STP Panel Operation Manual

Operation manual
For
ELECTRICAL CONTROL PANEL
Ashoka Iron Works (P) Ltd.,
Plant 2, belgaum
ECOSENSE ENGINEERING
“Shree Nilay”, CTS 1486, BCC 131, OLD DOOR NO.10 & 11, Beside
Vadgaon Vitthal Mandir, Bazar Galli, Vadgaon, Belgaum – 590005, Karnataka,
India
Contact Details
Ph.: 0831 – 2483599; Mobile: 08380817720
GST No.: 29ACCPA7398D1ZK
Website: www.ecosenseindia.com
Email: [email protected] / [email protected]
1. PROJECT OVERVIEW
a. Erection and Commissioning Work of Panel Completed On: 11/10/2020
b. System Brought Online: 12/10/2020
c. Person In-Charge of System: Shri. Atul Patel
d. Operator on the System: Shri. Omkar Nathaji
OPERATION MANUAL
This operation manual provides the detailed information of all the screens
of the PLC HMI for the information and operation of the Sewage
Treatment Plant. It is to be noted that, though the panel enables automatic
working of the majority of the system, the filtration backwash cycle needs
to be conducted on a manual basis. The details for the backwashing are
given in the STP Manual which was submitted during earlier project
works. The excerpt of the backwash process is included in this manual for
ready – reference.
PLC SCREEN
Auto Manual Changeover

Switch
Panel Front Side

(The Voltmeter in this photograph has been replaced with a Multiparameter Digital Meter as per clients request.)
SCREEN 1: FRONT SCREEN*
(Some details, such as manufacturer name and logo etc. are now changed. The screen will now show the name
of Ecosense Engineering, who is the supplier and designer of the panel)
SCREE 2: INPUTS
INPUT SCREEN 1
INPUT SCREEN 2
The Inputs screen can be accessed using the "INPUTS" Icon on the first screen. The Input
Screen provides the details of incoming supply to the various mechanical equipment,
components which are operations or in off condition. The screens are non-interactive,
information – display screens only. Press the "Main Screen" icon to return to the First
Screen.
SCREEN 3: MANUAL
The Manual Screen can be accessed using the "Manual" Icon on the First Screen. This is an
interactive, touch based screen used to operate the STP System in Manual Mode. To activate
the screen, the operator needs to first turn the "Auto-Manual Changeover Switch" to
Manual Mode. Only after this is done, the Manual Operation Console will be activated. Using
this console, the operator can switch the various systems in the STP unit manually. This
system is necessary to be accessed especially when the Filter Backwash is to be conducted.
SCREEN 4: MIMIC
The Process Flow Drawing Console can be accessed using the "MIMIC" Icon from the First
Screen. This is a non-interactive, information – display based console which gives the
operator the real-time information of the units running in the STP unit. RED indication
shows that a system is malfunctioning, GREEN indicates that the unit is in ON condition,
BLUE indicates that the unit is in OFF Condition.
SCREEN 5: OUTPUTS
The Outputs Screen can be accessed using the "OUTPUTS" Icon on the First Screen. The
Outputs Screen, similar to input screen, provides the info about the on-off position of the
units. The only change is that instead of the Input Supply to the Relay, this window provides
the information about the output supply to the unit via the PLC.
SCREEN 6: SETTINGS
This is the most important screen of the entire console which governs the actual working
cycles of each of the units incorporated in the STP unit. No changes should be made in
this unit without the prior approval of the process designer of the STP unit. This is
essential because the entire process stability depends on the settings of the units, and
hence, if changed without prior approval of the process designer, can cause inefficient
working of the plant.
The ON and OFF Time of Day depicts the timing for which the unit will run in 24 hours.
CYCLE ON and CYCLE OFF Time is the On- and Off – frequency of the unit during the
working hours.
UNIT WISE PROCESS LOGIC CRUX
The entire process of the STP is run on various pumps and blowers, the primary logic of
working of each of these being as given below:
a. Lifting Pump – Level sensor based working. Once the tank is filled to a certain
extent, the pump will be switched ON. Once a pre-set low level is reached, the
pump will be switched OFF.
b. Blower: Timer Based Working. Blower shall stay in working mode for 24 hours.
During the 24 Hrs working period, the blower will switch OFF after every 20
Minutes, and stay in OFF condition for 10 Minutes.
c. Sludge Recycle Pump: Timer Based Working. The Sludge Recycle Pump shall
stay in working mode for 24 hours. During the 24 Hrs working period, the Sludge
Recycle Pump will switch ON after every 20 Minutes, and stay in ON condition
for 2 Minutes.
d. Ozonation System: Timer Based Working. The Ozonation System shall stay in
working mode for 24 hours. During the 24 Hrs working period, the Ozonation
System will switch OFF after every 20 Minutes, and stay in OFF condition for 10
Minutes.
e. Filter Feed Pump – Level sensor based working. Once the Filter Feed tank is filled
to a certain extent, the pump will be switched ON. Once a pre-set low level is
reached, the pump will be switched OFF.
f. Treated Water Pump (Depicted as Filter Feed Pump 2 in the PLC Screen) – Level
sensor based working. Once the tank is filled to a certain extent, the pump will be
switched ON. Once a pre-set low level is reached, the pump will be switched
OFF.
FILTER BACKWASH CYCLE INFORMATION

The Filtration System is divided into three cycles
i. Service Cycle – Duration – 24 hrs.

ii. Backwash Cycle – 15 Minutes
iii. Rinse Cycle – 10 Minutes
Backwash should be done every day in the morning before the system is brought
online.
b. Backwash Process
Sr. No. Filter Vessel Backwash Rinse Time

Time (Min.) (Min.)
1. Multimedia Filter (MMF) 15 Min. 10 Min.
2. Activated Carbon Filter (ACF) 10 Min. 5 Min.
i. Switch off the filter feed pump (if on).

ii. Turn the Multiport Valve Knob on MMF in Clockwise Direction and Set
it to BACKWASH.
iii. DO NOT CHANGE THE POSITION OF VALVE IN THE ACF.
iv. Switch On the filter feed pump.
v. Run the pump for 15 minutes.
vi. Switch off the filter feed pump.
vii. Turn the Multiport Valve Knob on MMF in Clockwise Direction and Set
it to RINSE.
viii. DO NOT CHANGE THE POSITION OF VALVE IN THE ACF.
ix. Switch On the filter feed pump.
x. Run the pump for 10 minutes.
xi. Switch off the filter feed pump.
xii. Turn the Multiport Valve Knob on MMF in Clockwise Direction and Set
it to FILTER. Keep it in the same position for rest of the process.
xiii. Turn the Multiport Valve Knob on ACF in Clockwise Direction and Set it
to BACKWASH.
xiv. Switch On the filter feed pump.
xv. Run the pump for 10 minutes.
xvi. Switch off the Filter Feed Pump.
xvii. Turn the Multiport Valve Knob on ACF in Clockwise Direction and Set it
to RINSE.
xviii. Switch On the filter feed pump.
xix. Run the pump for 5 minutes.
xx. Switch off the Filter Feed Pump.
xxi. Turn the Multiport Valve Knob on ACF in Clockwise Direction and Set it
to FILTER and run the system for the next 24 hours as per requirement.
c. Maintenance – Check for any abnormalities and working issues (If any).
d. Precautions – Ensure that the Outlet Valve (Connected to the Reutilization Tank)
is always open.

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What are the different screens on the PLC HMI?

What is the purpose of the operation manual?

Operation manual

Auto Manual Changeover

Panel Front Side

UNIT WISE PROCESS LOGIC CRUX

FILTER BACKWASH CYCLE INFORMATION

i. Service Cycle – Duration – 24 hrs.

Sr. No. Filter Vessel Backwash Rinse Time

i. Switch off the filter feed pump (if on).

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