report of iets doc

7/16/2019 Report of IETS Doc

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CHAPTER 1: INTRODUCTION

1.1 Introduction

It is in everyones interest that an industrial effluent treatment system (IETS)

functions optimally to achieve an effluent quality that continuously complies with

the discharge standards. The operator of industrial effluent treatment systems

(IETS) is an important player behind any successful story of effluent treatment. In

successful organizations, typically the operators are tasked with specific

responsibilities that include such daily chores as general daily walk through

inspection of the IETS to ensure no effluent pipe leakages, and equipment

breakdown, preventive maintenance and performance monitoring (sampling,

record keeping and etc). These activities need to be conducted in a coordinated

manner to ensure proper functioning of all the IETS components. Even a state of

the art and expensive IETS, which is not run and maintained optimally, will not

produce the desired results.

Currently, the DOE enforce the requirement of competent person for IETS in the

nation through Written Approval or directives issued to factories or industries.

This is to ensure that awareness of pollution control and environmentconservation is set in each industry in order to give a better control of

environmental quality for all, especially to the next generation in future.

Performance monitoring of an IETS is the proactive and preventive monitoring of

all the major IETS components to ensure that each component is working

properly and optimally as designed. This requires someone to monitor some

relevant parameters and characteristic of the unit processes or unit operations of

the IETS on a scheduled basis. Performance monitoring concentrates on the

IETS itself not on the final effluent hence can be viewed as an upstream activity

as opposed to compliance monitoring, which is a downstream activity.

Performance monitoring is not the monitoring of the final effluent as

misunderstood by some industries. Focusing only on the final effluent may lead

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to a too-late situation where things have gone out of hand and consequently

difficult to control or get back on track.

1.2 Background of Company

TORAY MALAYSIA GROUP's traditional business in textile is conducted at the

four mills under Penfabric, a vertically integrated textile manufacturer involving

spinning, weaving, dyeing, printing and finishing operations to produce yarn, grey

fabric, finished fabric, yarn-dyed fabric (gingham) and grey and dyed yarn for

sewing thread. Four mills under Penfabric are;

Penfabric Mill 1 (Spinning of Yarn)

Penfabric Mill 2 (Weaving of Grey Fabrics)

Penfabric Mill 3 (Yarn-Dyed Woven Fabrics & Sewing

Thread Yarn)

Penfabric Mill 4 (Dyeing, Printing & Finishing of Fabric)

Figure 1.1: Product of Penfabric

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Penfabric Sdn Bhd Mill 4 is located at Plot 117-119 & 200-202, Prai Free

Industrial Zone, 13600 Prai, Penang. Penfabric Mill 4 is the single largest,

advanced, integrated finishing processor of grey fabric in the region. The

specialized finished fabrics are exported to international apparel manufacturers

in the USA, EU countries and other part of the world.

Figure 1. 2: Penfabric Sdn. Berhad Mill 4

Penfabric Mill 4 has approximately 614 staffs working in 3 shifts. Area of factory

site is about 266 000 square metres. Penfabric products comply to all standard

such as ISO 9001, ISO 14001, OKO TEX and regularly audited by external

bodies such as SIRIM, Marks & Spencer, customers and etc. Penfabric Sdn Bhd.

Mill 4 was certified with ISO 9001 in 1994 and ISO 14001 in 2005.

1.3 Organizational Structure

1.3.1 Companys environmental policy

This environmental policy was the existing policy. This policy was reviewed on

01st April 2009. Penfabric Sdn. Berhad Mill 4 environmental policy as below;

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Environmental Policy

Penfabric Sdn. Berhad Mill 4 is a manufacturer of dyed, white and printed wovenfabrics.

Penfabric is committed to its corporate and social responsibility for environmentalpreservation and sustainable development by:

Complying with applicable environmental legal requirements and otherregulations to which the company subscribes.

Continual improvement to prevent pollution, conserve energy and resourcesusing 3Rs (Reduce, Reuse & Recycle).

This policy should be understood, implemented, maintained at all levels and becommunicated to all persons working for or on behalf of the organization using

appropriate means such as meetings, booklets, brochures, strategically placedinformation, and other methods deemed necessary from time to time.

1.3.2 Emplacement and Functions of CePIETSO

CePIETSO are placed under Safety and Environment Department. Please refer

to Organization Chart as attachment 1.

The main duties of CePIETSO are as ;

1. Supervision on Operation of Waste Water Treatment Plant and Incinerator.

2. Control and monitoring of both Waste Water Treatment Plant and Incinerator.

3. Special waste water treatment and /or environmental project including related

laboratory analysis when deem necessary

Please refer to Job Description of Environment Officer as Attachment 2

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1.4 Nature of Business

The main products of factory are grey fabric, finished fabric and yarn-dyed fabric

(gingham). Currently the capacity of production is around 7.91 million-yard per

month. Those products are mainly for export purpose and not for domestic market.

So far, there are more than 30 over countries in all continents being exported from

Penfabric Sdn. Berhad Mill 4

1.5 Industrial Effluent Treatment System (IETS)

Various types of effluent treatment technology are introduced in the decades as

the public awareness to environmental pollution is increasing. In a practical way,

the industrial effluents usually contain various types of contaminants and may

require a few combinations of treatment methods or processes to remove the

contamination. The selection of the unit operations are depending on the

treatment methodology which may need to consider the factors below:

The characteristic of the effluent

Degree of treatment required

Capital investment & operating cost

Effluent standard imposed

Space availability of the premise

Manpower involved

The biological (aeration) treatment processes, which also known as biological

unit processes, are classified as secondary treatment in the design of removing

dissolved organic matters. Microorganisms are the fundamental element in this

contest as they are used to utilize the organic matters with presence of oxygen

which represented as BOD and COD. The activated sludge process is used

routinely for biological treatment in both industrial and municipal wastewater. A

basic diagram for activated sludge process consists of 3 components as

illustrated as below:

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Figure 1.3 : Basic diagram for activated sludge process

Typically, the biological processes are divided into 2 main categories: suspended

growth and attached growth (biofilm). The Conventional Activated Sludge,

Extended Aeration Activated Sludge, Contact Stabilization, Sequencing Batch

Reactor (SBR), Oxidation Ditch are suspended growth system where the bacteria

are kept in suspended form and part of the sludge are return to aeration tank for

mixing with influent and aeration. While Rotating Biological Contactors (RBC),

Upflow Anaerobic Sludge Blanket (UASB), Trickling Filters are attached growth

system. In the attached growth system, the bacteria will growth on a solid media,e.g. rocks, redwood or plastic materials and the slime layer will adsorb the

organic matter and nutrients from effluent. The sludge layer subsequently will be

getting thicker and thicker as the time passing. Below is the detail information of

Rotating Biological Contactors and Upflow Anaerobic Sludge Blanket

Rotating biological contactors (RBCs)

Rotating biological contactors (RBCs) are mechanical secondary treatment

systems, which are robust and capable of withstanding surges in organic load.

RBCs were first installed in Germany in 1960 and have since been developed

and refined into a reliable operating unit. The rotating disks support the growth of

bacteria and microorganisms present in the sewage, which breakdown and

stabilize organic pollutants. To be successful, microorganisms need both oxygen

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to live and food to grow. Oxygen is obtained from the atmosphere as the disks

rotate. As the micro-organisms grow, they build up on the media until they are

sloughed off due to shear forces provided by the rotating discs in the sewage.

Effluent from the RBC is then passed through final clarifiers where the

microorganisms in suspension settle as sludge. The sludge is withdrawn from the

clarifier for further treatment.

A functionally similar biological filtering system has become popular as part of

home aquarium filtration and purification. The aquarium water is drawn up out of

the tank and then cascaded over a freely spinning corrugated fiber-mesh wheel

before passing through a media filter and back into the aquarium. The spinning

mesh wheel develops a biofilm coating of microorganisms that feed on the

suspended wastes in the aquarium water and are also exposed to the

atmosphere as the wheel rotates. This is especially good at removing waste urea

and ammonia urinated into the aquarium water by the fish and other animals.

Figure 1.4: Rotating biological contactors

Upflow anaerobic sludge blanket (UASB)

Upflow anaerobic sludge blanket (UASB) technology, normally referred to as

UASB reactor, is a form of anaerobic digester that is used in the treatment of

wastewater.

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UASB uses an anaerobic process whilst forming a blanket of granular sludge

which suspends in the tank. Wastewater flows upwards through the blanket and

is processed (degraded) by the anaerobic microorganisms. The upward flow

combined with the settling action ofgravity suspends the blanket with the aid of

flocculants. The blanket begins to reach maturity at around 3 months. Small

sludge granules begin to form whose surface area is covered in aggregations of

bacteria. In the absence of any support matrix, the flow conditions create a

selective environment in which only those microorganisms, capable of attaching

to each other, survive and proliferate. Eventually the aggregate form into dense

compact biofilms referred to as "granules" A picture of anaerobic sludge granules

can be found here.

Biogas with a high concentration of methane is produced as a by-product, and

this may be captured and used as an energy source to generate electricity for

export and to cover its own running power. The technology needs constant

monitoring when put into use to ensure that the sludge blanket is maintained, and

not washed out. The heat produced as a by-product of electricity generation can

be reused to heat the digestion tanks.

The blanketing of the sludge enables a dual solid and hydraulic (liquid) retentiontime in the digesters. Solids requiring a high degree of digestion can remain in

the reactors for periods up to 90 days. Sugars dissolved in the liquid waste

stream can be converted into gas quickly in the liquid phase, which can exit the

system in less than a day

Figure 1.5 : Upflow anaerobic sludge blanket

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CHAPTER 2: INDUSTRIAL EFFLUENT TREATMENT SYSTEM

2.1 Description of IETS

Waste Water Treatment Plant in Penfabric Sdn. Berhad Mill 4 was use to treat

the continuous effluent from textile production (100% cotton and polyester/cotton)

with the maximum flow rate of 380 m3/hour.

Treated effluent discharge from the WWTP shall comply with Standard B (Third

Schedule of Environmental Quality (Sewage and Industrial Effluent) Regulation

1979) except for COD which the limit discharge is 250 mg/l as the Written

Approval SPE/04/2007 (attachment 3). The flow process of WWTP as below

Figure 2.1: Penfabric Sdn. Berhad Mill 4 Waste Water Treatment Plant Processflow

(4) Aeration Tank A

Waste Water (Aerobic process ) Neutralization

from Factory

(1)

Return Sludge

Aeration Tank B(Aerobic process)

Return Sludge

(6) Dry Bed

Indicator : Waste water

Return Activated Sludge

Treated Water

Waste Activated Sludge

WASTE WATER TREATMENT PROCESS FLOW.

(5) Settling Tank A

(5) Settling Tank B

(2) Buffer Pit (3) Anaerobic Lagoon

Treated

Water

Effluentto

drai

Treated

Water

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Description of process unit

(1) Neutralization

- To adjust the pH to 8~9 to optimize the anaerobic /aerobic process.

- We use sulfuric acid 98% to neutralize our inlet waste water.

(2) Buffer Pit

- To stabilize the waste water.

- To homogenize the waste water supply and reduce the fluctuation.

- Start the anaerobic process.

- Capacity of this pit are 8000 m3 .

- 1.6 days retention time.

(3) Anaerobic Lagoon

- Bacterial process that is carried out in the absence of oxygen.

- To breakdown the COD/BOD prior to treatment in aerobic condition.

- Provides retention time for further biological improvement.

- Capacity of lagoon are 36000 m3 .

- Retention time of 3.9 days.

(4) Aeration Tank

- At Penfabric Sdn. Berhad Mill 4, we have 2 aeration tanks.

- Aeration Tank is the heart of waste water treatment.

- Bacterial process occurring in the presence of oxygen.

- Under aerobic conditions, bacteria rapidly consume organic matter and

convert it into carbon dioxide.

- The point of control is on how to maintain bugs active and separate treated

water from sludge.

- Capacity of 8000m3 for Tank A and 6000m3 for Tank B. Tank A using air

diffuser aerators and Tank B using surface aerators.

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- 1.1 days retention time for Tank A and 1.6 days retention time for Tank B.

(5) Settling Tank

- At Penfabric Sdn. Berhad Mill 4, we have 2 settling tanks.

- Function of Settling Tank is for settling of sludge and separation of treated

water.

- It is important to have clear treated water by sludge separation and controlling

of Settling Tank correlating to aeration tank.

- Sludge settling status is affected by situation of ASM treatment, operation

condition and short pass of water may affects quality of treated water.

- Capacity of 2500m3 for Tank A and 2000m3 for Tank B.

(6) Dry Bed

- At Penfabric Sdn. Berhad Mill 4, we have 11 dry beds.

- These dry beds use to dewatering the waste activated sludge.

2.2 IETS performance monitoring committee

Figure 2.2: IETS performance monitoring committee

Under CePIETSO, there have 2 technicians that operate the IETS. These

technicians will operate this IETS under supervision of CePIETSO. Typical duties

of these technicians are;

Environment Chairman

MT Boey

CEPIETSOKairul Anwar

Committe

BleachingSS Chee

DyehousePY Lim

FinishingSP Ong

PrintingSB Saw

EnvironmentJaya Paul

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- Operation of Waste Water treatment Plant and Incinerator.

- Daily inspection and checking of both Waste Water Plant and Incinerator.

- Taking samples and conduct laboratory analysis for COD, BOD, Color (PtCo),

SS, MLSS, SV30 and etc. Arrange sample for external monthly laboratory

analysis.

- Collection, packing, labeling and storing of scheduled waste and maintain the

scheduled waste inventory.

- Minor maintenance and general cleanliness of plant and immediate

surrounding

- Others as requested by CePIETSO.

Any problem or upset condition will be reported daily to CePIETSO. If the

problem is major, CePIETSO will directly reported to Environment Management

Representative (EMR), Mr. Jaya Paul. He will then try to solve the problem by his

own experience or by consulting his superior. In every circumstance he will notify

the Environment Chairman.

Once every two months, Environment Meeting will be conduct to discuss all the

issues arise for environment items. Performance of waste water treatment plan,

upset condition, future plan, Environment Management Program and etc will also

been discussed in this meeting.

2.3 Conduct of performance monitoring

2.3.1 Formation of Performance Monitoring System In Penfabric Sdn.

Berhad Mill 4

Based on the technical guidance, the IETS in Penfabric Sdn Berhad Mill 4 falls

under the categories of Biological Unit Process. Table 2.1 below summarizes the

monitoring parameters and frequency based on the process category:

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Parameter Frequency

Flowrate (m3/hr) Daily

pH DailyDO Daily

SV30 (ml) Daily

BOD Weekly

COD Weekly

COLOR Weekly

SUSPENDED SOLID Weekly

SVI Weekly

MLSS Weekly

MLVSS Weekly

Table 2.1 : Monitoring parameter

2.3.2 Selection Of Sampling Points At IETS

The selection of sampling points at IETS was done based on the treatment

system process flow and the necessary information to calculate the removal

efficiency. Table 2.2 and Figure 2.1 below show the sampling points for different

parameters at different process stage.

Parameter Sample location

Flow rate (m3/hr) ASM 1 and ASM 2

pH ASM 1 and ASM 2

DO ASM 1 and ASM 2SV30 (ml) ASM 1 and ASM 2

BOD INFLUENTASM 1ASM 2

EFFLUENT

COD INFLUENTASM 1ASM 2

EFFLUENT

COLOR INFLUENTASM 1ASM 2

EFFLUENTSUSPENDEDSOLID

CLARIFIER ASM 1CLARIFIER ASM 2

SVI ASM 1 and ASM 2

MLSS CHANNEL 1 UNTIL 8 OF ASM 1CHANNEL 1 UNTIL 3 OF ASM 2

MLVSS CHANNEL 1 UNTIL 8 OF ASM 1CHANNEL 1 UNTIL 3 OF ASM 2

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Table 2.2 : Sampling Point

Figure 2.3: Location of Sampling Point

2.3.3 Sampling Method

The sampling bottles used are made of plastic, with wide mouth and have a

volume of 1000mL. During sampling, the sampling bottles are rinsed then filled to

the top with water sample before sending to the lab for analysis. For performance

monitoring, only grab sampling is apply. A grab sample may be defined as anindividual discrete sampling over a period of time not exceeding 15 minutes. It

can be taken manually using a scoop.

2.3.4 Monitoring and Analysis Method

(4) Aeration Tank A

Waste Water (Aerobic process ) Neutralizationfrom Factory

(1)

Return Sludge

Aeration Tank B

(Aerobic process)

Return Sludge

(6) Dry Bed

Indicator : Waste water

Return Activated Sludge

Treated Water

Waste Activated Sludge

WASTE WATER TREATMENT PROCESS FLOW.

(5) Settling Tank A

(5) Settling Tank B

(2) Buffer Pit (3) Anaerobic Lagoon

Treated

Water

Effluentto

drai

Treated

Water

Legend:

FlowratepH

DOBOD , COD & Color

SSMLSS& MLVSS

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The pH, DO and flow rate are checked in real time mode, data is recorded by

chart recorder and checked by technician. BOD, COD, MLSS and MLVSS are

monitored follow the Standard Methods for the Examination of Water and

Wastewater. SS and Color are monitored using HACH DR/2000.

2.3.5 Situation before course attendance

Before attending the course, the performance monitoring was already carried out

but does not follow the (Guidance Document on Performance Monitoring of

Industrial Effluent Treatment Systems DOE IETS 1, 2006.). Parameter such

as MLVSS was not recorded because we do not know the importance of

monitoring this parameter. Sampling point for some parameters was carried out

not appropriate such as MLSS. Before attending this course, we just carried out

random sampling point for this parameter.

2.3.6 Changes instituted

The changes after attending this course was summarize as the table below;

ITEM BEFORE AFTER

SAMPLINGPOINT

Not appropriate. Example,for MLSS we just pickrandom sampling point

Sampling point was carried out asinstructed in class and following theGuidance Document onPerformance Monitoring of IndustrialEffluent Treatment Systems DOE

IETS 1, 2006.

FREQUENCYOF SAMPLING

Not appropriate. Somefrequency of parameter wassampling not accurate.Example SV30,

Sampling point was carried out asinstructed in class and following theGuidance Document onPerformance Monitoring of IndustrialEffluent Treatment Systems DOE

IETS 1, 2006.

TYPE OFSAMPLING

Parameter such as MLVSSand suspended solid notcheck.

Quickly arranged to buy the furnaceand filtering apparatus. Now wealready test the MLVSS and SS

2.3.7 Current performance monitoring procedure

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The current practice for IETS performance monitoring was following the

Guidance Document on Performance Monitoring of Industrial Effluent Treatment

Systems DOE IETS 1, 2006.

For daily performance data record, we record the flow rate, pH, DO and SV30 for

both plant (ASM1 and ASM2). Summary of performance monitoring as below;

Parameter Samplelocation

Sample type

Flowrate(m3/hr)

ASM 1ASM 2

Flow rate meter

pH ASM 1ASM 2

In situ

DO ASM 1

ASM 2

In situ

SV30 (ml) ASM 1ASM 2

Grab

Meanwhile, for weekly performance data record, we record the BOD, COD,

COLOR, Suspended Solid (SS) and SVI for both plant (ASM1 and ASM2). For

MLVSS and MLSS, we record weekly at every channel of aeration tank for ASM1

and ASM2. Summary of performance monitoring as below;

Parameter Sample location Sample type


EFFLUENT

Grab


EFFLUENT

Grab

COLOR INFLUENT

ASM 1ASM 2EFFLUENT

Grab

SUSPENDEDSOLID

SETTLING TANK ASM 1SETTLING TANK ASM 2

Grab

SVI ASM 1ASM 2

Grab

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Grab

MLVSS CHANNEL 1 UNTIL 8 OF ASM 1CHANNEL 1 UNTIL 3 OF ASM 2

Grab

CHAPTER 3: DISCUSSION OF PERFORMANCE MONITORING RESULTS

3.1 Performance Monitoring Data

3.1.1 pH Control

Monitoring of pH is important from several standpoints. The optimum biological

activity of the microorganisms for the treatment process is in the pH range from

6.0 to 9.0. Below show the monthly pH control.

Figure 3.1 : Monthly pH Control

3.1.2 DO Control

Biological unit processes require a sufficient amount of dissolved oxygen (DO)

for growth and metabolism of microorganisms. In practice, depending on the type

of aerobic systems employed, the DO concentration of about 1.0 to 4 ppm needs

to be maintained in all the areas of the aeration tank. Higher DO concentration

will not necessarily increase the biodegradation efficiency hence represents

wasted energy. For every IETS an optimum DO concentration depending on the

type of microorganism and effluent characteristics can be evaluated by

optimizing the DO concentration and the removal efficiency of BOD and COD.

MONTHLY pH CONTROL

0.00

2.00

4.00

6.00

8.00

10.00

Jul-09 Aug-09 Oct-09 Dec-09 Jan-10

MONTH

pH

pH ULC

pH LLC

pH ASM 1

pH ASM 2

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DO been measured by using a portable hand held DO meter and measured

continuously by on line DO probe and transmitter equipped with recording

device. Below show the monthly DO control.

Figure 3.2 : Monthly DO Control

3.1.3 Monthly Variation of COD and BOD

The overall performance of a biological treatment process in treating an organic

effluent been monitored on chemical oxygen demand (COD) and biological

oxygen demand (BOD). Both IETS was functioning in good operating condition

and meet the regulation and written approval. The mean value for COD is 160

ppm and BOD is 18 ppm. Below show the monthly variation of COD and BOD.

MONTHLY DO CONTROL

0.00

1.00

2.00

3.00

4.00

5.00


MONTH

DO(

PP

DO ULC

DO LLC

DO ASM 1

DO ASM 2

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Figure 3.3 : Monthly Variation of COD

Figure 3.3 : Monthly Variation of BOD

3.1.5 Efficiency Removal of COD and BOD

The value of removal efficiency is important to show the performance of theIETS. The formula for computing the removal efficiency is as follows:

% Removal = Influent - Effluent

MONTHLY VARIATION OF COD

100

120

140

160

180

200

220240

260


MONTH

COD

(PPM)

COD DOE STD

COD ASM 1

COD ASM 2

COD EFFLUENT

MONTHLY VARIATION BOD

0

10

20

30

40

50

60


MONTH

BOD(

PPM) BOD DOE STD

BOD ASM 1

BOD ASM 2

BOD EFFLUENT

X 100

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Influent

Overall BOD5 removal efficiency is 96% and COD removal efficiency is 90%.

Figure 3.5 : Efficiency Removal of COD

Figure 3.6 : Efficiency Removal of BOD

Based on the performance monitoring conducted from 02nd July 2009 until 02

January 2010 and the data collected which were plotted for trend analysis and

EFFICIENCY REMOVAL OF COD

0

500

1000

1500

2000

2500

Aug-

09

Sep-

09

Oct-09Nov-09 Dec-

09MONTH

COD

(PPM

89.00

89.50

90.00

90.50

91.00

91.50

92.00

COD INFLUENT

COD EFFLUENT

COD % REMOVAL

EFFICIENCY REMOVAL OF BOD

0

100

200

300

400

500

600

Aug-09Sep-09Oct-09Nov-09Dec-09

MONTH

BOD

(PPM)

95.40

95.60

95.80

96.00

96.20

96.40

96.60

96.80

97.00

BOD INFLUENT

BOD EFFLUENT

BOD % REMOVAL

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statistically analyzed the following conclusion can be made about the IETS

operation:

a) The IETS was functioning in good operating condition with an overall BOD5

removal efficiency of 96% and COD removal efficiency of 90%.

b) The operational parameter of SVI, MLSS, MLVSS, SS, pH, DO and flowmeter

were all within the recommended ranges

c) The mean DO level of ASM 1 is 1.80 ppm and ASM 2 is 2.82 ppm in the

aeration tank was consider in the acceptable range.

d) The final effluent COD and BOD5 complied with the stipulated Standard B

CHAPTER 4: CORRECTIVE ACTIONS

ASM condition can become poor like treated water getting bad, sludge floating or

not settling in Settling Tank and even if experienced personal are controlling the

processes. However, it is possible to minimize a development of abnormalsituation and recover a upset condition in short period by well controlled daily

activities. It is also important to check ASM treatment everyday and work for

bacteria with affection as well as to take correct an appropriate action for

abnormal happening.

The upset conditions encountered during my field training were discussed as

below.

4.1 Sludge floating

Sludge does not settle but floats when apparent density of sludge get lower than

treated water. Floating sludge including tiny nitrogen bubbles caused by

nitrification.

4.1.1 Phenomena

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Sludge does not settle but floats when apparent density of sludge gets lower than

treated water. Floating sludge including tiny bubbles.

4.1.2 Troubles

Sludge flow out without settling and high TSS in treated water

4.1.3 Causes

Nitrification goes on when aeration tank is operated at low loading, low DO and

long detention time

4.1.4 Countermeasure

Prevent sludge flow out by reducing incoming waste water to aeration tank

Knock down showering on the floating sludge

Increase DO at aeration tank and decrease sludge detention time in clarifier

Depress nitrification reaction by lowering MLSS.

4.2 Pinpoint floc

Phenomena and causes on pinpoint floc are quite similar to bulking. The

countermeasures taken are slightly different from them because the supernate

gets murky.

4.2.1 Phenomena

Fine flocs are seen dispersed in supernate.

The border between sludge zone and supernate is not clear

4.2.2 Troubles

High TSS in treated water and reduction in MLSS concentration by sludgeoutflow

4.2.3 Causes

Introduction of high concentration water or overloading by high flow.

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Introduction of detergents

Early stage of acclimation

4.2.4 Countermeasure Optimize loading and dilute with fresh water

Increase MLSS by increasing return sludge rate

Keep DO high (3-4)

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CHAPTER 5: FURTHER IMPROVEMENT

In future we plan to buy new equipment for wastewater analysis such

as COD reactor, spectrophotometer and YSI BOD and. Now we use the

titration method to monitoring the COD and BOD and I thing thismethod is quiet difficult for technician to perform. So with this new

equipment, we can get the results faster and easy for technician to

carry out the test. With spectrophotometer, we can monitoring many

parameter such nutrient, COD, BOD, color (ADMI) and etc.

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CHAPTER 6: CONCLUSIONS

As a conclusion, implementation of performance monitoring has benefit to my

company. Performance monitoring of an IETS is the proactive and preventive

monitoring of all the major IETS components to ensure that each component was

working properly and optimally as designed. Performance monitoring

concentrates on the IETS itself not on the final effluent hence can be viewed as

an upstream activity as opposed to compliance monitoring, which is a

downstream activity. Focussing only on final effluent may lead to a too late

situation where things have gone out of hand and consequently difficult to control

or get back on track.

The implementation of performance monitoring system on IETS has enabled

Penfabric Sdn Berhad Mill 4 to evaluate the efficiency of our IETS and to make

plan to for improvement. In addition, it also helps to evaluate the effectiveness of

the operation and maintenance program.

Analysis of the performance trend will trigger early detection of any abnormality

or treatment system deficiencies and will enable us to take immediate action for

containment and rectification. Analysis on the influent chemical characteristic

enables us to determine the optimum chemical dosage setting at treatment plant

as well as to provide more effective control on chemical discharge which may

upset the capability of the treatment system.

The effective implementation of this performance monitoring system ensures the

sustainability and continuity of our business as well as safeguarding the company

from legal issues.

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Overall performance of my IETS was very good and can comply the DOE

regulation. The benefits from the implementation of performance monitoring are;

a) IETS in optimum operation at all times

b) prevent IETS failure hence avoid costly IETS recovery work

c) helps to maintain continued compliance hence improve corporate image and

avoid embarrassing enforcement action

d) maintains record of IETS performance which facilitates optimization of IETS

and analysis of performance.

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References:

1) Guidance Document on Performance Monitoring of Industrial Effluent

Treatment Systems DOE IETS 1, 2006.

2) Certified IETS operator training material

3) Success Stories of Performance Monitoring of Industrial Effluent Treatment

System issues 1/2008

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APPENDICESAppendix I

A list of analytical equipment used

No Equipment Manufacturer Photo

1 Incubator Velp Scientifica

2 Oven Memmert

3 Muffle Furnace WiseTherm

4 Filtering Appratus (WaterJet Pump

Duran

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5 pH meter Yokogawa

6 DO meter Horiba

7 Weighing balance Mettler Toledo

8 Heater for COD testing Extraction Mantle

Appendix II

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A table showing the locations of sampling point

Parameter Sample location

Flowrate (m3/hr) ASM 1ASM 2

pH ASM 1ASM 2

DO ASM 1ASM 2

SV30 (ml) ASM 1ASM 2


EFFLUENT


EFFLUENT

COLOR INFLUENTASM 1ASM 2

EFFLUENT

SUSPENDEDSOLID

CLARIFIER ASM 1CLARIFIER ASM 2

SVI ASM 1ASM 2


MLVSS CHANNEL 1 UNTIL 8 OF ASM 1

CHANNEL 1 UNTIL 3 OF ASM 2

Appendix III

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A table showing the list of performance monitoring parameters and the samplingfrequency

Parameter Frequency

Flowrate

(m

3

/hr)

Daily

pH Daily

DO Daily

SV30 (ml) Daily

BOD Weekly

COD Weekly

COLOR Weekly

SUSPENDEDSOLID

Weekly

SVI Weekly

MLSS Weekly

MLVSS Weekly

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Appendix IVAn example of an IETS Performance Monitoring Report submitted by you to the IETS Performance Monitoring Committeeas taught in the CePIETSO course.

PENFABRIC SDN BERHAD MILL 4

Prai Free Industrial Zone 1, 13600 Prai, Penang.

From: Kairul Anwar Abdul Rahim To : Mr. MT Boey

(Factory Manager)

IETS report for Month of December 2009

1. Daily record (Average)FLOWRATE (m3/h)(Control limit


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Appendix V

Performance monitoring record.

report of iets doc

Documents

spinning of yarn penfabric

expensive iets

effluent quality

major iets components

penfabric sdn bhd

unit operations ofthe

compliance monitoring

final effluent asmisunderstood