EcoMate

Standard Operating Procedures

Version: 1.0
Last Updated: January 2024
Maintainer: Operations Team

Overview

These Standard Operating Procedures (SOPs) ensure safe, efficient, and compliant operation of EcoMate wastewater treatment systems. All operators must be trained and certified on these procedures before independent operation.

Daily Operations

Pre-Shift Inspection (15 minutes)

Safety Check

  1. Personal Protective Equipment
    • Safety glasses, steel-toed boots, high-visibility vest
    • Gloves (nitrile for chemical handling)
    • Gas detector (if confined space entry required)
    • First aid kit accessibility verification
  2. Site Safety Assessment
    • Check for slip/trip hazards around equipment
    • Verify emergency stop buttons are accessible
    • Confirm emergency contact information is posted
    • Test emergency lighting and alarms

System Status Review

  1. Control Panel Check
    • Review overnight alarms and events
    • Verify all systems show “Normal” status
    • Check battery backup status (>80% charge)
    • Confirm communication links are active
  2. Visual Equipment Inspection
    • Pumps: No unusual noise, vibration, or leakage
    • Blowers: Normal operation, air filter condition
    • Tanks: Check for foam, scum, unusual odors
    • Electrical panels: No overheating, loose connections

System Startup Procedures

Cold Start (After Extended Shutdown)

  1. Pre-Start Verification
    • Confirm all isolation valves are in correct position
    • Check tank levels are within normal range
    • Verify electrical supply voltage and phase balance
    • Test emergency stop circuits
  2. Sequential Startup
    • Step 1: Start influent pumps (lowest speed)
    • Step 2: Start aeration blowers (50% capacity)
    • Step 3: Monitor dissolved oxygen rise to >2 mg/L
    • Step 4: Start effluent pumps when level permits
    • Step 5: Gradually increase to normal operating levels
  3. Startup Verification
    • All equipment running within normal parameters
    • No alarms or fault conditions
    • Flow rates match expected values
    • System pressures within design range

Warm Start (Normal Daily Operation)

  1. System Status Check
    • Review overnight operation data
    • Check for any alarm conditions
    • Verify equipment rotation schedules
  2. Parameter Adjustment
    • Adjust aeration based on load conditions
    • Set pump schedules for anticipated flows
    • Update control setpoints if required

Routine Monitoring

Hourly Checks (Automated/Remote)

4-Hour Checks (Manual)

  1. Process Parameters
    • Dissolved oxygen in aeration tank (2-4 mg/L)
    • pH in aeration tank (6.5-8.5)
    • Temperature (record for seasonal trends)
    • Turbidity of effluent (<10 NTU)
  2. Equipment Performance
    • Pump flow rates vs. setpoints
    • Blower air flow and pressure
    • UV lamp status and intensity
    • Chemical feed rates (if applicable)
  3. Visual Inspection
    • Effluent clarity and color
    • Foam or scum conditions
    • Equipment noise and vibration
    • Any leaks or unusual conditions

Daily Data Recording

System Shutdown Procedures

Planned Shutdown (Maintenance)

  1. Pre-Shutdown Preparation
    • Notify relevant authorities (if required)
    • Prepare bypass arrangements (if available)
    • Gather required tools and materials
    • Brief maintenance team on procedures
  2. Controlled Shutdown Sequence
    • Step 1: Stop influent pumps
    • Step 2: Continue aeration for 2 hours minimum
    • Step 3: Stop effluent pumps when tank level permits
    • Step 4: Stop aeration blowers
    • Step 5: Isolate electrical supplies (if required)
  3. Post-Shutdown Actions
    • Verify all equipment has stopped
    • Close isolation valves as required
    • Install lockout/tagout devices
    • Document shutdown time and reason

Emergency Shutdown

  1. Immediate Actions
    • Activate emergency stop if safety hazard exists
    • Isolate electrical supply if electrical hazard
    • Evacuate area if gas/chemical hazard
    • Call emergency services if required
  2. System Isolation
    • Close all isolation valves
    • Disconnect electrical supplies
    • Implement bypass procedures
    • Notify authorities and management

Weekly Operations

Comprehensive System Inspection (2 hours)

Mechanical Equipment

  1. Pump Inspection
    • Check guide rails for smooth operation
    • Inspect lifting chains and connections
    • Listen for cavitation or unusual noise
    • Check seal condition and leakage
    • Verify non-return valve operation
  2. Blower Assessment
    • Check air filter condition and pressure drop
    • Inspect belt tension and condition
    • Monitor bearing temperature
    • Check coupling alignment
    • Verify air flow distribution
  3. Tank and Piping
    • Inspect tank walls for cracks or damage
    • Check pipe supports and hangers
    • Verify valve operation and sealing
    • Inspect sampling points and access covers

Electrical Systems

  1. Control Panel Inspection
    • Check panel temperature and ventilation
    • Inspect connections for tightness
    • Verify indicator lights and displays
    • Test alarm functions
  2. Motor and Starter Inspection
    • Check motor temperature and noise
    • Inspect starter contacts and connections
    • Verify protection settings
    • Test emergency stop circuits

Process Performance

  1. Treatment Efficiency
    • Calculate BOD₅ and TSS removal efficiency
    • Review effluent quality trends
    • Compare performance to design standards
    • Identify any declining trends
  2. Energy Performance
    • Calculate specific energy consumption (kWh/kL)
    • Compare to previous periods
    • Identify energy optimization opportunities
    • Review equipment efficiency

Data Analysis and Reporting

Weekly Report Generation

Monthly Operations

Comprehensive Performance Review

System Performance Evaluation

  1. Treatment Efficiency Analysis
    • Monthly average removal efficiencies
    • Comparison with design performance
    • Seasonal variation analysis
    • Load vs. performance correlation
  2. Energy Efficiency Assessment
    • Monthly energy consumption analysis
    • Specific energy consumption trends
    • Equipment efficiency evaluation
    • Cost-benefit analysis of improvements
  3. Equipment Reliability Review
    • Equipment availability and downtime
    • Maintenance cost analysis
    • Failure mode analysis
    • Spare parts consumption

Compliance Assessment

  1. Regulatory Compliance
    • Permit limit compliance review
    • Sampling and monitoring compliance
    • Reporting requirement compliance
    • Corrective action effectiveness
  2. Environmental Performance
    • Discharge quality assessment
    • Environmental impact evaluation
    • Sustainability metrics
    • Community impact assessment

Maintenance Planning

Preventive Maintenance Scheduling

Resource Planning

Documentation and Reporting

Monthly Reports

  1. Operational Report
    • System performance summary
    • Key performance indicators
    • Compliance status
    • Issues and resolutions
  2. Maintenance Report
    • Maintenance activities completed
    • Equipment condition assessment
    • Spare parts consumption
    • Maintenance cost analysis
  3. Regulatory Submissions
    • Discharge monitoring reports
    • Compliance certifications
    • Incident reports (if applicable)
    • Permit renewal applications

Emergency Procedures

Alarm Response Procedures

High Priority Alarms (Immediate Response)

  1. High Level Alarm
    • Immediate Action: Check pump operation, start manually if required
    • Investigation: Inspect for blockages, electrical issues
    • Resolution: Clear blockages, repair equipment, adjust controls
    • Follow-up: Monitor for recurrence, update maintenance schedule
  2. Equipment Failure Alarm
    • Immediate Action: Switch to backup equipment if available
    • Assessment: Determine failure mode and safety implications
    • Response: Implement temporary measures, call service support
    • Documentation: Record failure details, maintenance actions
  3. Power Failure Alarm
    • Immediate Action: Verify backup power activation
    • Assessment: Determine outage duration and impact
    • Response: Implement emergency procedures, notify authorities
    • Recovery: Systematic restart when power restored

Medium Priority Alarms (Response within 4 hours)

  1. Low Level Alarm
    • Investigation: Check influent flow, system leaks
    • Assessment: Determine cause and impact
    • Response: Adjust controls, repair leaks
    • Monitoring: Verify resolution and normal operation
  2. Performance Alarm
    • Investigation: Review process parameters and trends
    • Assessment: Determine impact on treatment efficiency
    • Response: Adjust process controls, increase monitoring
    • Follow-up: Implement corrective actions

Low Priority Alarms (Response within 24 hours)

  1. Maintenance Reminder
    • Review: Check maintenance schedule and requirements
    • Planning: Schedule maintenance activities
    • Execution: Complete maintenance as planned
    • Documentation: Update maintenance records

Emergency Contact Procedures

Internal Contacts

External Contacts

Safety Procedures

Personal Protective Equipment (PPE)

Standard PPE Requirements

Task-Specific PPE

Hazard Management

Biological Hazards

Chemical Hazards

Electrical Hazards

Confined Space Hazards

Emergency Response

Medical Emergencies

  1. Immediate Response
    • Ensure scene safety
    • Provide first aid within training limits
    • Call emergency medical services (10177)
    • Notify management and safety personnel
  2. Follow-up Actions
    • Complete incident report
    • Investigate root causes
    • Implement corrective actions
    • Review and update procedures

Environmental Incidents

  1. Spill Response
    • Stop source if safe to do so
    • Contain spill using available materials
    • Notify environmental authorities
    • Begin cleanup using approved methods
  2. Discharge Exceedance
    • Immediately notify regulatory authorities
    • Implement corrective actions
    • Increase monitoring frequency
    • Submit incident report within required timeframe

Training and Competency

Initial Training Requirements

Ongoing Training

Competency Assessment

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