INDUSTRIAL TRAINING REPORT

SUNGAI HARMONI SDN BHD Loji Pembersihan Air Sungai Selangor, KM3, Jalan Bukit Badong, 45600 Bestari Jaya, Selangor

NAME

: MOHAMAD HADI BIN TAIRIN

MATRIC NO.: KB07 111 PROGRAM : DIPLOMA OF CHEMICAL ENGINEERING (PROCESS PLANT)

FACULTY OF CHEMICAL & NATURAL RESOURCE ENGINEERING UNIVERSITY MALAYSIA PAHANG JANUARY 2010-JUNE 2010

I hereby acknowledge that this Industrial Training Report has been verified and it does not contain any CONFIDENTAL information to be released to the public

Signature

: ..

Official Stamp: .. Date : ..

APPRECIATION

Assalamualaikum, Salawat and salutation worshiped to Prophet great reverence Muhammad SAW and friends and fighters crusade in road once Allah SWT. Firstly, I wish to convey thanksgiving to Allah SWT because with overflow and Allah award I can finish this training report industry with successful. In this opportunity, I this record wish a thousand thanks to Plant Manager SSP1, Tuan Haji Zulfikri Bin Suboh have vested opportunity for me to carry training industry in this firm. Do not forget to Encik Anuar Bin Sudin has given a little pep talk at the strating my beginning were in this company. I also wish to say a lots of thanks to Puan Hafisah Binti Ramli which account my Supervisor above her tired and perseverance in drafting and arrange various roster and projects which need undertaken by me. May God only those can reciprocate her noble service. Are not left behind vote of thanks to line staff and staff in every department whether which included directly or indirect above cooperation and treatment good and coaching all of you in ensuring all works able to proceed smoothly. Lastly, I want to apply forgiveness and apology to all of you if there is weakness and mistake emerge from myself whether deliberately or accidentally as I were in this company. I pray will all your welfare and always in simplify work during work in this company.

CHAPTER 1

INTRODUCTION

1.1 Corporate Profile 1.1.1 Introduction 1.1.2 Corporate Information 1.1.3 Corporate Statement 1.1.4 Corporate Structure 1.1.5 Award & Recognitions 1.2 Business Activity 1.2.1 Sungai Harmoni Operations 1.2.2 Taliworks Langkawi Operations 1.2.3 Engineering & Construction Division 1.2.4 Waste Management Division 1.2.5 Highway Division 1.3 Sungai Harmoni Phase 1 1.3.1 Organization chart

1.1

Corporate Profile

1.1.1 Introduction Taliworks. Water, Waste & Infrastructure Management Specialist Taliworks Corporation Berhad (Taliworks or the Company) was incorporated in Malaysia on 6 August 1965 as a private limited company under the name of The Carpet Manufacturing Company (Malaysia) Limited. On 12 November 1968, its name was changed to F&T Carpets (Malaysia) Sdn Bhd. On 26 February 1974, it was renamed Carpets International Malaysia Sdn Bhd and on 23 December 1982, it was converted into a public company and assumed the name of Carpets International Malaysia Berhad (Carpets). It was subsequently listed on the then Second Board of the Kuala Lumpur Stock Exchange (now known as Bursa Malaysia Securities Berhad (Bursa Securities)) on 27 July 1992. The principal activities of Carpets were the design, manufacture, distribution and laying of carpets and rugs. These operations ceased in 2002. On 31 July 2000, Carpets completed the acquisition of the entire equity interest in Sungai Harmoni Sdn Bhd and Taliworks (Langkawi) Sdn Bhd. These companies are involved in the management, operations and maintenance of water treatment, supply and distribution facilities. On 27 October 2000, the Company was transferred to the Main Board of Bursa Securities (which has since been merged with the Second Board into a single board known as Main Market) and subsequently on 24 November 2000, Carpets was renamed Taliworks Corporation Berhad. Taliworks together with its group of companies employs about 450 staff and contract workers in Malaysia and the Peoples Republic of China. The Company is currently listed on the Main Market of Bursa Securities under Trading / Services Sector (Name & Code: TALIWRK & 8524) with a market capitalization of approximately RM625 million as at 31 December 2009.

In 2005, Taliworks issued 70,440,000 warrants 2005/2010 pursuant to a renounceable rights issue which entitles the holders to subscribe for new shares in Taliworks. The warrants are listed on Bursa Securities (Name & Code: TALIWRK-WA & 8524WA). Warrants not exercised will lapse and cease to be valid on 21 September 2010. In 2007, the Company issued RM225, 000,000 nominal amounts of 2.25% unsecured convertible bonds 2007/2012 for business expansion, repayment of borrowings and general working capital purposes. The bonds, rated AA3 by RAM Rating Services Berhad, are not listed on any stock exchange. See the Figures 1 and Figure 2 for plant location.

Business background Today, Taliworks, an established company involved in water and waste-related businesses, has expanded its core expertise to include highway management, construction and engineering, and wastewater research and technology. Taliworks started out in the water management sector in 1987 as a pioneer in the privatization of the water supply in Malaysia and today, the water business still leads as the main core business activity of the Group. Since 2004, the Group has diversified its business interests to include the waste management segment in China and toll operations and highway management in Malaysia through a few strategic acquisitions. Taliworks core water business is in the privatized water supply sector which includes an operation and maintenance contract (expiring in 2030) for the Sungai Selangor Water Treatment Works Phase 1 (SSP1) that supplies to large parts of Selangor and Kuala Lumpur and a concession (expiring in 2020) for the water supply and distribution system in Langkawi, Kedah. The Group currently manages a total of 6 water treatment plants with a combined capacity of 1,039.5 million liters per day. In the waste management business sector, the Group holds a 21-year concession rights for the operation and management of the Tianjin Panlou Life Waste Transfer Station and its related assets in the city of Tianjin, China. The concession, held through a 90% owned subsidiary, Tianjin-SWM (M) Environment Ltd, Co and expiring in 2025, grants rights to this company to transport household waste deposited at the transfer station to the municipal landfills and in return collect tipping fees from the local city council for services provided. Other than being involved in solid waste management, the Group is also engaged in the wastewater sector through its indirect holding of a 56% stake in Puresino (Guanghan) Water Co. Ltd which manages and operates the 50 million liters per day Guanghan San Xin Dui wastewater treatment plant in Sichuan, China for a 30-year concession expiring in 2033.

In 2007, Taliworks acquired a 55% stake in a jointly controlled entity, Cerah Sama Sdn Bhd (Cerah Sama). Cerah Sama is the holding company for Grand Saga Sdn Bhd that owns and operates the Cheras - Kajang Highway concession until 2027. The acquisition was made in collaboration with the South East Asian Strategic Assets Fund (SEASAF) where Cerah Sama is positioned to be the flagship vehicle through which both parties will engage in the business of developing and operating toll roads in Malaysia and the ASEAN region. Other than the above-mentioned businesses, the Group is also undertaking the construction of the Padang Terap Water Supply Scheme in Kedah. It just completed the Klang Valley Flood Mitigation-Package Sungai Damansara project in Selangor. Currently, the water business in Malaysia accounts for the bulk of revenue and profitability of the Group. Taliworks intends to increase its revenue contribution significantly from overseas ventures to diversify its earnings base and geographical risk. The Group remains focus on its core business activities whilst seeking to acquire further strategic investments both domestically and in the foreign markets so as to re-position itself as a formidable and respected service provider for public utilities and infrastructure businesses in the region. Today, the Group has business presence in Selangor, Kedah, Tianjin, Sichuan, Xiamen and Shanghai.

1.1.2 Corporate Information Board Of Directors Chairman Y. Bhg. Dato Hj Abd Karim bin Munisar Executive Deputy Chairman Y. Bhg. Dato' Lim Chee Meng Executive Director Mr. Lim Yew Boon Senior Independent Non Execuitve Director Y. Bhg. Dato Hj Mohd Sinon bin Mudakir Independent Non Execuitve Director YAM Tengku Putri Datin Paduka Arafiah bte Al-Marhum Sultan Salahuddin Abd. Aziz Shah Al-Haj Y. Bhg. Dato Hj Abdul Karim @ Mohd Yusof B. Abdul Rahman Encik Sulaiman bin Salleh Non Independent Non Execuitve Director Y. Bhg Dato' Wan Puteh Bin Wan Mohd Saman Mr. Wong Yien Kim

Audit Committee Chairman Y. Bhg. Dato Hj Mohd Sinon bin Mudakir Members Encik Sulaiman bin Salleh YAM Tengku Putri Datin Paduka Arafiah bte Al-Marhum Sultan Salahuddin Abd.Aziz Shah Al-Haj Mr. Wong Yien Kim

Nomination Committee Chairman Encik Sulaiman bin Salleh Members YAM Tengku Putri Datin Paduka Arafiah bte Al-Marhum Sultan Salahuddin Abd.Aziz Shah Al-Haj Y. Bhg. Dato Wan Puteh bin Wan Mohd Saman Remuneration Committee Chairman Y. Bhg. Dato Hj Abd Karim bin Munisar Members Y. Bhg. Dato Wan Puteh bin Wan Mohd Saman Y. Bhg. Dato Lim Chee Meng Company Secretary Mr. Ng Yim Kong (LS 0009297) Unit 07-02, Level 7, Menara Luxor 6B Persiaran Tropicana 47410 Petaling Jaya Selangor Darul Ehsan Tel : 603 7804 5929 Fax : 603 7805 2559 Registered Office Unit 07-02, Level 7, Menara Luxor 6B Persiaran Tropicana 47410 Petaling Jaya Selangor Darul Ehsan Tel : 603 7804 5929 Fax : 603 7805 2559 Principal Office 28, Jalan Wan Kadir 1 Taman Tun Dr. Ismail 60000 Kuala Lumpur Tel Fax E-mail Website : 03-7725 7110 : 03-7725 7099 : info@taliworks.com.my : www.taliworks.com.my

Share Registrars Symphony Share Registrars Sdn Bhd (formerly known as Malaysian Share Registration Services Sdn Bhd) Level 6, Symphony House Block D13, Pusat Dagangan Dana 1, Jalan PJU 1A/46 47301 Petaling Jaya. Tel : 603 7841 8000 Fax : 603 7841 8008 Main Auditors PricewaterhouseCoopers Chartered Accountants Level 10, 1 Sentral Jalan Travers Kuala Lumpur Sentral 50706 Kuala Lumpur Tel : 603 2173 1188 Fax : 603 2173 1288 Main Bankers AmBank (M) Berhad HSBC Bank Malaysia Berhad Malayan Banking Berhad United Overseas Bank (Malaysia) Berhad Stock Main Market, Bursa Malaysia Securities Berhad Name & Code: TALIWRK & 8524 Stock Sector: Trading / Services Warrants Main Market, Bursa Malaysia Securities Berhad Name & Code : TALIWRK-WA & 8524WA Sector : Warrants / Loans

Trustess HSBC (MALAYSIA) Trustee Berhad Suite 9.01, 9th Floor Wisma Hamzah-Kwong Hing No 1, Leboh Ampang, 59200 Kuala Lumpur Tel : 603 2074 3200 Fax : 603 2078 0145

1.1.3 Corporate Statement Corporate Vision: Our vision is to be the respected and exemplary leader in the provision of quality drinking water in Malaysia and regionally.

Mission Statement: We are committed to; providing high quality drinking water to the customers and communities we serve through a customer focused service managing and preserving the environment in which we operate through undertaking relevant water industry research training and developing our human resources for career satisfaction leading to customer-oriented service Core Values: We constantly strive for the Pursuit of Quality and Excellence philosophy as our success depends on it. We believe in maintaining long term relationship of respect, trust and responsibility with our partners, associates, staff and customers. We are committed to improving the quality of life for the communities we serve trough the most professional, technologically advance and environmentally friendly water management expertise available.

1.1.4 Corporate Structure Refer to the Figure 3

1.1.5 Award & Recognitions Accreditation The Group has been accredited with the following high standards maintained for quality management systems and competency of test and calibration laboratories. Among the important accreditations are: MS ISO 9001: 2000 Quality Management Systems Requirements for the Operation and Maintenance of Water Treatment Plant for Sungai Selangor Water Treatment Works Phase 1, since 2003. MS ISO/IEC 17025: 2005 under Malaysia Laboratory Accreditation Scheme for Sungai Selangor Water Treatment Works Phase 1 Laboratory, since 2004. ISO 9001: 2000 under Provision of Highway Maintenance and Toll Collection, for Grand Saga Sdn Bhd, since 2007. MS ISO/IEC 17025: 2005 under Malaysia Laboratory Accreditation Scheme for Padang Saga and Sungai Baru Laboratory in Langkawi water operations, since 2008. ISO 9001: 2000 under SGS United Kingdom and Malaysia for Project Management of Construction of Water Supply Schemes, Buildings, Civil Engineering, Mechanical and Electrical Works under Turnkey and Conventional Contract, for the Engineering and Construction Division of Taliworks, since 2008.

Awards

2002 Forbes magazines list of 100 best smaller-sized enterprises in the Asia-Pacific 2003 Forbes magazines list of 100 best smaller-sized enterprises in the Asia-Pacific KPMG/The Edge Shareholder Value Awards * Ranked 21 out of Top 100 Companies * Ranked 2nd within the Infrastructure Grouping 2004 KPMG/The Edge Shareholder Value Awards * Ranked 85 out of Top 100 Companies 2005 The Edge 100 Top Best Companies in Terms of Returns (3 years) * Ranked 78 out of Top 100 Companies KPMG/The Edge Shareholder Value Awards * Ranked 40 out of Top 100 Companies 2006 Corporate Governance Survey Report 2006, published jointly by Minority Shareholder Watchdog Group and The University of Nottingham Malaysia Campus

* Ranked 124 out of the top 200 Public Listed Companies based on the market capitalization as at 31 December 2005. Dividend Survey 2006, published jointly by Minority Shareholder Watchdog Group and Universiti Teknologi MARA

* Ranked amongst the Top 212 Main Board companies selected based on the market capitalization as at 31 December 2005.

2007 Corporate Governance Survey Report 2007, published jointly by Minority Shareholder Watchdog Group and The University of Nottingham Malaysia Campus

* Ranked 87 out of 350 Main Board companies Dividend Survey 2007, published jointly by Minority Shareholder Watchdog Group and Universiti Teknologi MARA

* Ranked amongst the Top 500 Public Listed Companies selected based on the market capitalization as at 31 December 2006 2008 Corporate Governance Survey Report 2008, published jointly by Minority Shareholder Watchdog Group and The University of Nottingham Malaysia Campus

* Ranked 45 out of 960 Public Listed Companies 2009 Malaysian Corporate Governance Report 2009, published by Minority Shareholder Watchdog * Ranked amongst the Top 100 Public Listed Companies Group

1.2 Business Activity 1.2.1 Sungai Harmoni Operations

Management, operation and maintenance of the water treatment facilities under Sungai Selangor Phase 1 (SSP 1) that currently supplies to large areas of Kuala Lumpur, Petaling Jaya, Klang, Kuala Selangor, Kuang and Kundang.

SSP1 is one of the biggest Malaysias water treatment plant (Nominal Design Capacity of 950 MLD). Indeed, this was a milestone in achievements for Taliworks to be entrusted with the responsibility of running this facility.

SSP1 was conferred with MS ISO 9001:2000 Quality Management Systems Requirements (OPERATION AND MAINTENANCE OF WATER TREATMENT PLANT) accreditation on 21 March 2003. Before that, in October 2000, the SSP1 Laboratory was conferred with the Seal of Accreditation (ISO/IEC Guide 25) by Department of Standards Malaysia under the National Laboratory Accreditation Scheme (SAMM). The SSP1 Laboratory was subsequently elevated to the ISO 17025 accreditation in October 2002. In line with the commitment to water quality excellence, Sungai Harmoni has continued to carry out a comprehensive set of water quality testing of the treated water to ensure compliance with water quality standards at all times. It has, on its own accord, instituted a surveillance programme to monitor the raw water quality in the Sungai Selangor catchments upstream of the intake on a quarterly basis; this is to be forewarned of potential changes in the raw water quality that may require adjustments to the treatment regime. Backed by the most modern water treatment technology and computer-based telemetry monitoring of process data, this facility produces treated water, that complies with the quality standards of the Malaysian Ministry of Health and the World Health Organization. 18

1.2.2 Taliworks Langkawi Operations

Taliworks Langkawi operates and maintains the entire water supply and distribution facilities in Pulau Langkawi, Kedah and the Sungai Baru water treatment plant in Perlis for 25 years commencing from 1995. The operation covers the full spectrum of management, operation and maintenance as well as production, distribution and billing facilities. Among facilities managed by Taliworks Langkawi is 517 km of water distribution pipes of diameter 100mm and above and 38 km of submarine pipes from Sungai Baru, Perlis to Langkawi Island, Kedah. Taliworks Langkawi also using a computerized Geographical Information System (GIS) for more effective and systematic management and operation of the water supply system. Since the commencement of the privatization contract, Taliworks Langkawi managing a consumer account base of more than 17,595 accounts. In a pro-active approach to attend speedily to consumer complaints regarding pipe bursts and leaks and low pressures etc., Taliworks Langkawi has installed a toll free line for consumers to lodge their complaints.

Sungai Selangor Water Supply Scheme Phase 1 Refer to the Figure 4

Water Supply System in Langkawi Island. Refer to the Figure 5.

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1.2.3 Engineering & Construction Division The Group embarked on two projects since the previous year:

The design and construction of the water supply system for the Padang Terap Water Supply Scheme, in Kedah, and The Subang South Pond Project a flood migration pond project to avert flash floods caused by storm water from Sungai Damansara to its low lying river banks at Shah Alam Selangor.

with a combined contract value of approximately RM170 million.

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1.2.4 Waste Management Division The Groups maiden venture into China via a 90% stake in Tianjin- SWM (M) Environment Co. Ltd, (Tianjin-SWM) back in 2004 has put the Group in good stead to further expand its presence in the vast waste management sector. Other than being involved in solid waste management, the Group is also engaged in the wastewater sector through its 56% stake in Puresino (Guanghan) Water Co. Ltd which manages and operates the 50 MLD Guanghan San Xin Dui wastewater treatment plant in the province of Sichuan Tianjin-SWM (M) Environment Co. Ltd Tianjin-SWM holds the concession rights to manage operate and maintain the Tianjin Panlou Life Waste Transfer Station and its related assets for duration of 21 years ending 2025. The city of Tianjin is one of the locations chosen to host the recently concluded 2008 Olympics in China. The throughput at the Tianjin Panlou Transfer Station has been encouraging and on the uptrend and for 2008, the company managed to process 353,000 tonnes (or 966 tonnes per day) of household waste compared to 324,000 tonnes (or 899 tonnes per day) a year ago. Puresino (Guanghan) Water Co. Ltd Last year was the full year in which Puresino (Guanghan) Water Co. Ltd (Puresino Guanghan) operated the Guanghan San Xin Dui wastewater treatment plant since the commercial operations started in September 2007. The company has a concession to manage and operate the treatment plant until 2033. The plant treated 9.88 million m3 (or an average of 27 MLD) of wastewater. This works out to be 54% of the designed capacity and the company expects to raise the production to 10.7 million m3 (or an average of 29 MLD) in 2009.

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1.2.5 Highway Division The toll highway sector became part of the business activities of Taliworks when the Company acquired a 55% strategic stake in Cerah Sama Sdn. Bhd. (Cerah Sama) in late 2007 in collaboration with the South East Asian Strategic Assets Fund (SEASAF), which holds 35%. For more information, please visit Grand Saga Sdn Bhd's website at www.grandsaga.com.my

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1.3.1 Sungai Harmoni Phase 1 Refer to the Figure 6 for the organization chart.

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CHAPTER 2

TRAINING ACTIVITIES

2.1 Experiences during perform the industrial training 2.1.1 Summary of activities 2.1.2 Process flow of SSP1 Water Treatment Plant 2.1.3 Inlet works plant 2.1.4 Lamellar Pulsator Clarifier

2.2 Fluoride Dosing Control 2.2.1 Introduction 2.2.1 Procedure of Test 2.2.2 Result & Discussion

2.3 Raw Water Turbidity Test (check the travel time) 2.3.1 Introduction 2.3.1 Procedures of Test 2.3.2 Result & Discussion

2.4 Milk-Lime Concentration Test 2.4.1 Introduction 2.4.1 Procedures of Test 2.4.2 Result & Discussion

2.5 Sludge Blanket Concentration Test 2.5.1 Introduction 2.5.1 Procedures of Test 2.5.2 Result & Discussion

2.6 Sludge Draw-off Test 2.6.1 Introduction 2.6.1 Procedures of Test 2.6.2 Result & Discussion

2.1 Experiences during perform the industrial training

2.1.1 Summary of activities

As I is here, new there are a few things that had I study especially ways they run water processing work. At first, I were given a little bit information on operation in every part, used chemical material, types of equipment and machine and number staff which included in every shift. I also already in give several case-studies by my supervisor at here. Among them was Sludge Blanket Concentration Test, Sludge Draw-Off Test, Fluoride Dosing Control (calculate in g / min), Measure the Travel Time and Milk Lime Concentration test. From each those projects given this, I can learn every important little bit of information which I need to know and may be eliminated benefit on time future. This very important for one man titled student. They should always keep curious feeling and always asking. Because to me, here the student opportunity to know every little experience from old timer before stepping to job nature. I also often ask workers are here on problems which arose and way they control and work something out those problems. This one best opportunity to me. I very grateful above cooperation which gave by every staff work here. They so receptive in granting view. This to me an advantage for me.

See the Figure 7 for the summary of activities.

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2.1.2 Process flow of SSP1 Water Treatment Plant Aim of the plant. Supply drinking water to the state of Selangor. General view:

Aeration

: Oxidation of iron and manganese.

Pre-Chlorination : Bacteriological control and oxidation. Mixing Chamber : -pH adjustment : (Lime) Coagulation (Alum Sulphate) Flocculation (Polyelectrolyte) : Have 6 pulsators. : 24 filters.

Clarifiers Filtrations

Treatment Principles:From the aerator, the raw water flows to a mixing/ distribution structures by gravity. The water contains very fine colloidal or pseudocolloidal suspended solids which must be agglomerated into a voluminous and heavy floc in order to enable settling. The colloids are electrically charged at the interface, which prevents other particles from coming close. The action takes place in two stages after pH adjustment at the inlet of the mixing chamber:

Coagulation: To remove the charges from the colloids in order to create precipitation.

Flocculation: To increase the volume and cohesion of the floc formed by coagulation.

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Raw water analysis of Sungai Selangor River Degremont Analysis 21 November 1988 Refer to the Table 1. Flowrates Capacity of the Lamellar Pulsator clarifier:i. Nominal stream inflow= 500 MLD, with raw water suspended solid up to 1000mg/L. 6 x 3472 m3/h =20835 m3/h = 500 MLD.

ii.

Peak stream inflow = 570 MLD, with raw water suspended solid up to 500 mg/L. 6 x 3958 m3/h = 23750 m3/h = 570 MLD.

iii.

Hydraulic capacity = 600 MLD. 6 x 4167 m3/h = 25000 m3/h = 600 MLD.

Mixing In the mixing structure, after a first dissipation chamber, the water would flow through the following structures in sequences: One group of two chambers with a contact time of 15 + 15 seconds, for : Injection of lime and recirculated filter washwater at the inlet of the first chamber. Injection of alum sulphate at the outlet of the second chamber 30 seconds later. One group of two chambers with a contact time of 15 + 55 seconds (upstream from the distribution weirs) after injection of alum sulphate. One of the outlet basins towards each of the 6 clarifiers, downstream from the equal distribution weirs, in which the flocculation polyelectrolyte would be injected.
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The first chamber in each group is equipped with an electric stirrer designed to homogenize the raw water with the regents. These electric stirrers are featured by a Sabra impeller design which saves energy while providing a perfect stirring effect with a gradient above 300 second -1. Coagulation A metal salt, aluminium sulphate is used for this purpose. The dose required depends on the nature of the water to be treated: This is determined when the plant is started up by means of jar test. The greater the loading of the water with colloidal matter, and in particular plant matter, the more reagents will be needed for clarification. The nature of the organic matter effects coagulation. The pH of the medium is the key factor in determining coagulation and reagent dose. Flocculation If the particles of metal hydroxides and colloidal matter are to flocculate, they must come into contact with each other. The likelihood of contact between particles increases proportionally to their concentration in the water. This gave rise to the idea of increasing the concentration by retaining in the liquid high percentages of sludge formed by the previous treatment. It is essential that the old particles in contact with the liquid being treated should be in the same physical state as those formed by the added reagents. No attempt is made to make the sludge circulate in the Pulsator. The aim is simply to maintain the sludge in the form of an expanding mass, through which the water is passed intermittently from bottom to talk.

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See the Figure 8 for the design of Mixing Chamber. The very gentle stirring is performed by the inflows of the water to be treated. Within the sludge blanket, the sludge is in suspension. Its apparent volume is variables depending on its density and the rate of the water. No compaction can takes place in the blanket. The true separation takes places in the still zones on the clafiers, @ (the concentrator) Calibration of raw water inflow

Once the level is 20cm above the cone concentrator weirs, check the raw water inflow by measuring the time needed to fill by successive depths of 20cm. The last measurement must be made before the water level reaches the lower level of the channels.

Inflow calculation:Where, t= Time taken in seconds to fill with water to a depth of 0.2m S1= Total pulsator clarifier surface area in m2 (849 m2). S2= Ground surface area within vacuum chamber walls in m2 (5.55 m2). S3= Total ground surface area of pillars in m2 (3.2 m2). Q= Raw water inflow in m3/h The equation is; Q= (S1-S2-S3) x 0.2 x 3600 t

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2.1.3 Inlet works plant

General Raw water is pumped from the raw water pumping station to the inlet works at Bukit Badong treatment plant in two 2100mm diameter pipelines. The inlet works comprise the following: Pipework connecting to the raw water pumping mains, including a flow control/isolating 2100mm diameter butterfly valve on the pipe to Stream B and a valve cross-connection to Stream A. Aerator Aerator outlet Aerator overflow Aerator by-pass.

Inlet Pipework The 2100mm diameter butterfly flow control/isolating valve on the pipe to Stream B and the similar size cross-connection valve are power operated. The power supply is tapped from distribution board, DB B, located under the aerator structure. These valves are operated locally from the actuators mounted onto the valves. The 2100mm diameter inlet pipe to Stream B branches into two 1550mm diameter pipes and these pipes discharge into the inlet chambers from which the raw water overflows into the aerator over adjustable stainless steel weirs. The aerator is provided with a 1800mm diameter by-pass pipe, controlled by a poweroperated butterfly valve with local control facility.

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Aerator The aerator is cascading type with the following features: Height of aerator Number of drops : 2.0 m : 4.0

Number of cascade steps : 500 sq.m Inlet weir level Outlet weir level : 24 m LSD : 22.23 m LSD

See the Figure 9 for the design of aerator. The main function of aeration is to reduce iron contents in raw water though oxidization process. The aerator is designed to create turbulence to provide for the maximum contact between water and air. A 50 mm high lip is provided around the outside edge of each tray, so that water falls into shallow pool. Aerator outlet The flow from the aerator passed over stainless steel weirs into the outlet chamber. From this chamber, water is conveyed in two 1550mm diameter pipes to the chemical mixing chamber. Each pipes includes a power-operated isolating and control butterfly valve and a raw water flowmeter. Power supply for the valves is from DB B and for the flowmeter is from the Instrument Panel at the sludge pump house. At the inlet of the outlet pipes is the dosing point for pre-chlorine. Aerator overflow The aerator is designed for a hydraulic capacity of 570 MLD and provided with an overflow. The overflow weir level is 22.6m LSD. The overflow is discharged into the flood retention pond via 1800mm diameter RC pipes. The aerator is also equipped with a 300mm diameter drain pipe with manually-operated sluice valve.

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Aerator By-pass The aerator is provided with an 1800mm diameter by-pass pipe, controlled by a poweroperated butterfly valve with local control facility. The power supply is from DB B.

Quality Plan-SSP1 Water Treatment Plant See the Figure 10 and Figure 11.

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2.1.4 Lamellar Pulsator Clarifier Lamellar pulsator working principle The PULSATOR is a sludge blanket clarifier consisting of a flat-bottomed tank with a series of perforated pipes at its base to distribute the raw water uniformly over the entire bottom of the clarifier. A further set of perforated channels are provided at the top of the clarifier to collect the clarified water evenly and to prevent any velocity variation in the various parts of the tank. To provide an intermittent supply to the lower header, the raw water and reagents are admitted and stored in the upper part of the vacuum chamber for a given period. The hydraulic force thus created is then released, and the water and reagents are pulsed at a high flowrate into the clarifier. The principle consists of removing the air by suction from the vacuum chamber. As a result, the water level rises gradually inside the vacuum chamber. When it reaches a level between 0.60m and 1.00m above the clarifier water level, a contact suddenly opens an air inlet valve. Atmospheric pressure is therefore immediately applied to the water stored in the vacuum chamber, and the water rushes into the distribution pipes at high speed. When the water level inside the vacuum chamber is approximately 20cm above that in the clarifier, the air inlet valve is closed and the cycle is repeated once more. The sludge blanket in the lower part of the clarifier is subjected to alternating vertical motions. It expands during flushing, which is performed powerfully for a short time (5-10 seconds) and then pulses down during suction time (which lasts 20-40 seconds) when the velocity is low. The blanket gradually increases in volume because of the impurities contained in the water and flocculation reagents. The level of the blanket therefore rises regularly, and it overflows into the concentrations which are in fact zero flowrate zones. The sludge is extracted from the concentrators at regular intervals at the rate such that the quantity of suspended solids extracted corresponds to the quality entering the clarifier (raw water + reagents).

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The clarifier has no mechanical sludge stirring system. It is the sludge blanket itself, which is constantly in motion when production is taking place, which ensures: The complete and rapid formation of the floc movement by contact with sludge already formed. The filtration of the floc. Because of the height concentration in the sludge blanket, and its buffer action, faulty adjustment of the treatment dosing rate or a sudden sharp variation in the pH of the raw water have no immediate ill effect. In such cases, the turbidity of the clarified water varies slowly, which gives the operator time to take appropriate action. A set of hexagonal modules located in the upper part of the clarifiers prevents the floc from being carried away into the clarified water. They are inclined at a 60o angle to provide for the evacuation of the sludge. Vacuum Chamber The vacuum chamber is equipped with one float switch, two fans (1 operating one stand by) and two pneumatically controlled valves. The choice of the operating fan is made a changeover switch located on the Pulsator switchboard located in the vacuum house. Both valves operate together. The fan runs continuously as an extractor. When the valve is closed, air is sucked out of the vacuum chamber, the pressure decreases, and the water level rises until it reaches the preset level fixed on the level switch (about 80-100cm from static level). Then the valves open and air is admitted into the chamber. The water level falls down to the low level fixed on the level switch, where the valve close and the cycle start again. See the Figure 12 for the design of Pulsator House.

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Sludge Draw-Off Sludge draw-off is made through cylinder operated butterfly valves, located on pipes leading from the bottom of the sludge hoppers in the clarifiers to sumps outside the tanks. On auto mode each group of two valves (one on each side of the clarifier) is opened during a preset time at regular intervals. Opening time and interval between two openings are set on timers located in the general pulsators control panel, according to the quality of raw water and chemicals used. Opening will last about 30 seconds and the duration for interval will be from 10 to 30 minutes. On semi-auto mode, the operator uses a push button located in the control panel to initiate the opening of the group of two valves immediately which is due for desludging at the end of the current intervals. The opening of the valves lasts for the same time as in auto operation. After that, the auto operation resumes unless the operator pushes the semi auto push button again to open the next set of two valves. On manual mode, the operator uses the manual control of the solenoid valves to open the respective valve.

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Compressed Air Production Unit Two compressors (9 kW) are installed. Each of them is followed by an air dryer (fan power: 0.05 kW). The air storage tank common to both compressor is equipped with two pressure switches. The duty compressor is controlled by one of the pressure switches, set between 7 and 9 bars. The standby compressor is controlled by the other pressure switch, set between 6 and 9 bars. The changeover of the duty / standby compressors takes places automatically every week. The air dryer fan is controlled automatically, starting and stopping at the same time as its associated compressor. Lamellar Pulsator Clarifier See the Table 2. See the Figure 13 for the example design of the lamellar.

37

2.2 Fluoride Dosing Control

2.2.1 Introduction

38

2.2.2 Procedure of Test A. Procedure addition sodium silicofluoride into hopper Generally in work procedures to increase fluoride to hopper were as follows: 1. Make sure Hopper which operates and which has to add by looking hopper or heavy remainder. Make sure operation hopper run smoothly 2. If necessary added, managing dust extractor (make sure you fully clothed) 3. Take bags fluoride the respective and put in hopper the. Usually 2-5 bag (according to need) 4. By using knife, open bag fluoride and pour fluoride into hopper (record heavy hopper before and after fluoride added) 5. Record number bag fluoride are being used in FRM form / CP/02 Note: Make sure bags empty dumped into waste receiver prepared. B. Procedure adding / reducing VSD value To increase and reduce dose fluoride, operator would be increased or reduce VSD value subjected in MCC panel 1. After getting directive from Controller / Shift Superintend, make sure fluoride plant operating normal 2. In MCC panel, governing method VSD value is wanted by pressing button the respective only. 3. Record VSD value in decision form.

39

C. Operational process dry feeder Objective: This operation intend to carry out stirrer so that solution fluoride complete can produce before in dosed. Procedure: 1. Make sure be power supply and make sure hopper which is operating 2. In MMC panel make sure position auto / manual to place manual 3. Press green button to stirrer on, make sure signal flaring red color.

D. Procedure test gram / minute Objective: These tests carried out are to know how much real dosage fluoride on water treated. Procedure: 1. Prepare equipment; Arbitrator, former deliberate and timers (stop watch) 2. Go to hopper involved to do test 3. In vortex tank take rate fluoride exited in time 1 minute. Repeat as much as 3 times and able average reading Dose count fluoride: ppm= (g/min x 24 x 60) (Filter. Flow (MLD) x 1000

40

E. Safety equipment Other than fully clothed, following equipment also must be worn when run sodium silicofluoride 1. Face mask 2. Glove 3. Safety boots Note: are advised ala mode work must be washed immediately when you go home. See the Figure 14 for summary of the fluoride preparation process.

41

2.2.3 Result & Discussion

Result Stream A Refer to the Table 3 for result of Fluoride Dosing Control for Stream A.

Discussion

Graph.

1. Graph for frequency (VSD) vs. flowrate (gram/minute). Refer to Figure 15

2. Graph for: a) Total fluoride powder flowrate (gram/minute) vs. ppm. Refer to Figure 16.

b) Total fluoride powder flowrate (gram/minute) vs. Actual Fluoride. Refer to Figure 17

42

Result Stream B Refer to the Table 4 for result of Fluoride Dosing Control for Stream B.

1.

Graph for frequency (VSD) vs. flowrate (gram/minute). Refer to Figure 18

2.

Graph for: a. Total fluoride powder flowrate (gram/minute) vs. ppm. Refer to Figure 19.

b. Total fluoride powder flowrate (gram/minute) vs. Actual Fluoride. Refer to Figure 20.

Result After service hopper number 2B & 3B Refer to the Table 5 for the result.

1. Graph for frequency (VSD) vs. flowrate (gram/minute). Refer to Figure 21. 3 Graph for: a) Total fluoride powder flowrate (gram/minute) vs. ppm. Refer to Figure 22.

b) Total fluoride powder flowrate (gram/minute) vs. Actual Fluoride Refer to Figure 23

43

2.3 Raw Water Turbidity Test (check the travel time)

2.3.1 Introduction Objective: 1) To check the differences values of turbidity at aerator, Stream B and laboratory. 2) To calculate the travel time of raw water from aerator to laboratory. Turbidity is a measurement of how cloudy water appears. Technically, it is a measure of how much light passes through water, and it is caused by suspended solid particles that scatter light. These particles may be microscopic plankton, stirred up sediment or organic materials, eroded soil, clay, silt, sand, industrial waste, or sewage. Bottom sediment may be stirred up by such actions as waves or currents, bottom-feeding fish, people swimming, or wading, or storm runoff. Clear water may appear cleaner than turbid water, but it is not necessarily healthier. Water may be clear because it has too little dissolved oxygen, too much acidity or too many contaminants to support aquatic life. Water that is turbid from plankton has both the food and oxygen to support fish and plant life. However, high turbidity may be a symptom of other water quality problems. This is caused by suspended materials, such as organic material, bacteria, algae, clay, mud, lime or rust. The first three types will consume chlorine; the last four types may interfere with disinfection. The highest level of turbidity recommended by WHO is 5TU which is approximately the density at which turbidity becomes visible within a drinking glass. Low turbidity assists filtration; it is tested by pouring the water sample into a long clear plastic tube and observing the depth at which it is just impossible to see through the tube. Industrial processes and food processing, require clear water. Turbid water can clog machines and interfere with making food and beverages.

44

2.3.2 Procedures of Test (HACH 2100N Turbidimeter) SHL.TPE.079 1. The sample tube is filled with the water to be tested. 2. The glass plunger is inserted in the tube. 3. The tube is placed in the instrument 4. The dial at the side of the instrument is turned until the field seen in the eyepiece becomes uniform. 5. The value indicated on the dial is read and the turbidity content of the sample being tested is determined directly from a chart furnished with the instrument

45

2.3.3 Result & Discussion

A. For the test result, refer to the Table 6. B. Discussion a) Graph. i. Aerator vs. Laboratory. Refer to Figure 24

ii. Aerator vs. Stream B. Refer to Figure 25

iii. Stream B vs. Lab. Refer to Figure 26

iv. Percentages of (A-C) vs. Percentages of (A-E). Refer to Figure 27

v. Percentages of (A-C) vs. Percentages of (C-E). Refer to Figure 28

vi. Percentages of (A-E) vs. Percentages of (C-E). Refer to Figure 29

46

b. Travel Time.

Travel time =

Length (L) Velocity (v)

= Flowrate (Q) Area (A) The diameter pipe used is 1 inch. Area = A = (0.0127)
2

Velocity

= 0.0005067 m2 = 506.7 x 10-6 m2 The raw water flowrate in pipe is 100ml/second. Conversion unit: 1m3 0.001m3 1m3 -6 1 x 10 m3 x 0.0001 m3 = = = = = = 1000L 1.0L 1 x 106 mL 1 mL 100 mL 100 mL

Conversion unit 1 inch = 2.54 cm 1 meter = 100 cm 1 cm = 0.01 meter 2.54 cm = 0.0254 meter = diameter. So, the radius, j = 0.0127m.

100 mL s

0.1 L 100 mL

0.0001 m3 0.1 L

= 0.0001 m3/ s *So, the raw water flowrate is 0.0001 m3/s.

47

150m Aerator (i) Aerator Stream B Stream B.

226m Lab

Area of pipe= 506.7 x 10-6 m2 Length,L = 150 m

1

Flowrate,Q = 0.0001 m3/s Velocity,v = Q = 0.0001m3/s A 506.7 x 10-6 m2 = 0.197 m/s *Travel time = Length,L Velocity,v = 150 m 0.197m/s = 760.06 second = 12.67 minute.

(ii)

Stream B

Lab.

Area of pipe= 506.7 x 10-6 m2 Length,L = 226 m

1

Flowrate,Q = 0.0001 m3/s Velocity,v = Q = 0.0001m3/s A 506.7 x 10-6 m2 = 0.197 m/s *Travel time = Length,L Velocity,v = 226 m 0.197m/s = 1147.20 second = 19.12 minute.
48

2.4 Milk-Lime Concentration Test

2.4.1 Introduction Principle: Volumetric titration by means of a strong acid. The end point is detected by phenolphthalein colour index. Objective: 1) To measure the concentration of lime solution. 2) To calculate the value of ppm and percent of stroke dosing pump. Apparatus: 1. One burette graduated 1/10th mL with its support. 2. One 250 mL Erlenmeyer flask. 3. One pipette 5 mL. Reagents: 1. Hydrochloric acid 0.5N: One liter of this solution contains 18.232g of HCl. 2. Phenolphthalein: Dissolve 1 g of phenolphthalein (C20H14O4) into 99 g of absolute alcohol.

49

2.4.2 Procedures of Test

1) Shake vigorously the sample of milk of lime and transfer immediately 5 mL into the Erlenmeyer flask.

2) 50 ml of distilled water was added and two drops of phenolphthalein solution. The colour changes immediately to red.

3) The hydrochloric acid is added with the burette until the colour disappears completely. After a few seconds the colour may appears again. A small quantity of hydrochloric acid is added to get a stable end point during 1 minute.

4) The volume, V of acid used was read in the burette.

50

2.4.3 Result & Discussion

Result

Department Source Sample description Sampling Point Date/Time Sampled Date Received Method References Sample Size Weight of lime in 1 batch Specific Gravity (S.G) Hydraulic Acid (HCl) used So, the concentration, g/L The percentage of lime, %

: Production : Stream A : Lime Solution : Service Tank @ surface : 23/3/2010 @ 3:30 PM : 23/3/2010 : In House : 5 ml : 1.4 ton lime powder : 1.127 : 32.97 ml : 32.97 x 37 = 121.98 g/L 10 : 121.98 x 100 1127 : 10.82 %.

51

Discussion:

Concentration, C = g/L = V x 37 10 Chemical reaction:2HCl + Ca (OH)2 Ca (Cl)2 + 2H2O

Lime @ Ca(OH)2 Ca (OH)2 40 34 = 37 g/L *Total = 74/2 Notes :-

Normality;

Derive the equation:M1V1 = M2V2 N = Normality = Weight Molecular weight N1V1 = N2V2

Weight MW

x V1 = N2V2
Acid

WeightLime = N2V2 x MW V1 g/L = (0.5N x Vacid mL) x 37 g/L 5 mL (lime solution) = Vacid x 37 10

52

2.5 Sludge Blanket Concentration Test

2.5.1 Introduction Objective of test: 1. To calculate the difference concentration of sludge blanket formation. 2. To learn to accurate setting for pulsation rate. 3. To study about volume of suction. Sludge blanket formation

Recommended that only 50% of maximum flowrate is treated to form the sludge blanket.

The speed of sludge blanket formation depends on water and reagent doses needed to perform clarification. (normally at 6 hours)

The sludge blanket may form in three hours with turbid raw water and large quantities of reagents. Conversely the sludge blanket may take more than 24 hours to form with relatively clear water with low amounts of reagents.

During the first few hours of operation, carry out and record the result of the followings checks at regulars intervals: a) Raw water inflow b) flush height c) flush time d) Suctions time.

After 3 hours operation, perform the check indicated above every hour, and begin to check the sludge percentages of the sludge blanket.

53

Pulsation Rate

Calculate the sludge sediment after ten minute following the formula at below:-

Sludge Percentages = Volume of sludge sediment x 100 250 % sludge = 0.4 V

The different between both of reading top and bottom are around 4% - 6%. Basic adjustment of pulsation control device. Check that at minimum flowrate the clarified water orifices remain submerged in the clarifier tank. If not, bring the level up by raising the adjustable weir plate at the outlet of the clarifier water channels. Adjust the pulsation control device limiters so that : The upper level is 0.65m above the maximum water level on the clarifier. The lowest level is 0.20m above the maximum water level.

Adjustment of flushing time and pulsation rates.

Flushing : 7 to 10 seconds Filling : 30 to 40 seconds

54

Adjustment of pulsation in the light of measured concentration. 1. If the different concentration are between 4-6%. Its considered to be corrected. 2. If the readings are over than range above, adjust the pulsation rates. 3. The first step, adjust the flushing time. (reduce at 5 second) 4. If its not enough, reduce the suction time. (Make sure the suction flow rate < incoming flowrate). 5. When the result is not satisfied, increase the flush height until a maximum total height (0.80m). 6. In case these action is not be effected to the result collected, clear and clean that clarifier. This is last action which can solve the problem. 7. If the different concentration are corrected; Extend the suction time up to maximum 45 second. Extend the flush time (cant over than 10 second). Wait in 3 hours before run the test to taking the reading for sludge blanket concentration test result anytime after change the pulsation rates. 8. Generally, every modification of pulsation rate are depends on: Raw water characteristic. The higher amount of polymer used. Always repeat the pulsation rate which demands to obtain the sludge blanket homogenized and prevent the deposit from forming. Return to the floc is light: Reduce the suction flowrate, long term the period of suction time and flushes less vigorous.

55

 The rate can be determine as follows: Measure the average flowrate during the pulsation, which is equal to the evacuated volume, divide by the flush time and multiplied by 3600 seconds. Add the flowrate being treated. Divide by the surface area of the clarifier, after subtracting the surface area of the concentrators. The rate is normally 7 8 m/h for relatively clear water, but can rise to the 10 or even 12 m/h for very turbid meter.

56

2.5.2 Procedures of Test

1. Use 250ml test cylinder (at least 2 test cylinder are required).

2. Take 2 sample of sludge using a small siphon pushed through one module tube: One 20 cm above the upper level of the stalling plates. The other 20cm below the upper level of the cone concentrator.

3. Draw off 250ml of sludge-laden water from each sampling tap. Homogenize the sludge and then put the test cylinder in an area where the temperature is constant.

4. Note the volume of sludge deposited after a settling time of 10 minutes.

5. The percentages of sludge will be equal to: Percentages,%= volume,ml of sludge deposited x 0.4 For 500ml of volume sample, %=volume, ml of sludge deposited x 0.2

6. Once the height of the sludge blanket is about 50% of its total height, it is possible to gradually switch from half of full flowrate to full flowrate.

Equipment/Apparatus/Material 1. Test cylinder 250ml/500ml/1000ml. 2. Stop watch 3. Ruler

57

2.5.3 Result & Discussion Sludge blanket concentration test

Company/Department Source of Sample Sampling Point Flow of Raw Water Volume of Sample Range of RW Turbidity PAC Dosing (In range) Poly Dosing Pulsation Rate:1) Flush Time 2) Suction Time 3) Flush Height Desludging Rate:1) Interval 2) Duration

: Production : Stream A : Pulsator No. 1 : 320 MLD - 390 MLD : 500 ml/250ml : Below than 100 NTU : 32 - 59 ppm : 0.06 ppm

7 second

: 24 second : 60 cm : 36 minute : 1 minute

RW Turbidity (NTU) 75 90 96

Different Conc. (%) 4.0 4.3 2.0

Refer to the Table 7 until Table 12 for all of results at Stream A only. Then, refer to the Table 13 until Table 18 for all of results at Stream B only. See the Figure 30 for the summary of the experiment.

58

Discussion Check of correct pulsation adjustment 4. To make sure that the pulsations are correctly adjusted, it is necessary to check sludge blanket homogeneity. 5. The sludge samples are taken at various depths in the sludge blanket, and the volume deposited in 250ml test cylinder after settling times of 10 minutes and 30 minutes are compared. 6. Percentage,% = Volume x 100 = 100V 250 250 Where V=volume of sludge. 7. If the different of sludge concentration are around 4-6%, pulsation adjustment is considered to be corrected. Heavy sludge How to do this:1. Firstly, reduce the flushing time, by opening the manual venting valve (the time can be reduced to a minimum valve of 5 second). 2. Reduce the suction time, while ensuring that the suction flowrate is lower than the raw water inflow. 3. Increase the flush height up to a maximum of 80cm. 4. If these measures are not sufficient, as a last result raise the low level in the vacuum chamber for maximum pulsation effectiveness. This must only be done however if the sludge is heavily loaded, and not merely thickened following lengthy shutdown.

59

Case of lightly loaded sludge. 1. In this case, sludge homogeneity is obtained but the sludge blanket rises. 2. If this happens, first increases the flushing time although it must remain below 10 seconds to ensure pulsation effectiveness. If this does not solve the problem, reduce the flushing height (down to minimum of 30cm) and increases the suction time (up to a maximum of 50 seconds).

Optimization of adjustment Once the unit is operating at nominal flowrate, wait until the sludge blanket reaches the upper level of the concentrators, and until the sludge blanket concentration stabilities. Once the concentration has stabilized, check the homogeneity of the sludge blanket. This may be done using a siphon consisting of a vinyl tube weighted at one end, which is dipped into the Pulsator, is preferable. Samples may be taken for example at depths of 50 cm, 1.00m and 1.50m below the concentrator level. (Disregard any samples taken less than 15cm below the upper level of the sludge blanket). Put the sample into a 250ml test cylinder, and record the sludge volumes deposited after a settling time of 10 minutes. The corresponding concentrations are calculated as follows: Percentages, % = 100V 250

60

Interpreting result The homogeneity of the sludge blanket is obtained by means of the pulsation rate. The aim is to obtain a sludge blanket which is basically homogeneous. If the rate is too slow, the sludge blanket will tend to condense, and the measured concentration will be markedly higher in the lower part than in the upper part. If the pulsation rate is too fast, the sludge blanket will break up, and higher concentration will be found in the upper part, while floc will be entrained by the clarifier water. Conclusions must not however be drawn hastily, and any anomaly detected must be confirmed by taking several consecutive measurements with the unit operating at a stable flowrate. If the flowrate is reduced, the sludge tends to condense, and the measurements taken show higher values in the lower part. Conversely, if the flowrate is increased, the sludge expends and deconcentration in the lower part of the clarifier may be observed. For these reasons, only measurements taken after operation at a steady flowrate for at least 3 hours should be taken into account.

61

2.6 Sludge Draw-off Test 2.6.1 Introduction Objective 1. To measure the volumes and percentages of sludge during desludging. 2. To learn the accurate setting of pulsation rate and desludging rate. Sludge draw-off adjustment When the sludge blanket level reaches the upper edge of the concentrators, the draw-offs must be start-up. Draw-off time and draw-off frequency depends on the suspended solid in the raw water (to which reagent have been added), the settling of the sludge, and the instantaneous flowrate of each draw-off valve. Estimating of draw-off percentages A rough idea of the percentages to be extracted can be obtained by estimating the quantity of sludge obtained in flocculation. Using the raw water available, perform a laboratory flocculation test on five 1 liter beakers of water, to which the optimum amount of reagent have been added. After conducting the normal flocculation test, allow to settle for 10 minute. The draw-off the clarified water, collect the sludge from the 5 beakers, and put it into a 1-liter test cylinder, pouring the sludge gently so as not to break up the floc. Stir the sample by holding the test cylinder at the top and turning it through several revolutions.

62

Record the number P of cm3 sludge settled after a settling time of 15 minutes Where; P= The number of cm3 of sludge settled after a settling time of 15 minutes.

R= The percentages of sludge. The relationship will be: R= P 5000 Estimating of suspended solids in draw-off. Once the suspended solids content of the raw water and reagents is known, and draw-off rate indicated by the above percentages, it is possible to calculate the average suspended solids content of the draw-off. Equipment/Apparatus/Material 1. Test cylinder 250ml/500ml/1000ml. 2. Stop watch 3. Rule

63

2.6.2 Procedures of Test

1. Use 250ml/500ml/1000ml test cylinder (at least 2 test cylinder are required).

2. Take 2 sample of sludge through the desludging pipes: 1 cylinder test for 10 seconds after open valve. 1 cylinder test for 10 seconds before close valve.

4. Draw off 250ml of sludge-laden water from each sampling tap. Homogenize the sludge and then put the test cylinder in an area where the temperature is constant.

5. Note the volume of sludge deposited after a settling time of 10 minutes.

6. The percentages of sludge will be equal to: Percentages,%= volume,ml of sludge deposited x 0.4 For 500ml of volume sample, %=volume, ml of sludge deposited x 0.2

7. Once the height of the sludge blanket is about 50% of its total height, it is possible to gradually switch from half of full flowrate to full flowrate.

64

2.6.3 Result & Discussion Result Refer to the Table 19 until Table 25 for all of results at Stream B only. Discussion Adjustment of draw-off Once the sludge blanket level has reaches the concentrator weir: Start up the draw-off automatic control device, and more the following initial adjustment: Draw-off time : 15 second Frequency : 30 minutes.

The adjustment can be optimized by references to the draw-off rate and the percentages to be extracted as defined above. Otherwise, draw-off adjustment can be performed empirically, either by checking the concentration of extracted sludge, or by plumbing the level of sludge in the concentrators. i. Concentration check Take the 250 ml sample of sludge-laden water from the sampling valve 2 seconds after opening the draw-off valve, and another 250 ml test cylinder sample 3 seconds after closing the draw-off valve. Stir the sludge, and they allow to settle. Record the sludge percentages after settling times of 5, 10 and 30 minutes. The sludge percentages in the samples after 5 minutes should be around 99.0 %. After 30 minutes, the percentages should be similar in both test cylinder, or at least equal to 90.0 %. If after 30 minutes the percentages difference is greater than 10 %, reduce the sludge draw-off time. If this is not enough, reduce the interval between 2 draw-offs time.

65

ii. Adjustment by level in concentrators If the sludge blanket is stable, and to limit water losses, plumb the level of sludge in the concentrators and increases the intervals between draw-offs until the level of sludge in the concentrators. The kinds of adjustment are only applicable if the flowrate is constant, and provided that the level of sludge is regularly checked. If checks are not adequate, it is better to perform too many draw-off rather than not enough.

66

CHAPTER 3

GENERAL KNOWLEDGE

3.1 Volume of Suction 3.1.1 Basic operation 3.1.2 Standard Calculation

3.2 Backwashing Filter 3.2.1 Basic Operation 3.2.2 Information

3.3 Lime Preparation 3.3.1 Introduction 3.3.2 Work Instruction

2.7 Volume of Suction

2.7.1 Basic operation

Flush Height Weight

Float level

Static level

Flush height 60 cm

Stream B Area of one pulsator: 13.75 m2

2.7.2 Standard Calculation Example of standard calculation; 1. Stream B With setting of pulsation rate, Flush time = 6 second.

Suction time = 25 second. Flush height = 60 cm.

Area of one pulsator = 13.75 m2 Volume of suction: = 0.6m x 13.75m2 = 8.25 m3

Convert to Million Liter per Day (MLD), With 25 second of suction time. =8.25m3 x 60 25 =28.51 MLD. second x 60 minute x 24 hours 1000

2. Stream A

With setting of pulsation rate, - Flush time = 7 second.

- Suction time = 31 second. - Flush height = 45 cm. Area of one pulsator = 16.81 m2 Volume of suction: = 0.45m x 16.81m2 = 7.56 m3

Convert to Million Liter per Day (MLD), With 31 second of suction time. =7.56m3 x 45 31 =15.80 MLD. second x 60 minute x 24 hours 1000

3.2 Backwashing Filter 3.2.1 Basic Operation

Step of operation: 1. Draining (26 minutes). During drain; Filter water (FW) inlet valve is open. Settle water (SW) inlet valve is close. Wash water outlet is open. 1 minute air scouring (+ 4813 m3) 9 minute air + water (+ 1000 m3) Wash water outlet is open.

2. Backwashing -

3. Rinsing (12 minutes + 1500 m3) Use two wash water pumps. Air scouring is open.

3.2.2 Information Filter run-time is about 120 minutes. This explanation for one stream; Have 24 filters. Its have three modes 1. Auto 2. Semi-Auto. 3. Manual Size of one filter: Head lost = When hit a 2.4 miter, the backwash will be run automatically. See the Figure 31 for the explanation by picture.

3.3 Lime Preparation 3.3.1 Introduction: 1. To lime plant, for each stream there are as much as 2 unit lime mixing tank. 2. Purpose held lime mixing tank this was to enable process lime preparation held. 3. Concentration lime are prepared (1.2-1.4 tons) 4. Nominal capacity for a unit mixing tank was 6m3. Apparatus: i. Lime silo. ii. Lime mixing tank iii. Lime service tank. iv. Alum/lime MCC Panel. 3.3.2 Work Instruction: i. Pre Start-Up. Make sure have a power supply. Make sure service tank was empty to enable process transfer lime solution from mixing tank to lime service tank. Lime mixing tank shall apply in hygienic conditions and function. Channel feeder lime unclogs. Dust extractor like clockwork. Stirrer mixing tank function. Service waters no problems.

ii.

Manual Lime Preparation Go to lime plant Go to Alum / lime MCC Panel. Make sure have power supply. Put Auto button / manual to position manual. Choose mixing tank want to be used whether No.1 Or No.2 Fill in service water into mixing tank chosen.

iii. Fill eagle deep water mixing tank. Go to panel mixing tank. To mixing tank chosen, put black button @ service water inlet valve to position open. Make sure signal a scarlet. Put button high Pressure (HP) water inlet valve to position open. Make sure signal a scarlet. When water level filled in mixing tank is already at above ring level occur in mixing tank, invite kill service water inlet valve and HP inlet valve. iv. Procedures fill lime powder into mixing tank. Go to lime mixing tank panel. Managing fluidization water valve. Put black button to position open and make sure signal a scarlet. Managing screw feeder. Press green button. Make sure signal a scarlet. Managing dust collector shaker. Press green button. Make sure signal a scarlet. Managing stirrer. Press green button. Make sure signal a scarlet. Make sure number came down from lime silo are among 1.2-1.5 tons. This can see in weight indicator imprinted in panel mixing tank.

When weight (tone) lime in total require real enough, kill switch fluidization water valve, screw feeder and dust collector.

To stirrer and dust extractor, letting for 5-10 minutes. This to enable lime solution in mixing tank mixed perfectly and regular.

Kill switch stirrer Kill switch dust extractor. Record number mixing tank and time preparation in boring FRM / CP/02.NOTE:

Note: 1. To stream A, time adopt for lime preparation from lime silo to mixing tank for heavy between 1.2-1.3 tons was 5-10 minutes. 2. To stream B, time taken to lime preparation from lime silo to mixing tank for heavy between 1.2-1.3 tons was 15-25 minutes.