TRAINING ON FILTRATION

FOR

DARSAYT STP OPERATORS

PREPARED BY:

DAUD DOMINADOR VELASCO

INSTRUMENT SUPERVISOR
OWSC

AUGUST 2008

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 CONTENT

Filtration… … … … … … … … … … … … … … … … … … … . 1

Fitration Diagram… … … … … … … … … … … … … … … … .1

Methods… … … … … … … … … … … … … … … … … … … … 2

Flowing… … … … … … … … … … … … … … … … … … … … .2

Gravity Filtration… … … … … … … … … … … … … … … … ..2

Procedure for Gravity Filtration… … … … … … … … … … ...3

Filter Media… … … … … … … … … … … … … … … … … … ..4

Backwashing… … … … … … … … … … … … … … … … … … 4

Gravity Filter… … … … … … … … … … … … … … … … … … 5

Darsayt Filtration system… … … … … … … … … … … … … .6

Darsayt Filter Backwashing Procedures… … … … … … … ..7-11

Darsayt TE system P&ID… … … … … … … … … … … … … .12

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 PREFACE

This training document is written to establish operation training module to be use from time to
time it is needed. In 2007, after rehabilitation of the filter, training was conducted for several times
and it was successfully satisfied the operation specifically filtration. More than one year the system
operated at the highest reliability and availability.

Other reason why this training needs was establish is to prevent failure of operation which was
happened in 2006, Darsayt filter was blown and severe damage occur resulting to costly
rehabilitation and cost more than 200,000.000 OR.

This module begins by defining filtration, methods, procedures including the start up procedure.

My sincere hope is that this document will not only stimulate interest in the field of operation but
will also help technician with respect to troubleshooting.

My special thanks go to Mr. Faiz Al Maskiry, Mr. James Hestad and Mr. Salem Al Hajery for
supporting me to materialize this training requirements.

Daud Velasco

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FILTRATION

Filtration is a mechanical or physical operation which is used for the separation of solids from
fluids (liquids or gases) by interposing a medium to fluid flow through which the fluid can pass,
but the solids (or at least part of the solids) in the fluid are retained. It has to be emphasized that
the separation is NOT complete, and it will depend on the pore size and the thickness of the
medium as well as the mechanisms that occur during filtration.

• Filtration is used for the purification of fluids: for instance separating dust from the
atmosphere to clean ambient air.

• Filtration, as a physical operation is very important in chemistry for the separation of

materials of different chemical composition in solution (or solids which can be dissolved)
by first using a reagent to precipitate one of the materials and then use a filter to separate
the solid from the other material(s).

Filtration diagram

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Methods

There are many different methods of filtration; all aim to attain the separation of substances. This
is achieved by some form of interaction between the substance or objects to be removed and the
filter. In addition the substance that is to pass through the filter must be a fluid, i.e. a liquid or gas.

The simplest method of filtration is to pass a solution of a solid and fluid through a porous
interface so that the solid is trapped, while the fluid passes through. This principle relies upon the
size difference between the particles making up the fluid, and the particles making up the solid.

Flowing

Liquids usually flow through the filter by gravity. This is the simplest method, and can be seen in
Darsayt Filtration system, this is usually the most economical method.

Gravity Filtration

Gravity filtration is the method of choice to remove solid impurities from an organic liquid. The
"impurity" can be a drying agent or an undesired side product or leftover reactant. Gravity
filtration can be used to collect solid product, although generally vacuum filtration is used for this
purpose because it is faster.

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Procedure for standard gravity filtration
1) Select and fold the filter paper

Select the size of filter paper that, when folded, will be a few millimeters below the rim of your
glass funnel. Fold the paper into a cone by first folding it in half, and then in half again, as shown.

2) Filter the solution

Support the glass funnel in a ring or place it in the neck of an Erlenmeyer flask. Wet the filter
paper with a few milliliters of the solvent to be used in the following procedure. Wetting the paper
holds it in place against the glass funnel. Pour the mixture to be filtered through the funnel, in
portions if necessary.

Note: fluted filter paper is often better for gravity filtration with organic solvents

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Filter media

The type of filter media is a bed of granular material which retains the solid particles as it passes.
This type allows the solid particles, i.e. the residue, to be collected intact, this is less prone to
clogging due to the greater surface area where the particles can be trapped. Also, when the solid
particles are very fine, it is often cheaper and easier to discard the contaminated granules.

Filter media can be cleaned by backwashing.

Backwash is the backwards flow of air or water..

In water treatment (backwashing)

In terms of water treatment, backwash refers to the reversal pumping of water, and sometimes
intermittent with compressed air, through the process. Filters get dirty and must be maintained.
Filters can be rapid sand filters, pressure filters, granulated activated carbon (GAC) filters (Brita is
GAC), combination of gravel, sand & anthracite, etc. To keep them functional, they have to be
washed periodically.

The process, called "backwashing," involves several steps. First, the filter is taken off line and the
water is drained down to the filter bed. Then, the air wash cycle is started which pushes air up
through the filter material causing the filter bed to appear to boil. This breaks up the compacted
filter bed and forces the accumulated particles into suspension. After the air wash cycle stops, the
backwash cycle starts with water flowing up through the filter bed. Clean water is passed through
the filter bed in order to wash the material and remove most of the accumulated particles. This
cycle continues a fixed time or until the turbidity of backwash water is below a set value. In some
cases, the additional step of air/water wash (simultaneously) is done after air wash cycle and
followed by rinse water wash. These use less water compare to traditional step and have higher
removal efficiency which result the cleaner filter.

Backwashing is a form of preventive maintenance to prevent further clogging of the filter medium.
Backwashing in water treatment plants is an automated process, usually run by programmable
logic controllers (PLCs). The backwash cycle is usually triggered when the differential pressure
over the filter exceeds a set value.

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GRAVITY FILTER

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DARSAYT FILTER BACKWASH PROCEDURES-OWSC

Manual Operation
1. The backwash sequence can be operated entirely on ‘MANUAL’operation when the
switch for respective filter in ‘Manual’
2. All the valves are provided with OPEN and CLOSE Push Buttons on front of CP91. The
respective valve can be opened and closed with this.
3. The limit switches for each valve are wired to CP91. Hence the status of valve position i.e.
OPEN or CLOSE is indicated by lamps on front of CP91
4. The following can be operated in MANUAL Mode from CP91
A) Inlet penstock valve
B) Filter Inlet Slide Gate Valve
C) Filter outlet Butterfly Valve
D) Air Inlet Saunders Valve
E) Air Vent Valve
5. The following can be operated in MANUAL mode from Respective Electrical control Panel
A) Backwash Pump
B) Air Blower

Auto Operation
A) When the AUTO-MANUAL Switch for respective filters is in ‘AUTO’the respective filter
the following conditions will apply.
In AUTO position of selector switch, PLC will select the Filter backwashing in either 2
conditions
- If contact from Differential Pressure Transmitter is closed on High Differential Pressure
- If the filter has not been backwashed with in pre-programmed time. This time is User
Settable.
a) When differential pressure across any bed goes Higher than set point, that filter will
commence backwash. (HIGH DP condition)
b) The backwash is on PRIORITY START i. e. the first bed on HIGH differential will
commence first.
c) After the backwash, that filter will resume AUTO operation, if differential pressure is
normal.
D) If filter ‘A’is already is already backwash and another filter say ‘B’goes on HIGH
DIFFERENTIAL, Then ‘B’will commence backwash only after ‘A’backwashed is
completed, provided HIGH DP is still ON for ‘B’

One OVERRIDE pushbutton is provided for each filter. On pressing this button, that filter will go
to backwash irrespective of position of Auto-Manual switch.
(If no other filter is in Backwash)

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B) In case of normal differential pressure across any filter bed, the following will be the status;
a) Inlet penstock valve ; OPEN
b) Filter Inlet Slide Gate Valve ; CLOSE
c) Filter Outlet Butterfly valve ; On Level Control
(Level 0 to 100%, Valve opening from 0 to 100%)
d) Air inlet Saunders valve ; CLOSE
e) Air Vent valve ; OPEN

All limit switches are directly wired to relays on 24vdc circuit.

All the Solenoid is 230VAC circuit

NOTE:
In case of Air pressure failure, The PLC will stop backwash after preset time. On
restoration of Air pressure back to normal, the sequence will back to normal, the sequence
will commence from the beginning.
In case of power failure, the PLC will stop.
On restoration of power, PLC will perform logic based on its program and conditions at
that time.

BACKWASH SYSTEM AUTO OPERATION

Backwash set point table;

Filter bed # Set point
Filter bed 1 0.5
Filter bed 2 0.5
Filter bed 3 0.8
Filter bed 4 0.9
Filter bed 5 1.0

Closed inlet penstock valve

After 30 seconds = closed outlet valve, then Air release valve will close
After 10 seconds = open backwash air inlet valve
After 30 seconds = start air blower
After 180 seconds = stop air blower
After 10 seconds = close air inlet valve, then Air release valve will open
After 30seconds = open backwash inlet valve
After 10 seconds = start backwash pump
After 180 seconds = stop backwash pump
After 10 seconds = close backwash inlet valve
After 30 seconds = open filter outlet valve
After 100 seconds = open inlet penstock valve (on set point level control)
BACWASH FINISH
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FILTER BED TIMER SETTINGS-DARSAYT-OWSC

CLOSE FEEDBACK TIME FOR FIP 20 seconds (T1)

OPEN FEEDBACK TIME FOR FOV 30 seconds (T2)
CLOSE FOV AFTER 5 seconds (T3)
CLOSE FEEDBACK TIME FOR FOV 30 seconds (T4)
START AIR BLOWER AFTER 30 seconds (T5)
STOP AIR BLOWER AFTER 180 seconds (T6)
START BACKWASH PUMP AFTER 30 seconds (T7)
STOP BACKWASH PUMP AFTER 180 seconds (T8)
OPEN FILTER OUTLET VALVE 10 seconds (T10)
OPEN FIP AFTER 100 seconds (T11)
REPEAT BACKWASH AFTER 480 seconds (T12)

Prepared by ; D. S. VELASCO

Instrument Supervisor

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Darsayt Filter Checklist/SOP
1. TE tank normal level
2. Balancing Tank Level not high level
3. Backwash pump –Open path position
(Discharge and suction valves open). Common discharge valve limited to 40 to 50%
opening to reduce excessive flow of backwash pump.
4. Air Blower outlet valve –open
5. Instrument(compressor) air Supply –not less than 5bar
6. All Pneumatic valves/actuator individual instrument air supply isolating valves –Open
7. Air Blowers Circuit breaker (Power Supply) –ON
8. Backwash pumps Circuit breaker(power supply) –ON
9. Power Supply for PLC –ON
10. Before Performing backwashing, Valves are in normal position
Penstock valve –open
Outlet valve –Open
Air Release valve –Open
Air Blower valve –Close
Backwash valve –Close
11. Perform backwashing (Manual/Forced Auto/Auto)
In Manual;
Air Blower control selector –Manual
Backwash Pump control selector –Manual
Filter # 1,2,3,4,&5 control selector –Manual
(Perform backwashing base on manual procedures)
In Forced Auto Backwash;
Air Blower control selector –Auto
Backwash Pump control selector –Auto
Filter # 1,2,3,4,&5 Control selector –Manual
(Push Forced Auto Backwashing Button of any filter you want to backwash)
In Auto Backwashing;
Air Blower control selector –Auto
Backwash Pump control Selector –Auto
Filter # 1,2,3,4&5 control selector –Auto (it’s an option to select what filter
You want to put in auto mode)
12. After backwashing, Valves are in normal position
Penstock valve –Open
Outlet Valve –Open
Air release valve –Open
Air Blower –Close
Backwash valve –Close
(Make Sure valves are in normal position before leaving the area)
BY: Daud

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Darsayt Filter Backwash Procedures; Manual Mode

1. Close inlet penstock valve.

2. Close the Filter outlet valve. Confirm if it is closed, then
3. Close Air release valve
4. Open Air Blower valve (Air inlet valve), then
5. Start Air Blower. After 3 minutes
6. Stop Air Blower, then
7. Close Air Blower valve(Air inlet valve), then
8. Open Air release valve
9. Open Backwash inlet valve, then
10. Start Backwash pump(one pump only). Water level rising until it reached overflow, it means
backwashing confirmed. After 3 minutes
11. Stop backwash pump
12. Close Backwash inlet valve. Confirmed if backwash inlet valve closed, then
13. Open Filter Outlet valve. Confirm if really open, Water level falling down. After 100seconds
14. Open inlet Penstock valve.
Backwash finished..

Prepared by;
Mr. D. S. Velasco
Instrument Supervisor

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