Crown Beverages SOP for Water Treatment

CROWN BEVERAGES LIMITED
CLEAN & HYGIENIC CONDITIONS Page 1 of 8

Effective date:
Document no: SOP: 01/09/07
SOP 2.2.6 Cleaning & Sanitation
Revision No: 01
PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION
1.0 Bore hole

The bore hall is the source of Natural water located twenty meters from the Administrative
Block.
Occasionally sanitization is done on the well to reduce the level of microbiological
contamination before the water is pumped into the Bore hall raw water reservoir tank.
1.1 Sanitation of Bore hole

1.1.1 Purpose
To sanitize the bore hall to reduce bacteriological load especially whenever the
presence of Coliform is detected before water from the bore hall can be used for
packaging.
1.1.2 Scope
The procedure includes preparation of chlorine solution to be added to the bore
hole and its delivery to the well.
1.1.3 Responsibility
The Water Technicians are responsible for routine sanitation of the borehole
whenever need arises after microbiology tests.
The Quality Assurance Manager/Designated alternative is administratively
responsible in ensuring that the procedures of sanitizing the bore hole are
followed to achieve the desired level of sanitation.
1.1.4 Procedure
Switch of the pump for the borehole
Prepare 3% chlorine solution by dissolving four (4kg) of calcium hypochlorite in
one hundred liters of water.
By use of quarter inch small hose pipe, raise the chlorine solution in the container
above the bore hall pipes and siphon down the chlorine solution from the
container down to the borehole using the small hose pipe.
Empty all the one hundred liters of solution in to the Borehole
Collect twenty liters of clean tap water and drain down as above to rinse any
traces of chlorine in the pipes.
Do not run the pump for the next two hours.
Sanitation of the borehole is complete
Do microbiology after seventy two (72) hours
2.0 Borehole Raw Water Reservoir Tank Filling

The raw water tank contains high water level controls that automatically stop the Borehole
pump from pumping when it is full.
The tank has also the low water level control that has two functions:
To stop water draw out from the tank by the Sand bed pump (prevents the sand bed pump
from running dry) and start up the borehole water pump so as to maintain the water level in
the raw water reservoir tank.
2.1 Purpose
The purpose is to have water in the Raw Water tank that is readily available for
production of Mineral water.
Compiled by Process Plant Manager Revision

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Approved by: Quality Assurance Manager Controlled by: Process Improvement Coordinator
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Effective date:
Revision No: 01

2.2 Responsibility
The Water Treatment Technician is responsible in ensuring that the borehole pump is
switched on in time and that there is always water in Borehole raw water Reservoir
tank.
The Process Plant Manager or any designated alternative is administratively
responsible in ensuring that procedures are followed and that there is always enough
water in the raw water tank for production.
2.3 Procedure
Switch on the borehole water pump to auto.
Check on whether the indicator lamp is on.
2.4 Trouble shooting

Indicator Lamps do not come on –the water tank is full
Or may be the control level has failed at tank full position. However this is coupled
with failure of the sand bed pump and carbon bed pump since there will be no water
in the Holding tank.
3.0 Mineral Water treatment

The treatment process for water can be categorized into two i.e.;-Pre -treatment and
Post treatment
3.1 Pre-treatment Process

3.1.1 Chlorination of water
3.1.2 Removal of suspended matter
3.1.3 Removal of residual chlorine
3.1.4 Reducing the hardness
3.1.5 Removal of fine micron particles up to 5 Micron size
3.1.6 Removal of large microbes up to 0.2 micron.
3.1.7 Ultraviolet sterilization to kill microorganism.
3.2 Post treatment

This consists of preservation of the product by Ozonation of water to kill the
microorganisms.
3.3 Scope
The scope includes pumping of water from raw water reservoir tank, dosing chlorine of 4-
6ppm, filtering of coarse material using sand filter, holding of water for two hours with 4-
6ppm chlorine to destroy micro-organisms, dechlorination, 5micron filtration, 1 micron
filtration, 0.2 micron filtration and UV disinfection of water.
3.4 Responsibility
The Water Technicians are responsible for the treatment of raw bore hall water,
dechlorination, filtration and UV disinfection before sending it to the majonnier for final
treatment and filling.
The Process Plant Manager is responsible in ensuring that the procedures are followed
for the purpose of achieving high quality water for bottling.

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Effective date:
Revision No: 01
3.5 Sand filtration procedure

Open borehole inlet valve V1 located between NWSW reservoir tanks.
Start the Borehole water pump by switching on to auto mode.
Open out let valve BV2 for Borehole Raw water to flow to the sand bed
Open sand bed pump isolation valves A&B for pump Number 1 use (keep valve C&D for
pump number 2 closed). Alternatively you can use pump number 2 by opening C&D and
keep valves A&B closed.
Open valves V1&V5 found on the sand bed tank

Switch on main electric control switch of the water plant.
R-phase-phase and B-phase light indicators should come on
Turn switch selector to number 1 (for pump 1 to run)

Along the same line of switches set the last switch on the left to mode “filter”
Press the start button next to the pump selector switch.
Pump number 1 will pump water from the raw water tank through the sand filter to the
holding tank
Chlorine dosing pump will pump chlorine to the line as the water flows to the sand bed.
The sand bed pump number 1 will run till water level in tank 2 reaches high level then it
cuts off water supply.
Trouble shooting
The pump may not start if
There is low level of water in the raw water tank (Tank 1)
There is power over load.
The tank holding Tank Number 2 is full (Tank 2 high level indicator lump is on)
The main switch is not started.
3.6 Chlorine dosing

Purpose of the procedure is to ensure that water coming to the holding tank is dosed with
an appropriate amount of chlorine to effect sanitation of water before it can be used for
bottling
The Water Treatment Technicians are responsible for implementing the
procedures for the purpose of achieving the desired sanitation of water
The Process plant Manager is administratively responsible in ensuring that the
procedures are followed.
3.6.2 Scope
This includes preparation of Calcium Hypochlorite (Source of Chlorine), setting
dosing rate of the chlorine and testing of chlorine.
3.6.3 Safety ware
Gumboots or Industrial shoes
Nose/mouth mask
Overcoats

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Revision No: 01

Hand gloves
3.6.4 Procedure
3.6.4.1 Measure eight (8) kgm of Calcium Hypochlorite into the container
3.6.4.2 Add 100 liters of water
3.6.4.3 Agitate the solution until the powder is dissolved
3.6.4.4 Allow the solution to stand for one hour
3.6.4.5 Decant the solution leaving the sediment at the bottom of the container. (this
solution is approximately 5% concentration)
3.6.4.6 Add one hundred liter of water to the solution (reduce concentration to 2.5%)
3.6.4.7 Add the clear solution into chlorine dosing tank where the pump is attached.
3.6.4.8 Run the sand bed as in the sand filter procedure.
3
3.6.4.9 (Sand bed pumps are rated at 8m /hour, targeted chlorine concentration is 4-
6 ppm
3.6.4.10 Set the chorine dosing pump to deliver 34mls per minute of 2.5%
chlorine solution
3.6.4.11 Connect chlorine dosing pipe to the water supply line to the sand bed.
3.6.4.12 Run the sand filter pump
3.6.4.13 Open valve V2 to allow water flow to the drain
3.6.4.14 Take a sample of water and test for chlorine concentration.(Results
should be 4-6ppm)
3.6.5 Trouble shooting

3.6.5.1 Sand bed pump does not come on (check on water levels in the tanks)
3.6.5.2 No traces of chlorine in the water (bleed the chorine dosing pump by opening
the nipple just below the pump)
3.6.5.3 High /low chlorine concentration in water tested (adjust the chlorine dosage
rate down wards or upwards) by repeating the above settings.
Note.
This pump is synchronized with the Sand bed pump and will only run when
the sand bed pump runs.
3.7 Carbon bed tank (dechlorination)

3.7.1 Purpose.
The carbon bed is filled with Activated carbon. Activated carbon helps in
adsorbing chlorine previously used for water treatment and some off odours in
the water.
The purpose of the procedure is to ensure that all the chlorine previously added
to water for the purpose of disinfection is completely removed before water can
be used for any process
Water Treatment Technicians are responsible for the implementations of the
procedures so as to remove all traces of chlorine in the water before water goes
for filtration and UV disinfection.

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Effective date:
Revision No: 01

The Process Plant Manager or any designated person is responsible in ensuring
that all the procedures laid down are followed.
3.7.3 Scope
Includes pumping water from the holding tank (Tank2 where it has spend two
hours with 4-6ppm chlorine concentration) through the carbon bed where
dechlorination takes place.
3.7.4 Procedure
Ensure that there is power supply in the electric control panel.
Open valves 1, E, F, and V1&V5 on the carbon bed tank.
Open valves M, N, O, and Q located along the micron filters pipe lines. (keep all
other valves in the tank closed)
Start pump number 3 by turning selector switch to number 3
On the far left, put selector switch to Normal mode
Press a start button next to pump 3 switch selector.
(When using pump number 4, open valves G&H, and isolate pump number 3 by
closing valves E&F.
Pump 3 will pump water from the holding tank through the carbon bed to the
water
polishers or filters.
Open air vents on filter 5, 1 and 0.2 micron till water comes out then close the
vents.
Start the UV disinfectant lamp switch by tuning so that it is parallel to UV
housing.
All the four lamp indicators should light showing that each of the lumps is active.
Wait for 2-3minutes, the lamp percent intensity will progressively increase from
below 50% to 100%.
If the percent intensity coverage remains below 100% inform the Process Plant
Manager or any designated person for possible correction.
3.7.5 Maintenance
3.7.5.1 Multimedia Filter (Sand bed)
3.7.5.2 Backwashing
3.7.5.3 Purpose
The main purpose of backwashing the sand bed is to reduce the load of
foreign matter accumulated during the operation of the sand bed.
(Regenerate the sand bed)
If this load of organic matter of particulate matter is allowed to accumulate,
there is a tendency of it to migrate to the protected water tank (holding tank)
and the turbidity of water increases.
Backwash will be affected if
- there is turbidity increase in water
- pressure difference of 2bars or more between the incoming and out
going pressure
- or after 24 hours, which ever comes first.
The Water Treatment Technicians or any designated persons are responsible for
implementing the procedures during backwashing.

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Effective date:
Revision No: 01

The Process Plant Manager is administratively responsible in ensuring that the
procedures are followed and the backwash is affected when it is due.
3.7.6.1 Scope
Includes monitoring of the pressure difference, treated water turbidity and
backwashing sand bed.
Procedure.
All plant valves in close position.
Open valve (I) on the water Holding tank
Open valves K, A, B, V3&V2 (to run pump1) or K, C, D, V3, V2 (to run pump
2)
Switch on main power supply switch on the control panel
(Red, Yellow and Green indicator lights will come on).
Along switch 1&2 row, turn the last selector switch on the left to Backwash
position.
Switch on selector switch to pump 1 if valve A&B are open or to pump2 if
valve C&D are open.
Press on the blue button marked START
Water will flow from the holding tank through the sand bed to the drain
(upward flow)
Run the pump till the effluent is clear or for 20 minutes (which ever comes
first?)
(Pressure in the tank will be about 1+/- 0.2 bars.)
Stop the pumps by pushing on the red button on the same row with the
running pump marked STOP
Close valve K.
Open valves A, B, V1& V4 (to run pump 1) C, D, V1&V2 (to run pump 2)
Turn selector switch on the far left to FILTER position
Press the blue button market START on the same row with the running
pump.
The pump selected pumps water from the reservoir tank through the sand
tank (top to down flow) to the drainage.
Continue running the pump for 5 minutes or until the effluent is clear (which
ever comes first)
Press on the red switch market STOP on the same row with the running
pumps to stop the pump.
Close all the valves if the line is not running. or move to the running step .
3.8 ACTIVATED CARBON

Activated Carbon Bed Tank
3.8.1 Backwashing
3.8.2 Purpose
The main purpose of backwashing the Activated Carbon bed is to reduce the
load of chlorine adsorbed during the operation. (Regenerate the activated
carbon)
If this load of chlorine is allowed to accumulate it will start passing through the
carbon filter and is recovered after the filter in form of free chlorine or total
chlorine.

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Effective date:
Revision No: 01

This will directly affect the acceptability of this product by the customer.
Backwash will be affected if:
- There is a trace of chlorine in the water in form of free chlorine of total
chlorine.
- pressure difference of 0.5-1.0bars or more pressure difference between
the incoming and out going pressure
- Or after 24 hours, which ever comes first.
The Water Treatment Technicians or any designated persons are responsible for
implementing the procedures during backwashing.
The Process Plant Manager is administratively responsible in ensuring that the
procedures are followed and the backwash is affected when it is due.
3.8.4 Scope
Includes monitoring of the pressure difference in and after the carbon bed,
Treated water turbidity and backwashing sand bed.
3.8.5 Procedure.
All plant valves remain on close position.
Open valve (I) on the water holding tank
Open valves K, A, B, V3&V2 (to run pump1) or K, C, D, V3, V2 (to run pump 2)
Switch on main power supply switch on the control panel
Red, Yellow and Green indicator lights will come on.
Along the switch 1&2 row, turn the last selector switch on the left to Backwash
position.
Switch on selector switch to pump 1 if valve A&B are open or to pump2 if valve
C&D are open.
Press on the blue button marked START
Water will flow from the holding tank through the sand bed to the drain (bottom to
top flow)
Run the pump till the effluent is clear of for 20 minutes (which ever comes first?)
(Pressure in the tank will be about 1+/- 0.2 bars.)
Stop the pumps by pushing on the red button on the same row with the running
pump marked STOP
Close valve K.
Open valves A, B, V1& V4 (to run pump 1) C, D, V1&V2 (to run pump 2)
Turn selector switch on the far left to FILTER position
Press the blue button market START on the same row with the running pump.
The pump selected pumps water from the reservoir tank through the sand tank
(top to down flow) to the drainage.
Continue running the pump for 5 minutes or until the effluent is clear (which ever
comes first)
Press on the red switch market STOP on the same row with the running pumps
to stop the pump.
Close all the valves if the line is not running. Or move to the running step as
above

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Effective date:
Revision No: 01
Appendix I
Maintenance schedules for the plant
Item Schedule Comment

Sanitize Sand bed Weekly 50ppm chlorine for 30 minutes
Sanitize carbon bed Weekly Steam heat to 850 c for 15 minutes
Clean raw water reservoir tank Monthly Remove all silt at the bottom
Charge new carbon Yearly Or when there is chlorine carry over
Charge new sand bed After 3 years
Replace water cartridges Every six months Or when pressure difference is 2 bars
Replace UV lumps After 8000hrs run Or every year
Sanitize water line Daily after 8ppm chlorine concentration left in the
production process line.
Cleaning holding tank Every 3 months Removing any sediments and 50ppm
of chlorine for 30 minutes
Cleaning of UV tubes Every month Use liquid soap and soft cloth for
cleaning
Replace UV sleeves After one year Or when intensity is below 60% even
after cleaning and replacement of UV
tubes
Sanitize treated water line After production or Pump chlorine 10ppm chlorine
after 24 hours concentration from the holding tank
through the micron filters to majonnier
and allow it to stand till production
starts.
References
o Operation and Maintenance manual by Zen Engineering.

o Installation, maintenance and operation Manual for UV CSL series.

8 date:01/09/10
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Crown Beverages SOP for Water Treatment

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CROWN BEVERAGES LIMITED

CLEAN & HYGIENIC CONDITIONS Page 1 of 8

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

1.0 Bore hole

1.1 Sanitation of Bore hole

2.0 Borehole Raw Water Reservoir Tank Filling

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

2.4 Trouble shooting

3.0 Mineral Water treatment

3.1 Pre-treatment Process

3.2 Post treatment

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

3.5 Sand filtration procedure

Open valves V1&V5 found on the sand bed tank

Turn switch selector to number 1 (for pump 1 to run)

3.6 Chlorine dosing

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

3.6.5 Trouble shooting

3.7 Carbon bed tank (dechlorination)

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

3.8 ACTIVATED CARBON

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

Compiled by Process Plant Manager Revision

PEAK MINERAL WATER TREATMENT PLANT & BOREHOLE SANITATION

Maintenance schedules for the plant

Item Schedule Comment

o Operation and Maintenance manual by Zen Engineering.

Compiled by Process Plant Manager Revision

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