Volume 3 Section 2 Process Requirements-FINAL 10062010

Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements
Tender Documents
VOLUME III
SECTION 2: PROCESS AND DESIGN REQUIREMENTS
____________________________________________________________________________________ EuropeAid/128697/C/WKS/RS (08SER01/13/31) Page 1 of 63
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements Table of Contents
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3.2
PROCESS & DESIGN REQUIREMENTS
5
5 5 5 5 6 6 6 7 8 9 10 10 11 11 12 12 13 13 14 14 15 15 16 18 20 22 24 25 28 29 29 30 33 34 35 36 36 36 38 39 40
3.2.1 Introduction 3.2.2 Design Parameters 3.2.2.1 Design Horizon 3.2.2.2 Population Equivalents 3.2.2.3 Industrial Pollutants 3.2.2.4 Wastewater Quantities 3.2.2.5 Pollution Loads for Design of WWTP 3.2.2.6 Effluent Standards and Treatment Efficiencies 3.2.2.7 Construction Concept 3.2.2.8 Interim Operation during Completion Period 3.2.3 Process Requirements 3.2.3.1 Wastewater Treatment Concept 3.2.3.2 Sludge Treatment Concept 3.2.3.3 Adjusted Process Design 3.2.4 Particular Process & Design Requirements 3.2.4.1 The Wastewater Treatment Plant 3.2.4.1.1 General Layout 3.2.4.1.2 Sewer Connections 3.2.4.1.3 WWTP Effluent 3.2.4.2 The Wastewater Treatment Process 3.2.4.2.1 Primary Wastewater Treatment Facilities 3.2.4.2.1.1 Inlet Pumping Station 3.2.4.2.1.2 Screening Plant 3.2.4.2.1.3 Influent Flow and Quality Measurement 3.2.4.2.1.4 Grit and Grease Removal 3.2.4.2.1.5 Primary Sedimentation Tank (PST) 3.2.4.2.2 Secondary & Advanced Waste Water Treatment Facilities 3.2.4.2.2.1 Activated Sludge Tank (AST) 3.2.4.2.2.2 Phosphorus Precipitation 3.2.4.2.2.3 Blower Station 3.2.4.2.2.4 Distribution Chamber (FST) 3.2.4.2.2.5 Final Sedimentation Tank (FST 3.2.4.2.2.6 Return & Excess Sludge Pumping Station 3.2.4.2.2.7 Effluent Quality Measurement 3.2.4.2.2.8 Effluent Discharge Flow measurement Chamber 3.2.4.3 Sludge Treatment Process 3.2.4.3.1 Primary Sludge Thickening 3.2.4.3.1.1 Gravity Thickener PS 3.2.4.3.1.2 Gravity Pre-Thickener ES Optional 3.2.4.3.1.3 Raw Sludge Pumping Station Optional 3.2.4.3.2 Sludge Digestion Optional
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.3.2.1 Anaerobic Digester Optional 3.2.4.3.2.2 Secondary Sludge Thickener Optional 3.2.4.3.3 Sludge Dewatering 3.2.4.3.3.1 Mechanical Sludge Dewatering Optional 3.2.4.3.3.2 Option: Quick Lime Adding 3.2.4.3.3.3 Sludge Storage Area Optional 3.2.4.3.3.4 Supernatant Pumping Station 3.2.4.3.4 Digester Gas Utilization Optional 3.2.4.3.4.1 Digester Gas System Optional 3.2.4.3.4.2 Gas Storage Tank and Gas Flare Optional 3.2.4.3.4.3 Boiler Plant Optional 3.2.5 Plant Control Requirements 3.2.5.1 Control Philosophy 3.2.5.2 Measurement, Instrumentation and Control 3.2.5.2.1 Primary Wastewater Treatment Facilities 3.2.5.2.1.1 Screening Plant 3.2.5.2.1.2 Influent Flow & Quality Measurement 3.2.5.2.1.3 Grit and Grease Removal 3.2.5.2.1.4 Primary Sedimentation Tank 3.2.5.2.2 Secondary & Advance Wastewater Treatment Facilities 3.2.5.2.2.1 Activated Sludge Tank (AST) 3.2.5.2.2.2 Phosphorous Precipitation Optional 3.2.5.2.2.3 Blower Station 3.2.5.2.2.4 Distribution Chamber (FST) 3.2.5.2.2.5 Final Sedimentation Tank 3.2.5.2.2.6 Return & Excess Sludge Pumping Station 3.2.5.2.2.7 Effluent Quality Measurement 3.2.5.2.3 Primary Sludge Thickening 3.2.5.2.3.1 Gravity Pre-Thickener PS 3.2.5.2.3.2 Gravity Pre-Thickener ES 3.2.5.2.3.3 Raw Sludge Pumping Station 3.2.5.2.4 Sludge Digestion Optional 3.2.5.2.4.1 Anaerobic Digester Optional 3.2.5.2.4.2 Secondary Sludge Thickener Optional 3.2.5.2.5 Sludge Dewatering Optional 3.2.5.2.5.1 Mechanical Sludge Dewatering Optional 3.2.5.2.5.2 Option: Quick Lime Adding 3.2.5.2.5.3 Sludge Storage Area 3.2.5.2.5.4 Supernatant Pumping Station 3.2.5.2.6 Digester Gas Utilization Optional 3.2.5.2.6.1 Gas System Optional 3.2.5.2.6.2 Gas Storage Tank and Gas Flare Optional 3.2.5.2.6.3 Boiler Plant Optional 3.2.5.3 Electrical Consumers 3.2.6 Additional Design Requirements
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Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.6.1 Requirements for Buildings 3.2.6.1.1 Administration Building 3.2.6.1.2 Laboratory 3.2.6.1.3 Workshop The WWTP shall be provided with a Workshop. 3.2.6.1.4 Screen House 3.2.6.1.5 Blower House
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3.2
3.2.1
Process & Design Requirements

Introduction
The Employer's Process Requirements presented hereinafter are to be read in conjunction with the section of Volume III, of these Tender Documents, comprising the General Specifications for the tendered Works in accordance with the Conditions of Contract. In addition to Volume III Section 1, Sub-clause 3.1.5.4 Particular Design Parameters and following, the Employer's Requirements for Process Design and Particular Design Criteria are specified in this Section 2. The specifications presented hereinafter are based on the Beneficiary Conceptual Design (refer to Volume V) defining the minimum Process & Design Requirements for the main process units, and are deemed to form and shall be construed as an integral part of the Specification Requirements. Tenderers design proposals shall be in line with the DWA/ATV standards or equivalent internationally accepted standards and shall in particular consider the following design requirements for the main process units of the WWTP. 3.2.2 Design Parameters Design Horizon
3.2.2.1
In order to reflect the development of population, water consumption, wastewater generation, etc. in an appropriate way, five-year periods have been chosen, comprising an overall period of 20 years. It is intended to construct the WWTP in two phases, the first and the final phase. Commissioning of the first development phase of the WWTP is envisaged in 2013.
2020 First development phase 2030 Final development phase
The Contractor shall consider designing for the final stage of development while only the first stage as defined here further will be subject for implementation of the WWTP Vrbas and Kula and is subject to this Tender for the Works part. 3.2.2.2 Population Equivalents
In the area of Vrbas and Kula there are generally two different types of Population Equivalents (P.E.), which contribute to the definition of the size of the WWTP in terms of P.E. These are population and industrial with commercial pollutants. The following table shows a summary of the connected population equivalents, according to the chosen design horizons. Calculation and assessment of the values is outlined in the Conceptual Design Documentation based on which is processed the Building Permit number 1 12-35100268/2009 issued on 10.09.2009.
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Design Horizon
2022 P.E.
2030 P.E.
Total Total (rounded)
119,466 120,000
178,157 180,000
3.2.2.3
Industrial Pollutants
The Beneficiary takes the risk of any undefined industrial pollutants in the raw wastewater above the specified loads in this document. 3.2.2.4 Wastewater Quantities
The following flow quantities are to be considered, according to the chosen design horizons. Calculation and assessment of the values is outlined in the Conceptual Design Report, included in Volume V.
Design Horizon Population Equivalent 2020 120,000 2030 180,000
Dry flow
weather
daily m/d l/s m /h l/s m3/h l/s m3/h

3
30,000 550 2000 830 3000 1250 4500
42,000 830 3000 960 3450 1250 4500
Dry weather flow Wet weather flow Strom weather flow
The Contractor shall design the final stage for a maximum flow of 42,000 m3/d and build the WWTP for a maximum flow of 30,000 m3/d. The Contractor shall ensure an operational gravitational open channel bypass from the inlet pump station to enable direct discharge to the recipient of the surplus flow during storm weather conditions for 1,250.00 l/s. The same bypass channel shall be considered to be used when remedial interventions are needed on the: i) ii) iii) iv) Mechanical treatment part; Primary Sedimentation Tanks; Biology Treatment stage Final Sedimentation tanks
3.2.2.5
Pollution Loads for Design of WWTP
The total load discharged into the WWTP comprises the sum of the loads from domestic inhabitants, commercial and industrial pollutants. The influent concentrations of the WWTP have been derived from daily loads and water quantities.
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The plant shall be designed to accommodate the flows and loads given in the tables below and be able to meet the consent standards defined in the plant performance guarantee.
Influent Loads and Concentrations
60 g/PE x d
PE 120,000 180,000 10,800 260 21,600 515 13,500 320 2,340 55 450 11
BOD5-Load S0 Concentration f(S0;QDW) COD-Load C0 Concentration Dry Solids Load Concentration Ammonia Load TKN0
[kg/d] [mg/l]
7,200 240 14,400 480 9,000 300 1,560 52 300 10
120 g/PE x d
[kg/d] [mg/l]
75 g /PE x d 13 g/PE x d 2,5 g/PE x d
[kg/d] [mg/l] [kg/d] [mg/l]
Phosphorus Load P0
[kg/d] [mg/l]
The total load discharged into the WWTP comprises the sum of the loads from domestic inhabitants, commercial and industrial pollutants. The influent concentrations of the WWTP have been derived from daily loads and water quantities. 3.2.2.6 Effluent Standards and Treatment Efficiencies
The Contractors tender design proposal shall be based on the Employers conceptual design and shall consider the following Options:
Main Proposal: Optional:
Advanced wastewater treatment for carbon and nutrient removal (C-NP) with basic sludge treatment and dewatering; Employer requires proposals for optional solutions in accordance to the specified requirements.
For the Contractors Design Proposal, which shall be also constructed, limit values will be applied in accordance to EU-Standards (Urban Wastewater Directive 91/271/EEC) and current Serbian legislation. Furthermore it shall be applied for any adjusted Design Proposal.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements Table : Effluent Standards
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Limit values for WWTP discharge to Unit
The
Parameter
Less Sensitive area

Value Processed as 25 125 15 2.0 35
Average daily concentration for defined number of samples
BOD5 COD Tot- N Tot-P SS
mg/l mg/l mg/l mg/l mg/l
Contractor shall include in his design of the final solution for the Final Phase 2030
Effluent Standards
** For the
Advanced Treatment (Carbon & Nutrient Removal) First Phase 2020** Final Phase 2030**
detail of the
Design Horizon
Biological BOD5
Oxygen
Demand, mg/l mg/l mg/l mg/l mg/l
25 125 15 2 35
25 125 10 1 35
Chemical Oxygen Demand, COD Total Nitrogen, Ntot Total Phosphorous, Ptot Total Suspended Solids, DSS
requirements of the Council Directive 91/271/EEC and Council Directive 98/15/ EEC amending CD 91/271/EEC please refer to the original document (see http://europa.eu.int/comm/environment/water/waterurbanwaste/index_en.html)
3.2.2.7
Construction Concept
The Employers conceptual design proposal considers removal of the existing WWTP, demolishing of all existing buildings and water retaining structures, and completion of new facilities. The Conceptual Design has been elaborated for the first phase (Design Horizon 2020), including Preliminary & Secondary & Biological Wastewater Treatment for carbon & nutrient removal in accordance to the activated sludge process with separate sludge thickening and sludge dewatering. The dimensions, arrangement and layout/positioning of the required process units, buildings and structures are only proposed in the set of preliminary design drawings included in Volume V which reflects the conceptual design produced by the Beneficiary. The Tenderer shall follow the concept as far as he considers it is technically possible for him to guaranty the expected results. In general the concept can be described as follows:
Construction and completion of new lifting station and mechanical treatment facilities;
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Removal of the existing pumping station and the other structures after ensuring safe discharge of the incoming sewerage by the new bypass; Construction of all structures and installations for primary sedimentation basins, biological treatment and secondary sedimentation tanks as treatment facilities; Construction and completion of return and excess sludge pumping stations; Construction and completion of sludge thickening facilities Construction and completion of sludge dewatering facilities, incl. sludge storage area; Construction and completion of a new administration building and blower house; Demolishing of all unused facilities in the direct area of the rehabilitated Works, backfilling and levelling of water retaining structures; Completion of new infrastructure for roads and pathways, incl. fence, as required.
The Contractor shall follow the recommended design concept as a minimum requirement; further details are specified in Volume III, Section 1, Sub-clause 3.1.5.4.3 of these Tender Requirements. 3.2.2.8 Interim Operation during Completion Period
All works for the existing WWTP shall be completed during ongoing operation of the present discharge of incoming sewerage. To enable clear site from the old system, the Contractor shall construct the future bypass channel along the boundary of the site, as presented on the drawings of Volume 5, and redirect the outlet from the existing Pumping Station to the new channel. This solution shall be considered to be updated during the Works execution to ensure permanent and uninterrupted discharge of the incoming flows. The operation and maintenance costs of the old PS will be covered by the Beneficiary. Therefore the following strategy should be taken into consideration as a minimum requirement:
Phase 1: Preparatory works and demolishing of existing structures with the bypass connected on the existing discharge pipe to the recipient. Phase 2 Completion and pre-commissioning of the new mechanical treatment facilities with the bypass as new channel. Construction and completion and connection of the influent sewers; Changeover to operation of the new mechanical treatment plant. Phase 3: Construction and completion and pre-commissioning of the preliminary tanks, aeration tanks and secondary sedimentation tanks and blower houses Phase 4: Construction and completion and pre-commissioning of the sludge lines, and dewatering facilities. Phase 5: Commissioning of the Plant; Construction and completion of all infrastructure, a.s.o.
The Contractor shall have planned to overlap the above phase to the technically acceptable level but to ensure completion of all Works in accordance to the Contract requirements.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.3 Process Requirements Wastewater Treatment Concept
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3.2.3.1
The Contractors Tender Design Proposal for the new WWTP shall be based on his conceptual design and the above mentioned design requirements for the following Options:
Main Proposal: Optional:
Advanced wastewater treatment for carbon and nutrient removal (C-NP less sensitive area) with sludge thickening and dewatering; Sludge mechanical dewatering, anaerobic digestion, gas collection and utilization facilities. Tertiary treatment stage(C-N-P sensitive area).
Wastewater purification shall include primary with secondary wastewater treatment and shall be applied in accordance to the activated sludge treatment process under consideration of the following process technologies:
Secondary wastewater treatment: Carbon removal (C-N-P less sensitive area) with intermittent or pre-applied denitrification and simultaneous Phosphorous precipitation and basic sludge ticketing and dewatering line; Advanced wastewater treatment: Nutrient removal (C-N-P sensitive area) with intermittent or pre-applied denitrification and simultaneous Phosphorous precipitation. Separate (anaerobic) sludge stabilization and energy production.
Following the Employers conceptual design the newly rehabilitated WWTP shall consider in particular, but not limited to, the following process units:
Mechanical Wastewater Treatment (Primary) - Inlet Structure with Emergency Outflow - Screen Building with Local Sub/distribution and Control Center - Flow Measurement - Aerated Grit and Grease Chamber - Distribution Chambers - Primary Sedimentation Tanks (PST) - Primary Sludge Pumping Station Biological Wastewater Treatment (Secondary and Advanced) - Intermediate Pumping Station (Existing) - Activated Sludge Tank (AST) - Blower Station with Local Sub/distribution and Control Center - Final Sedimentation Tanks (FST) - Return Sludge Pumping Station - Excess Sludge Pumping Station
The individual process units shall include subsequent facilities and installations; such as screenings conveyance and compaction, grit classifier, grease and scum conveyance and treatment, a.s.o., as well as all arrangements for power supply and operation control.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.3.2 Sludge Treatment Concept
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The Contractors tender design proposal for the new WWTP shall consider sludge thickening and dewatering on drying beds. Optional for construction but obligatory to be designed is biological stabilization of primary and secondary sludge with mechanical sludge dewatering, in accordance to EU Directive 91/271/EEC and Sewerage Sludge Directive 86/278/EEC. Sludge treatment & stabilization shall be applied in accordance to the following process technologies:
Separate (anaerobic) sludge stabilization with mechanical sludge dewatering and digester gas utilization in accordance to the Employers conceptual design proposal.
Following the conceptual design proposal the new WWTP shall consider in particular, but not limited to, the following process units:
Sludge Treatment - Gravity Pre-Thickener for Primary & Excess Sludge - Anaerobic Digester with Local Sub/distribution and Control Center - Gravity Post-Thickener - Sludge Dewatering and Quicklime Adding with Local Sub/distribution and Control Center - Temporary Sludge Storage Area - Supernatant Buffer Tank & Pumping Station Gas Utilization - Gas Storage Tank and Gas Flare - Boiler Plant
The individual process units shall include subsequent facilities and installations; such as sludge conveyance, flocculent preparation and dosing facilities, digester gas purification, a.s.o. as well as all arrangements for power supply and operation control. 3.2.3.3 Adjusted Process Design
The Tenderers are explicitly invited to submit optional units technological design proposals in accordance to the specified effluent standards and overall process requirements with regard to Secondary and Advanced Wastewater and Sludge - Treatment. In particular, optional units design proposals shall be in line with the DWA/ATV standards or equivalent internationally accepted standards and shall consider the 2013 design horizons accordingly.
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3.2.4
Particular Process & Design Requirements
Fulfilment of the specified Design Criteria and Requirements is a precondition for acceptance of the Contractors Design Proposal. 3.2.4.1 The Wastewater Treatment Plant
The design shall fully comply with the overall plant design and these process requirements as well as with the contractual design flow rates, design capacities, design criteria, and technical specifications. As already mentioned before, the Contractors tender design proposal for the new WWTP shall consider all Options for the design while for Construction:
Advanced wastewater treatment for carbon and nutrient removal (C-N-P non sensitive area) with sludge thickening and dewateringon sludge drying beds; Agreed Options: Any agreed options at the end of the tendering process.
Therefore Solution C/N/P; as low-loaded activated sludge process for carbon and nutrient removal with basic sludge treatment shall be completed for the first phase. The Tenderers are free to submit alternative technological design proposals in accordance to the specified influent and effluent standards and overall process requirements for wastewater & sludge treatment. Measures for future extensions of the new WWTP shall in particular include the following activities:
Construction of digestion and gas systems; Construction of the sludge treatment facilities under utilisation of phase 1 structures; Tertiary treatment stage introduction Construction of all related infrastructure.
Therefore the additional site area to the existing WWTP might be considered. Moreover interim operation of the existing discharge system during execution of the works shall be considered and outlined by the Tenderers Design Proposal.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.1.1 General Layout
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In addition to Volume III Section 1 the layout of the WWTP shall consider the following minimum design requirements:
The process units shall be arranged in a modular way to easily allow future extensions of the WWTP in order to cope with the predicted extension of the treatment capacity as well as with increases of the effluent standards; Clear and logic arrangement of all process units considering evident flow paths and correlation of all process units among each other; Even number of units, where technically possible; Number of operational points shall be minimised; Logical and functional arrangement of the local power sub/distributions and local control centers; Length of pipes, channels, and cables between the process units shall be minimised; Accessibility shall be provided to all buildings and major structures by all-weather roads; Roads and general infrastructure (i.e. administration building, power distribution and service water system) as required; All structures, electrical and mechanical equipment shall be protected from physical damage by flooding through the use of appropriate drainage and pumping systems; The direction of the prevailing winds shall be considered in preparing the site layout.
The clear spatial arrangement of all main and affiliated technical facilities by definition of four operational areas on site results in a considerable simplification of both the upcoming construction measure and the following O & M requirements.
Mechanical wastewater treatment Biological wastewater treatment) Sludge Treatment (i.e. in the additional new area) Gas storage and utilization (i.e. in the additional new area)
Arrangement of the individual operational areas shall be considered for Contractors plant layout. 3.2.4.1.2 Sewer Connections The VBK Channel is the main receiving body of the Vrbas and Kula catchments. At present, the untreated wastewater from Vrbas and Kula is discharged into the channel. The raw wastewater is currently conveyed to the WWTP by a number of main sewers.
Sewer A municipal wastewater from the Kula area, (in construction); Sewer systems B1 & B2 delivering the wastewater from 5 villages, (in construction); Sewer C feeding municipal & industrial wastewater from Kula to Vrbas, (in completion); Sewer D feeding municipal & industrial wastewater from Vrbas in the main Collector, completed;
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Sewer E feeding industrial and municipal wastewater to the CWWTP Site;
During completion of this measure the main industrial polluters shall ensure pre-treatment to municipal wastewater quality before discharge in the main collectors. Two of the remaining main sewers lines shall be completed to a new collection chamber before the main collector of the WWTP site.
In the preparatory stage, the Tenderer shall provide for reconnection of the pressure line to the main inlet pipe of 1200mm. The invert level of the main pipeline shall be determined with high accuracy by the Contractor at the position according where his design will start with the new inlet structures. 3.2.4.1.3 WWTP Effluent The existing clear water outlet pipe, leading from the effluent measurement/sampling shaft of the WWTP into the recepient, including a new outlet structure, is included in the Contractors scope of works. The effluent discharge pipe shall be suitable for the flow rates of the final phase (2020), therefore it shall be designed under consideration of the relevant flow conditions of the River. The following design criteria shall be considered:
Dry flow
weather
daily m/d l/s m3/h l/s m3/h l/s m3/h 30,000 550 2000 830 3000 1250 4500 42,000 830 3000 960 3450 1250 4500
The design of the outlet structure shall consider the flow conditions of the channel for the relevant high-water level at 78.7 m.a.s.l and to design the outlet invert at 78.50 m.a.s.l.It shall be designed in such a way that prevents erosion of the channel bed and banks at the discharge point will be prevented. 3.2.4.2 The Wastewater Treatment Process
The following specifications are based on the Employers Requirements as mentioned in Volume III Section 1 and the Conceptual Design used for the obtaining of the Building Permit.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.2.1 Primary Wastewater Treatment Facilities
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New mechanical treatment facilities shall be completed to the following process units:
Inlet Structure with Emergency Effluent; Mechanical Course Screens, Lifting Pump Station Mechanical Fine screens two units and one manual incl. screenings compaction unit; Influent flow measurement and influent quality measurement (automatic sample taker); Aerated Grit Chamber, incl. grit classifier and grease and scum collection and removall; Primary Sedimentation Tank (PST) with sludge pumping station; Screen house-building with power sub-distribution, blower station for the grit chamber and local process control; Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The primary treatment facilities shall be provided with a power sub-distribution and local process control system which shall be located in the screen house and which shall be interlocked with the new WWTP process control (main control center). 3.2.4.2.1.1 Inlet Pumping Station The Pumping Station shall be completed for the first phase (2020). The Pumping Station shall be with submersible pumps feeding the fine screening station. It is shall be provided with state of the art switchboards and frequency converters for minimum 3 pumps.. Tenderer shall make his own provisions during the bid stage in order to validate the pump capacity in respect to his proposed position of the inlet PS from the existing inlet pipe. The Contractor shall using of the existing pumping station and shall integrate it in his technical proposal only as temporary works. Therefore an assessment on capacity and pressure head of the new pumps as well as on the elevations of the plant and MEICA & SCADA installations shall be made by, and on the sole responsibility of, the Contractor.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements The following design criteria shall be considered:
Design Horizon Population Equivalent Dry weather daily flow Qmin = Dry weather flow Qmax = Wet weather flow Total supernatant quantity, approx. Number of pumps Type of pumps P.E. m/d l/s l/s l/PE xd pcs. 2020 140,000 30,000 550 830 10.0 3+1 Submersible 2030 160,000 42,000 830 960
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Operation control of the pumps shall be modified by installation of frequency converters (FC) allowing for flow proportional control of the feed rate, in accordance to the influent flow measurement and the operation conditions of the activated sludge plant. The individual pumps shall be switched ON/OFF, in case of failure and in order to unify the operation hours of the individual pumps an automatic changeover Duty/Standby shall be considered. Water level measurement shall be established as continuous ultrasonic measurement (or equal); at least one measuring device per pump, with remote transmission to the local PLC shall be installed. Low-voltage power supply and operation control shall be arranged in the schreen house. The local PLC shall be interlocked with the main operation control of the plant.
3.2.4.2.1.2 Screening Plant The Screening Plant shall be designed for the final stage (2020) and constructed for the first phase (2013). Removal of coarse debris shall take place by an automatically operated screen assembly comprising fine screens with screenings conveyance and screenings dewatering installed in the new screen house. The following design criteria shall be considered:
Dry flow
weather
daily m/d l/s m3/h l/s m3/h 30,000 550 2000 830 3000 42,000 830 3000 960 3450
Dry weather flow Wet weather flow
Number of screens Type of screens 2 + 1 manual to bypass Climber screen/grab-bar type, reciprocating /step screen, wedge wire drum screen, or equal mm mm of fine m/s m/s l/PExa % 25 6 0.5 1.2 20 - 35
1
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Clear spacing, coarse screen Clear spacing, fine screen Flow velocity, screens upstream
between bars Specific screenings production compaction factor Number of conveyors Type of conveyor Screening press Type of press Number of containers Size of container m
3
50 1 per coarse/fine screen line Screw or belt conveyor 1 per fine screen line Screw press with spray mechanism and feed pipe n+2 1
The screen house-building shall be provided with at least 2 coarse and 2 fine screens in accordance to the finally expected flow rates. The screen house shall allow four sections for the installation of the screens and ancillary equipment, and a blower room for compressed air supply of the subsequent Grit Chambers. In addition the screen house shall allow for the solid waste treatment and storage area (screenings and grit), and the local power sub-distribution and control room. The screen section shall comprise a receiving and distribution channel with installation channels for the screen units and effluent channel to the Grit Chambers. Raw sewerage shall be feed into the receiving and distribution channel, shall be commonly distributed into the individual installation chambers/channels of the screens. The screens which shall be provided for open channel installation. A sufficient number of screens plus one standby unit shall be applied. The channels are to be designed as open concrete channels in monolithic design with installation platforms inside the screen house. Isolating channel gates up- and downstream of the screens as well as a complete covering with inspection manholes, access ladder and service platform with lifting devices for heavy equipment shall be provided accordingly. All channels shall be profiled in such a way that sedimentation of coarse matters will be prevented. Moreover sufficient flushing facilities (service water) shall be considered. Screenings shall be discharged into screw conveyors with spraying/washout device for conveyance into subsequent screening presses, which may feed the screenings containers, alternating.
With regard on the length of the influent sewers extreme divergence of this value should be considered for the design of the
screenings compaction and conveyance units, after dry periods and/or in case of backwater.
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Operation control of the screens shall be realized as water-level-difference control with secondary timer-control for each individual unit that shall be considered by the local PLC. Under normal operation conditions automatic operation of the screens will be controlled by continuous measurement of the up- and downstream water level in the installation channel. Depending on preset values for the water-level-difference control discontinuous operation of the cleaning mechanism shall be initiated. In addition, in case of failure or under low flow conditions the secondary timer control shall initiate regular cleaning of the screens. The operation of the screenings conveying system shall be synchronized accordingly. The solid waste treatment and storage area shall consider space requirements for arrangement of the screenings containers as well as for the grit classifier and containers, and the scum treatment facilities. A worksafe and approved transportation system for the containers, i.e. railsystem or container carriers, shall be provided. The special environmental conditions of raw sewerage treatment require construction of the concrete works with sulphate resistant concrete; finishing of floors and walls with ceramic tiles up to 2.0 meters above finished floor level; completion of all internal steel works (ladders, platforms, a.s.o.) shall be in stainless steel grade W 1.4571 (BS 320 S 31); completion of all internal pipe work shall be in stainless steel grade W 1.4571 (BS 320 S 31) or polyethylene (HDPE). With regard on possible emissions of hydrogen sulphide (H2S), bad odours and classification of the operation room as Ex-zone Ex1. It shall be made sure for sufficient ventilation of the screen house. The third operational section of the screen house shall comprise a blower room for arrangement of at least n+1 blowers (rotary piston blowers) for grit chamber aeration: n = 2. The blower room shall have sufficient size for installation of the blowers, local switchboards and compressed air pipework. It shall have sufficient natural lighting and ventilation; access shall be separate, from outside, only. Low-voltage power supply and operation control of the mechanical treatment facilities shall be arranged in a separate control room located at the screen house. It shall have sufficient size for installation of the required number of control cabinets for the individual electric drives, feeder and measuring cabinets of the local sub-distribution as well as control boards for PLC and measuring instruments. The local PLC shall be interlocked with the main operation control of the plant. It shall have sufficient natural lighting and ventilation; access shall be separately, from outside, only. 3.2.4.2.1.3 Influent Flow and Quality Measurement
The Influent Flow and Quality Measurement facilities shall be designed for the final stage (2030) and constructed for the first phase (2020). Measurement of the influent flow quantity shall be achieved by means of an ultrasonic flow measurement. It shall be installed in the link channel from the Screen House to the Grit Chambers. Moreover quality control for ph-value and temperature shall be located at the link channel. Additionally, an automatic sample-taker shall be installed nearby.
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Dry flow
weather
The measuring devices shall be microprocessor controlled with temperature compensation, provided within a field housing with local display and remote transmission to the PLC/operation control center. Online monitoring instruments for continuous measurement of certain influent quality parameters such as ph/conductivity/ temperature a.s.o., shall be applied. An automatic sampler shall be provided with arrangements to take flow proportional 2-hourcomposite or 24-hour-composite samples. All signals shall be processed by the control center (PLC-control-system) of the primary treatment facilities at the screen house and shall be furthermore transmitted to the main operation control center of the plant.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.2.1.4 Grit and Grease Removal
Tender Documents
The Grit Chambers shall be designed for the final stage (2020) and constructed for the first phase (2013). For grit and grease removal longitudinal aerated grit chambers with lateral grease traps and travelling suction scraper bridges shall be applied. The following design criteria shall be considered:
Dry flow
weather
daily m/d l/s m3/h l/s m3/h l/s m3/h 30,000 550 2000 830 3000 1250 4500
2 longitudinal (DIN 195513/PAN 4-4531/or equal) Scraper bridge or suction scraper m/s m/h min m l/PExa l/PExa m m N/m h
3 3
42,000 830 3000 960 3450 1250 4500

Number of grit chambers Type of chamber Type of sand/scum removal Flow velocity, horizontal Separation efficiency Surface load, qA (Qmin) Retention time, tR (Qmax) Ratio Width/Depth Length of chamber Specific sand production Specific grease production Type of aeration Diffuser depth, he Specific aeration capacity, coarse No. of Blowers Type of blowers Number of sand pumps Capacity Type of pump/impeller
0,2 100 % for 0.25 mm 25 10 0.8 - 0.9 15 - 50 5 1/1000 Coarse bubble 0.7 x water depth (0.07 + 0.76 ln he) n+1 Rotary piston blower n+1
-1.33
m /h
Corresponding to grid removal system plus 10 % submersible/vortex
Number of scum pumps Capacity Type of pump/impeller No. of Grit classifier Capacity m /h
3
Tender Documents
n+1 m /h
3
Corresponding to scum removal system plus 10 % submersible/vortex/single channel 1 Corresponding to grid discharge pumps plus 10 % Separator with screw conveyor n+2
Type of classifier Number of containers Size of container m

3
The Grit Chambers shall be designed and completed as parallel operated twin-chambers; n = 2. The grit chambers shall be completed as concrete buildings in monolithic design with peripheral grease chambers, in- and effluent chamber, sand and scum pumping station. Isolating channel gates in the influent and effluent sections of the grit chambers shall be considered. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. All channels shall be profiled in such a way that sedimentation of coarse matters will be prevented. Moreover sufficient flushing facilities (service water) shall be considered. The aeration system of the grit chambers shall comprise horizontally installed tube aerators, blowers and air distribution pipework, c/w. all required fittings and armatures. The blowers are to be installed in a separate blower room of the screen house; n = 2. It shall have sufficient size for installation of the blowers, local switchboards and compressed air pipework with natural lighting and ventilation. Travelling service bridges for discontinuous sand and scum removal shall be installed. Scraper blades shall apply sand removal from the bottom sand trap into sand hoppers at the grit chambers head. Height adjustable scum blades shall be provided for the grease traps in order to remove scum layers into grease pits at the front side of the tanks. Scrapers and scum blades are to be assembled at the travelling service bridges. Alternatively, sand removal shall be considered by submersible pumps which discharge the sand from the bottom sand trap into a lateral concrete effluent channel, which conveys the flow into a sand pumping station at the front side of the tanks. Option: The sand removal system shall be designed for application of a twin-type suction scraper system comprising travelling service bridges with suction pumps, c/w. pressure pipework into lateral sand discharge channel, alternatively. A grit classifier shall be provided for sand washing and dewatering, which shall be installed in the solid waste treatment and storage area of the screen house. Classified grit shall be feed into grit containers, which shall be provided in a sufficient number. Conveyance of the sand-water mixture from the sand hoppers or the sand pumping station at the grit chambers into the grit classifier shall be applied by air-lift pumps or submersible pumps.
Tender Documents
Submersible pumps to be applied for sand conveyance shall be in special, abrasive resistant design of pump-body and impeller. Separated scum and grease shall be discontinuously discharged from the grease pits at the grit chambers by submersible pumps. It shall be feed to a rotostrainer which is a wedge wire drum sieve in closed design, for removal of solid matter. The liquid phase shall be returned to the wastewater flow, the solids shall be disposed together with the screenings. The scum treatment facilities shall be located inside the screen house, too. Operation control of the travelling scraper bridge shall be realized by means of a PLC unit with timer control of the operation sequences, installed in a local switchboard, which is assembled onto the bridge with power supply via a motorized cable reel. The operation of the grit and scum discharging systems, incl. grit classifier and Rotostrainer, shall be synchronized accordingly. Completion of All submerged metal parts and pipework shall be shall be in stainless steel grade W 1.4571 (BS 320 S 31); completion of all connecting pipework and shall be in polyethylene (HDPE). The grit chamber effluent system shall be hydraulically uncoupled from the downstream units. 3.2.4.2.1.5 Primary Sedimentation Tank (PST) Parallel operated, longitudinal and horizontally flown sedimentation tanks with travelling scraper bridges shall be applied for removal of solid matters and scum. The following design criteria shall be considered:
Dry flow
weather
Number of tanks Type of tank Type of removal system Retention time, tR (Qmax) Surface load, qA (Qmin) Surface load, qA (Qmax) Depth of tank Flow velocity, horizontal h m/h m/h m m/s
2 DIN 19551-1/2 DIN 19552-1/2 or equal Scraper bridge C/N/P 0.5 4.0 6.0 2.0 3.0 0,3 0.5
Ratio Width/Depth Length of tank Type of effluent weir Weir load, qW (Qmin) Specific primary sludge production Dry solids content of PS Treatment efficiencies - BOD5-Reduction - COD-Reduction - Ammonia (Ntot) - Phosphorous (Ptot) - Total Suspended Solids, DSS Number of sludge pumps Capacity Type of pump Number of scum pumps Capacity Type of pump/impeller m /h
3
Tender Documents
0.17 - 0.25 m m/h g DS/PExd % 40 3-5 30 30 10 10 50 n+1 as required positive displacement n+1 as required Submersible/vortex/single channel 15 - 50 DIN 19558 Form B 5.0 30
per tank m /h
3
The Primary Sedimentation Tanks (PST) shall be designed and completed as parallel operated longitudinal concrete basins with horizontal flow; n = 2. The influent section of the PST shall be provided with a flow distribution channel and submerged inlets for common distribution of the flow across the cross section of the tank. Adjustable overflow weirs with scum baffles shall be installed at the effluent section of the tank. Isolating channel gates for the influent and effluent sections of the PST shall be considered. Travelling service bridges for discontinuous bottom sludge and scum removal shall be installed. Scraper blades shall apply primary sludge (PS) removal from the tank bottom into sludge hoppers at the PSTs head. The size of the sludge hoppers shall be chosen under consideration of the required dry solids content of the hydrostatically thickened PS, and under consideration of periodical PS discharge. Height adjustable scum blades shall be provided for scum removal into a scum-collecting channel at the front side of the tanks. Scrapers and scum blades are to be assembled at the travelling service bridges. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. A separate primary sludge pumping station shall be completed close to the PSTs. PS discharge shall take place by direct removal of the sludge from the individual sludge hoppers via the connection siphon pipes and positive displacement pumps, directly into the primary sludge thickeners. At least n + 1 pumps shall be provided for each PST considering discontinuous and alternating sludge removal from the individual sludge hoppers of each tank. Scum shall be discontinuously discharged from a separate pumping pit by submersible pumps/alternatively piped to the scum/grease pit of the grit chambers and pre-treated analogously.
Tender Documents
Completion of all internal steel works (ladders, platforms, a.s.o.) shall be in stainless steel grade W 1.4571 (BS 320 S 31); completion of all internal pipe work and submerged parts shall be shall be in stainless steel grade W 1.4571 (BS 320 S 31) or polyethylene (HDPE). With regard on possible emissions of methane in the pump room and classification of the pump room as Ex-zone Ex1. It shall be made sure for sufficient ventilation. The PS pumping station shall have a sufficient size for installation of the pumps, local switchboards, suction and pressure sludge pipework with natural lighting and ventilation. Sludge pipework; c/w. fittings and armatures, and service water connections. Lifting devices for heavy equipment, and coverings shall be provided accordingly. Operation control of the travelling scraper bridge shall be realized by means of a PLC unit with timer control of the operation sequences, installed in a local switchboard, which is assembled onto the bridge. Power supply shall be via a motorized cable reel. Operation control of the PS pumping station shall be synchronized in accordance to the operational conditions and requirements of the WWTP and the filling level of the primary sludge thickeners. The effluent system of the PSTs shall be hydraulically uncoupled from the downstream units. 3.2.4.2.2 Secondary & Advanced Waste Water Treatment Facilities The facilities for secondary & advanced wastewater treatment shall be designed within the area indicated on the proposed layout in Volume 5 drawing number 2.
It shall be constructed for the first phase (Design Horizon 2020) under consideration of the required extensions in the final phase (2030). The Contractors Main Proposal - Advanced wastewater treatment for carbon and nutrient removal (C-N-P) non-sensitive area comprising, but not limited to, the following process units:
Activated Sludge Tank (AST); Phosphorous Precipitation (Chemical Phosphorous Removal); Blower Station with power sub-distribution and local process control; Final Sedimentation Tank (FST); Return Sludge Pumping Station; Excess Sludge Pump Station; Effluent Quality Measurement; Technical Water Supply System and Effluent Flow Measurement Related pipelines infrastructure connections Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The secondary treatment facilities shall be provided with local power sub-distribution and local process control system that will be located in the blower house and shall be interlocked with the new WWTP process control (main control center).
Tender Documents
3.2.4.2.2.1 Activated Sludge Tank (AST) The Activated Sludge Tanks (AST) shall be designed and completed for the first phase (2018). Provisions for extension in the final phase (2030) shall be made. Main Proposal: Advanced wastewater treatment for carbon and nutrient removal (C-N-P) Removal of the organic loads shall take place in accordance to the activated sludge system for effluent standards as specified in this Tender Document. Advanced wastewater treatment concerning additional nutrient (N/P) removal shall be completed together with the secondary treatment facilities. The process of intermittent or pre-denitrification shall be applied! The AST shall be completed and incorporated in the existing, longitudinal secondary clarifiers. Therefore the existing basins shall be rehabilitated. The AST shall be designed for the following loads and design criteria under consideration of respective pre-treatment efficiencies and internal re-loads from sludge water recycling:
Design Horizon Population Equivalent
2020 120,000
2030 180,000
Dry flow
weather
daily m/d l/s m3/h l/s m3/h

kg/d kg/d kg/d kg/d kg/d
30,000 550 2000 830 3000 7,200 14,400 1,560 300 9,000
42,000 830 3000 960 3450 10,800 21,600 2,340 450 13,500

Biological Oxygen Demand Chemical Oxygen Demand Total Nitrogen, Ntot Total Phosphorous, Ptot Total Suspended Solids, DSS Pre-treatment efficiencies - BOD5-Reduction - COD-Reduction - Ammonia (Ntot) - Phosphorous (Ptot) - Total Suspended Solids, DSS
Pre-treatment efficiency 30 30 10 10 50
Re-loads from sludge water - BOD5-Reload - COD- Reload - Ammonia (Ntot) - Phosphorous (Ptot) - Total Suspended Solids, DSS AST Volume Temperature Volume-ratio Deni/AST Minimum sludge age, tDS Dry solids concentration, MLSS Excess sludge production, ESP = cB d kg/m
3
Tender Documents
Re-loads 5 5 5 5 5 10/12 0.3 0.5 10 13 3.5 - 4.5 1.15 0.05 0.1
kg/kg kg/m x d mg/l C kg/kg mmol/l mAMSL

3
+ cP
Sludge load, BDS Oxygen Supply Free O2-concentration required, cx Evidence for temperatures of Peak factors for max C/max. N loads OC-Load Minimum acid capacity Altitude of WWTP -value - membrane aerators - surface aerators
2 3
0,5/2 10/20 DWA A131 DWA A131 ( 2.5) 1.5 320 0.5 - 0.6 0.9 - 1.0 20 2.0 1.9 Fine bubble aeration, 0.3 2 pc./m 6.0 tube/disk membrane aerator 0 - 12 n + 1 per AST Rotary Piston/Turbo Blower 50% variable speed Vertical shaft aerator 6.0 n + 1 per AST
Oxygen yield membrane g O2/m N x m aerators 3 Economy membrane aerators - surface aerators kg O2/kWh Compressed Air Supply Type of aeration Diffuser depth Type of aerators Service range (i.e. tube aerator) Number of blowers Type of blower
m m /m x h pcs.
3
Surface Aeration Type of aerators Depth of tank Number of aerators
2 3
Theoretical value in clear water In wastewater, under operation conditions
AST Mixing Specific energy input Horizontal flow velocity Type of mixer Number of DO-meters Aeration Basins - No. -
Tender Documents
W/m m/s
2.0 5.0 0.3 submersible, slow motion.
2.0 5.0 0.3 submersible, slow motion
pcs. pcs.
1 per AST 2
The Activated Sludge Tanks (AST) shall be completed as parallel operated longitudinal concrete basins with horizontal flow in the sedimentation basins. An effluent weir with scum baffle at the lower end of the AST shall allow for the flow of the biologically treated wastewater into the Final Sedimentation Tanks (FST). The effluent system of the PSTs shall be hydraulically uncoupled from the downstream units. Oxygen supply shall be realized by a two-line system of compressed air. For compressed air aeration an aeration system comprising non-clogging membrane aerators, compressed air supply and distribution pipe work with blowers for compressed air generation are to be provided. A sufficient number of disc or tube aerators which are to be installed on a certain number of aerator panels, shall be distributed over the and bottom surface in such a way that an area-covering arrangement of the aerators can be made sure. Aerator panels shall be provided with a drain system and shall be connected to the supply pipe work individually via separate shut-off devices. A new blower station for compressed air generation shall be completed close to the AST. At least two DO-meters (dissolved oxygen content measurement) for continuous monitoring of the content of dissolved oxygen inside the AST volume shall be provided for each basin. Operational control of the aeration systems of the individual basins shall be achieved by control of the blower capacity in accordance to the measuring value against a pre-set standard value. Therefore the electric motors of the blowers shall be provided with frequency converters. Adequate mixing of the AST volume shall be made sure through continuous energy intake due to fine bubble aeration or, in case of intermittent aeration, with installation of submersible mixers from the slow motion Banana type. Operation control of the denitrification process shall be achieved by means of a combined Redox/DO control using a fuzzy logic controller. On-line measurements are required for each individual basin. Special attention has to be paid in the design regarding the change of any pipework under the aeration tanks for removal/maintenance. Low-voltage power supply and operation control shall be arranged in the adjacent blower house. The local PLC shall be interlocked with the main operation control of the plant. In case of surface aeration the operation control and sub-distribution shall be located in the administration building or within a separate building.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.2.2.2 Phosphorus Precipitation
Tender Documents
The facilities for Chemical Phosphorous removal shall be designed and completed for the first phase (2020). The chemical dosing facilities shall be designed for the following loads and design criteria under consideration of respective pre-treatment efficiencies and internal re-load from sludgewater recycling:
Dry flow
weather

kg/d kg/d kg/d kg/d kg/d
30,000 550 2000 830 3000 7,200 14,400 1,560 300 9,000
42,000 830 3000 960 3450 10,800 21,600 2,340 450 13,500

Biological Oxygen Demand Chemical Oxygen Demand Total Nitrogen, Ntot Total Phosphorous, Ptot Total Suspended Solids, DSS Pre-treatment efficiencies - BOD5-Reduction - COD-Reduction - Ammonia (Ntot) - Phosphorous (Ptot) - Total Suspended Solids, DSS Re-loads from sludge water - BOD5-Reload - COD- Reload - Ammonia (Ntot) - Phosphorous (Ptot) - Total Suspended Solids, DSS
Pre-treatment efficiency 30 30 10 10 50 Re-loads 5 5 5 5 5 0,01 1 FeCl3 or equal 41% dosing solution

3
P incorporated in activated sludge Effluent concentration (Ptot) Precipitant Dosent Relative density (dosing solution)
kg/kg mg/l % kg/dm % month
1.44 1,5 0,191 3
Specific reagent quantity

Factor - y Storage time for FeCl3 tank
mol ME/mol P
Chemical Phosphorous Removal shall be applied as simultaneous precipitation of the precipitant into the effluent flow from the AST and the distribution chamber FST, respectively.
Tender Documents
Storage and dosing facilities shall be located at the Blower House. Operation control of the dosing process shall be flow/proportional with preset dosing rates of the manually adjustable dosing pumps.
3.2.4.2.2.3 Blower Station The Blower Station shall be designed and completed for the first phase (2020). The Blower Station shall be completed adjacent to the AST. In case of pre-applied Denitrification at least n + 1 blowers per AST shall be provided; n = 2 whereas one blower per aeration basin shall operated with FC. For the process of intermittent Denitrification n + 1 blowers per AST shall be provided. The blower house shall consider two sections for the installation of the blowers with ancillary equipment and local control panels, and the local power sub-distribution and control room. The blower room shall be designed in such a way that the requirements for noise control and working security will be fully meet. Therefore each blower shall be provided with a sound protection hood. Access to blowers and components (such as valves and local control panels) shall be secure and unhindered. The blower room shall be provided with an overhead crane for installation and service requirements. With regard on the waste heat production of the blowers sufficient ventilation and natural lighting shall be made sure. Low-voltage power supply and operation control of the secondary treatment facilities shall be arranged in a separate control room located at the blower house. It shall have sufficient size for installation of the required number of control cabinets for the individual electric drives, feeder and measuring cabinets of the local sub-distribution as well as control boards for PLC and measuring instruments. The local PLC shall be interlocked with the main operation control of the plant. It shall have sufficient natural lighting and ventilation with access from the blower room and from outside.
3.2.4.2.2.4 Distribution Chamber (FST)
The Distribution Chamber shall be designed and completed for the first phase (2020).
Equal flow distribution of biologically treated wastewater plus return sludge flow into the individual sedimentation tanks shall be applied by a distribution chamber which will be built between AST & FST.
The following design criteria shall be considered:
Tender Documents
Dry flow
weather
daily m/d l/s m3/h l/s m3/h l/s m3/h

l/PE xd %
30,000 550 2000 830 3000 1250 4500

10.0 150 x Qmin
42,000 830 3000 960 3450 1250 4500
Total supernatant quantity, approx. Return sludge flow, QRSmax Number of effluent sections Type of effluent Type of effluent regulation system
Equal to No. of FSTs complete overflow manually adjustable weirs
The Distribution Chamber shall be completed as concrete building in monolithic design with central influent chamber and peripheral effluent pits. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. All channels and shafts shall be profiled in such a way that sedimentation of coarse matters will be prevented. Moreover sufficient flushing facilities (service water) shall be considered. The mixture of biologically treated wastewater and mixed liquor suspended solids (MLSS) shall be fed into a distribution well with complete overflow into lateral effluent shafts. Penstocks shall be installed in the tail-water-shafts in order to allow for setting out of operation for individual FSTs. Effluent weirs and all submerged metal parts shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31). Access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly.
3.2.4.2.2.5 Final Sedimentation Tank (FST The Final Sedimentation Tanks (FST) shall be designed and completed for the first phase (2013).. The FST shall be completed in the (to be) rehabilitated, existing, circular secondary clarifiers and shall be completed with travelling scraper or suction scraper bridges for removal of the MLSS from the treated wastewater.

Tender Documents
Dry flow
weather
daily m/d l/s m3/h l/s m3/h 30,000 550 2000 830 3000
2 DIN 19552-1/2 or equal Scraper bridge ml/g kg/m
2 3
42,000 830 3000 960 3450

Number of tanks Type of tank Type of removal system Sludge volume index, ISV
120 3.5 - 4.5 500 600 1.5 Qmin & 0.75 Qmax 1.2 2.0 3.5 20.0 DIN 19558 Form B 5.0 see above 35 0.7 1.0 1.2
Dry solids concentration, MLSS in AST Sludge volume surface loading, qSV Diluted sludge volume, VSV Return sludge rate, RV Surface load, qA (Qmax) Thickening time, tE (Qmax) Depth of tank in 2/3R Diameter of tank Type of effluent weir Weir load, qW (Qmin) Specific sludge production
l/(m x h) ml/l m/h h m m m/h kg/kg g DS/PExd %
Dry solids content
The Final Sedimentation Tanks (FST) shall be designed and completed as parallel operated circular concrete basins with horizontal flow, which shall be provided with rotating scraper bridges with systems for bottom sludge removal and scum removal. The mixture of biologically treated wastewater and MLSS shall be fed into the center distribution well of the clarifier from the distribution chamber by a inverted siphon pipe. The distribution well shall be integrated in the center machine bearing support structure. The wastewater-MLSS mixture will horizontally flow from the center structure to the peripheral effluent spillway. Due to the reduction of the flow velocity readily settable solids and floating materials will be separated from the effluent by gravity. Bottom sludge shall be continuously removed by a scraper blade assembly, which forms the shape of a logarithmic spiral. The scraper mechanism shall be designed as dragged scraper
Tender Documents
blades with lifting gear. The scum removal system comprises skimming troughs with manually operated scum discharge flaps, one of them with integrated pump sump. Floating materials and scum will be conducted to the pump sump and from there pumped by a submersible pump through the central bearing into the scum discharge pipe. Furthermore the scraper bridges shall be provided with antifoam measures comprising a spraying mechanism with pressurized service water supply, distribution pipework with spray nozzles, which shall be assembled under the scraper bridge. Clear water discharge shall be achieved via peripheral effluent channels with v-notched overflow weirs at both wall crests and a scum baffle at the inner circle. The scraper blades and scum removal system are to be assembled at the travelling service bridges. All submerged metal parts shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31). Access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. A separate secondary sludge pumping station shall be newly built close to the FSTs. Continuous sludge withdrawal from the sludge hoppers into the pump sump takes place by hydrostatic pressure. Operation control of the travelling scraper bridge shall be realized by means of a PLC unit with timer control of the operation sequences, installed in a local switchboard, which is assembled onto the bridge, with power supply via a central slip ring. The effluent system of the FSTs shall be hydraulically uncoupled from the downstream units.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.2.2.6 Return & Excess Sludge Pumping Station
Tender Documents
The Return & Excess Sludge Pumping Station shall be designed and completed for the first phase (2020). The secondary sludge, which will be continuously removed biologically treated wastewater by sedimentation shall be discharged to the new Return & Excess Sludge Pumping Station by gravity. Submersible pumps shall be provided for continuous Return Sludge (RS) conveyance back to the activated sludge system. Excess Sludge (ES) shall be discontinuously withdrawn into the excess sludge thickening facilities. The following design criteria shall be considered:
Dry flow
weather

Return sludge rate, RV Dry solids content Number of RS-pumps Type of RS-pumps Specific sludge production
1.5 Qmin & 0.75 Qmax % pcs. kg/kg g DS/PExd % pcs. 0.7 1.0 n+2 N-type impeller pumps see above 35 0.7 1.0 n+1 N-type impeller pumps
Dry solids content Number of RS-pumps Type of RS-pumps
The Pumping Station shall comprise a common pump sump, which shall be fed by inverted siphon pipes from the individual FSTs. Each feeder pipe shall be provided with a magnetic inductive flow measurement device (EFM) with remote control and transmission to the central operation control of the plant for process supervision. Return Sludge, as the major part of the separated secondary sludge, shall be continuously returned back into the activated sludge system in order to keep a constantly high concentration of microorganisms within the system. Submersible pumps with a low rotation speed shall be applied, which feed the RS back to the primary Sedimentation Tanks distribution chamber or directly into the AST, alternatively; n = 2.
Tender Documents
The RS-pumps shall be provided with frequency converters (FC) for pump capacity control. Operation control of the RS-pumps shall be initiated flow-proportional to the influent wastewater flow and processed in accordance to the requirements (operation conditions) of the AST. Excess Sludge as the minor part of the separated secondary sludge represents the growth of biomass that depends on the operational conditions of the plant. It shall be discontinuously removed from the system and shall be feed to the sludge treatment facilities, i.e. into the primary sludge thickening facilities by submersible pumps; n = 2. Excess sludge conveyance shall be initiated timer controlled, in accordance to the MLSS content in the ASTs, which shall be determined by day-to-day laboratory analysis. The pump sump shall be profiled in such a way that sedimentation of coarse matters will be prevented. Moreover sufficient flushing facilities (service water) shall be considered. The special environmental conditions require completion of all internal steel works (ladders, platforms, a.s.o.) shall be in stainless steel grade W 1.4571 (BS 320 S 31); completion of all internal pipe work shall be in stainless steel grade W 1.4571 (BS 320 S 31) or polyethylene (HDPE). Low-voltage power supply and operation control shall be arranged in the adjacent blower house. Remote signals of all relevant data as well as of operation signals (manual/auto/failure) of all main electric drives shall be stored and transmitted into the PLC-system. The local PLC shall be interlocked with the main operation control of the plant. 3.2.4.2.2.7 Effluent Quality Measurement The Effluent Quality Measurement Station shall be designed and completed for the first phase (2020). Monitoring of the purified wastewater quality shall be applied in accordance to the National legislative requirements and Urban Wastewater Directive 91/271/EEC at the effluent manhole, before discharging the effluent flow into the channel. It shall be completed in separate or in the same chamber with the effluent flow measurement and technical water supply system. The following design criteria shall be considered:
Dry flow
weather
Tender Documents
The effluent manhole shall comprise an influent section for connection of the effluent sewers from the FSTs with a diverting overflow wall, which separates the manhole into an influent & effluent section. A complete overflow into the tail-water-shaft of the manhole shall be applied at the discharge point of the treated wastewater from the manhole to the receiving water by gravity. For laboratory analysis & monitoring of the purified sewerage effluent an automatic sample taker comprising a closed cubicle for installation of 12 sample bottles with automatic probe pump, probe distribution in order to complete composite samples, incl. sufficient frost protection and ventilation, shall be installed on a service platform close to the effluent manhole. . 3.2.4.2.2.8 Effluent Discharge Flow measurement Chamber The Contractor shall design and construct discharge chamber where the technical water supply system will be installed before the effluent flow measurement system.
Tender Documents
3.2.4.3
Sludge Treatment Process
The following specifications are based on the Employers Requirements as mentioned in Volume III Section 1 and the Employers Conceptual Design included in Volume V of these Tender Documents. 3.2.4.3.1 Primary Sludge Thickening
The sludge thickening facilities shall be completed, preferably in the western area of the WWTP site. It shall be sized for the first phase (design horizon 2020), comprising but not limited to the following process units:
Gravity Thickener PS (Primary Sludge); Gravity Thickener ES (Excess Sludge); Optional Raw Sludge Pumping Station; Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The primary thickening facilities shall be provided with a local power sub-distribution and local process control system which shall be located at the adjacent operation building and which shall be interlocked with the new WWTP process control (main control center). 3.2.4.3.1.1 Gravity Thickener PS The new Primary Thickener shall be applied for primary sludge thickening shall be designed and completed for the first phase (2020). Raw primary sludge (PS) shall be fed form the primary sludge pumping station at the PSTs directly into the pre-thickeners. PS discharge shall be achieved by direct removal of the sludge from the individual sludge hoppers of the PSTs. Therefore an existing sludge thickener shall be rehabilitated in such a way that it should be used as lost shuttering or foundation of the new thickener.
Tender Documents
Dry flow
weather

g DS/PExd % %
30,000 550 2000 830 3000

40 approx. 3.0 1 approx. 5.0
42,000 830 3000 960 3450

30
Specific primary sludge production Dry solids content of PS Number of tanks Final dry solids content of thickened PS Type of tank Type of removal system Retention time, tR Dry solids load, qDS Surface load, qA Depth of tank Type of effluent weir
DIN 19552-3 or equal Picket Fence Rake d kg/m x d m/h m

2
1.5 50 1.5 4.0
1.5
DIN 19558 Form B
At least one thickener shall be designed and completed as circular concrete basin and shall be provided with a picket fence stirrer and scraper mechanism for bottom sludge removal into a central sludge hopper and scum removal system. Primary sludge shall be directly fed into the center distribution cylinder, which is assembled below the concrete installation bridge spanning the circular tank. The stirring arrangement shall comprise two wings which are attached with raking rods, covering the whole tank depth up to the sludge level and which are assembled to a rotating center tube. Due to continuous, slow motioning rotation of the stirrer vertical drainage channels will be opened in the sludge volume, which facilitates the separation of sludge water from the dry solids. Sludge water is drained up to the fluid level and will be withdrawn into the peripheral effluent channel with v-notched overflow and scum baffle. A bottom scraper blade assembly and sludge hopper scraper, which is assembled to a rotating center tube shall continuously remove thickened sludge into the center sludge hopper. The thickened sludge will then settle on the tank bottom. All submerged metal parts shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31). Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly.
Tender Documents
The suction pipe from the PS-feeding pumps of the sludge digestion plant shall complete thickened sludge withdrawal from the center sludge hopper of the primary thickener. The supernatant shall be conveyed by gravity into the supernatant pumping station of the WWTP. Operation control shall be realized by means of a PLC unit with timer control of the operation sequences, installed in a local switchboard, which is assembled onto the installation bridge. 3.2.4.3.1.2 Gravity Pre-Thickener ES Optional The Primary Thickeners for excess sludge thickening and storage shall be designed but is optional for construction. Excess Sludge (ES) will be discontinuously discharged from the return & excess sludge pumping station into a gravity homogenization thickener and storage tank at the sludge thickening facilities. The excess sludge storage tank shall be used for synchronisation of the excess sludge discharge cycles of the activated sludge system and the operation time of the mechanical thickening facilities. Application of these gravity homogenization thickeners will raise the raw sludge concentration by approximately 60 %, which minimizes the number and, type of the mechanical thickening facilities.The following design criteria shall be considered:
Dry flow
weather

g DS/PExd % d/w % m
30,000 550 2000 830 3000

35 0.7 1.0 7 n 2.5 4.0 circular not required d W/m
3
42,000 830 3000 960 3450
Specific excess sludge production Dry solids content of ES Discharge cycles (ES from AST) Number of tanks Final dry solids content of thickened ES Depth of tank Type of tank Type of removal system Retention time, tR Specific energy input Type of mixer Supernatant discharge
3.0 35
3.0
submersible, slow motion effluent weir & height adjustable effluent device
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The Homogenization-Thickeners shall be designed as parallel operated circular concrete basins and shall be provided with submersible mixers for intermittent operation as well as height adjustable supernatant discharge device. Surplus sludge shall be directly fed into the tanks by pressure pipes from the ES-pumping station. Furthermore scum from primary and secondary wastewater treatment as well as from PS prethickeners may be fed into the homogenization tanks. Thin sludge shall be concentrated by gravity separation of free sludge water that shall be withdrawn by the supernatant discharge device. The sludge volume shall be mixed and homogenized discontinuously in intervals in order to prevent compaction of sludge on the tank bottom. All submerged metal parts shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31). Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. The suction pipe from the PS-feeding pumps of the sludge digestion plant shall complete thickened sludge withdrawal from the center sludge hopper of the primary thickener. Supernatant shall be piped by gravity into the supernatant pumping station of the WWTP. Low-voltage power supply and operation control (PLC control with timer control) of the operation sequences shall be established from the control room of the adjacent blower house. 3.2.4.3.1.3 Raw Sludge Pumping Station Optional The Raw Sludge Pumping Station for Digester feeding shall be designed but is optional for construction. Thickened raw sludge shall be separately fed into the anaerobic digesting plant by eccentric (positive displacement) pumps, which shall be arranged as separate pumping station. The following principle shall be considered: Each digester shall be served with its own pumping station/group with at least n + 1 pumps per sludge source/thickener; n = 1. The following design criteria shall be considered:
Dry flow
weather

g DS/PExd % pcs.
30,000 550 2000 830 3000

40 approx. 5.0
42,000 830 3000 960 3450

30

Primary Sludge
Specific primary sludge production Dry solids content of thickened PS Number of RS(PS)-pumps
n + 1 per digester
Type of pumps Excess Sludge Specific primary sludge production Dry solids content of thickened ES Number of RS(ES)-pumps Type of pumps g DS/PExd % pcs. 35 5.0 n + 1 per digester positive displacement positive displacement
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The pumping station shall be comprised of individual groups of manually adjustable eccentric (positive displacement) pumps. Each group shall serve one digester and shall include separate pumps for thickened PS and ES, whereas each duty pump (or group of duty pumps) shall be provided with at least one standby unit. The pressure pipes are to be connected to the individual heat exchangers of the digesters via inline mixers and shall be provided with inductive flow measurement devices (EFM) for continuous sludge flow measurement as well as pH-value and temperature measurement with registration, remote transmission, and operation control of the digestion process. All piping shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31) or HDPE/Polypropylene pipes. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. The pumping station shall be located in the machinery house of the sludge digestion plant. Lowvoltage power supply and operation control of the raw sludge pumping station shall be interconnected with the central power supply and operation control of the sludge digestion plant. 3.2.4.3.2 Sludge Digestion Optional The new Digesters for anaerobic sludge stabilisation shall be designed, preferably in the reserve area of the WWTP site. It shall be sized for the second phase (design horizon 2013), comprising but not limited to the following process units:
Anaerobic Digester; Secondary Sludge Thickener; Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The sludge digestion plant shall include the digesters with pipe cellar, and machinery house which shall be provided with the central power supply and operation control, and which shall be interlocked with the new WWTP process control (main control center). 3.2.4.3.2.1 Anaerobic Digester Optional Thickened raw sludge shall be fed from the raw sludge pumping station directly into the digested sludge recirculation system of the digesters.
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Anaerobic sludge stabilisation shall be designed and operated in accordance to the process of intensified, alkaline, mesophilic anaerobic sludge digestion, for continuous heating of the raw and recirculation sludge, and digester mixing by gas injection. Alternatively vertically installed, slow motion submersible mixers corresponding to an egg-shaped design of the digester tank, can be applied. The following design criteria shall be considered:
Dry flow
weather

g DS/PExd % g DS/PExd % pcs. d kg oDS/m/d C energy W/m % C C W/m xK W/m
3 2 3
30,000 550 2000 830 3000

35 approx. 5.0 35 approx. 2.5 n 15 - 20 2.5 3.0 35 - 37 1.5
42,000 830 3000 960 3450

Primary Sludge
Specific primary sludge production Dry solids content of thickened PS Excess Sludge Specific primary sludge production Dry solids content of thickened ES Number of digesters Retention time, tR Dry solids load Digester sludge temperature Digester input mixing, specific
Efficiency of digestion Raw sludge temperature, approx. Air temperature, approx. Heat loss/dissipation of digester Heat demand/requirement Number of heat exchangers Recirculation volume
50 % reduction of organic DS 8 - 15 -20 +40 1.2 50 1 per digester 4-5 fold of raw sludge rate and min. 3 times of digester volume/day
pcs.
Number of recirculation pumps Type of RC-pumps
pcs.
(n+1) per digester Centrifugal, dry installed, Ntype impeller pumps
Gas production Specific power content l/kg oDS kWh/m
N
3
Tender Documents
400 q 450 6.5
At least n = 1 (parallel-operated) digester/s, c/w. heating and recirculation system, digester mixing system and equipment for sludge and digester gas withdrawal, shall be completed. Each digester shall be provided with independent installations, i.e. it shall have one separate heat exchanger per digester, n + 1 recirculation pumps (n = 2), separate feeding, recirculation and discharge pipework. (Nevertheless the pipework shall be connected in such a way that crosswise operation is possible (ground- and head-pipe)). The digester feeding system shall include one in-line mixer for homogenous mixing of the thickened raw sludge from the raw sludge pumping station, one heat exchanger and feeding pipes up to the digesters head, per each digester. The recirculation system shall be comprised of the digested sludge suction pipework, which enables withdrawal of digested sludge form at least three different zones, and recirculation pumps with pressure pipes to the heat exchanger. The RC suction and pressure pipes shall be provided with inductive flow measurement devices (EFM) and temperature measurement, furthermore one pH-value measurement device shall be equipped, per each digester. All instruments shall be with registration, remote transmission for operation control of the digestion process. Internal piping of the digester shall comprise suction and pressure pipework for connection of the recirculation and feeding system as well as the interior standpipe and sludge discharge pipe, and the exterior sludge and scum downpipe. The digesters shall be equipped with sufficient scum discharge device. Supernatant shall be fully mixed with the sludge and shall not be withdrawn. The digester mixing system shall be provided in accordance to the design of the digester, i.e. egg-shaped of flat bottom. It shall be designed in such a way that sedimentation of sludge can be, fully and permanently avoided. Mixing by external pumps will not be accepted. Each digester shall be provided with hot water counterflow tube in tube type heat exchangers that shall be supplied with heat water from a central hot water boiler plant or, preferably from the boiler plant or CHP units. In the first phase (2020) the CHP units are not required. The boiler plant shall be provided as primary heat producer and shall be dimensioned in accordance to the total heat requirement of the WWTP (administration and operation buildings) and sludge treatment facilities under consideration of the local climatic conditions and regulations. The CHP units and the boiler plant shall supply one common distributor to which all consumers shall be connected. Operation of the heating system shall be temperature and pressure controlled. Materials and equipment shall comply with the overall design requirements of this Tender Documents; all automated valves shall be provided with pneumatic drives or Ex-proof actuators, only! All piping shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31) or HDPE/Polypropylene pipes. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly.
Tender Documents
The sludge digestion plant shall include the digester/s with pipe cellar, and machinery house which shall be provided with the central power supply and operation control of the sludge digestion plant and which shall be interlocked with the new WWTP process control (main control center). All operation rooms shall be designed in such a way that all the requirements for noise/odour control and working security will be fulfilled. Access to the machines, pumps and components (such as valves and local control panels) shall be secure and unhindered. The operation rooms shall be provided with lifting devices for installation and service requirements, where required. With regard on the humid environment in the operation room sufficient heating, ventilation and natural lighting shall be provided. Low-voltage power supply and operation control of the digestion plant shall be arranged in a separate control room. It shall have sufficient size for installation of the required number of control cabinets for the individual electric drives, feeder and measuring cabinets of the local subdistribution as well as control boards for PLC and measuring instruments. The local PLC shall be interlocked with the main operation control of the plant. It shall have sufficient natural lighting and ventilation with access from outside, only. 3.2.4.3.2.2 Secondary Sludge Thickener Optional The new Secondary Thickeners shall be applied for digested sludge thickening and shall be designed for the first phase (2020). Digested sludge (DS) shall be fed form the digesters by displacement, directly into the thickeners. The following design criteria shall be considered:
Design Horizon Specific digested sludge production Dry solids content of DS Number of tanks Final dry solids content of thickened DS Type of tank Type of removal system Retention time, tR Dry solids load, qDS Surface load, qA Depth of tank Type of effluent weir d kg/m x d m/h m
2
2018 g DS/PExd % % 50 3-5 n approx. 5.0
2030 50
DIN 19552-3 or equal Picket Fence Rake 3-5 50 1.5 4.4 DIN 19558 Form B 3-5
The Secondary Thickeners shall be designed and completed as (parallel operated) circular concrete basin/s in accordance to the design requirements as specified before; for n = 1. Evidence of the storage capacity of the secondary thickeners shall be made under consideration of the operation cycles of digested sludge withdrawal from the digesters, including synchronization with digester feeding cycles, and the working time of the sludge dewatering facilities. The storage capacity should be sufficient to outlast at least the weekend plus one day!
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The thickener effluent pipework shall be equipped with additional connections for wet-sludge disposal via silo-trailers for agricultural reuse. 3.2.4.3.3 Sludge Dewatering The facilities for sludge dewatering shall be designed and completed, preferably in the reserve area of the WWTP site. It shall be sized for the second phase (design horizon 2020), comprising of all necessary structures and installation for the sludge drying and return of the drained water to the PST distribution chamber.
Optional Mechanical Sludge Dewatering system To be designed but is not considered for construction before 2020. It shall be sized for the first phase (design horizon 2013), comprising of but not limited to the following process units:
Mechanical Sludge Dewatering; Option: Quick Lime Adding; Sludge Storage Area; Supernatant Pumping Station; Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The sludge dewatering plant shall be provided with the local power supply and operation control which shall be interlocked with the new WWTP process control (main control center). 3.2.4.3.3.1 Mechanical Sludge Dewatering Optional Mechanical Sludge Dewatering Facilities shall be applied for dewatering of thickened, digested sludge and shall be designed for the first phase (2020). Digested sludge (DS) shall be fed form the secondary thickeners according to the operation cycles of the sludge dewatering facilities. The following design criteria shall be considered:
Design Horizon Specific digested sludge production Dry solids content of thickened DS Number of units Operation time, weekly Operation time, daily Final dry solids content of thickened DS d/w h/d % g DS/PExd % 2018 50 approx. 5.0 n+1 5 2x8 22 - 28 2030 50
Type of dewatering system Power requirement (without pumps) Number of feed-pumps Type of pumps Flocculent Dosent concentration Specific flocculent quantity Storage time for reagent tank Number of containers Size of container m3 % g/kg DS month W/m
3
Tender Documents
Belt press or decanter 250 n + 1 per unit positive displacement organic, polymeric reagent 0,1% dosing solution 3-7 3 n+2 3/5 pcs.
The Mechanical Sludge Dewatering Facilities shall comprise sludge dewatering machines with sludge feeding pumps, the dosing stations for polyelectrolyte with dosing pumps and in-line mixers, and local switchboards; n = 2. Each dewatering machine shall be provided n + 1 feed pumps from the positive displacement type and its own dosing station; n = 1. Digested and thickened sludge shall be fed from the secondary thickener/s to the mechanical dewatering machines by individual suction and pressure pipework. Each suction pipe shall be equipped with an inductive flow measurement device (EFM) for continuous sludge flow measurement with registration, remote transmission, and operation control of the sludge thickening process. The feeding pumps shall be equipped with frequency converters (FC) in order to adjust the flow rates to the operational requirements. Mechanical sludge dewatering takes place under consumption of organic flocculent; therefore eccentric (positive displacement) dosing pumps with (FC) shall be provided. Polyelectrolyte dosing control shall be flow proportional against a preset standard ratio, which depends on the particular sludge characteristics and which shall be determined during trial operation. Dewatered sludge cake shall be withdrawn from the machine discharge device/throw-off-chute in/onto a matching conveying system, which feeds the subsequent chemical post-stabilisation facilities. In addition, provision shall be made for sludge cake disposal into containers or disposal onto a trailer. In addition to the required number of containers one tractor (four-wheel-drive, P 80 HP, with cabin, heating and AC), as common in trade shall be provided together with two double-axle standard tractor-drawn trailer (with pneumatic breaks and hydraulic tilting mechanism, capacity approx. 8-10 tons). Filtrate shall be piped by gravity into the supernatant pumping station of the WWTP. All piping shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31) or HDPE/Polypropylene pipes. Inspection manholes, access ladders and service platforms with lifting devices for heavy equipment, and coverings shall be provided accordingly. The sludge dewatering facilities shall be located in an operation building that shall be comprised of two sections for the installation of the machinery with ancillary equipment and local control panels, and the local power sub-distribution and control room. The operation room shall be designed in such a way that all requirements for noise/odour control and working security are fulfilled. Access to the machines, pumps and components (such as valves and local control
Tender Documents
panels) shall be secure and unhindered. The operation room shall be provided with a crane hoist for installation and service requirements. With regard on the humid environment in the operation room sufficient heating, ventilation and natural lighting shall be provided. Low-voltage power supply and operation control of the mechanical dewatering facilities shall be arranged in a separate control room. It shall have sufficient size for installation of the required number of control cabinets for the individual electric drives, feeder and measuring cabinets of the local sub-distribution as well as control boards for PLC and measuring instruments. The local PLC shall be interlocked with the main operation control of the plant. It shall have sufficient natural lighting and ventilation with access from outside, only. 3.2.4.3.3.2 Option: Quick Lime Adding Chemical Post-Stabilization shall be applied for the dewatered sludge and shall be designed for the first phase (2020). The facilities for quick-lime adding for post-stabilization of the digested and mechanically dewatered sludge shall be supplemented to the sludge dewatering facilities.

Design Horizon Specific digested sludge production Dry solids content of thickened DS Number of units Operation time, weekly Operation time, daily Final dry solids content of sludge cake Type of mixer Dosent/Reagent Dosent information Specific dosing rate Silo volume % g/kg DS m
3
2018 g DS/PExd % d/w h/d % 50 22 - 28 1 5 2x8 30 - 35
2030 50
Heavy-duty double-shaft
Calcium hydroxide Powdery, 2.24 g/dm 250 60
3
The lime mixing, dosing and storage facilities shall be comprised of a heavy-duty double-shaftmixer with feeder, storage silo with filling and discharge equipment and sludge cake discharge conveyor. The facilities shall be supplemented to the sludge dewatering facilities in such a way that the sludge cake mixer is installed within the operation building. A Lime silo with feeder shall be arranged close to the building with traffic access for suppliers silo-trucks. The heavy-duty double-shaft-mixer shall be installed under the discharge chute of the sludge cake conveying system. The connection of the discharge chute to the media chute of the mixer shall be dust proof. Provisions for condensate removal shall be included. The mixer shall be
Tender Documents
provided with a manually adjustable geared motor in order to adjust the capacity to the operational requirements. The powdery lime shall be fed to the mixer by a screw conveyor in dust-tight design. The screw conveyor feed rate shall be manually adjustable to the dosing requirements by means of a adjustable geared motor. The influent media chute of the screw conveyor shall be assembled underneath of the silo-cone. The silo shall be provided as standard silo, common in trade, c/w. all required installations for feeding and discharge of powdery lime. Operation control and power supply of the facilities shall be included in the scope of works of the sludge dewatering facilities 3.2.4.3.3.3 Sludge Storage Area Optional The Sludge Storage Area shall be designed and completed for the first phase (2020). Long-term shortfalls between sludge accrual and disposal shall be temporarily bridged by storage of stabilised, dewatered and post-stabilised (if applied) sludge at the WWTP.

Design Horizon Specific sludge production Final dry solids content of sludge cake Number of storage fields Total storage time Operation time, daily Max. filling height d h/d m g DS/PExd % 2018 60 30 - 35 n 300/250 2x8 2.5 2030
The storage area shall comprise individual storage fields of equal number, as sludge drying beds. Each storage field shall be provided with concrete or bituminous pavement, suitable for heavyduty traffic. It shall be surrounded by enclosing walls and planned with a sufficient drainage system that shall be connected to the drainage system of the WWTP. Filling of the individual storage fields, sludge cake distribution, removal and loading of trucks shall be carried out by a front wheel loader, which will be provided by the Beneficiary. 3.2.4.3.3.4 Supernatant Pumping Station The Pumping Station shall be designed and completed for the first phase (2020). Filtrate, sludge water and supernatant from various sources of the sludge treatment and dewatering facilities shall be drained into one common pump sump and fed back into the rehabilitated intermediate pumping station. With regard on the high loads (i.e. COD, Nitrate and
Tender Documents
Phosphorous) of the supernatant the pump sump shall be designed as buffer tank. Submersible pumps shall be provided for supernatant conveyance. The following design criteria shall be considered:
Design Horizon Total supernatant quantity, approx. Retention time, tR Number of pumps Type of pumps Free passage Impeller mm l/PExd h pcs. 2018 10.0 8 - 12 n+1 submersible 80 N-type 2030
The Pumping Station shall be designed and completed for the final phase in 2030 and shall be equipped with submersible pumps; n = 2. It shall be completed as rectangular concrete building in monolithic design with concrete ceiling. Inspection manholes, access ladder and service platform with lifting devices shall be provided accordingly. Individual pressure pipes or a main header, c/w. all necessary armatures and fittings, shall be installed for supernatant conveyance into the distribution chamber. All piping shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31) or HDPE/Polypropylene pipes. With regard on possible odour emissions and the Ex-environment sufficient ventilation of the pump sump shall be provided. Operation control and power supply of the facilities shall be included in the scope of works of the sludge dewatering facilities. 3.2.4.3.4 Digester Gas Utilization Optional In the first phase (Design Horizon 2020) digester gas shall be designed to utilized for heat production. The facilities for gas withdrawal, storage and utilization shall be integrated in the sludge digestion plant. It shall be designed for the first phase (design horizon 2020), comprising but not limited to the following process units:
Digester Gas System; Gas Storage Tank and Gas Flare; Heat Generation Plant Power supply and connection to main control center; Related infrastructure connections; Interconnecting pipework & cabling
The digester gas utilisation system shall be designed with the central power supply and operation control system (i.e. net-compensation plant in case of optional CHP) and shall be interlocked with the new WWTP process control (main control center). 3.2.4.3.4.1 Digester Gas System Optional The Digester Gas System shall be designed for the first phase (2020).
Tender Documents
The digester gas system shall comprise the suction and connection pipework from the digesters to all apparatus, devices and consumers, in accordance to the requirements of Section 4 of this Tender Documents. The following design criteria shall be considered:
Design Horizon Specific primary sludge production Dry solids content of thickened PS Specific primary sludge production Dry solids content of thickened ES Digester sludge temperature Specific digester production g DS/PExd % g DS/PExd % C l/kg oDS l/PE Daily production period Digester gas composition, Methane Carbon dioxide Sulphur content h/d % % % 2018 30 approx. 5.0 35 approx. 2.5 35 - 37 450 15 - 20 20 65 35 5-6 2030
The gas piping system shall consist of gas bleed pipes leading from the gas dome at digesters head into a separate gas filter room where gravel and ceramic fine filters shall be provided for coarse and fine purification, and dehydration of the digester gas. The gas system shall furthermore be comprised of the connection pipework to the gasholder and gas flare as well as to the optional CHP units and to the boiler plant. The gas system shall be designed as low-pressure system against a balanced gasholder with counterweight for an operation pressure of 50 mbar. The gas discharge and connection pipework shall be designed with a general slope of 1 % towards condensate traps with ex-proof drains, installed at the deepest level of the pipe system and shall be completed shall be in stainless steel grade W 1.4571 (BS 320 S 31). At the gas dome an appropriate, automatic operated foam trap shall be installed in order to prevent the gas system from entering of foam and scum. The gas system must be provided with flame arrestors at all the bleed connections and at each individual consumer! Gas flow meters with metering orifice for continuous measurement of the total gas production shall be installed in the individual gas discharge pipe. The supply lines to the individual consumers (incl. gas flare) shall be equipped with gas flow meters from the positive displacement gas meter (rotary vane) type for continuous measurement of individual gas consumption. The flow meters are to be provided with temperature compensation for monitoring, summarising and registration of the gas flow, with local display and remote transmission to the Digestion Plant System Control. Pressure and vacuum gauges and indicators shall be supplied as necessary at different locations. 3.2.4.3.4.2 Gas Storage Tank and Gas Flare Optional
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Gas Storage Tank and Gas Flare shall be designed for the first phase (2020). The digester gas system shall be designed with a low pressure gasholder for flow and pressure compensation within the system. The following design criteria shall be considered:
Design Horizon Specific digester production l/kg oDS l/PE Daily production period Digester gas composition, Methane Carbon dioxide Sulphur content Volume (percentage of daily production) Operation pressure h/d % % % % mbar 2018 400 - 450 15 - 20 20 65 35 5-6 50 50 2030
The gas holder (n=1) comprises a cylindrical compartment made of sheet steel as steel-clad welded supporting structure with plate and dome-shaped roof, guidance, counterweight and gas tight diaphragm, mounted on a concrete bearing plate. The tank shall be equipped with a manhole cover, roof manhole, stairs and platform with railings from ground level, access and inspection openings in the center of the tank, ventilation ports in the roof, gas inlet and outlet connections, drainage pump (explosion - proof) and related fittings, connections and pipework. Pressure-less gas storage tanks will not be accepted! The gas flare shall be provided for perfect combustion of excess digester gas, in accordance to the filling level of the gasholder and the requirements of the digester gas utilization plant (CHP). A standard unit, completely made of stainless steel (SST), shall be arranged in shunt connection to the gasholder.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.4.3.4.3 Boiler Plant Optional The boiler plant shall be designed for the first phase (2020).
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The Boiler Plant shall be supplied from the low-pressure gasholder of the gas system. Liquid propane gas (LPG) supply from an adjacent LPG tank or natural gas supply shall be included. The following design criteria shall be considered:
Design Horizon Specific digester production l/kg oDS l/PE Daily production period Digester gas composition, Methane Carbon dioxide Sulphur content Number of units Operation time, weekly Operation time, daily Gas system operation pressure Type Efficiencies Thermal efficiency % h/d % % % pcs. d/w h/d mbar 2018 400 - 450 15 - 20 20 65 35 5-6 n+1 7 8 35 Industry standard 90 2030
A number of 1 + 1 heating water boilers as common in trade, for industrial applications, shall be provided and installed in the heating room of the machinery house at the sludge digestion plant. The boiler plant shall be provided with two independent gas supply lines for digester gas and propane/natural gas (diesel, or equal) and shall be completed together with the heating water recirculation system for medium temperatures. The boiler plant shall accordance to the total and sludge treatment regulations. Operation controlled. be provided as primary heat producer and shall be dimensioned in heat requirement of the WWTP (administration and operation buildings) facilities under consideration of the local climatic conditions and control of the heating system shall be temperature and pressure
Materials and equipment shall comply with the overall design requirements of this Tender Documents.
Tender Documents
3.2.5
Plant Control Requirements Control Philosophy
3.2.5.1
The WWTP shall be provided with Operation Control and SCADA system with a modular architecture that shall be designed and completed for the first phase (2020). Provisions for extension in the final phase (2030) shall be made. The main concept of the control and monitoring system is to assure a completely automatic and safe operation of all treatment units of the Plant. The design philosophy requires that monitoring and control will be developed on three different levels. The lowest level includes process control units for particular equipment or for groups of equipment to assure adequate operation of one particular process unit. The level is allocated to the local stations at each item plant. The second control level shall be the normal control point for all the equipment in the vicinity and will transmit all required information for adequate operation of the WWTP, to the Main Control Room/SCADA System. The SCADA system forms the third level of control. Unless otherwise specified or necessary; operation control shall be carried out by programmable logic controllers (PLC) in the local control centers. Plant status, measurements and alarms shall be displayed locally and in the main control center of the plant. Each drive shall be capable of being operated from;
Local control unit adjacent to the drive From the starter compartment push buttons on the local sub-distribution and control panel
Each starter compartment shall have selector switches to give: Remote - Control via the push buttons on the starter compartment door. Local Auto - Control from the local control unit adjacent to the plant item. - Control via the PLC / SCADA
Manual - Control via the push buttons on the doors of the Control Panels Each local control unit shall incorporate Stop/Start push buttons and a twist to reset mushroom head Emergency Stop button. These may be enclosed in a common enclosure. Each control panel section contains a PLC together with ancillary equipment to control and monitor the plant, which is connected to that unit. Where interlocking of plant items from different units in required this shall be achieved via the site communication system, which interconnects the local PLCs and SCADA. The failure of a PLC shall not affect the overall operation of the system. Manual and Auto control levels, and emergency stop safety circuits have to be strictly separated. Signals used for manual control has to be available also under fault conditions of the PLC. Automatic operation and process control of the plant shall consider the following exemplary schedule of measurements and instrumentation as a minimum requirement, for process related operation control.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.5.2 Measurement, Instrumentation and Control
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Instrumentation shall be provided to enable the required parameters and equipment to be monitored and the plant to be automatically operated and controlled. 3.2.5.2.1 Primary Wastewater Treatment Facilities Low-voltage power supply and operation control of the mechanical treatment facilities shall be arranged in a separate control room located at the screen house. The local Sub-distribution and PLC shall be interlocked with the main operation control of the plant. 3.2.5.2.1.1 Screening Plant The following measurement units and functions shall be provided, but not limited to: 1. Ultrasonic level measurement for water-level-difference control with secondary timer-control of the fine screens and conveyor system and screenings press (to be interlocked with screens);
In addition, safety measurements for Methane (CH4), Carbon Monoxide (CO) or Hydrogen Sulphide (H2S/HS) shall be considered optionally. All signals shall be processed by the control center (PLC-control-system) of the mechanical treatment facilities. 3.2.5.2.1.2 Influent Flow & Quality Measurement The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. 4. 5. Ultrasonic flow measurement for continuous flow measurement; On-line monitoring of Temperature; On-line monitoring of Conductivity; On-line monitoring of pH-value; Automatic sample taker for laboratory monitoring of the raw sewerage quality.
All signals shall be processed by the control center (PLC-system) of the mechanical treatment facilities. 3.2.5.2.1.3 Grit and Grease Removal The scraper system shall be provided with a local control switchboard with integrated PLCcontrol-system for scraper operation, operation of the suction pumps and the scum removal system. For control of the bridge travel movements and the lifting/lowering movements of the scum blade inductive proximity limit switches shall be used (included in the scope of supply for the scraper system). The following additional measurement units / functions shall be provided, but not limited to: 1. 2. Ultrasonic/capacitive water level measurement in the sand receiving pit for operation control of the sand discharge pumps and the grit classifier; Ultrasonic/capacitive water level measurement in the scum sump for operation control of the scum discharge pumps and the Rotostrainer.
Tender Documents
Operation control of the grit classifier and the drum sieve (Rotostrainer) shall be interlocked with the pump operation. Operation of the grit classifier shall be synchronized with the scraper bridge and grit feed pumps in such a way that parallel operation of more than one scraper bridge/sand conveyance at the same time is avoided. The operation of the blowers and the aeration system shall be manually controlled. All signals shall be processed by the control center (PLC-control-system) of the mechanical treatment facilities. 3.2.5.2.1.4 Primary Sedimentation Tank A local control switchboard with integrated control-system of the drive unit (incl. safety control) shall be provided and installed on the bridge. No explicit measurements and control circuits are required; travelling movement of the bridge shall be controlled manually. For control of the bridge travel movements and the lifting/lowering movements of the scum blade inductive proximity limit switches shall be used (included in the scope of supply for the scraper system). The following measurement units and functions shall be provided, but not limited to, for operation control of the PS pumps: 1. Magnetic inductive flow measurement (EFM) in the primary sludge main pressure pipe.
Primary sludge pumps shall be operated timer controlled in accordance to a preset value for each sludge hopper of the sedimentation tanks. It shall be operated alternating, pump cycles and durations shall be manually adjusted under consideration of the operational conditions of the plant. The local control center (PLC) shall be installed at the control room of the screen house. Remote signals of all relevant data as well as operation signals (manual/auto/failure) of all main electric drives shall be processed by PLC-system of the biological treatment facilities. In addition, detectors for Methane (CH4) and Carbon Monoxide (CO) shall be considered for the pump room (dry installation of pumps) accordingly. 3.2.5.2.2 Secondary & Advance Wastewater Treatment Facilities Low-voltage power supply and operation control of the secondary treatment facilities shall be arranged in a separate control room located at the blower house. The local Sub-distribution and PLC shall be interlocked with the main operation control of the plant. 3.2.5.2.2.1 Activated Sludge Tank (AST) Biological purification of the mechanically pre-treated wastewater shall be performed for carbon removal with Nitri-/Denitrification, in accordance to the process of intermittent or pre-applied Denitrification. Process control of the denitrification process shall be achieved by combined Redox-potential/DO control. Therefore on-line Redox potential measurements shall be provided for each individual basin. The Redox potential indicates the oxidation/reduction capacity of the wastewater as reference signal for maximum/minimum Nitrate concentration. Fuzzy logic PLC-systems shall be applied for operation control of the aeration system.
Tender Documents
Moreover on-line measurement of the dissolved oxygen content (DO) in the individual reactors is required for operation control of intermittent Denitrification. In addition laboratory analysis of the Nitrate or Ammonia concentration in the effluent flow (to final clarification) are required in order to verify the duration of aerobic (aeration for Carbon removal + Nitrification) and anaerobic periods (Denitrification) based on preset sequences. Achievement of an upper bound value for O2-content (tendency) indicates oxygen saturation and supersaturation in the activated sludge system, which furthermore indicates maximum nitrification of the ammonia content in the wastewater. Shutdown of the aeration system leads to decrement of the DO up to a lower bound value and Denitrification under anaerobic conditions. The duration of aerated and non-aerated periods shall be verified based on day-to-day laboratory analysis of the biologically treated wastewater. Modulation of compressed air supply of the individual aeration basins shall be realised by automatic control of the rotary piston blowers that shall be operated cascade controlled and/or FC-controlled, referring the preset upper/lower limiting values for DO and preset duration of periods. Submersible mixers shall be interlocked with the aeration process, and shall be switched ON/OFF corresponding to switching the aeration system OFF/MIN/ON, separately for the individual aeration basins. The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. 4. DO-online-meters (with temperature compensation) located at the aeration basins for regulation of the individual control-loops; Redox-potential (oxidation-reduction potential, with temperature compensation) located at the aeration basins for regulation of the individual control-loops; Flow meters for compressed air quantity measurement, installed within the common supply pipes of the individual basins; Pressure gauges, installed within the common supply pipes of the individual basins.
The local control center (PLC) for operation control of the AST shall be installed at the control room of the blower house. 3.2.5.2.2.2 Phosphorous Precipitation Optional The dosing system shall be a ready-made system including all internal measurements (i.e. level control of storage tank and leakage control of the receiving cubicle and dosing board, flow control of the precipitant) and PLC-operation control for automatic adjustment of the dosing rate flowproportional to the current wastewater flow quantity. 3.2.5.2.2.3 Blower Station The following measurement units and functions shall be provided, but not limited to: 1. 2. Flow meters with metering orifice for compressed air quantity measurement, installed within the supply and connection pipes to the individual basins; Pressure gauges, installed within supply and connection pipes to the individual basins.
Tender Documents
The local control center (PLC) for operation control shall be installed in a separate control room of the blower house. 3.2.5.2.2.4 Distribution Chamber (FST) Flow distribution to the subsequent process units shall be achieved via common effluent weirs, which shall be provided with motor actuated weir-type stoplogs for equal flow diversion into the individual tailwater shafts. The following measurement units and functions shall be provided, but not limited to: 1. Ultrasonic water level measurement in the upstream well for control of the effluent weirs.
The height of overflow shall be automatically adjusted by the actuators of the weir-type stoplogs; referring (proportional) to the current signal of the wastewater flow quantity measurement. 3.2.5.2.2.5 Final Sedimentation Tank A local control switchboard with integrated control-system of the drive unit (incl. safety control) shall be provided and installed on the bridge. No explicit measurements and control circuits are required; travelling movement of the bridge shall be controlled manually. For control of the bridge travel movements and the lifting/lowering movements of the scum blade inductive proximity limit switches shall be used (included in the scope of supply for the scraper system). 3.2.5.2.2.6 Return & Excess Sludge Pumping Station The following measurement units and functions shall be provided, but not limited to: 1. 2. Ultrasonic level measurement for sludge level indication in the pump sump; Magnetic inductive flow measurement (EFM) in the return sludge pressure pipes, indication and registration of the current flows and flow proportional operation control of the submersible pumps by frequency converters (FC); Magnetic inductive flow measurement in the excess sludge pressure pipes.
3.
Return sludge feed rates shall be set flow-proportional to the wastewater flow quantity and shall be processed in accordance to the requirements (operation conditions) of the activated sludge system. Excess sludge conveyance shall be controlled in accordance to dry-solids content (MLSS) in the AST, which shall be determined by day-to-day laboratory analysis. The local control center (PLC) shall be installed at the control room of the blower house. Remote signals of all relevant data as well as operation signals (manual/auto/failure) of all main electric drives shall be processed by PLC-system of the biological treatment facilities. 3.2.5.2.2.7 Effluent Quality Measurement The following measurement units and functions shall be provided, but not limited to: 1. pH-value measurement (continuous/on-line) for indication and registration as well as monitoring of the raw sewerage quality;
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 2. Automatic sample taker for laboratory monitoring of the effluent quality.
Tender Documents
All signals shall be processed by the control center (PLC-control-system) of the biological treatment facilities at the new blower house. 3.2.5.2.3 Primary Sludge Thickening Low-voltage power supply and operation control of the mechanical thickening facilities shall be arranged in a separate control room of the sludge dewatering building. It shall have sufficient size for installation of the required number of control cabinets for the individual electric drives, feeder and measuring cabinets of the local sub-distribution as well as control boards for PLC and measuring instruments. The local PLC shall be interlocked with the main operation control of the plant. 3.2.5.2.3.1 Gravity Pre-Thickener PS A local control switchboard with integrated control-system of the drive unit (incl. safety control) shall be provided and installed on the concrete service bridge. No explicit measurements and control circuits are required. Lifting/lowering movements of the scum blade, scum and supernatant discharge are to be manually controlled. The following additional measurement units / functions shall be provided, but not limited to: 1. Ultrasonic/capacitive water level measurement.
All signals shall be processed by the control center (PLC-control-system) of the sludge dewatering facilities. 3.2.5.2.3.2 Gravity Pre-Thickener ES The following measurement units and functions shall be provided, but not limited to: 1. Ultrasonic/capacitive water level measurement. All signals shall be processed by the control center (PLC-control-system) of the sludge dewatering facilities. 3.2.5.2.3.3 Raw Sludge Pumping Station The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. 4. 5. Ultrasonic/capacitive water level measurement; Magnetic inductive flow measurement in the pressure pipes; pH-value measurement (continuous/on-line); Temperature measurement (continuous/on-line); Pressure gauges, installed within the pressure pipes.
All signals shall be processed by the control centers of the sludge thickening and sludge digestion facilities.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.5.2.4 Sludge Digestion Optional
Tender Documents
Low-voltage power supply and operation control of the anaerobic sludge digestion plant shall be arranged in a separate control room located at the operation building of the digester. The local Sub-distribution and PLC shall be interlocked with the main operation control of the plant. 3.2.5.2.4.1 Anaerobic Digester Optional The following measurement units and functions shall be provided for each digester, but not limited to: 1. 2. 3. 4. 5. 6. 7. 8. 9. Capacitive/radio detection water level measurement for each digester; Temperature measurement (on-line) at three different levels of the digester; Temperature measurement (on-line) for suction and pressure pipes of the recirculation pipework; Temperature measurement (on-line) for feeding pipes; Temperature measurement (on-line) at heat-exchanger, hot water supply in-/effluent; Temperature measurement (on-line) at heat-exchanger, sludge in-/effluent; pH-value measurement (on-line) for pressure pipes of the recirculation pipework; Magnetic inductive flow measurement in the recirculation suction pipes; Pressure gauges, installed within the pressure pipes;
10. Methane (CH4) detectors with acoustical and optical alarm. The local control center (PLC) for operation control of the sludge digestion plant shall be installed in a separate control room of the digester machinery house. 3.2.5.2.4.2 Secondary Sludge Thickener Optional Refer to 3.2.4.3.1.1
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.5.2.5 Sludge Dewatering Optional
Tender Documents
Low-voltage power supply and operation control of the sludge dewatering facilities shall be arranged in a separate control room located at the sludge dewatering building. The local Subdistribution and PLC shall be interlocked with the main operation control of the digester plant and the WWTP. 3.2.5.2.5.1 Mechanical Sludge Dewatering Optional The following measurement units and functions shall be provided, but not limited to: 1. 2. Magnetic inductive flow measurement in the thickened sludge suction pipes; Magnetic inductive flow measurement in the Polyelectrolyte dosing pipes.
The polymer preparation and dosing system shall be a ready-made system including all internal measurements (i.e. level control of storage tank and leakage control of the receiving cubicle and dosing board, flow control of the precipitant) and PLC-operation control for automatic adjustment of the dosing rate flow-proportional to the current sludge flow. All signals shall be processed by the control center (PLC-control-system) of the sludge dewatering facilities. 3.2.5.2.5.2 Option: Quick Lime Adding The following measurement units and functions shall be provided, but not limited to: 1. Radio detection level measurement for the lime silo;
Operation control and power supply of the facilities shall be included in the scope of works of the sludge dewatering facilities. 3.2.5.2.5.3 Sludge Storage Area No measurements required. 3.2.5.2.5.4 Supernatant Pumping Station The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. 4. Ultrasonic/capacitive water level measurement; Magnetic inductive flow measurement in the pressure pipe; pH-value measurement (continuous/on-line); Pressure gauges, installed within the pressure pipes.
All signals shall be processed by the control centers of the sludge thickening and sludge digestion facilities.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.5.2.6 Digester Gas Utilization Optional
Tender Documents
Low-voltage power supply and operation control of the digester gas system shall be arranged in a separate control room located at the operation building of the digester. The local Sub-distribution and PLC shall be interlocked with the main operation control of the digester plant and the WWTP. 3.2.5.2.6.1 Gas System Optional The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. 4. Flow meters with metering orifice for total gas production measurement, installed in individual gas discharge pipes of the individual digesters; Flow meters from the positive displacement gas meter (rotary vane) type measurement of individual gas consumption for all consumers; Pressure and vacuum gauges to be supplied as necessary at different locations; Probe connections.
The local control center (PLC) for operation control shall be installed in the control room of the digester plant. 3.2.5.2.6.2 Gas Storage Tank and Gas Flare Optional The following measurement units and functions shall be provided, but not limited to: 1. 2. 3. Capacitive level measurement; Flow meters from the rotary vane type for the gas flare; Pressure and vacuum gauges to be supplied as necessary at different locations.
The local control center (PLC) for operation control shall be installed in the control room of the digester plant. 3.2.5.2.6.3 Boiler Plant Optional The heat production units shall be provided as ready-made systems including all internal measurements and controls. The following additional measurement units and functions shall be provided, but not limited to: Flow meters with metering orifice for installation in the digester gas supply pipe (per each); 1. 2. 3. Flow meters from the rotary vane type for the LGP gas tank; Temperature measurement in the machinery room; Methane (CH4) detectors with acoustical and optical alarm.
The local control center (PLC) for operation control shall be installed in a separate control room.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.5.3 Electrical Consumers
Tender Documents
Additional design requirements for plant completion are specified in Sub-clause 1.4 and 1.5 of the General Employers Requirements in Volume III. 3.2.6 Additional Design Requirements
The following design requirements are to be considered for the infrastructure. 3.2.6.1 Requirements for Buildings
The WWTP shall be provided with new building facilities for:
Plant Administration, Management & Labour quarter; Operation Control Center; Screen & Blower House with local Power Sub-distribution and Local Control Centers; Laboratory with new equipment; Workshop.
Any new building shall be designed and completed in accordance to national building law under consideration of the relevant structural and architectural requirements. Buildings shall be finished; incl. i.e. electrical and sanitary house installations, roof, rainwater, furniture, soffit boards, external walls, doors, windows heating and ventilation, a.s.o. The Tenderer shall consider the following minimum design and space requirements. 3.2.6.1.1 Administration Building The WWTP shall be provided with a new Administration Building with main low-voltage distribution and local sub-distribution, main and local control center, administrative area and labour quarter. The administrative facilities shall consider the following minimum space requirements: Administration Control Center Operator Engineer Store Personnel Day Kitchen Lavatory/Locker Room Male/Female Toilets 25 30 30 25 20 30 5 40 20 m m m m m m m m m 2 work places 2 work places 2-3 work places 2 work places
separate areas for male/female labour one per floor
The new administration building shall be designed in accordance to the local & national architecture and shall be completed with all necessary landscaping & gardening, access road and parking area for at least 4 cars. It shall be finished with all required electrical and sanitary house installations, incl. heating, ventilation and air conditioning in all office rooms, in acc. to national regulations and state of the art standards.
Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements 3.2.6.1.2 Laboratory
Tender Documents
The laboratory building shall be attached to the administration. It shall incl. all house installations as required and provided with the necessary laboratory installations as specified in Section 1 of required parameters to be analyzed and their frequency. The specified equipment and furniture represents a minimum requirement, which shall be completed by the Tenderer under consideration of the monitoring requirements acc. to Serbian Standards. 3.2.6.1.3 Workshop The WWTP shall be provided with a Workshop. The size of the building results from the space requirements of the chosen equipment plus the required workguard and safety distances. The administrative facilities shall consider the following minimum space requirements: Workshop Store Lavatory/Locker Room Male/Female Toilets 50 40 15 10 m m m m 2 work places
The new building shall be designed in accordance to the local & national architecture and shall be completed with all necessary landscaping & gardening, access road and parking area for at least 1 car. It shall be finished with all required electrical and sanitary house installations, incl. heating and ventilation in all office rooms, in acc. to national regulations and state of the art standards. 3.2.6.1.4 Screen House The WWTP shall be provided with a Screen House with low-voltage sub-distribution, and local control center. The size of the building results from the space requirements of the chosen MEICA equipment plus the required workguard and safety distances. The new building shall be designed in accordance to the local & national architecture and shall be completed with all necessary landscaping & gardening, access road and parking area for at least 2 cars. It shall be finished with all required electrical and sanitary house installations, incl. heating, ventilation and air conditioning in all office rooms, in acc. to national regulations and state of the art standards. 3.2.6.1.5 Blower House The WWTP shall be provided with a Blower House with low-voltage sub-distribution, and local control center. The size of the building results from the space requirements of the chosen MEICA equipment plus the required workguard and safety distances. The blower house shall be designed in accordance to the local & national architecture and shall be completed with all necessary landscaping & gardening and access road. It shall be finished with all required electrical and sanitary house installations, incl. heating, ventilation and air
Tender Documents
conditioning in all office rooms, in accordance to national regulations and state of the art standards.

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Central Waste Water Treatment Plant Kula and Vrbas Volume III Section 2 (Process and Design Requirements

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PROCESS & DESIGN REQUIREMENTS

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Process & Design Requirements

2020 First development phase 2030 Final development phase

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Total Total (rounded)

daily m/d l/s m /h l/s m3/h l/s m3/h

30,000 550 2000 830 3000 1250 4500

42,000 830 3000 960 3450 1250 4500

Dry weather flow Wet weather flow Strom weather flow

Pollution Loads for Design of WWTP

7,200 240 14,400 480 9,000 300 1,560 52 300 10

75 g /PE x d 13 g/PE x d 2,5 g/PE x d

[kg/d] [mg/l] [kg/d] [mg/l]

Main Proposal: Optional:

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Limit values for WWTP discharge to Unit

Less Sensitive area

BOD5 COD Tot- N Tot-P SS

mg/l mg/l mg/l mg/l mg/l

Demand, mg/l mg/l mg/l mg/l mg/l

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Main Proposal: Optional:

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Particular Process & Design Requirements

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Sewer E feeding industrial and municipal wastewater to the CWWTP Site;

Dry weather flow Wet weather flow Strom weather flow

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Dry weather flow Wet weather flow

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Dry weather flow Wet weather flow

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42,000 830 3000 960 3450 1250 4500

Dry weather flow Wet weather flow Strom weather flow

Corresponding to grid removal system plus 10 % submersible/vortex

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Type of classifier Number of containers Size of container m

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Dry weather flow Wet weather flow

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Design Horizon Population Equivalent

daily m/d l/s m3/h l/s m3/h

Dry weather flow Wet weather flow

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Re-loads 5 5 5 5 5 10/12 0.3 0.5 10 13 3.5 - 4.5 1.15 0.05 0.1

kg/kg kg/m x d mg/l C kg/kg mmol/l mAMSL

Surface Aeration Type of aerators Depth of tank Number of aerators

Theoretical value in clear water In wastewater, under operation conditions

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2.0 5.0 0.3 submersible, slow motion.

2.0 5.0 0.3 submersible, slow motion

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daily m/d l/s m3/h l/s m3/h

Dry weather flow Wet weather flow