1. TECHNICAL SPECIFICATIONS MECHANICAL ASPECTS 1.1.

. General Unless otherwise specifically described, the mechanical installations to be installed comprise all plant required for the proper functioning of the WWTP. These installations are described in this chapter as well as on the P&IDs and the drawings shown in Appendix I. Further general technical specifications are elaborated in volume 3C of these Employers Requirements and apply to these installations. Sufficient piping and valves shall be provided to ensure easy maintenance of the facilities without interrupting the wastewater treatment capacity (maximum design capacity). In some cases package units are specified. A package unit is an autonomously working unit with data communication with the process automation system. 1.2. Demolition Works All mechanical components which are no longer used in the rehabilitated plant (see Civil Aspects structures to be demolished), shall be demolished by the Contractor. Section 5.1 of Volume 3A is applicable. 1.3. Inlet The influent from Sibiu and the influent from Selimbar, Cisnadie and Mohu are collected in the inlet chamber of the Wastewater Treatment Plant (WWTP). After the inlet chamber at the WWTP inlet structure a static coarse screen shall be installed. Before the inlet chambers an overflow weir is located to discharge influent to the Cibin River in case of calamity. A slide damper will dampen turbulence in the main influent flow Mechanical installations for the inlet comprise, but are not limited to, the following equipment: - Static coarse screen (at the WWTP inlet structure). - Adjustable overflow weir (at the main weir gate). - Slide damper (at the main weir gate). general system requirements Static coarse screen Amount Mesh size Material Adjustable overflow to Cibin River Amount Length Material Slide damper Amount Length Material [-] [mm] : : : : : : : : : : 1 100 AISI 304 L 1 See drawing Rom32.1.3.103 AISI 304 L 1 See drawing Rom32.1.3.103 AISI 304 L

[-] [mm]

[-] [mm]

1.4. Automatic coarse and fine screens with screenings washing and handling The inlet of the waterline is provided with coarse screening to 25mm and fine screening to 6mm. Two automatic coarse screens and two automatic fine screens shall be installed. Two screenings conditioning units shall be provided operating as duty/duty with each unit sized to

take 100 % of the total flow. Each screening street shall be able to be operated individually, when the other street is out of operation. The screens shall be automatically cleaned by washing and brushing or by raking. The cleaning cycle shall operate on the differential water level across the screens. Non-potable water shall be used for flushing of the screening material. Reject water shall gravitate to the channels of the screens. Screenings of the fine and the coarse screens are washed, pressed and collected in two separate containers for removal. Isolation of the screens is effected via manually actuated penstocks. Two isolation penstocks shall be provided to allow full isolation of each set of coarse and fine screens. Penstock frames shall be of stainless steel with doors of a suitable composite plastic material. Containers shall be covered by an air extraction hood during filling to minimise obnoxious smells and connected to a stainless steel ventilation duct connected to the ventilation system. The requirements for the screening containers are that they must be draining through a screen at the bottom and that the water shall be discharged through a 60 mm stopcock above a large floor drain. The mechanical installation of the screens comprises, but is not limited to, the following equipment: - 2 coarse screens; - 2 fine screens; - 2 screw conveyers; - 4 connecting pieces between screens and conveyers; - 2 compactors with press-pipes; - 2 screenings washing systems using non-potable-water supplied from the non-potablewater system (could be combined with compactor); - 3 containers (2 duty, 1 exchange). general system requirements Automatic coarse screens Amount Mesh size Maximum velocity between bars Minimum velocity between bars Minimum flow coarse screen Maximum flow coarse screen Material screens Automatic fine screens Amount Mesh size Maximum velocity between bars Minimum velocity between bars Minimum flow fine screen Maximum flow fine screen Material screens Transport screws Amount Diameter Capacity [-] [mm] [m/s] [m/s] [m3/h/piece] [m3/h/piece] : : : : : : : : : : : : : : : : : 2 25 1.0 0.25 Approx. 2.300, See PFD Approx. 4.500, See PFD AISI 304 L 2 6 1.0 0.25 Approx. 2.300, See PFD 4.500, See PFD AISI 304 L 2 300 5

[-] [mm] [m/s] [m/s] [m3/h/piece] [m3/h/piece]

[-] [mm] [m3/h]

Material transport screws Wash and compacting screw Amount Capacity Nominal capacity Diameter Wash water Dryness screenings Material casing Material screw Container Number of containers Volume of each container Material container [-] [m3/h] [m3/h] [mm] [m3/h/piece] [solid %]

: : : : : : : : : : : :

AISI 304 L 2 5 1 300 Max 5 40 AISI 304 L Coated steel 3 6 Coated steel

[-] [m3]

1.5. Grit/grease removal Two double aerated grit/grease chambers for removal of inorganic particles like grit as well as floating substances such as grease and oil shall be equipped with the necessary equipment including air diffusers. Air supply to the grit/grease chambers is necessary to prevent removal of organic material. The aeration shall keep the organic material in suspension, only the grit will settle. A slide shall divide each of the two aerated grit/grease chambers. The current flow, agitated by the airlift of the aeration, shall push the grease under the slide of the so-called double chamber to the farest chamber. The grease shall be trapped in the furthest chamber and shall float to the surface. The floating substances shall be scraped to a common grease well, from where reject water is led to the internal wastewater system. The grease well shall be designed for easy collection of grease with a vacuum tanker-gully emptier. The grease scraping and collection systems shall be designed in order to avoid dead ends with unintended collection of grease. The settled grit at the bottom shall be scraped by two automatic operated grease/grit scraper trolleys to grit chambers. Each trolley shall cover two chambers. The removal of settled grit from the grit chambers to a grit dewatering device shall take place by one submersible grit pumps per line. The pumped grit/water mixture shall be dewatered with a dewatering device. The dewatered grit shall be delivered to a grit container via a screw. The requirements for the grit containers are that they must be draining the water through screens and that the water shall be discharged. Isolation of the pairs grease/grit chambers is possible via manually actuated penstocks. Two isolation penstocks shall be provided to allow full isolation of two grease/grit chambers. Penstock frames shall be of stainless steel with doors of a suitable composite plastic material. The mechanical installations of the grit/grease removal comprise, but are not limited to, the following equipment: - Two trolleys with each two grit scrapers and each one grease remover. - Aeration with coarse bubble diffusers including connecting pipes and valves. - Two grit pumps with connecting pipe work.

Two grease/reject water pumps with connecting pipe work. Access ladders/stairways and platforms for the grease/grit scraper trolleys and for other access to items like the aerators. Penstocks. Two grit containers each with a volume of 6 m3. Grit dewatering device. Sub-structures to support the units at the required level and discharge the grit at a suitable height for skip collection.

general system requirements grit/grease removers Grit Removal Grit fraction to be removed: Aeration Chamber 1 / 2 Chamber 3 / 4 Trolleys Amount trolleys Material trolleys Scrapers Amount grit scrapers Material scrapers Grease removers Amount grease removers Material grease remover [mm] [mn3/h] : [mn3/h] : [pieces] : : : : [pieces] : : > 0,105 750 750 2 Coated steel 4 Aisi 304 2 Aisi 304 For pumping grit to the classifier Grit +2 tot +25 By contractor (Approx. 5) Centrifugal pump By contractor (max 10) By contractor (Approx. 3) By contractor (Approx. 2) 10 min/h (1 pump in duty and 1 pump standby) Min 50 Centrifugal vortex pump 50 Self cleaning and non-clogging Steel coated Steel with rubber (protection against abrasive

grit pumps Application Medium Medium temperature Solid percentage Type Flow/head of the pump - nominal flow - Hstat - Hdyn - Operation management
Pump type Efficiency Impeller: - Type - Ball gauge diameter Remarks Materials: - Motor casing - Impeller

[C] max [%] [m/h] [mwc] [mwc]

: : : : : : : : : : : : : :

[%] [mm]

- pump casing Pump speed Material connecting pipes

[rpm]

: : :

wear) Cast Iron coated max. 1500 AISI 304

grease pumps Application Medium Type Flow/head of the pump - nominal flow - Hstat - Hdyn - Operation management Pump type Efficiency Impeller: - Type - Ball gauge diameter Remarks Materials: - Motor casing - Impeller - pump casing Pump speed Material connecting pipes
Grit Dewatering Amount Capacity Diameter Dewatering capacity Material casing Material screw Other technical arrangements Grit Container Amount Volume Drainage water outlet Material container

[m/h] [mwc] [mwc] [%] [mm]

: : : : : : : : : : : : : : : : :

For pumping grease to the grease well Grease Centrifugal pump By contractor By contractor By contractor 10 min/h (1 pump in duty and 1 pump standby) Min 50 Centrifugal vortex pump 50 Self cleaning and non-clogging Aisi 316 Cr-steel Aisi 316 max. 1500 AISI 304L

[rpm]

[-] [m3/h] [mm] [m3/h]

: : : : : : : : : : :

1 Max flow of a grit pump 300 Max 5 AISI 304 L Coated steel High level grit dewatering 2 6 Min 60 Coated steel

[-] [m3] [mm]

1.5.1. Blower Station for Grit/Grease Chambers Two blowers of the lobe type shall be installed for the air supply to the Grit/Grease Chambers and to the possible air lift pumps for the grit removal. A minimum of 100 % reserve capacity of the total aeration capacity shall be installed. Blower Station for Grit/Grease comprises, but is not limited to, the following equipment: - Complete blower installation existing of two blowers with connections to the piping system. - Noise hoods.

The foundation of the blowers, and connections to piping system shall be installed with necessary compensatory and vibration-absorbing arrangements. : : : : : : Aeration for the grit/grease removers 1 2 750 By contractor (approx. 1,3) atmospheric air

general system requirements Application Number compressors in operation: - Minimum - Maximum Capacity / compressor: Maximum discharge pressure Medium

[mn3/h] [bar absolute]

1.6. Distribution Chamber No. 1 The return sludge and the incoming influent are mixed in the distribution chamber No1 (static mixer). The flow is divided to the three activated sludge tanks. The weir plates in the distribution chamber for the Aeration Tanks shall be adjustable in height to obtain equal distribution of the wastewater to the tanks. The installation comprises, but is not limited to, the following equipment: - 3 adjustable weir plates; The adjustable weirs are manually actuated. A closed weir shall be provided to allow full isolation of an activated sludge tank. The overflow weirs shall be made of stainless steel with a minimum wall thickness of 2.5 mm. The lengths of the weir plates are indicated on the enclosed drawings. Stationary bridges are assumed to be necessary for operation of the weirs. 1.7. Activated Sludge Tanks Each Activated Sludge Tank is divided in different zones: - 1 x Denitrification zone. - 3 x Nitrification zone. The nitrification zones of the three Activated Sludge Tanks shall be aerated with fine bubble aeration by disc or plate diffusers. Mixers in denitrification zones shall keep the sludge suspended and prevent precipitation of the sludge. The aeration sections and mixers shall be placed thus that the best possible aeration and mixing is achieved and sediments and scum are minimised. The rotational speed of the mixers shall not disturb the biological process. Disc diffusers/Plate diffusers shall be installed in the nitrification zones. The membranes shall be made of EPDM/poly-urethane based rubbers. No ceramic disc diffuser shall be used. The disc diffusers/plate diffusers shall be mounted on plastic or stainless steel pipe work. The minimum lifetime guarantee of the manufacturer of the diffusers shall be 10 years. The design of the aeration system shall be based on the required oxygen quantity. Installations for the Activated Sludge Tanks comprise, but are not limited to, the following equipment: - air supply pipes; - aeration headers; - 12 mixers; - 3 recirculation pumps; - outlet weirs;

platforms; stairs; lifting equipment;

general system requirements Activated Sludge Tank Activated sludge tank Amount [-] Water depth [m] Volume per tank [m3] Total activated sludge volume [m3] Sludge content [kg/m3] BOD sludge loading rate [kg BOD/(kg MLSS d)] Recirculation flow [m3/h] Oxygen demand Oxygen demand alpha OC Alpha factor Required oxygen quantity Specific oxygen transfer Required volume of air [kg O2/h] [-] [kg O2/h] [g O2/mn3 m-1] [mn3/h]

: : : : : : : : : : : :

3 4,5 5.730 17.200 4,5 0.11 6.000, See PFD 1.266 0,65 1.947 17 25.500

1.7.1. Mixers Mixers shall keep the sludge in the denitrification zones in suspension. The amount of mixers is indicative. general system requirements mixers Propeller - Amount blades Jetring Materials - Propeller - bolts and nuts - motor casing Propellor speed [rpm] Sealing Oil chamber Additional Material leading beam

: : : : : : : : : :

3 No Stainless steel AISI 316 Stainless steel AISI 316 Stainless steel AISI 316 max. 315 Maintainable double mechanical seals Water in oil detection with relais Leading beam Stainless steel AISI 316

1.7.2. Recirculation Pumps One recirculation pump in each activated sludge tank shall recirculate the activated sludge mixture from the end of the oxic zones to the beginning of the anoxic zone. Each recirculation pump shall be installed with a non-return valve and a short pressure pipe. The pumps shall be axial, submersible pumps. general system requirements Recirculation Pumps Application : Recirculation activated sludge mixture in activated sludge tanks Medium : Activated sludge Medium temperature [C] : +2 tot +25 Type : Horizontal submersible axial impeller pumps Flow/head of the pump : - Nominal flow [m/h] : 2.000, See PFD

Hstat Hdyn Operation management

[mwc] [mwc]

: : : : : : : : : : : : :

By contractor (Approx. 0,1) By contractor (Approx. 1) Continuous Min. 40 % Axial impeller Self cleaning and non clogging Stainless steel AISI 316 Stainless steel AISI 316 Cast Iron coated Max. 1000 Double mechanical seal Water in oil detection with relay

Pump type Efficiency Impeller: - Type - Diameter Remarks Materials: - Motor casing - Impeller - Pump casing Pump speed Sealing Oil chamber

[%] [mm]

[rpm]

1.7.3. Additional Pump A portable submersible pump with enough capacity including flexible hoses (6 bar) for emptying one tank in 48 hours shall be included in the supply. 1.8. Intermediate Pumping Station The activated sludge mixture from the activated sludge tanks will flow by gravity to the intermediate pumping station. The activated sludge to Final Settling tanks 1 and 2 shall flow by gravity from the intermediate pumping station to the distribution chamber 3. 47 % of the total flow is pumped to distribution chamber 2. Submersible axial impeller pumps shall be installed in the intermediate pumping station for transport to distribution chamber No. 2. The activated sludge will be pumped from the pump sump to distribution chamber No. 2. The pumping station is equipped with 3 pumps. Two pumps are in operation and one pump is stand-by. Installations for the activated sludge tanks comprise, but are not limited to, the following equipment: - 3 transport pumps with valves and connecting pipe work; - platforms; - stairs; - lifting equipment. general system requirements Intermediate Pumping Station Application : Transport activated sludge from the intermediate pumping station to distribution chamber 2 Medium : Activated sludge Medium Temperature [C] : From +2 to +25 Type : Horizontal submersible axial impeller pumps Flow/head of the pump : - maximum [m/h] : 1.950, See PFD - Hstat [mwc] : By contractor (Approx. 1,3) - Hdyn [mwc] : By contractor (Approx. 0,7) - Operation management : Continuous Pump type Efficiency [%] : min. 40 %

Impeller: - Type - Diameter Remarks Materials: - Motor casing - Impeller - pump casing Pump speed Frequency converter Sealing Oil chamber

[mm]

: : : : : : : : : :

Axial impeller Self cleaning and non clogging Stainless steel Aisi 316 Stainless steel Aisi 316 Cast iron coated max. 1000 Yes double mechanical seal Water in oil detection with relay

[rpm]

1.9. Distribution Chamber No 2 The activated sludge flow in distribution chamber 2 is divided to the final settling tanks 3, 4, and 5. The installation comprises, but is not limited to, the following equipment: - 3 penstocks. Three isolation penstocks shall be provided to allow full isolation of each final settling tank. Penstocks shall be fitted with a suitably rated electric actuator, with local controls. 1.10. Distribution Chamber No 3 The activated sludge, which is pumped to distribution chamber No 2, shall be distributed in distribution chamber No 3. The activated sludge flow is divided to the final Settling tanks 1 and 2. The installation comprises, but is not limited to, the following equipment: - 2 penstocks. Two isolation penstocks shall be provided to allow full isolation of each final settling tank. Penstocks shall be fitted with a suitably rated electric actuator, with local controls. 1.11. Final Settling Tanks 1 + 2 For separating treated wastewater from sludge the existing final settling tank No 1 and No. 2 shall be refurbished. A Coanda tulip (type CTS7) is available on site for final settling tank No. 1 and can be used by the Contractor free of charge. The mechanical installations to be refurbished include an inlet with tapered openings, sludge pipes to the return sludge pumping station, rotating scrapers with all equipment including weir plates fixed to the outlet channel. In case the Coanda tulip is not used, scum collection in the feed well should be possible by an increased height of the feed well. Sludge evacuation system from the tanks shall be adapted to the geometry of the tanks. The sludge outlet flow shall be controlled by means of the return sludge pumps (frequency controlled). The outlet from the chamber in each tank shall be connected to the Return Sludge Pumping Station(s) with either new pipes or the existing pipes if these are in good condition, such to the judgement of the Engineer. The mechanical installation for the final setting tanks 1 + 2 comprise, but is not limited to, the following equipment: - half rotating bridge (walkway) including carriage; - central bearing construction;

scraper mechanism; sludge evacuation system; dive baffle; V notch weir plates; inlet diffuser drum; (train) rail construction at the topside of the tank wall.

general system requirements Final Settling Tanks 1 and 2 Refurbishment : Yes Application : Removal settled solids and floating materials Span rotating bridge [m] : 22,5 Surface loading at maximum flow [m3/m2/h] : 0,72 Design flow: - influent (average-max) [m3/h] : See PFD - return sludge (average-max) [m3/h] : See PFD - total (average-max) [m3/h] : See PFD Peripheral velocity rotating bridge [m/s] : 0,05 Diameter tank (inside running track) [m] : 45 Inclination gradient bottom : 1 : 12 Material rotating bridge and : Stainless steel AISI 304 accessories The velocities in the pipes of the[m/s] : 1.0 to 1.5 sludge water mix The velocity at the tapered openings[m/s] : < 0.7 of the inlet pipes 1.12. Final Settling Tanks 3, 4 and 5 The existing primary settling tanks shall be converted into three final settling tanks. The tanks No. 3, No. 4 and No. 5 shall be equipped with all new installations. The installations include inlet pipes with tapered openings, sludge pipes to the sludge pumping station, rotating scrapers with all equipment including weir plates fixed to the outlet channel. Scum collection in the feed well should be possible by an increased height of the feed well Sludge evacuation system from the tanks shall be trough sludge funnels. The scraper blades shall be placed at a 5 to 15 degrees angle to the rotating bridge to scrape the sludge to the funnels. The settled sludge in the funnels shall be pumped by the Return Sludge Pumps to the distribution chamber No. 1 for the activated sludge tanks. The scrapers for the final settling tanks comprise, but are not limited to, the following equipment: - 2/3th rotating bridge (walkway) including carriage; - central bearing construction; - scraper mechanism; - funnels; - skimmer blade; - outlet; - dive baffle; - V notch weir plates; - inlet diffuser drum; - (train) rail construction at the topside of the tank wall;

general system requirements Final Settling Tanks 3, 4 and 5 Refurbishment : No Application : Removal settled solids and floating materials Span rotating bridge [m] 17,5 Surface loading at maximum flow [m3/m2/h] : 0,72 Design flow: - influent (average-max) [m3/h] : See PFD - return sludge (average-max) [m3/h] : See PFD - total (average-max) [m3/h] : See PFD Peripheral velocity rotating bridge [m/s] : 0,05 Diameter tank (inside running track) [m] : 35 Inclination gradient bottom : 1 : 12 Material rotating bridge including : Stainless steel AISI 304 accessories The velocities in the pipes of the[m/s] : 1.0 to 1.5 sludge water mix The velocity at the tapered openings[m/s] : < 0.7 of the inlet pipes 1.13. Return sludge pumping station No 1 The sludge is flowing by gravity from the Final Settling tanks No 1 and No 2 to an existing pump sump (return sludge pumping station No 1). The existing two sludge/water pumps shall be replaced by three (1 service, 1 stand-by) new pumps for return sludge being pumped to the Distribution Chamber 1 for the Activated Sludge Tanks. general system requirements Return Sludge Pump Number [pieces] : 1 duty and 1 standby Application : Return sludge from the final settling tanks 1 and 2 to distribution chamber 1. Type : Submersible centrifugal pump Type : Medium : Sludge Efficiency [%] : min. 60 Capacity flow: [m3/h] : See PFD Capacity pressure [mwc] : to be defined by Contractor Maximum speed [1/min] : 1.500 Material : pump casing: grey cast iron 20 impeller: chrome steel (material 4R) Location : Return sludge building Specific requirements : - double mechanical seal; Motor : the pump/motor unit shall be suitable for variable speed drive over the entire power curve of the pump. 1.14. Return sludge pumps final settling tanks 3, 4 and 5 Three pumps shall be installed for return sludge being pumped to the Distribution Chamber 1 for the Activated Sludge Tanks. general system requirements Return Sludge Pump Number [pieces] : 3 x 2 (1 duty and 1 standby each tank) Application : Return sludge from the final settling tanks 3, 4, and 5 to distribution chamber 1. Type : Axial pump

Medium Efficiency Capacity flow: Capacity pressure Maximum speed Material Location Specific requirements Motor

[%] [m3/h] [mwc] [1/min]

: : : : : : : : :

Sludge min. 45 See PFD to be defined by Contractor 1.500 pump casing: grey cast iron 20 impeller: chrome steel (material 4R) Return sludge building - mechanical seal; - manometer and test cock - the pump/motor unit shall be suitable for variable speed drive over the entire power curve of the pump. - one frequency controller for two pump/motor combinations.

1.15. Surplus sludge pumping station Two submersible pumps will transport surplus sludge from final settling tank 1&2 to the gravitational Sludge Thickener. general system requirements Surplus Sludge Pump Number [pieces] : 1 duty and 1 standby Application : Surplus sludge from the sludge pumping station to the gravitational thickener. Type : Centrifugal pump Medium : Sludge Efficiency [%] : min. 60 capacity flow: [m3/h] : See PFD capacity pressure [mwc] : to be defined by Contractor maximum speed [1/min] : 1500 Material : pump casing: grey cast iron 20 impeller: chrome steel (material 4R) Location : Return sludge building specific requirements : - mechanical seal; - manometer and test cock Motor : the electric motor shall be direct driven. The velocities in the pipes of the sludge water mixture shall be between 1.0 and 1.5 m/s. 1.16. Centrifugal compressors 1.16.1. Design Centrifugal compressors shall be installed in the compressor building for the air supply to the Activated Sludge Tanks. Alternatively, lobe type air compressors are allowed to be applied conform the general mechanical specifications. The compressors shall keep the pressure in the header within a narrow bandwidth (constant pressure loop). The volume flow will be controlled by means of inlet guide vanes and diffuser vanes of the compressor. The capacity shall be controlled between 45 % - 100 % of the maximum capacity.

volume flow and reserve capacity Application Number of compressors Number compressors in operation: - Minimum - Maximum Capacity / compressor: - Minimum volume flow - Maximum intake volume (0C, 1,013 bar) Electrical consumption Medium Intake temperature: - Minimum - Average - Maximum Intake pressure Relative humidity Maximum discharge pressure

: : : : [mn3/h] [mn3/h] [kWel] [C] [C] [C] [%] [bar absolute] : : : : : : : : : :

Aeration of the activated sludge tanks 3 1 3 duty 5.000 25.500 app. 500 atmospheric air -/- 40 15 35 atmospheric Contractor, app. 1,6

The compressor-installations for the fine bubble aeration comprise, but are not limited to, the following equipment: - compressors with drive unit, start-up unloading device, pressure relief valve; - frame with vibration isolators; - pressure protection; - piping and isolation piping; - inlet filter, inlet silencer, start-up silencer; - acoustic enclosure; - control valves, non return valves, start-up valves; - calculations, inspection and tests; - LCP-units and MCP-unit, connecting to all the necessary measurements - all necessary protections, limit switches, etc. to ensure a safely operating and protected installation. In case one compressor is out of operation, the other two shall be able to provide 70% of the required maximum capacity. general system requirements Compressors Type Diffuser Pre-rotation Gearbox Construction - material rotor and shaft - sealing labyrinth (male) - sealing labyrinth (female) Cooling Electric motor Construction Starting features Therminal protection circuits Separate cooling fan : : : : : : : : : : : Single stage centrifugal compressor Yes Yes Yes Duraluminium, one piece Chrome steel Aluminium Oil cooling three-phase asynchronous motor, pole reversible soft starting / star delta switch Yes Yes

general system requirements Automatic valves for air supply Amount [pieces] : 9 Type : Plate valve with V-Notch Material sealing : EPDM Protection class : IP 67 Signals : - Max moment switches; - Open/close signal - Valve position signal : - Local manually actuated Safety Protection by means of heating element and thermo contact Location : Outside on the activated sludge tanks 1.17. Gravitational Sludge Thickener (Storage tank) One digester tank (1.500 m3) shall be converted to a gravitational sludge thicken er (storage) including all installations. The surplus sludge from settling tanks shall be pumped to the return sludge pumping station. general system requirements Gravitational Sludge Thickener (Storage tank) Application : sludge thickening by gravity Medium : surplus sludge Maximum flow [m3/h] : See PFD Peripheral velocity [m/s] : 0,05 Incline bottom : 1 : 12 Maximum water level [m] : See hydraulic profile Tank diameter [m] : 14,5 Material overflow weir [-] : AISI 304 L The gravitational sludge thickener comprises, but is not limited to, the following equipment: - in- and outlet pipes; - material certificates; - certificates of preservation (corrosion protection); - Overflow weir. 1.18. Thickened sludge pumps Two dry mounted progressive cavity pumps shall be used for thickened sludge being pumped from the gravitational sludge thickener (storage tank) to the sludge thickeners. Each of the pumps shall be connected to each of the two sludge belt thickeners. general system requirements sludge thickening pumps Number [pieces] : 1 duty for each sludge thickener Application : Pumping thickened sludge to one thickeners. Type : Dry mounted progressive cavity pumps Medium : Sludge approx. 2,0 % DS capacity flow: [m3/h] : See PFD capacity pressure [mwc] : To be defined by Contractor maximum speed [1/min] : 250 Material : Rubber chrome steel Location : Sludge building Specific requirements : - mechanical seal; - Shop testing;.

sludge

Motor :

manometer and test cock The electric motor shall be direct driven.

1.19. Sludge Thickeners The sludge from the sludge thickeners shall be to a minimum dry matter content of minimum 6 %. Two polymer dosing pumps shall be installed for dosing polymer into the sludge before sludge thickening. The reject water outlets from the sludge thickeners shall be in close connection with the floor drains in order to avoid any splashing. The reject water shall be led back to the Return Pumping Station. The thickened sludge pumps for the digester pump the thickened sludge to the digester. The sludge thickeners and the thickened sludge pumps for the digester shall be fully enclosed within the sludge dewatering building and be connected to the extract ventilation system.\ The sludge thickeners comprise, but are not limited to, the following equipment: - Two sludge belt thickeners (two duty); - Two hydraulic units - Two drive units; - in- and outlet pipes, wash pipes, reject water pipes; - Static mixers for PE-dosing; - Fans, covering and in- and outlet pipes; - Instrumentation and safety-equipment. Application Medium Minimum dry solids outlet Polymer dose Minimum capture dry solids Concentration polymer Relative solid capacity Hydraulic capacity Dry Solid capacity : : : : : : : : : Sludge Thickening Thickened sludge 6 4 97 0,1 325 2 x 15, See PFD 600 700

[%] [g PE/kg ds] [%] [%] [kg DS/h/m] [m3/h] [kg DS/h]

1.20. Sludge thickening pumps for the digester Two dry mounted progressive cavity pumps shall be used for thickened sludge being pumped from the sludge thickener into the pipework connected to the digester. Number Application Type Medium capacity flow: capacity pressure maximum speed Material Location Specific requirements [pieces] : : : : : : : : : : 2 duty and 1 reserve Pumping sludge from the sludge thickener into the pipe work of the digester. Dry mounted progressive cavity pump, Sludge approx. 6 % DS See PFD to be defined by Contractor 250 Rubber chrome steel Sludge thickener building - Inlet chute with paddles; - Automatic constant level control inlet chute - mechanical seal; - Shop testing;. - manometer and test cock - the pump/motor unit shall be suitable for

[m3/h] [mwc] [1/min]

Motor

variable speed drive over the entire power curve of the pump. 1.21. Recirculation Pump The cold thickened sludge of the sludge thickener shall be mixed with the circulation sludge in the suction-side of the sludge circulation pump. The sludge circulation pump shall pump the sludge through the heat exchanger into the digester. Number Application Type Medium capacity flow: capacity pressure maximum speed Material Location specific requirements [pieces] : : : : : : : : : : 1 duty and 1 reserve recirculating sludge through the digester. Dry mounted progressive cavity pump: rotary lobe pump Sludge approx. 4,7 % DS See PFD To be defined by Contractor 250 Rubber chrome steel Digester - Rotors pushed-on, quick-changeable rubber coated tips - mechanical seal; - Shop testing;. - manometer and test cock The electric motor shall be direct driven.

[m3/h] [mwc] [1/min]

Motor

1.22. Sludge heat exchanger The sludge digester shall be heated by the sludge heat exchanger on a temperature of 35 oC. The sludge digester shall be prevented form cooling down through enough isolation in the walls of the sludge tank. The energy flow to the sludge tank consists of the following two parts: - Heat for the cold sludge from the mechanical sludge thickeners; - Heat for the energy loss of the sludge digesters (convection & transmission). Heat consumption for sludge heating Sludge supply Begin temperature End temperature Specific Heat Factor Heat Heat (transmission) for digester Radiation Begin temperature End temperature Diameter Height Surface Heat (transmission) for digester Total Heat consumption Winter max. 7 5 35 4,2 10 0,5 2 -15 35 19 10 1300 57 67 : : 1 duty Heating sludge

m3/day C C kJ/kg/C kW W/m2/K C C m m m2 kW KW

General system requirements Heat Exchanger Number [pieces] Application

Type Medium capacity flow: Pressure Drop Design pressure Plate Area Material Location Specific requirements [m3/h] [mwc] [mwc] [m2]

: : : : : : : : :

Horizontal/vertical spiral heat exchanger Sludge approx. 5 % DS; (17% thickened sludge 83% digested sludge); See PFD To be defined by Contractor 30 23 Stainless steel AISI 316L Digester 50 oC - 70 oC; temperature range heating water.

1.23. Digester The sludge in the digester shall be stirred by a horizontal mixer. The mixing arrangement shall ensure that the entire contents of the digester are uniformly agitated and no short-circuiting occurs. The horizontal mixer shall keep the sludge in the denitrification zones in suspension. The sludge shall spend at least 20 days in the digester. general system requirements horizontal mixer in digester Materials - Propeller : Stainless steel AISI 316 - bolts and nuts : Stainless steel AISI 316 - motor casing : Stainless steel AISI 316 Propellor speed [rpm] : Specific requirements : The mixer is removable out of the digester in parts by a mobile crane. The sludge digester will be protected by the following necessary safeties. Safety cutout devices Temperature: - Minimum/Maximum Specific requirements

[C]

: :

from -30 to 35. - hydraulic over- and under pressure device (protected against frost); - hydraulic overflow protection by means of a sludge siphon; - gas overpressure protection by means of a sludge siphon.

1.24. Digested sludge pumping station Three dry mounted progressive cavity pumps shall be used for thickened sludge, digested and DWTP-sludge being pumped to the Sludge Dewatering Station and to the sludge drying bed. Each pump shall be connected to each of the two belt presses. If the belt presses are not available, the digested sludge shall be pumped to the sludge drying beds. general system requirements Digested Sludge Pumps Number [pieces] : 2 duty and 1 stand-by (2 service and 1 stand-by for WWTP sludge; 1 service for DWTP sludge and 1 service for WWTP sludge and 1 stand-by) Application : Pumping thickened sludge or DWTP-sludge to drying bed and to the belt presses.

Type Medium capacity flow: capacity pressure maximum speed Material Location specific requirements Motor [m3/h] [mwc] [1/min]

: : : : : : : : : :

Dry mounted progressive cavity pumps Sludge approx. 2,0 % DS, and Drinking water sludge approx. 4 % DS See PFD to be defined by Contractor 250 Rubber chrome steel Thickened sludge building - mechanical seal; - Shop testing;. - manometer and test cock the pump/motor shall be suitable for variable speed drive over the entire power curve of the pump.

1.25. Drainage water pit Two submersible pumps shall be used for drainage water/sludge being pumped to the Gravitational Sludge Thickener or to the return sludge building. general system requirements Drainage Water Pumps Number [pieces] : 1 duty and 1 standby Application : Drainage water from the sludge drying beds to the storage tank. Type : centrifugal pump Medium : Sludge capacity flow: [m3/h] : 20 capacity pressure [mwc] : to be defined by Contractor maximum speed [1/min] : 1.500 Material : pump casing: grey cast iron 20 impeller: chrome steel (material 4R) Location : Return sludge building specific requirements : - mechanical seal; - testing in accordance with ISO 9906. - manometer and test cock Motor : the electric motor shall be suitable over the entire power curve of the pump. 1.26. Sludge Storage Tank for Dumbrava Drinking Water Treatment Plant Sludge A mixer shall be placed in the storage tank (diameter 14,5 m) to keep in suspension the stored DWTP-sludge. The amount of mixers is indicative. general system requirements Mixers Medium Propeller - No. of blades Jetring Materials - Propeller - Bolts and nuts - motor casing Propellor speed [rpm] Sealing Oil chamber : : : : : : : : : : Anorganic sludge 3 No Stainless steel AISI 316 Stainless steel AISI 316 Stainless steel AISI 316 max. 315 Maintainable double mechanical seal Water in oil detection with relais

Additional Material leading beam 1.27. Sludge Dewatering

: :

Leading beam Stainless steel AISI 316

1.27.1. General The sludge from the digesters shall be dewatered by the belt presses (or decanters) to a minimum dry matter content of minimum 21 % by means of belt presses (or decanters). A polymer dosing system for solid polymer shall be installed. A complete standby line including polymer dosing shall be installed. Conveyors shall transport the dewatered sludge to the Sludge Containers. The reject water outlets from the dewatering equipment shall be in close connection with the floor drains in order to avoid any splashing. The reject water shall be led back to the Return Pumping Station. The dewatering equipment and the dewatered sludge transportation systems shall be fully enclosed within the sludge dewatering building and within the container room and be connected to the extract ventilation system. The sludge dewatering installation comprises, but is not limited to, the following equipment: - Two belt presses (two duty); - Hydraulic units - drive unit; - in- and outlet pipes, wash pipes, reject water pipes; - Static mixers for PE-dosing; Additional general system requirements Belt presses Digested sludge Application Medium Minimum dry solids outlet Polymer dose Minimum capture dry solids Concentration polymer Relative solid capacity Hydraulic capacity Dry Solid capacity [%] [g PE/kg ds] [%] [%] [kg DS/h/m] [m3/h] [kg DS/h] : : : : : : : : : Dewatering Digested sludge - Thickened sludge - DWTP sludge 21 9,5 97 0,1 325 2 x 5, see PFD. 487

1.27.2. Transport conveyors system Conveyors shall transport the dewatered sludge from the belt presses. Each belt press shall be connected to a conveyor system, filling up a container. general system requirements Dewatered Sludge Conveyors Number [pieces] : 2 duty (50 % reserve capacity) Application : Conveying dewatered sludge from the belt presses to the containers. Type : Medium : Sludge > 21,0 % capacity flow: [m3/h] : See PFD

maximum speed Material Location Specific requirements Motor

[m/s]

: : :

0,5 Aisi 304 Dewatering building Dual speed motor.

1.27.3. Sludge containers The dewatered sludge shall be conveyed into open containers. The containers shall be high enough to receive 10 tonnes of dewatered sludge from one outlet. The transportation system in the container area shall be enclosed as possible and connected to the extract ventilation system in the sludge dewatering building. 1.28. Polyelectrolyte preparation and dosing system There shall be two systems for polyelectrolyte (poly) preparation. The poly-electrolyte preparation system shall be also suitable for filling with liquid polymer. Each poly-electrolyte preparation system shall be suitable for preparing poly-electrolyte for both the sludge of the WWTP and the DWTP to the belt presses. The chemical dosing system for poly comprise, but is not limited to, the following equipment: - poly storage / metering hopper; - poly solution mixing tanks; - dosing pumps; - pipe work, valves, fittings and application arrangement; - static mixer after each injection point; - kerbed and bund areas for poly preparation and supply; - process control instrumentation comprising upstream flow meter; - monitoring equipment. polyelectrolyte storage The poly is stored in bags of 20 kg in the storage area of the sludge dewatering building. polyelectrolyte solution preparation The poly to be used in dosing shall be prepared in batches. The poly powder shall be dispatched in a storage hopper, large enough to hold the total poly consumption for one shift. The unloading of the poly bags shall be designed in such a way that it can be carried out in an ergonomically sound manner. time for preparation of the poly solution to take place at max. duty. strength of poly solution Slurry make up accuracy minimum residence time Unit size No of units for poly solution preparation poly electrolyte Dosing Pump pump type Number Application Medium Temperature strength of dosing solution 2 hours +/- 5 % to follow manufacturers recommendation to suit process design 2 units; Metering 4 duty + 1 spare dosing of poly for belt presses and sludge thickeners poly electrolyte ambient temperature

[pieces] : : : [C] : [%] :

capacity: - minimum / maximum capacity Accuracy Availability pump head Location

[l/h] : : +/- 5 % of set point : 99 % in any 24 hour period to be determined by contractor

1.29. Gas storage tank The gas storage tank comprises, but is not limited to, the following equipment: - Gas storage tank with telescope and internal balloon; - Mechanical en hydraulic safety valves; - Instrumentation Drain water in the gas storage tank shall be prevented by drains in the gas storage tank and drainage pits in the biogas pipeline to the gas burner, cogeneration units, and boiler. Application Type Medium Minimum volume Normal Pressure Maximum Pressure Maximum pressure (hydraulic overpressure device) Maximum overfilling (mechanical overfilling device) Material tank Material balloon : : : : : : : : : : Conserving biogas Dry gas storage tank (internal balloon) Biogas; 1.000 ppm H2S. 150 25 45 35 103 Stainless steel AISI 316 L Rubber, H2S-resistent

[m3] [cm mwc] [cm mwc] [cm mwc] [%] [-] [-]

1.30. Gas Burner The total amount of biogas shall be burnt in de gas burner in case of emergency. The gas burner shall be a closed system burner; the flame shall not be visible. Application Type Medium Maximum flow Minimum pressure Normal pressure Maximum pressure Material burner Specific requirements : : : : : : : : : Burning biogas Closed gas burner Biogas; 1.000 ppm H2S. 75 20 25 35 Stainless steel AISI 316 L Automatic control valves; instrumentation

[m3/h] [cm mwc] [cm mwc] [cm mwc] [-] [-]

The burner comprises, but is not limited to, the following equipment: - Closed gas burner; - Automatic control valve; - Instrumentation and safety. 1.31. Cogeneration units The biogas shall be burned continuous in one of the two generators and the other shall be standby. Both cogeneration units shall run continuous on biogas and on a supply of natural gas in case of emergency. The generated heat shall be used for heating the sludge and

heating the buildings. The emergency coolers shall cool down the gas motors in case of too much heat. Normal situation 50% of the maximum capacity 2.200 23 30% 175 175 100% of the maximum capacity 1.500 23 30% 125 350 Supply of natural gas

Daily amount gas Lower burning specific value Total efficiency gasmotor Bruto electricity Total bruto electricity Additional requirements Application Type Medium Maximum flow biogas Minimum pressure Normal pressure Maximum pressure Specific requirements

Nm3/day MW/Nm3 % kW kW

1.500 23 30% 120 120 : : : : : : : :

2.112 32 30% 225

[m3/h] [cm mwc] [cm mwc] [cm mwc] [-]

Cogenerating heat and electricity Gas motor units with gear and generator Biogas; 1.000 ppm H2S; Natural Gas 92 20 25 35 Automatic control valves for biogas and natural gas; instrumentation; Low-NOx gas motor units

The cogeneration comprises, but is not limited to, the following equipment: - Two cogenerations units; - Heat exchangers for cooling water, oil, and stack gasses; - Heating water circuit with appendages, pumps and emergency coolers; - Stacks; - Lubricant oil installations with buffer tanks for oil and rejected oil. - The necessary instrumentation and safeties. The cogenerations units shall be fully enclosed within the cogeneration unit building. The noise level outside the building shall be lower than 75 dB(a). The cogeneration-units shall be tested in a commissioning test run of 4 weeks. The commissioning test run shall be renewed after a failure of the cogeneration unit, independent of the cause of the failure. 1.32. Sludge heating boiler The sludge digester shall be heated around the year. Slightly drops of temperature will decrease the efficiency of the digestion process. A sludge heating boiler shall be installed as back-up service to sustain in emergency situations the temperature in the sludge digester. The boiler shall be designed to the worst case situation. Natural gas shall be burned in the boiler for start-up of the sludge digestion in case of emergencies. Daily amount gas Lower burning specific value Total efficiency gasmotor Heating capacity Nm3/day MW/Nm3 % kW 190 32 95% 67

Additional requirements Application Type Medium Maximum flow biogas Minimum pressure Normal pressure Maximum pressure Specific requirements

[m3/h] [cm mwc] [cm mwc] [cm mwc] [-]

: : : : : : : :

Generating heat Overpressure boiler Biogas; 1.000 ppm H2S; Natural Gas 10 20 25 35 Automatic control valves for biogas and natural gas; instrumentation; dual low-nox-burners

The boiler comprises, but is not limited to, the following equipment: - Boiler units with burners, equipped for biogas and natural gas; - Stack - Instrumentation and safeties. - Auxilary equipment: gas filter, water filter, valves, expansion vessel, circulating pumps (2 duty +1 standby), filling pump, treated water station (automated). A boiler shall be installed according to Romanian regulation ISCIR PT C-1-2003 about installation and use of the hot water and steam boilers. The contractor shall ensure that the heating system complies with all ISCIR regulations regarding D category boilers (especially C-1 and A-1), fire-fighting regulations, specific norms for gas use I 6-96 and general rules for heating installations according to I 13-94. The boilers shall be equipped with automated burners for gas (biogas and natural). The construction of boilers has to comply with the limits of D category according to ISCIR C-1. 1.33. Services 1.33.1. Heating system The heating system shall be completely renewed for the waste water plant. The contractor shall install a complete fully functional system. The capacity of the thermal heaters shall be calculated by the Contractor based on the heat/cold loads in each building to be heated as well as ventilation requirements. The required temperatures in the different buildings are: - Screening Station (5C). - Sludge Dewatering Station (5C). - Administration Building (22C). - Blower (5C). - Container building (5C). - Sludge pumping Station (5C). - Workshop (22C) The piping for hot water inside the buildings shall be insulated. The connection pipes between buildings shall be pre-insulated and mounted underground in accordance with the specifications of the pipe supplier. All pipes for hot water shall be seamless steel pipes. The functioning of the whole heating station shall be fully automated. 1.33.2. Ventilation Ventilation systems are required for the following buildings (the figure between brackets is the required number of air changes per hour): - Screening Station (6 x), - Sludge Dewatering Station (3x). - Administration Building (1x).

Blower (6x). Container building (3x). Sludge pumping Station (3x). Gas condense cellar (5x). Workshop (2x)

1.33.3. Internal potable water supply and non-potable water supply The contractor shall renew the complete systems for non-potable water as well as potable water for ordinary use. Infrastructure of the systems shall be the same as currently in use plus the added users from the improved WWTP design. Non-potable water shall be used for washing the following equipment: - The Sludge Dewatering Station to be used for flushing the belt presses. - The Screenings Station for washing the screenings. - The Grit Chamber and Grease Chambers for washing the grit. - to be used thinning the polyelektrolyte concentrate for the belt presses and the sludge thickeners. - to be used for flushing the sludge thickeners 1&2; A complete booster pump set including two (1 stand-by) dry mounted centrifugal pumps, valves, pressure control tank, necessary filter and piping system for supply of wash water shall be installed, including level control. 1.33.4. Air conditioning systems The Contractor shall install a split-type air conditioning system in the laboratory room in the administrative building. The air conditioner shall be sized to heat load and size of the room (smallest laboratory room). A minimum temperature of 22 C. shall be attainable at all times. 1.33.5. Sump pumps Sump pumps shall be installed in all rooms with pipelines containing water or sludge: - Administration Building. - Sludge Dewatering Building. - Thickened Sludge pumping building. - Gas condense cellar. - Sludge pumping Station. The sump pumps shall be connected to the site sewerage system. 1.34. Site sewerage The reject water shall be led to the site sewerage system. The sewer pipelines shall be large enough for gravity flow to the waterline in maximum operating situation. Otherwise, sewer pumps shall be installed for pumping the internal flow to the waterline. 1.35. Lifting Arrangements All Plant, materials housings, etc., that may be manually handled during the course of normal operations or maintenance shall be provided with lifting arrangements according to the following: - above 20 kg - Provision of suitably rated lifting arrangement; - above 500 kg - Provision of lifting beam with manual chain block; - above 1 tonne - Provision of overhead crane with manual chain block. Lifting arrangements and Plant shall be load tested on site after installation. Load test certificates shall be supplied for all lifting Plant.

1.36. Air delivery The necessary compressed process air shall be supplied to the equipment. Compressed air for tools shall be supplied to: - The administration building. - Workshop.