Table of Contents

FOREWORD......................................................................................................................................... 2
1.

2.

3.

WATER ANALYSIS .................................................................................................................... 3

1.1.

Raw Water Analysis ............................................................................................................. 3

1.2.

Water Quality Assurance of Product .................................................................................. 3

OPERATION ................................................................................................................................ 4
2.1.

Operation of Sand Filter and Carbon Filter....................................................................... 4

2.2.

Installation ............................................................................................................................. 5

2.3.

Start-up Procedures .............................................................................................................. 6

2.4.

Chemical Feeder (start-up) .................................................................................................. 7

2.5.

Final Examination ................................................................................................................. 7

FUNCTIONS, WAYS OF WORKING AND OPERATING EQUIPMENT........................... 8

FOREWORD

First of all, we would like to thank you for your purchase of our products : Sand Filter,
Carbon Filter, Flow Switch and Dosing Pump. This manual book is made for operator daily
operation and maintenance. For practical purpose, theory will not be exposed in details
instead of by giving operator principles how to operate the filters and softener. In addition
this manual is completed with trouble shooting for daily operation.
Although training has been given, not every trouble can be handled by operator. If this is the
case, please contact :

PT BANYU BIRU SEJATI

Tel. 021-8841762 Fax. 021-8856176
e-mail: ptbanyubiru.engineering@gmail.com

Bekasi, Februari 2015

PT BANYU BIRU SEJATI

1. WATER ANALYSIS
1.1.

Raw Water Analysis

Table 1.1. Parameter of Sand/Carbon Filter

Parameter
Physic :
- Odour
- TDS
- Turbidity
- Taste
- Temperature
- Color
Chemical :
- Mercuri ( Hg)
- Arsen
- Iron
- Fluoride
- Cadmium
- Kesadahan ( CaCO3)
- Chloride
- Chromium, Valensi 6
- Manganese
- Nitrat, as N
- Nitrit, as N
- pH
- selenium
- zink
- Sianida
- Sulfate
- Plumbum ( Pb)
Organic chemical:
- Aldrin and Dieldrin
- Benzena
- Benzo(a) pyrene
- Chlordane ( total Isomer)
- Coloroform
- 2,4 D
- DDT
- Detergen
- Gamma-HCN ( Lidane)
- Pertisida total
- Organic ( KMnO4)
Microbiology :
- Total coliform ( MPN)

1.2.

Unit

mg/L
NTU
0

C
TCU
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L

Raw Water Quality

Yes
244
13,4
No tested
27,8
89

mg/L
mg/L
mg/L

No tested
No tested
0,45
< 0,001
No tested
39,6
34
No tested
0,27
1,8
0,03
6,87
No tested
No tested
No tested
6,8
No tested

mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L

No tested
No tested
No tested
No tested
No tested
No tested
No tested
No tested
No tested
No tested
2,2

Qty per 100 ml

Qty per 100 ml

220

mg/L

Water Quality Assurance of Product

Based on regulation of Menteri Kesehatan RI: 416/Menkes/Pre/IX/1990

3

2. OPERATION
2.1.

Operation of Sand Filter and Carbon Filter

a. How the filter work

Sand Filter and Carbon Filter purchased in is automatic operation by timer i.e. water
filters which must be operated by using a special device namely controller. The
controller has internal valves which can be in open or close position according to the
filter operation. A total of units valve on the Sand Filter and Carbon Filter. Operating
valve positions to control both filters are as follows.
b. When service (position 1 See Table 2.1. and 2.2.)
Sand Filter and Carbon Filter work by allowing raw water enters from top and comes
out from the bottom of the media bed. This is known as downflow operation. Raw
water which still containing unwanted materials, such as suspended solid and colour,
will penetrate filtering media in the filter tank. Filtering media for sand filter is silica
sand while for carbon filter is activated carbon in the form of bed. Suspended solids
will be reduced by sand bed and makes the filtered water will have less in turbidity.
Colour and organic matter will be absorbed by activated carbon bed. The filtered
water then will less in suspended solid, organic matter and colour.
c. When Backwash (position 2 See Table 2.1. and 2.2.)
Backwash means to clean filtering media in the filter tank by entering raw water from
the tank bottom to the top and then waste them to the drain line. By this way, raw
water will flush any dirt and suspended solid in the filter bed out from the filter tank.
Backwash is done when there is difference in water pressure into the filter compared
to the previous. Usually the difference in pressure of 0.25 bar (kg/cm) is quite
inappropriate for the filter to perform this procedure. Time required for backwashing
periode is depend on several factors, such as raw water turbidity and filter operation
time in service position. However from experience during commisioning, this process
should be done at least 2 days.
d. When the rinse (position 3 See Table 2.1. and 2.2.)
After backwashing of sand and carbon filter, the filtration media in both filters are
relatively clean than before. But there may be still dirt inside them. Due to that matter,
the filter media must be rinsed after backwashing. At this position, raw water will
enter continuously into the filter tank for a period of time. The time required for rinsing
is shorter than for backwashing. By doing this way, raw water will flush the remaining
dirts or suspended soilds from sand bed and carbon bed and take them out from the
filter tanks into drain line. After rinsing process completed, the filters are brought back
into service position and ready for use.

Table 2.1. Sand Filter

-----------------------------------------------------------------------------------------------------------------------------------POSITION

CYCLE

TIME

===========================================================================
1.

Service

...

2.

Backwash

...

3.

Venting

20-30 second

Table 2.2. Carbon Filter

-----------------------------------------------------------------------------------------------------------------------------------POSITION

CYCLE

TIME

10

===========================================================================
1.

Service

...

2.

Backwash

...

3.

Venting

20-30 second

Notes:

B = Open , T = Closed

Time for each position depends on the raw water quality and the result of the test and
commisioning

Venting (dispose of air trapped in the filter tank) is done after backwash, without running
the backwash pump.

2.2.

Installation

Please follow the instruction below for installation.

1) Skid Mounted Installation
Put the skid mounted on the strong foundation. Concrete foundation is preffered. It is
more convenient if there is also a open drain near the skid mounted. The tanks level
must be vertically straight to make sure no slanting position.
2) Filter Installation
All inlet and outlet piping should be connected properly. Drain line from Sand Filter
and Carbon Filter must be free from clogging. If possible, it is better to install by pass
valve for filter/system isolation during maintenance or serivce.
Notes:
Drain line should be connected with open drain where flow of water can be observed.

3) Media Filling
Unscrew bolt and nuts ont the top manhole. Leave 1 bolt and nut to support the
manhole cover. Pour filter media into the filter tank carefully by using small bucket
through top manhole. Fine gravel is filled first before filter media. This media is used
as supporting media. First, enter the fine gravel up to a height of about 300 500
mm from the tank bottom. Futhermore, silica sand to enter the height reached 700
900 mm above average fine gravel. After Sand Filter media filling, activated carbon is
filled into Carbon Filter tank. After media filling has been done correctly for both
Sand Filter and Carbon Filter, the tanks are ready to fill up with raw water.

2.3.

Start-up Procedures

When all piping installation and filter media filling have been done correctly, follow the steps
bellow.
2.3.1. Sand Filter
1) Set the valve(s) to backwash position on the sand filter. But, open the valve to
backwash water inflow (valve 5) slowly. Do not open until filled.
2) Run one backwash pump manually. Clean water will enter from the top and out
into the drain line. Full water flow can cause the loss of sand due to overflowing
tank.
3) If it turns out to drain the water only, open the valve inflow carefully and do
Backwash until the water looks clear when stored in a container.
4) After backwash pump stops, set so the valve is in a position venting (position 3)
and observe the presence of air coming out of the drain line along a stream of
water. Leave on for 20 30 seconds or until there is no air flow and water coming
out.
5) Set valve to the service position
6) Sand filter ready for normal operation
7) Turn off the pump and set backwash position (position 1) on the Carbon Filter.
2.3.2. Carbon Filter
1) Set the valve(s) to backwash position on the sand filter. But, open the valve to
backwash water inflow slowly. Do not open until filled.
2) Run one backwash pump manually. Clean water will enter from the top and out
into the drain line. Full water flow can cause the loss of sand due to overflowing
tank.
3) If it turns out to drain the water only, open the valve inflow carefully and do
Backwash until the water looks clear when stored in a container.
4) After backwash pump stops, set so the valve is in a position venting (position 3)
and observe the presence of air coming out of the drain line along a stream of
water. Leave on for 20 30 seconds or until there is no air flow and water coming
out.
5) Set valve to the service position
6) Sand filter ready for normal operation
7) Run the feed water pump into auto position
6

2.4.

Chemical Feeder (start-up)

Dosing pump is applied for chlorine solution injection in the filtered water coming out from
carbon filter prior to reach clear water tank. Mixing between water and chlorine solution
occurs rapidly in static mixer. There are several types of dosing pump in the market. Dosing
pump from diaphragm type is used for this system.
If the dosing pump and chemical tank as well as all cable lines have been completed
properly installed and connected, follow the steps bellow.
1) A chemical solution which you shall make according to requirements
2) Chemical solution for chlorine (chlorine solution) is made with a level of 1% (1 Kg of
chlorine dissolved in 100 L of clean water)
3) A solution of a base (alkaline solution) are made with levels of 10% (10 Kg of alkalis
dissolved in 100 L of clean water)
4) Stirring is necessary to speed up the process chemicals to the water solubility
5) Run the dosing pump manually to ensure the chemical solution can be pumped
6) Adjust the position of chemical feeder on automatically.

2.5.

Final Examination

1) Valve on the correct position

2) Safe drain lines and uninterrupted
3) There are no leaks in the pipe or valve
Notes:
1) Sampling of raw water and water treatment result 2 3 liters taken after the system
can run well for 15 minutes.
2) Water samples were then taken to the laboratory designated to determine the
parameters predetermined.
3) In normal operation after the handover of work, this kind of water sample testing
should be performed every 3 months

3. FUNCTIONS, WAYS OF WORKING AND OPERATING EQUIPMENT

1) Filter Pump

Function:
Pumping raw water from wells in the heading to the water treatment
plant.
How the Filter Pump work:
When the water level in the product water storage tank reaches the
minimum point, then pump will work automatically. Coversely, if the
water level in the product water storage tanks reached the maximum
point, the pump will stop automatically. The pump number is 2 (two)
units, 1 (one) unit of work and 1 (one) other unit in standby.
Displacement between pump 1 and pump 2 is done by turning the
button switch on the control panel.
Operating:
a. Manually, pump 1 and pump 2 is executed by adjusting the button
switch on the MAN position and then push the ON/OFF button on
the control panel.
b. Automatically, pump 1 and pump 2 is executed by adjusting the
position of the button on the AUTO and pump will run
automatically. This operation is normally run every day.

2) Sand Filter

Function:
Reduce levels of turbidity and suspended solids from the raw water
through silica sand media.
How the Sand Filter work:
Raw water entering from the top of the media, and then penetrate the
sand bed for the next pile out of the tank filter. Suspended solids
particles contained in the raw water will be retained on the filter media,
so that the filtered water becomes clearer.
Operating:
When the filter pump runs, it will automatically filter also runs. For
washing and rinsing media regularly required of operators to set up
the control panel.

3) Carbon Filter

Function:
Reducing the levels of organic dye, phenol, turbidity and suspended
solids from the raw water through activated carbon media.

How the Carbon Filter work:

Raw water entering from the top of the media, and then penetrate the
filtration media for the next pile out of the tank filter. Dyestuffs, organic
subtances and phenol will be absorbed in the pores of the media,
while Suspended solids particles contained in the raw water will be
retained on the filter media, so that the filtered water becomes clearer.
Operating:
When the filter pump runs, it will automatically filter also runs. For
washing and rinsing media regularly required of operators to set up
the control panel.
4) Chemical Feeder (CF)
Function:
Pumping the chemical solution of the chemical tank into the piping in
the water treatment plant.
How the Chemical Feeder work:
If there is a flow of water in the piping, the flow switch will give a signal
to the control panel to instruct the dosing pump runs. Otherwise, if
there is no water flow, the dosing pump will stop automatically.
Operating:
a. Manually, executed by adjusting the button switch on the MAN
position and then push the ON/OFF button on the control panel.
b. Automatically, executed by adjusting the button switch on the
AUTO position and then dosing pump will run automatically. This
operation is normally run every day.
5) Backwash Pump (BP)
Function:
Pumping water from the process water stored in the water tank
product leading to the sand filter and carbon filter to clean the filtration
media.
How the Backwas Pump work:
This pump is run manually and only when necessary for the purpose
of backwash. Operation carried out by push the ON button on the
control panel to run and push the OFF button to stop it.