TECHNICAL SPECIFICATION FOR

WASTEWATER TREATMENT SYSTEM

PART 1: PACKAGE PLANT


CONTENTS

1 SCOPE 1

2 NORMATIVE REFERENCE 1

3 TERMS AND DEFINITIONS 1

4 FUNDAMENTAL REQUIREMENTS 3
4.1 Endorsement 3
4.2 Packaged Components of Package Plant 3
4.3 Arrangement of Tank 4
4.4 Flow Splitter and Distribution 4
4.5 Code and Model 4
4.6 Marking and Labelling 5
4.6.1 Prefabricated Tank 5
4.6.2 Inspection Cover 5
4.6.3 Permanence and Visibility 5

5 OPERATIONAL PERFORMANCE 5
5.1 Process 5
5.2 Civil and Structure 6
5.2.1 General 6
5.2.2 Foundation Work 6
5.2.3 Prefabricated Tank 6
5.2.3.1 Design Basis 6
5.2.3.2 Tank Integrity 7
5.2.3.3 Tank Strength 7
5.2.3.4 Watertightness 7
5.2.3.5 Partition Wall 7
5.2.3.6 J oints 8
5.2.4 Anchorage 8
5.2.5 Backfill Material 8
5.2.6 Retaining Wall 8
5.3 Design Service Life 8

6 PERFORMANCE CRITERIA 9
6.1 Unit Process 9
6.1.1 Effluent Weir 9
6.1.2 Sludge Treatment 9
6.1 Piping System 9
6.2.1 General 9
6.2.2 Inlet and Outlet Pipe 9
6.2.3 Air Pipe 9
6.2.4 Sludge Transfer Pipe 10
6.2.5 Effluent Pipe 10
6.3 Pumping System 10
6.3.1 Pump 10
6.3.2 Duct Foot, Transfer Pipe and Guide Rail 11
6.4 Air Lift System 11
6.5 Diffuser 11
6.6 Valve 11
6.7 Inspection Opening and Cover 11
6.8 Flow Distribution Chamber 13
6.9 Lifting Device 13
6.10 Control and Instrumentation 13






7 CONSTRUCTION OF PREFABRICATED TANK 13
7.1 Glass Fibre Reinforced Plastic (FRP) Tank 13
7.1.1 Design Basis 13
7.1.2 Material 13
7.1.3 Composition 13
7.1.4 Thickness 13
7.1.5 Surface Finish 14
7.1.6 Physical Properties 14
7.2 High Density Polyethylene (HDPE) Tank 14
7.2.1 Design Basis 14
7.2.2 Material 14
7.2.3 Composition 15
7.2.4 Thickness 15
7.2.5 Surface Finish 15
7.2.6 Physical Properties 15

7 DELIVERY AND INSTALLATION 15

9 TESTING AND CERTIFICATION 16
9.1 Type Testing 16
9.2 Process Performance Evaluation and Testing 16
9.3 Test Record 16

ANNEX

Annex A Normative Reference
Annex B External hydrostatic pressure
Annex C Internal pressure
Annex D Lateral loads for non-cylindrical shape tanks
Annex E Watertightness
Annex F Partition Wall
Annex G J oints
Annex H Thickness



LIST OF FIGURE

Figure 4.1 Scope of Biological Treatment System for Package Plant
Figure 4.2 Typical Concepts of Flow Splitter and Flow Distribution
Figure 4.3 Typical Marking and Labelling for Inspection Cover
Figure 6.1 Typical Pipe Support and Bracket
Figure 6.2 Typical Manhole Cover

LIST OF TABLE

Table 4.1 Maximum Numbers of Prefabricated Tanks for Package Plant
Table 4.2 Range of Model for Package Plant
Table 5.1 Minimum Design Service Life for Package Plant Components
Table 6.1 Material of Construction for the Valves
Table 6.2 Performance Requirements for Inspection Cover
Table 7.1 Physical Properties of Glass Fibre Reinforced Plastic Tanks at 27C 5C
Table 7.2 Physical Properties of High Density Polyethylene Tanks at 27C 5C
Table 9.1 Requirements of the Type Tests
Table 9.2 Criteria for Process Performance Evaluation and Testing of Package Plant

Part 1: Package Plant
1

STANDARD SPECIFICATION FOR WASTEWATER TREATMENT SYSTEM
Part 1: Package Plant


1 SCOPE

This Specification specifies operational performance requirements and performance criteria for
package plant used for the treatment of domestic wastewater for a population equivalent between 150
and 5000. The Specification specifies technical means of compliance and provides test specifications
to enable performance measurement of package plant.

The subjects in the Specification deal with the features of functional design, material, construction,
installation and testing that are a means of compliance with the operational performance requirements
of the package plant. The focus is made to the packaged biological treatment system comprising
prefabricated components of tanks, piping, aeration and pumping system, flow distribution and other
ancillary equipment, control and instrumentation.

The intended use of this Specification are to reveal a practise worthy of consideration in ensuring the
effective operational performance, reliability and durability of package plant to give the intended
results under normal operating conditions along its serviceable life. The requirements specified herein
are also to enable the testing agency to check the conformance of the package plant to the
Specification and to allow certification and accreditation in reference to the measurable components
of performance for quality assurance.

This Specification does not cover the design of treatment processes, mechanical and electrical
components and control and instrumentation. All these components shall be designed to best
engineering practice in compliance with the Guidelines and Standards recognised by the Commission,
bylaws, regulations and other regulatory agencies requirements relevant to the aspects.


2 NORMATIVE REFERENCE

The documents and publications that are indispensable and referred to for the application of this
Specification are listed in Annex A.


3 TERMS AND DEFINITIONS

For the purpose of this Specification, the terms and definitions given in MS 1228 and following apply:

3.1 Anchorage
A device or technique for holding the tank in the ground against hydrostatic uplift pressure

3.2 Assembly
Mechanical equipment that can be removed and replaced as a whole

Note: Example for an assembly is a pump, an air blower, a diffuser

3.3 Design Service Life
Operating time until breakdown of structural and machinery element under design loading, which is
reached by a certain percentage of the elements tested

Note: Design service life is different from both the warranty time and average service life of use, as used for cost
efficiency calculations.

3.4 Desludging
Removal of accumulated sludge from sludge holding tank

3.5 Extension
A structure used to bring the inspection cover to finished ground level
Part 1: Package Plant
2

3.6 Equipment
Any component which is installed in, mounted on, attached to, or operated on structures, in the
performance of their intended function

3.7 Inspection Opening
An opening in the top surface of the prefabricated tank fitted with a cover to allow access for visual
inspection of the interior of the tank and contents, removal of equipment and desludging, but not
intended to allow people to enter a tank

3.8 Laminate
For glass fibre manufacture, the set layer or layers of reinforcement impregnated with polyester or
other resin forming a thick structural membrane, excluding the gel-coat

3.9 Lateral Load
The load applied sideways onto a buried tank due to the combined effects of soil, water and traffic

3.10 Operational Performance
The functions that a system has to perform in order to operate as defined

3.11 Package Plant
A prefabricated factory-built sewage treatment installation

3.12 Partition Wall
An internal wall within a prefabricated tank

3.13 Performance Criteria
The qualitative or quantitative description of the operational performance

3.14 Production batch
A clearly identifiable collection of units, manufactured consecutively or continuously under the same
conditions, using material to the same specification

3.15 Sample
One or more units of product drawn from a batch, selected at random without regard to quality, the
number of units of product in the sample being the sample size.

3.16 Serviceable Life
The period of time in which with only normal and routine maintenance, the package plant and
associated fittings and equipment perform satisfactorily without failure

3.17 Structure
Any construction and its components built for the accommodation of equipment

3.18 Type testing
Testing, normally conducted by accredited laboratory performed to demonstrate that the material,
component, joint or assembly is capable of conforming to the requirements given in the Specifications

3.19 Unit Process
Any structure including any related equipment which is used as a process stage and which can be
isolated from other parallel, upstream or downstream structures

Note: Examples for a unit are a screen chamber, an aeration tank, a clarifier, a sludge holding tank.








Part 1: Package Plant
3

4 FUNDAMENTAL REQUIREMENTS

For package plant serving the population equivalent between 150 and 5000, the requirements in this
Specification shall be in addition to those specified in Malaysian Sewerage Industry Guideline (MSIG),
Vol. IV.

4.1 Endorsement

The calculations, engineering design and drawings of prefabricated packaged biological treatment
system of the package plant shall be duly endorsed by the manufacturer for each approved
application. The endorsement shall include the components of process, structural, hydraulic,
mechanical, electrical, control and instrumentation.

The Professional Engineers who are responsible in endorsing the calculations, engineering design
and drawings for the entire package plant covering inlet works, outlet works, packaged biological
treatment system and foundation shall ensure the installation and construction for all these
components at site conform to the design intent.

4.2 Packaged Components of Package Plant

The biological treatment system in which the scope extend 300 mm from the inlet pipe of first
prefabricated tank/ chamber to 300 mm from the outlet pipe of final prefabricated tank/ chamber as
shown in Figure 4.1 including:

a) inter tank piping;
b) air piping for aeration, mixing and air lift system;
c) pumping for sewage and sludge transfer;
d) mechanical equipment;
e) electrical, control and instrumentation components; and
f) concrete chamber constructed within this area

shall be packaged in terms of layout, arrangement, biological processes, piping system, pumping
system, aeration system, air lift system together with the size, type and numbers of mechanical
equipment, electrical, control and instrumentation components equipped in the systems. The
dimensions of each prefabricated tank shall be fixed.





















Figure 4.1 Scope of Biological Treatment System for Package Plant
Note: This layout shown is an indicative view of typical package plant for reference purposes
Legend:
Scope SHT Sludge holding tank FS Flow splitter
BT Balancing tank AET Aeration tank CL Clarifier
DC Distribution chamber AT Anoxic tank
FS
Blower
House
300 300


BT
CL
CL AET AT
SHT
AET AT
SHT Inlet
Works
DC
Outlet
Works
Part 1: Package Plant
4

4.3 Arrangement of Tank

Provided that it is proven in both process and hydraulic design, the prefabricated tanks in series
carrying out a complete process of a unit of process tank shall be considered as one (1) tank.

4.4 Flow Splitter and Distribution

As a mechanism to allow the diversion of flow, the flow splitter shall be provided in the flow system
distributing to maximum two (2) numbers of unit process tank and the flow distribution shall be
provided in the flow system distributing to maximum four (4) numbers of unit process tank.

Figure 4.2 shows the typical concept of flow splitter and flow distribution in package plant application.

























4.5 Code and Model

The coding requirements to name the model of package plant shall follow the sequence code of
identification with maximum characters as shown below.

AAA / BBB / 1234 / CCC Example: XXS/HKA/3000/CAS

where; AAA - Name of company
BBB - Brand / Model
1234 - Actual population equivalent of package plant
CCC - Type of treatment process

The model of package plant shall be limited to the range of population equivalents with minimum
intervals as shown in Table 4.2.

Table 4.2 Range of Model for Package Plant

Model Range Interval
150 P.E ~1000 P.E 50
1200 P.E ~3000 P.E 200
3500 P.E ~5000 P.E 500
CL
Figure 4.2 Typical Concepts of Flow Splitter and Flow Distribution
Flow Distribution
CL
2
1
CL
CL AET
3
AET
1
CL
4
AET CL AET
2
Flow Splitter
Stop
log
Stop
log
Part 1: Package Plant
5

4.6 Marking and Labelling

4.6.1 Prefabricated Tank

Each prefabricated tank shall be marked, as a minimum, with the following information:

a) Manufactures name or trademark.
b) Manufacturing serial number.
c) Manufacturing date (MM/YY).
d) Diameter and capacity.
e) Standard number.
f) Certification number.

4.6.2 Inspection Cover

Each inspection cover shall be properly marked and labelled as typically shown in Figure 4.3 with the
following information to ease identification of the unit process for the treatment system.

a) Model of the package plant.
b) Unit process for the tank.
c) Dimension of the tank (Length x Width x Diameter/ Height).
d) Standard number.
e) Certification number.

4.6.3 Permanence and Visibility

All marking and labelling shall be permanent, legible and clearly visible at time of installation. The
marking and labelling shall be stencilled, laminated or embossed to the tank.
















Figure 4.3 Typical Marking and Labelling for Inspection Cover



5 OPERATIONAL PERFORMANCE

5.1 Process

Under normal operating conditions of sewage treatment that receive medium concentration of
domestic raw sewage, the package plant shall be able to provide absolute Standard A effluent quality
according to Environmental Quality Act, 1979. The package plant shall also be capable:

Part 1: Package Plant
6

a) to encourage and provide sufficient amount of mixed liquor suspended growth (MLSS) in the
treatment system;
b) to provide minimum dissolved oxygen concentration of 2 mg/l to prevent oxygen diffusion
limitation from hindering substrate removal by the microorganism;
c) to provide sufficient mixing to keep the sludge in suspension without causing any settlement of
sludge in any part of the relevant unit process tanks, which require mixing;
d) to allow entry of wastewater with the minimum of disturbance to surface layers by maintaining
hydraulic flow and patterns throughout the treatment system without causing any increment in
surface loading and velocity current;
e) to provide good quality of sludge with normal settling characteristics indicated by sludge volume
index (SVI
30
) and sludge settled volume (SSV
30
) of the respective treatment system adopted;
f) to avoid likelihood of blockage in sewage and sludge transfer system within the package plant
boundary during its serviceable life.

5.2 Civil and Structure

5.2.1 General

The civil and structural components of package plant shall be designed by a relevant qualified
Professional Engineer, using appropriate design methodologies and relevant Standards to best
engineering practice.

The structures and construction of the package plant shall be:

a) stable to bear all loads during construction, operation and maintenance periods such as water
pressures, static and dynamic forces being induced by the equipment;
b) able to prevent the likelihood of damage from superimposed loads or normal ground movement;
c) resistant against chemical and biological attack from wastewater, sludge, air and gas components
and against temperature changes as appropriate;
d) able to retain the structural integrity including alignment, orientation and levelling and function
properly with only normal maintenance over their serviceable life.

5.2.2 Foundation Work

The foundation works for the installation of major and auxiliary components for the package plant shall
be designed and constructed so that component such as inspection chamber shall be secured to
avoid disruption to the operation and maintenance works and process of the system. The foundation
shall be able to prevent the possibility of sludge settlement, differential settlement between structures
and between structures and equipment such as pipeline.

5.2.3 Prefabricated Tank

5.2.3.1 Design Basis

The prefabricated tanks and its foundation shall be designed to achieve the required design service
life and long term structural integrity and shall meet the worst-case conditions not limiting to:

a) when the prefabricated tanks are fully emptied; and
b) during high groundwater conditions.

The construction and installation of the prefabricated tanks shall resist hydrostatic uplift pressures i.e.
uplift loads from groundwater and be protected against floatation in areas of high water table level or
when the tank is emptied. The bottom of an excavation for the prefabricated tanks shall provide a
uniform base to support the tanks in a level position.

Part 1: Package Plant
7

The structural design of a prefabricated tank shall consider all factors that can affect the strength and
integrity of the tank, like soil conditions and area of installation so that the entire structure of the
prefabricated tanks and its associated components are integrally sound. The resistance to load
incurred during transport and installation shall also be considered in the structural design of the tanks.

5.2.3.2 Tank Integrity

The integrity of the prefabricated tanks shall be such that no full penetration crack shall be developed
a width greater than 0.1 mm during any stage of production. Further widening or lengthening of any
crack shall not occur during subsequent handling, installation or use.

5.2.3.3 Tank Strength

All prefabricated tanks shall be structurally designed to withstand the maximum earth load equivalent
to an overburden depth of 1000 mm at maximum depth of cover of 1000 mm. The prefabricated tanks
shall be capable of withstanding loads imposed on its roof and walls i.e. top and lateral loads during
and after installation. Account shall be taken of any load imposed on the tank structure as a result of
the technique used to anchor the tank in the ground.

The following verification test methods shall be carried out to authenticate the strength of the
prefabricated tanks to withstand:

a) External hydrostatic pressure
When tested in accordance with Annex B, the prefabricated tanks shall not leak or fail of other
means after holding the external water pressure load equal to the tank diameter plus 1000 mm of
overburden depths for 24 hrs and additional superimposed negative internal pressure equal to the
depth of cover of 1000 mm times 9.78 kPa/m plus 18 kPa for 1 minutes.
b) Internal pressure
When tested in accordance with Annex C, the prefabricated tanks with a diameter 3000 mm or
less shall withstand pressure of up to 25 psig (172.5 kPa) and for prefabricated tanks with a
diameter greater than 3000 mm shall be able to withstand pressure of up to 15 psig (103.5 kPa).
c) Lateral loads for non-cylindrical shape tanks
When tested in accordance with Annex D, there shall be no structural failure, undue distortion or
in surface cracking in excess of that permitted in 5.2.3.2 due to external hydrostatic groundwater
and soil loading of 11 kPa/m depth acting on an empty tank.
d) Hydrostatic uplift
An installed prefabricated tank shall not move when subjected to uplift forces generated by
surrounding groundwater or be stressed to cause such cracks in excess of those in 5.2.3.2.
e) Impact Resistance
When tested in accordance with ASTM D3029, the internal tank wall surface for prefabricated
FRP and HDPE tanks shall withstand the impact of 0.36 kg (0.8 lb) steel ball at a distance equal
to the diameter of the tank above the tank bottom.

5.2.3.4 Watertightness

For cylindrical prefabricated tanks complete with attachments, when tested in accordance with Annex
E, tanks with 3000 mm diameter and less, shall not leak at pressure level of 5 psig (34.5 kPa) and
tanks greater than 3000 mm diameter, shall not leak at pressure level of 3 psig (20.7 kPa).

For other shape prefabricated tanks, when tested in accordance with Annex E, it shall have no
leakage and no damp patches.

5.2.3.5 Partition Wall

When a partition wall is used to divide the prefabricated tanks into different compartments,
assumptions regarding the arrangement of liquid loading shall cause the most critical effects such as:

a) Particular attention shall be paid to possible sliding and overturning due to differential moment;
Part 1: Package Plant
8

b) The partitions shall be structurally sound and fixed without diminishing the integrity of the tank;
c) The tank partition wall during pumping out shall not collapse, or permanently deformed. A
verification test shall be in accordance with Annex F.

5.2.3.6 Joints

The joints between fittings and the wall of prefabricated tanks and between tank components such as
the wall and lid, shall have a durable seal, be watertight, and have sufficient integral strength and
flexibility to maintain a sound structure. The verification test for joints around fittings shall be made in
accordance with Annex G.

5.2.4 Anchorage

The anchor system consist of straps, cables, turnbuckles and anchor hooks shall have strength of at
least 1.5 times the maximum uplift force of an empty tank without backfill in place. All the anchor
system components shall be made of Grade 304 stainless steel comply with ASTM A240/ A240M.

Details shall be provided by the prefabricated tank manufacturer with the installation instructions,
which shall show the recommended relationship between levels in the tank, groundwater levels
surrounding the tank, and anchorage requirements.

5.2.5 Backfill Material

The backfill material for the prefabricated tanks shall be of particle size and grading that allow the
specified relative compaction to be achieved with the intended compaction methods. The material
shall not contain organic material that affect the backfill material performance and free of materials
that be physically and chemically harmful to the tanks. The support and overlay material shall be
placed in layers of appropriate thickness for the method of compaction, to achieve the relative
compaction or soil modulus.

5.2.6 Retaining wall

The retaining wall shall be designed and checked accordingly by taking into account among others, all
possible factors involved contributing to the lateral earth pressure. The wall member shall also be
capable of meeting serviceability requirements at site condition.

5.3 Design Service Life

The minimum design service life against defects, deterioration and total failure of the components for
the package plant shall be as Table 5.1 below.

Table 5.1 Minimum Design Service Life for Package Plant Components

Component Standards Design Service Life
Prefabricated FRP tank
BS EN 4994, BS EN 13923 or
ASTM D4097
>50 years
Prefabricated HDPE tank AS/NZS 4766 or CSA B66-05
Civil and structure BS 8110-1 >50 years
Mechanical and electrical BS EN 12255-1 10 years
Control and instrumentation BS EN 12255-12 10 years
Corrosion resistance coating BS EN ISO 12944-1 to 8 10 years





Part 1: Package Plant
9

6 PERFORMANCE CRITERIA

6.1 Unit Process

6.1.1 Effluent Weir

The weir in sedimentation tank shall be accessible without causing obstruction and not posing any
health and safety issues. The weirs shall always be levelled for even distribution of flow. Slots in the
weir shall be provided to allow for level adjustment during the installation stage. Flow through over the
weir shall be calculated based on the actual type of weir used.

6.1.2 Sludge Treatment

The amount of wasted sludge, Q
waste
shall be used to size the sludge holding tank. The amount of the
wasted sludge in mass shall be balanced with the sludge accumulation rate in reference to the
computed sludge age.

An adequate air mixing mechanism and air supply shall be provided in the sludge holding tank to
ensure the sewage content is sufficiently mixed to keep it in suspension, without causing any
hardened sludge settled at the bottom of the tank between the desludging periods of 30 days.

The sludge treatment by anaerobic digester shall not be allowed as it require intensive health and
safety requirements and control system, which is not suitable for operation and maintenance of the
package plant within the serving population equivalent.

6.2 Piping System

6.2.1 General

The piping system for the package plant shall comply with the following criteria:

a) The arrangement of the piping system and interconnection pipes in the prefabricated tanks shall
not obstruct maintenance work of the equipment in the tanks;
b) All the buried piping shall be properly bedded and supported with the selected compacted fill
material;
c) All the above ground piping shall have a minimum distance of 75 mm from the ground level. It
shall be provided with a proper pipe support and bracket. The bracket shall be made steel coated
with hot dipped galvanised in compliance with BS EN ISO 12944. The typical pipe support and
bracket is shown in Figure 6.1;
d) The arrangement of the above ground piping shall minimise obstruction and maneuvrebility;
e) Any on-site installation or assemblies of pipe support that is attached to the prefabricated tank
shall not be allowed;
f) No bending is allowed at any sewage distribution pipe excluding the force main piping. Instead, a
chamber shall be provided to cater for any change of direction in sewage flow.

6.2.2 Inlet and Outlet Pipe

All openings for pipes connection of the prefabricated tanks shall be pre-fitted at the factory with a
socket, a spigot, a flange or a 300 mm length short piece of pipe. On-site drilling of openings for pipe
connection shall be prohibited.

6.2.3 Air Pipe

The air pipes that consist of air distribution pipes from blower, header pipes, drop leg/down pipes and
other pipes to convey the air for aeration, mixing or air lift purposes shall be:

a) able to withstand maximum air temperatures generated by the blower and pressures of 25% more
than the design pressure of the blower;
Part 1: Package Plant
10

b) painted in green with the air flow direction be painted in white at maximum interval of 3 m;
c) above ground for the air distribution pipes from the blower to the unit processes;
d) properly bracketed with Grade 304 stainless steel U-bolt in compliance with BS EN 10088-1:2005
for the down pipes to limit the movement of the diffusers;
e) designed to provide even and adequate air distribution to all relevant unit processes;
f) provided with instruments such as air gauge or pressure gauge for the pipes conveying air for
mixing and air lift purposes. The points to allow calibration shall be provided for the fixed
instrument, while points to allow measurement shall be provided for the portable instrument;

6.2.4 Sludge Transfer Pipe

All jointing to connect the sludge transfer pipes shall be double flange with Grade 304 stainless steel
bolts and nuts in compliance with ISO 3506-1 to ISO 3506-3. No thread union or coupling shall be
allowed in any jointing part of the pipes.

6.2.5 Effluent Pipe

The effluent discharge piping system that passes through or by-passes the disinfection treatment
facility shall be designed so as not to cause any nuisance.

The invert level of the effluent pipe shall be at a minimum of 300 mm from the top water level of the
receiving watercourse.






















6.3 Pumping System

6.3.1 Pump

The minimum control mechanism for the pumps installed within the package plant shall be:

a) automatic by float switch for sewage transfer pump;
b) automatic by timer and interlock with solenoid valve for return and waste sludge pump in
sedimentation tank;
c) manual by push button for sludge transfer pump to remove the sludge from sludge holding tank.

Non-submersible pumps shall be provided with parking bay with shade.

NOTES :-
1. ALL DIMENSIONS ARE IN MILIMETERS UNLESS OTHERWISE STATED.
10mm (MIN.) HOT DIP
GALVANISED BOLTS AND NUTS
HOT DIPPED GALVANISED PIPE
BRACKET AT AN INTERVAL OF
2000mm C/C (MAX.)
CONCRETE
SLAB
PIPE
GL
75
(MIN.)
(
M
I
N
.
)
7
5
(
M
I
N
.
)
GL
(
M
I
N
.
)
SAND BEDDING
5
0
5
0
Figure 6.1 Typical Pipe Support and Bracket
Part 1: Package Plant
11

6.3.2 Duck Foot, Transfer Pipe and Guide Rail

All pumps shall be completely installed with duck foot, guide rail and lifting chain comply with the
following requirements:

a) The duct foot shall be installed and assembled at the factory. No installation or assemblies at site
shall be allowed except for the connection of the transfer pipe and the guide rail;
b) The guide rail shall be properly bracketed with U-bolt to secure the movement of the pump;
c) All fasteners of the duct foot shall be watertight;
d) The guide rail, lifting chain and U-bolt bracket shall be made of Grade 304 stainless steel in
compliance with BS EN 10088-1.

6.4 Air Lift System

The solenoid valves shall be provided for intermittent air lift system for both return and waste sludge
and scum skimmer.

6.5 Diffuser

All diffusers shall be supported from the tank base and shall not be bolted to the bottom of the tank.
The diffusers shall be removable and easy to re-install onto the diffuser support.

The support for the diffusers shall be made of non-corrosive material and shall be designed to suit the
application. The support shall be capable to prevent buoyancy of the diffuser.

6.6 Valve

All valves shall be accessible and not obstruct maintenance work. The valves of 100 mm diameter
and above shall be installed in the inspection chamber.

Selection of materials to be used in the construction of body and seal of the valves shall be in
accordance with the application in order to optimize functional reliability, fluid compatibility,
serviceable life and cost. The material of the valve shall comply with requirements in Table 6.1 below.

Table 6.1 Material of Construction for the Valves

Type of
Valve
Standards
Material of Construction
Body Parts in contact with sewage
Solenoid
Valve
-
Brass and bronze. Polyamide
materials for plastic valves.
Austenitic corrosion-resistant steel
Gate Valve BS 5150 Ductile Iron Austenitic corrosion-resistant steel
Check Valve BS EN 12334 Ductile Iron Austenitic corrosion-resistant steel

6.7 Inspection Opening and Cover

The design and arrangement of the inspection cover in reference to the inspection openings shall be
consistent with the operational requirements of the package plant. The inspection cover shall be
installed at any location on top of the tank except at assembly joints, rib or reinforced ring location.

The inspection cover shall have a size of 600 mm x 600 mm or 600 mm diameter and shall be
equipped with a frame support together with hinge and handle made of Grade 304 stainless steel. For
inspection opening bigger than the size of inspection cover, bracing to support the cover made of
Grade 304 stainless steel shall be provided. All stainless steel Grade 304 shall comply with BS EN
10088-1.

Part 1: Package Plant
12

Y
Y
Y
Y
AAA/BBB/1234/CC
B
A
LA
N
C
IN
G
TA
N
K
X
X
6
0
0
600
6
0
0
X
X
NOTES :-
1. ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED.
STAINLESS STEEL HINGE
30mmFONT SIZE
AAA/BBB/1234/CC
BALANCING TANK
3.0(L)X3.5(W)X3.2(D)
GFRP/HDPE/CI MANHOLE COVER
STAINLESS STEEL HANDLE
STAINLESS STEEL HINGE
GFRP/HDPE/CI MANHOLE COVER
PREFABRICATED TANK GL
6 x 100 (min.)
STAILESS
STEEL HINGE
GFRP/HDPE/CI
MANHOLE COVER
PREFABRICATED
TANK
GL
STAINLESS STEEL
HINGE
30mmFONT SIZE
AAA/BBB/1234/CC
BALANCING TANK
3.0(L)X3.5(W)X3.2(D)
GFRP/HDPE/CI MANHOLE COVER
STAINLESS STEEL HANDLE
STIFFENER
600
50
PLAN
PLAN
SECTION Y-Y
SECTION X-X
The inspection covers shall be securely fitted and attached to the opening and shall have the
mechanism preventing it from being accidentally shut. The collar of the opening to place the
inspection covers shall be raised to a minimum height of 150 mm above ground level. The typical
inspection cover is shown in Figure 6.2.







150 (min)
150 (min)


























Figure 6.2 Typical Manhole Cover

The inspection cover shall provide an effective, durable and watertight seal and be able to withstand
superimposed loads at operating temperature of 27C to 35C with incorporation of thermal expansion
and contraction complying with the requirements as shown in Table 6.2 below.

Table 6.2 Performance Requirements for Inspection Cover

Parameter Standards Performance Requirements
Load Bearing Capacity BS EN 12255-1 3.5 kN/m
2

Maximum Deflection Limit BS EN 12255-1
10 mm or the span divided by 200,
whichever is smaller
Class BS EN 124 B 125
Personnel Load BS EN 124 125 kN for fully walk-able load
Design Safety Factor ANSI/ASCE 7-98
4:1 for allowable stresses shall be
met for all load combinations

Part 1: Package Plant
13

The inspection cover shall be sufficiently protected during its serviceable life, which similar to the
prefabricated tanks against degradation due to exposure to UV light and corrosion due to exposure to
corrosive sewage environment.

6.8 Flow Distribution Chamber

The design and construction of the flow distribution chamber shall prevent any sedimentation. The
adjustable features shall be provided within the flow distribution chamber and shall be constructed
using one of the following material:

a) Reinforced concrete with a minimum of Grade C30 in compliance with BS 8007;
b) FRP with minimum thickness of 5.0 0.5 mm in compliance with BS EN 4994, BS EN 13923 or
ASTM D4097;
c) Steel plate coated with hot dipped galvanised of 140 m or high build tar epoxy coating of 200 m
minimum dry film thickness. The steel plate and the coating shall comply with the requirements in
EN 10163-2 and BS EN ISO 12944-1 to BS EN ISO 12944-8 respectively;
d) Stainless steel of minimum Grade 304 in compliance with BS EN 10088-1;
e) Any other material that is approved by the Regulator to be used for this purpose.

6.9 Lifting Device

The lifting device shall be installed so that to avoid direct loading to the structure of the prefabricated
tanks. Where fixed lifting device is provided, it shall be supported by the spread footing to ensure
even distribution of loads exerted by the weight of the devices.

6.10 Control and Instrumentation

The necessary measuring and control equipment shall be specified taking into account the installation
conditions. This applies both to its location within the package plant and to the layout and size of the
structures as a function of the type of equipment in compliance with BS EN 12255-12.


7 CONSTRUCTION OF PREFABRICATED TANK

7.1 Glass Fibre Reinforced Plastic (FRP) Tank

7.1.1 Design Basis

The seams and openings of the glass fibre reinforced plastic tanks shall be designed in accordance
with BS EN 4994, BS EN 13923 or ASTM D4097. The tanks shall be able to operate under the
temperature of 17C to +50C.

7.1.2 Materials

The resin shall be unsaturated thermosetting polyester or epoxy resin that has minimum heat
distortion temperature of 65C when tested in accordance with ISO 75-2. The resin shall contain not
less than 50% w/w, by mass of non-volatile materials, no pigment or fillers and not more than 2% w/w
of thixotropic agents.

The glass fibre, which used as the reinforcing material shall be suitable grade of glass fibre having a
glass finish compatible with the resin used and complying with BS 3396.3, BS 3749, BS EN 14020-3
and BS EN 14118-3, as appropriate. The C-glass of fibre shall be added for corrosion protection.

7.1.3 Composition

The laminate shall contain not less than 30% w/w of glass fibre content. No fillers or pigments shall be
included in the laminate. Any parts or surfaces that are exposed to the sun shall be constructed with
ultraviolet-light inhibitors added to the laminate.
Part 1: Package Plant
14

7.1.4 Thickness

The minimum cylindrical wall and end panel thickness for cylindrical tanks shall be 8.0 0.5 mm. For
differentially shaped of tank, the minimum thickness of the structural tank wall shall be 8.0 0.5 mm.

The thickness of the partition wall and all other internal components shall be at least 5.0 0.5 mm. A
verification test shall be in accordance with Annex H.

7.1.5 Surface Finish

The exterior surface shall be relatively smooth with no sharp projections and be free of blisters larger
than 15 mm in diameter, delaminating, and fibre show.

The interior surface shall be resin rich with no exposed fibres. The surface shall be free of crazing,
delamination, blisters and wrinkles of 3.5 mm or greater in depth.

7.1.6 Physical Properties

In addition to the tests specified in 5.2.2, the following type test to verify the physical properties of the
glass fibre reinforced plastic tanks at 27C 5C shall be carried out using test specimens prepared in
accordance with ISO 1268-4.

Table 7.1 Physical Properties of Glass Fibre Reinforced Plastic Tanks at 27C 5C

Criteria Physical Properties Testing Standards
Flexural Strength 110 MPa ISO 14125
Modulus of Elasticity 4830 MPa ISO 14125
Impact Resistance

No surface cracks visible to normal
or corrected normal vision
ISO 179-2

Barcol Hardness 35 BS EN 13923
Water Absorption 0.75% ISO 62
Glass Fibre Content 30% w/w ISO 1172
Tensile Strength 65 MPa ISO 527-4
Tensile Elongation 1.5%. ISO 527-4
Tensile Modulus 7000 MPa ISO 527-4
Specific Gravity 1.5 ISO 62
Fire Rating

<25s ASTM E84
Class 1 BS476

7.2 High Density Polyethylene (HDPE) Tank

7.2.1 Design Basis

The seams and openings of the high density polyethylene tanks shall be designed in accordance with
AS/NZS 4766 or CSA B66-05.

7.2.2 Materials

The polymer resin used shall be a minimum of PE 80 with density 940 kg/m
3
970 kg/m
3
in the form
of powders, granules or pellets with no more than 10% of recycled materials. The materials shall be
as uniform in composition and size and as free of contamination.

Part 1: Package Plant
15

7.2.3 Composition

The carbon black or titanium dioxide shall be added to the polymer resin as UV stabiliser and shall
contain 2.5% 0.5% by mass with dispersion of not more than Grade 3 and toluene extract of not
more than 0.10% m/m.

7.2.4 Thickness

The minimum thickness of the tank walls, partition wall, other internal components, base and access
opening covers shall be 6.0 0.5 mm. A verification test shall be in accordance with Annex H.

7.2.5 Surface Finish

The exterior surface shall be ribbed, relatively smooth and impervious to liquid.

The interior surface shall be smooth and of even texture. The surface shall be free from surface
imperfections, which detract from the performance of the tank in use.

7.2.6 Physical Properties

In addition to the tests specified in 5.2.2, the following type test to verify the physical properties of the
high density polyethylene tanks at 27C 5C. The test specimens prepared shall reflect the
manufacturing process and typical cross section of the tank. The specimens shall be manufactured at
the same time as the tanks produced for installation.

Table 7.2 Physical Properties of High Density Polyethylene Tanks at 27C 5C

Criteria Physical Properties Testing Standards
Flexural Modulus 640 MPa to 1200 MPa ISO 178
Charpy Impact 45 KI ISO 179
Shore Hardness 62 ISO 868
Tensile Strength 17 to 28 MPa ISO 527-4
Tensile Elongation 200% ISO 527-4
Tensile Stress at Yield 23 MPa ISO 527-4
Tensile Modulus 22 MPa ISO 527-4
Vicat Softening Temperature 80 C ISO 306
Melt Index 0.58 ISO 306
Thermal Conductivity 0.4 W/mC ASTM E1225


8 DELIVERY AND INSTALLATION

The manufacturer/supplier shall properly plan the delivery route so as not to cause any damage to
road facilities and harm to road users.

The package plant shall be installed and constructed under the supervision of a Qualified Person and
in accordance with detail plans approved by the Commission or other relevant regulations authority.
An inventory list of every item to be installed shall be provided and to be checked against the
approved construction drawings. The list shall be endorsed by the Qualified Person.

No fabrication or moulding of any part of the prefabricated tanks and pipe holes drilling shall be
allowed at the site. All jointing and pipe holes connection shall be factory fabricated and moulded.


Part 1: Package Plant
16

9 TESTING AND CERTIFICATION

9.1 Type Testing

Table 9.1 sets out the requirements for the type testing, which the validity period for the test report
shall be limited to five (5) years. Where there is any change in design that affects the particular
performance or requirement or any change in process or material, the type testing shall be conducted
not governing by the validity period of the test report.

In the event of a test failure, further product within the batch of production shall be tested. If the first
two randomly selected additional tanks meet the requirements, the batch shall be deemed to meet the
test requirements. If one of the additional tanks fail, the batch shall be rejected or every tank
subjected to the relevant test.

The product certification for package plant shall be carried out to provide independent assurance of
the claim by the manufacturer that the package plant complies with this Specification and consistently
conform to the requirements of this Specification. The certification shall meet the criteria described in
ISO/ IEC Guide 28, and full type testing from independently sampled production and subsequent
verification of conformance.

9.2 Process Performance Evaluation and Testing

The process performance evaluation and testing shall be mandatory for all package plants. A
minimum of three (3) assessments at different day shall be conducted for a package plant that has
been installed for more than two (2) years. All tests and samplings for the performance evaluation and
testing shall be carried out by an accredited laboratory with the verification from the operator on the
data and sampling collected. Table 9.2 showed the criteria for the evaluation and testing.

The number of package plants to be sampled shall be calculated based on the 5% installed units on
all ranges of models and for package plants installed with less than 20 units, the performance of
minimum three (3) installed units shall be evaluated and tested. Report on the overall status of the
installed units shall be reported on a yearly basis to the Commission.

9.3 Test Record

The report shall include, not limiting to the following information for each test specimen:

a) Identification of person and organisation carrying out the test;
b) Identification of the sample tested;
c) Date of test;
d) The test result; and
e) Reference to the test method.
















Part 1: Package Plant
17

Table 9.1 Requirements of the Type Tests

Characteristics
Performance
Requirements and
Criteria Clause
Requirements Test Method
Design and construction
Hydraulic performance
5.2.3.7 J oints Annex G
5.2.3.6 Partitions Annex F
5.2.3.5 Watertightness Annex E
6.2.2 Inlet and outlet pipe Design review
6.7
Inspection opening and
cover
Design review
4.3 Dimension of tank Design review
Structural integrity
5.2.3.3 (a) External hydrostatic pressure Annex B
5.2.3.3 (b) Internal pressure Annex C
5.2.3.3 (e) Hydrostatic uplift Design review
5.2.3.3 (c) Lateral load Annex D
5.2.3.3 (f) Impact resistance ASTM D3029
Marking 4.7 Marking and labelling Design review
Materials and Manufacture
Glass fibre reinforced
plastic tank
7.1.2 Material Evidence by way
of appropriate
manufacturer
documentation of
approvals or tests
7.1.3 Composition
7.1.4 Surface finish
7.1.5 Thickness Annex H
7.1.6 Physical properties 7.1.6
High density
polyethylene tank
7.2.2 Material
Evidence by way
of appropriate
manufacturer
documentation of
approvals or tests
7.2.3 Composition
7.2.4 Surface finish
7.2.5 Thickness Annex H
7.2.6 Physical properties 7.2.6















Part 1: Package Plant
18

Table 9.2 Criteria for Process Performance Evaluation and Testing of Package Plant

Criteria Description
Standard Reference
for Testing Method
Results
Date/ Time
Weatherbility
Condition of Plant
Status of mechanical
equipment

Current flow/capacity
Flow condition
Influent characteristics
BOD
5
APHA 5210-B
COD APHA 5220-C
TSS APHA 2540-D
Oil and Grease APHA 5520-B
pH APHA 4500 H
+
-B
Ammonical Nitrogen APHA 4500-NH
3
E
Aeration tank characteristics
MLSS APHA 2540-D
Dissolved Oxygen APHA 4500 O-G
Sludge Settleability (SSV
30
) APHA 2710 C
Sludge Volume Index (SVI
30
) APHA 2710 D
Sludge settlement Sludge judge
pH APHA 4500 H
+
-B
Temperature APHA 2550 B
Clarifier characteristics
Sludge Blanket Sludge judge
Effluent characteristics
BOD
5
APHA 5210-B
COD APHA 5220-C
TSS APHA 2540-D
Oil and Grease APHA 5520-B
pH APHA 4500 H
+
-B
Ammonical Nitrogen APHA 4500-NH
3
E
Total Kjedahl Nitrogen APHA 4500N
org
B


Part 1: Package Plant
19

ANNEX A

NORMATIVE REFERENCE


AS 3750.2 Paints for steel structure-ultra high-build paint
AS/NZS 1546.1 On-site domestic wastewater treatment units Part 1: Septic Tank
AS/NZS 1546.2 On-site domestic wastewater treatment units Part 3: Aerated wastewater
treatment systems
AS/NZS 4766 Polyethylene storage tanks for water and chemicals

ISO 62 Plastics Determination of water absorption
ISO 75-2 Plastics Determination of temperature of deflection under load Plastics and
ebonite
ISO 75-3 Plastics Determination of temperature of deflection under load High strength
thermosetting laminates and long fibre reinforced plastics
ISO 179-1 Plastics Determination of Charpy impact properties Non-instrumented impact
test
ISO 179-2 Plastics Determination of Charpy impact properties Instrumented impact test
ISO 306 Plastics Thermoplastic materials Determination of Vicat softening
temperature
ISO 868 Plastics and ebonite Determination of indentation hardness by means of a
durometer (Shore hardness)
ISO 3506-1 Mechanical properties of corrosion resistant stainless steel fasteners Part 1:
Bolts, screw and studs
ISO 3506-2 Mechanical properties of corrosion resistant stainless steel fasteners Part 2:
Nuts
ISO 3506-3 Mechanical properties of corrosion resistant stainless steel fasteners Part 3:
Set screws and similar fasteners not under tensile stress
ISO 527-1 Plastics Determination of tensile properties General principles
ISO 527-2 Plastics Determination of tensile properties Test conditions for moulding and
extrusion plastics
ISO 527-4 Plastics Determination of tensile properties Test conditions for isotropic and
orthotropic fibre reinforced plastics composite
ISO 14125 Fibre reinforced plastics composites Determination of flexural properties
ISO/IEC GUIDE 7 Guidelines for drafting of standards suitable for use for conformity assessment

ASTM A240/A240M Standard specification for chromium and chromium-nickel stainless steel plate,
sheet and strip for pressure vessels and for general applications
ASTM D3029 Test method for impact resistance of flat, rigid plastic specimens by means of a
tup (falling weight)
ASTM D4097 Standard specification for contact moulded glass fibre reinforced thermoset resin
corrosion resistant tanks
ASTM E84 Standard test method for surface burning characteristics of building materials
ASTM E1225 Standard test method for thermal conductivity of solids by means of the
guarded-comparative-longitudinal heat flow technique

BS EN ISO 1461 Hot dipped galvanised coatings on fabricated iron and steel articles.
Specifications and test methods.
BS EN 12334 Industrial valves Cast iron check valves
BS EN ISO 12944-1 Paints and varnishes. Corrosion protection of steel structures by protective paint
systems. General introduction.

BS EN 124 Gully tops and manhole tops for vehicular and pedestrian areas Design
requirements, type testing, marking, quality control
BS 4994 Specification for design and construction of vessels and tanks in reinforced
plastics
BS 5150 British Standard Specification for cast iron gate valve
BS 8007 Code of practice for design of concrete structures for retaining aqueous liquids
BS 8110-1 Structural use of concrete. Code of practise for design and construction
Part 1: Package Plant
20

BS EN 10088-1 Stainless steels. List of stainless steels
BS EN 10088-2 Stainless steels. Technical delivery conditions for sheet/plate and strip of
corrosion resisting steels for general purposes.
BS EN 12255-1 Wastewater Treatment Plants Part 1: General construction principles
BS EN 12255-11 Wastewater Treatment Plants Part 11: General data required
BS EN 12255-12 Wastewater Treatment Plants Part 12: Control and automation
BS EN 13923 Filament wound FRP pressure vessels. Materials, design, manufacturing and
testing

ANSI/ASCE 7-98 Minimum Design Loads for Buildings and Other Structures

CSA B66-05 Design, material and manufacturing requirements for prefabricated septic tanks
and sewage holding tanks


Part 1: Package Plant
21

ANNEX B

DETERMINATION OF EXTERNAL HYDROSTATIC PRESSURE (EXTERNAL PRESSURE TEST
AND INTERNAL VACUUM TEST)

(Normative)

B1 SCOPE

This Annex outlines a method of testing external hydrostatic pressure for a unit of prefabricated tank.

B2 PRINCIPLE

The tank is subjected to external hydrostatic pressure and is then examined for signs of leakage.

Test tanks of each diameter used. If tanks with equal diameter, but of different lengths, testing of the
longest tank shall confirm performance of shorter lengths provided that the wall thickness is constant.
If wall thickness is varies with length, test each tank to prove conformance.

B3 TESTING

B3.1 Test Conditions for External Pressure Test

a) Install the empty tank in a test pit using the specified anchoring system and the specified
overburden depth and cover to comply with clause 5.2.3.3 (a);
b) Fill the pit with water to such a level that the tank is submerged to its maximum specified
overburden depth and cover;
c) Allow the tank to remain submerged for 24 hours;
d) While the tank is still submerged, it is to be subjected for 1 minute to a partial internal vacuum so
that the internal pressure on the tank is 29 kPa less than the external pressure imposed by the
hydrostatic head.

B3.2 Test Conditions for Internal Vacuum Test

a) Seal the empty tank and apply an internal vacuum calculated as per given in equation B1 below.
V =(1/2 D +h) x 0.88 inches Hg/ft (B1)
where; V is the vacuum in inches Hg,
D is the tank diameter in feet, and
h is the maximum specified cover depth in feet, but not less than 3 feet.
b) Hold the vacuum for 60 5 min and check for damage to the tank.

B4 TEST CRITERIA

Under external pressure test, the test tank shall not implode or otherwise be damaged.

Under internal vacuum test, each tank must withstand without rupture, an internal partial vacuum
according to the equation.
Part 1: Package Plant
22

ANNEX C

DETERMINATION OF INTERNAL PRESSURE (INTERNAL PRESSURE TEST)

(Normative)

C1 SCOPE

This Annex outlines a method of testing internal pressure for a unit of prefabricated tank.

C2 PRINCIPLE

The tank is subjected to internal pressure and is then examined for signs of leakage.

Test tanks of each diameter used. If tanks with equal diameter, but of different lengths, testing of the
longest tank shall confirm performance of shorter lengths provided that the wall thickness is constant.
If wall thickness is varies with length, test each tank to prove conformance.

C3 TESTING

The procedure shall be as follows:

a) Test each size of tank to the required pressure level; 25 psig (172.5 kPa) for the prefabricated
tanks with a diameter 3000 mm or less and 15 psig (103.5 kPa) for prefabricated tanks with a
diameter greater than 3000 mm;
b) Allow the tank to hold the pressure for a period of 1 min;
c) Run the test using a pressure gage graduated in increments of 1 psig (6.9kpa) or less.

C4 TEST CRITERIA

Failure to hold the required pressure as given in 5.2.3.3 (b) with 10% drops allowed for pressure
settlement is indication of failure.
Part 1: Package Plant
23

ANNEX D

DETERMINATION OF RESISTANCE TO LATERAL LOAD (HYDRAULIC TEST)

(Normative)

D1 SCOPE

This Annex outlines a method for testing the resistance of a non-cylindrical prefabricated tank to an
applied lateral load.

D2 PRINCIPLE

The lateral (side loading) forces on a tank due to soil in a fully or partially saturated state, together
with any incidental additional loading due to the presence of earth-moving equipment adjacent to the
tank wall may be represented by a circumferential load applied to the wall of the tank. These forces
equate approximately to the forces applied to an empty tank held submerged in water.

The test method requires that forces due to any anchorage technique normally used with the
prefabricated tank are simulated during the test.

D3 TESTING

The test procedure shall be as follow:

a) Install the empty tank in the test pit and restrain it as necessary. If it is necessary to reproduce
anchorage compression, weights shall be placed on the upper rim of the tank. Holding down the
tank in a manner that does not provide any lateral stability to the tank in excess of that provided
by the lid, when installed;
b) Fill the outer container with water up to the designed burial depth, including risers, of the test tank;
c) Maintain the tank under test for a minimum of 7 days.

D4 TEST CRITERIA

Inspection shall show that there have been no leaks and that the integrity of the tank has no
permanent damage. Inspection shall show that the deflection measured in the tank wall does not
exceed the wall thickness at that point.
Part 1: Package Plant
24

ANNEX E

DETERMINATION OF WATERTIGHTNESS (LEAKAGE TEST)

(Normative)

E1 SCOPE

This Annex outlines a method of testing the watertightness of unit of prefabricated tanks.

E2 PRINCIPLE

The tank is subjected to a hydrostatic pressure head and is then examined for signs of leakage.

E3 TESTING

E3.1 Test Conditions for Pneumatic Testing (Cylindrical Tank)

The tank undergoes an aerostatic test at the required pressure level above ground without special
support, using a pressure gauge graduated in 0.25 psig (1.75 kPa) increments or less.

The procedure shall be as follows:

a) While the tank holding the required internal pressure level as given in 5.2.3.3 (b), coat the entire
tank with a liquid composed of water and leak test fluid or detergent;
b) After coating, check the tank visually for leaks, giving special attention to tank openings.

The pressure may drop in this test as the tank makes a temperature adjustment. Do not start the
leakage test until the pressure settles and the tank holds the pressure. Make adjustments to the tank
pressure to maintain the required pressure during this settling period of 24 hours.

E3.2 Test Conditions for Hydrostatic Testing (Non-cylindrical Tank)

Tanks that can be stood in position without the need of support shall be placed on at least three
bearing blocks. Tanks that need support in order to remain in position shall be placed on timber
bearers and held in place with chocks. Horizontal tanks shall be supported sufficiently so as to
counter any bending and induced tension.

For the test, an elbow is plumbed into the outlet (temporarily). Start the test with the water level at a
mark about 50 mm up vertical. Measure the water needed to top tank up to that same sight mark.

The procedure shall be as follows:

c) Level the tank on the supports;
d) Fill the tank with water to the invert of the outlet pipe;
e) Allow to stand for a minimum of 4 hours;
f) Top up with water and start test observation; and
g) Observe for any leakage and count the drops per minute from any single point.

E4 TEST CRITERIA

For cylindrical tanks complete with attachments for 3000 mm diameter and less, it shall not leak at
pressure level of 5 psig (34.5 kPa) and for tanks greater than 3000 mm diameter, it shall not leak at
pressure level of 3 psig (20.7 kPa).

For non-cylindrical tanks it shall have no leakage and no damp patches for both FRP and HDPE tank.
Part 1: Package Plant
25

ANNEX F

DETERMINATION OF THE RESISTANCE OF A PARTITION TO A HYDROSTATIC HEAD
(PUMP OUT TEST)

(Normative)

F1 SCOPE

This Annex outlines a method for testing the resistance of a tank partition to the effects of pumping
out fluid from one side of the partition.

F2 PRINCIPLES

With the fluid is removed from one side of a partitioned tank during pump-out, the partition may be
subjected to a hydrostatic pressure head. This test reproduces those conditions and then checks for
any signs of weaknesses or failure of the partition.

F3 TESTING

The test procedure shall be as follows:

a) Fill the tank with water up to the top of the partition or to the level of any hole through it;
b) Pump out water from one side of the partition. If the partition is situated so that there is a greater
quantity / head of water on one side as compared to the other, the water shall be pumped out
from the side that has the least quantity / head;
c) Observe the reaction of the partition to the effect of the pump out process, and over a period of at
least 1 hour.

F4 TEST CRITERIA

The water in the tank shall be able to be pumped out without the partition collapsing or permanently
deforming.
Part 1: Package Plant
26

ANNEX G

DETERMINATION OF THE INSTALLATION OF FITTINGS IN A SOUND AND WATERTIGHT
MANNER

(Normative)

G1 SCOPE

This Annex outlines a method for testing for the installation of fittings in a sound and watertight
manner, whether the fittings are installed in the factory or on-site.

G2 PRINCIPLES

The fittings in a tank are subjected to a low hydrostatic pressure from inside the tank.

It is assumed that a fitting installation that is watertight in this situation will also be watertight against
water ingress to the tank through the filltings.

G3 TESTING

Tanks that can be stood in position without the need of support shall be placed on at least three
bearing blocks. Tanks that need support in order to remain in position shall be placed on timber
bearers and held in place with chocks. Horizontal tanks shall be supported sufficiently so as to
counter any bending and induced tension.

For the test, an elbow is plumbed into the outlet (temporarily). Start the test with the water level at a
mark about 50 mm up vertical. Measure the water needed to top tank up to that same sight mark.

The test procedure shall be as follows:

a) Install fittings in accordance with the manufacturers instruction;
b) Seal openings in the fittings to allow water to build up behind the fitting during the test;
c) Fill the tank with water to the rim;
d) Allow the tank to stand for at least ten minutes;
e) Observe the tank and fittings for any leakage.

G4 TEST CRITERIA

As for FRP and HDPE tanks it shall have no leakage and no damp patches.
Part 1: Package Plant
27

ANNEX H

DETERMINATION OF THICKNESS (THICKNESS TEST)

(Normative)

H1 SCOPE

This Annex outlines a method for testing the thickness of structural tanks wall, end panel, partition
wall and internal components for finish product of prefabricated tank.

H2 PRINCIPLES

The tanks are subjected to non-uniform thickness during the manufacturing process and are then
examined to ensure that each part complies with the required minimum thickness.

H3 TESTING

The minimum required wall thickness of the cylindrical tank shell at any fluid level shall be determined
by using a Fisher Scope. Vernier Calliper is use when testing the thickness of specimens which are
cut out from the shell.

The testing procedure shall be carried out by measuring the thickness at certain parts the determining
components of structural tanks wall, end panel, partition wall and internal components.

H4 TEST CRITERIA

The thickness of all parts measured shall comply with the minimum thickness specified in 7.1.5 and
7.2.5.