JAMMU & KASHMIR ECONOMIC RECONSTRUCTION AGENCY

REPLACEMENT OF WORN OUT PUMPING AND ELECTRICAL EQUIPMENTS,PLACEMENT OF D.G SETS AND

CONSTRUCTION OF CLARIFLOCULATOR-REVAMPING OF WATER TREATMENTS PLANT

OPERATION & MAINTANENCE MANUAL

FOR

WATER TREATMENT PLANT,SRINAGAR.

CLIENT : J&K ECONOMIC RECONTRUCTION AGENCY

CONSULTANT : INTERCONTINENTAL CONSULTANT & TECHNOCRAFT PVT. LTD.

CONTRACTOR :

TECHNOFAB ENGINEERING LIMITED

Hotel Remano4th floor, Zero Bridge, Raj BaghSrinagar, J&K State – 190 008NNNNN

Firdous Manzil, Raj bagh,Raj bagh,Near Modern Sweets, Sri Nagar-190 008, J& K.

507 ,Eros Apartmenrts,56,Nehru PlaceNew Delhi-110 019

PREFACE

The project involves the rehabilitation of water treatment plants at Srinagar in Alusteng.

The objective of the Operation and Maintenance Manual is to provide guidelines to the effective operation of the plant to achive optimum output of water in terms of quality and quantity and to operate and maintain the plant in cost effective manner. The instructions and data detailed in the following pages will provide this information in addition to general system description, design parameters and technical specifications of equipments supplied by us as a part of this system. This manual need not be considered as the final word on system operation. To foresee and predict each and every contingency that may arise during the life of the entire plant shall be through experience.These instructions are general in nature and should necessarily be detailed and supplemented by way of actual experience in system operations. Hence, it is essential that the personnel responsible for operation and maintenance of this system must acquaint themselves with the systems and facilities at site.

It is imperative that a well trained team of operation and maintenance personnel be developed so as to be able to safely and efficiently operate the system. Moreover, since fluid handled is of explosive nature, care and caution should be exercised during all operations.

The manual has been divided into volumes,according to the project sites as follows:

Volume 1 Alustang WTP 2 mgd Volume 2 Alustang WTP 4.8 mgd

CHAPTER – IIPROJECT DESCRIPTION

Srinagar is a District headquarter and summer capital of State of J & K. Srinagar is located at an elevation of 1585 m above Mean Sea Level and is surrounded by number of water bodies viz Dal, Nagin & Anchar lakes; River Jhelum and Sindhu. Its climate is characterized by temperate summer (7 to 31 º C) and cold/mild winters (-2 to 16ºC). The region is endowed with copious supply of water represented by glacier melts in rivulets and rivers; storage in lakes and fresh water from springs etc. Besides flourishing center of administrative and commercial activity, Srinagar city attracts large number of tourists every year.There are five water treatment plants namely Doodhganga, Rangil, Alusteng, Pokhribal and Nishat in Srinagar. Installed treated water production capacity of existing water treatment plants is 57.55 MGD. Augmentation of water treatment plants at Doodhganga, Rangil and construction of a new WTP at Mahjoor nagar are under process and expected to be completed by 2007-08. Enhanced capacity of water supply system in the city will be 71.05 MGD by 2007-08. The system, functioning with full capacity, will be sufficient to benefit a population of 2.0 million at water supply rate of 34 gallons per capita per day. The present package relates to increase in transmission capacity of Nishat and Doodhganga water supply systems.

Design capacity of Water Treatment Plants in SrinagarWTP Capacity (MGD) Source Type of Scheme

Doodhganga 7.75 Doodhganga Nalah LiftRangil 20 Sind Extn.Canal GravityAlusteng 6.8 Sind Extn.Canal GravityPokhribal 4 Nagin lake LiftNishat 19 Dachigam nalah/Dal Lake Gravity/Lift

Total 57.55

Expected Design capacity of Water Treatment Plants in Srinagar by 2007-08 (Augmentation in progress by PHE dept).

WTP Capacity (MGD)

Source Type of Scheme

Doodhganga 10 Doodhganga Nalah LiftRangil 30 Sind Extn.Canal GravityAlusteng 6.8 Sind Extn.Canal GravityPokhribal 4 Nagin lake LiftNishat 19 Dachigam nalah/Dal Lake Gravity/LiftMehjoor Nagar 1.25 River Jehlum LiftTotal 71.05

The major activities under this package, in general, are listed below. However, specific activities are applicable for specific WTP.

Construction/revamping of Clari-floculator including repair/construction of bridges, flocculation system and replacement of electrical motors

Construction/revamping of flash mixer Construction/revamping of Alum Dosing /Mixing System Construction/revamping of aerator Construction/revamping of Back Wash tank and Back Wash Pumps Revamping of valves Introduction of improved clarification system Replacement of filter media Introduction of improved/updated under drainage system Replacement of Air Blower and provision for stand by, along with necessary

switch gear Introduction of chemical solution tanks Improvement of chlorination system (pre & post) using liquid chlorine Introduction of flow Regulating System of Filter house Electrification under plant premises Electrification of pump house Introduction of Electro magnetic type Flow Meters Modification in the concept of processing according to raw water quality Improvement of intake arrangement Construction of baffle walls Construction of Chlorination System Construction of Laboratory Repair of civil structures

BRIEF REGARDING AWARD ON TECHNOFAB ENGINEERING LIMITED

01 Owner : J&K Economic Reconstruction Agency.

02 Technofab Ref.No. : D:O:3481

03 Scope of Work : Replacement of worn out pumping and electrical

equipments,placement of DG Sets and costruction

clari-floculator-revamping of water treatment plan,

Srinagar.

04 Letter of Award : J&K/US/WS/08/07/NCB/06

Dated: 10.15.2007

05 Contract Value : Rs.174620591.20 (Seventeen Crore Fourty Six Lacs Twenty Thousand Five Hundred Ninety one.)

PLANT OPERATION

2.1 Raw water pumping

2.1.1 GeneralThe Alustang Water Treatment Plant draws raw water from the ------River. The turbidity of the river in the dry season is mostly below 20NTU, with the average value below 10 NTU. The total hardness varies in range from 100 to 400 ppm and sometimes exceeds 500 ppm, which is the maximum desirable range of the WHO. The pH range of the water is generally between 6.5 to 8.5.

2.1.3 Chemical Dosing Point

Chemical Dosing of Alum and is carried out before the water reaches the Clarifies.

A turbidity measurement instrument is installed in the distribution chamber to check water turbidity, with the indicator installed in the chemical building.

2.2 Chemical House

2.2.1 General

Raw water pumped from the Intake works shall be dosed with laboratory- determined quantities of Alum and Lime at the dosing point in the Chemical building.

2.2.2 Alum dosing

ALUM PREPARATION

(a) Clean the Alum mixing tank in readiness for a fresh batch mix (to last for 8 hours).

(b) Prepare Aluminum sulphate flakes (in 50 kg bags) free of impurities.

(c) Fill selected tank ¾ full with water.

(WATER) Motor

SOLUTION PREPARATION TANK

(1) OPERATION

SOLUTION PREPARATION

(a) Start the stirrer in the tank ¾ full with water

(b) While the stirrer is running add required number of bags of alum to the water to prepare a solution to be used for 8hours.Qty of Alum bags will be decided by Lab Technologist on the basis of Raw water quality.

(c) Run the stirrer for a minimum of One – hour before allowing the solution to be transferred to the day storage tank by transfer pumps.

(d) The selected transfer pump (Capacity 0-160LPH) is transferring the solution from mixing tank to constant feed solution tank.

(e) In advance, Alum sol should be prepare for next 8hrs.

DOSING

(a) Open the feed rate valve (Diaphragm valve) –40 NB after the constant feed sol tank after obtaining enough solution head in the day storage tank & in constant feed sol tank.

(b) Regulate the opening of the feed rate valve in order to obtain the optimal dosage required as pre-determined by the test results from the laboratory.

NOTES

CONCENTRATION OF ALUM IN SATURATION

The concentration of ALUM solution prepared in the saturation tank shall be over 10 % (as Al2 (SO4)3 18H2O).

If the solution is prepared at higher concentration, the interval of preparation of the solution can be made longer.

The concentration of Alum can be known by measuring the specific gravity with a hydrometer.

2.3 Clarifiers

2.3.1 GeneralThe Eight clarifiers shall receive raw water at an average loading rate 1.5m/hr.

2.3.2 Quality control

During normal operation of the clarifiers, operator to should carry out the following sampling procedures:

PARAMETER FREQUENCY SAMPLING POINT

pH Twice daily INLET (Influent), OUTLET (Effluent)

Colour Daily INLET (Influent), OUTLET (Effluent)

Suspended solids Twice daily INLET (Influent), OUTLET (Effluent)

2.3.3 Clarifier system operation

Operator shall ensure all eight Clarifier inlet sluice gates from the raw water distribution channel are fully open.

There are ten outlet penstocks feeding the filter inlet channel and are normally in the Fully Open position.

2.3.4 Desludging system operation

There are Twenty-four manually operated gate valves for desludging of clarifiers. There are eight drain valves for completely draining the clarifier.

2.4 Rapid Gravity Sand Filters

2.4.1 Filter control philosophy

At the Kafuae Water Treatment Plant all filter units employ Degremont type siphon controller that allow constant flow regardless of the degree of clogging of the media. This control system allows a turndown of 60: 1 in terms of water level rise from a newly washed media to a fully clogged media bed, i.e. for a head loss of 1.0m the rise in the filter level is only 0.017M.

To achieve this the treated water leaves the filter via a concentric siphon, flowing upwards through the inner tube then downwards between the inner and outlet tubes. This water flow pattern naturally creates a vacuum in the neck of the siphon. In order to control the degree of vacuum the siphon neck is connected to the atmosphere via a needle type valve operated by a float, which is located at water level in the filter. When the filter is clean the tendency is to try to pass as large a flow as possible, thus lowering the water level slightly. As the water level drops the float opens the needle

valve thus allowing air into the vacuum at the siphon neck, reducing the effective siphon cross section. As the filter gradually clogs during the filter cycle, the water level rises and float closes the needle valve proportionally, reducing the air admission and increasing the siphon cross section until the point where a vacuum is reached in the siphon neck.

2.4.2 Filter process description

There are 10 Filters each of 50 square meters floor area. The depth of sand layer is 1000 mm of multi-media. The Filters are designed for a filtration rate of approximately 5m/hr.

Each Rehabilitated Filter has One inlet sluice gate Valve –400 mm x 400 mm, one partialisation box, one filter outlet valve butterfly type –250 NB, one backwash water butterfly valve-300 NB, one air valve –150 NB, syphon in the filter pipe gallery and one drain sluice gate valve -300 x 300 mm in the Filter Pipe gallery at near Pump House.

2.4.3 Operational procedures

2.4.3.1 Filtration

Listed below are recommended operation procedures that should be carried out for normal and effective operation of the filters at Kafuae water treatment plant. Also shown are the levels of personnel required to carry out the operation work.

The water enters into the filter through the Inlet sluice valve and exit through the outlet butterfly valve to the siphon chamber then through the treated water channel into clear water tanks.

Normal operation (10 filters in operation).

Operator to carry out the following tasks:

(i) At regular intervals inspect all the filters in operation; checking if they have an even distribution of water. Filtration rate can be checked by Head loss Gauges.

(ii) If Head loss gauge is showing 2-3m head. It means, filter require backwashing.

(iii) In case of Head loss gauge is not working, apply following procedure

(iv) If the filtration is low, select and determine the number of filters to close off until you achieve an even distribution of water in the remaining filters.

(v) If the water level rises above the weir on the wash out channel, this is an indication that there is loss of water head through the filter due to dirty sand.

Backwashing will be carried out every eight hours or when sufficient head loss is recorded indicating the filter sand is dirty. Backwashing the filter media will recover normal function of the filter.

2.4.3.2 BACKWASHING

(a) Before back washing the filter, The Senior Operator should carry out the following:

(i) Check the water level in the backwash tank (Clear Water Tank) by checking the indication on the remote water level indicator.

(ii) Before starting the backwash operation close the filter outlet valve, open backwash water valve and discharge valve of backwash pumps

(B) Operator should carry out the following tasks in the given order:

(i) Lowering the water level in filter. (ii) Air Scour for approx 3 to 5 minutes(iii) Air / water scour for approximately 5 minutes(iv) Backwash with water only for approximately 10 minutes or

unless clear water can be seen.

LOWERING THE WATER LEVEL

Before washing, lower the water level in the filter to get better efficiency of

air/water scouring. Confirm the filter Clack valve is closed and filter outlet valve is open. After lowering the water level, close the filtered water outlet valve

WASHOUT WEIR

WASTEWATERCHANEL S A N D

Figure 2. INDICATING OPTIMAL WATER LEVEL BEFORE STARTING AIR/WATER SCOURING

AIR SCOURING PROCEDURE

Open the scour air inlet valve. On the Control Panel, select the selector switch for Duty Blower Open the discharge valve of Duty Blower Operate the Start Push button of the Duty Blower Observe the even distribution of air over the filter Stop duty Blower by operating stop push button after 3 to 5 minutes.

AIR/WATER SCOURING PROCEDURE

Carry out the following steps to achieve effective air/water scouring:

Close filter outlet valve Open wash water inlet valve Start the Duty Air Blower and the Backwash pump. After 3 to 5 minutes Blower and Backwash Pumps will Switched off

manually

BACKWASHING WITH WATER ONLY

After air/water scouring, flush the detached turbid material out of the filter basin by the backwash pumps.

After 3 to 5 minutes of air / water scouring close air scour valve. Start the Backwash Pump for backwashing operation. Backwash Pump will be switched off manually after 10 minutes

RESTORATION OF FILTER TO NORMAL OPERATION Close the Wash water inlet valve. Open Filter inlet Sluice valve.

Check the other filters to see if the optimal water level / head is evenly distributed in all the filters and determine those that need backwashing.

After the backwash procedure is over, if it is observed that the sand is very dirty, then backwash the filter more frequently.

NOTES

The Kafuae WTP has been rehabilitated to facilitate a design flow of 56,000 m³/d, corresponding to a filter velocity of 5m/h.

SPECIFICATIONS

(1) The filters have been designed for the following flows:

Hydraulic load in filtration 5 m/h Air/water scouring 28 m/h Water 8 m/h Water rinsing (bed expansion) 20 m/h

(2) Specification for filter sand in rapid sand filters

Diameter of the filter sand 0.8 – 1.2mm

Uniformity Coefficient no more than 1.5

(3) Type of Nozzle

Nozzle - N2 Shaft - Black Shaft P/P

(4) Air blowers

Quantity: 1 Air velocity, capacity: 25 Cu.M/h.

(5) Backwash pumps

Quantity: 2 sets (1 main + 1stand by)

Two pump of 37Cu.M/hr at 17m head and 90 kW operated together with the air blower.

Drawings of Pump curves and detailed sections of filter arrangement see Manufacturers manuals and plant drawings.

Do not put excessive force to the wheel handle to avoid damaging the valve and shaft.

OPERATION OF BACKWASH PUMPS AND BLOWERS (Manual operation)

The backwash pumps and blower will be operated from Filter control stations, which are located in the filter gallery.

ADJUSTMENT OF FLOW RATE OF BACKWASH PUMP (Manual operation)

The outlet valves of Backwash pumps are preset. When backwash pumps are running, it is not necessary to adjust the backwash flow rate.

The pre setting of out let valve is done on the basis of required flow rate for Backwashing.

FREQUENCY OF BACKWASHING

The quality of filtrate collected and the head loss recorded shall govern the washing interval of the filter.

To prevent neglect of washing, it is recommended to continuously carry out inspection and monitoring of all the ten filters

QUALITY CONTROL

During normal operation of the Plant, operator to should carry out the following sampling procedures:

PARAMETER FREQUENCY SAMPLING POINT

pHEvery 2 Hours Raw Water.

Clarifier.Filter.Final Treated.

Conductivity Every 2 Hours Raw Water.Clarifier.Filter.Final Treated.

Turbidity Every 2 Hours Raw Water.Clarifier.Filter.Final Treated.

Colour Twice Daily INLET (Influent), OUTLET (Effluent)

Suspended solids Twice daily INLET (Influent), OUTLET (Effluent)

3.2 PUMPS

The Alusteng Water Treatment Plant is equipped with Flowmore pumps in the Pump Station. We shall therefore refer to their joint maintenance requirements in this section.

A pump house should be a clean and dry place. Daily maintenance should aim at keeping the room, motors, pumps, valves and pipes clean and dry. Even the smallest leak should be repaired immediately to maintain a proper working environment for both equipment and personnel.

Comprehensive Manufacturers' data sheets and operating and maintenance manuals for the pumps and motors are included in Section 5 of this O&M Manual. Please make comprehensive reference to them and familiarise yourself with the specific maintance requirements and procedures.

It is important to keep the pumps in good working order because a pump that lets you down when you need it most causes obvious losses of time and money. Not so obvious, but every bi t as costly, are losses you can incur with pumps that operate at less-than-peak efficiency.

A pump labouring under the handicap of a suction line air leak, a corroded discharge line or a clogged impeller gulps excessive amounts

of energy, takes longer than necessary to do the job, and subjects parts to undue stress, causing premature wear-out

The Operators and Maintenance Personnel should always look for these signs of inefficiency. Indications that a pump is costing more to operate than it should may not be dramatic but they're easily recognized. In addition to those tabulated in the Manufacturer's operation and maintenance manual, the following are some of the most common and obvious

> There is a noticeable difference in pump flow

Has the discharge flow visibly decreased? Is it taking your pump longer than it used to do the same job? The slow-up might be caused by a collapsed suction hose lining, a leaking gasket, plugged suction line, a damaged or worn impeller or wear plate.

> The pump is making excessive noise

Does it sound like a bunch of marbles rattling in a can? This may be cavitation and could be caused by too high of a suction lift, too long a suction hose, a clogged strainer or collapsed--suction hose lining, plugged suction line or combination of all these. Maybe the bearings are going out.

> The pump is clogging frequently

The suction valve may be clogged, the suction strainer, if installed, may be too large or small, or the strainer may be in mud plugging the suction side.

> The pump is overheating

Very li kely the flow of liquid into or out of the pump is being restricted. Improper impeller clearance could be slowing reprinting or the suction strainer may be clogged.

The following is guide to pump inspection and service, although it is not complete it does cover the more common conditions that can impair pump efficiency.

• Check impeller vanes, wear plate or wear rings. The removable cover plate on many pumps permits quick, easy inspection of the impeller and wear plate. These components should be inspected every six months or sooner, depending on pump application. They're subject to faster wear when pumping abrasive liquids and slurries. Wear plates and wear rings can be replaced without replacing expensive castings.

• Check impeller clearance. If the clearance between impeller and wear plate or wear rings is beyond recommended limits, pumping efficiency will be reduced. If the clearance is less than that recommended, components will wear excessively. If tolerances are too close, rubbing could cause an overload on the engine or motor. Check the impeller clearance against pump manual specifications and adjust if necessary.

• Check the seal. Most pumps are equipped with a double seal lubricated under pressure - with a spring-loaded grease cup or an oil lubricated tungsten titanium carbide seal for long, trouble-free service. If your pump has a single seal and it is lubricated with the water being pumped, sand and other solids can cause rapid wear. Check and replace the seal if worn. Replace seal liner or shaft sleeve if it has scratches.

• Check bearings. Worn bearings can cause the shaft to wobble. Eventually the pump will overheat and sooner or later it win freeze up and stop. Replace bearings at the first sign of wear.

• Check the engine or motor. The pump may not be getting the power it needs to operate efficiently. The engine may need a tune-up or the motor may need service