Egypt · 2024
Eight rapid gravity filters recharged with graded silica sand and a full four-layer gravel set during a phased shutdown.
The existing beds had been topped up rather than replaced for several years, mixing gradations to the point where backwash no longer fluidised the bed evenly. Turbidity breakthrough was occurring well before the design run time, and the plant could only take two filters offline at once.
Full media replacement rather than a top-up: complete removal, underdrain inspection, then a rebuilt bed of 0.5–1.0 mm sand at 700 mm over four gravel layers. Material was delivered in four phased consignments matched to the shutdown sequence, labelled by layer and loaded in installation order.
Filter runs returned to design duration and effluent turbidity held below 0.3 NTU across the run. Each filter was returned to service inside its allotted window.
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