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Dammam ISTP MEICA Technical Specs

Q: Evaluate the proposed materials and design considerations for the aeration system in the sewage treatment plant, focusing on durability and performance.

The proposed materials for the aeration system include stainless steel for grit pump impellers and piping, glass-reinforced bitumen coatings for buried pipes, and PVC for manifold pipes of diffusers . These materials were selected for their durability against corrosive wastewater and mechanical wear, ensuring long-term performance. The design includes features like air diffusers and safety mechanisms on blowers to prevent air backflow, enhancing system reliability and efficiency .

Q: Assess the rationale behind using stainless steel in the grit pump components of a sewage treatment plant, given its operating environment.

Stainless steel is chosen for grit pump components, such as impellers, pipes, and support frames, because of its resistance to corrosion and erosion caused by sand and wastewater . This material is ideal for the harsh operating environment within a sewage treatment plant, where durability against abrasive and corrosive elements is crucial for the longevity and reliability of the equipment .

Q: Discuss the importance of structured cabling in the communication systems of a sewage treatment plant and explain the architectural considerations mentioned.

Structured cabling is essential in a sewage treatment plant for reliable data and voice communication, enabling effective monitoring and control of plant operations . The architectural considerations include maintaining a cable run of no more than 90m from outlet to patch panel, using Cat 6e cables and metal containment to suit office layouts, and arranging for a broadband communications network connection with a regional provider . These considerations ensure optimal performance and scalability of the communication system .

Q: How does the proposed fire alarm system testing and training process ensure comprehensive system functionality and user preparedness?

The proposed fire alarm system testing and training process ensures comprehensive system functionality and user preparedness by mandating full testing, commissioning, verification, certification, and demonstration/trainings conducted by a specialist fire alarm supplier . This exhaustive approach ensures that not only is the system technically sound, but that personnel are well-trained to operate it effectively, thereby enhancing readiness for any fire incidents .

Q: How does the designed standby generator system ensure seamless power supply during power failures in a sewage treatment plant?

The standby generator system is designed to ensure seamless power supply during mains power failure by being appropriately sized to maintain essential plant operations at 100% capacity and being equipped with a power management system, synchronization panel, and sufficient fuel storage for continuous operation . These features allow the system to take over immediately during power outages, preserving critical functions of the sewage treatment plant .

Q: Why are spare capacities in control system inputs, outputs, and logic capacity crucial for the central control networks in a sewage treatment plant?

Spare capacities of not less than 25% for inputs and outputs, and 30% for system logic capacity, are crucial for the central control networks in a sewage treatment plant to accommodate future expansions, ensure resilience and flexibility in operations, and prevent overloading during unforeseen operational demands . This ensures robustness and longevity in maintaining seamless control and monitoring functionalities .

Q: What system design features are proposed for the central control and process monitoring system in the STP to ensure effective operation and monitoring?

The system design features for the central control and process monitoring system in the STP include a centralized control system based on an interconnected PLC network, multiple PCs providing master stations and operator panels, interactive control functions, and display of alarm and digital/analogue information . These features ensure effective operation and monitoring by providing a comprehensive interface for real-time operational awareness and control capabilities .

Q: What roles do automated and manual controls play in the management of sewage treatment plants, and how are these controls integrated to optimize operational efficiency?

Automated controls in sewage treatment plants manage routine operations and ensure efficient plant processes with minimal human intervention, using PLCs and SCADA systems for real-time monitoring . Manual controls serve as a backup during system failures or abnormal conditions, allowing staff to take localized control from switchboards, ensuring continuity and safety . Together, these control types are integrated to optimize operational efficiency by automatically handling standard operations while enabling manual oversight when necessary .

Q: What are the minimum backup power supply requirements for a control network system in a sewage treatment plant, and why are these requirements crucial?

The minimum backup power supply requirements for a control network system in a sewage treatment plant include the provision of UPS (Uninterruptible Power Supplies) in the main control room and for all sub-centres . These requirements are crucial because they ensure continuous operation and control of critical systems during power outages, thereby maintaining operational reliability and safety in managing sewage treatment processes .

Q: Describe the roles and importance of the various control and instrumentation systems in monitoring and managing the sewage treatment plant processes.

The control and instrumentation systems in a sewage treatment plant are responsible for process monitoring, utilizing PLCs, OPs, detectors, and back-up power supplies to maintain efficient operation . These systems provide full functionality for automatic process control, enabling minimal staffing, while ensuring safety and reliability through continuous monitoring and emergency shutdown capabilities .

The document appears to be technical specifications for an MEICA (mechanical, electrical, instrumentation, control and automation) system for a wastewater treatment plant. It includes sections on applicable standards, electrical details, control networks, the main control room, monitoring systems, instrumentation, mechanical details, and provides specifications for various components of the wastewater treatment process. The level of technical detail suggests this document is intended for contractors bidding on the wastewater treatment plant project.

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26 views61 pages

Dammam ISTP MEICA Technical Specs

Uploaded by

Mahmoud Ibrahim

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February 2018

Confidential

Dammam ISTP
Request for Proposals

Part II: Technical Specification

Appendix B: MEICA Specifications

2018

Table of Contents
1 Introduction............................................................................................................................... 4
1.1 Project Coordination.................................................................................................... 4
1.2 Supply of Power and other utilities..............................................................................4
2 APPLICABLE STANDARDS..................................................................................................... 6
2.1 Table of Standards...................................................................................................... 6
3 ELECTRICAL DETAILS............................................................................................................ 8
3.1 Power Requirements................................................................................................... 8
3.2 Supply of Electricity..................................................................................................... 8
3.3 MV Circuit Breakers..................................................................................................... 9
3.4 MV Switchboards 13.8kV............................................................................................ 9
3.5 Ring Main Units 13.8kV............................................................................................. 10
3.6 Transformers 13.8kV................................................................................................. 10
3.7 Cabling...................................................................................................................... 10
3.8 Battery and Battery Charger (Protection Relays).......................................................11
3.9 Distribution Boards (For Building Services)...............................................................11
3.10 Low Voltage (LV) MCC.............................................................................................. 12
3.11 Earthing and Lightning Protection..............................................................................13
3.12 Lightning Protection................................................................................................... 14
3.13 Lighting and Small Power Installations......................................................................14
3.14 Outdoor Lighting........................................................................................................ 15
3.15 Fire Alarms................................................................................................................ 15
3.16 Communication Systems........................................................................................... 16
3.17 Stand-by Diesel Driven Generator Set......................................................................16
4 ICA PARTICULAR SPECIFICATION......................................................................................17
4.1 Control Networks Requirements................................................................................17
4.2 Main Control Room.................................................................................................... 18
4.3 Central Operator Control and Process Monitoring System........................................19
4.4 PLC Panels................................................................................................................ 23
4.5 System Setpoints....................................................................................................... 24
4.6 Long Term Data Storage........................................................................................... 24
4.7 Communication System............................................................................................. 24
4.8 Uninterrupted Power Supply (UPS) System..............................................................24
4.9 General SCADA Monitoring.......................................................................................25
4.10 Instruments................................................................................................................ 25
4.11 Temperature Equipment............................................................................................ 26
4.12 Flow Measuring Equipment.......................................................................................27
4.13 Level Control Equipment........................................................................................... 27
4.14 Pressure Measuring Equipment................................................................................28
4.15 Sludge Solids Content Transmitter (if applicable)......................................................28
4.16 ORP Meter................................................................................................................. 28
4.17 pH Meter.................................................................................................................... 29
4.18 Gas Measuring Equipment........................................................................................ 29
4.19 Instrumentation Cables and Cabling..........................................................................29
4.20 Function Descriptions................................................................................................ 29
5 Mechanical............................................................................................................................. 34
5.1 Inlet Chamber............................................................................................................ 34
5.2 Screening Station...................................................................................................... 34
5.3 Aerated Grit Chambers.............................................................................................. 37
5.4 Primary Distribution Chamber and Flower meter chambers......................................39
5.5 Aeration Tanks.......................................................................................................... 40
5.6 Secondary Clarifiers.................................................................................................. 44
5.7 Tertiary Disc Filtration................................................................................................ 44
5.8 Disinfection, In-line Chlorination................................................................................45
5.9 Return and Surplus Sludge Pumping Station (if applicable)......................................45
5.10 Sludge Storage Tank (if applicable)...........................................................................47
5.11 Belt Filters (if applicable)........................................................................................... 47
5.12 Washing, Fire Protection and Site Irrigation System Units........................................52
5.13 Return Flow and Drain Pumping Station...................................................................54
5.14 Submersible pumps................................................................................................... 55
5.15 Conditioning monitoring............................................................................................. 56
5.16 Odour control............................................................................................................. 56
5.17 Plant Tagging and Labelling......................................................................................56

3
Glossary of Terms
Mizuho Bank, Ltd. as Lead and Financial Adviser
White & Case LLP as Legal Adviser
Advisers
WS Atkins & Partners Overseas and Engineering Consultants as
Technical Adviser

AC Alternating Current
Applicant An individual company or a Consortium of companies experienced in the
wastewater treatment sector
Pre-Qualified Applicant(s) who have fulfilled the eligibility requirements
Bidder set out in this RFQ and are not disqualified in terms of this RFQ and have
been issued a NPQ by the Procurers
BOOT Build, Own, Operate and Transfer
Customer Acceptance Test
CAT
A joint venture, partnership or other combination of international and/or
Consortium
KSA companies jointly participating as an Applicant
CDM Construction Design Management Regulations
cpi Characters per inch
DC Direct Current
DPi Dots per inch
Due Date the deadline for submission of RFP
EICA Electrical Instrumentation Control and Automation

ECA Export Credit Agency

EPC Engineering, Procurement and Construction
ESF Electrical Special Facilities
ESIA Environmental and Social Impact Assessment
FAT Factory Acceptance Test
FDS Functional Design Specification
FOC Fully Operational Capability
FQR Financial Qualification Requirement
Member of a Consortium that will rely on commitments from third party
Fund Investor
sources other than affiliates to meet its financial obligations.
GAMEP General Authority for Meteorology and Environment Protection
Government Government of the Kingdom of Saudi Arabia
HMI Human Machine Interface
HV High Voltage
HVAC Heating, Ventilation, Air Conditioning
ICA Instrumentation Control Automation
IO Input Output
ISTP Independent Sewage Treatment Plant
IW(P)P Independent Water (and Power) Plant
JSC Joint Stock Company
KSA Kingdom of Saudi Arabia
kV Kilo Volt
kW Kilo Watt
kWh Kilo Watt Hour
Lead Developer Main point of contact and manager in respect of a Consortium

1
LED Light Emitting Diode
LLC Limited Liability Company
LTC Levelized Treatment Cost
LV Low Voltage
MCC Motor Control Centre
MEP Mechanical, Electrical, Process
MEWA Saudi Ministry of Environment, Water and Agriculture
MFEC Minimum Financial Evaluation Criteria
Mg/l Milligram per litre
MOF Ministry of Finance of the Kingdom of Saudi Arabia
MTEC Minimum Technical Evaluation Criteria
MV Medium Voltage
NGR Neutral Grounding Resistance
NPQ Notice of Pre-Qualification
NTP Notice To Proceed
WEC National Water Company
O&M Operation and Maintenance
OP Operator Panel (HMI)
ORP Oxidation Reduction Potential
PABX Private Automatic Branch Exchange
PC Personal Computer

PCOD Plant Commercial Operation Date

Independent sewage treatment plant of total ultimate treatment capacity
Plant
of 350,000 m3/day in West Dammam, in the KSA

PLC Programmable Logic Controller

Project Develop, design, financing, engineer, procure, construction,

commissioning, complete, testing, ownership, operation, maintenance
and insurance of the Plant in the KSA
A new company to be formed to undertake the Project, incorporated and
Project Company
registered in the KSA as a closed JSC or LLC
PTFE Polytetrafluoroethylene
RMU Ring Main Unit
RMS Root Mean Square
RFP Request For Proposal
RFQ Request For Qualification
RTU Ring Terminal Unit
SAT Site Acceptance Test
SAR Saudi Arabian Riyal
SCADA Supervisory control and data acquisition
SEC Saudi Electricity Company
SCECO Saudi Consolidated Electric Company
SoC State of Charge
SOQ Statement Of Qualifications
STA Sewage Treatment Agreement
STP Sewage Treatment Plant
TQR Technical Qualification Requirement
US$ US Dollars

UPS Uninterruptable Power Supply

UV Ultra Violet
VDU Visual Display Unit
VFD Variable Frequency Drive
WEC Water and Electricity Company
STP Waste Water Treatment Plant

CMMS Computerised Maintenance Management System

OP Operation Panel

3
1 Introduction
This Appendix sets out the General and Particular Specification for Mechanical, Electrical,
Instrumentation, Control and Automation (MEICA) for the Dammam Sewage Treatment Plant (STP)
that the Project Company shall comply with. Where the Project Company is providing plant that is
outside of these specification clauses, the same standards and level of quality is to be applied as
detailed in these clauses to that plant.

The Project Company shall comply with the following WEC standards:

 Design Manual for Sewage Treatment Plants (Ministry of Water & Electricity; Feb 2007)
 Standard Technical Specification for Sewer Networks (Ministry of Water & Electricity; Sept
2007)
 Guide to the design of gravity sewers and manholes (NWC)
 Standard Technical Specifications Water Supply Networks (NWC)
 Saudi Building Code Requirements (SBC)

If there is conflict between the above WEC standards and the clauses in this appendix B then this
appendix B shall overrule.

This specification has been produced to describe the MEICA works associated with this project see
DMM RFP Part 2 Technical Specification for the project description.

In general, the Project Company shall carry out the scope of supply in accordance with this
specification and to the satisfaction of the WEC and shall be responsible for the technical
performance in all respects of the Project Company works and, for the adequacy, stability and safety
of the Project Company’s site operations.

MEICA installations work within the STP shall be designed and carried out by the Project Company in
accordance with the current regulations, specifications and project requirements.

1.1 Project Coordination

 The Project Company shall include for all necessary liaison costs associated with co-
ordinating his works with the WEC, Suppliers and other Sub-Project Company’s. This
shall include but not be limited to collaborative planning, programming and health and
safety liaison.

1.2 Application of specifications

It should be noted that the MEICA specifications prescribed in this document are based on the
infrastructure and equipment which is typically expected for a sewage treatment plant of this size and
nature. The final agreed specifications may be varied/adjusted to suit accepted proposals from the
Project Company. In in all instances acceptable best practices and applicable standards should be
followed.
1.3 Supply of Power and other utilities
1. The Project Company shall be responsible for the purchase, provision and payment of all
tariffs and costs of:

2. A new substation for the site to the Saudi Electricity Companies requirements, standards and
approved layouts for electricity substations and all other electricity cables, connections and
infrastructure necessary for the supply of electricity to the STP. The Project Company shall
be responsible for all negotiation with the SEC for the capacity and the supply tariff and all
payments for power for the Concession period;

3. potable water connections and related infrastructure necessary for the supply of potable water
to the Plant; and

4. telecommunication links, including telephone, facsimile and internet, to the Plant, (together
the Utilities Works),

and in all cases, the Project Company shall be responsible for connecting the same to the Utilities
Handover Points.

5. The Project Company shall ensure that the Utilities Works are carried out:

6. by an appropriately qualified Contractor selected from the list of approved Contractors

maintained by the relevant utility Company; and

7. to the standards required by such public utility companies.

5
2 APPLICABLE STANDARDS
2.1 Table of Standards
The current editions of the standards, codes and recommendations issued by the following
organizations shall apply for the design, construction, testing and commissioning of the Works.
All items provided by the Project Company shall be designed, supplied and installed in accordance with
the more stringent of the Kingdom of Saudi Arabia standards and international standards (ISO or
similar indicated below), but only to the extent that these international standards are not in conflict
with Saudi Arabian legislative requirements.

ISO International Standardization Organization

IEC International Electrotechnical Commission National
Standards
ANSI American National Standards Institute
BSI British Standards Institution
DIN Deutsches Institut für Normung
EN European Standards
JAPS Japanese Standard Organization Codes/Recommendations
ACI American Concrete Institute
AGMA American Gear Manufacturers Association
AIJ Architectural Institute of Japan
AISC American Institute of Steel Construction
AISE Association of Iron and Steel Engineers
AISI American Iron and Steel Institute
AMCA Air Moving and Conditioning Association
API American Petroleum Institute
ASCE American Society of Civil Engineers
ASHRA American Society of Heating, Refrigeration and Air
E Conditioning Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
AWS American Welding Society
AWWA American Water Works Association
HIS Hydraulic Institute Standards
IEEE Institute of Electrical and Electronics Engineers
IPCEA Insulated Power Cable Engineers Association
ISA Instrument Society of America
JEC Japanese Electrotechnical Institute
JEMA Japan Electrical Manufacturers Association
JIS Japanese Industrial Standards
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Standards
SASO Saudi Arabian Standards Organization
WEF Water Environment Federation
VDE Verband Deutscher Elektrotechniker

7
3 ELECTRICAL DETAILS
The Project Company’s shall provide everything necessary to ensure a fully functional Sewage
Treatment plant for the Concession period. The following sections describe the requirements of the
main expected elements to be featured in the electrical infrastructure. The Project Company shall fully
review all documents and submit their design as part of the tender.

3.1 Power Requirements

The power supply for the sewage treatment plant shall be appropriately sized for all the electrical
demands throughout the life of the plant. If the STP process capability is to be phased the Project
Company may consider a phased increase in supply capacity to suit. If the negotiations with the SEC
reveal that the SEC is unable to provide a sufficient capacity to meet the site requirements at any
phase, then the Project Company will include for the provision of additional site generated supplies to
provide the full capacity or to either augment what capacity the SEC is able to supply, or provide. If
this is in the form of diesel generators the Project Company will ensure the generators are suitable
and rated for continuous use. The Project Company shall note that standby power generators are not
usually suitable and rated for continuous use.

The site power supply shall be backed up by suitably sized standby generators to meet the
requirements of the critical processes and operation and maintenance needs. This will require the
provision of a Power Management System (PMS) that will load shed non-critical plant in the event of
power failure.

3.2 Supply of Electricity

The Project Company shall ensure that the construction of the Electricity Metering Stations and
connection thereto of the Plant is performed in a manner satisfactorily to SEC. The Project Company
shall provide SEC with all pertinent information and data regarding design, engineering materials,
equipment, construction and other specifications which the Project Company proposes to use to
connect the Plant to the Electricity Delivery Points, and shall coordinate with SEC to ensure prompt
and safe interconnection.

The Project Company shall:

(i) maintain the Electricity Delivery Points and Electricity Metering Stations in
accordance with the Law, Good Utility Practice and the requirements of SEC;

8. comply with all rules, regulation and requirements of SEC as regards to the
calibration and maintenance of the Electricity Delivery Points and Electricity
Metering Stations; and

9. communicate and coordinate with SEC in order to ensure the efficient operation
of the Electricity Delivery Points and Electricity Metering Stations.
The power supply to the STP shall be at Medium Voltage (MV): 13.8 kV, 60 Hz, 3 phases, 3 wires,
and ground/earth. The origin of the MV supply shall be determined by the Project Company and SEC.

Distribution transformers provided by the Project Company shall provide LV (Low Voltage): 380V,
60 Hz, 3 phase, 4 wire, solidly earthed supplies for the STP plant.

3.3 MV Circuit Breakers

The circuit breakers shall be of the Vacuum type with facilities for both busbar and line earthing.
Circuit breakers shall be capable of being both mechanically and electrically opened as a minimum.
Circuit breakers shall be engineered to meet the required functional performance of their application,
special consideration should be given where synchronising duty is required. Spring charging motors
shall be supplied if required by the system design.

The breakers shall be provided with indicating lamps for all cubicles. This shall include indication for
circuit breaker open position, circuit breaker closed position and circuit breaker tripped on fault
conditions.

Breakers shall be provided with remote operating controls and volt-free contacts for connection to a
remote central control desk and SCADA to provide ‘remote manual’ control and remote monitoring of
each circuit breaker.

Modern powered electronic (numerical) protection relays shall be provided at each circuit breaker to
suit the application and connected load type. A fully graded protection system shall be provided in
accordance with the power system requirements. Circuit breaker control design shall include close
first interlocks, inter-trip receive and trip send functions, trip circuit supervision relay, sync check relay
etc. as required.

In case of dual power supply, the circuit breakers shall also have a mechanical and an electrical
interlock installed across them to ensure they always are operated on a 2 from 3 basis at all times if
this is a requirement of the power system design.

Each circuit breaker shall be supplied complete with a manual spring-charged closing mechanism
having a trip-free feature and complete with on-off indication, DC shunt trip and auxiliary switches.
Automatic tripping of circuit breakers shall operate under fault or under voltage conditions.

3.4 MV Switchboards 13.8kV

13.8 kV, MV Switchboards shall be supplied and installed inside dedicated indoor ‘HV switch rooms’
as required by the STP power distribution network architecture. 13.8 kV Switchboards shall provide
MV power management and distribution across the site and provide metering, incomers, bus-
couplers, ring main feeders, distribution transformer feeders and feeders to other MV loads as
required.

Power distribution transformer low voltage windings (380 V) shall be connected to 380V switchboards
and MCCs to feed process equipment and loads at different locations.

All MV switchboards provided shall be capable of continuous operation within the internal environment
over an internal temperature of 5degC to 45degC

For MV switchgear each functional unit shall be constructed to form a rigid, free-standing enclosure
and adjacent enclosures shall be securely bolted together to form a rigid Assembly. The switchgear

9
sections shall be constructed from steel with a protective painting system giving a life to first
maintenance of at least 25 years.

The overall switchgear enclosure shall be to IP41. Internal compartments shall be IP3X.

Busbars shall be hard-drawn, high conductivity tinned copper. The busbars shall be suitably rated and be
capable of carrying the rated short circuit current of the switchgear for 3 seconds, an earth bar shall run the
whole length of the switchboard.

Ratings of current transformers, indicating instruments, electronic protection relays etc. shall be
determined by the Project Company with the approval of the Engineer. All cable entries to panels
shall be from below or rear side of the switchboard.

For all units, mechanical indicators on switches shall show on, off, earth position in Arabic and
English.

Each door to the high voltage switch room(s) shall be provided with a set of safety and warning
notices in Arabic and English with the inscriptions in accordance with statutory requirements approved
by the WEC Engineer.

3.5 Ring Main Units 13.8kV

Where MV ‘ring main’ distribution circuits are used to feed distribution transformers MV ring main units
(RMUs) shall be provided local to each distribution transformer. The actual MV power distribution
design shall be proposed by the Project Company and submitted to the Engineer for acceptance.

Each RMU shall comprise two ring switches and a tee-off vacuum circuit breaker, all mounted within a
common enclosure. Integral earthing switches shall be provided for each ring switch and the
transformer circuit.

The RMU shall be designed for front operation and indication, the RMU shall be suitable for both
indoor and outdoor mounting.

3.6 Transformers 13.8kV

Distribution transformers shall be installed in substations around the STP site to provide local power
centre supplies for process equipment. The design shall ensure compliance with the appropriate
standards for fire separation, fire zone management, bunding, forced air cooling etc. Distribution
transformers shall be fed from MV switchboards or Ring Main Units in accordance with the HV system
design.

Distribution transformers shall be liquid filled outdoor type, oil immersed and have naturally cooled
radiators.

Each substation shall include two transformers which shall operate as duty and standby units,
providing N+1 redundancy. Each transformer shall be rated to handle 100% of the connected load. All
transformer ratings shall be determined by the Project Company with the approval of the Engineer.

Transformers shall be suitable for operating in the site climatic conditions and this may include sun
canopies to protect the transformers. An assessment shall be carried out by the Project Company and
approval shall be sought from WEC for any solution that makes the transformers more suitable for
climatic conditions.
3.7 Cabling
All MV and LV cables including accessories such as pot-heads, cable splices, glands or terminals shall be
provided in accordance with the current Regulations of SCECO.

All cabling shall be supplied from WEC approved suppliers.

 All MV power, LV power, control and instrumentation field cables shall be steel wired
armoured (SWA) type.

 Cables routed inside buildings and through cable trenches shall be securely mounted on
heavy duty, galvanised steel (or GRP type) cable ladder or cable tray.

 Power cables shall be direct buried for outdoor runs with suitable trenching except for road
crossings where HV and LV ducts shall be provided. MV, LV, control and signal cables shall
be segregated for the whole length of the individual runs.

 Bending preparation and depth for the cables shall be suitable for the application.

 The thermal characteristics of the cable sand used for backfilling shall be suitable for the
cable trenches involved

 Cable testing shall be carried out, including insulation, continuity testing and associated
documentation to be provided and recorded on the CMMS.

 All HV cables shall be pressure tested prior to commissioning and following repairs or
alterations. The HV cables shall not be energised during the pressure test.

The cable installation design shall utilise ERAC/ETAP (or recognised equivalent) and load flow
models.

If due to working condition e.g. ambient temperature, atmospheric contamination, mechanical stress,
electrical interference, etc. more stringent methods of wiring are required to fulfil particular needs then
the most suitable cables and installation methods shall be used.

Fully detailed Cable Schedules shall be produced for each installation giving detailed information
about cable type, design load, cross-sectional areas and estimated route length. Cable lengths and
ratings of cables shall be appropriately sized. All cable information shall be recorded on the CMMS.

Installation routes and details of the cables shall be provided on drawings and submitted to WEC for
approval. For any modification required approval must be sought from WEC. In general, all required
cabling shall be provided and installed as per the approved design.

3.8 Battery and Battery Charger (Protection

Relays)
All protection relays on MV and LV switchboards and MCCs shall be DC battery powered and shall be
provided with a mains powered battery charger of suitable duty. This equipment shall be rated and
designed for protection relay applications.

11
3.9 Distribution Boards (For Building Services)
Each building shall be provided with building services distribution boards, for MEP services (lighting,
small power, HVAC, fire alarm system) The distribution boards shall be supplied and installed in
locations with the approval of the Engineer.

Separate dedicated distribution boards shall be provided for instrumentation and process critical
equipment. Building services distribution boards shall not supply instrumentation.

3.10 Low Voltage (LV) MCC

Low voltage MCCs shall be provided local to the process loads in the process buildings.

MCCs supplied shall be totally enclosed, freestanding, sectionalised, multi cubicle type, factory built
assemblies. They shall be equipped as required to provide incomers, bus-couplers, motor starters,
motors drives, feeders and ICA controls for the STP low voltage plant and equipment.

Construction shall be to (or equivalent to) Form 4 (in compliance with BS EN 61439) withdrawable
type.

Low voltage MCCs shall be supplied and installed inside dedicated indoor ‘LV switch rooms’.

Access to the field cable terminations shall be from the ‘rear’ or ‘front and rear’ of the MCC. Cable
entry shall be at the bottom.

All LV switchboards and MCCs provided shall be capable of continuous operation within the internal
environment over an internal temperature of 5degC to 45degC

The overall MCC enclosure shall be to IP54 minimum for non-ventilated equipment and IP41 for
ventilated equipment. Internal compartments shall be IP2X.

An air insulated, enclosed busbar chamber shall run along the length of the MCC/switchboard with an
external copper earth bar. Busbars, neutrals and earth bars shall be hard-drawn, high conductivity
tinned copper. The busbars shall be suitably rated and be capable of carrying the rated short circuit
current of the MCC for 3 seconds.

Circuit breakers rated 800A and above shall be Air type circuit breakers.

Ratings of current transformers, indicating instruments, electronic protection relays etc. shall be
determined by the Project Company with the approval of the Engineer.

Electricity KWH meters are to be provided on the incomers to MCCs and at principal feeders as
required to meet WEC energy management requirements.

Each MCC shall be provided with a minimum 20% spare cubicles.

Motors with nameplate ratings 11kW (15 HP) and above shall be provided with reduced voltage
starting e.g. star-delta, soft starter or variable frequency drive, depending on the motors ratings and
application.

All Motors shall have their own individual starter panels for isolation and correct lock-out procedures.
All package equipment shall be supplied with their own local control panels to provide operational
flexibility.

For all units, mechanical indicators on switches shall show on, off etc. in Arabic and English.
Each ‘LV switch room’ door shall be provided with a set of safety and warning notices in Arabic and
English with the inscriptions in accordance with statutory requirements approved by the WEC
Engineer.

Automatic Power factor correction (PFC) units shall be provided in the LV switch rooms to achieve an
overall power factor of 0.95.

3.11 Earthing and Lightning Protection

3.11.1 Substation MV and LV Earthing Installations
Separate MV and LV earthing systems shall be provided for all MV substations. The earthing design
and installed electrode systems shall meet the requirements of all KSA national standards and the
current regulations of the Ministry of Water and Electricity (MOWE) and SEC requirements. A
complete earthing system design is to be prepared by the Project Company. The design shall ensure
the safe operation of the electrical network during normal and abnormal conditions and the protection
of personnel and equipment. The safe operation shall be demonstrated by calculations and computer
models.
Soil resistivity tests shall be carried out on site and witnessed by the Engineer to determine the
location and the number of electrodes. Earthing resistivity for each electrode shall not exceed 2 ohms,
and for the whole earthing systems shall not exceed 1 ohm.

The earthing electrode systems shall consist of interconnected rods and buried tapes, it shall be
designed with multiple electrodes and provided with readily removable test connections to allow for
electrode testing. Double earthing electrode nests shall be installed at a location near to the
Substation that is approved by the WEC.

Connections to main earth rods shall be installed in a manner that electrode nests shall maintain
earthing even when one is not working or isolated.

A minimum of 4m separation shall be maintained between the MV and LV rod groups. At any location
where the MV earth does not maintain the 4m separation from the LV earth, the MV earth will be
insulated to maintain the electrical isolation between the two systems (if required).
The MV Main Earth Bar shall be connected to MV Main Earth Bars in adjacent substations.
Within each substation, the Main MV Earth Bar and Main LV Earth Bar shall be interconnected if the
earthing system design permits this interconnection. To ensure this arrangement is safe, the ground
potential rise will be calculated as per TES-P-119.10 and confirmed as lower than the acceptable
touch and step voltages within the same standard.

3.11.2 Bonding Conductors or Tapes

All metallic sections of cable trays, ladders and trunkings shall be bonded together. Bonding jumpers
(either the welded type used on steel trays or the lug type) must be placed across each joint. When
cable tray or trunking covers are used, they shall be bonded to the tray/trunk with a flexible conductor.
The trays, ladders, trunks themselves shall be bonded to the building steel (usually at every other
column) and to all conduits containing conductors common to the cable tray system. Where cable
support steelwork is insulated from the site’s steelwork e.g. concrete cable tunnels, the steelwork shall
be bonded direct to earth. This connection shall be made onto every section of insulated steelwork
using any convenient site’s earth cable carried on that section of steel work. In cases where there is
no earth cable on the section of steelwork, a separate earth cable shall be used, this cable being
connected into the nearest adjacent section of earth system. The terminations of the cable onto the
steelwork shall be provided.

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Where gates exist in steel fences or the doors of a total enclosure are of sheet steel, particularly if the
fence or door is discontinuous, they shall be bonded on both sides of the gate or door to avoid the
possibility of a potential developing across the gate or door.

Where there are metal structures or fences adjacent to a substation, potential differences may occur
between them and the metal parts of the substation or the fences, which may be within touching
distance. On the other hand, if such structures are bonded, or in contact with the substation steelwork,
then the potential may be carried a considerable distance from the substation, e.g. along the wires of
a fence with wooden posts and create a danger elsewhere. Substations must be designed and sited
to avoid these situations.

The size, type, connection details and installation method of bonding conductors or tapes shall be
designed in accordance with the American National Standards Institute.

3.12 Lightning Protection

Proper lightning arresters shall be installed at the connection points of overhead supply lines to the
Substation building. Lightning arresters shall be supplied and assembled for whole buildings.
The earthing of the lightning arresters shall be carried out to individual earth electrodes for lightning
protection. The earth electrodes of the lightning protection shall be interconnected, but the links
between the earthing of lightning protection and the earthing network of the plant shall be in
accordance with local earthing practice and electricity company guidance. Earthing and lightening
protection installations including materials such as earthing electrodes, conductors, cable shoes shall
be supplied and installed in accordance with relevant clauses of current regulations of Ministry of
Water and Electricity (MOWE) and SCECO.

3.13 Lighting and Small Power Installations

Lighting and small power installations shall consist of building's lighting and socket outlets. Generally,
weatherproof cables shall be installed at the buildings such as chemical/ process rooms, pumping
stations and valve rooms (except the Administration Buildings where ceiling or wall finishes permit
sealed installations). Therefore, all lighting switches, socket outlets and junction boxes shall be metal-
clad surface mounting type.

The lighting installation shall include normal task lighting, maintenance task lighting and emergency
lighting for all indoor areas.

The illumination levels of the lighting installation shall be as follows:

Internal Plant Areas : 200 Lux.
Switch rooms : 300 Lux.
Control room : 500 Lux.
Transformer shelters : 200 Lux.
Workshop : 300 Lux.
Offices. : 200 Lux
Stores, Corridors, Toilets : 150 Lux
Lighting fixtures shall generally be in accordance with the relevant clauses of the General
Specifications.

220 V single-phase socket outlets shall be provided in the Administration Building, Personnel Building
and Guard House and in other buildings on a distance as per engineer instruction and at least two in
every room of the Administration Building and Guard House and all plant areas at suitable locations.
380 V three-phase socket outlets shall be provided at least one per plant area where the Project
Company considers these necessary for operation and maintenance purposes. The Project Company
shall prepare detailed layout and installation drawings for approval by the Engineer. Lighting and
small power installations including all equipment and materials such as lighting fixtures, socket
outlets, Lighting Panels with miniature circuit breakers, lighting cables, wires and conduits shall be
provided and installed by the Project Company in accordance with the relevant clauses of the WEC
General Electrical Specifications.

3.14 Outdoor Lighting

Outdoor Lighting shall consist of concrete or steel lighting poles, pole-mounted type outdoor lighting
fixtures and underground cables.
The illumination levels of outdoor lighting shall be as follows:
Outdoor Plant Areas : 50 Lux.
Plant Operational Areas : 100 Lux
Main Entrances at Gates : 150 Lux.
Outdoor lighting cables shall be laid underground. Concrete pipes shall be used where outdoor
lighting cables cross the concrete pavements. Concrete manholes or cable draw-out pits shall be
installed where necessary.
Outdoor lighting circuits shall be contactor switched, controlled automatically by a photocell or
manually by push buttons.
The contactor, auto/manual selector switch and push buttons shall be incorporated in the lighting
panel of Pumping Station or Guardhouse. Photocells shall be wall mounted on the south face of the
building wall from where outdoor lighting is controlled.

3.15 Fire Alarms

An automatic fire detection and alarm system shall be provided to cover all indoor areas and
buildings. The system shall be designed to meet the requirements of the Project Company’s Fire
Safety Plan and the applicable KSA national fire standards. The Project Company shall be
responsible for liaising with the WEC’s Fire Officer to obtain approvals for the fire alarm system and its
configuration.

The fire alarm system shall be a fully addressable open protocol system. The fire alarm system shall
be configured into zones.

Electronic sounders shall be installed to achieve minimum audibility levels of 75dB (A). Audibility shall
be 10dB (A) above background noises where these persist for more than five seconds. Levels shall
be measured with all doors closed. Sounders shall incorporate strobes and be programmable from the
fire alarm panel.

Smoke detectors shall be installed to comply with BS5839 or equivalent specification. Optical smoke
detectors shall have a sensitivity adjustment over a three-step range to allow for variance in ‘air’
condition within any room or area.

Heat detectors shall be the combined fixed high temperature / rate of rise type. Detectors shall
possess a minimum of 6 possible selecting sensing states of operation.

Interface units shall be provided as necessary to ensure operation / shut-down of ancillary items of
equipment / plant etc. in the event of an alarm condition.

A label shall be securely fixed to each device clearly identifying the address notation in line with the
designs schedule of devices.

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The system shall be wired in MICC cable with a LSF over sheath, or approved equivalent, having and
enhanced circuit integrity when exposed to fire. Cables shall be manufactured to BS 7629 or
equivalent. Cables shall incorporate copper conductors rated at 300/500 volts and coloured red.

Break glass call points shall be provided at all points of egress from the buildings and additionally as
required by search distances.

The Fire Alarm System shall include a function to allow the operation of agreed elements to not be
affected during a fire alarm system test.

The Project Company shall include for the full testing, commissioning, verification, certification and
demonstration/training of the fire alarm system by the specialist fire alarm supplier.

3.16 Communication Systems

A structured cabling system shall be installed throughout administration and populated areas. The
system will comprise from Cat 6e cables, outlets, cable trays, conduits, and containment.
All data and voice cables will terminate inside the server room. The containment will consist of basket
at high level when concealed behind ceilings, with metal containment drops to individual points, and
dado trunking to suit office layouts.
The contractor shall ensure a cable run of no more than 90m is maintained from outlet to patch panel.

The Project Company shall arrange for a suitable broad band communications network connection
with the regional Communications provider.


3.17 Stand-by Diesel Driven Generator Set

A Standby diesel driven generator installation shall be supplied and installed. The standby setup shall
be sized to maintain the essential plant in operation at 100% capacity during the event of a mains
power failure. The generation voltage is anticipated to be at the level of 13.8 kV.
The generator system shall be provided complete with all auxiliaries required for the system operation
including the following as minimum
 Power Management System – To manage multiple generator operation, preserve
site power and run critical plant only.
 13.8kv switchgear complete with Synchronization panel
 Daily fuel tanks
 Bulk storage tanks with capacity of 4 days fuel requirement for 100% operation of
essential plant.
 Fuel storage area bunds sized to minimum 110% capacity of the fuel storage
capacity.
 Starting aid facility (air starting method)
 Earthing system including NGR if required by ERACs/ETAP modelling.
The units shall be installed inside a building suitable for safe operation of the units including
ventilation system, air intake system, lifting facility, lighting system and firefighting system.
The Project Company shall be responsible for the supply of sufficient generator systems to produce
electricity for the operation and lighting of the treatment plant and shall submit to the approval of the
Engineer.
It is to be noted that if the Project Company is providing continuous (I.e. not standby) power
generation to augment or substitute for SEC, where SEC is unable to meet the site required capacity,
the continuous power shall be from a different installation to the standby power installation.
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4 ICA PARTICULAR SPECIFICATION
The Project Company’s objective is to provide a fully functional Sewage Treatment plant. The
following sections describe the requirements of the main elements to be featured in the control
network infrastructure. The Project Company shall fully review all documents and submit their design
as part of the tender. Alternative solutions can be recommended.

4.1 Control Networks Requirements

This part of the specification details the main system and plant together with the proposed control
system of the Sewage Treatment Plant (STP)

The instrumentation and control system shall include the following items as minimum:

 New Central Operator Control and Process Monitoring System for the new plant (to be
located inside the existing control room for phase-1) complete with monitor screens,
processors, servers, printers and plotters.

 New Furniture for main control room

 Back-up power supplies equipment (UPS) in main control room

 Back-up power supplies equipment (UPS) for all sub-centres.

 Detectors, indicators, switches, transmitters and emergency shutdowns.

 Overvoltage/lightning protection for UPS, PLC and specially, for surge/lightning, exposed
equipment(s).

 PLCs, OPs, process and analytical instrumentation as appropriate for the approved design

 The central control system to be viewable from NWC’s existing regional SCADA system

The Central Operator Control and Process Monitoring System shall utilize a purpose designed cable
communications network, and a detailed specification for this network shall be submitted at the time of
Tender for approval by NWC.

An alternative solution other than the one described can be provided if approved by the WEC.

4.1.1 Sewage Treatment Works Design Parameters

The STP design shall perform to meet the influent and effluent design standards described elsewhere
in the specification pack.

The processes involved shall be selected to assist with the design parameters and this may affect the
types of instrumentation and controls involved. Once these are finalised approval must be obtained
from NWC.
4.1.2 Works Operating Philosophy / setpoints
The systems shall be provided for the automatic operation for the STP and their associated support
and subsidiary plant installations with minimum staffing level.

For normal STP operation, staff level shall be limited to:

 Work management and senior supervisory staff located in the Administration
Building.

 Plant shift supervisory staff located at specific plant areas within the works.
 Plant operating and labouring staff necessary for day to day routine manual operating
tasks, and associated work.
 Maintenance personnel necessary for routine day to day and periodic plant
maintenance tasks

4.1.3 Site Operation

The complete works shall be divided into "Areas of Responsibility", each with a Programmable Logical
Controller (PLC) and an Operation Panel (OP)

Within each plant area, the individual plant installations shall be controlled by their respective local
PLC and OP. The PLC systems shall monitor the operation and shall carry out interactive control
functions between the plant installations within their areas.

All the signals that are required for the process plant safety, operation, plant critical alarm/trips and
controls shall be hard wired between plant installations.

Under abnormal operating conditions or a control system failure, each plant installation shall be
capable of being switched to manual control mode from the local switchboards.

The sub masters shall pass all the information to the master station in the main control room in the
Administration Building.

Under normal conditions, each local PLC shall control the local plant and the master station shall
supervise the whole STP process. All local plant shall work automatically, but it shall allow local "take
over" if necessary. The "takeover" shall be activated by a command or action at the local control
panel.

Control shall revert to automatic by activating a further command at the local control panel. All local
and central control system shall include spare installed capacity of not less than 25% of each input
and output module together with a minimum of 30% spare system logic capacity.

4.2 Main Control Room

A complete Main Control Room installation shall be provided on site. This will enable the management
staff and main plant operators to monitor the current situation on all the relevant process parameters,
together with the operating condition of STP and the site electrical power system, and to carry out
emergency plant operation. The system design shall include facilities to monitor (read only) the plant
operation at three (3) Plant Managers offices in the new operation & maintenance building.

The Project Company shall design, supply and install all equipment in the main control room.
The equipment that is proposed to be installed shall include but not limited to the following:
 One (1) Central Operator Control and Process Monitoring System including state
of the art PCs and accessories in accordance with the approval of the Engineer.

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 One (1) Program Development System including state of the art PCs and
accessories in accordance with the approval of the Engineer.
 One (1) Calendar clock.
 Two (2) set of control room furniture and chair for plant and personnel.
 One (1) set of equipment in the Manager's office comprising one (1) PC and
accessories in accordance with the approval of the Engineer.
 One (1) UPS system supplied to provide stand-by power for 120 minutes. This
equipment shall be protected against lightning and power surge.
 Display screens for all the site video installations

4.3 Central Operator Control and Process

Monitoring System
The following is a proposed solution. The viability of the proposed solution shall be assessed before
proceeding with the works. The following also states the minimum requirements expected on site.

4.3.1 System Design

A centralized control system shall be provided to monitor the operation and performance of the work
and also to provide automatic or remote control of the plant.

The system shall be based on an interconnected PLC network for control with multiple PCs providing
master station(s) and operator panels (OPs)

The alarm, digital and analogue information from the plant and the digital and analogue commands
from the sub master to the plant shall be displayed at the OPs at the sub masters and transmitted to
the main control room for processing and storage by the master station. This information shall also be
displayed on the monitors in the main control room and on the monitor in the manager's office.

A program development system shall be provided in the main control room. It shall be capable of
amending the system configuration and control database to incorporate planned expansion to the
works and also to take advantage of future technological developments which may take place in the
field of STP applications software.

Adjustable set points to modify the parameters on any item of plant shall be accessed by password
protected User Access levels.

Each sub master station shall consist of a PLC housed in a panel. The OP shall be mounted in the
front door. The panel shall also be equipped with all equipment necessary for the control and
monitoring of the plant for which that Local PLC is responsible. The direct control from the motor
control switchboards/MCC shall be manual only.

Automatic control sequences for plant shall be carried out within the PLCs but under abnormal
operating conditions or a PLC failure, the plant shall be switched to manual control from the relevant
control panel(s) or motor control centre.

An Uninterruptable Power Supply (UPS) system shall be installed to maintain each sub master for 120
minutes under a mains failure condition.
4.3.2 System Hardware
The Project Company shall submit a proposed Control System Architecture diagram and hardware list
together with full technical description of the equipment with the tender.

As a minimum, the system shall incorporate the following features:

Sub master stations shall be able to scan the outstations in their areas of responsibility and retrieve all
information in maximum 3 seconds.

Central master station shall scan the sub masters. Block transfer of data shall be accepted. All alarm
and event time and data recorded at the sub masters shall be transferred to the master station.

Failure of any outstation equipment shall provide an alarm at the sub master and central master but
shall not halt the routine scan. The scan shall step over the failed outstation.

Equipment shall operate over the temperature range +0°C to +55°C with relative humidity at 25°C of
95% non-condensing
Plant signal input/output (I/O) technical requirements:
 Digital input
Volt free contact with galvanic isolation on input module
 Digital output
Galvanic isolation and to switch up to 2 A at 24 V D.C.
 Analogue Input:
4-20 mA or 0-10 V, with common mode noise minimum of 80 dB and series mode noise of
minimum 40 dB. Each input shall be signal isolated.
 Analogue Output:
4-20 mA or 0-10 V with linearity ± 0.2 %, with an overload capability of 25%

The mean time between failures shall be stated and shall not be less than 5,000 hours and mean time
to repair shall be stated. Factory Acceptance Tests(FATs), witnessed by the Engineer or his
nominated representatives, shall be included.

4.3.3 System Software

The Project Company shall be responsible for supplying the software licences as well as the basic
operating system etc. to enable the system to operate. Provision must be made for the adding of
further software as and when required. All software functions shall be ‘user friendly’ with instruction
and messages to aid the operator.

The computers shall utilise a real time multi-tasking and networked operating system with a proven
track record in real time control applications.

It is a requirement that the system shall be supported by ‘on line’ configuration and editing of all VDU
mimic displays and database and to create new displays and additional database.

A minimum of two active windows should be displayable concurrently. The system shall be designed
to minimise the operator’s use of the keyboard. All major functions shall be accessible on-screen by
the use of the mouse.

VDU mimics shall display dynamic colour details of flow rates, pressures, motor status, levels, alarms,
electrical power supplies and other general equipment status conditions.

The software shall be fully compatible with the current release Microsoft operating system factory pre-
loaded on all computers.

The software shall be fully compatible with the existing Airport 1 STP systems and requirements.

The system supplier shall demonstrate a track record of having interfaced with SCADA / remote
telemetry equipment (RTU) supplied by reputed manufacturers with open industrial protocol.

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User Access
The functions available on the system shall be fully flexible so as to allow users access levels to be
customised by the System Manager to suit individual user requirements.

Access to Management and Engineering levels shall be restricted by user-selectable password. The
security systems shall be based on a set of privileges, which may be granted or denied to individual
users by the System Manager. The following five levels of User Access shall typically be required;

- Level 1. Public level - Views Process Overview Screen and Operational

Mimic displays only.
- Level 2. Operator level - Gives Operators access to all Mimic Displays
and Routine Operational Setup Screens.
- Level 3. Supervisor level - Giving Supervisors access to all Mimic
Displays and all Operational Setup Screens.
- Level 4. Engineer level - Giving Engineers access to all Mimic Displays,
all Operational Setup Screens and all Engineering Setup Screens
- Level 5. System Manager Level - Giving System Managers full access to
all Mimic Displays, all User Accounts and all User Password
Configuration Changes, all other Utilities and all Windows Operating
System functions.

As a minimum the Operator, Engineer and System Manager levels of user access shall be utilised for
the System Manager.

When logging in and out a log file shall be recorded and time and date stamped. Log in and out time
and dates will be printed on relevant/configured printer.

The software structure shall be based upon a distributed automation system that can be divided into
three main areas:
1) Operation and monitoring including signalling and reporting
2) Communication between the automation equipment
3) Process automation (measuring, open or closed loop control)

Software Documentation

The configuration documentation shall be produced in accordance with the IEC standards.
The Project Company shall provide a Function Design Specification (FDS) which shall be submitted to
the Engineer for approval before manufacture and purchasing commences. There shall be one (1)
Arabic and one (1) English version.
The following material shall be included as a minimum:
 List of Contents
 Reference to supporting standards, manuals and specification.
 Description of the design and design criteria
 Relevant details of associated mechanical and electrical equipment
 Functional specification
 Complete set of supporting drawings
 Design documentation describing all the control programs furnished with the system
 Design documentation shall include the following as a minimum:
 A flow chart of each program module detailing the flow of control throughout the module.
 Analysis of normal control modes in manual, remote and automatic.
 Analysis of modes of faults and failure.
 Analysis of STP start-up and shutdown procedures.
 Hard copy documentation of all configuration data, all user accessible source code i.e.,
control program code, reports etc., and database contents including listings. All program
listing shall be clearly and completely commented so as to convey to the reader a full
understanding of the function of the program.
 Calculations
 Description of quality control methods and approvals
 Outline of test procedures
 Program for manufacture, delivery, installation and commissioning
 Appendices, as necessary, to include the information for the manufacturer
 Literature for each item of equipment supplied
 The FDS document shall be on A4 size, numbered sheets bound with covers showing the
Employers name, title of scheme, title of contract, Project Company’s name and
reference number.
All drawings shall be on A3 size sheet and include:
 Purchasers Name
 Title of Contract
 Project Company’s Name
 Title of Drawing Number
 Date
 Author
 Signature of Project Company to the effect that the drawing has been checked and
approved by him prior to submission.

4.3.4 Active Mimic Display

Displays shall be user configurable, with the user being able to construct any desired symbol for
display. Any display shall appear (excluding historical recall) within 3 to 5 seconds, or better, of
selection and the displayed data shall be updated from the database as information is recovered from
the RTUs. Alarms shall typically appear within 3 to 5 seconds of occurrence and within 1 second of
being received into the central system database.

Facility must be incorporated to permit easy construction and modification of the display pages by
using a standard library of shapes and symbols. The library shall be added to and modified by the
user as required. The configuration shall be object orientated for ease of use.

The initial application software shall provide for the display pages listed below and any pages
necessary for the system to function as a complete entity.
 Mimic displays.
 System geographical overviews.
 Graphic displays.
 Trend displays.
 Alarm summary tables with date and time.

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 Event logs of past 72 hours with date and time.
 Hydraulic overview.

4.3.5 Printers (Logging / Alarm)

Printers used for logging of system wide events and alarms shall comply with the following as
minimum:
- Print speed: 300 characters per second.
- Print quality: letter print with optional draft mode.
- Paper feed: adjustable width tractor feed mechanism.
- Paper width: 18 to 38 cm.
- Print pitch: 10 or 12cpi.
- Print width: 132 characters at 10cpi.
- Character set: full ASCII. Noise level: < 50dBA.

Colour Printers

A printer shall be used for the production of colour screen dumps and reports and shall have a
sufficiently sized buffer memory such that system performance will not be degraded when the colour
printer is operational and comply as a minimum with the following:
 Paper size: A3 and A4.
 Print speed: 6 A4 text sheets per minute.
 Print speed: colour graphics, 2 minutes per A4 page at 80% graphics.
 Colours: compatible with VDU graphics.
 Paper feed: A4 and A3 with auto sheet feeder mechanism and minimum 50
sheets per tray. Resolution: Minimum 600 DPI.

Report Printers – Monochrome (LASER)

 Print speed 8 pages per minute.
 Paper feed A4 with auto sheet feeder mechanism and minimum 250 sheets per
tray.
 Resolution 600 DPI.

4.3.6 Reports
A reporting system shall provide the following reports:
 Plant Alarm Lists Plant Status Lists
 Plant measured Variable Lists
 Daily reports and summary daily reports
 Weekly reports and summary weekly reports
 Monthly reports and summary monthly reports
 Yearly reports and summary yearly reports
 Maintenance reports and forecasts
It shall be possible for any operator to type a message into the system for use by management or
other shift operators. This message shall be displayed on the monitor and can be directed to the main
printer.

4.4 PLC Panels

The PLC system shall be housed in local PLC panels. PLC panels shall as a minimum comply with
ingress protection class IP 54 if installed inside and IP65 for outside installation. The panel shall be
complete with gland plates, internal lighting with door operated switch, the panel shall be equipped
with heater, cooling and ventilation system, the PLC panels shall be supplied from a dedicated UPS
as described below.

An OP (industrial PC) for the local plant shall be door mounted. Metal wiring plan pockets, size A3
port and a wiring plan shall be mounted on the inside of the front door.
The front door and the swinging frame shall not be hinged on the same side of the cubicle.

All PLC equipment and auxiliary components including but not limited to: processor, I/O cards,
communication cards, fieldbus cards, PLC power supply units, terminals, +25% spare terminals, cable
clamp rails, cable conduits, fuses, relays, etc. shall be mounted on the panel backplate.

Earthing bars for protective earth, shield earthing system and electronic earthing system, etc. shall be
provided.

The front door and the swing frame (if fitted) shall be earth protected. Wires to the front door and the
swing frame shall be protected by flexible cable conduit. All equipment in the PLC panel shall be
permanently labelled, all labels shall be readable without the need to remove any components.

4.5 System Setpoints

All processes that are to be under automatic control in the final approved design shall have setpoints that
can be changed locally on the local OP. A tolerance range set be designed for each setpoint.

4.6 Long Term Data Storage

A magnetic tape unit shall be included on the main computer system for the long-term storage of all
plant data held on the main computer system hard disk. The storage capacity shall be agreed with
WEC. Previous records of the performed works shall be stored.

Provision shall also be made to store the system database after amendment or additions have been
made to the system mimics, equipment and alarm lists or applications software.

4.7 Communication System

The Project Company shall supply and install a fibre optic cable ring for data transfer and
communication between different process locations and master SCADA system, cable size shall be
minimum 32 fibre.

25
4.8 Uninterrupted Power Supply (UPS) System
A UPS system comprising battery, charger, inverter and static switch shall be supplied to support the
master station and sub masters for at least 120 minutes on failure of mains power supply.

Each system shall:

 Maintain an AC output voltage of 220 V ± 2% over the entire range of load, DC voltage
and power factor.
 Maintain an output frequency constant within 1 % of nominal.
 Be capable of continuous operation under the ambient temperature specified.
 Maintain an overload of 125% for 10 minutes.
 Be equipped with an AC output filter to limit the total harmonic voltage distortion (THD)
across linear loads to 5% over the entire range of load, DC voltage and power factor.
 Be equipped with a DC input filter to ensure that the RMS value of the AC voltage does
not exceed 5% of the DC voltage.
 Maintain inverter output on loss of mains supply without any interruption.
 Provide a volt free alarm contact for:
 Charger failure
 Inverter failure
 Static switch failure Batteries discharging
 Provide instrumentation for:
 Charger output voltage
 Battery current (charge/discharge) Load current
 Output AC voltage
 Provide indications to show status of the component parts of the system.
 The UPS shall be mounted in a adequately ventilated steel cabinet with front access
door.
 Batteries shall be the nickel cadmium or alkaline type and shall be of adequate capacity
to maintain full operation of the specific load equipment plus 10%, for a period of at least
120 minutes during mains failure assuming a normal charge condition at the start of the
mains failure.

4.9 General SCADA Monitoring

The central system on site must be designed so that it can be monitored locally at NWC’s regional
SCADA system. Critical plant alarms shall be made available on the regional SCADA system

4.10 Instruments
The following sections detail the requirements of instruments that are anticipated to be in the final design.
There may be variations but approval must be obtained from NWC. Unless stated all instruments
shall be rated to IP67
4.10.1 Plant condition monitoring
The Project Company shall build in to all plant a high level of condition monitoring, using state of the
art instrumentation, reporting through the SCADA system to enhance as much as reasonably possible
the overall asset management on the site.

As a minimum all plant above 45kW, where applicable and within a state of the art manufacturer’s
norm, shall be fitted with:

 Vibration monitoring on all main load bearings;

 Temperature sensors on all bearings;
 Temperature sensors on all stator windings;
 Power monitoring;
 Oil in water sensors;
 Water in oil sensors;
 Rotation sensors;

Below 45kW plant is to be fitted with the maximum level of condition monitoring the plant
manufacturer provides.

4.10.2 Dissolved Oxygen Equipment

The general requirements of the dissolved oxygen equipment shall be at least:

 The electrode assembly shall be standard wall mounted assembly with quick release
facility. Automatic cleaning and calibration facilities shall also be provided.
 The equipment shall operate reliably and within specification throughout the climatic
conditions
 The equipment shall be resistant to the presence of Hydrogen Sulphide (H 2S).
 The Project Company shall state the maximum H2S tolerable level of equipment
 The output signal shall be 4-20 mA and the system accuracy shall be within ± 2% of span
between automatic calibration.
 The system shall be of the automatic calibration/cleaning type with the facility for manual
or remote automatic initiation with selectable time intervals in the range of 6 to 48 hours.
 Volt free alarm contacts to be provided for:
 System failed/power failed / Calibration failed
 Dissolved oxygen sensor failed / Dissolved oxygen outside control limits
The dissolved oxygen sensor shall be:
 Either galvanic (lead anode and silver cathode) or polarographic with gold cathode. A
solid gel electrolyte is preferred in either case in the form of a plug-in cartridge to be
exchanged at 12-month intervals with no electrolyte change guarantee.
 The cell shall utilize a polyethylene or P.T.F.E. membrane of adequate strength and
robustness to allow the following:
A measurement range of:
 0-200% saturation or 0-20 mg/l or 0-100% saturation or 0-10 mg/l
 An automatic temperature compensation of between SoC (State of Charge 0%) and 40°C
(100%) shall be provided utilizing an in-built thermistor within the probe.

27
 Power shall be supplied from respective plants UPS.

4.11 Temperature Equipment

The following instruments are anticipated to be involved in the design of the final STP. The ranges
and performance specification given is for guidance.

4.11.1 Temperature transmitter

The general requirements of the temperature equipment shall at least be:

 The probe shall be of the platinum type mounted in a wall-mounted assembly with a quick
release facility.
 Measuring range: - 0 C to 40°C
 The transmitter shall have an output of 4-20 mA or 0 -10 V
 The transmitter shall have an accuracy within a 1 % of its operating range, repeatability
within ±0.2% of span and a dead band not exceeding 0.2% of span.
 The transmitter shall provide a system to indicate sensor failure.
 Power shall be supplied from respective plants UPS.

4.12 Flow Measuring Equipment

4.12.1 Magnetic Flowmeter
The electromagnetic flowmeters shall be supplied, installed, commissioned as required for STP
process operation and control.

Each installation shall be provided with cleaning equipment. This facility either shall operate
continuously or shall include equipment for intermittent operation.

The flowmeter primary shall incorporate electrode(s) to detect when the pipe is not full. The detector
output shall control circuits within the converter to open circuit the analogue signal and initiate an
indication of the "pipe not full" condition.

Power shall be supplied from respective plants UPS.

4.12.2 Ultra-Sonic Open Channel Flow Measuring Equipment

The ultra-sonic equipment shall be designed, supplied, commissioned as required for STP process
operation and control. For this project, the control unit shall be micro-processor based incorporating
algorithms for converting level to flow in accordance with BS3680: Part 4A: 1981, Part 4B: 1969 or
Part 4C: 1981 as appropriate and shall provide a 0/4-20 mA or 0-10 V output proportional to flow. The
system shall be within ±1.0% of instrument span over the range 5% to 100% flow.

4.13 Level Control Equipment

Electrode Level Switch
The level switch shall be supplied, designed, commissioned and come complete with all necessary
brackets, fixings etc. for the complete installation
The electrode holder shall be of the heavy-duty type and be suitable for mounting in the open, or
within an enclosed tank, and shall be totally enclosed and with environmental protection to IP67 as
appropriate.

The electrodes shall be of stainless steel.

The switches shall have an LED for indication of switching status.
The switches shall have an adjusting element for works calibration.
Power shall be supplied from respective plants UPS.

4.13.1 Ultrasonic Level transmitter

The ultrasonic Level transmitter shall be supplied, designed, commissioned for water level monitoring
in individual process tanks if required as per the final design

The connection between the sensor and control unit shall be via commercially available screened
cable, and the equipment shall operate with up to 150 meters of such cable. Power shall be supplied
from respective plants UPS.

4.14 Pressure Measuring Equipment

4.14.1 Pressure switch
The pressure switches shall be supplied, designed, installed, commissioned monitoring on pump
discharge lines in each individual process stage as per the final design. Power shall be supplied from
respective plants UPS.

4.14.2 Pressure transmitter

The pressure transmitter shall be supplied, designed, installed, commissioned for control/ monitoring
on different process pipelines as per different process requirements.

Power shall be supplied from respective plants UPS.

4.14.3 Position Measuring Equipment

All the penstock supply and installation shall be provided with Position indicators. The position
indicators shall be inductive/capacitive solid-state position switch. All brackets, fixings etc. as
necessary for the complete installation shall be provided. The position switch shall be totally enclosed
and suitable for outdoor installation with IP 65. All position switch signals shall be transmitted to PLC
for penstock position monitoring and operation (close/open)

4.15 Sludge Solids Content Transmitter (if

applicable)
The sludge solids content measuring equipment can be either of the ultra-sonic wave attenuation
system or of infrared transmission system.
The transmitter shall be of rugged construction, suitable for application both in pipes and open tank,
and:
 Have a measurement range of 0 - 10% or 0 - 10 g/1 activated sludge.
 Have a resolution of 0.1 % or 0.1 g/l.
 Have a measuring accuracy of 5% or ±0. 1g/l, depending on the sludge involved.
 Have an electrical output of 0/4-20 mA or 0 - 10 V proportional to measuring range.

29
 Have a stainless steel sensing element.
 Have an automatic cleaning of the sensor or be easy to clean manually.
 Power shall be supplied from respective plants UPS.

Each sensor shall be installed on a robust and rigid structure provided for the purpose under this
Contract. The structure shall include a means of levelling the sensor so that the transmitter beam is
perpendicular to the liquid surface and shall provide a safe and easy access to the sensor for
servicing and maintenance.

Each installation shall be supplied installed complete with a local indicator which
shall be incorporated in the transmitter.

4.16 ORP Meter

The ORP meter shall have a redox sensor with PTFE ring diaphragm. It shall be able to operate at a
maximum temperature of 50°C and a maximum pressure of 6 bars. There shall be two (2) line display
with two (2) limit and one (1) alarm contact. Output range shall be based on 0/4 - 20 mA.
It shall be able to work in sludge type of liquid with a concentration of 2.5 - 5.0 kg/m 3 at a maximum
temperature of 35°C.

4.17 pH Meter
pH meters shall be able to work at a pH range from 0 to 14. Temperature and pressure ranges shall
be 0-50O C and 0- 6 bars respectively. There shall be a ring shaped teflon diaphragm and a platinum
temperature sensor. The pH meter shall have a temperature compensation function. The pH meter
shall be heavy-duty type and manufactured to operate in rough environment.
.

4.18 Gas Measuring Equipment

The gas measuring equipment shall be suitable for the detection of H 2S gases. The measurement
devices shall be of the electronic type and powered by rechargeable batteries. The detectors shall be
supplied by the UPS.

The detectors shall give an audible warning when H 2S is present in air above the lower safety limit.
The alarm signal shall also be transmitted to the PLC. If a H 2S gas monitor is installed inside a
building where H2S gas might be present, an audio-visual alarm must be installed at all the entry
points to the building.

4.19 Instrumentation Cables and Cabling

All cables necessary for the complete installation shall be provided and installed.
There shall be separate cables for different voltage to equipment that has different voltage on supply,
control, remote etc. All signal- and control- cables shall be shielded.

The cables for analogue and digital signals shall be segregated.

The incoming and outgoing signals cables from the PLC shall be segregated.
All signal- and control- cable shall be segregated from LV and MV cables.

All multi-pair cables shall include a minimum of 25% spare cores. This spare capacity shall be over
and above any cores that may be required for proposed future installations of extensions. All cores,
including the spare ones, shall be connected to terminals.

4.20 Function Descriptions

This following description, together with the General Instrumentation, Monitoring and Control
Requirements described above, are the basic requirements for the plant involved but it is the
responsibility of the Project Company to optimise the control system so that a complete and correct
function of the STP is achieved. The items of plant described below are typical plants involved in STP.
The Project Company in their final design of the STP may not require all of the plant described below.
However, guidelines are still given for each plant should they be required.

4.20.1 Motors
All motors in each plant area where applicable shall at least have the following indications;
 Off
 Hand/OFF/Auto (and Remote if required)
 Running
 Standing
 Available
 Tripped
 Fault
 Duty/Standby selection
 Information that is important for the operation of the plant shall be transferred from the
other equipment.
 Status information, alarms and warnings from other installations i.e. transformers, HV -,
MV -, LV-switch boards, heating-, cooling-, ventilation- system, fire alarm, gas alarm etc.
shall be taken care of by the control system.
 All status information shall be able to be read on each plant areas Operation Panel and
on the control equipment in the main control room.
 All alarms and warnings shall automatically be displayed on each plant areas Operation
Panel and on the control equipment in the main control room.
 The Project Company shall prepare a list of alarms, trips and warnings, that shall be
controlled and approved by the Engineer.

4.20.2 Fine Screens

Each group of interrelated screens, conveyors, screening compactors and screening wash water feed
shall be interlocked to operate based on the screening cycle.

The screens cleaning devices shall operate and stop according to the signals from the local control
panel. The time period between the signals shall be determined by experience.

The cleaning devices shall be interlocked by signals from the level indicators, which set the cleaning
devices in operation at a certain head loss through the screens.

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The cleaning system shall operate at a pre-set time interval for a pre-set duration. Conveyors,
compactors and wash water feed shall start based on screens operation and stops after a pre-set time
delay.

Each screen, conveyor and compactor shall have a force switch. The screen switches shall stop the
rakes when there is something stuck in the screen and an alarm shall be given. After cleaning the
screen, the cleaning devices shall be restarted from the local control panel.

The conveyor and compactor switches shall stop the equipment and its interrelated screens.
Emergency shutdown switches shall be provided for the screens, conveyors and compactors.

4.20.3 Grit Chambers

The travelling bridge and associated pumps shall automatically start based on time sequence
activated by signals from the local control panel. The time period between the start signals and the
number of bridge travels shall be determined by experience.

The grit classifier shall be interlocked to start with the bridge and shall have the same operation period
as the bridge with an additional pre-set period.

Blower room
The blowers for the aeration of the grit chambers shall operate continuously.

If one of the blowers fails, the stand-by unit shall automatically start. After the correction of the fault,
the operator shall manually, on the panel or MCC associated with the blowers, reset the system for
normal operation.

The blower duty cycle shall be alternated once a week to equalize the operating time of each the
blowers.

Motor valves
The motor valves shall be automatically controlled in accordance with the blower configuration and
shall be equipped with position indicators for information and interlocking.

Pressure instruments shall be provided on the air pipes for indication and alarms.

Scum sump
The sump level transmitter shall automatically control the scum pump in accordance with the water
level in the sump. A level instrument shall provide high level indications in the sump and give an
alarm.
The scum mixer shall work continuously.

4.20.4 Parshall Flume

The Parshall flume shall be equipped with an ultrasonic open channel flow meter. The flow meter shall
measure and register the incoming flow to the plant.

4.20.5 Primary Distribution Chamber

The primary distribution chamber shall be equipped with a level sensor and transmitter to monitor the
level in the chamber. High level alarms must be provided.

4.20.6 Flow Meters

Magnetic flow meters shall be installed on each pipeline going to the different Aeration Tanks to
measure the flow for each treatment stream.
4.20.7 Aeration Tanks
The mixers in the process tanks shall operate continuously.

The recirculation pumps shall be operated in cascade that is controlled by the inlet flow meter in order
to achieve a constant recirculation rate.

In order to keep a preset level of dissolved oxygen in the tanks, each tank shall be equipped with an
oxygen transmitter. These transmitters shall control the motor valves located on respective air-tubes
to maintain the preset level. The dissolved oxygen in the tanks shall be measured and registered.

In each unit, one tank shall be equipped with a temperature transmitter to measure and register the
temperature.

ORP meters and pH meters shall be placed in the necessary locations of the tanks by the approval of
the Engineer.

The tanks shall be equipped with motorized penstocks that shall not be connected to the central
automation system. The penstocks shall be equipped with position indicators.

4.20.8 Blower House

Blowers shall supply air for the process tanks.
The blower duty cycle shall be alternated once a week in order to equalize the operation times for the
blowers. The starting order shall be as below:
If one of the blowers fails, the stand-by blower shall automatically start. After the recovery, the
operator shall manually reset the system for normal duty operation.
The capacity of the blowers shall be controlled by pressure transmitters on the supply pipelines.
Blowers shall be supplied with VFD motors to allow air supply flow variation based on Dissolved
Oxygen demand.
The blowers shall be fitted with a silencer on the air vent on the blower.

4.20.9 Secondary Distribution Chamber

The secondary distribution chamber shall be equipped with a level sensor and transmitter to monitor
the level in the chamber.

4.20.10 Secondary Clarifiers

The travelling bridges shall operate continuously. However, the cleaning brush shall operate manually
from the bridge.
All clarifiers shall be equipped with sludge solids content measurement transmitters.

4.20.11 Return and Waste Sludge Pumping Station

Return Sludge Pumps
The pumps shall operate automatically and be controlled by electromagnetic flow meters in order to
achieve the required return sludge flow rate. The pumps shall be alternated once a day to equalize
the operation times.

If one of the pumps fails, the stand-by pump shall automatically start. After fixing the problem, the
operator shall manually, on the OP, reset the system for normal operation.

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The pump sump shall be equipped with an alarm and a level switch to stop the pump.
The penstocks in each station shall be equipped with position indicators.

Waste Sludge Pumps

The pumps shall operate automatically and be controlled by electromagnetic flow meters. The pumps
for each tank shall be controlled by a timer to remove the daily excess sludge. The operation times
shall be determined according to experience. The pump duty cycle shall be alternated once a day to
equalize the operation times.
If one of the pumps is fails, the stand-by unit shall automatically start. After rectification of the fault, the
operator shall manually, on the panel or MCC associated with the pumps, reset the system for normal
operation.
A level indicator, which will give an alarm as the sludge level rises in the wet-well, shall be provided.

4.20.12 Scum sump

The level transmitter, in the scum sump, shall automatically control the scum pump according to the
sludge level in the sump. The level indicator shall be used for high level indication.

4.20.13 Disk filter Units

Each filter shall be equipped with a water level sensor capable of transmitting to the control system a
continuous measurement of the level in the influent chamber. The backwash cycle shall be activated
either by high water level in the influent chamber as indicated by the level sensor or by placing the
corresponding control switch into the "Manual" position.

4.20.14 UV
Level transmitters shall be installed at the outlet of each UV channel to monitor the level at the outlet.
The level transmitters shall indicate level and initiate alarms indicating flooding due to high levels in
the UV channel.

4.20.15 Sludge Storage Tank (if applicable)

The level indicator shall be used for high level indication.

Mixers
The mixers in the sludge storage tank shall operate continuously.

Diffusers
The oxygen transmitter shall control the air going to the diffusers in the tank. There shall be one (1)
blower in duty and one (1) blower in stand-by status. The blowers shall be duty alternated once a
week to equalize the running times.

If the blower on duty fails, the stand-by unit shall automatically start. After the rectification of the fault,
the operator shall manually, on the OP, reset the system for normal operation.

4.20.16 Sludge Dewatering (if applicable)

The belt filter(s) shall operate automatically. The necessary automation details shall be given in the
proposal.

The sludge pumps and the dosing pumps shall be automatically operated. The belt filter(s) and the
sludge storage tank shall be interlocked so that a pressing cycle cannot be started unless sufficient
amounts of sludge are available in the storage tank.
4.20.17 Return flow and drainage Pumping Station
The level transmitter, in the pump sump, shall automatically control the pumps in accordance with the
water level in the sump. The pumps shall be duty alternated once a day to equalize the running times.
The level indicator shall be used for high level indication.
If the duty pump fails, the stand-by pump shall automatically start. After the rectification of the fault,
the operator shall manually, on the OP, reset the system for normal operation.
A magnetic flowmeter shall be installed on the outgoing pipe.

4.20.18 Flowmeter
Magnetic flowmeters shall measure and register the outgoing flow from the plant.

5 Mechanical
The number of process units and equipment shall be in accordance with the process design and
system requirements.
The following requirements shall be considered in the design, equipment supply and system
installation:
 all valves and penstocks shall be fitted with rising spindles type;
 all package equipment shall be supplied with local, dedicated control panels to enable
operation to be switched from remote to local control;
 operational flexibility and interchangeability shall be incorporated in the system design;
and
 The arrangement of plant and equipment shall be such that sufficient space for its
installation, removal, maintenance and safe operation is provided.

5.1 Inlet Chamber

The equipment detailed in this section comprises:
 penstocks / sluice gates; and
 manual screen for plant bypass

5.1.1 Penstocks / Sluice gates

The inlet chamber shall be equipped with penstocks to facilitate complete isolation of the plant. Also,
the bypass channel / pipeline shall be equipped with an isolation penstock. Penstocks / sluice gates
shall be supplied in accordance with the general specifications.

5.1.2 Manual Screen for plant bypass

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An inclined bar screen shall be installed in the bypass channel / pipeline. The screen shall have a bar
spacing of 15-25 mm bar spacing. The design shall provide for screenings to be manually raked,
using rakes supplied with the screen, into a perforated holding container. The screen, holding
container, rakes and associated fitting and fixtures shall be manufactured entirely from stainless steel.

5.2 Screening Station

The equipment detailed in this section shall comprise:

 2 stage mechanically cleaned inlet screens i.e. course and fine screens;
 belt conveyors, screw conveyors or screening trough;
 screening press and screening containers;
 manual screen for plant bypass;
 penstocks /sluice gates; and
 drain gate valve

5.2.1 Mechanically Cleaned Coarse / Fine Screens

Coarse and fine screens shall be cleaned by mechanically operated rakes.
Screen bars shall be made of stainless steel and be either rectangular or in cross-section or to the
manufacturer’s own profile. Bar spacing shall be 6 mm for fine screens and up to 15mm for coarse
screens.
At normal operating flow, velocities through screens should not be less than 0.4 m/s (to prevent
settling) and not greater than 1.0 m/s (to prevent forcing material through the bars).
The mechanical cleaning device shall be equipped with a rake that removes debris from the surface of
the screen at regular intervals. The rake shall be guided by roller chains, be flexibly supported and
have the facility to adjust the force the rake applies to the screen.
The machinery shall be equipped with overload protection devices that stop the machinery and give a
fault alarm in the event of overload.
The framework and covers, bar screen, rake, sliding plate and discharge plate shall be made of
stainless steel.
Screenings shall be collected and then deposited into belt or screw conveyors for transportation to a
screening press. The pressed screenings shall be transferred into the containers which shall be lifted
by electric hoist into vehicles for disposal off site.
The screens shall be designed to drop the screenings into either a duty or a standby conveyor which
shall be arranged in parallel behind the screens.
Proper access to the screens’ motors shall be provided from the walk side level to allow for safe
maintenance.
Penstocks / sluice gates shall be placed before and after the screens.
The wash water feed pipe shall be equipped with a solenoid valve and isolation ball valve. The wash
water shall be supplied from the plant wash water system at a pressure between 4 and 6 bar, or as
advised by the screen manufacturer, and will be controlled by a solenoid valve which will be open
when the screen is in operation and closed when it is not.
5.2.2 Belt Conveyors or Screw Conveyors
Duty and standby enclosed belt or screw conveyors shall be provided adjacent to the screens to
transfer screenings to the screening press.

The operation of the conveyor shall be interlocked with the that of the screen. The sequence shall be
adjustable in order to establish the most suitable operating regime.

An additional belt or screw conveyor with a bidirectional motor shall be provided to transfer the
compacted washed screenings to a duty / standby screenings container.

Belt conveyors shall have a minimum belt width of 600 mm and operate at a speed sufficient to
remove the maximum amount of screenings accumulated.

Belt conveyors shall be fitted with stainless steel side plates to ensure that the screenings are
retained on the conveyor and a suitable arrangement shall be made to drain excess water into a
drainage channel.

The entire equipment, including auxiliary components, shall be mounted on and supported by a robust
stainless steel framework,

The machinery shall be equipped with overload protection devices that shall stop the conveyor and
give a fault alarm in the event of overload.

The belt shall be manufactured from 3 ply cotton / nylon mixture and shall have oil resistant rubber
covers on the top and bottom faces with thicknesses of 2.5 mm and 1 mm respectively. The belt shall
be driven by an enclosed motorised conveyor roller.

A counter-balance type belt scraper shall be placed under the driving and tail discharge rollers. The
belt scraper shall have a renewable rubber blade to remove all adherent material

Each conveyor shall be provided with stainless steel chute which shall be designed to prevent
adhesion of screenings to its surface. The chute shall direct screenings from the conveyor into
containers. The belt conveyor shall be enclosed to connect to an odour control system.

Screw conveyors shall comprise an Archimedean shaft mounted screw running in a semi-circular
trough supported by heavy duty self-aligning bearings at the drive end and a bearing strip at the non-
drive end. Suitable bearings shall also be provided at the drive end to minimize axial loading of the
drive gearbox.

Screw blade thickness shall be a minimum 15mm. Screw conveyors shall be fabricated from grade
316L stainless steel, the component parts being bolted together with grade 316L stainless steel
fasteners, all joints being positively sealed with gaskets. The screw shall be designed in accordance
with BS4409.

The screw channel shall be protected by two layers of easily-replaceable differently coloured
hardened wearing surfaces.

The design of all the conveyors shall incorporate electrical switches on all the removable inspection
covers that will stop the conveyor if any of the covers are opened.

5.2.3 Screening Compactor for Fine Screens

A screening washer and compactor shall be provided to clean both coarse and fine screenings in
order to reduce their volume before transfer to waste containers.

The operating sequence of the press shall be interlocked with the automatic operation of the screens.
The sequence shall be adjustable in order to establish the most suitable operating regime.

37
The compactor shall be of the screw type. The compactor, including feed hopper and framework, shall
be manufactured from stainless steel 316L. The screw channel shall be protected by two layers of
easily-replaceable differently coloured hardened wearing surfaces.
.

The machinery shall be equipped with overload protection devices that stop the conveyor and
screening compactor and gives a fault alarm in the event of overload.

The wash water feed pipe shall be equipped with a solenoid valve and isolation ball valve. The wash
water shall be supplied from the plant wash water system at a pressure between 4 and 6 bar, or as
advised by the screen manufacturer, and will be controlled by a solenoid valve which will be open
when the compactor is in operation and closed when it is not.

5.2.4 Screening Containers

Each container shall have sufficient capacity to hold a minimum 5 days screenings and be equipped
with suitable fittings to facilitate handling by a lorry-mounted lifting device. The containers shall be
designed to permit self-dewatering of the screenings. The containers shall be welded and made of
mild steel plate and reinforced to provide a stiff and robust design. The containers shall be painted in
accordance with WEC standards. Strip of rollers, or similar, shall be fitted to facilitate for easy removal
or replacement.

5.2.5 Penstocks / Sluice gates

Penstocks / sluice gates shall be placed before and after all screens in accordance with the following
specification:

Penstocks
The penstocks shall be as per BS 7775 / BS EN 1984;
Penstocks shall be made of 316 stainless steel, may be either motor or hand operated. All shall be
equipped with hand wheels and rising spindles and have position indicators;
Penstocks shall be on seating or off seating as necessary; and
Penstocks shall be water-tight in one direction.
Sluice gates

Sluice gates shall have rising spindles.

Sluice gates shall be made of 316 stainless steel; be manually operated and be equipped with rising
spindles and position indicators.

Sluice gates shall be water-tight in both directions.

5.3 Aerated Grit Chambers

The equipment shall comprise:

 travelling grit bridge(s) with submersible grit pumps;

 gate valves for grit pumps;
 check valves for grit pumps;
 aeration system including blowers, pipes, diffusers and ball-valves;
 manually operated butterfly-valves and motorized butterfly-valves;
 grit hoppers with open screw conveyors;
 grit classifiers with washing and containers;
 penstocks;
 internal pipework;
 dismantling joints;
 drain gate valve;

Channels shall be designed to limit velocities during normal flow variations to less than 0.2 m/s. The
retention period shall be based on the size of particle to be removed. All aerated grit
removal facilities shall be provided with adequate control devices to regulate air supply and
agitation.

5.3.1 Travelling Grit Bridges

Travelling grit bridge(s) shall be provided and installed over the grit chambers.

Travelling bridge(s) shall be equipped with submersible pumps for pumping grit from the bottom of grit
chamber(s) to the stainless steel channel(s) and ultimately to grit classifiers.
Bridge(s) shall also carry surface scrapers to remove the scum from 1/3 the length of each line. The
scum shall be collected in outlet box(es).

Travelling bridge(s) shall be designed to carry the submersible pumps and all necessary stainless
steel works for the scum scraper(s). They shall be provided with replaceable rubber lined steel wheels
acting on the steel rails for both driving and guiding. Bridge(s) shall be equipped with any necessary
platforms.
Bridge(s) shall be equipped with an electrically driven traversing gear, furnished with overload
protection devices which. in the event of overload, stop the machinery and give a fault alarm.

Bridge(s) shall be made of coated steel and all material in contact with water, such as channels,
pipes, scrapers, etc., shall be made of stainless steel.

5.3.2 Submersible Grit Pumps

Submersible pumps shall be installed on the bridge. Grit pumps impeller(s) shall be of duplex
stainless steel to resist sand erosion. Pumps shall be in accordance with the general descriptions as
specified below and be designed to protect against the corrosive effect of wastewater. Submersible
grit pump pipes, support frames and channels shall be made of stainless steel.

5.3.3 Aeration System including Blowers, Pipes and Diffusers

Grit chambers shall be provided with an aeration system consisting of blowers, main air pipes with
valves, manifold pipes, ball valves on each manifold pipe, air diffusers and all necessary supports and
brackets.

Outer coatings of pipes installed under the ground shall be glass-reinforced bitumen.
Blowers, shall be provided and installed in a separate building close to the grit chamber(s).

Blowers shall be designed to supply sufficient air for the efficient operation of aeration system.
Blowers shall have a safety feature to prevent air backflow due to power loss.

Blowers shall be positive displacement rotary type and be air cooled. They shall be driven by electric
motors and mounted on a steel or cast-iron base plate.

Each blower shall be complete with shock insulation, flexible connectors, suction filters, resonance or
absorption type suction and discharge silencers, safety valves, check-valves, pressure gauges and
thermometers.

The drive between blowers and motors shall be through flexible pin and buffer couplings or of the V
-belt type.

39
The materials for the air diffusion system shall be as follows:

 Drop legs: stainless steel;

 manifolds: stainless steel;
 air laterals: stainless steel;
 supports: stainless steel; and
 anchors: stainless steel.

Diffusers shall be tubular type and placed parallel to the longer sides of the chambers. The main
distribution pipes between the blower house and grit chamber, branch pipes, manifold pipes and
diffuser pipes shall be properly sized and selected by the Project Company.

5.3.4 Ball Valves

Ball valves shall be made of stainless steel.

5.3.5 Manually Operated Butterfly Valves

A sufficient number of butterfly valves shall be provided and installed. There shall, as a minimum, be
one on each discharge pipe from the blowers.

5.3.6 Motorized Butterfly Valves

A sufficient number of automatically operating butterfly valves shall be provided and installed on the
manifold pipe after blowers to enable alternate operation of blowers.

5.3.7 Grit Classifiers

The Project Company shall provide sufficient number of grit classifiers for grit separation.
Sand/water entering the hopper shall be stuck to a properly sized stainless steel pool settling area.
The hopper shall be provided with an overflow pipe to provide water return to the inlet of grit chamber
or to the plant drain system.
The classifier mechanism shall be of the helical screw type, designed to maintain sufficient velocity to
retain organic matter in suspension and remove the nonorganic material on a 150-mesh screen.
Wash water at 4.0 to 6.0 bar will be supplied to the grit classifier and will be controlled by a solenoid
valve which will be open when the classifier is in operation and closed when it is not. The helical-
screw type classifier shall incorporate in its design arrangements for removal and replacement of the
screw for periodic maintenance. The screw shall be equipped with two layers of differently coloured,
easily-replaceable hardened wearing surfaces. The classifier tank shall be fabricated from stainless
steel plate of 6mm minimum thickness with a sufficient pool settling area as per the design and an
adjustable weir of a minimum of 600 mm length. The slope of the classifier shall be 3.5 to 12 (vertical
to horizontal). The screw-drive unit shall be mounted on top of the screw trough. The unit shall
consist of a totally-enclosed, ball-bearing, constant-speed heavy-duty motor with V-belt drive to a
worm-gear type speed reducer with oil-tight housing. A belt guard shall be provided. The output shaft
of the reducer shall be direct-connected to the upper end of the screw conveyor. Speed of the screw
shall not exceed 20 rpm.
The operation sequence of the grit classifier shall be guided by the automatic operation of the
travelling bridge including the submersible pumps.

5.3.8 Containers
Containers shall be designed and constructed as specified in Clause 5.2.4

5.3.9 Internal Pipework

Internal pipes and channels for sand/water shall have a slope of 5 %.

Pipes, channels and scum outlets, supports and brackets shall be made of stainless steel.

5.3.10 Dismantling Joint

Dismantling joints shall be provided and installed between the check-valve and gate-valve on each
pump discharge pipe.

5.4 Primary Distribution Chamber and Flower

meter chambers
Downstream of the Parshall flume a flow distribution chamber shall be provided to distribute the flow
to each of the biological treatment phases. In addition to the distribution chamber measurement of
flow shall be done to each of the biological treatment Phases.
The equipment to be included in this section comprises:
 penstocks;
 weirs;
 flow measurement;

5.4.1 Penstocks
All penstocks, shall be selected by the Project Company areas and be suitable for local environment
in which they are installed.

All penstocks shall be in accordance with the specification outlined in Clause 5.2.5.

5.4.2 Weirs
All weirs and fixings shall be of stainless steel and be carefully sized by the Project Company.

5.4.3 Flow Meter

A magnetic flowmeter shall be installed in the pump discharge header. A bypass system shall be
installed to allow for easy replacement of flowmeter. The flowmeter pipework shall allow for a strap
on type flowmeter to be fitted for calibration requirements when required.
The connection of the flowmeter to the outlet pipe shall be done by a sequence of reductions and a
dismantling joint to facilitate the flowmeter removal.

5.5 Aeration Tanks

The equipment to be included in this section shall comprise:

 submersible mixers / Submersible recirculation pumps / pumps

 gate valves for pumps;
 check valves for pumps;
 flap-valves for recirculation pumps ;
 slide-valves for recirculation pumps;
 dismantling joints;
 aeration Systems including Blowers, Pipes, Diffusers Motorized
butterfly valves, air regulating valves;
 butterfly valves;

41
 penstocks;
 internal pipework;
 drain gate valve; and
 dissolved oxygen meter, ORP meter, temperature transmitter, pH
meter

5.5.1 Submersible Mixers

Submersible mixers shall be provided and installed in each aeration tank to provide a minimum
horizontal velocity of 0.3 m/sec.

Mixer
General
A. Type: Each mixer shall be submersible with the motor close-coupled, directly connected to
the propeller. Gearbox designs shall not be acceptable. The propeller shall be capable of
handling solids, fibrous materials, heavy sludge, and other matter found in sanitary sewage
applications.
B. Submergence: All components of the mixer, including motor, shall be capable of continuous
underwater operation in both of the following conditions: (1) mixer blade completely
submerged, and (2) mixer blade partly submerged in an unbalanced hydraulic loading
condition. In addition, all components of the mixer, including motor, shall be capable of
continuous operation in air, i.e. completely unsubmerged, for a minimum of 2 hours.
C. Materials: Mixer components in contact with the liquid shall be of Type 316 stainless steel
with smooth surfaces devoid of blow holes and other irregularities. All exposed nuts, bolts,
fasteners, and hardware shall be of Type 316 stainless steel.
D. Propeller: The propeller shall be of Type 316 stainless steel, dynamically balanced, non-
clogging backward curved design. Each blade shall be laser cut and welded to the hub to
ensure that the propeller is properly balanced. The propeller shall be secured to the shaft by
a friction clutch which shall act to prevent damage to the propeller or shaft in the event an
object becomes jammed in the propeller. The shaft shall be Type 420 stainless steel.
E. Bearings: The shaft shall rotate on three permanently lubricated bearings. The outboard,
propeller end, bearing shall be an angular contact bearing. The inboard, motor end, bearings
shall be an angular contact to take up the axial loads and a radial bearing to take up the radial
loads. The bearings shall be pre-loaded by a bearing loading nut located on the motor end of
the shaft in order to reduce shaft deflection and increase bearing and seal life. Mixers without
pre-loaded bearings shall not be accepted. All bearings shall have a minimum L-10 rated life
of 100,000 hours.
Motor
F. General: The multi-pole motor shall be directly connected to the propeller. The motor shall
be a squirrel cage, induction, shell type design, housed in an air filled, watertight chamber.
The motor shall be designed for continuous duty, capable of sustaining a maximum of at least
ten evenly spaced starts per hour. The stator winding shall be insulated with moisture
resistant Class F insulation. The rotor bars and short circuit rings shall be made of
aluminium. Each motor shall be protected with an over temperature and moisture protection
system.
G. Cable: Provide sufficient length of cable to connect to terminal junction box where indicated.
The cable shall be sized according to the NEC and ICEA Standards, suitable for submersible
service. Cable entry seal design shall provide a watertight submersible seal.

Mounting Assembly
H. Each mixer shall be equipped with a mounting assembly and vertical support mast
designed to secure the mixer while in operation. The vertical support mast shall be
supported as appropriate.
I. All components of the mounting assembly including mixer mounting base plate, vertical
support mast, sliding bracket, and fastening hardware shall be Type 316 stainless steel.
J. Each mounting assembly shall be provided with a power crane with stainless steel lifting
cable, securely attached to the mixer with sufficient capacity to raise and lower the mixer
assembly.

5.5.2 Internal Recirculation

Recirculation inside the aeration tanks shall be provided by submersible recirculation.

The recirculation pumps shall be properly located to avoid extracting air bubbles with the wastewater
from the aeration process.

Submersible recirculation pumps shall be provided and installed in each aeration tank.
The pumps shall be suitable for continuous operation and equipped with VFD motors to allow for flow
rate variation based on process requirements and controlled by equipment specified under the
Electrical Works section.

The motor housing shall be made of cast iron and the propeller blades of stainless steel.
The pumps shall be fixed to pump-diffusers made of stainless steel. These shall be embedded, in the
concrete wall.

The pumps shall be supplied with lifting and guide arrangements for stationary installation. All
supports, brackets and guides shall be made of stainless steel.

Flap Valves for Recirculation Pumps:

Each pump-diffuser for the recirculation pumps shall be provided with a flap valve consisting of a
stainless-steel door closed by weight of the door only, and shall open under minimum flow conditions.

Slide Valves for Recirculation Pumps:

Each pump-diffuser for the recirculation pumps shall be provided with a slide valve installed between
the recirculation pump and diffuser. The slide shall be made of stainless steel according to grade 316
S13 (AISI 316L) and the spindle of stainless steel AISI 329.

5.5.3 Aeration Systems Including Blowers, Pipes, Diffusers

Process tanks shall be provided with an aeration system consisting of blowers in a separate building
and main distribution pipes, branch pipes, manifold pipes, valves and diffusers.
.
The Air Blowers shall each comprise as a minimum:
 Complete base frame mounted Air Blower units including:
o Turbo compressor type blower unit;
o Drive motor and gearbox;
o Inlet filter;
o Inlet and outlet silencer;
o Blow off silencer;
o Electric actuated blow off valve;
o Flexible connection at inlet and outlet;
o Discharge non-return valve;
o Oil lubrication system;
o Base frame;
o Anti-vibration mounts;
o Associated instrumentation for the control and monitoring of the Air Blowers.

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 Acoustic enclosures with ventilation fan/s, fire alarm systems and building services for each
blower unit.
 Local Control Panel (LCP) for each blower unit mounted externally to the acoustic enclosure
and on a fabricated steel base frame.

The blowers shall be suitable for variable flowrate to supply sufficient air for the efficient operation of
aeration system based on DO levels. The blowers shall have a safety feature to prevent air backflow
due to power loss.

Each blower system shall have an integral means of controlling the air flow. Check valves, couplings,
pressure lubricating system, safety controls and other accessories shall be provided with the blowers.
Each blower and its motor shall be mounted on a rigid steel or cast-iron skid. A minimum of or one
standby blower shall be provided and any blower shat be able to feed any diffuser line.

The drive between blowers and motors shall be through flexible pin and buffer couplings or of the V
-belt type.

The blowers shall have inlet silencers and inlet filters that are housed within the acoustic enclosure,
access to the filters will not be hindered by the enclosure. The inlet filters are to be raise off the
ground to reduce moisture and dust to enter the inlet of the blowers, especially during jetting/cleaning
of the surrounding area.

The discharge diffuser shall be mounted directly off the compensator on the blower discharge and
shall be insulated to reduce surface touch temperatures to a safe level. The diffuser is to extend
vertically from the blower.

An electrically operated blow-off valve with silencer shall be provided for each blower. It shall be open
when the blower is off-line and close after start-up. The compressed air shall be discharged into the
atmosphere outside of the blower enclosure through the blow-off silencer. There shall be no short-
circuiting between the blow-off valve discharge and air intake.

The acoustic enclosure doors shall open outwards to give clear access, and shall have a quick
release restraining mechanism to hold it in the open position. The acoustic cover shall not obstruct
the changing of filter elements. Extractor fan(s) shall extract the hot air from the acoustic enclosure to
atmosphere. Fresh air shall be supplied into the acoustic enclosure via duct/louvre at the opposite end
of the enclosure from the extractor fan discharge location. It shall be ensured that there shall not be
any short-circuiting between the discharge and the inlet points. The fans shall be thermostatically
controlled.

The main distribution pipes between blower house and aeration tanks, branch pipes, manifold pipes
and diffuser pipes shall be properly sized and selected.

The materials for the air diffusion system shall be as follows:

 Drop legs: Stainless steel

 Manifolds: Stainless steel or CPVC pipe (Sch 40) (upon the approval
of the Engineer)
 Air Laterals: Stainless steel or CPVC pipe (SDR 33.5 min) (upon the
approval of the Engineer)
 Supports: Stainless steel
 Anchors: Stainless steel
 Components: CPVC or stainless steel

The air distribution pipes between blower house and aeration tanks shall be made of hot dip
galvanized steel but buried sections shall be coated with glass reinforced bitumen.
Air regulating valves shall be installed as required for proper air distribution.
The piping from the butterfly valve to the bottom of the aeration basin shall be stainless steel.
EPDM type diffusers shall be preferred.
Each branch pipe shall be provided with a vacuum-valve downstream the motorized butterfly valve.
Airlines at the end of the lateral pipes shall be inter connected to form a ring main to provide equal
pressure across the system. Also, condensate withdrawal pipes and valves shall be included in the
piping system.

5.5.4 Motorized Butterfly Valves

Each branch pipe shall be provided with one motorized butterfly valve for regulating the amount of air
to each channel.

Each branch pipe shall be blind flanged and equipped with a small ball valve for draining the pipe.

5.5.5 Manually Operated Butterfly Valves

Each manifold pipe shall be provided with a manually operated butterfly valve.

5.5.6 Penstocks
All penstocks, shall be selected by the Project Company areas and be suitable for local environment
in which they are installed.

All penstocks shall be in accordance with the specification outlined in Clause 5.2.5.

5.6 Secondary Clarifiers

The equipment to be included in this section comprises rotating bridge scrapers; pipework; channels;
outlet boxes; telescopic valves; and submersible scum pump

5.6.1 Rotating Bridge Scrapers

Rotating full bridge scrapers shall be installed in each secondary clarifier and each fitted with a bottom
sludge scraper; surface scum scraper; walkway; drive arrangements; and electric driven brushes for
weir channel cleaning. The total design load of the rotating bridge shall not exceed 400 kg/m 2.

Electrically driven traversing gear, powered from the tank centre and fitted with overload protection
devices shall, in the event of overload, stop the machinery and give a fault alarm. The rotating bridge
shall be provided with rubber wheels, complete with sealed for life bearings, acting directly on the
concrete surface for driving

D class coated steel shall be used for the bridge and corrosion resistant material, such as stainless
steel, shall be used for all components in contact with sewage.

Rubber strips fitted to the bottom of the sludge scraper shall be readily removable. A vacuum system
for sludge removal is an acceptable alternative.

The electric driven brushes for cleaning both sides of weir channels shall be operated manually from
the bridge.

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5.6.2 Pipework, Outlet Boxes and Weirs
The outlet channel overflows, inlet chamber pipe, scum removal system and connecting pipework in
the secondary clarifiers shall be installed according to the approved drawings.

5.6.3 Telescopic Valves

All telescopic valves shall be made of stainless steel.

5.7 Tertiary Disc Filtration

Disc filters suitable for filtering domestic sewage following the secondary treatment stage shall consist
of a series of complete units for installation in concrete tanks with an influent channel and a common
outlet channel. Penstocks shall be placed at the inlet and outlet of each tank for isolation of the disc
filter unit.

Typically, the disc filter assembly shall comprise a centre drum; disc with filter media panels; support
frames; covers for the filter; backwash spray assembly with pumps; drive mechanism; automatic
control system; and other required components for complete functional system.

The disc filter frame shall be made of a corrosion resistant material, such as stainless steel SS316L,
and it shall be possible to detach individual filter discs from the frame. The filter frame shall have
spare attachment points, blinded when not in use, to which spare filter discs could be fitted

The disc filter backwash system shall be designed efficiently to simultaneously backwash the filters
from both sides. The backwash cycle shall be activated by a high-water level in the influent chamber
and backwash shall be returned to the Plant inlet.

5.7.1 Backwash Pumps

Backwash water pumps supplied as part of the disc filter package shall meet the system requirements
and be suitable for use with anticipated treated water quality.

5.8 Disinfection, In-line Chlorination

An ultraviolet (UV) system shall be used to disinfect the final effluent. Any such system shall be of
robust construction and be fitted with an integral cleaning mechanism. The chosen supplier
of this UV system must possess at least 10 years of experience of delivering similar
installations.
High intensity medium pressure ultraviolet (UV) lamps shall be used in the disinfection system.
The UV system shall have electronic ballasts with multiple power settings and incorporate an
automatic, in-situ, mechanical/chemical cleaning system. Mechanical cleaning only with
teflon wipers or air scour technology is not permitted.
UV system shall be capable of operating in an open channel and be of modular design.
Metal components in continuous contact with effluent shall be corrosion resistant as shall all material
exposed to UV light.
The UV lamp assemblies shall be cooled by the effluent and shall operate at a uniform temperature
by ensuring the major axis of the UV lamps is parallel to flow. Other arrangements are not
permitted.
Each lamp shall be enclosed in an individual quartz sleeve, with one end closed and the other sealed
with compressed O-rings. It shall be possible for operating personnel to replace individual
lamps and corresponding quartz sleeves.
All wires connecting the lamps to the main power supply shall be enclosed inside the frame of the
UV module and to prevent exposure to the effluent.
An automatic level controller shall be provided to maintain a minimum effluent level within the
channel sufficient to keep lamps submerged.
An On-Line Transmission Unit (UVT) that automatically tracks the transmissibility of the effluent at
the 253.7nm germicidal wavelength shall be provided with the system.
The control system shall turn the UV banks on and off according to a signal from an effluent flow
monitor and in conjunction with the signal from the UVT monitor. These control settings shall
be operator adjustable.
The design of the system shall enable 99% hazardous material and quartz capture in the event of
UV lamp fracture.
A chlorination system shall be provided as a back-up in the event of a failure of the UV disinfection.
The chlorination process shall be controlled automatically and stopped when there is no
water flow.

5.9 Return and Surplus Sludge Pumping Station

(if applicable)
The equipment to be included in this section shall comprise:
 submersible pumps;
 gate valves;
 check valves;
 dismantling joints;
 internal pipework for return sludge;
 penstocks;
 hoist;
 wet sump ventilation system;
 washing system;
 drain gate valve; and
 electromagnetic flowmeters and level control equipment.

5.9.1 Submersible Pumps

A sufficient number of submersible/immersible sludge return pumps, including one (1) as stand-by,
shall be used to transfer sludge back to the primary distribution chamber. Also, a sufficient number of
submersible surplus sludge pumps, including one (1) as stand-by, shall be used to transfer the
required amount of surplus sludge to the sludge storage tanks. The pumps and impellor type shall be
selected to prevent floc shear by the pumping action. Consideration can be given to Archimedes
Screw pumps as well as submersible/immersible.

5.9.2 Gate Valves for Return Sludge

One (1) gate valve shall be provided and installed on each return sludge pump discharge pipe and
one (1) gate valve shall be provided and installed on each return sludge manifold pipe.

5.9.3 Check Valves for Return Sludge

47
One (1) check valve shall be provided and installed on each return sludge pump discharge pipe
upstream of the gate valve.

5.9.4 Dismantling Joints

One (1) dismantling joint shall be provided and installed on each return sludge pump discharge pipe
and one (1) dismantling joint shall be provided and installed on each return sludge manifold pipe.

5.9.5 Internal Pipework for Return Sludge

The discharge pipes and manifold pipes of the submersible return sludge pumps shall be flanged
ductile iron pipe.

5.9.6 Penstocks
A sufficient number of penstocks shall be installed in the pump sump for closing the inlet pipes.
The penstocks shall be made of ductile cast iron and be manually operated with rising spindles. The
penstocks shall comply with section 525 above.

5.9.7 Hoist
One (1) hoist including trolley and runway beam shall be provided and installed for handling of
submersible sludge pumps.

5.9.8 Washing System

A pressurized washing system shall be supplied to clean submersible sludge pumps and pipes. The
pipe material shall be galvanized.

5.9.9 Flow Meter

Magnetic flowmeters shall be installed on each pump discharge header. The flowmeter is included in
the electrical works. The connection of the flowmeter to the outlet pipe shall be done by a sequence of
reductions and a dismantling joint to facilitate the flowmeter removal.

5.10 Sludge Storage Tank (if applicable)

The equipment to be included in this section shall comprise:
 submersible mixers aeration system;
 blowers;
 butterfly valves
 Internal pipework;
 drain gate valve; and
 dissolved oxygen meter, level control equipment.

5.10.1 Submersible Mixers

Submersible mixers shall be provided and installed in the sludge storage tank. The mixing propeller
material shall be stainless steel 316

5.10.2 Aeration System

The sludge storage tank shall be provided with an aeration system which shall be installed in the
sludge dewatering building or in the main blower house.

The main distribution pipes shall be made of stainless steel. The manifold pipes for diffusers shall be
made of PVC. Diffusers shall be membrane disc type. Pipe supports and brackets shall be made of
hot dip galvanized mild steel.
5.10.3 Blowers
A sufficient number of blowers, including one (1) stand-by. shall be installed in the sludge dewatering
building or blower house.

5.10.4 Butterfly Valves

One (1) butterfly valve shall be provided and installed on each blower discharge pipe. The valves shall
be manually operated.

5.10.5 Internal Pipework

The overflow pipe with support and brackets shall be made of ductile iron.

5.11 Belt Filters (if applicable)

Sludge dewatering shall be achieved by the use of belt filter presses. The equipment shall be placed
in the Sludge Dewatering Building and arranged such that dewatered sludge cake is
discharged directly onto conveyors for discharge into lorries or into a sludge storage area.
The sludge dewatering building shall be adequately ventilated.
The belt filter press shall be manufactured with heavy-duty components specifically designed for
stringent operating environments. It shall be factory tested prior to shipping to ensure all
functions operate properly. Minimum field assembly shall be required.
Each press shall have an effective belt width which shall contain shear/ pressure sections. In
addition, the equipment shall be provided with all necessary valves, inter-connecting piping
and wiring, instrumentation, anchor bolts and other necessary appurtenances for a complete
and operating installation.
Each belt filter press shall be of a continuous belt design with distinct dewatering zones; an
adjustable wedge or low-pressure zone; and a shear/pressure zone. It shall consist of a
structural frame; dewatering belts; an inlet distributor; belt support/wiper bars; a high rate
drainage system; drums, rollers and bearings; discharge blades; a belt drive unit, belt
tracking and tensioning systems; a belt wash system for all belts; and a filtrate/belt wash-
water drainage system. The gravity and pressure zones shall be independent of each other
so that it is possible to select different dewatering belts and vary the speed of each zone
independently of the other. The separation of the pressure zones shall, thus, optimize
throughputs and, with the use of belts of differing porosities, shall enhance the hydraulic
capacity of the press, particularly when processing dilute sludge so as not to hydraulically
limit the solids processing capabilities of the press. The gravity belt shall be readily
accessible and not be enclosed within a container. Each belt filter press shall be fully factory
assembled and shall be shipped as a complete assembly apart from the dewatering belts,
which shall be shipped separately in suitable containers to prevent accidental damage.
The equipment furnished shall be designed and constructed in accordance with the best practices
and methods and for continuous service at maximum conditions. All parts shall be so
designed and proportioned as to have liberal strength, stability and stiffness and to be fully
suitable for the intended conditions of service. Provisions shall be made to facilitate
lubrication, adjustment or replacement of all parts. Corresponding parts of multiple units shall
be interchangeable. Except as otherwise specified, steel plates and shapes shall have a
minimum thickness of 9.5 mm, sheet metal shall be 14-gauge minimum. All materials used
shall be of the best quality and fully suitable in every respect for the service intended. Unless
otherwise specified, all materials in direct contact with sludge, polymer or filtrate shall be
type 316 stainless steel or plastic. All fasteners shall be type 316 stainless steel.

5.11.1 Sludge Conditioning System

49
Each sludge conditioning system shall consist of an in-line polymer injection ring, a variable orifice
venturi type mixing valve and a press mounted flooded bottom distribution system for final
flocculation as well as even distribution of sludge across the full width of the press.
The polymer injection ring shall be of the multiport type to assure optimum polymer usage. It shall be
of polyethylene construction and be supplied with a polyethylene injection manifold complete
with tubing and fittings for distributing polymer to the injection points on the ring. The mixing
valve shall be of cast type 316 stainless steel construction and include provisions to vary the
throat area through an external adjustably weighted lever arm for most effective
instantaneous polymer/sludge mixing. The mixing valve shall also include a removable
inspection cover.
Each injection ring and mixing valve shall form a sludge/polymer mixing assembly that shall be
located directly in the sludge feed line. The contractor shall provide spool pieces at two
additional locations in each sludge feed line to allow for repositioning the mixing assembly.
Polymer dosing pipework and valving shall be arranged to accommodate these alternative
mixing assembly locations.
The flooded bottom distribution system shall be mounted on the feed end of the press and shall be
sized to provide an adequate residence time for effective floc formation. The distribution
system shall consist of a lower inlet section or feed hopper, an upper distribution and exit
section. All metal parts of the system shall be constructed of type 316 stainless steel. Sludge
shall directly overflow the hopper onto the full width of the distribution section. The sludge
inlet line to the tank shall incorporate a means of draining the feed hopper. The hopper shall
also be provided with a plugged drain connection. No mechanical or static mixing devices
shall be included in the hopper or distributor as such devices become fouled and require
frequent cleaning.

5.11.2 Shear/Pressure Section

Each press shall include a shear/pressure section containing dewatering drums arranged in a
horizontal configuration which shall apply compression and shear reversals to the sludge by
passing the sludge cake sandwiched between the two tensioned belts alternately over one
drum and under the next. Vertical shear/pressure sections shall not be permitted. The
shear/pressure section shall begin with a perforated drum which shall be self-bailing to
provide unimpeded filtrate drainage without rewetting of downstream cake and provide a
gradual transition into the shear/pressure section. The remainder of the dewatering drums
shall be solid surface drums and shall provide the proper combination of dewatering area,
applied pressure profile and time under pressure. Inactive belt runs between dewatering
drums shall be kept to a minimum.
Belts shall be seamed and shall be fabricated of wear-resistant monofilament polyester. The mesh
design, porosity and tensile properties shall be selected for optimum dewatering of the
sludge to be processed and for a minimum life of 2000 hours of continuous failure-free
operation. Each gravity belt shall be specially selected with a porosity for maximizing the
hydraulic loading rate. Each pressure belt shall be specially selected for its tensile strength
and pressure producing properties. Machines with pressure belts narrower in width than the
gravity belt shall not be permitted. Each belt shall have its own drive roller, tension roller and
tracking roller as well as a number of carrying rollers. The gravity belt shall have its own
independent drive motor. The pressure belts shall have a single drive motor common to both
belts; however, a single drive roller common to both pressure belts is not permitted.

5.11.3 Belt Wash System

Each press shall be furnished with a belt wash system consisting of a spray header, a spray
containment housing and a wash-water collection box so each belt can be thoroughly
cleaned after cake discharge. The belt wash system shall be suitable for use with plant
effluent furnished at a line pressure of 40 psig. A wash-water booster pump shall be
provided with each press to deliver the required operating pressure to the belt wash system
when adequate line pressure is not available.
A self-cleaning spray header shall be provided for each belt consisting of a schedule 10 type 316
stainless steel header; a series of replaceable type 317LM stainless steel spray nozzles
providing an overlapping spray pattern on each belt; a replaceable stainless steel nozzle
cleaning brush inside the header; and an external handwheel operator which shall make the
header self-cleaning. A full tum of the handwheel shall cause the brush to clean the nozzle
orifices and shall allow the flushing water to pass through the header for discharge directly to
the collection basin beneath the press through a rigid PVC pipe. Presses without this or
similar direct individual nozzle cleaning provisions are not permitted.
The spray headers shall be piped to a common wash-water inlet connection on the press. A NEMA
4X solenoid valve and NEMA 4X pressure switch shall be provided in the water inlet
manifold both for on-off control and to provide an alarm signal in the event of low wash-water
pressure. Each spray header shall have a 10 bar Victaulic clamp connection to the water
inlet manifold to allow for belt spray direction adjustment.
A wash-water booster pump shall be provided for each press to raise the system water pressure to
the required operating level. The pump shall be a horizontal end suction centrifugal pump of
type 316L stainless steel construction with mechanical shaft sealing. The pump shall be
driven by a direct coupled motor and shall be mounted on a common steel channel base for
the motor and pump and a coupling guard.
A hydraulic power unit shall be provided for each press consisting of a motor; a variable volume
pressure compensated pump; a system pressure gauge; a tension control/relieving valve; a
tension system pressure gauge; a breather type filler cap; a return filter with bypass; a level
sight gauge; and a thermometer all mounted on a 316 stainless steel reservoir. The power
unit shall be mounted on the press frame. All system hydraulic piping and tubing shall be
factory furnished and installed. A NEMA 4X pressure switch shall be included to sense low
system pressure and provide a signal to shut the entire system down and sound an alarm in
the event of the loss of system pressure.

5.11.4 Drums and Rollers

Each press shall be furnished with the necessary drums and rollers to provide shear/pressure
dewatering, belt drive, belt tension, belt tracking and general belt support. A minimum of one
perforated drum shall be provided, all others shall be solid surface drums and rollers.
Type 316 stainless steel shall be used for the perforated drum body and its end plates. The body
shall be 4.5 mm inch thick and end plates 12.5 mm thick. Perforated drum shafts shall be
type 17-4 PH stainless steel. All other drums and rollers shall be constructed of ASTM A-53
Grade B or ASTM A-106 Grade B carbon steel with wall thicknesses of 12.5 mm minimum.
Larger diameter major load carrying drums shall have a welded double end plate supported
stub shaft construction on each end with stainless steel shaft stock for the drive rolls and
AISI 4140 heat treated shaft stock for the dewatering drums. Smaller diameter nominal load
carrying rollers shall have either a welded double end plate supported stub shaft
construction with AISI 1045 shafts or a deep bored shrink fit and welded solid journal AISI
1045 stub shaft construction on each end.
Belt drive rollers shall have a 6.25 mm 85 durometer vulcanized rubber covering for gripping the
belts and for corrosion protection and shall have type 316 stainless steel end plates. All
other solid surface drums and rollers shall have a black fusion bonded applied nylon coating
for corrosion protection which shall cover the roller body, ends and shafts up to the point of
insertion into the bearings.

5.11.5 Bearings
Bearings shall be arranged for tapered adapter mounting to the drum and roller shafts. Bearings
shall contain Triple-Check contact seals and shaft mounted splashguards on the shaft side
to provide adequate sealing from moisture and grime. Non-shaft sides of bearing housings
shall be solid. Bearing housings shall have a factory applied black fusion bonded applied
nylon coating for added corrosion resistance. All bearing hardware shall be stainless steel.
All roller bearings shall be main frame mounted and shall be greaseable while the press is in
operation.

51
All roller bearings shall have an L-1O bearing life in excess of 800,000 hours with belts tensioned at
9 kg per linear cm with belts travelling at rated speed. Calculations shall be furnished
demonstrating compliance with these provisions.

5.11.6 Miscellaneous
Each press shall be complete with all intra-unit power and control wiring terminating in a single press
mounted NEMA 4X stainless steel junction box. All wiring shall be run in PVC coated rigid
conduit for added corrosion resistance.
Each press shall be complete with all intra-unit hydraulic system and wash water piping, Filtrate and
wash water drain lines shall be directed to the collection basin beneath the press. All wash-
water supply piping and hydraulic piping shall terminate at their respective single inlet
connection.
For maximum corrosion resistance, all miscellaneous parts such as brackets, spacers, etc. shall be
fabricated from type 304 stainless steel, and all guards shall be fabricated from type 304
stainless steel.

5.11.7 Electrical Control Panel

An electrical control panel shall be provided with each belt filter press to control the belt press
functions and those of the related auxiliary equipment specified herein.
The panel shall be preassembled and prewired and shall include all controls necessary for semi-
automatic system operation with provisions also for manual control of individual items when
desired.
The system shall include facilities to sample individual as well as combined concentrate from the
dewatering belt filter presses.
The flows from each pipeline of the following systems shall be measured:
 sludge feed line;
 polymer dosing; and
 makeup water.

5.11.8 Sludge Feed Pumps

Each press shall have its own feed pump interconnected to the suction and discharge headers to
provide operational flexibility. The pumps shall be suitable for sludge that may contain sand
or other erosion materials.

The pumps shall be of variable speed operation by means of electrical speed control systems. The
speed range shall be sufficient enough to enable the pump output to be increased to its
maximum.

A pipeline shall be taken from the wash water supply to a tapping point on the suction of each sludge
pump. Solenoid operated isolating valves shall be included in the individual pump
connections so that at the end of each pumping cycle water shall be used to purge the
sludge feed pipework.

Pump flow shall be detected by flow meters in discharge pipework to provide actual flow reading.

5.11.9 Steelwork Guard railing and Flooring

All necessary supporting steelwork for the press, including operational and maintenance access
platforms, stairways and guard railing, shall be supplied and installed, as a part of Mechanical
Engineering Works. Removable sections shall be provided to permit the installations of presses in the
future.
Steelwork shall be fabricated from substantial steel sections and plates, welded and bolted together
as appropriate. All steelwork shall be galvanised after fabrication.

An open mesh flooring platform, complete with all necessary supporting steelwork guard railing and a
ship's type ladder shall be installed over the sludge pump wheel to facilitate the operation of the
sludge delivery valves and permit access to the pump well. All steelwork shall be galvanised after
fabrication.

5.11.10 Polymer Storage and Transfer

Polymer shall be stored in an external silo. The silo shall be of steel construction and supported on
structural steelwork. The silo shall be provided with feed connection, level indicator, manhole, vent
and discharge point. A vertical access ladder and hand rail around the top of the silo shall be
included.

Discharge from the silo shall be through a conical base, into an enclosed screw conveyor. The
conveyor shall pass through the wall of the sludge dewatering house and discharge into the polymer
hopper of the polymer preparation unit. A vibrator shall be fitted to the outside of the silo at the base to
assist the flow of polymer into the screw conveyor inlet.

5.11.11 Polyelectrolyte Preparation

The preparation unit shall include:
 powder feeder, complete with hopper;
 disperser units to ensure complete wetting of powder; and
 solution make-up and holding tank.
Each make up water feed pipe connecting to the holding tanks shall have a flowmeter installed to
measure the feed water actual flow. The preparation unit shall be capable of an ageing time of 1 hour.

The mixing tank shall comprise at least three (3) compartments, one (1) mixing, one (1) storage
(aging) and one (1) storage/extraction. The compartments shall be separated by baffles designed to
eliminate the possibility of short circuiting. Mixers shall be provided in each compartment.

The tank shall be sized to produce a required concentration of polymer.

The powder feeder shall have a variable output with a range of at least 5 to 1.

Suitable heaters shall be provided in the powder feeding system to prevent condensation.

The tanks shall be manufactured from steel plate and section suitably reinforced, and shall have an
overflow pipe and a valved drainpipe both connected to the floor drainage system.

Separate flanged outlets shall be provided for each dosing pump.

5.11.12 Polymer Dosing Pumps

The Contractor shall provide a sufficient number of dosing pumps with interconnected suction and
discharge headers to provide operational flexibility. Pumps shall be of the progressive cavity type.

The speed of the pump shall be varied by means of a manually operated hydraulic variable speed
gearbox directly coupled between the pump and drive motor. The gearbox shall be designed to
operate at between 50% to 100% of mean speed.

A flowmeter shall be installed in the discharge pipework to give actual flow rate reading.

Discharge pipework shall include an in-line mixer and wash-water supply control valve to enable the
flow to be diluted from 0.5% to 0.1 %.

5.11.13 Pipework and Valves

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All pipework and valves necessary for the operation of the sludge dewatering plant shall be supplied
and installed. Pipework shall be supplied and installed as part of the Mechanical Engineering Works.

Sludge and concentrate pipework shall be flanged, ductile iron. Polymer dosing pipework shall be
made of PVC. Pipe sections and fittings shall be connected with solvent welded type joints, but
flanged joints must be made at connections to equipment and at intermediate positions for pipework
dismantling and cleaning of blockages.

5.11.14 Sludge Cake Conveyor System

The sludge cake conveyor system shall comprise the followings:
 screw conveyor troughs shall be lined with abrasive resistance material or include
replaceable liners to protect the steel casing. Conveyors shall include inlet and outlet
hoppers;
 belt conveyors shall include belt cleaning and belt tensioning devices;
 power to the conveyor drive motors shall be through a cable reeling drum;
 all support steelwork, fixings, walkways, ladders, open mesh flooring and guard rails
associated with the conveyor system shall be supplied and installed as part of the
Mechanical Engineering Works. All steelwork shall be galvanised after fabrication and
other materials selected for operation in a corrosive environment.

5.11.15 Dewatered Sludge Storage

The dewatered sludge storage silos shall be equipped with a load cell and inclined screw conveyors
fixed to the bottom to facilitate loading the predetermined sludge tonnage into trucks.

All pipework and valves shall be in stainless steel.

5.12 Washing, Fire Protection and Site Irrigation

System Units
The plant shall be provided with a proper system designed with sufficient capacity and capable of
delivering water at 10 bar.

Electrical and SCADA system rooms shall have proper firefighting system according to NFPA
Standards and in line with Local civil defence requirements.

5.12.1 Hydro-pneumatic Booster Unit

The Works to be included in this Section shall comprise one (1) hydro-pneumatic booster units
complete with pipework and ancillary equipment.
(i) Brief Description of the Works
The booster unit shall be capable of pressurizing the site treated effluent supply system to provide
water for firefighting, wash-down and irrigation. The unit shall be capable of providing a flow of 10
l/sec to standpipes and roof-mounted storage tanks. The system shall be capable of delivering a
pressure of at least 2 bars at a hose nozzle connected to the highest or furthest standpipe, whichever
is the greater duty.
(ii) Detailed Description of Diaphragm Booster Unit
A hydro-pneumatic booster comprising centrifugal pumps, air/water receiver, inter-connecting
pipework and a control cubicle mounted on a unit shall be provided.
The vessel shall be designed and manufactured in accordance with BS 5500. It shall include a
removable food grade butyl rubber diaphragm. The vessel shall also include the following:
 inspection door;
 pressure gauge;
 inlet /outlet connection with hand operated sluice valve;
 rain connection with hand operated sluice valve;
 air valve for the charging of the vessel;
After manufacture, the inside and outside of the vessel shall be hot dipped galvanised. The vessel
shall be mounted either directly on a plinth or on legs. If it is mounted on legs, it shall have minimum
of three mounting legs and stand at least 300 mm above the ground.

The pressure gauge, pressure switch and air inlet tapings shall be arranged to be above the possible
maximum level of membrane type diaphragm collector in the vessel. A pressure gauge, which reads
the air pressure in the vessel and thereby indicates the pressure in the system, shall be placed on the
tank.

A manually operated lockable air release valve shall be supplied for the vessel to vent excess
pressure before the system is drained.

Pressure switches shall be robustly constructed and be suitable for the arduous duties involved. They
shall be fully adjustable over their working range together with adjustable differentials.

Factory testing of the vessel shall be carried out in accordance with the BS 5500 and a test certificate
issued. The working and testing pressures shall be stamped clearly and visibly to the outside of the
vessel.

The unit shall be suitably protected against low/ no water in the reservoir.

A centrifugal pump of multi-stage end suction and direct driven type shall be fitted to the unit. The
casings shall be made of close grained cast iron. The parts in contact with rotating units shall be
protected with removable bronze or stainless steel wear rings. The impellers shall be made of bronze
or stainless steel secured by keys to the shaft which, where in contact with the water, shall be
protected by removable bronze or stainless steel sleeves. Water throwers shall be provided to prevent
ingress of water into the bearings.

The pump shall have its electric motor close coupled or shall have a suitable flexible coupling fitted
between the motor and pump spindle.

The pressurized vessel and pumps shall be mounted on a robustly constructed common baseplate.
The unit shall be complete with all necessary sluice and reflux valves. The pipes on the unit shall be
galvanised mild steel and shall be flanged or screwed. However, the termination points of pipes shall
be flanged.
(iii) Pipes and Valves
All associated valves, suction and delivery pipes shall be provided. The delivery pipes within the
station shall be made of galvanised steel and shall extend from the booster unit to an isolating valve
placed very close to the unit. The suction pipework shall be a minimum of 100mm diameter and shall
incorporate a foot valve.
(iv) Pressure Gauges
Pressure and combined gauges shall be provided for the pump and air vessel.
(v) Steelwork
The following steelwork shall be provided and fixed in the station: baseplate for pump and air vessel;
and support brackets of pipes

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(vi) Method of Control
All controls necessary to achieve the sequence of events detailed below shall be placed in a control
panel:
 both manual and automatic control shall be provided for the Booster Unit. A "Hand-off-Auto"
selector switch shall be provided;
 under manual control, starting and stopping of the pump shall be initiated from the control
panel;
 automatic control shall be such that the pump will start and stop due to signals coming from
the system pressure switches placed on the booster unit;
 failure of the duty pump shall initiate the alarm system and the stand-by pump shall
automatically be selected for duty; and
 one (1) float switch for automatic cut-out shall be provided to protect the pump in the event of
low water level in the reservoir.

(vii) Motors
The motor shall be of the squirrel cage type protected to IF.54 and shall be rated at 20 percent above
the calculated maximum power.

5.12.2 Metal Protection

All items of equipment shall be treated to suit the environment and the minimum design life
specified elsewhere.

5.13 Return Flow and Drain Pumping Station

A drainage system shall be provided to collect all process equipment and service water drainage and
filter backwash water. It shall be conveyed to the return flow and drain pumping station, where it shall
be returned to the inlet works. The plant to be included in this section shall comprise:
 submersible pumps;
 gate valves;
 check valves;
 dismantling joints;
 internal pipework;
 washing system;
 drain gate valve; and
 level control equipment, magnetic flowmeter.

5.13.1 Submersible Pumps

Submersible pumps n+1 shall be provided and installed for pumping process supernatant to the inlet
works.

5.13.2 Gate Valves

One (1) gate valve shall be provided and installed on each pump discharge pipe and one (1) gate
valve shall be provided and installed on manifold pipe for the drainage of the main pump line located
downstream of the pumping station.

5.13.3 Check Valves

One (1) check valve shall be provided and installed on each pump discharge pipe between the pump
and the gate valve.

5.13.4 Internal Piping

Discharge pipes from the submersible pumps and manifold pipes shall be flanged ductile iron.

5.14 Submersible pumps

Submersible pumps shall have the following characteristics and meet the following requirements:

 Pumps shall be of a non-clogging submersible type suitable for sewage or sludge handling;

 Pumps shall be capable of operating continuously at all flow rates within design capacity,
without vibration and shall be designed to have a continuously decreasing head-flow
characteristic to provide stable operation;

 pump discharge outlets shall be designed to be flange coupled fastened by stainless steel
bolts fitted with primary locking devices or to seal to duct foot bend counterpart;

 Motors shall run smoothly and vibration shall not exceed of 4.5mm/s Rotors shall be balanced
both statically and dynamically. Rotors shall be adjusted for dynamic balance with a tested by
an approved method;

 Cables shall be flexible twisted copper wire and shall be thoroughly coated with underwater
grade flexible twisted insulation;

 motors shall be designed to be sufficiently cooled by the surrounding environment or pumped

media. External cooling systems shall not be employed;

 Pump motors shall be designed for continuous duty whilst handling pumped media with a
maximum temperature of 40°C and be capable of up to 10 evenly spaced starts per hour;

 Motors and pumps shall be designed and assembled by the same manufacturer. The
combined service factor (combined effect of voltage, frequency and specific gravity) shall be a
minimum of 1.15. The motor shall have a voltage tolerance of plus or minus 10%;

 Motors shall be designed for operation at a maximum ambient temperature of 40°C and a
maximum temperature rise of 85°C;

 Motors and cable shall be capable of continuous submergence without loss of watertight
integrity according to protection class IF 68 (20 m). The pump shall have a non-overloading
characteristic with the motor not exceeding 90% of its design rating at any point along the
pumping curve;

 The oil chamber shall be filled with a medical grade white oil of paraffin. The oil shall be free
from aromatic hydrocarbons, be medically clean and be approved according to FDA 172.878;

 Pump and motor shaft shall be the same unit. The pump shaft shall be an extension of the
motor shaft. Couplings shall not be acceptable. The shaft material shall be AISI type 431
stainless steel. The use of stainless steel sleeves will not be considered equal to stainless
steel shafts; and

 The impeller shall be capable of handling solids, fibrous materials, heavy sludge and other
matter found in normal wastewater. Whenever possible, a fully vanned, non-vortexing,
impeller shall be used for maximum hydraulic efficiency, thus, reducing operating costs. The
impeller shall be capable of passing min 75 mm diameter solid.

 It shall be possible to either easily access the pumps for removal and maintenance (dry well
installation) or withdraw the pumps from a wet well easily. Necessary cranage and easy
chain connection systems for lifting the pumps shall be provided.

 Each pump shall be fitted with a non-slam check valve and isolation valve.

 All pumping stations shall have a minimum of one standby pump.

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5.15 Conditioning monitoring
The Project Company shall build in to all plant a high level of condition monitoring, using state of the
art instrumentation, reporting through the SCADA system to enhance as much as reasonably possible
the overall asset management on the site.

As a minimum all plant above 45kW, where applicable and within a state of the art manufacturer’s
norm, shall be fitted with:

 Vibration monitoring on all main load bearings;

 Temperature sensors on all bearings;
 Temperature sensors on all stator windings;
 Power monitoring;
 Oil in water sensors;
 Water in oil sensors;
 Rotation sensors;

Below 45kW plant is to be fitted with the maximum level of condition monitoring the plant
manufacturer provides.

5.16 Odour control

Odour control systems shall be of the wet or dry scrubber type to meet the performance parameters
described elsewhere in the documentation. The systems shall ensure:
 Good vehicle access for media/chemical replacement and operation and maintenance;
 Adequate lifting facilities for the above;
 Bunding and drainage control to contain all spillage;
 Sealed ducting systems, fans, covers and controls to meet the performance criteria;
 Safety showers where hazardous consumables are used;

5.17 Plant Tagging and Labelling.

Plant shall be labelled and tagged to comply with the Computerised Maintenance Management
System and Intelligent P&IDs.

Common questions