Interim Report 150 MLD

Interim Report
Contents
1.
INTRODUCTION
8
1.1
Background
8
1.2
Field Investigations
9
1.3
Bathymetry
9
1.4
Scope of this Interim Report

9
2.
SITE CONDITIONS
10
2.1
Site Appreciation
10
2.2
Finished Floor Level

12
2.3
Climate
12
2.4
Typical Oceanographic Conditions

13
3.
WATER QUALITY
14
3.1
Seawater Quality
14
3.1.1
Importance of Sea Water Quality

14
3.1.2
Temperature and Salinity Trends

15
3.1.3
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15
3.1.4
Water Quality Design Criteria

18
3.2
Water Quality Targets

20
3.2.1
Total Dissolved Solids

21
3.2.2
Boron
22
3.2.3
Jelly Fish Blooms

23
4.
DESIGN LIFE AND AVAILABILITY; PRIMARY FLOWS

24
4.1
Design Life
24
4.2
Operations and Availability

24
4.2.1
RO Rack Configuration
24
4.3
Primary Flows
25
5.
SEAWATER INTAKE
27
5.1
Primary Flows
27
5.2
Intake structure with Screen offshore

27
5.3
Active Screens before the Sea Water Pumps

28
5.4
Sea Water Pumping Station

29
5.5
Shock chlorination system

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32
5.6
Intake / Outfall Pipes

32
5.6.1
Pipe jacking
33
5.6.2
Main Jacking Station

33
5.6.3
Inter-jacks
34
5.6.4
Slurry System
34
6.
PRETREATMENT SYSTEM
35
6.1
Pretreatment Process
35
6.2
Sea Water Quality / Treatment Processes

35
6.2.1
Key Water Quality Parameters Pre-Treatment

35
6.2.2
The Pre-Treatment Processes- Scheme

37
6.3
pH Correction
37
6.4
Coagulation
37
6.5
Flocculation
38
6.6
Lamella Settlers
39
6.7
Dissolved Air Flotation (DAF)

40
6.8
Ultrafiltration (UF)
43
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6.9
Ultrafiltration Water Storage

44
7.
REVERSE OSMOSIS PLANT

45
7.1
Overview of RO Plant
45
7.2
Pumping System Design and Pressure Control

45
7.3
Cartridge Filtration
47
7.4
Oxidant Control
47
7.5
Scale Control
47
7.6
Reverse Osmosis Pumping and Energy Recovery System

47
7.7
RO Rack Design
52
7.8
RO Clean In Place System

54
7.9
Permeate Storage
56
POST TREATMENT
8.
57
8.1
Re-mineralization/Stabilization
57
8.1.1
Requirement for Stabilisation

57
8.1.2
Hydrated Lime & Carbon Dioxide

58
8.1.3
Key design Criteria

59
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8.2
Disinfection
61
9.
CHEMICAL SYSTEMS
67
9.1
Antiscalant
68
9.2
Carbon Dioxide
69
9.3
Chlorine Gas
69
9.4
Ferric Chloride
71
9.5
Hydrated Lime
71
9.6
Flotation Aid Polyelectrolyte

72
9.7
Sodium Hydroxide
73
9.8
Sodium (Meta)bisulphite
74
9.9
Sulphuric Acid
75
9.10 Ultra Filtration Chemicals

76
9.11 Miscellaneous Chemicals
76
9.11.1
Cleaning-in-place (CIP)
77
9.11.2
Flushing
78
10. WATER STORAGE AND TRANSFER

79
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10.1 Process water storage

79
10.2 Process water transfer pump station
79
11.
SEAWATER OUTFALL
80
11.1 Outfall Pipeline
80
11.2 Diffusers
80
12. POWER AND CONTROL

81
12.1 Power supply
81
12.1.1
Background
81
12.1.2
Design Considerations
81
12.1.3
110 kV / 11 kV Substation within the Plant premises

82
12.1.4
Pumping station electrical works, controls and electrical systems

82
12.1.5
Emergency power generation

83
12.1.6
Electrical Equipment
83
12.2 Control System

84
12.2.1
General Design Criteria

84
12.2.2
Plant Operation Methods

85
12.2.3
Control System Architecture

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85
13. CIVIL, BUILDING AND STRUCTURAL WORKS

87
13.1 Plant Buildings
87
13.1.1
General
87
13.1.2
Platforms, Access Ways and Stairways

88
13.1.3
Lifting Devices
88
13.2 Road works

88
13.3 Site Services
89
13.4 Storm water Drainage
89
13.5 Fire Systems
89
14. PRODUCT WATER MAIN

90
14.1 Annexure
96
14.1.1
Pipe sizing and pump capacity for 550 MLD

96
14.1.2
Pipe sizing and pump capacity for 2 X 275 MLD

99
14.1.3
Pipe size and pump capacity for 400 MLD

102
14.1.4

105
15. BENEIFTS OF LONG-TERM O&M CONTRACT

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108
Executive Summary
Survey Data
Significant findings in respect of Field Work and Historical Data gathering
including the data of existing 100 MLD Neemeli SWRO are as following:
1.
Sea Water quality is poor.

TSS measured in July/August 2013 on the seabed offshore from Perur
( for the proposed 400 MLD SWRO) was, on average, 73.3 mg/L, and 48.7
mg/L at the surface.
The specification for the Nemmeli desalination plant nominates a design

range for TSS of 50 mg/L to 200 mg/L. By comparison, the desalination
plant for Sydney is designed for TSS of 7 mg/L.
Intake water quality data from Nemmeli plant was provided for the period
from and including May 2013 to early December 2013. The data shows
poor water quality on a number of occasions as evidenced by frequent
spikes in turbidity. These spikes in turbidity resulted in plant shutdown on
13 days in the period of record ie a loss of production on 7% of days of
record.
In July 2013 the Nemmeli plant was closed for 5 days; the water quality
data shows that there was no discernible change in salinity in this period.
In the first week of December 2013 the plant was closed for 4 consecutive
days; the water quality data shows that the salinity dropped significantly
over this period indicating the influx of fresh water, which contained high
levels of suspended solids.
There is strong evidence that jelly fish are frequently in abundance along
the Chennai coast and have caused considerable nuisance in power
station intakes.
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In literature, algal blooms have been documented along both the west and
east coasts of India. It can be expected that algal blooms will impact upon
a desalination plant at Perur from time to time.
3.
Longshore sediment transport is generally to the north between April and

October, and to the south from November to March.
The influence of
littoral drift is significant and the annual net drift takes place in a northerly
direction.
Pre-treatment Processes
High levels of TSS, algae and jelly fish are expected to be drawn in at the
intake to the plant, either constantly or cyclically, and the pre-treatment
plant must be designed to maintain a high quality feed to the desalination
plant, over the long term.
Because of the jelly fish, at the intake offshore a vertical screen with 100
mm c/c have been proposed to have an approach velocity not exceeding
0.1 m/s at peak flows. A fish net is proposed to be placed outside the
vertical mesh screens to reduce the intake of jelly fish.
Fine screens will be provided before the sea water pumps to capture the
jelly fish and minimise the chance of breaking up the jelly fish, which
would make it harder to remove jelly fish particles.
The fine screens will be provided with 3 mm apertures, targeting jelly fish.
.
DAF process may be capable of handling 10-20 mg/L of TSS, but would not
be capable of handling greater than 75 mg/L of TSS.
For this reason
Lamella settlers, preceded by coagulation-flocculation and polymer

dosing have been suggested. It is expected that the Lamella settlers will
significantly reduce the TSS, but will be only partially successful in
removing the larvae, algae and jelly fish particles off neutral buoyancy;
this material should be removed effectively by the following DAF and
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filtration processes.
A DAF loading rate of 8 m/hr has been nominated, when operating with 20%
recycle. The nominated recycle rate is high, cf 10 to 12 m/hr at other plants,
so as to be able to handle the anticipated high solids loading rate. Lower
recycle rates will be available to the operator when the water quality is good.
The DAF will be followed by Ultrafiltration (UF), due to space constraints. The
gross flux shall be 50LMH.
RO Plant
Membrane Flux and Overall Recovery
The RO plant is a single stage/single pass design with an overall recovery of
46% specified.
SWRO membrane elements of 8-inch diameter have been selected.
Each
pressure vessel will house eight membrane elements. The design treated water
TDS for the RO plant is 300 mg/L. In sizing the RO plant, an average membrane
flux of approximately 13.5 L/m2/hour (LMH) has been selected. The provision
of 8% spare space for more membranes provides the flexibility to reduce the
flux if warranted, to reduce cleaning frequency or reduce power consumption.
Based on preliminary membrane projections for DOW and Hydranautics
membranes, it is anticipated that the required membrane pressure will range
between 51.6 bar and 65.3 bar, depending on feed water and membrane
conditions, and depending on the membrane selected. In order to provide the
above pressure range, and based on the design temperature and salinity
ranges set out depicted in the report, a combination of VSD driven booster
pumps and fixed speed RO HP pumps has been selected to provide operational
flexibility and minimise electrical energy costs.
With this design the RO Booster pumps will provide feed pressure adjustments
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suitable to cover the required membrane pressures for average to maximum

salinity events. For feed waters with below average salinities further controls
will be required in the form of a HP throttling valve, essentially burning-off
excess energy created by the pumping system upstream.
Potabilisation
This design nominates a target alkalinity of 40 to 60 mg/L as oppose to the ISO
standard of 200 mg/L (Desirable). This is because at this alkalinity, a positive
Langelier Index is achieved, which is the minimum requirement for addressing
the risk of corrosive water. Higher target alkalinity, while desirable (as it would
further reduce the risk of corrosive water by minimising pH change in the final
water) would require additional stabilisation chemicals, and therefore additional
cost.
The nominated target alkalinity thus represents a balanced approach
between water quality and cost.
Product Water Main

All pipes above 1.1 m dia have been proposed as Carbon Steel with internal and
external lining, whereas all pipes below 1.1m are stated to be Ductile Iron with
internal CC lining.
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1.
1.1
INTRODUCTION
Background
Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB) is the

statutory body responsible for providing water supply and sewerage infrastructure
to the entire city of Chennai, and although its present operation is limited to the
Corporation City limit, the Board is extending its services to the entire Chennai
Metropolitan Area as development progresses.
Water demand for City (for the year 2016)
1133.0 MLD
Industries
37.0 MLD
Bulk water supply to establishments
28.0 MLD
Sriperumpudur
17.7 MLD
SIPCOT Industrial estate
14.0 MLD
Added Areas of CMA

(such as Avadi, Pallavaram, Pammal and Tambaram
etc).
Total Water Demand
329.0 MLD
1559 MLD
Supply
831 MLD
GAP
728 MLD
As a step towards meeting the demand and matching the provision of

infrastructure with the citys growth, CMWSSB has commissioned consultancy
services to conduct prefeasibility studies, along with preparation of DPR, into the
construction of a Sea Water Reverse Osmosis (SWRO) Plant at Neemeli village
along the East Coast Road (ECR), within the premises of existing 100 MLD
Neemeli SWRO plant
1.2
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A major component of the seawater quality assessment study is to carry out a

seawater quality monitoring program to characterise seawater for the proposed
seawater intake as well for engineering and process design of the plant.
To fulfil the assignment, data on sea water quality, temperature, salinity, and
seasonal water quality was collected and is presented in sections below.
1.3
Bathymetry
The data collected from the survey reports of existing of 100 MLD Neemeli and the
oceanographic survey carried out for the proposed 400 MLD SWRO to be located
next to Neemeli, the bathymetry chart shows that the depth contours are generally
running parallel to the coast. The seabed exists with the gradient of 1:40-1:70 till 7
m depth and downstream showed the gradient of 1:150-1: 250.
1.4
Scope of this Interim Report

This Report covers draft design, drawing and technical specifications for the
proposed desalination plant and conveyance system to convey potable water to
the city of Chennai. The draft technical specifications are process focussed and
set out the design parameters for the equipment to be supplied for the said plant.
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2.
2.1
SITE CONDITIONS
Site Appreciation
The proposed site for 150 MLD desalination Plant is located within the premises of
existing 100 MLD Sea Water Desalination Plant at Nemmeli along East Coast Road,
Kancheepuram District, Tamilnadu, India. The site is located at eastern side of East
Coast Road (ECR) at 12 42' 08" North, 80 13' 29" East and is approximately 40 km
of south of Chennai city.
The climatic conditions are characterised by warm dry winters (27 OC average daily
max) and hot wetter summers (39 OC average daily max) with an annual average
rainfall of 1200mm. Cyclones are common in the area and the site is expected to be
effected by approximately 3 per year.
Fig 1:Site Location
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Fig 2:Site Location with respect to proposed 400 MLD Perur Desalination
Plant
The site for the proposed 150 MLD is spread over an area of around 9 acre,
placed within the premises of existing 100 MLD SWRO Neemeli. The area has
non-uniform width with around 100 m frontage on the sea side, which increases in
the middle of the site towards the ECR, however again on the road frontage is
tapered due to presence of existing Burial ground.
Therefore with the above site conditions, the uniformity of area available is a major
constraint, which in turn condenses the effective space utilization for engineering
and planning of the facility. Therefore with the above physical constraints, the plant
with membrane pre-treatment is proposed for an output capacity of 150 MLD.
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Interim Report
2.2
Finished Floor Level

The finished floor level of existing Neemeli 100 MLD SWRO plant is 6.5 m, which
had been kept 0.9 m above the last Tsunami level, therefore the Finished Surface
Level (FSL) of RL 6.5 is being proposed for the said plant. Finished Floor levels
shall be set at not lower than RL 6.8 m and equipment plinth levels not lower than
RL 7.0 for ease in operations.
2.3
Climate
Chennai, Tamil Nadu has a tropical wet and dry/ savanna climate (Kppen-Geiger
classification: Aw) with a pronounced dry season in the low-sun months, no cold
season, wet season is in the high-sun months. According to the Holdridge life
zones system of bioclimatic classification Chennai, Tamil Nadu is close to
the tropical dry forest biome.
Figure 3 Temperature profiles
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Figure 4 Rainfall (monthly averages)

2.4
Typical Oceanographic Conditions

The oceanography of this region is influenced by 3 climatic conditions viz.,
southwest monsoon (June September), northeast monsoon (Mid - October to
Mid - March) and a fair weather period (Mid - March to May). The coast is more
influenced by the northeast monsoon
than other two seasons. Wave action is
high during northeast monsoon and
Fig 5: Typical Cross Section of Coastal

Form
cyclonic period. Storm surge at Nemmeli has been estimated to be up to 4 metres

above chart datum (ie approximately RL 3.5). The coastal current within 5 km
distance from the shore is greatly influenced by wind and tides. The near shore
current
remains
more
dynamic
Fig
and
turbulent due to persistent action of

seasonal wind, high waves and coastal
currents. The distribution of temperature
and salinity indicates that the near shore
water is well mixed without stratification.
The influence of littoral drift is significant
Fig 6: Tidal Varitionas
and the annual net drift takes place in a northerly direction. The near-shore waters
support certain type of demersal fisheries with moderate bottom animal
community. Tourism and beach resorts are developing rapidly in this region.
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3.
WATER QUALITY
3.1
Seawater Quality
3.1.1
Importance of Sea Water Quality

Knowledge of seawater quality and variability (diurnal and seasonal) is important
for the engineering of SWRO desalination plants. The inherent seawater quality
and composition is a fundamental factor in the entire process technology of a
desalination plant, from pre-treatment selection to process plant design,
remineralisation requirements and impacts on the disposal of brine. These factors
often have a decisive impact on both capital investment costs and operation and
maintenance expenses of the plant.
Temperature and salinity are critical water quality parameters for SWRO design.
Information on the seasonal range in salinity and temperature of the source
seawater and ion composition is required to design a SWRO plant to meet drinking
water quality targets. Salt passage through the reverse osmosis membranes into
the RO permeate, increases with seawater salinity thus having impact on recovery,
membrane age etc. Seawater salinity and temperature also determine the energy
required to overcome the osmotic pressure in the source water with more energy
required to desalinate colder and more saline water.
In the RO process the membranes are subject to both fouling and scaling which
are very sensitive to feedwater quality. Therefore, it is widely recognised in the
desalination industry that the successful long term operation of a SWRO
desalination plant is contingent on the efficiency of its pre-treatment system in
minimising RO membrane fouling and scaling, thus preventing membrane
hydrolysis caused by any oil or petro-hydrocarbons present in the seawater.
Water quality parameters are important for pre-treatment selection and design of a
SWRO desalination plant include, for example, the range in turbidity, total
suspended solids, oil and grease, organics (TOC and DOC) and silt density index
(not often available), nutrients, particle size etc. In addition, it is critical to have an
understanding of what factors impact on seawater quality e.g. marine
hydrodynamics, point and diffuse pollution sources, riverine inputs during monsoon
seasons, marine activities such as shipping, dredging and the occurrence of algal
blooms that may impact on water quality in the vicinity of the sites.
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3.1.2
Temperature and Salinity Trends

The site, located on the Coromandel Coast on the western side of the Bay of
Bengal, experiences two monsoon periods, the north east monsoon from
October to mid-February when the area receives most of its seasonal rainfall (62%
between mid-October to December) and the south west monsoon from mid-March
to early September (33% of the rainfall). During and following the monsoon
periods, a significant volume of fresh water is flushed into the Bay of Bengal which
may impact on salinity and temperature of seawater at site.
Fig 7: Average Monthly Rainfall in mm, in Chennai
3.1.3
Water quality data was collected off Perur (Next to Neemeli) in late July - early
August 2013. The data was collected at the surface and at the bottom, on six
transects, at locations at 750 m, 1000 m and 1250 m to sea.
The data collected
has been analysed and the average results for the various analytes are tabulated
below, in Table 1
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Table 1
Field Investigations - Seawater Quality
Parameter
Unit
Average at Surface
Average at
Bottom
1
2
3
4
5
6
7
8
9
10
Temp. (C)
TDS (mg/l)
Salinity (ppt)
pH
DO (mg/l)
BOD (mg/l)
COD (mg/l)
Colour, Hazen Units
Odour
Taste
28.4
35,100
34.7
8.20
6.61
2.51
25.0
17.7
Odourless
Salty
27.9
35,200
34.7
8.21
5.89
1.83
39.3
18.7
Odourless
Salty
11
12
Total Alkalinity as CaCO3 (mg/l)

Total Hardness as CaCO3 (mg/l)
111.7
6137
116.0
6038
13
14
15
16
17
18
19
20
21
22
Bicarbonate (mg/l)
TSS (mg/l)
Turbidity (NTU)
NO2-N (mg/l)
NO3-N (mg/l)
Total Nitrogen (mg/l)
PO4-P (mol/l)
Total phosphorus (mol/l)
NH3-N (mol/l)
Magnesium as Mg (mg/l)
127.8
48.7
1.10
0.45
2.68
11.8
0.76
1.45
0.20
1191
126.3
73.3
1.88
0.97
4.08
14.5
0.93
1.36
0.18
1258
23
24
25
26
27
28
29
30
31
32
33
Calcium as Ca (mg/l)
Chloride as Cl (mg/l)
Potassium as K (mg/l)
Sulphate as SO4 (mg/l)
Sulphide as H2S (mg/l)
Colloidal Silica (mg/l)
Reactive Silica as SiO2 (mg/l)
Free Residual Chlorine (mg/l)
Fluoride as F (mg/l)
Oil & Grease (mg/l)
Phenolic compounds as C6H5OH
367
18302
375
2758
<0.01
<0.02
0.84
<0.2
1.49
<2
<0.01
467
18502
391
2878
<0.01
<0.02
1.38
<0.2
1.63
<2
<0.01
<0.5
3.25
<0.5
3.17
(mg/l)
34
35
Barium as Ba (mg/l)
Boron as B (mg/l)
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Interim Report
36
37
38
39
40
41
42
43
Cadmium as Cd (mg/l)
Cyanide as Cn (mg/l)
Iron as Fe (mg/l)
Lead as Pb (mg/l)
Manganese as Mn (mg/l)
Selenium as Se (mg/l)
Total Arsenic as As (mg/l)
Zinc as Zn (mg/l)
<0.01
<0.05
<0.01
<0.01
<0.05
0.022
<0.01
0.092
<0.01
<0.05
<0.01
<0.01
<0.05
0.023
<0.01
0.088
< indicates below the detection limit.

Nemmeli 2013: Intake water quality data from Nemmeli plant was taken for the
period from and including May 2013 to early December 2013, see Figure below.
The data shows poor water quality on a number of occasions as evidenced by
frequent spikes in turbidity. These spikes in turbidity resulted in plant shutdown on
13 days in the period of record ie a loss of production on 7% of days of record.
In July 2013 the Nemmeli plant was closed for 5 days; the water quality data shows
that there was no discernible change in salinity in this period. In the first week of
December 2013 the plant was closed for 4 consecutive days; the water quality data
shows that the salinity dropped significantly over this period indicating the influx of
fresh water, which contained high levels of suspended solids.
.
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3.1.4
Water Quality Design Criteria
The sea water quality adopted for design purposes is tabulated in and
is based on the water quality sampling program as cited above
Table 3 and
In the Normal values are based on the average data gathered from the field. The
Minimal and Maximum adopted values draw upon data gathered from the area, as
set out above, and upon the experience of the designers.
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Table 2
Seawater Quality Design Criteria
Criteria Description
Water Temperatures
- surface
- bottom
Turbidity
Total Suspended Solids
pH
Unit
C
C
NTU
mg/L
mg/L
Normal based
on field
measurements
Minimum adopted
Maximum adopted
28.4
27.9*
<10
75
8.2
35,200
26.0
25.0
10
50
7.7
32,000
30.0
32.0*
125
200
8.5
38,000
Note: * The design of the RO Plant will make provision for a rise in seawater temperature of 1 oC
resulting from the energy input at the pumps.
In
Table 3, the design values for the proposed plant are stated herewith.
Table 3
Seawater Quality Design Criteria Dissolved Solids
Criteria Description
Unit
Normal based on
average field
measurements
Temperature
Bicarbonate (HCO3)
Magnesium as Mg
Calcium as Ca
Chloride as Cl
Potassium as K
Sulphate as SO4
Reactive Silica as SiO2
Fluoride as F
Barium as Ba
Boron as B
Sodium Na
Nitrate NO3
Ammonium
C
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
27.9
35,200
126.3
1258
467
19,247
391
2,878
1.38
1.63
0
3.17
10,789
4
0.2
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Interim Report
3.2
Water Quality Targets

CMWSSB has specified that the water quality targets shall be as per IS 10 500:
1991 (reaffirmed in 1993). The quality parameters as per IS 10 500 1991 are
indicated in Table 4. It is to be noted that the water quality requirements fall into
two groups, Essential Characteristics and Desirable Characteristics.
Table 4: Drinking Water Quality Requirements as per IS 10 500 1991
Sl. No
Substance or characteristic
Requirement
Essential Characteristics
(Desirable
i.
Color, Hazen units, Max.
ii.
Odour
Unobjectiona
iii.
Taste
ble
Agreeable
iv.
Turbidity, NTU, Max.
v.
pH value
6.5 to 8.5
vi.
Total Hardness (as CaCO3) mg/l, Max.
300
vii.
Iron (as Fe) mg/l, Max.
0.3
viii.
Chlorides (as Cl) mg/l, Max.
250
ix.
Residual, free chlorine ,mg/l, min.
0.2
x.
Fluoride (as F) mg/l, max.
1.5
Desirable Characteristics
xi.
Dissolved solids mg/l, Max.
500
xii
Calcium (as Ca) mg/l, Max.
75
xiii.
Magnesium (as Mg) mg/l, Max.
30
xiv.
Copper (as Cu) mg/l, Max.
0.05
xv.
Manganese (as Mn) mg/l, Max.
0.1
xvi.
Sulphate (as SO4) mg/l, Max
200
xvii.
Nitrate (as NO2) mg/l, Max.
45
xviii.
Phenolic compounds (as C6H5OH) mg/l, Max
0.001
xix.
Mercury (as Hg) mg/l, Max
0.001
xx.
Cadmium (as Cd) mg/l, Max
0.01
xxi.
Selenium (as Se) mg/l, Max
0.01
xxii.
Arsenic (as As) mg/l, Max
0.01
xxiii.
Cyanide (as CN) mg/l, Max
0.05
xxiv.
Lead (as Pb) mg/l, Max
0.05
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Interim Report
xxv.
Zinc (as Zn) mg/l, Max
xxvi.
Anionic detergents (as MBAS) mg/l, max
0.2
xxvii.
Polynuclear aromatic hydrocarbons
Chromium (as 0.05
Cr6+) mg/l, Max

xxviii.
(as PAH) g/l, Max
xxix.
Mineral oil mg/l, Max
0.01
xxx.
Pesticides mg/l, Max
Absent
Substance or characteristic
xxxi
Radioactive materials *
a) Alpha emitters Bq/l, Max
0.1*
b) Beta emitters pci/l, Max
1*
xxxi.
Alkalinity mg/l, Max
200
xxxii.
Aluminium (as Al) mg/l, Max
0.03
xxxiii.
Boron mg/l, Max
xxxiv
Langlier Saturation Index
positive
3.2.1

IS 10 500 states that one of the desirable characteristics of drinking water is that
the maximum dissolved solids be limited, and not greater than 500 mg/L. For the
purposes of this report the design target has been set at 300 mg/L for permeate,
such that the dissolved solids in drinking water, after potabilisation, will not exceed
500 mg/L.
3.2.2
Boron
Boron emerged as a water quality issue with the increasing use of desalinated
seawater for both municipal drinking water supply purposes and for irrigation. The
human health effects of boron have been debated for some time with increasing
confidence, and higher allowable concentrations, from studies over the last 10
years. This is reflected by increases in guideline standards, whereby WHO have
changed their guidelines over the last ten years from 0.3, to 0.5 (2008) and now to
2.4 mg boron/L in the most recent (fourth) edition of the guidelines. A summary
statement on the World Health Organisations (WHO) recommended boron
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Interim Report
guideline value has been posted on the WHO Water Sanitation and Health website
at:
www.who.int/water_sanitation_health/dwq/chemicals/boron/en/.
The
new
guideline value of 2.4 mg/L was based on a human health point of view. The level
was derived based on an assumption that 40 per cent of a 60 kg adults total daily
intake of boron is a result of drinking 2 litre of water having a boron concentration
of 2.4 mg/L and a safety factor of 60x.
While sodium and chloride ions are well rejected by RO membranes, boron is not
well rejected because a high portion of the boron species is uncharged. The
rejection of boron is strongly dependent on feedwater pH. Under optimal neutral to
alkaline conditions, boron rejection is 70 to 80%, reducing to as low as 50 to 60%
under more acidic feed conditions.
IS 10 500 states that one of the desirable characteristics of drinking water is that
the maximum concentration of boron be not greater than 1 mg/L.
Modelling
indicates that single pass RO can reduce the concentration of boron to between
0.4 and 1.0 mg/L, assuming a maximum feedwater concentration in the source
water of 3.4 mg/L, depending on the age and type/brand of the membranes.
For the purposes of this report the design target for boron has been set at 0.75
mg/L at commissioning, ie with new membranes. The concentration of boron in
the permeate is expected to rise as the membranes approach their AMLT, and it is
expected that minor variations to the process operation, primarily adjustment of the
pH and the addition of anti-scalant, will allow the concentration of boron to be
maintained below the long term goal of < 1.0 mg/L.
3.2.3
Jelly Fish Blooms

Jelly Fish
Jelly fish ingress in a power station cooling system is reported on by S. Rajagopal
et al, Home 1989. The power station is located at Kalpakkam on the east cost of
India. Three peaks in the occurrence of jelly fish were noticed in May, July and
October 1988, which accounted for 286, 204 and 129 tonnes respectively. The
authors recommend that jelly fish ingress be controlled by preventing their inflow,
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or by letting them pass freely. To prevent jelly fish from flowing in with water
current, fish netting is proposed to be installed in front of the water intake where
inlet velocity is low. This method is adopted at many power stations including
Tarapur Atomic Power Station including existing SWRO plants.
4.
DESIGN
LIFE
AND
AVAILABILITY;
PRIMARY
FLOWS
4.1
Design Life
The infrastructure will be designed for a life in excess of:

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Interim Report
4.2
50 years for civil works, buildings & buried pipeline components;
50 years for concrete tanks.
25 years for mechanical and electrical equipment;
20 years for flexible membrane liners and covers to storages;
20 years for steel panel tanks;
15 years instruments;
10 years for polyethylene tanks;
8 years seawater reverse osmosis (SWRO) membrane life.
Operations and Availability

In order to specify design parameters for individual processes, the proposed
operation and availability of the RO plant is for foremost importance. Therefore all
the design parameters are based on 95% plant availability throughout the year.
4.2.1
RO Rack Configuration
The size of the RO train impacts on the number of trains, all equipments as well
as the pipework required, along with pump set efficiencies. To have the most
optimal of above, the RO racks have been selected within each train having the
following characteristic:
Table 5 : RO Racks (150 MLD Module)

Design Parameter
Details
RO Configuration
Single pass, single stage
Number of Duty Trains
Number of Rows per Train
13
Number of Columns per Train
20
Number of slots available
260
Number of PVs per Train required
240
Spare space for additional PVs
8% (20 PVs)
Number of Membranes per PV
Number of Membranes per Train
1920
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As shown in Table 5 space has been provided in the RO racks for additional PVs,
which may be installed to respond to operational and environmental changes, as
well as to compensate for deviations from the design of the plant or equipment
performances. The additional PVs would not be installed to increase the capacity
of the trains above the design value, but should be used to ensure maintenance of
the design capacity of the trains.
The RO building will be designed to house six trains, in a single row. There shall
be no standby train.
4.3
Primary Flows
Based on the proposed operation and availability of the plant as described above,
primary flows have been calculated and are tabulated below in Table 6. It is to be
noted that these flows are not the final design flows and can be expected to vary
slightly as the designs are developed.
Table 6 Primary Flows 150 MLD Plant
Section
Product Water Tank to Chennai
150 MLD
Utilities and Losses
3 MLD
Permeate Production
153 MLD (6 trains)
Permeate per Train
25.5 MLD
Peak Filtered Seawater Required to 356 MLD

RO (based on 43% recovery *)
Filtered Sea Water to Screens for 1.3
spray
UF Losses
30.0 MLD
Sludge and Float losses
7.0 MLD
To Pre-treatment
394.30 MLD say 395 MLD
Screened
Sea
Water
to
Pre- 395 MLD
treatment
Intake Flow
394 MLD
Peak Outfall Rate
242 MLD
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43% selected to provide a conservative estimate of flow for hydraulic design.

Process design is based on 46% recovery.
5.
5.1
SEAWATER INTAKE
Primary Flows
The intake system will be designed to have a hydraulic capacity of 394 MLD,
whereas the sea water pumping station will be designed to have a peak capacity of
395 MLD, wherein 1.0 MLD required for screen washing will be returned upstream
of screen.
The intake conduits shall be sized with 10% additional capacity to take care for
bio-growth which shall result in reduction of carrying capacity. Therefore the inlet
pipe shall be sized for a flow of 435 MLD.
The intake conduit shall be of 2100 mm (ID) diameter and the outlet conduit shall
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Interim Report
be of 1400 mm ID diameter to produce 150 MLD permeate capacity. The velocity

in the conduit at peak flow will be 1.45 m/s. Friction losses at this velocity would
be of the order of 1.5-1.6 metre in a pipeline 950 metres long.
One outfall will be provided with an internal diameter of 1400 mm. For a flow peak
flow of 242 MLD, the velocity will be 1.82 m/s. Friction losses at this velocity would
be of the order of 1.8-2.0 metre in a pipeline 650 metres long.
The exit losses through multiple ports at 7 m/s would be of the order of 2.5 metres,
giving a total head loss in the outfall of around 4.7 metres say 5 meters at peak
flows.
As cited in section above, the site frontage along sea side is nearly 100 m and
there are existing intake and outfall pipes, therefore it is proposed that the intake
and outfall be south of existing plant intake, with proposed outfall north of
proposed intake.
5.2
Intake structure with Screen offshore

A 100 mm screen in GRP construction will be provided at the intake to exclude
larger marine life. The screens will be 7 m diameter, 1.5 m high, starting 2 m
above the sea floor, in 9 metre depth of water. The approach velocity will be <0.15
m/s to minimise the entrapment of marine species.
A fish net with will be provided to minimise the ingress of jelly fish to the intake.
The fish net will be required to be inspected and replaced from time to time, as the
same is likely to be damaged by marine lives. The head loss through the intake
system will also be monitored, and in any increase in system losses indicating
fouling at the intake, or the growth of biomass within the intake conduit, the same
shall be cleaned through divers.
5.3
Active Screens before the Sea Water Pumps

Travelling Band Screens shall be provided before the Pumps on shore and shall
be the first level of defence to the plant against all foreign matter like floating, sea
shells, diatoms etc.
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The advantage of providing the screens before the pumps is to capture the jelly
fish that bypass the off shore screen and fishing net on the shore alive, thus
preserving the same and returning them to the sea in order to have a sustainable
ecosystem.
A typical band screen installation is shown in Figure 8 below.
Band screens have been in service for screening sea water for many years. They
provide efficient removal with relatively low maintenance costs and also have
Construction costs that are relatively low as compared to the total plant cost.
Through-flow band screens have been proposed herewith. Typically mesh sizes
vary from 2 mm to 10 mm, and, in view of the marine biomass problems at
Nemmeli, a mesh size of 3 mm has been selected.
Table 7 : Band Screen Design Parameters
Parameter
Units
Value
Seawater flow
MLD
395
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5.4
Duty
Stand by
Sea Water Flow Per screen
MLD
198
Stainless Steel mesh
mm
Approach Channel Width
4.0
Width Back opening
2.8-3 m
Channel Approach Velocity
m/s
0.85-0.90
Upstream water depth
2.2
Downstream water depth
1.8
Wash Water per screen
L/s
15-20
Sea Water Pumping Station

There shall be one number of 2,100 mm internal diameter intake conduit. The
conduit shall be constructed by pipe jacking from an onshore pit, which will
become/converted into the sea water pumping station once the conduits have
been installed.
Vertical shaft pumps in a wet well are particularly suitable for sites with a low tidal
range, such as is experienced at Chennai. Vertical shaft pumps in a wet well have
been selected.
The tides at Perur, next to the Nemeeli as well as site ( data taken from DPR of
Existing 100 MLD SWRO Neemeli) are as follows, in metres above Chart Datum,
and relative to the site datum:
Chart Datum
RL
Mean High Water Spring
1.15
RL 0.5
Mean High Water Neaps
0.84
RL 0.19
Mean Sea Level
0.65
RL 0.0
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Mean Low Water Neaps
0.43
RL 0.22
Mean Low Water Spring
0.14
RL 0.51
Onshore survey levels are recorded as metres above Mean Sea Level. Thus
Mean High Water Springs is 1.15 0.65 = RL 0.5, and Mean Low Water Springs is
0.14 0.65 = RL 0.51.
The low no flow level in the pump well has been taken as RL 0.50. At a flow of
395 MLD in intake conduit, the hydraulic grade line entering the proposed pumping
station will be approximately 1.7 m lower, at RL 2.2. A head loss of 0.8 is
provided/allowed for loss through screens resulting in low-low water levels in sump
cum pump station as RL-3.0.
Three (3) metres has been provided to the bottom of the pumps, which has been
assumed to be 0.5 m above the bottom of the pumping station at RL 6.5 to
ensure sufficient submergence for the pumps, and to allow for surging in the intake
line. Subject to the detailed design of the intake conduits, it is anticipated that the
intake conduit will enter the pumping station at between RL 6.5 and RL 4.5.
Therefore, the static lift at Mean Low Water Springs will be from RL -3.0 to around
RL 14.5, ie around 17.5 metres; and the static lift at Mean High Water Springs will
be from RL -2.0 to around RL 14.5, i.e. around 16.5 metres.
Pump Configuration
There shall be 3 W + 2 S pumps sets in wet well delivering as cited below
Three working pumps, delivering to a common manifold of 2.0 m diameter, with
a two pump as standby
With 3 pumps in operation each pump must be capable of delivering 132 MLD
(1528 L/s), at a head of around 25 metres.
Each pump will have a delivery line 1.1 metres in diameter (V = 1.60 m/s),
connected to the manifold 2.0 metres in diameter.
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Isolation valves along with flow meters shall be installed main and branch
manifolds.
These pumps are Vertical Turbine pumps with large clear passages. The intake
screen and net at the intake will prevent the ingress of material like to cause a
blockage.
Design parameters are set out in Table 8

Table 8 :Sea Water Intake Pumps
Parameter
Units
Value
Pumping Station Capacity
MLD
395
Wet Wells
Duty Pumps
Standby
Mean High Water Springs
RL
0.5
Mean Low Water Springs
RL
- 0.51
Intake Conduit loses at peak flow
1.7-1.8
Pipe diameter - Pump to manifold
1.1
Main Rising main diameter
2.0
Pump house Plinth Level
RL
7.0
Generic type of pump: vertical shaft mounted in pump well,
Materials: super duplex stainless steel, PERN No > 43
Equipment per pump unit: isolation valves, non-return valve and magnetic flow
meter,
5.5
Pump motors: electric variable speed,
Pump station control: by plant PLC based upon target flow rate,
Pump/equipment removal: by EOT,
Shock chlorination system

A shock chlorination system is proposed to minimise marine growth in the inlet
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pump station and pressure main. Criteria adopted for the shock chlorination
system are summarised below;
5.6
Type of chemical: chlorine gas through Vacuum Chlorinate
Max chlorine solution residual in inlet main: 8 mg/l,
Min chlorine solution residual in inlet main: 1 mg/l,
Dosing time: 2 hour per day,
Dosing point: Off shore inlet well,
For the same 45 kg/hr (3 W + 1S) Vacuum Chlorination is provided
Intake / Outfall Pipes

Jacking pipes shall be of precast concrete, designed and manufactured to meet
the requirements of:
BS5911 Specification for reinforced concrete jacking pipes with flexible joints.
BS EN ISO 9002 Manufacturing.
Or equivalent standards as appropriate.

All jacking pipes, including special designs, shall be sufficiently reinforced with
steel to withstand all stresses induced by handling, jacking, earth and water
pressures and all working loads at the depths at which they are to be used without
cracking, spalling or distortion. A load factor of not less than 1.5 shall be used in
the calculations to determine the strength of the pipes required. The clear cover to
any steel reinforcement shall not be less than 50mm.
The strength of the pipes shall be tested by a three edge bearing test. When
subjected to the design load in such a test, the maximum crack developed on the
pipe shall not exceed 0.25mm.
All pipes shall be manufactured by a supplier approved by the engineer. The
process of manufacture may be by centrifugal or vertical casting subject to
submission and approval by the Engineer.
The steel collar shall be fixed to the reinforcement cage prior to casting of the pipe,
to ensure full integration of the pipe components.
Pipes shall be fully cured and have reached the designed concrete strength prior
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to delivery.
5.6.1
Pipe jacking
The tunnel shall be constructed by pipe jacking techniques using a purpose made
TBM for excavation. The TBM shall be designed as a slurry machine offering
controlled support pressure to the tunnel face and allowing for the use of bentonite
Slurry where required. The complete system shall be purpose designed for the
project and shall include TBM, slurry, circuit, main jacking station, interjack stations
and automatic bentonite injection system for lubrication of the pipe annulus.
The jacking pipes for this project shall be 2100mm and 1400 mm I/D. They shall
be using steel (Super Duplex : PERN>43) banded joints with full section contact
between adjacent pipes. The design of the pipes shall be sufficient to withstand
the jacking and overburden pressures assuming that inter jack stations are
installed at 100m spacing. The design should also allow for driving the tunnel at a
100-150m radius.
5.6.2
Main Jacking Station

The main jacking station shall be of robust construction, and comprise a thrust ring
and cylinders fixed firmly to a back wall and slide rails.
The thrust ring only shall be used for advancing pipes. A local control shall be
provided at the pit bottom for use by the shaft bottom crew during pipe extensions
only. During normal advance the main jacking station is controlled from the TBM
operators console, however Cylinder pressures should be available to the operator
at all times.
An interlock arrangement shall exist to transfer control between the operators
console and the shaft, whereby only the operator in ownership of the control can
make the transfer at the time.
5.6.3
Inter-jacks
Interjack stations shall be designed to provide sufficient jacking force to overcome
the frictional resistance to pipe motion over the distance between them. The
interjack stations should have a minimum capacity of 1200 tonnes and a maximum
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Interim Report
spacing of 300 m. The seal shall be adjustable to exclude the ingress of ground
water and bentonite and shall be capable of withstanding working pressures in
excess of 4bar.
Hydraulic power to operate the inter jack stations shall be provided by power packs
situated in both the TBM and in the launch shaft. In order to minimise hose lengths
and subsequent power losses, the forward inter jacks shall be fed from the TBM
power pack and the rear inter jacks, from the shaft power pack.
On completion of tunnelling operations all interjack cylinders and seal assemblies
shall be removed. The exposed steelwork shall be properly cleaned and treated
with epoxy paint suitable for sea water conditions and the pipes shall be closed to
eliminate the gap. The adjustable interjack sealing systems shall be manufactured
to facilitate easy removal by hand within the tunnel.
5.6.4
Slurry System
The slurry system shall be designed to be capable of functioning with bentonite
slurry where required as a support medium. The slurry circuit shall be designed for
a minimum flow rate of 400m3/hr. The slurry circuit shall include flow meters on
both feed and discharge lines.
Feed pipes shall be 250mm nominal internal diameter and slurry discharge 200mm
internal diameter. Automatic valves shall be included at the shaft top to allow for
immediate closure by the operator in the event of burst system hoses. The
separation plant shall be sized to be 25% over capacity to account for any possible
flow surges within the slurry circuit.
All controls and indicators for running the slurry system shall be available at TBM
operators console.
A telephone system shall be installed to allow direct
communication between the TBM and the separation plant.
6.
6.1
PRETREATMENT SYSTEM
Pretreatment Process
The pre-treatment process has been sized assuming that there are 6 membrane
trains in operation to produce 150 MLD permeate.
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6.2
Sea Water Quality / Treatment Processes

The key water quality parameters relevant to the selection of pre-treatment
processes include:
Turbidity
Marine Biomass, jelly fish, larvae and algae
Other relevant factors are:
Capex
Opex
Ease of operation
Robustness
6.2.1
Key Water Quality Parameters Pre-Treatment

The results of Field Investigations into sea water quality are tabulated in Table 1.
The key water quality parameters in respect of the design of pre-treatment facilities
are discussed below.
Turbidity
The average of the turbidity measurements at the surface and at depth, offshore
from site, were 1.10 and 1.88 NTU respectively. These readings are normal for
sea water. Notwithstanding, turbidity must be reduced to less than 0.5 NTU to
protect the RO membranes.

The average of the TSS measurements at the surface and at depth, offshore from
site, was 48.7 and 73.3 mg/L respectively. These readings are very high. For
example, for Sydney desalination plant (250 MLD) the design maximum TSS is 7
mg/L.
The higher concentration of suspended solids at the bottom compared to the
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Interim Report
surface indicates that the suspended solids have a density slightly higher than sea
water.
Since the seawater intake is located near the seabed, the bottom
suspended solids readings are quite relevant to the design of the pre-treatment
system.
Marine Biomass
Marine biomass includes jelly fish, larvae and algae.
The presence of these
materials is highly variable and dependent on season, temperature and the

presence of nutrients.
However, operational experience at Nemmeli suggests that if provision were not
made for the removal of marine biomass it could be a significant problem; hence to
take care of same a Travelling Band Screen with 3mm mesh has been provided.
Organic Pollutants
The presence of organic pollutants is indicated by measurements such as BOD,
COD, NO2, NO3, and NH3. BOD is relatively low, however, COD is much higher;
the reason for high COD is not clearly correlated, but may be related to the high
suspended solids.
6.2.2
The Pre-Treatment Processes- Scheme
pH correction coagulation flocculation Lamella Settlers- Dissolved Air

Flotation (DAF) Ultra Filtration(UF)
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6.3
pH Correction
The seawater will be dosed with acid to achieve the optimum pH for coagulation.
The dosing system will consist of duty and standby dosing lances into each pretreatment train. The pH correction design parameters are summarised in
Table
9 below.
Table 9
pH Correction Design Parameters
Parameter
Units
Value
Design maximum seawater flow
MLD
395
Dosing location
At
head
of
Common
Coagulation/Flocculation
Type of pH correction chemical
Sulphuric Acid
Target pH
6.80
Dose rate
Number of dosing pumps
6.4
mg/L
35 approx.
2 duty / 1 standby lances
Coagulation
Seawater turbidity is usually low around 0.5 to 1.0 NTU, however at the proposed
site is high. Turbidity normally indicates the presence of mineral particles which
can cause colloidal-particle fouling of RO membranes, thus reducing the flux rate
of the membranes. For this reason it is important to reduce the turbidity to an
acceptable level, i.e. to less than 0.5 NTU, perhaps as low as 0.1 NTU.
A widely used test is the Silt Density Index (SDI). The test is a laboratory filtration
test detailed in an ASTM standard.
The aim of the pre-treatment system is to
produce filtered seawater with a Silt Density Index (15 minute test as per ASTM
D4189 95-2002) of less than 3.0 for 95%tile and less than 3.5 for 100%tile of the
time, under all operating conditions, to produce 150 MLD of permeate.
Mineral particles can be destabilized by the addition of coagulant. The pH is

adjusted first, then the coagulant is added and flash mixed with the water.
Coagulation is followed by flocculation; a flocculant is added at this stage.
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Thereafter the flocs are removed by processes such as floatation and filtration.
Coagulant will be dosed at the head of Lamella Settler block. Rapid mixing will be
implemented within a concrete structure with at least 30 seconds of detention time.
The coagulation and rapid mixing design parameters are summarised in Table 10
below.
Table 10: Coagulation and Rapid Mixing Design Parameters
6.5
Parameter
Units
Value
MLD
395
Type of coagulant
Ferric chloride
Mixer type
Flash mixer
Mixing energy (G)
s-1
600 minimum
Mixing time
30
Flocculation
Flocculation will be provided again at the head of each Lamella Settler.
Flocculation will be achieved in two flocculation tanks in series with each tank
consisting of one or two vertical mixers so as to have the mixing energy tapered.
Flocculent (flocculation aid) will be dosed at the entry to each flocculation tank.
Due to the warm temperature, 20 minutes of flocculation is proposed. The longer
flocculation time is proposed so as to compensate for the lower suspended solids
concentration expected as feed to RO. The flocculation and flocculent design
parameters are summarised in Table 11 below.
Table 11 Flocculation and Flocculation Aid Design Parameters
Parameter
Units
Value
MLD
395
Type of flocculation aid
polyelectrolyte
Dose rate average
mg/L
0.1
Dose rate maximum
mg/L
0.5
Number of flocculation tanks per cell
No.
Detention time (minimum)
min
20
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Type of mixers
6.6
Variable speed impellers
Mixing energy (G) stage 1
s-1
70 100
Mixing energy (G) stage 2
s-1
30 - 50
Lamella Settlers
Lamella settlers consist of a series of inclined parallel plates or tubes through
which the water passes.
The
plates are close together and the

suspended solids travel only a
short distance to the plate below
and then gravitate down the
inclined plate and are removed
from the flow. For this reason the
footprint of a Lamella settler is relatively small. Lamella settlers are considered

excellent roughing filters, ie Lamella filters can quickly remove large amount of
relatively coarse material. However, the turbidity of the water exiting a Lamella
settler may be higher than for plain sedimentation. Notwithstanding, low turbidities
may be achieved by providing filters following the Lamella plate settlers.
Coagulation and flocculation are provided prior to the Lamella settlers. The capex
and opex of Lamella plate settlers are reasonably low, and they are simple to
operate.
Table 12 Lamella Settlers Design Parameters
Parameter
Units
Value
MLD
395
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Interim Report
No. of settlers
Nos.
Lamella Type and Material
8
Plates/Tubes made from FRP
with 550-600 inclination with
horizontal
Lamella
Surface
loading
rate m/hr
<15
(vertically projected surface area)

Lamella Supports
Bottom Sludge Removal
Concrete
Chain and flight scrapers or
hydraulic vacuum; material of
construction to be suitable for
Clarified water collection
seawater
Concrete
troughs
with
triangular FRP weir plates

6.7
Dissolved Air Flotation (DAF)

Dissolved air floatation (DAF) is a high rate process using micro-bubbles to float
coagulated and flocculated particles to the surface of a clarification basin.
portion of the clarified water is drawn off and passed through a pressure vessel
where the water is saturated with air at high pressure. The pressurized water,
supersaturated with air, is released into the water as it enters the bottom of the
basin. The sudden release of pressure causes the formation of micro-bubbles
which attach to the preformed floc and carry it to the surface where it forms a thick
floating layer. The float is skimmed off, and the clarified water passes to filtration.
DAF in general adequately removes TSS of 75 mg/L, but above 100 mg/L there is
likely to be a higher carryover of solids to the filters, resulting in shorter run times.
The potential for short filter runs can be offset to some extent by designing the
filtration system at an optimal flux. Therefore to mitigate the said situation; the
membrane filtration has been designed at an optimal flux of 50 LMH, while
producing the required SDI.
DAF would be effective in the removal of algae, and should be reasonably effective
in the removal of other marine biomass, such as larvae and jelly fish particulate
matter. DAF would be effective in the removal of oils and greases.
Ideally, loading rates for DAF would be set after pilot plant testing, and if time
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Interim Report
permits, pilot plant testing at site, should be carried out to provide data on the most
suitable loading rate.
DAF a form of physical treatment of water that involves coagulating impurities then
removing these solids by using dissolved air to float them to the surface of the
water. Residual fine particles that are not floated off are removed by the filtration
downstream.
The flotation cell also requires occasional sludge removal to remove settled solids.
The DAF process is proven across the globe for a range of water treatment
applications including as a pre-treatment process in sea water desalination plants
for removal of fine solids and organics. It also copes well with algae because it is
removed in the flotation step, eliminating the possibility of filter blinding. A
simplified cross sectional schematic is as shown below.
Raw
water
Flotation
Flocculation
Filtration
Air
saturated water
Sludge
Filtered water
Table 123
Dissolved Air Flotation Design Parameters
Parameter
Units
Value
Design seawater flow
MLD
395 without recycle
MLD
474 with recycle
Number of DAF Cells
No.
22
DAF surface loading All units online
m/hr
8 (with recycle)
m/hr
8.5 (with recycle)
DAF area per cell
m2
95
DAF Recycle Rate
20
DAF Air Dose Rate
mg/L
10
rate
One unit offline
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Parameter
Units
Value
Air Saturator Efficiency
90
Air Saturator Pressure (Gauge)
kPa
800 (nominal)
Number of air saturator
No.
22
Saturator volume
7,500 (at 90 s detention time 50% full at 20% recycle)
Float Removal Type
Hydraulic float removal (and weir)
DAF recycle water will be drawn from the RO fed tank i.e. UF filtered water.
6.8
Ultrafiltration (UF)
Membrane filtration involves passing the water to be treated through a thin polymer
film called the membrane. The filtration process is loosely referred to as
microfiltration if the size of pores in the membrane is about 0.2 micron.
If the pores are smaller than approximately 0.1 micron the filtration process is
referred to as ultra filtration.
One of the key advantages of membrane filtration is that due to the small pore size
compared to media filtration, membrane filters usually require less coagulant to
achieve the required filtered water quality. Further since being a pressurized
membrane system the area required is generally 25-30% less than non-membrane
filtration.
The
pressure
arrangement
is
similar to an RO
plant
with
ultra-
filtration membranes
installed in pressure
vessels.
Feed
water is pumped through the membranes and unlike RO, UF is vertical in

configuration. However, with recent development even horizontal configurations are
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possible in UF like RO. Pressure systems are typically supplied as modular skid
mounted systems with skids varying in size depending on the duty requirement.
Table 14
Ultra Filtration Design Parameters
Flow to Self-
MLD
388
99.5%
MLD
386
92.5%
Flux
LMH
50
Total Number of
Nos.
32
Duty
Nos.
30
Standby
Nos.
Flow Rate to RO
MLD
356
Area of each skid
m2
17.5 x 4.5 m
Initial TMP
Bar
0.5
Cleansing filters
Assumed recovery from filters
Flow inlet to UF
UF Recovery Rate
skids
6.9
Ultrafiltration Water Storage

Filtered water i.e. UF permeate storage will be located immediately downstream of
the UF unit. This will serve as feed tank to Reverse Osmosis.
The tank has been sized to provide twenty minutes storage at a seawater flow of
388 MLD.
The backwash water for UF shall also be withdrawn from the same tank.
The design parameters for the Filtered Seawater Storage Tanks are summarised in
Table below.
Filtered Seawater Storage Design Parameters

Parameter
Units
Value
MLD
388
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Number of tanks
No.
Fill time
min
20
Capacity
ML/tank
5.5
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7.
REVERSE OSMOSIS PLANT
7.1
Overview of RO Plant
The RO plant will be a single stage/single pass design with an overall recovery of
46%.
The plant will be configured as six numbers of individual trains. Each of the six RO
trains will consist of one RO rack each, with dedicated pumping system and
Energy Recover Devices (ERDs).
The plant is to be designed such that full
production can be achieved through six trains. The trains will be configured to
allow for each individual train to be isolated for cleaning, maintenance, or
membrane replacement. However 2 sets of standby ERD, HPP and booster
pumps have been proposed.
SWRO membrane elements of 8-inch diameter have been selected.
Each
pressure vessel will house eight membrane elements.

The design treated water TDS for the RO plant is 300 mg/L. No allowance has
been made in the RO plant layout for a second pass RO system.
In sizing the RO plant an average membrane flux of approximately 13.5 L/m2/hour
(LMH) has been selected. The provision of 8% spare space for more membranes
provides the flexibility to reduce the flux if advantageous for reducing cleaning
frequency or reducing power consumption.
7.2

Based on preliminary membrane projections for DOW and Hydranautics
membranes, it is anticipated that the required membrane pressure will range
between 51.6 bar and 65.3 bar, depending on feed water, the membrane
conditions, and depending on the actual membrane selected.
In order to provide the above pressure range, and based on the design
temperature and salinity ranges as depicted in Section 3, a combination of VSD
driven booster pumps and fixed speed RO HP pumps has been selected.
schematic of the proposed pumping system design is shown Figure below.
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Under such design the RO Booster pumps would provide feed pressure
adjustments suitable to cover the required membrane pressures for average to
maximum salinity events. For feed waters with below average salinities further
controls would be required in form of a HP throttling valve, essentially reducing
(burning-off) excess energy created by the pumping system upstream. It should
be noted that correct sizing of the RO pumping system is critical, as under-sizing
will not achieve the required permeate flows and over-sizing may require excess
pressure to be burnt-off at the throttling valve.
An alternate option would be equipping the HP pumps with a VSD, while the
booster pumping system would be equipped with a fixed speed drive, only
providing sufficient pressure to overcome friction and head-losses within the
cartridge system, as well as ensuring adequate NPSH is available. Reasoning
behind not further pursuing this alternate option was informed by the following
matters:
The cost of large high voltage variable speed drives for high wattage HP
pumps is significant
Inclusion of a variable speed drive would (permanently) reduce the energy
efficiency of the associated drive by 2% to 3%
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Preference to have majority of pumping capacity driven by a fixed speed

drive and operating at the best efficiency point (BEP)
7.3
Cartridge Filtration
To protect the RO membranes, cartridge filtration will be provided for each RO train
downstream of the filtered water transfer pumps. The cartridge filters shall be of 5
microns.
7.4
Oxidant Control
The provision of sodium bisulphite (SBS) dosing is included in the design to
neutralize residual oxidants present in the feedwater due to intake shock dosing.
This will be controlled by measurement of oxidation reduction potential of the
SWRO feedwater. The details of the bisulphite dosing system are sated in
approaching sections.
7.5
Scale Control
Provision for scale control by means of antiscalant dosing is included in the design.
The sulphuric acid addition as part of the pre-treatment system will also assist with
prevention of scaling. Refer to chapter 9 for details of the antiscalant and acid
dosing systems.
7.6
Reverse Osmosis Pumping and Energy Recovery System

The energy recovery devices will be an isobaric design.
Either the Energy
Recovery International (ERI) or Calder DWEER technology could be used. The

design is based on the Calder DWEER technology but both suppliers are
considered acceptable.
Details of the booster pumps are shown in Table 15.
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Table 15 : RO and ERD Feed Booster Pumps Design Parameters

Parameter
Unit
RO Feed Booster ERD Feed Booster

Pump
Pump
No.
Total number of pumps for 150 No.
L/s
295
346
ML/d
25.5
29.9
bar
14.5
6.0
Variable speed
Variable Speed
Number of pumps per RO train
MLD module
Maximum flow capacity
(per train)
Delivery Pressure
(are dependent on final membrane and ERD
selection and performance)
Type of drive
Materials (PREN > 43 for contact with seawater or brine):

Casing
Stainless
(Super duplex)
Pump impeller
Shaft
Stainless
steel Stainless
steel
(Super duplex)
steel Stainless
steel
(Super duplex)
(Super duplex)
Stainless steel
Stainless steel
Design parameters for the high pressure RO pumps are shown in Table above.
Since the High Pressure RO pump is a fixed speed pump it is important that the
pressure capability is not too high as that could lead to significant power wastage
with new membranes and warm/low salinity feed water.
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Table 16
High Pressure Pumps Design Parameters
Parameter
Unit
Value
No.
Total number of pumps
No.
ML/d
25.5
L/s
295
bar
55.3
Delivery Pressure*
Type of drive
Fixed speed
Materials (PREN > 43 for contact with

seawater or brine):
Casing
Stainless
steel
(Super
steel
(Super
duplex)
Pump impeller
Stainless
duplex)
Shaft
Stainless steel
Notes: * Pressure requirements are dependent on final membrane selection and

performance.
Design parameters of the proposed ERD system are shown in Table 17

Table 17
Energy Recovery System Design Parameters
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Parameter
Unit
Value
Number of ERD systems per RO train
No.
Total number of ERD systems
No.
Number of ERD units per system
No.
Total number of units
No.
40
Type of system
Isobaric System
Type of energy recovery device
DWEER
Manufacturer of device
Calder AG
Design flow rate (Brine)
MLD
6.0 (per DWEER unit)
L/s
69
Maximum available head for recovery
bar
62
Efficiency at design point
~ 95+

Casing
Stainless
steel
(Super
duplex)
Piston
Other
parts
in
contact
with
Non Metallic
Stainless
seawater/concentrate
steel
(Super
duplex)
Table 18 ERD Booster Pumps Design Parameters

Parameter
Unit
Value
No.
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Total number of pumps
No.
MLD
29.9
L/s
346
bar
5.7
Maximum pumping head

Type of drive
Variable speed

Casing
Stainless
steel
(Super
steel
(Super
duplex)
Pump impeller
Stainless
duplex)
Shaft
7.7
Stainless steel
RO Rack Design
The membrane design parameters are shown in Table 19. Normal production will
be using 6 racks for 150 MLD module at a flux of approximately 13.5 LMH.
Table 19 RO Membrane Design Parameters
Parameter
Unit
Value
Number of RO membrane trains -Total
No.
Number of racks per train
No.
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Number of RO racks
No.
RO Plant Recovery
46
Material of membranes
Polyamide
Type of membrane/module
8 inch spiral wound
Membrane manufacturer
Hydranautics, Dow
Active area per membrane element
m2
41 (440 ft2)
RO membrane flux rate
Normal
LMH
13.5
Maximum
LMH
15.5
Salt rejection
Nominal
> 99.8
Boron retention
Nominal
> 93
Salt Passage Increase
%/a
10
Flux Decline
%/a
3.5
Number of pressure vessels per rack
No.
240
Number of membranes per vessel
No.
Total number of membranes per train
No.
1920
Total number of pressure vessels for 150 MLD No.
1440
Average
Membrane
Life
(AMLT)
permeate
Total number of membranes for 150 MLD No.
11520
permeate
Reserve space provided for installation of %
additional membrane modules

Feed Water SDI requirements
100th% ile <3.5
To allow trialling and testing of individual elements to determine performance, a

single one-element vessel will be installed and operated in parallel to one of the
RO racks.
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The piping material for the RO system is as shown in
Table 20
Table 20 Piping materials

Piping
Material
High pressure feed piping
Stainless
steel,
super
duplex, PREN > 43

High pressure feed and concentrate piping and Stainless
headers
super
duplex, PREN > 43
Connecting pipework feed/concentrate headers to Stainless
7.8
steel,
steel,
pressure vessels
duplex, PREN > 43
Product headers
Stainless steel
Product piping
Stainless steel
Piping for cleaning
GRP
Piping for shut-down flushing
GRP
super
RO Clean In Place System

A RO clean in place (CIP) system is included in the design. This includes a
chemical cleaning preparation tank, chemical cleaning buffering tank, a heat
exchanger, pumps, cartridge filters, cleaning chemical storage tanks, cleaning
network and cleaning recirculation loop piping and a neutralisation system.
Provision has been made in the design for storage and dosing of the following
cleaning and preservation chemicals:
Caustic soda
Sodium Bisulphite
Hydrochloric Acid
Phosphoric Acid
Citric acid
Detergents (surfactant)
Ammonia solution
Cleaning occurs intermittently and all of these chemicals would not be used at the
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same time. The amount and type of cleaning chemical required would vary
depending upon the degree of membrane fouling and the nature of the fouling.
Depending on the membrane selected, the system may be designed to enable
cleaning of the RO system from both directions, i.e. from the front to the back and
from the back to the front. This would allow employing specific cleaning
procedures for a particular type of fouling / scaling. The CIP system will be sized
to clean each individual RO rack separately. The system, including the chemicals
for the CIP will be located in a dedicated building located next to the main RO
building.
All wastes from the CIP process will be neutralized prior to being directed to the
outfall and for the same a Neutralization Tank has been provided.
After chemical cleaning and prior shutdown of membrane trains, the brine and
spent cleaning solution will be flushed out of the RO and ERD racks using RO
permeate. Flushing prior train shutdown will reduce potential for scale build up
and corrosion, and will also reduce fouling and the amount of high TDS water
produced on start up. The flushing system would consist of flushing pumps and
pipework allowing each RO train to be flushed individually.
Design parameters of the chemical cleaning preparation tank are shown in Table
21.
Table 21 Chemical Cleaning Preparation Tank Design Parameters
Parameter
Unit
Value
Number of tanks
No.
Net volume of tank
300
Body / ends
GRP
Pipes / valves
GRP/PVC/SS
Material:
Form of construction
Circular
Design parameters for the chemical cleaning pumps are shown in Table 22.
Table 22 Chemical Cleaning Pumps Design Parameters
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Parameter
Unit
Value
Number of pumps
No.
2W+1S
Flow capacity of each pump
L/s
300
Pumping head
bar
10
Number of stages
No.
Design parameters for the flushing pumps are shown in Table 23.
Table 23 Flushing Pumps Design Parameters
7.9
Parameter
Unit
Value
Number of pumps
No.
1W+1S
Flow capacity of each pump
L/s
295
Pumping head
Number of stages
No.
Permeate Storage
One permeate storage tanks will be located immediately downstream of the RO
plant. The tanks have been sized for at least 20 min storage at the maximum
permeate flow of 153 MLD. The design parameters for the Permeate Storage Tank
are summarised in Table 24.
Table 24 Permeate Storage Design Parameters
Parameter
Units
Value
Number of tanks
No.
Nominal volume per tank
ML/tank
2.125
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8.
POST TREATMENT
Post treatment of permeate is required to meet the statutory product water quality
requirements.
Post treatment will consist of remineralisation/stabilisation and
disinfection of the water.

8.1
Re-mineralization/Stabilization
8.1.1
Requirement for Stabilisation

Water produced by a reverse osmosis process has very low residual hardness and
alkalinity, which renders it very aggressive to most materials including steel and
concrete thus causing corrosion and premature aging of assets. The lack of
carbonate alkalinity as well as the low content of calcium and magnesium (i.e.,
very low hardness) causes desalinated water to be unstable and prone to
wide variations in pH due to its low buffering capacity and its inability to form
protective calcium carbonate films on pipe walls, which makes it corrosive.
Therefore, before the permeate from reverse osmosis be supplied to customers, it
needs stabilisation also known as remineralisation or conditioning to prevent this
from happening.
Product water remineralisation for corrosion protection has two aspects:
(1) protection of water distribution systems and household piping and fixtures from
damage caused by corrosion, and
(2) maintaining the desalinated water quality in terms of aesthetic appearance
(color and taste).
Table 25
Stabilisation General Design Parameters
Item
Requirement
Stabilization Process
Limewater/Carbon Dioxide Dosing
Target pH range
7.5 to 8.5
Target Langelier Index
Positive
Maximum Total Dissolved Solids
500 mg/L
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8.1.2
Hydrated Lime & Carbon Dioxide

Water shall be stabilised by the addition of carbon dioxide and lime (calcium
hydroxide). The calcium is dosed via limewater, which is produced by mixing
powdered hydrated lime with reverse osmosis permeate using a clarifier. As the
lime available in the country contains impurities a considerable volume of waste is
generated by the limewater clarifier. This waste is relatively inert and could be
readily dried onsite.
Left to Right: Lime Silo, Limewater Clarifier, Carbon Dioxide Storage Vessels
Carbon dioxide gas is added to the water. It reacts with the dosed lime to form
calcium bicarbonate, which buffers the water and increases the resistance to
changes in pH and thus reduces the corrosivity of the water. Carbon dioxide and
lime are currently in common use all parts of the world for treatment of drinking
water supplies for the said purpose. The Perth Seawater Desalination Plant (130
MLD) uses the said process for portabalization.
Equipment typically required for dosing of lime would consist of: lime storage silos,
mixing vats, limewater clarifier, lime-water storage tank and dosing pumps. Carbon
dioxide would be stored and dosed using a proprietary package plant consisting of
storage vessels, evaporators and dosing venturis.
The remineralization using lime and carbon dioxide follows the chemical reaction
presented below:
2CO2 + Ca (OH)2 Ca (HCO3)2
0.74 mg/L of hydrated lime (0.56 mg/L of quicklime) and 0.88 mg/L of carbon
dioxide would need to be added in order to increase desalinated water hardness
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and alkalinity by 1.0 mg/L (as CaCO3)
each.
Therefore, for a target
recommended dosage of alkalinity and hardness in the product water of 100 mg/L,
the water produced by the desalination system will need to be treated with 74 mg/L
of lime and 88 mg/L of carbon dioxide.
The lime product used for remineralisation is usually delivered and stored at the
desalination plant site in silos as either powdered hydrated lime or as
pebble-lime (CaO), which is than slaked to generate hydrated lime [Ca(OH)2].
This lime slurry is blended with the fresh water produced by the desalination
process and is thoroughly mixed in lime saturator tanks to create saturated
limewater, which is then injected into the unconditioned desalinated water.
Carbon dioxide is typically delivered to the desalination plant site in a liquefied
form and is stored under pressure in metal storage tanks.
The majority of desalination plants are designed to produce finished water of total
(calcium and magnesium) hardness of 80 to 120 mg/L as CaCO3. Since
desalinated water usually contains less than 2 mg/L of magnesium, over 90
precent of the total hardness of drinking water conditioned with lime is calcium
hardness.
8.1.3
Key design Criteria

Lime Silo and Slurry System
Lime is delivered to the desalination plant site as bulk powdered hydrated lime,
which is stored on site in cylindrical metal silos with a 60 cone bottom (lime bins).
These silos are often the tallest structures on the desalination plant site and
usually have a diameter between 2.0 and 6.0 m with a height of 5.0 to 15.0 m.
They are equipped with air vent filters and with bin vibrators to promote flow of lime
from the silo into a transition bin hopper. The feed of lime is controlled by a rotary
discharge (airlock) valve, which is motorized and closed or opened automatically
based on the level of lime in the hopper. Lime silos are typically welded/bolted
stainless-steel structures equipped with level sensors, a fill line with long-radius
elbows, and a truck hose loading fitting with dust cap.
Carbon Dioxide System
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Carbon dioxide is delivered to and stored at the desalination plant in compressed

liquid form [20 bars] of pressure at 20C. A typical carbon dioxide feed system
consists of liquid carbon dioxide storage tanks equipped with refrigeration units,
vaporizers, vapor heaters, carbon dioxide dosing system with pressurized gas
solubility panel, and an in-line gas feed diffuser.
Table 26
Carbon Dioxide Design Parameters
Component/Parameter
Specifications/Design Criteria
Carbon dioxide dosage (as 100% For lime/CO2 systems88 mg/L For
pure product)
calcite/CO2 systems44 mg/L per

1.0 mg/L of target alkalinity and
hardness concentrations (as CaCO3)

CO2 consumption (kg/day as 70.4105.6
100% pure product) per 1000 m
3 /day of desalinated water for
addition
of
alkalinity
and
hardness in a range of 80 to 120

m/L (as CaCO3
CO2 purity, %
Liquid CO2 storage
100
tank
(refrigerated)
Storage pressure/ temperature, 20 bars/20C
bars/C
Diameter, m
Length/Height, m
Storage time, days
Structurematerial type
Vaporizer
Type
Capacity,
horsepower/kg
0.83.0
515
1560
Carbon steel
Electric
0.030.05
CO2.day
Delivery pressure/temperature, 3 bars/12C
bars/C
Vapor Heater
Type
Capacity,
Electric
horsepower/kg 0.010.02
CO2.day
Key design Criteria Carbon Dioxide and Feed System
The dosage of carbon dioxide fed to the desalinated water is adjusted
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Interim Report
proportionally to the desalinated water flow rate by flow control valves installed on
the gas feed lines from the vaporizer to the point of chlorine dioxide gas injection in
the desalinated water conveyance pipe.
8.2
Disinfection
Disinfection has been used for over a hundred years, when it was first regularly
used to kill germs in the 1900s. Chlorination was first used in London in 1905 and
ozone was first used in Nice in 1908. From there, disinfection developed further
and was widely accepted as a method to treat water. Chlorination is the most
widely used method with ozone slowly becoming more popular. Chlorine dioxide is
also another disinfectant in the water treatment industry, but because of its high
cost not used commonly. UV disinfection is a relatively new disinfection method
even though it was also discovered approximately at the same time as the other
techniques.
Requirement for Disinfection
Disinfection is the process whereby water is treated to kill microorganisms in the
water, including essentially all pathogenic (disease-causing) bacteria. In addition
disinfection is undertaken to prevent bio-film (slime) growth inside the pipes and
mitigate the risk of recontamination.
Chlorine based disinfection (i.e. chlorination) has been considered for said project.
This is because this process is by far the most common form of disinfection in the
country and has a shell life as compared to other disinfection process which
usually doesnt have the required shell life in distribution system.
Chlorine is the most widely used water disinfection method. Chlorine kills the
micro-organisms by immobilising their metabolism rendering them harmless.
Chlorine is a slow stable reaction thus its main advantage of chlorine is the
formation of residuals which remain in the water for longer periods of time
protecting the system from bacterial contamination.
Necessity for Disinfection of RO Process Water

The need for continuous disinfection of the process water has been questioned,
since reverse osmosis permeate will have a relatively low/nil level of
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microbiological contamination. The reverse osmosis treatment process will remove

the majority of organic matter present. This results in a limited amount of short
chain carbon compounds available as a food source for micro-organism growth.
However to have a residual chlorine in the distribution network chlorination is
envisaged for the treated water out of the proposed plant.
Theory of disinfection and Chlorination
The rate of change in the number of viable organisms is the product of the reaction
rate constant for particular disinfectants and the number of viable organisms
(Tebbutt, 1992). It is expressed as:
dN/dT = - kN
Where k = rate constant for particular disinfectants

N = the number of viable organisms.
This expression is also defined as Chicks Law and is the first-order reaction of a
uni-molecular reaction (Crittenden et al., 2005). Integrating the formula and
changing to base 10 gives the formula:
Log (Nt/No) = - kT
Where;
Nt =
Number of micro-organisms at time t
No =
Number of micro-organisms initially
0.4343 K
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Rearranging the formula to determine the time required for the adequate disinfection is
expressed as:
t = (1/k) log(No/ Nt)
Since the number of micro-organisms can never be zero no matter how much
disinfected the water is, the percentage of removing micro-organisms can never be 100%.
However, majority of the water treatment plants must be able to remove or inactivate
99.9% (3-log) of Giardia cysts and 99.99% (4-log) of viruses (Critttenden et al., 2005).
Some micro-organisms are more vulnerable and have less resistance to certain
disinfectants therefore only 90% (1-log) reduction is required.
For effective disinfection there are numerous parameters that are required for killing
or inactivating micro-organisms. This includes the residual concentration, the time at
which the water is in contact with the disinfectant, the water temperature, the pH balance,
and the type of disinfection used.
If the concentration of disinfectant, C, measured in milligrams per litre (mg/l), and
the contact time, T, measured in minutes, are multiplied together it will produce a
value known as the CT value. This value is required to produce adequate parameters in
order to achieve the required log requirements. Different micro-organisms will require
different CT values therefore, in general, the contact time and the concentration of the
disinfectant must be able to remove the most resistant of the micro-organisms. It is
important for the water system to have an adequate CT value so that the water is treated
properly before being distributed.
In alkaline conditions, chlorine is more
effective and in acid conditions, the
hypochlorous acid is more effective.
Therefore it is recommended that the
typical pH for disinfection should be
lessmthan 8 and if chlorine is used,
then a lower pH is better.
Chloramine, which can be formed
during
chlorine
and
ammonia
Interim Report
chemical reaction, is a combined residual chlorine and is also an useful disinfectant.

Break point occurs once all the ammonia is reacted and the combined residual
chlorine is converted back to free chlorine (Refer figure above). Increasing the chlorine
concentration also increases the free-chlorine residual, however increasing it beyond the
break point is counterproductive due to the production of nitrogen and nitrogen trichloride, chemicals that have a strong unpleasant odour.
The break point is a good indicator when to supply sufficient amounts of chlorine to remove
any excess ammonia without the risk of producing less welcoming products including dichloramine and nitrogen trichloride.
Chlorine Dosing Considerations

It is important that personnel, engaged in chlorine plant or in any activity involving handling
of chlorine, should understand the hazardous properties of chlorine and should have a
good grasp of the basis of preventive measures. This will make them more conscious
about safety which would not be achieved if they are trained to follow certain instructions
mechanically. In India, Chlorine is deemed to be an explosive, when contained in any
metal container in a compressed or liquefied state, within the meaning of the Indian
Explosives Act, 1884. The filling, possession, transport and importation is governed by the
Gas Cylinder Rules, 1940.
Cylinders should be stored in an upright position. They should be
secured to prevent from falling over.
Full and empty cylinders should not
be stored together. Then containers
should be stored on their .sides.
They should not be stacked or
racked more than one high. All
safety measures shall be as per IS
4263 latest edition Code of Safety
for Chlorine and IS 10553 (Part I)
1983 Requirements of Chlorination
equipment for its safe operations. Also according to the Compressed Gas Cylinder Act
Interim Report
Government of India, it is necessary to obtain a storage license when five or more

containers are to be stored. For obtaining the storage license safety equipments are
essential along with scrubber system. Also the building has to be constructed as per
norms suitable for storing toxic gas cylinders with adequate ventilation systems and
handling accessories. Further as per Manufacture, Storage and Import of Hazardous
Chemicals Rules, 1989 maximum of 10 tonnes can be stored at site
Chlorine Dosing Rates
The recommended chlorine dosing rates for Potable water are;
Continuous disinfection of potable water using gaseous chlorine at a concentration
ranging between 2.0 3.0 mg/L, to achieve a residual chlorine of 0.2 mg/l as per IS
10500.
Disinfection of the produced water will be carried out using a standard chlorine gas
system. Both the process and potable quality product waters will be dosed. To
achieve is minimum Residual chlorine in distribution system, 2 mg/l of chlorine shall
be dosed using 20 kg/hr. (1 W + 1 S).
Table 27: Liquid Chlorine Characteristics
Properties
Appearance
Greenish Yellow
Physical state
Liquefied compressed Gas
Vapour pressure @ 35oC
27.48 mm Hg at 20oC
Boiling point /Range
-34 C (at 1 Atmospheric Pressure)
Melting point/Freezing Point
-101C
Vapour Density (Air Density= 1)
2.49
Liquid Density(Water density = 1)
1.47 at 20oC
Solubility in water
0.7 % at 20oC
Odour
Irritating, Bleach like Choking Odour
Others
Soluble in alkalis
Specifications
Chlorine Content Min.V/V
99.8%
Moisture
150 ppm Max.
Residue on Evaporation
Shall leave no residue when

evaporated on clean white tile
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Specification of Chlorine Tonner

Water Capacity (approx.) Kg.
780
Chlorine Capacity (approx.) Kg.
930
Design Pressure, Kg/cm
9.
19.9
Inside Diameter (approx.) mm
760
Shell Thickness, mm
10
Dished Ends Thickness, mm
9.6 (Min.)
Overall Length (approx.) mm
2085
Tare Weight (approx.) Kg.
620
Valve Outlet
5/8
Thread
14 tpi bsp
CHEMICAL SYSTEMS
The following chemicals will be required as part of the pre- treatment process:
Table 28 Desalination Plant Chemicals List
Chemical Name
Chemical Use
Antiscalant
RO scale prevention
Carbon Dioxide
Post treatment for water stabilisation
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Chlorine Gas
Post
treatment
for
disinfection
(process & potable product waters)

Ferric Chloride
Coagulant
Hydrated Lime
Post treatment for water stabilisation
Flotation Aid - Polyelectrolyte
DAF flocculation aid
Limewater clarification aid
RO CIP
Clarification/Filtration
Aid
Polyelectrolyte
Sodium Hydroxide
(Caustic Soda)
Sodium Hypochlorite
(prepared
Preparation of sodium hypochlorite
solution
Shock dosing for intake biofilm control
Protection of RO from oxidants
from
Sodium chlorine/hydroxide)
Metabisulphite
Sulphuric Acid
RO CIP
pH adjustment and scale control
RO CIP only
Miscellaneous Chemicals
(eg: Biocide, Detergent, Ammonia, Acids: Hydrochloric, Phosphoric, etc)
Details of the chemical systems are summarised in the following sections
9.1
Antiscalant
Antiscalant is required to be dosed into the reverse osmosis system to manage the
formation of mineral scale on the surface of the membranes. Design parameters of
the antiscalant system are shown in Table below.
Table 29 Antiscalant System Design Parameters
Parameter
Units
Value
Design RO system feed
ML/d
356
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flow rate
Antiscalant concentration
Form of supply
100
1000 L IBC
Dose rate
mg/L
Dosing point
0.7
RO
High
Pressure
Pump suction main

Antiscalant consumption
kg/day
Specific gravity of dosing
250
1.2
solution
Dosing
flow
rate
of
L/hr
Duty
No.
Standby
No.
Dosing pump capacity
L/hr
Number of antiscalant storage tanks
No.
None
antiscalant
direct
feed
from IBC
It is not proposed to dilute the antiscalant as the flow rates involved can be easily
dosed accurately and dilution can lead to degradation of the antiscalant. Adequate
mixing will be achieved by other means. At this stage the type of antiscalant to be
used has not been determined. This will be assessed at the next design stage.
9.2
Carbon Dioxide
Carbon Dioxide is required to be dosed in association with Hydrated Lime for pH
control and stabilisation of the permeate water. The chemical dosing design
parameters are summarised in Table 30.
Table 30 Carbon Dioxide Dosing Design Parameters
Carbon Dioxide Dosing
Units
Value
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Carbon Dioxide Dose Rate

Maximum
mg/L
90
Average
mg/L
70.4
Carbon Dioxide Dose
Average
kg/hr
575
Carbon Dioxide Vessels
Number Of
No.
Capacity
tonnes
25
days
Carbon
Dioxide
Storage
Period
9.3
Chlorine Gas
Chlorine is required for disinfection of the product water and for shock chlorination
Chlorine will be supplied as liquefied gas in 900 kg drums. The unloading of
chlorine drums from transport trucks will occur within the chlorine building, thereby
reducing the risk of a chlorine leak occurring outside the building. The system will
be configured as a vacuum gas draw system with vacuum valves connected
directly to the chlorine drums.
Design parameters for the proposed chlorination system are summarised in 31.
Table 31 Chlorination Design Parameters
Parameter
Units
Value
Minimum
mg/L
Maximum
mg/L
Treated Water Flow Rate
Nominal
ML/d
153
Chlorine gas flow range
Nominal
kg/hr
12.75
Maximum
kg/hr
19.125
Maximum
kg/day
459
Average
kg/day
306
Chlorine for Disinfection of Potable Water

Dose Rate
Chlorine Consumption
Chlorine Storage
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Total Chlorine Consumption
Maximum
kg/day
459
Chlorine Container Size
kg
900
Maximum Number of Drums Online
No.
days
15
On Site
Drum Storage Period
9.4
average
Ferric Chloride
Ferric Chloride is to be dosed to coagulate particles prior to the DAF. The design
parameters are summarised in Table 32.
Table 32 Ferric Chloride System Design Parameters
Parameter
Units
Value
ML/d
395
Ferric chloride concentration
% w/w
42.6
Specific
gravity
of
dosing
1.45
Solution
Dose rate
Ferric Chloride Consumption

Dosing Points
9.5
Typical
mg/L
16
Maximum
Mg/l
25
Typical
t/day
15.0
Flash Mixers U/S of
DAF
Hydrated Lime
Lime will be supplied to site as hydrated lime (Ca(OH)2) and converted onsite to
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lime water before dosing to permeate upstream of product water. Lime does not
dissolve quickly in water and is difficult to handle. Lime is mixed with water to
obtain lime water, and then the lime water is passed through a clarifier to remove
the un-dissolved lime; if not removed the product water will not meet specification.
Equipment for handling lime requires regular maintenance, and adequate standby
provisions must be made. Two lime water clarifiers will be provided. Lime is not
pure and significant amounts of sludge are produced and must be dewatered and
removed from site. The commercial lime available has a purity of 80% or less; a
purity of 75% has been adopted for design.
The lime dosing design parameters are summarised in Table 33.
Table 33
Lime Dosing Design Parameters
Parameters
Lime Properties
Units
Value
75
Utilisation of pure %
90
Purity
component
Lime Dose Rate (Total)
Lime Consumption
Lime Silos
Utilisation overall
67.5%
Typical
mg/L
50 as Ca(OH)2
Maximum
mg/L
75 as Ca(OH)2
Average
tonnes/day
11.35 t/day
Maximum
tonnes/day
17 t/day
Number
No.
Capacity
of
each tonnes
50
silo
Lime
of
Milk
Concentration
9.6
Flotation Aid Polyelectrolyte

Polyelectrolyte is required to be dosed to assist with the formation of floatable flocs
in the DAF process. The polymer will be dosed immediately prior to each DAF
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flocculation tank. The specific polymer to be used will be determined during a later
design stage. The dosing design parameters are summarised in table 34
Table 34
Flotation Aid Polyelectrolyte Dosing Design Parameters
Parameters
Units
Value
ML/d
395
% w/v
0.1 0.5
Poly Solution Strength
Nominal
Dosing Location
U/s of Lamella
U/s of DAF
Dose Rate (per dosing Minimum
mg/L
0.05
Maximum
mg/L
0.25
Average
mg/L
0.1
point)
9.7
Sodium Hydroxide
Sodium hydroxide is required to neutralize acids used in the cleaning of the UF
membranes and may also be used for cleaning of the RO membranes. Sodium
hydroxide may also be required to increase the pH of the RO feed water in order to
meet boron target levels.
Table 35 Sodium Hydroxide Dosing

Parameter
Units
Value
Hydroxide concentration
% w/w
50
Specific gravity of dosing solution

Storage Details
1.53
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9.8
No. of Tanks
No
Tank Volume
KL/tank
150
Dosage location
Inlet of Cartridge filter
Dosage
25 m/l average
Sodium (Meta)bisulphite
Sodium bisulphite (SBS) (NaHSO3) will be prepared by dissolving sodium
metabisulphite (SMBS) (Na2S2O5) in water. Dosing of bisulphite is required to
remove residual chlorine from the system resulting from intake shock dosing as
well as to neutralise oxidants used for cleaning of the UF membranes. Bisulphite
may also be used for the RO CIP process.
The redox potential (ORP) will be measured downstream of the dosing point to
ensure that the dosing is effective. The sodium bisulphite design parameters are
summarised in Table 36.
Ventilation shall be provided to manage any fumes that may be evolved in the
chemical area.
Table 36 : Sodium (Meta)bisulphite System Design Parameters
Parameter
Units
Value
Sodium bisulphite concentration
% w/v
40
1.34
Dosing for RO Protection

Dose rate (as sodium metabisulphite)
Dosing frequency / duration
ML/d
395
Maximum
mg/L
30
Typical
mg/L
15
Assume 1 hours once per day (at

time of intake shock)
Dosing point
Upstream of high pressure pumps
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9.9
No of Dosing pump
9 W+4 S
Capacity of each pump
125 L/hr
Sulphuric Acid
The sulphuric acid will be used to provide pH correction for optimum seawater
coagulation. In addition sulphuric acid is required for chemical enhanced
backwashing and cleaning of the UF membranes. The design parameters are
summarised in Table 37.
Table 37
Sulphuric Acid System Design Parameters
Parameter
Value
Sulphuric acid concentration

Specific
gravity
of
% w/w
dosing
98
1.84
solution
Seawater pH Correction
395
Dose rate
Typical
35
Dosing flow rate of chemical
Typical
350 L/hr.
Dosing point
Seawater
intake
pipeline
upstream of coagulant dosing
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9.10
Ultra Filtration Chemicals
Table 38
Ultra Filtration chemical Usages
Parameter
Oxidant
Value
backwash
with
Once a day
NaOCl (10%)
Number of tanks
One
Volume
Acid
M3 300
backwash
with
HCL
Once every 7 days
(35%)
Number of tanks
Volume
9.11
One
m3
Proposed Acid
HCl
Proposed Alkali
NaOH
Proposed Oxidant
NaOCl
Dosing Frequency
Once in 60 days
CIP tank Volume
5 m3
Miscellaneous Chemicals
This section covers miscellaneous chemicals used only for the purpose of cleaning
the RO membranes (i.e. RO CIP). Examples of these chemicals include (but may
not be limited to):
Biocide;
Detergent;
Ammonia solution; and
Acids (such as Hydrochloric, Phosphoric, etc)
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General storage space only has been included for these chemicals because:
It will not be known until the first year (or two) of operation which of the
chemicals are required;
The chemicals are used infrequently (say once per year); and
When used, only small volume of chemical is used each time.
The facility will be designed to meet the requirements of all of the chemicals that
may be used. Between uses, the facility will need to be drained and flushed.
Design details are provided in the following table.
Table 39 Miscellaneous CIP Chemical Dosing System Design Parameters
Parameter
Units
Value
Dosing point
RO CIP Tank
varies
Duty
No.
Standby
No.
Dosing pump capacity
kL/hr
Number of tanks
No.
Tank volume
kL/tank
Chemical delivery volumes
9.11.1
Multiple 1000L IBCs
Cleaning-in-place (CIP)
To manage membrane fouling and scaling, periodical cleaning is required.
Depending on the performance of the pre-treatment system and on the actual
operational envelope, it is anticipated that four cleanings per year per train are
necessary. Typical cleaning solutions include low pH, and high pH solutions and
special detergents. Preservation solution would also be prepared within the CIP
system.
To facilitate membrane cleaning a CIP system is required with the following
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features:
Make-up tank;
Chemical storage and dosing facilities for the preparation of various cleaning
solutions (typically includes Caustic Soda, Citric Acid, NaDDS, Sodium
Bisulphite);
Recycling pumps;
Cartridge filter (typically 5 micron);
Pipework allowing each RO train to be cleaned individually; and
If required, holding tank to neutralise spent cleaning solution and enable

discharge to environment.
9.11.2
Flushing
After chemical cleaning and prior shutdown of membrane trains the brine and
spent cleaning solution should be flushed out of the RO and ERD racks using RO
permeate. Flushing prior train shutdown will reduce potential for scale build up and
corrosion.
The flushing system would consist of flushing pumps and pipework allowing each
RO train to be flushed individually.
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10. WATER STORAGE AND TRANSFER

10.1
Process water storage

Treated process water will be stored on site prior to being transferred to the city for
consumption. The criteria for the storage tank are summarised below;
10.2
Total usable storage volume 6250 M3
Number of units : 1 x 6.25ML (1 hours storage for 150 MLD average flow),
Material of construction : RCC epoxy coating
Tank geometry : to suit site hydraulics and cost optimisation,
Covered
Process water transfer pump station

The design criteria adopted for design of the pump station is therefore as follows;
Type of pumps : centrifugal variable speed drive,
Number of units : 3 duty, 1 standby (for 150 MLD),
Nominal pump station duty : 2085 m3/hr,
Pump control : by level in the receiving tank,
Positive suction at all times,
11.
SEAWATER OUTFALL
11.1
Outfall Pipeline
The desalination plant will discharge rejected seawater concentrate and other
waste streams into the ocean via an outlet pipeline.
The criteria adopted for Section 1 of the outlet pipeline are as follows;
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Peak Flow : 242 MLD,
Diameter: 1400 mm ID RCC pipe
Max working pressure (including water hammer allowance):

20m head,
Note *
The head required to discharge seawater concentrate is provided by the residual seawater
concentrate pressure after the reverse osmosis process. This pressure would otherwise be fully
recovered and therefore has to be supplemented to make up for the loss of head to the outlet
pipeline. The outfall pipeline can therefore be considered as consuming energy (as with a pump
station) with an associated operating cost.
11.2
Diffusers
The outlet pipeline will discharge seawater concentrate and other waste flows into
the ocean via a system of diffusers. These comprise a large number of small
diameter nozzles discharging jets of seawater concentrate from the seabed into
the water body to entrain dilution flows. Wider dispersion of the saline plume is
achieved through the action of wind, waves and currents. Both the seawater
concentrate jets and the dispersion will be modelled using appropriate computer
models. The adopted criteria for the diffuser design is summarised as follows;
Flow range @ peak : 242 MLD,
Discharge temperature range: 0C > 3C above ambient,
Discharge
salinity
range:
32,500mg/l
-34,500mg/l
above
ambient,
Target dilution: 5% above ambient salinity,
Water depth: > 5m with no surface expression of seawater

concentrate jet,
Diffuser material: rubber / EPDM,
Backflow prevention: In line rubber check valve at diffuser,
12. POWER AND CONTROL

12.1
Power supply
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12.1.1
Background
The power supply arrangement for the desalination plant is based on provision of
one nos (1 no.) 110 kV feeders from a substation next (very adjacent) to the
existing Neemlai SWRO to be procured and operated by TNEB.
The major areas for power demand are the seawater supply pumps, the RO
treatment plant and the process water transfer pump station.
The substation for the proposed plant has been placed on the north end of the site
along the ECR front, since the area embarked for the plant doesnt have sufficient
space to accommodate the electrical sub-station.
12.1.2
Design Considerations
It is anticipated that the concept design and cost estimate of the HV infrastructure
and electrical plant will include and take into consideration the following:
System security;
System reliability;
Determination of appropriate voltages and load currents for the main pump
motors and other large motors as appropriate;
Redundancy requirements;
Electrical supplier requirements for connection and design of substations;
National Electricity Law;
National Electricity Rules;
Energy losses;
Environmental impacts;
Lifecycle costs.
A level of security and redundancy will be determined for the reference design.
The appropriate Indian Standards will form the basis for the design of electrical
works including standards for:
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Earthing
Protection
Switchgear, etc.
IEC Rules requirements will also be considered in the design.

12.1.3
110 kV / 11 kV Substation within the Plant premises

A 110 kV / 11 kV transformer shall be provided for the electrical supply to the
seawater intake pumps, the reverse osmosis high pressure pumps and the
process water transfer pumps. The L.T supply shall be from HT Panels. This
substation will be a double bus bar Gas Insulated System type (GIS) built with the
latest technologies, maximum operational safety and environmental friendliness
according to IEC 61850 and TNEB. Two incoming lines, coupler and four feeders
will be considered in the substation as minimum.
Two transformers 110/11 kV, ONAN / ONAF, will be installed and it is necessary to
consider civil works space for other two equal transformer (similar than
considered). The capacity of one transformer will be enough to feed the total
demand. Besides, it will contain all common equipment, no-load compensation and
necessary maneuvers considering three feeders in 11kV from spare transformer as
minimum.
12.1.4
Pumping station electrical works, controls and electrical systems

Voltages and load currents for the RO high pressure pumps and process water
pump motors (and any other large motors) will be 11 kV. Soft start or VSDs will be
provided for large motors (>400 kW).
11 kV Cables will be XLPE insulated, PVC sheathed, screened and comply with
the IEC 502.1. Low voltage power cables will be XLPE insulated and PVC
sheathed:
CU/XLPE/PVC type.
CU/XLPE/PVC type with concentric conductor, specific for frequency
converter outputs.
Rated insulation voltage: 1000 V.
The cores will be of copper.
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Minimum cross section: power 2,5 mm

Power factor measured in 11kV will be more than 0.95 with filters if necessary.
12.1.5
Emergency power generation

Battery backed UPS systems will be provided for instrumentation, telemetry,
emergency lighting and communication systems.
The DC and UPS system shall be redundant (2 x 100% batteries, 2 x 100%
220VDC rectifiers, 2 x 100% 24VDC converters, 2 x 100% 230A inverters), DC
system shall be sized for a minimum period of 2 hour of standby operation.
One emergency diesel generator (EDG) set shall be provided. The EDG shall be
mounted in an outdoor soundproof metallic canopy with anti-vibration supports and
a high grade exhaust silencer. It will be designed for 24 hours continuous operation
and maximum 250 hours operation per year.
12.1.6
Electrical Equipment
Electrical equipment design will be in compliance with IEC Standards.
The electrical cable trays shall be GRP.
Cables of different voltages will generally be laid on separate trays. Where this is
not possible, cables may be installed on the same trays with suitable barriers.
The transmission cables of analogical signals will be laid on trays different than the
power cables to avoid any electromagnetic interference.
Where there is a possibility of mechanical damage or fire hazard, cable trays will be
protected by sheet steel covers. The cable inlet to the equipment will be protected
with tight stuffing boxes IP-65, which guarantees a perfect tightness.
12.2
12.2.1
Control System
General Design Criteria
The control system for the desalination plant will be compatible with the overall
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control system and the design will take into account the following requirements:
The Process Control System (PCS) architecture covering the connection of field
instruments, controllers and associated input/output (I/O), Human Machine
Interfaces (HMI), communication networks and network equipment will be
designed for a process plant availability of at least 98%. This implies that that
the control system itself will have a system availability of at least 99.9%;
Use of equipment with a proven track record;
Provision of redundancy for critical items;
Redundant controllers, networks, power supplies in all locations;
Ensuring maintainability of selected equipment and standardisation of equipment

and spares;
Fibre optic will be provided as the primary bearer to link all units.
Process controls and equipment designed to fail to the safest condition;
I/O & instrument voltages selected to suit equipment and provided with battery
backup.
All on site power, control and communication cables to be run in accordance with
current industry practices, codes, standards and regulations;
Uninterruptible power supply (UPS) provided to all critical items (instruments,

control systems and telecommunications systems with a one hour battery backup with emergency power supply to UPSs within 15 minutes).
Field instrumentation will be rated IP56 and will have outdoor housing protection
from weather.
Lightning protection will be provided for all facilities. Surge protection is to be

considered for all facilities to provide protection to communications and other
electronic based equipment.
12.2.2
Plant Operation Methods

The following aspects of the plant operation will be taken into account in the design
of
the
control
communications.
system,
alarm
system,
supervisory
system
and
system
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All plant operations will be designed for automatic operation and minimal
requirement for manual intervention;
The desalination plant and process water pump station will be monitored 24
hours per day;
Outside of the manned hours of the desalination plant and pump station,
operations or maintenance will only be in response to automated alarm
notification to nominated personnel on call;
For backup to the automated alarm notification outside of manned hours, the site
will also have 24 hour monitoring of all operating parameters and alarms;
Operating protocols will be established such that only the desalination plant will
have control ownership of the complete water supply system.
12.2.3
Control System Architecture

The following are the minimum requirements of the control system:
The desalination plant will be controlled by its own stand alone control system.
This will include all equipment, cabling, buildings and services necessary for a
complete system;
The Process Control System (PCS) will be of the same manufacturer, make,
model, firmware as that used for the magnetite process plant and will follow the
same configuration/ programming criteria and standards;
The Controller architecture, communication protocol and cabling selected will be

suitable for the application and control system requirements in terms of
functionality, speed, durability, off site monitoring and control requirements,
serviceability, and local support;
The HMI interface system on site will be suitable for the application, control
system requirements in terms of functionality, speed, durability, local support;
All HMI systems will display alarms, alarm histories and trends. All data must be
stored for more than twelve months;
All PCS and communication systems will have at least 20% spare memory, I/O
and communication capacity;
Each controllable drive will have a local control station comprising an emergency
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stop (hard wired in the emergency stop circuitry for the drive which is not
disabled in auto mode), a local stop button and a local start button (for starting
the motor under maintenance /manual mode of operation). This local control
station will include a jog button when appropriate for some mechanical
equipment;
The PCS will incorporate monitoring of key alarms for other plant auxiliaries such
as the main low voltage electrical reticulation, building services and fire
suppression system.
Interim Report
13. CIVIL, BUILDING AND STRUCTURAL WORKS

13.1
Plant Buildings
13.1.1
General
The desalination plant will include the following buildings:
Intake Pump House
DAF (Dissolved air flotation) building
UF Building inc. UF fed Pumps and Self-Cleaning filters
RO Plant Building (inclusive of Cartridge Filters pressure vessels, booster and

HP pumps and energy recovery);
Administration and Control Building;
Chemical Dosing Buildings;
Chlorine Building;
Electrical Switchgear Buildings / Substation.
Buildings will generally be of concrete foundation slabs, sheet metal clad, insulated
and suitable for cyclonic conditions with a design life of 30 years. Buildings shall
comply with the relevant Indian Building Code.
Buildings will be provided with internal power, communications, lights, air

conditioning, ventilation, water, air and sewerage disposal facilities as well as
equipment and furnishings to provide fully functional facilities.
The Finished Floor Level (FFL) shall be a minimum of 300 mm above the external
finished ground level. External parking, laydown and walkway areas shall be
landscaped and illuminated.
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Equipment buildings will be provided with appropriate doors to suit the operation of
the plant including removal and replacement of all equipment. Some buildings will
be provided with precast concrete walls to reduce noise levels and provide heat
insulation.
13.1.2
Platforms, Access Ways and Stairways

Platforms, access ways and stairways will be included in the design to allow
sufficient access for operations and maintenance.
Ladders will be avoided
wherever possible.
13.1.3
Lifting Devices
Lifting devices will be included in the design where necessary. These will include
electrically operated Cranes (EOTs) for removal of pumps and air blowers etc.
Gantry cranes will be provided RO buildings and the Chlorine building. Mobile
cranes will be required to move pumping and other equipment to a suitable truck
loading area.
13.2
Road works
The desalination plant area will be designed as a large, evenly graded area with
provision for adequate access to the plant such that vehicles will not need to cross
open drains. Grading around the plant will be arranged to ensure drainage away
from the plant at an appropriate grade to minimise the potential for ponding or
flooding.
Working areas around the desalination plant will be surfaced in a road base or
appropriate capping layer to provide all-weather hard standing areas for
maintenance traffic. Areas of significant traffic, such as around workshops and
offices and roads between facilities plus roads surrounding and internal to the
process plant shall be bitumen sealed. Any areas that are sensitive to vehicle
impact, in particular building edges, workshop door openings etc, exposed items
such as fire hydrants and other vulnerable infrastructure, shall be protected by 150
mm diameter steel bollards painted or marked (in reflective material) and, filled
with concrete or by roadside type guardrail.
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All underground electrical cable in ducts /conduit will have concrete cable pits at
changes of direction. These pits will be provided with removable concrete covers at
plate level capable of taking the load from the outrigger of a 50 t rough terrain
crane. The covers will be levelled to the fished road level.
All Internal roads shall have a minimum carriage width of 6.0 m. Roads will be
wider in areas adjacent to chemical storage facilities to allow a chemical truck to be
unloading without restricting through traffic. Road widening will also be required at
bends to provide sufficient room for turning of a trailer. Road cross fall shall
generally be designed at 2% for sealed pavements and 5% for unsealed with
vertical and horizontal alignment to be designed in accordance with MORTH
publications.
13.3
Site Services
All electrical and communication services will be located in suitable underground.
Site pipework will be buried where feasible.
13.4
Storm water Drainage

Local drainage design around buildings will be based on a 1 in 5 year average
recurrence interval. Collector drains will be based on a 1 in 20 year return period
and over-all site drains will be designed for 1 in 100 year rainfall intensity. Drainage
flows will generally be handled by drains mostly covered. The drainage design will
be checked for a 1 in 100 year average recurrence interval rainfall event to ensure
that no facilities (including electrical equipment) suffer any permanent damage
from such a storm.
Storm water drainage from all facilities shall be contained and directed into run-off
channels. Drainage from process overflows will be returned back to the process.
13.5
Fire Systems
Fire services will be compatible with the requirements of Health, Safety and
Environment and relevant standards.
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14. PRODUCT WATER MAIN

Sound planning dictates the standard design criteria in the planning and design of
pumping/ transmission mains. Pipelines are designed in accordance with the
maximum anticipated flow conditions; hence pipelines need to be sized to carry
water during these events without excessive pressure losses.
A water transmission system is the physical works that deliver water from the water
source to the intended end point or user. It is designed to deliver sufficient water
quantity and quality to meet the requirements of the customer. Typically, this is
achieved by way of pumps and motors, water mains, service pipes, storage tanks
or reservoirs, and related equipment, in a closed system under pressure. The
transmission
main
is
normally
designed for the carrying capacity

needed to supply water demand on
the maximum consumption day at a
constant rate. All hourly variations in
the water demand during the day of
maximum
consumption
are
then
assumed to be evened out by the

service reservoir.
A water system has two primary requirements: First, it needs to deliver adequate
amounts of water to meet consumer consumption requirements plus needed fire
flow requirements. Second, the water system needs to be reliable; the required
amount of water needs to be available 24 hours a day, 365 days a year.
In a pipe unlike the free-flow, the hydraulic gradient and not the slope of the conduit
will govern the flow. The hydraulic laws of closed conduit flows, also commonly
called pressurized flows, apply in the design of the same. Pressurized pipelines
can be laid up- and downhill as needed, as long as they remain at sufficient
distance below the hydraulic grade line, i.e. a certain minimum pressure is
Interim Report
maintained in the pipe. Hence, for closed conduits the hydraulic grade line slopes
according to the head loss.
Therefore, pipe sizing is based upon taking consideration of following factors:
Quantum of flow ( Q in m/s)
Fluid velocity (V in m/s)
Pressure (m in terms of water column)
Head loss (m in terms of water column)Pipe material
C-factor (Hazen-Williams coefficient of friction dependent on pipe material)
The governing equation is given by,

D= [4*Q/(*V)] 1/2
Where,
D= Internal Dia. Of pipe (m)
Q= flow (m/s)
V= velocity of fluid (m/s)
Transmission by pumping is applied in cases when the water has to be transported
over large distances and/or to higher elevations. The pumping head is the total
head, and comprises the static head plus the friction head loss for the design flow
rate. The pump to be selected must be able to provide this head at rated flow.
The head loss corresponding to the design flow rate can be computed for several
pipe diameters using Modified Hazen William Equation.
h = [L (Q / CR) 1.81]/ (994.62*D4.81]
CR = pipe roughness coefficient
D = internal diameter of pipe in m;
h = friction head loss in m;
L = length of pipe in m; and
Q = flow in pipe in m3 / s
Each combination of the pumping head and corresponding pipe diameter should
be capable of supplying the required flow rate over the required distance, and up to
the service reservoir. Smaller pipe diameters will require a higher pumping head to
Interim Report
overcome the increase in head losses, and the other way round. As a result, one
pipe diameter will represent the least cost choice taking into account the initial
costs (capital investment), maintenance costs and the energy costs for pumping.
The total cost, i.e. the capitalized taking both capital and operational cost as the
least and economical, shall be the basis for selecting the most economical pipe
diameter. Therefore, pipe sizing is based upon engineering standards for
acceptable energy (i.e. friction loss = loss of pressure) loss related to the intended
use of the pipe transmission main.
For this analysis, the
calculated costs for
different pipe sizes
shall be are plotted
as in a graph shown
as side. Therefore,
when the capital cost
and
the
operation
cost are added the

concave up curve is
derived. The point of inflection indicates the minimum total Cost. From this point
draw a vertical line that will intersect the X-axis at the most Optimum diameter.
The most economical pipe diameter will tend to be large when energy costs are
high, unit costs of pipe low and capital interest rates low. Nevertheless, it should
not be forgotten that a larger pipe means lower velocity, i.e. potential water quality
problems. As a preliminary estimate, the range of possible most economic
diameters can be selected based on velocities around 1.0-1.8 m/s.
The materials of construction available for construction of large diameter water
transmission main segments include the following alternatives:
Ductile iron pipe (DIP)
Pre-stressed Concrete Cylinder Pipe (PCCP)
Carbon Steel
High Density Polyethylene pipe (HDPE)
Interim Report
Based on historical performance, life expectancy and durability, the use of cement
lined and bitumen lined, and coated DIP and fittings will provide an excellent
conveyance mechanism for all segments of the proposed transmission main for the
portions considered for open cut construction.
In selecting the most appropriate pipe material for the said scheme/project the
following consideration shall be made:
o
o
o
The ground conditions along the pipeline route, mainly conditions such as
traffic overload, proximity to sewer lines, and crowded residential areas.
The cost and local availability of different types of pipe
the design pressure in the distribution system
assess the performance of the pipe material in terms of
Durability,
Resistance to Chemical Attack,
Corrosion and Abrasion. (Suitable external and internal coating shall be made and
if required cathodic protection).
The above aspects are considered in conjunction with the cost of procurement and
installation to provide the most economical solution.
Ductile iron and steel are the strongest pipe materials, making them the best
choice when very high operating pressures are to be expected. These pipes are
almost impossible to tap without special tools and equipment, which is an
advantage in cases where illegal connections pose a real threat for the urban local
body. However, the costs of fittings, valves, etc. increase rapidly for higher pipe
pressure classes and it is therefore often advisable to reduce the maximum internal
pipe pressure through the provision of a pressure reducing valve or break-pressure
tank/ intermediate pumping. A break-pressure tank is generally more reliable than a
pressure reducing valve.
In spite of higher investment costs, ductile iron pipes are a better alternative than
cast iron pipes because they have a longer service life, are lighter and more
flexible and require hardly any maintenance. The pipe is practically corrosion
Interim Report
resistant due to coatings applied inside and outside. Moreover, this pipe material
may be subject to scale bursts when tapped without sufficient skill. Alternative
materials are in this case High-density polyethylene (PE).
High-density polyethylene (PE) is a very suitable pipe material for small-diameter
mains because it can be supplied in coil. The potential of laying this pipe in longer
lengths reduces the number of necessary joints. Particularly in cases where rigid
pipe materials would necessitate a considerable number of special parts such as
elbows and bends, the flexible PE makes for an ideal pipe material. Polyethylene
does not deteriorate when exposed to direct sunlight. Conventional jointing of the
PE-pipes may cause leakage and welding is considered to be a better alternative.
However PE pipes greater than 1600 mm diameter are not commercial available in
the local market, hence is a big constraint in selecting the said pipe material for
commercial use when the diameter requirement is above 1600mm OD.
To summarize, for pipelines of small-diameter (less than 300 mm) PE may
generally be the best alternative unless high working pressures are expected
(above 60 mwc). These pipes can also be used for medium- to large-sized
pipelines (diameters up to 500-600 mm) where lower pressures can be maintained.
However, Cast iron, Ductile iron and Carbon steel are generally only used for largediameter mains and also in cases where very high pressures necessitate their use
in small- or mid-range diameter pipes. Due to heavy weight and lower flexibility, CI
pipes are becoming less advantageous than DI, despite lower prices. Moreover CI
pipes are brittle as compared to DI pipes. Stringent measures that have to be
introduced while handling these pipes involve the prevention of the production and
inhalation of fibre dust (use of special saws cutting under wet conditions, protection
masks for the workers, etc).
Since DI pipe above 1.1m dia are not available commercially, hence all pipes
above 1.1m dia shall be Carbon Steel as per IS 3589 with internal Cement
Concrete Lining (CC) lining in accordance with Is11906 or ISO 4179 and outside
fusion bonded epoxy coating for prevention for corrosion and all pipes below or
Interim Report
equal to 1.1 m shall be DI with internal CC lining and outside fusion bonded epoxy
coating as per IS 8329.
The water pumped from the proposed facility shall be conveyed to existing or new
ground storage tanks for further distribution in the city. This shall be confirmed in
the interim stage, when all surveys are in place.
Water:
Product water
Mild steel (IS 2062,plate fabricated) with mortar lining

inside and fusion bonded epoxy /polyurethane/epoxy
coatings on exposed surface (above 1100 mm
diameter of pipe),
Ductile iron pressure pipes and fittings (Class K9)
shall comply with IS 8329 and IS 9523 (Upto 1100
mm Diameter of pipe).
Interim Report
14.1
Annexure
14.1.1
Pipe sizing and pump capacity for 550 MLD
Capacity
LENGTH
C
TOTAL STATIC HEAD (H)
PIPE MATERIAL (MS)
DESIGN VELOCITY
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
60000
0.8
6
IS 2062
UNIT
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
M/S
550.00
MLD
6.37
M/S
M
M
CALCULATED DIA
( M)
SELECTED
DIA ( M)
ACTUAL
VELOCITY
(M/S)
(Q/C)^1.81
2.846947987
2.714458399
2.598896054
2.496938563
2.406110204
2.324523298
2.250710005
2.183509431
2.121989743
2.06539315
2.013096227
1.964580755
1.919411941
1.877221912
1.837697024
2.9
2.8
2.6
2.5
2.5
2.4
2.3
2.2
2.2
2.1
2.1
2
2
1.9
1.9
0.96
1.03
1.20
1.30
1.30
1.41
1.53
1.67
1.67
1.84
1.84
2.03
2.03
2.25
2.25
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
42.69
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
994.62
D^4.81
167.5461
141.524
99.08817
82.05243
82.05243
67.42424
54.94281
44.36629
44.36629
35.47111
35.47111
28.05138
28.05138
21.9182
21.9182
STATIC
HEAD
(H)
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
15.37
18.20
25.99
31.39
31.39
38.20
46.88
58.05
58.05
72.61
72.61
91.81
91.81
117.51
117.51
REQUIRED PUMP
HEAD INCLUDING
MINOR LOSS (10 %)
IN 'M'
SELECTED
PUMP HEAD (M)
22.91
26.02
34.59
40.53
40.53
48.02
57.56
69.86
69.86
85.87
85.87
107.00
107.00
135.26
135.26
23.00
27.00
35.00
41.00
41.00
49.00
58.00
70.00
70.00
86.00
86.00
107.00
107.00
136.00
136.00
Page 99
HEAD IN
Kg/Cm
2.346
2.754
3.57
4.182
4.182
4.998
5.916
7.14
7.14
8.772
8.772
10.914
10.914
13.872
13.872
Interim Report
S.No.
A
Particulars
Formula/Symbol
Unit
option-i
optionii
optioniii
optioniv
option-v
optionvi
option-vii
optionviii
optionix
option-x
option-xi
optionxii
optionxiii
optionxiv
optionxv
Pipe sizing based on internal design pressure
A.1
Selected pipe ID
ID
mm
2900
2800
2600
2500
2500
2400
2300
2200
2200
2100
2100
2000
2000
1900
1900
A.2
Pipe OD
OD
mm
2940
2840
2634.4
2534.4
2534.4
2434.4
2332
2232
2232
2132
2132
2032
2032
1928.4
1928.4
A.3
Design Pressure
Dp
kg/sqcm
2.346
2.754
3.57
4.182
4.182
4.998
5.916
7.14
7.14
8.772
8.772
10.914
10.914
13.872
13.872
A.4
Design
Temperature
Td
deg.C
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
A.5
Allowable stress
Sa
kg/sqcm
(g)
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
A.6
Corrosion
allowance for
carbon steel
cm
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
A.7
Weld joint
efficiency for
ERW pipes
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
A.8
y factor (as per

ASME B31.1 table
104.1.2(A))
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
A.9
Minimum
calculated pipe
thickness
Tc = ((Dp x OD x
0.1)/(2 x (y x Dp +
Sa x J)) + C) x 10
mm
8.19
7.96
7.50
7.28
7.28
7.05
6.82
6.59
6.59
6.37
6.37
6.14
6.14
5.90
5.90
A.10
Mill negative
tolerance for pipe
thickness
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
A.11
Minimum required
wall thickness
(after considering
mill tolerance)
T* = Tc / ( 1 (M/100))
mm
9.36
9.10
8.57
8.31
8.31
8.06
7.79
7.53
7.53
7.28
7.28
7.02
7.02
6.75
6.75
A.12
Selected
thickness of pipe
(based on internal
load thickness
calculation)
Ts
mm
20
20
17.2
17.2
17.2
17.2
16
16
16
16
16
16
16
14.2
14.2
Page 100
Interim Report
Page 101
Interim Report
14.1.2
Pipe sizing and pump capacity for 2 X 275 MLD
Capacity
LENGTH
C
PIPE MATERIAL (MS)
60000
0.8
6
IS 2062
275.00
3.18
MLD
M/S
M
M
NOTE
1
SELECTED
DIA ( M)
ACTUAL
VELOCITY
(M/S)
(Q/C)^1.81
994.62
D^4.81
STATIC
HEAD (H)
TWO PIPES EACH ACCOMODATING 275 MLD , THE ENTIRE SYSTEM (2 x 275 MLD ) COMPRISING
PUMPS. REFER SCHEMATIC DIAGRAM PROVIDED IN THE SHEET.
4W + 2S
REQUIRED PUMP
HEAD INCLUDING
MINOR LOSS (10 %)
IN 'M'
SELECTED
PUMP
HEAD (M)
HEAD
IN
Kg/Cm
DESIGN VELOCITY
UNIT
CALCULATED
DIA ( M)
M/S
2.013096227
2.1
0.92
12.18
994.62
35.47111
20.71
28.78
29.00
2.958
1.1
M/S
1.919411941
1.01
12.18
994.62 28.05138
26.18
34.80
35.00
3.57
1.2
M/S
1.837697024
1.9
1.12
12.18
994.62
21.9182
33.51
42.86
43.00
4.386
1.3
M/S
1.76560219
1.8
1.25
12.18
994.62 16.89899
43.47
53.81
54.00
5.508
1.4
M/S
1.701376842
1.8
1.25
12.18
994.62 16.89899
43.47
53.81
54.00
5.508
1.5
M/S
1.643686187
1.7
1.40
12.18
994.62 12.83687
57.22
68.94
69.00
7.038
1.6
M/S
1.591492307
1.6
1.58
12.18
994.62 9.589967
76.59
90.25
91.00
9.282
1.7
M/S
1.543974326
1.6
1.58
12.18
994.62 9.589967
76.59
90.25
91.00
9.282
1.8
M/S
1.500473337
1.6
1.58
12.18
994.62 9.589967
76.59
90.25
91.00
9.282
1.9
M/S
1.460453502
1.5
1.80
12.18
994.62 7.030706
104.47
120.92
121.00
12.342
M/S
1.423473994
1.5
1.80
12.18
994.62 7.030706
104.47
120.92
121.00
12.342
2.1
M/S
1.389168374
1.4
2.07
12.18
994.62 5.045171
145.59
166.15
167.00
17.034
2.2
M/S
1.3572292
1.4
2.07
12.18
994.62 5.045171
145.59
166.15
167.00
17.034
2.3
M/S
1.327396343
1.4
2.07
12.18
994.62 5.045171
145.59
166.15
167.00
17.034
2.4
M/S
1.299448027
1.3
2.40
12.18
994.62 3.532381
207.94
234.73
235.00
23.97
Page 102
Interim Report
S.No.
A
Particulars
Formula/Symbol
Unit
option-i
optionii
optioniii
optioniv
option-v
optionvi
optionvii
optionviii
optionix
optionx
optionxi
optionxii
optionxiii
optionxiv
optionxv
A.1
Selected pipe ID
ID
mm
2100
2000
1900
1800
1800
1700
1600
1600
1600
1500
1500
1400
1400
1400
1300
A.2
Pipe OD
OD
mm
2140
2040
1934.4
1834.4
1834.4
1734.4
1632
1632
1632
1532
1532
1432
1432
1428.4
1328.4
A.3
Design Pressure
Dp
kg/sqcm
2.958
3.57
4.386
5.508
5.508
7.038
9.282
9.282
9.282
12.342
12.342
17.034
17.034
17.034
23.97
A.4
Design
Temperature
Td
deg.C
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
A.5
Allowable stress
Sa
kg/sqcm
(g)
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
cm
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
A.6
A.7
Corrosion
allowance for
carbon steel
Weld joint
efficiency for
ERW pipes
A.8
y factor (as per

ASME B31.1
table 104.1.2(A))
A.9
Minimum
calculated pipe
thickness
Tc = ((Dp x OD x
0.1)/(2 x (y x Dp
+ Sa x J)) + C) x
10
mm
6.39
6.17
5.93
5.71
5.71
5.48
5.25
5.25
5.25
5.02
5.02
4.79
4.79
4.78
4.55
A.10
Mill negative
tolerance for
pipe thickness
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
T* = Tc / ( 1 (M/100))
mm
7.31
7.05
6.78
6.52
6.52
6.26
6.00
6.00
6.00
5.74
5.74
5.48
5.48
5.47
5.20
Ts
mm
20
20
17.2
17.2
17.2
17.2
16
16
16
16
16
16
16
14.2
14.2
A.11
A.12
Minimum
required wall
thickness (after
considering mill
tolerance)
Selected
thickness of
pipe (based on
internal load
thickness
calculation)
Page 103
Interim Report
14.1.3
Page 104
Interim Report
Capacity
LENGTH
C
TOTAL STATIC HEAD
(H)
PIPE MATERIAL
(MS)
60000
0.8
M
-
400.00
4.63
MLD
M/S
IS 2062
(Q/C)^1.81
994.62
D^4.81
STATIC
HEAD
(H)
REQUIRED
PUMP HEAD
INCLUDING
MINOR LOSS
(10 %) IN 'M'
SELECTED
PUMP
HEAD (M)
DESIGN VELOCITY
UNIT
CALCULATED DIA
( M)
SELECTED
DIA ( M)
ACTUAL
VELOCITY
(M/S)
M/S
2.427885401
2.5
0.94
23.99
994.62
82.052429
17.64
25.40
26.00
2.652
1.1
M/S
2.314897901
2.4
1.02
23.99
994.62
67.424242
21.46
29.61
30.00
3.06
1.2
M/S
2.216346002
2.3
1.11
23.99
994.62
54.942813
26.34
34.97
35.00
3.57
1.3
M/S
2.129396361
2.2
1.22
23.99
994.62
44.366288
32.62
41.88
42.00
4.284
1.4
M/S
2.051937677
2.1
1.34
23.99
994.62
35.471112
40.80
50.88
51.00
5.202
1.5
M/S
1.982360129
1.47
23.99
994.62
28.051383
51.59
62.75
63.00
6.426
1.6
M/S
1.919411941
1.47
23.99
994.62
28.051383
51.59
62.75
63.00
6.426
1.7
M/S
1.8621031
1.9
1.63
23.99
994.62
21.918197
66.03
78.63
79.00
8.058
1.8
M/S
1.809638933
1.9
1.63
23.99
994.62
21.918197
66.03
78.63
79.00
8.058
1.9
M/S
1.761373197
1.8
1.82
23.99
994.62
16.89899
85.64
100.20
101.00
10.302
M/S
1.716774231
1.8
1.82
23.99
994.62
16.89899
85.64
100.20
101.00
10.302
2.1
M/S
1.675400097
1.7
2.04
23.99
994.62
12.836875
112.74
130.01
131.00
13.362
2.2
M/S
1.636880004
1.7
2.04
23.99
994.62
12.836875
112.74
130.01
131.00
13.362
2.3
M/S
1.600900225
1.7
2.04
23.99
994.62
12.836875
112.74
130.01
131.00
13.362
2.4
M/S
1.567193288
1.6
2.30
23.99
994.62
9.5899671
150.91
172.00
173.00
17.646
HEAD IN
Kg/Cm
Page 105
Interim Report
S.No.
A
Particulars
Formula/Symbol
Unit
option-i
optionii
optioniii
optioniv
option-v
optionvi
option-vii
optionviii
optionix
option-x
option-xi
option-xii
optionxiii
optionxiv
option-xv
A.1
Selected pipe ID
ID
mm
2500
2400
2300
2200
2100
2000
2000
1900
1900
1800
1800
1700
1700
1700
1600
A.2
Pipe OD
OD
mm
2534.4
2434.4
2334.4
2232
2132
2032
2032
1932
1932
1832
1832
1728.4
1728.4
1728.4
1628.4
A.3
Design Pressure
Dp
kg/sqcm
2.652
3.06
3.57
4.284
5.202
6.426
6.426
8.058
8.058
10.302
10.302
13.362
13.362
13.362
17.646
A.4
Design
Temperature
Td
deg.C
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
A.5
Allowable stress
Sa
kg/sqcm
(g)
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
cm
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
A.6
A.7
Corrosion
allowance for
carbon steel
Weld joint
efficiency for ERW
pipes
A.8
y factor (as per

ASME B31.1 table
104.1.2(A))
A.9
Minimum
calculated pipe
thickness
Tc = ((Dp x OD x
0.1)/(2 x (y x Dp
+ Sa x J)) + C) x
10
mm
7.28
7.05
6.83
6.60
6.37
6.15
6.15
5.92
5.92
5.69
5.69
5.46
5.46
5.46
5.23
A.10
Mill negative
tolerance for pipe
thickness
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
A.11
Minimum required
wall thickness
(after considering
mill tolerance)
T* = Tc / ( 1 (M/100))
mm
8.32
8.06
7.80
7.54
7.28
7.02
7.02
6.77
6.77
6.51
6.51
6.24
6.24
6.24
5.98
A.12
Selected thickness
of pipe (based on
internal load
thickness
calculation)
Ts
mm
17.2
17.2
17.2
16
16
16
16
16
16
16
16
14.2
14.2
14.2
14.2
Page 106
Interim Report
Page 107
Interim Report
14.1.4
Capacity
LENGTH
C
PIPE MATERIAL (MS)
DESIGN VELOCITY
60000
0.8
M
-
6
IS 2062
UNIT
CALCULATED DIA
( M)
NOTE
1
SELECTED DIA
( M)
150.00
1.74
MLD
M/S
ONE PIPE ACCOMODATING 150 MLD , THE ENTIRE SYSTEM WILL COMPRISE 3W + 2S PUMPS. REFER
SCHEMATIC DIAGRAM PROVIDED IN THE SHEET.
ACTUAL
VELOCITY
(M/S)
(Q/C)^1.81
994.62
STATIC
HEAD
(H)
D^4.81
REQUIRED
PUMP HEAD
INCLUDING
MINOR LOSS
(10 %) IN 'M'
SELECTED
PUMP
HEAD (M)
M/S
1.486770097
1.5
0.98
4.06
994.62
7.030706299
34.88
44.36
45.00
HEAD IN
Kg/Cm
4.59
1.1
M/S
1.417579666
1.5
0.98
4.06
994.62
7.030706299
34.88
44.36
45.00
4.59
1.2
M/S
1.3572292
1.4
1.13
4.06
994.62
5.045170546
48.60
59.46
60.00
6.12
1.3
M/S
1.303983636
1.4
1.13
4.06
994.62
5.045170546
48.60
59.46
60.00
6.12
1.4
M/S
1.256550073
1.3
1.31
4.06
994.62
3.532380874
69.42
82.36
83.00
8.466
1.5
M/S
1.213942701
1.3
1.31
4.06
994.62
3.532380874
69.42
82.36
83.00
8.466
1.6
M/S
1.175394966
1.2
1.54
4.06
994.62
2.403597776
102.02
118.22
119.00
12.138
1.7
M/S
1.140300611
1.2
1.54
4.06
994.62
2.403597776
102.02
118.22
119.00
12.138
1.8
M/S
1.108173001
1.2
1.54
4.06
994.62
2.403597776
102.02
118.22
119.00
12.138
1.9
M/S
1.078616395
1.1
1.83
4.06
994.62
1.581607864
155.04
176.54
177.00
18.054
M/S
1.051305217
1.1
1.83
4.06
994.62
1.581607864
155.04
176.54
177.00
18.054
2.1
M/S
1.025968838
1.1
1.83
4.06
994.62
1.581607864
155.04
176.54
177.00
18.054
2.2
M/S
1.002380195
1.1
1.83
4.06
994.62
1.581607864
155.04
176.54
177.00
18.054
2.3
M/S
0.98034717
2.21
4.06
994.62
245.21
275.73
276.00
28.152
2.4
M/S
0.959705971
2.21
4.06
994.62
245.21
275.73
276.00
28.152
Page 108
Interim Report
S.No.
A
Particulars
Formula/Symbol
Unit
option-i
optionii
option-iii
option-iv
optionv
optionvi
optionvii
optionviii
optionix
option-x
option-xi
optionxii
optionxiii
optionxiv
optionxv
A.1
Selected pipe ID
ID
mm
1500
1500
1400
1400
1300
1300
1200
1200
1200
1100
1100
1100
1100
1000
1000
A.2
Pipe OD
OD
mm
1540
1540
1434.4
1434.4
1334.4
1334.4
1232
1232
1232
1132
1132
1132
1132
1028.4
1028.4
A.3
Design Pressure
Dp
kg/sqcm
4.59
4.59
6.12
6.12
8.466
8.466
12.138
12.138
12.138
18.054
18.054
18.054
18.054
28.152
28.152
A.4
Design
Temperature
Td
deg.C
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
A.5
Allowable stress
Sa
kg/sqcm
(g)
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
1311.43
A.6
Corrosion
allowance for
carbon steel
cm
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16
A.7
Weld joint
efficiency for ERW
pipes
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
A.8
y factor (as per

ASME B31.1 table
104.1.2(A))
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
A.9
Minimum
calculated pipe
thickness
Tc = ((Dp x OD x
0.1)/(2 x (y x Dp +
Sa x J)) + C) x 10
mm
5.05
5.05
4.81
4.81
4.58
4.58
4.35
4.35
4.35
4.12
4.12
4.12
4.12
3.88
3.88
A.10
Mill negative
tolerance for pipe
thickness
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
A.11
Minimum required
wall thickness
(after considering
mill tolerance)
T* = Tc / ( 1 (M/100))
mm
5.77
5.77
5.50
5.50
5.24
5.24
4.97
4.97
4.97
4.71
4.71
4.71
4.71
4.44
4.44
A.12
Selected
thickness of pipe
(based on internal
load thickness
calculation)
Ts
mm
20
20
17.2
17.2
17.2
17.2
16
16
16
16
16
16
16
14.2
14.2
Page 109
Interim Report
Page 110
Interim Report
15.
BENEIFTS OF LONG-TERM O&M CONTRACT

Municipalities/utilities enter into long-term O&M Contract services to achieve a number of
goals, including:
Reducing costs, both capital and O&M costs;
Increasing efficiency;
Enhancing risk management;
Meeting capital investment needs;
Achieving regulatory compliance;
Overcoming lack of local expertise through private-sector experience; and
Saving time.
Some of these objectives may be contradictory. For example, it may not be possible to
extract the greatest financial value and, at the same time, reduce rates. Similarly, it may
not be able to realize significant cost reductions and, at the same time, protect
employees entirely. These choices are predicated on trade-offs, i.e. what can be
exchanged for the guarantees afforded by an O&M agreement. The stability and
continuity of a 10- 15-year contract is quite clear over greater immediate financial gains
possible through a short-term agreement.
The essence of public-private partnerships is the type and breadth of guarantees that are
rare and difficult to achieve under public operation and management. Essentially, the
guarantee aspect translates to an enhanced risk-management advantage. The more
responsibility given to the private sector, the better the risk profile from the government's
viewpoint. Guarantees in long-term O&M contracts often include:
Guaranteed annual operating budgets and costs;
Guaranteed system operations, regulatory compliance, service quality;
Guaranteed construction costs and facility start-up schedules:
Guaranteed customer service and response: and
Guaranteed revenues and revenue collection
Achieving these guarantees and goals often requires a long-term commitment to

improving the quality and efficiency of municipal water service delivery.
Page 111
Interim Report
In addition to direct cost, compliance, performance, and financial benefits, long-term

contracts for water services can enable local leaders to concentrate their energies on other
programs and functions. The day-to-day management of utility systems has become a
burden in many communities, draining professional and management resources that can
be better focused on other municipal and community needs. In addition, partnerships lead
to increased accountability, improved service levels, capital improvements, and additional
benefits to the community.
The basic main of having long term O&M contracts have Cost Saving and Accountability
As long-term agreements shift responsibility for compliance with all regulations to private
providers, many municipal officials feel a "peace of mind" knowing an experienced
private firm is handling operations and complying with regulations. The more discrete
project components that are tied together, the greater degree of accountability can be
achieved. Investor-owned utilities have also been able to provide a higher level of
customer service at a lower cost by integrating customer-service functions such as call-in
centers, billing and collections into parent company systems.
Through the risk-allocation provisions of a partnership, a community assigns to the
private partner financial responsibility for certain cost overruns, non-compliance, missed
schedules, and/or poor revenue collections. tinder continued public operation, the only
recourse is to raise rates, pay fines, incur additional debt, or subsidize operations.
Further, Long-term contracts often result in improved performance and more
efficient services. Private firms make greater up-front investments in advanced
computers and cutting-edge technology, knowing the costs can be amortized over a
longer period.
Private firms can not only generate significant O&M savings, but can also reduce
capital costs between 10 and 15 percent through the design/build/operate (DBO)
approach. Savings can be plowed back into system improvements and other capital
needs.
Long-term contracts can produce other important benefits for the community. Hiring
the existing workforce promotes continuity and helps avoid nasty, divisive labor battles.
Utilities can also enhance local economic development through long-term contracts.
Page 112

Interim Report 150 MLD

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Interim Report

Scope of this Interim Report

Finished Floor Level

Typical Oceanographic Conditions

Importance of Sea Water Quality

Temperature and Salinity Trends

Water Quality Design Criteria

Water Quality Targets

Total Dissolved Solids

Jelly Fish Blooms

DESIGN LIFE AND AVAILABILITY; PRIMARY FLOWS

Operations and Availability

Intake structure with Screen offshore

Active Screens before the Sea Water Pumps

Sea Water Pumping Station

Shock chlorination system

Intake / Outfall Pipes

Main Jacking Station

Sea Water Quality / Treatment Processes

Key Water Quality Parameters Pre-Treatment

The Pre-Treatment Processes- Scheme

Dissolved Air Flotation (DAF)

Ultrafiltration Water Storage

REVERSE OSMOSIS PLANT

Pumping System Design and Pressure Control

Reverse Osmosis Pumping and Energy Recovery System

RO Clean In Place System

Requirement for Stabilisation

Hydrated Lime & Carbon Dioxide

Key design Criteria

Flotation Aid Polyelectrolyte

9.10 Ultra Filtration Chemicals

10. WATER STORAGE AND TRANSFER

10.1 Process water storage

12. POWER AND CONTROL

110 kV / 11 kV Substation within the Plant premises

Pumping station electrical works, controls and electrical systems

Emergency power generation

12.2 Control System

General Design Criteria

Plant Operation Methods

Control System Architecture

13. CIVIL, BUILDING AND STRUCTURAL WORKS

Platforms, Access Ways and Stairways

13.2 Road works

14. PRODUCT WATER MAIN

Pipe sizing and pump capacity for 550 MLD

Pipe sizing and pump capacity for 2 X 275 MLD

Pipe size and pump capacity for 400 MLD

Pipe size and pump capacity for 150 MLD

15. BENEIFTS OF LONG-TERM O&M CONTRACT

Sea Water quality is poor.

The specification for the Nemmeli desalination plant nominates a design

Longshore sediment transport is generally to the north between April and

For this reason

Lamella settlers, preceded by coagulation-flocculation and polymer

suitable to cover the required membrane pressures for average to maximum

The nominated target alkalinity thus represents a balanced approach

between water quality and cost.

Product Water Main

Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB) is the

Bulk water supply to establishments

SIPCOT Industrial estate