Appendix 7[1].1. UNITANK Process &Technical Proposal 13

Appendix 7 :

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A.

LOTECO IZ

UNITANK

Single stage aerobic with nitrogen removal

Budget proposal

June 2004

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TABLE OF CONTENTS

A. Introduction 5

B. Process Part 7

B.1. WASTE WATER CHARACTERISTICS 7

B.2. DESIGN PARAMETERS 8

B.3. EFFLUENT QUALITY 9

B.4. PROCESS DESCRIPTION 10B.4.1. Description of the installation 10B.4.2. Description of the biological treatment 11

B.5. DESIGN AND DIMENSIONING 12B.5.1. Influent pump Pit (phase 1 & 2) 12B.5.2. Equalisation/Alarm Tank (phase 1 & 2) 13B.5.3. Physico-chemical pre-treatment 15B.5.4. Aerobic Treatment 16B.5.5. Excess Sludge Thickener 18B.5.6. Disinfection tank 19B.5.7. Sludge dewatering 20B.5.8. Venturi Channel 21

B.6. TOTAL CAPACITY OF THE WASTE WATER PLANT: SUMMARY 22B.6.1. Volumes 22B.6.2. Biosolids production 22

C. TECHNICAL PART 23

C.1. DESCRIPTION OF THE CRITICAL EQUIPMENT 23C.1.1. Equipment list for the biological treatment 23C.1.2. Specifications and documentation - biological treatment 25C.1.3. Equipment list for biosolids dewatering plant 47C.1.4. Specifications and documentation - biosolids dewatering 48C.1.5. Instrumentation 53

C.2. PIPING 60C.2.1. Piping 60C.2.2. Penstocks and valves 60

C.3. UNITANK - PROCESS CONTROL UNIT - THE PCU 63C.3.1. Description of the UNITANK - Process control unit 63C.3.2. Electricity - instrumentation - automation 64

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C.3.3. SCADA supervisory and control 70C.3.4. Process lab (optional) 72

C.4. CIVIL WORKS 73C.4.1. General 73C.4.2. Building area 73C.4.3. Soil conditions 74C.4.4. Dewatering and metal sheeting 74C.4.5. Concrete mix requirements 75C.4.6. Workmanship 75C.4.7. Structural design 76

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B. INTRODUCTION

This offer describes the design, the dimensioning and the technical

specifications for the LOTECO IZ (phase 1). Loteco phase 1 is designed

for 4000 m3/day, phase 2 will have a total capacity of 8000 m3/day.

For this type of wastewater Seghers Keppel Technology Group proposes a

UNITANK single stage aerobic as a very efficient and cost-effective solution .

The design of this installation is based on the design of other UNITANK waste

water treatment plants for industrial zones :

Bien Hoa industrial estate (physico-chemical pre-treatment & UNITANK single

stage aerobic), capacity 4000 m3/day first phase 1.

Jurong Island industrial estate Singapore (oil & grid removal pre-treatment &

UNITANK single stage aerobic), capacity 10800 m3/day.

The most striking advantage of this system is the very compact construction

method. All basins are rectangular, which offers several benefits. Compared to

the conventional round basins, the use of common walls is possible and less

concrete is needed. The result is a compact, modular and space-saving

design, realised in a tailor made installation.

Moreover, UNITANK is synonym for advanced treatment, expressed by a stable

and controlled process, high treatment efficiencies and advanced equipment and

instrumentation. This is made possible by an adaptive and intelligent process

control and a simple and flexible operation.

In comparison with the conventional activated sludge system, there is no distinct

sedimentation and less moving parts are needed.

These advantages are translated in a reduced investment and operational cost.

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Many years of research and the feed-back of several full scale plants resulted in

a very attractive waste water treatment installation, with an exceptional all-in

design, modular, compact and unobtrusive, providing top purification

performance in the most efficient and cost-effective way.

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C. PROCESS PART

C.1. WASTE WATER CHARACTERISTICS

The influent characteristics are as follows:

Total flow rate

Average m³/d 4000

m³/h 166

Peak m³/h 300

(max. 3 h per day)

During days/week

COD mg/l 500

SS mg/l 350

BOD mg/l 300

BOD/COD > 0,6

BOD/N > 4

PH 5-9

FOG mg/l 50

NTOT mg/l 75

NH3 mg/l 50

PTOT mg/l 4

Heavy metals present, but under non toxic

conditions

Phenol 0,05Coliform 1500000

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C.2. DESIGN PARAMETERS

Flow rate : 4000 m3/day

The influent characteristics are as follows:

Total flow rate

Average m³/d 4000

m³/h 166

Peak m³/h 300

(max. 3 h per day)

During days/week 7

COD mg/l < 500

BOD mg/l < 300

BOD load kg/day 1200

Ntot load kg/day 300

SS mg/l < 350

BOD/COD > 0,6

BOD/N > 4

BOD mg/l < 300

Temperature °C 20-30

Phenol 0,05Coliform 1500000

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C.3. EFFLUENT QUALITY

Guarantee(1)

BOD5 mg/l < 20

COD mg/l < 50

Suspended Solids mg/l < 50

Ntot mg/l < 30

pH 6 – 9

Coliform 5000

(1) The effluent guarantee can only be given for the treatment of wastewater with the same characteristics as specified above and in case no other toxic components then heavy metals mentioned are present in the wastewater.

In case the mentioned effluent quality is not obtained while the system treats wastewater within the above mentioned wastewater quality specifications in steady-state conditions, an independent and qualified lab will perform an aerobic biodegradation test.

The client is free to choose this lab, approved by Seghers Keppel Technology Group. The test reactor will be fed with the same wastewater as the full-scale plant.The test reactor will be a low-loaded1 aerobic activated sludge system (sequencing batch reactor or continuous system).

Seghers Keppel Technology Group guarantees an effluent quality of the UNITANK system, at least equal to the obtained effluent quality from the biodegradation test.

1 Volumetric BOD-loading < 0,4 kg/m³/day

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C.4. PROCESS DESCRIPTION

C.4.1. Description of the installation

The raw waste water(s) from the different production facilities of the industrial

zone is being send to the Influent pump Pit after removal of mineral oil, sand

and other inert materials by the factories. In case still some materials such as

wood, plastic, paper, etc.., in small amounts due to calamities are send to the

waste water treatment plant these will be retained at the inlet of the pit by means

of a Bar Screen followed by an automatic Fine Screen (optional).

From the pump pit the wastewater is pumped to the static fine screen before it

flows by gravity to the Equalisation/alarm Tank. In the equalisation/alarm tank

homogenisation and buffering (COD, flow rate, …) of the waste water will take

place a very important aspect of an industrial zone, before the waste water is

send to the physico-chemical pre-treatment system.

After buffering, the wastewater is pumped to the physico-chemical pre-treatment

from where it flows by gravity to the activated sludge system (UNITANK single

stage aerobic with nitrogen removal) which is described in detail in annex.

After biological treatment the effluent is monitored in a venturi channel, before

final effluent discharge.

Part of the effluent can be recycled back for reuse for the sludge dewatering.

Excess biosolids are removed from the sedimentation compartment and

collected in the Sludge Thickener. In here the sludge is thickened by

gravitational compaction to obtain a further reduction of the excess sludge

volume.

A sludge dewatering system with a belt filter press or decanter centrifuge is

foreseen.

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C.4.2. Description of the biological treatment

A detailed description of the biological treatment, UNITANK single stage

aerobic is enclosed in annex.

In addition you can find a description of UNITANK single stage aerobic with

nitrogen removal is enclosed in annex too.


C.5. DESIGN AND DIMENSIONING

C.5.1. Influent pump Pit (phase 1 & 2)

FUNCTION

The wastewater is collected in the Pump Pit. The pumps are protected by

means of a manual Coarse Screen and an automatic channel Fine Screen

(optional) installed at the inlet of the pit.

DIMENSIONING

Flow (peak flow) m³/h 300 (max 3 h)

Hydraulic retention time min 10

Hydraulic retention time (phase 1 & 2) min 5

Volume m³ +/- 50

Dimensions of pump pit

Length m 6

Width m 6

water height (max.) m 1,5

Number of pumps 2

Pump capacity (per pump) m³/h 300

Static head m WC 8

EQUIPMENT

1 manual coarse bar screen

1 static fine screen

1 automatic channel fine screen (optional)

2 submersible wastewater pumps (1 active, 1 stand-by)

a level control system: 4 level switches.


C.5.2. Equalisation/Alarm Tank (phase 1 & 2)

FUNCTION

The main function of the equalisation tank is to obtain buffering of the waste

water quality (pH, heavy metals, BOD, COD, SS,...) and quantity (flow). Due to

the foreseen retention time in the equalisation tank, acid and alkaline

wastewater-streams are mixed, resulting in an auto pH correction, which saves

neutralising chemicals in pre-treatment. The wastewater is kept in a continuous

state of suspension and anaerobic conditions are avoided.

DIMENSIONING

Average flow m³/h 166

Peak flow m³/h 300

Volume m³ 1320

Dimensions

Length m 22

Width m 12

Water height m 5

Hydraulic retention time h 8

Hydraulic retention time(phase 1 & 2)h 4


EQUIPMENT

2 submersible wastewater pump (1 active, 1 stand-by)

flow measurement & control valve

1 submersible mixer

1 hydro-ejector

1 level control system: a hydrostatic continuous measurement


C.5.3. Physico-chemical pre-treatment

FUNCTION

Separating and removing material with a density smaller then that of water by natural flotation and material with a density higher then water by gravitational sedimentation by mean of dosing coagulants.

By removal of these components, the downstream biological treatment step and equipment are protected.

DESIGN

Design parameters

Flow rate : 166 m³/h Number of units : 1

General dimensioning coagulation tank

Dimensions- length : : 3 m- width : : 3 m- waterdepth : : 2 m

General dimensioning sedimentation tank

Dimensions- length : : 12 m- width : : 5 m- waterdepth : : 1,75 m

EQUIPMENT

Top entry mixer

2 dosing pumps coagulant solution

2 dosing pumps flocculant solution

2 dosing pumps for base solution


Moving bridge with airlift system

C.5.4. Aerobic Treatment

FUNCTION

The wastewater is treated in a UNITANK single stage aerobic as described in

annex.

Here, organic (BOD, COD ) and suspended matter are efficiently removed by

oxidation and conversion into CO2, H2O and new biomass.

Air is introduced into the system to provide the activated sludge with a sufficient

amount of oxygen.

DIMENSIONING

1. Dimensioning figures

Flow m³/day 4000

m³/h 166

2. Dimensioning of aeration volume

Volumetric loading kg BOD/m³/day 0,4

Sludge concentration kg MLSS/m3 4

Sludge loading kg BOD/kg MLSS/day 0,1

Active volume m³ 3000

Dimensions of 1 outer compartment

Length m 16

Width m 8

Water height m 5


volume m3 640


Dimensions of inner compartment 1

Length m 16

Width m 10

Water height m 5

volume m3 800

Dimensions of inner compartment 2

Length m 26

Width m 12

Water height m 5

volume m3 2200

EQUIPMENT

Fine bubble aeration system

2 Submersible mixers

1 Roots blower

SEOS (new overflow weir)

UUCD (tube settler system)

2 automatic valves for effluent

2 recirculation pumps

2 excess sludge pumps (1 + 1 stand-by)


C.5.5. Excess Sludge Thickener

FUNCTION

Excess bio-solids have to be removed on a regular basis to maintain the sludge

concentration in the biological reactor at a fixed level. The excess sludge is

pumped from one of the outer compartments of UNITANK system into the

Sludge Thickener. In here, bio-solids are compacted by gravity. The thickener

can also be used as bio-solids storage tank in emergency cases (for example

intoxication of the biological system).

DIMENSIONING

Excess biological sludge production kg sludge/d 700

Physico-chemical

sludge production depending on waste water characteristics

Expected thickening level % 3

Thickened volume m³/d 8

Storage time d +/- 20

Volume m³ 198

Dimensions

Length m 6

Width m 6

Water height m 5,5

EQUIPMENT

1 thickening mechanism


C.5.6. Disinfection tank

FUNCTION

Disinfect the final effluent.

DIMENSIONING

Flow m3/h 166

Storage time min +/- 15

Volume m³ 42

Dimensions

Length m 14

Width m 2

Water height m 1,5

EQUIPMENT

2 hypochloride dosing pumps

1 hypochloride storage tank


C.5.7. Sludge dewatering

FUNCTION:

Using a mechanical dewatering installation the excess sludge volume can be reduced considerably.

DIMENSIONING BELT FILTER PRESS

For our sizing we assumed that the sludge treatment will work 8 hours per day, 6

days per week.

Excess biological sludge production kg sludge/d 700

Sludge production per week kg sludge/wk 4900

Capacity per hour kg sludge/h 100

Expected dewatering level % 10 .. 11

EQUIPMENT:

1 Belt filter press or centrifuge 1 Sludge dosing pump 1 polymer preparation and storage tank

Storage tank with vertical mixer Polymer dosing pump


DIMENSIONING CENTRIFUGE (OPTIONAL) :

For our sizing we assumed that the sludge treatment will work only 8 hours per

day, 3 days per week.

Excess Sludge production kg sludge/d 700

Sludge production per week kg sludge/wk 4900

Capacity per hour kg sludge/h 100

(small capacity machine doesn’t exist)

Expected thickening level % 10 .. 15

C.5.8. Venturi Channel

FUNCTION EFFLUENT VENTURI CHANNEL

The effluent passes the effluent Venturi Channel to be discharged in the sewer

system.

DIMENSIONING OF THE EFFLUENT VENTURI CHANNEL

A concrete effluent channel : 350 m³/h

Temperature and Flow Measurement


C.6. TOTAL CAPACITY OF THE WASTE WATER PLANT: SUMMARY

C.6.1. Volumes

Basin Number of

basin

Volume

m³

Length

M

Width

m

Height

m

Influent pump pit 1 50 6 6 1,5

Coagulation tank 1 18 3 3 2

Sedimentation tank 1 105 12 5 1.75

Buffering tank 1 1320 22 12 5

UNITANK single stage

aerobic with nitrogen removal

removam

4 3000 16 x 3

26 x 1

8 x 2

10 x 1

12 x 1

5

Sludge thickener 1 198 6 6 5,5

Desinfection tank 42 14 2 1,5

Total volume 9 4733

C.6.2. Biosolids production

Bio-solids production after thickener

Kg/day 700


D. TECHNICAL PART

A general layout with the basic configuration and the dimensioning of the

installation is represented in annex.

D.1. DESCRIPTION OF THE CRITICAL EQUIPMENT

D.1.1. Equipment list for the biological treatment

Function Type Capacity

P.PR.01.01/02

(1 + 1 spare)

Waste water transfer

from pump pit to

equalisation tank

Submersible

centrifugal pump

2 X 300 m³/h

Z.PR.11.03 Mixing of

equalisation tank

Submersible hydro-

ejector

1320 m3

A.PR.11.01 Mixing of

equalisation tank

Submersible mixer 1320 m3

A.PR.21.01 Mixing of coagulation

tank

Top entry mixer 18 m3

A.AE.13.01/02 Mixing of UNITANK Submersible mixer 2200 m3

P.PR.11.01/02

(1 + 1 spare)

Waste water transfer

from equalisation

tank to UNITANK

Submersible

centrifugal pump

167 m³/h

C.AE.11.01 Aeration of UNITANK

Roots blower 1200 kg

BOD/day

300 kgN/day

Z.AE.11.01,

Z.AE.12.01/02,

Z.AE.14.01

Air diffusers Disc diffusers 1200 kg

BOD/day

300 kgN/day

S.PR.01.02 Screening influent Coarse screen 300 m³/h

S.PR.01.01 Fine screening Static fine screen 300 m³/h

S.PR.01.03

(optional)

Fine screening Channel fine screen

with screw conveyor

300 m³/h

P.AE.11.01/14.01 (1

+ 1 spare)

Transfer of excess

biosolids

Submersible pumps Max. 25 m³/h

P.AE.11.02/14.02 Recirculation pumps Wall pumps 665 m3/h


P.CH.01.01/02 (1 + 1

spare)Dosing of coagulant Membrane dosing

pump

Max. 160 l/h

P.CH.02.01/02 (1 + 1

spare)

Dosing of flocculant Membrane dosing

pump

Max. 160 l/h

P.CH.03.01/02 (1 + 1

spare)

Dosing of base Membrane dosing

pump

Max. 160 l/h

P.CH.04.01/02 (1 + 1

spare)

Dosing of

hypochloride

Membrane dosing

pump

Max. 160 l/h

R.PR.21.01

C.PR.21.01

Bridge with top and

bottom scraper

/

R.SL.01.01 Raking thickener Slowly-rotating

scraper and

thickening

mechanism

SEOS system Advanced overflow

weir system

Capacity 167

m3/h

UUCD Increasing settling

area & efficiency

Tube settlers Capacity 167

m3/h

T.CH.01/03 Chemical storage

tanks

FRP storage tank 2 m3

T.CH.04 Chemical storage

tanks

FRP storage tank 10 m3


D.1.2. Specifications and documentation - biological treatment

Coarse screen S.PR.01.02

total number 1

Function Screening of wastewater before entering the pump pit to prevent damage to the pumps

Manufacturer Local

Type Coarse screen - flat bar screen (Basket type)

split width 30 mm

Operation Continuous

Location Entrance pump pit

Flow 300 m3/h

Inclination 90°

Materials Stainless steel


Static fine screen S.PR.01.01

Total number 2

Function Fine screening of the incoming waste water

Manufacturer REKO or equivalent

Type Static screen

Split width 1,5 mm


Location After pump pit

Flow 2 x 150 m3/h

Materials- curved screen plate- housing

Stainless steel


Channel fine screen (optional)

S.PR.01.03

Total number 1

Function Fine screening of the incoming waste water

Manufacturer SNOEK or equivalent

Type Static screen with screw conveyor for screenings

Split width 1,5 mm


Location Channel before pump pit and after coarse screen

Flow 300 m3/h

Materials- curved screen plate- housing

Stainless steel


Pump P.PR.01.01/02

Total number 2 (1 + 1 spare)

Function Pumping of waste water from pump pit to equalisation tank

Manufacturer KSB or equivalent

Type Submersible centrifugal wastewater pump type

Operation DiscontinuousSwitch off at minimum levelSwitch on at maximum level

Location Pump pit

Flow 167 m3/h

Discharge head 8 m WC

Degree of protection IP 68

Insulation class F

Shaft seal Double mechanical seal

Materials- pump and motor casing- impeller- shaft- bolts and nuts- guidance and accessories- chain

Cast ironCast ironStainless steel Stainless steel Stainless Steel

Stainless steel


Blower C.AE.11.01

Total number 1

Function Air transfer to the diffusers for aeration of activated sludge, to create aerobic conditions

Make Robuschi or equivalent

Country of origin EU

Type Three lobe roots blower

Operation Depending on the cycling operation, influenced by pressure and oxygen measurement

Location Blower room

Flow range: 50-100 %


Insulation class F

Seals Labyrinth seals

Material- shaft and gears- Three lobe rotors- Blower casing

Heavy duty machine steel Nodular cast iron GG40Cast iron GG25


Aerator Devices Z.AE.11.01, Z.AE.1201.Z.AE.1301

Location UNITANK basins

Function Fine air bubbles aeration of activated sludge in the UNITANK basins

Type Disc type

Make SKG or equivalent

Effective airflow 5 Nm³/h.piece

Installation depthEffective water depth

4,8 m5 m


SEOS


Function Improving effluent quality & reducing operation cost

Type Solids excluding overflow weir system

Make local

Capacity 167 m3/h

Material FRP or SS

UUCD


Function Improving effluent quality & reducing area and reactor volume

Type Ultra compacting UNITANK device

Make SKG

Capacity 167 m3/h

Material Plastic


Pump P.PR.11.01/02

total number 2 (1 + 1 spare)

Function Pumping of wastewater from equalisation tank to UNITANK



Operation Pumping a continuous flow to the pH correction tank, controlled by automatic valve and flow meter.Immergenty:Switch off at minimum level

Location Equalisation tank

Flow 167 m3/h



Insulation class F



Cast iron Cast ironStainless steel Stainless steel Stainless Steel

Stainless steel


Pump P.AE.11.01/14.01


Function Transfer of excess biosolids from the outer compartments of the UNITANK to the thickener



Operation DiscontinuousImmergenty:Switch off at minimum level


Flow 25 m3/h



Insulation class F




Stainless steel


Pump P.AE.11.02

total number 1

Function Recycling of sludge


Type Shaft pump type

Operation DiscontinuousImmergenty:Switch off at minimum level


Flow 665 m3/h

Discharge head 0,3 m WC


Insulation class F




Stainless steel


Hydro-ejector Z.PR.11.03

total number 1

Function Aeration and mixing of the waste water to achieve auto pH correction, homogenisation and prevent anaerobic conditions


Type Submersible centrifugal pump with venturi ejector and air injection pipe

Operation ContinuousSwitch off at minimum level


Power supply 3 * 400 V, 50 Hz


Insulation class F

Seal Double mechanical sealing

Materials- pump and motor casing- impeller- shaft- bolts and nuts- ejector house- ejector pipe- Air suction pipe- guidance and accessories- chain

Cast iron Cast iron Stainless steel Stainless steel Cast Iron Stainless steel PVC

Stainless steel Stainless steel


Mixer A.PR.21.01

total number 1

Function Mixing of coagulation tank

Manufacturer DOSAPRO or equivalent

Type Top entry mixer

Operation Operation controlled

Location Coagulation tanks

Installed power 1,5 kW


Insulation class F

Materials- housing- propeller- shaft- bolts and nuts

Cast ironStainless steel Stainless steel Stainless steel


Dosing pump P.CH.01.01/02


Function Dosing of coagulant

Manufacturer ALLDOS, DOSAPRO or equivalent

Type Diaphragm dosing pump


Location Near the pre-treatment

Flow 40 l/h

Discharge head Max. 8 bar


Materials- pump housing- motor housing- diaphragm- dosing head

Cast iron Cast iron PTFE (Teflon) PVC




Function Dosing of flocculant





Flow 40 l/h








Function Dosing of base solution





Flow 40 l/h








Function Dosing of hypochloride solution





Flow 40 l/h






Mixer A.PR.11.01

total number 1

Function Mixing of buffering tank

Manufacturer KSB , EMU or equivalent

Type Submersible mixer

Operation Depending on the cycling operation, time controlled


propeller speed 920 rpm

motor speed 1.450 rpm

degree of protection IP 68

insulation class F


Materials- housing- propeller- shaft- bolts and nuts- guidance and accessories- chain

Cast iron GG25Stainless steel 1.4571Stainless steel 1.4021Stainless steel 1.4401Stainless steel AISI 304

Stainless steel


Mixer A.AE.13.01

total number 1

Function Mixing of UNITANK basin

Manufacturer KSB , EMU or equivalent

Type Submersible mixer

Operation Depending on the cycling operation, time controlled


propeller speed 920 rpm

motor speed 1.450 rpm


insulation class F


Materials- housing- propeller- shaft- bolts and nuts- guidance and accessories- chain

Cast iron GG25Stainless steel 1.4571Stainless steel 1.4021Stainless steel 1.4401Stainless steel AISI 304

Stainless steel


Moving bridge with raking devices

R.PR.21.01/C.PR.21.01

Total number 1

Function To evacuate the physico-chemical sludge from the incoming waste water .

Manufacturer Local

Operation Continuous or discontinuous. (timer controlled)

Location Sedimentation tank of physico-chemical pre-treatment

Installed power 0,75 kW.

Degree of protection IP55

Insulation class F

Raking devicesBridge and mainstructure

Epoxy coated steelEpoxy coated steel


Rake mechanism R.SL.01.01

Total number 1

Function Enhance the gravity thickening of the biosolids with vertical thickening bars.Collect the thickened sludge centrally with bottom scrapers.

Manufacturer gearboxManufacturer steel structure

DEWEKON or equivalent

LocalType Slow rotating rake mechanism with vertical parallel

thickening bars and bottom scrapers.Operation Continuous

Location Thickener

Diameter 5,8 m (Thickener dimensions 6 m x 6 m )

Rotating speed 0,3 rpm

motor speed 750 rpm

Installed power 0,2 Kw


Insulation class F

Materials- Scrapers, thickening bars Epoxy coated steel


Chemical storage tank T.CH.01/03

total number 2

Function Storage of chemicals (coagulant, base solution)

Manufacturer Local

Instrumentation Low level measurement

Location Next to technical building

Volume 2 m3

Material FRP


Chemical storage tank T.CH.04

total number 1

Function Storage of chemicals (hypochloride solution)

Manufacturer Local

Instrumentation Low level measurement

Location Next to technical building

Volume 10 m3

Material FRP


D.1.3. Equipment list for biosolids dewatering plant

No. Function Type Capacity

P.CH.01.01 Polymer dosing

pump

Excenter screw pump 1 m³/h

P.SL.01.01 Transfer of excess

biosolids

Excenter screw pump 9 m³/h

NCH01 PE preparation unit Batch unit for powder

PE

10 kg/day

SSL01/

P.PO01.01

Belt filter press Belt filter 100 kg/h

SSL0101

(optional)

Centrifuge Decanter centrifuge 100 kg/h


D.1.4. Specifications and documentation - biosolids dewatering

Polymer Dosing Pump P.CH.01.01

Total number 1

Function Dosing of polymer solution to the centrifuge

Manufacturer SEEPEX ,NETZSCH or equivalent

Type Excenter screw pump with manual speed variator

Operation Simultaneous with sludge feeding pump PSL0101

Location Technical room

Flow 1 m³/h

Discharge head 10 mWC



Insulation class F

Sealing Stuffing box

Materials- housing- rotor- stator

Cast iron and epoxy coated steelStainless steelHypalon


Polymer Preparation and Storage Unit

NCH01

total number 1

Function Manual preparation of polymer - starting from powder

Manufacturer mixerManufacterer tank

Alldos, Dosapro or equivalentLocal

Operation Manual preparation of batch of polymer

Location Technical building

Capacity tank 1.500 l

Concentration of polyelectrolyte

0,5 to 0,1 %


Pump P.SL.11.01

Total number 1

Function Transfer of thickened biosolids to belt filter press

Manufacturer NETZSCH, seepex or equivalent

Type Eccenter screw pump with manual speed variator

Operation On/off dependent on time cycle - dewatering with belt filter press.

Location Technical room

Flow 9 m³/h

Discharge head Max 10 mWC



Insulation class F

Seal Mechanical seal

Materials- housing- rotor- stator

Cast iron 0.6025Chrome steel 1.2436Perbunan


Belt Filter Press SSL01

total number 1

Function Further dewatering of sludge coming from the thickener

Manufacturer Kamps or equivalent

Operation Continuous during 8 hours per day, 6 days per week (phase 1)


Power supply 3 * 400 V, 50 Hz

Belt width 1500 mm

Flow 5 m³/h of thickened sludge (100 kg/h of DS)

Wash water consumption +/- 7,5 m³/h

DS at the end of the table 10 .. 11 %Installed power 1 kW – Variable speed (Manual)

Material frame Coated steel

Weight 1.000 kg


Centrifuge (optional) SSL0101

total number 1

Function Dewatering of thickened biosolids

Manufacturer -Laval or equivalent

Operation Continuous during 8 hours/day and 6 days/week


Flow 100 kg DS/h

Installed power 30 kW


Insulation class F

Materials- frame- rotor- screw conveyor

Cast ironStainless steelStainless steel


D.1.5. Instrumentation

D.1.5.1. Instrumentation list

Ref. Description Type

LSL +

LSH

Level measurement pumppit

Control of influent pumps

Floating ball

level switch

LICA Level measurement equalisation tank

Control of equalisation tank aerator/mixer and

equalisation tank transfer pump

Hydrostatic continuous level

measurement

FICA Electromagnetic flow measurement Electromagnetic

PHICA PH-measurement in coagulation tanks

Control of dosing flow base or acid

pH-probe + transmitter

LSA L Low level alarm base tank

Control of base flow

Floating ball

level switch

LSA L Low level alarm coagulant tank

Control of coagulant flow

Floating ball

level switch

LSA L Low level alarm flocculant tank

Control of flocculant flow

Floating ball

level switch

O2 O2 measurement in UNIANK Probe + transmitter

FI Flow measurement in Venturi channel

Effluent of water treatment plant

Ultrasonic flow measurement


D.1.5.2. Description instrumentation

LA / LSA / LSL / LSH

Manufacturer ATMI – Mobrey or equivalent

Type Floating ball, level switch

Principle of measurement

A mercury switch changes contact depending on the float position.

Materials * a 3-wire cable, connected to the exchange contact in the float cabin in hypalon* a balance weight in hypalon on + 150 mm from the float cabin* a float cabin with a mercury exchange contact, sealed with polyurethane foam and in hypalon

Number 10

Location Influent pump pitEqualisation tankChemicals storage tankUNITANK

Electrical connections- output- degree of protection

Contact switch for 230 VAC, 2 A (spot)IP 68


LICA

Manufacturer ABB or equivalent

Type Hydrostatic level measurement


Continuous measurement of hydrostatic pressure. The pressure is converted into a 4-20 mA signal.

Materials * All parts in contact with the water are made of stainless steel or plastic* Casing of the electronic parts for outside erection

Number 1


Electrical connections- power supply- output signal- degree of protection

24 V DC (2 wire)4 – 20 mAIP 68 pressure cellIP 65 transmitter

Measuring range Zero and span can be adjusted

Linearity 0,5 % or better of the measured value


FI


Type Flow measurement – ultrasonic


In an open channel the flow is determined by the height of the water in the measuring channel. This height is the standard for the flow. The relation height – flow for a specified channel can be set up in the measuring converter so that this converter gives a 4 – 20 mA layout signal, proportional to the flow.

Materials Measuring converter + measuring probeIt is fit for outside use.

Number 1

Location Effluent venturi


230 V AC / 50 Hz4 – 20 mAIP 68 sensorIP 65 transmitter

Measuring range Zero and span can be adjusted

Accuracy Electronic part : 0,2 % for maximum measuring span and smooth surfaceVenturi + electronics + real circumstances : 5 - 10 %


PHICA


Type Potentiometric pH-measurement


Potentiometric pH measurement, using a combined electrode (glass and reference electrode)

Materials Submerged parts in PP or PVCIs fit for outside use.Mounting on wall

Materials Measuring electrode + immersion assembly + measuring converter + signal cable

Immersion assembly : PP or PVC

Number 1

Location Coagulation tank


230 V AC / 50 Hz4 – 20 mA (4 wire)IP 65 transmitter

Measuring range 2 – 12 pH

Accuracy 0,5 % of the measuring range


Item DO

Number 3

Manufacturer ABB

Type Oxygen-probe + electrode + transmitter

Measuring principle Potentiostatic 3 electrodes with membrane and internal temperature correction

Electrical connections- power supply- output signal

230 V AC / 50 Hz4 – 20 mA (4 wire)

Measuring range 0 – 15 mg/l

Accuracy 1 % FS


Item FICA

Total number 1


Type Electromagnetic flow measurement

Measuring principle A magnetic field generates a voltage in the flowing liquid. This voltage is proportional to the velocity of the fluid.

Location After equalisation tank

Electrical connections- power supply- output signal

230 V AC4 - 20 mA (4 wire)

Measuring range Depending on pipe diameter

Accuracy 1 % FS


D.2. PIPING

D.2.1. Piping

Our standard for the piping has the following specifications:

Medium Type of pipe Material

Piping for waste water and sludge Diameter < 100 mm HDPE

Piping for waste water and sludge Diameter > 100 mm Stainless steel

Header for compressed air Galvanised steel

Chemicals HDPE, PVC or

other depending

on the chemical

resistance

D.2.2. Penstocks and valves

D.2.2.1. Penstocks and Valves

Medium Type of valve

Influent Regulating butterfly valve

Wastewater - Influent/effluent in piping Butterfly valve

Wastewater - influent-effluent in channels Penstock

Excess sludge, thickened sludge Pinch valve

Butterfly valve

Sludge - pressure Gate valve

Sludge - highly concentrated ( > +/- 8 %) Diaphragm valve

Chemicals Ball valve - PVC

Pressure maint. Valve - PVC

Waste water in discharge pipes of

parallel working pumps Ball check valve


D.2.2.2. Description of penstocks and valves

Penstocks - manual

manufacturer Econosto or equivalent

operation handwheel

location in channel

Penstocks - automatic


operation electrical motor

motor Bernard or equivalent

location in channel

Butterfly valve - automatic


type butterfly valve - wafer type

handling double acting pneumatic actuators

operating pressure +/- 6 - 8 bar

Butterfly valve - manual



operation

diameter < 200 mm manual handle

diameter > 200 mm gearbox and handwheel

Butterfly valve - automatic - flow regulating



operation actuator + positioner

operation characteristics

pressure +/- 1,4 - 6 bar

electrical signal 4..20 mA


Pinch valves

manufacturer Dosapro or equivalent

type pinch valve, flanged type

operation pressurised air

operation +/- 6 - 8 bar

Diaphragm valves

manufacturer -Laval or equivalent

type diaphragm valve - flanged -

full passing

operation magnetic valve

operating +/- 6 -8 bar

Check valves

manufacturer ABS, Econosto or equivalent

type DN 50-250 ball - check valve

Ball valves

manufacturer -Laval or equivalent

type DN 50-250 ball valve

Pressure retention valve

manufacturer Alldos, Econosto or equivalent

type pressure retention valve with

adjustable pressure set point

Gate valves


type gate slide valve

Valves for chemicals

manufacturer Vink or equivalent

type PVC valves


D.3. UNITANK - Process control unit - the PCU

D.3.1. Description of the UNITANK - Process control unit

The UNITANK PROCESS CONTROL UNIT is the beating heart of the

wastewater treatment plant. It centralises the following items :

low-tension panel

sampling and monitoring instrumentation of the plant

PLC control

SCADA system


D.3.2. Electricity - instrumentation - automation

D.3.2.1. General

The low-tension panel consist of a motor power supply and a PLC control

section, combined in one unit.

cabinet RITTAL system or equivalent

type PS

protection class IP 55

finishing grounding + structure lacquer

In the cabinet, 20 % spare space is provided. In the panel the PLC part is clearly

separated from the power-part. A separate instrumentation-grounding rail is

provided.

The main power supply cable with earthing conductor has to be delivered and

installed until the connection terminals of the main distribution panel of the plant

by the client. SEGHERS KEPPEL technology group will carry out the connection

of the cable with the panel terminals.

The grounding system is supposed to be TN-S. ( 3 x 400 V + N ) 50 Hz


D.3.2.2. Electricity

a. Panel - Power distribution section

The power part consist of:

Set of 4 bus bars with a section according to the installed power, short circuit

resistant for the short circuit power of the arrival in the panel.

An earthing bus bar for safety earthings, through the entire power part of the

panel.

An earthing bus bar for the instrumentation mounted isolated from the panel,

connected to the main earthing bus bar.

A power switch build in front of electrical panel.

Universal power meter, DIRIS C - SOCOMES or equivalent. The DIRIS C is

a main analyser, able to measure and calculate all of the electrical

parameters of a three-phase system. One single unit can measure V, A, W,

VAR, cos and the frequency.

Transformer for control current

Motor protection circuits with :

A three pole motor protection switch with thermal and magnetic

protection.

A three pole contactor with the necessary auxiliary contacts.

A one pole automatic thermo-magnetic fuse for the motor control circuit.

Cable terminals according to the cable section

Feeder with automatic fuse for lighting.

Feeder with automatic fuse and differential switch for sockets.


b. Panel - Control section

The control section consists of :

1 switch Hand/Auto/off per motor en 1 switch open/close/auto per valve.

2 alarm lamps (25 mm diameter, red colour)

push buttons for lamp test and acceptance of alarms

PLC type SIEMENS S7-300 or equivalent

interface relays between PLC and motor-circuits

stabilised 24 VDC power unit


c. Cabling

Cables are placed on cable ladders made of galvanised steel. A tube protects

Cables not installed in cable trays, where necessary. The cable section is

adapted to the motor power and according to safety regulations .

d. Documentation

The following documentation will be delivered in case of order:

electrical diagrams

lists (terminal, motor, cable, instruments)


D.3.2.3. Automation

a. General

The complete installation is controlled by a PLC. The PLC is placed in the

control panel.

The control system is located in the PCU-unit.

b. PLC control

The PLC system is build modular and controls the UNITANK system. On line

some parameters can be changed freely on the operator panel system (OP).

After a power interruption the PLC and installation starts up automatically.

c. Functions of the PLC

1. Control of the installation using analogue and digital inputs and an especially

designed program in order to calculate the necessary actions (analogue and

digital outputs)

control of the biosolids pumps, the aeration system and the mixers

generating alarm signals when process failures occur

visualising status of equipment on the OP

2. Signals of process switches, alarm on measurements, motors, valves are

handled by the PLC and reported to OP.

3. Process interlocks to motor start/stop: if switch hand/off/auto of motor or valve

is in the auto position the necessary actions are done by the PLC. Only

critical interlocks (safety of personnel and installation) are carried out in

hardware (relays) without any PLC connections as well in Hand as in Auto.


d. Hardware

A SIEMENS S7-300 PLC is proposed.

The analogue signals are 4-20 mA signals and the digital signals 24 VDC.

The PLC is not connected to a network or to other PLC’s.

e. Software

All PLC software is written in instruction code (AWL). Standard documentation is

available after start-up.

The following documentation is delivered:

functional description

complete listing of all programme blocks

cross reference list


D.3.3. SCADA supervisory and control

D.3.3.1. General

To supervise and control the installation, a graphical human-machine interface is

delivered. This SCADA system is comprised of several components that

perform supervision, control and data acuisition.

One complete supervisory system [SCADA] is proposed to visualise and control

this Unitank® installation only.

D.3.3.2. Functionality

Visualisation of the installationBy means of synoptical images, a realistic representation is shown.Every equipment will be represented dynamically, showing the actual status of the equipment.All analogue measurements will be given in engineering units.

Control of the installationOperational settings can be adjusted.

Control of the equipmentEvery motor can individually be operated manually from the SCADA system. Every automatic valve can individually be operated manually from the SCADA system.As this is a manual operation, it might effect the process. The operator should be aware of the dangers and risks as he is entirely responsible for his manual actions.

Data acquisitionAll analogue measurements are trended [real time and historical].The logged trend can be converted into a csv-file for further analyses.

Password protectionTo prevend undesired control of the installation several password levels are developed.

Alarm reportingAll alarms are represented by a clear text.

Communication with control system


D.3.3.3. Software

Wonderware’s Intouch is used as system software.

Installation specific application software will be developed using this system

software.

A runtime license with 1000Tags will be delivered.

D.3.3.4. Hardware characteristics

A desktop Pc with the following minimum specifications is included:

One PC 1 GHz Pentium III

RAM 512MB – HD 8.4 GB

1.44MB 3.5” disk drive

40x CD-ROM drive

Windows XP preloaded

keyboard – mouse

one 19” monitor

one color A4 printer

The communication cable and accessories between the PLC and the SCADA

are not included.


D.3.4. Process lab (optional)

SKG has developed a complete lab-set for operators of a waste water treatment

plant. The goal of this lab-set is to analyse the water probes on a very fast and

accurate way. With the results of these measurements, the operator can control

and eventually optimise the process and the plant.

Lab furniture is provided with the necessary equipment and reagentia for

executing the following analyses:

temperature, pH, dissolved oxygen, settleable solids, sludge concentration,

DS, COD, nitrate-N, nitrite-N, NH4-N, ortho-phosphates

A microscope is provided to evaluate the structure of the micro-organisms.

All procedures are described very clear.

One working table + cupboard + reagents rack

For COD-measurement

COD-measurement kit (for +/- 100 measurements)

Digestion bloc

Colorimeter

For N-measurement

NH4+-N-measurement kit (for +/- 100 measurements)

NOx-N-measurement kit (for +/- 100 measurements)

Colorimeter

For P-measurement PO4

3+-measurement kit (for +/- 100 measurements)

Colorimeter

pH-meter

Oxygen-meter

Dry-oven

Balance

Microscope

Labware: Imhoff cones, graduated cylinders, pipettes, rack, beakers, funnels,

filter paper, petri dishes,...


D.4. Civil works

D.4.1. General

Preliminary design and cost estimation of civil works are based on the all

available data, information and drawings given by the client.

In case no sufficient information is available, design and cost estimation will be

based on standard conditions, which will be mentioned hereafter.

Cost estimation are based on European construction practices, conditions and

prices. Special local requirements (such as seismic constructions, typhoon

protected constructions,...) are not included, unless clearly mentioned otherwise.

D.4.2. Building area

Standard building area conditions are:

Construction site free from visible or invisible obstacles, such as old

foundations, debris, large vegetation, local rock or stone formations

Construction area is large enough for the proposed construction, including

space area for normal excavations, site installation and material storage.

Construction area is accessible for standard equipment, such as trucks, piling

machines, ...

The construction area as well as the access is free from cables, pipes,

sewers or other utilities.

The site is property of the client. Any governmental or private taxes related

to the construction are at charge of the client.

The existing grade level is supposed to be flat, without any significant

differences in elevation.


D.4.3. Soil conditions

Final foundation levels and foundation method will always be based on detailed

and final soil investigation reports according to the requirements of Seghers

Keppel Technology Group . Soil investigation will be executed on the exact

building location.

If no or insufficient soil reports are available, the following general soil conditions

will be assumed :

The construction will be build based on a general foundation slab at a level of

minus one meter below existing grade level, unless specified otherwise on

the drawings.

The thickness of the foundation slab is determinated according the

characteristics of a medium dense to dens sand layer.

Maximum allowable settlements according to the loads of the proposed

construction will be less than 30 mm unless specified otherwise.

Maximum differential settlements according to the minimum and maximum

loads of the proposed construction will be less than 8 mm unless specified

otherwise.

No special soil conditions as rock layers, hard gravel layers, cemented soils,

mining areas, etc. are included.

Evacuation and deposit of excess soils (if any) are supposed to be possible

within an area radius of max. 10 kilometres and free of charge.

No earth works in polluted soils are included.

D.4.4. Dewatering and metal sheeting

If not specified otherwise, no dewatering, metal sheeting or other special

excavation requirements or included.


D.4.5. Concrete mix requirements

Concrete mix design will be based on the chemical analysis of the waste water.

If no information about chemical aggressiveness of the retaining liquid is

available, the following standard concrete mix will be used :

Type of cement : Sulphate Resistant Portland or Blast-furnace cement (if

locally available)

Minimum 350 kg cement per m³ concrete mix

Water-cement ratio maximum 0,50

According European codes, this type of cement is resistant to a retaining liquid

with following chemical data :

Aggressive CO2 max. 6 mg/l

Ammonium NH4+ max. 60 mg/l

Magnesium Mg+ max. 1500 mg/l

Sulphates SO4-- max. 3000 mg/l

pH-value min. 4,5

Standard, no additional admixtures or coatings are foreseen.

D.4.6. Workmanship

Concrete, reinforcement and forms will be placed according international

standard practices.

Clear covering of reinforcement bars will be minimum 30 mm, unless specified

otherwise.

Forms will be of smooth type (type Plywood) if locally available.

Reinforcement will be of deformed type grade 460 (if locally available).


D.4.7. Structural design

Structural design - if established by SEGHERS - will be based on computerised

calculations using the method of finite elements.

The design will take in account the effects of temperature, shrinking effects and

all element dimensions will be chosen according the maximum resulting stresses

in the construction.

The design will be made to obtain a structural watertight construction with

maximal shrinking cracks of 0,25 mm according international approved codes.

All construction joints will be provided with a special “water stop” to prevent any

leakage at those spots.

Calculations are based on the latest European Codes. If required, other

international codes as ACI (American Concrete Institute), BS (British Standard),

DIN (Deutsche Industrie Normen) can be used.



Documents

Appendix 7[1].1. UNITANK Process &Technical Proposal 13