Jupiter Servive and Maintanence Manual

Jupiter Wastewater Treatment Plant – Operations & Service Manual
Table of Contents
1. Description of the Installation ................................................................................................................................... 3
2. Occupational safety and risk while working with Wastewater ................................................................................. 4
3. Main Components & Description .............................................................................................................................. 5
4. Detailed Component Description – Biozone and Clarifier ........................................................................................ 6
5. Detailed Component Description - Control Panel with alarms ................................................................................. 7
6. Detailed Component Description – Blower Types .................................................................................................... 8
7. Detailed Component Description - Pump well and inlet pumps............................................................................... 9
8. Detailed Component Description – UV Systems ..................................................................................................... 10
9. Maintenance Plan ................................................................................................................................................... 11
10. Detailed description of maintenance and safety ................................................................................................... 12
10.0 Initial Safety before Commencement of Maintenance.......................................................................................... 12
10.1 Maintenance of Septic Tank……………………………………………………………………………………………………………………………..13
10.2 Maintenance of Pump Well……………………………………………………………………………………………………………………………….14
10.3 Maintenance of Outlet ........................................................................................................................................... 17
10.4 Maintenance of the Biozone .................................................................................................................................. 19
10.5 Maintenance of the Clarifier + Sludge Returns ...................................................................................................... 24
10.6 Air Blowers, Control and Solenoid Valves .............................................................................................................. 27
11. Troubleshooting ..................................................................................................................................................... 29
11.1 Aeration system ..................................................................................................................................................... 29
12. Commissioning of Plants after Service and Test Function.........................................................................................33

1. Description of the Installation
Introduction
The Jupiter system is designed to treat ordinary household sewage having a broad range of people expectancy .
You may not lead any other water than grey- and black household sewage to the treatment plant unless
specifically approved by BioKube.
Maximum Load
The BioKube Jupiter systems are designed to treat ordinary household sewage. The plant allows for fluctuations in
both concentrations and volume of the incoming water. However, if the average daily load exceeds the designed
performance, a larger system must be installed.
3
2. Occupational safety and risk while working with Wastewater

This manual is for all personnel involved in servicing and maintaining the Biokube Jupiter system. Risk assessment
has been carried out. Submitted risk assessment and all precautions described herein, as well as the instructions
from this manual listed under the specific maintenance points, must be complied with at all times while working
with the plant. At the same time, special attention must be paid to the general dangers that exist when working
with wastewater.
Protective Equipment for direct contact with Wastewater
Along with "good" microorganisms that break down the nutrients in wastewater, wastewater also contains disease-
causing bacteria, viruses, fungi and parasites. In the event that service personnel cannot avoid direct contact with
wastewater, the following protective equipment should be used:
• Elbow-length rubber gloves
• Rubber trousers and jackets
• Protective goggles
• Disposable mask to be worn in dusty mud areas or areas with heavy
aerosols
• Efficient industrial washing machines that wash at high temperature
must be used when washing work clothes
Personnel involved in working with wastewater should take the
following precautions:
• Wash gloves before removing them.
• Wash hands before smoking and eating after contact with wastewater.
• Never store protective clothing and equipment near eating areas.
• Keep workwear protective gear and daily clothes in separate cabinets.
• Take bath and change into daily clothes before heading home.
• In the event of cuts or wounds sustained during the operation of the plant, rinse with large amounts of clean,
running water and soap, followed by disinfection with alcohol gel.
• Service technicians must have a tetanus booster vaccination every 10 years, and workers who have never been
vaccinated for polio should consult a physician for the purpose of acquiring it.
• Workers should receive Hepatitis-A vaccination. Workers working in sewers that may contain fresh blood or come
into regular contact with used syringes or body parts should receive the Hepatitis-B vaccination.
• Trucks carrying sewage-contaminated materials must be washed frequently.
• Records of worker’s major or minor illnesses, complaints of irritation and discomfort should be kept.
Seek medical attention when you have diarrhea or are ill. As physicians are often unaware of the links between
work area and illnesses, make sure to inform your personal physician about the work exposure to wastewater.
4
3. Main Components & Description
Single Jupiter Unit with plastic / fibre glass Double Jupiter Unit in series and Buffer Tank
septic tank and buffer tank with concrete septic tank
3.2 Jupiter Unit with Concrete Septic Tank
Note: Jupiter units can have multiple configurations based on customer requirements
# Description Function
Solids, fat, oil and grease are separated and permit the clarified wastewater continue for
1 Septic Tank
further treatment.
2 Pump well / The time-controlled pumping from the pump well / buffer tank evens out peaks in the
Buffer Tank incoming flow.
Inlet Pump The inlet pumps installed in the pump well pumps the water to the biological treatment
3
System zone. If the main pump fails, the duty stand-by pump kicks in.
The solution consists of Jupiter purification unit, containing (A) biological chamber and (B)
clearance zone.
A. In the biological chamber microorganisms, bacteria, treats the incoming wastewater.

The bacteria lives on the aerated bioblocks in the system and will reduce the organic
content of the water to the specified requirements.
BioKube B. From the clarifier the biological sludge is pumped back to the septic tank:
4 Treatment
1) Biological sludge, settled on the bottom of the clarifier and collected at the top, is
Plant
pumped back to the septic tank using air lift pumps and a top sludge skimmer. This
ensures a minimum of suspended matter in the effluent and continuous removal of bio
sludge.
2) A small part of the treated wastewater is to the septic tank with the settled sludge
ensuring stable operation - even during periods of low or no load - and Hydrogen
Sulfide(H2S) and other odors are eliminated from the Septic tank.
Control Cabinet
5 with blowers and Consists of air blowers and electric control unit.
control box
5
4. Detailed Component Description – Biozone and Clarifier
BioZone 1. Inlet via inlet pumps

Aerated chamber filled with BioBlocks. In this The wastewater is pumped from the pump well via
chamber, the primary reduction of BOD and COD the two inlet pumps
with the organic soluble substances takes place.
Clarifier 1
In the Clarification tank, sedimentation of solid
particles and bio sludge occurs from the
Biological Purification from Biozone 1. From this
chamber, the contents are returned to the
septic tank via airlift pumps
Bio Zone 2.
Aerated chamber filled with BioBlocks. In this
chamber, nitrification and conversion of
Ammonium / Ammonia to Nitrate takes place.
Clarifier 2
In Clarifier 2, a mechanical sedimentation of
solid particles and bio-sludge occurs from the
biological purification by Biozone 2. These fall to
the bottom and are flushed back to the Septic
tank via airlift pumps
Note: The image shows a Jupiter Plant with 2 Biozones

with 2 clarifiers. Number of biozones and clarifiers
Top Sludge Pump can vary based on project configurations
The top sludge pump pumps at specified
frequencies, sludge floats back via the return
flush pipe, to the septic tank.
Outlet
From the Clarifier, the waste water gravitates
through the outlet hole where it is pumped back
into the initial tank of the Jupiter plant. The sludge
is usually consists of dead bacteria and other
denser particles.
6
5. Detailed Component Description - Control Panel with alarms

Components in Control Panel Component
No. Switch Functionality
controlled
The “Biokube Standard Control Box” contains
the control logic for BioKube wastewater 1 Main Switch On/off
treatment system. Further, the Standard
Control Box serves as main power switch, and Man= Component Runs constantly
is therefore the only component which needs
2 Blower O = Component switched off
external power.
Aut = Pre-set program (normal operational mode)
Man= Component Runs constantly
3 Inlet Pump 1 O = Component switched off

2 3 4
4 Inlet Pump 2 O = Component switched off

6 5
7 Aut = Pre-set program (normal operational mode)

8 9
5 Top skimmer O = Component switched off

1
Return valve
6 O = Component switched off
1
Return valve
7 O = Component switched off
2
Note: Control Panel can have multiple
configurations based on customer Aut = Pre-set program (normal operational mode)
requirements
8 UV Light O = Component switched off
9 Alarm Turns alarm indicator (sound + visual) on/off.
Scan the QR Code

or click here for
Detailed Manual
7
6. Detailed Component Description – Blower Types
Root Blower in sound proof cabinet
The Air supply system is designed to supply air

to a BioKube biological treatment plant.
BioKube will supply all required pipes for the
specific project provided that the distance
from blower to treatment plant does not
exceed 10m.
Pipe dimensions should be according to
directions provided in the “Project
dimensioning and layout manual” or the
detailed specific project layout. Pipe
dimensions will vary depending on the number
Membrane Blower
of treatment chambers and distances to the
blower(s), but connection to the blower will be
as default.
Diaphragm blowers can be used for smaller
systems upon request. As standard, root
blowers will be used*.
Scan the QR Code *Note: Blower units can have multiple

or click here for configurations based on customer
Detailed Manual requirements
8
7. Detailed Component Description - Pump well and inlet pumps

From the Septic tank, the water flows to the pump well. The pump well is approx. 10-25% fo daily flow and
constitutes the system's buffer volume. The submersible pumps operate for a preset time, which is usually
15 minutes. This smoothens the hydraulic load on the system. The level in the pump well is adjusted with
three floats. At high water levels, pumping to the treatment zone increases by itself.
The pump’s timing and frequency are controlled by the PLC in the control box. Should the PLC become
defective, the emergency system takes over.
Float 3 - Top Float

Location: At the absolute maximum
permissible water height in the pump well.
Function: When this float activates, pump 2
run constantly until the float is reactivated as
a result of lowered water level. Pump 2 runs
directly on the flow switch, and is not
connected to the control PLC
Float 2 – Middle Float

Location: At 75% of the maximum permissible
water height in the pump well.
Function: When this float activates, pump
runs constantly until the float reactivates as a
result of lowered water level. If float is active
for 5 minutes, high water level alarm is
activated.
Float 1 - Bottom Float

Location: Located 40 cm from the bottom of
the pump well.
Function: By activating this float, pump 1 is
activated and runs according to pre-set
setting in the plc-controller. When the float is
de-activated the pump is protected from
running dry.
Scan the QR Code

or click here for
Detailed Manual
9
8. Detailed Component Description – UV Systems (Optional)
Ultraviolet water purification is the most effective method for disinfecting bacteria from
water. Ultraviolet (UV) rays penetrate harmful pathogens in the water and destroy illness-causing
microorganisms by attacking their genetic core (DNA). The UV system can be integrated into the Jupiter
outlet as required.
Item Part Function

1 SS radiation chamber UV radiation take place
The Quartz´s are fixed into “SS radiation
2 UV manifold bracket
chamber”
Prevent the UV lamps to overheat if no

3 UV level switch
water in system.
Ballasts are installed on the rack and is

4 UV-ballast rack
powered up here
Scan the QR Code

or click here for
Detailed Manual
10
9. Maintenance Plan
Part # Function Frequency

Initial security 0 Lock off area + safety equipment Half-yearly
1.1 Sludge level control and emptying Half-yearly
Septic tank
1.2 Check for defects in partition Half-yearly
Expiry Test 2.1 Take water sample in outlet Half-yearly
3.1 Water level control Half-yearly
3.2 Control of aeration Half-yearly

3.3 Oxygen Level Control Half-yearly
3.4 Check pH level Half-yearly
Bio Zone
3.5 Control of foam formation Half-yearly
3.6 Control of air-pipes and unions Half-yearly
3.7 Clean Bio Blocks Half-yearly
3.8 Clean diffusers Every 2 years
4.2 Sludge return function check Half-yearly
Clarifier + Outlet 4.3 Control of float / top sludge pump Half-yearly
4.4 Checking the outlet Half-yearly
4.5 Replace floats / top sludge pump Every 7 years
5.1 Functional check of inlet pumps Half-yearly
5.2 Functional check of float Half-yearly
Pump well / Buffer Tank 5.3 Check water level in pump well Half-yearly
5.4 Replace inlet pumps Every 7 years
5.5. Emptying and flushing Quarterly
6.1 Functional control of Every fan Half-yearly
Air blowers, control and 6.2 Replace membranes and coil housing Every 3 years
solenoid valves 6.3 Replace pump relay Annually
6.4 Replace solenoid valve Every 7 years
11
10. Detailed description of maintenance and safety
10.0 Initial Safety before Commencement of Maintenance
Lock off area and put on safety equipment

Work on the wastewater treatment plant must only
be carried out by trained personnel who have
completed BioKube's teaching and training in
occupational safety and service of the wastewater
treatment plant.
Prior to commencing all maintenance of the plant, it

is of the utmost necessity to ensure that the area is
secured and closed off for unauthorized persons, I.e.
the regulations of the sewage systems. This is for
hygienic reasons, and so that no unauthorized
person risks exposing themselves to danger in the
form of falls etc.
The barrier is made by locking the permanent barrier
in the form of a permanently established fence,
which is found at the treatment plant.
In addition, it is of the utmost necessity for every

service personnel to wear the correct safety
equipment as described.
All work on replacing or removing electrical
components must be carried out without voltage.
This is done via the main switch, the position of which
is shown in the picture to the right. The main switch
must be locked in the off position.
Work on electrical installations should only be carried
out by personnel who have the necessary knowledge
to work safely and correctly.
12
10.1 Maintenance of Septic Tank
Safety prior to commencement of maintenance of Septic tanks
Work on the Septic tank must only be carried out by instructed personnel who
have completed BioKube's teaching and training in work safety and service of the
treatment plant.
10.1.1 Check that regular sludge removal is complete
Check via the log if the Septic tank has been emptied. If the water pumped into the Jupiter system is
dirty, the Septic tank is presumably full and should be emptied. Emptying intervals should then be
carried out more frequently. The emptying intervals depend on the load on the system.
10.1.2 Check for partition defects
Visually check for any deformities in the Septic tank

through the manhole
13
10.2 Maintenance of Pump well
Safety and working environment before maintenance of pump well
Work on the pump well must only be carried out by instructed personnel who have completed
BioKube's training in occupational safety and service of the treatment plant.
Prior to commencing the maintenance and inspection of the Biozone, it is of the utmost necessity to
ensure that the area cited and blocked off for unauthorized persons.
The barrier is made by locking the permanent barrier in the form of the permanently established
fence, which is found at the treatment plant.
10.2.1 Functional check inlet pumps
Check the inlet pumps by switching off the system at
the main switch in the control box, wait 3 seconds
and reconnect the main switch.
Visually recognize that water is pumped from both
inlet sockets alternately into Biozone 1.
14
10.2.2 Functional control of floats
Perform float function control by using a hook on a

rod, and check that float functionality works as
described in section
Floats 3 - Top floats
Function: When this float deactivates, pump 2 runs
constantly until the float is reactivated as a result of
lowered water level.
Float 2 – Middle Float
Function: When this float activates, pump 1 runs
constantly until the float dereactivates as a result of
lowered water level. If float is active for 5 minutes,
high water level alarm is activated
Float 1 – Bottom Float
Function: By activating this float, pumping via pump 1
is activated via the pre-programmed "normal mode"
sequences. Protects the pumps from running dry.
10.2.3 Functional control of floats
The water level in the pump well must, during normal

running conditions, be between the lower and middle
float switches. Less water may be a sign that the
Septic tank has just been emptied.
15
10.2.4 Replacement of pumps and floaters
Danger: This operation shall take into account the

following: the safety assessment hass a risk of electric Electrical cabinet for connecting pumps (Optional)
shock. Before replacing this unit, the main switch must
therefore be switched off and locked
Disconnect the cord in the pump cabinet.
Mark height on floats, and free pump wires
Cut off plastic clips that acts as a wire holder
Pull the wires out through the guide tube.
Dismount pump connection
Install new pumps + float via quick couplings. It is not
necessary to go into the pump well to change pumps.
Ensure that floats are installed so that they cannot get
stuck in pipes, or each other
Connect the pump to the pump cabinet or directly to the
control box.
Complete function control.
10.2.5 Emptying and flushing of Pump Well / Buffer Tank
The pump well is emptied and flushed once annually

by sludge suction, at the same time as the Septic
tank.
16
10.3 Maintenance of Outlet
Safety when taking a water sample
In order to take a water sample, which is always

the first thing to be done when servicing the
plant, the lid for clearance zone must be opened.
Work on the clarifiers may only be carried out by

instructed personnel who have completed
BioKube's training in occupational safety and
service of the treatment plant.
Prior to commencing the maintenance and

inspection of the Biozone, it is of the utmost
necessity to ensure that the area is off for
unauthorized persons.
It is important to ensure correct lifting via the

thigh leg muscles, where the back is kept fully
stretched. See Figure 1-3.
After opening, the hatch must be secured against

falls via the installed lid holder, which must be
securely placed in the permanent metal at the
bottom of the lid. See Figure 4
Since the work of taking a water sample and other

servicing work with the clarifier requires free
access and open hatch, it is important that all
work around the open clarifier is carried out with
utmost vigilance.
It is a prerequisite for working with an open hatch

to the clarifier that there are always two men
present. The person who does not work with the
clarifier observes and is ready to provide
assistance in the event of a fall.
When taking a water sample, the necessary safety

equipment for protection against wastewater
must be used.
17
10.3.1 Sampling of Outlet
To ensure that the plant treats the wastewater

according to the specifications, it is important to Sampling Point
measure the water quality of the effluent at every
service.
To obtain as accurate a sample as possible, make

sure the sample bottles are clean and that the
sample is taken in the outlet clarifier near the
outlet and at least 10 cm below the surface.
Bottles with water samples should be stored cold,
preferably in a freezer or in a refrigerator until
analyzed, or frozen as soon as possible. Outflow
samples are analyzed in a laboratory.
18
10.4 Maintenance of the Biozone
Security before maintenance of the Biozone

The work with the biozone may only be carried
out by trained personnel who have completed
BioKube's training in occupational safety and
service of the treatment plant.
Prior to commencing the maintenance and NB: Two persons required when opening
inspection of the Biozone, it is of the utmost lid.
necessity to ensure that the area i closed off for
It is important to ensure correct lifting via the

thigh leg muscles, where the back is kept fully
stretched

securely placed in the permanent metal holder
at the bottom of the lid. See paragraph 4
19
10.4.1 Water level control
The water level in the Biozones should be at or

up to 5 cm above the bioblocks.
Excessive water levels may indicate a blocked

outlet.
Low water levels may indicate that the Septic

tank has just been emptied, or a possible tank
leak.
10.4.2 Control of aeration
BioKube treats the wastewater biologically. The

technique is based on submersible aerated
filters.
Submersible aeriation requires a good flow of
air evenly distributed throughout the Biozone.
The Jupiter system is designed and adjusted to
provide powerful aeration in the Biozone.
Normally, there will be nothing to service in the
Biozone as it is self-cleaning and maintains
itself.
The picture on the right shows the image of an
optimally aerated biozone.
Checking must be carried out to make sure of
uniform aeration throughout the biozone and
that it bubbles from all diffusers.
20
10.4.3 Oxygen level control
Measure the oxygen level with a standard

oxygen meter. The oxygen level should be> 70%
in all chambers and is expected to rise through
the chambers of the system. If the oxygen level
is too low, contact BioKube for adjustment and
troubleshooting, including adjusting the fan
capacity and fan operating time.
10.4.4 Check pH level

The pH value must be greater than 6.5 and less
than 8.5 in all chambers and is expected to fall
only slightly through the plant.
For a pH level outside this norm area, the inlet
water of the plant should be diagnosed. The pH
value can be measured with simple pH strips, or
more advanced pH meter equipment as seen in
the picture.
10.4.5 Foaming control

Until the bacterial culture is sufficiently
effective, aeration of sewage can create foam,
see Picture.
This is normal and will decrease after approx. 5
days of operation.
Recognized as a very bluish foam with inserts, it

may be indicative of a large supply of
strongdetergents or chemicals. See the trouble
shooting section for more details on this point.
21
10.4.6 Control of air pipes and unions for diffusers
Perform visual inspection of all visible air pipes

for cracks and fissures. (indicated on photo
with green arrow).
Perform visual check for condition of all visible

unions to the air system (indicated by photo
with yellow arrow). Tighten if hissing sound or
visual leaks are recognized. If the Union is
defective, it must be replaced.
10.4.7 Clean Bio Blocks
The bioblocks should not be cleaned under

normal circumstances.
If the Bioblocks are particularly clogged,
cleaning can be done by loosening the union,
marked in the picture, and blowing
compressed air from a hand-held compressor
into the pipes, via a simple pipe adapter. This
will cause temporary increased air scrupping of
the Bioblocks, and tear off excess Biofilm
material.
22
10.4.8 Clean diffusers
Diffusers should not be cleaned under normal

circumstances.
If a diffuser is recognized to be stopped, cleaning

can be done by loosening the union, marked in the
picture, and blowing compressed air from a hand-
held compressor into the pipes, via a simple pipe
adapter. This will cause temporary increased air
scrupping of the Bioblocks, and tear off excess
Biofilm material.
Alternatively, the diffusers can be cleaned by

closing 2 of 4 ball valves in the biozone air supply.
This will increase the air flow in the air strings kept
open.
23
10.5 Maintenance of the Clarifier + Sludge Return
Safety and working environment before maintenance of Clarifier
Work on the clarifier may only be carried out by

instructed personnel who have completed BioKube's
training in occupational safety and service of the
treatment plant.
Prior to commencing the maintenance and

inspection of the Biozone, it is of the utmost
necessity to ensure that the area is closed off for
It is important to ensure correct lifting via the thigh

leg muscles, where the back is kept fully stretched.
See Figure 1-3.

securely placed in the permanent metal at the
bottom of the lid. See Figure 4.
24
10.5.1 Water level control
The water level in the clarifier(s), should be at the

level of the outlet to biozone two, respectively, for
the first clearance zone, and at the level of the final
outlet for the second clearance zone, if present.
Excessive water levels may indicate a clogged outlet.
Low water levels may indicate that the Septic tank

has just been emptied, or may indicate a water
leakage in the tank.
10.5.2 Sludge return function check
Back flushing of bottom sludge is ensured through

airlift pumps, marked by the red arrows, located in
every clarifier(s). Airlift pumps supply air through
solenoid valves located in control cabinets.
Test the flushing function of the sedimented

bottom sludge by switching off the system at the
main switch in the control box, wait 3 seconds and
reconnect the main switch. Recognize visually and
audibly that water is pumped through the two airlift
pumps for the return rinse tube. The red mark the
airlift pumps.
10.5.3 Functional control of top sludge skimmer (Outlet Clarifier)
Check the top sludge skimmer by switching off the

system at the main switch in the control box, wait 3 The skimmer pump is equipped with a
seconds and reconnect the main switch. float that protects against dry suction.
Visually recognize that water is sucked through the
top sludge skimmer toward the return rinse tube.
The top sludge skimmer can be supplied as either air lif
pump or mechanical pump.
25
10.5.4 Checking the outlet
Check that the outlet has free passage and allows

the outlet water to pass freely.
Water that high in level in the outlet indicates a
clogged outlet.
10.5.5 Replacement of top sludge pump (If supplied as electric pump)

Danger: This operation shall take into account the
following: the safety assessment has a risk of electric
shock. Before replacing this unit, the main switch
must therefore be switched off and locked. Note:
This operation requires the presence of two service
technicians.
For replacement:
Empty the water clearance zone via return rinse
Disconnect cord in control cabinet.
Insert suitable ladder projecting at least 1.5 meters
above edge before descending into clearance zone.
Cut out plastic clips that act as a wire holder
Pull the wires out through guide tubes.
Disconnect pump connection
Unscrew pump from plastic sheet.
Attach new pumps.
Pull new cord through spring tube at spring
conductor.
Connect the pump in the control cabinet.
Perform function check.
26
10.6 Air Blowers, Control and Solenoid Valves
Safety and working environment before maintenance of

controls and blowers
Working with the blowers is associated with great danger in the form of electric shocks.
Therefore, work on these may only be carried out by instructed personnel who have completed
BioKube's training in occupational safety and service of the treatment plant.
All work with the replacement or disassembly of electrical components must be done without voltage.
The main switch is locked and the locally applicable LOTO (Log out/Tag Out) procedure is followed.
10.6.1 Functional control of blowers
Look / listen / feel for leaks

Listen / feel that all blowers are running.
Listen for unwanted noises.
Check if aeration of biozones is normal. The blowers
must be maintained according to the manufacturer's
instructions. Change of oil and air filters according to
manufacturer’s manual
10.6.2 Replacement of Membranes (Applicable for diaphragm blowers only)

Danger: In this operation, there is a risk of electric
shock. Before replacing the power supply must be
removed. Fan must be moved to a clean
workstation.
Replacement interval: 3 years
For changing this:
Unscrew the fan housing
Unscrew diaphragm block
Replace membranes
Reassemble the fan.
Perform functional check.
Reference is also made to the supplier's manual
27
10.6.3 Replace pump relay

shock. Therefore, before replacing this unit, the
main switch must be switched off and locked.
Follow local LOTTO procedure.
Only personnel with the requisite knowledge should
perform work on electrical installations.
For replacement:
Turn off electricity supply via main switch
Open the control box door to expose circuit boards
Replace relay as depicted in the diagram.
Complete functional control.
10.6.4 Replace solenoid valve

shock. Therefore, before replacing this unit, the
main switch must be switched off and locked.
Follow local LOTTO procedure.
Only personnel with the requisite knowledge should
perform work on electrical installations.
For replacement:
Unscrew lead to solenoid valve in control box
Replace solenoid valve
Attach cord.
Perform functional check.
28
11. Troubleshooting
11.1 Aeration system

If the fan is in operation, air is fed to the diffusers at the bottom of the biozones. Air is evenly distributed to
the system. The oxygen level must be above 70% in all aerated chambers.
Problems with diffuser or weak aeration in the Jupiter system can be related to fan failure, control, trachea
and diffusers, or a general overload of the system.
Problem Observation Cause Check Solution
Possible system
Full aeration The inlet volume See Instruction 6, quality of drains
overload
Blowers
Check that the fan is running with
worn,
Make sure that all the blowers normal sound. It is necessary to
defective,
are in operation. maintain the fan according to the
or turned
maintenance manual.
off
Make sure the air distribution Feel and listen for any leaks in the
Oxygen Air distribution system piping is connected air tubes from the fan and to the
level below system properly and that there are no diffusers. Repair if leaks are
70% leaks. observed.
None or little
aeration
Double the aeration for a few
minutes by closing the manual
valves in other parts of the system,
Diffusers Some diffusers may not work otherwise gently pushing on top of
the diffusers using a stick through
the bio-zone. It is important that at
all times, all valves are closed.
Double the aeration for a few

minutes by closing manual valves in
Bio-zone Sludge has clogged the bio-zone. other parts of the system or
cleaning biozone with high water
pressure / sludge suction
29
11.2 Sludge Return

Sludge return system pumps the biological sludge produced by the bacteria out of the treatment tank.
This ensures optimum performance of the plant and is an important functionality. A maximum of 20 cm of
biological sludge must accumulate on the bottom of the tank. This can be measured with special sludge level
tests carried out by Biokube's service techniques. If the sludge is rejuvenated to a level greater than 20 cm,
the sludge return pump settings must be changed.
Sludge problems in the biological treatment system may also be related to failure of the controller, solenoid
valve, fan or air blower.
Change settings to open the

Airlift pump - Functioning Settings of the airlift pump valve for airlift pump for a longer
period or more often
Separate a union after the

blowers and check if air is
Functioning of solenoid valve
blowing when solenoid valve is
Sludge Sludge in the open.
Returns system
Airlift pump – Not
functioning
Remove the airlift pump from the

Functioning of airlift pump. tank and clean the sludge return
pipes.
After the problem has been located and solved, sludge from the Jupiter unit must be removed before startup.
30
11.3 Hydraulics
It is important that inlet pumps ensure that variations in inlet volume are smoothened out using the buffer tank.
When the peak flows are allowed to enter the biozone, the plant will not treat wastewater as expected. Water is
supposed to be pumped automatically into Jupiter regularly, and the water level in the pump sump is expected to
be low during normal operation.
Hydraulic problems can occur when new water is pumped into the system over a short period of time, or if the
pipes are clogged
Controller is on and pumps Check alarm unit in the control

Hydraulic Septic tank/ Pump Water level high run box. Green light should glow.
overflow well for longer periods That water comes in from Pumps must be turned on
pump pipes automatically
The water level Check that internal pipes

WWTP rises high when between chambers, as well as Clean pipes
being pumped outlet pipes are not blocked
11.4 The quality of the purified wastewater

If the cleaning requirement is not met, the actual inlet ratio should be checked. Investigate (volume,
organic content or inhibitors) and check the mechanical and electrical equipment.
Action Effect
Control mechanical /electrical equipment according to the No defective components are accepted, the part must be
maintenance manual replaced.
Control the pre-treatment equipment according to the If there are discrepancies, correct these.
maintenance manual
Measure sludge in the plant No more than 20 cm of biological sludge on the bottom of the
plant is allowed, otherwise sludge is removed manually with a
pump and adjust sludge return timing in the control box.
Measure the oxygen content The oxygen level must not be below 70%, otherwise the fan
and air hoses must be changed
pH level is measured The pH value must not be below 6.5 or above 8.5, otherwise
the pH must be stabilized
Measure the inlet flow The inlet flow must be stable and not higher than what the
system is designed for.
31
Sample the incoming water Analyze the sample inlet for the same parameters as outlet
values and compare the concentrations against the design
parameters
If none of the above solutions solve the problem, it is very likely that the biological processes in the pre
treatment or in the BioKube plant will not work properly. This may be due to high concentrations of
antibacterial compounds such as e.g. hypochlorite or detergents that are toxic in such cases, the root
chemicals must be found and alternative solutions must be used. Please contact BioKube for further
assistance.
12. Commissioning of Plants after Service and Test Function
After starting the installation, the following shall be observed:
1. The installation undergoes a test function described below.
2. After about 1 minute, the test function is completed and the system starts aeration in the treatment
chambers (bubbles from diffusers under the Bioblocks).
3. Every 15 minutes, wastewater is pumped from the pump well to the first treatment chamber for about
30 seconds. Pumping of water also occurs when the floats in the pump well are activated. During
operation, the air blower stops for a minute after every 15 minutes.
4. There should be no alarm from the unit when the function test is completed.
12.1 Test Function

When the system is turned on or the test button is held down, the following test sequence is performed
● Inlet pump active: 3 sec, - Pause: 3 sec. - Dosing pump active: 3 sec. (If installed) - Pause: 3 sec. - Rinse
chamber 1 Pause: 3 sec. Rinse chamber 2 - Pause: 30 sec. - Alarm auditory active: 3 sec. Visual alarm: 3 sec.
Contact BioKube at 55 98 98 00 for any other issues
32
Maintenance Checklist
Completed
Category S. No Description Time-Frame Remark
(Yes/No)
Lock off area + safety
Initial security 0 Half-yearly
equipment
Sludge level control and
1.1 Half-yearly
Septic tank emptying
1.2 Check for defects in partition Half-yearly
Expiry Test 2.1 Take water sample in outlet Half-yearly
3.2 Control of aeration Half-yearly
3.3 Oxygen Level Control Half-yearly
3.4 Check pH level Half-yearly
Bio Zone 3.5 Control of foam formation Half-yearly
Control of air-pipes and
3.6 Half-yearly
unions
3.7 Clean Bio Blocks Half-yearly
3.8 Clean diffusers Every 2 years
4.2 Sludge return function check Half-yearly
Control of float / top sludge
Clarifier + 4.3 Half-yearly
pump
Outlet
4.4 Checking the outlet Half-yearly
Replace floats / top sludge
4.5 Every 7 years
pump
Functional check of inlet
5.1 Half-yearly
pumps
5.2 Functional check of float Half-yearly
Pump well /
Check water level in pump
Buffer Tank 5.3 Half-yearly
well
5.4 Replace inlet pumps Every 7 years
5.5. Emptying and flushing Quarterly
Functional control of Every
6.1 Half-yearly
fan
Air blowers,
Replace membranes and coil
control and 6.2 Every 3 years
housing
solenoid valves
6.3 Replace pump relay Annually
6.4 Replace solenoid valve Every 7 years
Technician Seal Date
33

Jupiter Servive and Maintanence Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Jupiter Servive and Maintanence Manual

Uploaded by

Copyright:

Available Formats

Jupiter Wastewater Treatment Plant – Operations & Service Manual

1. Description of the Installation ................................................................................................................................... 3

2. Occupational safety and risk while working with Wastewater ................................................................................. 4

3. Main Components & Description .............................................................................................................................. 5

4. Detailed Component Description – Biozone and Clarifier ........................................................................................ 6

5. Detailed Component Description - Control Panel with alarms ................................................................................. 7

6. Detailed Component Description – Blower Types .................................................................................................... 8

7. Detailed Component Description - Pump well and inlet pumps............................................................................... 9

8. Detailed Component Description – UV Systems ..................................................................................................... 10

9. Maintenance Plan ................................................................................................................................................... 11

10. Detailed description of maintenance and safety ................................................................................................... 12

10.0 Initial Safety before Commencement of Maintenance.......................................................................................... 12

10.1 Maintenance of Septic Tank……………………………………………………………………………………………………………………………..13

10.2 Maintenance of Pump Well……………………………………………………………………………………………………………………………….14

10.3 Maintenance of Outlet ........................................................................................................................................... 17

10.4 Maintenance of the Biozone .................................................................................................................................. 19

10.5 Maintenance of the Clarifier + Sludge Returns ...................................................................................................... 24

10.6 Air Blowers, Control and Solenoid Valves .............................................................................................................. 27

11. Troubleshooting ..................................................................................................................................................... 29

11.1 Aeration system ..................................................................................................................................................... 29

12. Commissioning of Plants after Service and Test Function.........................................................................................33

1. Description of the Installation

2. Occupational safety and risk while working with Wastewater

3. Main Components & Description

3.2 Jupiter Unit with Concrete Septic Tank

A. In the biological chamber microorganisms, bacteria, treats the incoming wastewater.

4. Detailed Component Description – Biozone and Clarifier

BioZone 1. Inlet via inlet pumps

Note: The image shows a Jupiter Plant with 2 Biozones

5. Detailed Component Description - Control Panel with alarms

Man= Component Runs constantly

3 Inlet Pump 1 O = Component switched off

Aut = Pre-set program (normal operational mode)

4 Inlet Pump 2 O = Component switched off

Man= Component Runs constantly

Aut = Pre-set program (normal operational mode)

Aut = Pre-set program (normal operational mode)

Man= Component Runs constantly

8 UV Light O = Component switched off

Aut = Pre-set program (normal operational mode)

9 Alarm Turns alarm indicator (sound + visual) on/off.

Scan the QR Code

6. Detailed Component Description – Blower Types

Root Blower in sound proof cabinet

The Air supply system is designed to supply air

Scan the QR Code *Note: Blower units can have multiple

7. Detailed Component Description - Pump well and inlet pumps

Float 3 - Top Float

Float 2 – Middle Float

Float 1 - Bottom Float

Scan the QR Code

8. Detailed Component Description – UV Systems (Optional)

Item Part Function

Prevent the UV lamps to overheat if no

Ballasts are installed on the rack and is

Scan the QR Code

Part # Function Frequency

3.2 Control of aeration Half-yearly

10. Detailed description of maintenance and safety

10.0 Initial Safety before Commencement of Maintenance

Lock off area and put on safety equipment

Prior to commencing all maintenance of the plant, it

In addition, it is of the utmost necessity for every

10.1 Maintenance of Septic Tank