SOP Guide for Pharma

SOP for Wastewater Management in Manufacturing Facilities

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SOP for Wastewater Management in Manufacturing Facilities

Standard Operating Procedure for Wastewater Management in Manufacturing Facilities

1) Purpose

The purpose of this SOP is to establish guidelines for the safe collection, treatment, and disposal of wastewater generated in manufacturing facilities, ensuring compliance with environmental regulations and minimizing risks to public health and the environment.

2) Scope

This SOP applies to all processes, equipment, and personnel involved in generating, handling, treating, and disposing of wastewater in manufacturing facilities, including production, cleaning, and utility operations.

3) Responsibilities

  • Supervisors: Ensure wastewater management processes are implemented, monitored, and documented.
  • Operators: Collect, treat, and handle wastewater as per this SOP.
  • Maintenance Personnel: Maintain wastewater treatment systems, ensuring functionality and efficiency.
  • Safety and Environmental Officers: Monitor wastewater compliance, perform audits, and liaise with regulatory authorities.

4) Procedure

4.1 Classification of Wastewater

Wastewater generated in manufacturing facilities can be categorized as:

  1. Process Wastewater: Wastewater from production processes that may contain chemicals, oils, heavy metals, or toxic substances.
  2. Utility Wastewater: Wastewater generated from cooling towers, boilers, or HVAC systems.
  3. Sanitary Wastewater: Wastewater from employee facilities such as restrooms, kitchens, or cafeterias.
See also  SOP for Identification of Hazardous Materials

4.2 Collection of Wastewater

  1. Segregation:
    • Segregate process wastewater, utility wastewater, and sanitary wastewater at the source to ensure proper treatment.
    • Label collection pipelines and holding tanks clearly for each category of wastewater.

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  2. Collection Systems:
    • Use
leak-proof drainage systems and pipelines for wastewater collection.
  • Install oil-water separators to remove oils and greases from process wastewater before storage.
  • Ensure designated collection tanks are labeled and checked for leaks regularly.
  • Monitoring Flow Rates:
    • Install flow meters on wastewater discharge points to monitor flow rates.
    • Record daily flow rates in the Wastewater Log (Annexure 1).

    • 4.3 Treatment of Wastewater

    All wastewater must be treated to meet environmental discharge standards before disposal or reuse. Follow these steps:

    1. Pre-Treatment:
      1. Filter solids and suspended particles using screens and sedimentation tanks.
      2. Use chemical precipitation for removing heavy metals.
      3. Neutralize acidic or alkaline wastewater using appropriate pH adjustment techniques (e.g., lime or acid dosing).

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    2. Primary Treatment:
      • Use clarifiers to separate solids from wastewater.
      • Install grease traps to remove oils and fats.
    3. Secondary Treatment:
      • Apply biological treatment methods such as:
        • Activated sludge systems
        • Trickling filters
        • Aeration tanks
      • Monitor biochemical oxygen demand (BOD) and chemical oxygen demand (COD) levels to ensure compliance.
    4. Tertiary Treatment:
      • Use advanced filtration techniques such as reverse osmosis (RO) or sand filters for final purification.
      • Disinfect wastewater using chlorine or ultraviolet (UV) light treatment.

    4.4 Wastewater Discharge

    1. Ensure treated wastewater meets environmental standards for pH, BOD, COD, and heavy metal content.
    2. Discharge treated wastewater into:
      • Municipal sewage systems (with approval from authorities)
      • Natural water bodies (only if discharge parameters meet regulations)

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    3. Record all discharge data, including:
      • Date and time of discharge
      • Flow rates and test results
      • Discharge location
    4. Use the Discharge Record Log (Annexure 2) for documentation.

    4.5 Reuse of Treated Wastewater

    Promote sustainability by reusing treated wastewater for:

    • Cooling towers
    • Boiler feed water
    • Landscaping and irrigation
    • Cleaning purposes (non-potable)

    4.6 Monitoring and Compliance

    1. Conduct regular sampling and testing of wastewater at various stages (pre-treatment, primary, secondary, tertiary):
      • Parameters: pH, BOD, COD, total suspended solids (TSS), heavy metals, and oil/grease.
      • Frequency: Weekly or as per regulatory requirements.

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    2. Maintain testing records and submit periodic reports to relevant environmental authorities.
    3. Conduct internal audits to identify non-conformities and implement corrective actions.

    4.7 Emergency Procedures for Wastewater Spills

    1. In case of leaks or spills:
      • Immediately isolate the affected area and contain the spill using absorbents.
      • Report the incident to the Safety Officer.
      • Dispose of contaminated materials as hazardous waste.

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    2. Record details of the incident in the Spill Incident Log (Annexure 3).

    5) Abbreviations, if any

    • BOD: Biochemical Oxygen Demand
    • COD: Chemical Oxygen Demand
    • RO: Reverse Osmosis
    • TSS: Total Suspended Solids

    6) Documents, if any

    • Wastewater Log
    • Discharge Record Log
    • Spill Incident Log

    7) Reference, if any

    • Environmental Protection Act (EPA) Guidelines
    • Central Pollution Control Board (CPCB) Wastewater Standards
    • OSHA Water Treatment Regulations

    8) SOP Version

    Version: 1.0

    Annexure

    Template 1: Wastewater Log
    Date Source Flow Rate (L/hr) pH BOD (mg/L) COD (mg/L) Handled By
    DD/MM/YYYY Production Unit 1 500 7.2 50 120 John Doe

    Template 2: Discharge Record Log
    Date Discharge Location Flow Rate (L/hr) Tested Parameters Compliance Status Authorized By
    DD/MM/YYYY Main Drainage 450 BOD, COD, pH Compliant Jane Doe
    See also  SOP for Safe Use of Compressed Gas Cylinders
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