Vous êtes sur la page 1sur 294

Table of Contents

Page

Section 1 Introduction and General Planning Requirements


1.1 Purpose of This Volume 3
1.2 Who Should Use This Volume 3
1.3 Related Reference Material 3
1.4 General Planning and Design Approval Requirements 4
1.5 Guidelines for Design Calculations 5
1.6 Guidelines for Drawings 7

Table 1.1 Recommended Population Equivalent 6


Figure 1.1 Typical Hydraulic Profile 9
Figure 1.2 Typical Process and Installation Diagram 10
Figure 1.3 Typical Process Flow Diagram 11
Figure 1.4 Typical Mass Balance Diagram 12
Figure 1.5 Typical Electrical Single Line Diagram 12

Section 2 Design Overview
2.1 Treatment Plant Classification 15
2.1.1 Classification by Biological Treatment 15
Processes
2.1.2 Classification by Treatment Plant Capacity 16
2.2 Treatment System Selection / Design 16
2.2.1 General Selection Considerations 16
2.2.2 Design Stages 20
2.2.3 Detailed Design Criteria 20
2.3 Safety and Health Principles 23
2.3.1 General Safety 23
2.3.2 Structural Safety 24
2.3.3 Equipment and Electrical Safety 25

Table 2.1 Classification by Treatment Plant Capacity 16

Section 3 Sewage Characteristics and Effluent Discharge Requirements


3.1 Introduction 29
3.2 EQA Effluent Standards 29
3.2.1 Purpose of Effluent Standards 29
3.2.2 Interpretation of EQA Effluent Standards 29

i
3.3 Design Requirements to Achieve EQA Effluent Standards 30
3.3.1 Purpose of Design Requirements 30
3.3.2 Design Values 30
3.4 Sewage Pollutants Removal 31
3.4.1 Biochemical Oxygen Demand (BOD5) 31
3.4.2 Total Suspended Solid (TSS) 32
3.4.3 Chemical Oxygen Demand (COD) 32
3.4.4 Oil and Grease (O&G) 32
3.4.5 Nitrogenous Compound 33
3.4.6 Phosphorus Compound 33
3.5 Sludge Characteristics and Treatment Requirements 34

Table 3.1 Design Influent Values 30


Table 3.2 Design Effluent Values 31

Section 4 Requirements for Physical Design


4.1 Introduction 37
4.2 Treatment Plant Siting 37
4.2.1 Buffer Zones 37
4.2.2 Siting Criteria 39
4.2.3 Environmental Impact Assessment 39
4.2.4 Hazard and Operability Studies 40
4.3 Treatment Plant Sizing 40
4.3.1 Modular Units 40
4.3.2 Standby Units 40
4.3.3 Back-up Capacity 41
4.3.4 Design Flow 42
4.4 Land Area Requirements 42
4.4.1 Class 1 and 2 Plants 42
4.4.2 Mechanised Class 3 to 4 Plants 42
4.4.3 Aerated Lagoons and Stabilisation Ponds 43
4.4.4 Imperfect Sites 43
4.4.5 Reduced Land Areas for STPs 43

ii
4.5 Mechanical and Electrical Requirements 53
4.5.1 Mechanical Installation 53
4.5.2 Vibration 54
4.5.3 Noise 54
4.5.4 Safety Around Equipment 55
4.5.5 Motors, Controllers and Motor Starters 55
4.5.6 Power Supply Systems 57
4.5.7 Back-up Generator 58
4.5.8 Switchgear and Control Gear Assemblies 59
4.5.9 Control Cabinets 60
4.5.10 Control Requirements 62
4.5.11 Supervisory Control and Data Acquisition 64
Systems (SCADA)
4.5.12 Early Warning System (EWS) 65
4.5.13 Instrumentation 65
4.5.14 Cables and Cabling Installation 67
4.5.15 Earthing and Lightning Protection 68
4.5.16 General Purpose Power 69
4.5.17 Manuals, Drawings and Labelling 69
4.5.18 Hazardous Areas 70
4.6 Material Requirements for STP Structures and Installations 70
4.6.1 Concrete and Reinforcement 70
4.6.2 Steel 72
4.6.3 Fibre Reinforced Plastic (FRP) 74
4.6.4 Aluminium 76
4.6.5 HDPE (High Density Polyethylene) 77
Table 4.1 Modulation Requirements 40
Table 4.2 Land Area Requirements for Class 1 44
Table 4.3 Land Area Requirement for Class 2 45
Table 4.4 Land Area Requirements for 45
Table 4.5 Land Area Requirements for 46
Table 4.6 Required Land Area for Stabilisation Pond and Aerated 47
Lagoons

iii
Figure 4.1 STP Land Area Requirements for Planning Layout Approval 49
for New Development
Figure 4.2 STP Land Area Requirements for Structure Plans 50
Figure 4.3 Guidelines For Buffer Zone 51
Figure 4.4 Plan View of Buffer Zone Requirements 52
Figure 4.5 Clear Working Space 57

Section 5 Requirements for Individual Treatment Processes


5.1 Introduction 81
5.2 Design of Primary Screens 84
5.2.1 Purpose of Primary Screens 84
5.2.2 Inlet Chamber 84
5.2.3 Design Requirements for Primary Screens 85
5.2.4 General Requirements 86
5.3 Design of Pump Stations 91
5.3.1 Purpose of Pump Stations 91
5.3.2 Design Requirements 91
5.3.3 General Requirements 95
5.4 Design of Secondary Screens 100
5.4.1 Purpose of Secondary Screens 100
5.4.2 Design Requirements 100
5.5 Design of Grit and Grease Chambers 101
5.5.1 Purposes of Grit and Grease Chambers 101
5.5.2 General Requirements 102
5.5.3 Design Criteria 103
5.6 Design of Balancing Tanks 105
5.6.1 Purposes of Balancing Tanks 105
5.6.2 Design Requirements 105
5.7 Design of Primary Sedimentation Stage 106
5.7.1 Purposes 106
5.7.2 Design Requirements 106
5.8 Design of Biological Treatment Stage 108
5.8.1 Introduction 108
5.8.2 Conventional Activated Sludge System (CAS) 109
5.8.3 Extended Aeration System (EA) 111
5.8.4 Rotating Biological Contactors (RBC) 114
5.8.5 Trickling Filter 116

iv
5.8.6 Sequencing Batch Reactors (SBR) System 117
5.8.7 Design Requirements for Hybrid Systems 120
5.8.8 Design for Nutrient Removal for Sensitive 120
Receiving Water
5.9 Design of Secondary Clarifiers 122
5.9.1 Purpose 122
5.9.2 Design Requirements 122
5.9.3 Multiple Hoppers 123
5.10 Disinfection 125
5.10.1 Design Requirements 126
5.11 Design of Flow Measurement Devices 130
5.11.1 Purpose of Flow Measuring Devices 135
5.11.2 Design Requirements for Flow Devices 135
5.12 Sludge Holding, Treatment and Disposal 136
5.12.1 Introduction 136
5.12.2 Sludge Strategy in General 137
5.12.3 Provision of Sludge Holding, Treatment and Disposal 138
5.12.4 Design Criteria 139
5.13 Tertiary Treatment 144
5.13.1 Introduction 144
5.13.2 Design Requirement 144

Table 5.1 Requirement for Inlet Chamber 84


Table 5.2 Provision of Primary Screens 85
Table 5.3 Design Parameters for Primary Screens 86
Table 5.4 Recommended Design Parameters for Inlet Pump Stations 99
Table 5.5 Provision Requirement of Secondary Screens 100
Table 5.6 Design Parameters for Secondary Screens 101
Table 5.7 Provision Requirement of Grit and Grease Removal System 103
Table 5.8 Design Parameters for Grit Chambers 103
Table 5.9 Design Parameters for Grease Chambers 104
Table 5.10 Design Parameters for Balancing Tanks 106
Table 5.11 Design Parameters for Primary Sedimentation 108
Table 5.12 Design Parameters for Conventional Activated Sludge 110
System
Table 5.13 Design Parameters for Extended Aeration 111
Table 5.14 Design Parameters for RBC Plants 112

v
Table 5.15 Design Parameters for Trickling Filter 117
Table 5.16 Design Requirements for SBR System 119
Table 5.17 Design Requirement for Biological Nutrient Removal 120
System
Table 5.18 Design Parameters for Secondary Clarifiers 124
Table 5.19 Requirements for Disinfection Facility 126
Table 5.20 Design Guides for Disinfection with Ultra-Violet (UV) 130
Table 5.21 Design Guide for Disinfection with Hypochlorite 133
Table 5.22 Design Guide for Intermittent Disinfection 134
Table 5.23 Design Parameters for Flow Devices 135
Table 5.24 Sludge Generation Rates 136
Table 5.25 Design Parameters for Sludge Thickening 139
Table 5.26 Design Parameters for Aerobic and Anaerobic Digestion 140
Table 5.27 Recommended Design Parameters for Sludge Treatment 141
Figure 5.1 Typical Treatment Process Flow Chart 82
Figure 5.2 Typical Elements and Process Flow Diagram of a Sewage
Treatment Plant 83
Figure 5.3 Typical Drawing of Double Penstock 85
Figure 5.4 Quantities of Screenings Collected From Primary Screens 88
Figure 5.5 Typical drawing of screen chamber based on depth. 89
(<5m for different PE)
Figure 5.6 Typical drawing of screen chamber based on depth. 90
(<5m for different PE)
Figure 5.7 Typical Dimensions of Wet-well Submersible Pump Station 93
Figure 5.8 Typical Dimensions of Dry-well Submersible Pump Station 94
Figure 5.9 Typical details of wet-well pump station 97
Figure 5.10 Typical details of dry-well pump station 98
Figure 5.11 Fine Bubble Diffuser Air – Extended Aeration System 113
Figure 5.12 Oxidation Ditch Activated Sludge System 114
Figure 5.13 Deep Shaft Activated Sludge System 116
Figure 5.14 Rotating Biological Contactor (RBC) Systems 119
Figure 5.15 Typical Process Flow Diagram for Biological Nutrient 121
Removal System
Figure 5.16 Schematic illustration of ultraviolet disinfection system 126
with stilling plate for flow conditioning and elongated
weir for level control

vi
Figure 5.17 Profile schematic of lamp modules relative to inlet and 127
outlet structure
Figure 5.19 Chemical-feed system schematic 127
Figure 5.20 Sludge Treatment and Disposal Strategy 143
Figure 5.21 Typical Roof Details for Covered Sludge Drying Bed 146

Section 6 Requirements for Ancillary Facilities


6.1 Introduction 149
6.2 Water Supply and Wash Water 149
6.3 Mess Facilities and Ablutions 150
6.4 Roads and Access 152
6.5 Drainage 153
6.6 Fencing and Security 154
6.7 Beautification Zone and Landscape 159
6.8 Stores and Workshops 159
6.9 Spares 159
6.10 Yard Lighting 161
6.11 Sampling Facilities 162
6.12 Auto Restart Facilities 162
6.13 Safety Facilities 163
6.14 Doors 163
6.15 Fire Hydrant 163
6.16 Power Supply 164
6.17 Internal Sanitation (Toilet) 164
6.18 Lifting Requirement 164
6.19 Ventilation 165
6.20 Process Water 168
6.21 Aesthetic 168
6.22 Close Turfing 168
6.23 Standard Roofing and related requirement 168
6.24 Painting 169

Table 6.1 Minimum Number of Recommended Water Stand 150


Pipe and Location
Table 6.2 Spare Part 161
Table 6.3 Numbers of Unit and Location of Compound Lighting 161

vii
Table 6.4 Common ventilation rates 167
Table 6.5 Painting System Index – Colour Standards 170
Figure 6.1 Standard Details for Stand Pipe 151
Figure 6.2 Typical for Administration and Mess Facilities Building 152
Figure 6.3 Typical Details of Road Pavement 152
Figure 6.4 Typical Road Section of Site Road 152
Figure 6.5 Typical Drawing of Brickwall Fencing and Gate 155
Figure 6.6 Brickwall Fencing 156
Figure 6.7 Precast Fencing 157
Figure 6.8 Masonry Fencing 158
Figure 6.9 Typical Details of Compound Lighting 162
Figure 6.10 Typical Detail of Guard Rail 171
Figure 6.11 Typical Detail of Lifting Davit 172
Figure 6.12 Typical Detail of A-Frame Lifting Facilities 172

Section 7 Special Requirements


7.1 Temporary Treatment Plants 175
7.1.1 Definition 175
7.1.2 Category 1: Temporary Treatment Plant for 175
Upgrading of Facilities
7.1.3 Category 2: Temporary Plants for New Housing 176
Development
7.2 Treatment Plants Located Within Buildings 179
7.2.1 Introduction 172
7.2.2 Specific Guidelines and Requirements 180
7.3 Fully Enclosed Treatment Plant 181
7.3.1 Definition 185
7.3.2 General Requirements 185
7.3.3 Specific Requirements 186
7.4 Covered and Buried Treatment Plants 194
7.4.1 Definition 194
7.4.2 General 194
7.4.3 Specific Requirements for Covered or Buried 194
Plants under 5,000 PE or Less

viii
7.5 Guidelines for Homestead Developments 197
7.5.1 Single Developments up to 30 Units or 150 197
PE in Total
7.5.2 Single Developments Over 30 Units in Total 197
with Average Housing Density Greater Than
Five Units per Hectare
7.5.3 Single Developments Over 30 Units in Total with 197
Average Housing Density Less Than Five Units
per Hectare
7.6 Non-Compliance with Standards 198
7.6.1 Introduction 198
7.6.2 Types of Incident’s that Can Cause Treatment 198
Plant Failure
7.7 Energy Saving 201
7.8 Recycle and Reuse 201

Section 8 Package Sewage Treatment Plant


8.1 Definition 205
8.2 Land Area Requirement 205
8.3 Design Requirement 206
8.4 Components of Package Sewage Treatment Plant 206
8.4.1 Layout, Piping and Arrangement of Prefabricated 206
Biological Treatment System
8.4.2 Prefabricated Tanks 206
8.4.3 Process Treatment Units/Components 207
8.5 Appurtenances 208
8.5.1 Piping system 208
8.5.2 Pumping System 209
8.5.3 Diffuser 210
8.5.4 Flow Distribution Chamber 210
8.5.5 Manhole Cover/Inspection Chamber Cover 210
8.5.6 Anchor System Loading 211
8.5.7 Landscaping 211
8.5.8 Odour Treatment 211
8.5.9 Ancillary Facilities 212
8.6 Marking and Labelling 212

ix
Table 8.1 Minimum Design Life Span of Package Sewage 206
Treatment Plant Components
Table 8.2 Recommended Number of Tanks and Effective Volume 207
Consideration for Various Unit Processes
Table 8.3 Technical Requirements of Pumping System 209
Table 8.4 Technical Requirements of Manhole Cover 210

x
Appendices
Appendix A Table
Table A1 Contaminants of Concern in Sewage Treatment 216
Table A2 Typical Composition of Untreated Domestic Sewage 217
Table A3 Major Biological Treatment Processes Used for Sewage 218
Treatment
Table A4 Interim National River Water Quality Standards for Malaysia 220
Table A5 River Clarification 221
Table A6 The Occupational Safety and Health Act 514, 1994 - Brief 222
Summary of Contents
Table A7 Permissible limits for potentially toxic elements in soil 223
Table A8 Options for disposal of Sludge and reuse of bio-solids 224

Appendix B References
Malaysian Standards 227
British Standard 228
European Standard 229
ASTM Standard 231
AS Standard 232
Other Reference Materials 232
Other Guidelines in This Set 232

Appendix C Supervisory Control and Data Acquisition System (SCADA)


C-1 Introduction: Overview 237
C-2 Purpose 238
C-3 General Requirements 238
C-4 Architecture 238
C-5 SCADA Requirement 239
C-6 Operator Interface 240
C-7 Database 241
C-8 Alarm/Event Management 241
C-9 Historian 243
C-10 Graphical Trending 243
C-11 Report Format 244
C-12 Security 244
C-13 Scripting 245

xi
C-14 Interfaces 245
C-15 Distributed Server Architecture 245
C-16 Web Server 245
C-17 Digital Video Monitoring 246
C-18 Integrated Maintenance Management 246
C-19 Application Report 247
C-20 Application Programming Interface 247
C-21 User Documentation 248
C-22 Specifications and Sizing 248

Appendix D Duty and Standby Requirements

Table D.1 Duty and Standby Requirements for Activated Sludge 268
Systems (Utilising Diffused Aeration)
Table D.2 Duty and Standby Requirements for Activated Sludge 269
Systems (Utilising Mechanical Surface Aerator)
Table D.3 Duty and Standby Requirements for Rotating Biological 270
Contactor Systems
Table D.4 Duty and Standby Requirements for Trickling Filter Systems 271

Appendix E Glossary of Abbreviations

Glossary of Abbreviations 275

xii
Section 1

Introduction and General


Planning Requirements
Introduction and General Planning Requirements

2 Volume 4 Malaysian Sewerage


Industry Guidelines
Introduction and General Planning Requirements

1.1 Purpose of This Volume


This volume sets out the requirements of the National Water Services
Commission (SPAN) (referred to as the Commission in this document)
for the planning, design and construction of sewage treatment plants.
This volume contains the following:

a) An overview of considerations and criteria for sewage treatment


plant design.
b) Effluent discharge standards requirements and the capacity of
different sewage treatment processes to meet these standards.
c) Requirements for the siting and sizing of sewage treatment
plants.
d) Requirements for each stage of sewage treatment.
e) Minimum requirements for facilities ancillary to a sewage treatment
plant.
f) Other special requirements for temporary treatment plants, treatment
plants within buildings, homestead developments and exemptions
for non-compliance with standards.
g) Requirements of sludge treatment process and disposal.

The owner must comply with the requirements set out in this volume
when submitting an application for approval to the Commissioner.

This volume does not cover any aspect other than Sewage Treatment
Plant requirements. All internal plumbing approvals need to be approved
by Local Authorities.

1.2 Who Should Use This Volume


This Volume is primarily for owners, developers, consulting engineers
and Public Authorities whose developments include sewage treatment
plants.

1.3 Related Reference Material


This Volume does not cover all aspects of design and construction of
sewage treatment plants. Where information is not covered in this volume,
the designer shall follow the requirements given in MS 1228.

However, the information in this Volume shall take precedence over


MS 1228 where similar aspects are covered in these documents or where
there is conflicting information between the two documents.

Sewage Treatment Plants Volume 4 3


Introduction and General Planning Requirements

The procedures for certification of sewerage services are given in the


Malaysia, Volume 2 Sewerage Works Procedures.

All Standards references adopted during this revision exercise are compiled
and given in Appendix B.

1.4 General Planning and Design Approval Requirements


The application procedures for sewage treatment plants approval shall
follow the requirements given in MSIG Volume 2. In general, the
application for approval of a treatment plant shall include:

a) Sufficient land area for the sewage treatment plants plus additional
area to allow for extensions to the plant, where necessary.
b) Land of suitable configuration shall be provided.
c) Sufficient buffer zones.
d) The location of a sewage treatment plant in relation to a particular
catchment area. The plant unit processes shall be located at an
elevation which is not subject to flooding/wave action, or shall
otherwise be adequately protected against all flooding/wave
action.
e) Sufficient topographic features shall be included to indicate its
location in relation to streams and the point of discharge of the
treated effluent.
f) Schematic flow diagrams showing utility systems serving the
plant processes and the flow through various plant units.
g) Pipeworks, including any arrangements for bypass from individual
units. The direction of flow and the content in the pipes shall
also be clearly and permanently painted onto all exposed piping
works.
h) Hydraulic profiles showing the flow of sewage, supernatant liquor,
and sludge.
i) Location, dimensions and elevations of all existing and proposed
plant facilities.
j) Capacity of the effluent receiving drain/water course shall be able
to cater for additional discharge flow from the treatment plant.
k) Consideration for odour and noise mitigation and control through
good facility design, effective operation, containment, collection
and treatment.
l) Point of discharge of treated effluent (effluent outfall) and elevations

4 Volume 4 Malaysian Sewerage


Industry Guidelines
Introduction and General Planning Requirements

of high and low water levels of the receiving watercourse to


which the plant effluent is to be discharged.
m) Type, size, features, and operating capacity of all pumps, blowers,
motors and other mechanical devices together with manufacturer
catalogues.
n) Minimum, average and maximum hydraulic flows, velocities and
top water level in profiles.
o) Accessibility, landscaping and fencing.
p) Flow measurement facilities.
q) Materials, dimensions and specifications.
r) Ground conditions including levels, type, groundwater level and
safe bearing pressure of foundation.
s) Details of foundation and other structural design. Slope protection
works are required, where applicable.
t) All other components of the sewage treatment plant.
u) A technical report, which covers the ‘whole life cost’ evaluation
of the plant.
v) Process and instrumentation diagram.
w) Mass balance calculation

x) Clean and legible detailed drawings in standard format


y) Operation and Maintenance needs of the plant to be addressed
at the early planning stage.
z) Where required, an EA or EIA report is needed to identify,
predict, evaluate and communicate information concerning the
adverse and beneficial impacts of the proposed treatment plant.
aa) HAZOP requirement is necessary to identify the safety and
operability deficiencies in the design and operation of the treatment
plant.

1.5 Guidelines for Design Calculations


Design calculation for all unit processes shall be in sequence starting
from inlet works to biological treatments and sludge treatments as
shown in Figure 5.1. The calculation shall include:

a) Sizing of each unit processes and all mechanical equipment


involved.
b) Mass balance for overall system and each unit process.
c) Influent values.

Sewage Treatment Plants Volume 4 5


Introduction and General Planning Requirements

d) Design influent and effluent values in compliance with Section


3.3.2.
e) Treatment plant shall be designed based on design flow.
f) Hydraulic profile across the treatment units to be indicated onto
to the drawings.
g) Each unit process must comply with the design parameters set
in Section 5.
h) Calculation of PE to be based on Table 1.1.

Table 1.1 Recommended Population Equivalent

Type of Premises/ Establishment Population Equivalent


(Recommended))

Residential 5 per house

Commercial: 3 per 100 m2 gross area


Includes offices, shopping complex,
entertainment/ recreational centres,
restaurants, cafeteria, theatres

Schools/ Educational Institutions:


- Day schools/ Institutions 0.2 per student
- Fully residential 1 per student
- Partial residential 0.2 per non-residential student
1 per residential student

Hospitals 4 per bed

Hotels with dining and laundry facilities 4 per room

Factories, excluding process water 0.3 per staff

Market (wet type) 3 per stall

Market (dry type) 1 per stall

Petrol kiosks/Service stations 15 per toilet

Bus terminal 4 per bus bay

Taxi terminal 4 per taxi bay


(Ref: Malaysian Standard 1228)

6 Volume 4 Malaysian Sewerage


Industry Guidelines
Introduction and General Planning Requirements

Table 1.1 - Recommended Population Equivalent (Cont)

Type of Premises/ Establishment Population Equivalent


(Recommended)

Mosque/ Church/ Temple 0.2 per person


Stadium 0.2 per person
Swimming pool/ Sports complex 0.5 per person
Public toilet 15 per toilet
Airport 0.2 per passenger
0.3 per employee
Laundry 10 per machine
Prison 1 per person
Golf course 20 per hole
(Ref: Malaysian Standard 1228)

1.6 Guidelines for Drawings


All drawings shall be of standard format and orientation. The drawings
required include:

a) Overall development plan showing the whole sewerage system


and plant location.
b) Site layout plan showing the arrangement of the plant, buffer
zone, internal set backs and all neighbouring developments.
c) Site layout plans showing all the process units, main pipe runs,
electrical conduit corridors, site services (water, drains, lighting,
other services), roads and paving, landscaping, buildings, fencing
and finished level contours (or spot levels). The set out and
overall dimensions of the plant shall also be shown.
d) Site elevations of the plant with at least one section through
the plant in each direction. These sections shall extend at least
30 m from the plant boundary and include an indication of the
surrounding development (in block form only).
e) Process and instrumentation diagram (P&ID) showing all tanks,
pipes, channels, valves, mechanical equipment, instrumentation
and control loops. The P&ID can also act as a summary of
the design. It provides key details of each piece of equipment,
tank, piping, valves and instruments.

Sewage Treatment Plants Volume 4 7


Introduction and General Planning Requirements

f) Hydraulic profile showing all hydraulic pathways through the


plant including bypasses. Information to be shown includes
pipe sizes, invert levels, flow velocities, tank coping level, top
water level and freeboard. Top water level and velocities at
minimum flow, average flow and peak flow under design load
must be clearly indicated.
g) Schematic flow diagrams and mass balances showing flow through
all process units in the plant.
h) General arrangement drawings of each unit process. These
drawings shall be in sufficient details to clearly describe the shape,
size and function of each unit. The drawings shall show the
structure of the unit, piping, valves and fittings, instrumentation,
mechanical and electrical equipment, buildings, handrails, stairs,
ladders, step irons, site services such as water and lighting,
adjoining paving, roadworks, fencing, drainage, etc. Drawings
of all items should show the elevations, plan view and sectional
view (horizontally and vertically), where applicable.
i) Details are required of any object that would affect the operation
or maintenance of the plant that is not covered by a standard
drawing.
j) Required to use standard symbols and legend formats for all
drawings.

8 Volume 4 Malaysian Sewerage


Industry Guidelines
CL CL
TWL
TWL TWL FLOOD LEVEL IN RECEIVING
F.G.L. F.F.L. F.G.L. F.G.L. TWL F.G.L.

Sewage Treatment Plants


I.L. F.G.L. I.L. F.G.L. TWL TWL F.G.L. WATERCOURSE
TWL

Sewage Treatment Plants


I.L.
I.L.
SECONDARY SCREEN NORMAL WATER LEVEL
CLARIFIER DISTRIBUTION
CHAMBER OUTFALL MEASUREMENT
PRIMARY PUMPING VALVE FLUME
SCREEN STATION CHAMBER CHLORINE CONTACT
AERATION TANK TANK
CLARIFIERS

2.0m

1.8m

1.6m
Introduction and General Planning Requirements

1.4m

1.2m

1.0m

Volume 4

Volume 4
0.8m

0.6m

0.4m

0.2m

FGL

-0.2m

-0.4m HIGHEST FLOOD WATER LEVEL


NORMAL WATER LEVEL
-0.6M
OUTFALL MEASUREMENT
Figure 1.1 – Typical Hydraulic Profile

PRIMARY PUMPING VALVE CLARIFIER DISTRIBUTION CHLORINE CONTACT


SCREEN STATION CHAMBER SECONDARY SCREEN AERATION TANK CHAMBER CLARIFIERS TANK FLUME

HYDRAULIC PROFILE NOTES :


Figure 1.1 Typical Hydraulic Profile

1. THE LEVELS SHOWN ARE FOR INDICATIVE PURPOSES ONLY.

2. ACTUAL LEVELS SHALL BE DETERMINE FROM HYDRAULIC CALCULATIONS


OF ACTUAL PLANT DESIGN AND ACTUAL SITE SURVEY.

Page 7
9
Introduction and General Planning Requirements
Introduction and General Planning Requirements

Figure 1.2 Typical Process and Instrumentation Diagram

10 Volume 4 Malaysian Sewerage


Industry Guidelines
SCREEN CHAMBER GRIT CHAMBER GREASE CHAMBER BALANCING TANK SEQUENCING BATCH

Sewage Treatment Plants


REACTOR

Sewage Treatment Plants


Q =
Q =
Q = BOD = BLOWER
Water =
Filtrate = SS = Q =
Q=
Vortex BOD =
BOD = Skimmer Supernatant Decanter
M Q = SS =
SS = Q =
BOD =
Q = BOD =
RAW SEWAGE SS =
MLSS = SS =

MEASURING
Screen TANK

Grit Pump
Screen
Q= Aerator
BOD =
Mixer Balancing

Volume 4
SS = Q =
Pump

Volume 4
BOD = Q =
RAW SEWAGE M M
Filtrate = BOD =
Raw Sewage SS =
Pump

Grit Classifier
Q= Waste Sludge
BOD = Pump
SS =

RAW SEWAGE SLUDGE


Raw Sewage
Pump HOLDING TANK

Q =
PUMPING STATION (EXISTING)
Figure 1.3 Typical Process Flow Diagram

BOD =
Figure 1.3 Typical Process Flow Diagram

Oil & Grease Pump Transfer Pump


SS =
Oil Holding Tank Oil Discharge Tank Floor Drain Pit

11
Introduction and General Planning Requirements
Introduction and General Planning Requirements

9
Introduction and General Planning Requirements
Introduction
Introductionand
andGeneral
GeneralPlanning
Planning Requirements
Requirements

Figure 1.4 Typical Mass Balance Diagram


Figure
Figure 1.4
1.4 –– Typical
Typical Mass Balance
Balance Diagram
Diagram
INFLOW
INFLOWPARTICULARS
PARTICULARS
QQ = =
BOD
BOD= = 10%
10%SSSStotobe
beremoved
removed
SSSS= = PHYSICAL
PHYSICALTREATMENT
TREATMENT
1)1)PRIMARY
PRIMARYSCREEN
SCREEN
2)2)SECONDARY
SECONDARYSCREEN
SCREEN

QiQi= =
BOD= =
BOD Qe
SS= = QQ == Qi
Qi ++ Qr
Qr ++ Qw
Qw Qe ==
SS BOD == BOD
BOD ==
BOD
SS ==
SS SECONDARY
SS
SS ==
SECONDARY CLARIFIER
CLARIFIER

AERATIONTANK
AERATION TANK
OVERFLOW
OVERFLOW SS
SS CONC
CONC== OUTLET
OUTLET
MLSS= = BOD
MLSS BOD ==

Qr
Qr++Qw
Qw==
Qr, Xr BOD =
Qr, Xr BOD =
Qr = X Qi = SS =
Qr = X SS =
BOD = Qi =
BOD
SS ==
SS =

AEROBIC DIGESTED
AEROBIC DIGESTED
SLUDGE HOLDING TANK
SLUDGE HOLDING TANK

Qw =
Qw ==
BOD
BOD
SS ==
SS ==
1%DS
1%DS =

SLUDGE THICKENER
SLUDGE THICKENER

Qw =
Qw ==
BOD
BOD
SS ==
4%DS
SS =
4%DS =
Qw OVERFLOW =
Qw OVERFLOW =

Sludge to be pumped to Sand Drying Bed


For Dewatering
Sludge to 25% to
to be pumped Dry SolidDrying Bed
Sand
For Dewatering to 25% Dry Solid

Figure 1.5 Typical Electrical Single Line Diagram


Figure 1.5 - Typical Electrical Single Line Diagram
Figure 1.5 - Typical Electrical Single Line Diagram
S IN G L E L IN E L A Y O U T D IA G R A M F O R A IR B L O W E R S IN G L E L IN E L A Y O U T D IA G R A M F O R
M O T O R S E .Q P U M P S A N D S S T P U M P R A W S E W A G E S U B M E R S IB L E P U M P
S IN G L E L IN E L A Y O U T D IA G R A M F O R A IR B L O W E R S IN G L E L IN E L A Y O U T D IA G R A M F O R
M O T O R S E .Q P U M P S A N D S S T P U M P R A W S E W A G E S U B M E R S IB L E P U M P
ARM Cable

ARM Cable
PUMP PUMP

PUMP PUMP
ARM Cable

ARM Cable
Using 4c x 2.5mm ARM Cable

Using 4c x 2.5mm ARM Cable

Using 4c x 2.5mm ARM Cable

Using 4c x 2.5mm ARM Cable


no.1 (3.7kW)

Air blower motor no.2 (3.7kW)

2 x 1.5mm sq. PVC

sq. PVCsq. PVC

SUBMERSIBRE
4c x 2.5mm

4c x 2.5mm
SUBMERSIBLE
EQ Pump no. 1 (0.6kW)

EQ Pump no. 2 (0.6kW)


ARM Cable

Using 4c x 2.5mm ARM Cable

Using 4c x 2.5mm ARM Cable

Using 4c x 2.5mm ARM Cable


Air blower motor no.1 (3.7kW)

Air blower motor no.2 (3.7kW)

x 1.5mm sq. PVC

PVCsq. PVC
SUBMERSIBRE
Outlet Outlet

x 2.5mm

x 2.5mm
SUBMERSIBLE
To Control Circuit

CIRCUIT
2 x 2.5mm
EQ Pump no. 1 (0.6kW)

EQ Pump no. 2 (0.6kW)


2.5mmmotor

D IS T R IB U T IO N B O X F O R
Using

Using
13A Socket
To Control Circuit
Airx blower

CIRCUIT
1.5mm
x 2.5mm

L IG H T IN G A N D P O W E R
Using 4c

Using 4c
RAW SEWAGE

RAW SEWAGE

TO CONTROL
NO.1 (2.4kW)

NO.2 (2.4kW)
E. STOP Using 2Using

Using 2Using

2 x sq.

D IS T R IB U T IO N B O X F O R
13A Socket

x 1.5mm

L IG H T IN G A N D P O W E R
Using 4c

TO COMPOUND LIGHTING (2 nos)


RAW SEWAGE

RAW SEWAGE

TO CONTROL
NO.1 (2.4kW)

NO.2 (2.4kW)

Using 2 Using

D S D S
TO 36W FLOUERECENT LIGHT

TO COMPOUND LIGHTING (2 nos)


TO 13A SOCKET OUTLET

D S D S D S
TO 36W FLOUERECENT LIGHT
TOR

TOR

TOR

TOR

TO 13A SOCKET OUTLET


E. STOP

D S
TOR

TOR
TOR

TOR

TOR

TOR

PSR
DOL

DOL

DOL

DOL

SPARE
TOR

TOR
A

A
20A SPN20A SPN
TPN

TPN

TPN

TPN

SPN

DOL
MCB 6APSR

DOL
DOL

DOL

DOL

DOL
MCB

MCB

MCB

MCB
MCB

MCB
MCB 20A

MCB 20A

MCB 16A

MCB 16A

SPARE
A

A
TPN20A TPN20A

TPN20A TPN20A
20A TPN

20A TPN

16A TPN

16A TPN

SPN6A SPN6A
6A SPN

MCB

MCB

MCB
DOL

DOL
MCB

R Y B
MCB

MCB

MCB

24T

3x5A
0 -5 0 0 V
R Y B
R YS /sB
w
3x5A
24T
10A

20A
20A

0 -4 0 A
6A

3x5A 0 -5 0 0 V
S /s w 0 -5 0 0 V R SY/s wB
S /s w
PSR P HA SE S EQ UENC E 3x5A 0 -3 0 A
10A

20A
20A

R E L A Y0 -4 0 A
6A

S /s w 0 -5 0 0 V
S /s w S /s w
4 0 /0 .3 A 4 p R C C B 4 0 /0 .3 A 4 p R C C B 4 0 /0 .1 A
2P R CCB
PSR P HA SE S EQ UENC E 0 -3 0 A
R E LA Y E E
40A TP N 10KA M C C B S P +N 30K A 3 0 A T P + N 1 0SK/s
AwM C C B
1 04 0K/0
A .1
MAC C B
4 0 /0 .3 A 4 p R C C B 2P R CCB 4 0 /0 .3 A 4 p R C C B
U S IN G 4 C x 1 6 m m P V C /S W A P V C A R M . C A B L E U S IN G 4 C x 1 0 m m P V C /S W A /P V C A R M . C A B L E U S IN G 2 C x 6 m
E m P V C /S W A /P V C A R M . C A B L E E
40A TP N 10KA M C C B 30A TP +N 10KA M C C B S P +N 30K A
10 KA M CCB
40A TP+N 30A TP +N 30A SP+N
U S IN G 4 C x 1 6 m m P V C /S W A P V C A R M . C AMBCL CEB U S IN G 4 C x 1 0 m m P V C /S W A /P V C A R M . CMACBCLB E U S IN G 2 C x 6 m m P V C /S W A /P V C A R M .MCCAC BBLE

40A TP+N R Y B 30A TP +N 30A SP+N


MCCB MCCB MCCB
6A 0 -50 0V
V .s .s w
R Y B
3 x 6 0 /5 A 0 -6 0 A
6A V .s .s w 0 -50 0V
V .s
P .s
HA wS E S E Q U E N C E
PSR
R E L A Y 0 -6 0 A
3 x 6 0 /5 A
6 3 /0 .3 A 4 pV .s
RC .sC
wB

PSR PHASE SEQUENCE E


6 0 A T P + N 2R5EKLAA Y
(4 P O L E ) M C C B

6 3 /0 .3 A 4 p R C C B

E
6 0 A T P + N 2 5 K A (4 P O L E ) M C C B S IN G L E L IN E L A Y O U T D IA G R A M F O R
415 V S U P P LY M A IN S W IT C H B O A R D
3 PHASE
T N B M E T E R IN G
PANEL S IN G L E L IN E L A Y O U T D IA G R A M F O R
415 V S U P P LY M U L T IC O R E A R M O U R E D
3 PHASE C ABLE TO M A IN S W IT C H B O A R D
T N B R E Q U IM E N T
T N B M E T E R IN G
PANEL
M U L T IC O R E A R M O U R E D
IN C O M IN G S C
U APBPLLEYT F
OR O M
T N B R E Q U IM E N T
M A IN D B 4 1 5 V

IN C O M IN G S U P P L Y F R O M
M A IN D B 4 1 5 V

12 Volume 4 Malaysian Sewerage


10 Volume 4 Industry Guidelines
Malaysian Sewerage
Industry Guidelines
10 Volume 4 Malaysian Sewerage
Industry Guidelines
Section 2

Design Overview
Design Overview

14 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

2.1 Treatment Plant Classification

2.1.1 Classification by Biological Treatment Processes

The microorganisms in sewage treatment can be grown in a form of


fixed film, suspension or a combination of both. Hence, biological
treatment processes for sewage treatment works can be classified under
one of the following headings:

a) Attached Growth Processes


b) Suspended Growth Processes
c) Combined Processes (Hybrid)

2.1.1.1 Attached Growth Processes

In an attached growth process, the active microorganisms grow and


attach on the mobile or immobile medium (rock or plastic) that is in
contact with sewage. The surface area of the biomass is used as the
practical measure of the total organism activity. Types of attached
growth processes include:

a) Trickling Filter (TF)


b) Rotating Biological Contactor (RBC)
c) Submerged Biological Contactor (SBC)
d) Fluidised Bed
e) Packed Bed Reactor

2.1.1.2 Suspended Growth Processes

In a suspended growth process, active microorganisms remain in


suspension in the sewage and their concentration is usually related to
mixed liquor suspended solid (MLSS) or mixed liquor volatile suspended
solid (MLVSS). This system was developed as a result of studies
that showed that if sewage is aerated over a long period of time, the
organics in the sewage are removed by the active microorganisms grow
during the process.

Types of suspended growth processes include:

a) Waste Stabilisation Pond System


b) Aerated Lagoon
c) Conventional Activated Sludge (CAS)

Sewage Treatment Plants Volume 4 15


Design Overview

d) Extended Aeration (EA)


e) Oxidation Ditch (OD)
f) Deep Shaft (DS)
g) Sequencing Batch Reactor (SBR)
h) Any other treatment processes which comply with the design
principles of one of the above processes.

2.1.1.3 Hybrid Processes - Attached Growth with Suspended


Growth

Recent developments in sewage treatment technology include the


combination of various attached growth and suspended growth processes
to obtain the best performance and most economical treatment of
sewage.

One of the advantages of Hybrid Process is the process combines the


stability and resistance to shock loads of an attached growth process
and the capability to produce high-quality effluent of an suspended
growth system.

Hybrid processes can be used to upgrade existing attached growth and


suspended growth process, in particularly plants with high suspended
solids in the final effluent due to poor solids settlement in the final
clarifier.

2.1.2 Classification by Treatment Plant Capacity

Sewage treatment plants are also classified in accordance to the design


capacity in terms of population equivalent (PE). Table 2.2 tabulates 4
clarifications to be adopted.

Table 2.1 - Classification by Treatment Plant Capacity

Classification PE
Class 1 ≤1000
Class 2 1001 – 5000
Class 3 5001 – 20000
Class 4 > 20000

2.2 Treatment System Selection / Design

2.2.1 General Selection Considerations

The following factors must be considered when selecting a sewage


treatment process:

16 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

Process The applicability of a process is evaluated on the basis of past


experience, data from full-scale plants and pilot data from
treatment plant studies. If new or unusual conditions are
encountered, pilot-plant studies are necessary.

Flow Range The selected process should be matched to the expected flow
range.

Flow Variation Most unit operation and processes work best with a constant
flow rate, although some variation can be tolerated. If the flow
variation is too great, flow equalisation may be necessary.

Influent Sewage The characteristics of the influent will affect the types of
processes to be used and the requirements for their proper
operation.

Inhibiting Identify the constituents present that may be inhibitory, and the
Constituents conditions they are in.

Climatic Temperature affects the rate of reaction of most treatment


Constraints processes.

Reaction Kinetics Reactor sizing is based on the governing reaction kinetics. Data
and Reactor for kinetic expressions are usually derived from experience,
Selection literature and results of pilot-plant studies.

Performance Performance is usually measured in terms of effluent quality,


which must be consistent with the given effluent discharge
requirements.

Treatment Residuals The types and amounts of solid, liquid and gaseous residuals
produced must be known or estimated.

Sludge Handling In many cases, a treatment method should be selected only


Constraints after the sludge processing and handling options have been
explored.

Environmental Nutrient requirements must be considered for biological


Constraints treatment processes. Environmental factors, such as the
prevailing winds and wind directions, may restrict the use of
certain processes, especially where odours may be produced.

Sewage Treatment Plants Volume 4 17


Design Overview

Chemical Classify chemicals and amounts that must be committed for


Requirements a long period of time for the successful operation of the unit
operation or process.

Energy The energy requirements, as well as probable future energy


Requirements costs, must be known if cost-effective treatment systems are to
be designed.

Other Resource Identify additional resources that must be committed to the


Requirements successful implementation of the proposed treatment system
using the unit operation or process in question.

Reliability Consider the long-term record of the reliability of the unit


operation or process under consideration.

Complexity Evaluate the complexity of the process to operate under


routine conditions and under emergency conditions
such as shock loadings, as well as the level of training
the operator must have to operate the process.

Ancillary Processes Identify the required support process and the effect on the
effluent quality, especially when they become inoperative.

Compatibility The unit operation or process shall be used successfully with


existing facilities, plant expansion and modifications.

Odour and Noise Odour and noise pollution should be minimised to the lowest
possible level.

Aesthetics The selected treatment process should aesthetically suit the


development site.

Safety and The chosen treatment process shall be designed with utmost care
Operability to facilitate safe operations at all times as well as to incorporate
safety features for the protection of operators. See Section 2.3.

18 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

Land Requirements A more compact plant component may perform equally well to a
component taking up more land and thus would be preferential,
provided there was no significant component cost differences.

Ease of Operation This will dictate whether plant has to be continuously or


and Maintenance intermittently operated and whether skilled or relatively
unskilled personnel would be required to carry out the operations
and maintenance works.

Modulation Modulation refers to the ability of process units to be expanded


in tandem with flow increases. Modulation minimises the time
that the plant sits idle before utilisation and lowers initial capital
outlay.

Standardisation This brings about economics on design effort, material


procurement, quality checks, spares and maintenance costs.

Adaptability Adaptability refers to the ability to readily upgrade or uprate


the performance of a treatment plant with relatively minor extra
works.

Sludge Management This is an important aspect that needs careful evaluation.


Treatment systems that minimise waste sludge production,
and which produce a relatively stable sludge should be given
preference. See Section 5.12

Overall Cost This will include considerations of capital, operation and


maintenance costs. Spare parts costs related to maintenance
can be hidden costs that also need consideration, particularly
where there may be long time delays obtaining parts or specialist
inputs are required.

Sewage Treatment Plants Volume 4 19


Design Overview

2.2.2 Design Stages

The design of a sewage treatment plant comprises the following


stages:

Process Design In this stage, a suitable sequence of processes are selected


to meet stipulated final effluent requirements for the plant
concerned.
Functional Design In this stage, calculation of capacities required are conducted
for all major units, channels, pumps and pipework and also
definition of control requirements. These include designs for
hydraulic, organic and solid loadings.
Detailed Design In this stage, structural design of units and channels, detailing
of pipelines, fittings and control valves, and selection of
mechanical, electrical and control equipment are conducted.

2.2.3 Detailed Design Criteria

For the following characteristics and requirements of a treatment plant,


the designer needs to consider a number of detailed design criteria:

a) Biochemical characteristics
b) Physical characteristics
c) Hydraulic characteristics
d) Mechanical & engineering requirements
e) Structural requirements
f) Constructional characteristics

2.2.3.1 Biochemical Characteristics

These involve the consideration of the following parameters:

a) Chemical characteristics of sewage


b) Good activity between microorganisms and waste materials
c) Optimal substrate concentration
d) Operational stability (half-life and activity decay profile)
e) Availability of suitable nutrients
f) Maintenance of favourable environment
g) Effect of filamentous growth & sludge bulking

20 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

h) Effect of dissolved oxygen


i) Productivity in lifetime usage
j) Minimum and maximum residence times
k) By-product formation
l) pH and temperature sensitivity
m) Storage stability
n) Reactor effluent quality-composition, colour, odour, etc.
o) Sludge production and frequency of desludging
p) Effective material balance analysis
q) Development of biochemical kinetic coefficient through pilot
plants

2.2.3.2 Physical Characteristics

These involve the examination of:

a) Particle shape and size distribution


b) Dry and wet bulk density
c) Swelling behaviour
d) Compressibility
e) Cohesion and particle attrition
f) Settlement
g) Floc formation
h) Settling velocity and sedimentation

2.2.3.3 Hydraulic Characteristics

These involve the examination of:

a) Hydraulic velocities in all unit processes


b) Mode of flow, upflow versus downflow
c) Axial dispersion and channelling
d) Pressure drop and head loss through plant
e) Residence time distribution and retention time
f) Stratification
g) Length to width ratio
h) Minimum velocity for onset of fluidisation

Sewage Treatment Plants Volume 4 21


Design Overview

i) Weir loadings
j) Overflow rate

2.2.3.4 Construction Characteristics

These involve the examination of:

a) Ground conditions and soil characteristics


b) Land availability
c) Type of plant depending on density and type of community to
be served
d) Distance to nearest habitation
e) Delivery and construction time
f) Recommended maintenance requirements
g) Start-up time and procedure
h) Noise levels
i) Technical capability to construct, operate and maintain the
system

2.2.3.5 Structural Requirements

a) Wall, slab, beams, columns and structure for sewage treatment


plant shall be in reinforced concrete.
b) Wall shall have minimum thickness of 225 mm.
c) Special foundation shall be provided where necessary.
d) Proper jointing to prevent breakage and leakage.
e) Water retaining and slope protection where applicable.

2.2.3.6 Mechanical & Electrical Requirements


a) The design shall simplify the equipment required, control system,
maintenance and operational procedures, while fulfilling the
intended performance and standard of service.
b) Equipment selected shall be from manufacturers (and models)
approved by the Commission.
c) Equipment, cable and cabling design and installation shall follow
IEE and TNB requirements.
d) Foundations shall be structurally designed and anchored to
withstand all loads imposed by the equipment. Reinforced
concrete foundations are preferred.

22 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

e) Joints shall be provided in all piping to allow removal of


equipment, meters, valves and other special items without causing
dismantling of the pipeline.
f) Equipment shall be equipped with safety protection (i.e. emergency
stop button, warning signage & etc.). See Section 4.5.
g) Pipeworks shall be neatly arranged and properly supported.
h) Appropriate type of control system provided for the treatment
plant. See Section 4.5.
i) Construction materials to be protected against corrosion due to
high humidity.
j) Earthing and protection against lightning.
k) System manuals, plant function diagrams, electrical system,
electrical circuit and instrument loop diagrams shall be provided
before the plant is pre-commissioned.
l) Detailed and shop drawing for equipment, instrumentation and
cable & cabling shall be provided.

2.3 Safety and Health Principles


Throughout the design, construction, commissioning, operation and
maintenance stages of a project, the following safety principles shall
apply:

2.3.1 General Safety

a) Malaysian Safety and Health legislations, standards and procedures


under Occupational Safety and Health Act (OSHA) 1994, Factories
and Machinery Act 1967 and etc. shall be followed.
b) Workforce, contractors, visitors and the public shall be safeguarded
against hazards, risk of serious injury and disease.
c) Adequate training shall be made available for the use of all
related equipment.
d) Appropriate training for end users to be identified and stipulated
in construction and procurement documents.
e) Appropriate responsibilities to be assigned throughout each stage
of a project.
f) Safety consciousness to be promoted by effective internal
communication, signs and media.
g) Safety performance shall be easily audited during operation and
maintenance.

Sewage Treatment Plants Volume 4 23


Design Overview

h) All accidents or potential serious incidents to be reported and


investigated.
i) Risk assessment to be undertaken at design of projects and
selection stage of procurement.
j) Safety information and operating documents to be provided by
suppliers.
k) Emergency contact list, showing telephone numbers of key
personnel and emergency services during office hours and out
of office hours, to be circulated to all parties involved in a
project.
l) Plant (certain sized) should be provided with Emergency Response
Plan (ERP)
m) All treatment plants, installation and construction sites, shall be
provided with perimeter fencing adequate to protect the public
from entry. All fencing shall be securely fixed and inspected.
n) All treatment plants, installations and construction sites shall
have adequate warning signs at or near the perimeter.
o) Access to construction sites shall be controlled to prevent
unauthorised access.

2.3.2 Structural Safety

a) Safe access to all working areas to be provided.


b) Routine requirement to enter confined spaces to be eliminated,
where practicable.
c) Any confined space requiring routine person entry, which contains
sewage, sludge or other foul water, to be ventilated.
d) Concrete slabs over wet wells, tanks and chambers shall have
double steel reinforcing.
e) Lifting eyes and bolts for slabs to be stainless steel or any other
durable and non-corrosive material.
f) Protection against falling (i.e. handrail, kick plate and toe plate)
to be provided.
g) Within plants and installations, all wells, sumps, channels,
chambers, tanks, etc. containing any liquid shall be covered,
walled or railed.
h) Major hazards to be identified and posted on site.
i) Protection and counter measures against spillage of dangerous
chemicals to be provided.

24 Volume 4 Malaysian Sewerage


Industry Guidelines
Design Overview

j) Permanent staircase shall be provided at inlet sumps, inlet wells,


inlet chambers and dry-wells. Steps and riser shall follow UBBL
Standard.
k) Adequate lifting facility shall be provided for heavy equipment,
which requires maintenance work.
l) Blower room shall not share common wall and foundation with
the control and genset room

2.3.3 Equipment and Electrical Safety

a) Electrical equipment and controls to be protected from unauthorised


access.
b) Individual electrical drives to be capable of being isolated and
locked off.
c) Electrical motors should be rated as continuous run.
d) Junction boxes for submersible pumps and float controls shall
be above floor level outside the wet-well.
e) All electrical equipment in sumps, wet-wells, inlet channels, inlet
chambers, sited below coping level to be explosion proof.
f) Lighting, appropriate to the needs of the end user, to be provided
in working areas.
g) Registration of electrical / motorised equipment with Department
of Safety and Health (DOSH).
h) Emergency stop button / isolator shall be provided for each
equipment.
i) Power driven machinery to be guarded.
j) All equipment to be regularly checked and prominently marked
accordingly

Sewage Treatment Plants Volume 4 25


Section 3

Sewage Characteristics and


Effluent Discharge
Requirements
Sewage Characteristics and Effluent Discharge Requirements

28 Volume 4 Malaysian Sewerage


Industry Guidelines
Sewage Characteristics and Effluent Discharge Requirements

3.1 Introduction

The Environmental Quality Act (EQA) 1974 specifies two standards


for effluent discharge: Standard A for discharge upstream of any raw
water intake, and Standard B for discharge downstream of any raw
water intake.

The current Third Schedule of the Environmental Quality Act 1974,


under the Environmental Quality (Sewage and Industrial Effluents)
Regulations, 1979, regulations 8 (1), 8 (2) and 8 (3) has been revisited
and the Department of Environment has proposed 8th Schedule for the
Act which stipulate effluent discharge limits for parameters specific
to domestic wastewater. The effluent discharge limits in 8th Schedule
are summarised in Table 3.2. All sewage treatment plants design shall
take into consideration of the 8th Schedule and shall comply with the
proposed limits.

3.2 EQA Effluent Standards

3.2.1 Purpose of Effluent Standards

Effluent standards are used to regulate the disposal of effluent from


STP to any receiving waters. The regulation of such discharges will
protect receiving waters and their associated aquatic ecosystems, and
will also protect public health from the harmful effects of untreated
sewage.

The need for these standards has been influenced by the fact that sewage
discharges contribute a significant amount of the biodegradable organic
matters, suspended solids and ammoniacal nitrogen to the nation’s
waterways.

3.2.2 Interpretation of EQA Effluent Standards

The EQA effluent standards have the following characteristics:

a) They represent maximum or absolute values which may not be


normally exceeded. For this reason, EQA effluent standards are
also referred to as absolute standards
b) Measurement of effluent quality is to be taken using a single
grab sample rather than a time averaged composite sample
c) Generally, effluent standards do not allow the flexibility for
them to be compromised through dilution and the assimilative
capacity of receiving water.

Sewage Treatment Plants Volume 4 29


Sewage Characteristics and Effluent Discharge Requirements

3.3 Design Requirements to Achieve EQA Effluent


Standards

3.3.1 Purpose of Design Requirements

The purpose of design requirements is to ensure that the effluent standards


can be met under the normal operations of a sewage treatment plant. The
quality of effluent from a STP is expected to vary due to the natural
variability in the flows and loads into the plant. Therefore, the design
effluent parameter shall be less than the required effluent standards to
ensure that, when the plant is under normal operation, any grab sample
of effluent will comply with the consent EQA effluent standards.

3.3.2 Design Values

Typical composition of untreated domestic sewage is given in Table


A.2, while Table 3.1 tabulates the design influent values to be adopted
in the design of a treatment plant.

Table 3.1 - Design Influent Values

Value (g/
Parameter Value (mg/l)
capita.day)
Biochemical Oxygen Demand (BOD5) 56 250
Suspended Solids (SS) 68 300
Chemical Oxygen Demand (COD) 113 500
Total Nitrogen (TN) 11 50
Ammoniacal nitrogen (AMN) 7 30
Total Phosphorus (TP) 2 10
Oil and Grease (O&G) 11 50

These design values allow for transient reductions in treatment efficiency,


due to periodic plant maintenance and unforeseen high impulse of
hydraulic and organic loadings on sewage treatment process units. All
STP shall be designed to produce final effluents with BOD5, SS, COD,
O&G and AMN values less than or equal to the design effluent values.
This is to ensure a high degree of consistent compliance with the
required effluent standards. The effluent E.Coli compliance is subject
to the sensitivity of the receiving watercourse and of the Commission’s
directive.

30 Volume 4 Malaysian Sewerage


Industry Guidelines
Sewage Characteristics and Effluent Discharge Requirements

Table 3.2 - Design Effluent Values


Effluent Discharge to
Effluent Discharge to Rivers / Stream
Stagnant Water Bodies*
Parameter
Standard A Standard B Standard A Standard B
Absolute Design Absolute Design Absolute Design Absolute Design
BOD5 20 10 50 20 20 10 50 20
SS 50 20 100 40 50 20 100 40
COD 120 60 200 100 120 60 200 100
AMN 10 5 20 10 5 2 5 2
Nitrate
20 10 50 20 10 5 10 5
Nitrogen
Total
N/A N/A N/A N/A 5 2 10 5
Phosphorus
O&G 5 2 10 5 5 2 10 5

Notes:
NA = Not Applicable
All values in mg/l unless otherwise stated.
* Stagnant Water Bodies refer to enclosed water bodies such as lakes, ponds and
slow moving watercourses where dead zone occur.

In cases where treatment plant discharge capacity is higher than the


receiving river flow rates, the final effluent quality has to be designed
to ensure minimal environmental impact.

3.4 Sewage Pollutants Removal

3.4.1 Biochemical Oxygen Demand (BOD5)

BOD5 is used to measure the biodegradable organic fraction in raw sewage.


Based on standard BOD5 measurement, the oxygen demand measured
is usually influenced by the following three (3) phenomena:

a) Oxygen demand by breakdown of soluble carbonaceous matter


b) Oxygen demand by breakdown of suspended particulate carbonaceous
matter
c) Oxygen demand by oxidation of ammonia to nitrate by nitrifying
bacteria present in the effluent sample

After undergoing biological treatment in the secondary reactor, residual


soluble carbonaceous BOD 5 matter present in the effluent reduces
in concentration to below 15 mg/l. Subsequently, nitrifying bacteria
populations tend to grow rapidly feeding on ammonia which is present

Sewage Treatment Plants Volume 4 31


Sewage Characteristics and Effluent Discharge Requirements

in the partially treated sewage. Nitrification may not be complete at


levels of 5 mg/l of residual soluble carbonaceous biodegradable matter.
It depends on whether sufficient oxygen is available for the oxidation
of ammonia to nitrate. Hence, all BOD 5 measurements shall adopt
nitrification inhibition step to ensure that the carbonaceous oxygen
demand is reflected accurately in the overall BOD5 measurement.

3.4.2 Total Suspended Solid (TSS)

Sewage contains solid materials that can settle at the bottom and also
give impact on the benthic life. They can also appear in suspension
solids form that can increase turbidity and affect the light availability
for aquatic life. The amount of solids in sewage is usually measured as
“total suspended solids” or TSS. The desired solid removal in sewage
treatment plants should not exceed the absolute TSS discharge limit of
50mg/l and 100mg/l for Standard A and Standard B, respectively.

To ensure effluent consistently complies with Department of Environment’s


Effluent Limits, provisions must be made to allow for future incorporation
of a flocculator in the clarifier. This will enhance clarification performance.
Chemical (polymer) can also be added in flocculation clarifiers to
further enhance solids settlement in the clarifiers. Otherwise, a dual
media filtration system following conventional secondary clarifiers can
also be used to ensure that TSS concentration of 20 mg/l to 40mg/l is
consistently achieved.

3.4.3 Chemical Oxygen Demand (COD)

COD content reflects the chemically oxidized organic matter. Hence,


it includes refractory fractions of organic matter as well as reduced
inorganic constituents present in the wastewater. The COD measurement
offers quick estimate of carbonaceous material compared to conventional
BOD measurement. Additionally, high COD reflects inert reduced
inorganic elements and also unbiodegradable organic that comes from
industrial contamination. Based on the bi-substrate hypothesis, COD
fractions comprising of readily biodegradable, slowly biodegradable
and unbiodegradable estimates are adopted in advanced modeling for
STP design. Such advanced modeling takes into consideration the
treatment process requirements of different COD fractions as it varies
in susceptibility to microbial respiration and degradation.

3.4.4 Oil and Grease (O&G)

O&G that is detected in domestic sewage refers to the fraction of organic


matter that is soluble in organic solvents such as hexane.

32 Volume 4 Malaysian Sewerage


Industry Guidelines
Sewage Characteristics and Effluent Discharge Requirements

The composition comprise primarily of wax, edible oils and fatty


matter of animal or vegetable origins. O&G (mixture of tri, di and
mono-glycerides) in its liquid form results in floatable scum formation
in treatment systems whilst its solid form causes the clogging of
systems.

O&G is separated from raw sewage by provision of grease chambers (be


it manual or mechanized scum skimmer removal) at primary treatment
stage. Removal at the primary stage is essential to prevent interference
of oil particles on biological reactions in the secondary treatment. It
also prevents undesirable organic load of extremely slow biodegradable
constituents into aerobic systems. Such first line oil and grease removal
protects against contamination in the treatment plant as well as in the
receiving water.

3.4.5 Nitrogenous Compound

Removal of nitrogenous compounds needs to be considered in STP design.


These compounds found in various forms (ammonia or ammoniacal
nitrogen, nitrate nitrogen and nitrite nitrogen) could be detrimental to
natural water bodies and potable consumption. Total organic nitrogenous
compounds in raw sewage typically comprise of nitrogen in the form
of proteins, amino acids and urea along with ammoniacal nitrogen.
Ammoniacal nitrogen results from the decomposition of organic nitrogen
particularly from hydrolysis of urea. Total Kjedhal Nitrogen (TKN)
analysis determines the organic nitrogen and the ammoniacal nitrogen
fractions.

There are two main biological processes for removing nitrogenous


compounds, namely the assimilation of ammonia nitrogen into the
microbial biomass and the nitrification-denitrification process. The
latter involves two conversion steps. Firstly, nitrification followed
by denitrification by microbial heterotrophs that convert nitrates into
nitrogen gas. Nitrification comprises two-step oxidation of ammonia
nitrogen into nitrate by nitrifying bacteria. All treatment systems shall
provide full nitrification and denitrification in the secondary biological
reactors with sufficient air supply to facilitate nitrification. This will
ensure that effluent discharge complies with the required discharge
limits.

3.4.6 Phosphorus Compound

The constituents of total phosphorus compounds in raw sewage are


organically bound phosphorus and inorganic phosphorus (orthophosphates
and polyphosphates).

Sewage Treatment Plants Volume 4 33


Sewage Characteristics and Effluent Discharge Requirements

Some fractions of the essential phosphorus nutrients from the influent


will be assimilated for microbial growth during secondary biological
treatment. However, excessive phosphorus nutrient will occur when above
the assimilated with stagnant receiving water bodies (e.g. ponds), which
will result in nutrient enrichment and produce harmful algae blooms.
Hence, the design for sewage treatment plant effluent that discharges
into stagnant water bodies should take into considerations the impact
of excess phosphorus contamination.

3.5 Sludge Characteristics and Treatment Requirements

Sludge treatment and management are as important as the sewage


treatment to minimise impacts to the environment. Sludge produced
from treatment process is usually in liquid form, which typically
contains 0.25 to 4.0% of solids, depending on the type of treatment
process being used. It also contains grease, fats, organic and inorganic
chemicals. High concentrations of certain components will determine
the type of sludge treatment process to be used.

Sludge shall be thickened, stabilized, conditioned and dewatered before


it is finally disposed off in accordance to requirement stipulated by
Department of Environment. The dried sludge must attain a minimum
of 20% dry solid content before off-site disposal. Close attention is
required when planning and designing sludge treatment processes to
ensure bio-solid to be disposed do not contain any harmful substance
that will affect the environment. Additionally, stabilization process should
be designed to reduce any potential presence of microbial pathogens.
Options of ultimate disposal include landfill and land application.

34 Volume 4 Malaysian Sewerage


Industry Guidelines
Section 4

Requirements for Physical Design


Requirements for Physical Design

36 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

4.1 Introduction

The induced physical, chemical and biological reactions that occur in a


sewage treatment plant (STP) lead to waste emissions in the following
forms:

a) gases and vapours, some of which contain obnoxious compounds,


including bacteria and viruses.
b) noise.
c) odour.
d) vibration.
e) unwanted solid matter.
f) undesirable by-product liquors containing highly concentrated
pollutants.
g) heat.

As such, a sewage treatment plant can degrade the amenity of its


surroundings, especially in residential areas.

Careful consideration of siting is required to minimise nuisance to the


public. Sufficient land needs to be set aside during the planning stage
to take into account regional treatment plant development and the
proper sewerage planning for housing, commercial and institutional
developments.

This section sets out the important factors and considerations associated
with the identification of proper sites to locate sewage treatment plants.
Typical workflows in the site for sewage treatment plants are illustrated
in Figures 4.1 and 4.2. It also addresses the selection of appropriate
treatment concepts and sufficient land area requirements for treatment
plants in relation to the effluent standards.

4.2 Treatment Plant Siting

4.2.1 Buffer Zones

Suitable buffer distances should separate a sewage treatment plant from


its surrounding areas. Buffer Guidelines for the Siting and Zoning of
Industries as recommended by the Department of Environment (DOE)
should be referred to during the planning of suitable location for
treatment plants. The buffer distances recommended in the guidelines
depend on the category of industry being considered.

Sewage Treatment Plants Volume 4 37


Requirements for Physical Design

The provision of buffer zones is essentially an environmental requirement


controlled by the relevant planning authority. The agreement of the Local
Planning Department on buffer zone and plant siting should be sought
at an early stage in the Town and Country planning procedures.

The buffer zone requirements for treatment plants to be observed under


this Guideline are as follows. Refer to Figures 4.3 and 4.4 in this
section for further clarification.

a) Minimum distance of 30 m from the fence of the treatment plant


to the nearest habitable building property line within residential
and commercial development.
b) Minimum distance of 20 m from the fence of the treatment plant
to the nearest property line within industrial development.
c) Minimum distance of 10 m from the fence of the treatment plant
to the nearest habitable building property line if the proposed
treatment plant is fully enclosed. A fully enclosed plant is defined
in section 7.3.1.
d) A minimum distance of 10 m from the fence of the treatment
plant to the nearest habitable building property line if the
proposed treatment plant is covered or buried. However, this
reduction in buffer requirement does not apply if the nearby
habitable buildings are of high rise type. A covered or buried
plant is defined in section 7.4.1.
e) Plants with PE less than 150 but are provided with proper odour
and noise mitigation measure may have a 10 m reduced buffer
at the discretion of the Commission.

The buffer zone can be used for any purpose except permanent habitable
buildings. For example, the buffer zone maybe used as a drainage
reserve, road or highway reserve, transmission reserve, utility reserve
or public park.

In the case where buffer area is to be regularly used by the residents


such as car park and playgrounds, proper precautions during design
stage must be taken to minimise nuisance such as odour, noise and
unpleasant sight to the surrounding environmental. Adequate and proper
screening, odour containment and treatment facilities must be provided
at the sewage treatment plant to address these issues.

38 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

4.2.2 Siting Criteria

The following criteria shall be observed when siting treatment plants.

a) Plants shall be located as far as possible from habitable building


to minimise nuisance to the surrounding.
b) Plants shall be located at the lowest point of a sewerage catchment
basin so that sewage can gravitate into the plant.
c) Plants shall be located near to a suitable watercourse that is able
to receive and assimilate treated effluent from the plant without
reducing beneficial uses of the water course downstream.
d) Plants shall be located on an area that is relatively flat or with
relatively mild slope across the site that would be useful in
promoting efficient hydraulics.
e) The shape of the land area selected shall be such as to minimise
the extent of unusable area within the lot.
f) Plants shall not be located in an area that will result in long
term operational problems or rapid deterioration of the assets.
g) Plants shall have proper access road leading to it.
h) Plants shall be sited away from the followings:
i) Existing cemeteries and gazetted reserves for cemetery.
ii) Religious centres.
iii) Eating places.

i) Plants shall be located such that sewers are easily connected/


conveyed to the proposed site.
j) If temporary treatment plants are to be provided, they shall be
located as near as possible to public trunk sewers.
k) For safety reasons, plants shall be located away from children
playgrounds.
Emergency bypass shall be provided either at the last manhole or wet-
well. The bypass shall discharge to the nearest drain which shall have
sufficient capacity to cater for the discharge during rainfall.

4.2.3 Environmental Impact Assessment

An environmental appraisal or environmental impact assessment (EIA)


study shall follow Environmental Quality (Prescribed Activities)
(Environmental Impact Assessment) Order, 1987 under Section 34A
of the Environmental Quality Act, 1974 (the EIA Order, 1987 and the

Sewage Treatment Plants Volume 4 39


Requirements for Physical Design

EQA, 1974 respectively). The type and scope of the study will depend
on the classification of the plant and the environmental sensitivity of
the locality being considered. EIA shall be conducted in compliance
with Volume 2 of the MSIG.

4.2.4 Hazard and Operability Studies

Hazards and Operability (HAZOP) study shall be conducted in compliance


with Volume 2 of the MSIG. The type and scope of the study will
depend on the classification of the plant.

4.3 Treatment Plant Sizing

4.3.1 Modular Units

Stage development of a STP is governed to a large extend by the timeframe


of the overall development plan of the catchments and the size, shape
and soil condition of the land reserved for the STP. Modular units will
be constructed to cater for the stage development. In determining the
appropriate number of modules and corresponding timing for a staged
development, it is crucial for the designer to estimate the flow capacity
build-up over the entire development phases. The modules must have
sufficient capacity to treat the sewage to meet the efficient discharge
standard, without compromising the economical viability of operation
and maintenance. Too many modules and unit processes will definitely
increase equipment maintenance. On the other hand, inadequate modules
will result in an inefficient treatment performance due to insufficient
capacity and flexibility during the early stage.

Table 4.1 Modularisation Requirements

STP Classifications No. of Modules No. of Trains


Class 1 (<1,000PE) 1 N/a
Class 2 (1,001PE – 5000PE) 1 Max 2
Class 3 (5,001PE – Min. 2, Max. 3 Max 2 for each
20,000PE) Module
Class 4 (>20,000PE) Min. 4, Max. 10 Max 2 for each
Module

Table 4.1 indicates the modularisation requirements in accordance to


sewage treatment plant classes to attain an efficient modularisation of
sewage treatment plant development. Each module shall be of equal size

40 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

and of similar treatment process. If the proposed process is different from


the original system, special approval is required from the Commission.
Certain unit processes are subject to the modularisation requirements
in Table 4.1 while other unit processes are designed for the ultimate
phase during the first stage of the development. An example of this
is the headworks of a STP designed for the ultimate phase while the
secondary processes are added progressively as the future phases come
on-line.

Modular treatment plants that are designed with two (2) or more parallel
streams must be provided with pipeworks and valves to isolate each
stream of unit process during maintenance and major shut down without
interfering normal operation of the remaining stream.

4.3.2 Standby Units

To avoid significant down time in sewage treatment and overloading


of the process units, standby units shall be provided for the following
processes:

a) Inlet Works/Pumps
b) Screen Facilities
c) Grit Chambers
d) Biological Treatment
e) Secondary Clarifiers
f) Sludge Facilities

The common standby mechanical equipments are as follows:-

a) Pumps (raw sewage, effluent, sludge, etc)


b) Mechanical screens
c) Blowers
d) Any other mechanical equipment

Detailed requirements of standby units shall follow the requirements


in Section 5.

4.3.3 Back-up Capacity

The back-up capacity provided shall be such that when one unit process
is taken out of operation, the remaining units shall not be overloaded
beyond 50% of their rated capacities.

Sewage Treatment Plants Volume 4 41


Requirements for Physical Design

4.3.4 Design Flow

It is recommended that unit processes that are designed on average flow


basis are sized to allow for infiltration in accordance with MS 1228.
Conveyance networks shall be sized to cater for peak flows, except for
those networks located downstream of an equalisation tank. All unit
processes shall be designed based on the maximum ultimate design
flow.

4.4 Land Area Requirements

The recommended land area requirements for various sewage treatment


plants capacities are derived from relevant treatment process concepts
and also taken into consideration other design criteria.

The land area requirements and buffer allowance for temporary sewage
treatment plants maybe reduced at the discretion of the Commission on
a case by case basis.

4.4.1 Class 1 and 2 Plants

The recommended land area requirements for Class 1 and 2 plants (up
to 5000 PE) are given in Table 4.2 and Table 4.3 respectively. The net
area does not include the 30 m buffer zone surrounding the plant, but
does include appropriate set backs and access paths within the plant. The
area requirements given are sufficient to achieve an effluent conforming
to Standard A discharge requirements. It is important that allowance
is made for sufficient buffers in planning approvals, to avoid future
complaints in relation to the siting of the plant.

4.4.2 Mechanised Class 3 to 4 Plants

For Class 3 and 4 plants with mechanised systems, the recommended


land area requirements are given in Table 4.4 and 4.5. These systems
are to be used in normal developed and urbanised areas. The net area
does not include the 30 m buffer zone surrounding the plant, but does
include appropriate set backs and access paths within the plant. The area
requirements given are sufficient to achieve an effluent conforming to
Standard A discharge requirements. It is important that allowance is made
for sufficient buffers in planning approvals, to avoid future complaints
in relation to the siting of the plant.

42 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

4.4.3 Aerated Lagoons and Stabilisation Ponds

For aerated lagoon and stabilisation pond treatment systems, the


recommended land area is as shown in Table 4.6. Sufficient buffer areas
shall be allowed for surrounding the plant as per paragraph 4.2.1.

4.4.4 Imperfect Sites

The recommended land area requirements represent an ideal case, where


it is possible to locate the STP within a rectangular land area that is
relatively flat. In practice, the allocated land may be irregular in shape,
sited in low lying or undulating to steep valley terrain. For such cases,
suitable adjustments to the land area requirement have to be made.

Thus, the shape and elevations of the land allocated for the STP development
must be determined during planning stage so that the configuration of
the STP can be planned properly in order to allocate adequate land for
the purpose. This also enables estimates for additional land required. It
may also be required to cut or fill operations to level the land.

4.4.5 Reduced Land Areas for STPs

The area requirements, as stipulated in Table 4.2, 4.3, 4.4, 4.5 and 4.6,
must be adhered to as strictly as possible. The required areas in these
tables include appropriate setbacks and access paths within the plant.
However the areas have not include any buffer zone surrounding each
plant as indicated in Section 4.2.1.

In developments where land is really a constraint the Commission may


consider for a reduced land area requirement. The project proponent will
have to demonstrate clearly the need for a reduced land area before an
approval can be granted. For this case, detailed design calculations of
all unit processes, together with the proposed layout, shall be submitted
at the planning stage for consideration of approval by the Commission.
Otherwise, the land area required under these guidelines must be
followed.

Sewage Treatment Plants Volume 4 43


Requirements for Physical Design

Table 4.2 Land Area Requirements for Class 1

Land Area
Population Requirement *
Equivalent
(m2) (acre)
100 210 0.052

150 285 0.070

200 360 0.089

250 430 0.106

300 485 0.120

350 545 0.135

400 600 0.148

450 655 0.162

500 700 0.173

550 745 0.184

600 790 0.195

650 835 0.206

700 870 0.215

750 905 0.224

800 940 0.232

850 980 0.242

900 1010 0.250

950 040 0.257

1000 1070 0.264

Note: * The required area only includes appropriate setbacks and access paths
within the plant but not the buffer zone surrounding each plant as indicated in
Section 4.2.1.

44 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Table 4.3 Land Area Requirement for Class 2

Population Land Area


Equivalent Requirement *
(m2) (acre)
1100 1115 0.276
1200 1160 0.287
1300 1200 0.297
1400 1240 0.306
1500 1275 0.315
1600 1310 0.324
1700 1340 0.331
1800 1370 0.339
1900 1395 0.345
2000 1420 0.351
3000 2226 0.55
4000 2671 0.66
5000 3076 0.76

Table 4.4 Land Area Requirements for


Mechanised Class 3 Plants

Population Land Area


Equivalent Requirement *

(ha) (acre)

5001 0.31 0.76

6000 0.40 0.99

7000 0.49 1.21

8000 0.59 1.46

9000 0.69 1.71

10 000 0.78 1.93

15 000 1.00 2.47

20 000 1.19 2.95

Note: * The required area only includes appropriate setbacks and access paths
within the plant but not the buffer zone surrounding each plant as indicated in
Section 4.2.1.

Sewage Treatment Plants Volume 4 45


Requirements for Physical Design

Table 4.5 Land Area Requirements for


Mechanised Class 4 Plants

Population Land Area Requirement *


Equivalent (ha) (acre)
20 001 1.19 2.95
25 000 1.37 3.38
30 000 1.53 3.79
35 000 1.81 4.48
40 000 1.97 4.88
45 000 2.12 5.25
50 000 2.23 5.52
55 000 2.37 5.84
60 000 2.52 6.22
65 000 2.67 6.61
70 000 2.93 7.23
75 000 3.27 8.07
80 000 3.49 8.61
85 000 3.69 9.12
90 000 3.89 9.61
95 000 4.07 10.06
100 000 4.25 10.49
110 000 4.57 11.29
120 000 4.87 12.02
130 000 5.14 12.70
140 000 5.39 13.32
150 000 5.63 13.90
160 000 5.84 14.44
170 000 6.05 14.95
180 000 6.25 15.43
190 000 6.43 15.89
200 000 6.60 16.32
250 000 7.36 18.20
300 000 7.98 19.73
450 000 9.36 23.14

Note: * The required area only includes appropriate setbacks and access paths
within the plant but not the buffer zone surrounding each plant as indicated in
Section 4.2.1.

46 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Table 4.6 Required Land Area for


Stabilisation Pond and Aerated Lagoons

Population Standard A* Standard B*


Equivalent
(ha) (acre) (ha) (acre)
2000 0.48 1.18 0.45 1.10
3000 0.69 1.69 0.59 1.45
4000 0.89 2.20 0.71 1.75
5000 1.09 2.68 0.82 2.04
10 000 2.03 5.01 1.31 3.24
15 000 2.92 7.2 1.72 4.25
20 000 3.78 9.3 2.09 5.16
25 000 4.62 11.4 2.42 5.99
30 000 5.45 13.5 2.74 6.77
35 000 6.26 15.5 3.04 7.50
40 000 7.05 17.4 3.32 8.2
45 000 7.85 19.4 3.59 8.9
50 000 8.63 21.3 3.86 9.5
55 000 9.40 23.2 4.11 10.2
60 000 10.16 25.1 4.36 10.8
65 000 10.92 27.0 4.60 11.4
70 000 11.68 28.9 4.83 11.9
75 000 12.42 30.7 5.06 12.5
80 000 13.17 32.5 5.28 13.1
85 000 13.91 34.4 5.50 13.6
90 000 14.64 36.2 5.72 14.1
95 000 15.37 30.0 5.93 14.6
100 000 16.10 39.8 6.13 15.2
110 000 17.54 43.3 6.54 16.2
120 000 18.97 46.9 6.93 17.1
130 000 20.38 50.4 7.31 18.1

Sewage Treatment Plants Volume 4 47


Requirements for Physical Design

Table 4.6 Required Land Area for Stabilisation Pond and


Aerated Lagoons (Continued)

Population Standard A* Standard B*


Equivalent
(ha) (acre) (ha) (acre)
140 000 21.79 53.8 7.69 19.0
150 000 23.18 57.3 8.05 19.9
160 000 24.57 60.7 8.40 20.8
170 000 25.95 64.1 8.75 21.6
180 000 27.32 67.5 9.09 22.5
190 000 28.68 70.9 9.43 23.3
200 000 30.04 74.2 9.76 24.1

Note: * The required area only includes appropriate setbacks and access paths within the
plant but not the buffer zone surrounding each plant as indicated in Section 4.2.1.

48 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Figure 4.1 STP Land Area Requirements for Planning Layout


Approval for New Development

Start

Determine catchment
served

Determine ultimate PE

Identified effluent
requirement

Apply sitting criteria

Is development Is development
> 2000 PE? in urban area? N

N Y

Use land area from Use land area from Use land area from
Table 4.2 Table 4.3,4 and 5 Table 4.6
(Class 1 plants) (Class 2 to 4 plants) (pond systems)

End

Sewage Treatment Plants Volume 4 49


Requirements for Physical Design
Requirements for Physical Design
Figure 4.2 STP Land Area Requirements for Structure Plans
Figure 4.2 – STP Land Area Requi rements for Structure Plans

Start

Local plan
Plan
formulation
Formulation

Perform the next two


steps concurrently

Determine natural Determine suitable


drainage catchments receiving waters

Calculate ultimate Identify effluent


catchment PE standards

Look up land area


requirements in
Tables 4.2, 4.3, 4.4 or 4.5

Table 4.3, 4 and 5:


Table 4.2: Table 4.5: For remote
Greater than1000
than1,000PEPE area siting of STP
Up to 1000
1,000PEPE
for urban areas

Apply siting criteria

Select and zone


suitable site

Consider multi-use of
buffer areas

Reserve land for STP

End

50 Volume 4 Malaysian Sewerage


Industry Guidelines

42 V ol ume 4 M al aysi an S ewerage


I ndustry G ui del i nes
Requirements for Physical Design
Requirements for Physical Design

Figure 4.3 Guidelines For Buffer Zone


Figure 4.3 Guidelines For Buffer Zone

Plants Situated In Residential / Commercial Areas


Treatment Plant Site Buffer Zone 30m Min. Residential /
Commercial Plot
5m Min.
Access And
Screening

STW Fence Property


Open Treatment Boundary
Plant

Beautification

Zone Buffer Zone 10m Min.


Treatment Plant Site Residential /
Commercial Plot
5m Min.
Access and
Screening

Property
Enclosed Plant STW Fence Boundary

Treatment Plant Site Buffer Zone 10m Min. Residential / Commercial Plot

5m Min.
Access And
Screening

STW Fence Property


Buried / Covered Boundry
Plant

Treatment Plant Site Buffer Zone 30m Min. Residential / High Rise

5m Min.
Access and
Screening

Property
Enclosed Plant STW Fence Boundary

Plants Situated In Industrial Areas


Treatment Plant Site Buffer Zone 20m Min. Industrial Plot

5m Min.
Access And
Screening

STW Fence Factory Fence


Open Treatment
Plant

Note : The buffer area can be used for roads, drains, utility reserve, agricultural or other similar
purposes.

Sewage Treatment Plants Volume 4 51

Sewage Treatment Plants Volume 4 43


44
52
Figure
Figure
Requirements for Physical Design
Requirements for Physical Design

30 m 30 m
4.44.4- Plan

STP LAND AREA


20 m REQUIREMENT 20 m
PlanView

10 m 10 m
View of

Volume 4
Volume 4
of Buffer
BufferZone

30m Surround For Residential and Commercial Note: Buffer areas can be used for roads, drains, utility reserve, public
Development parks, agricultural or similiar purposes other than permanent
ZoneRequirements

20m Surround For Industrial Development habitable buildings.


10m Surround For Fully - Enclosed Plants
Requirements

The land shall be relatively flat and of a regular shape. Any unusable
area within the plot shall be minimised.

Industry Guidelines
Malaysian Sewerage

Malaysian Sewerage
Industry Guidelines
Requirements for Physical Design

4.5 Mechanical and Electrical Requirements

Some general guidelines on the design and installation of mechanical


and electrical equipment are outlined below.

4.5.1 Mechanical Installation

I) Design Considerations

The designer shall consider incorporating the following criteria:

a) The design shall simplify the equipment required, control system,


maintenance and operational procedures, while fulfilling the
intended performance and standard of service.
b) The brand and models of major drive equipment (e.g.: pumps,
blowers, aerators, clarifier scrappers, etc.) shall be those approved
by the Commission.
c) The types and makes of equipment provided throughout the
facility shall be standardised, whenever possible.
d) Only new and genuine equipment shall be provided.
e) Equipment sizing and selection shall minimise energy and other
consumables costs.
f) The minimum economic life of equipment.
g) Material selection shall be in accordance with the Commission
specifications or/and other relevant international standards.
h) Components shall be robust and suitable for use. Where thin metal
sheeting is used, it shall be stiffened to minimise distortion.
i) Water storage tanks shall not be placed on the roof top of any
control room; all water supply system shall be homed with
separate entrance.

II) Installation

a) The base frame of rotational equipment or any equipment that may


induce vibration shall be provided with anti-vibration mount.
b) All moving parts shall be designed and installed in a manner
that is inherently safe to operate.
c) Foundations shall be adequately designed to include all dynamic
load and anchored to withstand all loads imposed by the equipment.
Reinforced concrete foundations are preferred.

Sewage Treatment Plants Volume 4 53


Requirements for Physical Design

d) Equipment shall be accurately located, levelled and secured


by holding down bolts. Non-shrink grout shall then be used to
complete the foundation. In some cases, a resilient connection
to the foundation is required, in which case, the manufacturers
instructions shall be followed.
e) Holding down bolts shall be of stainless steel and shall be of a
minimum grade 316 if in contact with sewage.
f) Puddle collar is required for all pipe passing through all
walls.
g) Appropriate joints shall be provided in all pipeworks to facilitate
the removal of equipment, meters, valves and other special items
without dismantling the entire pipeline.
h) Valves shall be provided for isolation purpose.
i) Outdoor and dry installation pump shall be provided with
housing.
j) The designer must ensure that the unit processes are arranged
in such a way to prevent/reduce criss-crossing of piping works,
unnecessary bends, choking of interconnected pipe and excessive
hydraulic losses through the system.
k) The platform level of mechanical equipment and controllers of
any process unit shall be located above design flood level.

4.5.2 Vibration

All revolving parts shall be properly balanced both statically and


dynamically so that in running up to, at full normal operating speeds,
and at any loads up to the maximum there shall be no undue vibration
anywhere in the machine or transmitted to the adjacent structure. The
criteria adopted for vibration severity shall be the RMS value of the
vibration velocity in millimeters per second.

The bare frame of rotational equipment or any equipment that may induce
vibration shall be provided with anti-vibration mount. Where rotational
equipment or equipment which may induce vibration is connected to
piping, then vibration isolator shall be provided.

4.5.3 Noise

Noise levels from machinery shall comply with the Factories and
Machinery (Noise Exposure) Regulations 1989 and Occupational Health
and Safety Act. Noise control measures and appropriate safety protection
for operators must be provided where necessary.

54 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Noise control measures shall be implemented to control the generated


noise level to below 65 dB at a distance of 2 m from the boundary
of the housed noise source at all times. Additionally, the general
noise levels generated shall be measured 10 m from any point of the
plant site within the nearest public space and/or occupied space to an
acceptable level stipulated by the appropriate regulators. Silencers and
acoustic enclosures shall be provided as required to achieve the above
noise level reduction.

Enclosures used to achieve these noise reductions shall permit ready access
to the equipment for routine maintenance. Adequate air ventilation shall
be provided to allow cooling of the enclosure to prevent overheating
of the equipment/motors.

Noise level measurement shall be made with a sound level meter which
complies with BS EN 60651 and which is fitted with an ‘A’ weighting
network. The sound pressure level shall be measured in dB (A).

Noise level for all electronically operated electrical device such as soft
starters, variable speed drives and others shall be conform to IEC, EN.
Thus it shall fulfil all EMC Immunity requirements complying with
EN500082-1, EN50082-2, EN50082-3.

4.5.4 Safety Around Equipment

All designs and equipment shall be made and installed with safety in
mind. Nothing in this Design Guidelines shall remove the designer’s
obligation to incorporate equipment or designs that would increase the
safety of the plant.

The installation layout and equipment design shall not allow any item
of equipment to be so positioned that danger could arise to operating
personnel and equipment during normal operation and maintenance.
Particular attention shall be paid to the positioning of switch board,
control panel, cables, switch gears, lighting, small power, rotational
equipment, other electrical equipment and accessories.

All facilities shall be designed to comply with the Occupational Safety


and Health Act 514, 1994; properly designed treatment plants will
enable the operator to safely handle the treatment plant throughout
its design life. The plant shall also be designed to comply with other
related Acts such as IEE, Akta Bekalan Elektrik 1990 (Akta 448) and
Peraturan-Peraturan Elektrik 1994.

Safety level for all electronically operated electrical device such as soft
starters, variable speed drive and others shall conform to IEC, EN, UL,
NFC and VDE. Thus it shall fulfill EN 50178, EN 60204-1, EN 60950
(2000, 3rd edition), IEC 61800-5.

Where appropriate, IEE and Akta 448 (1990) and Peraturan Elektrik
1994 must be complied within all electrical installation.

Sewage Treatment Plants Volume 4 55


Requirements for Physical Design

The following shall be provided:

a) All moving parts shall be protected by suitable guards. Where


inspection is required, an open mesh with frame and suitably
supported maybe used. The maximum aperture of the mesh shall
be 6 mm.
b) All guards shall be readily removable and replaceable to they
correct orientation only. However the guard shall be designed
with features to prevent accidental dislocation from its’ original
position. The fasteners when dropped during dismantling, must
be easily retrievable and should not damage any equipment or
endanger personnel, else fixed fasteners shall be used.
c) An emergency stop button, preferably of mushroom head type
shall be located adjacent to all equipment. More than one
emergency stop button shall be used, if access around the item
is restricted.
d) Long items, such as conveyor belts, shall have an emergency
lanyard applied to each accessible length of conveyor.
e) Surfaces which are greater than 50°C shall be guarded.
f) Permanent warning signs shall be posted at visible location at
all dangerous areas and shall clearly indicate the nature of risk
at that area. This includes warning signage at digesters area,
high tension room, low voltage room, generator room and other
hazardous areas.
g) Clear working space as recommended in Figure 4.5 shall be
provided.
h) Automatic CO2 discharge triggered by heat and smoke sensors
shall be installed in high voltage switch room, transformer room,
low voltage switch room and generator room.
i) High tension room shall have signage to clearly indicate the
purpose of the room and also safety signage to prevent unauthorised
entry.

56 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Figure 4.5 - Clear Working Space

Wall 1 m or 1.5 W or
whichever greater

Equipment Wall

1 m or 1.5 W or
whichever greater

W Equipment

L 1 m or 1.5 W or
whichever
greater

4.5.5 Motors, Controllers and Motor Starters

I) Motors

a) Provide readily replaceable anti-condensation heaters for motors


that do not require frequent operation.
b) At least three thermistors to be provided for motors which are
>50  kW.
c) Electrical motors should be rated as continuous run.
d) Motors > 22kW shall be protected with soft starter or variable
speed drive.
e) Where water hammer prevails, frequency inverter shall be
provided.
f) The appropriate cooling system based on the requirements of
the equipment shall be provided.

II) Controllers

a) Start push buttons to be green and recessed


b) Stop push buttons to be red and recessed

Sewage Treatment Plants Volume 4 57


Requirements for Physical Design

c) Emergency stop push button to be red and mushroom head


type
d) ON signal lamps to be green
e) OFF signal lamps to be red
f) Trip signal lamps to be amber

III) Motor Starters

a) Up to 3.7 kW – Direct-On-Line starters


b) Above 3.7 and up to 7.5 kW – Star/Delta starters
c) Above 7.5 and up to 22 kW – Auto-transformer starters
d) More than 22 kW – Soft starter
e) Above 50 kW – Variable speed drive is preferred

Soft starting of motors above 30kW or greater in size is necessary to


minimise power disturbances (e.g. power surge) and process disturbances
(e.g. water hammer). Variable speed drive shall be considered at
application where variable capacity maybe need to enhance the process
flexibility, for example, aeration device and blowers.

4.5.6 Power Supply Systems

Power supply to sewage treatment plants shall be as follows:

Sewage Treatment
Category Supply Requirements
Plant

A Single incomer with properly design control All Class 1, 2 and 3


overflow system during power failure (all STPs
electrical control system shall be located above
design flood level)

B B1) Single incomer with diesel generators for STP Class 4


back-up supply.

B2) Single incomer with control overflow system


and genset contribution fee.

a) Where a SCADA system is provided and essential parameters are


to be monitored during power supply interruptions, a DC supply
or a UPS (uninterrupted power supply) must be provided.

58 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

b) Batteries/UPS shall have the capacity to operate the SCADA


system for a minimum 6 hrs during power failure to safe last
event, to monitor the essential parameters and to enable early
warning system.
c) No direct tapping of power is allowed from distribution board
(DB). Proper protection shall be provided for any direct connection
from switchboard. Earth leakage current breaker (ELCB) shall
be provided for DB.
d) The power system distribution shall be designed to achieve a
minimum power factor of 0.9. For phase development, the plant
and power system distribution shall be designed for maximum
load and installed in appropriate modular unit to ensure that
the minimum power factor is achievable at all phases of
operation.
e) Equipment shall be protected by either moulded case circuit
breaker (MCCB) or miniature circuit breaker (MCB) based on
its suitability. Electrical design calculations shall be provided to
justify each selection.
f) Every control circuit shall be protected with separate MCB.
g) TNB meter panels shall be installed close to the site entrance or
adjacent to but physically separated from the main switchboard.
Suitable flexible steel conduit with approved adaptors shall be
supplied and fitted between the main switchboard.
h) All metering panel shall be located flush with the fence and
door opening from outside to enable TNB inspector to read the
kWh and kVAhr reading.
i) Provide earthing connected with Current Transformer (CT) for
Large Power Consumer (LPC) (i.e. consumption with more than
100A or 10kW).
j) To provide earthing connected to ELCB/RCCB/ELR or Over
Current & Earth Fault relay to protect overcurrent and surge
current to all wiring connected to TNB metering panel for Large
Power Customer (LPC) or Ordinary Power Customer (OPC). Test
for earthing system shall be below or equal 1 Ohm.

4.5.7 Back-up Generator

a) If diesel generators are to be provided they shall be used for


essential loads only (these include influent pumping in pump
station, feeding pumps in balancing tank, decanter for SBR;
minimum 30% aeration requirement; emergency services system,
essential lighting and ventilation system.
b) Where generators are installed, they must be accompanied with
the necessary supporting systems, including automatic cut-in

Sewage Treatment Plants Volume 4 59


Requirements for Physical Design

in the event of mains failure, fuel storage and transfer; and if


installed indoors, including ventilation, fire detection/protection
and working alarms.
c) In the event of power interruption/failure; when diesel generators are
used, the SCADA shall be powered by UPS or DC battery.
d) For plants ≥ 100 000 PE, the capacity of the back-up generator
may vary provided detail calculation must be provided to justify
that sewage can be kept in aerobic condition for a maximum
duration of 6 hours
e) Gen-set shall be sized to the incoming TNB voltage requirement.

4.5.8 Switchgear and Control Gear Assemblies

a) For simplicity, separate the Supply Authority Metering from the


main switchboard
b) Electro galvanised plates to be used to protect materials against
corrosion due to high humidity
c) Panel isolators and door locks to be capable of padlocking open
with 6  mmc - hasp padlock
d) Use separate panel boards for general purpose light and power
e) Group all motor starting equipment for an area into multi-motor,
starter control board
f) Cabinets are to be constructed to prevent the ingress of insects
and vermin
g) For incomer above 400 A, provide over current and earth fault
protection on all starter circuits in excess of 200 A
h) Where a circuit has a main and standby supply, provide an
isolator in each supply circuit
i) Junction boxes for submersible pumps and float controls shall
be above the floor or any possibility of flood level and must
not be located in the wet well.

4.5.9 Control Cabinets

(I) General

a) Provide 900 mm minimum clearance between an open door and


any fixed object.
b) Provide 900 mm clearance between open cabinet doors of facing
cabinets.

60 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

c) Front access cubicles to have the electrical clearance distances


between door mounted equipment and gear tray mounted equipment
as specified in the regulations.
d) Mount all equipment inside cabinets on gear trays.
e) All cabinets to have a base frame, at least 50  mm high.
f) All control panels shall be provided with phase sequence
relay.
g) All control rooms shall be isolated from invasive environment
of the sewerage system, where carbonisation, corrosion or
condensation may occurs that lead to short-circuiting.
h) Height to be no greater than 1600 mm internally.
i) Mount cabinet on reinforced concrete plinth, 200 mm minimum
above ground.
j) Provide a reinforced concrete paved area for the full width of
the cabinet and extending 1 m in front of the cabinet doors,
when they are opened.
k) Cable entry from the top only.
l) Provide forced ventilation fan for cubicles housing PLC
equipment.
m) Provide ventilation for variable speed drives and soft starters.
n) Natural ventilation is suitable for direct-on-line, star-delta and
auto transformer starters.
o) The minimum acceptable IP rating and tests required shall be
clearly specified.

(II) Outdoor Cabinets

a) Self contained, free-standing, weatherproof cabinets to be


constructed of marine grade aluminium, stainless steel grade
316 or glass reinforced plastic.
b) Mount control indication and alarm facilities on internal
doors enclosing compartments housing electrical plant and
equipment.
c) Provide external doors with security locking facilities.
d) Provide double roofs on cabinets to reduce solar effects.
e) Wall mounted outdoor weather proof control panel shall come
with an awning extended by at least 2 m from the wall.
f) Floor mounted outdoor weather proof control panel shall come
with a roof extended 2 m from the panel.
g) External weather proof control panel of equal and more than
100 A shall be provided with permanent CO2 fire extinguisher.

Sewage Treatment Plants Volume 4 61


Requirements for Physical Design

4.5.10 Control Requirements

This section outlines the general philosophy on control requirements


for the whole facilities.

EWS + PC
NO. TYPE OF PLANT (monitoring) / SCADA
Data Logger
Network Pumping Station
1. < 100 000 PE ≥ 100 000 PE
(NPS)
2a. Sewage Treatment Plant Class 3 STPs Class 4 STPs

Sewage Treatment Plant


2b. requires full automation, e.g. Class 1, 2 and 3 Class 4 STPs
sequencing batch reactor.
Sewage Treatment Plant
2c. Class 1, 2 and 3 Class 4 STPs
(Standard A)
Notes : EWS – Early Warning System
SCADA – Supervisory Control and Data Acquisition

I) General Considerations

a) PLC shall restart automatically once the power supply reinstate


after a power supply interruption.
b) PLC shall be equipped with manual over-ride features.
c) Continuously running drives shall restart automatically after a
power supply interruption.
d) Plant to have time delayed restarting sequences for equipment
to avoid overloading power supply.
e) Transducers shall be used to sense the signal for related warning
alarms.
f) Trip and shutdown to be measured by separate relays.
g) The operating status and condition of the process shall be verified
by measuring appropriate performance indicator and not by
inference.
h) SCADA room shall be air-conditioned.
i) Telephone line must be laid during construction for all sewerage
works to be equipped with SCADA.

62 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

II) Manual Control

a) Interlocks shall be provided to prevent damage to the equipment


during equipment start up, for example, bearing overload,
overheated, temperature, loss of cooling water, no flow when
operating.
b) Selector switches to be provided at one location so that an
equipment can be manually operated from that location.

III) Drive Systems

a) Each drive must be independently provided with the following


features :
i. ON - starts and runs the drive
ii. OFF - stops the drive
iii. AUTO - operates the drive in accordance with
automatic control system
b) Indicate operation by an ammeter
c) Record running hours with a local indicator and by computation
in a central SCADA system where applicable.
d) Local annunciation on motor starter of each fault condition.
e) Record kilo-Watt.hour (kWh) of major drive equipment.

IV) Automatic System Control Facilities

a) Displays operator adjustable parameters, examples set point of


top water level in a tank and the target dissolved oxygen level
for a process.
b) Ability for the authorised operator to adjust the set point of
operator adjustable parameters. A “default” value should always
be provided.
c) Displays to advise operator of the set points of non-operator
adjustable parameters. Examples would include the overflow
level on a tank and the trip temperature for a bearing.
d) Displays measured values by all instruments, used to measure
flow, level, DO, pH, temperature or applicable parameters.
e) The process control sequences must ensure system problems
such as water hammer overtorque or overpressure the equipment
of air compressors. Time delayed in starting and stopping of
equipment where multiple duty units are installed, use a value
with slower rate the final stage of closing, vary the speed of
equipment during starting and stopping are some of the option
for consideration in careful process automation.

Sewage Treatment Plants Volume 4 63


Requirements for Physical Design

4.5.11 Supervisory Control and Data Acquisition Systems


(SCADA)

SCADA is the acronym for Supervisory Control and Data Acquisition.


The term refers to a large-scale, distributed measurement (and control)
system. SCADA systems are used to monitor or/and to control chemical,
physical or transport processes. The following briefly describe the
requirements of SCADA while the detail requirements of SCADA are
listed in Appendix C.

The term SCADA usually refers to a central system that monitors


and controls a complete site. The bulk of the site control is actually
performed automatically by a Programmable Logic Controller (PLC).
Host control functions are almost always restricted to basic site over-
ride or supervisory level capability. Provision of SCADA system shall
be in accordance with Section 4.5.10.

I) Control Systems

a) All equipment shall be tagged in the SCADA system.


b) Develop sequential function diagrams to specify the control logic
to suit the process operation for each system.
c) Check the process operation against the resulting sequential
function diagram.
d) PLC programs to be written in modular form to aid fault finding
and commissioning.
e) Design programs to be ‘fail to safety’. That is, PLC failure will
cause plant to stop.
f) On restoration of supply, all controlled system shall be returned
to the ready position before automatic restart takes place.
g) Bench test all application programs for PLC, before program
installation on site.
h) Conduct functional control circuits tests for all items of
equipment.
i) Ensure PLC programming software licences are delivered.
j) Provide paper copy listing of all PLC application programs and soft
copies of application program (two copies of each required).
k) Despite the PE, all plants which requires automation and control
shall be provided with human machine interface (HMI) at site.

II) Supervisory Systems

a) Where supervisory systems are used, schedule all graphic displays


required to control plant using columns to define:
i) Graphic Name

64 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

ii) Information displayed


iii) Control features
b) Update times for screens to be not more than one second.
c) Nominate the alarm title to be used/displayed for each process-
generated fault input or fault generated internally by the PLC
program.
d) Nominate critical and non-critical alarms and the method of
differentiation. Examples would be: nominating an alarm on a
limit which has been reached as critical and an alarm on a limit
which is being approached as non-critical; differentiated by, for
example, red/amber lights or horn/bell).
e) At least eight variables to be displayed on a trend graph
simultaneously for ease of monitoring and comparison. This is
a measure of the level of software sophistication which should
be expected.
f) Supervisory system to log running hours for all plant items.
g) Nominate the reports to be generated for plant operation,
management and history. For example, reports to be daily,
weekly and monthly and the list of parameters to be reported
on in each.
h) Alarm analysis, that is, frequency of occurrence, similar plant
faults, etc, to be provided as part of the supervising programs.

4.5.12 Early Warning System (EWS)

The EWS is used to monitor the status of the equipment operating inside
the treatment plants such as pumps and aeration equipment. It shall act
as the means to communicate information via Short Messaging Service
(SMS), e-mail or via other telecommunication mean to technical staff
for the fast recovery of the treatment system.

EWS system shall be able to transmit digital and analog values from
the remote module to the operator through their inputs (equipment) via
SMS and e-mail messages in text mode. The modules shall be able to
interpret SMS message from the operator to activate or deactivate long
distance machine (remote control).

4.5.13 Instrumentation

Provision for instrumentation shall be in accordance with the following


Table 4.7. Instruments shall be installed in such a way that they can be
removed for maintenance without interrupting the process.

Sewage Treatment Plants Volume 4 65


Requirements for Physical Design

Table 4.7 Required Process Instrumentation

Treatment Unit Instrumentation STP Class


Inlet Pump Station Level/ Pressure All
Flow Measurement All
Gas Detector (H2S, CO2, O2 & 4
Combustible gases)
Aeration DO/pH/ Turbidity 4
Temperature 4
Blower Air flow/ pressure/ temperature/ All
rpm
Decanter Position Indicator /Speed All
Effluent Flow Measurement All
Sludge (WAS/RAS) Flow Measurement 4
Electrical Drive Am/Volt/HR/kW/Power Factor All
meter
Disinfection Dosage/Transmittance / All
Flowrate/outlet water level
indicator
Polymer Dosage/ Level Indicator/ All
Flowrate
Sludge Feed Flowrate/ Pressure All

For STP with PE 10 000 and above, a digital power meter is required to
be installed at all individual panel of major equipment such as raw sewage
pump, air blower, aerators, mechanical dewatering unit etc. The digital
power meter shall be able to monitor the following:

Real-Time Readings Current, Voltage, Real Power, Reactive Power,


Apparent Power, THD (V and I)
Energy Readings Accumulated Energy (Real kWh, Reactive kVarh,
Apparent KVAh)
Demand and peak Current, Real Power, Reactive Power, Apparent
Readings Power
Other: Power Factor, Load Operating Time

All parameters measured as mentioned must be retrievable at all time.

66 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

4.5.14 Cables and Cabling Installation

I) General

a) Segregate cables into the following categories:


i) power (less than 1000 V phase to phase)
ii) instrumentation/telemetry
iii) control
b) Wherever possible, use a separate cable-support system for each
cable category.
c) Separate such cable support systems by minimum clear distances
of 300  mm.
d) When one cable support system has to be used, separate cable
categories by minimum clear distances of 150 mm.
e) Secure cable at 900 mm intervals for horizontal runs and 300
mm for vertical runs.
f) Cable ties shall be made of non-corrosive material and if exposed
to the environment, shall have UV protection.
g) All cables shall be at least of double PVC protection, and if exposed
to the environment then armoured cable shall be provided.

II) Instrumentation

a) Use separate cables for digital and analog signals.


b) Marshal cables in a process or geographical area into junction
boxes.
c) Use multipair cables between areas.

III) Buried Cables

a) Install cables without trees or through joints, unless approved.


b) All buried cables shall be laid in ducts.

IV) Underground Ducts

a) Construct road crossings from uPVC conduit of minimum 100


mm diameter with 900 mm cover and encased on all sides with
150 mm concrete.

Sewage Treatment Plants Volume 4 67


Requirements for Physical Design

b) All other ducts to be PVC conduit laid with a minimum cover


of 600 mm. Ducts to be bedded in 75 mm sieved sand.
c) Provide draw strings in all ducts.
d) Provide cable pits to suit cabling layout and to allow drain-in of
cables through the duct work. Cable pits shall be provided no
greater than 100  m apart. They shall be fitted with trafficable
cast iron covers and equipped with drainage.
e) Seal ducts into buildings with approved systems providing a fire
rating of 30 minutes.

(V) Conduits

a) All cabling within buildings or structures where cable trays are


not permitted, and in all external locations, shall be installed
within conduits.
b) Conduits installed externally shall be arranged to minimise their
length and exposure. PVC heavy duty conduit is permissible,
where it is protected from physical damage and UV. Otherwise,
metal or flexible conduits shall be used.
c) Use flexible steel reinforced conduit for connections, where relative
movement and removal for maintenance has to be considered.

VI) Cable Support Systems

a) Ensure cable support systems in electrical switch rooms, equipment


(for example, pump) rooms and service galleries.
b) When run in common service galleries, ensure cables are not
adjacent to hot services.

4.5.15 Earthing and Lightning Protection

a) Provide earthing and lightning protection to meet local


regulations.
b) Use a specialist inspector to verify the installation.
c) Earthing test results shall be submitted and results shall be below
or equal to 1 ohm.
d) Lightning arrestor test results shall be submitted and results shall
not more than 5 ohms.
e) Earthing and lightning arrestor chamber shall be of pre-cast
material.

68 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

4.5.16 General Purpose Power

Provide general purpose power socket outlets as follows:

a) Single phase outlet rated at 10 A adjacent to, or inside each


control cabinet and within 10 m of all equipment installations.
b) Three phase outlet rated at 50 A within 20 m of every screen,
sludge scraper, clarifier rake, grit collector and conveyor.
c) Three (3) phase (with neutral) outlet rated at 50 Amp shall be
provided at an interval of at least 20 m.
d) These outlets shall be water proofed industrial type switch socket
outlets (SSO).

4.5.17 Manuals, Drawings and Labelling

a) Provide equipment manuals that are specific to the plant and


instrumentation supplied.
b) System manuals describe the way each system manages the
individual items of plant. Ensure these are available in draft
form, before testing and commissioning commences.
c) Provide plant function diagrams, electrical system, electrical
circuit, Process and Instrumentation Diagram(P&ID), instrument
loop diagrams, electrical design calculations and single line
diagrams with endorsement by qualified person, before the plant
is pre-commissioned.
d) All plant and equipment are to be provided with inscriptions and
labels to facilitate understanding and safe operation and to satisfy
the requirements of any standards and regulations applying to
the works. Labelling includes:
i) inscriptions on equipment, cubicles, instruments, process
controllers and on small equipment such as relays, control
switches, indicating lights, etc
ii) identification of cables at both ends and along their
lengths
iii) identification of terminations for cable cores and cubicle
wiring in accordance with the circuit diagrams
e) Drawings submitted shall show all unit processes to be constructed,
and equipment to be installed based on the ultimate capacity of
the sewerage system, especially for phase development where
the construction of unit processes and installation of equipment
will be based on phasing.

Sewage Treatment Plants Volume 4 69


Requirements for Physical Design

f) For treatment plant with PLC/SCADA systems, ladder diagram,


programme source codes and programming console unit shall be
provided before pre-commissioning of the treatment plant.

4.5.18 Hazardous Areas

a) A plan setting out various hazardous areas and classes of electrical


hazard is required. For example, flameproof area in the vicinity
of anaerobic digesters/sludge gas compressors, chemical storages
or laboratories.
b) Ensure the plant and methods of construction and installation
conform to the requirements of each defined area, as this plan
will be used by the Supply Authority to inspect the area for
conformance.

4.6 Material Requirements for STP Structures and


Installations

Materials permitted for structural fabrication in treatment plants are


concrete, reinforced concrete, steel, fibreglass reinforced plastic and
aluminium. The requirements for such materials shall be in accordance
with information provided in the following sub-sections. Any others
material used for STP structures and installations shall obtain special
approval from the Commission.

Structural design of treatment plant structures shall be submitted by


registered professional engineers. They shall be in accordance with the
requirements and standards given in this section and any other relevant
standards, as well as, sound engineering practices.

4.6.1 Concrete and Reinforcement

a) Concrete structures shall be designed in accordance with MS


1195, except that concrete structures for retaining sewage and
other aqueous liquids shall be designed in accordance with BS
8007.
b) Concrete shall generally comply with the relevant requirements
in MS 523.
c) Concrete for structures retaining sewage shall have a strength
grade not less than grade C35A. Strength grades higher than
C35A may be specified as required by the Commission.

70 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

d) Concrete for structures retaining sewage shall be designed for


buoyancy due to ground condition.
e) Concrete for purposes other than structures retaining sewage shall
have a strength grade not less than grade C20 where unreinforced,
and not less than grade C30 where reinforced. Strength grades
higher than the minimum may be specified as required by the
Commission.
f) Concrete structures retaining sewage, shall be lined with high
alumina cement mortar of 20 mm minimum thickness or other
approved liners/lining materials.
g) Concrete and cement mortar exposed to soils or groundwater
shall be made using a cement suitably resistant to sulphate attack,
as specified in this section. Where part of a concrete structure
is exposed to soils or groundwater, cement suitably resistant to
sulphate attack shall be used for the entire structure.
h) Cement to be used to resist sulphate attack shall be one of the
following:
i) sulphate-resisting portland cement complying with MS
1037.
ii) portland pulverised fuel ash cement complying with MS
1227.
iii) ground granulated blast furnace slag complying with
MS  1387.
iv) high silica content portland cement
v) supersuphated cement complying with BS 4248.
i) Aggregates shall comply with MS 29 and shall be coarse aggregate
of 20 mm nominal maximum size.
j) Approval for admixtures shall be obtained prior to inclusion in
the concrete mix. All admixtures shall comply with MS 822.
k) Steel reinforcement shall comply with:
i) MS 144 for cold reduced mild steel wire.
ii) MS 145 for steel fabric.
iii) MS 146 for hot rolled steel bars.
l) Welding of steel reinforcement shall be in accordance with
BS  7123.
m) Waterstops for sealing joints in concrete shall comply with
MS  1292.

Sewage Treatment Plants Volume 4 71


Requirements for Physical Design

4.6.2 Steel

I) Structural steel

a) Structural steel sections shall comply with BS 4 or otherwise


with:
i) EN 10162 for cold rolled steel sections.
ii) EN 10210 for hot rolled steel sections.
iii) EN 10025 for weldable structural steel.
iv) EN 10296, EN 10297 and EN 10305 for steel tube.
b) The use of structural steel in building shall be in accordance
with MS 416.
c) Minor structural steelwork shall be Grade 43A complying with
EN 10025. All other steelwork shall be of appropriate grade, as
determined using MS 416 and other appropriate standards. These
shall be determined by a qualified structural engineer.

II) Coating for steel

a) Steelwork that may be in contact with sewage through immersion,


splash or spray, or that is over tanks containing sewage, shall be
protected against corrosion using one of the following coating
systems:
i) high build tar epoxy system complying with AS 3750.2
and applied in two or more coats to give a total dry film
thickness of not less than 200 µm.
ii) high build micaceous iron oxide pigmented epoxy system
complying with AS 3750.12 and applied in two or more coats
to give a total dry film thickness of not less 200 µm.
iii) hot dip galvanised coating of 140 µm nominal thickness in
accordance with MS 740.
iv) sealed sprayed zinc coating of 150 µm nominal thickness
in accordance with EN ISO 2063.
b) Other coatings providing 10 to 20 years service, before first
maintenance, as selected using Table 3 Part 8 of BS 5493 shall
be considered for approval by the Commission. Steelwork that
is exposed to the external atmosphere, except severe marine
atmospheres, shall be protected against corrosion using one of
the following coating systems:

72 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

i) a prime coat of a two pack polyamide cured epoxy zinc


phosphate of dry film thickness 60 to 80 µm with a finishing
coat of a high build micaceous iron oxide chlorinated rubber
paint, spray applied to a dry film thickness of 60 to no
more than 80 µm.
ii) hot dip galvanised coating of 85 µm nominal thickness, in
accordance with MS 740.
iii) sealed sprayed zinc coating of 150 µm nominal thickness,
in accordance with EN ISO 2063.
c) Steel substrates shall be prepared before application of coatings,
in accordance with BS 7079.
d) Other corrosion protection coating systems for steelwork shall be
determined using BS 5493 or AS 2312 for tropical atmospheres
so as to provide 20 or more years to first maintenance.
e) Unprotected steelwork in contact with sewage shall be stainless
steel grade 316S31 complying with EN 10088: Part 1 and 3 or
EN 10029 and EN ISO 9445.
f) Successive coatings of the one component shall be tinted a
different colour to facilitate overcoating and inspection.
g) All coatings shall be applied strictly in accordance with the
coating manufacturer’s printed instructions.
h) Bolts, nuts, screws and other fasteners shall have either:
i) hot dip galvanised, in accordance with MS 739
ii) sherardized zinc coating, in accordance with BS 4921
iii) electro plating
i) Washers and other small components shall have either:
i) hot dip galvanised, in accordance with MS 740
ii) a sherardized zinc coating, in accordance with BS 4921
j) Nuts, bolts, screws and washers in contact with sewage shall be
stainless steel of Grade 316S31 steel complying with EN 10088:
Part 1 and 3 or EN 10029 and EN ISO 9445.
k) Fasteners of incompatible material to the component being
fastened shall have suitable isolating washers and sleeves.

III) Marine and Corrosive Environment

a) All areas within 5 km from the coast line or salt water bodies
shall be classified as marine environment. Sewerage facilities
in marine and corrosive environment e.g. where the atmosphere

Sewage Treatment Plants Volume 4 73


Requirements for Physical Design

or soil contains high levels of chloride, sulphates and corrosive


chemical elements or compounds shall be adequately designed
to withstand the corrosive actions of the chemicals prevalent in
the environment. Necessary protections shall be provided against
all corrosive actions of the environment.
b) Design requirement for facilities in marine and corrosive
environment shall include:
i) Two coats of sodium silicate shall be applied to all external
surfaces of concrete structures.
ii) Concrete shall be resistant to all chemical attacks and be
designed in accordance with BS 8110 Part 1: 1997.
c) Exposed metal shall be of corrosion resistant and of marine
grade. Proper smooth surface finishing shall be provided for the
metal. Unprotected metals acceptable for use are as follows:

i) SS316L
ii) Aluminium alloy
iii) Materials suitable for use in corrosive environment acceptable
by the Commission
d) All structural steelwork shall be thoroughly descaled to BS 7079
second quality and shall be painted with 2 coats of two pack
epoxy based red lead primer before leaving the manufacturer’s
works. In addition, all structural steelwork shall be provided
with protective paint for chloride, sulphate or the prevailing
chemicals in the site after installation.
e) Cathodic protection shall be provided for all load bearing steel
structures in marine environment for a minimum life of 50
years.

4.6.3 Fibre Reinforced Plastic (FRP)

Only FRP products approved by the Commission shall be used and


FRP products shall not be used for access purposes.

FRP tanks, vessels and appurtenances for sewage treatment processes


shall be designed in accordance with BS 4994 and EN 13923. The
thickness of the structural section of the FRP tank wall shall not be
less than 5 mm and shall be at least of wall thickness as given in
ASTM D 4097.

All other FRP products shall meet the requirements of ASTM C 582
for FRP laminates.

74 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

Notwithstanding any other requirements in standards, all FRP products,


including FRP tanks and vessels for sewage treatment processes, shall
conform to the following material requirements:

a) FRP properties shall be as determined by design to standards


mentioned in this Section and other relevant standards, but shall
not be less than the following values:
− Tensile strength - 80 MPa
− Tensile modulus - 7000 MPa
− Flexural strength - 140 MPa
− Flexural modulus - 6000 MPa
− Water absorption - ≤ 0.75 %
− Barcol hardness - 40
− Operating temperature - -40oC to +50oC
− Specific gravity - ≥ 1.5
− Fire rating – ASTM E84, < 25s or Class 1 BS476
b) Unsaturated polyester resins shall be used but shall only be
isophthallic, bisphenol A fumurate or terephthalic polyester resins
meeting the requirements of Type B or C of BS 3532.
c) All surfaces shall have a resin rich layer, gel coat. Surfaces in
contact with sewage, water or any moisture shall comprise of
a resin rich layer at least 1 mm thick. All other surfaces shall
comprise of a resin rich layer at least 0.25 mm thick. Up to 10%
by mass of corrosion resistant glass fibres, (that is, C-glass or
E-CR glass), polyester fibres or acrylic fibres may be used in
the surface layer.
d) A barrier layer shall be provided behind the surface layer and
shall be at least 1.5 mm thick. The barrier layer shall comprise
of 70 to 80 % by weight resin with the remainder by weight
being E glass or E-CR glass.
e) The structural layer shall comprise resin impregnated layers of
E glass or E-CR glass and shall comprise at least 25 % E glass
or E-CR glass. Aggregate and filler may be included.
f) E glass and E-CR glass shall conform to the requirements of:
i) EN 14020 for glass rovings.
ii) EN 14118 for chopped strand mat.
iii) BS 3396 for woven fabric.
iv) BS 3749 for woven roving fabric.

Sewage Treatment Plants Volume 4 75


Requirements for Physical Design

g) Glass fibres shall have a surface treatment compatible with the


manufacturing process to ensure bonding to the resin.
h) Aggregates shall only be used in FRP structural layers and
external layers. Aggregates shall be clean, washed, high grade
silica sand containing not less than 95 % silica. Aggregates
shall be of a size not greater than 20 % of the thickness of the
FRP structural layer with a particle size not less than 0.05 mm
and not greater than 5 mm.
i) Fillers shall only be used as a resin extender and shall comprise
of clean inert material, for example, silica, with particle size less
than 0.05 mm.
j) Surfaces exposed to sunlight shall incorporate provisions to
minimise ultraviolet degradation, such as, ultraviolet inhibitors,
screening agents or pigment in the outer resin rich layer.
k) Pigments and dyes shall not normally be required, but where
required by the Commission, shall be of a type and colour
specified by the Commission.
l) FRP water tanks shall comply with the above requirements and
requirements in:
i) MS 1241: 1991 where not constructed of FRP panels.
ii) MS 1390: 1995 where constructed of FRP panels.
m) All design of package plants using FRP materials shall take
into account for the buoyancy effects. This effect is of concern
during high ground water conditions and emptying of the tank
content during desludging works.
n) Anchor strap shall be at least stainless steel grade 304.

4.6.4 Aluminium

a) Aluminium is found primarily as the ore bauxite and is remarkable


for its resistance to corrosion (due to the phenomenon of
passivation) and its light weight. Structural components made
from aluminium and its alloys are very important in which light
weight, durability, and strength are needed.
b) Wrought aluminium and aluminium alloys shall comply with:
i) BS 1161 for structural purposes.
ii) EN 485 for sheet plate and strip.
iii) EN 754 for drawn tube.
iv) EN 755 for bars, extruded round tubes and sections.

76 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Physical Design

v) EN 1676 for ingots and castings.


vi) BS 4868 for profiled sheet.
c) Anodic oxidation coating on aluminium shall be in accordance
with EN 12373.
d) Requirements for structural design, materials, workmanship and
protection of aluminium shall be in accordance with BS 8118

4.6.5 HDPE (High Density Polyethylene)

High-density polyethylene (HDPE) is the high density version of PE


plastic. Its molecules have an extremely long carbon backbone with
no side groups. As a result, these molecules align into more compact
arrangements, accounting for the higher density of HDPE. HDPE is
stiffer, stronger, and less translucent than low-density polyethylene.
HDPE is lighter than water, and can be moulded, machined and joined
together using welding.

High-density polyethylene shall comply to the following physical


properties:-

− Tensile Strength 0.20 – 0.40 N/mm2


− Notched Impact Strength no break Kj/m2
− Thermal Coefficient of expansion 100 – 220 x 10-6
− Max Cont Use Temp 650C
− Density 0.944 – 0.965g/cm3
− Minimum Require Strength 8.0 MPa

Sewage Treatment Plants Volume 4 77


Requirements for Physical Design

78 Volume 4 Malaysian Sewerage


Industry Guidelines
Section 5

Requirements for Individual


Treatment Processes
Requirements for Individual Treatment Processes

80 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

5.1 Introduction

All new applications for sewage treatment plant approval shall follow
the design requirements as stipulated in this section. These requirements
have been formulated as a gradual change in sewage treatment methods
for Malaysia prior to enforcement of ultimate requirements as stipulated
in Sections 3 and 4 of this volume.

Design requirements for each stage of the sewage treatment process, as


shown in Figure 5.1 are given in this section.

Figure 5.2 gives an overview of the typical flow diagram and elements
of a sewage treatment plant. Figure 5.2 also shows how one facility
is closely related to another and thus has an impact upon the overall
design.

Sewage treatment plants must be designed to produce an effluent quality


that conforms to either Standard A or Standard B or any other special
requirements under the provisions of the Environmental Quality Act.

The major indices are those of BOD5, Suspended Solids, COD, Oil &
Grease, Ammoniacal Nitrogen, Nitrate Nitrogen and Total Phosphorus.

The requirement to comply with absolute standards, where no failures


are permitted by law, means that new sewage treatment plants must be
designed to produce average effluent qualities well below those permitted
by the Standard figures. Design values for final effluent shall be used in
the design of new treatment works are given in Table 3.2. These design
effluent levels serve as the basis for the design requirement of each unit
process given in the following sub sections.

General ventilation systems shall be provided in compliance to the OSHA.


The potential for odour generation, its impact and treatment, shall be
considered in all aspects of design. Odour treatment equipment shall be
selected that such odours be reduced to the lowest possible level and
in compliance to the EQA.

Sewage Treatment Plants Volume 4 81


Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Figure 5.1 Typical Treatment Process Flow Chart


Figure 5.1 Typical Treat ment Process Flow Chart

Treatment Requirements Function


Treatment Mandatory (M) Design
Stage Processes Optional (O) Requirements

Removes rocks, roots and


Primary Section 5.2
1 M rags
Screen

Lifts sewage and provides


Pump
2 consistent flow to the
Station M/O Section 5.3
treatment system
Pre
Treatment Secondary Removes smaller/finer
3 M Section 5.4
Screen particles from sewage

Grit/Grease Removes sand, gravel and


4 M Section 5.5 other inorganic materials;
Removal separates oil & grease

Balancing
5 Tank M/O Section 5.6 Balances and equalises flow

Removes settleable
Primary Primary
6 M/O Section 5.7 solids/materials
Treatment Sedimentation

Biological Remove major polutants


7 M Section 5.8 (BOD and SS)
Treatment

Secondary Separates treated effluent


8 M Section 5.9 and settled sludge
Secondary Sedimentation
Treatment

9 Destroy disease causing


Disinfection M Section 5.10
organisms

10 Flow Meter M Section 5.11 Measures and records flows

Reduces potential
Thickener detrimental effect on the
Bio Solids Stabilisation environment and converts
11 M/O Section 5.12 sludge to a form suitable for
Handling
Holding ultimate disposal
Dewatering

Sludge Disposal

82 Volume 4 Malaysian Sewerage


Industry Guidelines

70 V ol ume 4 M al aysi an S ewerage


I ndustry G ui del i nes
9
5 7
6 Disinfection
3 8 10
1 Balancing Biological System
Primary Clarifier Flow
Secondary Tank Final Clarifier Flow Meter
Primary Screen A. Conventional Distribution
Screen Activated Sludge
Figure

Effluent To
B. Extended Aeration
Raw Activated Sludge Nearest
4
Figure5.2

Sewage Receiving
C. Trickling Filter
Inlet Grit/Grease D. RBC Watercourse
2 Alternative

Sewage Treatment Plants

Sewage Treatment Plants


Sewage
Pump Station
5.2 Typical
Typical

Return Sludge
Pump Station
Incinerator/Dryer
Elements
Sewage
Requirements for Stages of Sewage Treatment

Elements

Alternate
Treatment
and and

Volume 4

Volume 4
Return Liquor
Sludge Storage Area
Treatment
Process

Mechanical Sludge
Dewatering
Process

Mechanical Sludge
PlantPlant

Thickener

Ultimate Disposal Sludge Digester


Flow Flow

Sludge Holding
Diagram

Tank

Sludge Drying Bed


Diagram of a
of a Sewage

Alternative

83
Requirements for Individual Treatment Processes

71
Requirements for Individual Treatment Processes

5.2 Design of Primary Screens

5.2.1 Purpose of Primary Screens

Upon reaching the sewage treatment plant, sewage flows through the
primary screening facility which is the first stage of treatment. The
screens must be provided upstream of all inlet pump stations and shall be
designed to protect downstream processes and equipment. The purposes
of primary screens are:

a) to protect equipment from rags, wood and other debris


b) to reduce interference with in-plant flow and performance

5.2.2 Inlet Chamber

Provision for inlet chamber before the primary screen channel is necessary
for proper operational and maintenance. The summarised requirements
for inlet chamber are as follows:

Table 5.1 Requirements for Inlet Chamber

Unit
Requirements Notes
Process
Mandatory
≤ 20 000 > 20 000 > 50 000 Single and dual
Type
PE PE PE penstocks are referring
to members of penstocks
Inlet Single Yes n/a n/a required. For more
Chamber
than 50 000 PE, the
Dual n/a Yes Yes main penstock must be
motorised.
Motorised n/a No Yes

n/a – Not applicable

a) A penstock shall be installed upstream to isolate the pump station


in the event of flooding in relation to the bypass and emergency
overflow.
b) For safety reasons, a double penstock system shall be provided
at the inlet works of all plants with pump station above
20 000 PE.
c) The penstock spindle shall extend to pump station ground level
and shall be suitably positioned to allow unrestricted operation of
the penstock.

84 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Figure 5.3 Typical Details of Double Penstock

CLEAR SPACING
MANUAL FINE SCREEN

FIRST PENSTOCK SECOND PENSTOCK

OVERFLOW PIPE
DISCHARGETO DRAIN

PRIMARY
SCREEN
INLET CHAMBER
CHAMBER

450mm

1:2 IL

5.2.3 Design Requirements for Primary Screens

Table 5.2 Provision of Primary Screens

Numbers of Primary Screen


Requirements
≤ 5000 PE > 5000 PE
Manual 1 Unit -
Duty
Mechanical - 1 Unit
Manual - -
Standby
Mechanical - 1 Unit
By Pass 1 Unit 1 Unit

Sewage Treatment Plants Volume 4 85


Requirements for Individual Treatment Processes

Table 5.3 Design Parameters for Primary Screens

Design Criteria
Description Unit Manually Mechanically
Raked Raked#
Maximum clear spacing mm 25 25
Slope to the vertical
30o – 45o 15o – 45o
Maximum approach velocity at m/s 1.0 1.0
the feed channel

Maximum flow through velocity m/s 1.0 1.0


at the screen face

Minimum freeboard mm 150* 150


Estimated volume of screenings m3 / 106 m3 30 See Figure 5.4
per volume of sewage
screenings skip storage capacity day 7 7
Minimum channel width mm 500 500
Minimum channel depth mm 500 500
RC Staircase with riser detail 1 unit Anti-skid and Anti-skid and
non-corrosive non-corrosive

Notes:
* Designer shall ensure that with 50% of blockage at the face of screen, sufficient
freeboard is provided to prevent the approach channel from overflowing
# Washing and dewatering of screenings shall be provided.

5.2.4 General Requirements

All plants must include:

a) An emergency manual bypass screen. In the event of system


failure and/or power outages, the flow shall be automatically
directed to the bypass. It shall also be able to cope with
maximum flow.
b) Hand railings, kick plates, standing platforms and other safety
features to improve maintenance

Screen chambers must be of open channel construction with proper ventilation.


Forced ventilation must be used if chambers are enclosed.

86 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Screens must be designed to withstand the flushing velocity. In the


event of the manual bypass screen being blocked, sewage must be able
to flow over the top of the screen without causing excessive backup
flooding or overflows.

Chambers design must have taken into consideration necessary health


and safety aspects. The chamber must also be hydraulically efficient to
prevent the settlement of solids in the chamber.

Macerators and communitors as replacements for primary screens are


generally not recommended. It may be considered if the consultant is
able to provide good engineering reasons for its application.

Reinforced concrete staircase with proper handrailing must be provided


to access screen chambers.

Shaftless screw conveyors and belt conveyors may be used where


required. The screw conveyor shall be equipped with easy to remove
covers. The frame and support of screw conveyor shall be of minimum
stainless steel Grade 304 while the screw shall be of high tensile steel.
The belt conveyors shall be of heavy duty reinforced rubber belts on
a protected mild steel frame. Conveyors shall normally be installed on
a very slight grade to allow drainage, with foul water returned to the
inlet channel.

All screenings raked from mechanical screen shall be dropped into a


skip.

A proper standpipe shall be provided and located within 3 m to the


screen chamber.

Figure 5.5 and 5.6 illustrate typical arrangement of screen chambers of


various depths.

Refer also to relevant clause of MS 1228 for more details.

Sewage Treatment Plants Volume 4 87


Requirements
Requirements for Individual
for Stages Treatment
of Sewage Processes
Treatment

Figure
Figure 5.4 Quantities
Quantities of ScreeningsCollected
of Screenings CollectedFrom
From Primary
Primary Screens
Screens

100

80
Average

Maximum
Screenings, m 3/ 10 6m 3 of Sewage

60

40

20

0
0 1 2 3 4 5 6
Opening Between Bars, cm

88 Volume 4 Malaysian Sewerage


Industry Guidelines

76 Volume 4 Malaysian Sewerage


Industry Guidelines
DRAIN

CONC. APRON LAID TO FALL WP

RAMP DOWN DRAIN

CONC. APRON WP
LAID TO FALL
MECHANICAL COARSE SCREEN

RAMP
GRATING COVER DOWN
INCOMING SEWER

Sewage Treatment Plants


GRATING

Sewage Treatment Plants


COVER
INCOMING SEWER
Figure 5.5 Typical

CHAIN GUARD

PENSTOCK
CHAIN GUARD A
A R.C STAIRCASE TO A A PENSTOCK
ENGR'S DETAIL

R.C STAIRCASE TO
ENGR'S DETAIL
PLAN
Requirements for Stages of Sewage Treatment

(PE > 5000) PLAN


(PE ≤ 5000)

PENSTOCK PENSTOCK

Volume 4
Volume 4
SCREENINGS COLLECTION BIN SCREENINGS COLLECTION BIN

HANDRAIL
(<5m for different PE)

HANDRAIL
(<5 m for different PE)

HANDRAIL HANDRAIL

PERFORATED SLAB

< 5m
R.C STAIRCASE R.C STAIRCASE
TO ENGR'S DETAIL TO ENGR'S DETAIL
< 5m

S.S PERFORATED
Drawing of Screen Chamber based on depth

TROUGH

INCOMING SEWER
INCOMING SEWER

STOP LOG STOP LOG


Figure 5.5 Typical Drawing of Screen Chamber based on depth

SECTION A-A

77
SECTION A-A

89
Requirements for Individual Treatment Processes
DRAIN

90

78
CONCRETE APRON DRAIN
LAID TO FALL WP
CONCRETE APRON
LAID TO FALL WP

RAMP
DOWN RAMP
DOWN

M.S GRATING COVER MECHANICAL COARSE


SCREEN M.S GRATING COVER MANUAL COARSE
INCOMING SEWER SCREEN

INCOMING SEWER
CHAIN GUARD CHAIN GUARD
PENSTOCK PENSTOCK
A A
A
A R.C STAIRCASE TO DN
DN
ENGR'S DETAIL
R.C STAIRCASE TO
ENGR'S DETAIL

PLAN VIEW PLAN VIEW


(PE > 5000) (PE ≤ 5000)

MECHANICAL
Requirements for Stages of Sewage Treatment

COARSE SCREEN
PENSTOCK
PENSTOCK
SCREENINGS SCREENINGS
Requirements for Individual Treatment Processes

COLLECTION BIN COLLECTION BIN

HANDRAIL HANDRAIL

Volume 4

Volume 4
HANDRAIL HANDRAIL
(>5 m for different PE)

R.C STAIRCASE R.C STAIRCASE


TO ENGR'S DETAIL TO ENGR'S DETAIL

R.C PERFORATED SLAB


R.C PERFORATED SLAB

< 5m
CAT LADDER CAT LADDER
> 5m

S.S PERFORATED
OPENINGS TROUGH

OPENINGS
INCOMING SEWER INCOMING SEWER

STOP LOG STOP LOG


Figure 5.6 Typical Drawing of Screen Chamber based on Depth.

Malaysian Sewerage
Industry Guidelines
Malaysian Sewerage
SECTION A-A SECTION A-A
Requirements for Individual Treatment Processes

5.3 Design of Pump Stations

5.3.1 Purpose of Pump Stations

Inlet pump stations must be preceded by primary screens to protect


the pumps from being damaged or clogged. The inlet pumps of the
treatment works must be capable of handling raw unscreened sewage.
Water pumps must not be used as they are not designed to cope with
matters that may be found in sewage and the variability and quantity of
sewage flow. The purposes of pump stations are:

a) to lift sewage to a higher point for treatment


b) to provide consistent inlet flows to the treatment system
c) to prevent overflow of raw sewage

5.3.2 Design Requirements

(I) Structural Requirements

a) Substructure shall be constructed with reinforced concrete


using cement resistant to chemical attack, aggressive soils and
groundwater.
b) Safe and suitable access to the wells shall be provided.
c) If cement used is not resistant to the chemical attack, internal
walls shall be made resistant to sulphide corrosion by coating
with high alumina cement or approved equivalent coating.
d) A controlled overflow from the last manhole upstream of the pump
installation shall be provided to allow emergency maintenance
works.
e) Access shall be provided at all locations where operation and
maintenance works take place.
f) Static screen shall be provided at specific locations where it needs
to protect downstream unit processes.
g) Access covers shall be hinged with a lifting weight not exceeding
16  kg.

Sewage Treatment Plants Volume 4 91


Requirements for Individual Treatment Processes

II) Ventilation Requirements

a) Ventilation shall be provided for all hazardous zones of the


pump station.
b) Below ground pits shall have mechanical ventilation.
c) Separate ventilation shall be provided for wet wells and dry
wells.
d) Lighting systems shall be interconnected with ventilation.
e) Permanent ventilation rate and air changes shall comply with
Section 6 of this Guidelines.

III) Odour Control Requirements

a) Isolate odorous gases from general ventilation by containing


identified odour generating sources with a separate local exhaust
system.
b) Containment of the odour sources shall be by installing lightweight
and corrosion resistant covers/enclosures designed for practical
operation and maintenance works.
c) Local exhaust rates for containment shall be designed to provide
a negative pressure preventing build up of toxic, corrosive or
explosive gases and to include provision for process air or air
displaced by changes in the level of liquid inside the covered
space.
d) The odourus air in the local exhaust system shall be conveyed
through well designed and balanced ductworks by a centrifugal
fan to an effective odour treatment system.
e) Odour treatment equipment shall be selected such that odour is
reduced to the lowest possible level and in compliance to the
EQA.
f) In situation where specific gases such as hydrogen sulphide and
ammonia are significantly present, provide a pre-scrubber unit
upstream of the main odour treatment equipment.
g) Containment, exhaust and treatment shall be designed as an
integrated package.
h) Consideration must be given to the life span of the odour control
system and associated costs in operating and maintaining such
a system.

IV) Wet Wells Requirements

a) Suction channels shall be designed to avoid “dead zones”, i.e.,


prevent solids and scum accumulation. All “dead zones” shall be
chamfered.

92 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual
Requirements Treatment
for Stages of Processes
Sewage Treatment

b)
b) Benching shall
Benching shallbebe such
such that that to minimise
to minimise deposition
deposition of solid of solid
matters
matters on the floor or walls of wet wells. The minimum
on the floor or walls of wet wells. The minimum slope of benching slope
shall be 45o toshall
of benching be 45o to the horizontal.
the horizontal.
c)
c) Benching shall
Benching shallpreferably
preferablybe be extended
extended up toupthetopump
the pump
intake.intake.
d)
d) Minimum hopper
Minimum hopper bottom
bottom slope
slopeshall
shallbe
be1.5
1.5vertical
verticaltoto1.0
1.0horizontal.
horizontal.
Tapered slope
Tapered slopeshall
shallbebe provided
provided upthe
up to to suction
the suction section.
section.
e)
e) Automatic flushing
Automatic flushingofofgrit
gritand
andsolids
solidsis is recommended
recommended for for plants
plants of
of PE > 2
PE > 2,000. 000.
f)
f) The difference
The differencebetween
betweenstopstopand
andstart
start levels
levels shall
shall be abemaximum
a maximum of
of 900 mm and a minimum
900 mm and a minimum of 450 mm. of 450 mm.
g)
g) The difference
The difference in
in level
level between
between start
start oror stop
stop ofof duty
duty and
and assist
assist
pumps shall be greater than or equal to
pumps shall be greater than or equal to 150 mm.150 mm.
h) The minimum internal width of wet well shall not less than 2m.
h) The minimum internal width of wet well shall not less than 2m
i) Where possible, wet wells shall be open and guarded by a handrail
i) Where possible, wet wells shall be open and guarded by a handrail
or open mesh grating. The grating shall be easily and safely
or open mesh grating. The grating shall be easily and safely
removed.
removed.

Figure
Figure 5.7
5.7 –Typical
Typical Dimensions ofWet
Dimensions of WetWell
Well
Submersible PumpStation
Submersible Pump Station

MIN 2000
QO (I/S)
(ℓ/S)

INCOMING SEWER
Qi (I/S)
(ℓ/S)
D2 HIGH LEVEL ALARM

STANDBY CUT IN LEVEL


≥ 150

CUT IN LEVEL
d

CUT OUT LEVEL


s

LOW LEVEL ALARM


k

D1
Note :

Q1 = Incoming flow rate

QO = Forcemain Discharge rate

D2 = Forcemain Diameter, min 100

d = Difference between stop & start level, Min 450 Max 900

s = Minimum submergence, depends on manufacturer recommendation

k = Minimum clearance between pump suction and wet-well invert

All dimension are in mm unless otherwise state

Sewage Treatment Plants Volume 4 93

Sewage Treatment Plants Volume 4 81


Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Figure 5.8 Typical Dimensions of Dry Well


Figure 5.8 – Typical Dimensions of Dry Well
Submersible Pump Station
Submersible Pump Station

IN
Qi COMI
(I/S NG
) SE
W ER
HIGH LEVEL ALARM

STANDBY CUT IN LEVEL

150
CUT IN LEVEL

D
CUT OUT LEVEL

LOW LEVEL ALARM/EMERGENCY


3 CUTOUT
D2 to D2
4
S

D2 to D2
2
QO (l/s)
D1
150

D2
150 (min)
ALLOW ADDITIONAL DEPTH
FOR SOLID HEAVY OBJECTS

IN
Qi COM
(I/S I NG
) SE
WE
R
HIGH LEVEL ALARM
150 S

STANDBY CUT IN LEVEL

CUT IN LEVEL
D

CUT OUT LEVEL

LOW LEVEL ALARM/EMERGENCY


CUTOUT
D2
D2 TO D2

D1 Q0 (l/S)
150

Note :

Q1 = Incoming flow rate


ALLOW ADDITIONAL DEPTH
FOR SOLID HEAVY OBJECTS
QO = Forcemain Discharge rate

D2 = Bellmouth Diameter

D1 = Suction Diameter, Min 100

D = Difference between stop start level, Min 450 and Max 900

S = Minimum depth above pump intake to prevent vortex formation

V) Lighting Requirements
(V) Lighting Requirements
a) Wet wells and dry-wells shall be adequately lit.
a) Wet wells and dry wells shall be adequately lit.
b)
b) Electrical installations
Electrical installationsshall
shallbebewater
waterproof and vapour
proof and vapour proof
prooforor
explosion proof.
explosion proof.
c)
c) If lights
If lights are
arefitted
fittedoutside
outsidethethe well,
well, then
then a spotlight
a spotlight system
system may may
be
be used to provide adequate illumination.
used to provide adequate illumination.

94 Volume 4 Malaysian Sewerage


Industry Guidelines

82 Volume 4 Malaysian Sewerage


Industry Guideline
Requirements for Individual Treatment Processes

VI) Level Controls

a) Either floats or ultrasonic level controller may be used for the


start-stop levels of pumps. Instrument with environmental friendly
features are recommended.
b) Ultrasonic level control is recommended due to its clog-free
nature.
c) Non-mercury type floats are recommended.
d) Hollow tube electrodes are not acceptable.
e) Level controller shall be placed where they are not affected by
the turbulence of incoming flow and where they can be safely
removed.

VII) Pump Hydraulic Design

a) The submission of pump hydraulic design and performance shall


include:
i) System curves
ii) Pump curves
iii) Operating points of pumps with respect to flow and total
dynamic head (TDH)
iv) Operating characteristics such as efficiency, horsepower and
motor rating
b) Pump shall be operating within their best efficiency range at
normal operating condition.
c) Pumps are to be equipped with an auto restart mechanism in the
event of power failure.
d) Dry-well mounted pumps shall be equipped with auxiliary services
such as cooling and gland seal water supply.
e) Pumps equipped with cutting or macerating facilities are not
acceptable.
f) Guide rail, lifting device and other wet well fittings must be
fabricated of stainless steel that is corrosion resistant. The use
of hot dip galvanised iron is not recommended.
g) Horizontal installation of pumps is not allowed. All pumps shall
be installed vertical, unless the Consultant is able to provide good
engineering reasons for horizontal installation.

5.3.3 General Requirements

a) Drainage of dry-wells and valve pits shall be provided. Drainage


lines shall be equipped with back flow protection to ensure that
the chamber is not flooded.

Sewage Treatment Plants Volume 4 95


Requirements for Individual Treatment Processes

b) The wet well shall not be housed with a building structure.


c) Where separate valve pits are used, the connecting pipes shall
incorporate at least two flexible joints to allow for differential
settlement.
d) Pipework
i) Pipe work shall be of ductile iron or cast iron with cement
internal lining. Other approved material by the Commission
may be used.
ii) External surface of pipework in chambers and wells shall be
epoxy coated.
iii) Buried ductile iron pipe shall have polyethylene sleeving.
iv) Pipe within wells and pits shall have flanged joints, while
pipe laid in the ground shall have spigot and socket joints.
v) Pipe work shall be adequately supported on concrete plinths
or steel structural supports.
vi) Flanges shall be located at least 150 mm away from
structures.
vii) Dismantling joints such as bends shall be provided.
viii) Pumping thrust shall be resisted using pipe supports inside
chambers and by mass concrete thrust blocks poured against
undisturbed soil in the ground outside chambers.
ix) No welding joints are allowed.
e) Valves
i) Gate valves are preferred with rising spindles operated by
a tee piece.
ii) The uses of counterweights are recommended. Tapping
(12 mm BSP) shall be located upstream and downstream of
check valves.

Also refer to additional requirements in relevant Clause of MS 1228.

96 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Figure 5.9 Typical Details of Wet-well Pump Station


Figure 5.9 Typical Details of Wet-well Pump Station

MECH. COARSE SCREEN


INCOMING SEWER
STEPS
GRATING COVER V.C.P
OVERFLOW PIPE
DISCHARGE TO DRAIN STAND PIPE

CONC. APRON

COLLECTION BIN
CLEAR SPACING
S.STEEL MANUAL OVERFLOW
FINE SCREEN CHAMBER INFLUENT PUMP
A PRIMARY SCREEN A
GRATING COVER
EXPLOSION PROOF
17 18 19 20 21 22 23 SPOT LIGHT
PUMP SUMP
CHECK VALVE
S.STEEL HANDRAIL FLEXIBLE COUPLING
STEPS
PENSTOCK GATE VALVE
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DELIVERY PIPE

R.C STAIRCASE TO ENGR'S DETAIL

PLAN VIEW
LIFTING I-BEAM C/W
CARRIER
MECH. COARSE SCREEN
HANDRAIL
CHAIN GUARD
CHECK VALVE
CLEAR SPACING PENSTOCK
MANUAL FINE SCREEN FLEXIBLE COUPLING
GATE VALVE
OVERFLOW DELIVERY PIPE
PIPE DISCHARGE
TO DRAIN NON-EXPLOSION SPOT LIGHT

DELIVERY PIPE
GUIDERAIL
OVERFLOW
S.S PERFORATED
CHAMBER TROUGH PUMP SUMP LIFTING CHAIN

PRIMARY SCREEN
CHAMBER

CONC. SLAB
R.C WALL TO
IL ENGR'S DETAIL

FRP STOP LOG C/W


1:2 HAND WHEEL OPENING
IL IL
ALARM
START
MANUAL COARSE SCREEN

STOP

SECTION A-A

Sewage Treatment Plants Volume 4 97

Sewage Treatment Plants Volume 4 85


Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Figure
Figure5.10 Typical
5.10 Typical Details
Details of Dry-well
of Dry-well Pump Station
Pump Station

OVERFLOW PIPE DISCHARGE


TO MONSOON DRAIN

OVERFLOW CHAMBER

3 LAYER CONC. VENTILATION


DRAIN LIQUID RETURN FROM OTHER UNIT PROCESSES BLOCK AT TOP AND BOTTOM LEVEL
RAMP DOWN WP
CONC. APRON LAID TO FALL
FORCEMAIN

MECHANICAL COARSE SCREEN


A

A CONC. THRUST BLOCK.


12
GATE VALVE.
13 11
14 10
15 9
NCOMING SEWER
16 8
AIR EXTRACTOR FAN CHECK VALVE. EXTRACTOR FAN
G.I CHAIN GUARD 17 7
18 6
PENSTOCK R.C STAIRCASE TO ENGR'S DETAIL.
19 5
GRATING COVER 3 LAYER CONC. CONC. THRUST BLOCK. 20 4
VENTILATION BLOCK
G.I CHAIN GUARD.

14 15 16 17 18 19 20 21 21 3
AT TOP AND BOTTOM
LEVEL 22 2 CONCRETE VENTILATION
23 1 BLOCK AT TOP AND BOTTOM LEVEL
DN
CHAIN GUARD.
R.C STAIRCASE TO ENGR'S DETAIL DN
13 12 11 10 9 8 7 6 5 4 3 2 1

SPOT LIGHT ADJUSTABLE GLASS


CHEQUER PLATE LOUVRES WINDOW

BRICKWALL C/W CEMENT DOOR


PLASTER ON BOTH SIDES
DRY PIT PUMPS

PLAN VIEW

COPPER TYPE LIFTING I-BEAM C/W


LIGHTNING ARRESTOR CARRIER R.C GUTTER TO ENGR'S DETAIL

RAIN WATER DOWN PIPE


TO NEAREST SUMP
MECHANICAL COARSE SCREEN
DOOR
SCREENINGS COLLECTION BIN
PENSTOCK BRICKWALL C/W
CEMENT PLASTER ON BOTH SIDES
WINDOW
HANDRAIL CHEQUER PLATE
3 LAYER CONC. VENTILATION
BLOCK

HANDRAIL

R.C STAIRCASE TO ENGR'S DETAIL

WET WELL
DRY WELL

PERFORATED SLAB

CAT LADDER

OPENINGS

ALARM
CHECK VALVE 2nd. STANDBY PUMP START
1st. STANDBY PUMP START
INCOMING SEWER 2nd. DUTY PUMP START
(FLOAT SWITCH) GATE VALVE 1st.. DUTY PUMP START
ALL PUMP STOP
STOP LOG

SUMP BWL

DEWATERING PUMP
DRY PIT PUMPS

SECTION VIEW

86 Volume 4 Malaysian Sewerage


Industry Guideline

98 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.4 Recommended Design Parameters for Inlet Pump Stations

≤ 1000 Design Parameters


Description Unit PE ≤1,000 1,000 < PE ≤ 5,000

Type of station Wet well Wet well


Number of pumps 2 2
(all identical and work 1 duty, 1 duty,
sequentially) 1 standby 1 stand-by
(100 % standby) (100 % standby)
Pumps design flow Each at Q Each at Q
peak peak

Maximum retention time at Q min 30 30


ave

Min pass through openings mm 75 75


Minimum suction and discharge
openings mm 100 100
Pumping cycle start/ 6 min 6 min
(average flow conditions) hour 15 max 15 max
Lifting device* Lifting davit lifting beam and
block
Design Parameters
Description Unit 5,000 < PE ≤ 20 000 PE > 20,000
Type of station Wet well or dry-well Wet well and dry
up to 10,000 PE well
10,000 PE above – wet
well and dry-well
Number of pumps 4 (2 sets) 6 (3 sets)
1 duty, 1 assist, 1 duty, 1 assist,
(all identical and work
per set per set
sequentially)
(100 % standby) (50 % standby)
Pumps design flow each at 0.5 Qpeak each at 0.25 Qpeak
Maximum retention time at min 30 30
Qave
Min pass through openings mm 75 75
Minimum suction and discharge mm 100 100
openings
Pumping cycle start/ 6 min 6 - 15
(average flow conditions) hour 15 max
Lifting device* Mechanical and block mechanical

Note: * Motorised hoists shall be provided when the lifting weight exceeds 100 kg

Sewage Treatment Plants Volume 4 99


Requirements for Individual Treatment Processes

5.4 Design of Secondary Screens

5.4.1 Purpose of Secondary Screens

After the inlet pump station, further screening is required to reduce the
remaining floating matter and finer particles in the sewage that will
disrupt the treatment process downstream. The purposes of secondary
screens are:

a) to remove material such as plastic, paper, cloth and other particles


that may cause problems to the treatment process downstream.
b) to minimise blockages in sludge handling and treatment
facilities.

5.4.2 Design Requirements

Plants of all sizes must be installed with secondary screens. The channel
shall be designed for Qpeak or pump flow whichever is greater. Approach
channel shall be design to ensure good contribution of velocity

A minimum of two screens are required for duty and standby. Facility
for a screened bypass must be provided in the event of clogging. Where
mechanically cleaned screening devices are installed auxiliary manually
cleaned screen shall be provided.

Table 5.5 Provision Requirement of Secondary Screens

Numbers of Secondary Screen


Requirements
≤5000 PE >5000 PE
Manual 1 Unit -
Duty
Mechanical - 1 Unit
Manual - -
Standby
Mechanical - 1 Unit
Bypass Screen 1 Unit 1 Unit

100 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.6 Design Parameters for Secondary Screens

Design Criteria
Description Unit Manually Mechanically
Raked Raked #
Maximum clear spacing mm 12 12
Slope to the vertical 30o – 45o 15o – 45o
Maximum approach velocity at m/s 1.0 1.0
the feed channel
Maximum flow through velocity m/s 1.0 1.0
at the screen face
Minimum freeboard mm 150* 150
Estimated volume of screenings m3 / 106 m3 See Figure 5.4
per volume of sewage
Screenings skip storage capacity day 7 7
Minimum channel width mm 500 500
Minimum channel depth mm 500 500
RC Staircase with riser detail 1 unit Anti-skid and Anti-skid and
non-corrosive non-corrosive

Notes:
* Designer shall ensure that with 50% of blockage at the face of screen, sufficient
freeboard is provided to prevent the approach channel from overflowing
# Washing and dewatering of screenings shall be provided.

5.5 Design of Grit and Grease Chambers

5.5.1 Purposes of Grit and Grease Chambers

This unit process is important to minimise problems associated with grit


and grease. Grit creates problems to pumps and also sludge digestion
and dewatering facilities. Grease creates problems at the clarifier and
is carried over in the final effluent.

In grit removal system, grit or discrete particles that have subsiding


velocities or specific gravities substantially greater than those of organic
putrescible solids, e.g. eggshells, sands, gravel are removed by gravitate
settlement or centrifugal separation. Same principle apply to oil and
grease removal system, where free oil and grease globules lighter than
water rise through the liquid and skimmed from the top surface.

Sewage Treatment Plants Volume 4 101


Requirements for Individual Treatment Processes

The particles must be removed at an early stage of the process


because:

a) the grit particles cannot be broken down by any biological


treatment.
b) the grit particles are abrasive and wear down equipment.
c) the biological treatment in sewage treatment works is not designed
to degrade grease.

5.5.2 General Requirements

A manual bypass shall be provided. In case of grit removal system


failure and/or power outages, the flow shall be automatically directed
to the bypass.

Where mechanical grit separator is used, they shall be installed at an


angle of at least 10° to allow drainage and foul water to be returned to
the inlet channel.

Where manual systems are used, allow for safe and easy access to remove
grit to a storage bin.

If pump systems are used, the suction pipe shall be short and straight.
Tees and short radius bends shall be avoided, if at all possible. Flanges
at strategic locations shall be provided so that they can be dismantled
to remove any blockages.

The mechanical oil and grease skimming device shall be designed to


minimise the water being remove while skimming the oil and grease.

Sand pit may be used for further dewatering of the grease removed before
ultimate disposal. The drainage from the sand pit shall be returned to
the inlet channel for further treatment.

102 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.7 Provision Requirement of Grit and Grease


Removal System
Number of Unit Processes
Requirements
≤ 5000 PE > 5000 PE
i) Grit Removal System
Duty Manual 1 Unit @ design flow -
Mechanical -1 Unit @ design flow
(up to 10 000 PE)
-
-2 unit @ 50% design flow each
( >10 000 PE)
Standby Manual 1 Unit @ design flow -
Mechanical - -
Bypass - Yes
ii) Grease Removal System
Duty Manual 1 Unit -
Mechanical -1 Unit @ design flow
(up to 10 000 PE)
-
-2 unit @ 50% design flow each
( >1000 PE)
Standby Manual 1 Unit @ design flow -
Mechanical - -
Bypass - Yes

5.5.3 Design Criteria

Design criteria are given in Tables 5.8 and 5.9.

Table 5.8 Design Parameters for Grease Chambers

Design Criteria
Description Unit
PE ≤ 5000* > 5000PE > 5000PE
Grease removal - Simple manual Manual interceptor Mechanical
Chamber type - Rectangular Baffled tank Aerated type
Minimum detention
time (Qpeak) min 3 3 3

Grit and grease storage


period before off-site day 30 7 7
disposal
Note:
* Combined grit & grease chamber is allowed. If combined, then total detention
time shall comply to 6 minutes at Qpeak.

Sewage Treatment Plants Volume 4 103


Requirements for Individual Treatment Processes

Table 5.9 Design Parameters for Grit Chambers

Design Criteria
Description Unit
PE ≤ 5000* >5000PE >5000PE
Grit removal - Manual Mechanical Mechanical
(tanker)
Chamber type - Horizontal Square, rotary or Aerated
flow (2 units vortex type simple
required for mechanised grit
duty and chamber
standby during
cleaning)
vortex also
acceptable
Minimum
detention time at minute 3 3 3
Qpeak
Maximum gravity
flow through m/s 0.20 0.20 0.20
velocity at Qpeak
Maximum
centrifugal flow m/s n/a <1.0 <1.0
through velocity
Head loss
- 35% of depth -
(at parshall flume)
Aeration l/s/meter - - 10.0
requirement length of tank
Chamber
dimension:
Manufacturer’s Manufacturer’s
Depth: Width - 1:2
Specification Specification
Length: Width 2:1

Estimated grit m3/103 m3 of


0.03 0.03 0.03
quantity sewage
Washing and
- No Yes Yes
dewatering of grit

Notes:
* Air lift pump for removal of grit is not acceptable.
* Water depth in tank to be controlled by weir outlet.

104 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

5.6 Design of Balancing Tanks

Balancing tanks are mandatory for all treatment processes that are not
designed at peak flow. The tanks are effective means of equalising
sewage flow. For extended aeration plants that are designed with a
retention time of more than 18 hours and clarifiers designed at peak
flow, the use of balancing tanks is not required.

5.6.1 Purposes of Balancing Tanks

The purposes of balancing tanks are to:

a) prevent flow variations entering secondary treatment processes.


b) reduce hydraulic loading into secondary treatment processes.
c) reduce potential overflows that may cause health hazard and
pollution.

5.6.2 Design Requirements

The design requirements for balancing tanks are:

a) All balancing tanks must be completely aerated and mixed.


b) Flow control shall be by a non-mechanical constant flow device,
such as an orifice, in order to avoid double pumping.
c) Allowance must be made for an emergency overflow.
d) Bypass and drain down facilities as well as suitable access for
cleaning shall be provided.
e) A dead water depth of 0.6 - 1.0 m is normally required.
f) For plants with PE > 10 000, where balancing tank is used,
minimum one (1) unit of balancing tank shall be provided. The
design flow of the upstream and downstream unit processes are
recommended as follow:
i) Where no balancing tanks is provided, design flow of unit
process at
 Upstream = Peak/pumped flow
 Downstream = Peak/pumped flow
ii) Where balancing tank is provided, design flow of unit process
at
 Upstream = Peak/pumped flow
 Downstream = Average flow

Sewage Treatment Plants Volume 4 105


Requirements for Individual Treatment Processes

Table 5.10 Design Parameters for Balancing Tanks

Description Unit Design Criteria


Volume of tanks m 3
1.5 hr detention at Qpeak
Mixing power W/m3 of
5 at TWL
requirements sewage
Aeration 1 m3 of air supply for every
m3 air/hour/
m3 of sewage stored per
m3 sewage
hour at TWL
Overflow bypass to down-
stream unit requirement - Yes

5.7 Design of Primary Sedimentation Stage


At primary sedimentation stage, the velocity of sewage is reduced to
subside settleable suspended organic matters in the sewage. The settled
matter is known as primary sludge.

5.7.1 Purposes

The purposes of primary sedimentation are:

a) to remove maximum amount of pollutants such as settleable


solids quickly and economically.
b) to separate sewage into sludge and settled sewage, which by
being treated separately are normally dealt with more efficiently
and economically.
c) When used as a preliminary step for further treatment, the main
function of primary sedimentation tank is to reduce the organic
loadings on the secondary treatment units and is a essential
component of secondary sewage treatment.

5.7.2 Design Requirements

The design requirements of primary sedimentation include the


followings:

a) Provide sufficient time for maximum settling under quiescent


conditions. Therefore, design factors require careful consideration
include: overflow rate, detention period, weir-loading rate, shape
and dimensions of the basin, inlet and outlet structures, and
sludge removal system.
b) Tanks can either be rectangular, circular or upward flow
(square).

106 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

c) Provisions for the removal of sludge on a daily basis.


d) Holding tanks for wasted sludge must be provided.
e) V-notch weirs with baffle shall be provided at the outlet.
Weirs shall be adjustable with notches 100 mm deep. Typical
variation in water level shall be no more than 50 mm under all
conditions.
f) Multiple hopper are not permitted.
g) Scum skimming shall be provided to remove both floating
materials and scum. These materials can be either discharged
to biosolid holding tank or sand drying bed. They shall not be
returned to the preliminary treatment units.
h) Flow distribution channel/ chamber shall be provided for flow
isolation or equal flow distribution.
i) Rectangular tank
i) Sludge hopper shall have side slopes of 60° or more
from horizontal with the sludge pump located in a pit at
hopper invert level. The length of suction pipe shall be
minimised. Provision for withdrawal pipe from the tanks
shall be provided.
ii) The capacity of hopper shall be equivalent to 2 hours
detention time at Qpeak.
iii) Additional water depth of minimum 400 mm should be
provided above the hopper in the vertical side-wall section
between the top of the hopper and the top water level. The
side-wall height should not be less than 400 mm.
iv) Equalise flow distribution across the inlet of the tank shall
be achieved using a multi-port wall and baffles.
j) Circular Tank
i) Circular tanks shall be no more than 50 m in diameter
and minimum water depth shall be 3.0 m.
ii) Circular tanks with more than 30 m diameter shall be
provided with perimeter walkway for cleaning the weir
and shall have appropriate drive system.
(k) The floor slab of the sedimentation tank shall be of reinforced
concrete type construct to gradient to enhance the sludge scraping
effectiveness.

Sewage Treatment Plants Volume 4 107


Requirements for Individual Treatment Processes

Table 5.11 Design Parameters for Primary Sedimentation

Description Unit Design Criteria


Sedimentation followed by secondary treatment
Detention time at Qpeak hr 2
Surface overflow rate at Qpeak
- circular (maximum) m /m /d
3 2
45
- rectangular (maximum) m /m /d
3 2
45
Weir loading at Qpeak m /m/d
3
150
Upward flow rate at Qpeak m/hr 1.2 - 2.0
Sizing of rectangular tanks
Length : Width > 3:1
Min water depth m 2.5
Width : Depth 1 : 1 to 2.5 : 1
Sizing of circular tanks
Min. side water depth m > 3.0
Floor slope wall 1:12

5.8 Design of Biological Treatment Stage

5.8.1 Introduction

Biological treatment is the heart of the sewage treatment process. It is


the processes where the dissolved and non- settleable organic material
remaining in the sewage are removed by living organisms.

For reasons of long term whole life economics, ease of operation and
maintenance, consistent effluent standards and standardisation, the
following types of biological treatment processes are recommended for
use in Malaysia.

Suspended Growth System

a) Conventional activated sludge (CAS) system


b) Extended aeration (EA)/Oxidation Ditch (OD) System
c) Sequencing Batch Reactor (SBR)/Intermittent Decant Extended
Aeration (IDEA)

108 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Attached Growth System


a) Rotating biological contactor (RBC) system
b) Trickling filter (TF) System
c) Hybrid System/Combination multistage design

All plants must be strictly designed to meet DOE Standard A/Standard


B requirements including, nitrification and denitrification to reduce
ammonia and total nitrogen removal level that ensure compliance with
the requirement stipulated in Section 3 earlier. Total phosphorus removal
must also be taken into account for plants where treated effluent is to
be discharged into stagnant water bodies.

Mass balance calculation must be computed and submitted for all biological
treatment system and other unit processes proposed for the STP.

5.8.2 Conventional Activated Sludge System (CAS)

5.8.2.1 General Description

The conventional activated sludge process is one of the many versions


of the activated sludge process. The activated sludge process is most
suitably used where land is limited and expensive, and where large
volumes must be treated economically, without creating nuisance to
neighbours.

The process involves the production of activated mass of microorganisms


capable of stabilising sewage aerobically. This is achieved by introducing
organic waste, produced from pre-treatment and primary treatment
facilities, into reactors where suspended aerobic bacterial culture oxidises
the organic matter into stable matters. These active bacteria cultures are
commonly known as activated sludge. During the process, new bacteria
cell are also produced.

5.8.2.2 Design Requirements for CAS

For the design of conventional activated sludge system, the aeration


tank shall be preceded with primary sedimentation system. An appropriate
amount of the bacteria culture, known as activated sludge must be recycled
to the upstream of the reactor while the remaining excess sludge must
be removed at secondary sedimentation system.
All conventional activated sludge system used at STPs for Class 3,
Class 4 and at where requested by the Commission must be designed with
anoxic zone to achieve a total nitrogen removal in order to comply with
the requirements in Section 3 of this Guidelines, as well as to minimise
potential rising sludge at secondary sedimentation system. The anoxic
zone must be mixed without inducing dissolve oxygen.
Sludge treatment and dewatering must be available on-site to handle the
large quantity of unstable sludge generated.

Sewage Treatment Plants Volume 4 109


Requirements for Individual Treatment Processes

Table 5.12 Design Parameters for Conventional/ Activated


Sludge System

Description Unit Design Criteria


Primary Sedimentation System Must be provided
Minimum number of aeration tanks 2
F/M ratio 0.25 - 0.50
Hydraulic retention time (HRT) hrs 6 -16 (for system where
only ammonia removal is
require)
12 -16 (for plants require
total nitrogen removal)
Oxygen requirements (for BOD and kgO2/kg substrate 2.0
ammonia nitrogen removal)
Mixed liquor suspended solids mg/l 1500 -3000
(MLSS) Typical: 2500
Dissolved oxygen (DO) level in tank mg/l 1.0
Aeration device rating Continuous, 24 hrs
Sludge yield kg sludge 0.8 - 1.0
produced/kg BOD5
consumed
Sludge age # day 5 - 10
Waste activated sludge, QWAS m3/d Refer to equation below †
Return activated sludge flow, QRAS m3/d 0/66
[ 4DYJ
&X  0/66
Cu is underflow concentration

QRAS / QINFLOW 0.75-1.0

Mixed liquor suspended solids 4 – 6 of Qavg


recirculation for denitrification
purpose
RAS pump rating hrs/day 24

Organic loading kg BOD5/kg MLSS 0.25 - 0.5


Volumetric loading kg BOD5/m3.d 0.3 - 0.6
Minimum mixing requirement W/ m3 20

110 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Stages of Sewage Treatment
Requirements for Individual Treatment Processes

Table 5.12 Design Parameters for Conventional


Table 5.12Activated
DesignSludge
Parameters
Systemfor Conventional
(cont.)
Activated Sludge System (continued)
Description Unit Design Criteria
Description Unit Design Criteria
Tank dimension
Tank dimension
Water depth m 3–5
Water depth m 3–5
Length:Width 3:1
Length:Width 3:1
Max width
Max width of
of joined
joined tank
tank m m <30 < 30

total solids in aeration tank


# Sludge Age =
excess sludge wasting / day + solids in effluent

ª VT u MLSS º
† «
«¬ T sludge »¼
>
»  Q avg u SSeff @
WAS =
Cu

Where:
vT = volume of reactor (m3)
3
MLSS = mixed liquor suspended solids (kg/m )
Tsludge = sludge age (days)
Qavg = average flow (m3/day)
SSeff = effluent suspended solids (kg/m3)
Cu = underflow concentration (kg/m3)

Refer Table D1 and D2 for aeration equipment duty / standby and also to
Refer Table
relevant D1ofand
clause MSD2 forfor
1228 aeration equipment duty/standby and also to
more details.
relevant clause of MS 1228 for more details.
5.8.3 Extended Aeration System (EA)
5.8.3 Extended Aeration System (EA)
5.8.3.1 General Discription
5.8.3.1 General Discription
The extended aeration process is similar to the conventional activated
The extended
sludge process aeration
except thatprocess is similar
it operates to the conventional
in the endogenous respirationactivated
phase of
sludge process
the growth curve,except
which that it operates
requires in theloading
a low organic endogenous
and longrespiration
aeration
phase of the
time. The growth
system curve,high
produces which
MLSS requires a low organic
concentration, high RASloading
pumpingand
long aeration
rate and time. wastage.
low sludge The system produces high MLSS concentration, high
RAS pumping rate and low sludge wastage.
The advantage of having long hydraulic retention times is that it allows the
The
plantadvantage
to operateofeffectively
having long overhydraulic retention
widely varying times
flow and is that loadings.
waste it allows
the plant toclarifiers
Secondary operate must
effectively over widely
be designed to thevarying flowin and
variations waste
hydraulic
loadings and high MLSS concentrations associated with this
loadings. Secondary clarifiers must be designed to the variations inprocess.
hydraulic loadings and high MLSS concentrations associated with this
process.

Sewage Treatment Plants Volume 4 111

Sewage Treatment Plants Volume 4 99


Requirements for Individual Treatment Processes

5.8.3.2 Design Requirements for EA

EA plants shall be designed as either plug flow or completely mixed.


Anoxic zone at the head of the reactor must be provided for denitrification.
The anoxic zone must be mixed without inducing dissolved oxygen

For Oxidation Ditches, the minimum velocity within the channel shall
be sufficient to keep the activated sludge in suspension. The minimum
velocity within the channel shall not be less than 0.3 m/s. The tank
configuration and aeration and mixing devices shall promote unidirectional
channel flow, so that the energy used for aeration is sufficient to provide
mixing in a system with a relatively long hydraulic retention time.

Table 5.13 Design Parameters for Extended Aeration

Description Unit Design Criteria


Minimum number of aeration tanks 2
F/M ratio 0.05 - 0.1
Hydraulic retention time (HRT) hrs 18 - 24
Oxygen requirements(for BOD and kgO2/kgsubstrate 2.0
ammonia nitrogen removal)
Mixed liquor suspended solids (MLSS) mg/l 2500 - 5000
Typical: 3000
Dissolved oxygen (DO) level in tank mg/l 2.0
Sludge yield kg sludge produced/kg 0.4 (at 24 hrs HRT)
BOD5 consumed 0.6 (at 18 hrs HRT)
Sludge age # day > 20
Waste activated sludge flow, QWAS m3/d Refer to equation †
Return activated sludge flow, QRAS m3/d 0/66
[ 4DYJ
&X  0/66

Cu is underflow
concentration
RAS pump rating hours/day 24
Recirculation ratio, QRAS/QINFLOW 0.5 - 1.0
MLSS recycle ratio 4 – 6 times of Qavg
Volumetric loading kg BOD5/m .d 3 0.1 - 0.4
Minimum mixing requirement W/m3 20
Tank dimension
Water depth m 3–5
Length:Width ratio 3:1
Max width of joined tank m < 60

112 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual
Requirements Treatment
for Stages of SewageProcesses
Treatment

Notes:
#
Sludge Age = total solids in aeration tank
Requirements for Stages of Sewage Treatment
ª VT u MLSS º

«
«¬ T sludge »¼
>
»  Q avg u SSeff @
Notes: excess sludge wasting/day + solids in effluen WAS =
# Cu
Sludge Age = total solids in aeration tank
ª VT u MLSS º
Where: « »  > Q avg u SSeff @
† «¬ T sludge »¼
vT excess sludge wasting/day
= volume+ofsolids in effluen
reactor (m3) WAS =
Cu
MLSS = mixed liquor suspended solids (kg/m3)
Tsludge = sludge age (days)
Where:
Qavg = average flow (m3/day)
vT = volume of reactor (m3)
SSeff = effluent suspended solids (kg/m3)3
MLSS = mixed liquor suspended solids (kg/m )
Cu = underflow concentration (kg/m3)
Tsludge = sludge age (days)
Qavg = average flow (m3/day)
SSeff
Refer Table D1 and D2 for aeration equipment duty /
= effluent suspended solids (kg/m3)
standby and also to
Cu relevant clauseconcentration
= underflow of MS 1228(kg/m for3more
) details.
Refer Table D1 and D2 for aeration equipment duty/standby and also to
relevant
Refer clause
Table of MS
D1 and 1228
D2 for for more
aeration details.duty / standby and also to
equipment
relevant clause of MS 1228 for more details.
Figure 5.11 – Fine Bubble Diffuse Air Extended Aeration System

Figure 5.11 Fine Bubble Diffuse Anoxic Zone


Air Extended
Aeration Tank Flow
Aeration System
Distribution
Final Clarifier

Figure 5.11 – FineScreens,


BubbleGrit Removal Diffuse Air Extended Aeration System Effluent
To River

Raw
Sewage
Inlet Anoxic Zone Aeration Tank Flow Final Clarifier
Distribution
Sewage
Pump Station
Screens, Grit Removal Effluent
To River

Return Sludge
Raw Pump Station
Sewage
Inlet
Sewage
Pump Station

Return Sludge
Liquor
Pump Station
Chemical
Dosing

Sludge Storage Area Mechanical Sludge


Dewatering
Liquor
Chemical Mechanical Sludge
Dosing Thickener

Sludge Holding Tank


Ultimate Disposal
Sludge Storage Area Mechanical Sludge
Dewatering
Sludge Drying Bed Mechanical Sludge
Thickener

Sludge Holding Tank


Ultimate Disposal
OPTIONAL
Sludge Drying Bed

OPTIONAL

Sewage Treatment Plants Volume 4 113

Sewage Treatment Plants Volume 4 101


Requirements for Individual Treatment Processes
Requirements for Individual Treatment Processes

Figure 5.12 Oxidation Ditch Activated Sludge System


Figure 5.12 – Oxidation Ditch Activated Sludge System

Flow
M echanical R otor Flow Final Clarifier M easurem ent
Distribution E ffluent
S creens, G rit R em oval To River

R aw
S ewage
Inlet O xidation Ditch
S ewage
P um p S tation

R eturn S ludge
P um p S tation

Chem ical
D osing

S ludge Storage A rea M echanical S ludge


Dewatering
M echanical Sludge
Thickener

S ludge Holding Tank


Ultim ate D isposal

S ludge D rying B ed

O P TIO N AL

5.8.4
5.8.4 Rotating Biological
Rotating BiologicalContactors
Contactors (RBC)
(RBC)
5.8.4.1
5.8.4.1 General Description
General Description

Rotatingbiological
Rotating biological contactors
contactors use a use
seriesa of
series of media
rotating rotating media for
for biological
biological treatment. The rotating medium, typically made from
treatment. The rotating medium, typically made from sheets of high quality sheets
of highprovides
plastic, quality aplastic,
surface provides
on which aorganisms
surface on which
grow. organisms
As the grow.
media rotate,
As the media rotate, the fixed film biomass is in contact with
the fixed film biomass is in contact with organic pollutions in sewage and organic
pollutions
oxygen in sewage alternately.
in atmosphere and oxygenLayersin atmosphere
of biomassalternately.
are sheared Layers
from theof
biomassofare
surface thesheared from the
media during the rotation
surface to
of prevent
the media during of
overgrown thetherotation
fixed
to prevent overgrown of the fixed film.
film.

RBCs are
RBCs are conventionally
conventionally submerged
submergedtoto40%40%ofof disc
discdiameter.
diameter. Increased
Increased
submergence ofofdiscs
submergence discsupuptotoabout
about 90%
90% is also
is also acceptable
acceptable if sufficient
if sufficient air
air supply is provided at the base of the tank. This system is normally
supply is provided at the base of the tank. This system is normally called
called
the the submerged
submerged biologicalbiological
contactor contactor
(SBC). (SBC).

5.8.4.2
5.8.4.2 Design
Design Requirements
Requirementsforfor
RBC Plants
RBC Plants
Preceding
Preceding the
the RBC
RBC must
must bebe aa primary
primary sedimentation
sedimentationtank
tankororaa secondary
secondary
screening with <6 mm opening. A flow balancing tank must also be
screening with < 6 mm opening. A flow balancing tank must also be
provided unless the plant is designed to peak flow.
provided unless the plant is designed to peak flow.
Units must be covered for aesthetics and odour control, and only approved
Units must
media typesbe
arecovered for aesthetics and odour control, and only approved
accepted.
media types are accepted.

114 Volume 4 Malaysian Sewerage


Industry Guidelines

102 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Table 5.14 Design Parameters for RBC Plants


Table 5.14 Design Parameters for RBC Plants
Description Unit Design Criteria
Minimum number of stages
Description Unit 3 Design Criteria
Total BOD specific
Minimum
5
loading
number g/m /d
of stages
2
5 - 10 3

Total tank volume


Total BOD5 specific loading g/m2/d Based on
5 -210
hrs at Qavg
Sludge yield
Total tank volume kg excess sludge/ 0.9 Based on 2 hrs at Qavg
kg BOD5 consumed
Sludge yield kg excess sludge/ 0.9
Disc diameter m kg BOD5 consumed 2.5 - 3.5
Speed of rotation rev / min 0.5 - 1.0
Disc diameter M 2.5 - 3.5
Maximum peripheral velocity m/s 0.3
Speed of rotation rev / min 0.5 - 1.0
Depth of disc submergence % 40 - 90
Maximum peripheral velocity m/s 0.3
Depth of disc submergence % 40 - 90
Refer also to Table D.3 for duty standby requirements and relevant clause of
MS 1228
Refer alsofor
to more
Table details.
D.3 for duty standby requirements and relevant clause of MS
1228 for more details.

Figure 5.13 Rotating Biological Contactor (RBC) Systems


Figure 5.13 – Rotating Biological Contactor (RBC) Systems

Rotating Biological
Contactor

Screens, Grit Removal, Fine Screen Flow


Flow Measurement Distribution
Final Clarifier
Effluent To
Raw River
Sewage Balancing
Inlet Tank
Sewage
Pumping
Station
Liquor

Chemical
Dosing

Sludge Storage Area Mechanical


Sludge Dewatering
Mechanical
Sludge Thickener

Sludge Holding Tank


Ultimate Disposal

SludgeDrying Bed

OPTIONAL

Sewage Treatment Plants Volume 4 115

Sewage Treatment Plants Volume 4 103


Requirements for Individual Treatment Processes
Requirements for Individual Treatment Processes
5.8.5 Trickling Filter
5.8.5 Trickling Filter
5.8.5.1 General Description
5.8.5.1 General Description
The trickling filter is an established biological treatment process removing
65 to 85%
The trickling filterBOD and suspended
is an5 established solids.treatment
biological The process
processconsists of a bed
removing
of highly 5permeable medium. An overhead rotating distributor applies
65 to 85% BOD and suspended solids. The process consists of a bed of
highlysewage
permeableto medium.
the media. An The flowrotating
overhead tricklesdistributor
over andapplies
flows sewage
downward to
to the the underdrain system.
media. The flow trickles over and flows downward to the underdrain
system.
The media provides a large surface area to develop biological slime
The media
growthprovides
whichaislarge
alsosurface
knownarea to developfilm.
as zoogleal biological slimecontains
The film growth living
which organisms
is also known as zoogleal film. The film contains
that break down organic material in the sewage. living organisms
that break down organic material in the sewage.
Many variations of the trickling filters have been constructed, however
Many the
variations of the trickling
recommended designsfilters have been
are given constructed,
in Table 5.15. however the
recommended designs are given in Table 5.15.
5.8.5.1 Design Requirements for Trickling Filters
5.8.5.1 Design Requirements for Trickling Filters
Secondary
Secondary screensscreens
(< 6mm) (<and
6 mm)
flow and flow balancing
balancing tanks to
tanks to equalise theequalise
flow the
flow
must be must before
provided be provided before
trickling filters.trickling filters.
Provisions
Provisions shall beshall be available
available for distribution
for even even distribution to achieve
to achieve complete
complete
wettingwetting of the
of the filter filter media.
media.

Figure
Figure 5.14 –5.14 Trickling
Trickling Filter Systems
Filter Systems

Biofilter
Fine
Pump Flow
Screen
Station Distribution
Screens, Grit Removal
Final Clarifier
Filter Effluent
Raw To River
Sewage
Inlet

Sewage
Pump Station

Liquor

Chemical
Dosing

Sludge Storage Area Mechanical Sludge


Dewatering
Mechanical Sludge
Thickener

Sludge Holding Tank


Ultimate Disposal

Sludge Drying Bed

OPTIONAL

116 Volume 4 Malaysian Sewerage


Industry Guidelines

104 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.15 Design Parameters for Trickling Filter

Description Unit Design Criteria


Organic loading kg BOD5/day/m3
(depending on filter type)
Low rate 0.08 - 0.15
Intermediate rate 0.15 - 0.5
High rate 0.5 - 2.0
Recirculation of flow to head of plant
Qrecycle > 1.0
Qinflow

(to maintain wetting rate and improve


flow)
Acceptable media HDPE, PVC, stone,
slag, coke, etc.
(random or standard
arrangement)
Hydraulic loading m3/day/m2
Low rate 1-4
Intermediate rate 4 - 10
High rate 10 - 40
Sludge Yields kg sludge / kg
Low-rate filters BOD5 influent 0.5
Intermediate filters 0.6 - 0.8
High-rate filters 1.0
Minimum depth of media m 1.5

Refer also to Table D.4 for duty standby requirements and relevant clause
MS 1228 for more details.

5.8.6 Sequencing Batch Reactors (SBR) System

5.8.6.1 General Description

Sequencing Batch Reactors system is suspended activated sludge system.


In this system, sewage flows into one or more reactors where biological
oxidation and clarification of sewage take place within the same reactors
sequentially on cyclical mode. There are five (5) basic sequences in a
cycle, namely:

Sewage Treatment Plants Volume 4 117


Requirements for Individual Treatment Processes

1. Fill
2. React (Aeration)
3. Settle
4. Decant
5. Idle

Typically, all actions in the reactor occur at different sequence of time.


In other words, the system is intermittently fill and intermittently decant.
Typical SBR plant consists of a minimum of two (2) reactors in a plant.
When one unit of the reactors is in fill mode, the other reactor(s) may be
in the stage of react, settle, decant or idle. Recent development of SBR
system leads to the emergence of variation in the operating sequences.
Continuous fill and intermittently decant system is one of the variations
of this system, where feeding into all rectors are continuous but the
other phases (react, settle, decant, idle) are run in sequence.

In the reaction stage, oxygen supplied to the system shall be in


accordance to the load to the system within the time frame of reaction
cycle. This generally requires higher oxygen capacity per unit time than
a continuously aerate system.

In the decant stage, there shall be sufficient time to allow for mixed
liquor suspended solids (MLSS) to settle before effluent decanting begins.
Decanting time is normally much shorter than fill time. Consequently,
the effluent flow rate will also be much higher than influent flow rate.
Hence the design of the decanting weir must be capable to handle high
over-flow rate without scouring the settled sludge. Therefore, sufficient
clear water depth between the minimum water level after decant and
the top of the settled sludge blanket must be allowed for to minimise
sludge carry over. Hence the depth of water decanted must be restricted
to prevent scouring of solids.

5.8.6.2 Design Requirements for SBR Plants

All SBR plants must be designed to cater for peak flows. A minimum
of a two (2) tanks system is required. Proven control system in the form
of Programmable Logic Controller (PLC) with complete instruction, and
operational and training manuals must be submitted together with the
design. All SBR systems must be preceded with complete preliminary
works. Allowance shall be provided to completely empty a tank for
maintenance purposes without interrupting the operating sequence of
the plant.

Table 5.16 highlights the key design requirements for an SBR plant.

118 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.16 Design Requirements for SBR System


Continuous Fill and Intermittently Fill and
Parameter Unit
Intermittently Decant Intermittently Decant
No. of Reactors unit Minimum 2 Minimum 2
Hydraulic retention hr 18 – 24 18 – 24
time at Qavg (at
average water level)
F/M ratio d-1 0.05 – 0.08 0.05 – 0.30
Sludge age d 20 – 30 10 – 30
Sludge Yield kg Sludge 0.75 – 0.85 0.75 – 1.10
kg BOD5 load

MLSS (End of decant) mg/l 3000 – 4500 3000 – 4500

Cycle Time hr 4–8 4–8


DO (Reactor) mg/l 0 ~ 6.5 0 ~ 6.5
DO (Effluent) mg/l 2.0 2.0
Oxygen Requirement kg O2 Cycle time 2.0 kg O2 Cycle time 2.0 kg O2
x x
kg Substrate Aeration Time kg substrate Aeration Time kg substrate

Decant time hrs ≥ 1.0 ≥ 1.0


Decant depth m Max 0.5 max 1.0
Decant volume % Not more than 25% of Not more than 30% of volume
volume of Biological of Biological Reactor at TWL
Reactor at TWL
Decanting device m3/m/hr ≤ 20 for decant draw-down ≤ 20 for decant draw-down
loading rate* from TWL from TWL
Minimum number of 2 nos. independent 2 nos. independent decanter
decanter decanter per tank per tank
Max. pecanter length m 4.0 4.0
WAS kg sludge/d Total solids in system Total solids in system
Was= Was=
Slude age Slude age
Fill volume m3 Vfill = (QP m3/hr x 1.5hr) Vfill = (QP m3/hr x 1.5hr) +
+ (Tfill –1.5) x QAVG (if no (Tfill –1.5) x QAVG (if no EQ)
balancing tank) Vfill = QAVG x Tfill (if preceded
Vfill = QAVG x Tfill (if by balancing tank)
preceded by
balancing tank)

* For continuous fill, length to width ratio shall be based on 3 : 1


* Decanting device loading rate shall be based on Vfill/decant time during
decanting.
† RAS maybe necessary where length to width ratio poses dilution affect
into the inlet.

Sewage Treatment Plants Volume 4 119


Requirements for Individual Treatment Processes

5.8.7 Design Requirements for Hybrid Systems

A hybrid system is a recent development in biological treatment combining


suspended solids and fixed film growth processes. The treatment system
may be considered if the design criterion to be adopted has proven
performance and result.

5.8.8 Design for Nutrient Removal for Sensitive Receiving Water

Nutrient removal is required for effluent discharge to lakes and stagnant


water bodies to prevent eutrophication or other potential impacts that
may impede the sensitivity of the receiving water. Nutrient removal can
be achieved via:
a) Biological treatment.
b) Physical treatment.
c) Chemical treatment.

It has been emphasised in the beginning of this chapter, all biological


treatment system shall be designed to achieve ammonia reduction and
where necessary anoxic zone/stage to be added to encourage denitrification
for total nitrogen removal.

The biological phosphorus removal mechanism is based on the fact that


bacteria are capable of storing excess phosphorus as polyphosphate and
removing simple fermentation substrates produced in the anaerobic zone
and assimilating them into storage products within their cells. Hence,
the design for of the biological treatment shall follow the following for
plants where nutrient removal (nitrogen and phosphorus) is required,
design parameters:

Table 5.17 Design Requirement for Biological


Nutrient Removal System

HRT MLSS
Item Design Parameters Internal recycle
(hrs) (mg/l)
1 1st stage anaerobic 1-2 2 000 – 6 000 RAS from clarifier
2 1st stage anoxic 2-4 2 000 – 6 000 2 to 1 (MLSS
recirculation ratio)
3 1st stage aerobic (oxic) 8 - 12 2 000 – 6 000 3 to 2 (MLSS
recirculation ratio)
4 2nd stage anoxic 2-4 2 000 – 6 000 Mixing
5 2nd stage anaerobic 1-2 2 000 – 6 000 Mixing
6 2nd stage aerobic (oxic) 4 2 000 – 6 000 -

120 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

It has been emphasised in the beginning of this chapter, all biological


It has been emphasised
treatment system shallin be
the designed
beginningtoofachieve
this chapter,
ammonia all reduction
biological and
treatment
wheresystem shallanoxic
necessary be designed to achieve
zone/ stage ammonia
to be added reduction and
to encourage where
denitrification
necessary anoxic zone/stage
for total nitrogen removal. to be added to encourage denitrification for
total nitrogen removal.
Figure 5.15 Typical Process Flow Diagram for
Figure 5.15 - Typical Process Flow Diagram
Biological Nutrient Removal System
for Biological Nutrient Removal System

To get To get
phosphate nitrate bac k

Back

Q 1st. 1st. 1st. 2nd 2nd. 2nd. Clarifier Effluent


Anaerobic Anoxic Aerobic Anoxic Anaerobic Aerobic
RAS

Alternatively, both both


Alternatively, physical and chemical
physical treatment
and chemical may be used
treatment maytoberemove
used to
Phosphorus
remove in wastewater.in wastewater.
phosphorus

TheThe
designer shallshall
designer taketake
all necessary consideration
all necessary in theindesign
consideration in relation
the design in relation
to the specific requirements of the receiving water in determining the
to the specific requirements of the receiving water in determining the actual
nutrient removal
actual requirement
nutrient removal on the case byon
requirement case
thebasis.
case by case basis.

Sewage Treatment Plants Volume 4 121

Sewage Treatment Plants Volume 4 109


Requirements for Individual Treatment Processes

5.9 Design of Secondary Clarifiers

5.9.1 Purpose

Effluent from biological processes contains large populations of micro-


organisms (MLSS). Secondary clarifiers provided after the biological
system allow the mixed liquor organisms/ solid to settle. Clear supernatant
is discharged as the effluent, while some of the settled microorganisms
are returned to the biological treatment system to maintain the MLSS
concentration and excess microorganisms are removed as biosolid to the
sludge treatment facility.

5.9.2 Design Requirements

The design requirements shall include:

I) General

a) Minimum retention time for settlement.


b) Maximum settling velocity for settlement.
c) Sludge hopper to collect settled sludge.
d) All clarifiers must be equipped with sludge scrapers to skim
sludge from the bottom unless they are designed with a 60o
hopper bottom.
e) All clarifiers must be equipped with scum skimmer to remove
scum from the surface. The scum collected must be drained
(where necessary) and disposed off. Returning the scum to the
preliminary system or the biological system is not permitted.
f) Multiple hopper are not permitted.
g) Stilling basin to prevent hydraulic shock circuiting.
h) Bottom slope at clarifier floor.
i) Facilities to dispose scum and sludge.
j) Appropriate feed and outlet pipe with hydraulic consideration.
k) Effluent collection channel to be of glazed finish/tiles.
l) Proper maintenance access to all components.
m) Properly designed air lift pumps are only permitted for PE less
than 1000.

II) Weirs

a) If insufficient length is available, then considerations shall be


given for the use of double weir.

122 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

b) Cascading V-notch is preferred over rectangular weirs.


c) Slots in the weir shall be provided to allow for level adjustment
during the installation stage.
d) Broad crested weirs are not encouraged.
e) All parts of the weirs must be visible and accessible for regular
cleaning.
f) Type of weir and the hydraulic calculation for the weir proposed
must be submitted.

III) Circular clarifiers

a) The maximum diameter permissible is 50 m and a reasonable


allowance between tanks shall be provided for vehicle access.
b) The minimum side water depth shall be 3.0 m. Greater side water
depths may be used if it can be shown that the mixed liquor is
well denitrified in the aeration tank.
c) Flow distribution channel/chamber shall be provided for flow
isolation or equalise flow distribution.
d) The scraper tip travelling speed shall not exceed 0.03 rpm. A
multiple stage reduction unit must be incorporated to achieve
such speed.

IV) Rectangular clarifiers


a) Shall not be wider than 6 m per tank to allow for scraper removal,
unless other approved scraper units are available.
b) Multiport wall and baffled inlet shall be provided.
c) Slide gates shall be used to isolate each tank.
d) Allowance also shall be provided for vehicle movement between
unit processes for maintenance purposes.
e) Scraper travelling speed shall be between 0.3 – 0.6 m/min.

Refer also to relevant clause of MS 1228 for more details.

5.9.3 Multiple Hoppers

Multiple hoppers are not accepted. This is due to the settling characteristics
of the particles in the flow. Larger and heavier particles settle faster
than smaller and lighter particles, creating difference in the distribution
of sedimentation in different hoppers. This will present operational
difficulties because sludge removal from the hoppers is unequal. To
avoid the non-uniform withdrawal of sludge, each hopper in the multiple
hopper configuration needs a separate pipe and pump or valve on each
outlet.

Sewage Treatment Plants Volume 4 123


Requirements for Individual Treatment Processes

Table 5.18 Design Parameters for Secondary Clarifiers

Design Criteria
Description Unit
PE ≤ 5,000 PE > 5,000
Minimum number of tanks 2* 2
Tank configuration Square Circular
Circular
Rectangular #
Rectangular
Minimum side water depth m 3** 3
Minimum hydraulic retention time hrs 2 2
(HRT) at Qpeak
Surface overflow rate at Qpeak m3/d/m2 ≤30 ≤30
Solids loading rate at Qpeak kg/d/m2 <150 <150
Solids loading rate at Qavg kg/d/m2 <50 <50
Weir loading rate at Qpeak m3/day/m <180 <180
Return activated sludge (RAS) Continuous Continuous
pumping rate
Waste activated sludge (WAS) Continuous or Continuous or
pumping rate batch batch
Sizing of rectangular tanks
Length : Width 3:1 or greater.
Maximum side water depth m 3.0
Width : Depth 1 : 1 to 2.5 : 1
Sizing of circular tanks
Side water depth, minimum m 3.0 **
Floor slope wall 1:12

Notes:
* For PE less than or equal to 1000 a single clarifier is acceptable.
#
Rectangular tanks are acceptable if equipped with automatic scraping and
desludging devices.
** For square clarifier with 600 slope minimum 1 m side water depth shall
be provided.

124 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

5.10 Disinfection
Disinfection refers to the selective destruction of disease causing organisms
in sewage effluent.

Methods of disinfection can be physical, chemical or radiation.

Continuous disinfection is required for those areas where the discharge


from the sewage works will cause detrimental effect onto the receiving
water course, such as bathing beaches, lakes, etc.

The Commission reserves the right to determine the need for the provision
of a continuous disinfection facility.

The common forms of disinfection that are available for wastewater


applications are:
a) Chlorination
b) Ultra-violet (UV)
c) Others

Chlorination is by far the most common type of disinfection used world-


wide. This is due to its effectiveness in providing a good pathogen
kill with relative simplicity in operation and maintenance. However,
chlorination using chlorine gas, requires a higher degree of operational
skills and poses potential health and safety hazards in the shipping and
handling aspects. Therefore, to reduce these hazards, only liquid or
solid hypochlorite (sodium or calcium) shall be used.

Ultra-violet (UV) disinfection differs from chemical disinfection in


that it uses irradiation to induce photobiochemical changes within the
micro-organisms. To ensure effective photochemical reaction taking
place, one of the conditions is that such radiation must be absorbed by
the target molecule (organism). The other condition is that sufficient
radiation energy to alter chemical bonds is made available. Given the
conditions above, it is critical that the effluent prior to disinfection must
be relatively clear of suspended solids. As such, for UV disinfection to
be highly effective in wastewater applications, filtration of upstream of
the UV unit must be made available.

Other forms of wastewater disinfection that are available are maturation


ponds and ozonation. Maturation ponds have been used widely and
successfully in Malaysia. However, the drawback is that a relatively
large area of land is required to provide sufficient retention time in the
pond for the decay of pathogens. Ozone disinfection involves the direct
ozone oxidation or by reaction with the radical by-products of ozone
decomposition. However, due to ozonation’s relatively new status in
wastewater applications and higher costs at small scale facilities, its
usage for disinfection is still limited.

Sewage Treatment Plants Volume 4 125


Requirements for Individual Treatment Processes
Requirements for Individual Treatment Processes

5.10.1
5.10.1 Design Requirements
Design Requirements

All new STPs must have provision for disinfection infrastructure such
All new STPs
as contact tankmust
andhave provision
other for structures.
necessary disinfection infrastructure
The provisionsuchof as
the
contact tankfacilities
disinfection and other and necessary
equipmentstructures. The provision
shall be in accordance of 5.19
to Table the
disinfection facilities andshall
below. The disinfection equipment shallout
be carried be in
in continuous
accordance orto intermittent
Table 5.19
below.
mode. The disinfection shall be carried out in continuous or intermittent
mode.
Table 5.19: Requirements for Disinfection Facility
Table 5.19: Requirements for Disinfection Facility
Description Continuous Intermittent
Class of STP*
Description Class 4
Continuous Class 1
Intermittent
Class of STP* Class 4 Class1 2
Class
Class2 3
Class
Type of Disinfection  Chlorination Chlorination
Class 3
Type of Disinfection ƒ Ultra-violet (UV)
Chlorination Chlorination
 Ozone
ƒ Ultra-Violet (UV)
Facility (1duty/1standby) for Basic facility structure.
Ozone
ƒequipment

*Facility
The Commission may impose separate
(1Duty/1Standby) for requirements on case by case
Basic facility
basis. equipment structure.

Figure* The Commission


5.16 may impose
Schematic separateofrequirements
illustration ultravioletondisinfection
case by case basis.
system with stilling plate for flow conditioning and
Figure 5.16 – Schematic illustration
elongated weiroffor
ultraviolet disinfection system with
level control
stilling plate for flow conditioning and elongated weir for level control

"A"
"A"

FLOW
PDC

COVER PLATES OR GRATING STAINLESS STEEL WEIR

TOP VIEW
(Cables removed for Clarity)

CONTROL PANEL AND


POWER DISTRIBUTION CENTRE

FRONT ACCESS

ULTRAVIOLET LAMP RACKS

COVER PLATES OR GRATING

STILING PLATES

LEVEL PROBE
FLOW

SECTION 'A' - 'A'

126 Volume 4 Malaysian Sewerage


Industry Guidelines

114 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Stages of Sewage Treatment
Requirements for Individual Treatment Processes
Requirements for Stages of Sewage Treatment

Figure Figure 5.17 schematic


5.17 – Profile Profile schematic of lamp relative
of lamp modules modules relative
to inlet and outlet
to inlet and outlet structure
structure
Figure 5.17 – Profile schematic of lamp modules relative to inlet and outlet
structure
Flapper Gate Disinfection Module
Level Control Power & Data UV Protective
Interconnect Cables

Flapper Gate Disinfection Module


Level Control Power & Data Flow
UV Protective
Effluent Interconnect Cables
Inffluent
Channel Channel
Flow
Flow
A A
Effluent Inffluent
Channel Channel
Flow
Service
A Area A

Service
Electrically Operated Power Distribution
Station Cleaning Area Jib Host Data center (PDDC)
Liner with covet
304 Stainless Steel
Station Cleaning drain Electrically Operated Power Distribution
Power Cable
Station Cleaning Jib Host Data center (PDDC)
Liner with covet Signal Cable
304 Stainless Steel from Plant Flow meter
Station Cleaning drain
PLAN VIEW Power Cable
Signal Cable
from Plant Flow meter

PLAN VIEW

Influent
Channel

Influent
Channel Influent
Channel

Influent
Channel SECTION "A - A"

SECTION "A - A"

Figure 5.18 Chemical-feed system schematic


Figure 5.18 Chemical-feed system schematic
Figure 5.18 Chemical-feed system schematic

CALIBRATION COLUMN
RELIEF VALVE

CALIBRATION COLUMN
RELIEF VALVE

BACK PRESSURE
CHEMICAL CONTROL
FEED PUMP
BACK PRESSURE
CHEMICAL CONTROL
FEED PUMP
STORAGE TANK

STORAGE TANK

Sewage Treatment Plants Volume 4 127

Sewage Treatment Plants Volume 4 115

Sewage Treatment Plants Volume 4 115


Requirements for Individual Treatment Processes

5.10.1.1 Continuous Disinfection

I) Disinfection with Ultra-Violet (UV)

a) Filtration ahead of the ultra-violet disinfection is a must in order


to ensure consistent and reliable disinfecting performance, as well
as, to reduce maintenance, such as, fouling of the UV lamps.
b) The performance of the UV unit shall meet a UV transmittance
level of secondary effluent of at least 60% on a filtered basis. If
a lower transmittance level is encountered, it shall be compensated
with the reduction in the spacing of lamps and/or usage of
an advanced higher intensity system to compensate the lower
tranmissibility of the sewage effluent.
c) The channel for the UV shall be open, long and narrow to
encourage plug flow and avoid short circuiting.
d) As a guide, the average sizing is roughly 10 conventional 1.5 meter
lamps per 1,000 m3/day at peak flow. However, the actual sizing
shall be site specific and subjected to effluent quality desired as
well as the level of upstream treatment provided.
e) In the design to house the UV modules, it is important to include
proper inlet and outlet structures and consider the approach and
exit flow conditions.
f) A stilling well is required to distribute the flows and equalise the
velocities across the cross-section of the channel. The stilling
plate shall be placed at least 5 meters in front of the first lamp
bank. Otherwise, the channel should have an undisturbed straight
line of two (2) or three (3) lamps length.
g) Sufficient distance shall be allowed between lamp banks (0.5 m
to 1.0 m) and two (2) to three (3) lamp lengths between the last
bank and the downstream level control device.
h) In large system applications, a multichannel configuration is
required. This is to allow the inlet structure to satisfy the dual
requirements of inducing flow and to allow even distribution of
flow among operational channels. Channel inlet structures shall
allow for hydraulic isolation of individual channels during low
flow and routine maintenance. In operation, the multichannel
design shall be controlled to maintain a minimum velocity through
any one channel.
i) Wastewater within the channel must be maintained at a constant
level with little fluctuations. This shall be accomplished by
using a mechanical counter balance gate downstream of the lamp
batteries.
j) It is crucial to avoid a dryness state in the channel during low
or no flow conditions to prevent the fouling of the quartz jackets

128 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

surrounding the lamps and/or causing damage to the UV modules.


To alleviate this, for a small STP, a fixed or adjustable weir
should be used.
However, sufficient weir length shall be provided to avoid water
level fluctuations. In larger STPs using the multichannel design,
these flow fluctuations can be attenuated by the opening and
closing of channels as needed.
k) Control systems should be simple. Its objective is to ensure that
the system loading can be maintained and disinfection accomplished,
while conserving the operating life of the lamps. In small STPs,
the control system shall consists, of a full duty unit in operation
at all times with a similar redundant unit on standby. Manual
control and flexibility should be made available to enable the
operator to bring portions of the systems in and out of operation,
as needed, to adjust for the changes in flow or water quality. In
larger STPs, a complete automation is warranted for plants using
the multi channel design.
l) Safety aspects of an UV disinfection facility involve mainly
the electrical hazards and protection from the exposure to UV
radiation. The exposure risks could be minimised as long as the
operating lamps are submerged and the lamp batteries are shielded.
The UV lamps shall not be operated in air and unshielded. All
systems must be equipped with safety interlocks that shut down
the modules if they are moved out of their operating positions
or the wastewater level falls, leaving any or all lamps exposed
to air. Electrical hazards can be minimised by the inclusion of
ground-fault-interruption circuitry with each module. This feature
is a requirement for all UV systems.
m) The design of the UV system shall allow for easy access to the
lamp modules for cleaning and other maintenance tasks. The
installation shall have adequate working area for maintenance
and servicing of the modules when taken out of the channels.
Cleaning of the lamps shall be accomplished using mechanical
wipers which may be fitted with chemical injectors and with
chemical baths when taken out of the channels.
n) A drainage system back to the head of the treatment works shall
be provided to drain back water from the reactors, channels
and other related tankage. In addition, a permanent clean-water
system is to be made available to allow for rinsing and cleaning
needs. A bypass around the UV disinfection facility is to be
made available in the event the system is shut down completely
for maintenance.

Sewage Treatment Plants Volume 4 129


Requirements for Individual Treatment Processes

Table 5.20 Design Guides for Disinfection with Ultra-Violet(UV)

Description Design Criteria


UV system Mounted in open channel type*
Must be preceeded with filtration.

Minimum UV Dose (at 254 nm) at end of 30 mJ/cm2 (30,000 µWs/cm2)


lamp life at Qpeak

Maximum Total Suspended Solids in < 10 mg/l


effluent to UV system

Maximum Mean Particle Size in effluent 20 microns

UV Transmittance at 254 nm 65%

Lamp life ≥ 12 000 hours

Minimum UV output at end of lamp life 80%

Operating Temperature 18 – 40 oC

Relative Humidity > 95% at 40 oC

UV detection System UV sensor, transmittance, dose pacing

Lamp Sleeve Cleaning system a. Mechanical wipers and out of


channel chemical cleaning.

b. Additional 25% more lamps shall be


provided for mechanical wipers.

Standby lamps 25% to be provided with min 2 lamp


banks

Disinfection Standards In accordance with receiving water


requirement or effluent usage

Note:
*Enclosed system shall be permitted under special circumstances

II) Disinfection with Hypochlorite

a) Calcium and sodium hypochlorite are hazardous chemicals to


handle and use. Calcium hypochlorite is classified as a corrosive

130 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

and rapid oxidant, while sodium hypochlorite is a corrosive


agent. Eye protection, access to an emergency eyewash system
and showers must be made available to the operators.
Also, direct contact with the undiluted hypochlorite is likely to
cause burns to the skin and clothing. Therefore, it is imperative
that protective clothing which includes rubber gloves, must be
worn by operators when working with these chemicals. When
calcium hypochlorite is being transported in the powder form and
mixed in water to form solutions, the operator should always wear
eye protection and dust masks. All areas exposed to hypochlorite
should be washed thoroughly.
b) Chlorine dosage ranges from 6 to 10 mg/l for effluent. The
dosage rate is affected by the suspended solids and ammonia
present in the effluent, mixing employed, contact time and the
control strategies used for dosing.
c) Proper mixing is important for effective disinfection.
d) If a hydraulic jump is employed as a mixing device, the submergence
of the diffuser shall not be less than 230 mm (9 in.) below
the water surface and placed before the hydraulic jump at the
minimum flow. The hydraulic jump is effective in mixing when
the head loss exceeds 0.6 m (2 ft). To ensure adequate mixing
is achieved, the evaluation of the flow characteristics should be
carried out. As a minimum, the Reynolds number shall be 2.1
x 104 for pipe flow and Froude numbers between 4.5 and 9 for
open channels is recommended.
e) Hypochlorinators are chemical-feed pumps used for feeding
sodium or calcium hypochlorite. The basic components are a
storage reservoir or mixing tank for the hypochlorite solution; a
metering pump that consists of a positive displacement pumping
mechanism, motor or solenoid and a feed rate adjustment device;
and an injection device. Depending on the size of the system, a
plastic or fiber-glass vessel may be used to hold a low-strength
hypochlorite solution. It is not acceptable to use metals commonly
used in the construction of storage tanks to hold the hypochlorite
solutions because of the corrosive nature of the chemical which
will also expedite the decomposition of the liquid hypochlorite.
f) Feeding of calcium hypochlorite will require a mixing device,
usually a motorised propeller or agitator located in the tank.
Also, in the tank is a foot-valve and suction strainer connected
to the suction inlet of the hypochlorinator.
g) The hypochlorinator shall be feed rate adjustable.
h) The injection fitting shall be similar to that used in the gas
chlorinator.

Sewage Treatment Plants Volume 4 131


Requirements for Individual Treatment Processes

i) A chlorine contact tank shall take the form of rectangular


serpentine chamber. Circular chambers for disinfection are not
acceptable.
j) Local supply of water shall be made available for the dilution of
powder calcium or sodium hypochlorite. A breaker tank for supply
of water is required for the proper running of the hypochlorinator.
If deemed necessary, the water pressure maybe increased with the
provision of water booster pump.
k) Pipe works should be suitable for chlorination applications and
well supported.
l) Provision for draining the chlorine contact chamber is required
for cleaning and maintenance purposes. This shall include a drain
valve located at the bottom of the downstream end of the chamber.
The point of discharge shall ensure that adequate treatment is
given and this could be done through pumping the content from
the chamber and return to the head of the treatment plant.
m) A bypass around the chlorine contact chamber shall also be
provided to enable flows to be bypassed during maintenance or
servicing. There shall be penstocks upstream and downstream
of the chlorine contact chamber for isolation purposes.
n) Adequate access with sufficient turning radius for the vehicle
to carry in the chemicals to the disinfection system shall be
provided.
o) A small housing structure shall be provided to house hypochlorinator,
associated chemicals and ancillaries. Some important consideration
have to be given in the design of adequate space for the operators
to replace and fill the chemicals, washing facility, eyewash, record
keeping of chemical dosing, effluent flowmeter data among others.
Due to the hazardous nature of the disinfection system housed,
a locking system shall be made available to deter vandalism and
promote safety of the plant.

The structure housing the hypochlorinator and the chemicals shall be


bunded to prevent the possibility of spillage. The sizing of bunds shall
correspond to the total volume of the storage/solution tanks.

132 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.21 - Design Guide for Disinfection with Hypochlorite

Type Calcium or Sodium


Dosage 6 – 10 mg/l
Mixing Mechanical, baffles or hydraulic jump.
Hypochlorinator Feed rate adjustable
system
Equipment 1 duty/ 1 standby
Contact Tank
Contact Period 15 minutes at Qpeak
Maximum depth 3m
Depth : Width 2:1
Min no. of passes 4
Length : Width at 6:1
each pass
Wetted Depth : < 2:1
Width

5.10.1.2 Intermittent Disinfection

The design requirements for intermittent disinfection facility shall comply


to the following:

a) Due to the infrequent usage and other health and safety considerations
in an intermittent disinfection system, ONLY liquid hypochlorite,
either calcium or sodium, shall be used.
b) A chlorine contact chamber shall be provided with a minimum of
15 minutes hydraulic retention time at peakflow. This chamber
shall be of a rectangular configuration with aspect ratios optimised
to promote plug flow conditions. The recommended aspect ratios
are as follows:
i) Length to width (each “Pass”): 6:1
ii) Minimum number of passes: 4
iii) Height to width of the cross-section of the wetted section:
< 2:1
iv) Depth of chlorine contact chamber is typically 2 – 3 m.
The corners shall be rounded to reduce the dead flow
areas and the velocity through the contact chamber shall
be sufficient to minimise solids deposition.

Sewage Treatment Plants Volume 4 133


Requirements for Individual Treatment Processes

v) horizontal baffles shall be used to ensure the plug flow


conditions are maintained and to minimise the possibility
of short circuiting.

vi) Upstream of the contact chamber, a dosing coupling for


easy hook-up of the mobile hypochlorite disinfection system
shall be an inherent part of the chamber design.

c) A breaker tank for supply of water adjacent to the contact tank is


required to provide water for the mixing of powder hypochlorite
and for cleaning or cleansing of the contact chamber. If deemed
necessary, a water booster system shall be provided to increase
the water pressure for the intended application.
d) Draining provision must be made available to allow for complete
drainage of the chlorine contact tank. For this purpose, a drain
valve shall be provided at the bottom of the downstream end of
the chamber.
e) Penstock/slide gate shall be provided at the upstream and downstream
end of the contact chamber. This allows for the effluent flow
from the treatment plant to bypass this chamber when its service
is not required.
f) Adequate access shall be provided for a portable hypochlorinator
unit mounted on a skid to be brought by a truck to the contact
chamber area when disinfection is required. A concrete pad
adjacent to the contact chamber shall be provided for the skid
mounted hypochlorinator to be situated when in use.
g) Power supply shall be adequately provided and located close to
the contact chamber to run the intermittent disinfection system.

Table 5.22 Design Guide for Intermittent Disinfection

Type Calcium or Sodium


Dosage 6 – 10 mg/l
Mixing Mechanical, baffles or hydraulic jump.
Hypochlorinator Feed rate adjustable
system
Equipment 1 duty/ 1 standby

134 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.22 Design Guide for Intermittent Disinfection (cont.)

Type Calcium or Sodium


Contact Tank
Contact Period 15 minutes at Qpeak
Maximum depth 3m
Depth : Width 2:1
Min no. of passes 4
Length : Width at each 6:1
pass
Wetted Depth : Width < 2:1

5.11 Design of Flow Measurement Devices

5.11.1 Purpose of Flow Measuring Devices

Flow measuring devices are necessary for monitoring of plant operation


and process control continuously. The purposes of flow devices are:

a) to maintain flow records periodically for future reference, especially


when plant expansion is needed.
b) to identify the flow pattern which may be due to population
growth or infiltration.
c) Statutory requirement by the DOE to maintain flow records at
all sewage works.
d) To establish operational cost for treatment of sewage.

5.11.2 Design Requirements for Flow Devices

Flow devices are mandatory for all STP, regardless of size.

Sewage Treatment Plants Volume 4 135


Requirements for Individual Treatment Processes

Table 5.23 Design Parameters for Flow Devices

Design Criteria
Description
PE ≤ 5,000 PE > 5,000
Location of flow Inlet or Outlet Inlet and Outlet
meter
Type of Flow Closed Conduit or Open Closed Conduit or Open
Measurement Channel Channel
Type of flow meter V- notch (Outlet Only) V-notch (Outlet Only)
Rectangular Weir (Outlet Only) Rectangular (Outlet Only)
Flumes Flumes
Electromagnetic Electromagnetic
Ultrasonic Ultrasonic
Method of • Automated or manual Automated devices linked to
measurement measurement of Staff gauge data logging with integrator
to measure height of crest and transmitted to chart
with calibration curves / recorder
tables (minimum 7 days chart time)
Measurement Continuous or Intermittent Continuous
times

5.12 Sludge Holding, Treatment and Disposal

5.12.1 Introduction

All treatment processes are capable of producing significant quantities


of sludge which requires to be further treated. The sludge comprises
essentially inert and organic matters that are biodegradable and non-
biodegradable present in sewage, and bacterial cells generated by the
biological treatment processes. The treated sludge, often referred as
biosolids is ready for safe disposal or reuse.

The importance of sludge management increases with the increase in the


amount of sewage treated. Space has to be allowed within the premises
of an STP to accommodate sludge treatment, handling and storage
facilities.

All sludge need to be treated for safe disposal back to the environment.
The minimum requirement for sludge treatment is to achieve stabilize
sludge with a 20% dry solid content.

136 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

For large scale development whereby the full sludge generation will
only be achieved over a certain time period, proper sizing/modulation
of sludge treatment facilities need to be provided in order to achieve
the immediate needs for sludge treatment.

5.12.2 Sludge Strategy in General

Figure 5.20 shows the typical sludge treatment and disposal strategy
which consists of three main stages.

a) Stage 1 - Preliminary treatment and digestion


b) Stage 2 - Conditioning and dewatering
c) Stage 3 - Utilisation and disposal

I) Stage 1 - Preliminary Treatmentand Digestion

Preliminary treatment may include reception or holding facility for


screened sludge, primary thickening and digestion facilities.

For imported sludge the reception facility may comprise of an unloading


area, screen chamber, reception tank and transfer pump(s).

Thickening equipment, such as, centrifuge, drum thickener or gravity


belt thickener is provided to thicken the raw screened sludge from
about 1% dry solids content to about 6% dry solids content. To assist
the thickening process, an ‘in-line’ polymer dosing system or chemical
conditioning shall be provided.

Two types of digestion facilities are available for digestion after the
thickening: aerobic and anaerobic digestion.

Secondary thickening is recommended to reduce the volume of digested


sludge, which will then reduce the size and the number of the next
treatment process unit, i.e., dewatering equipment.

II) Stage 2 - Conditioning and Dewatering

Dewatering can be achieved by two (2) methods : mechanical dewatering


and non-mechanical dewatering.

a) Mechanical dewatering such as belt filter press, centrifuge or


filter press is provided for sludge dewatering purposes. To assist
the mechanical dewatering equipment in achieving optimum level
of cake dryness, an ‘in-line’ polymer dosing system or chemical
conditioning shall be provided.

Sewage Treatment Plants Volume 4 137


Requirements for Individual Treatment Processes

b) Non-mechanical dewatering, e.g. drying beds or sludge lagoons


is often used

For a facility serving ≥ 10,000 PE, the drying beds must be


designed to support mechanical/machine lift for the purpose of
clearing the dried sludge.

Sludge lagoons of about 2 m depth are also used for sludge


stabilisation and drying. The sludge lagoons shall be sized to
receive sludge for a period of at least 6 months and are allowed
to undergo stabilisation through evaporation and drying for
another 6 months period. The lagoons shall be lined with either
PVC lining, concrete or 600 mm thick clay lining. An access
ramp shall be provided to allow mechanical equipment access
to clean dried sludge.

III) Stage 3 - Utilisation and Disposal

After the dewatering process, an on-site storage for 30 days of the


treated bio-solid shall be provided. The storage structure shall be
covered with roof and provided with partly opened walls to allow for
proper ventilation.

Finally, the bio-solid is either composted and/or applied directly for


land reclamation (i.e., for ex-mining land), land application (i.e., for
certain types of agriculture land and forest land/reforestation) or used
as top soil cover at land fill site. The ultimate disposal of bio-solid is
the responsibility of the plant operator.

5.12.3 Provision of Sludge Holding, Treatment and Disposal

The Service Licensee will advise on current capacity in its existing


sludge treatment facilities, suitable sludge stabilisation, dewatering and
final disposal of the sludge shall be provided.

If the Service Licensee has the capacity to receive sludge generated from
the development, then the project proponent has the option to negotiate
with the Service Licensee to dispose off the sludge at the existing
facility. In this case, a sludge storage tank with a minimum capacity to
hold for 30 days with the sludge thickened to 1% solids is acceptable.
Otherwise, the sludge shall be stabilised, dewatered and prepared in a
suitable form for disposal.

Different types of STPs produce different quantities of bio-solid. The


principal assumptions adopted on waste generation rates are summarised
in Table 5.24.

138 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

Table 5.24 - Sludge Generation Rates

Treatment System Unit Generation Rates Comments


Primary Sludge
Primary Clarifier 0.5 kg sludge/kg solids input Based on continuous
sludge withdrawal
Imhoff Tank 0.15 kg sludge/kg SS input Based on average 6 month
desludging period
Secondary Sludge
Conventional 0.8 to 1.0 kg sludge/kg BOD5 Standard A/B
Activated Sludge removed
System
Extended Aeration or 0.4 to 0.6 kg sludge/kg BOD5 Standard A/B
Oxidation Ditch removed
RBC/SBC/High 0.8 kg sludge/kg BOD5 removed Standard A/B
Rate Trickling Filter
System
Hybrid System 0.4 kg sludge/kg BOD5 removed Standard A/B

Note:
Based on the above assumptions, the quantity of waste sludge requiring treatment and disposal can
be estimated. Refer also to design guides related to each of the above individual processes.

5.12.4 Design Criteria

The ultimate aim of sludge treatment is to achieve at a minimum


stabilised sludge with dry solids content of 20% for final disposal.
A combination of various unit processes may be used to achieve this
minimum requirement.

I) Sludge Reception/Sludge Holding

a) An unloading area is normally provided to receive sludge tankers


delivering imported sludge to the facility, if necessary. It should
also includes a parking area for sludge tankers.
b) A mechanically raked screen with 12 mm opening together
with a manually raked by-pass screen shall be provided where
necessary.
c) Connection fitted female coupling with ball valve shall be
provided at the reception facility for the connection of desludging
tanker’s hose.

Sewage Treatment Plants Volume 4 139


Requirements for Individual Treatment Processes

d) Minimum three (3) days sludge holding capacity of between


1 to 4% dry solids content sludge (depending on the types of
sludge) shall be provided after the screening process.
e) Overflow pipe shall be provided at sludge holding tank to
aeration tank to avoid overflowing.
f) Adequate ventilation/air extraction fan shall be provided at the
thickening/dewatering house.

II) Solid Thickening

Thickening is a process used to increase the solids content of sludge by


removing a portion of the liquid fraction. It is generally accomplished
by physical means, including co-settling, gravity settling, flotation,
centrifugation, gravity belt and rotary drum. The design parameters for
sludge thickening equipment shall follow Table 5.25 below:

Table 5.25 - Design Parameters for Sludge Thickening

Speed of
Backwash
% Dry Polymer Sludge
Type of Thickening water
Solids System feed
system
pump

Picket Fence Gravity


1.5
Thickener
n/a n/a n/a
Dissolved Air
2
Flotation
Belt Thickener 4 Yes with
appropriate
Drum Thickener 4 polymer
< 300 rpm Yes
Centrifuge turndown
4 ratio

Note:
a) Mechanical thickener shall be designed for 8 hrs/day and 5 days/week
operation.
b) For belt, drum and centrifuge thickener, three polymer injection
points shall be provided
c) Potable water to be provided for polymer mixing system.

140 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

III) Solid Digestion

Sewage biosolids in its natural state (raw) is rich in pathogenic organisms,


easily putrescible and rapidly developing unpleasant smells. Stabilization
processes were developed with the purpose of stabilizing the biodegradable
fraction of organic matter present in the bio-solids, thus reducing the risk
of putrefaction as well as diminishing the concentration of pathogens.
The stabilization processes can be divided into:
a) Biological stabilization – specific bacteria promote the stabilization
of the biodegradable fraction of the organic matter.
b) Chemical stabilization – chemical oxidation of the organic matter
accomplishes sludge stabilization.
c) Thermal stabilization – heat stabilizes the volatile fraction of
sludge in hermetically sealed containers.

The most widely used stabilization process is biological stabilization


via anaerobic and aerobic digestion.

Table 5.26 - Design Parameters for Aerobic and Anaerobic Digestion

Design Criteria
Description Unit Aerobic Anaerobic
Digestion Digestion
Number of Tank, Minimum No. 2 2
Min. Solids Retention Time Days 10 18
Organic Loading Rate KgVS/m3.d 1.6 – 4.8 0.8 – 1.6
Typical Feed Solids % 2 2-6
Concentration
Type of Mixing Aerators Gas Injection
Diffusers Mechanical
Stirring
Mechanical
Pumping
Min. Water Depth, minimum m 3 7.5
Tank Shape Cylindrical Cylindrical
Rectangular Egg-Shaped
Tank Dimension, maximum m 25 diameter 25 diameter
25 length
Dissolved Oxygen mg/L 1-2 -

Sewage Treatment Plants Volume 4 141


Requirements for Individual Treatment Processes

IV) Sludge Dewatering

Table 5.27 Recommended Design Parameters


for Sludge Stabilisation and Dewatering

Design Considerations
Descriptions Unit
PE ≤ 2,000 PE > 2,000
Sludge Stabilisation
Type of stabilisation Simple anaerobic or Ambient anaerobic
process aerobic digestion digestion with good mixing
facility
Hydraulic retention time Days 30 30
(HRT) minimum
Dewatering
Type of device Belt press Belt press
Centrifuge Centrifuge
Filter press Filter press
Drying bed Drying bed *
Minimum dry solids % 20 20
(content after dewatering)
Operating period of 5 days/week # 5 days/week #
mechanical thickening 8 hours/day 8 hours/day
and dewatering facility 250 days/year 250 days/year
Handling capacity of 4 weeks cycle on 4 weeks cycle on
drying bed 450 mm thick feed † 450 mm thick feed †
Covered storage area 1 month holding 1 month holding

Notes:
a) Access ramp of at least 1.5 m wide shall be provided at all sludge drying
beds
* Drying beds must be designed to support mechanical/machine lift for more
than 10 000 PE.
#
Design to be based on one full-time working shift only.

In computing the area requirements of a sludge drying bed, the designer may
assume a maximum 450 mm depth of sludge feed to the bed. The actual
quantity of sludge from the upstream unit processes needs to be computed
before sizing the bed. Each bed may be designed to handle a maximum of
7 days continuous feed. The next feed to the same bed shall only be after
a minimum of 21 days from the last feed. A one-third (1/3) reduction in
actual land area requirement will be acceptable if fully covered drying beds
are provided. Reduction shall only apply to the total surface area of drying

142 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

bed. No reduction is allowed for theRequirements


drying bed for thickness. Structures
Stages of Sewage Treatment and
materials used for the drying bed covers shall be designed to an acceptable
structural strength
Structures and andused
materials of acceptable
for the dryingquality to withstand
bed covers local weather
shall be designed to an
conditions.
acceptable structural strength and of acceptable quality to withstand local weather
conditions.
Figure 5.20 Sludge Treatment and Disposal Strategy
Figure 5.20 – Sludge Treatment and Disposal Strategy

Untreated Sludge

Screening

Primary Thickening

Preliminary
Treatment
and Digestion

Anaerobic Digestion Aerobic Digestion (Optional)

Secondary Thickening Possible disposal


(Optional) of Liquid Sludge

Chemical Conditioning
Conditioning
and
Dewatering

Mechanical Dewatering Drying Beds Drying Lagoons

Storage at works
To inlet of STW
Utilisation
Composting or
and
on-site Liquor Treatment Plant
Disposal
Transportation from works

Land Application
Land Reclamation Landfill Site
Forestry/Agriculture

Sewage Treatment Plants Volume 4 143

Sewage Treatment Plants Volume 4 131


Requirements for Individual Treatment Processes

V) Ultimate Disposal

The treatment plant project proponent has to indicate in the


proposal the ultimate disposal options and actual volume for
disposal throughout the life time of the plant.

5.13 Tertiary Treatment

5.13.1 Introduction

Tertiary treatment is associated with the requirements to further reduce


or remove pollutants beyond the levels achieved by common secondary
treatment processes. Such requirements can be in the forms of the
removal of nutrients, such as, nitrogen and phosphorus; lower BOD5 or
SS levels; or trace elements of toxic constituents, such as, heavy metals
or refractory organics.

The various methods of tertiary treatment include simple maturation ponds,


adsorption, chemical treatment and filtration; air stripping, mambrane or
reoxygenation.

Tertiary treatment is required before discharging to very sensitive receiving


waters. The Commission will specify the need for such treatment on a
case-by-case basis, depending upon the sensitivity of the project.

5.13.2 Design Requirement

I) Filtration system
a) Filtration is the most common tertiary treatment system used to
remove suspended or colloidal matter in the effluent.
b) Backwashing shall be limited to once per day. The volume
of backwash water shall not exceed 10% of plant throughout.
Backwash water shall be stored in a buffer tank before being
return to the inlet of the plant.
c) Where used, the facility for dosing conditioners shall be provided
at the inlet of the filter system.
d) On-line turbidity meter, level detector and flow measurement shall
be utilized to measure filter performance.
e) If the filters are housed in a building, adequate and safe access
shall be provided for maintenance purposes.
f) The filters shall have automated backwash features and sized
adequately to allow continuous filtration.

144 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Individual Treatment Processes

g) For package plants, it is preferred to use FRP as the filter vessel.


However, fabricated steel is also acceptable provided that protective
coatings are included. For larger plants, the use of reinforced
concrete is encouraged.

II) Adsorption (Activated Carbon)


a) Activated carbon is used to remove small quantities of refractory
organics, as well as inorganic compounds, such as nitrogen,
sulficles and heavy metals.
b) Adsorption shall be preceded by filtration using granular media
to ensure a consistant feed quality, which is affected by pH,
temperature and flow rate.
c) Uniform feedwater to avoid any surges that might adversely affect
the carbon adsorption.
d) Clarity of feedwater is important to avoid restriction of pores or
build up of materials within the pore structure.
e) Backwashing rate and the frequency required depend on the
hydraulic loading and operational method. Typical duration of
backwashing is 10-15 minutes.

III) Chemical Treatment


a) Chemicals can be used as tertiary treatment for acid-base
neutralisation and precipitation of phosphorous.
b) Phosphorous precipitation requires the addition of coagulants,
which usually are lime, alum, sodium aluminate, ferric chloride
and ferrous sulfate.
c) Dosing systems and safety features to be provided to assure the
operation and maintenance of the systems can be carried out in
a safe and healthy environment.

IV) Air Stripping


a) This method is used to remove ammonia nitrogen (NH4 – N)
from effluent.
b) The design features shall depend on the required level of nitrogen
removal with the critical parameters being tower packing, quantity
of air supply, air and liquid temperatures and process control
measures.

V) Reoxygenation
a) This method is used to increase the dissolved oxygen (DO) levels
in the effluent.

Sewage Treatment Plants Volume 4 145


Requirements for Individual Treatment Processes

b) The different types of reoxygenation systems are cascade,


reoxygenation and mechanical reoxygenation
c)
Requirements Cascade
for reoxygenation
Individual Treatment is achieved using on the hydraulic design
Processes

of structures, such as, weir overflows, flumes, spillways, etc.


b) The different types of reoxygenation systems are cascade,
d) Mechanical reoxygenation
reoxygenation and mechanicalis achieved using mechanical equipment
reoxygenation
c)such Cascade
as surface aerators,is jet
reoxygenation diffusers
achieved or the
using on diffused
hydraulicair (coarse,
design of fine
bubble, etc.) such as, weir overflows, flumes, spillways, etc.
structures,
e) d)Design of structures
Mechanical or mechanical
reoxygenation equipment
is achieved using mechanicalisequipment
based on the
such as surface aerators, jet diffusers or diffused air (coarse, fine
amount of DO
bubble, etc.)
required for the effluent.
e) Design of structures or mechanical equipment is based on the
VI) Maturation ponds
amount of DO required for the effluent.

a) PondMaturation
(VI)
systems are normally not encouraged because it requires
ponds
large land area and the inherent difficulty in controlling algal
a) Pond systems are normally not encouraged because it requires large
growth. In special
land area cases, difficulty
and the inherent where land is in abundance,
in controlling algal growth.the
In project
proponent may where
special cases, choose
landtois in
use this system.
abundance, the project proponent may
choose to use this system.
Figure 5.21 Typical Roof Details for Covered Sludge Drying Bed
Figure 5.21 – Typical Roof Details for Covered Sludge Drying Bed

134 Volume 4 Malaysian Sewerage


Industry Guidelines

146 Volume 4 Malaysian Sewerage


Industry Guidelines
Section 6

Requirements for
Ancillary Facilities
Requirements for Ancillary Facilities

148 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities

6.1 Introduction
This section defines the minimum requirements of ancillary facilities
to be provided at the sewage treatment plants. These requirements are
crucial in ensuring the workability and operability of the plants.

6.2 Water Supply and Wash Water


Water shall be supplied to each site from standpipes and taps, to provide
for sanitary cleansing of plant areas, personal hygiene, safety, fire
fighting, process use and for equipment cooling and/or sealing. Water
shall be connected to potable supply that provides a minimum pressure
of 20 m head across the site. A ring main system shall be provided for
all treatment plants larger than 5000 PE.

Each sewage treatment plant or sludge treatment facility shall be


provided with water tank of at least 445 litre storage capacities or one
day water usage or whichever is higher.

Double backflow prevention shall be provided in all cases. This is to prevent


contamination of any potable water service, including the incoming supply
line.

The water supply system shall be sized to meet the following cases:

i) Fire fighting demand as instructed by the local regulations and


any essential plant water demands.
ii) All potentially simultaneous process uses, equipment uses and a
for plant cleansing.

All water supplies and its installation (piping, tanks, air conditioning
drainpipes, gutters and etc.) must be totally isolated from all potential
contact of electrical system by means of total enclosure or suitably
located the electrical system above flood level.

Where required, wash water shall be equipped with booster pump and
where possible, obtain from reclaimed water.

Drawings submitted for approval shall indicate locations of water tapping


point and piping layout. Approval for water tapping should be obtained
from water authority for permanent water supply before submitting
inspection form. All related document, such as water bills and transfer
of ownership, to be submitted before final inspection.

Table 6.1 tabulates the minimum number and location of stand pipe
required in a sewage treatment plant. Typical drawing of stand pipe
are shown in Figure 6.1

Sewerage Treatment Plants Volume 4 149


Requirements for Ancillary Facilities
Requirements for Ancillary Facilities

Table 6.1 – Minimum Number of Recommended Water


Table 6.1 Minimum Number of Recommended Water
Stand Pipe and Location
Stand Pipe and Location

Class of Population Minimum


Class of Population Minimum Location
STP Equivalent Numbers Location
STP Equivalent Numbers
1 ”1,000 1 Inlet Works
1 ≤1000 1 Inlet Works
22 1,001 –
1001 – 5000 2 2 Inlet Works
Inlet and
Works Treatment
and TreatmentProcess
ProcessUnit
Unit
5,000
33 5001 – 20– 000
5,001 2 2 Inlet
Inlet Works
Works and
and TreatmentProcess
Treatment ProcessUnit
Unit
20,000
4 >20 000 4 Inlet Works, Secondary Screen Area,
4 >20,000 4 Inlet Works, Secondary Screen Area,
Treatment Process Units and Dewatering
Treatment Process Units and Dewatering
Facilities.
Facilities.
Figure 6.1 Standard Details for Stand Pipe
Figure 6.1 Standard Details for Stand Pipe

800

76 648 76

Ø15 G.I PIPE


608

76
8
64

100
0
80
76

STAND PIPE

6.3
6.3 Mess Facilitiesand
Mess Facilities andAblutions
Ablutions

All
All treatment plants shall
treatment plants shallhave
havea aminimum
minimum of of
oneone sanitary
sanitary set consisting
set consisting of
of a toilet and wash basin. Washing facilities, toilets and showers
a toilet and wash basin. Washing facilities, toilets and showers shall be shall
be provided
provided for for operators
operators at allatClass
all Class
3 and 3Class
and 4Class
plants4with
plants
PE with PE
greater

150 Volume 4 Malaysian Sewerage


Industry Guidelines
138 Volume 4 Malaysian Sewerage
Industry Guidelines
Requirements for Ancillary Facilities
Requirements for Ancillary Facilities

greater than 5000. Additionally, mess accommodation shall be provided


than
at 5,000.
Class 4Additionally, mess accommodation
treatment plants with PE greatershall
thanbe20provided
000. at Class
4 treatment plants with PE greater than 20,000.
Guard house with water and power supply shall also be provided for
Guard house with water and power supply shall also be provided for plant
plant more than 20 000 PE.
more than 20,000 PE.
Figure 6.2 Typical for Administration and Mess Facilities Building
Figure 6.2 Typical for Administration and Mess Facilities
Building

16 Visitor’s / Staff Parking

Covered Porch

Manager’s /
2
Engineer’s Office
1 4
Reception Area General Office
3 Supervisor's Office

5
Meeting /
Briefing Room

14 12
Control Room
Workshop

8 Sample Reception
& Preparation

7 Male
Toilet

7 Female 9 9
Toilet Clean Locker Room Dirty Locker Room
Prayer Recreation Area
6
Room 10
Pantry
9
13 11 Toilet / Shower
General Store Eating Area

16 Motorcycles / Operational Vehicles Parking

Note : The numbers on the layout correspond to the numbers in Table B.1.
The layout is only for indicative purposes only and can be changed ( i.e. floor space and other arrangement)
to suit the plant’s needs and requirements.

Sewerage Treatment Plants Volume 4 151

Sewage Treatment Plants Volume 4 139


Requirements for Ancillary Facilities
Requirements for Ancillary Facilities
Requirements for Ancillary Facilities
Minimum internal floor area of mess facilities are 400 meter 2 .
Approval
Minimum from thefloor
internal Commission
area of messshall be sought
facilities if smaller
are 400 meter2. floor area
Approval
is to be provided. Typical
shallofarrangement ifof smaller
mess facilities . is shown
is to bein
2
from
Minimum theinternal
Commission
floor area be sought
mess facilities are 400 floor
meterarea Approval
Figure
from the 6.2
provided. Typical arrangement
Commission shall be ofsought
mess facilities
if smaller is shown
floor in Figure
area 6.2be
is to
provided. Typical arrangement of mess facilities is shown in Figure 6.2
6.4
6.4 Roads and
Roads andAccess
Access
6.4 Roads and Access
All-weather, surfaced
All-weather, surfaced roads
roads shall
shall bebe provided
provided to to permit
permit access
access toto all
all
treatment
All-weather, plants.
surfacedThe roads
roads must
shall withstand
be provided a load
to of
permitat least
access
treatment plants. The roads must withstand a load of at least 15 tonnes. 15 tonnes.
to all
Such roads
treatment
Such roads must
plants. also
mustThe be
beconstructed
alsoroads within
must withstand
constructed a the
within loadplant
the of atproviding
plant least access
15 tonnes.
providing to
access
each
Such
to process
roads
each must unit.
process also The
be
unit. construction
constructed
The shall
within
construction thecomply
shall plant
comply with
withPublic
providing accessWork
Public to
Work
Department
each process requirement.
unit. The Figure 6.3
construction and
shallFigure
comply 6.4 illustrate
with the
Public
Department requirement. Figure 6.3 and Figure 6.4 illustrate the typical typical
Work
section of road pavementFigure
Department and site road.
section of requirement.
road pavement and 6.3 siteand Figure 6.4 illustrate the typical
road.
section of road pavement and site road.
Figure 6.3 Typical Details of Road Pavement
Figure 6.3 Typical Details of Road Pavement
Figure 6.3 Typical Details of Road Pavement
40 THK. WEARING COURSE
60 THK.
40 THK. PREMIXCOURSE
WEARING BINDER COURSE
10 THK. SAND/QUARRY DUST
60 THK. PREMIX BINDER COURSE
10 THK. SAND/QUARRY DUST

300 THK. CRUSHER RUN


50 THK SAND
300 THK. CRUSHER RUN
50 THK SAND

Figure 6.4 Typical Road Section of Site Road


Figure 6.4 6.4 Typical
Figure TypicalRoad
RoadSection
Section of Site
SiteRoad
Road

4000

4000

ROAD KERB ROAD KERB


ROAD KERB ROAD KERB
FALL FALL

FALL FALL

40 THK. WEARING COURSE


60 THK. PREMIX BINDER COURSE
40 THK. WEARING COURSE
250 THK.
60 THK. ROADBASE
PREMIX BINDER COURSE
250150 THK.
THK. SUB-BASE
ROADBASE
GEOTEXTILE MEMBRANE APPROVED BY ENGINEERS
150 THK. SUB-BASE
GEOTEXTILE MEMBRANE APPROVED BY ENGINEERS

The on-site road shall be able to provide safe and convenient access for
trucks
The or other
on-site road machinery equipment
shall be able usedsafe
to provide for and
maintenance purposes.
convenient The
access for
152 trucks or other machinery equipment
Volume 4 used for maintenance purposes. The
Malaysian Sewerage
Industry Guidelines

140 Volume 4 Malaysian Sewerage


140 Volume 4 IndustrySewerage
Malaysian Guidelines
Requirements for Ancillary Facilities

The on-site road shall be able to provide safe and convenient access for
trucks or other machinery equipment used for maintenance purposes.
The minimum width of the road shall be 4 meter Where vehicles need
to pass frequently or parking is required along the road, the minimum
width shall be 6 m.

Corner of junction for perimeter internal road for tankers or trucks


access shall have a minimum inside radius of 6 meter. Inside radius
for perimeter road not intended for tankers or trucks access shall be
not less than 4 m.

Cul-de-sac at the end of roads shall be provided with turning area


reserve of not less than 9 m.

Where roads for maintenance vehicles or machineries are not required,


concrete or hard surfaced walkways of at least 900 mm width shall
be provided between each process unit. Concrete hardstanding area
can be laid where storage bins are located. The use of steps shall be
avoided, where possible.

Where the ingress or egress of the treatment plant is near a junction of


a public road, an adequate acceleration and deceleration lane must be
made available between the access road and the junction for vehicles
to safely enter and leave the treatment plant.

Vehicular access shall be provided to all unit processes that require


daily operation and maintenance.

6.5 Drainage
The area of the treatment plant shall be adequately drained and this
shall be arranged to prevent surface water run-off from entering the
process units.

Any cleaning or maintenance process wash water must be returned to


the inlet works via a separate drainage system.

External drainage facilities must be provided for treatment plant along the
slope area. Cut off drainage at the entrance must also be provided.

Treatment plant platform level shall be designed above flood level.


If the treatment plant is located in a flood prone area, flap gate shall
be provided to avoid back flow from the river/ main drain. The plant
hydraulic must be designed properly to ensure the discharge head is
adequate to open the flap valve at any circumstances.

Sewerage Treatment Plants Volume 4 153


Requirements for Ancillary Facilities

The effluent discharge shall be directed to the main drain or river


to avoid discharging effluent into a drain within the residential area.
Discharge to a retention pond is not allowed unless prior approval has
been granted.

The receiving drain/watercourse shall have sufficient capacity to accept


the run-off from the plant as well as the effluent discharge from the
treatment plant.

6.6 Fencing and Security

The boundary of a treatment plant, pumping station and/or sludge


treatment facility shall be secured by 3.0 meter high fence. The perimeter
fence shall have an entrance by double gates or sliding barrier to allow
access of maintenance vehicles. The gates shall be secured by padlocks
and shall comply with the requirements of the Commission. Where the
treatment plant is situated in a building, access to the plant must be
secured.

The fence shall be 2.4 meter solid wall with three strands of 0.6 meter
high barbed wire. Typical details of the fence are given in Figure 6.5,
6.6, 6.7 and 6.8.

STP project proponent is required to provide adequate warning/safety


and the Commission signboard before handing over the sewerage system
to the Commission.

154 Volume 4 Malaysian Sewerage


Industry Guidelines
3000 4200 2100
Figure 6.5

3 NOS. 2.5 DIA. BARBED WIRE 3 NOS. 2.5mm DIA. BARBED WIRE

Sewage Treatment Plants


3 THK. M.S. PLATE

Sewerage Treatment Plants


X X X X X X X X X X X X X X

600
X X X X X X X X X X X X X X X X
X X X X X X X X X X

BRICKWALL FENCE
BRICKWALL FENCE

2400
6"x6"

Volume 4
Volume 4
CONCRETE

150
COLUMN @ 3m

225
INTERNAL
900

225
63 x 63 x 6
THK. ANGLE
150

600 x 600 x 900 DEEP GRADE 20


600 SQ.
MASS CONCRETE STUMP
150 DIA. X 14.6 #
M.S. POST
Typical Drawing of Brickwall Fencing and Gate
Figure 6.5 Typical Drawing of Brickwall Fencing and Gate
Requirements for Ancillary Facilities

14 3
155
Requirements for Ancillary Facilities
156
3200

800
230

2T12 2T12 2T12 A 2T12

R6-200 R6-200
100 x 125mm COPING BEAM 100 x 125mm COPING BEAM 230 x 230mm RC COLUMN
AT 3.2m INTERVALS
A 4T12
LINKS R6-150
C C

2200
115mm THK BRICKWALL
PLASTERED ON BOTH SIDE

2200
SURFACE TO BE ROUGHENED

2T12 2T12
2T12 B 2T12 FINISHED GRD. LEVEL FINISHED GRD. LEVEL
R6-150 R6-150

300
300
2T12 2T12
115 x 300mm GROUND BEAM B

MIN. 900
MIN. 900
115 x 300mm GROUND BEAM

230
230
50mm LEAN CONCRETE 750 x 750 x 230mm
Requirements for Ancillary Facilities

RC FOOTING
750 750
750 750
50mm LEAN CONCRETE 4T12 B/W

FRONT VIEW OF BRICKWALL FENCING TYPICAL RC COLUMN DETAIL

R6-200 R6-100
3 STRANDS P.V.C. COATED BARBED 150 230
R6-200
WIRE ATTACHED TO POST BY 75
HEAVY SPLIT PINS 125 T12 T12
T12 T12

800
230
63 x 63 x 6mm M.S. ANGLE T12 T12

300
T12

100
WITH 3 STRANDS OF BARBED WIRE T12
45°
T12 T12
100 x 125mm COPING BEAM

Volume 4
300
SECTION A-A SECTION B-B SECTION C-C
115mm THICK CEMENT / SAND
BRICKWALL WITH 20 PLASTERING
BOTH SIDES NOTES :

1. ALL CONCRETE USED SHALL BE GRADE C25.

2200
2. MINIMUM COVER TO REINFORCEMENT SHALL BE 25mm.

3. ALL BRICKS USED SHALL BE FIRST QUALITY CEMENT / SAND BRICKS.

4. BRICKWORK SHALL BE REINFORCED WITH EXPANDED METAL OR "EXMET" AT EVERY FOURTH COURSE COMMENCINGS TWO COURSES ABOVE GROUND BEAM LEVEL.
Figure 6.6 Brickwall Fencing

150 x 300mm GROUND BEAM 5. BRICKWORK WALLS SHALL BE ANCHORED TO CONCRETE FACES USING GALVANISED FISHTAIL A NCHORS TO LAP IN WITH THE BRICK REINFORCEMENT AT EVERY

300
FOURTH COURSE COMMENCING TWO COURSES ABOVE GROUND BEAM LEVEL.

6. MORTAR FOR BRICKWORK SHALL BE SET IN 1:1:5 CEMENT-LIME-SAND MORTAR.

MIN. 900
230
750 x 750 x 230mm FOOTING 7. PLASTERING AND RENDERING TO SURFACE OF BRICKWALL SHALL BE FINISHED TO A MINIMUM THICKNERS OF 20mm WITH 1:3 CEMENT-SAND NORTAR.

750
PAINTING

TYPICAL CROSS SECTION OF BRICKWALL FENCING 1.) ALL EXPOSED WALL SHALL BE PAINTED WITH ONE UNDERCOAT OF APPROVED RESISTING PRIMER SEALER AND TWO COATS OF
APPROVED WEATHER RESISTANT EMULSION PAINT.

2.) TWO BANDS OF IWK'S COLOUR WITH OVERALL HEIGHTS OF 400mm SHALL BE PAINTED ON EXTERIOR FACE OF THE WALL.

3.) NTERIOR/EXTERIOR WALL COLOUR STANDARDS - DULUX TUNGSTEN (10412) OR EQUIVALENT

Industry Guidelines
Malaysian Sewerage
3200 3200

230

800

800

Sewerage Treatment Plants


4T12

LINKS R6-150
230 x 230mm
RC COLUMN
AT 3m INTERVALS
2200

2200
PRE-CAST CONCRETE
WALL 75mm THICK
SURFACE TO BE ROUGHENED

FINISHED GRD. LEVEL


FINISHED GRD. LEVEL

TYPICAL RC COLUMN DETAIL


FRONT VIEW OF PRE-CAST FENCING
R6-100 C/C
230

Volume 4
3 STRANDS P.V.C. COATED BARBED
WIRE ATTACHED TO POST BY 75 T12 T12
HEAVY SPLIT PINS
230

800
63 x 63 x 6mm M.S. ANGLE T12 T12
WITH 3 STRANDS OF BARBED WIRE

45°
SECTION A-A

300
PRE-CAST CONCRETE WALL
75mm THICK NOTES :
1. ALL CONCRETE USED SHALL BE GRADE C25.
Figure 6.7 Precast Fencing

2. MINIMUM COVER TO REINFORCEMENT SHALL BE 25mm.

2200
PRE-CAST CONCRETE WALL
75mm THICK 3. FOUNDATION AS PER THE DESIGN OF THE ENGINEER-IN-CHARGE.

PAINTING
1.) ALL EXPOSED WALL SHALL BE PAINTED WITH ONE UNDERCOAT OF APPROVED RESISTING
PRIMER SEALER AND TWO COATS OF APPROVED WEATHER RESISTANT EMULSION PAINT.
2.) TWO BANDS OF IWK'S COLOUR WITH OVERALL HEIGHTS
OF 400mm SHALL BE PAINTED ON EXTERIOR FACE OF THE WALL.
3.) COLOUR STANDARDS
TYPICAL CROSS SECTION OF PRE-CAST FENCING A.) INTERIOR/EXTERIOR WALL - DULUX TUNGSTEN (10412) OR EQUIVALENT
B.) BANDS - BLUE - DULUX GLOSS FINISH
(PANTONE 300C) OR EQUIVALENT
- GREEN - DULUX GLOSS FINISH
(PANTONE 354C) OR EQUIVALENT

157
Requirements for Ancillary Facilities
158

146
B
3 STRANDS P.V.C. COATED BARBED- WIRE
ATTACHED TO POST BY
HEAVY SPLIT PINS
63 x 63 x 6mm M.S. ANGLE
Requirements

WITH 3 STRANDS OF BARBED WIRE


Requirements for

390mmx190mmx190mm BOND BEAM BLOCK


for Ancillary

390mmx190mmx190mm FULL BLOCK


AncillaryFacilities

Figure
Facilities

1 NO HORIZONTAL REINFORCEMENT
Figure

390mm x 190mm x 190mm BOND BEAM BLOCK

B
ELEVATION
SECTION A-A

ANTI-CLIMB

Volume 4

Volume 4
SECTION B-B
6.86.8 Masonry
Masony

NOTE :-
1 NO. HORIZONTOL REINFORCEMENT 1. FOUNDATION AS PER THE DESIGN OF THE ENGINEER-IN-CHARGE
390mmx190mm190mm BOND BEAM BLOCK 2. ALL MASONRY UNITS (CONCRETE BLOCKS) USED MUST BE UNDER
SIRIM CERTIFICATION SCHEME
3. CONCRETE MIX USED FOR GROUTING TO BE GRADE 20
Fencing

4. CEMENT MORTAR USED FOR JOINTS TO BE 1:3 MIX


Fencing

PAINTING
390mmx190mmx114mm FULL BLOCK
1.) ALL EXPOSED WALL SHALL BE PAINTED WITH ONE UNDERCOAT
OF APPROVED RESISTING PRIMER SEALER AND TWO COATS OF
APPROVED WEATHER RESISTANT EMULSION PAINT.
2.) TWO BANDS OF IWK'S COLOUR WITH OVERALL HEIGHTS
OF 400mm SHALL BE PAINTED ON EXTERIOR FACE OF THE WALL.
1 NO HORIZONTAL REINFORCEMENT 3.) COLOUR STANDARDS
A.) INTERIOR/EXTERIOR WALL - DULUX TUNGSTEN (10412)
390mmx190mmx190mm BOND BEAM BLOCK
B.) BANDS - BLUE - DULUX GLOSS FINISH OR EQUIVALENT
(PANTONE 300C) OR EQUIVALENT
- GREEN - DULUX GLOSS FINISH
(PANTONE 354C) OR EQUIVALENT

Industry Guidelines
Malaysian Sewerage
Industry Guidelines
Malaysian Sewerage
Requirements for Ancillary Facilities

6.7 Beautification Zone and Landscape

Treatment plants shall be effectively and visually screened by a


beautification zone within the treatment plant site of not less than
2 m wide, on which selected species of trees and shrubs can be planted.
In congested or difficult locations, the Commission should be consulted
on these requirements.

Premix or Paved area shall be provided at this zone for all class 1
treatment plants with loading equal or less than 1000 PE or where
necessary.

6.8 Stores and Workshops

All Class 4 Treatment plants that exceed 20 000 PE and have a pump
station within the premises shall be provided with an active store and
workshop.

6.9 Spares

All mechanical units shall be provided with an adequate reserve supply of


critical spare parts. A list of proposed spare parts should be forwarded
for approval when detailed designs are submitted for verification and
approval.

All parts recommended by the manufacturer to be provided with spares


shall be so delivered at the stage of final inspection. Notwithstanding
that, all parts with a life span of 3 years or less shall be provided with
spares

Typical spare parts requirements are provided in Table 6.2. Spare parts
shall be obtained from the original manufacturer of the equipment and
shall be packed and protected for storage to BS1133 requirement.

A set of special tools if required and specific to an equipment including


lifting tackle and greasing equipment necessary for the maintenance,
repair, testing and overhauled of the equipment shall be supplied together
with the spares at the stage of final inspection.

Sewerage Treatment Plants Volume 4 159


Requirements for Ancillary Facilities

Table 6.2 Spare Part

No. Equipment Spare Parts Quantity


1. Pumps: Bearing one set
Raw Sewage o-ring one set
Submersible oil seal one set
Pumps. mechanical seal one set
Grit Pumps. wear ring one set
Feeding Pumps. Impeller (for 3 or more one set
RAS Pumps. pump of similar model) one set, whichever parts is
Sludge Pumps. (see Pumps, Motors, relevant
Effluent Pumps. Drives)
2. Motors (Electric): Bearing one set
o-ring one set
oil seal one set
mechanical seal one set
3 Drives
a)Direct Couple gear bearing one set
b)Chain chain one set
sprocket one set
c)Belt V-belt one set
4 Mechanically Raked Chain one set
Screens Chain link one set
Gear sprocket one set
(also see Motors, one set, whichever parts is
Drives) relevant
5. Diaphragm Pump diaphragm one set
6. Progressive Cavity rubber stator one set
(Mono) Pump
7. Blowers (see Motors, Drives) one set, whichever parts is
relevant
8. Aerator:
Diffused Air Diffusers 10% of total numbers
Mechanical (surface, (see Motors, Drives) one set, whichever parts is
brush) relevant
9. Scraper rotating collectors one set
wheel one set per clarifier
(see Motors, Drives) one set, whichever parts is
relevant
10. Conveyor (see Motors, Drives) one set, whichever parts is
relevant

160 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities

Table 6.2 Spare Part (continued)


6.10 Yard Lighting
No. Equipment Spare Parts Quantity

11. Filter Press oil seal for hydraulic one set


pump one pair out of every five
membrane cloth pair of plates
12. Belt Press oil seal for hydraulic one set
pump one set if the STP has only
Belt one press
13. Centrifuges (see Drives) one set, whichever parts is
relevant

6.10 Yard Lighting


Effective yard and building lighting systems shall be incorporated within
the treatment plant site in order to provide sufficient illumination for
operation and maintenance schedules to be carried out during day and
night periods. In addition, the entire treatment plant site shall have
sufficient street lights and perimeter lights for various operations, safety
and security reasons.

Compound lighting shall be provided at every 50 m interval for all


manned and security plants. However, sufficient lighting is required at
the strategic location such as entrance gate, inlet works and necessary
areas. Refer to Table 6.3.

All lighting shall be accessible for maintenance / removal. Typical details


of compound lighting are shown in Figure 6.9.

Table 6.3 Numbers of Unit and Location of Compound Lighting

Minimum
Class of Population
Numbers Location
STP Equivalent
of Unit

1 ≤1 000 1 Inlet Works or Entrance


Inlet Works and Treatment Process
2 1001 – 5000 2
Unit
Every Internal Corner of STP boundry
4 and nearby to Inlet Works, Treatment
3 5 001 – 20 000
Process Unit and Sludge Treatment
Entrance, Inlet Works, Mess Building,
50 meter Process Treatment Unit, Secondary
4 > 20 000
Treatment Unit and Sludge Treatment.

Sewerage Treatment Plants Volume 4 161


Requirements
Requirements for Ancillary
for Ancillary Facilities Facilities

Figure 6.9 Typical Details of Compound Lighting


Figure 6.9 Typical Details of Compound Lighting
670

105
290

105

6000
250 STANDARD GALVANISED
STREET LAMP POST

FRONT VIEW

SIDE VIEW

LAMP POST

6.11 Sampling Facilities


6.11 Sampling Facilities
Suitable sampling facilities shall be provided (preferably in the form of
an open
Suitable chamber)
sampling within
facilities shallthe
be boundary of the STP in
provided (preferably to the
allow representative
form of an
open samples
chamber)towithin the boundary
be taken safely by ofonetheperson.
STP toFor allow representative
treatment plants up to
samples to be taken safely by one person. For treatment
20 000 PE, sufficient space shall be allowed for proper plants up to
preparation
20,000of PE, sufficient
samples to bespace
takenshall
awaybetoallowed
central for proper preparation
laboratories for furtheroftesting
samples to be taken away to central laboratories for
and analysis. The sampling area shall contain sufficient further testing and space
bench
analysis.
and The sampling
storage spaceareafor shall contain
samples. Forsufficient
treatment bench space
plants and than
greater
storage
20 000 PE, the sampling area shall be provided in accordance the
space for samples. For treatment plants greater than 20,000 PE, with MS
sampling
1228.area shall ladder
Access be provided
shall in
be accordance
provided for withsampling
MS 1228. Access where
facilities
ladder shall be provided for sampling facilities where necessary. Internal
necessary. Internal surface area for sampling point shall be tiled with
surface area for sampling point shall be tiled with clear coloured tiles
clear coloured tiles

6.12 Auto Restart Facilities


6.12 Auto Restart Facilities
All electrical equipment shall be fitted with auto restart facilities for quick
All electrical
re-operation equipment
in the event of failureshall be fitted
of power with auto restart facilities for
facilities.
quick re-operation in the event of failure of power facilities.

162 Volume 4 Malaysian Sewerage


Industry Guidelines
150 Volume 4 Malaysian Sewerage
Industry Guidelines
Requirements for Ancillary Facilities

6.13 Safety Facilities

Safe access and walkways shall be provided at all process units and
equipment (valves, penstocks, aeration tanks, etc.) that require service
and maintenance. Safety handrails shall also be installed at walkways
and other working areas with a fall greater than 2 m. Typical details
of hand rail are shown in Figure 6.10

All chemical storage facilities shall be provided with a safety shower


and eyewash as well as appropriate warning signs. Liquid chemical
storage facilities shall be bund. Access to the area shall be restricted
using lockable doors/gates.

Provision for fire detection, alarm and fire fighting equipment shall
be complying with the latest requirements in the Uniform Building
Bylaws, the Institute of Electrical Engineers (IEE) guidelines and other
statutory requirements.

All tanks shall not exceed 1.2 m above ground.

Stair case and ladder exceeding 1.2 m shall be provided with


handrail

All plants located adjacent to earth slopes shall be provided with proper
slope protection structures. The slope protection design must be certified
by Qualified Professional Engineer.

6.14 Doors

All external doors shall be of weather proof and suitable for out-door
installation.

Door with sufficient width for the manoeuvre of equipment shall be


provided at the building of pump station, blower room, etc. For opening
more than 4 m wide or 5 m high, motorized roller shutter shall be
provided complete with manual over-ride button, which enables it to
be operated during power interruption.

6.15 Fire Hydrant

For treatment plants above 20 000PE, fire hydrant shall be provided


complying with the requirements of Jabatan Bomba.

Sewerage Treatment Plants Volume 4 163


Requirements for Ancillary Facilities

6.16 Power Supply

Power supply shall be provided to each plant from the approved


source. Drawings submitted for approval shall indicate the locations of
electrical power tapping point and schematic layout plan. Approval for
power supply tapping should be obtained from relevant authority for
permanent power supply before submitting inspection form. All related
document, such as electrical bills, transfer of ownership: to be submitted
before final inspection. Requirement of power shall be finalised prior
to obtaining design approval

Requirement of incoming permanent power supply shall be inline with


Section 4 this Volume.

6.17 Internal Sanitation (Toilet)

All plants shall be provided with toilet. The toilet shall consist of water
tap, water closet, shower and wash basin. The area for toilet shall
comply with Uniform Building By Laws. Toilet to be located beside
the control panel building. Toilets can also be located in the mess or
office building.

6.18 Lifting Requirement

Safe lifting weight in unrestricted area is 16 kg. For heavier objects and/
or very tight locations, provision of crane or access for truck mounted
crane to be made.

Lifting requirements are as follows:

- Weight < 16 kg: Manual lifting


- 16 kg ≤ Weight ≤ 250 kg: A davit or ‘A’ frame shall be arranged
to allow items lifted by using manual
chain hoist to be projected on a 1.2
m truck tray and positioned at 2 m
above road level. In the pump station,
motorized hoist is required for lifting
weight exceeding 100 kg.
- Weight > 250 kg: A gantry with motorised hoist shall
be arranged to allow items to be
projected on a 1.2 m truck tray and
positioned at 2 m above road level
truck tray.

164 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities

Lifting equipment shall be subjected to DOSH approval standards and


guidelines.

Safe Working Load with approved method of installation shall be rated


and printed for all lifting facilities. Height and lifting method must be
considered in the design for Safe Working Load of lifting facilities.

All portable motorised hoist shall be of 230 V operating voltage and fixed
electrical hoist shall be of 415 V operating voltage.

All fixed 3 axis type gantry shall come with additional safety features
such as travel stop limit switch, hoist over run limit switch, slow &
fast speed mode and emergency stop (for all type of hoist).

All fixed type outdoor lifting facility futures shall comprise of hoist
parking bay with shade. All fixed type lifting facility shall come with
working platform and excess ladder.

Typical drawings of lifting davits and A-frame lifting facilities are


shown in Figure 6.11 and Figure 6.12.

6.19 Ventilation

Ventilation is the process of letting in outside air into a space so that it


mixes with the inside atmosphere to dilute contaminants and replenish
oxygen. The purpose of ventilation in a sewage treatment plant is
to provide a comfortable and safe working environment for all plant
personnel.

Hence proper ventilation shall be provided as a mean of providing


sufficient fresh air and reducing poisonous or explosive gases in enclosed
or semi-enclosed spaces where access to human is allowed. Ventilation
can be achieved naturally or mechanically:

• Natural ventilation uses the force of nature such as air currents,


breezes, thermal gradients and pressure differences to move air
in and out of the space.

• Mechanical ventilation uses fans and blowers to force air


through space. It is also sometimes called forced ventilation.

Particular requirements are:


a) Ventilation shall be intrinsically safe with respect to explosive
gases (such as methane) where such gases may be present.
b) Ventilation shall be designed to deal with the different densities
of the various gases.

Sewerage Treatment Plants Volume 4 165


Requirements for Ancillary Facilities

c) Ventilation fans shall be located outside the enclosed space to


induce forced air into the plant. Intake locations shall be such
that only fresh air is drawn into the system and not air recirculated
from the exhaust.
d) Mechanical ventilation shall be used if the system is required to
remove contaminants.
e) Ventilation exhaust shall be directed to a suitable location for
discharge and it shall not be adjacent to the intake point.
f) Ventilation at rooms where heat generation may take place must
be adequate to dissipate the heat generated to ensure a comfortable
making ambient for the equipment and the operator.
g) Noise levels associated with operating fans and blowers, particularly
in a confined space, shall conform to the requirements in Section
4 of this Guidelines and other stationary requirements.
h) Optimise recurring cost for operation, maintenance and
replacement.
i) Regular testing and inspection of the equipment
j) Compliance with the suggested ventilation requirements. Table 6.4
presents some commonly used values for ventilation rates in typical
enclosed spaces of a sewage treatment plant: -

166 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities

Table 6.4 Common ventilation rates

Minimum Ventilation Rate


Space Remarks
(Air Changes/hour, ac/hr)
Wet-Well 30 intermittent Use 100% outside air. Step up
12 continuous to 24 ac/hr if hazardous gases
are detected. Consider odour
control, where warranted
Dry-Well 30 intermittent
12 continuous
Grit Removal/ 30 intermittent Same as wet well
Screen Area 12 continuous
Digester Gas 30 intermittent Same as wet well
Control Room 12 continuous
Sludge Gas 30 intermittent Same as wet well
Compressor Room 12 continuous
Enclosed Grit 30 intermittent Same as wet well
Loading Areas 12 continuous
Enclosed Primary 30 intermittent Same as wet well
Sedimentation Tanks 12 continuous
Scum Concentration 30 intermittent Same as wet well
Tank 12 continuous
Chlorine and 60 intermittent Hazardous areas, toxic fumes,
Sulphur Dioxide floor level exhaust required.
12 continuous
Rooms Interlock fans with manual
switches located at each
entrance. Also interlock fans
with chlorine and sulphur
dioxide detection. Use 100%
outside air
Filter/Dewatering 12 continuous Consider odour control for
Area exhaust air from dewatering
area, where warranted
All other enclosed 30 intermittent In particular at blower room,
unit processes not high tension room, low voltage
12 continuous
mentionedelsewhere room, switchboard and control
panel rooms, where there are
tendency of heat generation

Sewerage Treatment Plants Volume 4 167


Requirements for Ancillary Facilities

k) An audible and visible warning shall be provided at all entry


points. This shall automatically operate if the fan fails.
l) Where natural or forced ventilation is provided, it shall be
installed in such a manner so as to avoid any ingress of water
due to rain or other sources.
m) In areas with routine entry by personnel, the ventilation strategy
shall emphasize adequate control of contaminants and the
ventilation system shall be continuously operated.

6.20 Process Water

The designer is encouraged to provide recycle water facilities from


the treated effluent. The recycle water can be utilised for cleaning and
landscaping purposes.

6.21 Aesthetic

The structure of a treatment plant shall blend with the surrounding


development to improve the aesthetic value of the area. Roof, structure
wall or brickwall fancing can be designed with other than conventional
finishing.

6.22 Close Turfing

Unpaved area within the STP reserve shall be turfed with close turfing.
The type of grass must be “cow grass”. For slope area, turf must be
pegged to avoid grass wash away during water run-off.

6.23 Standard Roofing and related requirement

Roof for control panel shall be of flat roof and shall be installed with
water proving material on the final layer. The slope of flat roof shall
be 1: 20 and gutter shall be provided.

However, for the aesthetic purpose Pitch type roof may be provided.
The slope shall be 30 degree from horizontal. Suitable material for roof
such as roof tile is recommended.

The design of roof shall be considered from the following:

i) Suitable material for roof (flat or slope) including colour


ii) Adequate air for ventilations
iii) Enough heights for lifting facilities

168 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities

iv) Enough heights for access and headroom


v) Type of insulation
vi) Acoustic treatment where applicable

6.24 Painting

Painting shall include all plant and machinery inside buildings, including
pipework, grating, handrailing, internal walls below ground level and
all metal work including machinery.

The conduits and piping shall be appropriately named and labelled


indicating flow directions and painted with the following colour codes
for easy identification:
Chlorine line - yellow with double green bands
Compressed air line - green
Fuel gas line - orange
Potable water supply line - blue
Raw sewage line - black
Final effluent line - grey
Sludge line - brown
Non-potable water line - blue with double black bands
Other disinfectant lines - yellow with double red bands
Biogas line - yellow

The labels shall be stencilled on the piping in a contrasting colour with


the colour coded bands, if any, located at appropriate and strategic
points.

Colour codes selected for general equipment, building and others items
in a sewage treatment plants shall be adhered to colour standards as
detailed in Table 6.5. The types of paint and surface preparation used
shall be as recommended by the paint manufacturer.

Sewerage Treatment Plants Volume 4 169


Requirements for Ancillary Facilities

Table 6.5 Painting System Index – Colour Standards

Equivalent Colour
Item Colour
Guide
General Equipment including motors Dark Blue Dulux Regal Blue
(unless come with the original manufacturer 0013
approved colour code)
Par Mandarin Blue
0013
Penstocks/Valves/Manhole Covers Black Par Bituminous Black
Machinery Guards/Railings/Runways/ Yellow Dulux Lemon 2024
Overhead Cranes/Lifting Davit
Par Golden Yellow
Switchboards Light Grey Dulux Pewter 695
Par Willow Grey
00A05
Fencing poles/Gates Green Dulux A365-13449
Par Green 3666
Building and Walls – Exterior Grey Dulux BS 00A05-
(Weathersheild) 10235
Building and Walls - Interior White
Fencewall – Interior and Exterior Grey Dulux BS 00A05-
10235
Floors - Concrete Interior Green Leigh Green 3666
Building Stripes Green Dulux A910-13448
Par Green 3666
Blue Dulux A910-11482
Par Blue 2686
Indah Water Logo (where applicable) Indah Water Dulux A365-13449
Green Par Green 1006
Indah Water Dulux A365-11483
Blue Par Blue 1007

Notes:
The above painting requirements are not applicable to stainless steel, aluminium,
galvanised metal surfaces except where necessary to comply with statutory health
and safety requirement.

170 Volume 4 Malaysian Sewerage


Industry Guidelines
Requirements for Ancillary Facilities
Requirements for Ancillary Facilities

Figure 6.10 Typical Detail of Guard Rail


Figure 6.10 Typical Details og Guard Rail

550

1
21/4
1100

100 33

150-250
SIDE PALM BASE
TYPICAL RUN OF HANDRAIL AS
VIEWED FROM WALKWAY SIDE

FLAT BASE
TUBULAR STANDARDS
550

1
21/4
1100

12
100
150-250

100 36

TRIANGULAR BASE
TYPICAL RUN OF HANDRAIL AS
VIEWED FROM WALKWAY SIDE

ROUND BASE
TUBULAR STANDARDS

3000 C/C 3000 C/C


550
1100

550

DETAIL OF HOT DIPPED G.I. RAILING

Sewage Treatment Plants Volume 4 159

Sewerage Treatment Plants Volume 4 171


Requirements for Ancillary Facilities

Requirements for Ancillary Facilities


Figure 6.11 Typical Detail of Lifting Davit
6.11 : Typical Detail of Lifting Davit

50
0
90

75
Requirements for Ancillary Facilities 50

25

20 25 20
25

6.11 : Typical Detail of Lifting Davit


30° FL FL

6
450

30
120

6 FILLET WELDED

10
50 OD=98
0
SAFE WORKING 90
LOAD TO BE PLAT THICKNESS 10
INDICATED
75

50

25
1775

250

260
20 25 20
25

30° FL FL

6
450

30
120
DETAIL `A'
6 FILLET WELDED

10
OD = 118
OD=98

SAFE WORKING
LOAD TO BE PLAT THICKNESS 10 DETAIL `A'
INDICATED

SIDE VIEW SECTION


LIFTING DAVIT
LIFTING DAVIT
1775

250

260

NOTE : DEPTH OF SLEEVE SHALL VARIOUS WITH HEIGHT OF POLE ACCORDINGLY

DETAIL `A'

Figure 6.12 : Typical DetailDETAIL


of A`A'Frame Lifting Facilities
OD = 118

SIDE VIEW SECTION


LIFTING DAVIT
LIFTING DAVIT
1200 2160

203x203x46Kg/m UB 1800

NOTE : DEPTH OF SLEEVE SHALL VARIOUS WITH HEIGHT OF POLE ACCORDINGLY

Figure 6.12 Typical Detail of A-Frame Lifting Facilities


180

203x133x25Kg/m UB
315

203x133x
25Kg/m UB

Figure 6.12 : Typical Detail of A Frame Lifting Facilities

2160
2340

1200
2340

203x203x46Kg/m UB 1800
180

203x133x25Kg/m UB
315

203x133x
25Kg/m UB

300x300x12 PLATE BOLTED TO CONCRETE 300x300x12 PLATE BOLTED TO CONCRETE

1500

TO PROVIDE WITH ROLLER OR FIX TO THE CONCRETE TO PROVIDE WITH ROLLER OR FIX TO THE CONCRETE
2340

FLOOR (TO SYSTEM SUPPLIER DESIGN)


2340

FLOOR (TO SYSTEM SUPPLIER DESIGN)

SIDE VIEW FRONT VIEW

A-FRAME WITH I-BEAM A-FRAME WITH I-BEAM

300x300x12 PLATE BOLTED TO CONCRETE 300x300x12 PLATE BOLTED TO CONCRETE

1500

TO PROVIDE WITH ROLLER OR FIX TO THE CONCRETE TO PROVIDE WITH ROLLER OR FIX TO THE CONCRETE
FLOOR (TO SYSTEM SUPPLIER DESIGN) FLOOR (TO SYSTEM SUPPLIER DESIGN)

SIDE VIEW FRONT VIEW

A-FRAME WITH I-BEAM A-FRAME WITH I-BEAM

160 Volume 4 Malaysian Sewerage


Industry Guidelines

172 Volume 4 Malaysian Sewerage


Industry Guidelines

160 Volume 4 Malaysian Sewerage


Section 7

Special Requirements
Special Requirements

174 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

7.1 Temporary Treatment Plants

7.1.1 Definition

Temporary treatment plants refer to STP that are built to operate on a


temporary basis. The sewage will eventually be diverted to a centralised
sewerage system. After then, the temporary treatment plant will be
decommissioned.

There are 2 categories of temporary treatment plants:

Category 1
For temporary treatment of sewage during the upgrading of an existing
sewerage treatment facility

Category 2
For temporary treatment of sewage during initial stage of a new housing
development where it is not feasible to construct a plant of ultimate
capacity during initial stage or it is located within the catchment of a
centralised sewerage system.

7.1.2 Category 1: Temporary Treatment Plant for Upgrading of


Facilities

During the upgrading of an existing treatment plant, the sewage flows into
that plant shall be directed to a temporary treatment plant for treatment
before discharge. The treatment process of the temporary plant shall
be designed and calculated based on: the duration of the project, total
existing flow and the compliance requirements. The temporary treatment
shall be monitored at regular interval. Approval from the Commission
and DOE must be obtained prior any direct discharge of the untreated
sewage into the receiving watercourse. The temporary treatment plant
shall be located within the compound of the existing site. The temporary
treatment plant shall not be built on other site area unless approval is
granted by the Commission

7.1.2.1 Compliance Standards for Category 1 Temporary Treatment


Plants

Category 1 temporary treatment plant shall comply with the requirements


as stipulated in this Guideline and shall be operated and maintained
to the satisfaction of the Commission and the Director General of the
Department of Environment (DOE) at all times.

The temporary treatment plant shall be designed to comply with the


following minimum effluent requirements:

Sewage Treatment Plants Volume 4 175


Special Requirements

a) Standard B for STP located downstream of water intake points


and non-water catchment zones
b) Standard A for STP located upstream of water intake points

The above levels shall be interpreted as ‘absolute’ pollutant levels.


Final effluents will be monitored over the life of the temporary plant.
A license to contravene shall be obtained before the construction of any
temporary plant and the commencement of any upgrading works.

The temporary plant shall incorporate provisions to minimize adverse impacts


such as visual, noise, odour nuisance etc. to the surroundings.

7.1.2.2 Process Requirements for Temporary Treatment Plants

Alternative or innovative designs may be used for temporary plant to


meet the general design compliance as stipulated above.

Unit processes within the temporary treatment plant can be designed


to absolute standards. For example, a Standard A the effluent level of
temporary treatment plant of this category can be designed to 20 mg/l
BOD and 50 mg/l SS.

Materials for construction can be of semi-permanent installation such


as fiberglass tanks, mild-steel with epoxy coat, etc.

7.1.2.3 Operation of Temporary Treatment Plants

During the upgrading of an existing plant, the project proponent shall


appoint a class license to operate and maintain the temporary plant. If
the upgrading contractor is a licensed operator, they may be appointed
as the operator of the temporary plant.

7.1.3 Category 2: Temporary Plants for New Housing Development

I) Multiple Phases Hosing Development

Temporary plant shall be provided for multiple phases housing


development where it is not feasible to construct a plant with ultimate
capacity during initial stage.

STP reserves must be located as far as practicable from habitable


buildings. The needs of a temporary plant in a multiple phases housing
development project depend on phases of development, size of each
development phase, location of initial development and duration of the
phase lag and entire development plan.

176 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

The project proponent will construct a temporary treatment plant in


compliance with the following criteria:-
a) Temporary plant will be decommissioned by the developer within
time frame agreed between the Commission and the developer.
b) Implementation program for ultimate plant is confirmed in
accordance to an approved catchment study.
c) All temporary plant shall remain as private plant and shall be
operated and maintained by a licensed operator appointed by the
project proponent.

(II) Future Connection to Centralised STP

This applies to a catchment where implementation program to construct


a centralised STP is approved but the completion date could not meet
the project proponent’s needs. Under such circumstances, the project
proponent may be allowed to build a temporary treatment plant.

7.1.3.1 Provision of Land for Temporary Treatment Plants

The owner will be required to allocate land within the housing


development for the construction of all temporary works. However,
the site of the temporary treatment plant shall not be located on future
public amenities land.

The project proponent of the temporary treatment plant will be required


to construct the temporary sewer reticulation within the development to
convey sewage to the temporary treatment plant. At the same time, the
project proponent must also construct the permanent sewer reticulation
for the connection to the permanent plants or the centralised sewerage
system.

7.1.3.2 Compliance Standards for Temporary Treatment Plants

This category of temporary treatment plant shall comply with the


requirements as stipulated in this Guideline. The plant shall also be
maintained to the satisfaction of the Commission and the Director
General of the Department of Environment (DOE) at all times.

The temporary treatment plant shall be designed and maintained to


comply with the following minimum effluent requirements:

a) Standard B for STP located downstream of water intake points


and non-water catchment zones.
b) Standard A for STP located upstream of water intake points.

Sewage Treatment Plants Volume 4 177


Special Requirements

7.1.3.3 Process Requirements for Temporary Treatment Plants

Temporary treatment plants shall be designed to the requirements set


out in Sections 3, 4 and 6 of this volume.

An alternative design may be considered for the temporary treatment


plant that will be decommissioned within time frame agreed between
the Commission and the developers.

Materials for construction can be of semi-permanent installation such


as fiberglass tanks, mild-steel with epoxy coat, etc.

Filter systems may use refurbished filter material that meet the relevant
standards. However, other equipment used within the works shall be
new. Second-hand equipment is strictly prohibited.

7.1.3.4 Operation of Temporary Treatment Plants

Temporary plant shall remain as private plant. The owner must appoint
a licensed operator to operate and maintain the plant.

Temporary treatment plants shall strictly comply to the requirements as


stipulated by this Guideline and shall be operated to the satisfaction of
the Commission and the Director General of DOE at all times.

Temporary treatment plants shall be designed and constructed so as


not to present any nuisance in terms of odour, noise, safety and visual
impact to the nearby community.

7.1.3.5 Ancillary Requirement of Temporary Treatment Plants

Temporary treatment plants shall be provided with proper security


fencing in compliance with Section 6 of this Volume.

Adequate access roads and drainage shall be provided.

Landscaping of treatment plant shall be provided for better aesthetic


value surrounding the plant.

178 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

7.2 Treatment Plants Located Within Buildings

7.2.1 Introduction

The installation of treatment facilities within buildings whether occupied


or not, including basements of buildings, are not desirable and will
not normally approve. Every effort must be made to come up with an
alternative site or an arrangement to connect to a public system.

Owners must resolve these issues at an early stage of the planning


process. The Commission should be contacted early to establish if an
alternative option is feasible.

If approved, such installations will be subjected to stringent service


condition requirements for the following criteria:

a) Access
b) Ventilation
c) Electrical requirements for lighting system
d) Noise control
e) Process type
f) Inlet works
g) Pre-treatment
h) Confined space safety
i) Odour Control
j) Discharge systems
k) Flood mitigation measures
l) Operation and maintenance
m) General safety and health
n) Sludge handling
o) Sanitary and plumbing facilities
p) Fire Fighting Equipment

Treatment plants within buildings will be considered as private treatment


plants subject to eventual phasing out and replacement by a centralised
system.

Sewage Treatment Plants Volume 4 179


Special Requirements

7.2.2 Specific Guidelines and Requirements

The specific guidelines and requirements for the criteria specified in


7.2.1 are listed below.

I) Access

a) Vehicle access must be provided from the nearest public


highway.
b) Parking space for a desludging and service vehicle must be
within operating range.
c) Access must be continuously available and unobstructed.
d) Accessible to water and electricity supplies.
e) Sampling point to be available for final effluent.
f) Allowance must be made for installation and removal of
equipment.
g) Provision must be made for lifting of heavy equipment.
h) Suitable arrangements must be made for service and repair of
equipment.

II) Ventilation

Ventilation design shall be in compliance with the requirements in


Section  6 and the specific requirements listed below:

a) Suitable system must be provided to address poisonous, explosive


and lack of oxygen conditions.
b) Separate and independent (from the basement) ventilation must
be provided for the confined spaces.
c) Ventilation shall be of forced mechanical type.
d) Ventilation must be intrinsically safe with respect to explosive
gases such as methane.
e) Ventilation must be designed to deal with the different densities
of the various gases.
f) Ventilation fan must be located outside the enclosed space to
induce forced air into the plant. Intake locations shall be such
that only fresh air from outside the building id drawn into the
system and not air re0circulated within the building.
g) Ventilation exhaust must be directed outside the building for
discharge.

180 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

h) Ventilation air exchanges shall be as follows:


i) Intermittent: Minimum of 30 complete air changes per
hour
ii) Continuous: Minimum of 12 complete air changes per
hour
i) A backup fan must be provided in the event of duty fan failure
and must be automatic on entry.
j) A petrol driven generator with an auto restart facility must be
provided to continually operate the ventilation system in the event
of power failure.

III) Electrical Requirements for Lighting System

a) Only high-intensity, low-voltage discharge lamps to be used for


floodlighting of plant area during operation and maintenance.
b) The lighting and electrical equipment must be both vapour and
explosion proof.
c) A separate housing must be provided for electrical controls to
prevent electrical sparks from coming into contact with flammable
and explosive gases.
d) All electrical equipment must be water proof against
submersion.
e) Standby generators must be provided to allow the plant to operate
independently of the mains supply.

IV) Noise Control

a) Adequate dampening of noise must be provided to meet minimum


stipulated requirements by the local Building By-laws, DOE and/
or other regulatory bodies. Silencers and acoustic enclosures shall
be provided where required to achieve the stipulated noise level
reduction.
b) Noise control measures shall be implemented to control the
generated noise level to below 65 dB at a distance of 2 m from
the boundary of the housed noise source.
c) General noise levels (measured in decibel units) must also be
measured 10 m from any point of the plant site within the nearest
public space or occupied space or both to an acceptable level
stipulated by the regulator.
d) Enclosures used to achieve these noise reductions shall permit
ready access to equipment for routine maintenance. Adequate air
ventilation shall be provided to allow cooling of the air inside
the enclosure to prevent over heating of the equipment/motors.

Sewage Treatment Plants Volume 4 181


Special Requirements

V) Process Type

The type of treatment process must be limited to systems that are easy
to operate and maintain for reasons of:
a) lower sludge yield and more stable sludge characteristics
b) lower operational and maintenance requirements

VI) Inlet Works

The design shall incorporate some means of controlling the influent


velocity to prevent:
a) excessive wear due to scouring effects
b) excessive head loss in the inlet
c) uncontrolled overflow of raw sewage
d) release of sewer gases

VII) Pre-treatment

a) The design must include a macerator to


i) reduce toilet waste and large solids into smaller and finer
particles,
ii) reduce the quantity of screenings
iii) improve the ease of handling.
b) Screening must be provided at 10 to 12 mm clear spacing to
remove fine particles.
c) A combined grit and grease removal system must be provided.

VIII) Confined Space Safety

a) Operators must:
i) attend a recognised confined spaces training course,
ii) obtain training certificates, and
iii) be certified competent to operate in such an environment.
b) Confined space areas within the plant site must be clearly
identified before handover for operation.
c) Confined space areas must be demarcated and warning notices
placed.
d) Confined space procedures must be established and followed by
operatives.

182 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

e) The following must be provided:


i) rescue sets of breathing apparatus
ii) gas detection equipment, preferably electronic, and serviced
regularly
f) The design of the treatment plant shall be subject to a Hazard
and Operability Review (HAZOP) exercise to identify and reduce
the potential risks under the following scenarios:
i) electrical failure
ii) blockage of inlet and outlet
iii) equipment failure including lighting and ventilation
iv) blockage of any pipework
v) flooding of external discharge point
vi) failure of building drainage system
g) The consequences of such failures to operators may include:
i) flooding
ii) explosion
iii) drowning
iv) falling into open voids
v) asphyxia
vi) poison
vii) nausea

IX) Odour Control

a) Isolate odorous gases from general ventilation exhausts by


containing identified odour generating sources with a separate
local exhaust system.
b) Containment of the odour sources shall be by installing lightweight
and corrosion resistant covers/enclosures designed for practical
operation and maintenance works.
c) The local exhaust odorous air shall be conveyed through well
designed and balanced ductworks by a centrifugal fan to an
effective odour treatment equipment.
d) Odour treatment equipment shall be selected such that odours
be reduced to the lowest possible level and in compliance with
the EQA.
e) The potential of odour generation, its impact and treatment, shall
be considered in all aspects of design.

Sewage Treatment Plants Volume 4 183


Special Requirements

X) Discharge Systems

Most basement plants will lie below the level of the running drain
levels. Therefore, it is essential to:
a) provide an effluent collecting sump prior to pumped discharge.
b) provide a check valve at the end of the discharge pipe to prevent
the backflow from the monsoon drain to the treatment plant.
c) provide a 100% redundancy of the discharge pumping
capacity.

XI) Flood Mitigation Measures

a) Provision must be made for the isolation of the treatment plant


from flooding by external sources.
b) A sump pump shall be provided.

XII) Operation and Maintenance Agreements


a) All treatment plants installed in basements of buildings must be
subject to an Operation and Maintenance Agreement. An example
of the standard Operation and Maintenance Agreement is given
in MSIG Volume 2.
b) All treatment plants located within buildings must be operated by
a fully licensed operator and will be subject to periodic checks
by the Commission to ensure compliance.

XIII) Occupational Safety and Health

a) All treatment plants shall be designed to comply with the


Occupational Safety and Health Act, 1994. Properly designed
treatment plants will enable the operator to safely handle the
treatment plant throughout its design life. A brief summary of
the contents of Act 514 is attached in Appendix A.

XIV) Sludge Handling

a) An aerated sludge holding tank shall be provided to keep the


sludge from going septic
b) Permanent pipe work with proper coupling and isolation valve
should be provided adjacent to the access gate for easy coupling
sludge tanker’s hose of hose for during desludging of the sludge
holding tank.
c) To provide sludge pump for desludging purpose.

184 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

XV) Sanitary and Plumbing facilities

a) To provide stand pipe for cleaning purposes. Waste water to be


channelled back to the inlet of plant.

XVI) Fire fighting system

a) To provide appropriate fire fighting systems in accordance to


Fire Department and other statutory requirements.

7.3 Fully Enclosed Treatment Plant


7.3.1 Definition

A fully enclosed plant is defined as a treatment plant that is designed


such that their treatment unit processes are located within dedicated
buildings.

A fully enclosed plant is to be equipped with additional features


and requirements to minimize adverse impact to the surrounding
environment.

Fully enclosed treatment plant shall comply with the following


criteria:

a) Must be located within a dedicated sewage treatment site.


b) Provide with appropriate architectural enclosures building.
c) No unit processes shall be located outside the enclosed buildings/
architectural enclosures.
d) Individual treatment unit process may be covered with a permanent
structure or housed in an enclosed building.
e) Provide appropriate landscaping to adequately screen the treatment
plant from other developments in the vicinity.

Appropriate architecture style, landscaping, architecture surrounding


the treatment plant and fencing type must be used.

7.3.2 General Requirements

When approved, fully enclosed treatment plants must comply with the
general requirements set out in Section 3, 4 and 5 of this Volume and
also specific requirements in this Section 7.3 for the following:

i) Provision of odour control


ii) Noise control and mitigation measures

Sewage Treatment Plants Volume 4 185


Special Requirements

iii) Minimize visual impact


iv) Avoid aerosol effects
v) Enhance safety, health and operability

I) Odour Control

The potential for odour generation, its impact and treatment, shall be
considered in all aspects of design.
The range of odorous constituents in such biogenic odours is very
wide and they include: hydrogen sulphide, ammonia, thiols and other
organic sulfur compounds, amines, indole and skatole, volatile fatty
acids and a wide range of organic compounds produced by anaerobic
fermentation.
Particular problems can be found at: Inlet works, primary tanks,
secondary treatment, sites for transfer, storage and treatment of raw
sludges and leakages.
A separate local exhaust system, for containment and exhaust of odorous
air to treatment, will isolate such odours from the general ventilation
system.
Odour treatment equipment shall be selected such that odour is reduced
to the lowest possible level and in compliance with the EQA.
Containment, exhaust and treatment shall be designed as an integrated
package.

II) Noise Control

Adequate dampening of noise must be provided to meet minimum


stipulated requirements by the local Building By-laws, DOE and/or other
regulatory bodies. Silencers and acoustic enclosures shall be provided
required to achieve the stipulated noise level reduction.
Noise control measures shall be implemented to control the generated
noise level to below 65 dB at a distance of 2 m from the boundary of
the housed noise source.
The general noise levels generated shall also be measured 10 m from any
point of the plant site within the nearest public space and/or occupied
space to an acceptable level stipulated by the appropriate regulators.
Enclosures used to achieve these noise reductions shall permit ready
access to equipment for routine maintenance. Adequate air ventilation
shall be provided to allow cooling of the air inside the enclosure to
prevent over heating of the equipments/motors.

186 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

III) Aerosol Effects

Aerosol is defined as a suspension of colloidal particles in gases/


atmosphere. Aerosol control measures are important because aerosol
affects the human respiratory system.
If uncontrolled, aerosol could present a health hazard to the operator and
residents due to the reduced buffer zone around the treatment plant.
Screens, open channels and aeration tanks, where violent and turbulent
actions are encountered, may release aerosol. The design of the treatment
plant shall take into consideration any unit processes that are likely to
emit aerosol and mitigating measures shall be undertaken to counter
aerosol release to the atmosphere.

IV) Safety, Health and Operability

The design of a fully enclosed treatment plant shall address safety,


health and operability aspects. The guidelines given for treatment plants
located within buildings in Section 7.2 shall be followed.

7.3.3 Specific Requirements

I) Covers for Treatment Unit Processes

The purposes of these covers are to contain odour emission at source


and to reduce visual impact.

The design requirements for treatment unit processes are outlined


below.

a) Covers to contain odour emission shall be provided at all potential


sources of odour generation for all unit processes located within
the sewage treatment works.
b) Bins used for the storage of screenings and grit collected in the
pre-treatment area shall be completely covered to reduce visual
impact, odour and to keep vectors away. The designer shall
provide further considerations on the size, type and method of
emptying the bins.
c) Generally, all unit processes shall be covered or housed within
a building enclosure. This shall include all pre-treatment units,
aeration tanks, and sludge treatment and handling facilities. The
only exception is the secondary clarifier.
d) The bin shall be located on a bunded, paved area adjacent to an
access road to the treatment plant.

Sewage Treatment Plants Volume 4 187


Special Requirements

e) The cover shall comply with BS EN 124 if subject to loading.


It shall also be designed to meet the operating condition of the
odour extraction system as well as the location and application
appropriation.
f) If the cover is exposed to the environment,
i) Plastic or fiberglass cover if used, must be manufactured
with UV inhibitor and will not warp or deform due to
weathering effect.
ii) Metal covers if used, must have appropriate corrosion
resistant coating in accordance to Section 4 of this
Volume.
iii) Where chipping might occurs at the edge of the cover,
stainless steel reinforcement frame on all sides of a plastic
or FRP cover shall be provided.
g) Coatings for the concrete and steel shall include coal tar, vinyls
and epoxies in accordance to Section 4.
h) Covers should be hinged and weigh less than 16 kg to enable
lifting unaided. Beyond a cover weight of 16 kg, assisted lifting
is required.
i) All unit processes with covers or are housed in a building for
odour and visual impact reduction shall be provided with proper
air extraction and air scrubbing system. These devices shall be
safe to operate and maintain. Odour, noise and visual impact,
and aerosol are the major components for consideration in the
design of an enclosed wastewater treatment plant. Windows
and access hatches that give the operator an extended and
uninterrupted view of the treatment process are mandatory for
all unit processes that are covered.
j) Covers shall be designed to allow for easy dismantling and easy
access for cleaning of the enclosed plant.
k) The materials used for the cover structure depend on the type of
cover selected and the characteristics of the odorous environment.
In general, the materials shall be selected to provide durability, ease
of maintenance, corrosion resistance and be relatively inexpensive.
The three most common materials used for containing odours
are concrete, aluminum and FRP. The design requirements for
each of these are outlined below.
i) Concrete
Concrete can support the greatest weight but limits the
plant maintenance worker’s ability to remove the cover
for major repairs. Concrete covers are subject to corrosion
and should be treated with a protective coating, such as
an epoxy resin.

188 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

ii) Aluminum

Aluminum covers provide the greatest tensile strength with


the thinnest cross-sectional area and can be placed on a
light weight frame. The lightweight nature and thin cross-
sectional area of aluminum makes it easier to remove and
store the covers during maintenance operations.
Aluminum covers are generally less expensive than FRP and
concrete, but periodic maintenance in the form of an anodised
coating is necessary to help prevent corrosion. The design
of an aluminum cover shall consider the incompatibility of
aluminum with concrete and other metals. If not, disintegration
of the materials occurs and the structural integrity of the
system could be jeopardized.
iii) FRP

FRP is light weight and generally can be removed by


plant operator and stored during maintenance operations.
FRP covers also offer resistance to corrosion, but require
periodic maintenance with an ultraviolet inhibitor to enhance
durability, particularly, if exposed to sunlight on a prolonged
basis.

II) Ventilation system

Ventilation systems are required to supply fresh air for workers to


work in a more comfortable environment and to minimise health and
safety concerns.

All covered unit processes must have proper ventilation systems.

a) An exhaust ventilation system shall be provided with air distribution


patterns that effectively purge work areas.
b) For waste areas that workers must enter, both blowing and
drawing air shall be used to eliminate dead spots.
c) Areas designed for personnel entry must include relief systems
to avoid overpressure conditions. Designers must estimate cover
system leakage to determine fan capacity.
d) Force air ventilation systems should be inspected and tested
periodically to ensure proper air flow and air distribution.
e) Ventilation of enclosed plants can be either intermittent or
continuous. However, intermittent ventilation is not recommended
because it has a lower degree of safety and more difficult to
operate and maintain than continuous ventilation. Continuous
ventilation is typically more expensive to operate because of
higher electricity costs for running the blowers. Intermittent

Sewage Treatment Plants Volume 4 189


Special Requirements

ventilation typically requires a higher rate of ventilation. For


example, the wet well and grit removal facility requires 12 air
exchanges for continuos ventilation versus 30 air exchanges for
intermittent ventilation.
f) The requirement in Section 6 shall be refer for the design of
exchange rate. If the work site is classified as a confined space,
workers without proper respiratory equipment must not occupy
spaces that cannot be ventilated to less than 25% of the permissible
exposure limit (PEL) of the contaminant and less than 10% of
the lower explosive limit (LEL). For example, hydrogen sulfide
which is one of the most common contaminants in enclosed areas
exposed to wastewater has a ceiling concentration of 30 mg/m3
(20 ppm).
g) Combustible alarms set at a percentage of the LEL and ventilation
failure alarms should be installed in wet wells, screen rooms,
or other enclosed areas where a volatile atmosphere could exist.
These alarms must have both audible and visual indicators to
alert workers that the area is now potentially dangerous as well
as alerting those who are about to enter the problem area.
h) Before entering the enclosed plant, where there is potential for a
hazardous atmosphere to exist, the operator and/or worker must
be able to test for oxygen deficiency, and combustible and toxic
gases or vapors.
i) Ventilation systems shall be designed on the basis that the
potential odourous gases have been isolated and contained by
the local exhaust system for odour control.
j) Ventilation design criteria for work space are as follows:
i) Avoid positioning supply and exhaust registers at equal
elevations and on the same enclosure wall. This will
prevent short-circuiting the ventilation system and creating
dead zones (areas with no apparent ventilation or air
motion).
ii) Equip the makeup air supply and exhaust registers with
volume dampers to control the airflow rate. Makeup air
supply should be less than what is exhausted to create
negative air pressure within the enclosure.
iii) A duty and standby ventilation system are mandatory.
The standby shall be 100% that of duty.
iv) An external visual indicator, such as green/red light, to be
provided outside the enclosed plant to warn of ventilation
systems failure.

190 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

k) The design of the ventilation system shall take into account


the noise aspects. Generally, the design work shall include for
sound insulating material, resilient mountings or other appropriate
devices to ensure that the plant runs without noise or vibration
in its final installed position. Noise level from machinery shall
not exceed the level stipulated by the regulators.

III) Odour Control System

a) Isolate odorous gases from general ventilation systems by


containment of identified odour generating sources with a separate
local exhaust system.
b) Containment of the odour sources shall be by installing lightweight
and corrosion resistant covers/enclosures designed for practical
operation and maintenance works.
c) Local exhaust rates for containment shall be designed to provide a
negative pressure, prevent build up of toxic, corrosive or explosive
gases and include provision for process air or air displaced by
changes in the level of liquid inside the covered space.
d) The local exhaust odorous air shall be conveyed through well
designed and balanced ductworks by a centrifugal fan to effective
odour treatment equipment.
e) The overall performance of the odour control system shall
comply with the requirements of the Department of Environment
(DOE).
f) In situations where specific gases such as hydrogen sulphide and
ammonia are significantly present, consideration shall be given
for the installation of a pre-scrubber unit upstream of the main
odour treatment equipment.
g) Effective odour treatment equipment to be a minimum 90%
removal efficient.
h) Consideration must be given to the life span of the odour control
system and associated costs in operating and maintaining such
a system.

IV) Vent Stack

The vent stack shall at a minimum 5 m above ground level to ensure


sufficient dispersion of air. Where the stack is located adjacent to a
building, it should be located at least 1 m above the roof line of this
building.

Sewage Treatment Plants Volume 4 191


Special Requirements

V) Noise Level

All mechanical equipment that are likely to generate noise such as


blowers, compressor and pumps, shall be acoustically isolated to ensure
the noise generated are contained and reduced to below the levels
stipulated by the regulators.

VI) Sludge Handling

a) Due to the compactness of the site, it is not conceivable to have


sludge drying beds in an enclosed environment.
Instead, an aerated sludge holding tank shall be provided to
prevent the sludge from turning septic. Sand drying beds (either
covered or otherwise) are not an acceptable form of sludge
treatment in an enclosed plant.
b) Permanent pipework with female coupling and isolation valve
should be provided adjacent to the access gate for easy coupling
of tanker’s hose during desludge of the holding tank.

VII) Treatment Process Type

It is preferred that treatment in an enclosed environment employs extended


aeration activated sludge because it offers greater process stability and
less potential for generating odours. However, other treatment processes
warrant further considerations if proven that they have other distinct
advantages in an enclosed environment.

VIII) Siting of Plant

a) The enclosed plant needs to be located away from driveways


to allow for regular maintenance of the screens, grit and grease
removal units and wet well of pump stations. If this is not
possible, then bollards shall be erected to protect the workers
while maintaining the plant.
b) Where plants are located within the premise of a private property,
direct vehicle access is to be provided from the public road to
the plant via a gate in the perimeter fence.

IX) Groundwater Conditions

a) Adequate provision must be made to resist the uplift of the


structure due to hydrostatic ground water pressures. The side
and bottom walls shall be designed to withstand the anticipated
hydrostatic pressures.

192 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

b) The top of the plant shall be located at least 150 mm above the
finished surface level to prevent the inflow of surface run off
into the enclosed plant.
c) Good perimeter drainage is to be provided to ensure that the
plant is not flooded.

X) Installation and Removal

Installation and the subsequent removal of all mechanical and electrical


equipment need to be taken into account during the design of the cover.
The following requirements must be carefully catered for:

a) Adequate space for servicing must be provided in the design of


the enclosed plant.
b) If the installation and/or removal of the equipment require the
service of a crane or any lifting vehicle, then access must be made
available within the treatment plant for these lifting vehicles.
c) An adequate number of access covers and sizes of openings for the
removal and installation of the equipment shall be provided.
d) The design of an enclosed plant must allow for the plant to be
fully operational during the installation and/or removal of any
equipment. Alternatively, provisions for temporary bypass should
be accommodated to prevent disruption to the sewage flow while
this work is being carried out.
e) In situations where it is not possible to readily install a duty
and standby unit, the standby unit can be supplied as a separate
item which is kept in store, provided that the faulty unit can be
removed and the spare unit can be installed within two hours by
general maintenance workers using normal tools.

XI) Mechanical and Electrical Requirements

The wiring, lighting and other electrical or mechanical equipment and


appliances that have the potential to generate sparks that may trigger
an explosion shall be designed and installed to meet the relevant safety
codes to avert the possibility of an explosion.

XII) Building Plan Approval

If a building structure is used to house the enclosed treatment plant,


then the design of this building must comply with the requirements
stipulated by the relevant Building By-Laws.

Sewage Treatment Plants Volume 4 193


Special Requirements

7.4 Covered and Buried Treatment Plants


7.4.1 Definition

Covered and buried treatment plants refer to treatment plants with covers
that are placed below ground or not more than 1.2 m above ground level.
Covers are provided to reduce the odour, noise and visual impact.

This type of plant is only applicable to Class 1 and Class 2 sewage


treatment plant with treatment capacity no more than 5000 PE. Special
approval by the Commission must be obtained if the plant capacity
exceeds 5000 PE. A compromised buffer zone of 10 m minimum from
the fence to the nearest building boundary line must be provided for
this type of plants. However, the height of the structure is normally
limited to 1.2 m above ground.

7.4.2 General

Covered and buried treatment plants have inherent hazard and restriction
in operability in their actual operation and maintenance. The requirements
in the following sections serve to highlight the minimum improvements
that must be made to these plants in addition to those set out in Section
3, 4, 5 and 6 of this Volume.

7.4.3 Specific Requirements for Covered or Buried Plants of 5,000 PE


or Less

I) Openings of Covered and Buried Tanks

The design of these tanks must allow for adequate openings so that
the operator can carry out routine operation and maintenance works
in a safe, efficient and effective manner. These requirements apply to
all unit processes that are covered or buried from the inlet works to
the effluent chamber. Staggered square openings of roughly 600 mm
x 600 mm employed in the past for plants of this nature would not be
acceptable. These openings, as a minimum, must be opened top around
the periphery of the tank.

II) Access for Routine Operations and Maintenance of the


Plant

The designer must take into account the confined space and other related
safety issues for entry into such a tank. Provision of proper access into
each individual tank is mandatory. Where the depth exceeds 2.5 m,
steps with intermediate landings must be included. Other requirements,
such as adequate ventilation prior to tank entry, must be considered and
provided in the design.

194 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

III) Pipework and Aeration System Requirements

Piping for buried plant shall be exposed and accessible for ease of
maintenance. PVC pipes are not allowed.

The aeration system (diffuser) must be retrievable from top opening


without emptying the tank.

VI) Lighting

Adequate lighting must be provided through adequate opening at the


top of these covered or buried tanks to provide a good view of the
treatment process such as the air diffusion system, screening, degritting
and secondary clarification. This is important for daily plant operations
through visual inspection of the individual unit process and routine
maintenance of the plant.

V) Hand Railings

Hand railing provisions must be made to prevent falling into open spaces.
These hand rails must be provided on the perimeter of the open tanks
and further enhanced with kick plates.

VI) Desludging Activities

Adequate access within the proposed treatment plant site is to be made


available to allow for desludging tankers to be within the reach of the waste
activated sludge storage tanks without undue difficulty of maneuvering
the vehicle or damaging the buried tanks or pipe works.

VII) Labeling of Treatment Unit Process

Labeling of each treatment unit is to be provided, from the inlet works


to the secondary clarifiers, to avoid confusion with the similar geometry
and sizes used for most treatment units.

VIII) Noise Control

Due to the compromised buffer requirements and proximity to adjacent


developments, the potential for noise pollution is accentuated. The designer
must ensure all noise generating mechanical and electrical equipment
within the treatment plant must be contained and treated acoustically to
meet compliance to existing noise levels stipulated by the Department
of Environment and that set out in Section 4.

IX) Ventilation

Adequate ventilation must be made available to allow for the safe routine
operation and scheduled maintenance of the treatment plant. During

Sewage Treatment Plants Volume 4 195


Special Requirements

design, this ventilation aspect must be considered. The type of ventilation,


portable or permanent, must also be determined during design stage.

X) Odour Control

Odour Control systems to be provided as required in compliance to the


EQA.

XI) Buoyancy Effects

The designer must account for the buoyancy effects in the design of buried
or covered tanks. This effect is of concern during high groundwater
conditions and emptying of the tank content during desludging works.
Furthermore, the designer must ensure that the design of these tanks
accounts for the hydrostatic force exerted on the floor from the outside
does not exceed the compressive strength of these covered or buried
tanks. This is to prevent any breakthrough of the floor and subsequent
failure of the tank.

The designer must ensure that the design of these tank at worse case
scenario where the tank is fully emptied. This is to prevent any breakthrough
of the floor and subsequent failure of the tank.

XII) Covers

Covers if employed for odour, visual and noise impacts shall be subjected
to the following requirements:
a) Lifting may be unaided if the covers are hinged and weigh less
16 kg.
b) Assisted lifting is required if the covers weigh equal to or above
16 kg.
c) The cover shall comply with BS EN124 loading requirements.
d) If the cover is exposed to the environment,
i) Plastic or fibreglass cover if used, must be manufactured with
UV inhibitor and will not warp or deform due to weathering
effect.
ii) Metal covers if used, must have appropriate corrosion resistant
coating in accordance to Section 4 of this Volume.
iii) Where chipping might occurs at the edge of the cover,
stainless steel reinforcement frame on all sides of a plastic
or FRP cover shall be provided.

XIII) Fencing

Adequate fencing must be provided for all plants. Adequate security


shall be provided against unauthorised access.

196 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

7.5 Guidelines for Homestead Developments

7.5.1 Single Developments up to 30 Units or 150 PE in Total

Individual septic tanks may be allowed for single developments of up


to 30 units or 150 PE in total.

Septic tanks will be regarded as temporary treatment plants.

The owner must provide all septic tanks as part of the owner’s infrastructure
works.

Septic tanks must be constructed to standard design in compliable with


MSIG Volume 5.

7.5.2 Single Developments Over 30 Units in Total With Average


Housing Density Greater Than Five Units per Hectare

For single developments over 30 units in total with an average housing


density greater than 25 persons per hectare, a sewer reticulation and a
communal treatment plant must be provided.

The treatment plant may be classified as permanent.

Sewer reticulation must be appropriately designed to achieve acceptable


hydraulic conditions within topographic and routing parameters.

7.5.3 Single Developments Over 30 Units in Total with Average


Housing Density Less Than Five Units per Hectare

For single developments over 30 units in total and with an average


housing density of less than 25 persons per hectare, a sewer reticulation
and a communal treatment plant is preferred.

The treatment plant may be classified as permanent.

Where the terrain of the development is such that if a communal system


is constructed it will require the construction of too many intermediate
pump stations, then individual treatment facilities may be considered,
subject to the following conditions:

i) The individual system must be a system approved by the


Commission.
ii) Where the ground conditions permit, soakaway trenches must
be used for disposal of the final effluent from the treatment
systems.

Sewage Treatment Plants Volume 4 197


Special Requirements

iii) Developers shall ensure that home owners enter into an agreement
with the supplier of the systems or licensed contractors, to carry
out operation and maintenance of the system as per design
requirements.
iv) Tanks shall be desludged by the Service Licensee as per terms
of the agreement signed between the Services Licensee and the
Commission.
v) The Commission and DOE may impose stringent conditions, if
they believe that such measures are required to ensure that the
sewage from the development will not result in an adverse impact
on the environment.

All septic tanks shall be designed in accordance with the requirements


in MSIG Volume 5.

7.6 Non-Compliance with Standards


7.6.1 Introduction

This section describes the types of incidents, which are outside the
control of the operator that may cause a sewage treatment plant to fail its
effluent consent. Generally, the more sophisticated the treatment process,
the more a process is at risk of failure from one of these incidents. It
would be unreasonable to expect the operator of the treatment plants to
perform within the effluent quality standards following such incidents.
However, the operator must always use his best endeavours to rectify
the situation as soon as practicable following such an incident.

The following potential incidents are treated as special cases when


meeting absolute compliance with Standard A or Standard B.

7.6.2 Types of Incident’s that Can Cause Treatment Plant Failure

I) Power Interruption

An interruption in the power supply to a treatment plant will cause


failure in all mechanical treatment processes.

Some large treatment plants have emergency generators which can be


brought on stream to ensure inlet pumping continues.

However, the crude sewage will pass through the plant receiving only
rudimentary treatment and will probably fail to comply with Standard
A and Standard B.

Furthermore, all existing sewage treatment plants have to be restarted


manually once they are tripped through power failure.

198 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

On new works, all treatment plants will be fitted with auto-restart facilities
for immediate resumption of operation when power is reconnected.

II) Lightning

When buildings or cabinets housing electrical control equipment are struck


by lightning, fail safe surge protection equipment trips all mechanical
equipment.

This requires all the equipment to be reset and switched on again. On


an unmanned plant there will be a delay between the trip-out following
the lightning strike and the operators getting to the plant to reset the
equipment.

During this period the plant may fail to comply with the relevant
standards.

III) Storm and Flood

During periods of very heavy rain, areas of the local sewer network may
suffer such ingress of storm water that surcharge of the sewer system
will result, causing abnormally large flows to arrive at the STP inlet.

Under these conditions, the treatment plant would receive much higher flows
than that designed for and would suffer severe hydraulic overloading.

The effect would be a rapid wash through of sewage and solids causing
the works to fail to meet standards.

IV) Major Mechanical Breakdown

In many existing sewage treatment plants, particularly the small ones,


insufficient standby equipment has been provided by the developer.

All new plants must be equipped with standby units having an automatic
change over system in the event of failure.

Existing plants may be out of action for several days while repairs are
carried out to failed equipment. To help alleviate this problem, the operator
needs to carry critical spare parts to help speed the repair process.

V) Vandalism, Theft and Criminal Damage

If a treatment plant is subject to this form of interference, then the


treatment process is at risk until the necessary repairs are carried out.

Reasonable measures must be taken to deter vandalism.

Sewage Treatment Plants Volume 4 199


Special Requirements

VI) Deliberate Discharge of Toxic Chemicals

From time to time, irresponsible industrialists may discharge chemical


waste to the sewer in contravention of all the relevant legislation.

This may occur as a one-off dumping exercise, or may be the result


of a small continuous discharge from a trade process which affects the
treatability of the sewage and causes the treatment plant to fail.

VII) Accidental Discharge of Strong Loads or Toxic


Substances

From time to time, genuine accidents occur on industrial premises or


on the highway that result in abnormal discharges to the sewer. These
may take the form of serious fires at industrial premises, the sudden
failure of large storage tanks or a major traffic incident involving the
transport of liquid products.

Such discharges to the sewer system would almost always result in the
sewage treatment plant failing to comply until the effects of the discharge
have passed through the system.

VIII) Major Blockages in the Sewer Network System

A blockage in the main sewer network system often causes the sewage
to build up behind the blockage and turn septic.

The sudden release of this large volume of septic sewage by the clearance
of the blockage, may cause temporary overloading of the treatment plant
and lead to a reduction in effluent quality beyond the absolute standard
for a short period of time.

IX) Defect

Completed treatment plant to be inspected by competent personal. Visual


inspection to be conducted during the final stage of construction. Two
type of defect generally detected during inspection :

a) Minor Defect
Non-critical, do not immediately or unduly affect the performance
of the plant but nevertheless, require attention to rectify faults
within reasonable time frame.
b) Major Defect
Critical or serious and require immediate action to be taken in
rectifying faults, impair plant performance, unit processes, or
system components.

200 Volume 4 Malaysian Sewerage


Industry Guidelines
Special Requirements

Consultant’s responsibility to ensure compliance of the design standard


and good engineering practice.

7.7 Energy Saving

In selection of treatment process or equipment, the designer should


consider the best product which minimized the power consumption for
process and major plant equipment without compromising on the quality
of treatment discharge.

7.8 Recycle and Reuse

a) To promote/encourage designer to look into potential of energy


reuse.
b) To utilize the recycle water (reclaim water) for cleaning and
landscaping purposes,
c) To promote and encourage design to identify potential of sludge
reuse and/or recycle.

Sewage Treatment Plants Volume 4 201


Special Requirements

202 Volume 4 Malaysian Sewerage


Industry Guidelines
Section 8

Package Sewage
Treatment Plant
Package Sewage Treatment Plant

204 Volume 4 Malaysian Sewerage


Industry Guidelines
Package Sewage Treatment Plant

8.1 Definition
A package sewage treatment plant is a form of treatment plant both for fixed
film and suspended growth processes. It shall consist of a prefabricated
biological treatment system and be limited to the development of the
sewage treatment system between the ranges of 150 to 5000 populations
equivalent (PE).

The package sewage treatment plant is only applicable to Class 1 and


Class 2 STP as defined in Section 4 of this Guidelines. The prefabricated
biological treatment system shall have been given approval by the
Commission prior to the application.

The major components of a package sewage treatment plant are:

I) Inlet works
a) Primary screen.
b) Pump Station (if applicable).
c) Secondary screen.
d) Grit and grease chambers.

II) Biological treatment system


a) Balancing Tank.
b) Aeration/Anoxic Tank.
c) Clarifier.
d) Sludge Holding Tank.
e) Aeration System including blower house.
f) Sludge Dewatering System.

III) Outlet works


a) Disinfection that can be physical, chemical or radiation.

Package sewage treatment plants fall under the category of covered/


buried treatment plants.

8.2 Land Area Requirement


The land area requirements for package sewage treatment plants shall
comply with those recommended for Class 1 and Class 2 Plants in Section
2 of this Guidelines.
The net area does not include the 10 m buffer zone surrounding each
plant, but does include the 5 m set backs and access paths within the
plant.

Sewage Treatment Plants Volume 4 205


Package Sewage Treatment Plant

8.3 Design Requirement

a) All calculations regarding the inlet works, outlet works, biological


processes and hydraulics shall follow the design criteria as stipulated
in the Section 4 and Section 5 of this Guidelines.
b) All units of package sewage treatment plant and foundation shall
be designed to meet the extreme case scenario as follows:
i) When the tanks are fully emptied;
ii) During high groundwater conditions.
c) The structural design of a tank shall consider all factors that can
affect the strength and integrity of the tank, like soil conditions,
area of installation, etc. All tanks shall be structurally designed
to withstand the maximum earth load and hydrostatic pressure
equivalent to a backfill depth of 1 m.
d) All civil works of blower house, pump house and control panel room
shall be as recommended in Section 4 and 5 of this Guidelines.
e) The minimum design life span of the components of the package
sewage treatment plant shall be as Table 8.1 below:

Table 8.1 Minimum Design Life Span of Package Sewage


Treatment Plant Components
Component Design Life Span
Prefabricated tank and other structural
> 50 years
components
Civil > 50 years
Mechanical & Electrical 10 years

8.4 Components of Package Sewage Treatment Plant


8.4.1 Layout, Piping and Arrangement of Prefabricated Biological
Treatment System

The prefabricated biological treatment system shall be packaged in terms of


layout, piping, arrangement of the tanks and the biological processes.

The dimension of each tank shall be fixed for each model of the prefabricated
system. All these items shall not be changed once approved.

8.4.2 Prefabricated Tanks

The physical properties of the tanks for package plants shall meet the
material requirements for STP structures as stipulated in Section 4 of this
MSIG. The prefabricated tanks shall come as complete tanks, thus no

206 Volume 4 Malaysian Sewerage


Industry Guidelines
Package Sewage Treatment Plant
Package Sewage Treatment Plant

8.4.2 Prefabricated Tanks


welding, jointing, fabrication/moulding of tanks’ components is allowed
at The
site. physical
The routeproperties
for delivery of tanks
of the tanks shall be planned
for package plantsproperly, so as
shall meet the
notmaterial
to cause any damage to road facilities and harm to road users.
requirements for STP structures as stipulated in Section 4 of this
MSIG. The prefabricated tanks shall come as complete tanks, thus no
8.4.3 Process
welding,Treatment Units/Components
jointing, fabrication/moulding of tanks’ components is allowed at
site. The route for delivery of tanks shall be planned properly, so as not to
The following table provides the recommended number of tanks for each
cause any damage to road facilities and harm to road users.
unit process against the PE size. The effective volume consideration is
8.4.3 also incorporated
Process in the Units/Components
Treatment table.

The following table provides the recommended number of tanks for each
unit process against the P.E size. The effective volume consideration is also
incorporated in the table.
Table 8.2 Recommended Number of Tanks and Effective Volume
Table 8.2: Consideration
Recommendedfor Number
Various ofUnit
Tanks and Effective Volume
Processes
Consideration for Various Unit Processes

Max Number of Max Number of


Name of Tank Tanks Tanks
Tanks Effective Volume
PE ≤1 000 PE >1 000
Balancing 1 2
Tank

Aeration Tank 2 4

Anoxic Tank 2 4

Clarifier 2 4

Sludge 2 4
Holding Tank

Sewage Treatment Plants Volume 4 207


Sewage Treatment Plants Volume 4 191
Package Sewage Treatment Plant

Note: Low water level (LWL) is the minimum submergence level of the pumps
to protect it from damage. It is dependent on the type of the pumps, thus
the low water level shall be set according to the pump’s manufacturers
requirement Top Water Level (TWL) is the normal operating water level
with adequate freeboard provided.

8.5 Appurtenances
8.5.1 Piping system

8.5.1.1 General

a) The piping used shall be an approved product, supplied and


manufactured by a supplier/manufacturer approved by the Commission
and shall be suitable for the application.
b) The arrangement of the piping system and interconnection pipes
in the tanks shall not obstruct maintenance work of the equipment
in the tanks.
c) All the buried piping shall be properly bedded and supported with
the selected compacted fill material.
d) All the above ground piping shall have a minimum distance of
75 mm from the ground level.
e) It shall be provided with a proper pipe support and bracket. The
bracket shall be made of hot dipped galvanised steel.
f) The arrangement/layout of the above ground piping shall minimise
obstruction and maneuverability.
g) Any installation or assemblies of pipe support that is attached to
the prefabricated tank is not allowed.

8.5.1.2 Inlet and Outlet Pipes

All inlet and outlet pipes of the units of prefabricated biological treatment
system must be pre-fitted at the factory. On-site drilling for holes is
strictly prohibited. All jointing and pipe holes connection shall be factory
fabricated/moulded.

8.5.1.3 Aeration Pipes

a) The air distribution pipe used shall be rigid and can withstand
temperatures up to 150 ºC and pressures of 25% more than the
design pressure of the blower.

208 Volume 4 Malaysian Sewerage


Industry Guidelines
Package Sewage Treatment Plant

b) The air pipe from the blower to the process unit shall be above
ground.

8.5.1.4 Sludge Transfer Pipes

a) No thread union/coupling is allowed at the sludge transfer pump


piping. The connection shall be double flange with Grade 304
stainless steel bolt and nut.
b) No bending is allowed for the sewage distribution pipe. A chamber
shall be provided for any changing direction of the flow.

8.5.1.5 Effluent Pipes

The effluent discharge piping system that passes through/bypasses the


disinfection treatment facility shall be designed so as not to cause any
nuisance.

8.5.2 Pumping System

The pumps installed in the package system shall meet the requirements
as stated in Table 8.3 below:

Table 8.3 Technical Requirements of Pumping System


Sludge Transfer
Name of Pump Transfer Pump RAS/WAS Pump
Pump
Sludge Holding
Application Area Balancing Tank Clarifier
Tank
Minimum Throughlet 50 mm 50 mm 50 mm
Automatic control
Automatic control Manual control
Control by timer and
by float switch by timer
solenoid valve
1 duty for each
Number of Pump 1 duty, 1 standby 1 duty for each tank
tank
Mechanical PE < 1000 : Air lift
Mechanical
Submersible
Type of Pump Submersible PE ≥ 1000 :
Pump or Self
Pump Mechanical Pump
Priming Pump
Necessities Mandatory
All pumps shall be completely installed with duct foot, guide
Accessories
rail and lifting chain made of Grade 304 stainless steel.

Sewage Treatment Plants Volume 4 209


Package Sewage Treatment Plant

Note: 1) Non-submersible pumps shall be provided with parking bay with


shade.
2) The duct foot shall be installed and assembled at the factory. No
installation/assemblies at site are allowed except for the connection
of the transfer pipe and the guide rail. All fasteners of the duct
foot shall be watertight.

8.5.3 Diffuser

a) All diffusers must be supported from the tank base. A typical


drawing of the diffuser support is shown in Figure 8.1.
b) The diffuser shall not be bolted to the bottom of the tank.
c) The diffuser shall be removable and easy to re-install.

8.5.4 Flow Distribution Chamber

a) Distribution box shall be provided with adjustable features. A


typical drawing of the distribution box is shown in Figure 8.2.
b) The design and construction of the distribution chamber shall
prevent any sedimentation.

8.5.5 Manhole Cover/Inspection Chamber Cover

The manhole cover shall follow the requirements as in Table 8.4:

Table 8.4 Technical Requirements of Manhole Cover

Description FRP HDPE Ductile/Cast Iron

Size 600 mm x 600 mm or 600 mm diameter


Installation At any location on top of the tank except at assembly
joints, rib or reinforced ring location.
Load Bearing Capacity ≥ 3.5 kN/m2 (BS EN 12255-1:2002(E))
Maximum Deflection 10 mm or the span divided by 200, whichever is smaller
Limit (BS EN 12255-1:2002(E))
Class B 125 in accordance to BS EN 124:1994 or equivalent
Personnel Load 125 kN (fully walk-able) (BS EN 124:1994)
Design Safety Factor 4:1 for allowable stresses shall be met for all load
combinations (ANSI/ASCE 7-98)

210 Volume 4 Malaysian Sewerage


Industry Guidelines
Package Sewage Treatment Plant

Table 8.4 Technical Requirements of Manhole Cover (Continued)

Description FRP HDPE Ductile/Cast Iron

Temperature Range 27°C – 35°C (to incorporate thermal expansion and


contraction)
Standard colour Black Black Black
Coating Aliphatic acrylic - Epoxy coating of
polyurethane 200 µm
non-skid coating NA
- Hot dip galvanised
of 200 µm
Resin Corrosion
resistant
NA NA
general purpose
polyester
UV Protection Ultraviolet-light
inhibitors shall
Carbon black NA
be added to the
laminate

Note: 1. The collar of the manhole shall be raised with a minimum height
of 100 mm above ground level.
2. The cover shall be equipped with a frame support and hinge, and
attached to the manhole opening.
3. Each manhole cover must be properly labeled / marked for ease
of identification of the unit process of the system.
4. NA – not applicable

8.5.6 Anchor System Loading

The tank anchor system (straps, cables, turnbuckles, etc.) shall have
strength of at least 1.5 times the maximum uplift force of an empty tank
without backfill in place. All wire straps, cables and turnbuckles must
be made of Grade 304 stainless steel.

8.5.7 Landscaping

The landscaping of the sewage package system shall be in accordance


with those recommended in Section 6 of this Guidelines.

8.5.8 Odour Treatment

The odour treatment shall be incorporated into the package sewage treatment
plant and shall follow the requirements stipulated in Section 7.4.

Sewage Treatment Plants Volume 4 211


Package Sewage Treatment Plant

8.5.9 Ancillary Facilities

The requirement and criteria of other ancillaries such as lifting facilities,


road, water tank, stand pipe, etc shall be in accordance with the design
criteria as stipulated in Section 6 and special requirements in Section
7.4.

8.6 Marking and Labelling

Each tank shall at a minimum be marked with the following


information:
• Manufacture’s name or trademark
• Manufacturing serial number
• Manufacturing date (MM/YY)
• Diameter and Capacity
• Citation of the standard
The markings shall be printed and adhered to the tank.

212 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A

Tables
Appendix A - Tables

214 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A

Appendix A Tables
Table A1 Contaminants of Concern in Sewage Treatment
Table A2 Typical Composition of Untreated Domestic Sewage
Table A3 Major Biological Treatment Processes Used for Sewage Treatment
Table A4 Interim National River Water Quality Standards for Malaysia
Table A5 River Clarification
Table A6 The Occupational Safety and Health Act 514, 1994 – Brief
Summary of Contents
Table A7 Permissible limits for potentially toxic elements in soil
Table A8 Options for disposal of Sludge and reuse of biosolids

Sewage Treatment Plants Volume 4 215


Appendix A - Tables

Table A1 Contaminants of Concern in Sewage Treatment

Contaminants Reason for Concern

Suspended solids Suspended solids can lead to the development of sludge


deposits and anaerobic conditions when untreated sewage
is discharged in the aquatic environment.

Biodegradable Composed principally of proteins, carbohydrates and fats,


organics biodegradable organics are measured most commonly in
terms of BOD (biochemical oxygen demand). If discharged
untreated to the environment, their biological stabilisation
can lead to the depletion of natural oxygen resources and to
the development of septic conditions.

Pathogens Communicable diseases can be transmitted by the


pathogenic organisms in sewage.

Nutrients Both nitrogen and phosphorus, along with carbon, are


essential nutrients for growth. When discharged to the
aquatic environment, these nutrients can lead to the growth
of undesirable aquatic life. When discharged in excessive
amounts on land, they can also lead to the pollution of
groundwater.

Refractory organics These organics tend to resist conventional methods of


sewage treatment. Typical examples include surfactants,
phenols and agricultural pesticides.

Heavy metals Heavy metals are usually added to sewage from commercial
and industrial activities and may have to be removed if the
sewage is to be reused.

Dissolved inorganic Inorganic constituents such as calcium, sodium and sulphate


solids are added to the original domestic water supply as a result
of water use and may have to be removed if the sewage is
to be reused.

216 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A - Tables

Table A2 Typical Composition of Untreated Domestic Sewage

Concentration (mg/l)
Constituent
Strong Medium Weak
Solids, total 1200 720 350
Dissolved, total 850 500 250
Fixed 525 300 145
Volatile 325 200 105
Suspended, total 350 220 100
Fixed 75 55 20
Volatile 275 165 80
Settleable solids, ml/l 20* 10* 5*
Biochemical oxygen demand, 400 250 110
5 day, 20°C (BOD5, 20°C)

Total organic carbon (TOC) 290 160 80


Chemical oxygen demand (COD) 1000 500 250
Nitrogen (total as N) 85 40 20
Organic 35 15 8
Free ammonia 50 25 12
Nitrites 0 0 0
Nitrates 0 0 0
Phosphorus (total as P) 15 8 4
Organic 5 3 1
Inorganic 10 5 3
Chlorides 100 50 30
Alkalinity (as CaCO3) 200 100 50
Grease 150 100 50

* All values except settleable solids are expressed in mg/l.

Sewage Treatment Plants Volume 4 217


Appendix A - Tables

Table A3 Major Biological Treatment Processes Used for Sewage


Treatment

Type Common Name Use

Aerobic processes

Suspended Activated-sludge process Carbonaceous BOD removal (nitrification)


growth
Conventional (plug flow) Carbonaceous BOD removal (nitrification)
Continuous-flow stirred-tank Carbonaceous BOD removal (nitrification)
Step aeration Carbonaceous BOD removal (nitrification)
Pure oxygen Carbonaceous BOD removal (nitrification)
Modified aeration Carbonaceous BOD removal (nitrification)
Contract stabilisation Carbonaceous BOD removal (nitrification)
Extended aeration Carbonaceous BOD removal (nitrification)
Oxidation ditch Carbonaceous BOD removal (nitrification)
Sequencing batch reactor Carbonaceous BOD removal (nitrification)
Suspended-growth nitrification Nitrification
Aerated lagoons Carbonaceous BOD removal (nitrification)
Aerobic digestion Carbonaceous BOD removal (nitrification)
Conventional air Stabilisation, carbonaceous BOD removal
Pure oxygen Stabilisation, carbonaceous BOD removal
High-rate aerobic algal pond Carbonaceous BOD removal

Attached Trickling filters


growth
Low-rate Carbonaceous BOD removal (nitrification)
High-rate Carbonaceous BOD removal (nitrification)
Roughing filters Carbonaceous BOD removal
Rotating biological contactors Carbonaceous BOD removal (nitrification)
Packed-bed reactors Carbonaceous BOD removal (nitrification)

Combined Trickling filter, activated sludge Carbonaceous BOD removal (nitrification)


processes
Activated sludge, trickling filter Carbonaceous BOD removal (nitrification)

Anoxic processes

Suspended Suspended-growth denitrification Denitrification


growth

Attached Fixed-film denitrification Denitrification


growth
continued

218 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A - Tables

Table A3 (continued)

Type Common Name Use

Anaerobic processes

Suspended Anaerobic digestion Stabilisation, carbonaceous BOD removal


growth
Standard-rate, single-stage Stabilisation, carbonaceous BOD removal
High-rate, single-stage Stabilisation, carbonaceous BOD removal
Two-stage Stabilisation, carbonaceous BOD removal
Anaerobic contact process Carbonaceous BOD removal

Attached Anaerobic filter Carbonaceous BOD removal, stabilisation


growth (denitrification)
Anaerobic lagoons (ponds) Carbonaceous BOD removal (stabilisation)

Aerobic/anoxic or anaerobic process

Suspended Single-stage nitrification- Carbonaceous BOD removal, nitrification,


growth denitrification denitrification
Nitrification-denitrification Nitrification, denitrification

Attached Facultative lagoons (ponds) Carbonaceous BOD removal


growth

Combined Maturation or tertiary ponds Carbonaceous BOD removal


processes
Anaerobic-facultative lagoons Carbonaceous BOD removal
Anaerobic-facultative-aerobic Carbonaceous BOD removal
lagoons

Sewage Treatment Plants Volume 4 219


Appendix A - Tables

Table A4 Interim National River Water Quality Standards for


Malaysia

Classes*
Parameters (units)
II IIA IIB III IV V
Ammoniacal Nitrogen 0.1 0.3 0.3 0.9 2.7 >2.7
(mg/l)
BOD5 (mg/l) 1 3 3 6 12 >12

COD (mg/l) 10 25 25 50 100 >100


DO (mg/l) 7 5-7 5-7 3-5 <3 <1
PH 6.5-8.5 6-9 6-9 5-9 5-9 -
Colour (TCU) 15 150 150 - - -
Elect. Cond.# 1000 1000 - - 6000 -
(mmhos/cm)
Floatables N N N - - -
Odour N N N - -
Salinity# (0/00) 0.5 1 - - 2

Taste N N N - -
Total Diss. Solid# 500 1000 - - 4000
(mg/l)
Total SS (mg/l) 25 50 50 150 300 >300
Temperature (0C) - Normal - Normal - -
±2 ±2
Turbidity (NTU) 5 50 50 - - -
F. Colif. †(counts/100 10 100 400 5000 5000 -
ml)
Tot. Colif. (counts/100 100 5000 5000 (20 000)‡ (20 000)‡ > 50 000
ml)
50 000 50 000

N No visible floatable materials/debris, or no objectionable odour, or no objectionable


taste
* Classes are described on the following table
#
Related parameters, only one recommended for use

Geometric mean

Maximum not to be exceeded

220 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A - Tables

Table A5 River Clarification

Class Uses

I ♦ Conservation of natural environment


♦ Water supply I - practically no treatment necessary (except by
disinfection or boiling only)
♦ Fishery I - very sensitive aquatic species

IIA ♦ Water supply II - conventional treatment required


♦ Fishery II - sensitive aquatic species

IIB Recreational use with body contact

III ♦ Water supply III - extensive treatment required


♦ Fishery II - common, of economic value, and tolerant species
♦ Livestock drinking

IV Irrigation

V None of the above

Note: This data is adapted from the Water Quality Criteria and Standards for
Malaysia, Final Report July 1986, Department of Environment.

Sewage Treatment Plants Volume 4 221


Appendix A - Tables

Table A6 The Occupational Safety and Health Act 514, 1994 - Brief
Summary of Contents

Part No. Content

I Preliminary

II Appointment of Offices

III National Council for Occupational Safety and Health

IV General Duties of Employers and Self Employed Persons

V General Duties of Designers, Manufacturers and Suppliers

VI General Duties of Employees

VII Safety and Health Organisations

VIII Notification of Accidents, Dangerous Occurrence, Occupational Poisoning and


Occupational Diseases and Inquiry

IX Prohibition Against use of Plant or Substance

X Industry Codes of Practice

XI Enforcement and Investigation

XII Liability for Offences

XIII Appeals

XIV Regulations

XV Miscellaneous

The Occupational Safety and Health Act (OSHA) was enacted by the Parliament
in 1994. In general, it is an enabling law in that the duties, responsibilities,
penalties and guidelines are to be followed by each specific industry. The
following table provides an outline of OSHA.

Parts of OSHA have a specific target audience. For example, if the professional
is a designer, then Part V would be applicable with respect to Occupational,
Safety and Health in their design.

222 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix A - Tables

Table A7 Permissible limits for potentially toxic elements in soil

Parameters Limits (mg/kg)

Zinc 900

Copper 250

Nickel 150

Cadmium 12

Lead 1000

Mercury 4

Chromium 1000

Arsenic 150

Sewage Treatment Plants Volume 4 223


Appendix A - Tables

Table A8 Options for disposal of Sludge and reuse of bio-solids

Type of sludge/ Option for


Source/ Treatment
No Disposal or
by-product Process
Utilization
1 Liquid primary sludge and - Imhoff tanks D
septage - Primary and secondary
clarifiers
- Septic Tanks
2 Dewatered primary sludge - Drying beds C, D, I, S
and dewatered septage - Mechanical dewatering
equipment
3 Pond sludge - Oxidation ponds D, F, R
- Aerated lagoons
- Waste stabilization
ponds
4 Dewatered pond sludge - Drying beds C, D, F, I, R, S
- Mechanical dewatering
5 Digested sludge - Digesters D, F, R
- Sludge lagoons
- Anaerobic ponds
6 Dewatered digested sludge - Drying beds C, D, F, I, R, S
- Mechanical dewatering
7 Lime stabilised sludge - Lime stabilisation C, D, F, R, S
8 Compost product - Composting A, C, D, F, L, R, S
9 Thermally dried sludge - Thermal drying A, C, D, F, L, R,
(pellets/granules) S, SP
10 Incinerator ash - Incineration C, D, S, SP
NOTES:
A = Use in agriculture
C = Disposal to controlled dumpsites
D = Disposal to dedicated sludge disposal sites
F = Use in forestry/non-food crops
I = Incinerate
L = Use for landscaping at public amenity areas
S = Disposal to sanitary landfill sites
R = Use in rehabilitation of degraded
SP = Recycled into special product, e.g. building material

224 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix B

References
Appendix B - References

226 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix B - References

Malaysian Standards

♦ MS 29
Specification for aggregates from natural sources for concrete
♦ MS 144
Specification for cold reduced mild steel wire for reinforcement of concrete
♦ MS 145
Specification for steel fabric for the reinforcement of concrete
♦ MS 146
Specification for hot rolled steel bars for reinforcement of concrete
♦ MS 416
Code of practice for the use of structural steel in building
♦ MS 523
Specification for concrete including ready mixed concrete
Part 1 Guide to specifying concrete
Part 2 Methods for specifying concrete mixes
Part 3 Procedures to be used in producing and transporting concrete
Part 4 Procedures to be used in sampling, testing and assessing compliance of
concrete
♦ MS 739
Specification for hot-dip galvanised coatings on threaded fasteners
♦ MS 740
Specification for hot-dip galvanised coatings on iron and steel articles
♦ MS 822
Specification for sawn-timber foundation piles
♦ MS 1037
Specification for sulphate resisting portland cement
♦ MS 1195
Code of practice for structural use of concrete
Part 1 Design and construction
Part 2 Special circumstances
Part 3 Design charts for singly reinforced, doubly reinforced beams and
rectangular columns
♦ MS 1227
Specification for portland pulverised fuel ash cement
♦ MS 1228: 1991
Code of Practice for Design and Installation of Sewerage Systems

Sewage Treatment Plants Volume 4 227


Appendix B - References

♦ MS 1241
Specification for fibreglass water tanks - effective capacity of less than 2000
litres
♦ MS 1292
Specification for rubber seals – water stops for sealing joints in concrete
♦ MS 1387
Specification for ground granulated blast furnace slag for use with portland
cement
♦ MS 1390
Specification for glass-reinforced polyester panels and panel water tanks

British Standards

♦ BS 476
Fire tests on building materials and structures
♦ BS 1161
Specification for aluminium alloy sections for structural purposes
♦ BS 1615
Specifications for anodic oxidation coatings on aluminium.
♦ BS 3396
Woven glass fibre fabrics for plastics reinforcement
♦ BS 3532
Method of specifying unsaturated polyester resin systems
♦ BS 3749
Specification for E glass fibre woven roving fabrics for the reinforcement of
polyester and epoxy resin systems
♦ BS 4248
Specification for supersulfated cement
♦ BS 4848
Hot rolled structural steel sections
Part 2 Specification for hot finished hollow sections
♦ BS 4921
Specification for sherardized coatings on iron and steel
♦ BS 5493
Code of practice for protective coating of iron and steel structures against
corrosion

228 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix B - References

♦ BS 7079
Preparation of steel substrates before application of paints and related products
♦ BS 7123
Specification for metal arc welding of steel and concrete reinforcement
♦ BS 8118
Structural use of aluminium
Part 1 Code of practice for design
Part 2 Specification for materials, workmanship and protection

European Standard

♦ EN 10088
Stainless Steel
Part 1 List of Stainless Steels
Part 3 Technical delivery conditions for semi-finished products, bars, rods, wire,
sections and bright products of corrosion resisting steels for general
purposes

♦ EN 10029
Specification for tolerances on dimensions, shape and mass for hot rolled steel
plates 3 mm thick or above
♦ EN ISO 9445
Continuously cold-rolled stainless steel narrow strip, wide strip, plate/sheet and cut
lengths. Tolerances on dimensions and form
♦ EN 754
Aluminium and aluminium alloys. Cold drawn rod/bar and tube.
Part 1 Technical conditions for inspection and delivery
Part 2 Mechanical properties
Part 7 Seamless tubes, tolerances on dimensions and form
Part 8 Porthole tubes, tolerances on dimensions and form
♦ EN 755
Aluminium and aluminium alloys. Extruded rod/bar, tube and profiles.
Part 1 Technical conditions for inspection and delivery
Part 2 Mechanical properties
Part 3 Round bars, tolerances on dimensions and form
Part 4 Square bars, tolerances on dimensions and form
Part 5 Rectangular bars, tolerances on dimensions and form
Part 6 Hexagonal bars, tolerances on dimensions and form
Part 7 Seamless tubes, tolerances on dimensions and form
Part 8 Porthole tubes, tolerances on dimensions and form

Sewage Treatment Plants Volume 4 229


Appendix B - References

Part 9 Profile, tolerances on dimensions and form


♦ EN 1676
Specifications for aluminium and aluminium alloy. Alloyed ingots for remelting.
♦ EN 12373
Specification for aluminium and aluminium alloys. Anodizing.
Part 1 Method for specifying decorative and protective anodic oxidation coatings
on aluminium and its alloys.
♦ EN 10162
Specification for cold rolled steel sections. Technical delivery conditions. Dimensional
and cross-sectional tolerances.
♦ EN 13923
Filament-wound FRP pressure vessels. Materials, design, manufacturing and
testing.
♦ EN ISO 8503
Preparation of steel substrates before applications of paints and related products.
Surface roughness characteristics of blast-cleaned steel substrates.
Part 1 Specifications and definitions for ISO surface profile comparators for
the assessment of abrasive blast-cleaned surfaces.
♦ EN 10025
Hot rolled products of structural steels.
Part 1 General technical delivery conditions.
Part 3 Technical delivery conditions for normalized/normalized rolled weldable
fine grain structural steels.
Part 4 Technical delivery conditions for thermomechanical rolled weldable fine
grain structural steels
♦ EN ISO 2063
Thermal spraying. Metallic and other inorganic coatings. Zinc, aluminium and their
alloys.
♦ EN 14020
Reinforcements. Specification for textile glass roving.
Part 1 Designation
Part 2 Methods of test and general requirements
Part 3 Specific requirements
♦ EN 10210
Specification for hot finished structural hollow sections of non-alloy and fine grain
steels

230 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix B - References

Part 2 Tolerances, dimensions and sectional properties.

♦ EN 10296
Welded circular steel tube for mechanical and general engineering purposes. Technical
delivery conditions.
Part 1 Non-alloy and alloy steel tubes.
Part 2 Stainless steel

♦ EN 10297
Seamless circular steel tubes for mechanical and general engineering purposes.
Technical delivery conditions.
Part 1 Non-alloy and alloy steel tubes.

♦ EN 10305
Steel tubes for precision applications. Technical delivery conditions.
Part 1 Seamless cold drawn tubes
Part 2 Welded cold drawn tubes
Part 3 Welded cold sized tubes
Part 4 Seamless cold drawn tubes for hydraulic and pneumatic power
systems
Part 5 Welded and cold sized square and rectangular
Part 6 Welded cold drawn tubes for hydraulic and pneumatic power systems

♦ EN 14118
Reinforcements. Specification for textile glass mats. (chopped strand and continuous
filament mats).
Part 1 Designation
Part 2 Methods of tests and general requirements
Part 3 Specific requirements

♦ EN 10083
Specification for steels for quenching and tempering
Part 3 Technical delivery conditions for alloy steels

ASTM Standard

♦ ASTM D4097
Standard specification for contact-moulded glass-fibre-reinforced thermo set resin
corrosion-resistant tanks.

Sewage Treatment Plants Volume 4 231


Appendix B - References

♦ ASTM E84
Standard test method for surface burning characteristics of building materials.
♦ ASTM C582
Standard specification for contact-moulded reinforced thermosetting Plastic (RTP)
laminates for corrosion-resistant equipment.

AS Standard

♦ AS 3750.2
Paints for steel structures – Ultra high-build paint
♦ AS/NZS 3750.12
Paints for steel structures – Alkyd/micaceous iron oxide
♦ AS/NZS 2312
Guide to the protection of structural steel against atmospheric corrosion by the use
of protective coatings.

Other Reference Materials

♦ Buffer Guidelines for the Siting and Zoning of Industries, Department of


Environment
♦ Environmental Quality Act 1974
♦ Environmental Quality (Sewage and Industrial Effluents) Regulations,
1979
♦ Occupational Safety and Health Act, 1994 (OSHA)
♦ Water Quality Criteria and Standards for Malaysia, Final Report, July 1986,
Department of Environment
♦ Environmental Impact Assessment Guidelines for Municipal Solid Waste,
Sewage Treatment and Disposal Projects, Department of Environment.
♦ Factories and Machinery Act 1967 (Revised – 1974)
♦ Uniform Building By-Law (UBBL), 1984
♦ Town and Country Planning Act, 1976
♦ Sewerage Services Act 1993
♦ Water Services Industry Act 2006
♦ Electrical Act

232 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix B - References

Other Guidelines in This Set

The Malaysian Sewerage Industry Guidelines is comprised of 5 volumes:

♦ Volume 1 Sewerage Policy for New Developments


♦ Volume 2 Sewerage Works Procedures
♦ Volume 3 Sewer Networks and Pump Stations
♦ Volume 5 Septic Tanks

Sewage Treatment Plants Volume 4 233


Appendix C

Supervisory Control and Data


Acquisition System (SCADA)
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

236 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

C-1 Introduction: Overview


SCADA is the acronym for Supervisory Control And Data Acquisition, SCADA
or Human-Machine Interface (HMI). The system allows distributed input to be
continuously monitored without the intervention of an operator and allows supervisor
or operator (depending on security level) to remotely control of equipment operating
status.

Data acquisition begins at the Programming Logic Controller, PLC level and includes
meter readings and equipment statuses that are communicated to the SCADA as
required. Data is then compiled and formatted in such a way that a control room
operator using the HMI can make appropriate supervisory decisions that may be
required to over-ride normal PLC controls. (A SCADA system includes all the
pieces, HMI, controllers, I/O devices, networks, software, etc.).

SCADA systems typically implement a distributed database which contains data


elements called tag points. A tag point represents a single input or output value
monitored or controlled by the system. Tag points can be either “hard” or “soft”.
A hard point is representative of an actual input or output connected to the system,
while a soft point represents the result of logic and math operations applied to
other hard and soft points. The point values are normally stored as value-timestamp
combinations; the value and the timestamp when the value was recorded or calculated.
A series of value-timestamp combinations is the history of that point.

The SCADA provides a user-friendly front-end to a control system containing


programmable logic controller (PLC) that provide automated, pre-programmed control
over a process. This enables the SCADA system to gather data automatically and
remotely rather than manually and site in-situ.

A SCADA software can be linked to a database (normally SQL-Structured Query


Language), to provide instant trending, diagnostic data, scheduled maintenance
procedures, logistic information, detailed schematics for a particular sensor or
machine, and expert-system troubleshooting guides. Most major PLC manufacturers
have offered integrated HMI/SCADA systems, many of them using open and non-
proprietary communications protocols (such as MODBUS or Profibus).

In short, interfacing on of SCADA with PLC offers efficient monitoring and control
of process in a large installation site and with large number of distributed equipment
at a site. SCADA provide alarm notification, historical and on-line trending plots of
control parameters for effective process monitoring and control. SCADA system can
also be implemented with PPM schedule maintenance notification and reminder.

The SCADA that are installed at the remote sites can be linked to a Master Station
via communication system (Radio frequency or WIFI or other on-line communication
channels). The data from an equipment is collected via on-line data acquisition or,
unless otherwise allowed, on batch mode via data logging devices.

Sewage Treatment Plants Volume 4 237


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

The SCADA software can also activate alarm messaging to inform the operator
station for exceptional event (critical alarm) reporting. Remote Access Server (RAS)
features can provide for either via Internet or other dial-up method (fixed line and/
or wireless modem).

All the proposed SCADA software shall be scalable and flexible enough to allow the
integration of any additional SCADA controller in future expansion. It shall provide
with many industrial standard protocols to allow the user to integrate easily.

C-2 Purpose
This document will provide basic technical requirement for implementation of
integrated SCADA/HMI in sewerage system.

C-3 General Requirements


The SCADA system shall be scalable process control solutions designed to meet
the required automation needs in the sewerage industries. The system shall provide
the required level of performance, flexibility, ease of use, and low life-cycle cost
of ownership, making use of the following technology that includes:

The SCADA system shall be Window based client/server system and make use of
the following technologies: -

• Dynamic data caching, alarming, human machine interface, history collection,


and reporting functions;
• Web viewable, providing secure, advanced user interface HMI capabilities
based on an open industry standard html file format and Web Browser
access;
• Extensive list of communication interfaces;
• Secure Internet Browser based on-line documentation and support.

C-4 Architecture

The SCADA architecture shall be flexible and scalable to allow expansion requirements.
The basic architecture shall incorporate all but not limited to the followings:

• Standard based workstations;


• powerful Windows based server(s);
• Windows based clients;
• Industry communication standards shall follow IEEE specification;
• object-based configuration tools;

238 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

• controllers/remote terminal units;


• with power surge protection;
• Modem: digital or analog;
• Network switches or routers;
• Uninterrupted Power Supply (UPS);
• data logger & storage devices for continuous monitoring of operation in
the event of cessation of communication;

C-5 SCADA Requirement


The SCADA shall utilize all but not limited to the followings available technologies
and features:

• HMI Web – A web-based architecture that allows HMI and application


data which uses HTML display format to provide casual access of process
graphic displays.
• Real-time Database – a true Client/Server architecture where a real-time
database on the server provides data to a number of client applications
including:
o Operator stations
o Microsoft office applications (such as Microsoft Excel or Microsoft
Access)
o Internet explorer
• Open Systems – incorporates open technologies and standards including
SQL, ODBC, DDE, Visual Basic, and other OLE for process control.
• Infrastructure – in cooperate alarm/event management system; configure
reports, history collection and a variety of standard system trends.
• On-line documentation – provides users access to system information and
documentation.
• Interfaces – Data acquisition ability from a wide variety of remote terminal
units and controllers.

Other powerful supervisory control features include:

• Integrated detail displays, custom graphics, alarms, history, and reports


• Standard control functions
• Operator security
• Redundant Windows XP/server operation
• A common interface for SCADA and other control types such as Hybrid
Control
• Database and diagnostic integration with process and discrete controllers
• Graphical building tools
• Standard and user-definable application templates
• International system and local language support

Sewage Treatment Plants Volume 4 239


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

• Optional applications such as Alarm Pager interface, Downtime Analysis,


and statistical Process Quality Control

Standard facilities shall include but not limited to the followings:


• Windows based HMI

Multiple local and remote operator stations


Interface: TCP/IP, fieldbus, Modbus, Hart
• Support for redundant controller/RTU communications

Integration of multiple systems


Real-time data access for a wide variety of process connected devices
• Supervisory data acquisition and control of controllers and remote terminal
units
• alarm management
• Extensive historian and trending
• Flexible standard or customized reports
• Optional Live Video Capture integration
• Industry standard local and wide area network integration
• Secure data integration with third party applications
• ActiveX Document and Scripting support

C-6 Operator Interface


The operator interface station shall allow object based graphics to provide the
HMI for the user with object concern. The system shall employ industry de-factor
standards, such as Microsoft Windows, HTML and the Internet so as to minimize
operator training due to familiarity of operating environment.

Critical information is conveyed using dedicated enunciators for alarms, controller


communication failures, operator/controller messages and equipment downtime
conditions. A dedicated alarm line shows the most recent (or oldest) highest priority,
unacknowledged alarm at all times.

Software system displays shall include but not limited to the followings: -
• Menu/navigation displays
• Alarm summary
• Event summary
• Trends
• Operating groups
• System status displays
• Configuration displays
• Loop Tuning displays
• Diagnostic and maintenance displays
• Summary displays

240 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Optional Live Video integration shall provide remote viewing and viewing control
features.

Security software feature shall provide restricted access, no access and full access
(plant management).

Network access shall permit authorized operator stations on a network to share a


preconfigured number of connections to the system. This allows a number of users
on a network to access production data on off-line basis.

C-7 Database

The SCADA software shall but not limited to the following real-time database:
• Analog configuration parameters
• Digital configuration parameters
• Accumulator configuration parameters
• User defined configuration parameters

Each point in the database has a number of associated configurable parameters, all
of which can be referenced relative to a single ‘tag name’.

SCADA shall maintain the real time database that requires frequent high-speed
access as memory resident information and other less frequently accessed data as
disk resident data. Memory resident data is logged to data storage device every
specified time frame defined by the administrator to minimize the loss of data in
the event of loss of power.

C-8 Alarm/Event Management


The SCADA software System shall provide comprehensive alarm and event detection,
management, and reporting facilities. Alarm presentation of alarm / event management
shall include but not limited to the followings:

• Multiple alarm priorities


• Dedicated alarm zone
• Configurable alarm priority colors
• Associated display
• Audible alarms
• Alarm cutout
• Area assignment
• Operator log

Sewage Treatment Plants Volume 4 241


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

• Hierarchical alarming
• Alarm/event reporting
• Alarm/communication/ message/downtime annunciator
• Alarm priority escalation

The standard Alarm Summary display shall allow operators to focus on the problem
at hand by supporting filters. Alarms may be filtered by:

• Area or location or unit processes


• Acknowledge Status
• Priority

Colors for the various priority levels of alarms can be configured by the user for
display purposes in the Alarm Summary and on custom graphics. The recommended
color codes are provided in Appendix 1. The software shall support configuration
of alarm priority colors and display on all process graphic displays to enables
operators immediately determine critically of the alarm.

The alarm shall annunciate in the status zone blinks with the color of the highest
priority for unacknowledged alarm. The alarms configuration shall consist but not
limited to the followings:

• SPV Hi
• SPV Lo
• Transmitter Hi
• Transmitter Lo
• Trip
• Time out

With each of the configured alarms assigns a priority ranging from "Attention" -
acknowledge of non-critical alarm that required maintenance attention, "Responsive"
- action required with predefined period, "Urgent" - action required immediately.

The Alarm/Event summary shall list but not limited to the followings:
• Alarms
• Alarm Acknowledgments
• Return to normal
• Operator Control Actions
• Operator Login & Security Level Changes
• On-line Database Modifications
• Communications Alarms
• System Restart Messages

242 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

C-9 Historian
Historical trend shall provide wide range of sampling frequencies in both data-
point and average formats. The history trend intervals are shall be able to but not
limited to the following displays:
• second data-point of pre-defined scale
• minute data-point of pre-defined scale
• hour data-point of pre-defined scale
• minute-average of pre-defined scale
• hour-average of pre-defined scale
• day-average of pre-defined scale
• Month-average of pre-defined scale

The historical data is to be display in various formats describe herewith:


• Graphical trend plot displays (average, max, min, and other statically
format)
• Tabulation displays (average, max, min, and other statically format)
• Query databases of selected parameters.

C-10 Graphical Trending

Graphical trending configuration shall be able to configure by selecting the parameters


to be plot and its time-scales. Minimum trend types shall include but not limited
to the followings:
• Single and Multi bar graphs (selectable scales)
• Single and Multi-line trends plot (selectable scales)
• Multi-range trends plot (selectable scales)
• X-Y line and scatter trend plots (selectable scales)
• Mathematical plots (logarithm scale, moving average, etc)

Functions provided for analyzing and manipulating data include:


• Combination real-time/historical plots
• zooming, panning, and scrolling
• Configurable trend density
• Saving of trend plot and expert to various format (*.xls, HTML, XLM,
etc)
• clipboard copy/paste enable

Sewage Treatment Plants Volume 4 243


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

C-11 Report Format

The software shall provide but not limited to the following report formats:

• Alarm/Event Log reports - selectable time frame, filterable events and


alarms to enable traceability of alarm.
• Exportable Excel / Access format - able to save selected data/report format
to Microsoft Excel/Access format.
• Statistical data analysis format - generates reports of selectable statistical
functions such as Max/Min and standard deviation.
• Point Attribute Log - displaying specific attributes selectable from a
list.

Reports should be generated as required time frame (interval), event-driven, or on-


demand basis. Report may be directed to screen, printer, file, or directly to another
computer for analysis or viewing electronically.

C-12 Security
The SCADA software shall provide configurable security levels, control levels
and area assignments. These may be configured for each individual operator or
alternatively for each operator station. The security levels shall be able to configure
the following security levels:

Level 1:
Sign-on for View mode only
Level 2:
View only mode with alarm acknowledge
Level 3:
Level 2 plus control of field parameters
Level 4:
Level 3 plus field parameters of level 4, configure standard system
infrastructure such as reports
Level 5: Level 4 plus user configured field parameters
Level 6: Unlimited access

Operator sign-on/sign-off shall be logged. Any actions initiated by an operator are


logged in the Event database with the operator identifier. In addition any control
actions to a given point is only allowed if the control level configured in the
operator profile exceeds the level assigned to the point.

Logon password shall not be less than 6 alphanumeric characters and shall be
encrypted. Operators may change own passwords; however, new password shall
not be the same as the last 10 passwords used in the previous 3 months. Three
unsuccessful attempts of logon shall lock the operator out for a lock-out period.
Once logged on, an operator can log off at any time or will be automatically signed
off after a defined period of inactivity.

244 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Area assignments limit operator access to graphics, alarms and point data to assigned
areas, providing effective plant partitioning. Individual operator profiles, including
security levels, control levels and area assignments, are activated when operators
sign on to the system. In addition, area profiles can be created enabling plant areas
to be enabled or disabled for control, between certain time and date criteria.

C-13 Scripting
The software shall have the VB or VBA scripting language enable to allow user to
create script that will run when a display is active or scripts can also be attached
to server objects like point parameters, alarm events, report completion and other
events.

C-14 Interfaces
SCADA software provides Data Acquisition and Control facilities to communicate
with a wide range of controllers and Remote Terminal Units (RTUs). The controllers
connection type shall comply with the following communication protocol:

Serial / TCP/IP / ControlNet / Modbus+ / ASCII / TCP/IP / Ethernet

Data Acquisition –supports acquisition of data using either:


Periodic Scanning

C-15 Distributed Server Architecture


Distributed Server Architecture is integrated processes when there are multiple control
stations, or for segmenting control across units, providing the ultimate flexibility
for both operations and control. Distributed Server Architecture also provides the
maximum flexibility for geographically distributed sites.

C-16 Web Server


SCADA software shall provide Web Server capability to provide integration
mechanism for plant-centric operational information. Based on the SCADA software
Distributed Server Architecture, a web server bridges the Process Control and
Enterprise domains, dynamically tracking the “pulse” of the enterprise. Web server
brings many benefits to the end user:

• Isolation of non-critical enterprise functions from the process control


system
• Consolidated business system integration to/from many SCADA software
systems

Sewage Treatment Plants Volume 4 245


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

• Consolidation of casual users’ accounts and licenses in one location


• Cross-system reporting
• Minimal engineering requirements

C-17 Digital Video Monitoring

The software may have optional Digital Video Monitoring that integrates digital
video controls and storage with the software to assist in process monitoring. Some
of the features are:

• Remote monitoring of unmanned sites


• Integration with SCADA software, providing event-based capture and
storage of video images
• Event-activated, user-activated, and scheduled recording
• Ability to search stored video, based on SCADA software events
• Scalability from 4 cameras to more than 1,000 cameras.

The DVM shall base on open system hardware that digitizes video from standard
video cameras and transports the video to SCADA software clients anywhere on
the network for real-time viewing.

C-18 Integrated Maintenance Management

Integrated Maintenance Management (IMM) delivers computerized maintenance management


system (CMMS) – completely integrated with SCADA software. IMM shall deliver but
not limited to the following key benefits:

• More efficient preventive and predictive maintenance


• Reduced downtime of critical plant equipment
• Effective work scheduling
• Automated creation of work orders from SCADA software events and data
values

IMM enables the automated creation, assignment, tracking and closing of maintenance
work orders. If required, work orders can also be manually raised. This is all
managed from either your IMM SQL server database with full access available
through the open Web-based interface of IMM.

246 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

C-19 Application Report

The SCADA software shall have the capability to produce but not limited to the
following reports:

• Batch Report
• Downtime analysis
• Schedule maintenance
• Statistical Process & Quality Control (SPQC)
• Event archiving
• Alarm messaging (SMS or pager)

Batch Reporting –integrated reporting of batches process data, to be compiled


and archived by the SCADA software. The batch reports either as a CSV file or
Microsoft Excel, if available.

Downtime Analysis –to detect, record and code any equipment breakdowns or process
delays to provide plant downtime analysis. A list of all current downtime events is
maintained as well as the history of previous downtime events, with each assigned
a category and a reason code. Downtime reports may be printed periodically or
on-demand, showing downtime duration sorted by categories and reasons.

Schedule Maintenance –allows supervisory control to schedule at a specified time.


The maintenance report of the equipment is to be reported.

Statistical Process & Quality Control (SPQC) - generates statistical report of average
(of specified time period) of the real-time data collected by the system.

Event Archiving –archiving events logged data by the system that based on sampling
frequency and storage capacity.

Alarm Messaging – reports the alarm messages sent designated supervisors. The report
shall incorporate summary of alarm messages by alarm type and supervisors.

C-20 Application Programming Interface

Application programming interface (API) shall be provided for interfacing with


SCADA software server and the client network based.

The API (programmed in C/C++(visual) or programmed in VB (Visual Basic)) on


the server includes the following functions:

• read and write to control module parameters in the database


• access to historical data

Sewage Treatment Plants Volume 4 247


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

• initiate supervisory control actions


• access to the alarm/event subsystem
• access to user-defined database
• provide a prompt for operator input
• create alarms/events

C-21 User Documentation

SCADA software documentation shall be made available in three basic forms:


• Electronic On-line Documentation using HTML Internet Browser
• On-line Help (F1 function key from within applications)
• Printed documentation

C-22 Specifications and Sizing


SCADA software Client/Server Specifications

Basic Server Workstation Specifications

Processor Pentium Processor (Latest version)


Memory 1 GB
Hard Disk Size 200 GB
Display Resolution 1024 x 768, 65K colors
Operating System (Minimum) Microsoft Windows (Latest edition)
Network Protocols TCP/IP

Basic Client Workstation


Specifications

Processor Pentium Processor (Latest version)


Memory 1 GB
Hard Disk Size 200 GB
Display Resolution 1024 x 768, 65K colors
Operating System (Minimum) Microsoft Windows NT (Latest
Network Protocols edition)
TCP/IP, NFS

248 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

SCADA software Server Performance

Operational Display Update

Maximum Continuous Display Update Rate 1 sec

Typical Field Change to Display Update Time with < 2 sec


100 Parameters Per Display on a Single Station/
Server

Typical Display Call Up Time with 100 Parameters < 2 sec


on a Single Station/Server (call up time is dependent
on display complexity; this excludes the first initial
call up)

SCADA Storage Sizing

Standard Default Default Maximum Storage Capacity


Sampling Duration Samples Duration (maximum no. of
Rate samples)

1 minutes 24 hours 1441 69 days 100 000

6 minute 7 days 1682 416 days 100 000


average

1 hour 7 days 170 11.4 years 100 000


average

8 hour 3 months 281 91.2 years 100 000


average
24 hour 1 year 368 273.8 years 100 000
average

Sewage Treatment Plants Volume 4 249


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Attachment C - 1: Color Coding for Equipment Status

Status/Alarm Color & Blinking


Notes of Event
Event State Status
Running Green (Non-Blinking) Equipment is in operating
status

Standby Red (Non-Blinking) Equipment is in standby


operating status

Off Red (Blinking) Equipment is “Off” or “Manual”


mode.

Trip Amber (Blinking): Equipment “Tripped” due to the


followings reasons:
1) ELR detection;
2) PSR detection;
3) Over-current;
4) Over-heated motor;
5) MCB Trip;
SP High Level Yellow (Non-Blinking) Alarm event of high level than
set point

SP Low Level Light Blue (Non- Alarm event of lower level than
Blinking) set point

Transmitter Hi Yellow (Blinking) Alarm event due to transmitter


high (<=4mA) value.

Transmitter Lo Light Blue (Blinking) Alarm event due to transmitter


low (<=4mA) value.

Time Out Amber (Blinking) Alarm due to time out by PLC


timer or other timer.

250 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Attachment C - 2: SCADA Control and Monitoring Function


Requirement

Description Analog (A)/


Description of Monitoring of Control Digital (D)
SCADA Control /
Item

Point Point
Monitoring

Qty
(For Each Equipment) (For Each

AO

DO
AI

DI
Equipment)
Instrumentation        
Panel
Instrumentation Panel - Local Indicator 1     1  
  Instrumentation Panel - Remote Indicator 1     1    
Instrumentation Panel - Battery
  Indicator 1 1        
Low
  TNB Power (kWh meter) Data Record 1 1        
                 
  PLC System              
  PLC (battery Low) Measure 1 1       Alarm Low (Fault Report)
  Battery Charger Indicator 1     1   Alarm (Fault Report)
                 
  Penstock              
  Penstock Panel: Manual Switch Indicator 1     1    
  Penstock Panel: Auto Switch Indicator 1     1    
IP open close RTU via RS-485 Serial Link
  Penstock Position Actuator (%) 1        
control Alarm - High torque
  Penstock - Fully Open Indicator 1     1    
  Penstock - Fully Close Indicator 1     1    
Remote
  Penstock - To Open / To Close 1       1  
Control
  Penstock - UPS Low Indicator 1 1        
                 
UPS (battery Low) Inlet
  Measure 1 1        
Penstock
                 
  Primary Coarse Screen              
  Screen - Run Indicator 1     1   Counter - Number of start / stop
  Screen - Trip Indicator 1     1   Alarm (Fault Report)
  Screen - Auto Mode Indicator 1     1    
  Screen - Manual Mode Indicator 1     1    
Remote
  Screen - To Start / Stop 1       1  
Control
Reset of Hour-
  Screen - Run-hour record 0         Software counter running hours
Run meter
Control Start / Stop operation by
  Differential Level : Upstream Indicator 1 1      
diff. level
Differential Level :
  Indicator 1 1       Ref level for upstream.
Downstream
                 
  RSP Pumps              
  Pump - Run Indicator 1     1   Record number of Start / stop
  Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Pump - Off (MCCB) Indicator 1     1   Record non-operation hours
Remote Start/
  Pump - To Start / Stop 1       1 Software control / PLC
Stop
Reset of Hour-
  Pump - Run-hour record 0         Software counter running hours
Run meter
  Pump - Ampere Reading 1 1       Record when operation
  Pump - Voltage Reading 1 1       Record when operation

Sewage Treatment Plants Volume 4 251


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Digital (D)
Description of
Description of Monitoring
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

  Pump - Soft Starter Amp/Volt Parameters Setting


1 1       RJ45 / RS485
Comm. / Review
                 
  Float level              
  US Level Level
measurement 1 1        

  Float Level - L0 On/Off Indicator 1     1   Cut-off operation


  Float Level - L1 On/Off Indicator Control Start / Stop operation
1     1  
by diff. level
  Float Level - L2 On/Off Indicator Control Start / Stop operation
1     1  
by diff. level
  Float Level - L3 On/Off Indicator Control Start / Stop operation
1     1  
by diff. level
  Float Level - L4 On/Off Indicator Control Start / Stop operation
1     1  
by diff. level
                 
  Float Level - L0 Fault Indicator For fault identification (Alarm
1       1
Fault report)
  Float Level - L1 Fault Indicator For fault identification (Alarm
1       1
Fault report)
  Float Level - L2 Fault Indicator For fault identification (Alarm
1       1
Fault report)
  Float Level - L3 Fault Indicator For fault identification (Alarm
1       1
Fault report)
  Float Level - L4 Fault Indicator For fault identification (Alarm
1       1
Fault report)
                 
  Sump Pump / Dewatering  
           
Pump
  Pump - Run Indicator 1     1   Record number of Start / stop
  Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Pump - Off (MCCB) Indicator 1     1   Record non-operation hours
  Pump - To Start / Stop Remote Start /
1       1 Software control / PLC
Stop
  Pump - Run-hour record Reset of Hour-Run
0         Software counter running hours
meter
                 
  Ampere / Volmeters              
  Pump - Ampere Reading 1 1       Record when operation
  Pump - Voltage Reading 1 1       Record when operation
  Float level              
  Float Level - L0: ON / OFF Indicator 1     1   Cut-off operation
Control Start / Stop operation
  Float Level - L1: ON / OFF Indicator 1     1  
by diff. level
  Float Level - L0 Fault Indicator 1       1 For fault identification
  Float Level - L1 Fault Indicator 1       1 For fault identification
                 
  Secondary Fine Screen              
  Screen - Run Indicator 1     1   Record number of Start / stop
  Screen - Trip Indicator 1     1   Alarm (Fault Report)
  Screen - Auto Mode Indicator 1     1    
  Screen - Manual Mode Indicator 1     1    
  Screen - To Start / Stop Remote Control 1       1  

252 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Digital (D)
Description of
Description of Monitoring
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

Reset of Hour-Run
  Screen - Run-hour record 0         Software counter running hours
meter
                 
Mechanical Differential Level : Control Start / Stop operation
  Indicator 1 1      
Upstream by diff. level
Mechanical Differential Level :
  Indicator 1 1       Ref level for upstream.
Downstream
                 
  Screenings Conveyor              
  Screen c/v - Run Indicator 1     1   Record number of Start / stop
  Screen c/v - Trip Indicator 1     1   Alarm (Fault Report)
  Screen c/v - Auto Mode Indicator 1     1    
  Screen c/v - Manual Mode Indicator 1     1    
  Screen c/v - To Start / Stop Remote Control 1       1  
Software counter / Interlock
Reset of Hour-Run
  Screen c/v - Run-hour record 0         with screen operation with delay
meter
off.
                 
  Screenings Wash Water Pumps              
  Wash-water Pump - Run Indicator 1     1   Record number of Start / stop
  Wash-water Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Wash-water Pump - Auto Mode Indicator 1     1    
Wash-water Pump - Manual
  Indicator 1     1    
Mode
Wash-water Pump - To Start /
  Remote Control 1       1  
Stop
Software counter / Interlock
Wash-water Pump - Run-hour Reset of Hour-Run
  0         with screen operation with delay
record meter
off.
                 
  Grit / Grease System              
  Grit Blower - Run Indicator 1     1   Record number of Start / stop
  Grit Blower - Trip Indicator 1     1   Alarm (Fault Report)
  Grit Blower - Auto Mode Indicator 1     1    
  Grit Blower - Manual Mode Indicator 1     1    
  Grit Blower - To Start / Stop Remote Control 1       1  
Software counter / software
Reset of Hour-Run
  Grit Blower - Run-hour record 0         Timer control operation by
meter
rotation.
  Grit Pump : On Indicator 1     1   Record number of Start / stop
  Grit Pump : Trip Indicator 1     1   Alarm (Fault Report)
  Grit Pump - To Start / Stop Remote Control 1       1  
Software counter / software
Reset of Hour-Run
  Grit Pump - Run-hour record 0         Timer control operation by
meter
rotation.
  Grit Classifier : On Indicator 1     1   Record number of Start / stop
  Grit Classifier : Trip Indicator 1     1   Alarm (Fault Report)
  Grit Classifier - To Start / Stop Remote Control 1       1  
Software counter / software
Reset of Hour-Run
  Grit Classifier - Run-hour record 0         Timer control operation by
meter
rotation.
  Grit Auger : On Indicator 1     1   Record number of Start / stop
  Grit Auger : Trip Indicator 1     1   Alarm (Fault Report)

Sewage Treatment Plants Volume 4 253


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Digital (D)
Description of
Description of Monitoring
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

  Grit Auger - To Start / Stop Remote Control 1       1  


Software counter / software
Reset of Hour-Run
  Grit Auger - Run-hour record 0         Timer control operation by
meter rotation.
                 
  Grit Drum Screen : On Indicator 1     1   Record number of Start / stop
  Grit Drum Screen : Trip Indicator 1     1   Alarm (Fault Report)
Grit Drum Screen - To Start /
  Remote Control 1       1  
Stop
Software counter / software
Grit Drum Screen - Run-hour Reset of Hour-Run
  0         Timer control operation by
record meter rotation.
                 
  Auxiliary              
  LV System              
Main LV Board Main Breaker
  Indicator 1     1   Status
: ON
Main LV Board Main Breaker :
  Indicator 1     1   Alarm (Fault Report)
TRIP (Earth Fault)
Main LV Board Main Breaker :
  Indicator 1     1   Alarm (Fault Report)
TRIP (Over Current)
Main LV Board Main Breaker :
  Reading 1 1       Record
Ampere
Main LV Board Main Breaker :
  Reading 1 1       Record
Voltage
Room Temperature Monitoring
  Reading 1 1        
/ Alarm
  Bus Couple : ON Indicator 1     1    
  Bus Couple : OFF Indicator 1     1    
  kWHr Meter: Reading 1 1       Record
                 
  HT System              
  HT Income Panel VCB : ON Indicator 1     1   Status
HT Income Panel VCB: TRIP
  Indicator 1     1   Alarm (Fault Report)
(Earth Fault)
HT Income Panel VCB: TRIP
  Indicator 1     1   Alarm (Fault Report)
(Over Current)
  HT Income Panel VCB: Ampere Reading 1 1       Record
  HT Income Panel VCB: Voltage Reading 1 1       Record
  Battery Charger Indicator 1 1       Record (Alarm fault)
  Battery Low Indicator 1 1       Record (Alarm Low)
Room Temperature Monitoring
  Reading 1 1       Record / Alarm (High)
/ Alarm
  kWHr Meter Reading 1 1       Record
                 
  Transformer System              
  Transformer Temperature Alarm Indicator 1 1       Record / Alarm (High)
  Transformer Pressure Alarm Indicator 1 1       Record / Alarm (High)
                 
  CO2 System              
TNB Room: CO2 Panel
  Indicator 1     1   Record / Alarm (activated)
Activated
Switch Gear: CO2 Panel
  Indicator 1     1   Record / Alarm (activated)
Activated
Transformer Room: CO2 Panel
  Indicator 1     1   Record / Alarm (activated)
Activated

254 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Description of Digital (D)
Description of Monitoring
Control Point
Item
Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

  Main Switch Room: CO2 Panel Indicator


1     1   Record / Alarm (activated)
Activated
  MCC Room: CO2 Panel Indicator
1     1   Record / Alarm (activated)
Activated
  Gen Set- CO2 Panel Activated Indicator 1     1   Record / Alarm (activated)
  CO2 Panel DC supply Battery Indicator
1 1       Record / Alarm (activated)
Low
                 
  Gen Set System              
  Gen Set - Run Indicator 1     1   Record number of Start / stop
  Gen Set - Trip Indicator 1     1   Alarm (Fault Report)
  Gen Set - To Start / Stop Remote Start /
1       1 Software control / PLC
(Remote) Stop
  Gen Set - To Stop (Remote) Remote Start /
1       1 Software control / PLC
Stop
  Gen Set - Run-hour record Reset of Hour-Run
1         Software counter running hours
meter
  Gen Set -Battery Charge Indicator 1     1   Record / Alarm (Fault)
  Gen Set -DC Battery Low Indicator 1     1   Record / Alarm (Low)
  Gen Set -Diesel Fuel oil low Indicator 1     1   Record / Alarm (Low)
  Surge Vessel Compressors  
           
System
  Air Compressor - Run Indicator 1     1   Record number of Start / stop
  Air Compressor - Trip Indicator 1     1   Alarm (Fault Report)
  Air Compressor - Auto Mode Indicator 1     1    
  Air Compressor - Manual Mode Indicator 1     1    
  Air Compressor - To Start / Stop Remote Control 1       1  
Air Compressor - Run-hour Reset of Hour-Run
  0         Software counter running hours
record meter
  Surge Vessel Level Indicator Level Measure 1 1        
  Surge Vessel Pressure Indicator Pressure Measure 1 1        
                 
  Force Ventilation: Grit System              
  Fan : Manual Indicator 1     1    
  Fan : Auto Indicator 1     1    
  Fan : ON / OFF Indicator Status & Software counter
1     1  
running hours
  Fan : Trip Indicator 1     1   Alarm (Fault Report)
  Fan : To Start / Stop Remote Start /
1       1  
Stop
                 
  Gas Scrubber System              
  Scrubber Fan : Manual Indicator 1     1    
  Scrubber Fan : Auto Indicator 1     1    
  Scrubber Fan : ON / OFF Indicator Status & Software counter
1     1  
running hours
  Scrubber Fan : Trip Indicator 1     1   Alarm (Fault Report)
  Scrubber Fan : To Start / Stop Remote Start /
1       1  
Stop
                 
  Aeration Blower              
  Blower - Run Indicator 1     1   Record number of Start / stop
  Blower - Trip Indicator 1     1   Alarm (Fault Report)
  Blower - Off (MCCB) Indicator 1     1   Record non-operation hours

Sewage Treatment Plants Volume 4 255


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Description of Digital (D)
Description of Monitoring
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

  Blower - To Start / Stop Remote Start /


1       1 Software control / PLC
Stop
  Blower - VSD Parameters Speed Control 1 1       RTU via RS-485 Serial Link
  Blower - Run-hour record Reset of Hour-Run Software counter / software
meter 0         Timer control operation by
rotation.
  Blower - Ampere Measure 1 1       Record when operation
  Blower - Voltage Measure 1 1       Record when operation
                 
  Temperature Sensor              
  Blower - Temperature Measure 1 1       Record & Alarm (High Temp)
  Air Flow Meter              
  Air Flow Meter Measure 1 1       Record & Alarm (low level)
                 
  Force Ventilation: Blower  
           
Room
  Fan : Manual Indicator 1     1    
  Fan : Auto Indicator 1     1    
  Fan : ON / OFF Indicator Status & counter no. of start /
1     1  
stop
  Fan : Trip Indicator 1     1   Alarm (Fault Report)
  Fan : To Start / Stop Remote Start /
1       1  
Stop
  Fan : Run-Hour record Reset of Hour-Run Software counter / software
meter 1         Timer control operation by
rotation.
                 
  D.O. Meter              
  D.O. Meter Measure Record / Control Speed &
1 1      
Alarm (Low)
                 
  Anoxic Mixer              
  Anoxic Mixer - Run Indicator Status & counter no. of start /
1     1  
stop
  Anoxic Mixer - Trip Indicator 1     1   Alarm (Fault Report)
  Anoxic Mixer - Off (MCCB) Indicator 1     1   Record non-operation hours
  Anoxic Mixer - To Start / Stop Remote Start /
1       1 Software control / PLC
Stop
  Anoxic Mixer - Run-hour record Reset of Hour-Run
0         Software counter
meter
  Anoxic Mixer - Ampere Measure 1 1       Record when operation
  Anoxic Mixer - Voltage Measure 1 1       Record when operation
                 
  Primary or Secondary Clarifier              
  Clarifier - Run Indicator Status & counter no. of start /
1     1  
stop
  Clarifier - Trip Indicator 1     1   Alarm (Fault Report)
  Clarifier - Off (MCCB) Indicator 1     1   Record non-operation hours
  Clarifier - To Start / Stop Remote Start /
1       1 Software control / PLC
Stop
  Clarifier - Run-hour record Reset of Hour-Run
0         Software counter
meter
  Clarifier - Ampere Measure 1 1       Record when operation
  Clarifier - Voltage Measure 1 1       Record when operation

256 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Description of Analog (A)/


Description of Monitoring Digital (D)
Control Point
Item Point
(For Each SCADA Control /

Qty

AO

DO
(For Each Equipment)

AI

DI
Equipment) Monitoring
Status & counter no. of start /
  Pump - Run Indicator 1     1  
stop
  Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Pump - Off (MCCB) Indicator 1     1   Record non-operation hours
Remote Start /
  Pump - To Start / Stop 1       1 Software control / PLC
Stop
Reset of Hour-Run
  Pump - Run-hour record 0         Software counter
meter
  Pump - Ampere Measure 1 1       Record when operation
  Pump - Volt Measure 1 1       Record when operation
                 
  Sludge Flow Meter              
  RAS/WAS Flow Rate Meter Measure 1 1       Record
  RAS/WAS Flow Rate Totalizer Measure 1 1       Record
                 
  Flow Meter System              
Flow Meter
  Measure 1 1       Record
(Data record of flow rate)
  Flow Meter (Totalizer) Measure / Reset 1 1       SCADA Software Accumulator
                 
  Gravity Thickener              
Status & counter no. of start /
  G. Thickener - Run Indicator 1     1  
stop
  G. Thickener - Trip Indicator 1     1   Alarm (Fault Report)
  G. Thickener - Off (MCCB) Indicator 1     1   Record non-operation hours
Remote Start /
  G. Thickener - To Start / Stop 1       1 Software control / PLC
Stop
Reset of Hour-Run Software record of running
  G. Thickener - Run-hour record 0        
meter hours
  G. Thickener - Ampere Measure 1 1       Record when operation
  G. Thickener - Voltage Measure 1 1       Record when operation
                 
Thickened Sludge Digester Feed
               
Pump: Primary & Secondary
Status & counter no. of start /
  Feed Pump - Run Indicator 1     1  
stop
  Feed Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Feed Pump - Off (MCCB) Indicator 1     1   Record non-operation hours
Remote Start /
  Feed Pump - To Start / Stop 1       1 Software control / PLC
Stop
Reset of Hour-Run Software record of running
  Feed Pump - Run-hour record 0        
meter hours
  Feed Pump - Ampere Measure 1 1       Record when operation
  Feed Pump - Voltage Measure 1 1       Record when operation
Speed control : RTU via RS-485
  Feed Pump - VSD Parameters Speed Control 1 1      
Serial Link
                 
  Sludge Flow Meter              
  Sludge Feed Flow Rate Meter Measure 1 1       Record
  Sludge Feed Flow Rate Totalizer Measure 1 1       Record
                 
  Gas Blower              
Status & counter no. of start /
  Gas Blower - Run Indicator 1     1  
stop
  Gas Blower - Trip Indicator 1     1   Alarm (Fault Report)
  Gas Blower - Off (MCCB) Indicator 1     1   Record non-operation hours

Sewage Treatment Plants Volume 4 257


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Description of
Description of Monitoring Digital (D)
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring
Remote Start / Speed control : RTU via RS-485
  Gas Blower - VSD Parameters 1 1      
Stop Serial Link
Reset of Hour-Run Software record of running
  Gas Blower - Run-hour record 0        
meter hours
  Gas Blower - Ampere Measure 1 1       Record when operation
  Gas Blower - Voltage Measure 1 1       Record when operation
                 
  Temperature Sensor              
  Gas Blower - Temperature Measure 1 1       Record & Alarm (High)
  Gas Flow Meter              
  Gas Flow Meter Measure 1 1       Record
                 
  Digester Gas Detector Meters              
Record & Alarm (Detection &
  H2S Meter at Dewatering House Measure 1 1      
Fault)
Record & Alarm (Detection &
  Methane Gas Meter Measure 1 1      
Fault)
Record & Alarm (High-Low &
  PVRV Sensor Meter Measure 1 1      
Fault)
  Internal Digester Gas Analyzer Measure 1 1       Record & Report
                 
  Floating Roof Gas Holder              
Record & Alarm (High-Low &
  Floating Roof Level Measure 1 1      
Fault)
  High Lever Alarm Indicator 1     1   Alarm (High)
  Low Lever Alarm Indicator 1     1   Alarm (Low)
Record & Alarm (High-Low &
  PVRV Sensor Meter Measure          
Fault)
                 
  Gas Flare System              
Gas Control Actuator Valve: Full
  Indicator 1     1   Record & Timer
Open
Gas Control Actuator Valve: Full
  Indicator 1     1   Record & Timer
Close
Gas Control Actuator Valve:
  Indicator 1     1    
Manual
Gas Control Actuator Valve:
  Indicator 1     1   Program Control operation
Auto
Status & counter no. of start /
  Gas Control Actuator Valve: ON Indicator 1     1  
stop
Gas Control Actuator Valve:
  Indicator 1     1   Alarm (Fault Report)
TRIP
Gas Control Actuator Valve: To Remote Start /
  1       1 Software control / PLC
Turn Clockwise Stop
Gas Control Actuator Valve: To Remote Start /
  1       1 Software control / PLC
Turn Counter-Clockwise Stop
                 
Record & Alarm (flame
  Pilot Light Igniter Indicator 1     1  
distinguished)
  Flare Igniter : Manual Indicator 1     1    
  Flare Igniter : Auto Indicator 1     1   Program Control operation
  Flare Igniter : ON Indicator 1       1 Program Control operation
Record & Alarm (flame
  Flare Indicator Indicator 1     1  
distinguished)
                 
  Pressure Indicator: Inlet Measure 1 1       Record & Report Fault
  Pressure Indicator: Discharge Measure 1 1       Record & Report Fault
                 
  Sludge Feed Pump to Belt Press              
  Belt Press Feed Pump - Manual Indicator 1     1    

258 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Digital (D)
Description of
Description of Monitoring
Control Point
Item
Point
(For Each SCADA Control /

Qty

AO

DO
(For Each Equipment)

AI

DI
Equipment) Monitoring

  Belt Press Feed Pump - Auto Indicator 1     1   Program Control operation


Status & counter no. of start /
  Belt Press Feed Pump - Run Indicator 1     1  
stop
  Belt Press Feed Pump - Trip Indicator 1     1   Alarm (Fault Report)
Belt Press Feed Pump - Off
  Indicator 1     1   Record non-operation hours
(MCCB)
Belt Press Feed Pump - To Start/ Remote Start /
  1       1 Software control / PLC
Stop Stop
Belt Press Feed Pump - Run-hour Reset of Hour-Run Software record of running
  0        
record meter hours
  Belt Press Feed Pump - Ampere Measure 1 1       Record when operation
  Belt Press Feed Pump - Voltage Measure 1 1       Record when operation
Belt Press Feed Pump - VSD Speed control : RTU via RS-485
  Speed Control 1 1      
Parameters Serial Link
                 
  Belt Press Compressors System              
  Air Compressor - Run Indicator 1     1   Record number of Start / stop
  Air Compressor - Trip Indicator 1     1   Alarm (Fault Report)
  Air Compressor - Auto Mode Indicator 1     1   Program Control operation
  Air Compressor - Manual Mode Indicator 1     1    
Air Compressor - To Start/Stop/
  Remote Control 1       1 Software control / PLC
Stop
Air Compressor - Run-hour Reset of Hour-Run
  0         Software counter running hours
record meter
                 
  Sludge Cake Conveyor              
  Screen c/v - Run Indicator 1     1   Record number of Start / stop
  Screen c/v - Trip Indicator 1     1   Alarm (Fault Report)
  Screen c/v - Auto Mode Indicator 1     1   Program Control operation
  Screen c/v - Manual Mode Indicator 1     1    
  Screen c/v - To Start / Stop / Stop Remote Control 1       1  
Software counter / Interlock
Reset of Hour-Run
  Screen c/v - Run-hour record 0         with screen operation with delay
meter
off.
                 
Belt Backwash Washwater
               
Pumps
  Washwater Pump - Run Indicator 1     1   Record number of Start / stop
  Washwater Pump - Trip Indicator 1     1   Alarm (Fault Report)
  Washwater Pump - Auto Mode Indicator 1     1   Program Control operation
  Washwater Pump - Manual Mode Indicator 1     1    
Washwater Pump - To Start /
  Remote Control 1       1 Software control / PLC
Stop / Stop
Software counter / Interlock
Washwater Pump - Run-hour Reset of Hour-Run
  0         with screen operation with delay
record meter
off.
                 
  Polymer Preparation Unit              
  Polymer Mixing - Run Indicator 1     1   Record number of Start / stop
  Polymer Mixing - Trip Indicator 1     1   Alarm (Fault Report)
  Polymer Mixing - Auto Mode Indicator 1     1   Program Control operation
  Polymer Mixing - Manual Mode Indicator 1     1    
  Polymer Mixing - To Start / Stop Remote Control 1       1 Software control / PLC

Sewage Treatment Plants Volume 4 259


Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Analog (A)/
Digital (D)
Description of
Description of Monitoring
Control Point
Item

Point
(For Each SCADA Control /
(For Each Equipment)

Qty

AO

DO
AI

DI
Equipment) Monitoring

Software counter / Interlock


Polymer Mixing - Run-hour Reset of Hour-Run
  0         with screen operation with
record meter
delay off
                 
  Polymer Dilution Skid - Run Indicator 1     1   Record number of Start / stop
  Polymer Dilution Skid - Trip Indicator 1     1   Alarm (Fault Report)
Polymer Dilution Skid - Auto
  Indicator 1     1   Program Control operation
Mode
Polymer Dilution Skid - Manual
  Indicator 1     1    
Mode
Polymer Dilution Skid - To Start/
  Remote Control 1       1 Software control / PLC
Stop
Software counter / Interlock
Polymer Dilution Skid - Run- Reset of Hour-Run
  0         with screen operation with delay
hour record meter
off.
                 
Force Ventilation: Sludge Feed
               
& Dewatering Room
  Fan : Manual Indicator 1     1    
  Fan : Auto Indicator 1     1    
Status & counter no. of start /
  Fan : Run Indicator 1     1  
stop
  Fan : Off Indicator 1     1   Alarm (Fault Report)
Remote Start /
  Fan : To Start / Stop 1       1  
Stop
Reset of Hour-Run Software record of running
  Fan : Run-Hour record 1        
meter hours
                 

Notes:
AI = Analog Input AO = Analog Output DI = Digital Input DO = Digital Output
Qty = Quantity

260 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix C - Supervisory Control and Data Acquisition System (SCADA)
Appendix C - Supervisory Control and Data Acquisition System (SCADA)

Attachment C - 3: Representation of SCADA Control Symbols


Attachment C - 3: Representation of SCADA Control Symbols
PUMPS & AERATION DEVICES
PUMPS & AERATION DEVICES

EQUIPMENT OFF MODE ON MODE

  
PUMPS  
(Centrifugal)






 
 
PUMPS
(Progressive Cavity)

 
BLOWER

 

 
SURFACE AREATOR  
 
 
 
 
 
 

Sewage Treatment Plants Volume 4 261

234 Volume 4 Malaysian Sewerage


Treatment Plant
Appendix C - Supervisory Control and Data Acquisition System (SCADA)
Appendix C - Supervisory Control and Data Acquisition System (SCADA)
ACCESSORIES & FITTINGS
ACCESSORIES & FITTINGS

EQUIPMENT OFF MODE ON MODE

Valves
(General)

BUTTERFLY VALVE

AGITATOR

CONVEYORS

CONVEYORS SCREW

262 Volume 4 Malaysian Sewerage


Industry Guidelines

Sewage Treatment Plants Third Edition Page 235


Volume 4
Appendix C - Supervisory Control and Data Acquisition System (SCADA)
Appendix C - Supervisory Control and Data Acquisition System (SCADA)
OTHERS
OTHERS

EQUIPMENT SYMBOLS

PLC CONTROLLER

WIRELESS COMMUNICATION

SCADA WORKSTATION

POWER TRANSMISSION

METER

COMPRESSOR

TANK

Sewage Treatment Plants Volume 4 263

236 Volume 4 Malaysian Sewerage


Treatment Plant
Appendix D

Duty and Standby Requirements


Appendix D - Duty and Standby Requirements

266 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix D - Duty and Standby Requirements

Appendix D Duty and Standby Requirements

Table D1 Duty and Standby Requirements for Activated Sludge Systems


(Utilising Diffused Aeration)
Table D2 Duty and Standby Requirements for Activated Sludge Systems
(Utilising Mechanical Surface Aerator)
Table D3 Duty and Standby Requirements for Rotating Biological Contactor
Systems
Table D4 Duty and Standby Requirements for Trickling Filter Systems

Sewage Treatment Plants Volume 4 267


Appendix D - Duty and Standby Requirements

268 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix D - Duty and Standby Requirements

Sewage Treatment Plants Volume 4 269


Appendix D - Duty and Standby Requirements

270 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix D - Duty and Standby Requirements

Sewage Treatment Plants Volume 4 271


Appendix E

Glossary of Abbreviations
Appendix E - Glossary of Abbreviations

274 Volume 4 Malaysian Sewerage


Industry Guidelines
Appendix E - Glossary of Abbreviations

Glossary of Abbreviations

ABF Activated Biofilter


AL Aerated Lagoon
AS Activated Sludge
ATU Allyl Thio Urea
BOD Biochemical Oxygen Demand
BOD5 Total Five Day Biochemical Oxygen Demand
CAS Conventional Activated Sludge
CF Certificate of Fitness
CMAL Complete Mixed Aerated Lagoon
CMAS Conventional Mode Activated Sludge
COD Chemical Oxygen Demand
CPR Cardio Pulmonary Resuscitation
DMF Dual Media Filtration
DO Dissolved Oxygen
DOE Department of Environment
DOSH Department of Occupational Safety and Health
DS Deep Shaft
EA Extended Aeration
EAMAS Extended Aeration Mode Activated Sludge
F/M Food to Microorganism ratio
FAL Facultative Aeration Lagoon
FWSP Facultative Waste Stabilisation Ponds
GRP Glass Reinforced Plastic
HAZOP Hazard and Operability Review
HRT Hydraulic Retention Time
HRTF High Rate Trickling Filter
MCRT Mean Cell Residence Time
MLSS Mixed Liquor Suspended Solids
MLVSS Mixed Liquor Volatile Suspended Solids

Sewage Treatment Plants Volume 4 275


Appendix E - Glossary of Abbreviations

MOD Modified Oxidation Ditch


MP Maturation Pond
MS 1228 Malaysian Standard 1228: Code of Practice for Design
and Installation of Sewerage Systems
OD Oxidation Ditch
OP Oxidation Pond
OASH Occupational Safety and Health Act
PE Population Equivalent
Qavg Average Flow
Qpeak Peak Flow
QRAS Return Activated Sludge Flow
RAS Return Activated Sludge
RBC Rotating Biological Contactor
SBC Submerged Biological Contactor
SBR Sequential batch Reactor
SIRIM Standards and Industrial Research Institute of Malaysia
SS Suspended Solids
SPAN Suruhanjaya Perkhidmatan Air Negara (National Water
Services Commission)
SST Secondary Settlement Tank
STP Sewage Treatment Plant
TDH Total Dynamic Head
TF Trickling Filter
TOL Total Organic Load
VSS Volatile Suspended Solids
WAS Waste Activated Sludge

276 Volume 4 Malaysian Sewerage


Industry Guidelines
PRINTED BY
PERCETAKAN NASIONAL MALAYSIA BERHAD
KUALA LUMPUR, 2009
www.printnasional.com.my
email: cservice@printnasional.com.my
Tel: 03-92366895 Fax: 03-92224773

Vous aimerez peut-être aussi