Operations and Maintenance Report for Muscat Bay STP (May 2024)
Date: June 8, 2024
Introduction
The Muscat Bay Sewage Treatment Plant (STP) has not achieved its operational target of 750 m³/day in May 2024. This report delves into maintenance discrepancies, tanker management inefficiencies, operator monitoring challenges, flow rate inconsistencies, and unscheduled shutdowns, aiming to enhance the plant's performance to its designed capacity.
Key Issues and Findings
Maintenance Discrepancies
A lack of regular maintenance on Membrane 2 has been identified, with no similar preventive maintenance (PPM) as conducted on Membrane 1. The absence of comprehensive maintenance logs and monthly reports, despite clear requirements, suggests a systemic issue in maintenance execution and documentation, impacting overall plant efficiency.
Reporting Inconsistencies
Frequent missing daily reports, specifically on May 3, 28, 29, and 30, signify lapses in compliance with established reporting procedures, undermining the ability to track and rectify operational issues promptly.
Operator Performance and Shutdown Analysis
There have been multiple early morning shutdowns due to low levels in the equalization tank, indicating a potential neglect in night-time operations and a failure in maintaining necessary operational thresholds, which could point to operator error or oversight.
Plant Performance
The plant has persistently operated below its capacity, indicating inefficiencies in the treatment process and suboptimal use of plant resources, as highlighted by the variability in TSS (Total Suspended Solids) effluent water output and fluctuating daily inflow volumes.
Technical Analysis
A detailed technical analysis reveals significant operational lapses, including inappropriate scheduling of tanker discharges and poor inflow management, leading directly to the variability in inflow volumes and shutdown occurrences.
Recommendations for Improvement
- Immediate Actions (0-1 month):
- Maintenance: Conduct comprehensive cleaning and maintenance for Membrane 2.
- Monitoring: Install automated monitoring systems for real-time surveillance of the equalization tank to prevent unscheduled shutdowns.
- Procedures: Establish stricter protocols for operator activities during night shifts, including regular checks and balances.
- Mid-term Actions (1-3 months):
- Operational Adjustments: Standardize maintenance schedules across all membranes to ensure uniformity in operational treatment.
- Training: Implement a rigorous training program focusing on operational best practices and emergency response protocols.
- Long-term Actions (3-6 months):
- Process Improvement: Utilize Lean and Six Sigma methodologies to identify inefficiencies and streamline operations.
- Technology Upgrade: Upgrade system technology to enable predictive maintenance capabilities and enhance real-time data processing and reporting.
Conclusion
Addressing these operational challenges through a structured improvement plan will significantly enhance the reliability and efficiency of the Muscat Bay STP. Regular monitoring and adaptation of operational strategies are imperative to meet and exceed the designed treatment capacity, ensuring sustainable operational practices.