P0408 HM TP M TS 003

Treatment Plant Functional Description 1(61)
Client: National Water Supply & Drainage Board,

Sri Lanka
Project Title: Integrated Water Supply Scheme for Un-

served areas of Ampara District Phase III
Contract No: 152003
Outotec
Project No: P0408
Area: Himidurawa Water Treatment Plant
Document: Treatment Plant Functional Description

P0408-HM-TP-M-TS-003
D 27/08/2012 For Review pump curves included JT/PK ID

C 23/08/2011 Issued for Review PK/SM ID NWSDB
B 01/08/2011 Issued For Review PK/SM ID PK
A 20/07/2011 Issued for Internal Review PK/SM ID PK
Rev Date Description By Chk App
Table of Contents
1.0 General Notes.............................................................................................. 4
2.0 System Overview ......................................................................................... 5
3.0 Dissolved Air Flotation Equipment ............................................................... 9
4.0 Filtration Equipment and Backwashing ...................................................... 13
5.0 General Sequence of Treatment Plant Controls ........................................ 18
6.0 Operating Systems .................................................................................... 19
7.0 Dual Media Filtration & Backwashing ........................................................ 30
8.0 Floated Sludge & Backwash Water Handling ............................................ 38
9.0 Polymer Dosing System............................................................................. 42
10.0 PACL / Alum Dosing System ..................................................................... 45
11.0 Lime Dosing System .................................................................................. 47
12.0 PAC Dosing System .................................................................................. 50
13.0 Chlorine Dosing System ............................................................................ 53
14.0 Water Quality Equipment ........................................................................... 56
15.0 Service Water System ............................................................................... 58
16.0 Power Failure............................................................................................. 60
Annex A Drawings .............................................................................................. 61

Annex A Drawings
Drawing Number Description
P0408-HM-TP-W-PI-100 PID Symbols
P0408-HM-TP-P-PI-002 Schematic - Phase III Water Distribution
P0408-HM-TP-P-PI-100 P&ID - Intake Pump Station & Rapid Mixer
P0408-HM-TP-P-PI-101 P&ID - DAF Filter 1
P0408-HM-TP-P-PI-105 P&ID - Filtered Water Tank and Backwash System
P0408-HM-TP-P-PI-106 P&ID - DAF Dispersion Vessels & Recycle Water Pumps
P0408-HM-TP-P-PI-107 P&ID - Waste Water Handling System
P0408-HM-TP-P-PI-108 P&ID - Thickener & Sludge Drying Beds
P0408-HM-TP-P-PI-109 P&ID - Filter Air Scour Blowers
P0408-HM-TP-P-PI-200 P&ID - Polymer Preparation & Dosing System
P0408-HM-TP-P-PI-201 P&ID - Lime Handling & Dosing System
P0408-HM-TP-P-PI-202 P&ID - Alum Batching & Dosing System
P0408-HM-TP-P-PI-203 P&ID - Chlorine Dosing System
P0408-HM-TP-P-PI-204 P&ID - PAC Handling & Dosing System
P0408-HM-TP-P-PI-001 P&ID-Water Sampling System
P0408-HM-HL-P-PI-101 P&ID - High Lift Pump House

1.0 General Notes

1. Each drive will be protected by its hardwired circuits such as:
Dry run protection
Thermal overload motor protection
Thermistor protection
VSD Fault
2. Where duty and standby items exist then duty in these instances is either duty as
selected or standby if duty fails. Duty selection is made by rotation on each start.
3. The various drive starters each have a MCC selector switch and can be changed to
either auto, off or manual. It is normal practice when the drive is serviceable and
available for the local selector switch to be switched in the AUTO position.
4. To enable a drive to be controlled by the PLC the following conditions must be met
o Drive must be in AUTO on the MCC

o Drive must be ready in the MCC (all protection in a normal state)
o Drive must not be failed by the MCC (start, motion, torque, flow)
When any of the above conditions have not been satisfied a fault light on the
switchboard will be illuminated.
5. PID Controllers will be used for the following functions:

Raw Water Pumps- To maintain fixed flow at set point
DAF Dispersion Pumps-To maintain discharge pressure at set point
Dispersion Vessel Feed Control Valves DVLC V01P, DVLC V02P-To maintain
level in dispersion vessel at set point.
Waste Water Pumps-To maintain fixed flow at set point.
6. A number of alarms generated by the PLC are latched and so require the operator to
reset them before the drive can be restarted. A reset button is provided for this
purpose.
7. Major plant faults, requiring plant shut down, act by stopping raw water pumps. The
balance of the plant is allowed to shut down in orderly fashion as a consequence of the
normal loss of raw water flow.
8. Note that rapid mixer, Flocculators, lime slurry mixers, wash water tank mixer,
thickener rake and sludge tank mixer remain in operation even if raw water is not
flowing.
9. Air supply compressors operate as stand alone devices external to PLC control,
although if compressors fail, plant shutdown is initiated.
10. Service water pumps operate as stand alone devices external to the PLC control,
although if service water pumps fail, plant alarm is initiated.
11. For pumps equipped with VSDs the following set points are programmed into the PLC
o Minimum frequency for the pump drive

o Maximum frequency for the pump drive
2.0 System Overview

2.1 Status
Selection switches on the switchboard will allow the operator to select each filter as online or
offline.
The PLC shall track filter status and assign a status to each filter cell as:
Available filter is not running but all other operations are complete and it
is ready for filtration mode. Selection switch on switchboard is
set to auto.
Running filter is operating in normal filtration mode
Backwash requested filter has exceeded at least one parameter for backwash and is
in backwash queue. Filter status will be concurrently running
or unavailable depending on which parameter has been
exceeded.
Backwashing backwash in progress
Unavailable filter has faulted or is selected as off at the switchboard. Filter

cannot be used until fault condition is rectified or switchboard
selection is changed to online.
The PLC shall use the filter status for filter selection and to organise the backwash queue
2.2 Selection
The selector switch on the switchboard will allow the operator to enter the required plant flow
rate set point. To standardise operating procedures the selectable flows will be limited to (0,
25, 50, 75 and 100% of full operating capacity = 340L/sec)
The number of filters operating at any time shall be based on the minimum filters required to
achieve the flow given that the maximum flow through one filter = 25% of 340 L/sec at any
time.(ie.off, 1,2,3, or 4 filters will correspond to the five selector positions).
The filters are arranged in an available queue and the PLC selects the required number of
filters from this queue. The queue is arranged in order of the operating time.
If the number of filters required exceeds the number available the intake pumps will not start
until the correct number of filters are available, or the operator sets selector switch for the
correct number of available filters.
In the event that a backwash is requested then the filter at the front of the available queue
will be brought online at the start of the backwash sequence. Following a backwash the
backwashed filter reverts to available and it is put to the end of the available queue to be
called to run when required. In this way the available filters are cycled through after each
backwash ensuring that they all get even operation time. In the event all four filters are
operating at 100% and a backwash is requested, then the plant flow rate will be dropped to
75% to complete the operation.
2.3 Start Up and Shutdown

Plant Start is operator initiated by a selection on the control panel.
Plant start consists of starting the required raw water pump(s). Once raw water flow is
selected the pre-dosing and post-dosing equipment, DAF system and filters will start.
Plant Shut down will occur due to the following:
o Major plant failure

o Operator selection at the control panel (0% / off)
o High level in filtered water tank
o High level in clear water tanks
Plant shut down consists of stopping the raw water pump(s). Once raw water pumps stop
operation the pre-dosing and post-dosing equipment, DAF system and filters will stop.
The plant start is overridden and stopped in the event of a major plant failure. These failures
may come from the following alarm conditions:
o High level in the filtered water tank

o High level in clear water tanks
o High level in the raw inlet channel
o Power Failure
o Inadequate filters available for selected plant flow
o Intake pump fault (failure of duty and standby pumps)
o Alum fault (pump fault or low tank level)
o Low compressed air pressure
o Low service water pressure
2.4
The following alarms are generated in the PLC
o DAF equipment failure alarms and shuts down DAF but does not shutdown plant
(plant continues to operate in direct filtration mode)
o Backwash failure inhibits further backwashes but does not shut down the plant.
o Lime low level alarm
o Chlorine no flow alarm
o Alum low level alarm
o Backwash alarm
o PAC low level alarm
2.5 Panel (Equipment Status)

A plant overview panel mounted in the control desk displays the status of selected critical
equipment.
2.6 Pump Operation

The number of intake pumps operating and their respective operating frequencies is based
on the Treatment Plant flow setting as determined by the selection made on the switchboard
selector switch i.e. 25%, 50%, 75% or 100%. Start up and shut down of the raw water pumps
is to be ramped in a controlled fashion.
2.7 Water Flow Control

The raw water flow meter analogue device is included to monitor raw water flow. Raw water
flow set points have been established for 25%, 50%, 75% and 100% of the maximum flow of 340l/s,
the set point selections are made at the selector switch.
Items initiated by raw water flow set point are required to be correctly selected to automatic
operation.
These items are as follows:
o Rapid Mixer
o Alum Dosing Pumps
o PAC Dosing Plant (when required)
o Post Lime Dosing Plant
o Dispersion Pumps
o Chlorine booster pumps / Chlorinators
o Sludge removal timers
2.8 Grit Pumps

Submersible pumps are located at the intake channel and are used to remove grit. Pumps
are manually operated as required.
2.9 of Components
Raw Water Pumps INM01, INM02, INM03
Vertical turbine Pumps with VSD
Selection switch on the panel at the Intake actions the following:
Off - Motor isolated, or stopped if running.
Manual - Motor runs subject only to individual motor protection devices,

which are as follows:
o Thermal Overload Motor Protection.

o VSD fault
o Thermistor protection
Auto - Motor runs subject to the following conditions:
o Protection devices listed in Manual selection

o Automatic control systems:
Plant selector switch (Auto)

Plant Inhibit not active
- Filter Water High Level
- Clear Water High Level
- Inlet channel High level
Raw Water Flow Meter RWFM001
600mm Electromagnetic flow meter, 0-500 L/Sec. With 4-20mA output
Functions are as follows:
o Local indication & reports to PLC
Submersible Grit Pumps GPM01, GPM02
Grit pump fixed speed
Selection switch on the panel at the Intake actions the following:
Off - Motor isolated, or stopped if running.
Manual - Motor runs subject only to individual motor protection devices,


o Protection devices listed in Manual selection
3.0 Dissolved Air Flotation Equipment

3.1 OF COMPONENTS
RMM01 Rapid Mixer
Rapid mixer fixed speed
Selection on Switchboard
Off - Motor not available to run, or stopped if running.
Manual - Motor runs subject only to individual motor protection device,


o Thermister Protection
o Protection device as per Manual selection.

o Plant start-up and shut down sequence.
FLOCM01A FLOCM04B Flocculators for each filter
No.1 flocculator, No. 2 flocculator, each with VSD drive.

o Thermal Overload Motor Protection. (within VSD)

o VSD fault

o Automatic control systems
SRM01 SRM04 DAF Sludge Rollers 1 for each filter
Horizontal roller, fixed speed

Selection at Switchboard

o Thermal Overload Motor Protection

Raw Water Flow Initiate.

DAF Sludge Roller Run Timer
DAF Sludge Roller Delay Timer
Associated filter selection
DRM01 DRM03 DAF Recycle Pumps 2 duty & 1 standby
Centrifugal multistage pumps, each with VSD , 28L/sec @80m head

o Thermal Overload Motor Protection. (within VSD)

o VSD fault
o Low water level in Filtered Water Tank

Raw Water Flow Initiate.

Dispersion pump pressure transmitter
Duty rotation
DVISV01AP DVISV02AP Dispersion Vessel Inlet Valve
Butterfly valve, open/closed, pneumatic with solenoid and open/close limit switches
Controlled by filter stop start
Dispersion Valves Filters 1 to 4 DN V1aM to DN V4jM (10 valves per filter)
Manually set at DAF chimney
DVLCV01P DVLC02P Dispersion Vessel Inlet Flow Control Valve
80mm Segmented ball valve, 4-20mA position controlled from level in the vessel
SPV01P SPV10P Cutting Spray Solenoids valves - 1 per filter
Water solenoid valve.
Open - Valve energised and opens.
Close - Valve de-energised and closes.
Auto - Valve opens subject to automatic control system, which is as

follows:
o DAF Sludge Roller Run Timer

o DAF Sludge Roller Delay Timer
o Raw Water Initiate
DVFM01 DVFM02 Dispersion Flow 1 per vessel
Electromagnetic flow meter, 80 mm, 0-35 L/Sec with 4-20mA output
Functions - Local indication
DPPT01 Dispersion pumps pressure transmitter
Differential pressure transmitter, 0-1000kpa 4-20mA output
Functions - Local indication and dispersion pump control.

FWLLS01 Filtered water tank level switch
Ball float in the filtered water tank, one active point
Designation Action
LL Inhibits the dispersion system and backwash (back-up)
FWLT01 Filtered water tank level transmitter
Ultrasonic level transmitter in the filtered water tank, 3 active points
Designation Action
H Initiates plant shut down
L Inhibits the dispersion pumps
LL Inhibits the backwash pumps
4.0 Filtration Equipment and Backwashing

4.1
Conditions precedent for automatic backwash to occur
o Air scour valves closed on all filters

o Air scour blowers available
o Air scour soft start valve available
o Backwash inlet valve on all filters available
o Backwash pumps available
o Sufficient capacity in the wastewater holding tank.
o Sufficient supply capacity in the filtered water tank
4.2
Alarms contributing to common backwash fault are:
o Any actuated valves for the backwashing filter not selected auto.
o Any actuated valve for the backwashing filter failed
o Both air blowers not selected auto.
o If at least two Backwash pumps not selected auto
o Filtered water tank low level.
o Failure of duty and standby equipment (backwash pumps or air blower)
If a filter backwash fails the backwash sequence shall cease immediately with alarm and the
filter status shall be set to unavailable. The backwash sequence for that filter shall cease by
stopping the air scour blower and backwash pumps and closing all valves if possible. The air
scour soft start valve shall fail open.
4.3 Valve Fault

Each open or close sequence shall be verified by feedback from the valves position
switches. Any failure to verify valve as open or closed shall change the filter status to
unavailable. If this happens during a backwash a backwash fault will be raised.
4.4 Pump Fault (Two duty - One 50% standby)

If a backwash pump fails the PLC shall change its status to unavailable and raise an alarm. It
shall then start the standby pump. If no pump is available a backwash fault alarm will be
raised.
4.5 Scour Blower Fault

If a blower fails, the PLC shall change its status to unavailable and raise an alarm. It shall
then start the standby blower. If no blower is available a backwash fault alarm will be raised.
4.6 level alarms

High-level signal is provided in the filtered water tank with the action of shutting down the
plant
4.7 OF COMPONENTS
ASBM01 ASBM02 Air Scour Blowers. Common to all filters
Positive displacement blower, fixed speed,



Backwash automatic control sequence.
BWM01 BWM03 Backwash Pumps Common to all filters
Centrifugal pumps, Fixed Speed

Selection on switchboard



Backwash automatic control sequence.

FOV01P FOV04P Filter Outlet Control Valves One each filter
Butterfly valve, pneumatic with 4-20mA positioner and closed limit switch
Open - Valve energised and opens subject to position signal.

follows:
o Backwash automatic control sequence

o Filter level control
INV01P INV04P Filter Inlet Valve One each filter
Butterfly valve, open/closed, pneumatic with solenoid and limit switches.

follows:
o Filter Selection
BIV01P BIV04P Up wash / Backwash Valve One each filter


follows:

WOVA01P, WOVB01P WOVA04P, WOVB04P Washout Valves One each filter

follows:
ASIV01P ASIV04P Air scour valve One each filter

follows:
ASSV01P Air Scour Soft Start Valve - Common to all filters
Butterfly valve, open/closed, normally open, electric actuated & limit switches.
PLC operated during backwash cycle


follows:

FLHPT01 FLHPT04 Filter Head loss One each filter
Differential pressure transmitter, 0-3M 4-20mA output
Functions - Local indication and reports to PLC.

- Provides initiation signal for automatic backwash due to
headloss.
Designation Action
H Initiates backwash requested
FLT01 FLT04 Filter Level Transmitters One each filter

Level transmitter (Pressure) 0 - 500mm 4-20mA pressure transmitter
Functions - Local indication and reports to PLC.

- Provides control of filter outlet valve
FLS01 FLS04 Filter level switches
Float switch, one active point.
Designation Action
L Drain down level, stops drain down ready for air scour
BWFM01 Backwash flowmeter
Magflow 0 - 750L/sec 4-20mA
Functions - Local indication and reports to PLC

5.0 General Sequence of Treatment Plant Controls

1. Plant flow rate selected 25%, 50%, 75%, 100% of capacity
2. Raw Water Pumps are enabled
3. Plant Start
4. PLC enables the following systems subsequent to readiness checks of

individual systems/equipment. These systems/equipment will operate within
their respective start/stop control regime;
5. Select no. of filters to suit flow rates selected by opening inlet valves
6. Select no. of dispersion vessels corresponding to the no. filters selected
7. Select no. of dispersion pumps corresponding to no. of filters selected
8. Enable rapid mixer and flocculator mixers
9. Enable sludge rollers
10. Enable selected dual media filter outlet control valves
11. Enable Backwash pumps
12. Enable Air scour blowers
13. Enable Waste water pumps
14. Enable Alum dosing pumps
15. Enable Polymer dosing pumps
16. Enable Lime & PAC system volumetric screw feeders
17. Enable Lime & PAC system slurry mixers
18. Enable Chlorine system
19. Enable sampling pumps
20. Enable High Lift Pumps
21. Enable Service water pumps
22. Enable thickener

6.0 Operating Systems
6.1 Water Intake Pump Station
Overview
Three (3) raw water pumps are provided with one (1) pump to be always on standby. Each of
the three (3) Raw water pumps are provided with Danfoss VSD system. These VSDs are
interconnected to provide a cascading control system with a duty pump as fixed lead pump.
The duty pump is rotated periodically.
The raw water pump drives are hardwired to the wet well level switches for dry run
protection.
In auto mode the intake pumps would follow the following sequence:
The operator selects required plant flow of 25%, 50%, 75% or 100% (based on plant
stop / starts limited to 2 per day)
Start raw water pump Treatment Plant starts automatically
Danfoss VSD system selects the no. of pumps required for the selected plant flow
Flow selector input is fed in to the PID controller as target flow
Due to varying static heads flow from the pump would vary at a fixed speed
VSD cascade controller modulates the pump(s) speeds to maintain the set point flow
by receiving feedback from the flow meter RWFM001.
VSD Cascade
Controls
Flow meter VSD. Pump.1
PID
VSD. Pump.2
VSD. Pump.3
Flow Set Point from flow selector
Figure 1 PID Controls for Raw Water Pumps

6.2 of Raw Water Pumps
(A) Operation at Plant Flow 25%= 85 L/s

Intake pumps switched to auto mode
Flow selector set at 25%
Flow set point Input in to PID controller is automatically set at 25%=85 L/s
System Start activated
VSD cascade controls selects the number of pumps required to achieve the
flow set point
In this case a single pump is selected
The duty pump completes the internal protection checks
Duty pump starts and ramps up to reach the flow set point
Feedback from flow meter RWFM001 is received by the PID Controller
PID controller directs the VSD cascade controls to achieve the flow set point
as shown in the curves in Fig.2 below
At low static, pump would run at 35Hz
At high static , pump would run at 39 Hz
Intake Pumps at 25% Plant Flow

35.0
30.0
25.0
20.0
Head-m
15.0 85, 13 (39Hz)
10.0
85, 10 (35 Hz)
5.0
0.0
0 50 100 150 200
Flow-L/s
Head m 0.3
Head Flooded
Head m 0.03
Head Flooded
Single pump for 25% plant flow at low static
Single pump for 25% plant flow at high static
25% plant target flow at low static
25% target flow at high static
Figure 2 System curves and Pump Operation Curves at 25% Flow

(B) Operation at Plant Flow 50%= 170 L/s

flow set point
In this case a single pump is selected
The duty pump completes the internal protection checks
Intake duty pump completes the internal protection checks
Duty intake pump starts and ramps up to reach the flow set point
as shown in the curve below
At low static, pump would run at 44Hz
At high static , pump would run at 48 Hz

35.0
30.0
25.0
20.0 170, 14 (48 Hz)
Head-m
15.0
10.0
170, 11 (44 Hz)
5.0
0.0 Flow-L/s
0 50 100 150 200 250
Head m 0.3
Head Flooded
Head m 0.03
Head Flooded
50% target flow at low static
Single pump for 50% plant flow at low static
Single pump for 50% plant flow at high static

(C) Operation at Plant Flow 75%= 255 L/s

flow set point
In this case a two pumps are is selected
The 1st duty pump completes the internal protection checks
VSD cascade controls switches on the 2nd duty pump
The 2nd duty pump completes the internal protection checks
VSD cascade controls set both pump at same speed to achieve the set point
At low static, each pump would run at 40Hz
At high static , each pump would run at 45 Hz

35.0
30.0
25.0
20.0 255, 15 (45 Hz)

Head-m
15.0
10.0
255, 11 (40 Hz)
5.0
0.0
0 50 100 150 200 250 300 350 400 450 500
Flow-L/s
Head m 0.3
Head Flooded
Head m 0.03
Head Flooded
Two pumps at 75% flow at low static
Two pumps at 75% plant flow at high static
Two pumps for 75% plant flow at low static

(D) Operation at Plant Flow 100%= 340 L/s

flow set point
In this case a two pumps are is selected
The 1st duty pump completes the internal protection checks
VSD cascade controls switches on the 2nd duty pump
The 2nd duty pump completes the internal protection checks
VSD cascade controls set both pump at same speed to achieve the set point
At low static, each pump would run at 45Hz
At high static, each pump would run at 49.5 Hz

35.0
30.0
25.0
340, 16 (49.5 Hz)
20.0
Head-m
15.0
10.0
340, 11 (45 Hz)
5.0
0.0
0 50 100 150 200 250 300 350 400 450 500 550
Flow-L/s
Head m 0.3
Head Flooded
Head m 0.03
Head Flooded
Two pumps for 100% plant flow at low static
Two pumps for 100% plant flow for high static

The following items are incorporated in this section:
o RWFM001 Raw water flow meter

o INM01 Intake pump no.1
6.3 Mixer and Flocculator Mixers
6.3.1 Overview
Raw water from the intake pumps enters the rapid mixer. There is one (1) rapid mixer, which
ensures coagulant is well mixed, before water flows into the raw water channel. The raw
water channel is the entry point for water to flow through inlet valves into separate flocculator
trains for each filter. There are 4 filters, and thus four trains of two stage flocculator banks,
with a total of eight (8) flocculator mixers operating in the flocculation zone. Two (2)
flocculator mixers assigned to each filter.
The rapid mixer runs at fixed speed and the flocculator mixers are driven by VSDs. The
flocculator mixer speeds are manually set during commissioning to achieve the desired
flocculation.
6.3.2 Operation of Mixers

The rapid mixer is activated as the system operation begins and it runs continuously.
The flocculator mixers will operate as long as the corresponding filter is set on auto mode
Flocculator mixers are switched off only when a corresponding filter is taken out of service
for maintenance.
6.4 Air Filtration (DAF)
6.4.1 Overview
Gravity fed pre-dosed water passes through the flocculation compartments and the DAF
section before entering the filters.
The DAF system is a continuous process, with intermittent floated sludge removal
The following items are included in this section:
o FLOCM01A FLOCM04A Flocculator No.1 - Filters 1 to 4

o FLOCM01B FLOCM04B Flocculator No.2 - Filters 1 to 4
o SRM01 SRM04 DAF Sludge Rollers Filters 1 to 4
o DRM01 DRM03 DAF Recycle Pumps 1 to 2 / and 1 standby
o SPV01S SPV4S Cutting Spray Solenoid Valves Filters 1 to 4
o DVFM01 DVFM02 Dispersion Flow meters 1 to 2
o DRIV01P DRIV04P Dispersion inlet valve Filters 1 to 4
o DVISV01AP DVISV02AP Dispersion vessel inlet valve Vessels 1 to 2
o DVLCV01P DVLCV02P Dispersion control valve Vessels 1 to 2
o DPPT01 Dispersion pumps pressure transmitter
(for pump no. & speed control)
o FWLLS02 Filtered water tank low level switch
6.4.2 Operating systems
Dispersion Equipment
1. The dispersion system starts immediately on plant run. This applies to DAF Recycle
pump(s), which are required to be correctly selected to automatic mode. There are 3
recycle pumps ie. 2 duty and 1 standby. These pumps are known as recycle pumps
because they pump water back from the filtered water tank to the dispersion tank.
2. The dispersion pumps are controlled via VSDs. On start up the number of pumps started
is determined by the PLC in accordance with the number of filters selected for operation
based on Table 3.4.2
3. The pumps speed is controlled such that the dispersion pumps pressure as measured by
the pressure transmitter is maintained at the set point (nom 600 to 700KPA). Pump duty
is rotated on each start
4. Each dispersion vessel includes a level device, which controls the inlet valve to the
dispersion vessel to maintain correct level of water in the dispersion vessel. Dispersion
control is ultimately set by adjustment of the dispersion valves at the DAF chimney.
5. Each dispersion vessel supplies two filters. The inlet and outlet valves to each vessel
remain closed unless one or both of its associated filters are operating. The outlet valve
should open in sequence prior to the inlet valve.
6. The compressed air plant is controlled as a stand alone service and is always in
operation. A pressure-regulating valve maintains the air pressure in the dispersion vessel
at a set value (usually 600kPa).
7. The DAF cutting sprays are supplied with water from this system.
8. Low level in the filtered water tank will inhibit the Dispersion system from operating such
that the plant will operate as a direct filtration plant until there is sufficient level in the
filtered water tank for the dispersion pumps to operate.
Floated Sludge Removal

9. Floated sludge is removed on a run and delay timer basis by the DAF sludge roller, aided
by the use of cutting sprays around the DAF tank wall.
10. Once the plant is in operation and raw water flow has been established a delay timer
commences (typically 2hrs). When this timer, times out the cutting spray solenoid opens
& remains open while the DAF sludge roller operates. After a period typically set at 10
minutes, the selected cutting spray solenoid closes and the DAF sludge roller stops.
12. Both the sludge removal duration and the frequency timers are manually set by
authorized personnel in the PLC.
6.4.3 Operation of DAF Filters
When the raw water intake pumps are initiated, the rest of the plant is automatically
started.
The selection of no. of filters and dispersion system are carried out automatically as
follows:
Table 1 Plant flow Vs. Filters/Dispersion Vessels/Dispersion Pumps

Plant Flow No. of Dispersion Pumps
Filters
25% Plant flow 1 x Filter 1 x Dispersion pump
50% Plant flow 2 x Filters 1 x Dispersion pump

Plant set on auto mode

All actuated valves switched to auto mode
Dispersion pumps switched to auto mode
Backwash pumps switched to auto mode
Air scour blowers switched to auto mode
PLC carries out the following functions:

(a) Filter Inlet Valve
PLC selects and opens the valve corresponding to the first available filter banks
according to Plant flows as shown in Table.1
Table 2 Filters and Inlet Valves

Filter.1 Inlet valves INV01P Inlet.1
Filter inlet valve can be shut in manual mode
(b) Flocculator Mixers (switched to auto mode)

PLC selects the pair of Flocculator mixers corresponding to the selected filter(s)
Table 3 Filters and Flocculator Mixers

Filter.1 Flocculator mixers M01A & M01B
The flocculator mixers operate at pre-set fixed speed with VSD

The flocculator mixers operate continuously in auto mode
The flocculator mixers can be stopped in manual mode
(c) DAF Recycle Water Inlet Valves (switched to auto mode)
PLC selects the Recycle Inlet Valve corresponding to the selected filter(s)
Table 5 Filters and Recycle Water (Dispersion) Inlet Valve

Filter.1 Recycle Inlet Valve DRIV01P
Recycle inlet valve can be shut in manual mode.

(d) Operation of DAF Recycle Water Pumps
DAF Recycle Water Pumps
Table 6 DAF Recycle Water Pumps
Pump.1 DRM01
Pump.2 DRM02
Pump.3 DRM03
The recycle water pumps are provided with Danfoss cascading control VSD system.
The following functions to be read in conjunction with the pump curves given below:
25% Plant flow

PLC selects the duty recycle pump available as lead pump. The lead pump ramps
up to 30Hz. At this speed the pump would deliver the required 10.25 L/s at 75m head
50% Plant flow
The lead pump ramps up to 39 Hz to deliver 20.25 L/s @ 75m head
75% Plant flow

Two pumps ramp up to 41 Hz to deliver 30.75 L/s @ 75m head
100% Plant flow

Two pumps ramps up to 45 Hz to deliver 41.0 L/s @ 75m head
Table 7 Plant Flow/ Recycle Water Pump flows Vs. Running Speed
25% Plant flow 10.25 L/s 1x pump at 30 Hz
50% Plant flow 20.25 L/s 1x pump at 39 Hz
75% Plant flow 30.75 L/s 2x pumps at 41 Hz
100% Plant flow 41.00 L/s 2 x pumps at 45 Hz
The dispersion water pressure would vary with the following changes:
1. Float spray nozzles activation,
2. DAF dispersion vessel feed valve modulation
3. Plant flow variation during filter backwash
VSD Cascade
Pressure Controls
sensor
feedback VSD. Pump.1
PID
VSD. Pump.2
VSD. Pump.3
Pressure Set Point from PLC-75m
Figure 6 DAF Recycle Water Pump Pressure Controls

DAF Dispersion Water Pumps Curves

160
140
120
100 1 x pump at 50
2x pumps at 50Hz
Head-m
80
2x pumps at 45
60 1 x pump at 39
1x pump at 30Hz 2x pumps at 41 Hz

40
20
0
0 10 20 30 40 50 60
Flow-L/s
Single pump curve Duty point for 25% Plant flow
Duty point at 50% plant flow Duty point at 75% plant flow
Figure 7 Dispersion Water Pump Curves
(e) Vessel Level Control
The two (2) dispersion vessels are provided to serve the four (4) DAF filters with dispersion
water, which is a mixture of Filtered water from the filtered water tank and compressed air.
Compressed air is supplied to the dispersion vessel at constant pressure from the
compressed air receiver.
The water level in the dispersion vessel fluctuates due to:

1. Float spray nozzles activation,
2. Plant flow variation during filter backwash
3. Dissolving of compressed air in the vessel
Hence, dispersion vessel inlet control valves ( DVLC01P, 02P) are provided to maintain a
constant water level inside the vessel. A PID controller is programmed with a level set point,
so that it drives the valve positioner by receiving a constant feedback from the vessel level
sensor, thus maintaining a constant level in the dispersion vessel.
Vessel level
feedback To Dispersion
vessel
PID
Vessel level Set Point from PLC
Figure 8 DAF Dispersion Vessel Level Controls
Vessel Set Points
Table 8 Dispersion Vessel Level Set points record

Dispersion Vessel Level Set Points
No. 1
No. 2
(f) Air System
The compressed air system is provided to supply clean and dry compressed air for the
following functions:
1. Dispersion water vessels
2. Instrument air to the valve actuators
The Compressed air system consists of two (2) air compressors, two (2) refrigerant air dryers
and a common receiver. The compressors will be utilised as duty/standby. In order to
changeover the duty cycle between the compressors, isolating valves have to be manually
operated to effect a switchover.
A pre-set pressure set point will be maintained inside the receiver by the internal controls of
the air compressors.
The main PLC monitors the pressure in the air receiver at all times as compressed air is
crucial for the plant operation. In the event of drop in pressure in the vessel < (______ set
point) over a period of ( T= ____mins), the PLC will shut down the treatment plant.
Table 9 Compressed air system set points record
Parameter Set Point

Air Receiver Pressure set Point (kPa)
Time delay before plant
shutdown ___________(mins)
7.0 Dual Media Filtration & Backwashing

7.1
Subnatant water from below the DAF float sludge passes through the filter media and into
the filtered water tank. The modulated filter outlet control valve ensures that the filter
operates at a sensibly constant level suitable for DAF sludge removal.
Filter backwashing is initiated by head loss, operating time or operator intervention and then
proceeds automatically. Backwashing consists of air scour followed by high rate water wash.
Duty / standby air scour blowers are provided for air scouring. Water for backwashing is
pumped from the filtered tank using two duty pumps and one 50% standby pump.
The following items incorporated in this section are :
o INV01P INV04P Filter inlet valve filters 1 to 4

o ASBM01 ASBM02 Air scour blower duty / standby
o FOV01P FOV04P Filter outlet valve filters 1 to 4
o WOVA01P WOVA04P Filter washout valve filters 1 to 4
o WOVB01P WOVB04P Filter washout valve filters 1 to 4
o ASIV01P ASIV04P Air scour valve filters 1 to 4
o ASSV01P Air scour soft start valve
o BIV01P BIV04P Up wash / backwash valve filters 1 to 4
o FLT01 FLT04 Filter level sensor / transmitter filter 1 to 4
o FLS01 FLS04 Filter Level switch filters 1 to 4
o FLHPT01 FLHPT04 Filter headloss DP transmitter filters 1 to 4
o BWM01 Backwash pump 1
o BWFM01 Backwash flow meter
o FWLLS01 Backwash supply low level switch
o WWHT LT01 Waste water holding tank level transmitter
7.2 Pump Flow Setting
Backwash flow rate for the dual media filters are as follows:
1. Sand media- 555 L/s

2. Coal media- 500 L/s
Three (3) duty pumps ( 2 duty/1 standby) are provided for the backwash operation.
The above required backwash flow rate is to be achieved with two (2) pumps operating in
parallel at fixed speed.
The appropriate flow rate from the backwash pumps will be set at the common discharge
butterfly valve, with the aid of the backwash flow meter BWFM01. This setting will be done
during commissioning.
Fig.10 illustrates the two throttling curves to achieve the desired backwash rate when two (2)
pumps are operating in parallel.
Backwash Pump Curves

20.00
18.00
16.00
14.00
12.00
Head-m 10.00
8.00
6.00
4.00
2.00
0.00
0 100 200 300 400 500 600 700
Flow-L/s
System Curve Backwash duty -Sand Media

Flow Throttling for Coal Media Flow Throttling for Coal Media
Backwash duty-Coal Media Pump curve
2x pumps
Figure 9 Backwash Pumps and System Curves
7.3 SYSTEMS
Raw Water Flow

The plant inlet flow is reduced to 75% throughout a backwash if operational status is at 100%
otherwise standby filter is used for backwash. If the number of filters required exceeds the
number available the operator must select the correct number of filters available, reduce the
plant flow rate by selector switch or shut the plant down.
Inflow to each filter is via individual inlet weirs, which provide equal inlet flow to each
operating filter.
Filter Outlet Control

Filter outlet valve with positioner modulates to accommodate change in flow or filter headloss
and maintains the water level in the filter at a virtually constant level under control of the filter
level sensor / pressure transmitter.
When backwash is initiated the filter outlet valve positioner maintains position to allow the
filter to drain down gradually to the level switch. At completion of drain down the filter outlet
valve is closed and air scour sequence is initiated.
Filter Outlet Control Valves (switched to auto mode)

PLC selects the Outlet Control Valve corresponding to the selected filter(s)
Table 10 Filters and Filter Outlet Control Valves

Filter 1 Control Valve F0V01P
Filter level control:

Filter
level
signal
PID
Filtered water
Filter level set point Filter outlet control

valve
Figure 10 PID controls for filter level control
The filter outlet control valve modulates to maintain the level set point in the corresponding
filter, by receiving continuous feed back from the filter level sensor.
Filter Level Set Points

Table 4 Filters level Set Points Record
Filter Levels
Filter 1
Filter 2
Filter 3
Filter 4
Backwashing Automatic Initiate

The backwash sequence shall be initiated by the following conditions / parameters
1. Initiation by head loss - occurs when the high level limit of the filter head loss DP cell is
reached, or
2. Initiation on elapsed time - occurs when the Filter Elapsed Run Time Clock times out.
This filter run timer corresponds to actual filtration time for that filter. Note the run timer
set point is set normally at 24 hours, or
3. A button on the switchboard achieves manual initiation of automatic backwash.
In an emergency the backwashing process can be performed by manual changeover of

valves and manual operation of equipment.
If any of these conditions occur during normal filtration operation, the status of that filter shall
change to backwash requested and that filter shall be placed in the backwash queue.
The backwash queue shall be maintained in order of filters changing status to backwash
requested with the exception of operator initiated backwashes, these shall be placed at the
head of the queue following completion of any backwash that is currently being performed.
Backwashes started prior to plant shutdown will be finished.
Filter Drain Down & Re-fill Levels

The filter has a level switch which is used in the backwash sequence for signalling when
drain down level has been reached
In automatic sequence alarms are triggered if the drain down level is not reached in
reasonable time.
On plant shut down the filter outlet flow control valve will close instantly.
Filter Valves
Each valve has a panel mounted selector switch on the switchboard. For the automatic
backwash sequence to proceed successfully every valve must be in Auto position. A filter
will shut down if every associated valve is not in the auto position. All actuated valves will be
supplied with open and closed limit switches.
A summary of the action of each valve during backwash is typically as follows:
Inlet Valve Closed
Outlet Valve Opened for drain then closed during backwash
Up wash /Backwash valve Open for backwashing
Washout Valve Opened after completion of air scour in

backwash sequence and then closed after
backwash to allow re-fill
Air scour Valve Open for air scour
Air Scour Soft Start Valve Normally open, closes after blower starts &
reverts to open when blower stops.
Backwash Sequence
1. Backwash is initiated by time, head loss or operator initiation
The following functions are directly controlled by the PLC:

Filter head loss triggered back wash is initiated by one of the following differential
pressure sensor /transmitters:
Filter No. Transmitter No.

Filter 1 FLH PT 01
Filter 2 FLH PT 02
Filter 3 FLH PT 03
Filter 4 FLH PT 04
2. Correct number of filters must be selected for the plant flow in order for backwash to
begin. The next available filter, which is not currently running, is started by opening its
inlet valve.
3. If the plant is at 100% capacity, flow is reduced to 75% during backwash (See plant
flow reduction logic)
4. Sludge roller and cutting sprays run for nominal 10 minutes with filter still in production
mode. Inlet valve, outlet valve, dispersion valve and dispersion vessel valves are open.
Sludge roll step can be bypassed by selecting roller or sprays out of auto
5. Filter inlet valve is closed for the filter to be backwashed
One of the following valves corresponding to the selected filter is closed prior to
backwash:
6. DAF re-cycle water inlet valve for the filter being backwashed is closed
One of the following valves corresponding to the selected filter is closed prior to
Backwash:
7. Filtered water outlet valve is opened to 50% so that filter drains down to air scour level
switch 100mm above filter sand. Filter outlet valve then closes
Select filtered water valve corresponding to the selected filter from the following:
Filter.1 Control Valve F0V01P
Airscour level switch:
Filter.1 FLS01
Filter.2 FLS02
Filter.3 FLS03
Filter.4 FLS04
8. Air scour inlet valve to the associated filter opens
Select air scour inlet valve corresponding to the selected filter from the following:
Filter.1 ASIVO1P
Filter.2 ASIVO2P
Filter.3 ASIVO3P
Filter.4 ASIVO4P
9. Duty Air blower starts:

The second blower remains on standby
Air Scour Blower.1 ASB 01
Air Scour Blower.2 ASB 02
If the duty blower fails to start, then the standby blower is automatically energised.
If the standby blower too fails, backwash failure alarm is activated.
10. Timer nominally 30 seconds expires.
11. Air blower soft start valve (normally open) slowly closes.
Air blower soft start valve is hardwired to the blower starter control circuit.
Air blower soft start valve ASSV 01P

The soft start valve will follow the same sequence even on manual mode start.
12. Air blower operates until an air blower timer (nominally set at 5 min) runs out at which
time the air blower stops and air blower soft start valve opens and air scour inlet valve
closes
13. Settling timer runs for nominal time of 2 min
Washout valve opens.
Select washout valve corresponding to the selected filter from the following:
Filter.1 WOVA 01P
Filter.1 WOVA 01P
Filter.2 WOVA 01P
Filter.2 WOVA 01P
Filter.3 WOVA 01P
Filter.3 WOVA 01P
Filter.4 WOVA 01P
Filter.4 WOVA 01P
14. Backwash valve opens
Select backwash valve corresponding to the selected filter:

Filter.1 WOVA 01P
Filter.2 WOVA 02P
Filter.3 WOVA 03P
Filter.4 WOVA 04P
15. Duty Backwash pumps (two) start sequentially with 20 seconds start delay on second
pump. The backwash flow rate is maintained by fixed setting manually operated valve
(selected at Coal wash rate L/sec),
Backwash pump.1 BW M01
If the backwash pumps fail to start, a backwash failure alarm is activated.
16. Backwash timer (nominally set at 300 sec) runs out (backwash pumps continue to run)
17. Washout valve is closed
18. When the filter level as measured by the filter level transmitter reaches the refill level
backwash pumps stop and the up wash / backwash valve closes.
Filter Level Transmitters:

Filter.1 FL T01
Filter.2 FL T02
Filter.3 FL T03
Filter.4 FL T04
19. The filter outlet control valve control loop is reactivated

20. The filter status is set back to available and the filter is idle (not running) until it is
required by the PLC.
Backwash trigger
PLANT FLOW REDUCTION LOGIC BY PLC FOR BACKWASH
Start
Check Plant
Flow
No No No
Is Flow Is Flow Is Flow Is Flow
=100%? =75%? =50% =25%
Yes Yes
Yes
Reduce flow to
=75% No
Is there a No Is there a Is there a
Reduce flow to No standby
standby standby Reduce flow to
filter? =50% filter? =25% filter?
Is Flow Shut Down

=75% Yes Yes Yes Plant
No Is Flow No No
=50% Is Flow Activate Standby
Activate Standby Activate Standby =25%?
Filter Filter
Filter
Yes Yes Yes Yes Yes Yes
Proceed to Proceed to Proceed to Proceed to Proceed to Proceed to

Backwash Backwash Backwash Backwash Backwash Backwash
Figure 11 Plant Flow Reduction Logic Diagram

8.0 Floated Sludge & Backwash Water Handling

8.1 WATER TREATMENT OVERVIEW
The filter backwash water and the DAF sludge is gravitated to the Waste Water Holding Tank
where it is kept constantly mixed. Waste Water Transfer Pumps convey the mixed waste to a
sludge thickener. Polymer is dosed into the thickener inlet pipe
Supernatant from the thickener overflow gravitates to environmental discharge.
Sludge from the thickener underflow is pumped (controlled by a duration and frequency
timer) sludge drying beds, with the addition of polymer into the pipeline.
Major Items incorporated in this section are :
o WWTM01, WWTM02 Wastewater transfer pumps VSD driven

o WWHTFM01 Wastewater transfer flow meter
o WWHTLT01 Wastewater holding tank level transmitter
o WWHTM01, WWHTM02 Waste water holding tank mixers
o TM01 Thickener drive and scraper
o UFPM01 Thickened underflow sludge pump
o UFPM02 Thickened underflow sludge pump
8.2 SYSTEMS
holding tank
Wastewater holding tank transfer pumps are available to operate only when the wastewater
plant is operating. The pumps start on high level in the wastewater holding tank and stop
once low level is achieved. The pump rate is to be set manually by the operator via a pump
VSD so that the flow as measured by the flow meter does not exceed the acceptable flow to
the thickener. The flow rate is also to be kept constant by PID loop (flow varies as a result of
changing water levels).
Wastewater holding tank mixers operates continuously while the level is above the mixer
shut off level. The mixers operate independently of the water treatment plant stop or start.
High level in the wastewater holding tank prevents a backwash from occurring.
Thickener
Thickener scraper drive operates continuously and independently of the wastewater
treatment plant start or stop.
The thickener sludge is pumped under control of a frequency and duration timer.
8.3 OF COMPONENTS
WWTM01, WWTM02 Waste water transfer pumps
Centrifugal submersible pumps, VSD driven


o VSD Fault

Waste water holding tank level.
UFPM01, UFPM02 Underflow pumps
Progressive cavity pumps VSD driven, fixed speed.


Duration and frequency timer.

WWHTLT01 Wastewater holding tank level transmitter
Ultrasonic, 4 derived points.
Designation Action
HH Prevents backwash from occurring
H Starts duty wastewater transfer pump
L Stops duty wastewater transfer pump
LL Stops mixers
WWHTLS01 Waste Water Holding tank
Float switch, one active point.
Designation Action
LLL Stops mixer and inhibits wastewater transfer pumps
8.4 Water Pumps Operation
The Waste Water pumps WWT M01 and M02 will be ready to operate as enabled by the
main PLC during the main start up. The pumps will start on high level (LSH) signal in the
waste water tank and will stop at tank low level (LSL).
Refer system curves in Figure 12:

The static head would vary in the waste water pumping system, according to tank water
level, as shown in Figure12. In order to maintain a constant flow to the thickener, the motor
speed needs to be varied to cope with the above changes.
The pump has to operate at 46.5Hz during high static head condition and has to ramp down
to 41Hz for the minimum static condition.
Desired flow rate is fed in to the PID controller as the flow set point. The PID controller
receives continuous feedback from the flow meter WWTFM01. The PID controller in turn
drives the VSD of the duty pump to adjust the pump flow to match the set point .
Flow meter
feedback
VSD. Pump.1
PID
VSD. Pump.2
Flow Set Point from operator
Figure 13 PID controls for Waste Water Transfer Pumps flow control
Waste Water Pump Curves
30.0
25.0
20.0
Head-m 15.0
30, 13
10.0
30, 9 50 Hz
5.0 46.
41
0.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Flow-L/s
Max. static system curve Min. Static system curve
Pump at 100% speed Pump at 46.5Hz
Pump at 41Hz Max. Duty point
Figure 12 Waste water pumps system curves

9.0 Dosing System

9.1
Polymer powder is manually added to a hopper. An automated plant prepares batches of
polymer solution, which are then transferred to a dosing tank. The Polymer powder
handling, solution preparation and batching are handled by the vendor supplied Polymer
Control panel.
Duty and standby dosing pumps are provided to dose polymer to the thickener and drying
bed feed dosing point. Polymer batching and dilution water is provided from the service
water system. Pump speed, and hence output, is manually set by the operator to give the
correct poly dose. The polymer dosing pumps are controlled from the Chemical Building
MCC.
o Automated batching Batching system with local control

o TPDM01 Thickener feed polymer dosing pump 1
o TPDM02 Thickener feed polymer dosing pump 2
o SBPDM01 Sludge Drying bed feed polymer dosing pump 1
o SBPDM02 Sludge Drying bed feed polymer dosing pump 2
o TDWFS01 Thickener feed polymer dilution flow switch
o PDTLL01 Poly dosing tank low level switch
o TPDV01SV Thickener feed polymer dilution solenoid valve
o SBPD V01SV Sludge Drying bed feed polymer dilution solenoid valve
9.2 SYSTEMS
Polymer Dosing Pumps

1. Thickener and drying bed feed polymer dosing pump speed is manually adjusted
according to the required dose.
2. The thickener feed polymer pump is automatically stopped and started in conjunction
with the duty wastewater transfer pump.
3. The drying bed polymer feed pump is automatically stopped and started in conjunction
with the duty thickener underflow pump.
9.3 OF COMPONENTS
TPDM01, TPDM02 Thickener feed polymer- dosing pump
Progressive cavity pump, variable speed,


o VSD Fault

Duty wash water transfer pump.

Poly dosing tank level switch.
SBPDM01, SBPDM02 Drying bed feed polymer- dosing pump
Progressive cavity pump, variable speed,


o VSD Fault

Poly dosing tank level switch.

Thickener feed polymer dilution water solenoid valve

follows:
o Duty thickener feed polymer dosing pump
Drying bed feed polymer dilution water solenoid

follows:
o Operating thickener underflow pumps
Polymer Batching Unit

Batching unit with polymer hopper, batching tank, dosing tank, service water solenoids and
level switches and local control.
Alarm Output
Designation Action
L Dosing tank low level
10.0 PACL / Alum Dosing System

10.1
Alum is manually batched and mixed in a tank with strength up to 20%. Two tanks are
provided so that the operator can batch on a duty rotation basis. Duty and standby dosing
pumps are provided to dose alum at the plant inlet. Alum dose is controlled manually by the
operator by adjusting pump speed and stroke. A mechanical flow meter is used to determine
the quantity of water introduced into the tank at the time of batching. The number of bags is
determined from a table to achieve the correct concentration for the volume of water added.
Alum bags are loaded manually. Alum or PACL can be used. In the event of low flow the
Flow Switch (AFS 01) will trigger a treatment plant shutdown.
o ALDM01 Alum dosing pump No.1.

o ALDM02 Alum dosing pump No.2.
o ALBMM01 Alum batch tank no.1 mixer
o ALBMM02 Alum batch tank no.2 mixer
o ABTLL01/ABTHL01 Tank No 1 Level switch
o ABTLL01/ABTHL02 Tank No 2 Level switch
o AFS 01 Flow switch
10.2 SYSTEMS
Pumps
Alum dosing pump speed is determined by plant flow rate by selector switch, and stroke is
manually set by the operator for the required mg/L dose.
10.3 OF COMPONENTS
ALDM01, ALDM02 PACL / Alum Dosing Pump

Metering pump, variable speed and stroke.


o VSD Fault

Raw water flow initiate

ALBMM01, ALBMM02 PACL Alum batch tank mixers
Alum mixer fixed speed
Selection at switchboard


o Thermister Protection

Motor run continuously.

11.0 Lime Dosing System

11.1
Lime is supplied in bulk storage bags. Lime bags are suspended over a vibrating hopper
where lime falls by gravity into a screw feeder from where it is transferred into the slurry tank.
A constant volume is maintained in the tank by means of a float valve connected to service
water. Lime slurry is drawn from the slurry tank by means of a venturi ejector, and delivered
to the post dosing point.
The speed of the lime powder feeder is set by the operator.
A VSD and mechanical variator input is used to give the required mg/L dose
o LFM01 Lime Feeder

o LMV01SV Lime motive solenoid valve
o LMV01AV Lime slurry actuated valve
o LSMM01 Lime slurry mixer
o LHLS01 Lime hopper level switch
o LVM01 Lime hopper vibrator
o LH01 Lime feeder heater
o LDM01 Lime room dust extractor
11.2 SYSTEMS
Storage
A bag loading frame and monorail allows for the loading of bulk bags onto the lime feeder.
Storage for the bags is provided in the lime dosing room. A vibrator is mounted on the
hopper to facilitate the flow of lime to the feeder. The vibrator operates on a duty and
frequency timer nominally 10 seconds every 2 minutes.
Plant Start
When the plant is started at the main selector switch in the control room the feeder starts, the
vibrator timer starts and the motive water solenoid valve opens
Plant shutdown
At the time of plant shutdown the feeder stops, the vibrator timer stops and the motive water
solenoid valve closes, after a flush cycle has been completed by closing lime suction ejector
solenoid valve.
Flushing Cycle on shutdown

To reduce the frequency of cleaning required a flush cycle is performed to the lime dosing
line. This involves closing the valve on the suction line of the lime slurry ejector and opening
the lime motive water solenoid. This should be left running for approx 20 minutes or until the
line is fully flushed.
Note: Lime mixer and heater remain in operation even when plant is shutdown.
11.3 OF COMPONENTS
LFM01 Lime feeder

Lime feeder VSD speed
Selection at chemical dosing switchboard

o Thermal Overload Motor Protection (VFD)

o VFD Fault

Plant start up and shut down sequence.
LMV01SV Lime motive water solenoid valve

follows:
o Plant start up and shut down sequence

o Flushing cycle
LMV01AV Lime slurry actuated valve

follows:
o Flushing cycle
LSMM01 Lime slurry mixer
Lime slurry mixer fixed speed

Note : Mixer runs continuously
LHLS01 Lime hopper level switch

Bin rotary paddle, one active point.
Alarms when activated.

Designation Action
L Lime low level alarm
LH01 Lime feeder heater

Heater on screw feeder. Operates all the time
LVM01 Lime vibrator
Lime vibrator


Filter start-up and shut down sequence.

Duty frequency timer
12.0 PAC Dosing System

12.1
Powdered Activated Carbon (PAC) is not expected to be needed continuously if at all. If
required, its use is likely to be seasonal during peak dry season, low water level and under
algal bloom conditions. The decision must be made by site staff when to start dosing.
Operators must set the PAC plant to automatic to begin operation. Typical triggers for
dosing include taste and odour in treated water, or alert levels of concentrations of particular
algae.
PAC is supplied in bulk storage bags. PAC bags are suspended over a vibrating hopper
where PAC falls by gravity into a screw feeder from where it is transferred into the slurry
tank. A constant volume is maintained in the tank by means of a float valve connected to
service water. PAC slurry is drawn from the slurry tank by means of a venturi ejector, and
delivered to the dosing point.
The speed of the lime powder feeder is set by the operator.
A VSD and mechanical variator input is used to give the required mg/L dose
o PACFM01 PAC feeder

o PACMV01SV PAC motive solenoid valve
o PACLS01 PAC hopper level switch
o PACSMM01 PAC slurry tank mixer
o PACVM01, PAC hopper vibrator
o PACH01 PAC feeder heater
o PACDM01 PAC dust extractor
12.2 SYSTEMS
Storage
A bag loading frame and monorail allows for the loading of bulk bags onto the PAC feeder.
Storage for the bags is provided in the chemical building. A vibrator is mounted on the
hopper to facilitate the flow of PAC to the feeder. The vibrator operates on a duty and
frequency timer nominally 10 seconds every 2 minutes.
Plant Start
If PAC is required, when the plant is started at the main selector switch in the control room
the feeder starts, the vibrator timers start and the motive water solenoid valve opens
Plant shutdown
At the time of plant shutdown the feeder stops, the vibrator timers stop and the motive water
solenoid valve closes
Flushing Cycle on shutdown

To reduce the frequency of cleaning required the operator should on a regular basis perform
a manual flush of the PAC dosing lines. This involves closing the manual valve on the PAC
slurry ejector suction line and opening the lime motive water solenoid bypass. This should be
left running for approx 20 minutes or until the lines are fully flushed.
Note: PAC mixer and heater remain in operation even when plant shutdown
12.3 OF COMPONENTS
PACFM01 PAC feeder
PAC feeder VFD speed

o Thermal Overload Motor Protection (VFD)

o VFD Fault

Plant start up and shut down sequence.
PACSMM01 PAC slurry mixer
PAC slurry Mixer fixed speed

Note Mixer runs continuously

PACMV01SV PAC motive water solenoid valve

follows:
PACLS01 PAC hopper level switch

Bin rotary paddle, one active points.
Alarm when activated

Designation Action
L PAC low level alarm
PAC01 PAC feeder heater

240V heater. Operates all the time
PACVM01, PAC vibrator
PAC vibrator


Filter start-up and shut down sequence.

Duty frequency timers
13.0 Dosing System

13.1
Chlorine is stored in chlorine drums, which are mounted on scales.
Three (3) Chlorinators are provided for the following purpose:
Duty/Standby Chlorinators for Post Chlorination

Automatic Chlorinator.1 ,CLCN001
Automatic Chlorinator.2 ,CLCN002
Single Chlorinator for Pre Chlorination

Manual Chlorinator.3 ,CLCN003
The duty / standby automatic chlorinators (CLCN001& N002) are provided to dose chlorine
into the filtered water tank. The target chlorine residual is manually entered into the SFC
controller. In response to the feedback from the Chlorine Residual Analyser, the SFC
controller maintains the target residual by controlling the Chlorine gas flow in to the
respective educators.
Motive water for the chlorine ejectors is provided by the Service Water Pumps located at the
High Lift Pump Station. In addition, two (2) duty / standby chlorine booster pumps are
provided in the chlorine room to provide motive water in the event of undue drop in service
water pressure. The switching to the local chlorine booster pumps will be manual.
A manual chlorinator is provided for pre chlorination if required. Pre-chlorine when required
will be dosed in to the Raw Water pumping main. The source of motive water is service water
as for post-chlorination.
o CBPM01 Chlorine booster pump 1

o CBPM02 Chlorine booster pump 2
o CLCN001 Automatic Chlorinator.1 & SFC Controller
o CLCN002 Automatic Chlorinator.2
o CLCN003 Manual Chlorinator.3
o CLLT01, CLLT02 Gas leak detector 1 and 2
o CH01, CH02 Chlorine heaters
o CLSC01 CLSC02 Chlorine drum scales
o CLMV01SV, CLMV01SV, Chlorine motive water isolation solenoid
o CLMV01SV
o CLSH01, CLSH02 Chlorine drum auto shut system
o CBFS01 Chlorine booster flow switch
13.2 SYSTEMS
Storage
Two chlorine drums are available on line in the chlorine drum room. The drums are operated
on a duty / standby basis, connected to auto changeover regulators which switch over when
one drum is empty. The drums are mounted on load cell weigh scales, which monitor the
remaining chlorine in the drums.
Automatic Chlorinators
1. Motive water is always available from the service water reticulation. The Chlorine system
is enabled at the start-up of the treatment plant. The duty chlorinator and duty ejector are
manually selected by valve settings.
2. Chlorine dosing is controlled by a positioning device, which operates based on chlorine
residual feedback provided by chlorine residual analyser.
3. Low motive water flow will be detected by switch (CB FS01) to shut the chlorine gas
supply to the eductor
4. A gas detection unit alarms if chlorine leak is detected.
5. A chlorine drum isolation actuator is provided to close the chlorine drum in the event of a
chlorine leak. An auto shut panel communicates with the fume warning panel for the shut
signal.
6. Chlorine failure will set off an alarm, but will not shut down the treatment plant.
7. Scales determine the amount of chlorine available in each bottle. The duty drum is
automatically switched over when empty. A warning alarm is activated when drum is
empty.
Manual Chlorinator
1. Motive water is always available from the service water reticulation. When the manual
chlorinator is initiated the corresponding solenoid valve opens to provide motive water to
the ejector.
2. Chlorine will be dosed in the Raw Water Main at fixed rate set the manual chlorinator
(CLCN003) controller.
13.3 OF COMPONENTS
CBPM01, CBPM02 Chlorine booster pumps
These pumps will be started manually to provide motive water, if the service water supply
pressure becomes inadequate for chlorine dosing.
Selection at chlorine switchboard


Plant start-up and shut down sequence.

Chlorine booster pump duty / standby rotation
Motive water flow switch
CL01, CL02 Chlorinator positioner
Wallace and Tiernan positioner
Auto - Actuator opens subject to automatic control system, which is

as follows:
o Plant start-up and shut down sequence

o Chlorine residual loop
CLLT01, CLLT02 Chlorine leak detectors
Chlorine leak detectors, one active point.
Designation Action
HH Alarms and shuts down plant
HH Chlorine bottle auto shut
CH01, CH02 drum heater

240V heater. Operates all the time
CLMV01SV Motive water isolation solenoid valve

follows:
CLSC01 CLSC02 Chlorine drum scales
Weight cells output, 0-1000kg
Designation Action
LL Low chlorine alarm for each drum
Auto Shut Down Compressed Air System
Compressed air is supplied to a receiver from the main system in the Filter Building.
14.0 Quality Equipment

14.1
Water quality equipment is provided to monitor the process and to raise alarms. Selected
water samples are piped to the laboratory
o DWpH01 Dosed water pH

o FWT01 Filtered water turbidity
o FWCR01 Filtered water chlorine residual
o CWpH01 Clear water pH
14.2 OF COMPONENTS
DWpH01 Dosed Water pH
In-line pH probe, mounted in inlet channel, 0-14 pH.
FWT01 Filtered Turbidity
In-line flow through turbidimeter, mounted in field 0-10 NTU.
CWpH01 Clear Water pH
pH meter, mounted in laboratory supplied from service water system, 0-14 pH.
FWCR01 Filtered Water Chlorine Residual
In-line chlorine residual meter, mounted in field, 0-5 mg/l.
Functions - Local indication and feedback for chlorine dosing loop
Filtered Water Tank Sample Pumps (SPM01 and SPM02)

Two (2) sample pumps (duty/standby) are located at Filtered Water Tank to draw water and
pump to the Chlorine Residual and Turbidity analysers in the laboratory.
The duty pump is automatically enabled at the treatment plant start-up. In the event of a duty
pump failure, the chlorine system fill shut down as there will not be any residual
measurement and feedback to the chlorinator. This event will trigger an alarm without
shutting down the treatment plant.
14.3 SAMPLE STREAMS
Sample streams are located in filter building as follows:
Clear Water piped to laboratory (1st floor)

Filter 1- Filtered and Floated Water Stream piped to basin (1st floor)
Filter 2 - Filtered and Floated Water Stream piped to basin (1st floor)
Combined Filtered Water Stream piped through turbidity instrument to drain.
Combined Filtered Water Stream piped through residual chlorine instrument to drain.
Raw water raw water inlet pipe (before chemical addition)

Floated water from DAF subnatant sample pipe for each filter, after
DAF clarification before filtration
Filtered water from filtered water outlet pipe for each filter
Combined filtered water sample pumped from filtered water tank
Clear water from service water system supplied from clear water
tanks
15.0 Service Water System

15.1
The service water system provides water to the entire plant from the Clearwater Tanks. The
service water is an independently controlled system comprising of a bank of pumps mounted
on a skid and pumping into a header, located within the Highlift Pump Station. The service
system is controlled to a constant pressure by means of frequency inverter drives which alter
the pump speed. Pressure transducers provide the necessary feedback for this control. The
control panel is mounted locally on the pressure system skid. Pumps are duty rotation.

o SWTS01 Service water pressure transmitter
o SWM01 Service water pump 1
o CWTLS03 Low level switch, pump stop - tank No 1
o CWTLS04 Low level switch, pump stop - tank No 2
15.2 SYSTEMS
1. Service water is provided from either tank 1 or 2
2. Pump pressure is maintained at a constant set point of nominally 600 kPa.
3. The service water pumps are stopped if the clear water tanks are at low level.
15.3 OF COMPONENTS.
SWM01,SWM02, SWM03 Service water pump 1, 2 and 3
Centrifugal multistage pumps
Selection at the Local Panel

o Thermal Overload Motor Protection (VSD)

o VSD Fault

Service water pressure transmitter.

Clear water tank low level inhibit
SWPS01 Service Water Pressure Transmitter
Pressure transmitter, mounted on service water discharge manifold.
CWTLS03 CWTLS04 Clearwater Tank No 1 and 2
Ultrasonic in Clearwater Tank No1 and 2
Designation Action
L Stops service water pumps
16.0 Power Failure

Power failure means a failure in the supply of electricity to the plant.
Items incorporated into this section are:
Plant restart timer

Plant phase failure
Generator
In the event of failure of the electricity supply the power supply is automatically changed over to
the generator (generator must be selected in auto mode).
Phase failure at the plant will have the same effect as a total power cut.
Re-start of the plant will not be permitted until power has been restored and the restart timer
(nominally set at 4 minutes) times out.
If power failure occurs during a backwash, on resumption of power the filter will resume
backwash at the beginning of the same step, provided all conditions are met. If conditions are
not met a backwash is triggered.
New alarm conditions generated solely as a result of power failure should not be latched and
should be automatically cleared on the resumption of power such that the plant can restart
automatically.
Annex A Drawings
Drawing Number Description
P0408-HM-TP-W-PI-100 PID Symbols
P0408-HM-TP-P-PI-002 Schematic - Phase III Water Distribution
P0408-HM-TP-P-PI-100 P&ID - Intake Pump Station & Rapid Mixer
P0408-HM-TP-P-PI-105 P&ID - Filtered Water Tank and Backwash System
P0408-HM-TP-P-PI-106 P&ID - DAF Dispersion Vessels & Recycle Water Pumps
P0408-HM-TP-P-PI-107 P&ID - Waste Water Handling System
P0408-HM-TP-P-PI-108 P&ID - Thickener & Sludge Drying Beds
P0408-HM-TP-P-PI-109 P&ID - Filter Air Scour Blowers
P0408-HM-TP-P-PI-200 P&ID - Polymer Preparation & Dosing System
P0408-HM-TP-P-PI-201 P&ID - Lime Handling & Dosing System
P0408-HM-TP-P-PI-202 P&ID - Alum Batching & Dosing System
P0408-HM-TP-P-PI-203 P&ID - Chlorine Dosing System
P0408-HM-TP-P-PI-204 P&ID - PAC Handling & Dosing System
P0408-HM-TP-P-PI-001 P&ID-Water Sampling System
P0408-HM-HL-P-PI-101 P&ID - High Lift Pump House

P0408 HM TP M TS 003

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P0408 HM TP M TS 003

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Treatment Plant Functional Description 1(61)

Client: National Water Supply & Drainage Board,

Project Title: Integrated Water Supply Scheme for Un-

Contract No: 152003

Area: Himidurawa Water Treatment Plant

Document: Treatment Plant Functional Description

D 27/08/2012 For Review pump curves included JT/PK ID

1.0 General Notes.............................................................................................. 4

2.0 System Overview ......................................................................................... 5

3.0 Dissolved Air Flotation Equipment ............................................................... 9

4.0 Filtration Equipment and Backwashing ...................................................... 13

5.0 General Sequence of Treatment Plant Controls ........................................ 18

6.0 Operating Systems .................................................................................... 19

7.0 Dual Media Filtration & Backwashing ........................................................ 30

8.0 Floated Sludge & Backwash Water Handling ............................................ 38

9.0 Polymer Dosing System............................................................................. 42

10.0 PACL / Alum Dosing System ..................................................................... 45

11.0 Lime Dosing System .................................................................................. 47

12.0 PAC Dosing System .................................................................................. 50

13.0 Chlorine Dosing System ............................................................................ 53

14.0 Water Quality Equipment ........................................................................... 56

15.0 Service Water System ............................................................................... 58

16.0 Power Failure............................................................................................. 60

Annex A Drawings .............................................................................................. 61

Drawing Number Description

P0408-HM-TP-W-PI-100 PID Symbols

P0408-HM-TP-P-PI-002 Schematic - Phase III Water Distribution

P0408-HM-TP-P-PI-100 P&ID - Intake Pump Station & Rapid Mixer

P0408-HM-TP-P-PI-101 P&ID - DAF Filter 1

P0408-HM-TP-P-PI-102 P&ID - DAF Filter 2

P0408-HM-TP-P-PI-103 P&ID - DAF Filter 3

P0408-HM-TP-P-PI-104 P&ID - DAF Filter 4

P0408-HM-TP-P-PI-105 P&ID - Filtered Water Tank and Backwash System

P0408-HM-TP-P-PI-106 P&ID - DAF Dispersion Vessels & Recycle Water Pumps

P0408-HM-TP-P-PI-107 P&ID - Waste Water Handling System

P0408-HM-TP-P-PI-108 P&ID - Thickener & Sludge Drying Beds

P0408-HM-TP-P-PI-109 P&ID - Filter Air Scour Blowers

P0408-HM-TP-P-PI-200 P&ID - Polymer Preparation & Dosing System

P0408-HM-TP-P-PI-201 P&ID - Lime Handling & Dosing System

P0408-HM-TP-P-PI-202 P&ID - Alum Batching & Dosing System

P0408-HM-TP-P-PI-203 P&ID - Chlorine Dosing System

P0408-HM-TP-P-PI-204 P&ID - PAC Handling & Dosing System

P0408-HM-TP-P-PI-001 P&ID-Water Sampling System

P0408-HM-HL-P-PI-101 P&ID - High Lift Pump House

1.0 General Notes

o Drive must be in AUTO on the MCC

5. PID Controllers will be used for the following functions:

o Minimum frequency for the pump drive

2.0 System Overview

Running filter is operating in normal filtration mode

Backwashing backwash in progress

Unavailable filter has faulted or is selected as off at the switchboard. Filter

2.3 Start Up and Shutdown

Plant Shut down will occur due to the following:

o Major plant failure

o High level in the filtered water tank

2.5 Panel (Equipment Status)

2.6 Pump Operation

2.7 Water Flow Control

These items are as follows:

2.8 Grit Pumps

Raw Water Pumps INM01, INM02, INM03

Vertical turbine Pumps with VSD