1. Purpose and Field of Application
This guide is intended for the technical maintenance of the wastewater treatment system, including the aeration system, slag pumps and pH regulation calibration. These procedures are performed during scheduled maintenance, upon detection of unsatisfactory efficiency indicators, or after equipment failure. The guide is intended for technical services, maintenance managers and reliability engineers.
2. Safety warnings
Power Off and Protection Against Backfeeding — before performing any work on the equipment, carry out the lockout/tagout (LOTO) procedure to ensure personnel safety.
Use of PPE — use appropriate personal protective equipment, including work gloves, eye protection, wool gloves, and a protective mask for work with chemical liquids.
Working with Chemical Liquids — when calibrating pH sensors, avoid direct contact with liquids, use protective equipment and ventilation.
Electrical Energy — avoid contact with electrically conductive parts of the equipment that may be energized.
Disconnection of Power — disconnect the power supply of the system before performing any work.
3. Required Tools and Materials
| Tool Name | Specification | Quantity |
|---|---|---|
| Torque head | Torque 15-60 N·m | 1 |
| Multimeter | Microchip 3-200 V, 0.01-20 MOhm | 1 |
| Micrometer | 0–25 mm | 1 |
| Laser aluminum aluminum aluminum aluminum aluminum aluminum aluminum | Length 2 m, accuracy ±0.02 mm | 1 |
| Cleaning tools | Humidity paper, foil, rubber | 1 |
| Thermometer | Liquid mercury, range -20 to 150 °C | 1 |
4. Check List Before Maintenance
| Item | Check | Acceptance criteria | Notes |
|---|---|---|---|
| 1 | Disconnection of energy | Disconnection performed, signature | Perform the LOTO procedure |
| 2 | Tool Preparation | All tools are ready, matched | Check the availability of all tools |
| 3 | Check of the condition of aerators | No cracks, wear | Use a micrometer |
| 4 | Slag Pump Inspection | No leaks, wear | Check for leaks |
| 5 | pH Sensor Check | Sensor is clean, no leaks | Use the liquid for cleaning |
5. Step by step procedure
- Power Off
Turn off the system power and perform the LOTO procedure. Use a multimeter to check for absence of voltage.
Error: shutdown not performed — dangerous situation.
- Cleaners of Aerators
Use wet paper and foil to clean the internal parts of the aerators. Check for wear of the aerators using a micrometer.
Torque head — set torque to 15 N·m for securing aerators.
Error: incorrect torque usage — wear occurs.
- Control of the aeration system
Use a laser aluminum aluminum aluminum aluminum aluminum aluminum for measuring the distance between aerators. Set the distance to 120 mm.
Error: distance deviates — uneven air distribution occurs.
- Slag Pump Service
Remove the slag pump using a torque wrench with 30 N·m. Use a micrometer to check the rotor wear.
Error: No wear - replacement is required.
- pH Sensor Calibration
Use standard pH 4.01 and 7.00 liquids for calibrating the sensor. Measure the temperature of the liquid within the range of 20-25 °C.
Error: use of incorrect fluids — incorrect pH value occurs.
- Leak Check
Check all connections for leaks. Use a thermometer to check the equipment temperature.
Error: turns detected - seal replacement is required.
- Energy Recovery
Return the system power supply and perform the LOTO procedure. Check the system operation.
Error: system not working — diagnostic required.
6. Inspection after maintenance
| Test | Expected result | Actual | Pass/No pass |
|---|---|---|---|
| 1 | No leaks | No leaks | Pass |
| 2 | Correct distance between aerators | 120 mm | Pass |
| 3 | pH values within the range 6.5-7.5 | 6.8 | Pass |
| 4 | Temperature of the equipment 20-25 °C | 22 °C | Pass |
| 5 | Slag Pump Operation | The pump is working | Pass |
7. Fault Finding Guide
| Symptom | Possible cause | Search |
|---|---|---|
| Incorrect pH values | Incorrect sensor calibration | Check the sensor calibration |
| Pump Coils | Sealing Wear | Replace the seal |
| Uneven operation of aerators | Incorrect distance between aerators | Measure the distance |
| Energy recovery not performed | Incorrect LOTO procedure | Perform the LOTO procedure |
| Aerator Wear | Increased loading | Replace aerators |
8. Recommended Maintenance Schedule
| Task | Frequency | Estimated duration | Skill Level |
|---|---|---|---|
| Checking of aerators | Monthly | 1 year | Average |
| Slag Pump Cleaning | Quarterly | 2 years | Average |
| pH Sensor Calibration | Monthly | 1 year | Average |
| Leak Check | Monthly | 1 year | Average |
| Aerator Restoration | Annual | 4 years | High |
9. References to Spare Parts
| Part description | Standard specification | Category UNITEC-D |
|---|---|---|
| Aerator | Diameter 150 mm, material stainless steel | UNITEC-D 2300 |
| Pump Seal | Nickel material, diameter 25 mm | UNITEC-D 3400 |
| pH Sensor | pH range 0-14, temperature 0-100 °C | UNITEC-D 1200 |
| Calibration fluid | Standard 4.01 and 7.00 | UNITEC-D 2100 |
| Cleaning tools | Humidity paper, foil | UNITEC-D 1100 |
For more information about spare parts, visit UNITEC-D e-catalog.
10. References
- DSTU 3015-95 — Requirements for the Production and Operation of Wastewater Treatment Equipment
- EN 12101-2 — Wastewater Cleaning Equipment
- ISO 14001 — Environmental Management Systems
- CE — Conformity Certification
- UkrSEPRO — Compliance Certification in Ukraine
