MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

1.0) INTRODUCTION

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

1.0) INTRODUCTION

The purpose of this manual is to provide an on-the-job reference for operators of Waste Water
Treatment Plant (WWTP). It is intended to assist operators in establishing Process control
techniques and in optimizing the performance of this Waste Water Treatment Plant (WWTP), so
the end user can continue monitor and improve the working condition and system performance at
WWTP. Please take note the following settings are based on the current wastewater quantity and
quality. It shall be reset in future should there is change in the wastewater flow pattern.

At present, we recommend all the rotating equipment shall be set to auto mode for convenient of
operation but consistent monitoring shall be required by well trained operators and executive
personnel to ensure the equipment and process are functioning well. All level sensors have been
set and pH meters have been calibrated.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

1.0) PROCESS DESCRIPTION

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

DESCRIPTION OF TREATMENT PROCESS

The wastewater treatment plant is designed to treat wastewater from production process. Waste
water shall be discharged and homogenized at an Equalization Tank before being pumped to
Biological Treatment System to remove the suspended solid, BOD and COD. Then, the
wastewater shall undergo Chemical Treatment System to further remove the suspended solid,
BOD, COD & heavy metal. Next, the wastewater will pump to the Sand and Carbon Filter.
Finally, the treated waste water will discharge to drain. Effluent (comply with Standard A) shall
be discharged to the drainage system.

The sludge from Chemical Treatment System and Biological Treatment System will be
dewatered using a filter press. The sludge cake is then disposed at licensed premises.

Equalization Tank

Raw wastewater from various sources shall pass flow into an Equalization Tank, where the
wastewater pollutant load will be homogenized before transferred to downstream process.
Furthermore, it‟s able to avoid shock loading to the wastewater treatment plant. The pH shall be
adjusted to optimum pH to protect the downstream processes.

Biological Treatment

Activated sludge is colony of mixed aerobic microbes namely bacteria, protozoa, mold, yeast,
algae, etc. The activated sludge method is a water purification process using the life activity of
the activated sludge. In other words, the activated sludge added into the wastewater, absorbs and
takes in organic matters contained in the wastewater. In this way, organic matters are removed
out of the system in the way of assimilation or dissimilation.

It involves the utilization of oxygen to convert organic matter to new microorganism cells and
other end products that are simpler in nature.
bacteria
COHNS + O2 + nutrients CO2 + NH3 + C5H7NO2 + other end products (new bacteria
cells)

After the biological treatment, the mixed liquor (waste water together with the activated sludge)
will flow into a Bio-Clarifier.

The sludge will be separated from the wastewater via gravity. The settled sludge is then pumped
back to the aeration tank for reseeding purpose. This process is known “Return Activated
Sludge” while the wastewater shall flow into the retention tank.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

Chemical Treatment

The wastewater from the Bio-Clarifier is then flow to a retention tank before being pumped to
the next process for treatment, which is the Chemical Treatment. The pH of wastewater is first
adjusted by using redox, followed by coagulant to chemically precipitate the dissolved pollutant
to form pin-flocs. To increase the sludge density so in order to allow sludge settling in the
Clarifier, flocculant is added in to bind all the pin flocs to form larger flocs. The wastewater is
then overflow to Clarifier.

Clarifier Tank

The wastewater after chemical treatment is allowed to be settled in the Clarifier where the
process of solid-liquid separation is taking place. The supernatant will flow gravitationally to the
Final Holding Tank while the wasted sludge is pumped to the Sludge Tank.

Filtration

The clear supernatant treated effluent from the batch tank will be pumped through Filter Pump to
Sand Filter & Carbon Filter in order to polish out the excess suspended solid or partially carried
over sludge contents in the treated water before being discharged into the drainage system.

Sludge Dewatering

The sludge from Sludge Tank shall be pumped into filter press for sludge dewatering. The slurry
is pumped into the filter press and contained in the filter compartment where as the water will
pass through the filter cloth and come out as filtrate. The filtrate will then flow by gravity to the
Equalization Tank. At the discharge of the press, the cake is scrapped off by dismantle the plates
and stored in labeled drum before disposed at licensed premises.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

3.0) DESIGN CRITERIA

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

3.0) DESIGN CRITERIA

3.1) General : Industrial Waste Water Treatment System

3.2) Design Basis

 Total Design Capacity : 10 m3/day @ 20 hours maximum

i) Raw Wastewater Quality (From Production)

Parameters Incoming Raw Waste Water

pH : <5
BOD5, mg/l : 2750
COD, mg/l : 7327
TSS, mg/l : 76
Temperature, oC : < 50 oC
Copper, mg/l : 0.71
Nickel, mg/l : 0.3
Iron, mg/l : 1.35
Oil&Grease, mg/l : 10

ii) Treated Wastewater Quality

To comply with Environmental Quality Act 2009, Environmental Quality

(Industrial Effluent) Regulations 2009, Standard. A.

Parameters Discharge Effluent

pH : 6.0 - 9.0
Temperature, °C : < 40
BOD, mg/l : < 20
COD, mg/l : < 80
TSS, mg/l : < 50
O&G, mg/l : <1
Copper, mg/l : < 0.2
Nickel, mg/l : < 0.2
Iron, mg/l : <1

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

4.0) EQUIPMENT SPECIFICATION

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

4.0) EQUIPMENT SPECIFICATION

1) Cooling System

1.1) Cooling Circulation Pump c/w Level Sensor

Material : Cast Iron
Capacity : 10 m3/hr @ 20m Head
Quantity : 1 unit

1.2) Flowmeter
Material : Plastic Body c/w ABS Float
Range : 0-15 m3/hr
Quantity : 1 unit

1.3) Bag Filter

Material : SS 304
Quantity : 2 units

1.4) Cooling Tower

Capacity : 15 HRT
Quantity : 1 unit

2) pH Adjustment in Equalization Tank

2.1) pH Meter c/w pH Sensor

Range : 0-14
Quantity : 1 unit

2.2) Chemical Pump for Acid & Redox

Material : PVC Head c/w Telfon Diaphragm
Range : 30 L/hr
Quantity : 2 units

2.3) Chemical Tank for Acid & Redox

Material : PE
Range : 200 L
Quantity : 2 units

3) Biological Treatment

3.1) Nutrient Pump

Material : PVC Head c/w Telfon Diaphragm
Range : 10 L/hr
Quantity : 1 unit

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

3.2) Nutrient
Material : PE
Range : 10 L/hr
Quantity : 1 unit

3.3) Diffuser & Piping

Type : Disc Type Diffuser
Quantity : 100 pcs (50 pcs/tank)

3.4) Flowmeter for Bio-Feed Pump

Material : Plastic Body c/w ABS Float
Range : 0-15 m3/hr
Quantity : 1 unit

3.5) Bio-Clarifier – Inclined Plate

Plate Size : 1900mm x 650mm x 300 thickness
Quantity : 50 pcs

3.6) Retention Tank

Material : FRP/HDPE
Capacity : 10 m3
Quantity : 1 unit

3.7) Waste Transfer Pump c/w Level Sensor

Material : Cast Iron
Capacity : 10 m3/hr @ 10m Head
Quantity : 1 unit

3.8) Flowmeter for Transfer Pump

Material : Plastic Body c/w ABS Float
Range : 0-15 m3/hr
Quantity : 1 unit

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

5.0) PROCEDURE OF PLANT START-UP

- OPERATION OF MAIN SWITCH BOARD

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

5.0) PROCEDURE OF PLANT START-UP

5.1) BEFORE START-UP

Before supplying power to the waste water treatment system, the following equipment
should be checked.

Read instruction manual for different type of equipment and understood before
operating the system.

5.2) LEVEL SENSOR

Checks all the collection tank and equalization tank waste water level and ensure that the
level sensors are working in order. The system can only activate in „Auto‟ mode when the
water level reaches the high level of the level sensor.

5.3) TRANSFER PUMPS

Ensure that all transfer pumps is properly primed and check that there is no leakage at
suction pipe. Make sure the discharge valve is turned on.

5.4) CHEMICAL METERING PUMP

Check all the metering pumps are working by activating the manual switches. Unit
should be tested with water (not chemical) to ensure that there are no leaks. Ensure that
all discharge hoses are tightly secured as corrosive chemicals such as redox. It is
important to drain and dry out all the water in the redox tank, redox metering pump and
all the discharge line after run with water. This is to prevent the generation of excessive
heat during the start-up with redox.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

5.5) pH CONTROLLER

The controllers provided are the pulse length proportional type. The setting and
calibration re-explained in the instruction manual of the controller attached. The pH
controller should be buffered checked and calibrate. NEVER let the pH probe hanging
dry during tank cleaning for long period.

5.6) CHEMICAL

After checking and ensuring that the metering pumps are working in order, top up at least
half of the chemical tank. For chemical preparation, refer to section (7). Safety goggles
and hand gloves must be worn during chemical preparation and top-up.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

5.7) Operation of Main Switch Board

No. Item Description

1) Equalization Transfer Pump - Control by LS1 (L@H)

(P1) - Cut off when (LS1-L or LS1-H)

2) Retention Transfer Pump - Control by LS2 (L@H)

(P2) - Cut off when (LS2-L or LS2-H)

3) Cooling Tower Transfer Pump - Interlock with Equalization Transfer Pump (P1)
(CT)

4) Redox Pump (MP1) - Interlock with Equalization Transfer Pump (P1)

5) Nutrient Pump (MP2) - Interlock with Existing Equalization Pump

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

6.0) CHEMICAL PREPARATION

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

6.0) CHEMICAL PREPARATION

6.1) The chemicals as recommended by Watertech Chemistry (M) Sdn Bhd for the wastewater
treatment plant as follow:

Chemical Stock Concentration Used Concentration

a) Coagulant 18% (Liquid) 18% (Direct In Use)

b) Redox 48% (Liquid) 48% (Direct In Use)

c) Activated Carbon 100% (Powder) 5% (Dilution Liquid)

d) Polymer 1% (Liquid) 0.1% (Dilution Liquid)

e) Nutrient 20% (Liquid) 20% (Direct In Use)

6.2) CHEMICAL TANK

Tank Dimension Capacity

a) Coagulant 580 Diameter x 1120 Ht 200L

b) Redox 580 Diameter x 1120 Ht 200L

c) Activated Carbon 820 Diameter x 1120 Ht 500L

d) Flocculant 580 Diameter x 1120 Ht 200L

e) Nutrient 580 Diameter x 1120 Ht 200L

6.3) WASTEWATER TREATMENT PLANT CHEMICAL PREPARATION

6.3.1) Coagulant 18%

These chemical are stocked in liquid form. It is prepared to direct use and no need
dilution.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

6.3.2) Redox 48%

These chemical are stocked in liquid form. It is prepared to direct use and no need
dilution.

6.3.3) Activated Carbon 100%

The stock chemical is in powder form. Therefore it required to prepare to 5 % in the

chemical tank.

a) Fill up the Carbon tank with clean water up to 500 liter.

b) To ensure the carbon air blow must be „ON‟. After that add the Activated Carbon
Powder slowly into the Carbon tank.
c) For every 100 liter of water, add 5 kg of activated carbon into the chemical tank.

Caution:

The Activated Carbon Powder has to be dissolved slowly into water to ensure complete
dissolution of the chemical. Keep the air valve open in order to ensure no lump of
Chemicals present which can clog up the dosing pump.

Preparation of 5% Carbon Solution

Water Volume Activated Carbon Powder (100%)

100 L 5 kg
200 L 10 kg
300 L 15 kg
400 L 20 kg
500 L 25 kg
*Assume: Density of 100% Activated Carbon Powder is 1000kg/m3

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

6.3.4) Polymer 0.1%

The stock chemical is in liquid form. Therefore it required to prepare to 0.1% in the chemical
tank.
a) Fill up the chemical tank with clean water up to 100 liter.
b) To ensure the polymer air supply valve must be „ON‟, after that add the polymer liquid
slowly into the chemical tank.
c) For every 100 liter of water, add 10 liter of flocculant/Polymer into the Flocculant
tank.

6.3.5) Nutrient 20%

These chemical are stocked in liquid form. It is prepare to direct use and no need dilution.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

7.0) SAFETY IN PLANT OPERATION

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

7.0) SAFETY IN PLANT OPERATION

7.1) GENERAL PRECAUTION FOR HANDLING CHEMICALS

Acid and Redox / Sodium Hydroxide solutions must be handling with extreme caution
since direct contact has a destructive effect on human tissue. Put on protective eye
glasses, rubber hand gloves and if necessary, protective clothes to avoid chemical injury.
NEVER inhale fumes given off and provide adequate ventilation where the acid is being
used.

A shower, eyewash bath and medication should be close to chemicals handling areas and
should be inspected frequently for maintenance and replenishment. Food should never be
stored or eaten in or near chemical handling area.

7.2) REDOX / SODIUM HYDROXIDE (NaOH)

Redox / Sodium Hydroxide (Caustic) is a very dangerous alkaline which can cause
serious burns on contact with skin or eyes. Always add caustic to water, never in reverse
order. Clothing to be worn while handling caustic should be cotton denim and rubber. Do
not use wool or leather. For eye burns apply a steady flow of water at least 15 minutes,
holding the lids open. Then apply compresses saturated lids open. Then apply saturated
with 5 percent boric acid solution. Do not attempt to remove burned tissue from the eyes
or eyelids. For skin burns flush with large amounts of water. Remove clothing if wet. Do
not use soap. After washing, treat the burned area with weak vinegar or a 1 percent acetic
acid solution. For the body particularly use a 5 percent boric acid solution. For the mouth
or lips, use a 2 percent boric acid solution. Wash again with water.

If redox / caustic have been swallowed, the victim should drink a cup of water with weak
vinegar or a 1 percent acetic acid solution, or circuit fruit juices, and then followed with
milk or white of egg in water. Do not induce vomiting, Call a doctor at once.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

7.3) CHEMICAL PREPARATION OR REPLENISHMENT

Caution: all the chemicals use in the wastewater treatment plant can‟t mix with each
others during replenishment or preparation either by intentionally or accidentally.
These will cause a violently or explosively chemical reaction.

The following chemical should avoid each other‟s:-

1. H2SO4 should not mix with:

a) Water
b) NaOH

2. NaOH should not mix with:

a) Water
b) Coagulant
c) H2SO4
d) HCL

7.4) GENERAL PRECAUTION FOR OPERATION OF CONTROL PANEL

a) Keep the surrounding area of the control panel dry and the hand of the operator to
operate the panel must be free from water.
b) Do not open the control panel without the charge-man attention.
c) To avoid dangerous or fatal electrical shock, turn OFF isolation switch before
working an electrical connection.

7.5) PUMPS AND AGITATOR

a) Pump should only be services by qualified personnel.

b) To avoid dangerous or fatal electrical shock hazard, turn OFF power to motor before
working on pump or motor.
c) Do not blocks pump suction! To do so with body parts or hair may cause several of
fatal injury.

Keep away the body parts or hair from the motor cooling fan to avoid any accident occurs.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

8.0) PLANT OPERATION WORK SCHEDULE &

DAILY CHECKLIST

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

8.0) PLANT OPERATION WORK SCHEDULE & DAILY CHECK LIST

8.1) PLANT OPERATION WORK SCHEDULE

A) Daily Checking / Service Work

1. Ensure enough chemical to operate the plant for the next 12 hours minimum,
replenish if necessary.
2. Ensure that all the transfer pump and chemical dosing pumps are in working order.
All motors do not exit abnormal noise, temperature and vibration.
3. Recording the daily inspection checklist.

B) Weekly Service Work

1. To remove the deposit or adhere impurities of probe sensor by wiping with wet cotton
wool.
2. Check and clean suction and deliver valve units of the chemical pumps.

C) Monthly Service Work

1. Calibrate pH probe with pH buffer and solution.

2. Dismantle the pumps and transfer pumps and check the wear and tear on impeller,
wear plate and mechanical seals.
3. Check the suspended solid content after settling tank. The suspended solid should be
less than 50 mg/l.
4. Conduct cleaning on the lamella plates by high pressure water jet at least once a
month.

Note: Detail checking and maintenance work is as per attached.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

8.2) PLANT OPERATION WORK SCHEDULE

For a full and correct achievement of the wastewater treatment plant, daily operation
management, maintenance and inspection are essential.

Consistently, perform maintenance and inspection to manage the equipment.

Item Management Item Frequency

Treatment Condition Quality - Water flow rate confirmation Daily

- pH checking Daily

Treated Water Quality - pH checking (By portable pH sensor) Daily

- Water analysis lab test. Weekly

Coagulation & Flocculation - Chemical consumption Daily

Tank - Chemical remainder confirmation Daily
- Chemical top-up Daily

Water Transfer Pump - Abnormal pumping check Daily

- Suction pipe checks & cleans Weekly

Chemical Dosing Pump - Abnormal Pumping check Daily

- Suction pipe check & clean weekly

pH Meter - pH probe cleaning Daily

- pH probe calibration Every 2 weeks

Agitator - Abnormal vibration or noise Daily

- Gear motor oil check Every 3 months

Control Panel - Routine checks the functionality of the Daily

switch button.
- Check wiring connection Every 3 months

Solenoid Valves - Check if the function is correct Daily

- Check for air leakage from connections Daily
- Check for heat generation and abnormal Daily
noise

Flowmeter - Check that indication and reading are Weekly

correct
- Check for dirt and damage

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 MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

CORRECTIVE ACTION FOR UPSET CONDITIONS RECORD

DATE TYPE OF DIAGNOSIS OF ANY NON- CORRECTIVE WHEN CONDITION SIGNATURE

UPSET CAUSE OF COMPLIANCE ACTION RETURNED OF
CONDITION UPSET CONDITION * TAKEN TO NORMAL REPORTING
OFFICER

* Give Explanation for any Non-Compliance of Discharge Standard occurred.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

10.0) SLUDGE HANDLING

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

10.0) SLUDGE STORAGE LABELLING AND INVENTORY UPDATE

10.1) Sludge waste from waste water treatment plant should be weighted and stored in sealed
water proof drums / containers. If possible plastic bags could be used to fill up that sludge
before putting them into drums.

10.2) A “toxic substance” sticker should be displayed on every drums and the sludge code
“SW204” be written clearly. An example of the sticker is attached.

10.3) A covered area should be reserved to store and start up the drums.

10.4) In order to monitor the quantity of sludge produce / stored, each drum could be
numbered.

10.5) The attached inventory of schedule waste from is normally used to record the amount and
type of sludge generated. Monthly record of the sludge generated should be sent to DOE
to keep them informed.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

SW204

FIFTH SCHEDULE

(Regulation 11)

ENVIRONMENTAL QUALITY ACT 1974

ENVIRONMENTAL QUALITY( SCHEDULED WASTE)

REGULATIONS 2005

INVENTORY OF SCHEDULED WASTE

AS AT:

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

* * Waste * Name * Quantity * Waste Handling

a b
Date Category of Waste Generated Method Quantity in Placec
Code (Metric Tonnes) Metric
Tonnes

Note:
* Inventory of the current generation of scheduled wastes
a Date when the scheduled wastes are first generated
b Stored, processed, recovered for materials or product from such scheduled wastes,
incinerated, exchanged or other methods (specify)
c Give name and address of the facility

I hereby declare that all information given in this form is to the best of my knowledge and belief is
true and correct in all respect.

Name of Reporting Officer :

Designation :

Signature : Date :

I.C. Number :

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

11.0) EQUIPMENT ROUTINE MAINTENANCE

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

11.0) EQUIPMENT ROUTINE MAINTENANCE

This consists of keeping the entire system clean and tidy. The following equipment
should be periodically checked and inspected and should include but not limited to:

11.1 TANKS

Inspect tanks regularly and check for sign of ageing for tank material. Look for sign of
cracks. All external painting to be carried out periodically to upkeep the treatment plant
in tip-top condition.

11.2 AGITATOR AND MOTOR

Motor should be checked periodically to see that it is operating normally. Any abnormal
noise shall indicate the motor need a check-up. Greasing should done as per manufacturer
recommendation and replace any worn-out parts e.g. bearing immediately.

11.3 PUMPS

Pumps should not be left running dry. Ensure the foot-valve (transfer pumps) are
working and there is no foreign particles stuck which may cause leakage. Clean foot-
valve regularly.

Mechanical seal should be taken from the pump for inspection every 6 months. If there is
any wear and tear have it replaced.

11.4 i) STANDARDIZATION/MAINTENANCE OF GLASS PROBE

Standardization should be carried out at regular interval. The precise time interval will
depend on the use of the electrode system and cannot be stated definitely, but normally
should take place weekly or more frequently if conditions demand it. Initially checks
should be carried out daily, then with experience the time interval may be extended to
longer periods. Frequent standardization of the electrodes will ensure that optimum
accuracy be obtained.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

ii) ELECTRODE CLEANLINESS

Routine cleaning of electrodes should be carried out by rinsing in distilled water,

removing any adhering impurities by wiping carefully with soft cloth or used toothbrush.
More tenacious deposits, particularly organic origin, may require the use of an
appropriate solvent.

iii) CLEANING

a) The need for cleaning of the electrode becomes apparent when it responds becomes
sluggish with possibly a fall off in calibration.
b) If the cleaning procedures described below do not eliminate these symptoms, the
electrode assembly should be changed.
c) During cleaning, avoid rough handling of the electrode membrane. Wiping with a
cloth soaked in suitable solvent for the deposits for washing with a strong jet of water
are preferred methods.
d) When the cleaning process for the electrode necessitates soaking for a time, it is
advisable to exchange the electrode system with a standby system, so that interruption
to the measurements is minimal.

WARNING:
DO NOT USE ORGANIC SOLVENT WHICH MAY ATTACH MATERIAL IN
THE ELECTRODE ASSEMBLY.

iv) METHOD OF REMOVING VARIOUS TYPES OF DEPOSITS IS GIVEN

BELOW: -

Wipe with cotton wool soaked in concentrated HCL to remove the deposits and rinse
thoroughly. An alternative treatment is to wipe the electrode and soak it overnight (no
longer if necessary) in a 10% solution of E.D.T.A. followed by re-activation in 0.1M
HCL and rinsing with water.

Heavy deposits formed during effluent neutralization are after removed by using one
(1) mixture of concentrated HCL and water.

For the detail equipment operation and maintenance, refer to Equipment Catalogue
enclosed.

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

12.0) TROUBLE SHOOTING GUIDE

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

12.0) TROUBLE SHOOTING GUIDE

Symptom Possible Cause Remedies

1) Wastewater Transfer Pump No power to motor Check of electric

A) Failed pump Operation a) Overload tripped in the panel a) Reset overload in the panel
b) Power supply fuse blown b) Replaced fuse
c) Interlocking circuit failed c) Check control circuit

B) Motor run, but not a) Suction foot valve leaking a) Open up check valve, clear of
Pumping all debris, re-prime pump
b) Air locked in suction pipeline b) Repair any loose connection
of the suction pipeline
c) Suction foot valve blocked c) Lift up foot valve, check and
with debris clear
d) Clogged impeller with a d) Check and remove all rags or
tendency to blocking other impeller bodies

2) Chemical Dosing Pump

A) Motor and pump runs but a) Suction on discharge valve is a) Disassemble and clean
no Chemical liquid is Clogged with foreign matter
pumped b) Strainer is clogged b) Disassemble and clean
c) Air locked at suction and c) Repair any loose connection
discharge side of the suction tube, breed air
out from the air vent

B) Motor does not run a) No power supply to the motor a) Check on the interlocking
circuit circuit and the power supply
fuse

3) pH Control System

A) pH valve indicated out a) Excess or shortage of a) Adjust the amount of

control range chemical dosing in the chemical dosage
system
b) Refer to fault rectification
from conduct a pH/Redox
measurement operating
instruction

B) Instrument fault e.g. Same as 3A Same as 3A

undefined, unstable
reading or left, fails to
calibrate and others

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

Symptom Possible Cause Remedies

4) Flocculation‟s Flocs
Formation

A) Fine, no flocs or a) pH in the batch tank is a) Re-adjust the pH value from

appearance of the liquid below or higher from the the pH controller
turbid set point value.
b) pH controller showing fault b) Check and use standard
pH reading buffer solution to calibrate
the pH controller
c) The dosage of coagulant or c) Re-adjust the coagulant and
flocculant not enough in the flocculant dosage
system

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

PUMP Problem – Solution Table

Problem Solution
1. Failure to deliver liquid A,B,C,D,E
2. Pump does not deliver rated capacity C,D,E,G,H,N,S
3. Pump does not develop rated pressure A,E,H,K,N,S
4. Pump overloads driver H,L.M,N,O,S,X
5. Vibration C,D,K,P,Q,R,S,T,U,V,X
6. Bearings wear rapidly Q,T,Q,X,Y
7. Motor heating up H,O,Z
8. Seized Pump B,F,S,X
9. Irregular delivery D,G,K,P
10. Pump does not prime A,B,E,G
11. Noisy Pump C,D,G,H,K,P,Q,R,S,T,U,V,X,Y

A = Wrong Direction or rotation O = Specify gravity higher that rated

B = Pump not filled with liquid P = Starved suction
C = Inlet or suction pipe insufficiently Q = Misalignment
Submerged
D = N.P.S.H. available too low R = Worn or loose bearings
E = Pump not up to related speed S = Impeller blocked or damaged
F = Foreign matter in pump T = Bent shaft
G = Air leaks in suction line U = Improper location of discharge valve
H = Viscosity greater than reacted V = Foundation not rigid
K = Gas or vapour in liquid W = Bearings badly installed
L = Speed too high X = Pipes exert forced on pump
M = Total head lower than rated Y = Vibration (See problem: Vibration)
N = Total head higher than rated Z = Speed too high, check motor nameplate

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MONIN ASIA KL SDN BHD WWTP Operation & Maintenance

14.0) DRAWINGS
- P & I DIAGRAM
- CONTROL PANEL LAYOUT
- POWER CIRCUIT LAYOUT
- CONTROL CIRCUIT LAYOUT

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