The Centrifuge Changes Everything About Your Maintenance Log
A belt press plant and a centrifuge plant look similar on a process flow diagram. On the ground, they're different animals. The centrifuge operates at differential speeds between the bowl and the scroll, generating forces that will destroy bearings in weeks if the torque parameters drift unchecked. You don't get a visual warning like you do with a belt press — no cake coming off wet, no obvious channeling. By the time the centrifuge vibrates enough for the operator to notice, the scroll wear is already past the point of a simple hard-facing repair.
This template was built for a plant that runs centrifuge dewatering, and the inspection section reflects it: primary motor vibration, secondary motor vibration, mono-screw feed pump stator temperature, seal condition, and — the field that matters most — verification of working parameters including torsion and differential RPM. That last field is a rating, not a free-text entry, which means the operator must assess whether the machine is within spec as a yes/no judgment rather than logging raw numbers. The raw numbers belong in the SCADA historian. What belongs here is the human assessment: does the machine sound right, does the cake discharge look right, does the centrate clarity indicate proper polymer conditioning.
Sand Classification: The Stage Everyone Forgets
Most small-to-medium activated sludge plants skip grit removal or treat it as an afterthought. This template doesn't. The classificatore sabbie gets two independent ratings — general functionality and vibration/noise — plus its own big-bag tracking for collected sand: area cleanliness, bag substitution, and the six-point fill level from vuoto to pieno.
Sand accumulation in the biological reactor destroys mixer impellers, abrades pump casings, and settles in dead zones where it steals hydraulic volume from the process. The operators who track sand bag fill rates over months are the ones who catch seasonal inflow changes — construction season upstream pushing grit loads up thirty percent — before the damage materializes in the aeration basin.
The Ultrasonic Flow Meter Nobody Calibrates
Buried between the settler section and the sludge thickening fields sits a pair of entries most operators scroll past: ultrasonic flow meter functionality check and a free-text field for recording the instrument reading. This is the discharge flow measurement. The number that goes into your regulatory compliance report. The number ARPA uses to calculate your per-capita treatment load.
If the transducer face is fouled with biofilm or the pipe section has air entrainment from a leaking flange upstream, that reading is fiction. The cleaning and functionality rating is what separates a plant that reports accurate hydraulic data from one that discovers a 20% flow measurement error during the next regulatory audit.
Polyelectrolyte Dissolution: Where Chemistry Meets Plumbing
The polymer preparation section tracks the dissolution reactor as a distinct subsystem: inter-reactor flow control, final solution quality, equipment vibration, and level probe cleanliness — all separate from the dosing station upstream. The template separates the dosing centralization unit (powder silo, mains water pressure, water-to-polymer ratio, screw dosing function, heater check) from the dissolution reactor because the failure modes are completely independent.
A clogged dosing screw with a clean dissolution reactor means the polymer powder is bridging in the silo — a mechanical problem. A clean dosing screw with poor final solution quality means the dissolution reactor agitation is inadequate or the heater failed and the polymer isn't hydrating — a process problem. Conflating them into one "polymer system OK/not OK" field is how you end up replacing an entire dosing station when all you needed was a new heating element.
The stator temperature field on the polymer dosing pump catches thermal runaway from running dry or from viscous polymer solution overloading the progressive cavity elements. By the time a mono-screw pump seizes from a hot stator, the rotor-stator clearance is gone and you're looking at a full rebuild — two weeks of lead time on the stator elastomer alone.