Professional Documents
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A. Drawing Approved.
B. Drawing Approved with Comments. Proceed with Fabrication/
Construction Considering Comments.
H. Information furnished on the drawing is noted and the document/
drawing is retained for our records
Signature: Initials : MV
DESIGN DIVISION
WOG Technologies Pte. Ltd.
#13-01, City House, House No. 36,
Robinson Road, Singapore - 068877
Ph : +65-82682912, 65-66965990
Fax : +65-81458050
E-mail: info@woggroup.com
Web: www.woggroup.com
TABLE OF CONTENTS
5. PROCESS DESCRIPTION........................................................................................................................... 7
11. ELECTRICALS............................................................................................................................................ 27
Rev No Date
05 07/05/2015
04 02/03/2015
03 14/01/2015
02 22/01/2014
01 15/10/2103
00 07/08/2013
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WOG GROUP. The data and information provided is furnished on a restricted basis and is not to be used in any way detrimental to the interests of WOG GROUP.
1. EXECUTIVE SUMMARY
M/s. PT PUNJ LLOYD INDONESIA, JAKRATA, INDONESIA has assigned the project to
W.O.G Group for Engineering, Construction, and operational support of their proposed
Effluent Treatment Plant for the proposed 3 x 18 MW units of coal fired power plant at
Sangatta, East Kalimantan, Indonesia.
The scope of work includes process design, basic and detailed engineering,
procurement, inspection, expediting, supply, supervision of installation,
instrumentation, testing, pre-commissioning, commissioning of Effluent Treatment
Plant (ETP) as described in the process specifications.
This design Package covers the process description, treatment synopsis detailed design,
engineering and installation specifications for Effluent Treatment Plant (ETP) with a
total handling capacity of 2 M3/hr effluent.
The entire plant is designed on the concept of free oil; no emulsified oil has been
considered.
This Basic Design Package (BDP) has been prepared taking into account the technical
details provided in the Technical requirement Document and/or subsequent
discussions/ clarifications, the record notes of technical inputs collected during the
discussion & visit of WOGs Engineers.
This BDP Document (Doc # WOG / 2013 / ETP/ PTPL/ 105 Rev 04) contains various
details related with the Basic Design, Process Design, Hydraulics, and process
datasheets along with a host of technical information as necessary and required so as to
make this document as a self-contained package. The details presented in the
succeeding paragraphs have been worked out consequent to the BDP document
incorporating necessary details as desired.
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WOG GROUP. The data and information provided is furnished on a restricted basis and is not to be used in any way detrimental to the interests of WOG GROUP.
2. DESIGN BASIS
WOG Group designed the system based on the following effluent analysis:-
PROCESS CHARACTERISTICS
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3. TREATED WASTE WATER CHARACTERISTICS
It is envisaged that the Treated Waste water from the waste water treatment plant shall meet
the following quality after treatment.
1. pH s.u. 6.0-9.0
2. Oil mg/l 10
NOTE : - The above quality of treated water is achieved subject to the following:
The feed quality as considered is presented in Sr. # 2.0 of this BDP. In case of any change
in the quality of raw water, there may be certain impacts on operating parameters or on
end results of the system.
The operation of Plant is strictly carried out as per WOG Operation Manual and
Instructions.
Pure chemicals, original spares and consumables specified by us are used in above
treatment Plant.
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WOG GROUP. The data and information provided is furnished on a restricted basis and is not to be used in any way detrimental to the interests of WOG GROUP.
4. PROCESS DESIGN BASIS
The treatment of effluent flow of 2 M3/hr shall include the following treatment components as
per the design requirements:-
PRELIMINARY TREATMENT
Receipt of the effluent from different sources in local collection sumps by client.
From local sumps effluent is transferred via respective pumps in an oily effluent
common collection pit.
Transfer of the collected wastewater to the corrugated inclined plate type oil water
separator via feed pumps.
Sludge from the bottom of CPI will be taken up till PT sludge pit and oil from top of
CPI is skimmed by oil skimmer and is collected in oil drum.
Treated effluent from CPI is passed to flash mixer tank for physio-chemical
treatment via gravity.
Sludge from clarifier will be taken up till PT sludge pit via gravity.
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5. PROCESS DESCRIPTION
The Treatment philosophy of the effluent treatment plant is described in brief as follows:
The effluent from different sources will be received in 4 Nos sumps i.e. transformer yard waste
water pit (switchyard), transformer yard waste water pit (TG building near grid 1 3),
transformer yard waste water pit (TG building near grid 6 8) and turbine hall floor wash
drain. From these sumps & pits effluent is pumped in to oily effluent common collection pit.
Effluent from LDO area is also made to collect into common collection pit with other effluents.
The collected waste water from the pit will be pumped to the Corrugated Plate Interceptor (CPI)
via effluent feed pumps.
The Corrugated Plate Interceptor (CPI) consists of a number of inclined corrugated plates
mounted parallel to each other at spacing (Figure 1). The raw water containing the oil and
suspended solids passes between the plates from top. Laminar flow conditions are essential for
the effective gravity separation of the water, the oil and suspended contaminants. In the course
of passing from pack inlet to pack outlet, the oil floats upwards into the tops of the corrugations
and rises up the incline of the plate to the surface of the system where it is removed by a
skimmer. The sludge moves towards the bottom of the corrugations and slides down the incline
of the plate spacing. From there the sludge will be taken suitably upto PT sludge pit.
The simultaneous migration of oil droplets into the corrugation tops and of sludge particles into
corrugation bottoms has a major effect upon the operation of the separation system. In the
corrugation tops a very high oil concentration is established. This is the ideal condition for oil
coalescing to take place (coalescing is the formation of a few large oil drops out of many small
droplets due to droplets due to droplets (collisions).
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Figure 1
In the corrugation bottoms a high 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.)
The oily water, from the top of the pack and then over an effluent weir, flows into the treated
water chamber. The oil droplets coalesce into larger droplets and flow counter-current through
the pack into the surface. Here, a layer of oil forms which is then skimmed off via a slotted pipe
skimmer.
The Treated water from the treated water chamber of CPI will be taken for physio-chemical
treatment. Slop Oil removed from CPI is routed to Oil drum from where it will be taken by
client.
The treated wastewater is then sent to the Flash mixer Tank for coagulation. Flash mixing is
carried out with the objective of mixing the chemicals thoroughly with the effluent water such
that the coagulation/ neutralization reactions can take place uniformly and completely. The
hydraulic retention time of the flash mixer is designed to be 5 minutes. Coagulant dosage into
the flash mixer will be varied depending on the turbidity and suspended solids concentration in
the wastewater. Flash Mixer will be equipped with an Agitator.
The outlet of flash mixing tank will connect with the flocculator Tank. The function of flocculator
as required to flocculating the particulates formed in the flash mixer along with coagulated inlet
05 07/05/2015 ISSUED FOR APPROVAL RT SM SDM
REV. DATE DESCRIPTION PREPARED BY REVIEWED BY APPROVED BY
PROJECT EFFLUENT TREATMENT PLANT PAGE No. Page 8 of 30
CLIENT PT CITRA KUSUMA PERDANA DOCUMENT NO.
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turbidity / suspended solids and form settle able flocs. The flocculator, designed on Retention
Time of 30 minutes, will be equipped with 1 No. Slow speed agitator, which provide gentle
agitation and assist in the flocculation process. The flocculated water enters the Lamella
Clarifier, which is designed on the basis of loading rate, to settle down particulate matter and
flocs formed during the coagulation / flocculation process under quiescent conditions. The
thickened sludge will be collected at the bottom from where it will be taken upto the PT sludge
pit.
Treated effluent from lamella clarifier will be collected in common monitoring basin. A
provision for alkali/acid addition by Alkali/acid dosing system shall be provided in order to
correct / neutralize the ph of incoming effluent as per discharge standards.
Boiler blow down quenched water will be collected in common local blow down collection pit
for unit-3, 4 & 5 boilers and then, will be pumped to CMB pump discharge line.
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6. PROCESS EQUIPMENT CALCULATIONS
The following are the detailed unit size calculations for the offered design.
3 FLOCCULATOR TANK
Quantity Offered 1.000 Nos
Flow rate per Hour 2.000 M3/Hr
Recommended Retention Time 30.000 Minutes
Capacity Required 1.000 M3
No of Compartments/Units 1.000 Nos
Volume of each compartment 1.000 M3
Considered Volume of each compartment 1.000 M3
Material of Construction MSEP
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Volume, Provided 2.500 M3
No of Compartments/Units 1.000 Nos
Area of each compartment 1.00 M2
Considered Area of each compartment 1.000 M2
7 SLUDGE CALCULATIONS
PRIMARY SLUDGE FROM CPI
Feed TSS 800.000 PPM
TSS Loading Rate 1.600 Kg/hr
TSS Reduction Considered 70.000 %
TSS Reduced 1.120 Kg/hr
Sludge Consistency 1.000 %
Sludge Generated from CPI 0.112 M3/hr
CHEMICAL SLUDGE
TSS in Lamella Clarifier 240.000 PPM
Coagulant Dosing 10.000 PPM
TSS Sludge generated 11.520 Kg/Day
Sludge due to Coagulant Dosing 0.480 Kg/Day
Dry Sludge due to coagulant dosing 0.288 Kg/Day
Total Dry solids 11.808 Kg/Day
Sludge Consistency 2.000 %
Sludge Generated from Lamella Clarifier 0.590 M3/Day
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Flow Rate 2.0000 M3/hr
Expected Dosage Rate 40.0000 ppm
Chemical Required at 100% concentration 0.0800 Kg/hr
Coagulant Considered PAC
Coagulant Availability as powder form 30.0000 %
Chemical Required at market availability 0.2666 Kg/hr
Dosage Concentration 10.0000 %
Solution required 2.667 Litres/hr
Retention Time of Dosing Tank 24.0000 hours
Dosing Tank Capacity 63.984 Litres
Design Margin 15.0000 %
Required Dosing Tank Capacity 73.5816 Litres
Provided Dosing Tank Capacity 100.0000 Litres
COAGULANT DOSING PUMPS
Required Dosing Pump Capacity 2.6667 LPH
Design Margin 15.0000 %
Required Dosing pumps Capacity 3.067 LPH
Provided Dosing pumps Capacity 4.0000 LPH
*Note: PAC being strong coagulant than Alum/Ferric chloride requires lesser
dosages rate .The dosing calculations mentioned herewith are indicative only (based
on our experience) & subjected to change/modify or optimize as per the results
obtained from jar testing at actual site conditions.
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10 ACID DOSING SYSTEM
ACID DOSING TANK
Flow Rate 10.0000 M3/hr
Dosage Rate (Only If Required) 50.0000 ppm
Chemical Required at 100% concentration 0.5000 Kg/hr
Acid Considered HCl
Acid Availability 33.0000 %
Chemical Required at market availability 1.51 Kg/hr
Dosage Concentration 10.0000 %
Solution required 15.15 Litres/hr
Retention Time of Dosing Tank 24.0000 hours
Dosing Tank Capacity 363.6 Litres
Design Margin 15.0000 %
Required Dosing Tank Capacity 418.14 Litres
Provided Dosing Tank Capacity 500.0000 Litres
ACID DOSING PUMP
Required Dosing Pump Capacity 15.15 LPH
Design Margin 15.0000 %
Required Dosing pumps Capacity 17.42 LPH
Provided Dosing pumps Capacity 20.0000 LPH
*Note: The dosing calculations are indicative only & subjected to change/modify or
optimize as per the results obtained from jar testing at actual site conditions.
**Expected dosages are considered to have the flexibility in case of process
setbacks/Intermittent streams flow/Shock flow. Treated water is expected to
remain in range of 6-9 & continues dosages for pH correction shall not be required.
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Design Margin 15.0000 %
Required Dosing pumps Capacity 6.38 LPH
Provided Dosing pumps Capacity 8 LPH
*Note: The dosing calculations are indicative only & subjected to change/modify or
optimize as per the results obtained from jar testing at actual site conditions.
**Expected dosages are considered to have the flexibility in case of process
setbacks/Intermittent streams flow/Shock flow. Treated water is expected to
remain in range of 6-9 & continues dosages for pH correction shall not be required.
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7. LIST OF UNITS IN THE OFFERED SYSTEM
The following are the detailed list of units envisaged for the project.
Quantity of pumps : 1 No
Quantity of pumps : 1 No
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4. EFFLUENT FEED PUMPS
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Additional accessories : Associated piping, fittings, valves, etc.
Casing: CI
MOC :
Rotor: CF8M
8. CMB TRANSFER PUMPS
Quantity of pumps : 2 Nos.
Type of pumps offered : Horizontal centrifugal
Required Capacity : 10 M3/hr
Discharge Pressure : As per hydraulics
Motor Type : Inline TEFC squirrel cage motor, IP-55
Additional accessories : Associated piping, fittings, valves, etc.
Casing: CI
MOC :
Rotor: CF8M
9. FLASH MIXER TANK
Quantity : 1 No.
Capacity : 200 Litres
Retention Time : 5 minutes
MOC : MSEP
Mixer : 1 No; included
Mixer MOC : MSEP
10. FLOCCULATOR TANK
Quantity : 1 No.
Capacity : 1000 Litres
Retention Time : 30 minutes
MOC : MSEP
Mixer : 1 No; included
Mixer MOC : MSEP
11. LAMELLA CLARIFIER TANK
Quantity : 1 No.
Capacity : 2500 Litres
Surface Loading : 2.0 m3/hr/m2
MOC : MSEP
Plates : 1 Lot
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Plates MOC : FRP
12. POLY DOSING PUMPS
Quantity offered : 2 Nos (1 Working + 1 Standby)
Type : Positive Displacement
Required Capacity : 0 - 1 LPH
Capacity Adjustment Range : 0 100%
Suction Pressure : Flooded
Discharge Pressure : 3.0 kg/cm
Motor Rating : 0.18 kW
Motor Type : Inline TEFC squirrel cage motor, IP-55
Additional accessories : Associated piping, fittings, valves, etc.
MOC : PP
13. POLY DOSING TANK
Quantity : 1 No.
Capacity : 50 litres
Disposition : Vertical
Retention Time : 24 Hrs
MOC : FRP
14. POLY DOSING TANK - MIXER
Quantity : 1 No.
Type : Manual
MOC : SS 316
15. COAGULANT DOSING PUMPS
Quantity offered : 2 Nos (1 Working + 1 Standby)
Type : Positive Displacement
Required Capacity : 0 - 4 LPH
Capacity Adjustment Range : 0 100%
Suction Pressure : Flooded
Discharge Pressure : 3.0 kg/cm
Motor Rating : 0.18 kW
Motor Type : Inline TEFC squirrel cage motor, IP-55
Additional accessories : Associated piping, fittings, valves, etc.
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MOC : PP
16. COAGULANT DOSING TANK
Quantity : 1 No.
Capacity : 100 litres
Disposition : Vertical
Retention Time : 24 Hrs
MOC : FRP
17. COAGULANT DOSING TANK - MIXER
Quantity : 1 No.
Type : Manual
MOC : SS 316
18. ACID DOSING PUMPS
Quantity offered : 2 Nos (1 Working + 1 Standby)
Type : Positive Displacement
Required Capacity : 0 - 20 LPH
Capacity Adjustment Range : 0 100%
Suction Pressure : Flooded
Discharge Pressure : 3.0 kg/cm
Motor Rating : 0.18 kW
Motor Type : Inline TEFC squirrel cage motor, IP-55
Additional accessories : Associated piping, fittings, valves, etc.
MOC : PP
19. ACID DOSING TANK
Quantity : 1 No.
Capacity : 500 litres
Disposition : Vertical
Retention Time : 24 Hrs
MOC : FRP
20. ALKALI DOSING PUMPS
Quantity offered : 2 Nos (1 Working + 1 Standby)
Type : Positive Displacement
Required Capacity : 0 - 8 LPH
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Capacity Adjustment Range : 0 100%
Suction Pressure : Flooded
Discharge Pressure : 3.0 kg/cm
Motor Rating : 0.18 kW
Motor Type : Inline TEFC squirrel cage motor, IP-55
Additional accessories : Associated piping, fittings, valves, etc.
MOC : PP
21. ALKALI DOSING TANK
Quantity : 1 No.
Capacity : 200 litres
Disposition : Vertical
Retention Time : 24 Hrs
MOC : FRP
22. ALKALI DOSING TANK - MIXER
Quantity : 1 No.
Type : Manual
MOC : SS 316
23. PIPES, VALVES & FITTINGS WITHIN TERMINAL POINTS
Quantity : As required
Piping MOC : HDPE/CPVC
24. EARTHING SYSTEM (ABOVE GROUNDING)
Quantity : As required. (Refer electrical documents for
details)
25. CABLES & ACCESSORIES
Quantity : As required.
Accessories : RIO panel with necessary cables and cable
accessories with cable tray to interface with
WTP PLC Panel.
26. pH ANALYZER
Quantity : As per Piping & Instrumentation Diagram
27. OIL ANALYZERS
Quantity : As per Piping & Instrumentation Diagram
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28. TEMPERATURE TRANSMITTER
Quantity : As per Piping & Instrumentation Diagram
29. JUNCTION BOXES
Quantity : As required.
30. PRESSURE GAUGES
Quantity : As per Piping & Instrumentation Diagram
Type : Diaphragm
31. LEVEL SWITCH
Quantity : As per Piping & Instrumentation Diagram
Type : Displacer
32. LEVEL GAUGES
Quantity : As per Piping & Instrumentation Diagram
Type : Tubular Type/ Float & Board Type
33. PRESSURE SWITCH
Quantity : As per Piping & Instrumentation Diagram
NOTES:
The discharge pressure of all pumps shall be provided after the finalization of
Layout plan & Hydraulic flow diagram.
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8. CIVIL UNITS (PTPLI SCOPE)
The following are the detailed list of civil units envisaged for the project:-
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8. EQUIPMENT FOUNDATION FOR TANKS ETC.
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9. POWER REQUIREMENT
UNITS
ENERGY
ABSORBED MOTOR
INSTALLED
WORKING
Sl. OPERATING CONSUMED
DESCRIPTION POWER RATING
No. HOURS PER DAY
(BKW) (KW)
(kWH/DAY)
NOTE:
1. The above requirement has been worked out on the basis of continuous operation
of equipment whereas in actual practice, several equipments will operate on
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intermittent duty. As such, the realistic operating power requirement for the
proposed capacity will be much less than the indicated above.
2. The load list mentioned herewith is indicative only & subjected to change as per the
required discharge pressure, after finalization of Layout & Hydraulic flow diagram.
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10. CHEMICAL REQUIREMENT
The following chemicals are envisaged for regular consumption at various stages of treatment
system. These dosages are indicative only and needs to optimize during jar test study at site.
CHEMICAL REQUIREMENT
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11. ELECTRICALS
The Electricals will be complete with installation of Electrical System comprising the following:
(a) MCC
(g) Starters, Cables, Cable Trays with structural steel supports for additional feeders of
STP motors
MCC shall be of non draw out single/double front type. Panel shall confirm IP42 Degree of
protection with air-conditioning room or else will conform to IP54.
All Bus bars shall be coloured, sleeved and of Electrolytic grade copper conductor material
suiting to fault current 40KA.
LT cable shall be 600/1000V (E) grade, XLPE insulated, extruded PVC inner sheath, GS Flat Strip
round wire armoured, overall extruded FRLS PVC, Outer Sheathed, Copper stranded conductor
cables. Max operating temp for XLPE insulation cables shall be 90 Degree C conforming to IEC
60502.
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12. TERMINATION POINTS
The following are the termination points envisaged for the offered waste water treatment plant
10. Instrument Air & Service Water Line 1 m away from ETP area
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13. INSTRUMENTATION & CONTROLS
Taking into account the Operational and Control Philosophy and the requirement of
Instruments/Controls as governed by the Operational Regimes of the proposed ETP, a Write up
on Control Philosophy along with C&I facilities for the Plant is described hereunder :
The proposed plant will physically monitored & Control of various sequences of the Plant
operation will done manually as per the defined operational & control philosophy.
All analog parameters will also be made at the respective field. Alarms and trips get
automatically initiated when process conditions exceed preset limits.
Each of the Motors in the Plant is provided with a Local Control Station mounted over the
respective Motor. START/STOP Push Buttons are provided in order to facilitate Local Testing of
the equipment.
Taking into account the Operational and Control Philosophy and the requirement of
Instruments / Controls as governed by the Operational Regimes of the proposed ETP will be
provided.
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14. LIST OF DRAWINGS
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