BGR Energy Systems LTD Power Projects Division Kakatiya PTP O&M Manual GID-082-ME-BS-1123

BGR ENERGY SYSTEMS LTD
POWER PROJECTS DIVISION Sheet 1 of 38
KAKATIYA PTP O&M MANUAL

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GID-082-ME-BS-1123
ANDHRA PRADESH POWER GENERATION CORPORATION
KAKATIYA THERMAL POWER PROJECT
STAGE-I, UNIT-1, 1 X 500 MW
KAKATIYA PTP O&M MANUAL
BGR ENERGY SYSTEMS LIMITED

POWER PROJECTS DIVISION
443, ANNA SALAI
TEYNAMPET, CHENNAI - 600018
PH 044 24326171, FAX 044 24315678
E Mail – ppd@bgrenergy.com
SEPTEMBER – 2010
18-09-2010
DATE PREPARED BY CHECKED BY APPROVED BY

PRAVIN V.PUVIARASAN V.BALASUBRAMANIAN
KAKATIYA PTP O & M MANUAL

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CONTENTS
Sr. No Title Page no
1.0 INTRODUCTION
1.1 General 5
1.2 Location 5
1.3 scope of work 5
1.4 Plant Description 7
2.0 DESIGN PARAMETERS
2.1 Raw Water Characteristics 9
2.2 Treated Water Quality 9
3.0 PROCESS DESCRIPTION
3.1 Pre-Chlorination 10
3.2 Flow Measurement 11
3.3 Flash Mixer 12
3.4 Flocculation Process 13
3.5 Clarification Process 14
3.6 Filtration Through Rapid Gravity Sand Filters 15
3.6.1 Operation in General 16
3.7 Sludge Thickening 18


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4.0 PLANT COMPONENTS DESCRIPTION
4.1 The Treatment units of the plant area under 19
4.2 Description of Dosing System & Other Compound 19
5.0 PROCESS DESCRIPTION AND TREATMENT

PHILOSPHY
5.1 Stilling Chamber & Flash Mixer 20
5.2 Alum Dosing System 21
5.3 Lime Dosing System 21
5.4 Poly Dosing system 22
5.5 Clariflocculator 23
5.6 Sludge Pit 23
5.7 Sludge Thickener 24
5.8 Sludge Feed pump 24
5.9 Centrifuge 25
5.10 Rapid Gravity Filter 26
6.0 MAJOR DESIGN PARAMETERS
6.1 Cascade Aerator 30
6.2 Stilling Chamber 30
6.3 Parshall Flume and Inlet Channels 31
6.4 Flash Mixer 31
6.5 Clariflocculator Sizing 31
6.6 Rapid Gravity Filter 33
6.8 Spent Backwash Water Sump 36


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6.9 Sludge System Design 37
5.10 Chemical Dosing System 38
REFERENCE DOCUMENT & DIAGRAM
Sr. No Dwg. No. Title
1. GID-082-ME-XB-1042 P&I Diagram PT Plant
2. GID-082-ME-BS-1108 Design Basis Report- PT Plant
3. GID-082-CI-CP-4054 Control Philosophy of Pre Treatment Plant


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1.0 INTRODUCTION
1.1 GENERAL
The work involved Execution of Balance of Plant works for the 1x 500MW coal based
thermal power plant at Kakatiya Thermal Power Station, Stage I, Unit 1 being developed
by Andhra Pradesh Power Generation Corporation Limited.
1.2 LOCATION
The Site is located between villages Dubbapalli and Mahabubpalli in Ghanpur Mandal,
Warangal District. The scope of work includes the services as specified in the tender
documents and will be executed on an Engineering-Procurement-Construction (EPC)
turnkey basis.
1.3 SCOPE OF WORK
The scope of work includes design, engineering, manufacture, inspection, testing, packing,
transportation to site, unloading & storage at site, erection, testing, start-up,
commissioning and performance testing of raw water treatment system comprising of
clarification plant and dual media gravity sand filtration plant (within battery limits) for 1
x 500 MW Coal based Thermal Power Plant at Kakatiya Thermal Power Station, Stage-1,
Unit-1 of M/s APGENCO.
Broadly the scope of work shall include the following:
 Control station raw water inlet comprising of electrically actuated butterfly valve
along with isolation and bye-pass valves
 1 No. Stilling Chamber, Parshall Flume, Flash Mixer common for 2

Clariflocculators with accessories for rated capacity of 2200 M3/Hr.
 Clariflocculators rated capacity CF 1 - 1800 M3/Hr. + CF 2 - 250 M3/Hr


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 1 Lot Alum & 1 Lot Lime Storage Preparation and Dosing System comprising of
alum & lime dosing equipment (tank instruments, dissolving basket, agitators,
metering pumps, etc. and 1 No. Weighing machine).
 1 Lot Clarifier Sludge Disposal system with sludge chamber and sludge disposal
pumps (2 x 100%) and sludge disposal piping up to gravity thickener
 2x 100% Thickened Sludge Pumps
 Nos. Centrifuge units
 Centrifuge Supernatant collection & return system to the stilling chamber.
 Nos. 3 T Trolleys for disposal of sludge
 4 Nos. Rapid Gravity Dual Media Filters for Non DM each of minimum 500
M3/Hr. 2 Nos DM Rapid Gravity Filter each of minimum 250 M3/Hr including
filter house piping and pneumatically actuated valves
 x 100% Filter Air Blowers
 Filter Backwash Arrangement comprising of backwash piping from terminal point

from filter house up to the Spent Filter backwash collection sump.
 1 PLC based control system common for Clariflocculators and Rapid Gravity
Filters along with suitable UPS with battery backup.
 1 Lot inter-connecting piping, fittings, valves and accessories within battery limits.
 1 Lot instruments and control hardware including junction boxes within battery
limits.
 Start-up & commissioning spares as per requirement (no specific list)
 Mandatory spares as per list provided with enquiry.
 Special maintenance tools and tackles, if any applicable.
 Earthing system up to the riser provided by the purchaser within battery limits.
 Initial fill of lubricants and consumables (excluding chemicals i.e. alum, lime etc.)

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1.4 PLANT DESCRIPTION
The raw water pre-treatment plant shall comprise of the following main units –Cascade
Aerator, Stilling chamber, inlet channel with parshall flume, DM & Non DM flash mixer,
DM & Non DM clariflocculators, DM & Non DM Rapid gravity dual media filters,
thickener and centrifuges besides support systems viz. chemical dosing, pumps, piping,
valves etc. The filtered water from the filters shall be used as make-up to the cooling
tower, plant service and potable water requirements and for filter back wash.
Chlorine shall be dosed in stilling chamber. From the stilling chamber water shall be led to
inlet channel provided with flow measuring device (parshall flume). The parshall flume
shall be provided with flow indicator and transmitter unit for flow measurement and local
and remote indication. The inlet channel shall lead the raw water to a DM & Non flash
mixer unit provided with an agitator mechanism. Chemicals (alum & lime) shall be dosed
into the parshall flume or flash mixer for complete mixing of chemicals with raw water.
The raw water from flash mixer shall then be led to two (2) nos. clariflocculator units.
The clariflocculators shall be fed through pipes entering into the clariflocculators at the
bottom. The clariflocculators shall be provided with a flocculation and clarification zones
separated through RCC framed brick wall. The clariflocculators shall be provided with
peripherally driven mechanism with suspended flocculation paddles for development of
flocs and removal of sludge from the clarifier. The overflow from the clarifiers shall be led
to inlet channel of filter house.
Four (4) Nos. Rapid Gravity Sand Filters, dual media type each of Normal 500 M3/Hr for
Non DM & 250 M3/Hr for DM net capacity shall be provided.. The filtered water from the
filters shall be conveyed through open channel to filtered water Tank.
The filters shall be first given an air scour followed by wash water for washing of filters.
For air scouring of filters air blowers shall be provided which shall supply air to filter
under-drainage system. After air scour, wash water shall be pumped to the filter under
drainage system. The dirty water shall be collected through a network of troughs into the
central gullet of filter from where it shall be conveyed to a common backwash water

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collection channel. The backwash water shall be conveyed through this channel to
backwash water sump.
The underflow from the clarifiers shall be withdrawn by gravity into a sludge pit through a
timer operated automatic blow-down valve. The sludge from the sludge pit is then pumped
to a sludge thickener. The thickened sludge from the thickener shall be pumped to
centrifuges for dewatering. The dewatered cake from centrifuge shall be collected directly
to a trolley located below the chute of the centrifuge. The filtrate from the centrifuge shall
be conveyed by gravity to the stilling chamber / back wash water sump. The overflow of
thickener shall be conveyed to Stilling Chamber. A poly dosing system comprising of a
solution preparation tank, agitator and dosing pumps shall be provided for on-line feeding
to Sludge Pit .
For chemical dosing, chemical dosing tanks with agitator (alum & lime), dosing pumps
shall be provided in chemical house with piping and valves upto flash mixer.

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2.0 DESIGN PARAMETERS

The Analytical laboratory provides shift wise data on quality parameter in addition to
online instruments. The treatability standards are displayed in the table below:
2.1 RAW WATER CHARACTERISTICS:
Sl.
Parameter Units Raw Water
No.
1 Ph @ 25.C 7.65
2 Turbidity NTU 150 Normal

<1000 Max.
3 Colour ° Hazen <5
4 Conductivity µS/cm 845
5 Dissolved Solids mg/l 496
6 Odour Odourless
7 BOD ppm 5
8. COD ppm 8
2.2 TREATED WATER QUALITY
The following effluent analysis shall be
1. At DM & Non DM Clariflocculator outlet

Turbidity + Suspended solids: Less than 10 NTU at design flow rate and
maximum indicated raw water turbidity.
2. At DM & Non DM Gravity Filter outlet

Turbidity + Suspended solids: Less than 2 NTU at design flow rate and maximum
indicated raw water turbidity.

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3.0 PROCESS DESCRIPTION
The raw water undergoes the following treatment steps to make it suitable for the purpose
of drinking water.
The sequence of processes in the Water Treatment Plant comprises the following:
 Pre-chlorination in the Stilling Chamber for the purpose of disinfection,

 Flow measurement in the Parshall Flume,
 Coagulation with alum dosage in the downstream channel.
 Flocculation of the chemically dosed raw water in the Flocculation Tank,
 Clarification and sedimentation in the Clariflocculator,
 Filtration through Rapid Gravity, Constant Head and Dual Media Filters,
 Recirculation of Dirty Back Wash Water to the Stilling Chamber,
 Post-chlorination in the Filter water sump for the purpose of disinfection of the
filtered water and maintenance of residual chlorine level (Existing facility),
 Sludge bleeding (Continuous) from the Clariflocculator,
 Sludge thickened through Sludge thickener followed by centrifuge.
3.1 PRE-CHLORINATION
Raw water pumped to the plant through the Pumping main. The raw water enters the
Stilling Chamber through a motorized control valve (VCB04C105) installed in the raw
water main. Pre-chlorination is done by chlorine solution in the Stilling chamber.
The primary objectives of the pre chlorination of raw water, is to control the growth of
algae and other microorganisms. Otherwise such growth would lead to the following
consequences:
 Interference with the process of coagulation and flocculation, hence an increase in

the coagulant dosage.
 Clogging of the inclined plates, if the growth is allowed to happen unchecked


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 Slime growth in the filters. Thus leading to formation of mud balls in the media.
This would reduce the filter efficiency and interferes with proper backwashing.
The effect of chlorination is due to the oxidizing effect of chlorine on organic matter and
its germicidal effect in killing germs and viruses. When chlorine gas is dissolved in water,
it hydrolyzes rapidly as below:
Cl2 + H2O  H+ + Cl - + HOCl
The hypochlorous acid (HOCl) is a weak acid and tends to undergo partial dissociation as
follows:
HOCl   H+ + OCl -
When the pH value of the chlorinated water is 7.5, 50% of the chlorine concentration
present will be undissociated hypochlorous acid (HOCl) and 50% will be the hypochlorite
ion (OCl -). Lower the pH value of the chlorinated water, proportionally higher the amount
–
of HOCl. It may be noted that HOCL has a better germicidal efficiency than the OCl
ions.
The Stilling Chamber well has the provision to receive the spent backwash water from the
Spent Backwash Sump.
3.2 FLOW MEASUREMENT
The incoming raw water flow is measured by open channel flow measurement technique,
namely Parshall Flume. The Parshall Flume comprises three sections namely convergence,
throat and divergence section. An ultrasonic flow meter is installed in the Parshall Flume,
which measures the raw water flow as per the relation between flow rate and the head as
recorded on the Flow Meter hardware.
Alum and Lime dosage is also carried out in the Downstream of the Parshall Flume. Alum
acts as a coagulating agent and it requires intense mixing with the raw water to enhance
the process of coagulation.

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3.3 FLASH MIXER
After the dosage of alum in the Parshall Flume, the raw water flows to the Flash Mixing
Tank. The particles to be removed from raw water are either suspended or colloidal and
are composed of clay, other inorganic materials, organic substances, bacteria, viruses and
even colour. These particles are allowed to usually carry a negative charge. If particles
maintain the same charge with respect to each other, they will remain permanently
suspended due to electromagnetic repulsion among them. Thus, the process of coagulation
is resorted to.
Coagulation is the effect produced by addition of a chemical to a suspension, resulting in

particle destabilization. Operationally this is achieved by the addition of appropriate
chemical followed by rapid and intense mixing, for obtaining uniform dispersion of the
chemical. In this particular case Alum is used as the coagulant chemical and dosed at the
downstream of the Parshall Flume.
A typical reaction of alum may be expressed as:
Al 2 (S O 4) 3.18 H2O  2 Al 3+ + 3 SO4 - + 18 H2O
2 Al3 + 6 OH -  Al 2O 3. X H2O
Hydroxyl ions necessary for the conversion of aluminium oxide to hydrate are available
because of the alkalinity present in the raw water. The pH of the water plays a very
important part in the coagulation phenomena. With the raw water pH ranging from 6.4 to
7.85, the required alum dosage, determined by Jar Test, is maintained to ensure good
coagulation.
Rapid and intense mixing of the chemicals with the raw water is provided in the form of
mechanical agitation by the use of agitator provided in the Flash Mixing Tank. The mixing
is allowed to take place for a short time of around 60 seconds. This helps in the formation
of microflocs and also in proper utilization of the chemical coagulant, viz. Alum, lime,

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prevention of localization of concentration and premature formation of hydroxides, thus

resulting in less effective utilization of the coagulant.
The flash mixing process supplements the process of coagulation to destabilize the
negatively charged colloidal particles. These negatively charged impurities have a high
anti coagulant stability. In order to coagulate the impurities it is essential to disturb their
anti coagulant stability by intense mixing and to minimize their electric charge. The
mixing also achieves uniform dispersion of chemical, preventing localization of
concentration and premature formation of hydroxide. Coagulation of water is the process
of aggregation of colloidal and dispersed particles as they stick together under the
attraction of molecular forces resulting in the formation of larger flocs, which are visible to
naked eye and separate from liquid phase. Alum dosed as main coagulant enters the
process of hydrolysis to form the Aluminium Hydroxide suspension. The positively
charged trivalent Aluminium ion induces the coagulation by means of interaction of two
unlikely charged are mutually neutralized which facilitates aggregation and decantation.
Polyelectrolyte solution at 1% strength is also dosed as a flocculent aid for better

formation of flocs and it enhances the settling tendency of the flocs. A baffle wall is
provided at the inlet side of flash mixing tank to prevent any short circulation of flow.
3.4 FLOCCULATION PROCESS
Flocculation is the second stage of formation of settable flocs from destabilized colloidal
particles. Gentle and prolonged mixing using paddle agitation at slow speed results in the
formation of large and readily settleable flocs by bringing together finally divided matter
into contact with microflocs formed during rapid mixing. It has been demonstrated by
results of experiments that the process of flocculation depends substantially on intensity
and time of stirring in flocculation tanks, with the intensity of stirring being the prime
factor and the time being the other.
A retention time of 30 minutes is provided in the Flocculator Zone along with gentle and
prolonged mixing also. The water moves successively through all sections and then
reaches the outlet.

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The slowly revolving paddle type agitators in the Flocculation Tank ensure repeated
collisions so that the microflocs agglomerate and grow bigger in size for ready settling in
the downstream sedimentation unit.
Also, Polyelectrolyte dosed as coagulant aid accelerates the flocculation process producing
dense and rapid settling flocs. Jar Test determines the optimum dosage requirement of
Alum and Polyelectrolyte for better flocculation. The Jar Test Procedure is separately
included in this manual.
3.5 CLARIFICATION PROCESS:

(SEPARATION OF SOLIDS BY CLARIFLOCCULATOR)
Clarification is the process of enhanced rate of sedimentation with the aid of external
reagents namely coagulating agents. Sedimentation is the separation of suspended
particles, which are heavier than water, by means of gravitational settling. For the purpose
of clarification of flocculated raw water, the high rate sedimentation unit, viz.,
Clariflocculator is provided.
It is a well-known fact that the depth of a Clariflocculator has little effect on its settling
capacity. The most significant design aspect is the available settling area, since the
throughput (m3/hr) divided by the available settling area (m2) must not exceed the settling
velocity of the slowest settling particle to be separated – usually between 1 and 2 m/hr.
Suspended Particles formed after flocculation settles from liquid under the action of force
of gravity. The process of settling takes place in Clariflocculator in moving liquid from
inlet to outlet of the settler.
The velocity of water plays an important part in the process of settlement in

Clariflocculator. The Clariflocculator of RCC construction receives the raw water and
recycled sludge from the Flocculator Zone. The Clariflocculator is of circular shape
construction, with bottom of circular configuration, suitable for sludge scrapper
mechanism.

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It has distinct separation zone, sludge zone, and clear water zone. The agglomerated sludge
particles can have a settling rate of more than ten times the settling rate of the individual
floc particles in the influent.
3.6 FILTRATION THROUGH RAPID GRAVITY SAND FILTERS
Filtration is a process of separation of suspended and colloidal impurities, in suspension,

from water through a porous medium. Filtration is one of the main processes of Water
Treatment applied to improve the quality of water to the standard of potability. Removal of
turbidity through filtration is to achieve not only aesthetic acceptability but also efficient
disinfection by reducing the bacterial load on the disinfection process. Suspended solids,
which serve as the medium for bacterial growth and hideouts will actually require higher
dosage of disinfectant, viz. chlorine.
In most Water Treatment Plants, Filtration is the final stage of treatment carried out after
flocculation and clarification. Water with impurities is passed through filtering material,
which is permeable to liquid and impermeable to impurities. The physical and chemical
properties of the filter media and colloidal particles further contribute to the removal of the
suspended solids.
These physical and chemical properties include:
 Chemical bonding between the media and the colloidal particles; and
 Physical attraction between the media grains and the colloidal particles.
Suspended particles are passed through the filtering media and they get trapped in the
filter sand layer. This allows the water to become clear and free from suspended particles.
Generally the outlet water from the filters has maximum turbidity Less than 2.0 NTU.
The Filters adopted for the project are of down flow, Dual media, rapid gravity constant
head filters in which the flow control is achieved by flow control valves.

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The filter media of the filters is supported on a false bottom floor of R.C.C construction.
The filters also have Filter box and are fitted with state-of the-art nozzles for the under
drainage system. The distinctive features of rapid gravity filters are that they use higher
filtration rates of up to 8 m³/m²/h. Another feature of such a system is coarser but more
uniform filter media to utilize greater depths of the filter media for trapping influent solids
without excessive head loss. The backwashing for cleaning the entire depth of filter of
filter bed is done by reversing the flow direction.
Conceptually the removal of particles that takes place within a deep granular media filter
takes place in two distinct steps – a transport and an attachment step.
The particle transport is a physical process, which is principally affected by physical

variables that govern mass transfer, such as size of filter medium, filtration rate, density
and size of the suspended particles and water temperature. The impurity particles are
brought from the bulk of the liquid to the pores close to the surface of the medium or the
previously deposited solids on the medium.
The under drain system fitted with nozzles ensures uniform draw-off of filtered water and
also uniform distribution of wash water and air (during scouring) over the entire area of
the Filter.
3.6.1 Operation in General
The clarified water from the Clariflocculator typically enters the filter at top and flows
down through the filter media and the under drain. There are 4 Nos for Non DM and 2 Nos
for DM of Rapid Gravity Filters operating for the design flow. The under drain system
conveys the water to a filter outlet box. Water flows out of the outlet box into the outlet
pipe from where water is conveyed to the weir chamber through the outlet pipe and then
flows into the clear water reservoir through the filtered water channel. After running for a
period of time, the filter media will become clogged with accumulated solids removed
from the water. The filter must then be cleaned or backwashed to remove the accumulated
solids. This operation involves closing the inlet and outlet valves and opening the wash
water and waste wash water valves. This results in water flowing into the filter outlet box

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and through the under drain system towards the filter sand media layer. Water flows
upward through the nozzle floor layer into the filter media. As it flows through the media,
the bed expands and the water picks up the deposited solids carrying them into the Spent
Backwash water tank through the Back wash Water Channel. The waste back wash water
is then recycled back to the Still Chamber.
The filters are designed for a maximum filtration rate of 6 m3/m2/hr when one filter is
taken out of service for backwashing/maintenance. The flow to the filters is conveyed from
the feed channel and the flow divided among the filters by the use of individual over flow
weir for each filter. The filtered water outlet is controlled by a control valve installed in the
outlet pipe of each filter, thus maintaining a constant level in the filter. A level
transmitter/controller located in each filter controls the filter outlet control valve. The over
flow weir at the outlet chamber of each filter maintains a minimum water level in the filter
beds, such that the filter bed never gets dry.
The Filters will normally be washed automatically on a 24-hour cycle or when the filter
bed is clogged up to the admissible filter loss, measured by a level transmitter installed in
the bed. The filter shall be designed for conjunctive air and water backwashing
sandwiched between air scouring and water wash. To reduce down time of Filters no
sectional backwash is envisaged. Interlocks shall be incorporated to prevent simultaneous
washing of two filters.
Each filter bed is provided with the complete set of under drain system of the latest
improved pattern of proven practice, incorporating ‘sand tight’ polypropylene nozzles
fixed on a reinforced concrete false floor. This system is designed for efficient collection
of filtrate and also for the uniform distribution of compressed air and wash water over the
entire filter area, during the filter wash.

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Two units of existing Air Blowers of capacity 2100m3/hr each are supplying air for
scouring during the back washing of the filters, out of which one is in operation and the
other is on standby. During the back washing of the filters, high backwashing rates of 30
m3/m2/hr for water and upto 54 m3/m2/hr for air are used.
The spent backwash water generated from the filters during backwashing is sent to the
spent Backwash sump through a Spent Backwash water channel. The filtered water
channel, to the Filter water Sump, conveys the filtered water from the filter house.
3.7 SLUDGE THICKENING
The sludge, which settles on the floor of the Clariflocculator, is scrapped by a mechanical
scrapper into the central pit, from where the sludge is discharged into the Sludge pit,
continuously through a common pipe, which gets input from individual underflow pipes
from each clariflocculator installed with Pneumatically operated Gate valve. The sludge
collected in the Pit is pumped to the sludge thickener arrangement by means of the sludge
Transfer pumps. There are two nos of Sludge Transfer Pumps for the purpose and out of
which one working and one standby. These pumps have a capacity of 50 cum/h at 25 mwc.
The thickened sludge (6%) in the sludge thickener will be pumped to Centrifuge
arrangement through Centrifuge Feed Pumps. The overflow from thickener will be routed
to stilling chamber.
The Sludge Fed into the Centrifuge will be dewatered and the cakes will be disposed
through trolley. The centerate from the centrifuge will be routed to the stilling chamber
through gravity.

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4.0 PLANT COMPONENTS DESCRIPTION
4.1 THE TREATMENT UNITS OF THE PLANT ARE AS UNDER
1. Stilling Chamber
2. Flow Measurement Channel
3. Flash Mixing Tank
4. Flocculation Tank
5. Clariflocculator
6. Rapid Gravity Sand Filter
7. Filter water Sump
8. Spent Back Wash Sump.
9. Sludge Pit
10. Sludge Thickener
11. Centrifuge Feed Pump and Centrifuge
12. Filter Gallery Sump pumps
4.2 DESCRIPTION OF DOSING SYSTEM
1. Alum Dosing Tank and Alum Dosing Pumps

2. Lime Dosing Tank and Lime Dosing pump
3. Polyelectrolyte Preparation cum Dosing System
4. Pre and Post Chlorination System
4.3 OTHER COMPONENTS
Air Scour Blowers (Existing) and Air Compressor


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5.0 PROCESS DESCRIPTION AND TREATMENT PHILOSOPHY
5.1 STILLING CHAMBER & FLASH MIXER:
The incoming Raw Water pumped through raw water pumps (RAW-VP-01, RAW-VP-02
& RAW-VP-03) will be dosed with chlorine solution for oxidization of organic & bacteria
control, then the water will be gravitated to Flash Mixer 1 (NON-DM service) and Flash
Mixer 2 (DM service). Lime & Alum solutions from their respective Tanks will be dosed
into flash mixer, which has an agitator and the added chemicals and incoming water
are intimately mixed & passed to clariflocculator.
OPERATION:
The raw water pumps (RAW-VP-01, RAW-VP-02 & RAW-VP-03) and Flash mixer
agitators (RAW-AV-01 & RAW-AV-02) will be operated from the OWS by the operator.
Raw water pumps can also be operated through hardwired illuminating push buttons.
CONTROL & INDICATION:

Motor operated Inlet valve (VCB04CI05) can be operated from OWS.
The Incoming raw water flow can be measured by Ultrasonic Flow Transmitter (RWA-
FT-01) for NON-DM service and (RWA-FT-02) for DM service. The flow sensing
mechanism is Parshall flume. The instantaneous flow & total flow will be indicated on
the OWS.
“ON” and “OFF” status of raw water pumps (RAW-VP-01, RAW-VP-02 & RAW-VP-03),
stilling chamber inlet MOV (VCB04CI05) and flash mixer agitator (RAW-AV-01 & RAW-
AV-02)) will be indicated on the OWS.
ALARM:
Alarm annunciations on OWS for off/trip condition of raw water pumps and Flash
mixer agitator.

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5.2 ALUM DOSING SYSTEM:
Alum dosing system comprising of three dosing tanks with agitators, Level Indicators
(CMD-LI-01, CMD-LI-02 & CMD-LI-03)) for local indication and Level Switches (CMD-
LS-01, CMD-LS-02 & CMD-LS-03). Dosing tanks discharge will be connected to two
numbers (1w + 1s) of dosing pumps to transfer the dosing chemical to flash mixer.
OPERATION:
The Metering Pumps (CMD-DP-01 & CMD-DP-02) & dosing tank agitators (CMD-AV-
01, CMD-AV-02 & CMD-AV-03) will be operated from the OWS by the operator.
Top Mounted level Switch with Low Contact will be hooked up with dosing pumps
(Metering pumps) so as to stop the pump at “Low Level” of dosing tanks.
“Running” and “Stopped” status of agitators (CMD-AV-01, CMD-AV-02 & CMD-AV-

03)) and dosing pumps (CMD-DP-01 & CMD-DP-02) will be indicated on the OWS.
ALARM:
Alarm annunciation on OWS on Low level of dosing tanks
Alarm annunciation on OWS on dosing pump off/trip condition
5.3 LIME DOSING SYSTEM:
Lime dosing system comprising of two dosing tanks with agitator, Level Indicators
(CMD-LI-04 & CMD-LI-05) for local indication and Level Switches (CMD-LS-04 & CMD-
LS-05). Dosing tanks discharge will be connected to two numbers (1w + 1s) of dosing
pumps to transfer the dosing chemical to flash mixer.
OPERATION:
The Metering Pumps (CMD-SP-01 & CMD-SP-02) & dosing tank agitators (CMD-AH-01
& CMD-AH-02) will be operated from the OWS by the operator.

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(Metering Pumps) so as to stop the pump at “Low Level” of dosing tanks.
“Running” and “Stopped” status of agitators (CMD-AH-01 & CMD-AH-02) & dosing
pumps (CMD-SP-01 & CMD-SP-02) will be indicated on the OWS.
ALARM:
5.4 POLY DOSING SYSTEM:
Poly dosing system comprising of two dosing tanks with agitator, Level Indicators
(CMD-LI-06 & CMD-LI-07) for local indication and Level Switches (CMD-LS-06 & CMD-
LS-07). Dosing tanks discharge will be connected to two numbers (1w + 1s) of dosing
pumps to transfer the dosing chemical to Clariflocculator.
OPERATION:
The Metering Pumps (CMD-DP-03 & CMD-DP-04) & dosing tank agitators (CMD-AV-04
& CMD-AV-05) will be operated from the OWS by the operator.
(Metering Pumps) so as to stop the pump at “Low Level” of dosing tanks.
“Running” and “Stopped” status of agitators (CMD-AV-04 & CMD-AV-05) & dosing
pumps (CMD-DP-03 & CMD-DP-04) will be indicated on the OWS.
ALARM:


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5.5 CLARIFLOCCULATOR:
Clariflocculator is an integral mechanism for flocculation & sedimentation.

Clariflocculators 1 & 2 for NON-DM service and DM service are provided. The
coagulated raw water will be passed to clariflocculator feed well where flocculent will
be dosed. Then the water will rise to centre reaction zone to get the flocculent react
with the water for the agglomeration of the flocs. The reaction zone will be provided
with slow mixing arm for flocculation. After the reaction the water will reach to
settling zone where the flocs will get settling due to their terminal velocity & the
overflow will be collected through launder & gravitated to gravity filter.
OPERATION:
Clariflocculator peripheral drive (RAW-CF-01 (NON-DM) & RAW-CF-02 (DM)) can be
operated from a local panel (located in the field) and OWS.
Flocculator drives (RAW-FL-01 (NON-DM) & RAW-FL-02 (DM)) can be operated from
local panel (located in the field).

“Running” and “Stopped” status of clariflocculator drives (RAW-CF-01 & 02 and RAW-
FL-01 & 02) will be indicated on the OWS.
ALARM:
Alarm annunciations on OWS on off/trip condition of clariflocculator drives.
5.6 SLUDGE PIT:
Clariflocculator bottom liquid/slurry will be gravitated to sludge pit through a timer

operated valve (VCG29CI02 & VCG29CI04) located at the bottom of the
clariflocculator and the Pit is provided with two submersible pumps to transfer the
slurry to sludge thickener. The sludge pit will be provided with Level Indicator (SDS-
LI-01) for local indication & Level Switch (SDS-LS-01).
OPERATION:
The sludge transfer pumps (SDS-SU-01 & SDS-SU-02) will be operated from the OWS
by the operator.

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Top Mounted level Switch with High, Low & Low Low Contacts will be hooked up with
sludge transfer pumps so as to stop the pump at “Low Level” of sludge pit.
“Running” and “Stopped” status of sludge transfer pumps will be indicated on the
OWS.
ALARM:
Alarm annunciation on OWS on High level of sludge pit
Alarm annunciation on OWS on sludge transfer pumps off/trip condition
5.7 SLUDGE THICKENER:
The clariflocculator sludge from sludge pit will be transferred to sludge thickener by
sludge transfer pumps to concentrate the sludge. The sludge thickener bottom
concentrated slurry will be pumped to centrifuge by sludge feed pumps for
dewatering. The supernatant from the thickener will be collected in sludge thickener
over flow sump. The thickener will be having motor driven racker arm device.
OPERATION:
The sludge thickener racker arm drive (SDS-ST-01) will be operated from the OWS by
the operator.

“Running” and “Stopped” status of thickener drive will be indicated on the OWS.
ALARM:
Alarm annunciation on OWS on thickener drive off/trip condition
5.8 SLUDGE FEED PUMP:
The concentrated sludge from the bottom of the sludge thickener will be transferred to
centrifuge by two numbers (1w+1s) of sludge feed pumps for dewatering purpose.

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Both the pumps discharge will be having pressure switches (SDS-PS-01 & SDS-PS-
02). Sludge feed pump and Centrifuge both are interconnected.
OPERATION:
The sludge feed pumps (SDS-SP-01 & SDS-SP-02) will be operated from the OWS by
the operator.

“Running” and “Stopped” status of sludge feed pumps (SDS-SP-01 & SDS-SP-02) will
be indicated on the OWS.
Pressure switches (SDS-PS-01 & SDS-PS-02) provided at the discharge of the pumps
is interlocked with sludge feed pumps for protection.
ALARM:
Alarm annunciation on OWS on sludge feed pumps off/trip condition
5.9 CENTRIFUGE:
Centrifuge is the equipment used for dewatering the sludge. The concentrated sludge
from sludge thickener will be pumped to centrifuge by sludge feed pumps. The
muddy cake from centrifuge is removed manually in trolleys and sent to waste
disposal yard. The supernatant from the centrifuge will be sent to stilling chamber.
OPERATION:
The centrifuge (SDS-HD-01 & SDS-HD-02) will be operated from the OWS by the
operator. Centrifuges can be operated after sludge feed pump operation with a time
delay.

“Running” and “Stopped” status of the centrifuge drives will be indicated on the OWS.
ALARM:
An alarm annunciation on OWS of centrifuge drives off/trip condition.

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5.10 RAPID GRAVITY FILTER:

Gravity filter is media filtration operated in gravity flow. The clariflocculator over flow
will be gravitated to rapid gravity filter to trap suspended particles getting carry over
from the clariflocculator. There shall be 6 nos. of rapid gravity twin bed sand filters 2
for DM service and 4 for NON-DM service.
The over flow water from clariflocculator comes to Filtered water inlet channel and
then goes to Rapid Gravity Filters. Each Gravity Filter will be having, Service
Inlet/Outlet and Backwash Inlet/Outlet on off Valves operated by solenoid and each
valve will be having two limit switches for open and close indications. These valves
will operate through PLC as per bingo chart and will have service/backwash and air
injection cycles through timer built in PLC.
The system will be configured as such only one filter is under Back wash at a time and
the system will prevent second filter coming into Back wash mode even if a command
is given by mistake by the operator. Each filter is provided with DP Switch (CLW-DPS-
01 to 06) and DP Indicator (CLW-DPI-01 to 06) to measure the DP across the media.
Level Switches (CLW-LS-01 to CLW-LS-12) are provided on each section of filters to
drain the selected filter to preset level.
OPERATION:
There are two modes of operation in Gravity Filter (GF)
1. Service mode; 2. Backwash mode.
1) SERVICE MODE:
 Selection of Gravity filters (working) from OWS.

 Open service inlet valves (VCL10CI01, VCL10CI03, VCL10CI05, VCL10CI07,
VCL10CI09 & VCL10CI11).
 Open the filter outlet valves (FWD-FCV-01,FWD-FCV-02,FWD-FCV-03,FWD-
FCV-04,FWD-FCV-05,FWD-FCV-06,FWD-FCV-07,FWD-FCV-08,FWD-FCV-
09,FWD-FCV-10,FWD-FCV-11 & FWD-FCV-12) from PLC.
 Continue the service run for 20 hours before starting backwash mode.
 Stop the service run when DP across the filter exceeds the set value of 0.5
Kg/cm2 or elapse of the timer after 20 hours.

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 In case of both the above said conditions occurs stop the service run by
tripping clariflocculator through PLC.
2) BACKWASH MODE:
Step – 1: AIR SCOURING
 Selection of Air scouring blower (BAD-BL-01 & BAD-BL-02) from OWS.

 Start the selected blower (A/B) by opening the respective discharge valves
manually and Filter air inlet valve VCB10CI01, VCB10CI02, VCB10CI07,
VCB10CI08, VCB10CI13, VCB10CI14, VCB10CI19, VCB10CI20, VCB10CI25,
VCB10CI26, VCB10CI31 & VCB10CI32) through PLC for 10 minutes.
Step – 2: BACKWASHING
 Selection of Filter Backwash Pumps (FWD-VP-01, 02 & 03) through OWS.

 Open the corresponding discharge valves (VCB07CS01, VCB07CS02 &
VCB07CS03) for 8 to 10 minutes manually.
 Open the Filter backwash inlet valve (VCB10CI03, VCB10CI04, VCB10CI09,
VCB10CI10, VCB10CI15, VCB10CI16, VCB10CI21, VCB10CI22, VCB10CI27,
VCB10CI28, VCB10CI33 & VCB10CI34) and outlet valve (VCL10CI02,
VCL10CI04, VCL10CI06, VCL10CI08, VCL10CI10 & VCL10CI12) for 10 minutes
through timer.
 When the backwash time completed close all the valves.
 Stop Filter Backwash pump (FWD-VP-01, 02 & 03) after the DP across the filter
fall below the set value or elapse of timer whichever happens first.
 Drain valves (VCB10CI05, VCB10CI06, VCB10CI11, VCB10CI12, VCB10CI17,
VCB10CI18, VCB10CI23, VCB10CI24, VCB10CI29, VCB10CI30, VCB10CI35 &
VCB10CI36) can be operated through PLC whenever draining is required.
OPERATION:
The filter backwash pumps (FWD-VP-01, FWD-VP-02 & FWD-VP-03) and filter
backwash blowers (BAD-BL-01 & BAD-BL-02) will be operated from the OWS by
operator. Filter backwash pumps and Backwash blowers can also be operated through
hardwired illuminating push buttons.

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Gravity filters Service Inlet/Outlet, Backwash Inlet/Outlet, Air scouring inlet and Drain
ON/OFF valves status will be indicated on the OWS. “Running” and “Stopped” status
of the filter backwash pumps (FWD-VP-01, FWD-VP-02 & FWD-VP-03) and filter
backwash blowers (BAD-BL-01 & BAD-BL-02) will be indicated on the OWS.
DP Switch across Inlet and Outlet of each Filter to warn PLC of Filter choking and
based on this condition PLC will start backwash cycle. Normally the filters will be
taken into Back wash mode based on preset output or time cycle.
Flow sensor - Flow Transmitter (FWD-FT-01 to 06) is in close loop with Filter water
outlet control valves (FWD-FCV-01 to 12) to control outlet flow. The system is
configured to drain the selected filter to preset level, start the Back wash pumps and
the Air Blowers in a systematic preset manner to carry out the Back wash operation
and stop to await command from the operator to put the filter in service mode.
OPERATION:
The filter backwash blowers (BAD-BL-01 & BAD-BL-02) and filter backwash pumps
(FWD-VP-01, FWD-VP-02 & FWD-VP-03) will be operated from the OWS by the
operator. Filter backwash blowers and filter backwash pumps can also be operated
through hardwired illuminating push buttons.
ALARM:
Alarm annunciation on OWS on high DP of preset value across the filter
5.11 FILTERED WATER SUMP & TRANSFER PUMPS:

The filtered water from the rapid gravity filter will be collected in filtered water
storage tank through Filtered Water Outlet channel. Filter water sump segregated into
two parts one for DM services another for NON-DM service. Level instruments are
provided in both services. FWD-LT-01, FWD-LS-01, FWD-LS-02, FWD-LS-05 & FWD-
LS-06 is provided in NON-DM service part. Level Transmitter (FWD-LT-01) is
interlocked with Filter Backwash Pumps (FWD-VP-01, FWD-VP-01, and FWD-VP-02 &
FWD-VP-03).

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5.12 SPENT FILTER WATER SYSTEM:
Filter backwash water from filters stored in spent filter backwash sump. This system
consists of spent filter backwash pumps (FWD-VP-09 & FWD-VP-10) in 1W+1S
arrangement.
OPERATION:
The spent filter backwash pumps (FWD-VP-09 & FWD-VP-10) will be operated from
the OWS by the operator. Spent filter backwash pumps can also be operated through
hardwired illuminating push buttons.

Level switches (FWD-LSH-31, FWD-LSL-32 & FWD-LSLL-33) provided in the sump are
interlocked with spent filter backwash pumps.
Pressure switch (FWD-PS-31) provided at the discharge of the pumps is interlocked

with spent filter backwash pumps for protection.
“Running” and “Stopped” status of spent filter backwash pumps will be indicated on
the OWS.
NOTE:
The operation of the total system starting from the Inlet valve of the
Clariflocculators to the various Level controls in the Filtered water storage
tank and the operation of the pumps located on the Filtered water tank in a
safe manner is to be reviewed and built in to the control system as needed by
contractor.

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6.0. MAJOR DESIGN PARAMETERS
For Non DM:

6.1Cascade Aerator:
Area Required = QCA x CFRCA

4 x (DCAO 2 - DCAI2) = QCA x CFRCA
Where, DCAO = Outside Diameter top Aerator DCAI = Feed Pipe Diameter
= {[4 x (QCA/3600)] / ( x Velocity)}1/2
= {(4 x (2200/3600)] / x 1 .0}1/2
= 0.881 m
Say about 1.0m (NB 1000) 1.2. Now, / 4 x (DCAO2 - DCAI2) = QCA x CFRCA
/ 4 x (DCAO2 - 12) = 2200 x 0.045
DCAO = 11.27m
Considering the steps of 500mm Tread and 250mm Rise, no. of steps
required
= {(11.27 – 1) / 2} /
(500/1000) = 10.27 Steps
Say No. of steps = 11
The revised, DCAO = (11 x 0.5) x 2
+ 1.0 = 12.0m
Height of Aerator section = No. of
Steps x Rise =
11 x 0.25 =
2.75m
6.2 Stilling Chamber
Holding Capacity, QSC = Flow Area x Depth
= (π x DSC2/4) x HSC
Where DSC and HSC are Diameter and Height of Flash Mixer
Selected Diameter, DSC = 2.5m


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Hence, HSC = 6.3m
The Stilling Chamber dimension is 2.5m Diameter (Inside) X 6.3m High.
6.3 Parshall Flume and Inlet Channels
Parshall Flume and Inlet Channels:

Design Flow of Parshall Flume, QPFDd= 2200 m3/h
= 2200 x 1000 x 24 x 1 0- 6 Million Liters
per Day = 52.8 MLD
From Reference Document # 3.2 above (Refer Attachment -1), the following
dimensions will be adopted for Parshall Flume:
W = 300mm
• W = •300mm
W = 300mm W = 300mm
A = 1350mm
• • •
A = 1350mm
A = 1350mm
A = 1350mm
B = 1322mm
• • •
B = 1322mm
B = 1322mm
B = 1322mm
C = 600mm
• • •
C = 600mm
C = 600mm
C = 600mm
D = 831mm
• • •
D = 831mm
D = 831mm
D = 831mm
F = 600mm
• • •
F = 600mm
F = 600mm
F = 600mm
G = 900mm
• • •
G = 900mm
G = 900mm
G = 900mm
K = 75mm
•
Z = 225mm • •
K = 75mm
K = 75mmK = 75mm
• Z = 225mm
• Z = 225mm
• Z = 225mm
• • •
6.4 Flash Mixer • W = 300mm
•
6.4.1 Holding Capacity,
A =Q FM = Flow Area x Depth
1350mm
•
B = 1322mm
= •
C (LFM X WFM) x HFM
= 600mm
•
D ==831mm
Selected Height, HFM 3.0m
•
F = 600mm
3.25m(LFMn ) x 3.25m(W FMn ) x 3.0m(HFMn ) is acceptable. Free board of 500mm will be
•
added. G = 900mm
•
K = 75mm
• Z = 225mm
6.5 Clariflocculator Size
Surface Flow Rate = QCLDn / Clariflocculator Flow

2
Area = QCLDn / ( x DCLn /4)

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Where, DCLn = Inside Diameter of the Clariflocculator Tank in metres
2
Hence 1.2 = 1900 / ( x DCLn /4)
DCLN = 44.89m
Where, DCLn = Inside Diameter of the Clariflocculator Tank in metres
2
HCLn = 1900 / ( x DCLn /4)
= 44.89m
= 48m
2
Detention Time = ( x DCLn /4) x HCLn / (QCLDn / 60)
2
= ( x 48 /4) x HCLn / (1900/60)
= 3.149m (Side Water Depth)
The selected dimensions of Clariflocculator are 48m Diameter (DCL) X 3.6m (HCL) to
account for volume of wall of central column, Flocculator mechanisms, etc.
6.5.1 Detention Time of Flocculator, TCLn2 = 30 Minutes

Detention Volume of Flocculator,
VCLn2 = TCLn2 x QCLDn
= (30/60) x 1900
= 950 M3 /h
Also,
VCLn2 = ( x DCLn22/4) x HCLn

950= ( x DCLn22/4) x 3.6 DCL
= 18.33m
Hence, the Flocculator dimension is 20m Diameter X 3.6m High to account

for volume of wall of central column, etc.
6.5.2 Peripheral Launder of Clariflocculator:
Design Flow of Launder, QLn = QCLR/2 = 1800/2

= 900 m3/h

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6.5.3 Design Launder velocity, vLn = 0.4 m/s (Max.)

6.5.4 Flow Area, ALn = (QL/3600) / vLn
= (900/3600) / 0.4
= 0.625m2
6.5.5 Assuming the Width of launder as 1 .0m, the flow water depth will be 0.625m.
Considering, 300mm free board, the peripheral launder dimension will be 1.0m
(W) x 1.0m (D).
6.5.6 Launder Surface Area = x (DCLn + Width of the Launder) x Width of the
Launder = x (48+1) x 1
= 153.94m
Launder Loading = QCLRn / Launder Surface
Area = 1800/153.94
3 2
= 11.69 m /m /h < 12.30
3 2
m /m /h Hence, Launder design is acceptable.
6.6 Rapid Gravity Filter:

6.6.1 Selection Design of Rapid Gravity Filter is as Follows:
 Total No. of Gravity Filters = 4 Nos.
 No. of Sections per Filter = 2 Nos.
 Capacity of Each Filters, QBFDn = 600 m3 / h
 Design Rate of Filtration, RFBFDn = 8 m3/m2/h
 Filtration Area = QBFDn / VBFDn
= 600 / 8
= 75 m2
To obtain minimum filtration area 75 m2, a 9.5m Long x 8.0m Wide per Filter
(Actual
Filtration Area = 76 m2) with anthracite coal, quartz sand and gravel will be
provided.
Each filter will have two (2) nos. equal sections.
6.6.2 The Depth of Gravity Filter above bottom of will be as follows:

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GID-082-ME-BS-1123
• = 500mm
Gravel (2 to 5mm size at top to 50mm at bottom)
• = 250mm
Sand (Size = 0.5mm, UC = 1.5)
• = 500mm
Anthracite (Size = 1.0mm, S.G = 1.55)
= 2500mm
• Water Depth Over Sand to accommodate the terminal
pressure drop of 2.0m
•
=
Total Depth over Bottom of Filter Media 3750mm
6.6.3 Laterals and Orifices:

Total Perforation Area = 0.003 x Filtration Area
= 0.003 x 76
= 0.228 m2
 Total Cross section Area (CSA) of Laterals= 3 x Total Perforation
Area = 3 x 0.228
= 0.684 m2
Perforation Area per Section will be 0. 0.342 m2 (0.684/2 m2)
Selected Diameter of the Lateral = 80mm (0.08 m)

 CSA per Lateral = x 802
/4 = 5026.4
mm2 =
5.026 x 1 0-3
m2
 No. of Laterals = Total CSA / CSA per
Lateral = 0.684 / 5.026 x
10-3 = 136 Nos.
Total 140 Nos., i.e., 70 Nos. laterals per section of filter will be provided.
 Perforations per Lateral = Total Perforation Area
No. of Laterals

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GID-082-ME-BS-1123
= 0.228 / 140
= 1.628 x 10-3 m2
 Considering 12mm dia. (CSA = 1.13 x 10-4 m2) Orifice,

Total no. of orifice per lateral = Perforations per Lateral / CSA
of Orifice
-3
= 1.628 x 10 / 1.13
x 10-4 = 14.40 Nos.
Total 16 nos. Orifices per lateral will be provided.

 Considering One no. manifold per section (70 Nos, laterals per manifold
located equally on either side of the each manifold),
Cross Section of Manifold each Manifold = 1.5 x Total CSA of Laterals per
Section
= 1.5 x (0.684/2)
= 0.513 m2
Hence, Manifold of 850mm Dia. (Flow CSA = 0.567 m2) will be provided.
Length of the Lateral per Filter Section = (Filter Width / 2) – 300mm for end
clearance - Manifold Size
(8.0/2) – 0.2 – 0.85
2.95m
Length of Lateral of each Lateral 2.95 / 2

1.475m
Length of Lateral / Diameter of Lateral = 1.475 / 0.08

= 18.43 < 60, Hence Acceptable.
Spacing of Orifice = Length of Lateral / No.
Orifice = (1.475 / 16) x
1000mm
= 92.19 mm
Hence, 16 nos. Orifices at 90mm C/C spacing will be provided.
 Summary of Laterals and Orifices:

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GID-082-ME-BS-1123
SL. DESCRIPTION VALUE

NO
1. No. of Filter Sections = 2 Nos.
2. No. of Manifolds = 2 Nos.
3. Diameter of Manifold = 850mm
4. = 70 Nos.
No. of Lateral per Filter Section
5. Diameter of Laterals = 80mm
6. = 1475mm
Length of Laterals
7. Size of Orifice = 12 mm
8. = 16 Nos.
No. of Orifices per lateral
9. Total No. of Orifices per Filter = 2240
10. = @ 90mm C/C

Spacing of Orifices
6.7 Spent Backwash Water Sump
Assuming Square tank, L x B x H of the tank will be 9m(L) x 9m(W) x 2.5 m(D)
with a net capacity of 200 m3. A local sump of 4(L) x 2m(W) x 2m(D) size will be provided
for pump bowl including minimum submergence and bottom clearance of pump. The gross
capacity will be 218.5 m3.
6.7.1 Spent Backwash Water Pumps
 The selected pump capacity is 1400 m3 /hr at total bowl head of 10mwc. For
this purpose two (2) nos. (1 Working + 1 Standby) pumps have been
considered.

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6.8 Sludge System Design
6.8.1 Sludge Thickener
 A Sludge Pit of 4.5(L) x 4.5(W) x 3.0(H) with a net capacity of 50 m3 of will

be provided.
 As per APGENCO Specification, to feed the Sludge Thickener from Sludge

Pit, two (2) nos. (1 working + 1 standby) Sludge Transfer Pumps of 50 m3/h.
@ 25mwc will be provided.
 Sludge Thickener of 50 m3/h capacity will be provided.
 Solid Concentration in Clarifier Underflow = 2%
Hence, the Solid load in Clarifier underflow = 2% x 50
= 1 m3/h
= 1.2 tons /h (SG = 1.2)
 Considering solid loading rate for as 80 kg/m2/d, required flow area of Sludge
Thickener = (1.2 x 1000 x 24) / 80
= 360 m2
Hence, Sludge Thickener of 22.6 (ID) x 4.0m (SWD) will be provided.
6.8.2 Centrifuges
 Considering outlet concentration of Sludge Thickener as 5%,
Sludge Thickener Underflow = 1.2 / 5%
= 24.00 tons/h
= 21.81 m3 /h (SG = 1.1)
Hence, two (2) nos. (1 working + 1 standby) Centrifuges of 25 m3 /h will be

provided.
 Two (2) nos. (1 working + 1 standby) Sludge Feed Pumps of 25 m3 /h will be

provided to feed the Centrifuges.

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6.9 Chemical Doing System

6.9.1 Alum Dosing System:
 Dosing Rate = 50mg/l = 50 g/m3
 Alum Requirement = (QCLDn + QCLDd) x Dosing Rate
= (1900+300) x 50
= 110,000 g/h = 110 kg/h
 Considering 10% concentration of Alum in Water, the solution dosing rate will
be = Alum Requirement / Alum Concentration
= 110 / 10%
= 1100 kg/h
= 1210 lph (S.G=1.1)
 Hence, Two (2) Nos. (1 Working + 1 Standby) Plunger / Diaphragm Pumps of
1500lph @ 20mlc will be provided dose Alum at Flash Mixer.

3
As per APGENCO Specification, Two (2) Nos. 7.5m capacity Alum Preparation
Tank with top mounted SS agitator and SS Dissolving Basket will be provided.
The size of the tank will be 2.2m (L) x 2.2m (W) x 2.0m (H) with gross volume of
9.68 m3.
6.9.2 Lime Dosing System:
 Dosing Rate = 20mg/l = 20 g/m3
 Lime Requirement = (QCLDn + QCLDd) x Dosing Rate
= (1900+300) x 20
= 44,000 g/h = 44 kg/h
 Considering 5% concentration of Lime in Water, the solution dosing
rate will be = Lime Requirement / Lime
Concentration
= 44 / 5%
= 880 kg/h
= 968 lph (S.G = 1.1)

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GID-082-ME-BS-1123
 Hence, Two (2) Nos. (1 Working + 1 Standby) Screw Pumps of 1500lph

@ 20mlc will be provided to Dose Alum at Flash Mixer.
 As per APGENCO Specification, Two (2) Nos. 6.0m3 capacity Lime
Preparation
Tank with Side mounted CS agitator and SS Dissolving Basket will be
provided.
The size of the tank will be 2.2m (L) x 2.2m (W) x 2.0m (H) with gross
volume of
9.68 m3.
6.9.3 Polyelectrolyte Dosing:
 Dosing Rate = 0.05mg/l = 0.05 g/m3
 Poly Requirement = (QCLDn + QCLDd + Sludge Feed) x Dosing
Rate = (1900 + 300 + 50) x 0.05
= 112.5 g/h = 112.5 x 10-3 kg/h
 Considering 1% concentration of Poly in Water, the solution dosing
rate will be = Poly Requirement / Poly
Concentration
= 112.5 x 10-3 / 1%
= 11.24 kg/h
= 12.37 lph (S.G = 1.1)
 Hence, Two (2) Nos. (1 Working + 1 Standby) Plunger / Diaphragm Pumps of

500lph @ 20mlc will be provided to Dose Poly at Sludge Thickener.
 As per APGENCO Specification, Two (2) Nos. 5.0m3 capacity Poly Preparation
Tank with top mounted CS agitator and SS Dissolving Basket will be provided.
The size of the tank will be 1.8m (L) x 1.8m (W) x 2.0m (H) with gross volume of
6.48 m3.

BGR Energy Systems LTD Power Projects Division Kakatiya PTP O&M Manual GID-082-ME-BS-1123

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BGR Energy Systems LTD Power Projects Division Kakatiya PTP O&M Manual GID-082-ME-BS-1123

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BGR ENERGY SYSTEMS LTD

POWER PROJECTS DIVISION Sheet 1 of 38

KAKATIYA PTP O&M MANUAL

ANDHRA PRADESH POWER GENERATION CORPORATION

KAKATIYA THERMAL POWER PROJECT

STAGE-I, UNIT-1, 1 X 500 MW

KAKATIYA PTP O&M MANUAL

BGR ENERGY SYSTEMS LIMITED

DATE PREPARED BY CHECKED BY APPROVED BY

KAKATIYA PTP O & M MANUAL

Sr. No Title Page no

1.3 scope of work 5

1.4 Plant Description 7

2.0 DESIGN PARAMETERS

2.1 Raw Water Characteristics 9

2.2 Treated Water Quality 9

3.0 PROCESS DESCRIPTION

3.2 Flow Measurement 11

3.3 Flash Mixer 12

3.4 Flocculation Process 13

3.5 Clarification Process 14

3.6 Filtration Through Rapid Gravity Sand Filters 15

3.6.1 Operation in General 16

3.7 Sludge Thickening 18

KAKATIYA PTP O & M MANUAL

4.0 PLANT COMPONENTS DESCRIPTION

4.1 The Treatment units of the plant area under 19

4.2 Description of Dosing System & Other Compound 19

5.0 PROCESS DESCRIPTION AND TREATMENT

5.1 Stilling Chamber & Flash Mixer 20

5.2 Alum Dosing System 21

5.3 Lime Dosing System 21

5.4 Poly Dosing system 22

5.6 Sludge Pit 23

5.7 Sludge Thickener 24

5.8 Sludge Feed pump 24

5.10 Rapid Gravity Filter 26

6.0 MAJOR DESIGN PARAMETERS

6.1 Cascade Aerator 30

6.2 Stilling Chamber 30

6.3 Parshall Flume and Inlet Channels 31

6.4 Flash Mixer 31

6.5 Clariflocculator Sizing 31

6.6 Rapid Gravity Filter 33

6.8 Spent Backwash Water Sump 36

KAKATIYA PTP O & M MANUAL

6.9 Sludge System Design 37

5.10 Chemical Dosing System 38

REFERENCE DOCUMENT & DIAGRAM

Sr. No Dwg. No. Title

1. GID-082-ME-XB-1042 P&I Diagram PT Plant

2. GID-082-ME-BS-1108 Design Basis Report- PT Plant

3. GID-082-CI-CP-4054 Control Philosophy of Pre Treatment Plant

KAKATIYA PTP O & M MANUAL

1.3 SCOPE OF WORK

Broadly the scope of work shall include the following:

 1 No. Stilling Chamber, Parshall Flume, Flash Mixer common for 2

 Clariflocculators rated capacity CF 1 - 1800 M3/Hr. + CF 2 - 250 M3/Hr

KAKATIYA PTP O & M MANUAL

 Nos. Centrifuge units

 Centrifuge Supernatant collection & return system to the stilling chamber.

 Nos. 3 T Trolleys for disposal of sludge

 x 100% Filter Air Blowers