In 2020 and 2021, the operation, maintenance, and management of Mashhad Wastewater Treatment Plants No. 4 and 5 were contracted to Nilab Sanat Alborz for a long-term period of 20 years. These two facilities, as critical components of urban wastewater management infrastructure, rely on the stable performance of advanced process equipment. Among the various equipment, aeration blowers, considered the heart of the biological treatment system and one of the most crucial elements in aeration lines, play a decisive role in the process efficiency and operational stability of the treatment plants.
Blowers are considered strategic equipment due to their capital value, design complexity, operational sensitivity, and the need for specialized maintenance. Limitations imposed by sanctions, difficulties in procuring original equipment manufacturer (OEM) parts, the lack of well-equipped repair centers nationwide, and the high sensitivity of this equipment to minor deviations in assembly and settings have consistently presented significant operational and financial challenges for operators. The stoppage or degradation of blower performance can lead to a severe reduction in aeration efficiency, an increase in output organic load, disruption of the activated sludge process, and ultimately, interference with environmental monitoring. Therefore, specialized maintenance and rapid repair response are essential for these units.
To address these challenges and reduce reliance on external services, Nilab Sanat Alborz launched a specialized blower repair workshop in 2022 at the site of Wastewater Treatment Plant No. 4. This initiative aimed to enhance in-house repair capacity, shorten equipment downtime, manage maintenance costs, and establish a sustainable infrastructure for repairing advanced aeration equipment.
This workshop, utilizing specialized personnel and precise equipment, is capable of performing a range of specialized operations, including:
- Complete disassembly of Roots, Screw, and Centrifugal blowers, adhering to factory tolerances.
- Replacement and installation of bearings according to OEM standards, with adjustments for axial and radial loads.
- Precise gear timing to set backlash, prevent mechanical impact, and reduce noise and vibration.
- Rotor modification, balancing, and adjustment to prevent rotor rubbing and maintain efficiency.
- Measurement of clearances, alignment checks, and adjustment of clearances to achieve stable performance.
- Reconstruction of damaged parts, including pulleys, shafts, seals, and housings.
- Functional testing and final performance trials after complete assembly and before re-commissioning.
The establishment of this specialized workshop has transformed the blower repair and maintenance process from a dependent and time-consuming procedure into an in-house, rapid, standardized, and controllable cycle. The results of this initiative are visibly evident in the increased operational readiness of the equipment, reduced downtime costs for aeration units, and enhanced stability of the activated sludge process. Furthermore, this infrastructure now provides the capability to offer repair services to other projects and treatment plants in the region.
