DAYLIFF WG Water Treatment Plant Instruction Manual

DAYLIFF WG Water Treatment Plant

Congratulations on selecting a Dayliff WG Water Treatment Plant. They are manufactured to the highest standards and if installed and operated correctly will give many years of efficient and trouble-free service. Careful reading of this Installation Manual is therefore important, though should there be any queries they should be referred to the equipment supplier.

SPECIFICATIONS

The DAYLIFF ‘WG’ Water Purifier is an integrated water treatment plant specifically designed to treat the majority of surface waters including the removal of silt, suspended solids and bacteria in small-scale domestic, institutional and commercial applications. The units are simple to operate, low cost and easy to maintain and can provide consistent water quality to WHO standards. Features include:-

• Four-stage treatment process including flocculation, settlement, filtration and chlorination providing treated water to the highest standards.
• GRP (fiberglass)construction for strength, low maintenance, and indefinite life.
• High-efficiency vertical flow type settlement basin incorporating sludge bleed.
• The alternative of a large-capacity gravity sand filter for gravity applications or a Dayliff DX sand filter for pumped applications provides efficient filtration and simple operation.
• Automatic SEKO or proportional feed chemical dosage using ‘Dosatron’ chemical feeders. These unique dosers use energy in the water flow as their power source providing accurate and consistent dosage regulated by plant output.
• In-line flow meter to adjust and monitor plant output.
• Simple in-line installation with three adjustable legs to assist leveling.
• Fully automatic control – the plant matches output to site demand.

With an output of up to 12,000 liters a day of averagely contaminated raw water and more for lightly polluted waters, the DAYLIFF ‘WG’ Purifier is suitable for settlements of up to 100 people. Using only basic water treatment chemicals (Floculant and Chlorine), high-quality treated water is available. This high level of performance combined with long life GRP construction, simple maintenance and easy installation make DAYLIFF ‘WG’ Purifiers the ideal solution for all small-scale water treatment requirements.

OPERATING CONDITIONS

• Capacity: 500 l/hr or approx 12,000 liters per day at maximum output.
• Raw Water Quality: Surface water containing suspended particles, silt, and bacteria. The plant is not suitable for the treatment of any dissolved solids, hardness or salinity.
• 0 Maximum Water Temperature: +30 C.
• Inlet Pressure: Minimum 0.5Bar, Maximum 3Bar

SPECIFICATIONS

• Sedimentation Basin: 1200 liters upward flow basin with a conical base and sludge bleed.
• Retention time is 2.4 hours at the rated flow.
• 2 Filter: Gravity sand filter of 0.75m area containing approximately 0.25m3 filtering media for gravity installations or Dayliff DX300 deep bed GRP pressure sand filter with simple to use multiport valve for pumped installations.
• Chemical Dosage: Dayliff SEKO pump or Dosatron D25 automatic proportional feeders with a set 2% dosage rate drawing from 100l concentrate tanks. Endurance at maximum rated flow and standard concentrations is 8hrs.
• Balance Tank: Capacity 150 liters (when fitted)

Transfer Pump
AC Mains Power Supply: Pedrollo Pkm60 0.37kW 240AC peripheral pump with a maximum delivery pressure of 3Bar.
Weight: 105kgs (empty), 1800kgs (full).

INSTALLATION

Transport
The DAYLIFF WG plant is supplied as a complete unit with only the chemical containers and filter media lose. The equipment should be protected from impacts on its sides during transport.

Siting
Siting of the plant is critical to the efficient operation of the water system in which it is installed. Principal features of note are as follows:-

• The physical location should preferably be as close as possible to either the clean or raw water source, whichever is preferable. A major aspect of the siting is a suitable place for monitoring output and performing routine maintenance operations. Also of importance is whether raw water input will be by gravity.
• Raw water input preferably be by gravity or as a spur off a main supply pipe.
• Direct pumping to the raw water inlet will lead to control problems. If the water source requires pumping from the source, then a break tank should be installed between the source and the WG plant.
• Clean water delivery can either be by gravity to a tank or consumption point (the siting must be higher than the outlet point) or via a transfer pump to an outlet higher than that of the plant. This latter arrangement requires a balance tank to facilitate control.
• Preferably the plant should be mounted on a concrete slab. An overhead cover would be recommended to protect the pumps from direct rain.

Erection and Assembly

• On commencing installation proceed as follows:-
• Loosely screw the three legs onto the leg spigots and place the purifier on its base plinth ensuring it is level.
• Using a spirit level and bar adjust by screwing the legs to ensure absolute levelness. If a spirit level is unavailable fill the plant with water to the line of the conical base and adjust accordingly.

Levelness is essential during installation or the plant will not work at full efficiency.

• Fill the basin with water to just below the output holes to provide stability.
• Fill the sand filter with the sand or glass media provided, according to the instruction manual attached.
• Connect up the inlet and outlet pipes as necessary, according to the installation drawing attached. For best results, 1″ inlet and outlet piping should be used.
• Complete filling the raw water and commission by filling the chemical dosage tanks and running treated water to waste for 24hrs.
• When the plant is fully installed, the correct flow direction should be as follows:
• Raw water flows into the plant first through an optional Doser pump for pH correction then flows through a second doser pump for flocculant dosage.
• The flocculant water is directed into the sedimentation basin and released around the bottom of the sedimentation tank.
• Flocculation occurs as clear water rises to the top of the sedimentation tank and flows through exit points on its side, into the balance tank.
• A booster pump installed below the balance tank pumps water from the balance tank through to the sand filter.
• The water from the sand filter flows through the chlorine doser and out to supply.

OPERATION

Sedimentation Basin
There are no mechanical components in the settlement process and due to the nature of its design, the basin’s input and output will always be equal. It is important, however, to check that all inlet and outlet valves are fully open. The basin is conical in section in order that the sediment may collect at its apex. The sediment will build up over time and periodically (recommended daily) the scour valve should be opened and the sediment drained to waste. The scour valve should be open for as long as the wastewater is observed as excessively discolored.

Chemical Dosage Principle of Operation
Provided with the unit are 2No chemical Chambers with a dosing pump mounted on top, one for Alum and the other for chlorine. The operating sequence is as follows:-

• A chemical solution is stored in each of the chambers.
• Whenever there is treated water flowing into the sedimentation tank, and from the balance tank to the high-level storage tank, the chemical dosage pumps inject a metered amount of chemicals (Alum and Chlorine) into the flow of water passing through the system. The pumps provide a constant feed rate with the dosage rate being varied by the concentration of the chemical.
• Alum is dosed into the raw water inlet pipe and chlorine into the discharge pipe thus ensuring good mixing.
• When the flow of water stops, either because the balance tank is full, or because the clean water storage tank is full, the chemical dosage pumps will also stop.
• The system is fully automatic and no adjustment is provided other than to the solution tank concentration.

Alum
Aluminium Sulphate Al (SO ) (Alum) is a flocculant that assists effective 2 4 3 sedimentations by combining the dirt particles in suspension to form larger and thus heavier particles that are more easily settled and filtered. Dosage rates are between 30 – 60 mg/l depending upon the raw water properties. Generally, a rate of 50 mg/l is satisfactory though as the raw water quality will vary throughout the year this concentration may need to be varied. The amount of Alum required is a complex matter depending principally upon the amount of suspended solids in the raw water and its pH, and though dosage guidelines are given it is up to the operator to determine by experiment the optimal dosage rate to give maximum settlement.

Chlorination
Chlorination is necessary to sanitize the raw water and ensure that any bacteria present are removed prior to use. The recommended chemical to be used is Dayliff Chlorine 65%, which has a chlorine concentration of approximately 65%. Dosage is done using klorman tablet dispenser or AML dosing pump or a Dosatron which is a simple in-line disinfection system that utilizes a compacted calcium hypochlorite chlorine cartridge that releases active chlorine into the water flow. A simple adjustment is provided by varying the projection of the cartridge into the water stream to accommodate different flow rates as well as adjustment of water flow and pressure through the unit. Dosage rates of chlorine varys between 4 – 7mg/l, a common average being 5 mg/l, though the operator must ensure that there is adequate chlorine dosage by testing for chlorine residual at the filter outlet. This can be done using a Chlorine Test Kit.

Amount of chemicals required to refill each solution tank
The chemical solution flow rate must be determined on site by measuring the rate of dosage with the injector valve inserted, and with the filter pump working. Insert the value obtained in the first row of the calculation table below. Evaluation of this row will yield the length of time the chemical solution tank will take to empty if the pump runs continuously (Tank Endurance).

• The operator might need to vary these amounts of alum and chlorine obtained from the calculation, in order to achieve the optimal value for maximum settlement of suspended solids and the required residual of 1ppm of chlorine at the clean water storage tank.
• Next insert the dosage rate for the particular chemical compound being used (30 ppm for flocculants and 5 ppm for chlorine 65) and the value of the water flow rate from the filter pump as measured under site conditions in the second row of the calculation. Evaluation of this yields the weight of dry chemical required per hour.
• Finally, the product of the Tank Endurance and chemical required per hour will give the amount of chemical (in grams) required each time the solution tank is refilled.

Chemical Solution Preparation

Alum is generally supplied in powder form and readily dissolves on mixing with water. The alum solution should be mixed in a separate container then decanted into the alum solution tank, to avoid the build-up of un-dissolved sediment in the tank.

Chlorine
Dayliff Chlorine 65% is supplied in powder form and dissolves on stirring. However, the lime part of the compound is insoluble and the solution should be prepared in a separate container (preferably a plastic bucket) and allowed to settle after thorough stirring. The dissolved portion should then be decanted into the chlorine solution tank leaving the lime residue in the bucket. This exercise will minimize the likelihood of clogging the pump and solution-feed equipment.

Filter Pump
The pump operation is automated. Low-level control is achieved by means of a float switch mounted on the balance tank, to prevent dry-running. High-level control is to be achieved by means of a float switch fitted on the high-level tank. The pump will work whenever there is site demand.

Filters
The DAYLIFF WG range of treatment plants is fitted with a DAYLIFF DXD filter which is charged with inert silica sand or glass media. The DAYLIFF filter is fitted with a Multi- Port Valve to control filter operation. There are six positions on the valve and various operations possible. The most common position to be used with the WG are described below:-

Backwash
BACKWASH position is used to clean the filter by reversing flow through the media and flushing to waste. This operation normally takes two to three minutes and should be continued until the water in the sight glass on the side of the MPV is observed as clear.

Rinse
After backwashing the filter media needs to be rinsed to flush retained debris and avoid it being pumped to a clean water tank. Water is pumped into the top and out of the bottom of the filter as for normal filtering but the water is then discharged to waste. Rinsing should not take more than one minute and again the sight glass on the side of the valve can be used to see when the water is clear.

Dosage Rates

the operator might need to vary the weight of chlorine added in order to achieve the required residual chlorine of about 1ppm at the plant outlet. The residual chlorine level must always be checked, using a chlorine test kit provided.

Water Quality
The equipment installed is purposely designed to provide a consistent quality of potable water by the removal of suspended solids and sterilization. This will not affect the chemical balance of the raw water nor will it affect hardness. Actual water quality, however, is totally dependent upon plant operation, especially with respect to chemical dosage and the plant operator must use discretion to establish appropriate dosage rates depending upon raw water quality. Daily testing of the following forms part of plant operation: –
Clarity – Water is visually clear with no suspended solids or color apparent. pH – Between 7 and 7.6. If pH is too low reduce Alum dosage level. (WHO pH levels for drinking water is between 6.5 and 8.5) Chlorine Concentration – Residual amount of 1ppm apparent at clean water storage tank. In addition, periodic routine sampling and monthly laboratory testing is recommended. If the plant is not operated correctly water quality will deteriorate to dangerous levels. It is therefore vital that competent and reliable operators are employed and that these instructions are implemented completely.

MAINTENANCE

Routine maintenance should be carried out as follows:-
Daily

• Scour the sedimentation basin by opening the drain or scour valve.
• Check the clarity of treated water.
• Test chlorine level.
• Test the pH of treated water.
• Check booster pump flow rate (To be not more than 8 lit/min).
• Backwash sand filter.

Weekly

• Sluice out all chemical solution tanks whenever re-filling.
• Check the operation of the Dosatron doser or Seko pump, and clean the suction tube as necessary.
• Hand-rake filter sand bed.

TROUBLESHOOTING

TERMS OF WARRANTY

General Liability

• In lieu of any warranty, condition or liability implied by law, the liability of Davis & Shirtliff (hereafter called the Company) in respect of any defect or failure of equipment supplied is limited to making good by replacement or repair (at the Company’s discretion) defects which under proper use appear therein and arise solely from faulty design, materials or workmanship within a specified period. This period commences immediately after the equipment has been delivered to the customer and at its termination all liability ceases. Also the warranty period will be assessed on the basis of the date that the Company is informed of the failure.
• This warranty applies solely to equipment supplied and no claim for consequential damages, however arising, will be entertained. Also the warranty specifically excludes defects caused by fair wear and tear, the effects of careless handling, lack of maintenance, faulty installation, incompetence on the part of the equipment user, Acts of God or any other cause beyond the Company’s reasonable control. Also, any repair or attempt at repair carried out by any other party invalidates all warranties.

Standard Warranty

General Terms
If equipment failure occurs in the normal course of service having been competently installed and when operating within its specified duty limits warranty will be provided as follows:-

• Components making up the plant or system are covered individually under the specific item’s warranty terms.
• Consumable e.g. cartridges are not covered by warranty.

The warranty on equipment supplied or installed by others is conditional upon the defective unit being promptly returned free to a Dayliff retailer office and collected thereafter when repaired. No element of site repair is included in the warranty and any site attendance costs will be payable in full at standard chargeout rates. Also, proof of purchase including the purchase invoice must be provided for the warranty claim to be considered.

DAYLIFF is a brand of Davis & Shirtliff for inquiries contact Davis & Shirtliff, Ltd. P.O. Box 41762 – 00100, Nairobi, Kenya Tel: 6968000/ 0711 079 000 or visit www.davisandshirtliff.com for details of the nearest branch or stockist.

References

• Davis & Shirtliff | The Leader in Water & Energy Solutions in Kenya, Uganda, Tanzania, Zambia, Rwanda, Ghana, Zimbabwe, South Sudan, Ethiopia, Burundi - Davis & Shirtliff Group

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