MAINTENACE OF WATER TREATMENT

PLANTS

Gamini Ranaweera
OPERATION & MAINTENACE(O&M)

 O&M of a water supply/ET system involves all the activities needed to run the system
continuously to provide the necessary service.

 Maintenance is planned technical activities carried out to ensure that all the
equipment are functioning effectively.

 To do that plant personnel requires

SKILLS
SPARES
TOOLS
 PROGRAMME
Importance of maintenance
Types of mechanical equipment in a water
treatment plant
Introduction to basic electrical circuit when
starting a machine
Types of maintenance procedures.
Operators role in maintenance
The life time of a treatment plant is determined by factors such as:
Material of construction
Contract specification
Facility location
Level of maintenance carried out

Without proper maintenance usable life of any piece of equipment

is much shorter than its design life cycle.

Breakdown mtce – Repairing equipment that has broken down

,abandoning it or replacing it with new equipment is not a good
mtce practice.
 TYPES OF MECHANICAL EQUIPMENT IN A
TREATMENT PLANT

 PUMPS 1) Centrifugal
2) Submersible
3) Diaphragm
4) Dosing

 BLOWERS

 FEEDERS

 AGITATORS
INTRODUCTION TO PUMPS & PUMP PARTS
CENTRIFUGAL PUMPS
IDENTIFICATION OF PARTS OF A CENTRIFUGAL PUMP
TYPES OF CENTRIFUGAL PUMPS
SPECIFIC MTCE POINTS ABOUT CENTRIFUGAL PUMPS
SUBMERSIBLE PUMPS
IDENTIFICATION OF PARTS OF A SUBMERSIBLE PUMP
DIAPHRAGM PUMPS
IDENTIFICATION OF PARTS OF A DIAPHRAGM PUMP
GEAR PUMPS
PLUNGER PUMPS
DOSING PUMPS
Dosing pump is a small positive displacement pump designed to pump precise flow rate
of chemical into water.
TYPES OF DOSING PUMPS
1) SOLENOID PUMP

 Uses a strong electromagnet to actuate a diaphragm within the flow

chamber of the pipe head.
2) MOTOR PUMPS
 Uses an electric motor to drive a crank mechanism which converts the rotary motion
of the motor to linear motion.
 Far more powerful than the solenoid pumps.
3) PERISTALTIC PUMP

 Pumping is based on the alternating compression and relaxation of the hose

tube drawing the liquid and propelling it away from the pump
BLOWERS
IDENTIFICATION OF PARTS OF A ROOTS BLOWER

LOBE

HOUSING

LOBE
BASICS OF LUBRICATION FOR
CENTRIFUGAL PUMPS/BLOWERS
CHEMICAL FEEDERS IN WATER/EFFLUENT
TREATMENT PLANTS
 Mechanical device for measuring a quantity of chemical and applying it to water at a
preset rate.

CHEMICAL FEEDERS

LIQUID FEEDERS DRY FEEDERS

(Apply chemicals in suspensions) ( Apply chemicals in dry or powdered form)

VOLUMETRIC GRAVIMETRIC
FEEDERS FEEDERS
(Chemical is measured by volume) (Chemical is measured by weight)
TYPES OF AGITATORS USED IN WATER
TREATMENT PLANTS
Mechanical Features of an Agitator
TYPES OF AGITATORS
1)Propeller Agitator
Called marine type propellers
2)Turbine impeller
3)Anchor Agitator
THREE PHASE MOTOR CONTROL CIRCUITS
PIPING AND VALVES
VALVE: Any device by which the flow of fluid may be started /stopped /regulated by a
movable part that opens or obstructs the passage.

TYPES OF VALVES
 Butterfly Valves
 Gate Valves
 Globe valves
 Diaphragm valve
 Ball valve
 Needle valve
 Check valve

BUTTERFLY VALVE
 Compact
 Can be used to control flow in either direction
IDENTIFICATION OF PARTS OF A BUTTERFLY VALVE
GATE VALVE
 Either stops or allows flow thro’ the valve
GLOBE VALVE
 Used for flow controlling
DIAPHRAGM VALVE
 Uses “pinching “method” to stop the flow thro’ the valve using a flexible diaphgram.
BALL VALVE
 A simple quarter turn completely opens or closes the valve.
 Offers very good shut off capabilities.
NEEDLE VALVE
 Used to make relatively fine adjustments in the fluid flow.
CHECK VALVE
 Designed to prevent the reversal of flow in a piping system.
 Activated by the flowing material in the piping system.

PISTON TYPE CHECK VALVE

PIPE SIZE
1) Seamless Steel Pipes
 Pipe size is designated by
 Outside Diameter
 Wall Thickness
 Length

 Nominal Pipe Size(NPS) & SCHEDULE(SCH)

2) uPVC Pipes
MAINTENANCE PROCEDURES AND PLANT
OPERATORS ROLE IN MAINTENACE
 LIFE CYCLE OF AN EQUIPMENT
යන්ත්රයක ජීවන ක්රියාවලිය
හා වියදම
NEED
DISPOSAL
අවශයතාව
බැහැර කිරීම
SPECIFICATION

DESIGN

INVSETMENT APPRAISAL
ආයයාaජනය ඇගයිම
PURCHASE(CAPITAL COST
REPLACEMENT
මුලික වියදම
ආයේශ කිරීම
INSTALLATION
සවිකිරීම

COMMISSIONNING

USE
භාවිතය
• TO MAXIMISE THE PROFITS: ලභය උපරිම කිරීම
සදහා:
Time from need to first use and the total
investment should be as small as possible
අවශයතාවයේ සිට යන්ත්රය භාවියට ගන්තනා
දිනය දක්වා කාලය සහ ආයයාaජනයද අවම
විය යුතුය.
and
The operating life and the total return should be as
large as possible.
 5000
Aircraft initial Rs 4640 m
4500
C0st Rs 4000 m
4000
3500
3000
Cumulative
Cost (Rs m) 2500
2000
1500
1000
500
0
2 4 6 8 10 12 14
Years in Series

යන්ත්රයක ජීවිත කාලය තුල ලබාගත හැකි ලාභය එහි

නඩ්තුව මත රදා පවති.
 THE REASON AND NATURE OF MAINTENANCE WORK
යන්ත්ර නඩ්තු කිරීමට අවශ්ය ඇයි?
• Many of the components have been designed with a
useful life greater than the longest production cycle
but less than that of the plant itself.
• යන්ත්රයක් සැදී තියබන යකාටස්වල ආයු කාලය
යන්ත්රයේ ආයු කාලයට වඩා අඩුය
• Maintenance is inevitable and generate from failure at
component level.
• එබැවින්ත නඩ්තුව යනු යනාවලැක්විය හැකි
කටයු්තකි.
• EXPECTED MAINTENANCE LOAD(බලායපායරා්තු
විය හැකි නඩ්තු කාර්ය භාරය): Weak
components have been identified at the design stage
and made easily replaceable. සැලසුම් කල හැක
Easy to deal with since the need for maintenance can
be forecast and planned for.
•UNEXPECTED MAINTENACE
LOAD(බලායපායරා්තු විය යනාහැකි
නඩ්තු කාර්ය භාරය): Failures due to poor design,
poor operation and poor maintenance
Difficult to forecast සැලසුම් කිරීමට අපහසුය
 At any point of time the Plant is in
one of the following stages
a) In production and only running maintenance can be carried out.
නිශ්පාදනයේ පවතී නඩ්තු කටයුතු කල යනාහැක
b) Not wanted for production. නිශ්පාදනයට අවශ්ය නැත

c) Taken out of production for scheduled (preventive)

maintenance. නිශ්පාදනයයන්ත නිදහස් කර ඇත.
Preventive සදහා
d) Failed unexpectedly and corrective maintenance is carried out
under emergency conditions. හදිසි breakdown එකක්. හදිසි
නඩ්තු කටයුතු සිදුයවමින්ත පවතී
e) Failed but due to shortage of maintenance resources is
“Waiting for maintenance” හදිසි breakdown එකක්. නමු්
අවශ්ය සම්ප් යනාමැති බැවින්ත බලා සිටීමට සිදුවී
ඇත Tup (a)+(b)
PLANT AVAILABILITY= Tup + Tdown = (a)+(b)+(c)+(d)+(e)
ESTABLISHING A MAINTENANCE PLAN
නඩ්තු සැලසුමක් පිලියයල
කිරීම
• What is to be maintained? නඩ්තු කල
යු්ය් යමානවාද?
• PLANT
• UNIT
• ASSEMBLY
COMPLEX REPLACEABLE ITEMS
•
• ITEMS
• SIMPLE REPLACEABLE ITEMS
• Determine the most appropriate procedure
for each item. සෑම item එකක් සදහාම
නඩ්තු පිලියවත තීරනය කරන්තන
 MAINTENANCE PROCEDURES
නඩ්තු පිලියව්
• PERIODIC MAINTENANCE කාල පරාසයකට
අනුව සිදුකරන නඩ්තු
• PREDICTIVE MAINTENANCE අනාවැකි
නඩ්තුව
• IMPROVEMENT MAINTENANCE වැඩි දියුනු
කරන නඩ්තුව
• AUTONOMOUS MAINTENANCE ස්වයං
නඩ්තුව
• OPERATE TO FAILURE
 PERIODIC MAINTENANCE
කාල පරාසයකට අනුව සිදුකරන නඩ
PREDICTIVE MAINTENANCE අනාවැකි නඩ්තුව
IMPROVEMENT MAINTENANCE
වැඩි දියුනු කරන නඩ්තුව

DOWN TIME= WAITING TIME + REPAIR TIME

AUTONOMOUS MAINTENANCE
ස්වයං නඩ්තු
• “`n

PRODUCTION ENGINEERING

“I OPERATE YOU MAINTAIN”