appendix 7[1].1. unitank process &technical proposal 13
Post on 15-Oct-2014
202 Views
Preview:
TRANSCRIPT
Appendix 7 :
document.doc page 1
A.
LOTECO IZ
UNITANK
Single stage aerobic with nitrogen removal
Budget proposal
June 2004
document.doc page 2
TABLE OF CONTENTS
A. Introduction 5
B. Process Part 7
B.1. WASTE WATER CHARACTERISTICS 7
B.2. DESIGN PARAMETERS 8
B.3. EFFLUENT QUALITY 9
B.4. PROCESS DESCRIPTION 10B.4.1. Description of the installation 10B.4.2. Description of the biological treatment 11
B.5. DESIGN AND DIMENSIONING 12B.5.1. Influent pump Pit (phase 1 & 2) 12B.5.2. Equalisation/Alarm Tank (phase 1 & 2) 13B.5.3. Physico-chemical pre-treatment 15B.5.4. Aerobic Treatment 16B.5.5. Excess Sludge Thickener 18B.5.6. Disinfection tank 19B.5.7. Sludge dewatering 20B.5.8. Venturi Channel 21
B.6. TOTAL CAPACITY OF THE WASTE WATER PLANT: SUMMARY 22B.6.1. Volumes 22B.6.2. Biosolids production 22
C. TECHNICAL PART 23
C.1. DESCRIPTION OF THE CRITICAL EQUIPMENT 23C.1.1. Equipment list for the biological treatment 23C.1.2. Specifications and documentation - biological treatment 25C.1.3. Equipment list for biosolids dewatering plant 47C.1.4. Specifications and documentation - biosolids dewatering 48C.1.5. Instrumentation 53
C.2. PIPING 60C.2.1. Piping 60C.2.2. Penstocks and valves 60
C.3. UNITANK - PROCESS CONTROL UNIT - THE PCU 63C.3.1. Description of the UNITANK - Process control unit 63C.3.2. Electricity - instrumentation - automation 64
document.doc page 3
C.3.3. SCADA supervisory and control 70C.3.4. Process lab (optional) 72
C.4. CIVIL WORKS 73C.4.1. General 73C.4.2. Building area 73C.4.3. Soil conditions 74C.4.4. Dewatering and metal sheeting 74C.4.5. Concrete mix requirements 75C.4.6. Workmanship 75C.4.7. Structural design 76
document.doc page 4
B. INTRODUCTION
This offer describes the design, the dimensioning and the technical
specifications for the LOTECO IZ (phase 1). Loteco phase 1 is designed
for 4000 m3/day, phase 2 will have a total capacity of 8000 m3/day.
For this type of wastewater Seghers Keppel Technology Group proposes a
UNITANK single stage aerobic as a very efficient and cost-effective solution .
The design of this installation is based on the design of other UNITANK waste
water treatment plants for industrial zones :
Bien Hoa industrial estate (physico-chemical pre-treatment & UNITANK single
stage aerobic), capacity 4000 m3/day first phase 1.
Jurong Island industrial estate Singapore (oil & grid removal pre-treatment &
UNITANK single stage aerobic), capacity 10800 m3/day.
The most striking advantage of this system is the very compact construction
method. All basins are rectangular, which offers several benefits. Compared to
the conventional round basins, the use of common walls is possible and less
concrete is needed. The result is a compact, modular and space-saving
design, realised in a tailor made installation.
Moreover, UNITANK is synonym for advanced treatment, expressed by a stable
and controlled process, high treatment efficiencies and advanced equipment and
instrumentation. This is made possible by an adaptive and intelligent process
control and a simple and flexible operation.
In comparison with the conventional activated sludge system, there is no distinct
sedimentation and less moving parts are needed.
These advantages are translated in a reduced investment and operational cost.
document.doc page 5
Many years of research and the feed-back of several full scale plants resulted in
a very attractive waste water treatment installation, with an exceptional all-in
design, modular, compact and unobtrusive, providing top purification
performance in the most efficient and cost-effective way.
document.doc page 6
C. PROCESS PART
C.1. WASTE WATER CHARACTERISTICS
The influent characteristics are as follows:
Total flow rate
Average m³/d 4000
m³/h 166
Peak m³/h 300
(max. 3 h per day)
During days/week
COD mg/l 500
SS mg/l 350
BOD mg/l 300
BOD/COD > 0,6
BOD/N > 4
PH 5-9
FOG mg/l 50
NTOT mg/l 75
NH3 mg/l 50
PTOT mg/l 4
Heavy metals present, but under non toxic
conditions
Phenol 0,05Coliform 1500000
document.doc page 7
C.2. DESIGN PARAMETERS
Flow rate : 4000 m3/day
The influent characteristics are as follows:
Total flow rate
Average m³/d 4000
m³/h 166
Peak m³/h 300
(max. 3 h per day)
During days/week 7
COD mg/l < 500
BOD mg/l < 300
BOD load kg/day 1200
Ntot load kg/day 300
SS mg/l < 350
BOD/COD > 0,6
BOD/N > 4
BOD mg/l < 300
Temperature °C 20-30
Phenol 0,05Coliform 1500000
document.doc page 8
C.3. EFFLUENT QUALITY
Guarantee(1)
BOD5 mg/l < 20
COD mg/l < 50
Suspended Solids mg/l < 50
Ntot mg/l < 30
pH 6 – 9
Coliform 5000
(1) The effluent guarantee can only be given for the treatment of wastewater with the same characteristics as specified above and in case no other toxic components then heavy metals mentioned are present in the wastewater.
In case the mentioned effluent quality is not obtained while the system treats wastewater within the above mentioned wastewater quality specifications in steady-state conditions, an independent and qualified lab will perform an aerobic biodegradation test.
The client is free to choose this lab, approved by Seghers Keppel Technology Group. The test reactor will be fed with the same wastewater as the full-scale plant.The test reactor will be a low-loaded1 aerobic activated sludge system (sequencing batch reactor or continuous system).
Seghers Keppel Technology Group guarantees an effluent quality of the UNITANK system, at least equal to the obtained effluent quality from the biodegradation test.
1 Volumetric BOD-loading < 0,4 kg/m³/day
document.doc page 9
C.4. PROCESS DESCRIPTION
C.4.1. Description of the installation
The raw waste water(s) from the different production facilities of the industrial
zone is being send to the Influent pump Pit after removal of mineral oil, sand
and other inert materials by the factories. In case still some materials such as
wood, plastic, paper, etc.., in small amounts due to calamities are send to the
waste water treatment plant these will be retained at the inlet of the pit by means
of a Bar Screen followed by an automatic Fine Screen (optional).
From the pump pit the wastewater is pumped to the static fine screen before it
flows by gravity to the Equalisation/alarm Tank. In the equalisation/alarm tank
homogenisation and buffering (COD, flow rate, …) of the waste water will take
place a very important aspect of an industrial zone, before the waste water is
send to the physico-chemical pre-treatment system.
After buffering, the wastewater is pumped to the physico-chemical pre-treatment
from where it flows by gravity to the activated sludge system (UNITANK single
stage aerobic with nitrogen removal) which is described in detail in annex.
After biological treatment the effluent is monitored in a venturi channel, before
final effluent discharge.
Part of the effluent can be recycled back for reuse for the sludge dewatering.
Excess biosolids are removed from the sedimentation compartment and
collected in the Sludge Thickener. In here the sludge is thickened by
gravitational compaction to obtain a further reduction of the excess sludge
volume.
A sludge dewatering system with a belt filter press or decanter centrifuge is
foreseen.
document.doc page 10
C.4.2. Description of the biological treatment
A detailed description of the biological treatment, UNITANK single stage
aerobic is enclosed in annex.
In addition you can find a description of UNITANK single stage aerobic with
nitrogen removal is enclosed in annex too.
document.doc page 11
C.5. DESIGN AND DIMENSIONING
C.5.1. Influent pump Pit (phase 1 & 2)
FUNCTION
The wastewater is collected in the Pump Pit. The pumps are protected by
means of a manual Coarse Screen and an automatic channel Fine Screen
(optional) installed at the inlet of the pit.
DIMENSIONING
Flow (peak flow) m³/h 300 (max 3 h)
Hydraulic retention time min 10
Hydraulic retention time (phase 1 & 2) min 5
Volume m³ +/- 50
Dimensions of pump pit
Length m 6
Width m 6
water height (max.) m 1,5
Number of pumps 2
Pump capacity (per pump) m³/h 300
Static head m WC 8
EQUIPMENT
1 manual coarse bar screen
1 static fine screen
1 automatic channel fine screen (optional)
2 submersible wastewater pumps (1 active, 1 stand-by)
a level control system: 4 level switches.
document.doc page 12
C.5.2. Equalisation/Alarm Tank (phase 1 & 2)
FUNCTION
The main function of the equalisation tank is to obtain buffering of the waste
water quality (pH, heavy metals, BOD, COD, SS,...) and quantity (flow). Due to
the foreseen retention time in the equalisation tank, acid and alkaline
wastewater-streams are mixed, resulting in an auto pH correction, which saves
neutralising chemicals in pre-treatment. The wastewater is kept in a continuous
state of suspension and anaerobic conditions are avoided.
DIMENSIONING
Average flow m³/h 166
Peak flow m³/h 300
Volume m³ 1320
Dimensions
Length m 22
Width m 12
Water height m 5
Hydraulic retention time h 8
Hydraulic retention time(phase 1 & 2)h 4
document.doc page 13
EQUIPMENT
2 submersible wastewater pump (1 active, 1 stand-by)
flow measurement & control valve
1 submersible mixer
1 hydro-ejector
1 level control system: a hydrostatic continuous measurement
document.doc page 14
C.5.3. Physico-chemical pre-treatment
FUNCTION
Separating and removing material with a density smaller then that of water by natural flotation and material with a density higher then water by gravitational sedimentation by mean of dosing coagulants.
By removal of these components, the downstream biological treatment step and equipment are protected.
DESIGN
Design parameters
Flow rate : 166 m³/h Number of units : 1
General dimensioning coagulation tank
Dimensions- length : : 3 m- width : : 3 m- waterdepth : : 2 m
General dimensioning sedimentation tank
Dimensions- length : : 12 m- width : : 5 m- waterdepth : : 1,75 m
EQUIPMENT
Top entry mixer
2 dosing pumps coagulant solution
2 dosing pumps flocculant solution
2 dosing pumps for base solution
document.doc page 15
Moving bridge with airlift system
C.5.4. Aerobic Treatment
FUNCTION
The wastewater is treated in a UNITANK single stage aerobic as described in
annex.
Here, organic (BOD, COD ) and suspended matter are efficiently removed by
oxidation and conversion into CO2, H2O and new biomass.
Air is introduced into the system to provide the activated sludge with a sufficient
amount of oxygen.
DIMENSIONING
1. Dimensioning figures
Flow m³/day 4000
m³/h 166
2. Dimensioning of aeration volume
Volumetric loading kg BOD/m³/day 0,4
Sludge concentration kg MLSS/m3 4
Sludge loading kg BOD/kg MLSS/day 0,1
Active volume m³ 3000
Dimensions of 1 outer compartment
Length m 16
Width m 8
Water height m 5
document.doc page 16
volume m3 640
document.doc page 17
Dimensions of inner compartment 1
Length m 16
Width m 10
Water height m 5
volume m3 800
Dimensions of inner compartment 2
Length m 26
Width m 12
Water height m 5
volume m3 2200
EQUIPMENT
Fine bubble aeration system
2 Submersible mixers
1 Roots blower
SEOS (new overflow weir)
UUCD (tube settler system)
2 automatic valves for effluent
2 recirculation pumps
2 excess sludge pumps (1 + 1 stand-by)
document.doc page 18
C.5.5. Excess Sludge Thickener
FUNCTION
Excess bio-solids have to be removed on a regular basis to maintain the sludge
concentration in the biological reactor at a fixed level. The excess sludge is
pumped from one of the outer compartments of UNITANK system into the
Sludge Thickener. In here, bio-solids are compacted by gravity. The thickener
can also be used as bio-solids storage tank in emergency cases (for example
intoxication of the biological system).
DIMENSIONING
Excess biological sludge production kg sludge/d 700
Physico-chemical
sludge production depending on waste water characteristics
Expected thickening level % 3
Thickened volume m³/d 8
Storage time d +/- 20
Volume m³ 198
Dimensions
Length m 6
Width m 6
Water height m 5,5
EQUIPMENT
1 thickening mechanism
document.doc page 19
C.5.6. Disinfection tank
FUNCTION
Disinfect the final effluent.
DIMENSIONING
Flow m3/h 166
Storage time min +/- 15
Volume m³ 42
Dimensions
Length m 14
Width m 2
Water height m 1,5
EQUIPMENT
2 hypochloride dosing pumps
1 hypochloride storage tank
document.doc page 20
C.5.7. Sludge dewatering
FUNCTION:
Using a mechanical dewatering installation the excess sludge volume can be reduced considerably.
DIMENSIONING BELT FILTER PRESS
For our sizing we assumed that the sludge treatment will work 8 hours per day, 6
days per week.
Excess biological sludge production kg sludge/d 700
Sludge production per week kg sludge/wk 4900
Capacity per hour kg sludge/h 100
Expected dewatering level % 10 .. 11
EQUIPMENT:
1 Belt filter press or centrifuge 1 Sludge dosing pump 1 polymer preparation and storage tank
Storage tank with vertical mixer Polymer dosing pump
document.doc page 21
DIMENSIONING CENTRIFUGE (OPTIONAL) :
For our sizing we assumed that the sludge treatment will work only 8 hours per
day, 3 days per week.
Excess Sludge production kg sludge/d 700
Sludge production per week kg sludge/wk 4900
Capacity per hour kg sludge/h 100
(small capacity machine doesn’t exist)
Expected thickening level % 10 .. 15
C.5.8. Venturi Channel
FUNCTION EFFLUENT VENTURI CHANNEL
The effluent passes the effluent Venturi Channel to be discharged in the sewer
system.
DIMENSIONING OF THE EFFLUENT VENTURI CHANNEL
A concrete effluent channel : 350 m³/h
Temperature and Flow Measurement
document.doc page 22
C.6. TOTAL CAPACITY OF THE WASTE WATER PLANT: SUMMARY
C.6.1. Volumes
Basin Number of
basin
Volume
m³
Length
M
Width
m
Height
m
Influent pump pit 1 50 6 6 1,5
Coagulation tank 1 18 3 3 2
Sedimentation tank 1 105 12 5 1.75
Buffering tank 1 1320 22 12 5
UNITANK single stage
aerobic with nitrogen removal
removam
4 3000 16 x 3
26 x 1
8 x 2
10 x 1
12 x 1
5
Sludge thickener 1 198 6 6 5,5
Desinfection tank 42 14 2 1,5
Total volume 9 4733
C.6.2. Biosolids production
Bio-solids production after thickener
Kg/day 700
document.doc page 23
D. TECHNICAL PART
A general layout with the basic configuration and the dimensioning of the
installation is represented in annex.
D.1. DESCRIPTION OF THE CRITICAL EQUIPMENT
D.1.1. Equipment list for the biological treatment
Function Type Capacity
P.PR.01.01/02
(1 + 1 spare)
Waste water transfer
from pump pit to
equalisation tank
Submersible
centrifugal pump
2 X 300 m³/h
Z.PR.11.03 Mixing of
equalisation tank
Submersible hydro-
ejector
1320 m3
A.PR.11.01 Mixing of
equalisation tank
Submersible mixer 1320 m3
A.PR.21.01 Mixing of coagulation
tank
Top entry mixer 18 m3
A.AE.13.01/02 Mixing of UNITANK Submersible mixer 2200 m3
P.PR.11.01/02
(1 + 1 spare)
Waste water transfer
from equalisation
tank to UNITANK
Submersible
centrifugal pump
167 m³/h
C.AE.11.01 Aeration of UNITANK
Roots blower 1200 kg
BOD/day
300 kgN/day
Z.AE.11.01,
Z.AE.12.01/02,
Z.AE.14.01
Air diffusers Disc diffusers 1200 kg
BOD/day
300 kgN/day
S.PR.01.02 Screening influent Coarse screen 300 m³/h
S.PR.01.01 Fine screening Static fine screen 300 m³/h
S.PR.01.03
(optional)
Fine screening Channel fine screen
with screw conveyor
300 m³/h
P.AE.11.01/14.01 (1
+ 1 spare)
Transfer of excess
biosolids
Submersible pumps Max. 25 m³/h
P.AE.11.02/14.02 Recirculation pumps Wall pumps 665 m3/h
document.doc page 24
P.CH.01.01/02 (1 + 1
spare)Dosing of coagulant Membrane dosing
pump
Max. 160 l/h
P.CH.02.01/02 (1 + 1
spare)
Dosing of flocculant Membrane dosing
pump
Max. 160 l/h
P.CH.03.01/02 (1 + 1
spare)
Dosing of base Membrane dosing
pump
Max. 160 l/h
P.CH.04.01/02 (1 + 1
spare)
Dosing of
hypochloride
Membrane dosing
pump
Max. 160 l/h
R.PR.21.01
C.PR.21.01
Bridge with top and
bottom scraper
/
R.SL.01.01 Raking thickener Slowly-rotating
scraper and
thickening
mechanism
SEOS system Advanced overflow
weir system
Capacity 167
m3/h
UUCD Increasing settling
area & efficiency
Tube settlers Capacity 167
m3/h
T.CH.01/03 Chemical storage
tanks
FRP storage tank 2 m3
T.CH.04 Chemical storage
tanks
FRP storage tank 10 m3
document.doc page 25
D.1.2. Specifications and documentation - biological treatment
Coarse screen S.PR.01.02
total number 1
Function Screening of wastewater before entering the pump pit to prevent damage to the pumps
Manufacturer Local
Type Coarse screen - flat bar screen (Basket type)
split width 30 mm
Operation Continuous
Location Entrance pump pit
Flow 300 m3/h
Inclination 90°
Materials Stainless steel
document.doc page 26
Static fine screen S.PR.01.01
Total number 2
Function Fine screening of the incoming waste water
Manufacturer REKO or equivalent
Type Static screen
Split width 1,5 mm
Operation Continuous
Location After pump pit
Flow 2 x 150 m3/h
Materials- curved screen plate- housing
Stainless steel
document.doc page 27
Channel fine screen (optional)
S.PR.01.03
Total number 1
Function Fine screening of the incoming waste water
Manufacturer SNOEK or equivalent
Type Static screen with screw conveyor for screenings
Split width 1,5 mm
Operation Continuous
Location Channel before pump pit and after coarse screen
Flow 300 m3/h
Materials- curved screen plate- housing
Stainless steel
document.doc page 28
Pump P.PR.01.01/02
Total number 2 (1 + 1 spare)
Function Pumping of waste water from pump pit to equalisation tank
Manufacturer KSB or equivalent
Type Submersible centrifugal wastewater pump type
Operation DiscontinuousSwitch off at minimum levelSwitch on at maximum level
Location Pump pit
Flow 167 m3/h
Discharge head 8 m WC
Degree of protection IP 68
Insulation class F
Shaft seal Double mechanical seal
Materials- pump and motor casing- impeller- shaft- bolts and nuts- guidance and accessories- chain
Cast ironCast ironStainless steel Stainless steel Stainless Steel
Stainless steel
document.doc page 29
Blower C.AE.11.01
Total number 1
Function Air transfer to the diffusers for aeration of activated sludge, to create aerobic conditions
Make Robuschi or equivalent
Country of origin EU
Type Three lobe roots blower
Operation Depending on the cycling operation, influenced by pressure and oxygen measurement
Location Blower room
Flow range: 50-100 %
Degree of protection IP 54
Insulation class F
Seals Labyrinth seals
Material- shaft and gears- Three lobe rotors- Blower casing
Heavy duty machine steel Nodular cast iron GG40Cast iron GG25
document.doc page 30
Aerator Devices Z.AE.11.01, Z.AE.1201.Z.AE.1301
Location UNITANK basins
Function Fine air bubbles aeration of activated sludge in the UNITANK basins
Type Disc type
Make SKG or equivalent
Effective airflow 5 Nm³/h.piece
Installation depthEffective water depth
4,8 m5 m
document.doc page 31
SEOS
Location UNITANK basins
Function Improving effluent quality & reducing operation cost
Type Solids excluding overflow weir system
Make local
Capacity 167 m3/h
Material FRP or SS
UUCD
Location UNITANK basins
Function Improving effluent quality & reducing area and reactor volume
Type Ultra compacting UNITANK device
Make SKG
Capacity 167 m3/h
Material Plastic
document.doc page 32
Pump P.PR.11.01/02
total number 2 (1 + 1 spare)
Function Pumping of wastewater from equalisation tank to UNITANK
Manufacturer KSB or equivalent
Type Submersible centrifugal wastewater pump type
Operation Pumping a continuous flow to the pH correction tank, controlled by automatic valve and flow meter.Immergenty:Switch off at minimum level
Location Equalisation tank
Flow 167 m3/h
Discharge head 5 m WC
Degree of protection IP 68
Insulation class F
Shaft seal Double mechanical seal
Materials- pump and motor casing- impeller- shaft- bolts and nuts- guidance and accessories- chain
Cast iron Cast ironStainless steel Stainless steel Stainless Steel
Stainless steel
document.doc page 33
Pump P.AE.11.01/14.01
total number 2 (1 + 1 spare)
Function Transfer of excess biosolids from the outer compartments of the UNITANK to the thickener
Manufacturer KSB or equivalent
Type Submersible centrifugal wastewater pump type
Operation DiscontinuousImmergenty:Switch off at minimum level
Location Equalisation tank
Flow 25 m3/h
Discharge head 5 m WC
Degree of protection IP 68
Insulation class F
Shaft seal Double mechanical seal
Materials- pump and motor casing- impeller- shaft- bolts and nuts- guidance and accessories- chain
Cast iron Cast ironStainless steel Stainless steel Stainless Steel
Stainless steel
document.doc page 34
Pump P.AE.11.02
total number 1
Function Recycling of sludge
Manufacturer KSB or equivalent
Type Shaft pump type
Operation DiscontinuousImmergenty:Switch off at minimum level
Location Equalisation tank
Flow 665 m3/h
Discharge head 0,3 m WC
Degree of protection IP 68
Insulation class F
Shaft seal Double mechanical seal
Materials- pump and motor casing- impeller- shaft- bolts and nuts- guidance and accessories- chain
Cast iron Cast ironStainless steel Stainless steel Stainless Steel
Stainless steel
document.doc page 35
Hydro-ejector Z.PR.11.03
total number 1
Function Aeration and mixing of the waste water to achieve auto pH correction, homogenisation and prevent anaerobic conditions
Manufacturer KSB or equivalent
Type Submersible centrifugal pump with venturi ejector and air injection pipe
Operation ContinuousSwitch off at minimum level
Location Equalisation tank
Power supply 3 * 400 V, 50 Hz
Degree of protection IP 68
Insulation class F
Seal Double mechanical sealing
Materials- pump and motor casing- impeller- shaft- bolts and nuts- ejector house- ejector pipe- Air suction pipe- guidance and accessories- chain
Cast iron Cast iron Stainless steel Stainless steel Cast Iron Stainless steel PVC
Stainless steel Stainless steel
document.doc page 36
Mixer A.PR.21.01
total number 1
Function Mixing of coagulation tank
Manufacturer DOSAPRO or equivalent
Type Top entry mixer
Operation Operation controlled
Location Coagulation tanks
Installed power 1,5 kW
Degree of protection IP 68
Insulation class F
Materials- housing- propeller- shaft- bolts and nuts
Cast ironStainless steel Stainless steel Stainless steel
document.doc page 37
Dosing pump P.CH.01.01/02
total number 2 (1 + 1 spare)
Function Dosing of coagulant
Manufacturer ALLDOS, DOSAPRO or equivalent
Type Diaphragm dosing pump
Operation Continuous
Location Near the pre-treatment
Flow 40 l/h
Discharge head Max. 8 bar
Installed power 0,09 kW
Materials- pump housing- motor housing- diaphragm- dosing head
Cast iron Cast iron PTFE (Teflon) PVC
document.doc page 38
Dosing pump P.CH.02.01/02
total number 2 (1 + 1 spare)
Function Dosing of flocculant
Manufacturer ALLDOS, DOSAPRO or equivalent
Type Diaphragm dosing pump
Operation Continuous
Location Near the pre-treatment
Flow 40 l/h
Discharge head Max. 8 bar
Installed power 0,09 kW
Materials- pump housing- motor housing- diaphragm- dosing head
Cast iron Cast iron PTFE (Teflon) PVC
document.doc page 39
Dosing pump P.CH.03.01/02
total number 2 (1 + 1 spare)
Function Dosing of base solution
Manufacturer ALLDOS, DOSAPRO or equivalent
Type Diaphragm dosing pump
Operation Continuous
Location Near the pre-treatment
Flow 40 l/h
Discharge head Max. 8 bar
Installed power 0,09 kW
Materials- pump housing- motor housing- diaphragm- dosing head
Cast iron Cast iron PTFE (Teflon) PVC
document.doc page 40
Dosing pump P.CH.04.01/02
total number 2 (1 + 1 spare)
Function Dosing of hypochloride solution
Manufacturer ALLDOS, DOSAPRO or equivalent
Type Diaphragm dosing pump
Operation Continuous
Location Near the pre-treatment
Flow 40 l/h
Discharge head Max. 8 bar
Installed power 0,09 kW
Materials- pump housing- motor housing- diaphragm- dosing head
Cast iron Cast iron PTFE (Teflon) PVC
document.doc page 41
Mixer A.PR.11.01
total number 1
Function Mixing of buffering tank
Manufacturer KSB , EMU or equivalent
Type Submersible mixer
Operation Depending on the cycling operation, time controlled
Location UNITANK basins
propeller speed 920 rpm
motor speed 1.450 rpm
degree of protection IP 68
insulation class F
Seal Double mechanical sealing
Materials- housing- propeller- shaft- bolts and nuts- guidance and accessories- chain
Cast iron GG25Stainless steel 1.4571Stainless steel 1.4021Stainless steel 1.4401Stainless steel AISI 304
Stainless steel
document.doc page 42
Mixer A.AE.13.01
total number 1
Function Mixing of UNITANK basin
Manufacturer KSB , EMU or equivalent
Type Submersible mixer
Operation Depending on the cycling operation, time controlled
Location UNITANK basins
propeller speed 920 rpm
motor speed 1.450 rpm
degree of protection IP 68
insulation class F
Seal Double mechanical sealing
Materials- housing- propeller- shaft- bolts and nuts- guidance and accessories- chain
Cast iron GG25Stainless steel 1.4571Stainless steel 1.4021Stainless steel 1.4401Stainless steel AISI 304
Stainless steel
document.doc page 43
Moving bridge with raking devices
R.PR.21.01/C.PR.21.01
Total number 1
Function To evacuate the physico-chemical sludge from the incoming waste water .
Manufacturer Local
Operation Continuous or discontinuous. (timer controlled)
Location Sedimentation tank of physico-chemical pre-treatment
Installed power 0,75 kW.
Degree of protection IP55
Insulation class F
Raking devicesBridge and mainstructure
Epoxy coated steelEpoxy coated steel
document.doc page 44
Rake mechanism R.SL.01.01
Total number 1
Function Enhance the gravity thickening of the biosolids with vertical thickening bars.Collect the thickened sludge centrally with bottom scrapers.
Manufacturer gearboxManufacturer steel structure
DEWEKON or equivalent
LocalType Slow rotating rake mechanism with vertical parallel
thickening bars and bottom scrapers.Operation Continuous
Location Thickener
Diameter 5,8 m (Thickener dimensions 6 m x 6 m )
Rotating speed 0,3 rpm
motor speed 750 rpm
Installed power 0,2 Kw
Degree of protection IP 55
Insulation class F
Materials- Scrapers, thickening bars Epoxy coated steel
document.doc page 45
Chemical storage tank T.CH.01/03
total number 2
Function Storage of chemicals (coagulant, base solution)
Manufacturer Local
Instrumentation Low level measurement
Location Next to technical building
Volume 2 m3
Material FRP
document.doc page 46
Chemical storage tank T.CH.04
total number 1
Function Storage of chemicals (hypochloride solution)
Manufacturer Local
Instrumentation Low level measurement
Location Next to technical building
Volume 10 m3
Material FRP
document.doc page 47
D.1.3. Equipment list for biosolids dewatering plant
No. Function Type Capacity
P.CH.01.01 Polymer dosing
pump
Excenter screw pump 1 m³/h
P.SL.01.01 Transfer of excess
biosolids
Excenter screw pump 9 m³/h
NCH01 PE preparation unit Batch unit for powder
PE
10 kg/day
SSL01/
P.PO01.01
Belt filter press Belt filter 100 kg/h
SSL0101
(optional)
Centrifuge Decanter centrifuge 100 kg/h
document.doc page 48
D.1.4. Specifications and documentation - biosolids dewatering
Polymer Dosing Pump P.CH.01.01
Total number 1
Function Dosing of polymer solution to the centrifuge
Manufacturer SEEPEX ,NETZSCH or equivalent
Type Excenter screw pump with manual speed variator
Operation Simultaneous with sludge feeding pump PSL0101
Location Technical room
Flow 1 m³/h
Discharge head 10 mWC
Installed power 0,37 kW
Degree of protection IP 54
Insulation class F
Sealing Stuffing box
Materials- housing- rotor- stator
Cast iron and epoxy coated steelStainless steelHypalon
document.doc page 49
Polymer Preparation and Storage Unit
NCH01
total number 1
Function Manual preparation of polymer - starting from powder
Manufacturer mixerManufacterer tank
Alldos, Dosapro or equivalentLocal
Operation Manual preparation of batch of polymer
Location Technical building
Capacity tank 1.500 l
Concentration of polyelectrolyte
0,5 to 0,1 %
document.doc page 50
Pump P.SL.11.01
Total number 1
Function Transfer of thickened biosolids to belt filter press
Manufacturer NETZSCH, seepex or equivalent
Type Eccenter screw pump with manual speed variator
Operation On/off dependent on time cycle - dewatering with belt filter press.
Location Technical room
Flow 9 m³/h
Discharge head Max 10 mWC
Installed power 2,5 kW
degree of protection IP 54
Insulation class F
Seal Mechanical seal
Materials- housing- rotor- stator
Cast iron 0.6025Chrome steel 1.2436Perbunan
document.doc page 51
Belt Filter Press SSL01
total number 1
Function Further dewatering of sludge coming from the thickener
Manufacturer Kamps or equivalent
Operation Continuous during 8 hours per day, 6 days per week (phase 1)
Location Technical building
Power supply 3 * 400 V, 50 Hz
Belt width 1500 mm
Flow 5 m³/h of thickened sludge (100 kg/h of DS)
Wash water consumption +/- 7,5 m³/h
DS at the end of the table 10 .. 11 %Installed power 1 kW – Variable speed (Manual)
Material frame Coated steel
Weight 1.000 kg
document.doc page 52
Centrifuge (optional) SSL0101
total number 1
Function Dewatering of thickened biosolids
Manufacturer -Laval or equivalent
Operation Continuous during 8 hours/day and 6 days/week
Location Technical building
Flow 100 kg DS/h
Installed power 30 kW
Degree of protection IP 54
Insulation class F
Materials- frame- rotor- screw conveyor
Cast ironStainless steelStainless steel
document.doc page 53
D.1.5. Instrumentation
D.1.5.1. Instrumentation list
Ref. Description Type
LSL +
LSH
Level measurement pumppit
Control of influent pumps
Floating ball
level switch
LICA Level measurement equalisation tank
Control of equalisation tank aerator/mixer and
equalisation tank transfer pump
Hydrostatic continuous level
measurement
FICA Electromagnetic flow measurement Electromagnetic
PHICA PH-measurement in coagulation tanks
Control of dosing flow base or acid
pH-probe + transmitter
LSA L Low level alarm base tank
Control of base flow
Floating ball
level switch
LSA L Low level alarm coagulant tank
Control of coagulant flow
Floating ball
level switch
LSA L Low level alarm flocculant tank
Control of flocculant flow
Floating ball
level switch
O2 O2 measurement in UNIANK Probe + transmitter
FI Flow measurement in Venturi channel
Effluent of water treatment plant
Ultrasonic flow measurement
document.doc page 54
D.1.5.2. Description instrumentation
LA / LSA / LSL / LSH
Manufacturer ATMI – Mobrey or equivalent
Type Floating ball, level switch
Principle of measurement
A mercury switch changes contact depending on the float position.
Materials * a 3-wire cable, connected to the exchange contact in the float cabin in hypalon* a balance weight in hypalon on + 150 mm from the float cabin* a float cabin with a mercury exchange contact, sealed with polyurethane foam and in hypalon
Number 10
Location Influent pump pitEqualisation tankChemicals storage tankUNITANK
Electrical connections- output- degree of protection
Contact switch for 230 VAC, 2 A (spot)IP 68
document.doc page 55
LICA
Manufacturer ABB or equivalent
Type Hydrostatic level measurement
Principle of measurement
Continuous measurement of hydrostatic pressure. The pressure is converted into a 4-20 mA signal.
Materials * All parts in contact with the water are made of stainless steel or plastic* Casing of the electronic parts for outside erection
Number 1
Location Equalisation tank
Electrical connections- power supply- output signal- degree of protection
24 V DC (2 wire)4 – 20 mAIP 68 pressure cellIP 65 transmitter
Measuring range Zero and span can be adjusted
Linearity 0,5 % or better of the measured value
document.doc page 56
FI
Manufacturer ABB or equivalent
Type Flow measurement – ultrasonic
Principle of measurement
In an open channel the flow is determined by the height of the water in the measuring channel. This height is the standard for the flow. The relation height – flow for a specified channel can be set up in the measuring converter so that this converter gives a 4 – 20 mA layout signal, proportional to the flow.
Materials Measuring converter + measuring probeIt is fit for outside use.
Number 1
Location Effluent venturi
Electrical connections- power supply- output signal- degree of protection
230 V AC / 50 Hz4 – 20 mAIP 68 sensorIP 65 transmitter
Measuring range Zero and span can be adjusted
Accuracy Electronic part : 0,2 % for maximum measuring span and smooth surfaceVenturi + electronics + real circumstances : 5 - 10 %
document.doc page 57
PHICA
Manufacturer ABB or equivalent
Type Potentiometric pH-measurement
Principle of measurement
Potentiometric pH measurement, using a combined electrode (glass and reference electrode)
Materials Submerged parts in PP or PVCIs fit for outside use.Mounting on wall
Materials Measuring electrode + immersion assembly + measuring converter + signal cable
Immersion assembly : PP or PVC
Number 1
Location Coagulation tank
Electrical connections- power supply- output signal- degree of protection
230 V AC / 50 Hz4 – 20 mA (4 wire)IP 65 transmitter
Measuring range 2 – 12 pH
Accuracy 0,5 % of the measuring range
document.doc page 58
Item DO
Number 3
Manufacturer ABB
Type Oxygen-probe + electrode + transmitter
Measuring principle Potentiostatic 3 electrodes with membrane and internal temperature correction
Electrical connections- power supply- output signal
230 V AC / 50 Hz4 – 20 mA (4 wire)
Measuring range 0 – 15 mg/l
Accuracy 1 % FS
document.doc page 59
Item FICA
Total number 1
Manufacturer ABB or equivalent
Type Electromagnetic flow measurement
Measuring principle A magnetic field generates a voltage in the flowing liquid. This voltage is proportional to the velocity of the fluid.
Location After equalisation tank
Electrical connections- power supply- output signal
230 V AC4 - 20 mA (4 wire)
Measuring range Depending on pipe diameter
Accuracy 1 % FS
document.doc page 60
D.2. PIPING
D.2.1. Piping
Our standard for the piping has the following specifications:
Medium Type of pipe Material
Piping for waste water and sludge Diameter < 100 mm HDPE
Piping for waste water and sludge Diameter > 100 mm Stainless steel
Header for compressed air Galvanised steel
Chemicals HDPE, PVC or
other depending
on the chemical
resistance
D.2.2. Penstocks and valves
D.2.2.1. Penstocks and Valves
Medium Type of valve
Influent Regulating butterfly valve
Wastewater - Influent/effluent in piping Butterfly valve
Wastewater - influent-effluent in channels Penstock
Excess sludge, thickened sludge Pinch valve
Butterfly valve
Sludge - pressure Gate valve
Sludge - highly concentrated ( > +/- 8 %) Diaphragm valve
Chemicals Ball valve - PVC
Pressure maint. Valve - PVC
Waste water in discharge pipes of
parallel working pumps Ball check valve
document.doc page 61
D.2.2.2. Description of penstocks and valves
Penstocks - manual
manufacturer Econosto or equivalent
operation handwheel
location in channel
Penstocks - automatic
manufacturer Econosto or equivalent
operation electrical motor
motor Bernard or equivalent
location in channel
Butterfly valve - automatic
manufacturer Econosto or equivalent
type butterfly valve - wafer type
handling double acting pneumatic actuators
operating pressure +/- 6 - 8 bar
Butterfly valve - manual
manufacturer Econosto or equivalent
type butterfly valve - wafer type
operation
diameter < 200 mm manual handle
diameter > 200 mm gearbox and handwheel
Butterfly valve - automatic - flow regulating
manufacturer Econosto or equivalent
type butterfly valve - wafer type
operation actuator + positioner
operation characteristics
pressure +/- 1,4 - 6 bar
electrical signal 4..20 mA
document.doc page 62
Pinch valves
manufacturer Dosapro or equivalent
type pinch valve, flanged type
operation pressurised air
operation +/- 6 - 8 bar
Diaphragm valves
manufacturer -Laval or equivalent
type diaphragm valve - flanged -
full passing
operation magnetic valve
operating +/- 6 -8 bar
Check valves
manufacturer ABS, Econosto or equivalent
type DN 50-250 ball - check valve
Ball valves
manufacturer -Laval or equivalent
type DN 50-250 ball valve
Pressure retention valve
manufacturer Alldos, Econosto or equivalent
type pressure retention valve with
adjustable pressure set point
Gate valves
manufacturer Econosto or equivalent
type gate slide valve
Valves for chemicals
manufacturer Vink or equivalent
type PVC valves
document.doc page 63
D.3. UNITANK - Process control unit - the PCU
D.3.1. Description of the UNITANK - Process control unit
The UNITANK PROCESS CONTROL UNIT is the beating heart of the
wastewater treatment plant. It centralises the following items :
low-tension panel
sampling and monitoring instrumentation of the plant
PLC control
SCADA system
document.doc page 64
D.3.2. Electricity - instrumentation - automation
D.3.2.1. General
The low-tension panel consist of a motor power supply and a PLC control
section, combined in one unit.
cabinet RITTAL system or equivalent
type PS
protection class IP 55
finishing grounding + structure lacquer
In the cabinet, 20 % spare space is provided. In the panel the PLC part is clearly
separated from the power-part. A separate instrumentation-grounding rail is
provided.
The main power supply cable with earthing conductor has to be delivered and
installed until the connection terminals of the main distribution panel of the plant
by the client. SEGHERS KEPPEL technology group will carry out the connection
of the cable with the panel terminals.
The grounding system is supposed to be TN-S. ( 3 x 400 V + N ) 50 Hz
document.doc page 65
D.3.2.2. Electricity
a. Panel - Power distribution section
The power part consist of:
Set of 4 bus bars with a section according to the installed power, short circuit
resistant for the short circuit power of the arrival in the panel.
An earthing bus bar for safety earthings, through the entire power part of the
panel.
An earthing bus bar for the instrumentation mounted isolated from the panel,
connected to the main earthing bus bar.
A power switch build in front of electrical panel.
Universal power meter, DIRIS C - SOCOMES or equivalent. The DIRIS C is
a main analyser, able to measure and calculate all of the electrical
parameters of a three-phase system. One single unit can measure V, A, W,
VAR, cos and the frequency.
Transformer for control current
Motor protection circuits with :
A three pole motor protection switch with thermal and magnetic
protection.
A three pole contactor with the necessary auxiliary contacts.
A one pole automatic thermo-magnetic fuse for the motor control circuit.
Cable terminals according to the cable section
Feeder with automatic fuse for lighting.
Feeder with automatic fuse and differential switch for sockets.
document.doc page 66
b. Panel - Control section
The control section consists of :
1 switch Hand/Auto/off per motor en 1 switch open/close/auto per valve.
2 alarm lamps (25 mm diameter, red colour)
push buttons for lamp test and acceptance of alarms
PLC type SIEMENS S7-300 or equivalent
interface relays between PLC and motor-circuits
stabilised 24 VDC power unit
document.doc page 67
c. Cabling
Cables are placed on cable ladders made of galvanised steel. A tube protects
Cables not installed in cable trays, where necessary. The cable section is
adapted to the motor power and according to safety regulations .
d. Documentation
The following documentation will be delivered in case of order:
electrical diagrams
lists (terminal, motor, cable, instruments)
document.doc page 68
D.3.2.3. Automation
a. General
The complete installation is controlled by a PLC. The PLC is placed in the
control panel.
The control system is located in the PCU-unit.
b. PLC control
The PLC system is build modular and controls the UNITANK system. On line
some parameters can be changed freely on the operator panel system (OP).
After a power interruption the PLC and installation starts up automatically.
c. Functions of the PLC
1. Control of the installation using analogue and digital inputs and an especially
designed program in order to calculate the necessary actions (analogue and
digital outputs)
control of the biosolids pumps, the aeration system and the mixers
generating alarm signals when process failures occur
visualising status of equipment on the OP
2. Signals of process switches, alarm on measurements, motors, valves are
handled by the PLC and reported to OP.
3. Process interlocks to motor start/stop: if switch hand/off/auto of motor or valve
is in the auto position the necessary actions are done by the PLC. Only
critical interlocks (safety of personnel and installation) are carried out in
hardware (relays) without any PLC connections as well in Hand as in Auto.
document.doc page 69
d. Hardware
A SIEMENS S7-300 PLC is proposed.
The analogue signals are 4-20 mA signals and the digital signals 24 VDC.
The PLC is not connected to a network or to other PLC’s.
e. Software
All PLC software is written in instruction code (AWL). Standard documentation is
available after start-up.
The following documentation is delivered:
functional description
complete listing of all programme blocks
cross reference list
document.doc page 70
D.3.3. SCADA supervisory and control
D.3.3.1. General
To supervise and control the installation, a graphical human-machine interface is
delivered. This SCADA system is comprised of several components that
perform supervision, control and data acuisition.
One complete supervisory system [SCADA] is proposed to visualise and control
this Unitank® installation only.
D.3.3.2. Functionality
Visualisation of the installationBy means of synoptical images, a realistic representation is shown.Every equipment will be represented dynamically, showing the actual status of the equipment.All analogue measurements will be given in engineering units.
Control of the installationOperational settings can be adjusted.
Control of the equipmentEvery motor can individually be operated manually from the SCADA system. Every automatic valve can individually be operated manually from the SCADA system.As this is a manual operation, it might effect the process. The operator should be aware of the dangers and risks as he is entirely responsible for his manual actions.
Data acquisitionAll analogue measurements are trended [real time and historical].The logged trend can be converted into a csv-file for further analyses.
Password protectionTo prevend undesired control of the installation several password levels are developed.
Alarm reportingAll alarms are represented by a clear text.
Communication with control system
document.doc page 71
D.3.3.3. Software
Wonderware’s Intouch is used as system software.
Installation specific application software will be developed using this system
software.
A runtime license with 1000Tags will be delivered.
D.3.3.4. Hardware characteristics
A desktop Pc with the following minimum specifications is included:
One PC 1 GHz Pentium III
RAM 512MB – HD 8.4 GB
1.44MB 3.5” disk drive
40x CD-ROM drive
Windows XP preloaded
keyboard – mouse
one 19” monitor
one color A4 printer
The communication cable and accessories between the PLC and the SCADA
are not included.
document.doc page 72
D.3.4. Process lab (optional)
SKG has developed a complete lab-set for operators of a waste water treatment
plant. The goal of this lab-set is to analyse the water probes on a very fast and
accurate way. With the results of these measurements, the operator can control
and eventually optimise the process and the plant.
Lab furniture is provided with the necessary equipment and reagentia for
executing the following analyses:
temperature, pH, dissolved oxygen, settleable solids, sludge concentration,
DS, COD, nitrate-N, nitrite-N, NH4-N, ortho-phosphates
A microscope is provided to evaluate the structure of the micro-organisms.
All procedures are described very clear.
One working table + cupboard + reagents rack
For COD-measurement
COD-measurement kit (for +/- 100 measurements)
Digestion bloc
Colorimeter
For N-measurement
NH4+-N-measurement kit (for +/- 100 measurements)
NOx-N-measurement kit (for +/- 100 measurements)
Colorimeter
For P-measurement PO4
3+-measurement kit (for +/- 100 measurements)
Colorimeter
pH-meter
Oxygen-meter
Dry-oven
Balance
Microscope
Labware: Imhoff cones, graduated cylinders, pipettes, rack, beakers, funnels,
filter paper, petri dishes,...
document.doc page 73
D.4. Civil works
D.4.1. General
Preliminary design and cost estimation of civil works are based on the all
available data, information and drawings given by the client.
In case no sufficient information is available, design and cost estimation will be
based on standard conditions, which will be mentioned hereafter.
Cost estimation are based on European construction practices, conditions and
prices. Special local requirements (such as seismic constructions, typhoon
protected constructions,...) are not included, unless clearly mentioned otherwise.
D.4.2. Building area
Standard building area conditions are:
Construction site free from visible or invisible obstacles, such as old
foundations, debris, large vegetation, local rock or stone formations
Construction area is large enough for the proposed construction, including
space area for normal excavations, site installation and material storage.
Construction area is accessible for standard equipment, such as trucks, piling
machines, ...
The construction area as well as the access is free from cables, pipes,
sewers or other utilities.
The site is property of the client. Any governmental or private taxes related
to the construction are at charge of the client.
The existing grade level is supposed to be flat, without any significant
differences in elevation.
document.doc page 74
D.4.3. Soil conditions
Final foundation levels and foundation method will always be based on detailed
and final soil investigation reports according to the requirements of Seghers
Keppel Technology Group . Soil investigation will be executed on the exact
building location.
If no or insufficient soil reports are available, the following general soil conditions
will be assumed :
The construction will be build based on a general foundation slab at a level of
minus one meter below existing grade level, unless specified otherwise on
the drawings.
The thickness of the foundation slab is determinated according the
characteristics of a medium dense to dens sand layer.
Maximum allowable settlements according to the loads of the proposed
construction will be less than 30 mm unless specified otherwise.
Maximum differential settlements according to the minimum and maximum
loads of the proposed construction will be less than 8 mm unless specified
otherwise.
No special soil conditions as rock layers, hard gravel layers, cemented soils,
mining areas, etc. are included.
Evacuation and deposit of excess soils (if any) are supposed to be possible
within an area radius of max. 10 kilometres and free of charge.
No earth works in polluted soils are included.
D.4.4. Dewatering and metal sheeting
If not specified otherwise, no dewatering, metal sheeting or other special
excavation requirements or included.
document.doc page 75
D.4.5. Concrete mix requirements
Concrete mix design will be based on the chemical analysis of the waste water.
If no information about chemical aggressiveness of the retaining liquid is
available, the following standard concrete mix will be used :
Type of cement : Sulphate Resistant Portland or Blast-furnace cement (if
locally available)
Minimum 350 kg cement per m³ concrete mix
Water-cement ratio maximum 0,50
According European codes, this type of cement is resistant to a retaining liquid
with following chemical data :
Aggressive CO2 max. 6 mg/l
Ammonium NH4+ max. 60 mg/l
Magnesium Mg+ max. 1500 mg/l
Sulphates SO4-- max. 3000 mg/l
pH-value min. 4,5
Standard, no additional admixtures or coatings are foreseen.
D.4.6. Workmanship
Concrete, reinforcement and forms will be placed according international
standard practices.
Clear covering of reinforcement bars will be minimum 30 mm, unless specified
otherwise.
Forms will be of smooth type (type Plywood) if locally available.
Reinforcement will be of deformed type grade 460 (if locally available).
document.doc page 76
D.4.7. Structural design
Structural design - if established by SEGHERS - will be based on computerised
calculations using the method of finite elements.
The design will take in account the effects of temperature, shrinking effects and
all element dimensions will be chosen according the maximum resulting stresses
in the construction.
The design will be made to obtain a structural watertight construction with
maximal shrinking cracks of 0,25 mm according international approved codes.
All construction joints will be provided with a special “water stop” to prevent any
leakage at those spots.
Calculations are based on the latest European Codes. If required, other
international codes as ACI (American Concrete Institute), BS (British Standard),
DIN (Deutsche Industrie Normen) can be used.
document.doc page 77
document.doc page 78
top related