7 major tips for Maintaining Your Industrial Water Treatment Plant for Optimal Performance

Industrial Water Treatment Plant

During the early stages of industrialisation, untreated wastewater was commonly released into adjacent rivers and streams, leading to considerable harm to the environment and public health. However, the treatment of industrial wastewater has progressed through multiple phases, resulting in the development of sophisticated and efficient industrial water treatment solutions and processes that we have today.

An industrial wastewater treatment plant is a system that cleans water that has been polluted by industrial activities. The type of contamination and the characteristics of the resulting effluent determine the technologies used in an industrial wastewater treatment plant, which can include physical, chemical, and biological treatment methods. The specific treatment method or combination of methods used is determined by the type and concentration of pollutants in the wastewater, as well as the regulations and standards governing the discharge of treated water. Another important purpose of industrial water treatment solutions is to ensure that the water used in industrial processes meets the required quality standards. It is a common misconception that water can be used directly from its source without any treatment. In reality, the composition of input water must be altered by removing or adding certain constituents to make it suitable for different industrial uses.

Proper maintenance is crucial for the optimal performance of industrial wastewater treatment plants. Regular maintenance helps to ensure that the treatment processes are functioning efficiently and effectively and that the plant is able to consistently meet the required standards for treated wastewater. Without proper maintenance, the performance of the treatment processes can deteriorate over time, leading to reduced treatment efficiency and potentially resulting in non-compliance with regulations.

Regular maintenance of industrial water treatment plant equipment helps to optimize performance, reduce operating costs, prolong asset lifespan, and enhance operational reliability and safety.

7 major tips for Maintaining Your Industrial Water Treatment Plant for Optimal Performance

1. Regular Inspections

Regular maintenance is crucial for ensuring the optimal performance of an industrial water treatment plant. Failing to conduct periodic inspections and maintenance can lead to equipment deterioration, overheating, and eventually equipment failure. Adequate maintenance can ensure service continuity, treatment quality, and equipment longevity, while reducing operating costs. Preventive Maintenance and Corrective Maintenance are two types of maintenance. Preventive Maintenance involves periodic routine activities and measures taken to prevent system malfunctions, including mechanical adjustments, repairs, corrective action, and planned maintenance. Corrective Maintenance involves addressing breakdowns that have occurred by replacing or correcting defects. Preventive Maintenance is more cost-effective than Corrective Maintenance as it provides uninterrupted service and avoids the need for corrective maintenance.

2. Monitor Water Quality Parameters

Monitoring the output water quality parameters from water treatment plant equipment such as pH, turbidity, and chlorine levels is important to ensure that water is safe for re-use and meets regulatory standards for drinking water quality or for industrial purposes. Proper monitoring can help reduce risks associated with chemical underfeed or overfeed, improve compliance with environmental regulations, improve the quality of plant operation, increase water and energy savings, and improve plant productivity. Monitoring of the water treatment process can be classified into two main types: Manual Monitoring and Continuous On-line Monitoring. Manual Monitoring involves conducting chemical tests and comparing the results to specified chemical control limits, which is typically done by plant operators or technicians. On the other hand, Continuous On-line Monitoring uses automatic instrumentation to achieve a higher degree of precision in monitoring and controlling water treatment programs.

3. Equipment Maintenance

Equipment maintenance is crucial for maintaining the optimal performance of an industrial water treatment plant. Without periodic inspections and maintenance, equipment deterioration and burnout may occur. Equipment maintenance in industrial water treatment plants involves regular inspection, cleaning, lubrication, calibration, replacement, and record-keeping. Proper maintenance helps maintain continuity of service and treatment quality, extends equipment service life, optimizes functional availability, and minimizes overall operating costs. Additionally, regular maintenance is required for the mechanical and electrical equipment to function correctly, including pumps, valves, motors, and control systems which are key components of any industrial water treatment system. Regular maintenance can identify potential equipment failures, improve energy and water usage efficiency, and comply with regulatory limits. It can also address minor issues before they turn into significant problems and repair safety hazards to maintain employee and environmental safety.

4. Cleaning and Sanitization

Cleaning and sanitization help to remove organic material such as dirt, soil, and debris from water treatment plant equipment. This can be a breeding ground for a variety of bacteria, so cleaning is essential. Sanitization helps to reduce the number of microorganisms on surfaces to a safe level. Following are a few routine cleaning tasks:

  1. Filters cleaning 
  2. Tanks and reservoirs cleaning 
  3. Equipment sanitization 
  4. Membrane cleaning 
  5. Surfaces sanitization 
  6. Pipelines flushing 
  7. Sludge handling equipment cleaning
  8. Aeration system cleaning

5. Train and Educate Employees

Any system is only as good as the men maintaining it. Training and educating employees is vital for maintaining the optimal performance of an industrial water treatment plant. Proper training can help ensure that personnel are thoroughly trained to carry out the actions required in the plan of maintenance. This includes understanding how to operate the equipment, control the processes, and monitor the plants that treat water to make it safe for discharge or reuse. Employees who receive regular training and upskilling can identify potential problems with the equipment and processes before they lead to significant issues. This can help minimize breakdown and ensure that the plant operates efficiently and effectively. Regular training programs help identify potential replacements for key positions in the plant which ensures that operations run efficiently and even if certain key personnel are suddenly unavailable.

6. Maintain Chemical Levels

Maintenance of chemical levels is essential to ensure the optimal running of an industrial water treatment plant. Most industrial water treatment systems are dynamic and constantly undergo changes because of seasonal variations in water chemistry, varying plant operating conditions and other factors making it vital to regularly monitor and maintain chemical levels to ensure that the treatment process remains efficient. More specifically, chemical levels are important for preventing corrosion and scaling, controlling microbiological growth, and ensuring efficient operation of the water treatment system. Chemical inhibitors prevent corrosion and scaling by forming a protective layer on metal surfaces and binding to minerals in the water. Biocides prevent microbiological growth by killing or inhibiting the growth of microorganisms. Proper chemical levels ensure that dosing rates are correct, resulting in optimal treatment and reduced operating costs.

7. Develop a Maintenance Schedule

A well-planned maintenance schedule can help keep the industrial water treatment process running smoothly, and minimize the risks associated with equipment failure, which can lead to significant losses in production. It helps to optimize functional availability while minimizing overall operating costs. A maintenance schedule typically includes listing the technical features of all equipment, defining maintenance operations, their nature, frequency and duration, having planning and control tools, forming and maintaining a stock of spare parts, statistically appraising the reliability and maintenance costs associated with each item of equipment, and publishing effectiveness assessment indicators. Moreover, the safety of employees and the environment is a top priority in industrial plants, and a maintenance schedule ensures that equipment is operating safely and that any safety issues are addressed promptly.

In summary, regular maintenance is an investment that pays off in the long term by ensuring the continued effectiveness and sustainability of industrial wastewater treatment processes.

Wipro Water Approach

Wipro Water is a division of Wipro Infrastructure Engineering, offering the industry’s most comprehensive range of water and wastewater treatment solutions and plant operation & maintenance services for industries and communities. With over 40+ Years of Domain Expertise, and having served 500+ Global Customers across 25+ Industry Segments, Wipro Water provides End-to-end, custom-designed integrated plants for various sectors. Wipro Water executes complex projects optimally by understanding business requirements by deep diving into the various processes. Wipro Water offers a comprehensive range of sustainable industrial water treatment solutions specifically designed to assist businesses in reducing water consumption, lowering costs, and minimizing environmental impact.

Wipro Water maintains industrial water treatment plants through comprehensive maintenance plans tailored to each customer’s needs. Skilled professionals with extensive experience and training use advanced monitoring and control systems that provide real-time alerts. Wipro Water’s maintenance contracts are built upon a data-driven approach to maintenance that prioritizes proactive and targeted actions while emphasizing the safety of employees and the environment.