OPERATION & MAINTENANCE MANUAL

OPERATION & MAINTENANCE MANUAL

FOR
65,000 LITERS/DAY
SOFTENING PLANT

SUBMITTED TO

VISHWASRI-OAK PARK
COIMBATORE

SUBMITTED BY

GRM ENVIRO TECH SOLUTIONS

Head Office: -
No: 303, S.P Arcade, 3st floor
Sarojini Street,
Ramnagar post, Coimbatore - 641009
Telefax:0422-4378596
Mob:+91 9600772583 , +91 9003826461/62/64
Mail: info@getsenviro.com website: www.getsenviro.com

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CONTRACT DETAILS

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CONTRACT DETAILS

Name of the Client : Vishwasri Property India Pvt Ltd

Trichy Road,
Coimbatore.

Name of the Project : Softening Plant – 65 KLD

Work Order No & Date : Verbal.

Designed,Supplied, : GRM Enviro Tech Solutions

Erected And Chennai & Coimbatore
Commissioned By

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CONTENTS PAGE NO

DESIGN CRITERIA 05

PROCESS DESCRIPTION 07

OPERATION OF THE PLANT 10

PROCESS DESIGN DETAILS 14

EQUIPMENT SPECIFICATIONS 16

PROCESS FLOW DIAGRAM 20

LOG SHEET 24

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DESIGN CRITERIA

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DESIGN BASIS:-

The Softener Plant is designed for a treatment Capacity of 65 KL @ 10000 LPH

Operation.

Raw Water Characteristics taken for design basis:-

Total Hardness : 500 mg/lit

10% Safety Factor : 50 mg/lit
:
Total Hardness : 550 mg/lit

Raw Water Characteristics taken for design basis:-

Sl.No Description of the Parameter Value

1 pH 7.25
2 Total Hardness 756 mg/lit

Treated Water Characteristics:-

Sl.No Description of the Parameter Value

1 pH 6.5-7.5
2 Total Hardness <50mg/lit

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PROCESS DESCRIPTION

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PROCESS DESCRIPTION:-

FILTRATION SYSTEM:

The raw water from the raw water tank is pumped by filter feed pump to the
pressure sand filter to remove the suspended solids, iron traces & Activated Carbon
Filter to remove the suspended solids like sediments, organics, oil, dechlorination,
color, odor present in water.

DUAL MEDIA FILTER:

The Pressure Vessel in MSEP with graded filter media supported on layers consists
of pebbles, sand and activated carbon. The filtration media is chosen from
carefully cleaned, sieved and graded filter sand. A mixture of coarse, fine sand
and activated carbon in predetermined proportion facilitates in depth filtration.
In-depth filtration provides longer runs between backwashes and better quality of
filtrate compared to surface filtration.
The activated carbon provided as high iodine value (1200PPM) and isoporus
structure for maximum adsorption of organics, oil, dechlorination, colour, odour
etc.

SOFTENER

The water from the ACF is passed through the softener vessel to reduce the hardness
by Ion Exchange process.

Almost all components/equipments of the WTP unit will be pre-engineered, pre-

wired, pre-tested and ready for use after giving necessary interconnections. Each unit
will be a product of high quality workmanship, skilled and experienced mechanical
design.

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OPERATI0N OF THE PLANT

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0PERATION OF THE PLANT

All the units should be clean from debris, waste material, bolts, nuts, wires or any
extraneous material otherwise they would spoil the pump & ensure that all the pumps
are in 3 phase & 430V.

1. MECHANICAL,CHEMICAL & ELECTRICAL CHECK UP

 The self priming pump should be filled with water to ensure self priming.
 Measure the No load current of all the motors and check if it is within limits.
 All valve and lines should be checked and cleaned before start up.
 The fresh water is passed through the various units and all the tanks are filled
up to the overflow levels .This also helps to check the leakages if any. All the
valves, pumps and other mechanical items are checked. The overflow levels in
the weirs is checked to see that they are uniform throughout.
 All chemicals should be in ready conditions.
 PSF, ACF should be backwashed and kept in service.

2. START UP OF PLANT

 Switch on the Hypo Dosing Pump, Alum Dosing Pump and then start the Filter
Feed Pump.
 Maintain the Feed Flow Rate 3.6 m3/hr.
 Start dosing the chemicals as per prescribed doses.
 Monitor the Hardness of the Raw water & Outlet water at regular intervals.

3. REGULAR OPERATION

Gradually increase the flow at an interval by opening the respective valves in

the pumps to meet the plant capacity and put into the plant for regular
operation.

Follow the same procedure as in the normal startup. In addition to that

following
has to be monitored while normal operation. Requisition

 Chemicals Hypo & Alum has to be dosed as per our instruction.

 Backwashing & Rinsing of filters should be done once in a day.
Backwash Duration – 20-30 min.
Rinse Duration – 5-10min ( Check clarity of water, if it is not ok then do the
Backwash again).
 Flow to be monitored at regular intervals. It should be filled in the log sheet.
 Solid or cloggy materials should not be allowed nearby the pump suction.
 Refer respective manuals for the operation of mechanical equipments like
pumps, Dosing system etc.

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 Maintain water analysis report regularly.

 Maintain the chemical stock for one month.

START UP OPERATION OF PSF, ACF

a) AIR RELEASE
- Press the handle pointed out in Diaphragm Valve
- When the water starts coming down close the handle pointed out
in Diaphragm Valve.

b) BACK WASHING
- Check whether the pump has been switched off
- Handle in Butterfly Valve should be kept in Backwash Position
- Now switch on the pump for Backwash
- After 20 minutes or when the water is clearly switch off the pump
- This completes backwash operation.

c) RINSING

- Check whether the pump has been switched off

- Handle in Butterfly Valve should be kept in Rinsing Position
- Now switch on the pump for Rinsing
- After 10 minutes (approx) check the clarity of water.

OPERATING CONDITIONS:

1. Inlet water pressure should not exceed 3.5 kg/cm 2. Min operating pressure
2.0 kg/cm2. Do not exceed the max Operating flow rate as this may
deteriorate the quality of outlet water.
2. Analyze Inlet water for Suspended Solids content every week, if found
consistently more than the design limit, consult authorized Representative
for additional dosing or modification prior to the Filter.
3. Inlet water should be free of oil and grease.
4. Inspect the vessel, piping externally once in a year for damaged to the
painting Repaint as necessary.
5. Inspect vessel internally once in a year and replace if required.
6. Inspect the Filter media every year and replace if required.
7. Give extended back wash to the filter once in a week for 45 minutes.

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DO’S AND DONT’S

 Never exceed the filter service flow.

 Never run the filter at higher than designed inlet Turbidity.
 Analyze inlet water for Turbidity regularly.
 Always, check inlet water or Oil & Gaseous content. Don’t allow such
water to pass through the filter.
 Do periodical Maintenance as described in the manual.
 Do annual media Check up and replacement as required.
 Backwash the filter regularly as per manual.
 Never allow corrosive liquids to pass through the filter.
 Always use genuine spare parts.
 If filter pressure exceed 1.0 kg/m2, do the backwash.

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EQUIPMENTS SPECIFICATIONS

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EQUIPMENTS SPECIFICATIONS
1. Feed Pump
DESCRIPTION
Quantity 2Nos(1W+1S)
Flow 10.0m3/hr
Head 10m
Motor 1.5HP/Three phase
MOC CI
Type Submersible
Make Grundfos/Kirloskar

2. Dual Media Filter

DESCRIPTION
Quantity 1 No
MODEL 4272
capacity 1360 litres
Normal Flow 10.0m3/hr
Maximum Pressure 3.5Kg/cm2
Minimum Pressure 2.0Kg/cm2
Bursting Pressure 10Kg/cm2
M.O.C MSEP
Pipe Line 50 NB
Type Vertical
Valve Multiport
Media Pebbles/ silxes, Acivated
carbon
Media Make GETS/ Equivalent

3. Softener
DESCRIPTION
Quantity 1 No
MODEL 4272
capacity 1020 litres
Normal Flow 10.0m3/hr
Maximum Pressure 3.5Kg/cm2
Minimum Pressure 2.0Kg/cm2
Bursting Pressure 10Kg/cm2
M.O.C MSEP
Pipe Line 50 NB
Type Vertical
Valve Multiport

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Resin Na Based Cation

Resin Make Axion / Equivalent
Quantity of resin 893 Liters
OBR 1 day once or 65,000
litres once

4.Brine Tank
DESCRIPTION

Quantity 1 No
Capacity 500 Litres
MOC HDPE sintex
Salt Required 130 Kg / regeneration
Water Required 390 Litres
agitator inbuilt

5. Piping
DESCRIPTION
Interconnected UPVC 1 Lot
Pipes, Fittings and
Valves
Make Finolex/ supreme

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PROCESS FLOW DIAGRAM

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PROCESS FLOW DIAGRAM

RAW WATER
FROM
SUMP

FILTER TREATED WATER

Dual Media SOFTENE FOR ALL USAGE
FEED
Filter R
EXCEPT DRINKING
PUMPS
AND KITCHEN

A B C

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