PHE Consultants professional engineers, technocrats, town planners and management consultants. Associate consultants

Meat processing & abattoir waste management

Solid waste management

Community development &
slum sanitation

Waste water system

Privatized o & m,
training and manuals

Water supply

OPERATION AND MAINTENANCE OF COMMON EFFLUENT
TREATMENT PLANT FOR VAPI INDUSTRIES ASSOCIATION

PHE Consultants in association with M/s. R.V Anderson Associates Limits, Ottawa, Canada Has completed an assignment of Operating and maintaining a 55 MLD Common effluent Treatment Plant (CETP) at Vapi for Vapi Industries Association, Gujarat for a period of two Years (Fee US $ 3 million).

The CETP at vapi is among the largest in Asia spread over an area of 22 acres, provides combined physical, chemical & biological effluent treatment. It provides treatment of the industrial wastewater generated within GIDC ,Vapi by settling , by addition of chemicals and by the activated sludge treatment process (extended aeration). The plant has been designed for a capacity of 55 MLD with further expansion possible to 90 MLD which is maximum flow anticipated from the ultimate development of the industrial estate. Approximately 800 industries are based in GIDC Vapi, in a diver5se range of market sectors such as dyes, textiles, pharmaceuticals, pulp and paper, metal finishing , etc. each of which releases a diverse nature of effluent to the CETP.

One of the key tasks associated with commissioning and the plant was that all the mechanical and electrical equipment had to be serviced and restored to operational fitness levels. This was extremely important, as some of the equipment were lying idle for over 11/2 years. PHE-RVA were successful in commissioning and operating all the equipment in the plant with minimum capital replacement. An exhaustive computerized preventive maintenance program for all the electrical , mechanical and automation equipment was organized to ensure truble free operation of the plant. PHE-RVA's tasks included.

Process, instrumentation and equipment audi

Assistance in plant staffing.

Assistance in equipment commissioning.

Review of plant and process design & performance, safety provisions.

Rectification of plant design deficiencies and provision of adequate safety measure.

Set-up of the laboratory and review of the laboratory equipment requirement

Start-up of the plant.

Plant commissioning (i.e. commissioning of the process)

Recruitment of staff and training.

Monitoring of effluents from members of association (700 industries).

Provision of operation and maintenance manuals.

Operation & Maintenance of the commissioned plant for twelve (36) months.

Delivery o0f training for the plant operators.

Set up a computerized predictive and prevent6jive maintenance program for all mechanicalAnd electrical equipment.

Though the plant was designed to treat incoming effluent with inlet COD at a 1000 ppm to250 ppm, significantly higher incoming loads (up to 2300 ppm) were received at the plant causing serve shock loading of the system. Inspite of these short coming and mechanicaland electrical equipment failures and frequent power outages the PHE-RVA team managed the plant capably and were able to deliver commendable reduction in all parameter. Infact,over 800 industries at Vapi were given consent to operate based on the performance of the CETP. PHE-RVA have also prepared a modification design brief for upgrading the exiting CETP to enable it to accept higher loads and flow for treatment and optimize the plant &process with a view to reducing O&M costs.