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KLARO Maintenance Manual

1. C Oxygen measuring instrument HACH LANGE HQ30d with sensor LDO101 6 KLARO GmbH KLARO Maintenance Manual Measurement of ammonium Assessing whether the aeration Ammonium test strips is enough Measuring range 0 to 400 mg l Measurement of nitrate Measuring range 0 to 500 mg l Nitrate nitrite test strips Measurement of nitrite Measuring range 0 to 80 mg l Measurement of total phosphate Phosphate test strips Measuring range 0 to 80 mg l Determining the pH value pH measurement strips 100 pieces Measuring range pH 4 5 10 Hygiene hand gloves Protecting the hands from germs Sterilisation agent Protecting the hands from germs Removal of shaft covers made of Manhole cover remover concrete cast iron Socket wrench 17 mm for ope ning small shaft covers made of PE Socket wrench KLARO GmbH 7 KLARO Maintenance Manual Determination of the sludge level height and water levels Opening all KLARO switching cabinets for indoor and outdoor installation Philips slotted screwdriver for dismantling the controller out door cabinets Blade length at least 14 cm Socket wrench for fastening hose clamps 1 mm Reading from controller KLplus controller Fastening hose pipes 13 19 mm Reading from the controller ZK Interface cable ZKplus and KLbasic controllers Measuring capacitance voltage Multimeter current and conductance 8 KLAR
2. Empty precipitant canister Defective dosing pump Disruption of the supply flow KLARO GmbH NOTE If the hose is attached to a pipe or rod and inserted vertically into the canister down to its bottom the hose can no longer curl up inside the precipitant canister and suck in air In addition clogging of the lines may also block the uptake of chemicals Clogging is usually due to the following Causes e Incrustation in the canister e Crystallisation of the solution be cause of low temperatures In such cases the clogging must be removed and the precipitant must be replaced In addition the precipitant flow may be prevented by defects in the dosing line causing the precipitant to no longer be pumped up to the small wastewa ter treatment plant The line must be checked for leaks If the dosing line is leaking or broken discharge into the soil must be prevented External impact loads resulting in an increase of phosphate compounds must be discussed with the operator of the small wastewater treatment plant Elevated phosphorous loads are usually due to the introduction of food residues Elimination _ amount duration with a new dosing pump Correct insertion of the dosing hose into the precipitant canister In addition attachment of the hose to pipe rod Increased ne value KLARO Maintenance Manual Dysfunction regarding the uptake of chemicals into the hose incrustation crystallisation Leaki
3. O mg l treatment of wastewater Impurities Oxygen concentration inthe water wastewater lead to great wastage of oxygen Hence the oxygen concentration of raw wastewater is equal to zero Table 12 Wastewater parameters This Maintenance Manual of KLARO is just a recommendation and is not entitled to completeness 38 KLARO GmbH The KLARO principle Maximum operating reliability Our benefits Almost all possible approvals Extremely short delivery times thanks to optimised production Legal threshold values undercut by up to 90 98 treatment performance in 6 hours T V tested switch cabinets EPP indoor switch cabinet outdoor switch cabinet No mechanics pumps or electrical parts in the wastewater All components are permanently connected to the filtering tank All transportation processes are performed by the air lift pump All electrical parts are located securely outside the tank in the switch cabinet Certified underload detection Only one tank required for sys tems of up to 20 PE Personnel Fully biological mode of operation Equivalent Quality products with extremely high customer satisfaction levels Suitable for retrofitting to practi cally any tank shape Minimal power consumption T Retrofitting possible in single All transportation processes per twin triple and multi chamber pits formed by air lift pum ie Installation possible in any type of tank from plastic to
4. cm Air filter replaced Total power on hours Discharge Valve Recirculation Valve 4 3 Replace the lamp after power on hours OOL OLI Aeration Valve 2 blue Excess sludge air lift Valve 4 white Condenser OK Replacing the diaphragms Cooling fan OK Maintenance has been recorded in the logbook The operator is requested to pay attention to the materials not to be fed see logbook The tank is jammed and the operator must ensure discharge Shut down the tank arrange for disposal of the sludge storage Date and signature 36 KLARO GmbH KLARO Maintenance Manual 8 Wastewater parameters Wastewater parameters BOD mg l Biochemical oxygen demand COD mg l Chemical oxygen demand SS mg l Suspended solids NH N mg l Nitrogen Ammonium Ne mg l Total nitrogen are mg l Total phosphorous SS ml I Settleable solids Explanation Measure for the total of the biolo gically decomposable wastewater constituents BOD indicates the amount of oxygen that is need for the biological decom position of organic substances ina period of five days Measure for the total of all organic wastewater constituents including those that are difficult to decompose COD indicates the amount of oxygen that is necessary for complete oxidati on of organic wastewater constituents Parameters for the degree of con tamination Measure for th
5. has ended or has been inter rupted by the restart the cyc le function KLbasic and KLplus display KLARO GmbH Be careful when withdrawing an out let sample During the functional test for valve 3 the air lift generally trans fers contaminated or water that has not settled adequately from the SBR chamber into the integrated samp ling facility Sampling for laboratory analyses is then no longer possible Hence always remove samples PRI OR to the functional test the current aeration period set currently in hours per day with T18 Modifications in the aeration times can be tracked easily here The Aeration phase T5 re mains untouched Increasing it may lead to the maximum permissible total cycle time getting exceeded This then leads to loss of the next cyc le the controller switches to Cycle pause and to reduc tion in the total aeration peri od for the day e Adjusting the number of cleaning or treatment cycles In case of plants that are constantly under loaded e g only one person at home the number of cleaning or treatment cycles may be reduced from four cycles to two cycles You can achieve this most easily by increasing the cycle time for the Settlement phase T8 from the default setting of 90 min to 100 min As a result the maximum total cycle time permissible gets exceeded and only every second cycle gets executed In between the plant switches to the C
6. 24 KLARO GmbH NOTE A clogged or choked air filter leads to reduced air compression capacity and cooling of the equipment Figure 32 Checking the air filter e Checking the slider width at least every 3 000 hours of operation Record the slider width measu red in the maintenance report in order to be able to track wear and tear and procure spare sli ders in time NOTE If the slider width goes below the minimum permissible value the rest of the slider may break and block the rotor e Checking the starting capacitor at least every 3 000 hours of opera tion Figure 33 Measuring the capacitance of the capacitor KLARO Maintenance Manual Disconnect the capacitor Use a multimeter with capaci tance measurement feature with crocodile clips For measuring leads having test tips you should use a clamp see figure for as sistance Measurement directly on the terminal board will distort the result just as when you use your fingers to press the test tips on the leads of the capacitor Target value mF is embossed on the nameplate of the com pressor Figure 34 Checking the slider KLARO GmbH D 58 mm Ci 60 mm H 40 mm H 40 mm Ho 909519 No 909542 NOTE The starting capacitor causes the compressor to run in the right direc tion when it is switched on A worn very weak capacitor may start the compressor in the wrong direction suction instead of compression 25 KLAR
7. after the aeration phase that is during the feeding se dimentation and extraction phase Pa NC tr ni Me ea i a a a 7 8 8 a 4 3 I q Figure 17 Typical trend of the oxygen concentration in the KLARO SBR chamber in the course of the day In KLARO SBR plant that have also been designed for denitrification short bursts of aeration are used prior to the actual aeration to achieve circulation of the activation tank the so called pre aeration phase In the process the denitrified microorganisms are stimulated to convert nitrate into its started now It measures the content of oxygen dissolved in the wastewater automatically flexi Figure 16 Display unit of the oxygen measuring instrument the oxygen concentration reduces in contrast see the following diagram for this purpose fh OF onde MEURT Figure 18 Typical trend of the oxygen concentra tion in the KLARO SBR chamber with additional denitrification during the day element nitrogen The oxygen concen tration reduces considerably during the Deni phase O 0 mg l In order to ensure optimal denitrification the oxy gen concentration should not be more than 0 5 mg l during the denitrification Thus the oxygen concentration in the activation tank of the wastewater treat KLARO GmbH ment plant depends on the respective phase of the SBR process and a more accurate interpretation of the oxygen concentration measured directl
8. e There may be fluctuations depen ding on the season The dissolu tion behaviour of oxygen is better in cold weather than in warm wea ther Hence the measured values in winter are often somewhat high er than in summer e The oxygen concentration also de pends on the quantity of the acti 16 KLARO GmbH e One sided gt Moderate if multiple membrane aerators have been installed in the tank vated sludge gt SV If the quan tity of activated sludge increases more oxygen is consumed and the oxygen concentration comes down This aspect must be kept in mind particularly in plants having seasonal fluctuations and when the time for sludge recirculation in the controller is modified Figure 14 Measurement of the oxygen concentration in the sample container Measurement in the activation tank The aeration of the activation tank re mains switched on for the measurement of the oxygen concentration The probe Figure 15 Immersed probe of the oxygen measuring instru ment during aeration Since the SBR process in the activa tion tank for wastewater treatment or cleaning takes place in four different phases one after another chronologi cally feeding aeration sedimentation KLARO Maintenance Manual of the measuring instrument must now be immersed in the activation tank The measuring instrument may be and extraction the oxygen concent ration increases during the aeration phase Before and
9. fibreglass to concrete Treat water and introduce it back into the natural cycle Telephone 49 0 921 16279 0 Fax 49 0 921 16279 100 E Mail info klaro eu More information at www klaro eu l Technical hotline E 49 0 921 16279 330 Photo copyright KLARO GmbH KLARO GmbH Bayreuth 2013 Art No KKA 0062 01 13 engl
10. high water levels any signs of leakage if the level falls below the minimum water level e Any signs of possible corrosion damage gt particularly in the case of concrete tanks accompanied in most cases with technical problems and lack of aeration and bleeding This is why the same random sam ple may be used for determining the quantity of BOD No separate sample bottle is required for this purpose e An exact quantity of 1 0 litre of wastewater is needed to deter mine the quantity of SS This is why we recommend that you fill an additional random sample in ano ther sample bottle for the exact determination of the substances that can get deposited The ran dom sample must be removed ca refully from the bottle and stored under refrigeration until the analy sis is conducted 11 KLARO Maintenance Manual Figure 3 Withdrawing a random sample from the sampling vessel black using a bucket Figure 4 Different sample bottles Filling the random sample The sample bottles must be labelled in a comprehensible manner Name Date Place Finally the samples must be kept under refrigeration and stored in a dark place A refrigeration box with a cold pack is ideal for this purpose The samples 12 should be brought to the laboratory as soon as possible since the composition may change with time The parameters with respect to which the samples should be analysed de pend on the local require
11. if the current water tempera tures are within the range greater than 12 C Increasing the aeration Temporarily switch off the sludge recirculation Readjust the pH value by using lime soda or soda lye 6 1 4 Increased N value During denitrification nitrate is trans formed into elemental nitrogen N via nitrite under anoxic conditions oxygen free phase Most bacteria contained in the activated sludge are capable of this process For an effec tive denitrification both sufficient or ganic carbon and nitrate are needed If a high concentration of ammonium or nitrate is measured at the outlet this is indicative of insufficient nitro gen degradation An improper excess sludge recircula tion which heavily reduces the sludge content in the bioreactor does not only impair nitrification performance but also denitrification performance Observation Increased Not value Table 7 Elimination of increased total KLARO Maintenance Manual The oxygen input is of critical impor tance for the denitrification perfor mance An excess oxygen supply has an inhibiting effect on the denitrifying bacteria In addition there must be a sufficient contact between the wastewater and the denitrifying bacteria On the one hand this is ensured by means of a complete mixing inside the bioreac tor through short aeration periods and on the other hand by means of a 30 minute contact time A sufficiently long contact tim
12. may be edited saved and printed out e g as an enclosure to a maintenance report Figure 27 Reading out data on SD card 21 5 2 4 Functional test In the Manual Mode menu you can switch the loads on briefly and then again off to test all of them one after another A malfunction in the electrical system is indicated by the controller as a fault Proper working of the compo nents should be checked visually in the wastewater treatment plant NOTES e In the ZK and ZKplus control lers the 9V battery is checked in parallel in the background KLARO Maintenance Manual e With the underloading detec tion activated in the KLplus and ZKplus controllers the level is measured when valve 1 is in ma nual mode e As an alternative to switching the valves 1 4 manually the option operation test may be activated in the service menu After a waiting period of two minutes the controller automa tically switches the valves 1 4 on for a few seconds and then again switches them off 5 2 5 Setting optimal operational values The controllers are preset with the loading embossed PE number and the class of treatment of cleaning In the process for the sake of safety continuous maximum loading of the plant is assumed The controller set tings may be adjusted to the actual conditions at site We recommend that such adjustments are made only after a safe start up phase for example in the course of the first mainte
13. A random sample of the discharge from the plant is withdrawn for subsequent laboratory analyses For this purpose wastewater is carefully withdrawn with the help of a bucket from the integrated sampling vessel not the SBR chamber While doing so do not touch the walls of the vessel for drawing samples since otherwise deposits come loose and worsen the sample disproportionately The random sample is filled carefully into the sealable sample bottle There are different sample bottles depending on the laboratory and the parameters to be analysed e To determine the quantity of BOD the bottle must be filled complete ly and without any bubbles as far as possible To do this tap on the filled and open bottle so that the air bubbles get released from the edge of the bottle Fill up the sam ple bottle once again until it over flows Close the cap at this stage e For the determination of COD N and P compounds often bott les are used that already contain sulphuric acid H SO As a re sult all decomposition processes cease and there is no falsification in the analysis resulting from the period of transportation to the la boratory e To determine the quantity of SS about 0 5 litres of the random sample must be filtered and the filter residue must be weighed In general glass fibre filters or paper filters having pore widths of 0 3 to 1 um are used for the filtration KLARO GmbH gt Ingress of drainage water and
14. CID No Others Emptying necessary No No No No No No No No No No No No Air temp L L strong strong strong plenty SBR chamber frozen foul _ beige _ opaque C earthy brown C mg l mg l 35 KLARO Maintenance Manual 3 SBR Reactor Proportion of sludge by volume Oxygen concentration Air intake Aeration Aeration pattern Aeration Remarks 4 Pre clarification Sludge storage buffer Sludge height om moderate fine bubbles __ Floating sludge height The operator should arrange for emptying out the septic tank Remarks 5 Maintenance of the machines Air filter _ Air filter cleaned Controller Faults have been read Remarks Controller type Charging Valve 1 Aeration Valve 2 UV reactor Remarks Data has been read L L L L Functional test check performed Charging air lift Valve 1 red Discharging air lift Valve 3 black Remarks Compressor Compressor type Compressor OK Checking the blades Width of the blades _ Replacing the filter Remarks 6 Supplementary Remarks Logbook is available Programming has been changed The fault has been rectified Supplementary Remarks 7 To be initiated by the operator ml I maximum 400 ml l mg l normal about 4 6 mg l at least 2 mg l intensive circulation is clearly identifiable uniform
15. H 10 11 11 11 12 13 13 14 14 14 14 15 16 16 17 18 18 19 19 20 20 20 20 20 21 21 22 22 23 23 23 24 24 25 26 26 26 27 27 28 28 29 30 31 31 32 33 34 34 34 34 35 36 37 38 KLARO Maintenance Manual Table of figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Visual inspection of the tank Minimum water level reached the pump cannot be lowered any more Withdrawing a random sample from the sampling vessel black using a bucket Different sample bottles Filling the random sample Filling the sample Determining the substances that may get deposited in the Imhoff funnel Random sample in a measuring cup for assessing the odour coloration and turbidity Determining the pH value using measurement or test strips Removal of a sample of the activated sludge for testing the proportion of sludge by volume Filling a sample of the activated sludge in the standing cylinder Sludge quantity at the beginning of the 30 minute standing time Sludge volume after a standing time of 30 minutes Oxygen measuring instrument wit
16. KLARO Maintenance Manual Table of contents E SS Introduction Safety instructions Maintenance accessories Maintenance work in the plant 4 1 Visual impression 4 2 Analysis of wastewater and sludge 4 2 1 Drawing samples from the plant outlet for laboratory analysis 4 2 2 Determining the substances that can be deposited SS 4 2 3 Assessing the odour coloration and turbidity 4 2 4 Measuring the water temperature 4 2 5 Determining the pH value 4 3 Analysis in the SBR chamber aeration tank 4 3 1 Determining the volume of sludge SV 4 3 2 Assessment of the aeration pattern 4 3 3 Measuring the oxygen concentration 4 3 4 Simplified assessment of nitrification and denitrification 4 4 Sludge level measurement 4 5 Cleaning work Maintenance of the machines 5 1 Air filter 5 2 Controller 5 2 1 Reading fault messages 5 2 2 Power on hours 5 2 3 Reading out data 5 2 4 Functional test 5 2 5 Setting optimal operational values 5 3 Compressor 5 3 1 NITTO piston compressor 5 3 2 BECKER or RIETSCHLE rotary slide compressor Troubleshooting 6 1 Poor purification performance 6 1 1 Increased SS value 6 1 2 Increased COD or BOD value 6 1 3 Increased NH N value 6 1 4 Increased N value 6 1 5 Increased P value 6 1 6 Increased decreased pH value 6 2 Bulking sludge 6 3 Floating sludge and foam 6 4 Smells 6 4 1 Smell of gas 6 4 2 Smell of ammonia 6 4 3 Smell of rotten eggs Maintenance report Wastewater parameters KLARO Gmb
17. O GmbH KLARO Maintenance Manual Smoke cartridge Work gloves Battery Controllers Solenoid valve Testing the bleeding of the plant Protecting the hands while wor king on the plant Replacement batteries for the ZK and ZKplus controllers 9V Spare controllers KLbasic and KLplus including the connection cables Spare coil with armature and spring with a straight stem from 07 2002 to 05 2006 with conical stem from 06 2006 Replacement of clogged air fil ters of a piston or reciprocating compressor NITTO different sets for LA60 80 LA120 and LA200 Air filter for the Nitto compressor 2 A slow speed 8 A medium speed Micro fuses Disc aerator Replacement of defective disc aerators KLARO GmbH 9 Cooling fan i Sealing tape Table 1 Maintenance accessories 4 Maintenance work in the plant 4 1 Visual impression Figure 1 Visual inspection of the tank After opening the shaft manhole cover you first obtain an overview of the visual impression of the KLARO plant You need to take decisions regarding e the general accessibility to the plant 10 KLARO Maintenance Manual As a spare for cabinets with a rotary slide compressor or to re trofit cabinets with reciprocating compressors As replacement if grommets break off Angled or straight In order to reseal hose connec tions and threads Chamber 1 Chamber 2 Figure 2 Minimum water level r
18. O Maintenance Manual 6 Troubleshooting 6 1 Poor purification performance A poor purification performance along with a possible exceedance of limit values is an indicator of the small waste water treatment plant either not working correctly or increased pollutant levels in the feed A properly planned and regularly main tained small wastewater treatment plant which is not subject to overloading generally exhibits very stable purifi cation behaviour Malfunctions need to be expected if the measured values are not in the usual range of variation or are higher than the anticipated values If limit values are exceeded action must be taken Before considering operational or struc tural changes the measured value must first be checked for plausibility If increased levels are measured at the outlet of the small wastewater treatment 6 1 1 Increased SS value If the small wastewater treatment plant is adequately dimensioned and the bioreactor works smoothly the SS value at the outlet should be about 10 mg l Consequently an in creased solids overflow only applies if the SS value exceeds 30 to 50 mg l at the outlet 26 plant the first thing to be checked should be the execution of sampling In the case of random samples it must be ruled out that e the sample container contained residues of cleaning agents or another sample e too many solids are present in the sample due to contamination of the integrated sampli
19. ased decreased pH values Control of bulking sludge Elimination of floating sludge and foam Wastewater parameters KLARO GmbH 10 10 12 12 12 13 13 14 15 15 15 15 16 16 17 17 17 18 18 19 19 20 20 21 21 21 24 24 24 24 25 25 25 30 5 10 18 23 27 28 28 29 30 31 31 32 33 37 38 The KLARO Maintenance Manual 1 Introduction As a result of the robust wastewater treatment system and with proper ope ration the KLARO wastewater treat ment plant achieves optimal cleaning or Clarification performance and long service life It is necessary to check and maintain the plant regularly for proper operation The requirements and regulations for operation and maintenance are not uniform in the EU but are governed and specified by each country inde pendently In Germany these requirements are governed and specified by the German Institute for Building Technology DIBt They include self checks and self tests by the operator of the system as well as maintenance work by a specialist agency The self checks and self tests are described precisely in the logbook that is supplied along with every KLARO plant The tasks of the maintenance specialist are meant to be explained here in detail This manual is to be considered as a recommendation It is closely in line with the maintenance rules and regulations of the DIBt and is based on more than ten years of practical experience that
20. d only be increased gradually A poorly settleable and easily floa ting sludge structure bulking sludge may also lead to an increased COD or BOD value Bulking sludge refers to excessive growth of filamentous microorganisms In contrast to floc forming microorganisms they exhibit poorer settling properties and are discharged from the small wastewa ter treatment plant together with the clear water In most cases sludge bulking is due to an insufficient oxy gen supply or an insufficient mixing within the bioreactor Reduced oxy gen conditions stimulate the growth of filament formers Therefore the oxygen supply should be checked and increased if necessary In addition to filamentous microor ganisms the augmented disintegra tion of sludge floc may result in an increased sludge overflow and thus increased outlet values Floc integra tion is usually caused by e The destruction of the structural substance of the sludge floc due to the pH in the bioreactor being too low or too high e Inhibiting substances in the waste water treatment plant feed e Salt impacts in the wastewater treatment plant feed KLARO GmbH For this reason the pH must always also be determined If the pH is below 6 5 or above 9 0 this usually results in floc disintegration and an inhibition of purification performance In order to stabilise the pH chemical addi tives alkalis must be added to the bioreactor in such an amount and un ti
21. e is required as deni trification does not begin immediate ly but only after the dissolved oxygen has been used up by the bacteria Increased oxygenation during the denitrification phase 7 Insufficient nitrification E m Contact time too short Amount of activated sludge too low Water temperature below 10 C nitrogen values KLARO GmbH If the anoxic phase is too short and if the mixing inside the bioreactor is insufficient the nitrate will only be denitrified incompletely If denitrification is impaired by the contact time being too short or an unfavourable arrangement of the cycle starting times the denitrifica tion period and the cycles must be readjusted Extending the denitrification phase Improving the nitrification perfor mance by raising the oxygen content in the ventilation phase Extending the mixing process Shortening or temporarily switching off the excess sludge removal 29 6 1 5 Increased P value Thanks to the addition of a precipitant the dissolved phosphates contained in the wastewater are transformed to an undissolved form and can thus be separated Possible precipitants primarily include iron compounds iron chloride iron sul fate iron chloride sulfate or aluminium compounds poly aluminium chloride aluminium chloride sodium aluminate aluminium sulfate The precipitation performance signi ficantly depends on the dosage the pH and the precipitation conditions P
22. e sources of wastewaters containing ammonium liquid manure etc The H S contained in the plant can be converted by means of FeCl KLARO Maintenance Manual 7 Maintenance report Location address Maintenance Company Serial number Plant size Operator s name Postcode City Is industrial wastewater also introducted CL Restaurant without a kitchen Grease separator available NG Date of maintenance Order no Actual connection Street Tel no 1 Visual impression structural condition of the filled plant The system is accessible The manhole cover is in good connection Feed pipes and drain pipes are free Installed components OK Water levels OK Aeration tank has no floating sludge No foam formation No grease deposits Aeration and bleeding OK Partitions OK Corrosion damage The plant is not leak proof externally Remarks 2 Analysis of wastewater and sludge Sampling Sampling time Sampling point Sample transport Odour Coloration Turbidity Floating substances SS 0 BOD 5 COD NH N 4 None None None None OOOO O L mg mg l mg mg l CID Hours Sample container cooled to 4 C weak weak weak low Water temp pH value SS N total KLARO GmbH LC Restaurant with a kitchen Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes LILI O UU
23. e totality of the un dissolved wastewater constituents that are removed by filtration In raw wastewater the undissolved sub stances make up about 1 3 of the contamination Measure for the oxidative decompo sition of nitrogenous compounds by nitrifying bacteria nitrification Proportion of nitrogen in the waste water in the form of ammonium Measure for the efficiency of the ni trogen decomposition nitrification and denitrification Total of the organic and inorganic nitrogenous substances in the was tewater Measure for the pollution of raw waste water with phosphorous compounds The elimination of P takes place to a large extent via the P precipitation Measure for the totality of the water constituents that settle down within two hours The substances that settle down make up about 1 4 of the total wastewater constituents KLARO GmbH 3 Feed and discharge Limit values Raw KLARO pro cess values wastewater 20 40 150 500 90 150 300 1000 fs ex I NO ex I i ex N KLARO Maintenance Manual Measure of the hydrogen ion concen tration and thus for the acidity of the wastewater The lower the pH value pH value the more acidic is the wastewater The efficiency of the bacteria to be decomposed depends on the pH value Optimum 6 5 8 0 Measure of the concentration of dis solved oxygen in the wastewater The oxygen is essential for the aerobic
24. eached the pump cannot be lowered any more gt Shaft manhole cover can be reached easily not delivered e the condition of the shaft manhole cover gt Breakages cracks functionality of the child lock for PE covers KLARO GmbH e the condition of the feed pipes and drain pipes gt Any signs of clogging e the completeness and proper ar rangement of the components in stalled gt Aeration equipment air lift pump air hose pipes and sampling e the water levels of the individual chambers gt Any signs of overflow in the cham bers hydraulic overload and prob lems with the air lift pumps e possible formation of floating sludge in the aeration chamber Surfactant foam solid white foam that remains sta ble when touched Indication of the use of excessive detergent of washing agent Egg white foam KLARO Maintenance Manual greyish foam which collapses imme diately when touched gt An indication that there is biology in the build up often observed du ring the start up phase e Signs of grease deposits espe cially in case of restaurants gt Grease separator overloaded or disposal is due e the aeration and bleeding of the plant gt via the building roof shaft manho le cover or other aeration equipment e the leak tightness of the tank ex ternally 4 2 Analysis of wastewater and sludge 4 2 1 Drawing samples from the plant outlet for laboratory analyses
25. een 6 5 and 8 0 4 3 Analysis in the SBR chamber aeration tank Apart from removing a random sample direct analyses also need to be carried out in the activation tank e Proportion of sludge by volume e Assessment of the aeration pat tern e Oxygen concentration 4 3 1 Determining the volume of sludge SV The sludge volume is equivalent to the volume of 1 litre of the activated sludge after a settling down period of 30 minutes The volume of sludge is a measure of the quantity of biologically active sludge This value is an important pa rameter in the field of wastewater ana lysis since the performance capability of the activation plant is controlled by the sludge volume 14 For determining the volume of sludge SV the aeration of the activation tank must be active or it must be switched on in manual mode valve 2 As soon as the activation tank is well mixed a sample of the activated sludge can be removed with the help of a bu cket from the activation tank The sample withdrawn must be filled in a standing cylinder up to the 1 000 ml mark KLARO GmbH may be dispensed with l Figure 8 Determining the pH value using measurement or test strips For this purpose the aeration of the ac tivation tank must be active or switched on in manual operation mode Valve 2 The sample filled in the standing cylin der must now be kept upright without any vibrations and protected from direct sunli
26. ent plant is not completely free of smells If the ven 6 4 1 Smell of gas In the event of a detectable smell of gas and possible streaks in the wastewater it is likely that readily combustible gases and or liquids have entered the small wastewater treatment plant There is an acute risk of explosion and fire The following immediate measures must be taken 6 4 2 Smell of ammonia If a smell of ammonia is detected this may indicate an increased feed of ammonium compounds 6 4 3 Smell of rotten eggs If there is a smell of rotten eggs the feed contains an increased amount of sulphurous substances Deposits 34 KLARO Maintenance Manual ting of the small wastewater treat ment plant is intact no smells are detectable while the plant is in its closed condition Only if ventilation is e Electrical equipment in the area of the small wastewater treatment plant must be switched off The equipment must be switched off via the main switch or by remote control e The airlift pumps feed clear wa ter and excess sludge lift must be adjusted In addition to increased outlet valu es the oxygen consumption in the bioreactor is higher The feed must in the pipes leading to the small was tewater treatment plant cause the formation of hydrogen sulphide H S KLARO GmbH insufficient smells may escape from the small wastewater treatment plant e The feed situation must be che cked be inspected for possibl
27. f the aeration pattern In order to assess the functionality of the wastewater aeration the aeration and bubble pattern in the activation tank is observed while aeration is being done Pay attention to the following characteristics e Moderate gt Intensive circulation is clearly identifiable e Coarse bubbles gt Fine bubbles 4 3 3 Measuring the oxygen concentration The oxygen content in the activation tank or the random sample is an im portant control parameter for waste water treatment plants The oxygen concentration is obtained with the help of measuring instruments for which certain basic knowledge calibration maintenance and storage is required The user manual of the measuring instrument must be studied for this purpose The measured values are highly accurate when they are used properly Measurement in the sample container Hold the measuring probe of the oxygen measuring instrument in the sample container and take a new measurement The oxygen concentration should be at least 2 mg l In case of substantial deviations the aeration time of the controller must be adjusted gt see the section Setting optimal operational values We recommend e O lt 2 mg l gt Increase the aeration e O 2 to 6 mg l Figure 13 Oxygen measuring instrument with the associated probe gt Do not modify the aeration e O gt 6 mg l gt Reduce the aeration You need to consider also the following
28. ght for 30 minutes KLARO Maintenance Manual iy 1 En Figure 9 Removal of a sample of the activated sludge for testing the proportion of sludge by volume 4 ee Figure 10 Filling a sample of the acti vated sludge in the standing cylinder The volume of sludge is rounded off to 10 ml l If the volume of sludge is more than 250 ml l the measurement must be repeated after dilution For this purpose the activated sludge sample is diluted with wastewater The sample now diluted should have a sludge volume between 200 and 250 ml l The new measured value obtained must be multiplied with a dilution factor 3 i ar the be ginning of the 30 minute standing time Figure 11 Sludge quantity at It is sufficient to make only one mea surement to determine the sludge vo lume This measurement reasonably reflects the volume of the sludge in the activation tank of the SBR plant This is why we recommend to dilute the sludge sample and to repeat the measurement if the sludge volume is more than 250 ml l However after 30 minutes if the sludge volume in the standing cylinder is more KLARO GmbH Figure 12 Sludge volume after a stan ding time of 30 minutes than 400 ml l the period of sludge recirculation must be increased If the sludge volume is considerably below the 200 ml mark the recirculation period may be reduced or disabled completely 15 KLARO Maintenance Manual 4 3 2 Assessment o
29. h the associated probe Measurement of the oxygen concentration in the sample container Immersed probe of the oxygen measuring instrument during aeration Display unit of the oxygen measuring instrument Typical trend of the oxygen concentration in the KLARO SBR chamber in the course of the day Typical trend of the oxygen concentration in the KLARO SBR chamber with additional denitrification during the day Inserting the sludge pipette Sludge level measurement with a sludge pipette Sludge pipette in the storage pipe Determining the sludge level height with a yardstick Removing the aeration grate Checking the filter mat Reading out the data manually Reading out data via cable and PC Reading out data on SD card Opening the cover of NITTO compressors Checking the air filter Open housing for replacing the piston Pistons Checking the air filter Measuring the capacitance of the capacitor Checking the slider P module in the concrete cabinet List of tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Maintenance accessories Evaluation of nitrification denitrification test strips Adjustment of aeration times Elimination of increased SS values Elimination of increased COD or BOD values Elimination of increased ammonia nitrogen values Elimination of increased total nitrogen values Elimination of increased total phosphorus values Elimination of incre
30. haracterised by e A large compact floating sludge layer and e Brown greasy foam Moreover the foam cannot be remo ved by means of hosing In most cases the process is not im paired by foam formation The pro cess quality is only influenced if the foam flakes reach the sampling unit or directly enter the outlet The formation of floating sludge foam is mainly an operational and aesthe tic problem which leads to an increa sed effort when it comes to removal work Like sludge bulking the forma tion of floating sludge foam occurs in seasonal transition periods spring summer and autumn winter The formation of floating sludge and foam preferably occurs if an increa sed amount of longchain fatty acids is formed in the wastewater Long chain fatty acids are degrada tion products from fats and surfac tants detergents In addition they are created due to septic wastewater in the preliminary settlement chamber or with sludge deposits Foamforming bacteria es pecially form in so called stagnation zones due to insufficient mixing As soon as the effects of an insuffici ent oxygen supply creating a growth advantage for filamentous bacteria and septic water enabling the forma tion of fatty acids combine floating sludge and foam are formed A targeted elimination of floating sludge foam formation is only possi ble to a limited extent The measures e Hosing and e Discharge into the preliminary se
31. isk of sludge overflow When determining the sludge volume SV under such conditions there is no compact sludge structure at the bot tom of the measuring cylinder even after a settling time of 30 minutes The sludge floc is of light brown co lour and appears very voluminous Bulking sludge is caused by about 30 different filamentous bacteria which are most readily identified by means of a microscope The increased growth of filamentous bacteria is due to wastewater related plant related and operational causes e Wastewater related causes Nutrient deficiency nitrogen phosphorous Septic wastewater hydrogen sulphide Extreme pH values KLARO Maintenance Manual Plant related causes Long sludge storage times di gestion Poor mixing Operational reasons Insufficient aeration low oxygen supply Prior to taking measures against sludge bulking keep in mind that bulking sludge mainly occurs in tran sition periods autumn winter and spring summer In such transition periods the overall biocoenosis of the activated sludge is subject to more intense changes due to tempe rature fluctuations The filamentous bacteria are less sensitive to such changes and propagate more intensi vely during this time Meanwhile the activated sludge is bulking but still exhibits a good performance If the purification performance is not yet impaired by the overflowing sludge it is not necessarily required t
32. l the pH is set to a range of 6 5 8 0 For cost reasons the addition of lime is recommended A hydraulic overload may result in an increased input of solids from the primary settlement chamber into the bioreactor The bioreactor is then overloaded with increased pollutant levels Moreover an increased input of so lids into the bioreactor is also caused by a full primary settlement cham ber In such a case sludge disposal should be arranged for 2 Observation Increased COD or BOD value KLARO Maintenance Manual Cause Increased solids concentration in the bioreactor Sludge bulking Floc disintegration i E Hydraulic overload Incorrect or insufficient aeration Full primary settlement chamber High proportion of substances with poor degradability or that do not degrade at all Humic materials Table 5 Elimination of increased COD or BOD values 6 1 3 Increased NH N value In small wastewater treatment plants with additional nitrification the in organic nitrogen compound am monium NH of the raw waste water is oxidised into nitrate NO This transformation requires a large amount of oxygen In order to mea sure the nitrogen balance ammo nia nitrogen NH N is used If the ammonium content at the outlet is elevated possible causes generally include a reduced activated sludge performance and insufficient aerati on It must be kept in mind that the Increased NH N value nitrificati
33. ments The KLARO GmbH Figure 5 Filling the sample enclosure or appendix contains an overview of typical wastewater para meters and values which are meant to assist you with the interpretation of the measured values 4 2 2 Determining the substances that can be deposited SS The substances that may get depo sited SS sample indicate the proportion of the contained in the random solid content and include undissolved contaminants that may get deposited The quantity of substances that may get deposited is determined in an Imhoff funnel coneshaped glass The Imhoff funnel must be placed upright in a frame for this purpose The random sample is filled up to the 1 000 ml mark in the Imhoff funnel The quantity of substan ces that may get deposited must be determined by reading the volume of substance at the tip of the funnel after a standing time of 2 hours KLARO Maintenance Manual 120 Since solid substances get deposited on the slanted wall of the funnel it is turned to and fro with a jerk 15 minutes prior to the completion of the standing time The quantity of the substances that may get deposited should not be more than 0 3 ml l Since the determination of the subs tances that may get deposited takes 2 hours we suggest that this measure ment should not be carried out at site but in your own factory or laboratory Until then the sample must be kept under refrigeration 4 2 3 Assessing the odou
34. nance In general considerably lower running times may be achieved as a result Control to lower levels should be done in small steps and recorded in the logbook or the maintenance report so that you can track the modification at the time of the next maintenance Typical adjustments are e Adjustments of the PE number or cleaning treatment class The current values set are displayed in the setup report menu for example KLARO 8 EW C Any other table may be selected in the service menu and activated by pressing NOTES The new table selected is dis played in the setup report menu only when the old cycle has ended or has been inter 22 rupted by the restart the cyc le function e An overview of all controller tables is given in the enclosure or appen dix The controller has a capaci ty to hold maximum 25 tables or spreadsheets Tables or spread sheets may be copied with the help of KLARO kom Tool for spe cial applications Consult KLARO for this purpose e Adjustment of the aeration times in order to reduce or increase the entry of oxygen during the aera tion phase the clock cycle Ae ration ON T6 and Aeration OFF T7 may be changed in the service menu under the option duration period setup NOTES When modifying a clock cycle time always confirm with The modified cycle times are displayed in the setup report menu only when the old cycle
35. needs to be evaluated If there are no suspended solids in the random sample the sam ple has no turbidity If on the contrary there are plenty of suspended solids in the random sample it becomes highly turbid Intense turbidity or a large amount of suspended solids are a sign of sludge output Figure 7 Random sample in a measu ring Cup for assessing the odour coloration and turbidity 13 KLARO Maintenance Manual 4 2 4 Measuring the water temperature A scoop thermometer must be used for measuring the temperature This must be held for 1 2 minutes in the random 4 2 5 Determining the pH value The pH value is the easiest to measure with special test strips You only need to immerse the test or measurement strip in the random sample As soon as the test strip has been dipped in the sample it takes up a certain colour This colour now needs to be compared with the colour scale There are two types of measuring or test strips universal and special test strips The universal test strip can measure pH values in the range between 1 and 12 The special test strip measures the value in a smaller range e g pH 5 8 and has greater accuracy sample Since the temperature is also measured with the oxygen measuring instrument the scoop thermometer In addition measuring instruments are available which measure the pH value in multiples of 0 1 pH after calibration The pH value should lie in a weakly alkaline range betw
36. ng dosing line External impact loads with phospho Removal of clogging Replacement of the crystallised pre cipitant Avoiding the introduction of food Replacement of the dosing line Table 8 Elimination of increased Pot values rous compounds 6 1 6 Increased decreased pH value An increased or decreased pH value is mostly due to external factors As an example a pH of more than 8 5 is a detectable indicator for the introduction of alkaline substances cleaning agents for the removal of fats and oils The risk posed to bac teria and thus the risk of an insuffici ent purification performance of the small wastewater treatment plant increases with the amount duration and lye concentration of the intro duced substances Even though the wastewater in the small wastewater treatment plant has a certain buffe ring effect causing the alkalis to be essentially neutralised and preven ting damage to the biological com ponents a pH of more than 9 0 due to the alkalis introduced may inhibit or destroy the bacteria in the biore actor Moreover in combination with elevated wastewater temperatures a high pH result in the formation of am monia NH Ammonia has a strong inhibiting effect on nitrification If the alkalis are already present in the acti vation bioreactor it is only possible to take measures which limit the po tential consequences for the purifica tion performance The following measures are rec
37. ng unit the dipper or the sample container leading to distortion e a mix up could be possible be cause of missing inappropriate or incorrect identification of the sam ple container The most common causes for an ele vated SS value are e Full primary settlement chamber sludge storage e Increased solids concentration in the bioreactor SV gt 400 ml l e Sludge bulking KLARO GmbH NOTE When taking samples by means of a dipper it must be ensured that the dipper does not scratch the bottom during the scooping movement or the walls when inserting and removing the dipper If the results are implausible a se cond measurement must be perfor med If the increased outlet value measured is plausible and if there is no overloading of the small was tewater treatment plant the cause of the present malfunction must be determined When doing so keep in mind that it does not always have to be a single cause which is respon sible for elevated measured values Increased outlet values may also be due to the combined effect of several causes e Floc disintegration e Hydraulic overload Observation Increased SS value KLARO Maintenance Manual Cause Increased solids concentration in the bioreactor Sludge bulking Hydraulic overload Gradually increase excess sludge recirculation Increase oxygen supply work paint paste etc Check the inlet volumes Check built in and electrical com
38. o take intensive countermeasures For controlling excessive sludge bul king several measures are possible Cause Removal of deposits from the se wer system and the plant which result in the wastewater beco ming septic Increase of the oxygen supply by intensifying aeration intervals Increase of the excess sludge discharge Addition of calcium hydroxide iron or aluminium salts in order to weigh down the activated sludge External nutrient addition when detecting nutrient deficiency in the plant s feed Elimination 7 Removal of all deposits from the sewer system and the plant Adjust pH by means of lime soda or caustic soda Check feed for inhibiting substances disinfectants medicaments food residues residues from renovation work paint paste etc Septic wastewater Extreme pH values Increased sludge bulking Check the nitrogen and phosphorous concentration in the feed In case of a deficiency external ad dition of nutrients Check aeration intervals and readjust if necessary Arrange for draining of the primary settlement chamber Nutrient deficiency Incorrect or insufficient aeration Long sludge storage times Table 10 Control of bulking sludge 32 KLARO GmbH KLARO Maintenance Manual 6 3 Floating sludge and foam A dysfunction similar to sludge bul king is the formation of floating sludge and foam inside the bioreactor The formation of floating sludge and foam is c
39. om mended against an increased pH e Intensified aeration maximum possible oxygen supply e Addition of iron and aluminium salts PAC in order to neutralise the alkalis and e Monitoring further pH develop ment If the pH falls below 6 5 this may be due to the introduction of acidic sub residues stances The risk posed to the puri fication performance rises with an increasing amount and acidity of the substance When introducing acidic substances into the bioreactor the inhibition or destruction floc disinte gration of the biological components cannot be ruled out In addition there is an increased risk of corrosion for built in components The following measures are recom mended for controlling a decreased pH e Addition of alkaline neutralisers calcium hydroxide soda caustic soda Observation Cause Elimination Increased pH 7 Introduction of alkaline substances Intensified aeration Addition of iron and aluminium salts PAC Addition of alkaline neutralisers cal Decreased pH un Introduction of acidic substances E Table 9 Elimination of increased decreased pH values KLARO GmbH cium hydroxide soda caustic soda 31 6 2 Bulking sludge If bulking sludge activated sludge with very poor settling properties is present the activated sludge stands in the bioreactor without settling properly during the sedimen tation phase This results in a very high r
40. on performance depends on the temperature in the bioreactor If the water temperature inside the bio reactor falls below 10 C the nitrifica tion performance is inhibited When eliminating faults with the nit rification the oxygen content should be checked first If the oxygen con tent at the outlet is less than 2 mg l this represents an insufficient oxy gen concentration Defective devices such as disc aerators hoses and compressors are possible causes for an insufficient oxygen concentration Cause Insufficient oxygenation Water temperature below 10 C nn Aerobic sludge age too low pH value is too low lt 6 5 gt 9 or too high Table 6 Elimination of increased ammonia nitrogen values 28 KLARO GmbH Gradually increase excess sludge recirculation Increase oxygen supply Adjust pH by means of lime soda or caustic soda Check feed for inhibiting substances disinfectants medicaments food residues residues from renovation work paint paste etc Check the inlet volumes Check built in and electrical com ponents switch cabinet Check aeration intervals and readjust if necessary Arrange for the desludging of the primary settlement chamber Informing the operator about prob lematic substances NOTE Increased NH N values at the out let at water temperatures of below 10 C do therefore not represent a malfunction The same applies to previous temperature fluctuations even
41. ossible causes for increased P values at the outlet are e Underdosage of precipitant e Empty precipitant canister e Defective dosing pump e Disruption of the supply flow e Dysfunction regarding the uptake of chemicals into the hose e Leaking dosing line e External impact loads In case of a malfunction regarding phos phate precipitation the overall dosing mechanism dosing pump precipitant canister hoses must be checked first For this purpose the dosing of the precipitant is to be activated manually and the dosing point is to be checked The dosing point for the precipitant is exposed inside the small wastewater Increased ae value 30 KLARO Maintenance Manual treatment plant and is therefore visible from the outside An underdosage of precipitant can be rectified through an increase in the case of pumps with potentiometers or an extension of the pumping duration If the precipitant canister contains a sufficient amount of precipitant and the dosing pump runs properly possible causes for an insufficient phosphate precipitation include the disruption of the liquid flow or a dysfunction re garding the uptake of chemicals into the hose The supply flow may be disrupted if air instead of precipitant is sucked into the hose This is caused by the hose having been incorrectly inserted into the precipitant canister Figure 35 P module in the concrete cabinet Cause Underdosage of precipitant
42. parts that you should keep in order to be able to carry out maintenance professionally Maintenance accessories m Characteristics Figure h Bkm i mt ar F o Determining the sludge level in the pre clarification sludge storage DN40 2m 1m Sludge pipette Withdrawal of bailed samples from the plant outlet from the integrated sampling facility and Buckets telescopic extraction sludge samples SV from the stick SBR tank Plastic cup 500 ml Telescopic rod 1 0 3 0 m KLARO GmbH 5 KLARO Maintenance Manual Determining the proportion by volume of the sludge SV 1 000 ml 65 mm Measuring cylinder Plastic or glass cylinder gradu ated and completely transparent Determining the substances that can be deposited SS o Imhoff funnel holding frame Ce den 1 000 ml Determination of odour colorati y on and turbidity easuring cup Glass cup with divisions and spout 1 000 ml Sealable wide neck bottles made of HDPE For laboratory analyses 1 000 ml for BOD and SS 500 ml for COD N P transfer red with 2 ml H SO Sampling bottles refrigeration box Reagent cuvettes with chemi cals for photometric COD mea surement COD cuvettes COD photometer Analysis of the COD value Eye protection when handling Safety glasses l dangerous chemicals Measurement of dissolved oxy gen mg l in the activation tank and sampling combined with temperature measurement
43. ponents switch cabinet i Floc disintegration D Adjust pH by means of lime soda or caustic soda Check feed for inhibiting substances disinfectants medicaments food residues residues from renovation Arrange for desludging of the pri Full primary settlement chamber rrange for desludging of the primary settlement chamber Table 4 Elimination of increased SS values 6 1 2 Increased COD or BOD value In new small wastewater treatment plants it generally takes some time for the activated sludge required for biological purification to form Up until this moment the purification performance will not yet reach its full potential Moreover an increased COD or BOD value at the outlet is due to both par ticulate and dissolved substances For example depending on the orga nic content 1 mg l solids has a COD value of 0 8 1 6 mg l As with the increased SS value this may have several reasons The most common causes include for examp le e Increased solids concentration e Sludge bulking e Floc disintegration e Hydraulic overload e Incorrect or insufficient aeration An increased solids concentration in the bioreactor may reduce the sedi mentation effect Clear water can no longer sufficiently separate from the sludge floc which results in sludge overflow An efficient means to coun teract solids overflow is an increased excess sludge recirculation Howe ver the excess sludge recirculation shoul
44. poor nitrification ca 0 mg l lt 50 mg l excellent denitrification ca 0 mg l lt 100 mg l good denitrification ca 0 mg l gt 100 mg l ssl denitrifica Nitrification ca 50 mg l NH content Denitrification NO content Table 2 Evaluation of nitrification denitrification test strips Note The result of the test strips is specified as NH and or NO The threshold values are usually speci fied as NH N and or NO N 4 4 Sludge level measurement The sludge level height in the pre clarification sludge storage has a direct impact on the cleaning or treatment performance of a wastewater treatment plant or septic tank This is why it is indispensable to check the sludge level height The level is measured with the help of a sludge dip stick acrylic glass tube 18 For this purpose you need to shift the layer of floating sludge to the side and dip the transparent sludge dip stick with the open valve in the pre clarification sludge storage right up to the base of the tank The valve is closed by pulling a control cable provided with a ball valve or with a forceful jerk in case of a non return valve and the dip stick may now be pulled out again sludge pipette KLARO GmbH Figure 19 Inserting the Figure 20 Sludge level measurement with a sludge pipette KLARO Maintenance Manual es eee ss mone bu e Figure 21 Sludge pipette in the storage pipe The contents of
45. r coloration and turbidity Traditional property parameters of a wastewater sample are the odour co loration and turbidity The assessment of these semi qualitative parameters reflects an excellent method of recor ding the condition of the treatment or cleaning performance of a wastewater treatment plant without using measu ring instruments It is best to evaluate the parameters immediately after withdrawing the ran dom sample Odour For the odour test the measuring cup must be shaken with the sample filled The type of the odour is differentiated subsequently none weak strong or intense The sample should have a neutral or earthy smell If it smells of moulds or has a foul or sanious smell the cleaning power of the wastewater treatment plant is faulty e g on account of inadequate aeration Coloration To assess the coloration the colour strength and the shade of the colour are viewed against a white background and evaluated The random sample should be clear to yellowish A brown or grey coloration indicates inadequate KLARO GmbH Figure 6 Determining the substan ces that may get deposited in the Imhoff funnel cleaning or treatment Turbidity Turbidity means the weakening of ra diation passing through the sample Turbidity is caused by suspended so lids To assess the turbidity the random sample must be held in a measuring cup against sunlight and the weake ning of the light radiation
46. s as well as the utilisation only for KLplus and ZKplus must be read out and recorded 20 Figure 24 Checking the filter mat e Display errors or faults for KLbasic and ZK This is where the latest message is displayed with the date and time By or button you can go to the previous messages pressing the To do this call up the following in the operator menu of the controller KLARO GmbH NOTE There is a capacity to store 128 messages If this number has been reached every new message deletes the oldest one The memory may be deleted by the maintenance techni cian in the service menu using the Clear logbook command e operating hours meter reading for KLplus and ZKplus e Operating hours report for KLbasic and ZK The power on hours of the compressor provide an indication of whether it is due for maintenance The work load xx only in KLplus and ZKplus provides the ratio of how 5 2 3 Reading out data Reading out data via cable and PC The logbook of the controller may be read out on external storage media There are the following options available at site for this purpose Reading out with cable PC all KLARO controllers To read out the logbook via cable you need the following at site KLARO Maintenance Manual many treatment cycles have actually been executed A standard plant com pletes four cycles per day 100 The display primarily serves the p
47. sludge storage 19 5 Maintenance of the machines 5 1 Air filter The filter for aerating the switch ca binet aeration grate on the left and right side of the housing wall in the indoor cabinet or on the back side in the outdoor cabinet must be checked and cleaned or replaced if necessary To do this the grate outside the cabi net must be removed The clamp lock must be loosened by pressing lightly KLARO Maintenance Manual with a screwdriver and the grate must be pulled by hand The filter mat lies in the ventilation shaft without any other fixture and may be shaken or blown off NOTE Clogged or choked filter mats impair the aeration and bleeding efficiency of the switch cabinet Permanent consequences may include e Overheating in the cabinet gt Temperature alarm of the control ler gets triggered e Increased wear and tear of the electrical components particular ly the compressor and solenoid valves e Reduced oxygen inlet by the com pressor into the wastewater treat ment plant Figure 23 Removing the aeration grate 5 2 Controller 5 2 1 Reading fault messages You need to check the faults that have occurred since the time of the previous maintenance in the logbook of the con troller To do this call up the following in the operator menu of the controller e read out old errors for KLplus and ZKplus 5 2 2 Power on hours The total power on hours of the loads valves compressor
48. the chamber are re produced in the sludge pipette as a closed column The sludge layer of the pre clarification sludge storage can thus be read directly To do this the sludge layer the solid constituents must be clearly identifiable from the solid free zone The sludge height is recorded in the report It is required to arrange for proper disposal of the sludge from the pre clarification sludge storage for proper operation It is necessary to dispose of the sludge storage latest 4 5 Cleaning work Finally general cleaning work should be done within the plant e Removing deposits when 70 of the sludge storage is filled The attention of the operator must be drawn to the need for disposal The sludge removed with the help of the sludge pipette must be emptied out again in the pre clarification sludge storage By immersing the pipette again in the aerated chamber it becomes clean inside The sludge pipette at best must be stored in a PVC pipe after use for the sake of hygiene The storage pipe is sealed at the bottom side with a stop per in order to trap any residual liquid e Clearing any clogging or jamming e Replacing damaged installed components or kinked hose pipes KLARO GmbH a A See Lo ees Le di y AN EN i be ath 4 B H a e E Figure 22 Determining the re eve height with a yardstick e Skim off the floating sludge on the activation chamber and put in the pre clarification
49. ttlement chamber can only be successful for a short time In contrast it is efficient to re move the floating sludge layer from the small wastewater treatment plant Observation Cause ration of the preliminary settlement Septic wastewater chamber sludge storage Floating sludge and form formation in the bioreactor Impact loads with surfactants and fats In addition the excess sludge discharge should be increased tem porarily in order to reduce the sludge age inside the bioreactor lower so lids content in the bioreactor Since the nitrification performance of the bioreactor is reduced this measure should only be used for plants requi ring nitrification if this is absolutely necessary NOTE Foam is also formed in the biore actor during the break in period However this is due to the growth of biomass The foam is light beige in colour degrades very quickly and does not represent a malfunc tion Change of the inlet water e Less washing machine cycles per day e Changeover to bio degradable detergents and cleaning agents e Reduced use of fat and oil in the kitchen _ Check aeration intervals and readjust Incorrect or insufficient aeration if necessary fo High sludge age Increase excess sludge discharge Table 11 Elimination of floating sludge and foam KLARO GmbH 33 6 4 Smells As with municipal wastewater treat ment plants the operation of a small wastewater treatm
50. type of compressor 5 3 1 NITTO piston compressor Detailed instructions on the operation and maintenance as well as drawings are given in the Operating Manual We recommend the following for main tenance e Checking the air filter with EVERY maintenance e Replacing the piston set after 25 000 hours of operation NOTES If the compressor is operated beyond the 25 000 hours of operation the air compressi on capacity may get impaired This must be compensated by increasing the aeration peri od If tinkling or tapping noises can be heard the piston set must be replaced immediate KLARO GmbH ly otherwise the equipment may get damaged irreparably There is a video clip available that demonstrates the mainte nance of the compressor in an illustrative manner You may send us a request for a copy free of charge 23 KLARO Maintenance Manual Figure 28 Opening the cover of NITTO compressors Figure 29 Checking the air filter Figure 30 Open housing for replacing Figure 31 Pistons the piston 5 3 2 BECKER or RIETSCHLE rotary slide compressor Detailed instructions on the operation e Checking the air filter with EVERY and maintenance as well as drawings maintenance but at least semi are given in the Operating Manual annually We recommend the following for main Omitted for the smaller design tenance BECKER DT 4 4 4 8 Blow off or replace contamina ted air filters
51. urpose of plausibility check to see whether the e PC Laptop e Serial read cable RS 232 e Possibly USB serial adapter e Reading software KLARO kom To read out the data the RS 232 connector of the cable connected to the socket on the back side of the Reading out with an SD card only KLplus In order to read the data the rubber stopper at the front of the controller is removed and an SD memory card is inserted into the free slot In order to start the data transmission you need to switch to the service menu to the SD Card option and confirm with Set As soon as the data has been Figure 25 Reading out the data ma nually transmitted completely the display SD Card OK appears Now by pressing once again you can exit from the service menu and remove the SD memory card Finally seal off the card slot in the controller carefully in order to prevent the ingress of moisture The data read out in the PC is trans Figure 26 Reading out data via cable and PC KLARO GmbH function level measuring has been set meaningfully controller With the help of the KLA RO kom software data is transmitted and transferred to preformatted Excel spreadsheets These spreadsheets may be edited saved and printed out e g as an enclosure to a maintenance report ferred with the help of the KLARO kom software from a PC to prefor matted Excel spreadsheets These spreadsheets
52. we have with the KLARO SBR technology 2 Safety instructions While doing maintenance work on wastewater treatment plants special precautionary measures need to be adopted since there may be viruses pathogenic germs and worm eggs in the wastewater and on all surfaces that come into contact with wastewater Inadequate or improper hygiene mea sures may lead to diseases prevention of direct contact with wastewater and KLARO GmbH Before we begin what we particularly recommend to you is the following document and record every maintenance with the help of the KLARO maintenance report en closure carry out the work steps in the sequence in which they are listed in this manual and in the mainte nance report to note down the serial number of the switch cabinet for any queries is embossed on the nameplate in or fixed on the cabinet surfaces coming into contact with it The precautionary measures include Wearing protective gear or safety clothing Wearing hygienic hand gloves Wash and sterilise hands af e Consulting a doctor if wastewater with harmful gases within the ter they come into contact with has been swallowed plant wastewater e Entry into the plant by any person e Do not drink or eat while working e Vaccination for tetanus and hepa must be safeguarded by another titis B person since you need to reckon 3 Maintenance accessories We have compiled a list of equipment tools and spare
53. y from the tank is often very difficult This is why we recommend that the oxygen concentration be determined in the sample container 17 KLARO Maintenance Manual 4 3 4 Simplified assessment of nitrification and denitrification In order to quickly and easily assess the effectiveness of the nitrification denitrification semi qualitative test strips can be used as an aid Here a test strip for ammonium or nitra te nitrite is always dipped into the taken sample Afterwards the con centration contained in the sample can be compared on the basis of a colour scale The more the test strip changes its colour the higher is the concentration In order to define the effectiveness of the nitrification NH N degradation a sample is taken from the pre clarification chamber sludge storage first chamber and an effluent sample from the outlet is taken from the sample container The concentration of the sample from the pre clarification chamber sludge storage should be approx 50 mg l and the concentration of the effluent sample from the outlet lt 10 mg l If the concentration of the sample from the pre clarification chamber sludge storage is much higher than 50 mg l the inlet conditions must be exami ned Pre clarification Effluent sample from Result esu sludge storage the outlet good nitrification O lt 10 mg l o content sufficiently ca 50 mg l gt 10 mg l poor nitrification gt 50 mg l gt 10 mg l
54. ycle pause status e Adjusting the sludge recirculati on time The period of the sludge recirculation may be reduced or increased via T12 In the ZK and ZKplus this is done in steps of mi nutes In the KLbasic and KLplus this may be set to the nearest second The sludge recirculati on time should be changed by a maximum of one minute or 60 se conds e Adjusting the underloading fea ture only in ZKplus and KLplus The underloading feature serves EXAMPLE KLARO Maintenance Manual primarily to conserve energy The fill level which leads to the com mencement of a cleaning or treat ment cycle may be adjusted in the service menu under Adjust fill level measurement The work load in the operating hours me ter reading menu provides an in dication of the actual ratio of the cleaning cycles to the pause cyc les Adjustment options Reduce water level start at xxx cm if the loading level displayed is low fill levels in the tanks how ever are high and the discharge quality is unsatisfactory Increase water level start at xxx cm if the loading displayed is high the fill levels in the tanks however is low the dischar ge quality is good but the plant operator is dissatisfied with the energy conservation Clock cycle Function ACTUAL value Reduce increase _ Table 3 Adjustment of ventilation times 5 3 Compressor The maintenance work and intervals depend on the

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