mandatory national
STP general. standard.
Specifically, check the following: Good engineering practice
• Drain provided for all tanks.
• Sump provided to catch any
accidental spillage
• Floor is anti-slippage type and free of
obstacles such as pipelines
• Floor is sloped toward the drainage
sump
• A pump is provided to empty the
sump into equalization tank.
7 Fire safety The STP area must meet the V Mandatory Compliance with a mandatory national
requirements of National Building Code standard.
Part IV (Fire and life safety)
Safety of operators and other service
personnel
8 Documentation 1. Operating manual covers all units V Mandatory For proper record-keeping
2. Maintenance manual covers all units
3. The following charts are provided:
3a. Flow chart
En 3b. Layout drawing
gin
eer 3c. Labeling of all tanks with
ing capacities and Depth as safety
che
cks
warning
for 3d. Standard Operating Procedure
the
ST
P |
9 Lighting Adequate illumination for operator V Mandatory Operator comfort, ease of
comfort maintenance activities
12
3
12 10 Ladders Adequate, safe ladders to access tanks V Mandatory Safety requirement - Otherwise
4 operator may fall into tank Typical
Th measures:
e
ST 1. Ladders with safety railings
P
Gui 2. Anti skid, wide treads
de
– 3. Rungs are NOT safe (the operator
De has to use them frequently)
sig
n, 4. Slope of ladder should be less than
Op
era 45º
tio
n
5. Provide landings for long ladders
an
d
6. In general, follow the National
Ma Building Code.
int 11 Platform with Proper operating / observation platforms V Mandatory Safety requirement
ena
nce hand-rail with safety hand-rail
12 Water meter Water meter at the outlet of ACF V Mandatory KSPCB-mandated consent condition
13 Fresh water Fresh water supply in STP for various V Mandatory For good housekeeping, chemicals
supply activities like area cleaning, chemical solution preparation
solution preparation, Filter cloth washing
etc.
14 Acoustic If STP is in close vicinity to residences, V Mandatory Noise attenuation This must happen
isolation acoustic treatment to be provided for the regardless of vicinity to residences.
STP room/doors and windows.
15 Seating • Sitting area provided for the operator V Mandatory Operator comfort
Arrangement
• Shielded from the noise of machinery
for operator
• Should provide a clear view of the
entire plant
• Provision to maintain logbook.
• Well-lit and ventilated
• Not too comfortable so as to allow
dozing off
16 Labeling of All units (as listed above) are labeled V Mandatory Quick identification of all parts of the
units clearly with permanent labels plant
17 Storage for • Proper storage area for all V Mandatory Systematic and safe storage
consumables consumables and spares
• Away from sewage spillage to avoid
rusting
• Clearly labeled
En
gin
eer
ing
che
cks
for
the
ST
P |
12
5
Operational checks for the STP
The following tables show how to check for important operational aspects of the STP. Each table describes checks for a particular stage
of STP.
The methods of checking are as follows:
Code Method How to check-

V Visual Check for presence (or absence) of the indicated feature (olfactory checks are clubbed here)
M Measurement Measure the indicated dimensions and compare against specified limits.
T Performance test Conduct a test and compare the results against the specified limits.
D Documentation check Check in drawings and calculations
(typically for aspects that cannot checked with visual inspection or other testing methods)
Note that some of the units have alternative designs. For example, the clarifier tank may be either hopper-bottom (gravity-operated) or
mechanized (with a rotating rake). Similarly, the sludge-recirculation subsystem may use one of the three approaches: (a) an airlift
pump, or (b) a direct-suction electric pump or (c) electric pump with a buffer sump.
Separate tables are provided for each alternative design. Please select the correct table first and then use them.
Preparation
Sl. Check Acceptance Criteria Method Rationale
1 Engineering • The Engineering checklist is D Unless the STP has successfully passed the Engineering
check fully filled checks, do not proceed.
results
• Any deviations are reviewed (Passing of Engineering checks means the design and
and approved. engineering of the plant meet the acceptance criteria)
2 Visual check All stages are as inspected during V If the plant was modified in any way after passing at the
PCFO (no tampering was done engineering approval, review the reasons and the actual changes
afterward) carried out in the STP.
Repeat the relevant engineering checks and review the results.
3 Load The actual load has reached >80% M For the operational checks to be meaningful, the load must be at
of rated load. (Check the volume least 80% of the rated load.
of the treated sewage for a day. If
there is a weekly peak in sewage
generation, select that day for ALL
measurements.)
Bar Screen Chamber

1 Working on Observe the operator as he collects debris. T If the debris-collection
platform is not comfortable, it
• Posture is normal during working
will stop in a few days;
• Does not have to balance on platform leading to a clogged
and dysfunctional bar
• Can see the whole chamber easily.
screen chamber.
• Not facing any difficulty
• Can easily reach the grill and floor.
• No struggle to remove parts stuck in grill.
2 Handling of Observe the operator as he disposes off debris. T Disposal of debris must
debris be easy and hygienic.
• Operator can easily use the platform (or a basket) to let the debris drip-
dry
• Operator can easily place the collected debris into a garbage bag
Equalization tank
1 Actual level Check for overflows – telltale coloration on side walls/ freeboard M To determine if
fluctuations equalization tank size
is adequate to handle
peak inflows
12
8 2 Aeration and Bubbles rise across the entire surface of the aeration tank (no dead V This is the end-result of
Th mixing zone in any area, especially edges and corners) proper diffuser selection
e and placement; and
ST • There is no odor
also correct air-
P
Gui • There is no localized violent bubbling/ boiling pressure.
de 3 Maintenance of Select a few diffusers (typically the diffuser in the most remote corner) T The STP should allow
–
De diffusers and execute a mock repair cycle. easy maintenance
sig of diffusers without
n,
• Easy to isolate from the rest of the system
significant interruption
Op • Easy to retrieve the chosen element
era
of its process.
tio • Easy to dismantle the element without disturbing the other plumbing.
n
an • Easy to clean the element
d
Ma • Easy to lower it back at the exact spot
int
ena
nce
Raw Sewage Lift Pumps tank
1 Easily Simulate a repair cycle on the pump that is more difficult to access. V The STP should allow
accessible easy maintenance
of pumps without
• Easy to dismantle significant interruption
of its process.
• The rest of the plumbing is not disturbed
• Easy to carry it outside its area
• Easy to place it back and assemble it
Aeration tank
1 Baffle wall The sewage is let into the baffle zone – No splash or overflow V These signs indicate
function wrong dimensions of
There is no bubble-free “dead” zone adjacent to the baffle wall on the
the baffle wall.
“tank”
2 Diffuser • Bubbles rise uniformly across the surface V To get optimum results,
function you may need to adjust
• No dead zone (especially near walls and corners)
the placement of
• No large bubbles bursting through. diffusers and/or air-
pressure in individual
diffusers.
3 Maintenance of Simulate a service cycle on sample diffusers (select the most remote T Maintenance of
diffusers elements): diffusers should
not disrupt the STP
functioning.
• Easy to retrieve the chosen element
• Easy to dismantle the element without disturbing the other plumbing.
• Easy to clean the element
• Easy to lower it back at the exact spot
4 Membrane Pull out and check if membranes are in good condition V

type diffuser
5 Split aeration Easy to isolate and empty EACH tank for repairs V
tank
• Cut off compressed air
• (Check safety function)
• Equal flow of sewage and recycle sludge to each compartment
Op
era 6 Biomass in 1. Healthy brown biomass V
tio Aeration tank
nal 2. Check MLSS level in Aeration tank T
che
cks
for
the
ST
P |
12
9
13 Secondary settling tank (Hopper-bottom)
0 Note:
Th
e Based on the STP design, select this table (for non-mechanized settling tank) or the next table (for mechanized clarifier tank).
ST
P
Gui Sl. Check Acceptance Criteria Method Rationale
de
– 1 Settling of • Sludge settles without vortex V
De sludge
sig • No sludge drawn up near the weir
n,
Op
• No significant sludge trace in the launders
era • No clumps/ balls of rising sludge
tio
n 2 Fine mesh • Easy to service the mesh: T
an basket at outlet
d • Easy to remove
Ma
int • Easy to clean
ena • Easy to fit it in place
nce
Secondary Clarifier tank (mechanized, with Rotating Rake)

Note:
Based on the STP design, select the previous table (for non-mechanized settling tank) or this table (for mechanized clarifier tank).

1 Settling of • Sludge settles without vortex V
sludge
• No sludge drawn up near the weir
• No significant sludge trace in the launders
• No clumps/ balls of rising sludge
2 Fine mesh Easy to service the mesh: T
basket at outlet
• Easy to remove
• Easy to clean
• Easy to fit it in place
3 Bridge • Bridge allows safe travel up to motor and gear box. T
• The safety railing has closely spaced balusters to prevent accidental
fall from under the railing.
4 Maintenance Simulate a repair cycle for the motor and gearbox T If the motor and gear
of motor and box cannot be made
• Safe access to the motor and gearbox
gearbox functional within 30
• Allows safe removal of motor and gearbox minutes, the bacteria
may start dying.
• Allows safe carrying of parts out of tank
• Allows safe re-fitting of parts
• Check rotational speed of rake M
5 Weir level Check for uniform overflow of water over the entire length of the weir(s) T
Sludge Recirculation pumps-Airlift

Note:
Based on the STP design, select this table (for an airlift pump) or the next table (for electric pumps used in direct-suction or buffer
sump variations)

1 Air lift Check if recirculation sludge flow is roughly between 60 -100 % of V
Op sewage inflow
era
tio
nal
che
cks
Sludge Recirculation pumps-Electric
for Note:
the Based on the STP design, select the previous table (for an airlift pump) or this table (for electric pumps used in direct-suction or
ST
buffer sump variations)
P |
13 Sl. Check Acceptance Criteria Method Rationale

1 1 Air lift Check if recirculation sludge flow is roughly between 60 -100 % of V
sewage inflow
13 Sludge Recirculation system-Direct suction
2
Th Sl. Check Acceptance Criteria Method Rationale
e 1 There are no additional checks.
ST
P (See the requirements above.)
Gui
de
–
De
sig Sludge Recirculation system- With a buffer sump
n, Sl. Check Acceptance Criteria Method Rationale
Op
era 1 Aeration and • Bubbles rise across the entire surface (no dead zone in any area, V This means the system
tio mixing especially edges and corners) does not pose a threat
n
an in sludge sump to the bacteria.
• There is no odor
d
Ma 2 Maintenance of Simulate a repair cycle (select the pump that is more difficult to access): Although availability of
int pump a standby drastically
ena • Easy to cut off from the rest of the system
reduces the risk,
nce
• Easy to remove it should be easy
(and fast) to repair a
• Easy to carry outside STP
defective pump.
• Easy to assemble back.
• Check if recirculation sludge flow is roughly between 60 -100 % of
sewage inflow
Clarified water tank

1 Aeration and Bubbles rise across the entire surface (no dead zone in any area, V
especially
mixing edges and corners)
• There is no odor
• No accumulation of solids in the tank
Filter feed Pumps

1 Maintenance of Simulate a repair cycle (select the pump that is more difficult to access): T
pump
• Easy to cut off from the rest of the system
• Easy to remove
• Easy to assemble back.
Backwash pumps
Note:
This table is applicable only when the design uses a separate set of pumps for backwash (not by reversing the flow of the filter-
feed pumps)

1 Maintenance of Simulate a repair cycle (select the pump that is more difficult to access): T
pump
• Easy to cut off from the rest of the system
• Easy to remove
Op • Easy to assemble back.

era
tio
nal
che Pressure Sand Filter
cks
for Sl. Check Acceptance Criteria Method Rationale
the 1 Filter operation Filter is able to handle design flow of water without excessive pressure T
ST
drop
P |
2 Filter Backwash filter for 5-10 minutes and check if initially lot of solids come T
13 Backwash out, gradually becoming clearer and finally clear water is observed.
3
13 Activated Carbon filter
4
Th Sl. Check Acceptance Criteria Method Rationale
e 1 Filter operation Get analysis reports and compare quality at inlet to filter and outlet of T
ST
P filter
Analysis
Gui
de 2 Filter Backwash filter for 5 minutes and check if initially lot of solids come out, T
– Backwash gradually becoming clearer and finally clear water is observed.
De
sig
n,
Op
era
Disinfection system
tio Sl. Check Acceptance Criteria Method Rationale
n
an 1 Hypo dosing Check Residual chlorine level with test kit T
d
Ma Must be more than 1 PPM after 30 minutes of standing
int
ena
nce
Sludge-Handling system
1 Filter press Run an entire sludge dewatering cycle of one batch, and check quantity T
operation (weight) of sludge cake produced
Air Blowers
1 Noise Measure the noise. Results close to 80+ dB(A) indicate corrective T
measures are needed.
2 Capacity Check if air in sufficient quantity is delivered to all connected tanks T
simultaneously, as visual indications for each tank as described above
MISC
1 Pressure Gauges Check all gauges for calibration. T
• Preferable to have colored bands for OK/ Not OK conditions
• Compare each gauge against the limits given in the operating
chart
2 Exhaust/ Ventilation There must not be any odor or fumes in the STP. V
System if in basement
Check for tell-tale signs of premature/ excessive rusting of metal
room
parts such as hand-rails, etc.
3 Drainage Open the drain plug of all tanks (one by one). Turn on the drain T
pit motor.
• The ground clearance must be sufficient to open the plugs
easily.
• Check if the sewage under pressure is contained in drain or
spills out on electrical parts.
• Check if the drains and the drain pit and motor can handle the
volume.
4 Documentation Verify the manuals vis-à-vis the actual STP D
5 Acoustic isolation The noise as measured outside STP at the nearest public area M
must not be more than 55 dB(A) (during day) and 45 dB(A)
(during night).
Op 6 DG Operation Switch to DG from Mains and check if all critical motors can be T
era
tio
operated simultaneously
nal 7 Quality of Treated Water Sample for analysis in a NABL-approved Laboratory T
che
cks
for
the
ST
P |
13
5
Appendices

Maintenance
Managing the Microbes MLSS
The desired median age of microbes to be maintained in the system is 25-30 days, because they can MLSS (Mixed Liquor Suspended Solids) is a measure of bacteria that is contained in the aeration tank.
digest the sewage at the maximum rate at the age of 25-30 days, as shown below.
In the strict sense, MLSS is a gravimetric unit – mg/L and the normal design level is between 3500 to
4000 mg/L in the Aeration Tank. However, in the field, since the operator does not have ready access
to an electronic weighing machine, we do a volumetric measurement using a 1 liter measuring cylinder
(or jar).
Stationary Phase
Take one liter of the Aeration Tank sample (The Mixed Liquor) and allow to settle in the jar for 30
minutes. At the end of the 30 minutes, measure the volume occupied by the settled sludge. If it is 350
mL, we take the MLSS to be 3500 mg/L. If it is 400 mL, the take MLSS to be 4000 mg/L.
Metabolic Rate
The assumption here is that the STP is functioning normally, and therefore the so-called “Sludge
Volume Index – SVI) is 100, meaning dry solids weighing 1 gram occupy 100 mL volume after 30
minutes of settling. And so, 4 gram of microbes (4000 mg) will occupy 400 mL volume in the cylinder.
The STP is operated within a band of say 3500 mg/L (350 mL) and 4500 mg/L (450 mL). When the
MLSS exceeds 450 mL, the excess sludge is taken out of the system to bring the MLSS down to the
say 350 mL, and the process continues until the sludge again builds up to 450 mL.
Days Normally STP should be operated in a smaller band within the allowable MLSS limits.
0 10 20 30 40 50 60
MLSS level can be less than the design level only under the following conditions :
1. The STP is in the start-up phase
However, the sewage remains for less than 20 hours in aeration tank and settling tank.
2. STP design and engineering is poor, so sludge is slipping out of the system
Microbes are much like humans in their metabolic activities, although they are life forms that are
orders of magnitude lower than an average human being. They feed on the pollutants (= food) present 3. STP operation is poor
in the wastewater: They require Oxygen (from the air pumped into the aeration tank) for their
4. There has been a sudden shock to the STP ( pH drop/ toxic elements etc.)
respiration. They need vitamins and minerals in the form of nutrients such as Nitrogen and
Phosphorus (already present in abundance in domestic sewage), and a whole lot of other elements at
nano levels for their health and well being, to grow and to multiply.
Any imbalance in even one of the above ingredients in the recipe (Population density, Food, Oxygen,
or Nutrients) will render the process extremely vulnerable to failure. Indeed, Microbes are much more
sensitive to the slightest of environmental disturbances than humans.
The basic biochemical reaction occurring in an Aeration tank may be summarized by the following
simplistic equation:
Microbes + Pollutants (food) + O2 More microbes + CO2 + H2O + energy release + byproducts
A typical growth reaction with a number of other products, the most important of which is Carbon
Dioxide:
• Accumulated Carbon Dioxide gets converted to Carbonic acid and corrodes metallic parts in the
STP.
• The carbonic acid also depresses the pH of the wastewater, thus affecting treatment performance
138 | The STP Guide – Design, Operation and Maintenance Appendices | 139
Glossary pH A measurement that indicates the acidity or alkalinity of any solution.
Acidic solutions have a pH<7; and alkaline solutions have a pH>7) Solutions
with pH=7 are neutral.
Term Meaning
Treatment efficiency Percentage removal of any pollutant parameter in the STP.

Backwashing The periodic operation in a filter, where flow of water is reversed to flush out
the accumulated solids by agitating and fluidizing the filter media.
TSS Total Suspended Solids
Backflushing Same as backwashing (see above), but more commonly used in the context
of membrane filtration systems.
Clarifier tank A term generally used for a mechanically raked sedimentation tank.
Depending on the placement in the STP, the clarifier tank is qualified as
follows:
BOD Biochemical Oxygen Demand is the amount of dissolved oxygen needed by
aerobic biological organisms in a body of water to break down organic Primary Clarifier Clarifier used ahead of the Aeration tank
material present in a given water sample at certain temperature over a
Secondary Clarifier Clarifier used following the Aeration tank
specific time period.
Tertiary Clarifier Clarifier used following the secondary clarifier tank
COD Chemical Oxygen Demand is the amount of oxygen required to oxidize an

organic compound to carbon dioxide, ammonia, and water. This is an indirect Settling tank A term generally used for an unmechanized, hopper-bottom sedimentation
measure of the amount of organic pollutants found in water. tank
E. Coli A species of bacterium normally present in the intestinal tract of humans and
other animals. Water and food contaminated with it may cause diseases.
Extended aeration Activated Sludge Biological system operating at low F/M ratio, resulting in
lower loading rates and longer retention times in the aeration tank
F/M The Food/ Microorganisms ratio, which is to be set for a given STP. It can be
in the range 0.05 to 0.40 (5% to 40%).
Freeboard Distance in a closed tank from the sewage level to the top of the tank.
MLSS The contents/ mixture in the aeration tank is called Mixed Liquor. The
suspended solids in this Mixed Liquor is called MLSS ( which is taken to be
the microbes).
O&G Oil and grease
140 | The STP Guide – Design, Operation and Maintenance Appendices | 141
About the Author
Dr. Ananth S. Kodavasal is an environmental
expert, with a B. Tech in Chemical Engineering
at IIT Madras and M.S. and PhD from Vanderbilt
University, Nashville, USA.
His interest in environmental engineering was
awakened when he had the great fortune to be
mentored by the legendary professor Wesley
Eckenfelder at the Vanderbilt University, who
happens to be the author of the first textbooks in
the field of environmental engineering.
This interest led him to choose the subject of
Computer Modeling And Simulation Of Non
Linear Adsorption Kinetics on Activated Carbon
for Advanced Wastewater Treatment for his
doctoral dissertation.
After returning to India, he set up his own
company, Ecotech Engineering Consultancy
Private Limited, that has over 500 clients in
India and abroad for various services, such
as water resources management, wastewater
management, treatability studies, operation &
maintenance services, eco management and
audit systems, professional development
programs and upgradation of treatment plants.
He is a keen environmentalist, and spends a
large part of his personal time in evangelizing
with public about the scientific methods of water
resource management. He is also concerned
about the worsening water scenario in India, and
believes that with proper public guidance and
improved laws, the situation can be salvaged to
a large extent. He has carried out several
campaigns on this subject, and even this book is
an extension of that effort.
In his spare time, he likes to relax with his
beloved family, and pet golden retriever, Toffee.
142 | The STP Guide – Design, Operation and Maintenance | 143

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Design, Operation and Maintenance

Author Dr. Ananth S. Kodavasal

2 | The STP Guide – Design, Operation and | 3

2 | The STP Guide – Design, Operation and Maintenance Content | 3

Raw Sewage Lift Pumps.........................................................................................36

4 | The STP Guide – Design, Operation and Maintenance Content | 5

Excess Sludge Handling.........................................................................................70

4 | The STP Guide – Design, Operation and Maintenance Content | 5

13.3 Construction And Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Equalization tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

13.3.1 Plate-and-Frame Filter press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

13.3.2 Bag-type dewatering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Aeration tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

13.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Secondary Clarifier tank (mechanized, with rake) . . . . . . . . . . . . . . . . . . . . . . . 106

Miscellaneous Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Sludge Recirculation pumps-Airlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Design and Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Sludge Recirculation pumps-Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

STP Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Sludge Recirculation system-Direct suction . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Design Criteria for STP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Clarified water tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Sewage Quantity (STP Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Filter feed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Bar Screen Chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Backwash pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Equalization Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Pressure Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Activated Carbon filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Aeration Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Disinfection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Clarifier Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Sludge-Handling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Airlift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Air Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Electric Pumps for Return Sludge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 MISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Sludge-holding sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Operational checks for the STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Pressure Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Activated Carbon Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Bar Screen Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Sodium Hypo Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Equalization tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Sludge-Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Raw Sewage Lift Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Engineering checks for the STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Aeration tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

6 | The STP Guide – Design, Operation and Maintenance Content | 7

Sludge Recirculation pumps-Airlift.............................................................................................131

Sludge Recirculation pumps-Electric.........................................................................................131

Sludge Recirculation system-Direct suction..............................................................................132

Sludge Recirculation system- With a buffer sump.....................................................................132

Clarified water tank.................................................................................................................... 132

Filter feed Pumps...................................................................................................................... 133

Backwash pumps...................................................................................................................... 133

Pressure Sand Filter.................................................................................................................. 133

Activated Carbon filter............................................................................................................... 134

Disinfection system.................................................................................................................... 134

Sludge-Handling system............................................................................................................ 134

Air Blowers................................................................................................................................ 134

Managing the Microbes............................................................................................................. 138

8 | The STP Guide – Design, Operation and Maintenance Content | 9

Bangalore Dr. Ananth S Kodavasal

12 | The STP Guide – Design, Operation and Maintenance Preface | 13

Dr. Ananth S Kodavasal

14 | The STP Guide – Design, Operation and Maintenance Acknowledgements | 15

18 | The STP Guide – Design, Operation and Maintenance Background | 19

Canteen drain Sewage

Oil, grease, grit trap Bar Screen Chamber

Clarified Water Sump Conditioning

Sand Filter Dewatering System

Activated Carbon Filter Dewatered Sludge

Treated Water Tank

Water Softener Micron Filter

Chlorination Ultra Filter

Water for reuse RO Filter

example, the C minut

n 7 The outlet is through a T-joint pipe,

A typical Oil and grease/grit trap is 2.3 Desig Remove both

The level fluctuates throughout the