Water Management Business Division

OPERATION & MAINTENANCE MANUAL

FOR

FLOATING AERATOR

SUPPLIED BY :

VOLTAS LIMITED
WATER MANAGEMENT BUSINESS DIVISION
VOLTAS HOUSE - B, GROUND FLOOR
T B KADAM MARG
CHINCHPOKLI
MUMBAI 400 033

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 INDEX

CHAPTER ITEM DESCRIPTION

1 INTRODUCTION

2 OBJECT

3 PROCESS

4 INSTALLATION PROCEDURE

5 PRECOMMISSIONING
INSPECTION

6 OPERATION AND
COMMISSIONING

7 PREVENTIVE MAINTENANCE

8 AERATION TANK

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 CHAPTER-1

INTRODUCTION

This Manual is prepared mainly to serve as a Technical Guide to the personnel concerned

with the operation & maintenance of VOLTAS Floating type Aerator. It is intended to give

the basic principles of equipment and the normal operating procedure that is necessary to

keep the machine in working condition.

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 CHAPTER-2

OBJECT

Reduction in the bio-chemical oxygen demand is achieved by oxidation of the effluent. Design

parameters for sizing the tank and power requirement are beyond the scope of this manual.

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 CHAPTER-3

PROCESS

The aeration system is the heart of the entire plant. The process employed is surface

aeration, where the oxygen near the surface of the effluent is transferred into the aeration

tank liquor.

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 CHAPTER-4

INSTALLATION PROCEDURE FOR FIXED AERATORS

Pre-erection Checks :

1) Check all dimensions that the civil work of the Aeration Tank is carried out as per
the Mechanical General Arrangement Drawing & Civil Drawing.

2) Check level of the inlet and outlet launders by water level and ensure that the
same is uniform all along.

3) Once the civil structure accuracy is ensured, proceed with mechanical erection.

4) Check Anchoring hooks of aerators positioning and layout as per site condition.

Mechanical Erection

1) Check all the parts as per the packing list and store them near the aeration tank.

2) Position the gear box mounting studs at the aerator platform provided. Check that
welded collar of the stud is resting on the platform properly. Then insert the
studs, plate, plain washer, nut & lock nut from the bottom of the platform and
lock nut and nut with washer from the top of the stud as shown in the Mechanical
drawing (GA) and maintain the stud top distance accordingly.

3) Before installing the gear box, check the following:

a) Check by hand the free rotation of the gears;

b) Check that output coupling nut and check nut are tightened properly;
c) Check that love-joy coupling is in position at the gear box input shaft;
d) Check the functioning of oil drains, oil levels, dip stick etc;
e) Ensure that leveling pads on the gear box top cover and motor mounting
stool top are properly cleaned

4) Now lift the gear box and keep the same in position at the stud assembly. and
check the level of the gear box and then insert top washers and nuts.

5) Position the aerator cone on an even level and join the drive tube with cone.
Ensure that fasteners are torqued/tightened properly.

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 6) The cone with drive tube can be lifted and assembled with gear box output
coupling. Ensure that fasteners are torqued properly.

7) Check the TOL (Top of Liquid) mark on the cone with respect to TWL (Top
Water Level) of the Aeration Tank. Keep this TOL mark-up than the TWL of
approx. 125 mm.

8) Fit the love-joy coupling half portion on the motor shaft. Place the love joy
coupling spider at the gear box input shaft coupling.

9) Now install the motor properly on the motor mounting stool top. Ensure that love-
joy coupling fitment is OK and there is a gap of 2 to 3 mm between the coupling
halves.

10) Now remove the fan end cover of the motor and check by hand the free rotation of
the motor and gear box.

11) Fill the recommended oil up to the indicated level and carry out proper greasing at
all greasing points.

12) Now make electrical connection to the motor. Check overload relay setting on the
MCC and set the same as per motor overload current. After ensuring the above,
power can be switched “ON” and check that the direction of the rotation of
aerator cone as marked on the cone.

13) Ensure that all nuts and bolts are tightened properly and final alignment of gear
box is ok.

14) Floating aerator should not be operating until the ballast is in position and
properly levelled.

15) Proper moving arrangement for the floating aerator.

16) Floats are free of any leakages. This can be checked by opening of inspection
cover.

17) Top of liquid level on cone is properly adjusted by studs’ bolts.

18) Floats will be the polyurethane foam suitably.

After assembling the aerator, it must be checked once again for, if any misalignment and
levelling by a trial run. After ensuring that everything is OK, aerator can now be
commissioned

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 CHAPTER-5

PRE-COMMISSIONING INSPECTION

* Check the free rotation of the aerator by hand

from input side only.

* Check the oil level in the gear box and grease

all bearings.

* Check that the direction of rotation of aerator

corresponds to the curvature of the cone blade.

* Check that the aerator is set level with

reference to effluent level.

* Check the electrical equipment for direction

of rotation.

* Check that the aeration tank is cleaned free

of debris.

* Check for plumbness of aerator drive tube.

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 CHAPTER-6

OPERATION & COMMISSIONING

1. Description - The Floating Aerator is made up of an Aerator mounted on floats and

consists of aerator motor,gear box, mounting studs, aerator cones, drive tube, 2 Nos. of
floats. mounting frame and connecting cross tube as indicated in G.A. drawing of Floating
Aerator.

2. Installation instructions -

Assemble floats by connecting with each other through drive support frame and also by
connecting cross tubes.

Ensure that all floats are in level by providing necessary shims at joints.

Ensure that fasteners are tightened properly and are provided with spring washers so as
to avoid getting them loosened during running.

3. The floating assembly is to be assembled in aeration tank without water and then water
can be allowed in the aeration tank after the floating aerator assembly is completed.

4. Locate aerator cone in between the floats and connect the drive tubes with aerator cone.

5. Instal mounting studs on drive support frame and after the studs are locked, instal aerator
drive and lock the aerator gear boxes after levelling the same.

6. Assemble the electric motor with aerator gear box.

7. Connect aerator drive tube with coupling of the aerator gear box and torque bolts
properly.

8. Adjust the aerator gear box level so as to bring water level mark on the aerator cone in
line with that marked on floats and both these on line with the water level on the tank.

9. Ensure the free movement of cone by moving the fan of the electric motor by hand.

10. Fill the recommended gear oil in the gear box as per the level marked/dipstick and make
the electric connection with the motor.

11. Take the no-load run of the motor and observe the no-load movement of the aerator.

12. In case any vibrations or abnormality are observed, tighten the fasteners properly or
correct the elements, if required.

13. Moor the floating aerator by mooring ropes with mooring points i.e. tie one end of
mooring rope into eye bolt provided on each float and at other end into the channel
provided in the mooring column.

14. Ensure sufficient sag in the ropes for free upward movement of floats when the water is
fill

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 15. Allow the water in aeration tank with the quantity just enough for floating aerator to start
the floating.

16. Check the level of floating aerator and achieve the level as well as immersion upto the
water level marked on each end of float by adding dry sand or concrete ballast blocks as
a ballast into float compartments and also check the TOL mark of the cone with respect
to the TWL of tank.

17. Take a trial run and if floating aerator is found to be steady, allow further water in the
aeration tank as per the requirement.

18. Run the floating aerator for a few hours (approx. 4 hrs.), check the temperature, check
the fasteners and if found normal, the floating aerator can then be cleared for operation.

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 CHAPTER-7

PREVENTIVE MAINTENANCE

* Routine preventive maintenance for aerator

consists of preventive maintenance for -

 Cone and drive tube

 Inspection of fasteners

 Aerator gear box

 Aerator motor and junction box

Aerator cone & drive tube

We recommend that the aerator cone and drive

tube should be provided with necessary surface

protection every year to give a long life to it.

Fasteners

It is recommended to check the fasteners every

year and if found corroded, they may be replaced

suitably.

Aerator gear box & lubrication

A lubrication and maintenance manual of the manufacturer of the gear box is enclosed,
which should be followed.

The lubricating oil should be replaced after the first 800 operating hours by fresh oil
after draining out the used oil and flushing with new oil. Subsequently a change of oil is
recommended after 2000 working hours. Oil level should be checked at least once a
fortnight during operation and topping up to be done,if necessary. Lubricating oil should
be as recommended in the gear box manual. It is important that this recommendation is
strictly followed. Please note that we do not take any responsibility for failure caused due
to non-adherence to this recommendation. Abnormal temperature of oil should be
intimated to us. Inferior or any unsuitable oil may cause excessive temperature rise and
possible damage and hence above caution.

Aerator motor & junction box

Standard maintenance for motors should be followed.

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 CHAPTER-8

AERATION TANK

1) Objective

Objective of this biological treatment is to convert organic matter into biological cell mass thereby
reducing the biochemical oxygen demand (BOD). The biological matter consumes dissolved
oxygen for respiration and mechanical surface aerators are provided to replenish oxygen thus
used up.

2) Process

Wastewater is carried to aeration tank. In addition to this, return sludge from clarifier is admitted
to the aeration tank. In the aeration tank, the effluent is aerated to enable active biological cells
to respire. Micro-organisms present in the return sludge oxidise the organic matter and use it as
food and form their own cell mass. These cell mass can be removed by settling, thus
leaving effluent free of oxygen demand. During steady state operation, the rate at which cells are
removed (sludge bleed off) is controlled to ensure a constant level of Micro-organisms in the
aeration tank.

The aerators provided on the platform maintain the contents in aerobic conditions by maintaining
adequate oxygen transfer rate. They also provide adequate mixing of the contents and thereby
contents do not settle on the floor of the tank. The flow from aeration tank goes to the clarifier.

3) Operation

Start up :

Before commissioning the plant, all loose material like nuts, bolts, rods, wooden pieces etc., must
be removed from the tank and pipes.
A. Ensure that gear box and motor are properly lubricated and maintained as per
manufacturer's instructions

B. Turn the aerator shaft by hand to make the aerator runs freely. This can be done by
rotating the coupling.

C. Check that the shaft is vertically plumb, base frame is levelled and the impeller is
levelled.

D. Check all electrical wiring for power and safety, damage etc.

E. Start and stop instantly to check that the direction of rotation is correct. If not,
interchange the phases of motor.

F. The distance between top liquid level and underside of basic frame should be maintained
as per the manufacturer's specification. If this limit is exceeded, it will impose
undesirable loads on gear box, thus reducing life of bearings.

G. Liquid level above the top of blade does not exceed that specified by manufacturer,
otherwise motor is likely to be burnt out.

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 H. Check motor amperage readings of aerators.

I. Check reduction gear and motor for overheating and unusual noise.

Commissioning

A. Fill up the aeration tank with fresh water.

B. Fill final clarifier with water.

C. Check to see if sludge recycle pumps and recycle pipeline are in order.

D. Start all aerators one by one.

E. Initially, start pumping surplus activated sludge from adjacent plant. Simultaneously allow
the waste to flow into the aeration tank. During this phase of commissioning, the sludge
recycle line must be kept in operation continuously. Care must be taken to ensure that
the plant is not loaded upto the design flow load all of a sudden. This must be done
gradually so as to enable the micro-organisms to get acclimatized to the effluent.

F. Take samples from inlet chamber and overflow from clarifier.

G. Monitor MLSS/MLVSS/SVI in the tank and develop MLSS above 3000 mg/l. It will take
three weeks or more to develop MLSS. Operate the return sludge ( 100% recirculation of
sludge) continuously during the time that the MLSS are being developed and also check
PH of the effluent. Continue same till plant gets stabilized and healthy biomass is
developed. The best way to speed up flow growing process is to truck in loads of liquid
activated sludge from other plants.

Normal operation

- Start the aerator.

- After five minutes take readings of the aerators at motor control centre of aerators.

- Aerators should work continuously and smoothly and should not wobble.

- Always check the submergence over the aerator impeller.

- Check reduction gear unit/motor for overheating. MLSS in the tank should be 3000 to 4500 mg/l.

Shutdown operation

- Press stop button for aerator. Allow the impeller to be stand still.

- For temporary shut-down, stop the aerator but do not stop return sludge.

- If inflow is stopped for a short interval there is no need to stop aerators.

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4) Abnormal operation

A. In the event of power failure, aerators and return sludge pump will stop. If power failure
continues for a long time, aerator may be run on generator.

B. MLSS drops below 2500 mg/l. This drop will not occur suddenly but will be indicated by
a gradual drop of MLSS over a period of days. This may be due to insufficient aeration or
insufficient BOD in procedure is to be carried out.

a. Recirculate the sludge by 100% (by closing bleed off valve).

b. If MLSS does not rise to desired range, incoming waste has to be analysed for lack of
nitrogen, phosphorus and carbon and presence of the toxic material.

c. If carbon, nitrogen, phosphorus ratio changes from desired 100:5:1, action must be
taken to rectify the imbalance. To increase carbon, add sugar in the form of glucose or
fructose form, for nitrogen add 5% conc. Urea and for phosphorus add 5% conc.
diammonium phosphate solution.

C. Presence of toxicity in any form is intolerable to the micro-organism in the system. Efforts
to locate and eliminate the source of toxicity will have to be made along the discharge
lines from the plant. Ensure that effluent entering tank has almost neutral pH value.

D. MLSS growing beyond 5000 mg/l.

This means that bacterial pollution has increased disproportionate to the amount of
incoming food and hence sludge bulking might take place. Reduce the addition of return
sludge to stabilize MLSS to 3000 mg/l.

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