Klargester P6 BioTec Sewage Treatment Plant Repair in Cupar, Fife

Caledonia Environmental recently attended a Kingspan Klargester P6 BioTec sewage treatment plant in Cupar, Fife, following a high-level condition and flooding caused by a failed final effluent outlet pump.

The visit involved diagnosing the pump fault, replacing the failed outlet pump and a seized non-return valve, and carrying out a full electrical and mechanical service of the sewage treatment plant.

Additional maintenance included servicing the SECOH JDK-60 air blower, replacing its heavily contaminated intake filter and clearing a small blockage within the sewage distribution cone.

Klargester P6 BioTec Sewage Treatment Plant Inspection

The Klargester P6 BioTec is an aerated sewage treatment plant that uses biological treatment media and an air blower to treat wastewater.

When a final effluent outlet pump fails, wastewater may no longer discharge correctly, causing water levels to rise and potentially leading to flooding or wastewater backing up within the system.

At this property in Cupar, the outlet pump failure had caused a high-level condition and flooding, requiring a callout and repair.

Failed Final Effluent Outlet Pump Replaced

During the inspection, the final effluent outlet pump was confirmed to have failed.

The defective pump was removed and replaced with a new like-for-like Grundfos pump suitable for the existing installation.

The outlet pump is responsible for transferring final effluent away from the sewage treatment plant where gravity discharge is not available.

A failed outlet pump can cause rising wastewater levels, high-level alarms and flooding if the fault is not addressed.

SECOH JDK-60 Air Blower Service

As part of the service, the SECOH JDK-60 air blower, manufactured in 2022, was inspected and electrically tested.

The following readings were recorded:

• Supply voltage: 227V AC
• Blower running current: 0.316A
• Blower operation: Satisfactory
• Air intake filter: Heavily contaminated

The blower was found to be operating within specification, with no electrical faults identified.

The blower housing and associated electrical equipment were inspected, with the control panel and wiring found to be in good condition.

Old vs New SECOH JDK-60 Air Intake Filter

One of the maintenance findings during the service was the condition of the SECOH JDK-60 air blower intake filter.

The existing filter was heavily contaminated with dirt and debris and required replacement.

Air intake filters help prevent dust and debris from entering the blower. Over time, contamination can restrict airflow and potentially affect blower performance.

The contaminated filter was removed and replaced with a new SECOH JDK-60 intake filter.

The photograph below shows the difference between the old, heavily contaminated filter and the new replacement.

Seized 1¼-Inch Non-Return Valve Replaced

Further inspection of the outlet pumping arrangement identified that the existing 1¼-inch non-return valve was seized.

The defective valve was removed and replaced with a new non-return valve as part of the repair.

A non-return valve helps prevent discharged wastewater from flowing backwards through the pump discharge pipework when the pump stops.

A seized or defective valve can interfere with normal pump operation and should be repaired or replaced when identified.

Sewage Distribution Cone Blockage Removed

The sewage treatment plant had been emptied the previous day, resulting in a low operating water level.

Due to the reduced liquid level, sewage was initially not being distributed across the treatment media.

During inspection, a small blockage of accumulated fat was identified within the sewage distribution cone.

The blockage was removed, allowing a small amount of liquid to pass through the distribution system and across the treatment media.

As the plant had recently been emptied, normal sewage distribution and treatment performance could not be fully assessed during the visit.

The distribution system should be reassessed once the plant has refilled to its normal operating water level.

Electrical Inspection and Alarm Testing

A full electrical inspection was completed as part of the Klargester BioTec service.

• Control panel inspected and found in good condition
• Control panel wiring inspected and found in good condition
• All electrical connections checked and confirmed tight
• Supply voltage measured at 227V AC
• SECOH JDK-60 blower electrically tested at 0.316A
• Loss-of-power alarm tested successfully
• No additional electrical faults identified

Enkamat Treatment Media Inspection

During the mechanical inspection, the existing Enkamat treatment media was found to be ageing and brittle.

Replacement of the Enkamat has been recommended during the next scheduled service to prevent further deterioration and maintain the treatment media arrangement in good condition.

No Enkamat replacement was carried out during this visit.

Maintenance and Repairs Completed

The following work was completed during the callout and service:

• Failed final effluent outlet pump removed
• New like-for-like Grundfos outlet pump installed
• Seized 1¼-inch non-return valve replaced
• Full electrical and mechanical inspection completed
• SECOH JDK-60 air blower inspected and electrically tested
• Heavily contaminated blower intake filter replaced
• Fat blockage removed from sewage distribution cone
• Sewage inlet cleaned
• Loss-of-power alarm tested successfully
• Control panel and electrical connections inspected
• Ageing Enkamat treatment media identified for replacement at the next scheduled service

Further Maintenance Recommendations

The existing Enkamat treatment media should be replaced during the next scheduled service.

Normal sewage distribution should also be reassessed once the plant has refilled following its recent emptying.

No additional immediate mechanical or electrical repairs were identified during the visit.

Common Signs of Sewage Treatment Plant Pump Failure

A failed final effluent outlet pump can cause wastewater to accumulate within a sewage treatment plant or adjoining pump chamber.

Common warning signs include:

• High-level alarms activating
• Wastewater levels rising above normal
• Flooding around the sewage treatment plant
• Wastewater backing up within the system
• Outlet pump failing to start or discharge
• Repeated electrical trips or pump faults

These symptoms can also be caused by float switch faults, electrical problems, blocked discharge pipework or defective non-return valves. A proper inspection is required to identify the cause.

Klargester BioTec Servicing and Repairs in Cupar, Fife

Caledonia Environmental provides Klargester BioTec servicing, sewage treatment plant repairs, electrical fault finding and outlet pump replacements across Cupar, Fife and throughout Scotland.

Our services include:

• Klargester P6 BioTec servicing and maintenance
• Sewage treatment plant fault finding and repairs
• Grundfos outlet pump replacement
• Non-return valve replacement
• SECOH air blower servicing and filter replacement
• Control panel and alarm testing
• Sewage distribution system inspections
• Enkamat treatment media inspection and replacement
• Routine preventative servicing

If your Klargester P6 BioTec has developed a fault, the outlet pump has stopped working or the treatment plant is due a service, contact Caledonia Environmental to arrange an inspection or repair.