HMWS & SB
REACTORS
Division Box – I
Purpose: The rising main from the Main Pumping Station will be connected to the Division Box – I
having central common compartment. The flow will be then divided into six equal parts and
distributed to Division box –II via 900mm diameter DI pipe.
Division Box - I – 02 Nos
Out Lets per Div. Box - I – 06 Nos
ROUTINE MAINTENANCE
The distribution boxes shall be cleaned regularly.
Check for leakage / blockage of division box – I & II.
Division Box – II
The Division Box – II will receive the flow from the Division Box – I. the flow will then be split
proportionately to four equal parts and distributed to Distribution Boxes via 450mm diameter DI
pipe line.
Division Box - II – 12 Nos
Out Lets per Div. Box -II – 04 Nos
ROUTINE MAINTENANCE
The distribution boxes shall be cleaned regularly.
Check for leakage / blockage of division box –II.
DISTRIBUTION BOXES
Two distribution boxes are provided in each Reactor, each of this box shall consist one central
compartment and 8 individual compartment. The distribution box will receive the flow from the
Division Box –II and distribute the UASB reactor. 180 OD HDPE pipes will be provided to convey this
flow to feed inlet boxes placed on top of UASB Reactor.
Distribution boxes per Reactor – 02 Nos
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 34
HMWS & SB
Out Lets per Distribution Box – 08 Nos
ROUTINE MAINTENANCE
The distribution boxes shall be cleaned regularly.
Check for leakage / blockage of distribution boxes.
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 35
HMWS & SB
UASB REACTORS
WASTE WATER FLOW DISTRIBUTION
UASB Reactors – 24 Nos
Feed Inlet Boxes per Reactor - 16 Nos
Outlet per feed Inlet Box – 14 Nos
UASB (Upflow Anaerobic Sludge Blanket)
Reactors – 24 Nos
Size (in Mtr) – 32 X 28 X 5.8 LD
Solids Retention Time – 33 Days
Upflow Velocity During Avg. Flow – 0.65 m/hr
During Peak Flow – 1.3m/hr
Angle of GLSS – 500
Hydraulic Retention Time – 8.88 Hrs (Avg)
– 4.44 Hrs (Peak)
SLUDGE PRODUCED GAS PRODUCED
1380 Cum/Day 6423 Cum/Day
82780 Kg/Day
Manure 165 Cum/Day
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 36
HMWS & SB
PURPOSE : The basic idea is flocculent or granular sludge developed in the reactor depending on
the wastewater characteristics and operational parameters will tend to settle under gravity
when applying moderate upward velocity in the reactor. Anaerobic bacteria are developed in
the reactor and are kept in the biological reaction compartment for sufficient time. Organic
compounds present in the wastewater in the absorbed or unabsorbed from on the sludge
particles in the reactor zone during its passage through the sludge bed. Organic compounds
after getting anaerobically biodegraded converting it into methane –enriched biogas and a
small part into the new bacterial mass. Biogas consists of Methane (CH4), Carbon dioxide (CO2),
Hydrogen (H2), Hydrogen Sulfide (H2S) and traces of Ammonia (NH3) and Nitrogen (N2).
Methane enriched biogas having high calorific value is converted into a usable energy recourse
like heat energy, electricity etc., and mineralized excess sludge produced in UASB reactor for its
usage as manure for agricultural purpose.
A Gas liquid solid separator (GLSS) is provided below the gas collectors in order to provide an
opportunity to the sludge particles to which Biogas bubbles are attached to lose biogas and
settle back into the reaction compartment. In between two gas collectors a settling zone
provided where virtually no gas bubbles are present in the liquid. The sludge particles carried
along with wastewater flow are settled in the settling zone and slide down into the biological
reaction zone. Wastewater enters the UASB reactor from the bottom and travels through the
reactor in the upward direction. In order to ensure sufficient contact between the incoming
wastewater and the anaerobic bacterial mass present in the reactor, the wastewater is fed
uniformly all over the bottom of the reactor. Further mixing in the reaction zone is achieved by
the production of the biogas traveling in the upward direction, settling velocity of the sludge
partials and the density currents in the sludge mass.
UASB alone can not achieve desired results in terms of effluent discharge standards prescribed
for BOD and TSS hence a simple post treatment in the form of facultative type of Aerated
Lagoon is considered after UASB reactors.
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 37
HMWS & SB
Routine Maintenance of UASB Reactors,
During the operation of the treatment plant, samples from the reactor should be taken periodically
for analysis. The operational parameters such as hydraulic retention time can be adjusted
depending upon the sample results. The following illustrates the maintenance aspects of the UASB
reactor:
All the FRP piping and PVC piping should be checked for gas leakage and should be repaired
immediately
The levels of the inlet gutters of every reactor should be frequently checked
The floating layer, whenever it forms, should be removed from the gas collectors
The railing and other metallic works such as valves should be painted
For every 4 to 5 years, the grit accumulated inside the reactor should be removed and the
inside concrete surface should be given a new coat of epoxy paint.
The sludge pits should be properly maintained
The weir level of V-notches is checked and if needed the level shall be adjusted by
adjusting screws to distribute the sewage equally in the reactors.
The obstructions accumulated near the opening of V-notches of the weir plate shall be
removed regularly.
The personnel shall not step on the gutters.
Feed Inlet Boxes
The main problem with the feed inlet box is that the inlet pipes get frequently choked up. In case
of choking, water hosepipe should be introduced so as to build up the pressure. If it so happens,
that the choking of pipe cannot be removed by means of water hosepipe, a flexible rod should be
used to clean up the feed inlet pipe.
Sludge Discharge System
Sludge is discharged from each reactor on daily basis or as per the instructions of lab technician
reports.
After getting the reports, the quantity of sludge to be discharged from the reactor shall be
determined.
Check the operation of valves at sludge sampling ports. Replace the non-functioning valve.
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 38
HMWS & SB
The sludge withdrawal pits are cleaned regularly. The sludge conveying pipes from reactor to sump
shall be washed daily after withdrawal of sludge.
Gas Collection System
Record the rise / fall level of the MS gas dome.
If biogas production is excessive and it is not possible / feasible to use it for production of electricity
than, divert the gas to the gas flare system.
Check that the pulley of the MS gas dome of the gasholders is freely moving over the rails.
Record the quantity of the biogas production in the data collection sheet daily.
Record the moisture content in the gas (Before and after the scrubber) at the time of recording the
gas production.
Check the operation of gas scrubbing system regularly. Cleaning of scrubber and replace of the gas
is done as and when required.
Check FRP gas hoods and gas pipes for leakage regularly. Repair the damaged portions of the gas
collection system wherever necessary.
Check the water level in the gas holder daily and add water when required.
Check the pressure in the gas holder daily.
Around gas collection system following precautionary measures is strictly followed:
No open fires or sparks near the reactor, Gas holder, Gas flaring system, Bio Gas Generator room,
Gas flow meter and other gas collection system.
Take extreme care against the hazard while replacing / repairing the accessories provided in the gas
collection system.
Declare and display the gas collection system area as “NO SMOKING” zone.
Display and follow the fire preventive instructions displayed at different places in the plant.
Operation and Maintenance Manual for 339 MLD STP at Amberpet Page 39
