SAPPHIRE WATER ENGINEERS

#143/144, GROUND FLOOR, KEMPEGOWDA LAYOUT

OUTER RING ROAD, LAGGERE,

BANGALORE-560 058.

OPERATION MANUAL

FOR

SAND FILTER

CLIENTS NAME: M/s. SANTECH ENGINEERS PVT LTD

PROJECT: M/s. URBAN FOREST

PLANT MODEL: 1500 mm Dia X 1500 mm HOS Pressure Sand Filter

1
 INTRODUCTION

The Down flow sand Filters are designed to filter Suspended matter with more efficiency

in relation to flow rate, Area of Filteration and Turbidity loading.

The Water to be filtered is passed through the Filter in Downward direction. The Filter

media comprising 16 x 30 mesh and 16 x 32 mesh Quartz Sand results in INDEPTH

filtration of the suspended matter. The suspended matter present in the water accumulates

in top 2” – 3” layer of Filter media.

The accumulated suspended particles are removed by BACKWASHING the filter media

with upward flow of water.

2
 DESCRIPTION

The Filter consists of Mild Steel pressure vessel complete with top and bottom dished end

and internal distribution and collecting systems.

The unit is fitted with a set of Mild Steel Frontal Pipework with Diaphragm / Butterfly

Valves and Pressure Gauges. The Filter is filled with Under bed material (Pebbles &

Gravels) and Filter media i.e., Sand. The bed depth of the under bed media is maintained at

400 mm and that of Filter media at 900 mm. The filter vessel is internally painted with

Epoxy paint OR internally lined with natural / Nitrile rubber.

The unit is internally fitted with Inverted funnel type inlet distributor for uniform

distribution of Raw Water on the filter media bed. Bottom of the vessel is fitted with

inverted chamber type collecting system for uniform collection of filtered water.

The unit is provided with an air releasing pipework having 25 nb Diaphragm valve to vent

out air.

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 VALVE SCHEDULE

MARK DESCRIPTION SIZE

V1 Raw Water Inlet Valve 65 nb

V2 Treated Water Outlet Valve 65 nb

V3 Backwash Inlet Valve 65 nb

V4 Backwash Outlet Valve 65 nb

V5 Drain Valve 65 nb

V6 Air Release Valve 25 nb

OPERATION

SERVICE : With all the Valves closed, Open V1 and V2.

Adjust V1 to obtain required Flowrate. Open air
release valve V6 to release air trapped inside vessel.
BACKWASH : Close Valve V1 and V2. Open Valves V3 and V4.
Once the water coming out of V4 is clear, Close

Valve V3 and V4.

RINSE : Open Valve V1 and V5. Allow the water to drain

for about 5 minutes. After 5 minutes, close Valve V5

and open Valve V2 for Service.

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 MAINTENANCE
Monthly maintenance:

1. Apply grease to valves.

2. Check condition of external painting of vessel. Replenish paint if necessary.

Quarterly Maintenance:

1. Open top manhole covers and inspect the condition of Filter media.
2. Give extended backwash with open manhole to remove any accumulated dirt from
the Media.
3. Check for internal condition of the vessel

Half Yearly Maintenance:

1. Remove the Filter media from the column and Clean.

2. Clean the Under bed material and top up if necessary.
3. Paint internal surface of the vessel with Anti Corrosive Bituminous Paint or Epoxy
paint. In case of rubber lined units, check condition of rubber lining.

Yearly Maintenance:

1. Replace Filter media and under bed materials.

2. While replacing media, clean internal surface of the vessel.
3. Check for proper fitment of internal distribution and collection system.

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 TECHNICAL DATA

Max. Treatment Flow : 24 m3/Hr.

Min. Treatment Flow : 20 m3/Hr.

Max. Operating Pressure : 3.5 kg/cm2

Min. Operating Pressure : 2.0 kg/cm2

Backwash Flow : 18 m3/Hr.

Unit Diameter : 1500 mm

Height on Straight : 1500 mm

Filter Media : Quartz Sand with Under bed

Materials

Max. Pressure drop across the unit : 1 kg/cm2 (Maximum)

Quantity of Filter Media : Sand - 1100 kg.s

Gravels - 400 kg.s

Pebbles - 400 kg.s

Core silex - 400 kg.s

Fine silex - 400 kg.s

6
 SAPPHIRE WATER ENGINEERS
#143/144, GROUND FLOOR, KEMPEGOWDA LAYOUT

OUTER RING ROAD, LAGGERE,

BANGALORE-560 058.

OPERATION MANUAL

FOR

WATER SOFTENING PLANT

CLIENTS NAME: M/s. SANTECH ENGINEERS PVT LTD

PROJECT: M/s. URBAN FOREST

PLANT MODEL: 1500 mm Dia X 1800 mm HOS Water Softener

7
 INTRODUCTION
The softener consists of a bed of Ion exchange resins. The raw water to be
softened is passed through the resin bed in downward direction and in the process,
the Ion exchange resins exchange sodium Ions for hardness forming calcium and
magnesium ions present in raw water. Thus all the calcium and magnesium salts
present in water are converted to sodium salts, which does not form scale. This
process of softening of hard water continues till the ion exchange resins have no
more sodium ions available for exchange. Then the ion exchange resins are
REGENERATED with sodium chloride (common salt) solution to replenish the
sodium ions. Thus the cycle of alternate softening and regeneration is continued.

Following equations illustrates the chemical reactions taking place in the ion
exchange resin bed during softening and regeneration process.

1. WATER SOFTENING

| CaCl2 |
| MgCl2 | | NaCl | | Ca ++ |
H20 | Ca(HCO3)2 | + R-Na+ - - - -H2o | NaHCO3 | + R - | |
++
| Mg(HCO3)2 | | Na2 So4 | | Mg |
| CaSO4 |

(Raw Water) + (Regenerated) ----- (Soft Water) + (Exhausted Resin)

Resin

2. REGENERATION

|Ca++ | | CaCl2 |
- - +
R | | + H2O(NaCl) ------- R Na + H2O | |

|Mg++ | | MgCl2 |

Exhausted + Sodium Chloride ------- Regenerated + Waste Water to drain

Resin salt solution Resin

8
 DESCRIPTION
Water softeners consist of a mild steel pressure vessel with top dish and bottom
scud. The pressure vessel is filled with one charge of under bed material and
cation resin. The under bed material comprising of layers of 4 different sizes of
pebbles and 2 different sizes of Silex, retains the resin in column. The vessel is
provided with top distributor fitted with disc type strainers, which ensures uniform
distribution of water and brine (salt solution), while retaining the ion exchange
resins in the vessel.

The unit is fitted with a set of frontal pipework comprising Seven numbers cast iron
ebonite lined diaphragm valves, One PP Diaphragm Valve and one mild steel
ebonite lined hydraulic ejector. The brine (salt solution) required for
“REGENERATION” of softener is stored in a FRP brine tank provided with the unit.
The brine is injected into softener by means of hydraulic ejector, which operates
with a maximum operating pressure of 3.5 kg/cm2 as specified in enclosed
technical data.

One hardness test kit is provided with each softener to measure the treated water
hardness.

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 VALVE SCHEDULE

V1 : RAW WATER INLET VALVE

V2 : TREATED WATER OUTLET VALVE

V3 : BACKWASH INLET VALVE

V4 : BACKWASH OUTLET VALVE

V5 : EJECTOR POWER WATER VALVE

V6 : BRINE SUCTION VALVE

V7 : DRAIN VALVE

V8 : AIR RELEASE VALVE

OPERATION

START

To start the unit, switch on the RAW WATER PUMP open Raw Water Inlet valve
V1 and Drain Valve V7. Allow the water to drain till the treated water hardness is
less than 5 PPM as CaCO3. Once the treated water hardness is less than 5 PPM
as CaCO3, close valve V7 and open Treated Water Outlet valve V2 to take the unit
to service.

STOP

To stop the unit, switch off the Raw Water Pump and close valves V1 and V2.

REGENERATION

A) PREPARATION OF BRINE

Charge required quantity of Sodium Chloride (Common Salt) into regeneration

tank. Allow the required quantity of water into regeneration tank. Preparation of
salt solution should be done at least an hour prior to Regeneration to ensure
required concentration (i.e. 1.2 gm/cc) of brine.

NOTE: The quantities of Sodium Chloride (Common Salt) and water for dilution of
salt are given is enclosed technical data sheet.

1
B) BACK WASH

Open Backwash Inlet Valve V3 and Backwash Outlet Valve V4. Duration of
Backwash is 10 Minutes.

During Backwash, the water enters softener from bottom of resin bed and leaves
from the top distributor. Because of upward flow of water, resin bed is fluidized the
dirt accumulated in the resin bed would be cleaned and washed away by the
water.

C) BRINE INJECTION

Open Ejector Power Water valve V5, Drain valve V7 and Brine suction valve V6.
Control ejector power water valve V5 so that the required quantity of brine is
injected in about 25 to 30 minutes.

During Brine injection, the salt solution enters the resin bed through the top
distributor. The salt solution flows down the resin bed and regenerates the resin.

D) SLOW RINSE

After Brine injection close brine suction valve V6 and fully open ejector power water
valve V5. Duration of SLOW RINSE is 25 to 30 minutes.

During slow rinse, the water enters the resin bed through the top distributor and
flows down displacing the salt solution down to the bottom layers of resin bed.

E) FINAL RINSE

Open Raw Water inlet valve V1 and Drain valve V7. Control final rinse outlet valve
V7 to maintain specified maximum/Average flowrate through the unit. After 10
minutes’ test water sample from final rinse outlet valve V7 for hardness. If
satisfactory close valve V7 and open and regulate treated water outlet valve V2 to
maintain required soft water flow rate to service subjected to minimum and
maximum flow rate as per technical data enclosed.

During Final Rinse, the water enters the resin bed from the top distributor and
flows down the resin bed displacing the excess salt solution out of resin bed.

NOTE: 1. Final rinse should be terminated (i.e. closing of valve V7 and opening
valve V2) only after the test of sample from V7 for hardness is satisfactory.
2. To ensure adequate density of brine, always maintain about 4-6” of
undissolved salt in brine tank and also prepare the brine at least one hour
before regeneration.

1
 SUMMARY OF VALVE OPERATION

OPERATION VALVES OPEN DIRECTION TIME DURATION

FLOW
SERVICE V1 & V2 Downward Till the treated
water hardness is
less than 5 PPM
BACKWASH V3 & V4 Upward 10 Minutes
BRINE V5, V6 & V7 Downward 20 to 25 minutes
INJECTION
DOWN RINSE V4 & V5 Downwards 20 to 25 minutes
FINAL RINSE V1 & V3 Upwards Till the treated
water hardness
reaches below
5 PPM

1
 MAINTENANCE
Weekly Maintenance:

1. Clean Salt dilution tank to avoid accumulated dirt entering Softener Resin.
2. Backwash Softener for 20 to 30 minutes before regeneration to ensure resin bed is
completed cleaned.
3. Check & rectify any leakage.

Monthly maintenance:

3. Apply grease to valves.

4. Check condition of external painting of vessel. Replenish paint if necessary.
5. Check and record Raw Water hardness.

Quarterly Maintenance:

3. Open top manhole cover and inspect the condition of resin.

4. Give extended backwash with open manhole to remove any accumulated dirt from
the resin (Care should be taken not to allow resin to escape from the column during
open manhole backwash)
3. Check for internal condition of the vessel

Half Yearly Maintenance:

4. Remove the resin from the column and de foul with 10 % W/V Hydrochloric Acid.
5. Clean the Under bed material and top up if necessary.
6. Paint internal surface of the vessel with Anticorrosive Bituminous Paint or Epoxy
paint.
7. Clean the resin thoroughly and remove any fine or broken resin beads.
8. Top up required quantity of resin.
9. After reassembling, regenerate softener with double quantity of brine.

1
 TROUBLE SHOOTING

I. Treated Water Quality Not Satisfactory.

Possible Cause Remedy

1. High Flow across the Check and maintain flow between max. & min.
softener Flow as per in the Technical Data Sheet.

2. Leakage of untreated water Check and rectify

through BACKWASH INLET
valve in down flow units and
EJECTOR POWER WATER
valve in up flow units.

3. Improper Regeneration a. Check for quantity & Concentration of Brine

Solution. (should be minimum 1.2 gms/cc)
b. Check for brine injection and rinse time.
Brine injection time should be between 20 to 35
mins.

4. Resin Dirty Check and clean the resin bed. Presence of dirt
in resin bed leads to channeling resulting in
improper quality of water

5. Insufficient resin Quantity Check and top up if required

6. Increased raw water hardness Analyze the raw water and adjust operating
parameters accordingly.

7. Resin deteriorated Replace the resin

II. Out Put between regeneration is not as per design

Possible Cause Remedy

1. High Flow across the Check and maintain flow between max. & min.
softener Flow as per in the Technical Data Sheet.

2. Improper Regeneration a. Check for quantity & Concentration of Brine

Solution. (should be minimum 1.2 gms/cc)
b. Check for brine injection and rinse time.
Brine injection time should be between 20 to 35
mins.
3. Resin Dirty Check and clean the resin bed. Presence of dirt

1
 in resin bed leads to channeling resulting in
improper quality of water

4. Insufficient resin Quantity Check and top up if required

5. Increased raw water hardness Analyze the raw water

6. Resin deteriorated Replace the resin

III. Brine Injection not taking place

Possible Cause Remedy

1. Inlet Pressure Low Check raw water pump

2. Ejector nozzle blocked Check and rectify

3. Ejector suction line is leaking Check and rectify

leading to air suction

4. Ejector Power Water Valve Check for faulty valve and rectify
or Drain valve not fully open

5. Resin dirty Check and clean the resin bed. Presence of dirt
in resin bed leads to increased pressure drop
across the resin bed.

6. Strainers Choked Check and clean

IV. Resin Being Lost

1. High Backwash Flow Rate Check and maintain backwash flow rate as per
Technical Data Sheet.

2. Faulty Collecting System Check for loose strainers in case of Up flow

leading to resin loss during softeners. In case of down flow softeners,
service under bed material layer might have been
disturbed. Check and rectify.

1
 TECHNICAL DATA

Max. Treatment Flow : 24 m3/hr

Min. Treatment Flow : 20 m3/hr

Max. Operating Pressure : 3.5 kg/cm2

Min. Operating Pressure : 2.0 kg/cm2

Output per Regeneration : 192 m3 based on 600 PPM of

Raw Water Hardness

Unit Diameter : 1500 mm

Height on Straight : 1800 mm

Resin Quantity : 2100 ltrs

Resin Type : Strong Acid Cation in Sodium form

Salt Required per Regeneration : 325 kgs

Water for Dilution : 1500 ltrs

Backwash Flow rate : 18 m3/Hr.

Treated Water Quality : Total Hardness < 50 PPM

1
 HARDNESS TESTING PROCEDURE

Total Hardness is the Measurement of Total Calcium and Magnesium content in

water. Usually, it is measured in PPM as CaCO3. (PPM: Parts Per Million)

ANALYSIS PROCEDURE:

1. Take 25 ml of water sample in a given measuring jar.

2. Add pinch of REAGENT – TH 1.
3. Add 5 to 6 drops of REAGENT – TH 2.
If water color turns BLUE, the Total Hardness is less than 2 PPM.
If water turns PINK…………………….
4. Add REAGENT – TH 3 drop by drop and keep shaking till color changes
to BLUE.

CALCULATION:

No. of drops of REAGENT – TH 3 X 2. E.g.: 5 drops X 2 = 10 PPM.

(Note: For raw water testing use Reagent TH – 4 instead of TH – 3. Calculation
for TH – 4 is No. of drops of REAGENT – TH 4 X 10. e.g.: 5 drops X 10 = 50
PPM.)