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251-02-12 Rev.5
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Table of Content
PHILOSOPHY OF OPERATION
TABLE OF CONTENT
1.1 INTRODUCTION
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APPENDICES
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1.1 Introduction
The North Jeddah Main Lift Pump Station is designed to cater for an ultimate average design
flow of 750,000 m3/day of domestic effluent, with peaking factor of 1.5 times DWF, in 2
Phases with the current contract designed to cater for a design flow of 250,000 m3/day and
this operating scenario is based on the current proposed Phase 1 flows. This staged
construction is in compliance with Contract Specifications Volume-3, Section 01, Clause 2.1
and 3.1. and the System Operating Philosophy is in accordance with requirements of
Volume-7, Section 01, Clause 4.5 where applicable. Details of proposed operating levels and
flows for Phase 2 are also shown within the document. This document is generated based
on the following Documents:
o
P&ID Drawings
HAZOP Study
The station comprises of the following: (Refer to Flow Scheme Section 3 Appendices)
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Nevertheless the as built situation of the tunnel between Shaft 1A and NJPS entry at Screen
shaft B3 is now fully different of the design profile. The new situation has now to integrate a
counter slope of 0.80 m located at recovery shaft N 2 (RShaft2) between shaft 2B ab 3B.
The main consequences are following:
o
The slope between shaft 1A and RShaft2 is lowered from 1.4 mm/m to 0.7 mm/m,
but the shape of the invert generates a permanent storage with settlings of max 0,8
depth between 1A and RShaft2
The slope between RShaft2 and the inlet of NJPS at the screen shaft B3 is increased
from 1.4 mm/m to 2.02 mm/m. The consequence is higher speed at B3 entry with
lower Water Level and control problem for the pumps operation. An operating
solution has been developed for solving this problem
The frame basement of the Safety Penstock at Shaft 1B will be subject to fine sand
settlements up to 0.3 or 0.4 meters. This situation can prevent the safety penstock
from closing. An operating solution can solve this problem
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Design flow range of 1.45 m3/sec to 13.2 m3/sec when operating between 1 and 6
duty pumps in 2 Pump Shafts.
Minimum flow velocity of 0.5 m/sec at all times to avoid solids settlement.
To meet the requirements of the above minimum acceptable velocity a design flow
of 2.9 m3/sec (2 pumps operating at minimum flow of 1.45 m3/s) is adopted
specifications
Comments:
After study of all combinations of rotation speeds of the pumps and the consequences on
the downstream equipments so as the Airport 1 treatment plant and the velocities in the
downstream screens, channels and suction headers it appears that the minimum velocity of
0.5 m/s will have many adversely affects:
o
Long stop periods over the day at actual and short term flow ( 150,000 to 200,000
m3/d), during these stop periods the velocity in any process stage is equal to ZERO
and the fine and microscopic sand in waste water will settle everywhere. These
settlements have thixotropic properties and cannot easily be resuspended in the
wastewater flow.
A permanent velocity in the system corresponding to a minimum flow which is
physically possible due to the minimum possibility of the VFDs for example
between 1.5 and 1.7 m3/s will permit to insure 0,31 respectively 0.35 m/s in the
suction header.
1.5 and 1.7 correspond to 168,000 respectively 190,000 m3/d with an observed peak
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factor of 1,3 on Airport 1 WWTP this hypothesis matches the actual and short
term situation.
o
Safety: if 1 pump is out of service there will be no internal pumping safety in 1 one
shaft and needs to change the duty shaft, which should be avoided.
For these reasons we advise and propose to implement following Philosophy for the
pumping :
Keep always 1 pump operating until low level (or stop level)is reached. Take 2nd pump into
operation if pump 1 is on max flow and level still raising. Pumping flow can be adjusted
taking in account table A
2 PHILOSOPHY OF OPERATION
A said above, the philosophy of operation had to, and has been reviewed in order to
manage the new as built situation in the tunnel, and also the necessity to avoid pump stop:
The incoming water levels have been compensated in order to mitigate the high water
speed. The type of the compensation which has been fixed is linear between the +0.30 (WL
= 0.48 + 0.30 =0.78) at 1.45 m3/s flow up to +0.72 m (WL = 1,48 + 0.72 = 2,20) at 13.2 m3/s
The corresponding speeds are decreased from 1.86 m/s to 0.93 m/s and 3.43 m/s to 2.08
m/s. Now the incoming speeds are compatible with good practice in pumping station
operation
The new control/regulation of the pumping integrates as well the start/stop set points of
the pumps up to 6.6 m3/s (3 pumps at 100% flow) as the flow/frequency
adjustment/regulation in order to adapt the flow to the theoretical compensated WL in
the inlet of B3 (Table A)
The previous developed scenario 1-1A based on level regulation is obsolete and is deleted.
The scenario 2 based on flow regulation only is deleted
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The needed energy to operate these 2 safety penstocks has been specially secured:
Shaft 5B
2 SCECO sources + autonomous internal oil pressure tank permitting 1 complete cycle
closing + opening for penstock in 5B. (Mainframe and balancing gate closure and opening
times: 2 minutes each)
Shaft 1B and Shaft 5B
2 Generators thereof 1 stand-by + autonomous internal oil pressure tank permitting 1
complete cycle closing + opening for Penstock in 1B. (Mainframe and balancing gate
closure and opening times: 2 minutes each)
The closing command signal comes from level validated by HHL from B3 Shaft meter with
report to SCADA. The local automation is assured by local PLCs connected to SCADA
Due to the deviation in the as built profile of the tunnel the excercise (Level 3 weekly)
operation of the Safety Penstock in Shaft 1B is modified as follows: when closing the
Penstock at average flow (between 2.2 m3/s and 2.4 m3/s , there has to be a stop at 90%
from the top or 10% opening of the diameter (0.35 to 0.40 cm) in order to flush the
settlements on the bottom of the penstock(Flushing Velocity in the restricted section: 4m/s
at 2.2 m3/s 1 pump full flow). After the flushing time out (to be set) resume the exercise.
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spiral conveyor which - depending on the setting of the manually operated hopper flap transports the material into one of the two wash presses.
Line 2:
Identical to Line 1.
Automatic Control from Local HMI:
Automation of the plant, (Line 1 and 2), which is set up via the Screening Panel HMI, is
effected via a programmable logic controller from Siemens, type S7-300. All processrelevant parameters (filling levels, times and counters) are visualized by means of a
monochrome 5.7 touch panel, type KTP 600 from Siemens. All rated and actual values can
be read and set via this touch panel and so be adjusted or altered according to the operating
conditions. Therefore, no PLC programmer is required for optimizing the process sequences
to the local circumstances and conditions.
shifts
the
screenings
across
the
chute
into
the
provided
double
conveyors/compactors.
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The defined philosophy of operation, viz differential level control and 2 speed operation will
automatically cater for varying degrees of screenings encountered as a result of varying
flows and amounts of debris and thus providing optimum operating conditions at all times.
A manually commanded reverse operation of the screens permits to unblock the screen(s) if
necessary.
The screening plant operates independently of the pumps with a purpose to provide
screening of the incoming wastewater and thus protection for the pumps and thus the
differential control is applicable overall operating levels within the screen channels
independent of pump operation.
During Stage 1 a single duty screen is operated, in the selected line, and duty rotation is
arranged automatically on a daily basis to provide flushing of any accumulated solids
upstream of non operating units. The respective penstocks, upstream and downstream of
the screens is closed on the duty unit and opened on the selected changeover unit
automatically at the same time. Nevertheless it may be necessary that 2 screening channels
have to be operated in case of high inflow of trash, (for example after a longer period of
sewerage storage in the tunnel and/or storm water inflow (see FHR p22). This can also be
the case in Phase 1A. It has to be noted that the opening/closing time of the up and
downstream penstocks of the screens is around 15 min
2.2.1.1 Water level difference (differential level, speed 1)
Each of the 3 KUR Revolving Chain Screens is equipped with a pole-changing drive and thus
two rotational speeds. Depending on the water level in front of and behind the screen, it is
operated at the first or second rotational speed.
An ultrasonic sensor is installed in front of and/or behind each screen in order to detect the
filling levels in front of and behind the screen. The respective filling level is transmitted via a
4-20 mA signal to the automation system. At this point the differential level is calculated
(level in front of the screen - level behind the screen) and visualized via touch panel in the
switch cabinet door and in the hydraulic profile screen.
The exact level differential is monitored during commissioning to gauge optimum level;
however this is expected to be in the range of 150mm (low differential) to 300 mm (High
Differential). Comment: the nett value of WLC due to clogging of the screen can be
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calculated
depending
on
flow
or
recorded
as
table
in
PLC
WLC = WL WLHEADLOSS
This could be useful for high flows, to avoid permanent operation of the screens
As soon as the specified limit value for "differential level ON" is exceeded, the respective
screen will start at the first rotational speed. When the differential level drops below the
specified limit value for "differential level OFF", the screen will stop after an adjustable runon time.
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fed with solid matter. The hinged flap must be adjusted manually with a lever.
Position 1: Operating mode selector switch (key switch) Selection of the operating mode in
which the respective double spiral conveyor is to be operated.
Automatic mode (Point 3.2)
0 (off)
Manual mode
Position 2: Pushbutton used to activate the 1. Spiral forwards in Jog mode (Manual
operation).
Position 3: Pushbutton used to activate the 2. Spiral forwards in Jog mode (Manual
operation).
Position 4: Emergency-Off button which, when operated, stops the screening plant (Line
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2.2.5 Mixers
The volume underneath the slab of screening channels at -30m (around 4000 m3 on each
line) is equipped with two mixers (each line) these mixers are working in an autonomous
way and are not linked to any external device. The control is local with back information to
the SCADA. They work only if the concerned volume is flooded.
.
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of 20 minutes minimum.
Levels are selected to provide optimum flow velocities in screen approach channels as
determined by the tunnel slope.
Minimum pump operating frequency of 55Hz would equate to operating level for flow of 1,5
m3/sec (-28.44) and maximum design capacity of 4.4 m3/sec (2 pumps full flow) would
equate to level of -27.94
HHL alarm would be set at -26.33 at which level the inlet penstock would close.
LLL at which point pumps cut out would be set at -30.00
Sequences:
o
Pump no1 operates constantly, start at minimum flow at WL -28.38, increases the speed
of VFD when flow increases up to 2,2 m3/s, following the flow/height table A up to
-28.16 m (WL 2.9 ) at maximum flow
If WL decreases go to yellow column and speed will decrease down to stop level ( -28.
43), if WL (re)increases in this sequence, increase speed/flow etc..
If WL reaches -28.16m and continues raising then start pump no 2 at min flow and
decrease pump no 1 to min flow , so total pumped flow = 2.9 m3/s
If WL 4.4 is reached AND is decreasing, decrease frequency of VFDs and follow flow down
to WL
2.9,
stop level of Pump 2 and stop pump 2, follow the flow with pump 1 (up or constant to
stop level of pump 1)
Start pump no 3 until WL decreases, stop pump 2 & 3 at stop level P 2&3 (-28.30)
Continue following Flow/Level with pump no1 until stop or WL increases again
Tunnel emptying:
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Regulate Balancing gate and Main gates so that the current WL will remain
constant (+/- 5 cm) around WLEmptying Tunnel
WLEmptying Tunnel
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Table A
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Table B
2 Pumps
Min Flow
2 Pumps
2.5
m3/sec
1.45
2.2
2.9
4.4
m/sec
0.30
0.45
0.59
0.90
1 Pump
4 Pumps
2.5
m3/sec
m/sec
4.4
0.90
5 Pumps
*
**
* One shaft with 2 pumps and 2nd shaft with 3 pumps and Q of 4.4 and 6.6 m3/sec respectively
** Velocity of 0.9 m/sec for 2 pump operation and 1.34 m/sec for 3 pump operation
Acceptable Velocity for microscopic and very
fine sand
Acceptable Velocity
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3 Pumps
Comments
6 Pumps
Comments
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Evaluation of the normal incoming flow through statistics at the give time
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then be operated if a duty unit fails. After the Ionisation Section the air then passes
into the main discharge duct. The discharge duct descends to level -21.2m AOD
and is branched off to serve the various areas, with volume control dampers
(VCDs) to control the volume of air being distributed on each duct.
The Combined Air Volume being delivered by the two duty Terminodour Units is
12.38m3/s.
The ionization process on this site is designed to permanently operate to ensure
that all odours are eliminated (i.e. 24 Hrs. / day).
Auto operation
1. Select Duty Fans.
2. Switch auto / off / manual selector switch to auto.
3. Switch Ionisation auto / off / manual selector switch to auto.
4. The ionisation system will then be ready to start.
5. The Duty Fans will start when the fan auto / off/ manual switch is selected in
Auto, if required an enable signal is to be given by ops. The relevant fan running
lamp is illuminated.
Note: Both switches (Ionisation and Fans) must be in auto for the complete
ionisation system to operate. A de-bounce timer is required to start the duty fan.
6. The supply differential pressure switch is to prove airflow (N/O contacts close
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Fault conditions.
1. Soft Start / O/L failure fan 1, fan 2 or fan 3.
a) Differential pressure switch drops out and switches off Ionisation units
b) Duty fan trip lamp illuminates on appropriate fan starter section, HMI will show
failed fan indication and alarm via Ethernet to Telemetry/SCADA
c) Duty fan stops and running lamp goes out along with running indication on HMI.
d) Standby fan starts running lamp illuminates and running indication shown on
HMI.
e) On confirmation of airflow the 30-second timer will run and allow the system to
be purged prior to the Ionisation units being re-energized.
f) The Ionisation units running indication is shown on HMI.
Note: If Standby Fan fails or is already isolated the Ionisation Units will switch off
and that system will stop.
2. Airflow failure (Start-up)
a) Differential Pressure Switch fails to make. (Ionisation Unit timer does not start)
b) Airflow failure indication is shown on HMI and alarm via Ethernet to
Telemetry/SCADA.
c) Duty fan stops and running lamp goes out with fan trip failure also shown on
HMI.
d) Standby fan starts running lamp illuminates and running indication shown on
HMI.
e) On confirmation of airflow the 30-second timer will run and allow the system to
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containing MV and LV are critical and essential for the good operation and for
the life time of equipments. Therefore a special care has to be given to this
process.
3 APPENDICES
The appendices as referred to below are attached to the Final Hydraulic Summary Report and
can be accessed via that document.
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