5.2.1.

2 Redundancy Requirements
All pump stations shall be provided with at least two pumps of equal capacity with
capacity of each pump equal to the total flow to be pumped. Where more than one
duty pump of equal capacity is required to meet the maximum design flow conditions,
consider an additional pump of similar capacity as standby unit. For pump stations
with four or more duty pumps, it is recommended to have at least two standby pumps.
For rest of the equipment’s consider n+1 redundancy where n is the number of
equipment’s required to function under design conditions. In all cases single point of
failure shall be avoided.
[Link] Power Connection Requirements
The pump station shall be provided with three (3) phase main power supply to
adequately operate pumps; equipment, instrumentation and control system and
other auxiliary power systems and equipment. All power lines within the site should
be underground. No overhead power line should be allowed to cross the site.
All electrical equipment and wiring specified shall be suitable for the area and
environment to which it will be exposed. The Designer shall prepare an area
classification document in accordance with SBC 401 chapter 720 and IEC 60079-
10-1 and IEC 60079-10-2 with plan showing the classification and hazardous areas
including the zones.
[Link] Pump Operation Schedule
The cyclic alternation of the pump should be incorporated in the pump station control
philosophy. In order to reduce the number of starts for a particular pump and
minimize the required sump volume, the last pump to start should be always the last
pump to stop. The pump shall be selected to match with most favorable flow
conditions to maximize the equipment life.
Structures
Sewerage pump stations can be broadly classified as follows:
a) Wet well/dry well pump stations;
b) Wet well only submersible pump stations.
In general the pump station should be of wet well submersible pump design.
However wet well/dry well pump stations can also be considered where capacity of
the individual pumps is too high for submersible installation. Also for larger stations
the maintenance aspect of the pump also need to be evaluated.
The requirements for each type of pump stations are detailed below.
[Link] Wet Well
The HI Standard ANSI/HI 9.8 Rotodynamic pumps for pump intake design should be
utilized as a reference and guide in the design of wet wells In general, Major points
to be considered in the design of the wet well is provided below:
a) The size of the wet well shall be adequate for accommodating pump and piping;
b) Ensure proper approach flow pattern by limiting the following adverse hydraulic
phenomena that can affect the pump performance:

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 i. Surface vortices;
ii. Submerged vortices;
iii. Swirl of flow entering the pump;
iv. Non-uniform distribution of velocity at the pump impeller; and
v. Entrained air or gas bubbles.
c) Avoid entrapment of air in the sewage due to falling water by providing baffle
walls in the inlet;
d) Avoid dead space inside the wet well where solid can accumulate;
e) Provide benching in the wet well floor to direct the flow to the pump suction;
f) Distribute the incoming flow evenly towards the pump;
g) For large pump stations; consider compartmentation of the wet well to facilitate
cleaning and maintenance;
h) Provide openings of sufficient dimensions to allow the installation of the pump.

The storage required in a wet well is a function of the sewage inflow and the chosen
pump capacity. The active sump volume required for a single constant-speed pump
shall be calculated based on allowable starts per hour for pump/motor and flow. The
minimum live volume (i.e. the volume between the start level and the stop level of
the pump) is calculated using the formula:
V = 0.25 QT
Where:
V = live volume of the sump in m3.
Q = single pump capacity in m3/sec
T = on off cycle time in seconds = 3600 / starts per hour recommended by
manufacturer. The number of starts per hour for the pump/motor shall be minimum
10 for smaller motors (Up to 30 Kw) and for larger motors refer to the limitation
provided in NEMA MG 1 for number of starts per hour and consecutive starts.
However the motor manufacturer should be consulted to determine the allowable
number of starts and rest times according to project requirements.
Start and stop levels for successive pumps should be separated by at least 200 mm
to 300 mm for liquid-level sensing devices to operate reliably. Provide a time delay
of 5 to 10 sec on starting to avoid premature operation caused by turbulence.
For large pumping stations flow (0.5 m3/s), Computation Fluid Dynamics (CFD)
numerical model and physical models shall be considered.
[Link] Dry Well
The dry well structure shall be sized to provide sufficient space to allow personnel to
move around the pumps and accessories as well as to dismantle and assemble the
units. The space required for removal of pump covers, etc. should suit the largest
machinery to be installed. Maintain at least 1 m clearance around the equipment for
maintenance. Sloped ladders should be provided for accessing the wet well.

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 The dry well floor should be graded to a drain sump with
permanently installed sump pump. The discharge point of the sump pump shall be
above the pump station maximum flood level to avoid siphoning back to the drywell.
Provide adequate lifting headroom for equipment. An allowance for sling length or
lifting beams between equipment lift points and crane or hoist hook also needs to be
included.
Place wash down stations in logical areas to facilitate clean-up and pipe flushing.
[Link] Equipment
The equipment selected shall be reliable, and well suited for the required type of
service. The following equipment’s to be considered for each pump station.
a) Wet well pump station:
i. Inlet penstock;
ii. Close coupled submersible sewage pump with automatic coupling and lifting
mechanism;
iii. Hoisting and conveying equipment (motorized hoists, monorails, or cranes);
iv. Interconnecting penstock between wet well compartments if applicable;
v. Sewage screening, washing and compaction units;
vi. Separate valve chamber with isolation valve and non-return valve;
vii. Separate chamber with electromagnetic flow meter;
viii. Wet well water level sensor and transmitter;
ix. Wet well H2S level sensor;
x. Pressure gauges and pressure transmitters inside valve chamber;
xi. Odor control system;
xii. HVAC units for electrical and control room;
xiii. Complete electrical, instrumentation and control system;
xiv. Standby power generation units as applicable.
b) Wet well and dry well station:
i. Inlet penstock;
ii. Dry well installed close coupled sewage pump with submersible type motor;
iii. Equipment lifting arrangement;
iv. Interconnecting penstock between wet well compartments if applicable;
v. Sewage screening, washing and compaction units;
vi. Pump suction and isolation discharge valves and non-return valve inside dry
well;
vii. Electromagnetic flow meter in the discharge header;
viii. Wet well water level sensor and transmitter;
ix. Wet well H2S level sensor;

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 x. Pressure gauges and pressure transmitters;
xi. Odor control system;
xii. HVAC units for electrical and control room, dry well and other manned
building;
xiii. Firefighting system for electrical and control building and other building as
required by authority having jurisdiction.
[Link] Ventilation
All the structures within the pump station shall be adequately ventilated to prevent
build-up of hazardous gases. The requirement specified hereunder are based on
NFPA 820 Standard for Fire Protection in Wastewater Treatment and Collection
Facilities. Except for confined spaces that are not routinely entered, all mechanically
ventilated spaces shall be served by both supply and exhaust fans.
Following minimum Air Changes per Hour (ACH) shown in Table 5-1 are specified
as per SBC 401, NEC and NFPA 820.
Table 5-1: Minimum Air Changes per Hour
Location or Area Minimum Air Changes/Hour

Equipment Rooms 15

Underground Vaults 12
Emergency Ventilation for Wastewater Head
15-60
Space
Wastewater Pump Station Wet Well, where Odor
12
is not a Concern – Class 1, Div. 1 (NFPA 820)
Wastewater Pump Station Wet Well, where Odor Greater of 4 ACH or maximum
is a Concern – Class 1, Div. 1 (NFPA 820) influent rate
Wastewater Pump Station Dry Well – Unclassified
>8
(NFPA 820)

Pumps
The sewage pump should be vertical non clog self-contained, close coupled
pump/motor units designed to operate at continuous full load either submerged or
non-submerged condition.
[Link] Fixed/ Variable Speed Pumps
The type (fixed/variable) and number of pumps should be selected to meet the
variable capacity requirements during peak and lean flow period. Careful evaluation
must be performed in selecting a suitable characteristic pump performance curve,
operational speed range, and in determining the performance envelope associated
with combining pumps. The total head requirements for parallel operation shall
intersect with individual pump curve within the Preferred Operating Region (POR) of
the pump. Incorporate necessary measures in the design of the pumping system in
order to deal with the flow build-up in the future. These measures include variable
speed drive for pumps, parallel pump operation and phased implementation.
Variable speed drives should be utilized for large stations directly connected to
sewage treatment plant where sudden inflow cannot be tolerated.

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[Link] Units/Capacity
The capacity of the pump shall be selected to match with the peak inflows to minimize
the risk of flooding the station. Where pump stations are delivering to a treatment
works, the design capacity shall be compatible with the treatment works.
[Link] Energy Efficiency of Pumps/ Best Efficiency Point
Select the pump with highest efficiency possible to maximize energy cost savings.
The pump should be selected so that the Best Efficiency Point (BEP) of the pump is
close to the duty point where the majority of pumping operations will occur.

[Link] Pump Power Calculation

The pump power shall be calculated using the following formula.
𝑄𝜌𝑔𝐻𝜂
𝑃=
3.6 𝑋 106
Where;
P: Pump Power (kW),
Q: Flow rate (m3/hr),
Hi: the Total Pump Head,
𝜂: Pump Efficiency.

[Link] NPSHa Calculation

The pump station wet well shall provide the pumps with sufficient net-positive suction
head available (NPSHA) and the submergence depth corresponding to the
established pump suction free-water surface operating range. NPSH margin of at
least 1 meter should be considered for the pump.
Net Positive Suction Head Available (NPSHa) shall be calculated using the following
formula. NPSHa = Ha – Hvpa – Hst - Hf
Ha = Absolute pressure acting on the surface of the liquid.
Hvpa = vapor pressure
Hst = static head
Hf = friction head

[Link] Station Piping/Controls

a) Station Piping:
i. All piping inside pump station including valve chamber should be flanged
ductile iron pipe;
ii. The arrangement of the pipework shall be in a such a way that total
dismantling is not necessary for the replacement or maintenance of any one
component;
iii. Provide non return valve and Isolation valve on the delivery side of each
pump. Position the isolation valve downstream of the non-return valve. The

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 isolation valve shall be of unobstructed full port
design to ensure minimum resistance to the flow;
iv. For wet well only pump stations valves on the discharge pipework shall be
mounted in a separate valve chamber adjacent to the wet well;
v. Isolations valves shall be provided in the suction line for dry installed pumps;
vi. Provide dismantling joints close to valves for easy dismantling and
maintenance.
vii. Provide pressure tap, drain and reducer to match the piping to the size of the
pump inlet.
viii. The outlet side of the pump shall typically include an increaser, an air relief
valve (At the high point), a pressure gauge or transmitter, drain and flow
meter.
ix. Eccentric reducers should be located at least one pipe diameter away from
the pump inlet or pump suction elbow for every pipe size reduction.
b) Pump Control:
i. Complete and functional controller comprising of PLCs and associated
equipment including SCADA system shall be considered;
ii. The operation of the pumps shall be fully automatic. Automatic operation of
the pumps shall be accomplished through level control.
Emergency Operation at Power Failure
As a minimum, provide provision in the electrical panel to connect portable
emergency generator for pump station with low risk of flooding. For higher risk and
larger pump stations provide emergency diesel generator with automatic transfer
switch. Dual feed also can be considered in place of diesel generator in consultation
with power supply company.
Un-interruptible Power System (UPS) shall be provided to power the associated
instrumentation, control and automation equipment for at least 8 hours after the
failure of power supply.
5.3 DESIGN REQUIREMENTS FOR FORCE MAINS
Design requirements for force mains are described as below. Designers shall bear
in mind that pump stations and a hereto connected force main form hydraulically
speaking an inseparable unit which is why a separation between the two within two
Construction Contracts following the EPC philosophy shall be avoided alone for
reasons of risk minimization and liability gaps.
System Layout / Alignment / Location
Force mains should be of shortest possible length to reduce dynamic head losses,
the production of malodorous, toxic, and corrosive gases, and cost. Location of other
services, buildings and structures should be considered while selecting the pipeline
route. Pipeline profile should avoid intermediate high points if feasible. Ideally top of
the force main should be maintained below the hydraulic grade line at the minimum
pumping rate. The design of the force main shall ensure that the pipeline remain full
in all conditions.

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 To keep hydraulic losses in force mains low, directional
changes of 900 should be avoided, instead 2 directional changes of 450 should be
provided.
The use of twin mains should be considered on a case-by-case basis. The main
factors for consideration include various design elements such as velocity in the
pipeline, the risk assessment and cost benefit analysis.
The following should be taken into consideration regarding the choice of pipeline
alignment:
a) Present and future underground infrastructure works;
b) Local changes in the nature of the soil;
c) Accessibility of the pipeline during laying, management and removal;
d) Expansion possibilities for internal pressure and temperature changes;
e) Bends in pipelines in connection with thrust effect and/or thermal expansion;
f) High-voltage cables and induction on steel pipelines or pipe sections.
Pipeline crossings and clearances shall be as follows:
a) The minimum horizontal and vertical clearance between various dry and wet
utility shall be according to relevant authority specification;
b) Vertical clearance: Provide minimum 45 cm vertical clearance between water
and sewer pipeline which are crossing and provide minimum 30 cm clearance
when the sewer pipes are crossing other utilities. The sewer lines must always
be installed under potable water line;
c) Horizontal Clearance: Provide a minimum of 1.5 m horizontal separation between
water/sewer pipelines and other utilities and structures (manholes, inlets, vaults,
poles, etc.).
[Link] Line Valves
For long rising mains, isolating valves should be included at strategic locations to
allow sections to be isolated and emptied within a reasonable time. Washout valves
shall be provided at all low points in the pipeline for complete draining of pipe during
maintenance.
[Link] Aeration valves
Air/vacuum valves shall be installed at all high points for expelling or admittance of
air. The size of the air/vacuum valve should be based on manufacturer's valve
performance curves. The valve size should be determined by considering both
normal operating conditions and catastrophic conditions such as water column
separation due to hydraulic transient conditions or line breakage at a low point.
[Link] Manholes / Chambers
a) All valves and underground devices shall be located in a RCC valve chamber,
sized to allow valve operation and reasonable maintenance clearances. The
chamber covers should be ductile iron medium duty and epoxy coated. The word
of “Sewage” in English and Arabic should be casted on the covers. Valve

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 chamber with depth more than 1.5 m should be
provided with heavy duty GRP ladder 400 mm wide.
b) The bottom of the chamber shall have a minimum slope of 2% and provided with
a sump with a provision to install sump pump;
c) Do not construct the chamber in the carriageway and the cover level of the valve
chambers should be flushed with surrounding finished ground level;
d) Flexible joints “rocker pipe” shall be provided in the upstream and downstream
of the valve chamber to control differential settlement of the structures. This
requirement is not valid for HDPE solid wall pipes;
e) A minimum clearance of 500 mm from the walls of the chamber to the equipment
and to the pipe joints should be considered. The minimum clearance between
bottom of pipe and floor should be 400 mm;
f) For non-restrained pipe systems, the chamber shall be designed to take the full
thrust load at valve shut of conditions. Also puddle pipes shall be used to connect
the piping with valve chamber;
g) All the equipment used in the chamber must be properly fixed and supported;
h) Dismantling joints should be specified for easy dismantling of valves inside the
chamber;
i) Flood detector and gas monitors should be installed as necessary in consultation
with the Client / Engineer;
j) The washout concrete chamber should consist of dry and wet chamber. The drain
pipe with blind flange should terminate in the wet chamber;
k) The inner surfaces of the wet chamber shall be protected with GRP / HDPE liner.
[Link] Corrosion Protection
The presence of hydrogen sulfide in sewerage leads to the formation of sulfuric acid
with a correspondingly high degree of corrosion with unprotected metallic
construction materials. Components made of metallic materials are therefore to be
employed only with satisfactory corrosion protection measures in place. All metallic
components. Structures and piping shall be coated and lined as required by the
design.
Furthermore, electrical system installed in wet wells shall be specified for corrosive
conditions.
Hydraulic Design
The guidelines for hydraulic design are summarized below.
[Link] Hydraulic Modelling (steady state- and transient flow conditions)
Hydraulic modelling involves using a computer model of the pipeline to predict the
behavior of the system to solve a wide variety of design and operation issues.
Hydraulic modelling tools should be used to calculate system curves of distribution
systems so that pumps are selected that provide the necessary head and flow.
Proposed pumps are then used in the model across the range of operating conditions
to determine how well they satisfy variety of operating conditions.

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 The software package utilized for hydraulic analysis
should have following capabilities.
a) The software package should have the ability to perform steady state analysis
and extended period simulation;
b) The package should have the ability to model pumping units (incorporating pump
characteristic curves), pipes and nodes as well as flow and pressure regulating
devices;
c) The software package should provide a graphical representation of the results
which allows the user to see a schematic of the pipeline system;
d) The software should have system configuration error reporting capabilities;
e) Selective reporting of results based on user selection;
f) Capability to export and import model data and model results to and from other
applications, such as spreadsheets, databases, and GIS systems;
g) Capability to generate various scenarios by applying various combinations of
demands, facilities, and operating parameters (such as regulating valve and
pumping unit settings).
In order to provide good simulation results, it is important that the pipeline geometry
used in the model is a good representation of the true pipeline elevation profile.
Prepare single-line isometric schematic from pump suction piping origin to point of
system discharge for development of the model in the software. Indicate line sizes,
dimensions, fittings, and piping materials in the schematic.
Sensitivity analysis on key model parameters shall be performed to determine which
factors strongly influence pressures and flows. The most limiting demand conditions
should be established and simulated with the model. The model should be tested to
ensure that it predicts pipeline behavior within acceptable limits.
Hydraulic model simulations are divided into three different categories: steady state,
extended period simulation, and transient simulation.
Steady state analysis provides an overview of pipe system conditions at any instant
in time. Steady state analyses should be used to evaluate maximum day, and peak
hour flow conditions. Perform steady-state simulations at first to evaluate the pipeline
and work out the improvement required in the conceptual design, and perform
extended-period simulations to evaluate the final design.
Hydraulic transient simulations are used to predict very rapid pressure changes that
are a result of pump failure events or sudden changes in valve position. Maximum
allowable incidental pressure (MAIP) and allowable negative pressure shall be in
accordance with relevant national and international piping codes and standards and
pipe manufacturer recommendation. Negative pressures can be allowed if the pipe
strength is sufficient to withstand this condition, but in all cases subject to piping
manufacturer recommendation.
The main scenarios to be considered for surge analysis are as follows:
a) Complete pump trip;
b) Single pump trip to determine check valve requirements;

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 c) Unintended valve closure; and
d) Emergency shut-down procedures.
[Link] Design Basis
The major factors to consider in analyzing the pipeline hydraulics include the design
flow and friction losses.

[Link].1 Design Flow and Pipeline Operation

The design flow rate through the force main shall be based upon the peak design
flow. If a pump station is planned to be built in phases for the ultimate future flow
prediction, consideration should be given to the various flows build up at the different
project phases. Pump selection should be based not only on the ultimate capacity
requirements, but also on the interim development phase flows.

[Link].2 Pipe Roughness

The roughness coefficient for the varies with pipe material, size, and age. The
pipeline should be analyzed for both new and old condition and corresponding
roughness coefficient must be input in to the hydraulic calculation.

[Link].3 Applied Principle of Frictional Losses Calculation

This section describes the basic parameters and formulas needed for computing the
pump total dynamic head conditions and associated system head curves for the
pump.

[Link].3.1 Total Dynamic Head.

The Total Dynamic Head (TDH) is the total head against which the pump must work.
TDH is determined by adding the total static head, the frictional head losses, the
velocity heads associated with the selected boundary conditions and the fitting and
minor losses (energy losses associated with pipe bends, isolation valves, pipe
entrances and exits, and fittings).
The total static head is the difference in elevation in meters between the discharge
free-water surface level in the discharge tank or structure and the free-water surface
level in the pump suction wet well.

[Link].3.2 Friction Head Losses

Different methods/formulas can be used to determine the head loss in the pipe. The
following formulas are widely accepted for the head loss calculation.
Hazen-Williams formula
Darcy-Weisbach formula
Manning
The Hazen-Williams equation is applicable to water pipes under conditions of full
turbulent flow. In metric terms, Hazen Williams' formula is given below:
𝑄1.85
ℎ𝑓 = 10.67 x 𝐿 x
𝐶1.85 ∙ 𝐷4.87

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 Where:
hf = Friction head losses of the pipe in m
L = Length of the pipe in m
Q = flow through the pipe in m3/s
D = Inside diameter of the pipe in m
C = Coefficient depending on the pipe diameter, dimensionless as shown in Table
5-2 below.
Table 5-2: Hazen Williams C Coefficient
Pipe diameters Hazen Williams “C” Coefficient

Pipe diameters > 500mm 140

Pipe diameters < 500mm 135

In metric terms, the Darcy-Weisbach formula is:

Where:
hf: Friction head losses of the pipe in m
f = Friction factor, dimensionless
L = Length of the pipe in m
Q = Flow through the pipe in m3/s
g = Gravity acceleration = 9.81 m/s2
D = Inside diameter of the pipe in m
The friction factor, in its more general expression, is calculated from the Colebrook-
White equation:
1 𝐾𝑠 2.51
= −2 log10( + )
√𝑓 3.7𝐷ℎ 𝑅𝑒 √𝑓
Where:
Re = Reynolds number, dimensionless
Ks = Roughness coefficient in mm, as shown in Table 5-3 below.
Table 5-3: Ks Roughness Coefficient

Flow Velocity (m/sec) Colebrook-White, Ks (mm)

From 1.1 m/sec to 1.8 m/sec 0.15 mm

Less than 1.1 m/sec 0.3 mm

The Manning equation typically solves gravity flow problems where the pipe is only
partially full and is under the influence of an elevation head only.
Qm = (1,000/n)(S)0.5(A)(R)0.667
Where:
Qm = Flow rate, L/sec

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 n = Manning roughness coefficient
S = Hydraulic slope, m/m = (H1 – H2)/L
H1 = Upstream elevation, m
H2 = Downstream elevation, m
L = Length of pipe section, m
A = Cross-sectional area of pipe, m2
R = Hydraulic radius (A/Wp), m
Wp = Wetted perimeter of pipe, m

[Link].3.3 Localized Head Loses

Energy losses associated with pipe bends, isolation valves, pipe entrances and exits,
and fittings are generally determined by multiplying a minor loss coefficient (K) by
the velocity head, which is defined as the velocity squared divided by two times the
gravity constant (g).

Where:
hL = Localized head losses of the pipe in m
K = Resistance coefficient, dimensionless
V = Velocity in the pipe in m/s
Q = flow through the pipe in m3/s
g = gravity acceleration = 9.81 m/s2
D = Inside diameter of the pipe in m
The K value from the following sources are acceptable.
a) Tables for the Hydraulic Design of Pipes, Sewers and Channels: 8th edition (by
HR Wallingford (Author), D.I.H Barr (Author);
b) AWWA manual for different pipe materials;
c) Other internationally recognized sources and hydraulic text books.
Wherever possible, manufacturer published figures shall be used for valves and
accessories. The pressure drop shall be calculated by considering valve in fully
open condition.
[Link].3.4 System Head Curves
A plot of the system head over a range of flow rates is called the system curve.
System head curve for both maximum and minimum Total Dynamic Head (TDH)
conditions shall be developed considering the below points.
a) Minimum TDH: Minimum friction head loss in the pipe plus minimum static lift;
b) Maximum TDH: Maximum friction head loss in the pipe plus maximum static lift.

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 The point at which the system curve and pump curve
intersect is the operating point, or duty point, of the pump. The duty point of the pump
to be determined by superimposing the characteristic curve of the centrifugal pump
on the system-head curve. The performance and service life of the pump are
optimized when the operating point intersects at the Best Efficiency Point (BEP) of
the pump. At the BEP the hydraulic efficiency is at maximum. Also the flow remains
well controlled within a range designated as the preferred operating region (POR) of
the pump. Typically The POR for most centrifugal pumps is between 70 percent and
120 percent of BEP. Within this region the service life of the pump will not be
significantly affected by hydraulic loads, vibration, or flow separation. The Allowable
Operating Region (AOR) is the range of rates of flow that is recommended by the
pump manufacturer over which the service life of a pump is not seriously
compromised. Pump manufacturer shall be consulted if the operating point is outside
the POR and in any case the operating point shall be within AOR at all operating
conditions. The above details are indicated in Figure 5-1 Pump Curve (H-Q Curve)
The combined performance of two or more pumps operating in parallel is plotted by
adding the capacities of each pump at the identical corresponding total head based
on each pump’s characteristic pump performance curves as indicated in Figure 5-2
Parallel Pump Operation. Variable frequency pumps also can be utilized to increase
the head and flow capacity range of a pumping system as indicated in Figure 5-3 H-
Q Curve for Variable Speed Pump

Figure 5-1 Pump Curve (H-Q Curve)

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 Figure 5-2 Parallel Pump Operation

Figure 5-3 H-Q Curve for Variable Speed Pump

[Link].3.5 Hydraulic Profile

Hydraulic profile shall be prepared for peak and minimum flow conditions. The
hydraulic profile should be plotted directly onto the pipeline profile to verify all pipeline
highpoint elevations are below the calculated Energy Grade Line (EGL) and
Hydraulic Grade Line (HGL) at each location. If the calculated EGL elevation fall
below the pipeline highpoint, then the calculated total dynamic head may not be
sufficient to achieve the required design capacity, which may result in a pump station
that will not be capable of achieving the required design flow capacity range.

[Link].4 Minimum and Maximum Velocities

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 The velocity of flow in the discharge main shall be 1
m/sec at minimum flow and 2 m/sec at peak flow conditions. The velocity of flow in
the suction line shall be in the range of 0.8 to 1.5 m/sec.

[Link].5 Minimum and Maximum Pipe Cover

The depth of cover should be established based on an evaluation of specific project
conditions, such as pipe diameter and stiffness, soil type and stiffness, and live load
type and magnitude.
The minimum cover of the buried piping shall be as follows.
a) Without protection 1.2 m (depth to top of pipe);
b) With protection 0.5 m (depth to top of protection).
Pipeline protection can either be via concrete protection slab, concrete encasement
/ sleeve subject to the site conditions and design requirements.

[Link].6 Flow Control Valves and Valve Characteristics

Wastewater pumps are normally “non-throttled”, without any pressure/flow control
valves installed at the pump discharge to regulate the flow. Non-throttled operation
is recommended to avoid plugging of the discharge main from debris.
However, valves designed to specifically control surge and efficiently protect pump
stations should be considered based on the system design requirement. The valve
shall have following characteristics.
a) The opening and closing of the valve shall be with the help of hydraulic actuator
for quick action;
b) Closing percentage and time shall be adjustable depending on the hydraulic
characteristics of the line;
c) Fully functional during power failure (fail to close);
d) Valve design shall be in such way that unobstructed and smooth flow;
e) Surge protection measures.
In order to mitigate unacceptable transient pressures, one of the following control
measures should be investigated by the hydraulic system modeler:
a) Modification of pipeline design (diameter, material of construction, changing
pipeline profile and alignment, etc.);
b) Various operational control measures such as slower valve closure, and or;
c) Anti-surge devices.
Surge control devices that are typically recommended as part of a surge analysis
include flywheels on pumps, combination air admission/air relief valves strategically
located along a pipe profile, surge tanks that are open to the atmosphere, and hydro
pneumatic tanks. Reliance on combination air/vacuum valves are generally not
recommended.

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6 SEWAGE TREATMENT
PLANTS
6.1 INTRODUCTION AND SCOPE
The purpose of this chapter of the Design Manual is to provide a solid foundation for
the design of sewage treatment plants. The following sections provide guidance in
respect to the Waste Water Treatment Plant (WWTP) influent parameters, WWTP
effluent requirements, redundancy requirements and other general requirements of
WWTPs. The main body of this section is intended as a guide by providing the design
aspects, fundamental design approaches and requirements of commonly applied
primary, secondary and tertiary treatment wastewater and sludge treatment
processes and technologies. A complete documentation of design parameters and
design equations is beyond the scope of this section. This chapter of the Design
Manual does however, attempt to cover the most important and fundamental ones
and provides reference to design standards, guidelines and literature for more
detailed information.
A section presenting multi-criteria analysis, as a tool to support the decision-making
process and to help choosing an adequate technology for wastewater treatment
plants, is included. As are guidelines on odor control and the principles of hydraulic
design of WWTPs, simulation of wastewater treatment plant process and
decentralized treatment plants, etc. amongst others

6.1.1 National Context

The Kingdom of Saudi Arabia (KSA) is classified as one of the most water-scarce
nations on the planet. Water supply in KSA primarily depends on non-renewable
groundwater resources and expensive desalination.
Historically in KSA, various types of biological wastewater treatment technologies
have been applied, such as stabilization ponds, trickling filters and activated sludge
process.
Larger plants, driven by low electricity prices, frequently were designed to apply
rather energy-intensive activated sludge type treatment processes (e.g. oxidation
ditch or activated sludge with aerobic sludge stabilization).
However, following the ‘Saudi Vision 2030’ a paradigm shift towards a more energy-
efficient and sustainable water sector is underway. Currently large wastewater
treatment plants in KSA typically are designed with anaerobic sludge digestion.
Furthermore, in order to conserve scarce and more costly water resources, there is
a strong trend towards further increasing the percentage of treated wastewater
reuse, for industrial, commercial and irrigation purposes, with the objective of 70%
of all treated wastewater being reused.

6.1.2 Principle Design Considerations

The project specific particular specifications serve to define the Client’s specific
requirements and specific design considerations. This Design Manual includes
general design considerations regarding plant location, plant footprint, redundancy
requirements as well as operational and maintenance aspects in plant design.

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6.1.3 Regulatory Framework
In respect to treated effluent and sludge/biosolids quality requirements, the
respective regulations and laws are issued by the Presidency Of Meteorology And
Environment (PME) and Ministry of Water, Environment and Agriculture (MEWA).
Details are given in Chapter Error! Reference source not found. of this Design M
anual.
Designers are advised to familiarize themselves with the requirements of all
legislation dealing with sewage treatment works. The particular project specifications
may impose design values for treated sewage effluent (TSE) or sewage
sludge/biosolids that are more stringent than the requirements given in the
respective laws and regulations. In this case the Designer has to consider the more
stringent TSE or biosolids requirements for design.

6.2 WWTP INFLUENT PARAMETERS

For design of WWTPs, the Designer should refer to the influent wastewater
characteristics provided for the specific project in the tender documentation.
Wherever possible, Designers are encouraged to use actual data obtained from
sewage treatment plant flow records, operational studies, etc., rather than use
arbitrary design parameters.
As a reference, influent parameters based on the WWTP projects in KSA for the
average and minimum values and MEWA standards for maximum values are
summarized in below.
Table 6-1: Raw Sewage Characteristics
U
Parame Aver Maxi Mini
n
ter age mum mum
it
pH 6-8.5 9 -
0
Temper
28 38 20
ature C
Total
m
Dissolve <2,5 <2,50
- g
d Solids 00 0
/l
(TDS)
m
BOD5 250 500 200 g
/l
m
COD 500 1000 400 g
/l
Total
Suspen m
ded 290 600 250 g
Solids /l
(TSS)
Total
m
Kjeldahl
50 120 38 g
Nitrogen
/l
(TKN)
Ammoni
m
a
27 80 15 g
Nitrogen
/l
(NH4-N)

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 Phosph m
orus (P 8 25 6 g
Total) /l

Industrial wastewater are characterized by high COD values compared with the
municipal wastewater. The COD values for the various industrial wastewater
(Source: Industrial Pollution Control by Eckenfelder) are provided in the below table
as a reference.
Table 6-2: COD Values for Industrial Wastewater
Wastewater COD, mg/l
Pharmaceutical 5,780
Tannery 4,360

Tobacco 4,270

Paper Mill 686

Coke 2,291
Textile dye 951
Kraft Paper Mill 1,153
Vegetable Oil 6,302

6.3 WWTP EFFLUENT QUALITY REQUIREMENTS

Regulatory KSA Standards for Treated Effluent Quality Requirements

There are two (2) regulatory standards the Designer has to consider when designing
a wastewater treatment plant in respect to treated effluent quality requirements.
These are:
a) “KSA National Environmental Standard Industrial and Municipal Wastewater
Discharges” issued by Presidency Of Meteorology And Environment (PME);
b) “Executive Regulations of Law of Treated Sewage Water and its Reuse Thereof”
Ministry of Water, Environment and Agriculture (MEWA).
The Designer to consider suitable technologies in preventing the contamination to
receiving land/water bodies. The Designer shall use the latest version of the above
mentioned rules and standards for WWTP design. A short description of the above
mentioned rules and standards is given in the following sections.

KSA National Environmental Standard Industrial and Municipal Wastewater

Discharges (PME)
The relevant Article in this Standard is Article IV – Discharges to the Environment.
Appendix A of the standard classifies the receiving water bodies as follows:
a) Groundwater;
b) Inland surface water bodies (including wadis, rivers, canals, lakes, ponds,
wetlands, marshland and man-made reservoirs);

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 c) Coastal water with three (3) sub-classes:
i. Marine;
ii. High value (eco-sensitive);
iii. Industrial.
The effluent quality requirements (discharge limits) for treated effluent discharge for
inland surface water discharge and coastal water discharge are given in Table B1 of
Appendix B - Prescribed concentrations and values. The coastal water effluent limits
differ depending on the type of coastal water (Red Sea or Gulf) and Sub Class
(marine, sensitive, industrial).

Executive Regulations of Law of Treated Sewage Water and its Reuse

Thereof (MEWA)
This Regulation consists of twenty-six (26) articles aiming to:
a) Identify methods and levels of wastewater disposal;
b) Develop standards for safe levels of wastewater reuse;
c) Protect public health against the harmful effects of sewage pollution;
d) Expand the utilization of the treated water as a non-traditional source of water;
e) Monitor the quality of treated wastewater;
f) Monitor wastewater treatment plants.
Discharge standards are provided as listed below as per MEWA regulations :
a) Standards for wastewater discharge into sewer networks (Table 1);
b) Secondary treated wastewater standards (Table 2);
c) Tertiary treated wastewater standards (Table 3);
d) Standards for use of treated wastewater for agricultural purposes unrestricted
use (Table 4);
e) Standards for use of treated wastewater for agricultural purposes restricted use
(Table 5);
f) Chemical standards for use of sludge in agricultural purposes (Table 6);
g) Biological standards for use of sludge in agricultural purposes (Table 7).

Comparison of KSA MEWA and EU Requirements for TSE Reuse for

Agricultural Irrigation
The KSA MEWA executive regulations for wastewater treatment and TSE reuse
considers two (2) irrigation classes for TSE reuse in agriculture as follows:
a) Unrestricted irrigation – Irrigation of all types of crops without exception – only
permissible with tertiary treated sewage effluent
b) Restricted irrigation – Irrigation of all types of crops except vegetables, tuber
corps, and plants where the fruit touches treated water, whether eaten fresh or
cooked – permissible with secondary or tertiary treated sewage effluent

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 In addition the KSA MEWA executive regulations
defines permissible methods for irrigation for unrestricted and restricted irrigation.
The parameters and the limit values as given in the MEWA executive regulation
(dated 13/2/1422 HD), English translation, are given in the table below (Note Values
are maximum limits unless indicated):
Table 6-3: MEWA treated effluent limits (as given in Law of Treated Sewage Water
and its Reuse Thereof, issued by Royal Decree No. (M/6) dated 13/2/1422 HD.)
Secondary Tertiary
Unit Treatment Treatment
Group Parameter Symbol
Effluent Limit Effluent Limit
Value Value
Floating Materials - None None
Total suspended
Physical solids TSS mg/l 40*1 10*2
Parameters Turbidity Turb NTU 5.0 5.0
Potential of
hydrogen pH - 6-8.4 6-8.4
Free Chlorine Cl2 mg/l ≥ 0.5 ≥ 0.5*3
Biochemical
oxygen demand
Chemical
over 5 days BOD5 mg/l 40*1 10*2
parameters
Fat, Oil and
Grease (FOG) FOG None None
Phenols - mg/l 0.002 0.002
Nitrate-Nitrogen NO3-N mg/l 10.0 10.0
Nutrients Ammonia-
Nitrogen NH4-N mg/l 5.0 5.0
Fecal coliforms -
colony forming
units per 100 CFU/100
Microbial
millilitres FC ml 1,000 2.2*4
parameters
Viable eggs of
intestinal worms
per liter No/l - 1
Aluminium Al mg/l 5.0 5.0
Arsenic As mg/l 0.1 0.1
Berylium Be mg/l 0.01 0.1
Boron B mg/l 0.75 0.75
Cadmium Cd mg/l 0.01 0.01
Chromium Cr mg/l 0.1 0.1
Cobalt Co mg/l 0.05 0.05
Copper Cu mg/l 0.4 0.4
Metals, heavy Flouride F mg/l 1.0 1.0
metals and Iron Fe mg/l 5.0 5.0
trace elements Lead Pb mg/l 0.1 0.1
Lithium Li mg/l 2.5 2.5
Manganese Mn mg/l 0.2 0.2
Mercury Hg mg/l 0.001 0.001
Molybdenum Mo mg/l 0.01 0.01
Nickel Ni mg/l 0.2 0.2
Selenium Se mg/l 0.02 0.02
Vanadium V mg/l 0.1 0.1
Zinc Zn mg/l 4.0 4.0

Notes
*1 monthly average value
*2 monthly average limit value, weekly average limit value: 15 mg/l
*3 minimum of 0.2 mg/l if chlorine is used for disinfection

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 *4 weekly average, spot sample maximum 23 CFU/100
ml
The EU regulation 2020/741(dated 25.5.2020) defines the minimum requirements
for water reuse in the EU member states. EU member states have to comply with
the minimum requirements defined in the EU regulation. There are four (4) reclaimed
water quality classes A, B, C and D, the parameters and the respective parameter
limit values are given in the table below.
Table 6-4: EU treated effluent limits for reuse of reclaimed water for agricultural
irrigation (as given in EU regulation 2020/741 (dated 25.5.2020) and Council Directive 91
Reclaimed
Type of crops, Indicative E-coli
water BOD5 TSS Turbidity
irrigation technology (CFU /
quality (mg/l) (mg/l) (NTU)
method target 100
class
ml)
All food crops
consumed raw
where the edible Secondary
part is in direct treatment,
contact with tertiary
A ≤ 10 ≤ 10 ≤ 10 ≤5
reclaimed water filtration,
and root crops and
consumed raw - disinfection
all irrigation
methods
Food crops
consumed raw
where the edible
part is produced
above ground
and is not in
direct contact
Secondary
with reclaimed
treatment
B water, processed ≤ 100 -
and
food crops and
disinfection
non-food crops
including crops
used to feed milk-
or meat- ≤ 35
producing (>10,000
animals - all PE)
irrigation methods
≤ 25
Food crops ≤ 60
consumed raw (2,000 -
where the edible 10,000
part is produced PE)
above ground
and is not in
direct contact
Secondary
with reclaimed
treatment ≤
C water, processed -
and 1,000
food crops and
disinfection
non-food crops
including crops
used to feed milk-
or meat-
producing
animals - Drip
irrigation or other

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 irrigation method
that avoids direct
contact with the
edible part of the
crop
Industrial, energy Secondary
and seeded crops treatment ≤
D -
- all irrigation and 10,000
methods disinfection

In addition to the limit values given in the table above, for each reclaimed water
quality class the following addition requirements apply:
Legionella spp.: < 1,000 cfu/l where there is a risk of aerosolisation
Intestinal nematodes (helminth eggs): ≤1 egg/l for irrigation of pastures or forage
The compliance criteria in the EU regulation is defined as follows:
a) The indicated values for E. coli, Legionella spp. and intestinal nematodes are
met in 90 % or more of the samples; none of the values of the samples exceed
the maximum deviation limit of 1 log unit from the indicated value for E. coli and
Legionella spp. and 100 % of the indicated value for intestinal nematodes;
b) The indicated values for BOD5, TSS, and turbidity in Class A are met in 90 % or
more of the samples; none of the values of the samples exceed the maximum
deviation limit of 100 % of the indicated value. Samples for BOD5 and TSS are
based on flow-proportional or time-based 24-hour composite samples.

Expected Treated Wastewater Characteristics

Expected treated wastewater characteristics for secondary treatment followed by
conventional filtration/disc filter/membrane filtration are provided in the below Table
6-5.
Table 6-5: Expected Treated Wastewater Characteristics
Process BOD (mg/l) TSS (mg/l)
Secondary Treatment (ASP) Followed
<10 <10
by Conventional Filtration/Disc Filter
Secondary Treatment Followed by
<8 <5
Membrane Filtration
Secondary Treatment (MBBR)
<10 <10
Followed by Disc Filter

On the other hand, industrial wastewater effluent quality required for disposal to
Sewerage system after Pre-treatment shall be as under.
Parameter Maximum Unit
pH 9
Temperature 38 0C

Total Dissolved Solids

<2,500 mg/l
(TDS)
BOD5 500 mg/l
COD 1000 mg/l
Total Suspended Solids
600 mg/l
(TSS)
Total Kjeldahl Nitrogen
120 mg/l
(TKN)

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 Ammonia Nitrogen (NH4-
80 mg/l
N)
Phosphorus (P Total) 25 mg/l

6.4 SAMPLING PROGRAM AND PROCEDURE

The sampling program and procedure used should be in accordance with Standard
Methods for the Examination of Water and Wastewater (latest edition), US EPA
sampling standards or any internationally approved sampling procedures.

Sampling Locations
Influent wastewater are preferably sampled at locations of highly turbulent flow in
order to ensure good mixing. However, in many WWTPs the most desirable location
is not accessible.
Effluent wastewater should be collected at the WWTP site after the treatment as
specified in the Contract.

Sampling Procedure
Two types of sampling techniques are used for collecting wastewater, grab and
composite sampling. Grab samples are single samples collected at a specific spot at
a site over a short period of time. Composite samples are collected over time, either
by continuous sampling or by mixing discrete samples. Various methods of
composite sampling are available and are based on either time or flow proportioning.
Wastewater samples should typically be collected either by directly filling the sample
container (manual sampling) or by using an automatic sampler. Manual sampling is
normally used for collecting grab samples and for immediate in-situ field analysis.
The best method to manually collect a sample is to use the actual sample container
which will be used to transport the sample to the laboratory. This eliminates the
possibility of contaminating the sample with intermediate collection containers.
Automatic samplers are used to collect composite samples or grab samples. The
automatic samplers can be used to collect time composite or flow proportional
samples.
Properly planned procedures will ensure sample integrity from collection to data
reporting. This includes the ability to trace possession and handling of the sample
from the time of collection through analysis and final disposition.
All samples requiring preservation must be preserved as soon as practically
possible, ideally immediately at the time of sample collection. Samples shall be
labelled to prevent sample misidentification. Usage of sample seals would help to
detect unauthorized tampering with samples up to the time of analysis. Recording all
information pertinent to field survey or sampling in a log book would be helpful. The
samples should be delivered to the laboratory as soon as practicable after collection
with the sample analysis request sheet. After the sample has been analyzed, it shall
be disposed.

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6.5 SLUDGE REQUIREMENTS
The biosolids/sludge can be treated and dewatered to produce Class A (disposal for
unrestricted land application and landfills), Class B (disposal for restricted land
application and landfills) or neither Class A/B standards (disposal for landfills,
provided landfill allows unstabilized sludge or for other specific uses).
There are two (2) regulatory standards, the Designer has to consider when designing
a wastewater treatment plant in respect to sludge quality requirements. These are
listed below:
a) “General Environmental Regulations and Rules for Implementation” (GER) Year
2001 Appendix 4 – Hazardous Waste Control Rules and Procedures (Document
01.1423);
b) “Executive Regulations of Law of Treated Sewage Water and its Reuse Thereof”
Ministry of Water, Environment and Agriculture (MEWA).
According to the Appendix 1 to Appendix 4 of the GER, residues from pollution
control processes are classified as “Waste”. In this respect sewage sludge generated
from wastewater treatment plants treating primarily domestic wastewater is
understood to be classified as “waste” (not as “hazardous waste”).
Appendix II to Appendix 4 of the GER defines the methods of waste disposal. For
sewage sludge this includes incineration (e.g. mono-incineration or incineration in
cement kilns), landfilling and land application.
In selecting the appropriate methods of sludge processing and disposal,
consideration shall be given to the above listed regulations on sludge handling and
quality and on any other general guideline regulations as applicable in KSA. In
addition, the Client specific sludge treatment and quality requirements as defined in
the particular project design specification have to be considered in design of the
facility.
The sludge quality requirements depend on the applicable regulations / country
policy and in addition on the selected sludge disposal / reuse pathway. In European
Countries, the predominant sludge reuse or disposal pathway is rather
heterogeneous. Countries like Norway almost exclusively rely on land application of
sewage sludge, while e.g. in Germany incineration (mono- or co-incineration) is the
predominant sludge disposal pathway. Co-incineration is practiced in coal power
plants, cement kilns or municipal waste incineration plants.
Some innovative new sludge treatment methods such as pyrolysis and sewage
sludge humification are applied, albeit rather infrequently and in small scale.
Pyrolysis, a process which produces biochar has been implemented in a few
wastewater treatment plants in Germany. However the process has not yet been
applied in larger scale due to unfavorable regulatory framework and uncertainty of
the market potential and price for biochar generated from sewage sludge. In July
2021 EU-wide regulatory approval for use of biochar from sewage sludge as fertilizer
product has been granted, which can be expected to lead to more widespread
adoption of this process. Sewage sludge humification converts the sludge into
product similar to soil rich in humus, which can be reused in agriculture.

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 US EPA Standard
The US EPA standard is one of the acknowledged standards used worldwide, for
sludge quality. The details of the US EPA standard is provided as a reference for
Designer, to be followed if specified in the particular project design specifications.
The U.S. EPA promulgated in 1993 at 40 Code of Federal Regulation (CFR) Part
503, Standards for the Use or Disposal of Sewage Sludge. The intention of this
regulation is to ensure that sewage sludge is used or disposed of in a way that
protects both human health and the environment. The regulation is divided into five
(5) subparts:
a) General provisions;
b) Land application;
c) Surface disposal;
d) Pathogens and vector attraction reduction; and
e) Incineration.
The pathogen and vector attraction reduction requirements of US EPA 40 CFR Part
503 apply to biosolids and their application to or placement on the land for beneficial
use or disposal.
The US EPA 40 CFR Part 503 regulations classifies the quality of biosolids based
on their pathogen content into two categories; Class A and Class B.
Biosolids meet Class A designation if pathogens are below detectable levels.
Biosolids, which can be used for application to land without restrictions are termed
as Class A.
The following pathogen concentration limits apply for Class A Biosolids:
a) Density of faecal coliform in the biosolids < 1000 MPN (most probable number)
per gram of total solids (dry weight basis) or density of salmonella sp. bacteria in
the biosolids < 3 MPN per 4 g of total solids (dry weight basis);
b) Biosolids are designated Class B if pathogens are detectable but have been
reduced to levels that do not pose a threat to public health and the environment
as long as actions are taken to prevent exposure to the biosolids after their use
or disposal. All biosolids that are land applied or placed on surface disposal sites
(except sludge placed on a surface disposal site that is covered with soil or other
material) shall meet Class B pathogen requirements.
Class B pathogen reduction requirements include the following:
a) Density of faecal coliform in the biosolids < 2.0 x 106 MPN/g total solids (dry
weight basis) or density of faecal coliform < 2.0 x 106 CFU/g total solids (dry
weight basis).
Commonly used disinfection “processes to significantly reduce pathogens” (PSRP)
for Class B and “processes to further reduce pathogens” (PFRP) for Class A
biosolids are shown in Table 6-6 (over).

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 Table 6-6: Regulatory Definition of Processes for
PSRP and PFRP (US EPA 1993, 2003)
PSRP (Class B) PFRP (Class A)
Heat Drying: Dewatered biosolids are dried by
Anaerobic Digestion: Sludge is treated
direct or indirect contact with hot gases to
in absence of air for a specific SRT at a
reduce moisture content to 10 percent or
specific temperature. Values for the
lower. Either the temperature of solids particles
SRT and temperature shall be between
exceeds 800C or the wet bulb temperature of
15 days at 35 -550C and 60 days at
the gas in contact with the sludge, as it leaves
200C
the dryer exceeds 800C.

Composting: Using either within vessel or

Aerobic Digestion: Sludge is agitated static aerated pile composting, the temperature
with air or oxygen to maintain aerobic of the biosolids is maintained at 550C or higher
conditions for a specific SRT at a for 3 days. Using windrow compositing, the
specific temperature. Values of SRT temperature of the waste water sludge is
and temperature shall be between 40 maintained at 550C or higher for 15 days or
days at 200C and 60 days at 150C longer. During this period a minimum of five
windrow turnings are required.

Lime Stabilization (Alkaline Thermophilic Aerobic Digestion: Liquid

Stabilization): Sufficient lime is added biosolids are agitated with air or oxygen to
to raise the pH of the biosolids to pH 12 maintain aerobic conditions, and the SRT is
and maintained for 2 h of contact. maintained for 10 days at 55 to 600C
Composting: Using either the within-
vessel, static aerated pile, or windrow
composting method, the temperature of
Pasteurization: The temperature of the sludge
the sludge is raised to 40°C or higher
is maintained at 70°C or higher for 30 minutes
and remains at 40°C or higher for 5
or longer
days. For 4 hours during the 5 days, the
temperature in the compost pile
exceeds 550C.

The Designer can also propose alternative pathogen reduction

methods/technologies (other than those specified above), if suitable references in
WWTPs are provided.
Vector (insects, rodents and birds) attraction is a consequence of poor stabilization
and high volatile suspended solids concentration in the sludge produced. It is closely
related to odor. The US EPA 40 CFR Part 503 also regulates vector attraction
reduction requirements with processing or physical barriers.
The Designer should follow one of the options mentioned below for the vector
attraction reduction for both Class A and Class B biosolids:
a) At least a 38% reduction in volatile solids content is achieved during sludge
treatment;

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 b) Addition of sufficient alkali to raise the pH to at least
12 at 250C and maintain a pH of 12 for 2 hours and a pH of 11.5 for 22 more
hours;
c) For liquid sludge that is withdrawn from an aerobic process, the Specific Oxygen
Uptake Rate (SOUR) at 20°C is ≤ 1.5 mg O2/([Link] solids).
The Designer can also propose other options/technologies as stipulated by US EPA
for meeting the vector attraction reduction requirements for Class A and Class B
biosolids.
The heavy metal concentration of biosolids to be land applied are also regulated and
the ceiling concentration for heavy metals are provided in Table 6-7 below.
Table 6-7: Ceiling Concentrations of Heavy Metals
Chemical Ceiling Concentration, mg/kg
Arsenic 75
Cadmium 85
Chromium 3,000
Copper 4,300
Mercury 57
Lead 840
Molybdenum 75
Nickel 420
Selenium 100
Zinc 7500

If land application is the defined sludge management pathway, the Designer should
ensure that the biosolids generated comply with the following requirements:
a) Not exceed the pollutant ceiling concentrations;
b) Meet Class B requirements for pathogens;
c) Meet the vector attraction reduction requirements.

Comparison of KSA and EU Requirements in Respect to Sewage Sludge

Quality for Sludge Reuse in Agriculture
The KSA limit concentrations for heavy metals in sewage sludge as given in the
MEWA regulation are identical to those given in US EPA Part 503. The below table
compares the KSA MEWA regulation limit values to the values given in EU Directive
86/278/EEC on the protection of the environment, and in particular of the soil, when
sewage sludge is used in agriculture (dated 12th June 1986 AD).

Table 6-8: Comparison of limit values for heavy metals concentrations in sludge
for reuse in agriculture
Limit values Limit values
Element Symbol
KSA MEWA EU Directive

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 regulation 86/278/EEC (mg/kg
(mg/kg dry matter) dry matter)
Arsenic As 75 -
Cadmium Cd 85 20 to 40
Copper Cu 4,300 1,000 to 1,750
Chromium Cr 3,000 -
Mercury Hg 57 16 to 25
Molybdenum Mo 75 -
Nickel Ni 420 300 to 400
Lead Pb 840 750 to 1,200
Selenium Se 100 -
Zinc Zb 7,500 2,500 to 4,000

Generally, the EU minimum sludge quality requirements in respect to heavy metal

content for sludge reuse in agriculture are more stringent than the corresponding
KSA MEWA limit values. It has to be noted that the EU Directive 86/278/EEC only
defines the minimum requirements to be fulfilled by the EU member states. Each EU
member states is free to impose more stringent requirements through national
legislation. Consequently, the maximum permissible limits for land application of
sewage sludge differs considerable between the individual EU Member states. For
example countries such as Germany, Denmark, Sweden and the Netherlands have
imposed much more stringent limit values, while e.g. France, Belgium have more
stringent limits and countries such as Spain, Italy, Portugal, Estonia have set
maximum permissible limits similar to the minimum requirements given in the EU
sewage sludge directive. The KSA MEWA regulation additionally imposes limits in
respect to the pathogen content of sewage sludge, while the EU Directive
86/278/EEC does not include such limits.

6.6 SLUDGE DISPOSAL

Refer to [Link].3 and 2.9.4

6.7 PLANT LOCATION AND FOOTPRINT

There are several aspects affecting the selection of the plant site. The most important
factors affecting the selection of plant location are listed below. These factors are for
guidance only, special factors and requirements for certain locations may have to be
considered in addition.
a) Future developments:
The location of the treatment plant, and also the treatment technology applied,
should be selected with due consideration of future developments in the
catchment area, respectively development plans for the area (e.g. regional
masterplans). Preferably a future expansion at the Site in respect to:
i. Future upgrades in respect to treated effluent quality;
ii. Future capacity expansion of the Plant.

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 b) Topography:
Generally the plant site should be selected to result in a reduction in the number
of lifting stations to minimize construction, operation and maintenance costs. This
can be achieved by locating the plant in low lying areas. However, flood
protection measures may be required in such areas.
The Designer should review the site conditions supporting the hydraulic gradient
scheme of the WWTP. For gravity flow, the Designer should take advantage of
the low lying areas, if available at the Site.
c) Distance from residential and commercial areas:
The treatment plant should be sufficiently far away from the residential areas and
it is advisable to have a buffer zone between the location of the plant and the
neighboring residential areas. The location of the STP should not be chosen so
that foul or distinctive odor does not affect inhabited areas.
d) Road and utility access:
The treatment plant should have nearby access to utilities. Easy access of trucks
via roads to the site shall be ensured.
e) Soil conditions and other obstacles:
The soil properties affect the construction costs. For this reason the geotechnical
conditions at the site may affect site selection.
The Designer should select the treatment process and treatment unit arrangement
considering the available area of the site and future expansion requirements. As a
general guideline, treatment plants applying activated sludge type processes
typically have an area demand in the range of 0.05 to 0.35 hectares/MLD, depending
on the capacity of the plant and the specific type of wastewater treatment process
applied.
Furthermore, design for WWTP should incorporate drainage protection as per the 25
year flood factor specific to the project area and as per data from civil defense.

6.8 REDUNDANCY REQUIREMENTS AND OPERATIONAL SAFETY

Wastewater treatment plants are essential infrastructure components that shall
remain operational at all times to protect human health and safety and the
environment. The overall WWTP concept should enable the Operator to deal with
temporary malfunctions, breakdowns of facilities as well as regular revision and
maintenance works without any drop in the treatment capacity below the design
capacity and with the effluent and sludge requirements being met at all times.
Unless otherwise defined in the particular project design specification the liquid
treatment process should be designed as two (or more) equal-capacity parallel
treatment trains with each train can be operated independently from each other. This
requirement also applies for the collection and distribution chambers and the pipe
connections between the treatment processes. If treatment unit trains are combined
in one structure, dividing walls between the trains will have to be provided in order
to allow independent operation under all flow and operation conditions. For this
degree of redundancy to be achieved, the Designer shall provide sufficient standby
equipment and by-pass options regarding all relevant water and sludge treatment

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 units as well as regarding the main equipment needed
for power supply and plant control. As a minimum, multiple parallel treatment process
tanks and systems at each treatment step should be provided, such that at least one
process tank or system can be taken out of service while maintaining compliance
with the Functional Guarantees under all flow and load conditions.
The Designer shall provide a detailed redundancy concept demonstrating the plant
operation during breakdowns or regular revision and maintenance works for all
relevant plant facilities.

Standby Equipment Requirements

Unless otherwise stated in the particular project design specification, the following
general rule should be applied for installed equipment (such as pumps, blowers, fans
or the like):
a) 1 to 4 units in operation : 1 standby unit (n+1);
b) > 4 units in operation : 2 standby units (n+2).
If units with different capacities are supplied, the standby unit(s) shall be sized to
match the unit(s) with the greatest capacity.
For vital equipment components, where the installation of standby units is not
practicable (e.g. mixer in anoxic zones of the activated sludge reactor or the digester
mixers) a respective number of cold standby units would have to be provided.

Redundancy Requirements
Unless otherwise stated in the particular project design specification, the wastewater
treatment units shall be designed in such a way that the maximum flow shall pass
through the plant with n-1 units in operation, where n is the number of units.
Furthermore, the sludge generated under design load conditions shall pass through
the treatment unit with n-1 units in operation, yet with reduced treatment efficiency,
where n is the number of units.

6.9 SEWAGE TREATMENT

General Design Aspects

When designing a wastewater treatment plant, there are a number of fundamental
aspects to be considered in the design, as listed below:
a) Each of the treatment units shall be identical in terms of design, size and
capacity;
b) Where flow containing grit and/or sludge is to be distributed, provide mixing as
required to ensure that liquid flow, grit and/or sludge are all distributed equally;
c) Precautions have to be taken, which allow each treatment unit to be taken out of
operation and emptied individually;
d) For the design of the Plant, and especially for the design of the secondary
treatment stage, the design shall be robust and suited to accommodate peak
loads and should take variations in the pollution concentration and load and in

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 the wastewater composition during day time and
night time, as well as seasonal variations into consideration;
e) The design shall furthermore consider seasonal wastewater temperature
variations;
f) Where flow containing sludge is to be distributed, the design shall ensure that
liquid flow or sludge are all distributed equally, mixing as required shall be
provided;
g) Probes (such as DO, pH, and/or ORP probes) shall be located in a place that
can be reached easily by operators. These probes often clog or foul and need
cleaning and calibration;
h) All components that require regular inspection, cleaning or maintenance should
be readily and safely accessible and where appropriate, replaceable.

[Link] Treatability of Wastewater

In order to achieve the treated water quality as per the standards and regulations
mentioned under Section 6.2: WWTP INFLUENT PARAMETERS, the inlet design
parameters should be as per the Table 6-9 provided below:
Table 6-9:Treatability of Wastewater
Parameter Values
COD/BOD Ratio <3
Total Dissolved Solids <2000
pH 6-8.5

In case the parameters are exceeding the limits mentioned in the above table, pilot
plants shall be constructed. Wastewater treatment pilot plants are compact plants,
comprised of systems that are used for the validation of engineering, research, as
well as technology used within a manufacturing unit or company. It also allows to
compare alternative or conventional water treatment methodologies for existing
plant’s expansion or construction of new plants. The wastewater treatment pilot
plants are used for testing out critical business requisites such as regulations,
compliance, design optimization, experiment safety, technological requirements, as
well as training of professionals for water treatment.

Pre-treatment and Sewage Tanker Receiving Station

Raw wastewater contains large solids and rags (screenings), abrasive inert material
(grit), floating debris, and grease. Pre-treatment, or preliminary treatment, is the first
and basic important step of the waste water treatment process. The purpose of pre-
treatment is to remove those wastewater constituents, which potentially would harm
the reliability of operation and performance of the downstream processes from the
raw wastewater influent.
Pre-treatment processes as provided below consists of various steps which can be
combined or used individually, depending on the inlet wastewater characteristics and
other project boundary conditions:
a) Screening;

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 b) Degritting;
c) Oil and Grease Removal.
The configuration of the pre-treatment facilities depends on the quality of the waste
water to be treated and type of downstream processes and equipment to be
protected.
For small WWTPs, mechanized compact pre- treatment units providing fine
screening and grit and grease removal are preferred techno-commercially.
Sewage tanker receiving station
The sewage tanker receiving station is required for receiving sewage tankers in
WWTP. These facilities check the quality of the wastewater before being used in the
treatment plant. The capacity of the sewage tanker receiving station would depend
on capability of the facility to unload the number of trucks simultaneously.
The total amount of external sewage received has to be duly considered in plant
design.

[Link] Screening

[Link].1 Overview
Screening devices are typically classified into four (4) categories based on screen
opening size, as listed below:
a) Trash Racks;
b) Coarse screens;
c) Fine screens;
d) Microscreens.
Depending on the type of screens applied they remove larger objects from the
wastewater stream that could damage influent pumps or block flow in raw sewage
channels and piping systems or remove finer objects to protect sensitive downstream
equipment including MBR, IFAS or MBBR systems.
Typically four (4) types of screening media used: bars, wedge wire, perforated plate,
and mesh. A short characterization of each screen category is given below.

[Link].2 Trash Racks and Coarse screens

Trash racks are bar screens with large openings typically in the range from 36 to 144
mm that prevent logs, timbers, stumps, bricks, and other large, heavy inorganic
debris from entering treatment processes. Trash racks are commonly used in
facilities receiving wastewater from combined sewer systems that can contain large
objects or in larger plants separate upstream of inlet pumping stations. They are
typically followed by screens with smaller openings.
Coarse screen devices consist of parallel bars, rods or wires, wire mesh or a
perforated plates with openings generally of circular or rectangular shape applying
bar screens with openings typically ranging from 6 to 36 mm for removal of coarse
screenings (e.g. rags, sticks, leaves, food particles, bones, plastics, bottle caps).

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 Coarse screens are commonly used today in dual-stage
screening processes to provide protection and reduce blinding of the downstream
arranged fine screens.
Depending on the method of screen cleaning applied, trash racks and coarse
screens can be classified into:
a) Manually cleaned bar screens;
b) Mechanically cleaned screens.
Based on the above, trash racks and coarse screens may be either implemented as
manually (cleaned with hand rake) or mechanically cleaned screens.
Manually cleaned bar screens require little to no mechanical maintenance, but do
require routine cleaning by an operator.
Manually cleaned bar screens may be an appropriate alternative for coarse
screening for very small and package plants with low screenings generation or for
trash racks in medium sized plants. Manually cleaned screens may be also applied
as stand-by for mechanically cleaned coarse screens for smaller plants.

[Link].3 Fine Screens

Fine screen devices have openings typically ranging from 0.5 to 6 mm that remove
coarse screenings along with a higher degree of rags, wipes, stringy material, and
organic matter. Fine screens typically employ wire cloth, wedge wire elements or
perforated plates. Fine screens shall be automated / mechanically cleaned.

[Link].4 Microscreens
Microscreens devices have an opening of less than 0.5 mm to retain fine, screenable
particles and stringy material (such as hair) in the wastewater. Typically mesh is
applied for microscreens. Microscreens shall be automated / mechanically cleaned.
Microscreens are typically used for processes that required fine particle removal
(such as certain membranes) or as a replacement for primary treatment processes.

[Link].5 General Design Requirements for Screening

Detailed design requirements are provided for the most commonly applied coarse
and fine screens below. Generally the design of trash racks should follow the
fundamental coarse screening requirements, the design of microscreens should
follow the fundamental fine screening requirements.
Adequate safety factor for determining peak screening quantities shall be carefully
considered in the Designer´s design of the screenings conveyors, washer and
compactors. To this end, suitable screening channels for the installation of the
screens shall be provided and the screen channel shall be covered and connected
to the odorous air extraction system. Finally but importantly, screenings shall be
properly managed to ensure safe handling and disposal.

[Link] Coarse Screening

Coarse screening is the first unit operation used in the WWTP. The purpose of
coarse screening is to protect downstream equipment from damage or obstruction

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 due to large objects present in raw waste water.
Typically coarse screens are positioned upstream of the fine screens, in order to
protect them from large debris.
One of the following type of coarse screen should be used by the Designer:
a) Climber-type bar screens;
b) Chain and rake bar screens/ multi rake screens;
c) Flexible rake bar screens;
d) Catenary bar screens;
e) Spiral screens.

[Link].1 Design Considerations

The major design considerations for coarse screens, which should be taken into
account by the Designer, are outlined below:
a) Arrangement;
b) Approach velocity;
c) Redundancy and configuration;
d) Type of screen;
e) Clear openings between bars or mesh size;
f) Head loss through screens;
g) Screening handling;
h) Controls.
[Link].1.1 Arrangement
The coarse screens are installed at the intake of the plant ahead of inlet pumping (if
any) and ahead of fine screening.

[Link].1.2 Approach Velocity

The screen channel shall be designed to prevent the settling and accumulation of
grit and other heavy materials. An approach velocity of at least 0.5 m/s is
recommended to minimize the solids deposition in the channel. The Designer shall
ensure that the waste water approach velocity to the screen does not fall below the
self-cleaning value.
The flow velocity through rack opening should be less than 1 m/s at maximum flow
in order to prevent pass through of debris through the screen.

[Link].1.3 Redundancy and Configuration

The Designer should adopt in the design, the desired degree of redundancy,
depending on the size of the plant and project specific requirements. Depending on
the plant capacity, there are different screen configurations permissible as described
below. Nevertheless, the configuration will need to be submitted to the Client for
review and approval.

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 a) For plants with a design capacity of ≤ 5,000 m³/d:
Automatic screen sized for 100% of the max. hourly peak flow Q h, peak and one
safety (standby) bypass fitted with a manual bar screen sized for 100% of hourly
peak flow. The flow bypassed re-joins the channel just after the automatic screen;
b) For plants with a design capacity > 5,000 m³/d: One or multiple (n) parallel
automatic screen unit(s) each with a capacity of Q h,peak / n. One additional stand-
by screen with a capacity of 1/n of the hourly peak flow.

[Link].1.4 Type of Screen

Based on the cleaning method, coarse screens can be operated manually or
automatically.
The degree of permissible clogging of a bar screen will vary with the size of the
screen and the wastewater quality. For mechanically raked bar screens, the clogging
can be anywhere between 30% to 50%. For manually raked screens, the degree of
clogging will be greater due to infrequent cleaning.
Coarse screening should be performed by the use of automatically raked coarse
screen or other types of coarse screen as specified in the particular project design
specification, each located in a separate channel. Each channel should be equipped
with a shut-off device up and downstream of each screen unit. The screens and
screenings conveyors should be of the enclosed type with air extraction system,
connected to the odorous air treatment system to prevent the escape of odorous air.
The screening channels shall also be completely covered (with removable covers for
accessibility) and the screening building shall be connected to the air extraction and
treatment system.
Manual screens should be used (if required) only as a stand by screen in the bypass
channel. Generally Manual bar screen solution should be avoided due to the
requirement of frequent intervention of the operator. Automatic screens should be
operated locally and remotely through SCADA/DCS.

[Link].1.5 Clear Openings

Automatic bar screens have typical bar spacing in the range of 10 to 75 mm and
inclination at 150 to 300 from the vertical. The Designer should typically consider bar
spacing of >10 mm for the coarse screens.
Manual coarse bar screens are with a bar spacing traditionally of approximately 25
to 50 mm. These bar screens are normally inclined at 300 to 450 from the vertical to
ease cleaning,

[Link].1.6 Head Loss

Head loss through the mechanically/manually cleaned coarse screens should be
limited to 150 mm. The Designer should ensure that head loss through the screening
device at maximum flows will not surcharge influent sewers enough to impair
upstream services. Hydraulic losses through bar screens are a function of approach
velocity and velocity through the bars.
The head loss through a clean or partially clogged bar screen is provided below:

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 hL = k (VB2-V2) / 2g

hL : head loss, m
VB : velocity through bar screen, m/s
V : velocity upstream of bar screen, m/s
g : acceleration due to gravity, 9.81 m/s2
k : friction coefficient

The head loss through a screen indicated by Kirschmer formula is given below:
hL = β (w/b)1.33 h sin θ

β : bar shape factor as provided in table below

w : maximum cross sectional width of bars facing upstream, m
b : minimum clear spacing of bars, m
h : upstream velocity head, m
θ : angle of bar screen with horizontal

The bar shape factor for various bars are provided in Table 6-10 below.
Table 6-10: Bar Shape Factor
Sr. No Bar Type β
1 Sharp edged rectangular 2.42
2 Rectangular with semi-circular upstream face 1.83
3 Circular 1.79
4 Rectangular with semi-circular upstream and downstream faces 1.67

[Link].1.7 Screening Washing, Compaction and Handling

The screenings from the coarse screens with a bar spacing <50 mm should be
cleaned, dewatered and compacted.
Screened material should be transported to screenings handling equipment by a
suitable screening conveyor to skips for further disposal.
Compactors should be designed to provide an increase in dry solids content of
screenings, ≥ 50% (on weight basis)..
The Designer should take into consideration the following requirements for the
design and operation of screen conveyors.
a) Ensure that the conveyor-running signal stops upstream equipment (screens) in
the case of a conveyor failure;
b) When all screens are stopped, the conveyors are stopped in cascade upstream
to downstream (in order to completely empty them);
c) An emergency stop shall be fitted to each conveyor;
d) The conveyors are enclosed and the air is extracted directly to odor treatment.

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