Periodic maintenance of wastewater treatment system optimizes costs

Maintaining the wastewater treatment system is a way to optimize the operating costs of the system. This process will help the system operate effectively, save time and improve performance. So what should be noted when maintaining the wastewater treatment system? In this article, we will provide you with the necessary information.

What is wastewater treatment system maintenance?

Wastewater treatment system maintenance is the process of maintaining and adjusting the system components to ensure its efficient and stable operation. Maintenance is carried out to keep the system running smoothly, minimize failures, extend the life of the equipment and ensure that the treated water meets environmental standards.

System components such as pipes, tanks, filters and other parts can become clogged with debris and impurities. Therefore, periodic cleaning and maintenance is necessary to remove debris and restore system performance. System components can undergo wear and tear over time. Replacement of damaged components is necessary.

Reasons to maintain wastewater treatment system

Maintaining the wastewater treatment system is very important, helping to ensure the system operates more stably. Below are the reasons for maintaining the wastewater treatment system that you should know:

• Ensure system stability by inspecting, cleaning, and replacing worn parts so that all components operate properly and do not cause problems.
• Increase equipment life, reduce replacement costs.
• Ensure system processing performance.
• Regular maintenance can help prevent unnecessary breakdowns and wear, thereby minimizing the cost of repairing and replacing system components.

Problems when using wastewater treatment system for a long time

When a wastewater treatment system is used for a long time without regular maintenance, a number of problems may occur that affect the performance and operation of the system. Below are two common problems that may occur:

Microbial sludge incident

Biological sludge is a common problem in wastewater treatment systems. If not properly managed and treated, biological sludge can accumulate and form thick layers of sludge in tanks and piping systems. This can cause problems such as pipe blockage, reduced filter performance, and unpleasant odors. Measures such as regular sludge washing, the use of sludge-degrading bacteria, and optimization of sludge treatment processes can help minimize this problem.

Mechanical failure

Over time, the machinery and equipment in a wastewater treatment system may experience wear and tear. This can cause the system to stop working and affect the efficiency of wastewater treatment. Causes of failure may include wear, corrosion, or damage due to improper use. To minimize this problem, it is important to perform regular maintenance, inspection, and maintenance of machinery and equipment.

Wastewater treatment system maintenance process 

Pipeline system

The piping system is a very important part of the wastewater treatment system, supporting the transportation of wastewater to the treatment site. To ensure the efficient operation of the piping system is part of the wastewater treatment system maintenance process that needs attention.

Pump system

Besides the piping system, the pumping system also needs to be ensured to operate properly.

Submersible pump system

For submersible pump systems in wastewater treatment system maintenance, it is necessary to ensure that the phase wire of the pump motor operates stably. Periodic checks should be made and the remaining oil in the pump system. In case of detecting strange noises, the pump bearings should be checked. Pump voltage measurement should be performed daily, the current must be guaranteed. After the pump has been operating for 6000 hours or 12 months, an inspection should be carried out. After 2-5 years of use, the pump should be overhauled.

Centrifugal pump system

• Impeller: Periodically check the impeller, gasket, locking screw, and locking ecu.
• Mechanical gasket: Clean and check the mechanical gasket, sealing ring, ensure the surface is smooth, no scratches or dirt.
• Pump shaft and shaft bushing: Check the surface of the pump shaft and shaft bushing at the gasket installation location, ensure it is clean and smooth.
• Bearing: Check noise, vibration, and temperature to detect abnormalities.
• Lubricating oil: Check the oil level and condition through the oil sight of the pump shaft bearing.
• Closed circuit: Check the pump and piping. Every 3-6 months, check and tighten the pump base and bolts. For split shaft pumps, change the oil or grease after 3 months or 2,000 hours of operation. In harsh environments, shorten the grease change period.
• Split shaft centrifugal pumps: Check the flexible shaft coupling, align or replace worn parts such as pulleys and finger bolts.

Dosing pump 

• Regular maintenance: Clean the pump, check valve, and diaphragm to avoid clogging.
• External inspection: Check the bracket, vibration, noise, and tighten the bolts and screws.
• Periodic maintenance: Monthly or quarterly, check the coil resistance, insulation resistance, and load current.
• Oil change: First time after 1,000 hours of operation. Subsequent times after 5,000 hours (standard pump) or 2,000 hours (ATEX pump). Shell Omala 320 or Mobil Gear 632 oil is recommended.
• Pump diaphragm replacement: After 8,000 hours of intermittent operation. After 12,000 hours of continuous operation.
• Pump bearing replacement: After 10,000 hours of maximum operation. After 20,000 hours of normal operation.

Screw machine

Periodic maintenance of the wastewater treatment system for screw pumps after 5,000 hours of operation or at least after 2 years, requires disassembling and cleaning the entire pump, replacing bearings, cleaning all detailed parts, and replacing lubricating oil. The amount of oil to be replaced depends on the size and capacity of each type of pump.

For example, with the NM038BYO1L06B – NETZSCH pump, the coupling oil needs to be changed at 15 cm³ per joint (each machine has 2 couplings) with KLUBER UH1 6-460 oil, every 2 years. The gearbox oil needs to be changed at 2.6 liters per time with ISO VGO 220 oil, every 10,000 hours.

Submersible stirrer

• Coil resistance and insulation resistance: The phase coil resistance must be equal or have a negligible difference. The insulation resistance between phases and between phase and ground must be greater than 0.5 MΩ, the higher the better.
• Stirring chamber oil: If the amount of oil drained is less than the initial amount, this shows that the seal is still working well, just need to add engine cooling oil. If the drained oil has stains, water may have entered the oil chamber, need to check the seals, especially the mechanical seals, and replace with new oil.

• Agitator motor bearings: If there is a loud noise or abnormal vibration, check the bearing condition and take corrective measures.
• Waterproof cable and cable head: Visually check whether the cable and cable head are burst or water-soaked due to long-term immersion in water. If damage is found, it should be treated or replaced to avoid the risk of fire and damage to the machine due to water seeping into the cable.

Air blower

Check working pressure, vibration, noise, inlet air temperature (<40°C), load current, belt tension and lubricating oil level. In addition, check coil resistance, insulation resistance, load current. Clean the muffler, add blower oil if necessary, check and lubricate bearings

Sludge dewatering machine

For sludge presses, periodic monthly and weekly checks should be carried out as follows:

• Daily and weekly: Check the machine’s working pressure. Observe the machine’s vibration and noise. Make sure the inlet air temperature does not exceed 40°C. Check the load current to ensure it does not exceed the rating. Check the belt tension and the lubricating oil level at the air blower oil eye.
• Monthly: Check the coil resistance, insulation resistance, and load current to ensure they meet the rated values. Clean the suction muffler. Check and add oil to the air blower if needed. Grease the motor bearings and the air blower head bearings. Check and adjust the belt if necessary..

• Annually: Check and replace the belts. Note to replace all belts synchronously, do not replace damaged belts individually.
• 3 to 4 years: Replace the motor bearings and air blower bearings. Replace the gaskets and seals when disassembling the machine. Check and replace the air blower gear when disassembling. Replace the air inlet filter.

Air compressor machine

To maintain the air compressor, first check the power supply and installation location to ensure compliance with the manufacturer’s regulations. Next, check the condition and tension of the belt. The machine needs to be cleaned regularly, including draining the air tank and cleaning the air filter. The machine oil must be changed periodically, using an additive-free lubricant and absolutely do not use hydraulic oil to avoid serious damage to the machine.

Garbage separator

When maintaining the trash separator, pay attention to three main issues: First, check the motor and gearbox to detect any abnormal vibration or noise. Next, evaluate the lubrication and operation of the transmission parts, bearings, adjusting screws, and drive chain.

Finally, make sure to clean the screen, scraper blade, and the entire machine, removing any foreign objects and debris.

Centrifugal exhaust fan

• Drive motor: Check for vibration, noise, bearings, and insulation.
• Lubrication: Ensure grease lubricates the drive belt and drive bearings.
• Routine cleaning: Clean the fan and check for vibration and noise.
• Routine inspection and maintenance: Apply oil and grease before operation, ensure oil level reaches ½ of the sight glass for shaftless fans. Ensure grease fills 2/3 of the bearing space, not too much or too little, for integral and shaftless centrifugal pump bearings and shafts. Check daily or weekly and add oil if leaks are detected.
• Oil Change Period: After the first 150 hours of operation, inspect, adjust, and change the lubricating oil. After every 1000 hours of operation, continue to inspect, adjust, and change the oil. Use ISO VG32, Mobil DTE Oil Light VG32, or Total Azolla ZS32.
• Fan Components Inspection: Regularly inspect the joints, especially the fan blades, and clean the inside and outside of the fan to maintain fan performance and life.

Motor deceleration

Gear reducers are connected to motors, increasing load capacity, extending service life and adjusting motor speed as required. Gear reducers operate electrically and are commonly used in production lines, factories, workshops, warehouses and daily life. They reduce angular velocity, increase torque and connect electric motors to the working parts of the machine. For this motor, it is necessary to ensure the transmission ratio to avoid overloading and burning the motor.

Generator

To increase the life and ensure the generator operates smoothly, technicians need to pay attention to the following tasks:

• Starting battery: Check regularly.
• Air filter: Clean regularly, increase frequency in dusty environments.
• Lubricating oil: Change oil filter regularly, or at a ratio of 2 oil changes, 1 oil filter change.
• Coolant: Maintain a ratio of 30%-50% between LCC solution and water. Add LCC of the same brand and concentration.
• Bleed and water: Push air out of the fuel supply pipe when restarting the engine.

Electrical control panel system, electrical cabinet

Checking control panels and electrical cabinets is an important part of wastewater treatment plant system maintenance. Technicians need to perform the following tasks:

• Measure current and voltage.
• Check noise level (not exceeding 80 dB).
• Adjust voltage not exceeding 10% of specified level.
• Clean for easy heat dissipation.

Important notes when maintaining wastewater treatment systems 

Wastewater treatment system maintenance is an important part of ensuring system performance and reliability. Here are some important considerations:

• Establish and adhere to a maintenance schedule so that all necessary maintenance steps are performed properly and on time.
• Perform periodic inspections of all system components such as pumps, valves, piping and control devices to detect problems and prevent them in time.
• Replace and periodically service worn and damaged components such as piping, pumps and valves to maintain optimal performance.

See more:

• Top 5 most modern and optimal wastewater treatment technologies today
• The most advanced and cost-effective industrial wastewater treatment scheme

Reputable wastewater system maintenance unit

With over 10 years of operation in the field, Song Phung Wastewater Treatment Company has accumulated valuable knowledge and experience, thereby ensuring the provision of the most effective and optimal solutions for customers. With a team of experienced and highly qualified technicians, utilizing advanced technology and modern methods, Song Phung is committed to bringing maximum satisfaction to customers.

Song Phung provides a wide range of wastewater treatment system maintenance services, including routine inspections, cleaning and sanitization, replacement and maintenance, water quality testing, and system upgrades. We ensure that all services are performed in a professional and timely manner.

Song Phung is proud to be a reliable partner in wastewater treatment system maintenance. With professionalism, experience and commitment to quality, we are always willing to support customers in maintaining and servicing their systems, contributing to environmental protection and public health.