INDUSTRIAL INSIGHT: VA TECH WABAG LTD

AN INTERNSHIP REPORT

Submitted by
ROHIT KUMAR (21BCH1044)

Under the supervision of

Mr. KAPIL VARMA

at
VA TECH WABAG LTD.

in partial fulfilment for the award of the degree of

27, JANUARY –16, MAY, 2025

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 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to VA Tech Wabag for providing me with the
opportunity to undertake my internship at their esteemed organization. It has been a
valuable and enriching experience that has significantly contributed to my academic and
professional growth. I am deeply thankful to Mr. Kapil Varma and Mr. Piyush Pandey,
whose guidance, encouragement, and support throughout the internship helped me gain
practical insights into the field of water and wastewater treatment. My heartfelt thanks also
go to all the staff and team members at VA Tech Wabag for their cooperation, friendliness,
and willingness to share their knowledge, which made my learning experience both smooth
and enjoyable.

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 TABLE OF CONTENT

LIST OF TABLES .......................................................................................................................................................... 5

LIST OF FIGURES ........................................................................................................................................................ 6
ABSTRACT .................................................................................................................................................................. 7
1. INTRODUCTION ..................................................................................................................................................... 8
1.1 Background of the Internship .......................................................................................................................... 8
1.2 Purpose of Internship ...................................................................................................................................... 8
1.3 Scope of Internship .......................................................................................................................................... 9
1.4 Duration and Location of Internship ............................................................................................................... 9
2. COMPANY PROFILE .............................................................................................................................................. 10
2.1 Introduction to VA TECH WABAG LTD. .......................................................................................................... 10
2.2 Areas of Expertise .......................................................................................................................................... 10
2.3 Major Projects and Achievements................................................................................................................. 10
2.4 Vision, Mission and Values ............................................................................................................................ 11
3. DEPARTMENT AND AREA OF INTERNSHIP........................................................................................................... 12
3.1 Monthly Department Distribution: ............................................................................................................... 12
3.2 Key Functional Areas and Departments ........................................................................................................ 12
3.3 Water Chemistry............................................................................................................................................ 13
3.3.1 Water Quality Parameters ...................................................................................................................... 13
3.3.2 Various Water Quality Parameters......................................................................................................... 13
3.3.3 Biological Oxygen Demand (BOD) .......................................................................................................... 15
3.3.4 Chemical Oxygen Demand (COD) ........................................................................................................... 15
3.3.5 Total Suspended Solids (TSS) .................................................................................................................. 15
3.3.6 Faecal Coliform Bacteria ......................................................................................................................... 16
3.3.7 Total Phosphorous .................................................................................................................................. 16
3.3.8 Salinity and Salt Content......................................................................................................................... 16
3.3.9 Turbidity ................................................................................................................................................. 17
3.4 Steps of Waste Water Treatment .................................................................................................................. 17
3.4.1 Preliminary Treatment ........................................................................................................................... 18
3.4.2 Primary Treatment / Primary Sedimentation ......................................................................................... 21
3.4.3 Secondary Water Treatment .................................................................................................................. 22
3.4.4 Tertiary Treatment ................................................................................................................................. 26
3.5 Types of Water Treatment Facilities ............................................................................................................. 29
3.5.1 Sewage Treatment Plant (STP) ............................................................................................................... 30
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 3.5.2 Effluent Treatment Plant (ETP) ............................................................................................................... 31
3.5.3 Desalination ............................................................................................................................................ 31
3.6 Reverse Osmosis (RO).................................................................................................................................... 32
3.6.1 Guidelines for RO Feed Water ................................................................................................................ 32
3.5.2 RO Configuration Stages ......................................................................................................................... 33
3.6.3 Parameter of Designing RO .................................................................................................................... 33
3.7 Engineering Learnings ................................................................................................................................... 33
3.7.1 Sewage and related terms ...................................................................................................................... 33
3.7.2 Factors affecting Sewage Flow ............................................................................................................... 34
4. P&ID (PIPING AND INSTRUMENTATION DIAGRAM) ............................................................................................ 35
[Link] REPORT ......................................................................................................................................................... 36
5.1 Site Location .................................................................................................................................................. 36
5.2 Rithala Project Objective ............................................................................................................................... 36
5.3 Rithala Flow ................................................................................................................................................... 36
5.4 Water Quality ................................................................................................................................................ 36
5.5 Process Flow Diagram.................................................................................................................................... 37
5. CONCLUSION ....................................................................................................................................................... 42

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 LIST OF TABLES

Table 1: Timeline...................................................................................................................................................... 12
Table 2: Physical Parameters ................................................................................................................................... 14
Table 3: Chemical Parameters ................................................................................................................................. 14
Table 4: Biological Parameters ................................................................................................................................. 15
Table 5: Various physical treatment in preliminary stage ........................................................................................ 18
Table 6: Key Parameters used in Grit chamber ....................................................................................................... 22
Table 7: Various Anaerobic processes ..................................................................................................................... 23
Table 8: Types of Aeration System ........................................................................................................................... 24
Table 9: Stages of Water Treatment ........................................................................................................................ 27
Table 10: Various Water Treatment Plants .............................................................................................................. 30
Table 11 Inlet Parameters ........................................................................................................................................ 36

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 LIST OF FIGURES

Figure 1: Water molecular structure and its properties ......................................................................................... 13

Figure 2: Showing various water quality parameters ............................................................................................. 13
Figure 3: Showing BOD ............................................................................................................................................ 15
Figure 4: Showing TSS .............................................................................................................................................. 16
Figure 5: Showing Faecal Coliform Bacteria ............................................................................................................ 16
Figure 6: Comparing sea water and fresh water ..................................................................................................... 17
Figure 7: Showing Turbidity .................................................................................................................................... 17
Figure 8 Steps Of Water treatment ......................................................................................................................... 17
Figure 9:Screens used in Water Treatment ............................................................................................................. 19
Figure 10 Grit Chamber Diagram ............................................................................................................................. 20
Figure 11: Primary Clarifier ...................................................................................................................................... 21
Figure 12: Biological Anaerobic Treatment Detail ................................................................................................... 22
Figure 13: Aeration Tank Flow ................................................................................................................................. 23
Figure 14 Secondary sedimentation ........................................................................................................................ 26
Figure 15 Disc filter .................................................................................................................................................. 28
Figure 16 A Flow Diagram of STO process ............................................................................................................... 30
Figure 17: A Flow Diagram showing ETP process .................................................................................................... 31
Figure 18: Showing Desalination Plant .................................................................................................................... 31
Figure 19: Reverse Osmosis ..................................................................................................................................... 32
Figure 20: RO Configuration stages ......................................................................................................................... 33
Figure 21: Designed Flow......................................................................................................................................... 36
Figure 22 Screening ................................................................................................................................................. 37
Figure 23 Grit Chamber ........................................................................................................................................... 38
Figure 24 Parshall Flume.......................................................................................................................................... 39
Figure 25 Sedimentation Tank ................................................................................................................................. 39
Figure 26 Aeration Tank ........................................................................................................................................... 40
Figure 27 Anoxic And Aeration Zone ....................................................................................................................... 41
Figure 28 CCT ........................................................................................................................................................... 41
Figure 29 Hydro Generator ...................................................................................................................................... 41

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 ABSTRACT
This internship report provides an overview of my experience at VA Tech Wabag, where I worked in the
Process & Proposal Department and the Engineering Department. Over the course of the internship, I
gained hands-on exposure to water treatment solutions, engineering designs, and proposal development
processes.

In the Tender and Proposal, I contributed to analysing tender documents, understanding bidding
strategies, and evaluating project feasibility, gaining insight into the competitive landscape of water
treatment projects. Meanwhile, my experience in the Engineering Department helped me understand
process flow diagrams (PFDs), piping & instrumentation diagrams (P&IDs), and water purification
techniques.

Throughout this internship, I developed key technical and analytical skills, along with problem-solving
abilities and team collaboration experience. This report highlights my tasks, learnings, challenges, and
recommendations to enhance the efficiency of the internship program.

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 1. INTRODUCTION

1.1 Background of the Internship

In the evolving landscape of environmental engineering, water scarcity, contamination, and

sustainability have emerged as global challenges. Addressing these issues requires not just theoretical
knowledge, but practical experience in handling real-world systems and technologies. As part of the
curriculum for a Bachelor’s degree in Chemical Engineering, internships play a crucial role in
bridging the gap between classroom learning and industrial application.

To gain such industrial exposure, I undertook an internship at VA Tech Wabag, a multinational

company known for delivering innovative and sustainable water and wastewater treatment solutions
across the globe. The organization’s strong focus on technology-driven water purification and
recycling aligns closely with the core principles of chemical engineering and environmental
stewardship.

This internship provided a valuable opportunity to observe, understand, and interact with modern
treatment technologies and systems that are pivotal in large-scale municipal and industrial water
management. It served as a platform to gain practical insight into plant operations, engineering design,
process optimization, and sustainable practices implemented in real-time scenarios.

1.2 Purpose of Internship

The primary aim of the internship was to acquire practical knowledge of water and wastewater
treatment processes and to develop an understanding of the design, operation, and maintenance of
treatment plants. The specific objectives of the internship were:

 To observe and learn about key technologies used in water treatment process.

 To gain exposure to the project execution process, plant layout, and process flow.

 To understand the practical challenges involved in water treatment and the solutions adopted by
industry experts.

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  To enhance personal and professional skills, including teamwork, communication, and time
management.

1.3 Scope of Internship

 Observing the design and operation of water and wastewater treatment plants.

 Exposure to engineering drawings, P&IDs, and plant layout diagrams.

 Visiting project sites and learning about on-site execution and commissioning.

 Gaining knowledge of the operation and maintenance (O&M) of treatment plants.

 Understanding project management and coordination activities within the team.

 Learning about industry standards and safety protocols followed in plant environments.

 Observing the integration of sustainable practices in wastewater treatment and resource recovery.

1.4 Duration and Location of Internship

The internship at VA Tech Wabag was carried out over a period of 4 months, starting from 27th Jan
2025 to 16th May 2025. During this period, I was exposed to various aspects of water and wastewater
treatment projects under the guidance of experienced professionals and engineers.

The internship was conducted at VA Tech Wabag Corporate Office, Noida, which provided a dynamic
and practical learning environment. These locations offered access to both office-based engineering
design work and field-based operational experiences.

The location selection was vital in understanding how theoretical concepts are applied in real-time
operations, how engineering drawings and process designs are implemented on-site, and how each
unit process is controlled and maintained. The exposure to live projects gave me insight into both the
technical and managerial aspects of working in a professional engineering setup.

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 2. COMPANY PROFILE

2.1 Introduction to VA TECH WABAG LTD.

VA Tech Wabag Ltd. is an Indian multinational company focussed on desalination and water
treatment for municipal and industrial users. WABAG’s water saga spans over a century, making
it an industry leader today in the field of total water management. With presence in four continents,
WABAG is a pure-play water technology multinational offering a wide range of solutions focused
on conservation, optimisation, recycling and reuse of resources, directed at addressing water
challenges across the world. With strong Research & Development and a passion for innovation,
WABAG has honed its skills in handling EPC projects of any scale across any sector or region.
WABAG has dedicated R&D centers in Europe and India, and holds over 125 IP Rights. The
company’s key competences, developed over 100 years of plant-building experience, lie in the
turnkey execution and operation of water and wastewater treatment plants for both the municipal
and industrial sectors. WABAG has a successful track record of executing over 6500 municipal
and industrial projects globally with quality and commitment to timely delivery.

2.2 Areas of Expertise

VA Tech Wabag provides a full suite of water solutions, including:

 Water Treatment Plants (WTP)

 Sewage Treatment Plants (STP)
 Effluent Treatment Plants (ETP)
 Sea Water Desalination
 Industrial Wastewater Recycling
 Operation and Maintenance (O&M) Services

2.3 Major Projects and Achievements

Some of the landmark projects delivered by VA Tech Wabag include:

 Koyambedu Water Treatment Plant in Chennai, India – one of the largest water reuse facilities in
South Asia.

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  Qatar Sewage Treatment Plant – a world-class facility serving urban and industrial needs.
 STP Projects in New Delhi, India under the Yamuna Action Plan, helping reduce pollution in the
river.
 Sea Water Desalination Projects in Oman, Algeria, and Saudi Arabia.

2.4 Vision, Mission and Values

Vision: WABAGites enrich Life by Preserving Resources, Protecting Environment, Powering
Economies through innovative and sustainable water solutions.

Mission: W – Win approach with customer and every stakeholder

A – Advanced Technology and Value Engineering Solutions

B – Build an empowered, entrepreneurial and creative team

A – Aspirational leadership with courage and care

G – Growth guided by responsibility and values

Values: W – Will to act decisively and commit to deliver the organizational goals

A – Agile to be energetic, adaptable and resilient, to dynamic business environment.

T – Trust to be accountable and transparent to all our stakeholder

E – Empathy to build long-term relationship based on care, understanding

R – Resolve to create sustainable solutions that benefits people and

Environment

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 3. DEPARTMENT AND AREA OF INTERNSHIP

3.1 Monthly Department Distribution:

JANUARY FEBRUARY MARCH

• INDUCTION • PROJECT • ENGINEERING
PROGRAMME MANAGEMENT • INDUSTRIAL
• PROCESS & SAFETY
PROPOSALS

APRIL
• SITE VISITS

Table 1: Timeline

3.2 Key Functional Areas and Departments

 Process Engineering Department – Responsible for designing process flow diagrams (PFDs),
selecting appropriate treatment technologies, and optimizing operations.

 Project Execution Team – Manages timelines, resources, and on-site implementation of projects,
including civil, mechanical, and electrical works.

 Operations & Maintenance (O&M) Team – Handles the day-to-day functioning of treatment
plants, equipment monitoring, troubleshooting, and ensuring compliance with discharge standards.

 Procurement & Supply Chain – Ensures the timely delivery of materials and equipment needed for
project execution.

 Quality Assurance and HSE Team – Focuses on safety regulations, quality control, and
environmental compliance.

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3.3 Water Chemistry
Water Chemistry deals with the composition, properties, and reactions of water. It is
eessential for water treatment, environmental science, and industrial applications.

Figure 1: Water molecular structure and its properties

3.3.1 Water Quality Parameters

Water quality parameters are indicators that determine the physical, chemical, and biological
characteristics of water. It is essential for assessing water pollution, treatment, and environmental impact.

Figure 2: Showing various water quality parameters

3.3.2 Various Water Quality Parameters

Water quality parameters are categorized into three main types:

1. Physical parameters – related to the physical appearance and properties.

2. Chemical parameters – related to the chemical composition.

3. Biological parameters – related to the presence and activity of microorganisms.

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 PHYSICAL PARAMETERS
DESCRIPTION
Affects biological activity, reaction rates, and
Temperature
solubility of gases.
Cloudiness caused by suspended solids. Affects
Turbidity
light penetration and filtration.
Caused by organic matter or metals; affects
Colour
aesthetics and may indicate pollution.
Indicators of organic material, microbial activity,
Taste & Odor
or industrial contamination.
Combined suspended and dissolved solids
Total Solids (TS)
affecting clarity and treatment needs.
Table 2: Physical Parameters

CHEMICAL PARAMETERS
DESCRIPTION

Indicates acidity or alkalinity; ideal drinking

pH
water is between 6.5–8.5.
Essential for aquatic life; low levels indicate
Dissolved Oxygen (DO)
pollution.
Amount of oxygen needed by microbes to
Biochemical Oxygen Demand (BOD)
decompose organic matter.
Total oxygen required to oxidize all organic and
Chemical Oxygen Demand (COD)
inorganic matter.
From fertilizers/sewage; harmful to infants (blue
Nitrates (NO₃⁻)
baby syndrome).
Promote algal growth; lead to eutrophication in
Phosphates (PO₄³⁻)
natural waters.
Indicates fresh pollution from sewage or
Ammonia (NH₃/NH₄⁺)
fertilizers.
Table 3: Chemical Parameters

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 Biological Parameters
Description

Indicator of potential contamination by

Total Coliform Bacteria pathogens; presence means possible faecal
pollution.
More specific indicator of faecal contamination;
Faecal Coliform / E. coli
implies sewage or animal waste.
Disease-causing organisms like Giardia,
Pathogens (viruses, protozoa, bacteria)
Cryptosporidium, and Hepatitis viruses.
Table 4: Biological Parameters

3.3.3 Biological Oxygen Demand (BOD)

It is the mount of oxygen required by microorganisms to decompose organic matter.
High BOD indicates high organic pollution.

Figure 3: Showing BOD

3.3.4 Chemical Oxygen Demand (COD)

It is the measure of the total amount of oxygen required to oxidize both organic and inorganic substances.

Higher COD values indicate significant pollution levels.

3.3.5 Total Suspended Solids (TSS)

It is the particles suspended in water that do not dissolve. High TSS can reduce light penetration and affect
aquatic life.

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 Figure 4: Showing TSS

3.3.6 Faecal Coliform Bacteria

They are the bacteria found in the intestines of warm-blooded animals which is an indicator of sewage
contamination.

Figure 5: Showing Faecal Coliform Bacteria

3.3.7 Total Phosphorous

It is the sum of all Phosphorous forms in water which is expressed in mg/L Excess of it leads to algae
blooms and eutrophication.

3.3.8 Salinity and Salt Content

It is the measure of total salt concentration in water for example sseawater intrusion, industrial discharge.
It effects soil and drinking water quality.

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 Figure 6: Comparing sea water and fresh water

3.3.9 Turbidity
It is the optical characteristic of water and is a measurement of the amount of light that is scattered by
material in the water when a light is shined through the water sample. High turbidity reduces light
penetration and water quality. Measurement of Nephelometric Turbidity Units (NTU).

Figure 7: Showing Turbidity

3.4 Steps of Waste Water Treatment

Wastewater treatment is a crucial process that involves the removal of contaminants from domestic,
industrial, and commercial effluents before they are released into the environment or reused. The treatment
process typically includes physical, chemical, and biological methods to eliminate solids, organic matter,
nutrients, and harmful microorganisms. Primary treatment focuses on the removal of large solids through
screening and sedimentation. Secondary treatment uses biological processes, such as activated sludge or
biofilm reactors, to degrade organic matter. Tertiary treatment further purifies the water by removing
nutrients like nitrogen and phosphorus, along with pathogens and trace contaminants. Efficient wastewater
treatment helps protect public health, conserve water resources, and maintain ecological balance.

Figure 8 Steps Of Water treatment

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3.4.1 Preliminary Treatment
Preliminary water treatment is the first stage in a water or wastewater treatment process. Its primary
purpose is to remove large physical impurities and protect downstream equipment from damage or
clogging. This stage does not treat dissolved contaminants, but it plays a crucial role in ensuring the overall
efficiency and longevity of the treatment plant.

Unit/Process Purpose Description

Removes large floating solids like Uses bar screens (coarse or fine) to filter large
Screening
plastics, rags, and leaves materials from the influent

Removes sand, gravel, and other Settles out heavy inorganic particles through
Grit Removal
dense particles velocity control in a chamber

Flow Uses storage tanks to maintain consistent

Balances hydraulic load variations
Equalization flow and load into secondary units

Table 5: Various physical treatment in preliminary stage

Screening
Screens are devices with openings, generally of uniform size for removal of bigger suspended or floating
matter in the sewage such as plastic bags, paper, cloth etc.

 Coarse Screen: Screen with larger size openings, above 40mm

 Medium Screen: opening size 10mm to 40mm

 Fine screen: opening size less than 10mm

Methods of Screen Cleaning

 Manual Screen- Hand Cleaned

 Mechanical Screen- Cleaned with mechanical rakes

 Screenings Compactor - It is simply a machine that compacts, dehydrates, and transports wet
screenings discharge.

Design of Screens
1. Approach Velocity (V)

 Should be between 0.3 to 0.9 m/s to avoid settling of solids or carry-over.

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 V=QA

Where:

o V = Approach velocity (m/s)

o Q = Flow rate (m³/s)

o A = Net open area of screen (m²)

2. Bar Spacing (S)

 Coarse screen spacing: 25–150 mm

 Fine screen spacing: 1.5–6 mm

3. Bar Rack Angle (θ)

 Typically, 45° to 60°

 Helps in manual or mechanical raking and self-cleaning

Note: As debris accumulates, head loss increases, hence automatic cleaning mechanisms are often used.

Figure 9:Screens used in Water Treatment

Grit Removal

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Grit removal is a vital preliminary treatment step in wastewater treatment plants, particularly in Sewage
Treatment Plants (STPs). The purpose is to eliminate heavy inorganic solids such as:

 Sand

 Gravel

 Eggshells

 Coffee grounds

 Broken glass and other particles

These particles, if not removed early, can:

 Cause wear and tear on equipment like pumps.

 Settle in tanks, reducing treatment efficiency.

 Block pipes and disrupt flow dynamics.

Figure 10 Grit Chamber Diagram

Design of Grit Chamber

[Link] Design Objectives

 Remove grit (sand, gravel, cinders) ≥ 0.2 mm.

 Maintain a velocity of 0.3 m/s to keep organic solids in suspension.

 Ensure a detention time of 30–60 seconds.

 Prevent grit deposition outside the chamber.

2. Design Parameters and Formulas

a. Flow Rate (Q)

Usually given in m³/day or m³/s. Convert to m³/s if needed for velocity calculation.

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b. Cross-sectional Area (A)

To maintain the target velocity:

A= Q /V

c. Length of Chamber (L)

L=v×t

Where:

L = Length (m)

t = Detention time (s), usually 30–60 seconds

d. Depth (D)

Depends on the volume required:

D =Volume / (L× Width)

3.4.2 Primary Treatment / Primary Sedimentation

Primary sedimentation is a crucial stage in wastewater treatment where suspended solids and organic
matter settle out of the wastewater. The process occurs in large sedimentation tanks, allowing gravity to
separate solid particles from the liquid. Heavier particles, known as sludge, sink to the bottom, while
lighter materials, such as oils and grease, float to the surface and are skimmed off. This stage significantly
reduces the biochemical oxygen demand (BOD) and suspended solids, making the water easier to treat in
subsequent stages. The settled sludge is later processed through digestion and dewatering, while the
clarified water moves forward to secondary treatment for further purification.

Its main purpose is to remove settleable solids and floating materials (scum) from waste water after grit
removal and before biological treatment.

Figure 11: Primary Clarifier

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Working Principle:

 Wastewater is held in a large rectangular or circular tank.

 The flow velocity is reduced, allowing heavier particles to settle and lighter ones to float.

 Sludge settles at the bottom and is scraped and collected for further treatment.

 Scum (oils, fats) is skimmed off the top.

Parameter Typical Range

Detention Time 1.5 – 2.5 hours
Surface Overflow Rate
25 – 40 m³/m²/day
(SOR)
Removal Efficiency 50–70% for TSS, 25–40% for BOD
Table 6: Key Parameters used in Grit chamber

3.4.3 Secondary Water Treatment

Its main purpose is to remove dissolved and suspended organic matter from wastewater that remains after
primary treatment, using biological processes (mainly microorganisms).

Biological treatment of Sewage is used to lower the organic load of wastewater. There are two main types
of biological treatment adopted:

• Aerobic Biological Treatment

• Anaerobic Biological Treatment

Secondary treatment removes dissolved and suspended biological matter. Secondary treatment is typically
performed by indigenous, water-borne microorganisms in a managed habitat. Secondary treatment may
require a separation process to remove the microorganisms from the treated water prior to discharge or
tertiary treatment.

Figure 12: Biological Anaerobic Treatment Detail

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Anaerobic Process

The anaerobic process is a biological treatment method in which microorganisms break down organic
matter in the absence of oxygen. It’s commonly used for high-strength organic wastewater and sludge
digestion.

Stage Description

Complex organics (carbohydrates, proteins, fats) are broken down into simpler
1. Hydrolysis
soluble compounds.

Simple molecules are converted into volatile fatty acids, alcohols, CO₂, and
2. Acidogenesis
hydrogen.

3. Acetogenesis Fatty acids and alcohols are converted into acetic acid, CO₂, and H₂.

Methane-forming bacteria convert acids and hydrogen into methane (CH₄) and
[Link]
carbon dioxide (CO₂).

Table 7: Various Anaerobic processes

Aerobic Process

The aerobic process is a biological treatment method where microorganisms break down organic matter
in the presence of oxygen. It is widely used in secondary wastewater treatment.

Figure 13: Aeration Tank Flow

In this process……

 Oxygen supply is provided either by mechanical aerators or air diffusers.

 Aerobic bacteria metabolize organic contaminants.

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  Treated water flows into a secondary clarifier, where the biomass (sludge) settles out.

 A portion of the sludge is recycled to maintain microbial population; the rest is removed as waste.

Aeration Tank

The aeration tank is a key unit in the secondary treatment stage (biological treatment). Its role is to:

 Promote the growth of aerobic microorganisms that break down organic pollutants.

 Supply oxygen needed by these microbes for metabolism.

In this process……

 Wastewater from the primary sedimentation tank enters the aeration tank.

 Air (or pure oxygen) is pumped into the tank using diffusers or mechanical aerators.

 The aerobic bacteria consume organic pollutants (measured as BOD), converting them into:0

 Carbon dioxide (CO₂)

 Water (H₂O)

 More microbial cells (sludge)

 This "mixed liquor" (wastewater + microbes) is later passed to the secondary clarifier for
separation.

System Type Description

Diffused Aeration Air bubbles released from diffusers at tank bottom; highly efficient

Mechanical Aeration Surface aerators mix air into water by agitation

Jet Aeration Pressurized water mixed with air through nozzles

Pure Oxygen Aeration Uses concentrated oxygen for high-efficiency treatment

Table 8: Types of Aeration System

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Secondary Clarifier
Secondary treatment is the biological phase of wastewater treatment, where microorganisms break down
organic pollutants present in the water. This process significantly reduces the biochemical oxygen demand
(BOD) and removes dissolved and suspended organic matter.

 Key Processes in Secondary Treatment:

Aeration & Activated Sludge Process:

 Wastewater is mixed with microorganisms in aeration tanks.

 Oxygen is supplied to support bacteria that consume organic pollutants.
 The mixture is then sent to secondary clarifiers, where sludge settles.
 Some sludge is recycled to maintain microbial populations, while excess sludge is removed.

Trickling Filters & Biofilms:

 Water is sprayed over a bed of rocks or plastic media, which hosts beneficial bacteria.
 Microorganisms form a biofilm and consume organic waste
 The treated water moves on for further purification.

Anaerobic Treatment:

 Carried out in oxygen-free reactors, mainly for high-strength industrial wastewater.

 Anaerobic bacteria digest organic pollutants, producing methane gas as a by-product.
 Used sludge is further treated or disposed of.

Oxidation Ponds & Lagoons:

 Large ponds containing algae and bacteria naturally treat wastewater.

 Sunlight, oxygen, and microbial activity break down pollutants.

Secondary treatment removes up to 85-90% of organic pollutants, making the water much safer before
tertiary treatment or discharge.

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 Figure 14 Secondary sedimentation

In this process….

 After aeration, the mixture of wastewater and microbes (mixed liquor) enters the secondary clarifier.

 Flocs settle under gravity, forming return activated sludge (RAS) and waste activated sludge (WAS).

 Clear effluent overflows to the next treatment or discharge.

3.4.4 Tertiary Treatment

In wastewater management, tertiary treatment represents an advanced stage that follows primary and
secondary treatment methods. It is designed to substantially degrade the biological content of the sewage,
which is derived from human waste, food waste, soaps, and detergents. Known as the final cleaning
process, tertiary treatment improves effluent quality before being released into the environment or reused.
It involves using sophisticated technology to remove residual inorganic compounds, organic substances,
bacteria, viruses, and other pathogens that secondary treatment could not eliminate.

Tertiary treatment methods vary significantly based on the composition of the wastewater and the required
quality of the effluent according to regulatory standards. Common tertiary processes include filtration,
carbon adsorption, nutrient removal, and disinfection. These steps ensure that the treated water meets
the safety standards for public health and environmental protection. Moreover, introducing advanced
technologies, such as membrane filters and ultraviolet disinfection, has significantly enhanced the
effectiveness and efficiency of tertiary wastewater treatment systems.

Comparison with Primary and Secondary Stages

In contrast to tertiary treatment, primary treatment involves the removal of large solid materials through
processes like screening and sedimentation. Following this, secondary treatment typically employs
biological processes to substantially degrade the biological content of the sewage, mainly derived from
26
human waste, food waste, soaps, and detergents. The tertiary treatment stage goes beyond by applying
more sophisticated technologies, including filtration, disinfection (e.g., using ultraviolet light or chlorine),
and advanced methods like activated carbon adsorption or ion exchange to achieve water of the highest
quality. The comparison table below summarizes the different stages:

Stage Process Contaminants Removed

Primary Screening, sedimentation Solids, inorganic matter

Biological processes (e.g.,

Secondary Biodegradable organics, some pathogens
activated sludge)

Filtration, disinfection, Nutrients, suspended solids, pathogens, remaining

Tertiary
advanced methods organics, trace chemicals

Table 9: Stages of Water Treatment

Process used for Tertiary Treatment

 Filtration (Reverse Osmosis)
Reverse Osmosis (RO) is an advanced water purification process that removes dissolved salts,
contaminants, and impurities from water by forcing it through a semi-permeable membrane. It is
widely used in desalination, industrial water treatment, and wastewater recycling.

Advantages of Reverse Osmosis

✔️ Removes up to 99% of dissolved impurities (salts, fluoride, arsenic, and bacteria).

✔️ Desalination capability – Converts seawater into fresh drinking water.

✔️ Used in wastewater recycling for industrial and municipal applications.

✔️ Produces clean and safe water for drinking, agriculture, and industry.

 Ultrafiltration

Ultrafiltration (UF) is a membrane filtration process that removes suspended solids, bacteria,
viruses, and larger molecules from water. It is a physical separation method, using a semi-
permeable membrane with pore sizes ranging from 0.01 to 0.1 microns, making it highly effective
for purification.
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 Figure 15 Disc filter

Applications of Ultrafiltration

✔️ Drinking Water Treatment: Removes pathogens, making water safe for consumption.

✔️ Wastewater Treatment: Used as a pre-treatment step before Reverse Osmosis (RO).

✔️ Food & Pharmaceutical Industries: Purifies liquids by removing bacteria and proteins.

✔️ Industrial Water Reuse: Ensures clean water for industrial applications.

 Ultraviolet (UV) filtration

UV is a powerful and chemical-free method of disinfecting water by using ultraviolet light to kill
bacteria, viruses, and other microorganisms. It works by exposing water to high-intensity UV
rays, which damage the genetic structure of pathogens, preventing them from reproducing or
causing infections.

This process is highly effective in eliminating harmful microbes without altering the taste, odor,
or chemical composition of water. Unlike chlorine-based disinfection, UV filtration does not
introduce harmful byproducts, making it an environmentally friendly solution. It is commonly
used in drinking water purification, wastewater treatment, and industrial applications where
microbiological safety is essential.

However, UV filtration is most effective when used in conjunction with pre-filtration, ensuring
that the water is free from sediments and particles that may block the UV light. With its ability to

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 provide rapid and reliable microbial inactivation, UV filtration plays a crucial role in ensuring
safe and potable water for consumption and industrial use.

 Chlorination

A Chlorine Contact Tank (CCT) is a crucial component in water and wastewater treatment used
for disinfection before the treated water is released or reused. The primary function of a CCT is to
provide sufficient retention time for chlorine to effectively kill bacteria, viruses, and other
pathogens in the water.

How It Works:

Chlorination: Chlorine is added to water, either as liquid chlorine, sodium hypochlorite, or chlorine
gas, to initiate the disinfection process.

Mixing & Contact Time: The water flows through a CCT designed with baffles, ensuring proper
mixing and maximizing the contact time between chlorine and pathogens.

Pathogen Inactivation: The chlorine reacts with microorganisms, destroying their cellular
structures and ensuring microbiological safety.

DE-chlorination (If Required): If excess chlorine remains, neutralizing agents (like sodium
bisulfite) can be added to prevent environmental harm when discharging the treated water.

Key Design Considerations:

✔️ Retention Time: Typically, 15-30 minutes to allow chlorine to work effectively.

✔️ Tank Shape & Baffles: Baffles increase hydraulic efficiency, preventing short-circuiting and
ensuring uniform chlorine distribution.

✔️ Chlorine Dosage: Determined based on water quality, demand, and required pathogen removal.

3.5 Types of Water Treatment Facilities

A water treatment plant (WTP) is a facility that treats raw water—sourced from rivers, lakes, reservoirs,
or underground aquifers—and transforms it into potable (drinkable) water by removing physical,
chemical, and biological contaminants.

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 Table 10: Various Water Treatment Plants

3.5.1 Sewage Treatment Plant (STP)

An STP (Sewage Treatment Plant) is a facility designed to treat domestic or industrial wastewater (also
known as sewage) before it is safely discharged into the environment or reused. The goal is to remove
contaminants such as organic matter, pathogens, nutrients, and suspended solids to protect public health
and the environment.

Raw Sewage Inlet Chamber

Primary
Raw Sewage Sump
Clarifier Secondary Clarifier
Mechanical Coarse Screen
Manual Coarse Screen Aeration Tank
Distribution
Chamber

Treated sewage to
Fine screen Parshall Flume Distribution Nallah
Grit Chamber Chamber
Return Activated
Sludge Line

Primary Sludge Line

Excess Sludge Thickener

Secondary Sludge Pumping

Primary Sludge Pumping Station
Station

Digested Sludge Pumping

Sludge Digester
Station
Centrifuge

Primary Sludge Thickener Thickened Sludge Pumping Dewatered Sludge to

station Biogas to flare landfill

Figure 16 A Flow Diagram of STO process

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3.5.2 Effluent Treatment Plant (ETP)
An Effluent Treatment Plant (ETP) is a facility designed to treat wastewater (effluent) coming from
industrial processes. Its primary aim is to remove harmful pollutants, chemicals, and toxic substances
before the water is discharged into the environment or reused.

Figure 17: A Flow Diagram showing ETP process

3.5.3 Desalination
Desalination is the process of removing dissolved salts and minerals from seawater or brackish water to
produce freshwater suitable for drinking, irrigation, or industrial use. It’s a critical solution in arid regions,
islands, and coastal cities facing water scarcity.

Figure 18: Showing Desalination Plant

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3.6 Reverse Osmosis (RO)
Reverse Osmosis is a water purification process that uses a semi permeable membrane to separate water
molecules from other substances.

Figure 19: Reverse Osmosis

3.6.1 Guidelines for RO Feed Water

• SDI- Less than 3 to 5.

• Turbidity: Turbidity should be less than 0.2 to 0.5 NTU.

• Oil and grease: should be less than 0.1 ppm.

• Iron: should be less than 0.1 ppm.

• Manganese: should be less than 0.05 ppm

• Free Chlorine: should be less than 0.1 ppm.

• Total Organic Content: should be less than 2 ppm.

Common issues for poor feed water:

 Membrane fouling (due to suspended solids, organics, biofilm)

 Scaling (due to hardness, silica)

 Oxidation damage (from chlorine or ozone)

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  Reduced permeate quality and shorter membrane life

3.5.2 RO Configuration Stages

In an RO system, water is pushed through semi-permeable membranes under high pressure to remove
salts, minerals, and other impurities. To make this process more effective, membranes are arranged in a
specific configuration of stages and passes.

Figure 20: RO Configuration stages

3.6.3 Parameter of Designing RO

 TDS of feed water

 Recovery goals

 Membrane type

 Flow and pressure balance

3.7 Engineering Learnings

In engineering department, we learned various processes used in a water treatment plant and learned the
designing of equipment used in water treatment process. Also, we took an overview about P&ID and
Flow diagrams that depicts specific water treatment plants of ongoing projects in the company. As we
went through various tenders, we were able to understand the flow of process and designing more
effectively.

3.7.1 Sewage and related terms

• Sewage: Wastewater from communities, containing solid & liquid excreta from homes, streets,
factories, and industries.

• Sludge: Wastewater that does not contain human excreta.

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Amount of Sewage that flows in sewers depends upon:

• Habits of the day

• Times of the day

The average amount of sewage which flows through the sewerage system in 24 hours is called the ‘dry
weather flow.

3.7.2 Factors affecting Sewage Flow

At the center, the term "SEWAGE" is surrounded by six factors that influence the quantity and
characteristics of wastewater in an urban system:

Population Density – Higher populations generate more sewage due to increased water usage.

Climate & Weather – Heavy rainfall can increase sewage flow, especially in combined sewer systems.
Dry climates may result in lower flow rates.

Industrial Discharge – Factories contribute to variations in sewage composition, adding chemical

pollutants or higher organic loads.

Time of Day – Sewage flow peaks in the morning and evening when people engage in daily activities like
bathing, cooking, and laundry.

Water Consumption – Higher domestic and industrial water usage directly increases sewage generation.
Conservation practices can help regulate flows.

Infrastructure & Maintenance – Poorly maintained sewage networks cause blockages and
inefficiencies, impacting flow rates and system capacity.

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 4. P&ID (PIPING AND INSTRUMENTATION DIAGRAM)

A P&ID (Piping and Instrumentation Diagram) is a detailed engineering drawing used to represent the
mechanical and control components of a process plant. It provides a graphical representation of the flow
of fluids, gases, and chemicals through various pipelines, valves, tanks, pumps, and instruments in a
facility such as a Water Treatment Plant (WTP) or Wastewater Treatment Plant (WWTP).

Purpose of P&ID:

 To visualize the entire process from input to output.

 To understand the connection between various pipelines, equipment, and control systems.
 To act as a reference document for engineering, commissioning, and maintenance teams.
 To help in design, troubleshooting, and safety planning.

Key Elements in a P&ID:

1. Pipes and Flow Lines – Indicate the direction and type of fluid or gas being transferred.
2. Valves – Show control over the flow (e.g., gate valve, check valve, control valve).
3. Pumps and Equipment – Represent the machinery involved in the process (e.g., centrifugal pumps,
blowers, tanks).
4. Instruments and Sensors – Include pressure gauges, level transmitters, flow meters, and analyzers.
5. Control Loops – Indicate how the system is automated or manually operated.

Importance in Water Treatment Projects:

 Ensures clear communication between process engineers, mechanical teams, and instrumentation
departments.
 Helps identify process flows, shutdown mechanisms, and safety features.
 Used during HAZOP studies (Hazard and Operability Analysis) for safety evaluation.
 Acts as the foundation for control system programming (PLC/SCADA).

During the internship, I observed how P&IDs are used extensively in the design and operation of treatment
plants. Engineers at VA Tech Wabag refer to P&ID sheets for:

 Laying pipelines
 Installing instruments

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 [Link] REPORT

5.1 Site Location

The site is located within the existing Rithala Wastewater Treatment Plant (WWTP) premises situated on
northern part of Delhi near the Rithala metro railway station and easily accessible from anywhere in Delhi.

5.2 Rithala Project Objective

The objective of project is essentially to improve sewage conveyance system and wastewater treatment
plant so that the domestic water can be treated to desired standards before being discharged in the river
thereby improving the quality of river water.

The YAP (III) project is essentially to improve sewage conveyance system and wastewater treatment plant
in the command of Okhla, Kondli & Rithala drainage zone so that the domestic wastewater can be treated
to desired standards before being discharged in the river Yamuna thereby improving the
quality of river water

5.3 Rithala Flow

The Waste Water treatment facilities is designed for the floe mentioned below:

Flow MLD MGD

Average Design Flow 182 40

Peak Design Flow 364 80

Figure 21: Designed Flow

5.4 Water Quality

Inlet Water Quality with designed Value:

Table 11 Inlet Parameters

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Outlet parameters:

5.5 Process Flow Diagram

Chlorine contact De-chlorination

Inlet chamber
tank tank

Primary clarifier Tertiary filters Hydro-generator

Anoxic/Aeration Secondary
Treated sewage
tanks(MLE) clarifier

Fine Screen Channels: The raw sewage from the inlet chamber shall flow by gravity to fine screen
channels and flow shall be distributed equally to each screen channel. Each channel shall be provided with
fully automatic mechanical fine screens to remove particles larger than 6 mm.

Figure 22 Screening

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The mechanical screens shall be continuous operation under normal condition & with all working screen
during design flow and minimum flow. The individual screen channel shall be provided with electrically
operated inlet and outlet isolation sluice gates.

Grit chambers

De-gritting is required for removal of all grit and other inorganic solids of specific gravity 2.65 and above
with particle size of 0.15 mm and above from wastewater. De-gritting shall be accompanied with grit
washing to ensure that grit is free from organic matter before disposal.

Figure 23 Grit Chamber

Grit separators are to be provided after the screening and before the primary treatment. The grit chamber
shall be low head loss type, capable of being installed in the available head. The vortex type grit chamber
consisting of a tank in which the flow shall enter tangentially creating a vortex flow pattern is required.

The centrifugal or airlifts pumps shall be deliver the collected solids from grit collection tank into grit
classifier or grit washer wherein solids are washed and organic material is returned to the plant, and the
washed solids are collected in grit bins.

Parshall Flume

The de-gritted wastewater from Grit Chambers shall flow to a common channel connected to the Parshall
Flume Channel equipped with Ultrasonic Flow meter.

The outlet flow from the Grit Chamber is measured by the Parshall Flume with proper clear distance of at
least ten times the throat width downstream of channel and fitted with an ultra-sonic level measuring
device to provide local and remote read out of the flow into the plant.

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 Figure 24 Parshall Flume

Primary Clarifier

The primary clarifier is a large, sedimentation tank designed to remove settleable solids and floating
materials from raw wastewater through gravitational settling.

The primary clarifier serves as the first major treatment step after preliminary screening and grit removal.
Its main purpose is to significantly reduce the suspended solids and organic load before the wastewater
enters secondary treatment. This helps to improve the efficiency of downstream biological processes and
reduces the oxygen demand on the system.

Water enters the clarifier at a controlled velocity to allow heavier particles (sludge) to settle at the bottom
of the tank, while lighter materials like grease, oil, and scum float to the surface. Mechanical scrapers at
the bottom of the tank continuously push the settled sludge towards a hopper for removal. Similarly,
surface skimmers collect the floating scum, which is also removed for further processing or disposal.

Figure 25 Sedimentation Tank

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Primary Scum pit & sump

Scum generated from each Primary Clarifiers shall be collected through scum pit & suitable size pipes to
primary scum sump. From primary scum sump the scum shall be pumped to thickened sludge sump or
anaerobic digester.

Aeration Tank
As part of the biological treatment stage at the wastewater treatment plant, I observed the operation of the
bioreactor which plays a central role in the secondary treatment process. A bioreactor is an engineered
system where microorganisms biologically degrade the organic matter present in the wastewater.

The primary function of the bioreactor is to biologically oxidize dissolved and colloidal organic matter. It
uses a community of aerobic microorganisms that consume organic pollutants as their food source,
converting them into more stable forms such as carbon dioxide, water, and new microbial cells (biomass).
This process significantly reduces the Biological Oxygen Demand (BOD) and Chemical Oxygen Demand
(COD) of the effluent.

Figure 26 Aeration Tank

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 Figure 27 Anoxic And Aeration Zone

Chlorination Tank

Figure 28 CCT

Hydrogenator

Figure 29 Hydro Generator

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 5. CONCLUSION

My internship in water and wastewater treatment has been an enriching experience, providing both
practical and theoretical insights into environmental and chemical engineering. I had the opportunity to
explore engineering design, operation, and optimization of treatment systems, deepening my
understanding of Sustainable Water Resource Management and its real-world applications.

Throughout this internship, I engaged in detailed studies of Sewage Treatment Plants (STPs), Effluent
Treatment Plants (ETPs), and advanced purification technologies like desalination and Reverse Osmosis
(RO). I gained hands-on exposure to designing screening and grit removal systems, analysing
sedimentation and aeration tanks, and understanding biological processes such as aerobic and anaerobic
treatments. Additionally, learning about methane gas production from anaerobic digestion highlighted the
sustainability aspect of wastewater treatment.

A major focus was on Effluent Treatment Plants (ETPs), where I examined complex chemical and
biological treatment methods used for industrial wastewater purification. Studying RO system
configurations and membrane fouling prevention broadened my perspective on desalination technologies
and their practical applications.

This internship solidified my interest in environmental engineering, enhancing my problem-solving,

analytical, and design skills. It reinforced the importance of interdisciplinary approaches in achieving
sustainable water treatment solutions. Moving forward, I am excited to contribute to innovative, efficient,
and eco-friendly water treatment systems that support environmental conservation and global
communities.

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