Piping

Pipe line size criteria are based on following fluid velocities through the pipe:
i. Pump Discharge : 2.0 m/sec (maximum)
ii. Pump Suction : 1.2 m/sec (maximum)
iii. Gravity Lines : 0.8 m/sec (maximum)
Head requirements of all pumps are derived tentatively.
Subject to change during Design Detailed Engineering.

6.5 STILLING CHAMBER

Raw water will be taken through a flow regulating control valve with Auto level control to
the stilling chamber. The Chamber has been designed to minimize the turbulence of
incoming water by reducing its velocity. Feed Water will be let into the stilling chamber at
the bottom end and flow will be from bottom to top. Volume of stilling chamber will have a
retention time of 30 Minute.

STILLING CHAMBER
DESCRIPTION PARAMETER / DATA
Quantity: 2 No.
Tag No. For Tank 0 – 7150-SC-1 / 2
Location: each at the upstream of each mixing Channel
Type: Rectangular
Actual Flow: (Per stream) 95 m 3/hr
Design Flow: (Per Stream) 100* m 3/hr
Retention Time: 30** min
Required Tank Volume: (One Streams) 47.5 m 3
Designed Tank Volume: (One Streams) 50 m 3
Required Tank Volume: (Two Streams) 95 m 3
Height on Straight: 3.2 m
Area of the Tank: 15.625 m 2
Sides of the Tank: 3.95 m
Tank Dimension: 4.0m x 4.0m x 3.2m + FB: 0.3m
Material Of Construction:
Tank RCC

*Marked values are taken from tender document (PC-E-546-R0) which has been verified by
Shivsu to satisfy and to obtain the desired output required by NPCIL.
** Buffer tank to control turbulence and Based on our past experience in similar kind of
treatment.
6.6 MIXING CHANNEL
The mixing channel consists of a tank with a vertical shaft rapid mixer. The mixer has been
sized to provide effective rapid mixing for the designed volume. The mixer tank has been
designed for the retention time of 2 minute (Ref. Note1) at the design flow rate.
The impeller assembly consists of three blades bolted to a shaft assembly. The mixer shall
be of high shear mixer to accomplish rapid dispersion of the coagulant. Vertical shafted
mixer has been considered with 75% length of the mix chamber height, gear reducer and
motor.
The mixer has an intermediate guide support and all seals and bearings will be placed
above the water surface. The shaft and its bearing have been selected to have the
capability of withstanding the entire static and dynamic thrust load and radial load with a
factor of safety 2.0.
Water from mixing channel will pass over a “V” Notch weir (for flow measurement) to
flocculator chamber. Chemicals such as Coagulant will be added in Mixing Channel where
the rapid mixing will not allow the formation of flocs.
Lime dosing is not considered in the PTP as there is an alternate coagulant aid
(polyelectrolyte) which will itself enhance with coagulant to give better settling of sludge.
Lime also increases pH value which in turn affects the water chemistry and also increases
TDS value of water.

MIXING CHANNEL
DESCRIPTION PARAMETER / DATA
Quantity: 2 No.
Tag No. For Tank 0-7150-MC-1 / 2
Tag No. For Mixer 0-7150-MX-1/2
Location: Each at the upstream of each Flocculator
Type: Rectangular
Actual Flow: (Per stream) 95 m 3/hr
Design Flow: (Per Stream) 100* m 3/hr
Retention Time: 2 min
Required Tank Volume: 3.17 m 3
Designed Tank Volume: 3.3 m 3
Height on Straight: 2.4 m
Area of the Tank: 1.39 m 2
Sides of the Tank: 1.178 m
Tank Dimension: 1.2m x 1.2m x 2.4m + FB: 0.3m
No. Of Mixer 2 No. (1 no. for Each Tank)
Speed of Mixer 100 RPM
Motor Power 1 HP
Material Of Construction:
Tank RCC
Mixer SS 316

6.7 FLOCCULATOR:
The flocculation tank of the clarifier consists of a propeller type mixer to enable a gentle mixing
action. Flocculation Chamber has been designed with minimum retention time of 15 minute (Ref.
Note2) at the design capacity. Flocculator will comprise of mixer paddles, variable gear reducer
and motor. The mixer paddle will be designed with a maximum peripheral speed of maximum 0.6
m/sec.
The mixer shaft and its bearing have been selected to have the capability of withstanding the
entire static and dynamic thrust load and radial load with a factor of safety 2.0. The mixer shaft
will be provided with rigidity mounted intermediate supports and all seals and bearings will be
above the water surface. Poly Electrolyte shall be added in flocculator chamber where the easy
flocculation can occur in the thoroughly mixed water from mixing channel with chemicals like
FeCl3.

FLOCCULATOR

DESCRIPTION PARAMETER / DATA

Quantity: 2 No.
Tag No. For Tank 0-7150-FC-1 / 2
Tag No. For Mixer 0-7150-MX-3 / 4
Location: One per clarifier at the Downstream of Flash mixer
Type: Rectangular
Actual Flow: (Each Stream) 95 m 3/hr

Design Flow: (Each Stream) 100* m 3/hr

Retention Time: 15 min
Required Tank Volume: 23.75 m3
Designed Tank Volume: 25 m3
Height: 3.2** m
Area of the Tank: 7.8 m2
Sides of the Tank: 2.8 m
Tank Dimension: 2.8m x 2.8m x 3.2m + FB:0.3m
No. Of Mixer 2 No. (1 no. for Each
Tank)
Speed of Mixer 6 RPM
Motor Power 0.5 HP
Material Of Construction:
Tank RCC
Mixer SS 316

6.8 LAMELLA CLARIFIER:

The cross flow plate pack consists of a number of corrugated plates mounted parallel to each other
at a close spacing. The raw water containing suspended solids passes in horizontal direction
between the plates. Laminar flow conditions are established while the water flows across the pack
from the inlet to the outlet die. Laminar flow conditions are essential for the effective gravity
separation of the water and suspended continents. The course of passing raw water from pack
inlet to pack outlet, the sludge will move towards the bottom of the corrugations and slides down
the incline of the plate. From there the sludge is collected in a hopper to be discharged
intermittently through a blow off valve. Settled sludge cannot pollute the treated water.
In the corrugation bottoms a sludge concentration is established. This is the ideal condition for
particle agglomeration to take place. (Agglomeration is the formation of large and relatively heavy
particles from small and relatively light particles.) Moreover, since sludge moves in down direction,
and perpendicular to the flow of the water, the danger of particle re-entertainment has been
completely eliminated in the design of the cross flow separator. Supports with so-called place
“spacers” hold the corrugated plates in place providing strength and rigidity to the pack structure.

EQUIPMENT DESCRIPTION
NAME: LAMELLA CLARIFIER
Quantity: 2 No.
Tag No. : 0-7150-LC-1 / 2
No. of Channel Per Clarifier: 1 No.
Actual m 3/hr
(Per Stream) 95
Flow:
Design Flow: (Per Stream) 100* m 3/hr
Flow Direction Cross Flow
Type of plates Corrugated
Settling Velocity: 1 m/hr
Effective surface area required 95 m 2
Installed Area Required 195.02 m 2
Installed Area Provided 198 m 2
No. of Plates / Pack Variable m 2
Angle of inclination of packs: 55°
Plate spacing: 50 mm
Tank Dimension: 3.7 m x 3.2 m x 3.6 m
Material Of Construction: MS FRP
Clear Water Chamber:
Quantity 1 No.
Retention Time 1 hr
Capacity: 184 m 3
MOC RCC
Tag No. 0-7150-TK-9

CHEMICAL DOSING SYSTEM FOR PRETREATMENT PLANT:

Flocculants, Coagulant will be dosed in the raw water feed to the Clarifier to settle down
colloidal particles & suspended solids in the raw water. FeCl3 and Poly electrolyte will be
used for the coagulation and flocculation requirements. Dosing system for each chemical
will have two dosing tanks (1W+1S) in FRP construction and three electronic diaphragm
dosing pumps (2W+1S) in PP construction. The capacity of dosing tank and pump will meet
the requirement of one day dosing in both the PTP.

COAGULANT DOSING SYSTEM

Chemical Name: FeCl3
Location: At Mixing Channel
Dosing Rate 15* ppm
Dosing Concentration 5 %
Required Dosing Pump Capacity 22.5 l/hr
Selected Dosing Pump Capacity 0 – 25 l/hr

Dosing Solution Requirement per stream 400 l/day

Selected Dosing Tank Capacity ( incl of dead

volume)
1200 L
Bulk Chemical Required 72 kg/day
Coagulant Dosing Tank 2 No. (1W+1S)
Tag No. 0-7150-DTK-1 / 2
Capacity 1200 L
MOC PP FRP
Type Vertical Cylindrical
Agitator for Dosing Tank
Quantity 2 No. (1W+1S)
MOC SS 316
Tag No. 0-7150-AG-1/2
Speed 100
Motor Rating 0.5 HP
Coagulant Dosing Pump 4 No. (2W+2S)
Capacity 0 – 25 LPH @ 30 m
MOC PP
Type Electronic Diaphragm

0-7150-DP-1, DP-2, DP-3,

Tag No. DP-27

POLY ELECTROLYTE DOSING SYSTEM

Chemical Name: Poly Electrolyte
Location: At Flocculator
Dosing Rate 2* ppm
Dosing Concentration 5 %
Required Dosing Pump Capacity 6 l/hr
Selected Dosing Pump Capacity 0 – 12 l/hr
Dosing Solution Requirement per stream 200 l/day
Selected Dosing Tank Capacity 450 L
Bulk Chemical Required 9.6 kg/day

Poly Electrolyte Dosing Tank 2 No. (1W+1S)

Tag No. 0-7150-DTK-3 / 4
Capacity 450 L
MOC PP FRP
Type Vertical Cylindrical
Agitator for Dosing Tank
Quantity 2 No. (1W+1S)
MOC SS 316
Tag No. 0-7150-AG-3/4
Speed 100
Motor Rating 0.5 HP
Poly Electrolyte Dosing Pump 4 No. (2W+2S)
Capacity 0 – 20 LPH @ 30 m
MOC PP
Type Electronic Diaphragm

0-7150-DP-4, DP-5,DP-6,
Tag No. DP-29

6.10 PRESSURE SAND FILTER:

Pressure Sand Filter vessel will be vertical and designed for surface flow rate <7.5 m3/m2/hr. The
Pressure sand Filter will be in mild steel construction with FRP lining from inside. Filter Feed pump
4 no. (2W+2S) have been provided on the upstream of the vessel. The turbidity at outlet of filter
will be below 2 NTU. Each pressure filter vessel has been provided with one manhole and one
hand hole. Sand bed has been designed to withstand the maximum pressure drop encountered
during the operation, without breakdown of filter media. Total depth of media and supporting media
will be 1.6 meter.
Each Filter vessel has been designed with 85% free board. Selected Filter sand will be hard
siliceous material free from carbonates and other foreign material. Filter media will be non-toxic
and will impart no color, odor or taste to the water. The supporting bed made of gravel will be
rounded material free from clay and limestone. The distribution and collection system of waste
water will be of corrosion resistant material. The inlet distribution system has been designed to
give uniform distribution of water over filter bed. The under drain collection system have been
designed for uniform collection of filtered water and distribution of back-wash water.
With the bottom collector of nozzle plate type provision have been made to attend to the internal
surfaces of bottom dished end. RO Stage-I concentrate will be used as Filter back wash water.
Tank has been located on roof of DM Plant where has been stored. It will not be by reversal of inlet
flow. Only one pressure filter shall be back-washed at a time and each pressure filter shall be
back-washed once a day.

DESCRIPTION DATA Unit

Design Flow: (Each Filter) 100* m 3/hr
Actual Flow: (Each Filter) 92* m 3/hr
Tag No. 0-7150-PSF-1 / 2
Surface flow rate: 7* m 3/hr/m2
Backwash flow rate: 22* m 3/hr/m2
Air Scouring rate: 40* Nm3/hr/m2
Filter Area: 14 m2
Filter Diameter: 4.2 M
Height of vessel: 3.0 M
Vessel MOC: MS FRP
Details of Filtering Medium of PSF
Type of Media: Quartz Sand
Type of Supporting Media: Gravel
Depth of Filter Media: 1200* Mm
Depth of supporting Media: 400 Mm
Particle Size of Sand: 0.6 -1.2 Mm
Uniformity Coefficient: 1.3 -1.7
Silica Content: More than 99.8%
Specific Gravity of Media: 2.55 – 2.65
Particle size of Gravel (Top/Bottom): 2-6 /6-12/25-40 Mm
Filter Feed Pump: 100* m 3/hr
Head: 35* M
Quantity: 4* No.(2W+2S)
Type Centrifugal pump
MOC: SS 316*
Tag No. 0-7150-P-5 / 6 / 7 / 8

Backwash Pump: 314 m 3/hr

Head: 25 M
Quantity: 3 No.(2W + 1S)
MOC: SS 316*
Tag No. 0-7150-P-9 / 10 / 11

Air Blower : 530 Nm3/hr

Head: 4 M
Quantity: 2* No.(1W + 1S)
Type: Twin Lobe*
MOC: Cast Iron*
Tag No. 0- 7150 – AB-1 / 2
Filter Back Wash Tank:
Quantity 1 No.(With 2 compartments)
Holding Capacity: To hold the water required for 2 backwash
Capacity: 250 m (Total 2 compartments)
 3
MOC RCC
Tag No. 0-7150-TK-7 / 8
Filtered Water Tank:
Quantity 4 No.
Each Tank Capacity 140 m (Each)
3
MOC RCC
Tag No. 0-7150-TK-3 / 4 / 5 / 6
Domestic Water Transfer Pump to OHT 40 m 3/hr
Head: 79 M
Quantity: 2 No.(1W + 1S)
MOC: SS 316*
Tag No. 0-7150-P- 3 / 4
Domestic Water Transfer Pump to Air washer 40 m 3/hr
Head: 47 M
Quantity: 2 No.(1W + 1S)
MOC: SS 316*
Tag No. 0-7150-P-1 / 2

Dm Water Feed Pump 64 M3/HR

Head: 40 M
Quantity: 4 No.(2W + 2S)
MOC: SS 316*
Tag No. 0-7160-P-6/7/8/9

6.26 SLUDGE DEWATERING SYSTEM:

The sludge from the clarifier/settler will be collected in sludge pit through piping with isolation
valve. This sludge will be discharged to plant drainage system by suitable transfer/pumping
system. The total water loss due to sludge blow down shall be limited to 5% of the total in flow to
clarifier unit.
The settled sludge in the clarifier has been collected in the common sludge pit having two (2)
tanks, each has been sized to take care of eight (8) days sludge storage and sludge will reach the
sludge drying bed from sludge pit by sludge disposal pumps (1W+1S). Overflow water from bed
will be collected in separate Tank (1W + 1S). Tank has been sized for 8 hours capacity. The waste
water from each Tank shall be pumped with one submersible Pump to nearest Plant Drain
Chamber (PDC).
Above system will be provided with all instruments to measure the raw water in flow and level in
storage tanks and Sludge Pit along with its interlocks with respective pumps. Dewatering systems
have been provided with approach roads and adequate space for movement of vehicles to
facilitate easy disposal of sludge cake collected.
Angle of inclination of sludge hopper will be minimum 55° to horizontal plane for effective collection
sludge. Sludge removal system shall be designed to thicken the sludge to minimum 2%
consistency before disposing from separator bottom. All the pipelines carrying the sludge shall be
provided with flushing connection.

SLUDGE DEWATERING SYSTEM

DESCRIPTION DATA Unit
SLUDGE PIT
Description Buffer tank prior to sludge drying bed.
Capacity 27 m3
Quantity: 2
MOC: RCC
Size: 3.0 m x 3.0 m x 3.0 m Partition
Tag No. 0-7160-SP-1/2
:SLUDGE DISPOSAL PUMP:
Type
Quantity 2 No.(1W+1S)
Capacity of each Pump 6 m3/hr
Head 25 m
MOC SS 316
Tag No. 0-7160-P-42/43
:SLUDGE DRYING BED:

Quantity: 2* No.
Holding Capacity: 8* days
Maximum Sludge Flow considered: 6 m 3/hr
Manual scrapping of dry sludge ( Standard

Type Practice)
Capacity: 828 m3
Dimension: 18.2m x 18.2m x 2.5m + FB:0.3m
Tag No. 0-7160-SDB-1/2