Project : 17 MLD STP Plant –Activated sludge process

1.0 SEWAGE GENERATION AND CHARACTERISTICS

The 17 MLD Sewage Treatment Plant is designed using the Activated Sludge Extended
Aeration Process for the following sewage flow rate and characteristics:

Design Year 2026

Average Flow Rate : 17.0 MLD i.e. 17000.0 M3/Day

= 708.3 M3/Hour
= 0.197 M3/s
Peaking Factor : 2.25
Peak Flow Rate : 17000.0 x 2.25 i.e. 38250.0 M3/day
= 1593.8 M3/Hour
= 0.443 M3/s

Design Year 2041

Average Flow Rate : 25.0 MLD i.e. 25000.0 M3/Day

= 1041.7 M3/Hour
= 0.289 M3/s
Peaking Factor : 2.25
Peak Flow Rate : 25000.0 x 2.25 i.e. 56250.0 M3/day
= 2343.8 M3/Hour
= 0.651 M3/s

Note: The Raw Sewage Pumping Station is designed for raw sewage flow rate
corresponding to Design Year 2041 whereas the balance STP is designed for raw sewage
flow rate corresponding to Design Year 2026. Raw Sewage Pumps will be designed and
supplied to cater to raw sewage flow rate corresponding to Design Year 2026 and
sufficient vacant space will be provided for installation of additional pumps in future.

BOD : 300.0 mg/l

COD : 700.0 mg/l
Suspended Solids SS : 600.0 mg/l
Bio-Degradable VSS : 330.0 mg/l (Considered)
Non Bio-Degradable VSS/FSS : 270.0 mg/l (Considered)

2.0 TREATED SEWAGE QUALITY

PROCESS DESIGN CALCULATION STP Page 1

 The Treated Sewage Quality shall conform to NRCD Guidelines, as follows:

BOD < 20.0 mg/L

SS < 30.0 mg/L

3.0 RECEIVING CHAMBER

No. : 1
Material of Construction : RCC
Year 2041 Peak Flow Rate : 0.651 M3/s
Plan Dimensions : 2.8 M x 2.8 M
Side Water Depth : 1.0 M
Volume : 2.8 x 2.8 x 1.0 i.e. 7.8 M3
Hydraulic Retention Time : 7.8 / 0.651 i.e. 12.0 s

4.0 MECHANICAL COARSE BAR SCREEN CHANNEL

No. : 1 (Working)
Material of Construction : RCC, with SS 304 Coarse Bar Screen
Design Basis : Year 2041 Peak Flow i.e. 0. 651 M3/s
Angle of Inclination : 800
Length : 5.0 M
Side Water Depth : 0.95 M
Inclined Submerged Screen : (0.95 / Sin 800) i.e. 0.96 M
Length
Velocity (through Screen : 1.2 M/s
at Peak Flow, NIL Clogging)
Clear Width : 0. 651 M3/s / (0.96 M x 1.2 M/s)
i.e. 0.565 M
Clear Spacing : 20 MM
No. of Openings : 0.565 M/ 0.020 M
i.e. 28.3, say 29
No. of Bars : 29 + 1 i.e. 30
Bar Size : 8 MM x 40 MM
Screen Channel Width (Minimum) : (29 x 0.020) + (30 x 0.008)
i.e. 0.820, say 0.85 M
Side Margin for Operating : 0.3 M
Mechanism
Screen Channel Width (Overall) : 0.85 + 0.3 i.e. 1.15 M
Approach Velocity (Average Flow) : 0. 289/ (1.15 x 0.95) i.e. 0.26 = 0.3 M/s
(approx.), i.e. OK
Screen Height : SWD (U/s) + FB (U/s) + Conveyor Height +

PROCESS DESIGN CALCULATION STP Page 2

 0.5 M i.e. 0.95 + 3.35 + 0.6 + 0.5 + 0.3
(Safety Factor) = 5.7 M (approx.)
Head Loss (Design) : 0.15 M
Operation : Automatic (Timer Controlled)
Service : Continuous/ Intermittent
Accessory Equipment : Electric Motor/ Drive Mechanism w/
Mechanical Travelling Rakes/ Control
Panel/ Belt Conveyor (w/ Electric Motor and
Drive Arrangement)/ MSEP/ FRP Wheel
Barrows (2 Nos.)

Notes:

1. Due to difficulty associated with underground construction of deep Screen

Channels of narrow width, the Screen Channel will be constructed at below
Ground Level on a RCC Platform covering portion of the Raw Sewage Collection
Sump (Wet Well). The Conveyor Belt will be installed at the Raw Sewage
Collection Sump (Wet Well) Top of Structure Level i.e. 0.5 M above Ground
Level.
2. Screenings will be mechanically collected on to a Conveyor Belt and then
disposed off mechanically by gravity to Wheel Barrow at Ground Level.
3. The Belt will start automatically when the Mechanical Screen starts and will stop
automatically after a lag period of 60 seconds after the Mechanical Screen stops.
4. Height of Screen/ Conveyor Belt are subject to modification depending on
Manufacturer Specifications.

Inlet Isolation Sluice Gate

No. : 1
Type : Flange Back Frame Thimble Mounted,
Rising Spindle, Flush Bottom Closure
Design Standard : IS: 13349
Material of Construction : Cast Iron
Peak Flow Rate : 0.651 M3/s
Size : 800 MM x 800 MM
Velocity (at Peak Flow) : 0.651 / (0.8 x 0.8) i.e. 1.02 M/s
Operation : Manual

Note: Outlet Isolation Sluice Gates are not required as the screened sewage will directly
free fall to Raw Sewage Collection Sump (Wet Well) below the Mechanical Coarse
Screen Channel through bottom perforations at the outlet end of the channel.

5.0 MANUAL COARSE BAR SCREEN CHANNEL

PROCESS DESIGN CALCULATION STP Page 3
 No. : 1 (Stand-By)
Material of Construction : RCC, with SS 304 Coarse Bar Screen
Design Basis : Year 2041 Peak Flow i.e. 0. 651 M3/s
Angle of Inclination : 600
Length : 5.0 M
Side Water Depth : 0.95 M
Inclined Submerged Screen : (0.95 / Sin 600) i.e. 1.10 M
Length
Velocity (through Screen : 1.2 M/s
at Peak Flow, NIL Clogging)
Clear Width : 0.651 M3/s / (1.10 M x 1.2 M/s)
i.e. 0.493 M
Clear Spacing : 20 MM
No. of Openings : 0. 493 M/ 0.020 M
i.e. 24.7, say 25
No. of Bars : 25 + 1 i.e. 26
Bar Size : 8 MM x 40 MM
Screen Channel Width : (25 x 0.020) + (26 x 0.008)
i.e. 0.708, say 0.75 M
Approach Velocity (Average Flow) : 0. 289/ (0.75 x 0.95) i.e. 0.41 M/s, i.e. OK
Screen Height : SWD(U/s) + FB(U/s) i.e. 0.95+ 0.5 =1.45 M
Head Loss (Design) : 0.15 M
Operation : Manual
Service : Intermittent

Accessory Equipment : MSEP Rakes (2 Nos.)/ Bucket Chain Pulley

Screenings Removal Arrangement

Notes:

1. Due to difficulty associated with underground construction of deep Screen

Channels of narrow width, the Screen Channel will be constructed at below
Ground Level on a RCC Platform covering portion of the Raw Sewage Collection
Sump (Wet Well).
2. Screenings will be manually raked on to a RCC Perforated Platform and then
transferred to Raw Sewage Collection Sump (Wet Well) Top of Structure Level
through Bucket - Chain Pulley Arrangement and disposed off manually to Wheel
Barrow at Ground Level.

Inlet Isolation Sluice Gate

No. : 1
Type : Flange Back Frame Thimble Mounted,
Rising Spindle, Flush Bottom Closure

PROCESS DESIGN CALCULATION STP Page 4

 Design Standard : IS: 13349
Material of Construction : Cast Iron
Peak Flow Rate : 0.651 M3/s
Size : 800 MM x 800 MM
Velocity (at Peak Flow) : 0.651 / (0.8 x 0.8) i.e. 1.02 M/s
Operation : Manual

Note: Outlet Isolation Sluice Gate is not required as the screened sewage will directly
free fall to Raw Sewage Collection Sump (Wet Well) below the Mechanical Coarse
Screen Channel through bottom perforations at the outlet end of the channel.

6.0 RAW SEWAGE PUMPING STATION

Raw Sewage Collection Sump (Wet Well)

No. : 1
Material of Construction : RCC
Peak Flow Rate : 0. 651 M3/s
Hydraulic Retention Time : 7.5 Minutes
(at Peak Flow)
Volume (Required) : 0.651 x 60 x 7.5 i.e. 293.0 M3
Diameter : 16.5 M
Side Water Depth : 1.4 M
Volume (Provided) : (Π/4 x 16.5 x 16.5 x 1.4) i.e. 299.4 M3
Hydraulic Retention Time : 299.4/ (0. 289 x 60) i.e. 17.3 Min, i.e. OK
(at Average Flow)
Accessory : Ultrasonic Level Sensor (Linked to PLC/
SCADA)

Raw Sewage Transfer Pumps

Nos. : 5 (4 Working + 1 Stand-By – Peak Flow)

: 5 (2 Working + 1 Stand-By –Average Flow)
Design Basis : Year 2026 Peak Flow i.e. 1593.8 M3/Hour
Capacity : 1593.8/ 4 i.e. 398.5 say 400.0 M3/Hour
Discharge Head : 12.0 MWC
Type : Submersible Non Clog, Wet Well
Installation
Operation : Automatic (Controlled by Ultrasonic Level
Sensor, linked to PLC/ SCADA)
Material of Construction
Casing : Cast Iron
Impeller : Stainless Steel ASTM A 743 CF8M

PROCESS DESIGN CALCULATION STP Page 5

 Shaft/ Fasteners/ Foundation Bolts : Stainless Steel 316
Guide Rail : Stainless Steel SS 304
Accessory Equipment : Submersible Electric Motors/ Lifting
Chains/ Guide Rails

Individual Pump Delivery Lines

Size : 300 NB
Design Velocity : 400.0/ 3600/ (Π/4 x 0.3 x 0.3) i.e.
1.57 M/s
Material of Construction : DI K7
Accessory Equipment : Non Return Valve/ Butterfly Valve
(Electrically Actuated)/ Pressure Gauge

Combined Pump Delivery Header

Design Flow : 400.0 x 4 i.e. 1600.0 M3/Hour

Size : 500 NB
Design Velocity : 1600.0/ 3600/ (Π/4 x 0.5 x 0.5)
i.e. 2.26 M/s
Material of Construction : DI K7

Dry Well

Note: The Dry Well be constructed above the Raw Sewage Collection Sump (Wet Well)
and will be used for access to the Submersible Pumps for operation and maintenance as
required.

No. : 1
Material of Construction : RCC Slabs/ Walkways w/ Hand Railing
Length : 16.5 M
Width : 6.0 M
Accessory : 3.0 Ton Capacity Manual Chain Pulley
Hoist with ISMB 300 Monorail

Pump House Electric Panel Room

No. : 1
Material of Construction : RCC Slabs/ Columns, Brick Masonry Side
Walls as applicable
Plan Dimensions : 6.0 M x 4.0 M
Height : 4.0 M

PROCESS DESIGN CALCULATION STP Page 6

 7.0 STILLING CHAMBER

No. : 1
Material of Construction : RCC
Plan Dimensions : 1.95 x 1.95 M
Straight Water Depth : 3.6 M
Volume : 1.95 x 1.95 x 3.6 i.e. 13.7 M3
Hydraulic Retention Time : 13.7/ 0.443 i.e. 30.9 s
(at Peak Flow)

Bypass Sluice Gate

No. : 1
Type : Flange Back Frame Thimble Mounted,
Rising Spindle, Flush Bottom Closure
Design Standard : IS: 13349
Material of Construction : Cast Iron
Peak Flow Rate : 0.443 M3/s
Size : 500 MM x 500 MM
Velocity (at Peak Flow) : 0.443 / (0.5 x 0.5) i.e. 1.77 M/s
Operation : Manual

Bypass Chamber

No. : 1
Material of Construction : RCC
Peak Sewage Flow Rate : 0.443 M3/s
Plan Dimensions : 1.95 M x 1.2 M
Side Water Depth : 2.4 M

Bypass Sewage Pipeline, Bypass Chamber to Outfall Manhole

No. : 1
Material of Construction : RCC
Peak Flow Rate : 0.443 M3/s
Size : 700 NB
Velocity (at Peak Flow) : 0.443/ (Π/4 x 0.7 x 0.7) i.e. 1.15 M/s

Bypass Man Holes

PROCESS DESIGN CALCULATION STP Page 7

 Nos. : 3
Material of Construction : RCC (w/ RCC Top Cover Slab)
Diameter : 1.1 M
Side Water Depth : 2.4 M (Max)

8.0 MECHANICAL FINE SCREEN CHANNELS

Nos. : 2 (1 Working + 1 Stand-By)

Type : Mat/ Step Fine Screen
Material of Construction : RCC, with SS 304 Fine Screen
Design Basis : Peak Flow i.e. 0.443 M3/s
Angle of Inclination : 400
Length : 6.0 M
Side Water Depth : 1.0 M
Height of Screen Protection : 0.225 M
Plate (Blind Step)
Inclined Submerged Screen : (1.0 / Sin 400 – 0.225) i.e. 1.331 M
Length
Velocity (through Screen, at : 1.0 M/s
Peak Flow)
Clear Width : 0.443 / (1.331 x 1.0)
i.e. 0.333 M
Clear Spacing : 6 MM
No. of Openings : 0.333 / 0.006
i.e. 55.5, say 56
No. of Bars : 56 - 1 i.e. 55
Bar Thickness : 2 MM
Screen Width : (56 x 0.006) + (55 x 0.002)
i.e. 0.446 M, say 0.45 M
Side Margin for Operating : 0.3 M
Mechanism
Screen Channel Width : 0.45 + 0.3 i.e. 0.75 M
Approach Velocity (Average Flow) : 0.197/ (0.75 x 1.0) i.e. 0.26 = 0.3 M/s
(approx.)
Height of Screen : SWD + Free Board (d/s) + Height
(Conveyor) + Free Fall i.e. 1.0 + 0.5 + 0.6 +
0.5 = 2.6 M (Minimum)
Head Loss through Screen : 300 MM (Maximum)
Design Clogging : 49% (Maximum)
Operation : Automatic (Controlled through Level
Sensor)
Service : Intermittent

Hydraulic Check

PROCESS DESIGN CALCULATION STP Page 8

 Approach Velocity : 0.443/ (0.75 x 1.0) i.e. 0.59 M/s
(at Peak Flow)
Velocity through Screen : 0.443/ ((1.331) x (56 x 0.006) x (1.0 - 0.0))
(at NIL Clogging) = 0.99 M/s
Head Loss (at NIL : 1/0.7 x (0.992 – 0.592) / (2 x 9.81)
Clogging) = 0.043 M
Velocity through Screen : 0.443/ ((1.331) x (56 x 0.006) x (1.0 – 0.49))
(at 49% Clogging) = 1.94 M/s
Head Loss (at 49% : 1/0.6 x (1.952 – 0.582) / (2 x 9.81)
Clogging) = 0.290 < 0.3 M i.e. OK

Accessory Equipment : Drive Mechanism, Control Panel, Belt

Conveyor (w/ Electric Motor and Drive
Arrangement)/ MS Epoxy Painted/ FRP
Chute/ Wheel Barrows (4 Nos.)

Notes:

1. Ultrasonic Differential Level Sensor will be provided so as to activate Mechanical

Fine Screen Drive Mechanism when Upstream Level touches 300 MM above
Downstream Level and shuts off Screen Drive Mechanism when Upstream Level
reduces to 60 MM above Downstream Level.
2. Screenings will be mechanically collected on to a Conveyor Belt common to both
Fine Screens and then disposed off via Chute to Wheel Barrow at Ground Level.
3. The Conveyor Belt will start automatically when the Mechanical Screen starts and
will stop automatically after a lag period of 60 seconds after the Mechanical
Screen stops.

Inlet Isolation Sluice Gates

Nos. : 2
Type : Open Channel, Rising Spindle, Flush
Bottom Closure
Material of Construction : Cast Iron
Peak Flow Rate : 0.443 M3/s
Width : 350 MM
Height : 1300 MM SWD + 300 MM FB
Velocity (at Half Peak Flow) : 0.443 / (0.35 x 1.3) i.e. 0.97 M/s
Operation : Manual

Outlet Isolation Sluice Gates

Nos. : 2

PROCESS DESIGN CALCULATION STP Page 9

 Type : Open Channel, Rising Spindle, Flush
Bottom Closure
Material of Construction : Cast Iron
Half Peak Flow Rate : 0.443 M3/s
Width : 400 MM
Height : 1000 MM SWD + 300 MM FB
Velocity (at Peak Flow) : 0.443 / (0.4 x 1.0) i.e. 1.12 M/s
Operation : Manual

9.0 MECHANICAL GRIT CHAMBERS

No. : 2 (Working)
Material of Construction : RCC, with MS Epoxy Painted Grit Scraper/
Rake Classifier/ CI Organic Return Pump
Design Basis : Half Peak Flow, i.e. 38250.0/ 2
= 19125.0 M3/day
i.e. 0.221 M3/s
Design Surface Loading Rate : 720.0 M3/M2-day
Plan Area (Required) : 19125.0 M3/day / 720.0 M3/M2-day
i.e. 26.6 M2
Plan Dimensions : 5.2 M x 5.2 M
Hydraulic Retention Time : 60s
Volume : 0.221 x 60 i.e. 13.3 M3
Side Water Depth : 13.3 / (5.2 x 5.2) i.e. 0.49 M
Grit Storage Depth : 0.41 M
Overall Depth : 0.49 + 0.41 i.e. 0.9 M

Note: Settled grit in Grit Chamber will be mechanically scraped to Rake Classifier
Channel, lifted through Rake Classifier and dropped in to Wheel Barrow positioned at
Ground Level.

Inlet Isolation Sluice Gates

Nos. : 2
Type : Open Channel, Rising Spindle, Flush
Bottom Closure
Material of Construction : Cast Iron
Design Basis : Peak Flow
Peak Flow Rate : 0.443 M3/s
Width : 450 MM
Height : 950 MM SWD + 300 MM FB
Velocity (at Peak Flow) : 0.443 / (0.45 x 0.95) i.e. 1.04 M/s
Operation : Manual

PROCESS DESIGN CALCULATION STP Page 10

 10.0 PARSHALL FLUME CHANNEL

No. : 1
Material of Construction : RCC
Peak Flow Rate : 0.443 M3/s
Throat Width : 1.0 Feet (0.305 M)
Length : 7.5 M
Upstream Head : 0.746 M
Downstream Head : 0.521 M (Considered)
Head Loss : 0.746 – 0.521 = 0.225, say 0.25 M
Side Water Depth (d/s) : 0.75 M
Width : 0.55 M
Downstream Velocity : 0.443/ (0.55 x 0.75) i.e. 1.07 M/s
Side Water Depth (u/s) : 0.75 + 0.25 i.e. 1.0 M (Approx.)
Flow Measurement : Ultrasonic Sensor (Linked to PLC SCADA)

EQUILIZATION TANK IS MISSING. IT IS NEEDED

11.0 AERATION TANK

The design sewage characteristics entering the Aeration Tank will be as given in Clause
1.0 above.

No. : 1
Material of Construction : RCC
Type of Aeration : Fine Bubble Diffused Aeration
Design Basis : Average Flow, i.e. 17000.0 M3/day
i.e. 708.3 M3/Hour
Inlet BOD to Aeration Tank : 300.0 mg/l
Inlet BOD Load : 0.300 Kg/M3 x 17000.0 M3/day
i.e. 5100.0 Kg BOD/ day
MLSS Concentration, X : 5000.0 mg/L
Food to Micro-Organism : 0.15 Kg BOD/ Kg MLSS - day
Ratio
Hydraulic Retention Time : 300.0 mg/L BOD/ (5000 mg/L MLSS x
0.15)
i.e. 0.4 days (9.6 Hours)
Volume (Required) : 17000.0 M3/day x 0.4 days
i.e. 6800.0 M3
Side Water Depth : 5.0 M
Plan Area : 6800.0 M3 / 5.0 M
i.e. 1360.0 M2
Diameter : 41.7 M

PROCESS DESIGN CALCULATION STP Page 11

 Plan Area Provided : ∏/4 x 41.7 x 41.7 i.e. 1365.7 M2, i.e. OK
Accessory : On-Line DO Meter (Linked to PLC/
SCADA)

Aeration Tank Inlet Channel

No. : 1
Material of Construction : RCC
Peak Sewage Flow Rate : 0.443 M3/s
Return Sludge Flow Rate : 0.197 M3/s
Total Sewage Flow Rate : (0.443 + 0.197) i.e. 0.639 M3/s
Width : 0.95 M
Side Water Depth : 0.65 M
Channel Velocity : 0.639/(0.95 x 0.65) i.e. 1.04 M/s

Aeration Tank Inlet Annular Channel

No. : 1
Material of Construction : RCC
Peak Sewage Flow Rate : 0.443 M3/s
Return Sludge Flow Rate : 0.197 M3/s
Total Sewage Flow Rate : (0.443 + 0.197) i.e. 0.639 M3/s
Width : 0.7 M
Side Water Depth : 0.5 M
Nos. Orifices : 15
Orifice Size : 250 NB
Orifice Spacing : 1.2 M c/c
Orifice Velocity : 0.639/(15 x ∏/4 x 0.25 x 0.25)
i.e. 0.87 M/s

Aeration Tank Outlet Weir Launder

No. : 1
Material of Construction : RCC
Peak Sewage Flow Rate : 0.443 M3/s
Return Sludge Flow Rate : 0.197 M3/s
Total Sewage Flow Rate : (0.443 + 0.197) i.e. 0.639 M3/s
Peripheral Length : 131.0 M
Width : 0.7 M
Side Water Depth (U/s) : 0.45 M
Side Water Depth (D/s) : 0.4 M

PROCESS DESIGN CALCULATION STP Page 12

 Aeration Tank Outlet Chamber

No. : 1
Material of Construction : RCC
Peak Sewage Flow Rate : 0.443 M3/s
Return Sludge Flow Rate : 0.197 M3/s
Total Sewage Flow Rate : (0.443 + 0.197) i.e. 0.639 M3/s
Plan Dimensions : 1.8 M x 1.8 M
Side Water Depth : 7.15 M
Volume : 1.8 x 1.8 x 7.15 i.e. 23.2 M3
Hydraulic Retention Time : 23.2/ 0.639 i.e. 36.3 s

Pipeline, Aeration Tank to Secondary Clarifier

Peak Sewage Flow Rate : 0.443 M3/s

Return Sludge Flow Rate : 0.197 M3/s
Total Sewage Flow Rate : (0.443 + 0.197) i.e. 0.639 M3/s
Pipeline Diameter : 900 NB
Pipeline Velocity : 0.639/ (∏/4 x 0.9 x 0.9) = 1.01 M/s
Pipeline MOC : DI K7
Accessory : 65 NB Flushing Connection (with Valve)

Sludge Generation

Non Bio-Degradable VSS/ : 0.27 x 17000.0 i.e. 4590.0 Kg/d

FSS
Biological Sludge Generation : 30% of Inlet BOD Load
: 0.3 x 5100.0 i.e. 1530.0 Kg/day
Total Sludge Generation : 4590.0 + 1530.0 i.e. 6120.0 Kg/day

Clarifier Underflow TSS, XR : 10000 mg/l

Sludge Recirculation Ratio : X / (XR - X) = 5000 / (10000 – 5000)
i.e. 1.0

12.0 AERATION TANK POWER CALCULATIONS

BOD Oxidation : 1.2 x Inlet BOD Load

= 1.2 x 5100.0 Kg O2/d
Oxygen Requirement i.e. 6120.0 Kg O2/d, say 255.0 Kg O2/ Hour
Type of Aeration : Fine Bubble Diffused Aeration
Field Oxygen Transfer : 15%
Efficiency (at 5.0 M SWD)

PROCESS DESIGN CALCULATION STP Page 13

 Air Density : 1.2 Kg/M3
Oxygen Content in Air : 23%
Air Flow Rate : 255.0 / (0.23 x 1.2 x 0.15)
i.e. 6159.4 M3/ Hour
Nos. Air Blowers : 3 (2 Working, 1 Stand-By)
Air Blower Capacity : 6159.0/ 2 i.e. 3079.5 say 3100.0 M3/Hour
Discharge Pressure : 0.6 Kg/cm2
Accessory : VFD Drives (Linked to PLC/SCADA)

13.0 SECONDARY CLARIFIER

No. : 1
Material of Construction : RCC, with MS Epoxy Coated Peripheral
Drive/ FRP V Notch Weir
Flow : Average Flow 17000.0 M3/d
Design Surface Loading Rate : 14.0 M3/M2-d
Diameter : (17000.0 M3/d / 14 M3/M2-Day x 4/Π) 1/2
i.e. 39.3 M
Side Water Depth : 3.0 M
Volume : Π/ 4 x 39.3 M x 39.3 M x 3.0 M
i.e. 3639.1 M3
Hydraulic Retention Time : 3639.1/ 17000.0 x 24 i.e. 5.1 Hours
Peak Flow Loading Rate : (17000 x 2.25) / (Π/4 x 39.3 x 39.3)
= 31.5 M3/M2- Day, i.e. OK
Solids Loading Rate : 17000 x (1 + 1) x 5 / (Π/4 x 39.3 x 39.3)
(at Average Flow) = 140.1 Kg/M2- Day, i.e. OK

Channel, Secondary Clarifier to Chlorine Contact Tank

Design Flow Rate : Peak Flow i.e. 0.443 M3/s

Channel Width : 0.85 M
Channel Side Water Depth : 0.5 M
Channel Velocity : 0.443/ (0.85 x 0.5) = 1.04 M/s
Channel MOC : RCC

14.0 CHLORINE CONTACT TANK

No. : 1
Material of Construction : RCC (w/ Brick Masonry Baffles)
Hydraulic Retention Time : 30 Minutes
(at Average Flow)

PROCESS DESIGN CALCULATION STP Page 14

 Volume (Required) : 17000.0/ 24/ 60 x 30 i.e. 354.2 M3
Diameter : 12.2 M
Straight Water Depth : 3.0 M
Volume : Π/4 x 12.2 x 12.2 x 3.0 i.e. 350.7 M3, OK
Chlorine Dose : 5 PPM (Max)
Chlorine Requirement : 17000.0 M3/d x 0.005 Kg/M3
= 85.0 Kg /Day i.e. 3.5 Kg/Hour (Max)

Chlorine Contact Tank Outlet Chamber

No. : 1
Material of Construction : RCC
Plan Dimensions : 2.5 x 3.2 M
Straight Water Depth : 2.8 M
Volume : 2.5 x 3.2 x 2.8 i.e. 22.4 M3
Hydraulic Retention Time : 22.4/ 0.443 i.e. 50.6 s
(at Peak Flow)

Flushing Pumps

Nos. : 2 (1 Working, 1 Stand By)

Type : Submersible Non Clog, Wet Well
Installation
Capacity : 12.0 M3/Hour
Discharge Head : 25.0 MWC
Operation : Manual
Material of Construction
Casing : Cast Iron
Impeller : Stainless Steel ASTM A 743 CF8M
Shaft/ Fasteners/ Foundation Bolts : Stainless Steel 316
Guide Rail : Stainless Steel SS 304

Accessory Equipment : Submersible Electric Motors/ Lifting

Chains/ Guide Rails

Note: The Flushing Pumps will pump treated sewage as required to the Centrifuges for
flushing purpose and to Polyelectrolyte Tanks for preparing polyelectrolyte solution.
Flushing Connection (with Valve) will also be provided from the Pump combined
Delivery Header to the Aeration Tank – Secondary Clarifier Pipeline, Secondary Clarifier
Outlet Sludge Pipeline and to the Gravity Sludge Thickener Sludge Outlet Pipeline.

Individual Pump Delivery Lines/ Combined Delivery Header

PROCESS DESIGN CALCULATION STP Page 15

 Size : 65 NB
Design Velocity : 12.0/ 3600/ (Π/4 x 0.065 x 0.065)
i.e. 1.00 M/s
Material of Construction : GI Class C
Accessory Equipment : Non Return Valve/ Isolation Gate
Valves/ Pressure Gauge

Channel, Chlorine Contact Tank Outlet Chamber to Outlet Manhole

Design Flow Rate : Peak Flow i.e. 0.443 M3/s

Channel Width : 0.8 M
Channel Side Water Depth : 0.5 M
Channel Velocity : 0.443/ (0.8 x 0.5) = 1.11 M/s
Channel MOC : RCC

15.0 CHLORINATION BUILDING

No. : 1
Material of Construction : RCC Roof/ Columns, PCC Floor, Brick
Masonry Side Walls for Chlorinator Room,
Side Open for Tonner Shed
Chlorinator Room : 5.0 M x 4.0 M
Height : 4.5 M
Chlorine Tonner Shed : 5.0 M x 6.0 M
Height : 5.0 M

Vacuum Chlorinators

Nos. : 2 (1 Working, 1 Stand-By)

Capacity : 5.0 Kg/ Hour

Chlorine Tonners

Nos. : 3 (1 Working, 2 Stand-By)

Chlorine Tonner Capacity : 950.0 Kg
Total Chlorine Storage : 950.0 x 3 / 85.0 i.e. 33.5 Days

Chlorine Dosing Booster Pumps

PROCESS DESIGN CALCULATION STP Page 16

 Nos. : 2 (1 Working, 1 Stand-By)
Capacity : 4.0 M3/ Hour
Discharge Head : 40.0 MWC
MOC : Cast Iron

Accessories : Control Panel, 3.0 Ton Capacity Manual

Hoist complete w/ Manual Geared Traveling
Trolley and Monorail, Tonner Lifting Beam,
3.0 Ton Capacity Dial Type Load Indicator,
Auto Switchover Facility, Leak Detection/
Absorption Equipment, Safety Equipment

16.0 RETURN SLUDGE SUMP

No. : 1
Material of Construction : RCC
Return Sludge Flow Rate : Average Flow x 1.0 i.e. 708.3 M3/Hour
Hydraulic Retention Time : 10.0 minutes
Volume (Required) : 708.3/ 60 x 10 i.e. 118.1 M3
Plan Dimensions : 7.0 M x 3.5 M
Side Water Depth : 5.25 M
Volume (Provided) : 7.0 x 3.5 x 5.25 i.e. 128.6 M3, i.e. OK
Accessory : Ultrasonic Level Sensor (Linked to PLC/
SCADA)

Return Sludge Pumps

Nos. : 3 (2 Working, 1 Stand By)

Type : Submersible Non Clog, Wet Well
Installation
Return Sludge Flow Rate : 708.3 M3/Hour
Sludge Generation : 6120.0 Kg/Day
Sludge Concentration : 1%
Sludge Flow Rate : 6120.0 Kg/Day / (1000 Kg/M3 x 0.01)
= 612.0 M3/Day i.e. 25.5 M3/Hour
Pump Capacity (Required) : (708.3 + 25.5) / 2 i.e. 366.9 M3/Hour
Pump Capacity (Provided) : 370.0 M3/Hour
Discharge Head : 7.5 MWC
Operation : Automatic (Controlled by Ultrasonic Level
Sensor, linked to PLC/ SCADA)
Material of Construction
Casing : Cast Iron
Impeller : Stainless Steel ASTM A 743 CF8M
Shaft/ Fasteners/ Foundation Bolts : Stainless Steel 316

PROCESS DESIGN CALCULATION STP Page 17

 Guide Rail : Stainless Steel SS 304

Accessory Equipment : Submersible Electric Motors/ Lifting

Chains/ Guide Rails/ 2.0 Ton Capacity
Manual Chain Pulley Hoist/ ISMB 200
Monorail

Note: The Return Sludge Pumps will recycle back the settled sludge from Secondary
Clarifiers to the Aeration Tank on a continuous basis. A tapping from the Return Sludge
Pumps will waste excess activated sludge to the Gravity Sludge Thickener continuously/
intermittently as required.

Pipeline Secondary Clarifier to Return Sludge Sump

Size : 500 NB
Design Velocity : 370.0 x 2/ 3600/ (Π/4 x 0.5 x 0.5)
i.e. 1.05 M/s
Material of Construction : DI K7
Accessory Equipment : Knife Edge Gate Valve

Individual Pump Delivery Lines

Size : 300 NB
Design Velocity : 370.0/ 3600/ (Π/4 x 0.3 x 0.3) i.e. 1.45 M/s
Material of Construction : DI K7
Accessory Equipment : Non Return Valve/ Knife Edge Gate Valve/
Pressure Gauge

Combined Pump Delivery Header

Size : 400 NB
Design Velocity : 370.0 x 2/ 3600/ (Π/4 x 0.4 x 0.4)
i.e. 1.64 M/s
Material of Construction : DI K7
Accessory Equipment : Isolation Knife Edge Gate Valve
(Electrically Actuated)

Waste Sludge Line to Gravity Sludge Thickener

Size : 100 NB
Design Velocity : 25.5/ 3600/ (Π/4 x 0.1 x 0.1) i.e. 0.9 M/s
Material of Construction : DI K7

PROCESS DESIGN CALCULATION STP Page 18

 Accessory Equipment : Knife Edge Gate Valve (Electrically
Actuated)

17.0 GRAVITY SLUDGE THICKENER

No. : 1
Material of Construction : RCC w/ Central Drive/ Scraper
Sludge Generation : 6120.0 Kg/d, Dry Solid Basis
Design Sludge Loading Rate : 40.0 Kg/M2-day
Diameter : (6120.0 Kg/d / 40.0 Kg/M2-day x 4/∏) 1/2
i.e. 14.0 M
Side Water Depth : 4.5 M
Volume : Π/4 x 14.0 x 14.0 x 4.5 i.e. 692.7 M3
Thickened Sludge : 3.0 %
Concentration
Thickened Sludge Flow Rate : 6120.0 Kg/d / (1000 Kg/M3 x 0.03)
to Centrifuge i.e. 204.0 M3/d
Hydraulic Retention Time : 692.7/ 204.0 i.e. 3.4 Days
(w.r.t. Thickened Sludge)

18.0 CENTRIFUGE SHED

Sludge Flow Rate : 204.0 M3/day

Centrifuge Operation Hours : 18.0 Hours/day (Max)
Centrifuge Capacity : 204.0/ 18.0 i.e. 11.3 M3/Hour
(Required)

No. Centrifuges Provided : 2 (1 Working/ 1 Stand-By)

Centrifuge Type : Solid Bowl
Centrifuge Capacity : 12.0 M3/Hour
(Provided)

Centrifuge Feed Pumps

Nos. : 2 ( 1 Working, 1 Stand By)

Type : Helical Screw Positive Displacement
Capacity : 12.0 M3/hour
Discharge Head : 0.6 Kg/cm2

Note: The Centrifuge Feed Pumps will draw thickened sludge from the Gravity Sludge
Thickener and feed the Solid Bowl Centrifuges continuously/ intermittently as required.

PROCESS DESIGN CALCULATION STP Page 19

 The Gravity Sludge Thickener and Centrifuge Supernatant will be recycled back through
gravity to the Terminal Pumping Station Wet Well.

Poly-Electrolyte : 1.5 Kg/ Ton Dry Solids x 6.12 Tons/day

Requirement (Max) i.e. 9.2 Kg/d
Poly Solution Strength : 0.1 %
Poly Solution Flow Rate : 9.2/ (1000 x 0.001) i.e. 9.2 M3/day
i.e. 511.1 LPH

No. Poly Tanks : 2

Poly Tank MOC : RCC
Poly Tank Volume (Required) : 9.2 / 2 i.e. 4.6 M3
Poly Tank Plan Dimensions : 1.8 M x 1.8 M
Poly Tank Side Water Depth : 1.5 M
Poly Tank Volume (Provided) : 1.8 x 1.8 x 1.5 i.e. 4.9 M3 i.e. OK
Velocity Gradient : 200 s-1
Accessory : Electric Motor/ Worm Gear Box/ SS 304
Agitator :

No. Poly Dosing Pumps : 2 (1 Working, 1 Stand-By)

Pump Capacity : 1000 LPH
Pump Discharge Head : 2.0 Kg/cm2
Pump MOC : PP

Centrifuge Shed Dimensions

Plan Dimensions : 8.0 M x 6.0 M

Ground Floor Height : 4.0 M
Top Floor Height : 4.5 M

19.0 OUTFALL MANHOLE

No. : 1
Material of Construction : RCC
Diameter : 2.0 M
Side Water Depth : 1.7 M

Note: Treated Sewage will be discharged from Outfall Manhole to disposal by Client.

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