6.

1  Primary Flows 51 

6.2  Intake structure with Screen offshore 52 
Contents 6.3  Active Screens before the Sea Water Pumps 52 
6.4  Sea Water Pumping Station 54 
1.  INTRODUCTION 14 
6.5  Shock chlorination system 56 
1.1  Background 14  6.6  Intake / Outfall Pipes 57 

2.  FIELD INVESTIGATIONS 16  6.6.1  Pipe jacking 57 

6.6.2  Main Jacking Station 58 
Seabed Surveys 16 
6.6.3  Inter-jacks 58 
2.1.1  Methodology 16 
6.6.4  Slurry System 59 
2.1.2  Results 23 

7.  PRETREATMENT SYSTEM 60 

3.  SITE CONDITIONS 29 
7.1  Pretreatment Process 60 
3.1  Site Appreciation 29 
7.2  Sea Water Quality / Treatment Processes 60 
3.2  Tides, Storm Surge and Wave Runup 32 
7.2.1  Key Water Quality Parameters – Pre-Treatment 60 
3.3  Waves 32 
7.3  The Pre-Treatment Processes- Scheme 62 
3.4  Storm Surge 32 
7.4  pH Correction 62 
3.5  Tsunami 33 
7.5  Coagulation and Flocculation 62 
3.6  Finished Floor Level 33 
7.5.1  Coagulation 62 
3.7  Climate 33 
7.5.2  Flocculation 64 
3.8  Typical Oceanographic Conditions 35 
7.6  Lamella Settlers 65 
3.9  Geotechnical conditions 36 
7.7  Dissolved Air Flotation (DAF) 66 
3.10  Coastal Regulation Zone 37 
7.8  Dual Media Gravity Sand Filters 68 
4.  WATER QUALITY 38  7.9  Gravity Filtered Water Storage 71 
4.1  Seawater Quality 38 
8.  REVERSE OSMOSIS PLANT 71 
4.1.1  Importance of Sea Water Quality 38 
8.1  Overview of RO Plant 71 
4.1.2  Temperature and Salinity Trends 39 
8.2  Pumping System Design and Pressure Control 72 
4.1.3  Field Investigations 39 
8.3  Cartridge Filtration 74 
4.1.4  Water Quality Design Criteria 42 
8.4  Oxidant Control 74 
4.2  Water Quality Targets 44 
8.5  Scale Control 74 
4.2.1  Total Dissolved Solids 45 
8.6  Reverse Osmosis Pumping and Energy Recovery System 74 
4.2.2  Boron 45 
8.7  RO Rack Design 78 
4.2.3  Jelly Fish Blooms 46 
8.8  RO Clean In Place System 81 
5.  DESIGN LIFE AND AVAILABILITY; PRIMARY FLOWS 47  8.9  Permeate Storage 83 
5.1  Design Life 47 
9.  POST TREATMENT 84 
5.2  Operations and Availability 48 
9.1  Re-mineralization/Stabilization 84 
5.2.1  RO Rack Configuration 48 
9.1.1  Requirement for Stabilisation 84 
5.2.2  Operation 48 
9.1.2  Hydrated Lime & Carbon Dioxide 85 
5.3  Primary Flows 50 
9.1.3  Key design Criteria 86 
6.  SEAWATER INTAKE 51  9.2  Disinfection 88 

Page 1 Page 2
10.  CHEMICAL SYSTEMS 93  14.2.1  General Design Criteria 117 

10.1  Antiscalant 94  14.2.2  Plant Operation Methods 118 

10.2  Carbon Dioxide 95  14.2.3  Control System Architecture 118 

10.3  Chlorine Gas 95  14.2.4  Off Site Communication 119 

10.4  Ferric Chloride 97 

15.  CIVIL, BUILDING AND STRUCTURAL WORKS 123 
10.5  Hydrated Lime 97 
15.1  Plant Buildings 123 
10.6  Flotation Aid Polyelectrolyte 98 
15.1.1  General 123 
10.7  Sodium Hydroxide 99 
15.1.2  Platforms, Access Ways and Stairways 124 
10.8  Sodium (Meta)bisulphite 99 
15.1.3  Lifting Devices 124 
10.9  Sulphuric Acid 100 
15.2  Road works 124 
10.10  Miscellaneous Chemicals 101 
15.3  Site Services 125 
10.10.1  Cleaning-in-place (CIP) 102 
15.4  Storm water Drainage 125 
10.10.2  Flushing 103 
15.5  Fire Systems 125 
11.  WATER STORAGE AND TRANSFER 104 
16.  PRODUCT WATER MAIN 126 
11.1  Process water storage 104 
16.1  Annexure 132 
11.2  Process water transfer pump station 104 
16.1.1  Pipe sizing and pump capacity for 550 MLD 132 
12.  WASTE MANAGEMENT 105  16.1.2  Pipe sizing and pump capacity for 2 X 275 MLD 134 

12.1  Screenings 105  16.1.3  Pipe size and pump capacity for 400 MLD 137 

12.2  Pre-Treatment Waste Water 105  16.1.4  Pipe size and pump capacity for 150 MLD 140 

12.3  Other Wastes 105 

17.  BENEIFTS OF LONG-TERM O&M CONTRACT 144 
12.3.1  Membrane CIP Wastewater 105 
12.3.2  Limewater Clarifier Waste 105  18.  COMMISSIONING PLAN 146 
12.3.3  Domestic Waste - Sewage 105  18.1  Purpose of the Plan 146 
12.3.4  Spent Membranes 106  18.2  Objectives 146 
18.3  GLOSSARY OF TERMS 147 
13.  SEAWATER OUTFALL 107 
18.4  Organization and Roles 148 
13.1  Outfall Pipeline 107 
18.5  Phased Commissioning Management Structure 148 
13.2  Diffusers 107 
18.6  Commissioning Scope: Lifecycle and Interfaces 148 
14.  POWER AND CONTROL 109  18.7  Commissioning Process & Interfaces Management 151 
18.8  Interface between D&C and O&M 155 
14.1  Power supply 109 
18.8.1  Interface between Commissioning and O&M 155 
14.1.1  Background 109 
14.1.2  Design Considerations 109  19.  COMMISSIONING MANAGEMENT SYSTEMS 156 
14.1.3  110 kV / 11 kV Substation within the Plant premises 110 
19.1  Work Breakdown Structure (WBS) 156 
14.1.4  Power Distribution 111 
19.2  Programming 156 
14.1.5  Power Factor Correction 114 
19.2.1  COMMISSIONING MANAGEMENT SYSTEM 156 
14.1.6  Electrical System Component 114 
19.3  DOCUMENTATION 157 
14.1.7  Pumping station electrical works, controls and electrical systems 116 
19.3.1  PRE-COMMISSIONING DOCUMENTATION 157 
14.1.8  Emergency power generation 116 
19.3.2  COMMISSIONING DOCUMENTATION 160 
14.1.9  Electrical Equipment 116 
19.3.3  RECTIFICATION OF DEFECTS 160 
14.2  Control System 117 

Page 3 Page 4
20.  COMMISSIONING STRATEGY 161  24.2.2  Procedures 184 

20.1  RO Plant Overall Commissioning Strategy 161  24.2.3  Continuous Supervision and Tracking 184 

20.2  Seawater Lift Pump Station 163  24.3  Supervision with SCADA System 185 
20.3  Pre-Treatment 163  24.3.1  Reports 186 

20.4  Reverse Osmosis 166  24.4  Consumables Management 187 

20.5  Potabilisation 168  24.4.1  Electricity 187 

20.6  Rest of Plant 168  24.4.2  Reagents 188 

20.7  Utilities 169  24.4.3  RO Pre-Treatment 188 

20.8  POWER 169  24.4.4  RO Treatment 188 

20.9  Main Power Supply 169  24.4.5  Remineralization 188 

20.10  HV/LV Electrical Systems Energisation 171  24.4.6  Water 188 

24.4.7  Other Consumables 188 
21.  OCCUPATIONAL HEALTH AND SAFETY 173 
25.  MAINTENANCE MANAGEMENT 189 
21.1  Access Control 173 
25.1  General Principles 189 
22.  TRAINING 174  25.2  The maintenance philosophy is detailed in Technical information chapter 4. 189 
22.1  General 174  25.2.1  In our philosophy, the Maintenance Manager is a key role in plant operation 189 
22.2  Training Philosophy 174  25.2.2  Preventive Maintenance 190 
25.2.3  Preventive Maintenance Plan 191 
23.  APPROACH AND METHOD STATEMENT FOR OPERATION AND
MAINTENANCE OF A RO PLANT 176  25.2.4  Corrective Maintenance 192 
25.2.5  General Maintenance 192 
23.1  MOBILIZATION PLAN & START-UP OF THE OPERATION AND MAINTENANCE 176 
25.3  Application 192 
23.1.1  Follow-up of the works and plant start-up 176 
25.3.1  Work to be carried out 192 
23.1.2  Process monitoring and follow-up sheets implementation. 176 
25.3.2  Procedures 193 
23.1.3  Flow monitoring 177 
25.3.3  Continuous Control and Tracking 194 
23.1.4  Analytical parameters monitoring 177 
25.4  Computer Resources 195 
23.2  Electric Power Consumption Monitoring 178 
23.2.1  Chemicals Consumptions Monitoring 178  26.  ASSET MANAGEMENT PLAN 196 
23.2.2  Other Monitoring and O&M Log. 178 
26.1  Spare Parts and Spare Equipments 196 
23.3  Industrial start-up and routine operation 178  26.2  Paint - Protection against Corrosion 197 
23.3.1  Operation and Production 178 
26.3  Lubricants 197 
23.3.2  Maintenance Plan Implementation 179 
26.4  Workshop and Stores 197 
23.3.3  Suppliers Chain Assessment and Management Plan 179 
26.5  Equipment Renewal Plan 197 
23.4  Communication and Reporting 180 
23.4.1  Staff training 180  27.  ORGANIZATION OF THE LABORATORY 198 
23.4.2  Implementation of a real Occupational Health & Safety (OHS) policy 181  27.1  General Principles 198 
23.5  Staff Mobilization Plan 181  27.2  Analytical Monitoring 199 
23.6  EPC/O&M scope of supply 181  27.2.1  General Principles: Plant monitoring and Environmental monitoring 199 
27.2.2  Equipment and Methods 199 
24.  OPERATION: TREATED WATER PRODUCTION MANAGEMENT 182 
27.2.3  Analytical Monitoring of final water 199 
24.1  General principles 182 
27.2.4  Analytical Monitoring of Environmental Impact Assessment 200 
24.2  Application 184 
27.3  Analytical Means 200 
24.2.1  Work to be carried out 184 
27.4  Reliability and Traceability of Analysis Results 200 

Page 5 Page 6
 27.5  Consumables 201 

28.  SUPPLY CHAIN MANAGEMENT PLAN 202 

28.1  Stock Management Procedure 202 
28.2  Procurements Procedure 202 
28.3  Procurements Reception Inspection Procedure 203 
28.4  Supplier assessment procedure 203 
Executive Summary
29.  HUMAN RESOURCES 204 
29.1  Proposed Manpower and Organization 204 
29.2  Key Personnel Selection 204 
29.3  Management of Human Resources 204  Survey Data
Significant findings in respect of Field Work and Historical Data gathering include the
30.  COMMUNICATION AND REPORTING 207 
following:
30.1  Operation Log 207 
30.2  Activity Reports to the Client 207 
30.2.1  Monthly Reports 207  1. Sea Water quality is poor.
30.2.2  Annual Report 208 

31.  INCIDENT MANAGEMENT PLAN 209  – TSS measured in July/August 2013 on the seabed offshore from Perur was, on
31.1  Identification of an Emergency Situation 209  average, 73.3 mg/L, and 48.7 mg/L at the surface.
31.2  Alert and Information Transmission 210 
31.3  Final Incident Assessment Report 210 
– The specification for the Nemmeli desalination plant nominates a design range for
32.  SAFETY, HEALTH, WORKING CONDITIONS AND ENVIRONMENT 211  TSS of 50 mg/L to 200 mg/L. By comparison, the desalination plant for Sydney is
32.1  Safety, Health and Working Conditions Considered in the Plant’s Design 211  designed for TSS of 7 mg/L.
32.2  General Principles of Health and Safety for Plant Operation 211 
32.3  Health and Safety 212 
– Intake water quality data from Nemmeli plant was provided for the period from and
33.  THE QUALITY APPROACH 214  including May 2013 to early December 2013. The data shows poor water quality
33.1  Quality Objectives and Approach 214  on a number of occasions as evidenced by frequent spikes in turbidity.
33.2  Certification 214 

34.  PROJECT FINANCIALS 216  – There is strong evidence that jelly fish are frequently in abundance along the
34.1  Capital Cost 216  Chennai coast and have caused considerable nuisance in power station intakes.
34.2  Operational Cost 220 

– 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.

2. 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

Page 7 Page 8
 is significant and the annual net drift takes place in a northerly direction.
3. Seabed offshore from Perur
– The nearshore seabed, up to 1,500 m offshore, is comprised of ‘sandy clay’ and
‘clayey sand’. At a distance of 500 m offshore the sediment cover to the
acoustic basement is around 6 m, and at 1,200 m offshore the cover is around 7
m. These conditions should be suitable for the construction of intake and
outfall pipelines by pipe jacking. Twin intakes extending 1,200 m offshore at a
depth of 11 m below chart datum are under consideration. An outfall extending
700 m offshore at a depth of 7.5 m below chart datum is under consideration.
– The survey identifies exposed rock some 1,200 m offshore from the southern
end of the Perur site. This rock outcrop should be suitable for the construction
of an intake tunnel by tunnel boring machine, and then the construction of drill
down intakes from the rock outcrop. The rock outcrop at 1,200 m offshore is
around 10.5 m below chart datum.
– The candidate intakes for Perur are located about approximately 1,000 m to
1,200 m northeast of the Nemmeli outfall. Modelling is required to quantify any
impact of the Nemmeli and Perur outfalls on the Perur intake, prior to the
finalisation of the design of the intakes and outfall.
Pre-treatment Processes
– Notwithstanding the paucity of water quality data offshore from Perur, 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.
Page 9
– 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 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 dual media filters. The filter loading rate is the same
as for the DAF: 8 m/hr. The filters are to operate as ‘in depth’ filters, with the
material being removed being held in the pores of the filter media. For this
reason the filter media is deep to store the material and have reasonable periods
between backwashing. Dual media filters have been nominated. The sand will
be 900 mm deep, ES 0.6 mm. The anthracite will be 900 mm deep, ES 1.43 mm
RO Plant Redundancy
Each train will be subject to planned and unplanned shutdown. For the said module,
planned shutdown will be primarily for cleaning-in-place (CIP): 1 CIP per train per
three months, resulting in 36 cleans per year, or once every ten days, for a duration of
1 to 2 days. A number of short term shutdowns can also be anticipated and
infrequent long term shutdowns. Short term unplanned shutdowns can be expected
to be 6 hours or less. Long term shutdowns will be a function of design, construction
Page 10
and supervision, and materials supplied. Provision can be made for long term
shutdown, but cannot be programed. Sydney desalination plant is designed to deliver
250 MLD for 94% of the time.
From time to time production at Perur may fall below 400 MLD, and it will be desirable
to ‘catch-up’ on production; redundancy is required to allow ‘catch-up’. ‘Catch-up’
could be achieved by simply increasing the pumping rate through the membranes;
this is not desirable as it may result in flows exceeding the guarantees for the
membranes. The alternative is to increase the size of all trains, or to provide a
standby train. The number of pressure vessels is similar in both cases; however, the
provision of a standby train requires the installation of another set of high pressure
and booster pumps. Provision of a standby train is proposed: Sixteen duty trains and
1 standby train for 400 MLD module. ‘Catch-up’ can then be achieved by running all
the duty trains plus the standby train for relatively short periods.
To allow this to happen, pipework and pumps have been designed for flows assuming
all duty trains are in operation, plus the standby train. However, increasing the
capacity of upstream processes such as DAF and filtration would be costly, and
cannot be justified for these relatively short term operations. Upstream processes
have been designed for flows associated with 16 trains operating, and process design
parameters have been selected to be sufficiently robust to operate on overload for
short periods. Potabilisation and chlorination have been designed for peak flows.
Space has been provided in the RO racks for additional pressure vessels, which may
be installed to respond to operational and environmental changes, as well as
compensate for deviations in equipment performances. It is not intended that the
additional pressure vessels be installed to increase the capacity of the trains above
the design value, but rather to make sure that the design capacity of the plant is
achieved.
The cycling of the standby train will need to be relatively frequent as standby duration
without preservation is approximately 48 hours. The provision of a standby train
should ensure the consistent delivery of 400 MLD, from each module; that is, a design
target of 100% of design capacity delivered over the short, medium and long term.
Page 11
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.
Pumping System Design and Pressure Control
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
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.
Page 12
Product Water Main 1. INTRODUCTION
All pipes above 1.1 m dia have been proposed as Carbon Steel with internal CC lining
as per IS 3589 and external coating/lining, whereas all pipes below 1.1m are stated to 1.1 Background

be Ductile Iron with internal CC lining. The product water main is designed for 550
Chennai Metropolitan Area (CMA) is spread over an area of 1189 sq. km and
MLD, to cater to the 150 MLD flow from the proposed 150 MLD SWRO next to the
comprised of Chennai Corporation, 16 Municipalities, 20 Town Panchayats and
said facility.
214 Village Panchayats comprised in 10 Panchayat unions and one cantonment
namely St. Thomas Mount with the total population of about 8.0 million. Rapid
urbanization is taking place not only in the city but also in the surrounding urban
local bodies (ULBs), Municipal areas, and Town Panchayats. Due to this rapid
urbanization, it warrants for providing essential municipal infrastructures.

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.

Pipe borne water supply system was first provided in Chennai about 100 years
back and has been expanded over time to satisfy the increasing demands for
water since its inception. However during the last 20 to 30 years, water demand
has increased drastically due to the natural growth of the Chennai City and
substantial inward migration of people from rural areas. But, the supply of water
has virtually remained constant and has increased at a very slow rate.

The population of Chennai as per 2011 census was 6.726 Million with projection of
7.4 Million for 2016. The water Demand in 2011 was 1042 MD and in 2016 with
155 LPCD shall be 1133 MLD. In addition to 1133 MLD in 2016 another 37 MLD
shall be required for industries, 28 MLD for bulk water supply to establishments,
17.7 MLD to Sriperumpudur and 14 MLD to SIPCOT Industrial estate. Also
Another 329 MLD shall be required for additional areas of CMA such as Avadi,
Pallavaram, Pammal, Tambaram etc. thus summing the total water demand for
2016 shall be 1526 MLD with supply of approx 831 MLD including 200 MLD from
existing two SWRO one in north and the other in south of the city.

Page 13 Page 14
The main sources of water supply to the Chennai city is from surface water 2. FIELD INVESTIGATIONS
sources such as Poondi, Cholavaram and Redhills reservoirs and also from
ground water sources from Araniar and Korataliar basin. The water supply
source has been augmented with distant sources such as Krishna Water A major component of the seawater quality assessment study is to carry out a
Supply scheme with supply from the State of Andhra Pradesh and by Chennai seawater quality monitoring program to characterise seawater at the proposed
Water Supply Augmentation Project with supply from Veeranam Tank. A seawater intake sites for engineering and process design of the plant.
desalination plant of capacity 100 MLD has been commissioned in July
To fulfil the assignment it was required to complete a range of surveys (Terrestrial
2010 near Kattupalli village, Minjur in North Chennai and is in successful
topographical & geotechnical), oceanographic and marine studies (hydro graphic
operation. Another 100 MLD capacity Desalination plant with Central
survey).
Government funds is operational at Nemmeli at the southern outskirts of
Chennai. The demand has been calculated with 2017, since most of the The studies are to collect data on sea water quality, temperature, salinity, seasonal

associated water supply projects are due for completion in 2017. water quality and tidal variation along with other data.

The intention of the studies was to characterise the aspects of the site with the
Water demand for 2017
area of study including; benthic communities and habitat; bathymetry;
Chennai City 760 MLD
oceanographic conditions (such as wind waves, tides, and currents); water quality
42 ULB’s merged with Chennai City 393 MLD and coastal processes.

Added Area Committed by CMWSSB (Avadi, Pammal, 341 MLD

Indomer Coastal Hydraulics (P) Ltd., Chennai had been awarded the assignment

Tambaram, Pallavaram, Sriperumbudur etc.) for carrying out the relevant oceanographic investigations for the proposed plant.

Bulk water supply to industries 100.0 MLD

Seabed Surveys
Total Water Demand 1594 MLD
2.1.1 Methodology
Supply in 2017 831 MLD
1.2.1.1 Reference Spheroid:
Deficit 763 MLD
WGS 84 spheroid was followed for entire surveys and for the presentation in the
report.
As a step towards meeting the demand and matching the provision of
infrastructure with the city’s growth, CMWSSB has commissioned consultancy 1.2.1.2 Horizontal control

services to conduct prefeasibility studies, including Financial Viability evaluation,
into the construction of a 400 MLD Sea Water Reverse Osmosis (SWRO) Plant at
Perur village along the East Coast Road (ECR). With commissioning of the said
facility the demand supply gap shall drastically reduce to 363 MLD. Also further
there is proposal of another 150 MLD SWRO within the premises of Existing 100
MLD SWRO at Nemmeli, thus further mitigating the supply demand gap.
Reference station: The DGPS Beacon Transmitter
installed at Pondicherry Light House by Department of
Lighthouse and Navigation, Pondicherry was taken as
reference station. The transmitting frequency of this
reference station DGPS Beacon transmitter was 315
kHz.

Page 15 Page 16
 Mobile station: The horizontal positioning of the mobile unit was carried out using
Hemisphere R100 Series DGPS Beacon Receiver. It combines high-performance
GPS reception with a DGPS-capable receiver in a lightweight, durable housing and
comes with a separate antenna. It gives the horizontal position to an accuracy of
close to 1 m.
1.2.1.3 Bathymetry survey
Area of survey: Bathymetry survey was carried out covering an area of 2.5 km
along the coast and 3 km into the sea at 25 m lines pacing. The survey at less than
5 m water depth where there was a limitation due to boat draught was carried out
using a shallow fiber boat with portable echo sounder which can be connected to
PC through serial port.
Sequence of Survey: ODOM Echotrac CVM Digital Dual Frequency Echo sounder
manufactured by ODOM Hydrographic Systems, USA was used for the deeper
water survey where the water depth was more than 5 m. The configuration of
various arrangements for conducting the bathymetry survey is shown below.
Page 17
The survey vessel MFV SRINIVASA was used for data collection. The
echosounder transducer was mounted on the star board side of the vessel by
positioning it at 1.0 m below the sea surface. The DGPS receiver antenna was
mounted on the mast vertically in line with the transducer, so that it represents the
exact coordinates of the location where the depth is simultaneously measured by
the transducer. The Heave Sensor was attached in line with transducer stem on
the boat deck in order to measure the residual vertical displacement of the boat
induced by external disturbances and to carry out the correction. The DIGIBAR-
PRO sound velocity meter was used to measure the sound velocity across the
vertical and entered as input for calibrating the transmitting frequency of the
instrument. The bar check was also carried out by lowering the rigid plate at
different depths and comparing with the displayed depth. The necessary inputs
were given in HYPACK data collection software before the commencement of the
survey. The planned track lines were displayed on the monitor at wheel for
navigation. Watch guards were positioned at bow, transducer/antenna, heave
sensor and at rear end. The data were continuously collected at onboard PC along
each transect. After a day of data collection was completed, entire data were down
loaded to external hard disc and stored. The recorded data included: date, time,
latitude, longitude, X coordinate, Y coordinate, heave and depth. The depth data
were recorded at 0.5 sec interval. A tide recorder was erected at site and the water
level variation was recorded separately in the internal memory. The recorded
depth data were processed in the laboratory by applying corrections for tidal
variation and transducer draught.
OFF SHORE BATHYMETRY SURVEY
CVM Echosounder Heave compensator Transducer - Installation
Page 18
 NEAR SHORE BATHYMETRY SURVEY
Echosounder Installation Data display DGPS antenna
1.2.1.4 Shallow seismic survey
Area of survey: Shallow seismic survey was carried out covering an area of 2.5 km
along the coast and 3 km into the sea at 25 m line pacing.
Sequence of survey: Benthos CAP 6600 Chirp III Acoustic Sub-Bottom Profiler
CAP 6600 Chirp III dual frequency acoustic Sub-Bottom Profiler manufactured by
TELEDYNE BENTHOS, Inc., USA was used for carrying out the shallow seismic
survey.
The tow fish was mounted 2.0 m below the sea surface at star board side of the
survey vessel MFV SRINIVASA. The tow-fish cable was connected to the
Page 19
transreceiver. The connection between transreceiver and PC was established by
RJ 45 link cable. The DGPS antenna was mounted on the mast vertically in line
with the tow fish and necessary inputs were given in HYPACK software before the
commencement of the survey. The planned track lines were displayed on the
monitor at wheel for navigation. Watch guards were positioned at bow, tow vehicle
/antenna and at rear end. SONAR WIZ.MAP software was adopted for seismic
data collection. The data in the form of *.SEG-Y format (Society of Exploration
Geophysicist) were logged continuously in the hard disc and the anomalous
geological features were noted. The entire data were copied in the external hard
disk and DVD.
The system uses advanced Chirp technology to produce high resolution sub-
bottom profiles of both the shallow and deep sub bottom layers. The system is
modular in design as it can be configured with a variety of tow vehicles, as well as
hull mounted transducer arrays. The system comprises the CAP 6600 Chirp III
Workstation and a Tow vehicle TTV-170.
SHALLOW SEISMIC SURVEY
Sub-bottom profiler - Sub-bottom profiler - Onboard data display
Towfish Deployment
Chirp sonar technology used uses digitally produced linear FM transmitted signals
along with digital signal processing for matched-filter processing of reflected
energy to produce high resolution images. In Chirp technology, a greater dynamic
range is attained as long FM pulses provide an additional 20 dB to 30 dB of
dynamic range over conventional sub-bottom sonar systems. Enhanced resolution
is achieved with matched filter processing and the transmitted wave forms are
repeatable. The pulse characteristics are programmable, as the pulse length, span
of frequency sweep and phase/amplitude calibration of the transmitted waveform
can be varied without hardware changes. The sonar data can be stored for off-line
Page 20
 processing in SEG-Y format.
Together with the processor, the software and the transceiver serve to process, to
display and to store both channels of sub-bottom sonar data. The CAP-6600 Chirp
III work station also integrates and stores navigation data from the ship’s
navigation system and can generate output through a variety of user-configurable
formats. In addition, the processor provides remote programmable receiver gain
control of the remote controlled transmit/ receive module.
The Chirp waveforms are input to the transceiver from the processor and are
amplified by the power amplifiers which drive the transducers. Received signals
are input to the transceiver, filtered and then output to the processor. The
transceiver also includes a pre-amplifier with adjustable gain for amplifying the
output of non-Chirp systems.
1.2.1.5 Side scan sonar survey
Area of survey: Side scan sonar survey was carried out covering an area of 2.5
km along the coast and 3 km into the sea at 25 m line spacing.
Sequence of survey: C3D-LPM SIDE SCAN SONAR BATHYMETRY SYSTEM
manufactured by TELEDYNE BENTHOS, Inc., USA was used for carrying out the
side scan sonar survey. The configuration of various arrangements for conducting
the side scan sonar survey is shown below.
1.2.1.6 Tides
SIDE SCAN SONAR SURVEY
Page 21
C3D side scan sonar Installation of C3D Onboard data display
side scan
The side scans sonar tow fish was mounted 2 m below the sea surface on the star
board side of the survey vessel MFV SRINIVASA. It was connected to the trans-
receiver unit through the LAN cable. The DGPS antenna was mounted on the mast
vertically in line with the tow fish so that it records the exact coordinates of the
locations where the tow fish collects the seabed reflection characteristics. The
necessary inputs were given in HYPACK data collection software before the
commencement of the survey. The planned track lines were displayed on the
monitor at wheel for navigation. Watch guards were positioned at bow, tow vehicle
/antenna and at rear end. The data were continuously recorded at onboard PC
along each transect. After that day data collection was made, entire data were
down loaded to external hard disc and stored. Using the SONARWIZ.MAP survey
software we interfaced the coordinates of the DGPS and the sea bed reflection
characteristics. The real time data also included time, date, latitude and longitude.
The collected data were stored in ".XTF” format with the help of CODA
GEOSURVEY software.
Tide measurement was carried at Fishing harbor using Aanderaa Water Level
Recorder (WLR 7) for a period of 20 days from 27.07.2013 to 15.08.2013. The tide
data were recorded at 15 min interval.
Aanderaa Water Level Recorder (WLR 7) is manufactured by Aanderaa
Instruments, Norway. It has a pressure sensor, which is based on a high precision
Page 22
 quartz crystal oscillator. The pressure is measured every 0.5 seconds and 1024 The various tide levels with respect to Chart Datum for Chennai as presented in
samples are taken (512 seconds) and stored in internal RAM. The instrument is Indian Tide Table 2013 are shown below:
housed in a pressure case and has the arrangement for shallow and deep water
Mean High water Spring 1.15 m
moorings. A mode switch with a test and serial communication setting, a depth-
setting switch and a recording interval switch is built into this board. The quartz Mean High Water Neap 0.84 m
pressure sensor is also attached to the board by a shock-absorbing bracket. A
Mean Sea Level 0.65 m
specially designed bottom mounting frame was used for installing the instrument
on the seabed. The sensor is of quartz pressure type based on a pressure- Mean Low Water Neap 0.43 m
controlled oscillator having frequency of 30 – 45 kHz. It has a range of 0-690 kPa,
Mean Low Water Spring 0.14 m
with an accuracy of 210 Pa and a resolution of 7 Pa.

1.2.2.2 Bathymetry survey

1.2.1.7 Survey boat and instrument arrangement
The bathymetry chart is prepared in WGS 84 spheroid with UTM coordinates
(Zone 44) supplemented by geographical coordinates indicating the latitude and
The seabed surveys were carried out using the survey vessel MFV SRINIVASA,
longitude. The bathymetry chart is prepared in 1:5000 scale, which is enclosed to
fitted with Echosounder, Heave
the said report. The depths are represented in a 25 m x 25 m grid with respect to
compensator, Shallow seismic profiler,
MFV SRINIVASA Chart Datum.
DGPS positioning system, Onboard
Computers and the VHF communication The bathymetry chart shows that the depth contours are generally running parallel
system. to the coast. The seabed exists with the gradient of 1:70 till 7 m depth and in the
region between 7 m and 15 m water depth showed the gradient of 1: 250. The
Echosound

water depth of 16 m appears at a distance of about 3 km from the shore.

It has been noticed that the depths near the existing outfall and intake locations
have become deeper due to the existence of construction debris, dredging
activities, burying of pipelines etc. The offshore beyond 11 m water depth is found
to be slightly shallower on the southern side compared to the northern side.

The variation of water depth with distance from the shore is as shown below.

2.1.2 Results

1.2.2.1 Tides

Page 23 Page 24
 clayey sand, coarse sand with scattered rocky outcrops.
Depth w.r.t. CD (m) Distance from shore (m) Spread of submerged rocks
2 150
3 200 The higher amplitude acoustic signals on the sonogram shows the presence of

4 225 about 20 rocky outcrops on the seabed. The rock-outcrops are scattered on the
seafloor at various random locations with different elevations above the seafloor.
5 340
Al places, the rock-heads are carpeted by the seashells and coarse sand.
6 140
7 520 Southern side: Four submerged rocky patches of various spatial extents are seen
on the nearshore region till the distance of about 1300 m from the shore. Beyond
8 660
that, the rocks are not visible from side scan records till 2000 m from the shore.
9 835
Further, six patches of submerged rocks are demarcated till the end of the survey
10 1040
limit.
11 1360
Northern side: The nearshore is observed by the absence of rock-outcrops till 1.5
12 1890
km from the shore. Beyond that, the seabed shows the patches of linear rocky
13 2160
outcrops in NE-SW direction. It has been noticed that the stretch of linearrock is
14 2480
about 1 km long in NE-SW direction. It exists at 2 km offshore.
15 2720
Existence of pipelines
16 2950
The intake and outfall pipelines of existing 100 MLD Neemeli SWRO which are
partially buried have been observed on the seafloor. The construction debris and
1.2.2.3 Side scan sonar survey
trenches are also noticed in the side scan records along the pipeline corridor.
The side scan sonar data acquired in the field were processed using CODA
Seabed covered by sediments
GEOKIT software in the laboratory. Several geophysical signal processing
techniques such as low pass, high pass and band pass filters were adopted to
The rest of the seabed apart from rock-heads is carpeted by mainly sandy clay and
eradicate the noise on side scan sonar records. The processed data were
clayey sand. The patches of coarse sand with different grain sizes are noticed to
interpreted using various image interpretation techniques like tone, texture,
be distributed on the seafloor. The presence of seashells is also illuminating the
pattern, alignment, etc. The inferred results were used to prepare the seabed
side scans sonogram at few locations.
surface sediment distribution map.

The analyzed records reveal that the seabed is generally covered by sandy clay, 1.2.2.4 Shallow seismic survey

Page 25 Page 26
The shallow seismic data acquired in the field were processed using CODA shore. At the northern side, rocks are not seen till 1500 m from the shore. Beyond
GEOKIT software in the laboratory. Several geophysical signal processing that, patches of linear rocks are located randomly.
techniques such as low pass, high pass and band pass filters were adopted to filter Buried Rocks
noise level on the seismic records. The processed data were interpreted using
The gradual increase on the sediment thickness close to the rocky-outcrop
various image interpretation techniques like tone, texture, pattern, alignment, etc.
indicates the extension of buried rock beneath the seabed. The buried rocks are
The inferred results were used to prepare isopach maps and construct vertical
extending beneath near the submerged rocky patches at various directions. As the
sections of sub-seabed.
limitation of acoustic basement depends on the mask of seismic multiples, the
dipping angles and depth of extension of buried rocks are not described further
The isopach map thus prepared explains the configuration of minimum sediment
deep.
thickness i.e. the sediment thickness between seabed and acoustic basement. For
example, the isopach contour of 9 m implies that the sediment column is present
for atleast 9 m thickness without presence of any hard strata in between. Sedimentation

Acoustic basement: In the seismic records, the maximum penetration limit of the
acoustic wave is defined by the acoustic basement. The penetration of the
acoustic wave is controlled by the compactness of the sediments/rock formations
occurred below the seabed. It does not penetrate more consolidated
sediments/bedrocks. So the recorded data signifies the nature of the sedimentary
formations occurred between the seabed and acoustic basement.
Characteristics of sub-seabed
The shallow seismic study reveals that the sub-seabed consists of sedimentary
layer such as sand and clay up to few meters below seabed. The submerged and
buried rocks are also noticed within the study region.
Generally, the sediment thickness (till acoustic basement) within the survey
boundary varies up to 9 m.
Southern side: The sediment thickness appears slightly lesser than the northern
side and varies up to 5 m at the nearshore. The sediment thickness increases
towards offshore till the distance of about 2 km from the shore. Further, the
isopach values decrease due to the presence of submerged and buried rocks. The
sediment thickness of 9 m appears on the southern side at a distance of about 1
km from the shore.
Northern side: At the northern side, the sediment thickness is varying between 3
m and 7 m till the distance of about 1.5 km from the shore. Beyond that, it

Submerged Rocks
The seismic records are showing higher amplitude signals at few places which are
indicating the rocks submerged above the seabed. The isopach contours less than
1 m are showing the rocky out crops that are located randomly at different
elevations.
decreases due to the existence of linear NE-SW rocky patches. The offshore sub-
seabed is found to be composed by sand and clay varying the thickness between
7 m to 9 m.
The detailed report is annexed as Annexure-I to the Said Report.

The submerged rocks are identified on the southern region (nearshore) at a

distance of about 850 m from the shore. The nearshore rock spreads has quite
large spatial extents on the seabed extent. The offshore seismic records also
reveal the presence of the submerged rocky patches beyond 2000 m from the

Page 27 Page 28
3. SITE CONDITIONS

3.1 Site Appreciation

The proposed site for 400 MLD desalination Plant is located at Perur (Nemmeli
Village) quite adjacent to the 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' 44" North, 80°
14' 26" East and is approximately 40 km of south of Chennai city.

The climatic conditions are characterised by warm dry winters (270C average daily
max) and hot wetter summers (390C 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 2:Site Location with respect to existing 100 MLD Nemmeli Desalination
Plant

The front face of the site towards the sea face is fully planted with Causirina
Plantations well grown and maintained by Department of Forest, Government of
Tamil Nadu. Some of palm trees also existed at the boundary of site, which is quite
evident from the site Photographs on next page.

Fig 1:Site Location

Page 29 Page 30
 3.2 Tides, Storm Surge and Wave Runup

The tides at Perur are as follows, in metres above Chart Datum:

Chart Datum RL

Mean High Water Spring 1.15 RL 0.5

Mean High Water Neaps 0.84 RL 0.2

Mean Sea Level 0.65 RL 0.0

Site View from Sea Face 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, on shore.

3.3 Waves

Site View from EC Road
There are several heritage sites in close proximity to site mainly being
Mahabalipuram sea-shore temple which is about 11 km and Tiger Cave which is
about 7 km respectively from the proposed site and are recognised as World
Heritage sites.
Further as cited above an existing 100 MLD Nemmeli Sea Water desal plant is
next to the site and a prominent atomic power generation unit named “Indira
Gandhi Centre of Atomic Research” is about 18km from the proposed site.
3.4
The data compiled based on the ship observed deep-water waves over the region
between the latitude 10°N - 15°N, and longitude 80°E - 85°E is considered for the
present project. It is observed that the significant wave heights varied between
0.5 and 1 m during February to April, 1 and 3.0 m during May to September and,
between 1 and 2 m during rest of the year. The zero crossing period of the waves
varied between 5 and 8 s. The project area is located in the region which is
significantly influenced during the northeast monsoon. The wave climate remains
rough from May to November. The occurrence of storms and depressions during
northeast monsoon often increase the wave activity in this region.
Storm Surge

Storm surge at Nemmeli has been estimated to be up to 4 metres above chart

datum (ie approximately RL 3.5).

Page 31 Page 32
3.5 Tsunami

The occurrence of a Tsunami along the Indian coast is an extremely rare event
with a very low frequency of less than once in 500 years. One such tsunami event
was witnessed on 26th December 2004 along the Tamil Nadu coast. From
records of tide gauge data during the 2004 tsunami event, the run up due to
tsunami at different stretches along the coast was observed to vary between 1 m
and 3.5 m. The water level rise due to this Tsunami near the project region was
around 2.0 m and the run-up crossed over the highway (ECR). Eye -witness
accounts say that each high tsunami wave that approached the coast was like a
solitary surging / tidal bore wave, and the rise in water level near the coast due to
such surging wave existed for a short duration of nearly 30 minutes.

. Figure 3 Temperature profiles

3.6 Finished Floor Level

To mitigate the above effect, 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 7.0 is being proposed for the said
plant. Finished Floor levels shall be set at not lower than RL 7.3, and equipment
plinth levels not lower than RL 7.5 for ease in operations.

3.7 Climate

Chennai, Tamil Nadu has a tropical wet and dry/ savanna climate (Köppen-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 4 Rainfall (monthly averages)

Page 33 Page 34
3.8 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 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 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 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. Measured tides
and offshore currents and directions are shown in Figure below, respectively.

Fig 6: Typical Cross Section of Coastal Form

3.9 Geotechnical conditions

The proposed site for 400 MLD desalination Plant is located at Perur (Nemmeli
Village) quite adjacent to the existing 100 MLD Sea Water Desalination Plant at
Nemmeli along East Coast Road, nearer to the sea in Kancheepuram District,
Tamilnadu, India

Sub Soil is made up of three distinctive layers, they are:

 Greyish silty fine sand – 0.0 to 10.0 to 13.0m with SPTs N = 10 to 64

 Brownish silty stiff clay – form 10.0 to 13.0 with SPTs N = 7 to 9
 Soft disintegrated rock – from 13.0/15.0 m to 19.0 m with SPTs N => 100
Fig 5: Tidal Elevations  Hard rock – from 17.0 m to 23.0 m

The detailed report is annexed as Annexure-II to the Said Report.

Page 35 Page 36

3.10 Coastal Regulation Zone
The Central Government has declared the following areas as Coastal Regulation
Zones (CRZ),
i. The land between the High Tide Line (HTL) to 500 metres on the
landward side along the sea front;
ii. Land associated with tidal influenced water bodies such as tidal
creeks;
iii. The land area falling between the hazard line as defined by the
Ministry of Environment and Forestry (MoEF), and 500 metres from
HTL on the landward side;
iv. The land area between the HTL and the Low Tide Line (LTL), which is
referred to as the intertidal zone;
v. The water and the bed area between the LTL to the territorial water
limit, 12 nautical miles offshore.
Central Government has prohibited certain activities within the CRZ, and has
declared certain activities permissible with clearance from the MoEF. Desalination
plants are permissible activities with permission from the MoEF, refer Section 4 (ii)
(h) of the Coastal Regulation Zone Notification.
CRZ-I, II, III and IV areas are defined in the notification. CRZ zones III and IV are
relevant at Perur:
 CRZ-III: Are areas that are relatively undisturbed.
 CRZ-IV: Is the water area from the Low Tide Line to twelve nautical miles
on the seaward side.
Within CRZ-III there are two designated zones, a “No Development Zone” and the
“200 m to 500 m zone”. Within both these zones, “Foreshore activities for
desalination plants and associated facilities” are permitted activities, refer Section
III, CRZ-III, A (iii)(h), and CRZ-III, B (v). In CRZ-IV areas, the activities impugning
on the sea and tidal influenced water bodies are regulated. The construction of
intake and outfall conduits, and intake and outfall structures, are regulated in this
area.
Page 37
4. WATER QUALITY
4.1 Seawater Quality
4.1.1 Importance of Sea Water Quality
Knowledge of seawater quality and variability (diurnal and seasonal) at the
proposed intake (and outlet) locations 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 ongoing 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 and for warmer water and in
response to various process parameters such as 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. Salinity will also determine capital costs
through the system recovery and hence intake and brine plant flows, pump sizes,
etc.
In the RO process the membranes are subject to both fouling and scaling and 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, and in preventing membrane
hydrolysis caused by any oil or petro-hydrocarbons present in the seawater.
Water quality parameters important for pre-treatment selection and design for a
SWRO desalination plant include, for example, the range in turbidity, total
Page 38
 suspended solids, oil and grease, organics (TOC and DOC) and silt density index the various analytes are tabulated below, in Table 1
(not often available), nutrients, particle size etc. In addition, it is critical to have an
Table 1 Field Investigations - Seawater Quality
understanding of what factors impact on seawater quality e.g. marine
hydrodynamics, point and diffuse pollution sources, riverine inputs during monsoon Parameter Unit Average at Surface Average at
Bottom
seasons, marine activities such as shipping, dredging and the occurrence of algal 1 Temp. (°C) 28.4 27.9
blooms that may impact on water quality in the vicinity of the sites.
2 TDS (mg/l) 35,100 35,200

3 Salinity (ppt) 34.7 34.7

4.1.2 Temperature and Salinity Trends
4 pH 8.20 8.21
Perur, located on the Coromandel Coast on the western side of the Bay of Bengal,
5 DO (mg/l) 6.61 5.89
experiences two monsoon periods, the north – east monsoon from October to mid-
6 BOD (mg/l) 2.51 1.83
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 7 COD (mg/l) 25.0 39.3

September (33% of the rainfall). During and following the monsoon periods, a 8 Colour, Hazen Units 17.7 18.7
significant volume of fresh water is flushed into the Bay of Bengal which may 9 Odour Odourless Odourless
impact on salinity and temperature of seawater at Perur.
10 Taste Salty Salty

11 Total Alkalinity as CaCO3 (mg/l) 111.7 116.0

12 Total Hardness as CaCO3 (mg/l) 6137 6038

13 Bicarbonate (mg/l) 127.8 126.3

14 TSS (mg/l) 48.7 73.3

15 Turbidity (NTU) 1.10 1.88

16 NO2-N (mg/l) 0.45 0.97

17 NO3-N (mg/l) 2.68 4.08

18 Total Nitrogen (mg/l) 11.8 14.5

19 PO4-P (mol/l) 0.76 0.93

20 Total phosphorus (mol/l) 1.45 1.36

Fig 7: Average Monthly Rainfall in mm, in Chennai
21 NH3-N (mol/l) 0.20 0.18
4.1.3 Field Investigations 22 Magnesium as Mg (mg/l) 1191 1258
Perur. Water quality data was collected off Perur in late July - early August 2013. 23 Calcium as Ca (mg/l) 367 467
The data was collected at the surface and at the bottom, on six transects, at
24 Chloride as Cl (mg/l) 18302 18502
locations at 750 m, 1000 m and 1250 m to sea. The data as collected is appended
25 Potassium as K (mg/l) 375 391
in Appendix A. The data collected has been analysed and the average results for

Page 39 Page 40
26 Sulphate as SO4 (mg/l) 2758 2878

27 Sulphide as H2S (mg/l) <0.01 <0.01

28 Colloidal Silica (mg/l) <0.02 <0.02

29 Reactive Silica as SiO2 (mg/l) 0.84 1.38

30 Free Residual Chlorine (mg/l) <0.2 <0.2

31 Fluoride as F (mg/l) 1.49 1.63

32 Oil & Grease (mg/l) <2 <2

33 Phenolic compounds as C6H5OH <0.01 <0.01

(mg/l)

34 Barium as Ba (mg/l) <0.5 <0.5

35 Boron as B (mg/l) 3.25 3.17

36 Cadmium as Cd (mg/l) <0.01 <0.01

37 Cyanide as Cn (mg/l) <0.05 <0.05

38 Iron as Fe (mg/l) <0.01 <0.01 4.1.4 Water Quality Design Criteria

39 Lead as Pb (mg/l) <0.01 <0.01 The sea water quality adopted for design purposes is tabulated in Table 2 and
40 Manganese as Mn (mg/l) <0.05 <0.05 Table 3 and is based on the Perur water quality sampling program.
41 Selenium as Se (mg/l) 0.022 0.023 In Table 2 the ‘Normal’ values are based on the average data gathered from the field.
42 Total Arsenic as As (mg/l) <0.01 <0.01 The ‘Minimal’ and ‘Maximum’ adopted values draw upon data gathered from the area,

43 Zinc as Zn (mg/l) 0.092 0.088 as set out above, and upon the experience of the designers.

< 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,. The data shows
poor water quality on a number of occasions as evidenced by frequent spikes in
turbidity.

Table 2 Seawater Quality – Design Criteria

Page 41 Page 42
 Normal – based Sodium Na mg/L 10,789
on field Minimum - Maximum -
Criteria Description Unit measurements adopted adopted
Nitrate NO3 mg/L 4
Water Temperatures
Ammonium mg/L 0.2
- surface °C 28.4 26.0 30.0
- bottom °C 27.9* 25.0 32.0*
4.2 Water Quality Targets
Turbidity NTU <10 10 125 CMWSSB has specified that the water quality targets shall be as per IS 10 500:
Total Suspended Solids mg/L 75 50 200 1991 (reaffirmed in 1993). The quality parameters as per IS 10 500 – 1991 are

pH 8.2 7.7 8.5 indicated in Table 4. It is to be noted that the water quality requirements fall into
two groups, ‘Essential Characteristics’ and ‘Desirable Characteristics’.
Total Dissolved Solids mg/L 35,200 32,000 38,000

Alkalinity mg Table 4: Drinking Water Quality Requirements as per IS 10 500 – 1991

(as mg CaCO3/L) CaCO3/L 110 100 120 Sl. No Substance or characteristic Requirement
Note: * The design of the RO Plant will make provision for a rise in seawater temperature of 1oC Essential Characteristics
resulting from the energy input at the pumps.
i. Color, Hazen units, Max. 5
ii. Odour Unobjectiona
In Table 3, the design values for the proposed plant are stated herwith. iii. Taste Agreeable
iv. Turbidity, NTU, Max. 5
Table 3 Seawater Quality – Design Criteria – Dissolved Solids
v. pH value 6.5 to 8.5
Criteria Description Unit Normal – based on vi. Total Hardness (as CaCO3) mg/l, Max. 300
average field
measurements vii. Iron (as Fe) mg/l, Max. 0.3
Temperature °C 27.9
viii. Chlorides (as Cl) mg/l, Max. 250
Total Dissolved Solids mg/L 35,200 ix. Residual, free chlorine ,mg/l, min. 0.2
Bicarbonate (HCO3) mg/L 126.3 x. Fluoride (as F) mg/l, max. 1.5
Magnesium as Mg mg/L 1258 Desirable Characteristics

Calcium as Ca mg/L 467 xi. Dissolved solids mg/l, Max. 500

xii Calcium (as Ca) mg/l, Max. 75
Chloride as Cl mg/L 19,247
xiii. Magnesium (as Mg) mg/l, Max. 30
Potassium as K mg/L 391
xiv. Copper (as Cu) mg/l, Max. 0.05
Sulphate as SO4 mg/L 2,878
xv. Manganese (as Mn) mg/l, Max. 0.1
Reactive Silica as SiO2 mg/L 1.38 xvi. Sulphate (as SO4) mg/l, Max 200
Fluoride as F mg/L 1.63 xvii. Nitrate (as NO2) mg/l, Max. 45

Barium as Ba mg/L 0 xviii. Phenolic compounds (as C6H5OH) mg/l, Max 0.001
xix. Mercury (as Hg) mg/l, Max 0.001
Boron as B mg/L 3.17

Page 43 Page 44
 xx. Cadmium (as Cd) mg/l, Max 0.01 confidence, and higher allowable concentrations, from studies over the last 10
xxi. Selenium (as Se) mg/l, Max 0.01 years. This is reflected by increases in guideline standards, whereby WHO have
xxii. Arsenic (as As) mg/l, Max 0.01 changed their guidelines over the last ten years from 0.3, to 0.5 (2008) and now to
xxiii. Cyanide (as CN) mg/l, Max 0.05 2.4 mg boron/L in the most recent (fourth) edition of the guidelines. A summary
xxiv. Lead (as Pb) mg/l, Max 0.05 statement on the World Health Organisation’s (WHO) recommended boron

xxv. Zinc (as Zn) mg/l, Max 5 guideline value has been posted on the WHO Water Sanitation and Health website

xxvi. Anionic detergents (as MBAS) mg/l, max 0.2 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
xxvii. Polynuclear aromatic hydrocarbons Chromium (as 0.05
was derived based on an assumption that 40 per cent of a 60 kg adult’s total daily
Cr6+) mg/l, Max
intake of boron is a result of drinking 2 litre of water having a boron concentration
xxviii. (as PAH) g/l, Max
of 2.4 mg/L and a ‘safety factor’ of 60x.
xxix. Mineral oil mg/l, Max 0.01
While sodium and chloride ions are well rejected by RO membranes, boron is not
xxx. Pesticides mg/l, Max Absent
well rejected because a high portion of the boron species is uncharged. The
Substance or characteristic
rejection of boron is strongly dependent on feedwater pH. Under optimal neutral to
xxxi Radioactive materials *
alkaline conditions, boron rejection is 70 to 80%, reducing to as low as 50 to 60%
a) Alpha emitters Bq/l, Max 0.1*
under more acidic feed conditions.
b) Beta emitters pci/l, Max 1*
xxxi. Alkalinity mg/l, Max 200 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
xxxii. Aluminium (as Al) mg/l, Max 0.03
indicates that single pass RO can reduce the concentration of boron to between
xxxiii. Boron mg/l, Max 1
0.4 and 1.0 mg/L, assuming a maximum feedwater concentration in the source
xxxiv Langlier Saturation Index positive
water of 3.4 mg/L, depending on the age and type/brand of the membranes.

4.2.1 Total Dissolved Solids
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.
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.

4.2.2 Boron
4.2.3 Jelly Fish Blooms
Boron emerged as a water quality issue with the increasing use of desalinated
Jelly Fish
seawater for both municipal drinking water supply purposes and for irrigation. The
Jelly fish ingress in a power station cooling system is reported on by S. Rajagopal
human health effects of boron have been debated for some time with increasing

Page 45 Page 46
 et al, Home 1989. The power station is located at Kalpakkam on the east cost of  50 years for civil works, buildings & buried pipeline components;
India. Three peaks in the occurrence of jelly fish were noticed in May, July and  50 years for concrete tanks.
October 1988, which accounted for 286, 204 and 129 tonnes respectively. The  25 years for mechanical and electrical equipment;
authors recommend that jelly fish ingress be controlled by preventing their inflow,
 20 years for flexible membrane liners and covers to storages;
or by letting them pass freely. ‘To prevent jelly fish from flowing in with water
 20 years for steel panel tanks;
current, fish netting is proposed to be installed in front of the water intake where
 15 years instruments;
inlet velocity is low. This method is adopted at many power stations including
 10 years for polyethylene tanks;
Tarapur Atomic Power Station including existing SWRO plants’.
 8 years seawater reverse osmosis (SWRO) membrane life.

5.2 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.

5.2.1 RO Rack Configuration

The size of the RO train impacts on the number of trains, all equipment’s 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

Design Parameter Details

RO Configuration Single pass, single stage
Number of Duty Trains 16
Number of Standby Trains 1
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 8
5.    DESIGN LIFE AND AVAILABILITY; PRIMARY FLOWS
Number of Membranes per Train 1920
5.1 Design Life
The infrastructure will be designed for a life in excess of: 5.2.2 Operation

Page 47 Page 48
One standby train has been provided for the complete capacity of the plant,
primarily to provide for the shutdown of individual trains. Each train will be subject
to planned and unplanned shutdown. Planned shutdown will be primarily for
cleaning-in-place (CIP).
In general there shall be one (1) CIP per train per three months, resulting in 36
cleans per year, or once every ten days, for duration of 1 to 2 days. However
unplanned short term shutdowns can also be anticipated as well as infrequent long
term shutdown. Short term unplanned shutdowns can be expected to be 6 hours
or less, whereas Long term shutdowns will be a function of design, construction
and supervision, and materials supply. However, provision can be made for long
term shutdown, but cannot be programed. Hence a Standby train has been
provided to take care of the said eventualities to meet the plant availability criteria
as per design.
of the trains above the design value, but rather to ensure maintenance of the
design capacity of the trains. RO building will be designed to house Seventeen
trains, with one row of eight trains and other row for nine trains.
There may also be a scenario, when demand for potable water is low, or major
scheduled maintenance is occurring, then the plant may be required to operate at
a reduced capacity.
5.3 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 8. 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.

The cycling of the standby train will need to be relatively frequent as standby
Table 6 Primary Flows – 400 MLD Plant
duration without preservation is approximately 48 hours.
Section Normal Flow Peak Flow
The provision of a standby train should ensure the consistent delivery of 400 MLD
of the product water from the facility. However, from time to time production may Product Water Tank 400 MLD 425 MLD
fall below 400 MLD, and it will be desirable to ‘catch-up’ on production which could
be achieved by increasing the pumping rate through the membranes. However, Utilities and Losses 8 MLD 8.5 MLD
this is not desirable as it may result in flows exceeding the guarantees for the Permeate Production 408 MLD (16 trains) 433.5 MLD (17 Trains)
membranes. Therefore alternative is to provide for running of standby train on
Permeate per Train 25.5 MLD 25.5
occasions for relatively short periods. However, to allow this to happen, pipework
Peak Filtered Seawater Required 948.85 MLD 1008.20 MLD
and pumps must be designed to pass the additional flows and this can be
to RO (based on 43% recovery *)
achieved at a relatively low cost, and pipework and pumps have been designed for
flows associated with 17 trains operating. However, increasing the capacity of Filtered Sea Water to Screens for 2.6 MLD 2.6 MLD
upstream processes such as DAF and filtration is not justified for these short term spray
operations. Hence, upstream processes have been designed for flows associated Sludge and Float losses 22.5 MLD 24.0 MLD
with 16 trains operating; however process design parameters are have been
Filter Backwash Losses 38 MLD 40.0 MLD
selected to be sufficiently robust to operate on overload for short periods to take
Filter to waste losses** 33 MLD 35.2 MLD
care for additional flows.
To Pre-treatment 1044.95 1110 MLD
As shown in Table 5 space has been provided in the RO racks for additional PVs,
say 1045 MLD
which may be installed to respond to operational and environmental changes, as
well as compensate for deviations from the design of the plant or equipment Intake Flow
performances. The additional PVs would not be installed to increase the capacity

Page 49 Page 50
 Normal 1043 MLD of screen.

Peak 1108 MLD Two intake conduits and a single outlet conduit each of 2400 mm ID has been
proposed for the plant to produce 400 MLD permeate capacity. The velocity in the
Screened Sea Water to Pre-
conduit at peak flow will be 1.47 m/s. Friction losses at this velocity would be of
treatment
the order of 1.5-1.7 metre in a pipeline 1,200 metres long.
Normal 1045
One outfall will be provided with an internal diameter of 2400 mm. For a flow peak
Peak 1110 flow of 700 MLD, the velocity will be 1.79 m/s. Friction losses at this velocity would
be of the order of 1.6-1.8 metre in a pipeline 700-800 metres long; exit losses
Peak Outfall Rate 700 MLD 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. For a
* 43% selected to provide a conservative estimate of flow for hydraulic design.
nominal outfall the velocity shall be 1.5 m/sec.
Process design is based on 46% recovery.
6.2 Intake structure with Screen offshore
** Filter is brought back into service following backwashing, the water quality can be
poor and it is good practice to discharge the first product water from the filters to
A 100 mm screen in GRP construction will be provided at the intake to exclude
waste. If this water is not discharged to waste there is the potential for higher loads
larger marine life. One intake chamber and screen will be provided on each
on the cartridge filters and ultimately membrane fouling.
conduit. There shall be two intake heads with screen offshore separated by a
minimum distance of 1500 mm. The screens will be 8.5 m diameter, 1.5 m high,
starting 2 m above the sea floor, in 10 metre depth of water. The approach
velocity will be <0.1 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.

6.3 Active Screens before the Sea Water Pumps

6. SEAWATER INTAKE
6.1 Primary Flows 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
The intake system will be designed to have a hydraulic capacity of 1108 MLD, shells, diatoms etc.
whereas the sea water pumping station will be designed to have a peak capacity of The advantage of providing the screens before the pumps is to capture the jelly
1110 MLD, wherein 2 MLD required for screen washing will be returned upstream fish that bypass the off shore screen and fishing net on the shore alive, thus

Page 51 Page 52
preserving the same and returning them to the sea in order to have a sustainable
Stand by 2
ecosystem.
Sea Water Flow Per screen MLD 277.5
Stainless Steel mesh mm 3
Travelling Band Screens Approach Channel Width m 4.5

A typical band screen installation is shown in Figure 8 below. Width Back opening m 3.0
Channel Approach Velocity m/s 0.85-0.90
Upstream water depth m 2.2
Downstream water depth m 1.8
Wash Water per screen L/s 15-20

6.4 Sea Water Pumping Station

As noted in Section 6.1, two numbers of 2,400 mm internal diameter intake

conduits are proposed as intake options. These conduits are to 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. The wet wells will be
connected, and a penstock will be provided to allow isolation of each wet well and
intake conduit.

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 are as follows, in metres above Chart Datum, and relative to the

Band screens have been in service for screening sea water for many years. They site datum:

provide efficient removal with relatively low maintenance costs and also have
Construction costs that are relatively low as compared to the total plant cost.

Chart Datum RL
Through-flow band screens have been proposed herewith. Typically mesh sizes
Mean High Water Spring 1.15 RL 0.5
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. Mean High Water Neaps 0.84 RL 0.19

Table 7 : Band Screen Design Parameters Mean Sea Level 0.65 RL 0.0

Parameter Units Value Mean Low Water Neaps 0.43 RL – 0.22

Seawater flow MLD 1110 Mean Low Water Spring 0.14 RL – 0.51
Duty 4

Page 53 Page 54
 Design parameters are set out in Table 8

Onshore survey levels are recorded as metres above Mean Sea Level. Thus Table 8 :Sea Water Intake Pumps
Mean High Water Springs is 1.15 – 0.65 = RL 0.5, and Mean Low Water Springs is
Parameter Units Value
0.14 – 0.65 = RL – 0.51.
Pumping Station Capacity MLD 1110
The low no flow level in the pump well has been taken as RL – 0.50. At a flow of
Wet Wells - 1
580 MLD per conduit (10% additional to take care for biofouling), the hydraulic
Duty Pumps in wet well - 6
grade line entering the proposed pumping station will be approximately 1.7 m
Standby Pumps in wet well - 3
lower, at RL – 2.2. A head loss of 0.8 is provided/allowed for loss through screens
Mean High Water Springs RL 0.5
resulting in low-low water levels in sump cum pump station as RL-3.0.
Mean Low Water Springs RL - 0.51
Three (3) metres has been provided to the bottom of the pumps, which has been Intake Conduit loses at peak flow m 1.8
assumed to be 0.5 m above the bottom of the pumping station at RL – 6.5 to
Pipe diameter - Pump to manifold m 1.30
ensure sufficient submergence for the pumps, and to allow for surging in the intake
Rising mains to each module - 2
line. Subject to the detailed design of the intake conduits, it is anticipated that the
Rising main diameter m 1.8
intake conduit will enter the pumping station at between RL – 6.5 and RL – 4.5.
Pump house Plinth Level RL 7.5
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; the static lift at Mean High Water Springs will be
 Generic type of pump: vertical shaft mounted in pump well,
from RL -2.0 to around RL 14.5, i.e. around 16.5 metres.
 Materials: super duplex stainless steel, PERN No > 43
Pump Configuration  Equipment per pump unit: isolation valves, non-return valve and magnetic flow

There shall be 6 W + 3 S pumps sets in each wet well delivering to a 400 MLD meter,

module as below  Pump motors: electric variable speed,

 There shall be 6 pumps in operation each pump must be capable of delivering  Pump station control: by plant PLC based upon target flow rate,
185 MLD (2141 L/s), at a head of around 30 metres.  Pump/equipment removal: by EOT,

 Each pump will have a delivery line 1.30 metres in diameter (V = 1.61 m/s),
connected to the manifold 1.8 metres in diameter. 6.5 Shock chlorination system
 Pair of three pumps shall form one manifold to a module of 12 Settlers. The A shock chlorination system is proposed to minimise marine growth in the inlet
diameter of each manifold 2,600 mm (2.6 m), with a velocity of 1.20 m/sec. pump station and pressure main. Criteria adopted for the shock chlorination

These pumps are Vertical Turbine pumps with large clear passages. The intake system are summarised below;

screen and net at the intake will prevent the ingress of material like to cause a  Type of chemical: chlorine gas through Vacuum Chlorinate
blockage. Run times between major maintenance are expected to be long,  Max chlorine solution residual in inlet main: 10 mg/l,
therefore for these reasons a 50% standby configuration has been proposed.
 Min chlorine solution residual in inlet main: 1 mg/l,

Page 55 Page 56
  Dosing time: 1-2 hour per day,
 Dosing point: Off shore inlet well,
 For shock chlorination Hypo has been proposed and sizing is calculated in
Chapter 10.
6.6 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
to delivery.
6.6.1 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
Page 57
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 2400mm 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.
6.6.2 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 operator’s
console and the shaft, whereby only the operator in ownership of the control can
make the transfer at the time.
6.6.3 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
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
Page 58
 power pack and the rear inter jacks, from the shaft power pack.

On completion of tunnelling operations all interjack cylinders and seal assemblies 7. PRETREATMENT SYSTEM
shall be removed. The exposed steelwork shall be properly cleaned and treated
7.1 Pretreatment Process
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 The pre-treatment process has been sized assuming that there are 16 membrane

to facilitate easy removal by hand within the tunnel. trains in operation to produce 400 MLD of Permeate water.

6.6.4 Slurry System

7.2 Sea Water Quality / Treatment Processes
The slurry system shall be designed to be capable of functioning with bentonite
The key water quality parameters relevant to the selection of pre-treatment
slurry where required as a support medium. The slurry circuit shall be designed for
processes include:
a minimum flow rate of 400m3/hr. The slurry circuit shall include flow meters on
 Total Suspended Solids
both feed and discharge lines.

Feed pipes shall be 250mm nominal internal diameter and slurry discharge 200mm  Turbidity

internal diameter. Automatic valves shall be included at the shaft top to allow for  Marine Biomass, jelly fish, larvae and algae
immediate closure by the operator in the event of burst system hoses. The
Other relevant factors are:
separation plant shall be sized to be 25% over capacity to account for any possible
flow surges within the slurry circuit.  Capex

All controls and indicators for running the slurry system shall be available at TBM  Opex
operator’s console. A telephone system shall be installed to allow direct  Ease of operation
communication between the TBM and the separation plant.
 Robustness

7.2.1 Key Water Quality Parameters – Pre-Treatment

Field Investigations

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 Perur, 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.

Page 59 Page 60
Total Suspended Solids 7.3 The Pre-Treatment Processes- Scheme

The average of the TSS measurements at the surface and at depth, offshore from pH correction – coagulation – flocculation – Lamella Settlers-Dissolved Air
Perur, was 48.7 and 73.3 mg/L respectively. These readings are ‘very high’. For Flotation (DAF) – Gravity Dual Media Filters
example, for Sydney desalination plant (250 MLD) the design maximum TSS is 7
mg/L, which is only one-tenth the measurement at Perur.
7.4 pH Correction
The higher concentration of suspended solids at the bottom compared to the
The seawater will be dosed with acid to achieve the optimum pH for coagulation.
surface indicates that the suspended solids have a density slightly higher than sea
The dosing system will consist of duty and standby dosing lances into each pre-
water. Since the seawater intake is located near the seabed, the bottom
treatment train. The pH correction design parameters are summarised in
suspended solids readings are quite relevant to the design of the pre-treatment
Table 9 below.
system.

Table 9 pH Correction Design Parameters

Marine Biomass
Parameter Units Value
Marine biomass includes jelly fish, larvae and algae. The presence of these
Design maximum seawater flow MLD 1110
materials is highly variable and dependent on season, temperature and the
presence of nutrients. Dosing location At head of Common
However, operational experience at Nemmeli suggests that if provision were not Coagulation/Flocculation
made for the removal of marine biomass it could be a significant problem, hence to
Type of pH correction chemical Sulphuric Acid
take care of same a Travelling Band Screen with 3mm mesh has been provided.
Target pH 6.80

Dose rate mg/L 35 approx.

Organic Pollutants
Number of dosing pumps 8 (8duty / 8 standby)
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;
7.5 Coagulation and Flocculation
the reason for high COD is not clearly correlated, but may be related to the high
7.5.1 Coagulation
suspended solids.

Seawater turbidity is usually low at 0.5 to 1.0 NTU, however at Perur 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, ie to less than 0.5 NTU, perhaps as low as 0.1 NTU.

Page 61 Page 62
 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 4.5 for 100% of the time, under all operating
conditions.
7.5.2 Flocculation
Flocculation will be provided at the head of each Lamella. 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 at the head of

Mineral particles can be destabilized by the addition of coagulant. The pH is the lamella to allow for a longer flocculation time so as to compensate for the lower
adjusted first, then the coagulant is added and flash mixed with the water. suspended solids concentration expected as feed to RO. The flocculation and
Coagulation is followed by flocculation; a flocculant is added at this stage. flocculent design parameters are summarised in Table 11 below.
Thereafter the flocs are removed by processes such as floatation and filtration.
Table 11 Flocculation and Flocculation Aid Design Parameters

Coagulant will be dosed at the head of each Lamella block. Rapid mixing will be Parameter Units Value
implemented within a concrete structure with at least 30 seconds of detention time.
Design maximum seawater flow, MLD 1110
The coagulation and rapid mixing design parameters are summarised in Table 10
below. Type of flocculation aid polyelectrolyte

Table 10: Coagulation and Rapid Mixing Design Parameters Dose rate – average mg/L 0.1

Parameter Units Value Dose rate – maximum mg/L 0.5

Design maximum seawater flow MLD 1110 Number of flocculation tanks per cell No. 2

Type of coagulant Ferric chloride Detention time (minimum) min 20

Dose rate mg/L 16 approx. Type of mixers Variable speed impellers

Mixer type Flash mixer Mixing energy (G) – stage 1 s-1 70 – 100

Mixing energy (G) s-1 600 minimum Mixing energy (G) – stage 2 s-1 30 - 50

Mixing time s 30

Page 63 Page 64
7.6 Lamella Settlers Chain and flight scrapers or
Bottom Sludge Removal
Lamella settlers consist of a series of hydraulic vacuum; material of
inclined parallel plates or tubes through construction to be suitable for
which the water passes. The plates are seawater
close together and the suspended solids Clarified water collection Concrete troughs with
travel only a short distance to the plate triangular FRP weir plates
below and then gravitate down the Size provide 18m x7.5 m
inclined plate and are removed from
the flow. For this reason the
7.7 Dissolved Air Flotation (DAF)
footprint of a Lamella settler is
Dissolved air floatation (DAF) is a high rate process using micro-bubbles to float
relatively small. Lamella settlers
coagulated and flocculated particles to the surface of a clarification basin. A
can quickly remove large amount of
portion of the clarified water is drawn off and passed through a pressure vessel
relatively coarse material. However, the turbidity of the water exiting a Lamella
where the water is saturated with air at high pressure. The pressurized water,
settler may be higher than for plain sedimentation. Notwithstanding, low turbidities
supersaturated with air, is released into the water as it enters the bottom of the
may be achieved by providing filters following the Lamella plate settlers.
basin. The sudden release of pressure causes the formation of micro-bubbles
Coagulation and flocculation are provided prior to the Lamella settlers. The capex
which attach to the preformed floc and carry it to the surface where it forms a thick
and opex of Lamella plate settlers are reasonably low, and they are simple to
floating layer. The float is skimmed off, and the clarified water passes to filtration.
operate.
DAF in general adequately removes TSS of 75 mg/L, but above 100 mg/L there is
Table 12 Lamella Settlers Design Parameters 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 the provision of
Parameter Units Value
deep dual media filters. Therefore to mitigate the said situation; two stage filtration
Design seawater flow (average) MLD 1045 with deep filter/media beds have been proposed which shall be capable to take
high load of TSS, while producing the required SDI.
Design seawater flow (peak) MLD 1110

No. of settlers Nos. 24 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
Lamella Type and Material Plates/Tubes made from FRP
matter. DAF would be effective in the removal of oils and greases.
with 550-600 inclination with
horizontal Ideally, loading rates for DAF would be set after pilot plant testing, and if time
permits, pilot plant testing at Perur should be carried out to provide data on the
Lamella Surface loading rate m/hr <15
most suitable loading rate.
(vertically projected surface area)
DAF a form of physical treatment of water that involves coagulating impurities then
Lamella Supports Concrete
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 filters

Page 65 Page 66
 downstream.
Parameter Units Value
The flotation cell also requires occasional sludge removal to remove settled solids.
DAF Air Dose Rate mg/L 10
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 Air Saturator Efficiency % 90
for removal of fine solids and organics. It also copes well with algae because it is
Air Saturator Pressure (Gauge) kPa 800 (nominal)
removed in the flotation step, eliminating the possibility of filter blinding. A
simplified cross sectional schematic is as shown below. Number of air saturator No. 60

Raw Float Removal Type Hydraulic float removal (and weir)

water Flotation
Flocculation

Filtration
DAF recycle water will be drawn from the small tank just downstream of gravity
filters to minimize pipework distances and variation in hydraulics.
Filtered water
Air Sludge
saturated water
7.8 Dual Media Gravity Sand Filters
.
Clarified water from the DAF outlet shall feed to the inlet channel of the gravity

Table 13 Dissolved Air Flotation and Filtration Design Parameters filters. Each filter inlet shall include an isolation valve/Gate and in filtering mode,
the feed water shall be fed into the filter, above the filter media, in such a manner
Parameter Units Value so as the filter media is not disturbed. The water shall flow through the filter media,

Design seawater flow MLD 1030 without recycle through filter floor nozzles, and into a chamber underneath the filter floor. Filtered
water shall flow from the filtrate collection chamber, through a flow control or into
MLD 1236 with recycle the tank beneath the filter house or placed separately.

Peak seawater flow MLD 1094 without recycle The inlet distribution channel and the outlet filtered water collector channel shall be
equipped with motorized penstock to isolate and bypass the DMF in case
MLD 1313 with recycle operation and maintenance requirements or as the case may be.

Number of DAF Cells No. 60 When in backwash mode, water from the backwash tank shall be pumped by
dedicated duty/ standby backwash pumps, through control and isolation valves into
DAF surface loading All units online m/hr 8 (with recycle)
a single filter filtrate chamber. The backwash water shall flow up through the filter
rate
media support, up through the filter media, removing filtered solids from the filter
One unit offline m/hr 8.5 (with recycle) bed, and into the backwash water troughs, running the length of each filter. The
backwash water troughs shall be designed to ensure that dirty backwash water is
DAF area per cell m2 90
removed evenly from the whole length of the filter. Backwash effluent shall pass
DAF cell dimensions (internal) m 15 x 6 from the backwash troughs, through the effluent isolation valve, and to the
backwash effluent tank. The system shall ensure that no more than 5% of the top
DAF Recycle Rate % 20
media is lost over a one year period, and this shall be tested during the

Page 67 Page 68
 performance test. Backwash Air–water
The type, uniformity, size, and depth of filter media are of key importance for the Average filter cell run duration 24hr
performance of pre-treatment filters. Dual-media filters shall have two layers of Flow distribution to individual cells Tapered concrete to keep velocity in the
filtration media distribution channel above 2 m/s at all times
Filtration Velocity 8m/hr ; N-1: 8.5 m/hr
No of Filter Beds (Twin Section) 40 nos.
Size of each 15.5 x 8.5 m
Table No 14: Media Gravity Filters
Filter cell length-to-width ratio 2:1 approx.
Maximum water depth above filter 2.5 m (should be equal to or slightly higher than
An upper layer of coarse material with low density - typical is
bed filter bed head loss, which usually is 1.8 to 2.4m)
anthracite of 0.5 m -1.0 m depth.
Filter Media Sand
A bottom layer of fine material with higher density for refinement, ES mm 0.6
which typically is sand of depth of 0.8-1.5 m. UC - 1.4
The above filtration medium shall be typically supported by a Depth mm 900
layer of gravel bed. The gravel bed is graded in three to six Anthracite
layers and is located on the top of a filter under drain system ES mm 1.43
UC - 1.3
Depth mm 900

Sand specific gravity tons/m3 2.65

3
Sand bulk density tons/m 1.5 to 1.9
Back Wash Water Rate m/h 36
Air Scour m/h 60
Duration (total air plus water) 20 to 30 min (includes filter cell draining and fill-up)

A small water storage tank will be located immediately downstream of each bank of
filters; each tank will provided with an overflow weir to maintain the water level in the
filters, and to store water for recirculation to the DAF process. Two such tanks will be
provided, for equalized flow. Water that overflows these weirs will flow to the Filtered
Water Storages; filter backwash water will be drawn from the Filtered Water Storages

Table 15: Dual Media Gravity Filters A maturation tank is proposed to collect the effluent/wash water of GDMF maturation
Filter type Dual media, down flow process. This tank shall collect also the overflows of filters backwash water tank and

Page 69 Page 70
 overflows from dirty water tanks. The effluent from the tank shall be discharged to sea The RO plant will be a single stage/single pass design with an overall recovery of
via outfall. 46%.

7.9 Gravity Filtered Water Storage
Filtered water storage will be located immediately downstream of the Gravity Dual
Media filtration system. This will serve as control storage between the filtration
system and the RO plant. It will ensure that the flow to the RO trains will be
constant while the production from the pre-treatment system fluctuates due to
backwashing. The tanks have been sized to provide twenty minutes storage at a
seawater flow of 1110 MLD.
The design parameters for the Filtered Seawater Storage Tanks are summarised
in Table 16.
The 400 MLD modules will be configured as Seventeen individual trains. Each of
the Seventeen (17) 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 Sixteen (16) trains.
The trains will be configured to allow for each individual train to be isolated for
cleaning, maintenance, or membrane replacement.
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.

Table 16 Filtered Seawater Storage Design Parameters 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
Parameter Units Value
provides the flexibility to reduce the flux if advantageous for reducing cleaning
Design seawater flow MLD 1110 frequency or reducing power consumption.

Number of tanks No. 1

8.2 Pumping System Design and Pressure Control
Fill time min 20
Based on preliminary membrane projections for DOW and Hydranautics
Capacity ML 15 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
Table 17: Filtered Seawater Storage conditions, and depending on the actual membrane selected.

Parameter Units Value 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
Design seawater flow MLD 584
driven booster pumps and fixed speed RO HP pumps has been selected. A
MOC - Concrete with inside schematic of the proposed pumping system design is shown Figure below.
protective coating

8. REVERSE OSMOSIS PLANT

8.1 Overview of RO Plant

Page 71 Page 72

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%
Page 73
Preference to have majority of pumping capacity driven by a fixed speed
drive and operating at the best efficiency point (BEP)
8.3 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 housed in PVDF housing. Cartridge filter shall used for safety and
protection of high pressure pumps and shall not operated as a pre-treatment
stage. FRP/PVDF vessels shall be provided for housing cartridge filters with quick
opening hold-down bolts shall be provided of sufficient capacity to meet the
maximum flow of the Plant without exceeding pressure drop limits when fully
fouled. The vessel shall be designed in accordance with ASME Section-X, design
of vessels.
8.4 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.
8.5 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.
8.6 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.
Page 74
Details of the booster pumps are shown in Table 18. Table 19 High Pressure Pumps Design Parameters

Parameter Unit Value

Table 18 : RO and ERD Feed Booster Pumps Design Parameters
Number of pumps per RO train No. 1
Parameter Unit RO Feed Booster ERD Feed Booster
Total number of pumps No. 17
Pump Pump

Maximum flow capacity ML/d 25.5

Number of pumps per RO train No. 1 1

Total number of pumps No. 17 17 L/s 295

Delivery Pressure* bar 55.3

Maximum flow capacity L/s 295 346

(per train) Type of drive Fixed speed

ML/d 25.5 29.9 Materials (PREN > 43 for contact with

seawater or brine):
Delivery Pressure bar 14.5 6.0
(are dependent on final membrane and ERD Casing - Stainless steel (Super
selection and performance)
duplex)
Type of drive Variable speed Variable Speed
Pump impeller - Stainless steel (Super
Materials (PREN > 43 for contact with seawater or brine): duplex)

Casing - Stainless steel Stainless steel Shaft - Stainless steel

(Super duplex) (Super duplex) Notes: * Pressure requirements are dependent on final membrane selection and
performance.
Pump impeller - Stainless steel Stainless steel
(Super duplex) (Super duplex)

Shaft - Stainless steel Stainless steel

Design parameters for the high pressure RO pumps are shown in Table 19. 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.

Design parameters of the proposed ERD system are shown in Table 20

Page 75 Page 76
Table 20 Energy Recovery System Design Parameters
Parameter Unit Value

Number of pumps per RO train No. 1

Total number of pumps No. 17

Maximum flow capacity MLD 29.9

Parameter Unit Value
L/s 346
Number of ERD systems per RO train No. 1
Maximum pumping head bar 5.7
Total number of ERD systems No. 17
Type of drive Variable speed
Number of ERD units per system No. 5
Materials (PREN > 43 for contact with seawater or brine):
Total number of units No. 85 Casing - Stainless steel (Super

Type of system - Isobaric System duplex)

Pump impeller - Stainless steel (Super

Type of energy recovery device - DWEER
duplex)
Manufacturer of device - Calder AG
Shaft - Stainless steel
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+

Materials (PREN > 43 for contact with seawater or brine):

Casing - Stainless steel (Super

duplex)

Piston - Non Metallic

Other parts in contact with Stainless steel (Super

seawater/concentrate duplex)

Table 21 ERD Booster Pumps Design Parameters

8.7 RO Rack Design

Page 77 Page 78
 The membrane design parameters are shown in Table 22. Normal production will
Total number of membranes per train No. 1920
be using 16 racks to produce 400 MLD of product water at a flux of approximately
13.5 LMH. Total number of pressure vessels No. 4080

Table 22 RO Membrane Design Parameters Total number of membranes No. 32,640

Reserve space provided for installation of % 8

Parameter Unit Value
additional membrane modules
Number of RO membrane trains No. 16 + 1 (Duty /
Feed Water SDI requirements 100th% ile <4.5
standby)

Number of racks per train No. 1

Number of RO racks No. 17 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.
RO Plant Recovery % 46
Projections are attached as Annexure III to the report.
Material of membranes Polyamide
The piping material for the RO system is as shown in Table 23
Type of membrane/module 8 inch spiral wound
Table 23 Piping materials
Membrane manufacturer Hydranautics, Dow
Piping Material
Active area per membrane element m2 41 (440 ft2)
High pressure feed piping Stainless steel, super
RO membrane flux rate Normal LMH 13.5
duplex, PREN > 43
Maximum LMH 15.5
High pressure feed and concentrate piping and Stainless steel, super
Salt rejection Nominal % > 99.8 headers duplex, PREN > 43

Boron retention Nominal % > 93 Connecting pipework feed/concentrate headers to Stainless steel, super
pressure vessels duplex, PREN > 43
Salt Passage Increase %/a 10
Product headers Stainless steel
Flux Decline %/a 7
Product piping Stainless steel
Average Membrane Life a 3.5
(AMLT) Piping for cleaning GRP

Number of pressure vessels per rack No. 240 Piping for shut-down flushing GRP

Number of membranes per vessel No. 8

Page 79 Page 80
8.8 RO Clean In Place System 24.

A RO clean in place (CIP) system is included in the design. This includes a

Table 24 Chemical Cleaning Preparation Tank Design Parameters
chemical cleaning preparation tank, chemical cleaning buffering tank, a heat
exchanger, pumps, cartridge filters, cleaning chemical storage tanks, cleaning Parameter Unit Value
network and cleaning recirculation loop piping and a neutralisation system.
Number of tanks No. 1
Provision has been made in the design for storage and dosing of the following
cleaning and preservation chemicals: Net volume of tank m³ 600

 Caustic soda Material:

 Sodium Bisulphite
Body / ends - GRP
 Hydrochloric Acid
 Phosphoric Acid Pipes / valves - GRP/PVC/SS
 Citric acid
Form of construction Circular
 Detergents (surfactant)
 Ammonia solution
Cleaning occurs intermittently and all of these chemicals would not be used at the Design parameters for the chemical cleaning pumps are shown in Table 25.
same time. The amount and type of cleaning chemical required would vary
Table 25 Chemical Cleaning Pumps Design Parameters
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 Parameter Unit Value
cleaning of the RO system from both directions, i.e. from the front to the back and
Number of pumps No. 4+2
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 Flow capacity of each pump L/s 300
to clean each individual RO rack separately. The system, including the chemicals
Pumping head bar 10
for the CIP will be located in a dedicated building located next to the main RO
building. Number of stages No. 1
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 Design parameters for the flushing pumps are shown in Table 26.

Page 81 Page 82
 Table 26 Flushing Pumps Design Parameters

Parameter Unit Value 9. POST TREATMENT

Number of pumps No. 2+2 Post treatment of permeate is required to meet the statutory product water quality
requirements. Post treatment will consist of remineralisation/stabilisation and
Flow capacity of each pump L/s 295
disinfection of the water.

Pumping head m 3 9.1 Re-mineralization/Stabilization

Number of stages No. 1 9.1.1 Requirement for Stabilisation

Water produced by a reverse osmosis process has very low residual hardness and
8.9 Permeate Storage alkalinity, which renders it very aggressive to most materials including steel and

Two permeate storage tanks will be located immediately downstream of the RO concrete thus causing corrosion and premature aging of assets. The lack of

plant. Each tank has been sized for at least 0.5 hours storage at the maximum carbonate alkalinity as well as the low content of calcium and magnesium (i.e.,

permeate flow. The design parameters for the Permeate Storage Tank are very low hardness) causes desalinated water to be unstable and prone to

summarised in Table 27. 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.
Table 27 Permeate Storage Design Parameters Therefore, before the permeate from reverse osmosis be supplied to customers, it
needs stabilisation also known as remineralisation or conditioning to prevent this
Parameter Units Value
from happening.
Number of tanks No. 2
Product water remineralisation for corrosion protection has two aspects:

Nominal volume per tank
Minimum residence time
ML/tank 4.6 (1) protection of water distribution systems and household piping and fixtures from
damage caused by corrosion, and
hr 0.5 (all tanks, at full plant
capacity) (2) maintaining the desalinated water quality in terms of aesthetic appearance
(color and taste).

Table 28 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 350 mg/L

Page 83 Page 84

9.1.2 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
9.1.3
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
Page 85
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
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.
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
Page 86
Carbon dioxide is delivered to and stored at the desalination plant in compressed Component/Parameter Specifications/Design Criteria
liquid form [20 bars] of pressure at 20°C. A typical carbon dioxide feed system Type Electric
consists of liquid carbon dioxide storage tanks equipped with refrigeration units, Capacity, horsepower/kg 0.01–0.02
vaporizers, vapor heaters, carbon dioxide dosing system with pressurized gas CO2.day
solubility panel, and an in-line gas feed diffuser.
Key design Criteria Carbon Dioxide and Feed System

The dosage of carbon dioxide fed to the desalinated water is adjusted

Component/Parameter Specifications/Design Criteria
proportionally to the desalinated water flow rate by flow control valves installed on
Carbon dioxide dosage (as 100% For lime/CO2 systems–88 mg/L For
the gas feed lines from the vaporizer to the point of chlorine dioxide gas injection in
pure product) calcite/CO2 systems–44 mg/L per
the desalinated water conveyance pipe.
1.0 mg/L of target alkalinity and
hardness concentrations (as CaCO3) 9.2 Disinfection
CO2 consumption (kg/day as 70.4–105.6
100% pure product) per 1000 m Disinfection has been used for over a hundred years, when it was first regularly
3 /day of desalinated water for used to kill germs in the 1900s. Chlorination was first used in London in 1905 and
addition of alkalinity and ozone was first used in Nice in 1908. From there, disinfection developed further
hardness in a range of 80 to 120 and was widely accepted as a method to treat water. Chlorination is the most
m/L (as CaCO3 widely used method with ozone slowly becoming more popular. Chlorine dioxide is
CO2 purity, % 100 also another disinfectant in the water treatment industry, but because of its high

Liquid CO2 storage tank cost not used commonly. UV disinfection is a relatively new disinfection method

(refrigerated) even though it was also discovered approximately at the same time as the other

Storage pressure/ temperature, 20 bars/−20°C techniques.

bars/°C Requirement for Disinfection

Diameter, m 0.8–3.0 Disinfection is the process whereby water is treated to kill microorganisms in the
Length/Height, m 5–15 water, including essentially all pathogenic (disease-causing) bacteria. In addition
Storage time, days 15–60 disinfection is undertaken to prevent bio-film (slime) growth inside the pipes and
Structure–material type Carbon steel mitigate the risk of recontamination.
Vaporizer Chlorine based disinfection (i.e. chlorination) has been considered for said project.
Type Electric This is because this process is by far the most common form of disinfection in the
Capacity, horsepower/kg 0.03–0.05 country and has a shell life as compared to other disinfection process which
CO2.day usually doesn’t have the required shell life in distribution system.
Delivery pressure/temperature, 3 bars/12°C
Chlorine is the most widely used water disinfection method. Chlorine kills the
bars/°C
micro-organisms by immobilising their metabolism rendering them harmless.
Vapor Heater
Chlorine is a slow stable reaction thus its main advantage of chlorine is the

Page 87 Page 88
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
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
k = 0.4343 K
Page 89
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 a chlorine and ammonia
Page 89
chemical reaction, is a combined residual chlorine and is also an useful disinfectant. Government of India, it is necessary to obtain a storage license when five or more

Break point occurs once all the ammonia is reacted and the combined residual containers are to be stored. For obtaining the storage license safety equipments are

chlorine is converted back to free chlorine (Refer figure above). Increasing the chlorine essential along with scrubber system. Also the building has to be constructed as per

concentration also increases the free-chlorine residual, however increasing it beyond the norms suitable for storing toxic gas cylinders with adequate ventilation systems and

break point is counterproductive due to the production of nitrogen and nitrogen tri- handling accessories. Further as per Manufacture, Storage and Import of Hazardous

chloride, chemicals that have a strong unpleasant odour. Chemicals Rules, 1989 maximum of 10 tonnes can be stored at site

The break point is a good indicator when to supply sufficient amounts of chlorine to remove Chlorine Dosing Rates

any excess ammonia without the risk of producing less welcoming products including di- The recommended chlorine dosing rates for Potable water are;

chloramine and nitrogen trichloride. 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.
Chlorine Dosing Considerations
Disinfection of the produced water will be carried out using a standard chlorine gas system.
It is important that personnel, engaged in chlorine plant or in any activity involving handling Both the process and potable quality product waters will be dosed. To achieve is
of chlorine, should understand the hazardous properties of chlorine and should have a minimum Residual chlorine in distribution system, 5 mg/l of chlorine shall be dosed
good grasp of the basis of preventive measures. This will make them more conscious using 30 kg/hr. (3 W + 2 S).
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 Table 29: Liquid Chlorine Characteristics
metal container in a compressed or liquefied state, within the meaning of the Indian Properties
Explosives Act, 1884. The filling, possession, transport and importation is governed by the
Appearance Greenish Yellow
Gas Cylinder Rules, 1940.
Physical state Liquefied compressed Gas
Cylinders should be stored in an upright position. They should be
secured to prevent from falling over. Vapour pressure @ 35oC 27.48 mm Hg at 20oC

Full and empty cylinders should not Boiling point /Range -34 °C (at 1 Atmospheric Pressure)
be stored together. Then containers
Melting point/Freezing Point -101°C
should be stored on their .sides.
Vapour Density (Air Density= 1) 2.49
They should not be stacked or
racked more than one high. All Liquid Density(Water density = 1) 1.47 at 20oC
safety measures shall be as per IS Solubility in water 0.7 % at 20oC
4263 latest edition Code of Safety
Odour Irritating, Bleach like Choking Odour
for Chlorine and IS 10553 (Part I)
1983 Requirements of Chlorination Others Soluble in alkali’s

equipment for its safe operations. Also according to the “Compressed Gas Cylinder Act” Specifications

Page 90 Page 91
Chlorine Content Min.V/V 99.8% 10. CHEMICAL SYSTEMS
Moisture 150 ppm Max. The following chemicals will be required as part of the pre- treatment process:

Residue on Evaporation Shall leave no residue when Table 30 Desalination Plant Chemicals List
evaporated on clean white tile
Chemical Name Chemical Use
Specification of Chlorine Tonner
Antiscalant  RO scale prevention
Water Capacity (approx.) Kg. 780
Carbon Dioxide  Post treatment for water stabilisation
Chlorine Capacity (approx.) Kg. 930
Chlorine Gas  Post treatment for disinfection
Design Pressure, Kg/cm2 19.9 (process & potable product waters)
Inside Diameter (approx.) mm 760  P i
Coagulant f di h hl i
Ferric Chloride
Shell Thickness, mm 10
Hydrated Lime  Post treatment for water stabilisation
Dished Ends Thickness, mm 9.6 (Min.)
Flotation Aid - Polyelectrolyte  DAF flocculation aid
Overall Length (approx.) mm 2085  Limewater clarification aid
Clarification/Filtration Aid -
Tare Weight (approx.) Kg. 620 Polyelectrolyte
Sodium Hydroxide  RO CIP
Valve Outlet 5/8”
 Preparation of sodium hypochlorite
Thread 14 tpi bsp (Caustic Soda)
solution
Sodium Hypochlorite  Shock dosing for intake biofilm control

(prepared from
Sodium Metabisulphite  Protection of RO from oxidants

 RO CIP
Sulphuric Acid  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

Page 92 Page 93
10.1 Antiscalant mixing will be achieved by other means. At this stage the type of antiscalant to be

Antiscalant is required to be dosed into the reverse osmosis system to manage the used has not been determined. This will be assessed at the next design stage.

formation of mineral scale on the surface of the membranes. Design parameters of

the antiscalant system are shown in Table below. 10.2 Carbon Dioxide

Carbon Dioxide is required to be dosed in association with Hydrated Lime for pH

Table 31 Antiscalant System Design Parameters
control and stabilisation of the permeate water. The chemical dosing design

Parameter Units Value parameters are summarised in Table 32.

Design RO system feed ML/d 1008 Table 32 Carbon Dioxide Dosing Design Parameters
flow rate
Carbon Dioxide Dosing Units Value
Antiscalant concentration % 100
Carbon Dioxide Dose Rate
Form of supply 1000 L IBC
Maximum mg/L 90
Dose rate mg/L 0.7
Average mg/L 60
Dosing point RO High Pressure
Carbon Dioxide Dose Average kg/hr 1085
Pump suction main
Carbon Dioxide Vessels Number Of No. 10
Antiscalant consumption kg/day 706
Capacity tonnes 25
Specific gravity of dosing 1.2
solution Carbon Dioxide Storage At peak flow days 6

Dosing flow rate of L/hr 25 Period

antiscalant Carbon Dioxide Storage At average flow days 9

Number of dosing pumps Duty No. 10 Period

Standby No. 5
10.3 Chlorine Gas
Dosing pump capacity L/hr 2.5 Chlorine is required for disinfection of the product water and for shock chlorination

Number of antiscalant storage tanks No. None – direct feed Chlorine will be supplied as liquefied gas in 900 kg drums. The unloading of
from IBC 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

It is not proposed to dilute the antiscalant as the flow rates involved can be easily be configured as a vacuum gas draw system with vacuum valves connected

dosed accurately and dilution can lead to degradation of the antiscalant. Adequate directly to the chlorine drums.

Page 94 Page 95
 10.4 Ferric Chloride

Design parameters for the proposed chlorination system are summarised in 33. Ferric Chloride is to be dosed to coagulate particles prior to Lamella Settler. The
design parameters are summarised in Table 34.
Table 33 Chlorination Design Parameters
Table 34 Ferric Chloride System Design Parameters
Parameter Units Value
Parameter Units Value
Chlorine for Disinfection of Potable Water
Design seawater flow ML/d 1110
Dose Rate Minimum mg/L 2
Ferric chloride concentration % w/w 42.6
Maximum mg/L 5
Specific gravity of dosing
Treated Water Flow Rate Nominal ML/d 408 1.45
Solution
Maximum ML/d 433.50
Dose rate Typical mg/L 16
Chlorine gas flow range Nominal kg/hr 37
Maximum Mg/l 25
Maximum kg/hr 91
Consumption at maximum
t/day 65.20
Chlorine Consumption Maximum kg/day 2170 flow

Chlorine Storage Dosing flow rate of chemical Typical L/hr 1900 L/hr.

Total Chlorine Consumption Maximum kg/day 2170

Chlorine Container Size
Maximum Number of Drums Online
On Site
Drum Storage Period
10.5 Hydrated Lime
kg 900
Lime will be supplied to site as hydrated lime (Ca(OH)2) and converted onsite to
No. 4 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
average days 20
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 35.

Page 96 Page 97
 Table 35 Lime Dosing Design Parameters Table 36 Flotation Aid Polyelectrolyte Dosing Design Parameters

Parameters Units Value Parameters Units Value

Design seawater flow ML/d 1110
Lime Properties Purity % 75
Poly Solution Strength Nominal % w/v 0.1 – 0.5
Utilisation of pure % 90
Dosing Location U/s of Lamella
component
U/s of DAF
Utilisation overall % 67.5% Dose Rate (per dosing Minimum mg/L 0.05
point)
Lime Dose Rate (Total) Typical mg/L 50 as Ca(OH)2
Maximum mg/L 0.25
Maximum mg/L 75 as Ca(OH)2 Average mg/L 0.1

Lime Consumption Average tonnes/day 32.2 t/day 10.7 Sodium Hydroxide

Maximum tonnes/day 48.20 t/day

Sodium hydroxide is required to neutralize acids used in the cleaning of the UF
Lime Silos Number Of No. 8 membranes and may also be used for cleaning of the RO membranes

Capacity of each tonnes 54 Table 37 Sodium Hydroxide Dosing

silo
Parameter Units Value
Lime of Milk % 4
Hydroxide concentration % w/w 50
Concentration
Specific gravity of dosing solution 1.53
10.6 Flotation Aid Polyelectrolyte
Storage Details
Polyelectrolyte is required to be dosed to assist with the formation of floatable flocs
in lamella clarifier the DAF process. The polymer will be dosed immediately prior to No. of Tanks No 1
each Lamella & DAF flocculation tank. The specific polymer to be used will be
Tank Volume ML/tank 3
determined during a later design stage. The dosing design parameters are
summarised in table 36

10.8 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

Page 98 Page 99
 may also be used for the RO CIP process. The sulphuric acid will be used to provide pH correction for optimum seawater

The redox potential (ORP) will be measured downstream of the dosing point to coagulation. In addition sulphuric acid is required for chemical enhanced

ensure that the dosing is effective. The sodium bisulphite design parameters are backwashing and cleaning of the UF membranes. The design parameters are

summarised in Table 38. summarised in Table 39.

Ventilation shall be provided to manage any fumes that may be evolved in the Table 39 Sulphuric Acid System Design Parameters
chemical area.
Parameter Units Value
Table 38 : Sodium (Meta)bisulphite System Design Parameters
Sulphuric acid concentration % w/w 98
Parameter Units Value
Specific gravity of dosing 1.84
Sodium bisulphite concentration % w/v 40 solution

Specific gravity of dosing solution 1.34 Seawater pH Correction

Dosing for RO Protection Design seawater flow ML/d 1110

Design seawater flow ML/d 1110 Dose rate Typical mg/L 35

Dose rate (as sodium metabisulphite) Maximum mg/L 30 Dosing flow rate of chemical Typical L/hr 500 L/hr.

Typical mg/L 15 Dosing point Seawater intake pipeline

upstream of coagulant
Dosing frequency / duration Assume 1 hours once per day (at
dosing.
time of intake shock)

Dosing point Upstream of high pressure pumps

No of Dosing pump 9 W+9 S 10.10 Miscellaneous Chemicals

This section covers miscellaneous chemicals used only for the purpose of cleaning
Capacity of each pump 350 L/hr
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)
General storage space only has been included for these chemicals because:
10.9 Sulphuric Acid

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  It will not be known until the first year (or two) of operation which of the 
Chemical storage and dosing facilities for the preparation of various cleaning
chemicals are required; solutions (typically includes Caustic Soda, Citric Acid, NaDDS, Sodium

 The chemicals are used infrequently (say once per year); and Bisulphite);

 When used, only small volume of chemical is used each time.


Recycling pumps;

The facility will be designed to meet the requirements of all of the chemicals that

Cartridge filter (typically 5 micron);
may be used. Between uses, the facility will need to be drained and flushed. 
Pipework allowing each RO train to be cleaned individually; and
Design details are provided in the following table. 
If required, holding tank to neutralise spent cleaning solution and enable
Table 40 Miscellaneous CIP Chemical Dosing System Design Parameters discharge to environment.

Parameter Units Value 10.10.2 Flushing

Dosing point RO CIP Tank After chemical cleaning and prior shutdown of membrane trains the brine and

Specific gravity of dosing solution varies 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
Number of dosing pumps Duty No. 1
corrosion.
Standby No. 1
The flushing system would consist of flushing pumps and pipework allowing each
Dosing pump capacity kL/hr 2
RO train to be flushed individually.
Number of tanks No. 2

Tank volume kL/tank 3

Chemical delivery volumes Multiple 1000L IBCs

10.10.1 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

features:

Make-up tank;

Page 102 Page 103

 12. WASTE MANAGEMENT
11. WATER STORAGE AND TRANSFER
12.1 Screenings

11.1 Process water storage Screenings will be flushed from the screens into wire baskets and the wash water
from the screens will be returned upstream of the screens, and the screenings will
Treated process water will be stored on site prior to being transferred to the city for
be disposed of to a municipal landfill.
consumption. The criteria for the storage tank are summarised below;

 Total usable storage volume 35,000 M3 12.2 Pre-Treatment Waste Water

 Number of units : 35 ML (2 hours storage for average flow), Waste Water will be generated in the pre-treatment system by the following

 Material of construction : RCC epoxy coating treatment units

 Tank geometry : to suit site hydraulics and cost optimisation, Lamella settlers – settled sludge.

DAF float
 Covered
Filter backwash from gravity dual media filters.
11.2 Process water transfer pump station

The design criteria adopted for design of the pump station is therefore as follows; All the discharges will be directed to the ocean via the outfall.

 Type of pumps : centrifugal variable speed drive,

12.3 Other Wastes
 Number of units : 6 duty, 3 standby

 Nominal pump station duty : 2800 m3/hr with no peaking, 12.3.1 Membrane CIP Wastewater

 Pump control : by level in the receiving tank,

The membrane CIP wastewater after neutralisation will be directed to the ocean via
 Positive suction at all times, the outfall, for the same a neutralization tank has been provided in the design.

12.3.2 Limewater Clarifier Waste

The waste from the limewater clarifier will be dewatered and trucked from the site
as a solid. The total provision for the same has been made in the potablization
area.

12.3.3 Domestic Waste - Sewage

Domestic sewage waste will be treated independently from all liquid other wastes.
A dedicated sewage treatment package plant will be used to treat this waste to a

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 standard suitable for re-use for irrigation or similar. For the same an STP is 13. SEAWATER OUTFALL
proposed within the plant premises.
13.1 Outfall Pipeline

The desalination plant will discharge rejected seawater concentrate and other
12.3.4 Spent Membranes
Spent membranes will be disposed of to a credited inert landfill. These will need to waste streams into the ocean via an outlet pipeline.

be rinsed with fresh water (or permeate) prior to disposal. The criteria adopted for Section 1 of the outlet pipeline are as follows;

 Peak Flow : 700 MLD,

 Diameter: 2400 mm ID RCC pipe
 Max working pressure (including water hammer allowance): 20m head,

Coastal currents flow from south to north from August to October and from north to
south from November to March each year. The currents from the south to the north
are stronger than the currents from the north to the south. For this reason the outfall
will be located to the north of the intake, as at Nemmeli. Consideration was given to
locating the outfall at about 700 m offshore, generally along profile 25 ( of Sea Bed
Sesmic), albeit at an angle to the profile. At 700 m offshore the seabed is about 7.5 m
below chart datum, and the sediment cover over the acoustic basement is about 6 m.
This site is considered an acceptable candidate site for a pipe jacked outfall

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.

13.2 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;

Page 106 Page 107

  Flow range @ peak : 700 MLD,
 Discharge temperature range: 0C > 3C above ambient, 14. POWER AND CONTROL
 Discharge salinity range: 32,500mg/l -34,500mg/l above ambient,
14.1 Power supply
 Target dilution: 5% above ambient salinity,
14.1.1 Background
 Water depth: > 5m with no surface expression of seawater concentrate jet,
The power supply arrangement for the desalination plant is based on provision of
 Diffuser material: rubber / EPDM,
two nos (2 nos.) 110 kV feeders from a substation next to the existing Neemlai
 Backflow prevention: In line rubber check valve at diffuser,
SWRO to be procured and operated by TNEB. There shall be two separate feeders
feeding to the 400 MLD modules. The estimated power requirement of the plant is
When the pipe jacked outfall has been constructed, a diffuser section will be attached to the 85MWe.
end of the conduit Sixty (60) diffusers, 200 mmm diameter, will be provided, 30 each side
of the pipeline at 5 m spacing, offset by 2.5 from the diffusers on the other side. The major areas for power demand are the seawater supply pumps, the RO
treatment plant and the process water transfer pump station.

It is planned to set up a 110kV outdoor receiving sub-station in the direction of

proposed TNEB Outdoor sub-station inside the 400 MLD SWRO plant. It is
proposed to draw the power requirement of 85MWe through 2x110kV Over-Head
Feeders from the proposed TNEB sub-station. The Over-Head Lines shall
terminate in the TNEB Metering Yard inside the periphery of 400MLD SWRO plant
boundary.

14.1.2 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;

Page 108 Page 109

  Energy losses; yard shall be equipped with Lightning arrestors, CVT, Isolators, CTs, Circuit

 Environmental impacts; Breakers and other hardware etc. as required. Each outgoing bay shall be
provided with 110kV/11.5kV, 40/50MVA transformers. The 11kV output of these
 Lifecycle costs.
Transformers shall be terminated on 11kV Indoor Switch-Board (4-Incoming
A level of security and redundancy will be determined for the reference design. Feeders, 3-Bus Couplers and approx. 20-24 Outgoing Feeders) located in the Main
The appropriate Indian Standards will form the basis for the design of electrical Receiving Sub Station (MRSS) building to further distribute the power to various
works including standards for: loads / load centers / sub stations at 11 kV / 0.433 kV through underground cables.
 Earthing The MRSS building shall be located adjacent to the proposed 110kV switchyard.

 Protection All protection and metering equipment of 110kV system outdoor switch yard shall
be installed in Relay and Control panel located in control room on the first floor of
 Switchgear, etc.
MRSS Building. Remote Tap Changer Control panels (RTCC) of 40/50 MVA
IEC Rules requirements will also be considered in the design.
transformers shall automatically regulate the Transformer input voltage. The RTCC

14.1.3 110 kV / 11 kV Substation within the Plant premises and 11kV (MV) Switchgear (receiving input supply from Transformer output) shall
be installed in the MRSS substation.
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 Medium Voltage (MV) shall be 11 kV, 3-phase, 50Hz and Low Voltage (LV) shall

water transfer pumps. The L.T supply shall be from HT Panels. This substation will be 433V, 3-phase & Neutral, 50Hz.

be a double bus bar Air/Gas Insulated System type built with the latest
14.1.4 Power Distribution
technologies, maximum operational safety and environmental friendliness
a. Medium Voltage (11 kV) Distribution System 
according to IEC 61850 and TNEB. Two incoming lines, coupler and four feeders
will be considered in the substation as minimum. The secondary of each power transformer shall be connected to 11kV, 3000A MV

Two transformers 110/11 kV, ONAN / ONAF, will be installed and it is necessary to switchgear in Main MV Switch Board through 11kV, 2500A MV bus duct.

consider civil works space for other two equal transformer (similar than Microprocessor based multifunction meters with RS 485 connectivity will be

considered). The capacity of one transformer will be enough to feed the total provided for metering system. Numerical protection relay with communication

demand. Besides, it will contain all common equipment, no-load compensation and capability will be provided for protective functions of various feeders. The energy

necessary maneuvers considering three feeders in 11kV from spare transformer as data of the various 11kV feeders and the input energy data will be passed on to

minimum. DCS for energy accounting and periodic report generation.

The estimated power requirement of the plant is 85MWe. Tamil Nadu Electricity The power from Main MV Switch Board in MRSS Building to plant loads shall be

Board (TNEB) has proposed to set up a 230/110kV Over Head Line Outdoor distributed via 11kV Switchboards located close to the electrical loads in different

Switch Yard Sub-Station at a distance of approx. 750mtrs away from the 400 MLD process departments through 11kV (UE) cables. The MV loads are basically 11kV

SWROD plant site. motors / pumps etc. and 11kV/433V Distribution Transformers.

The planned SWRO 110kV switch yard shall be equipped with two incoming line
bays, one bus coupler bay and four outgoing bays. The various bays of the switch

Page 110 Page 111

 To attain transformer standardization, the distribution transformers shall be of 1600
kVA, 2000 kVA and 2500 kVA sizes. Special transformers for variable speed drives
b. 11 kV Switchboards  
may deviate from the above standardization. The transformer capacity shall be
The other MV Switch Boards and distribution Transformers being fed from Main
selected within the above mentioned standard sizes and shall not be less than total
MV Switch Board (located in MRSS), shall be located in the following departments:
installed kW capacity of all LV loads connected to it.
 Intake Pump Station
To cater to LV load of approx. 14MWe, following capacities and quantities of
 Dissolved Air Floater & Dual Media Gravity Filter 11/0.433kV distribution transformers (considering 60% loading of transformers)
 RO Building have been envisaged:

 Potablization Unit  2500kVA : 10 Nos. (5 working + 5 standby)

 Product Water Tank  2000kVA : 10 Nos. (5 working + 5 standby)

 Any other  1600kVA : 8 Nos. (4 working + 4 standby)
The MV switchboards shall be assembled in a line-up of factory fabricated, metal Actual configuration of the transformer capacities and quantities to be chosen shall
clad cubicles with draw-out type truck-mounted circuit breakers. Vacuum Circuit depend on the detailed designing of the system and shall be optimized as the load
Breakers shall be used for incomers, bus couplers, outgoing distribution feeders details start getting finalized.
and motor feeders. Each switchgear shall have necessary metering, protection and
control functions to suit the application through multifunction composite
e. Power Control Centers (PCCs – LV Switch Boards) 
microprocessor based numeric relays having serial bus compatibility with plant
DCS based system. The departmental PCCs shall receive the power at 415V from the output of the
distribution transformer and further distributes power to various MCCs and
Auxiliary Distribution Boards. These PCCs shall have their own LV Capacitor
c. Low Voltage (433V) Distribution System 
Banks for automatic improvement of Power Factor. The PCCs shall be designed to
The power supply at 11kV shall be stepped down to 433V at various load centers guarantee selective fault isolation, isolating a faulty circuit from the main electrical
through 11/.433 kV distribution transformers and connected to LV Switch Boards system.
(PCCs) to cater to LV loads of the plant. The entire low voltage power distribution
system shall be designed to guarantee selective fault isolation, isolating a faulty
f. Motor Control Centres (MCCs) 
circuit from the main electrical system.
The MCCs shall receive the power at 415V from the output of PCCs and shall feed
various LV motors / pumps and other utility loads of a particular load centre. These
d. 11/ 0.433 kV Distribution Transformers 
MCCs shall have their own LV Capacitor Banks for automatic improvement of
3 Phase, Dyn11, mineral oil filled, ONAN, copper wound distribution transformers Power Factor.
complete with off load tap changers (OLTC) and all specified accessories shall be
Department wise intelligent MCCs controlling a group of interconnected and
considered to feed the low voltage loads at the respective departmental PCCs.
simultaneously operated loads during the process are envisaged, and shall be

Page 112 Page 113

 located in decentralized electrical rooms in the respective departmental sub-
stations / plant buildings.
Each feeder module of the MCC shall incorporate a mini-processor for serial bus
connectivity, and shall be connected to the CPU through daisy-chain serial data
link. Further, the MCCs shall comprise of all equipment for a safe remote control of
the different plant sections and consist of process power feeders only.
 
14.1.5 Power Factor Correction
For maintaining a high overall power factor, static / automatic power factor control
capacitor banks of suitable kVAR rating and voltage grades shall be considered, as
required.
In the envisaged scheme, suitably sized capacitors shall be directly connected
across the stator switch terminals of respective 11 kV MV motors, wherever
required.
For compensation of LV loads, multi-step Automatically Controlled Capacitor
Banks shall be installed for connection on the respective departmental PCCs and
MCCs to improve the power factor to 0.95 or above.
14.1.6 Electrical System Component
i. Drives
The type of drives considered shall be based on following requirements:
 Speed / torque characteristics of the driven equipment
 Enclosure protection depending upon the work environment
 Performance characteristics, i.e. high power factor and efficiency at
operating points
 Accuracy and range of speed control required for specific application.
All motors, generally above 250kW (>250kW) shall be connected at 11kV and
motors up to 250kW (<=250kW) at 433V.
Power saving equipment like Medium Voltage AC Variable Frequency / Speed
(MVAC) Drives (with converter transformers, wherever required) and Low Voltage
Page 114
AC Variable Frequency / Speed (LVAC) Drives shall be taken into consideration to
minimize energy costs as well as to achieve precise speed control.
ii. Illumination
An energy efficient illumination scheme for the process buildings shall be provided.
The illumination in process buildings shall be arranged by use of energy efficient
luminaries suitable for High Bay / Low Bay mounting depending upon the structure of
the building. Adequate lux level shall be maintained for safety and ease of plant
operation.
Sufficient number of lighting distribution boards shall be considered for automatic
control of lighting fixtures at the various locations of the plant.
Street Lighting shall be preferably on solar energy.
 
iii. Cabling
Overhead ACSR Panther Conductors have been envisaged from TNEB 230/110 kV
sub station to 400MLD SWROD Plant’s 110kV, 85 MW Switch Yard.
11kV Bus Ducts have been envisaged from the output of 31.5/40MVA Transformers
to Main MV Switch Board located in MRSS Building.
The cables from MV Switch Board in 11kV MRSS to various departments and further
to process building shall be through underground cables.
Following type of cables shall be used in the plant:
Power (MV) : 11 kV (UE) PVC sheathed XLPE insulated Aluminium cables
Power (LV) : 1.1 kV PVC sheathed XLPE insulated copper/Aluminium cables
Control : 1.1 kV PVC sheathed PVC insulated Cu cables 1.5 and 2.5 mm2
Instrumentation : 0.6 kV screened PVC insulated copper cables, 0.5 and 1.0 mm2
iv. Earthing/ Lighting Protection
System earthing and earthing of MV and LV equipment’s shall be considered for
safety of operating personnel as well as for proper operation as per the requirements.
Copper rod earth electrodes connected together with strip shall form the main earth
mat, which shall be interconnected together.
Earth continuity conductor shall be run along with major cable routes to provide
grounding to the equipment. Tall structures shall be protected against lightning by
Page 115
 use of horizontal mesh of conductors and vertical spikes. All the lightning rods,
lightning mesh wires and down conductors shall be of stranded copper.
A separate electronic earth mat and network shall be considered for DCS and other
associated control panels.
The Earthing values at 110kV, 11kV & 433V sub-stations shall be <0.5 ohm and for
433/230V in home shall be < 1 ohm. Earthing Rod Depth shall be minimum 3M and
maximum 6M and the material shall be MS Bar, MS rod and MS Flat.
The System Fault Level value at 110kV TNEB s/s is considered as 5000 MVA for
design purposes.
v. Fire Suppression System
There shall be automatic Fire Suppression System for 11kV and 433V Panels and
Cable Ducts.
14.1.7 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 VSD’s will be
provided for large motors (>400 kW).
14.1.8 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.
14.1.9 Electrical Equipment
Electrical equipment design will be in compliance with IEC Standards.
Page 116
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.
14.2 Control System
14.2.1 General Design Criteria
The control system for the desalination plant will be compatible with the overall
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;
Page 117
  Uninterruptible power supply (UPS) provided to all critical items (instruments,
control systems and telecommunications systems with a one hour battery back-
up with emergency power supply to UPS’s 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.
14.2.2 Plant Operation Methods
The following aspects of the plant operation will be taken into account in the design
of the control system, alarm system, supervisory system and system
communications.
 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.
14.2.3 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
Page 118
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
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.
14.2.4 Off Site Communication
The minimum design requirements of the control system for off-site communication
will be:
 The control system will communicate the water transfer system parameters and
alarms to the mine control system to enable the mine operators to monitor the
transfer system parameters & alarms;
 The water transfer parameters will also be viewable though the PCS at the mine
processing site. The transfer pumps can only be controlled from one location at
any time.
Page 119
Distributed Control System comprising of programmable controllers and operator stations
with peripherals shall be considered for remote operation of plant from a Central Control
Room (CCR).
Separate control rooms shall be considered for the 110kV Switchyard and the water
treatment plant.
1 Plant Control System
For sequential control of drive and supervision of various process variables, distributed
microprocessor based control system shall be considered.
2 Process Instrumentation
An elaborate instrumentation comprising of field sensors, transducers etc. shall be set
up for monitoring of processes.
The Control system envisaged shall incorporate following essential features for safe
operation of plant & machinery and provide necessary operating data to evaluate the
plant performance and fault monitoring:
 Client/ server configuration for easy configuration and maintenance.
 Programmable controllers for sequence interlocking and automatic closed loop
control through PI and PID action.
 Serial bus connectivity for MCC, Drives, Sub-controls and MV Drives.
 Operator stations with colour graphic and alphanumeric display with equipment
fault monitoring system and plant remote control.
 Process optimization system to achieve improved process stability.
 An engineering station, which shall provide engineering tools to update PLC,
programmes.
 An energy management system for control and monitoring of electrical energy.
 MIS station, which shall generate reports and provide process mimics as well.
The control system shall be structured as under: -
a. Level – I (Field level)
At field level the instruments and sensors shall be installed in accordance with
process requirements. For certain systems e.g. mills, silos, weighing systems etc.
sub-control systems shall be allocated in the field.
b. Level – 2 (Department Control level)
Programmable controllers with input / output devices shall ensure safe operation of
machines and supervise production processes.
c. Level – 3 (Supervisory level)
Page 120
In the Central Control Room, four operator stations with supervisory processor visual
display unit, keyboards, etc. for efficient man/ machine interface for the remote
operation on the plant.
The functions of operator level PCs shall be as under:
 Sequential interlocks for group starting and stopping.
 Analogue signal processing by real time acquisition of plant process parameters
for monitoring of process and safety of equipment.
Necessary field sensors shall be installed to monitor process variables like pressure,
temperature, flow, level, speed etc. The sensors shall be linked to Plant Control
System through field transmitters / transducers to display the parameters on Operation
Station and exercise the desired controls. The broad technical features of sensors and
instruments are described below:
a. Temperature, Pressure, Diff. Pressure, Flow and Level Transmitter
Transmitters shall be employed for measuring of pressure, temperature and flow at
various locations in different utilities of the plant.
Smart Transmitters shall be used which shall be configured, calibrated and tested
from the Control Room itself. Transmitters shall provide very high accurate values
and shall have robust field housing. The transmitter shall preferably have serial bus
connectivity for interface with plant DCS system.
b. Pyrometers
For temperature measurement in hot zones, non-contact type radiation pyrometers
shall be used. Pyrometers shall include air purging and water-cooling arrangements.
c. CCTV
CCTV’s wherever required, shall be employed at strategic locations. The cameras
shall be provided with air purging and water-cooling arrangements.
d. Level Sensors
RF admittance type sensors for point level control and for continuous level ultrasonic
/ electromechanical type of instruments shall be used.
Special designed level sensors shall be deployed for monitoring and control of water
levels, wherever required.
e. Speed Switches
These shall be deployed to achieve zero speed protection for various equipments.
The unit chosen shall have built in initial by-pass time delay and designed to operate
over a range of speed. The primary sensor shall be non-contact type designed to
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 achieve unlimited number of operations. The unit as well as sensor shall have a high
degree of environment protection.
3 Intercommunication Equipment
15. CIVIL, BUILDING AND STRUCTURAL WORKS
A Public Address System with paging and party facility for CCR operator to contact the
field operator and vice versa shall be considered in order to facilitate plant operations. 15.1 Plant Buildings

For administrative purpose and inter-departmental communication, a telephone

exchange shall be considered which shall also supplement the public address system. 15.1.1 General
4 Fire Alarm and Detection System The desalination plant will include the following buildings:
Fire detection of fires in electrical buildings, cable cellars, switchgear rooms and control
 Intake Pump House
rooms etc., suitable designed detectors shall be installed. Multi zone type fire alarm
panel shall be deployed for audio-visual alarm.  DAF (Dissolved air flotation) building
5 Uninterrupted Power Supply  Dual Media Gravity Filters Building
Separate UPS systems shall be planned at CCR and local control rooms to provide
 RO Plant Building (inclusive of Cartridge Filters pressure vessels, booster and
power to microprocessor-based sub controls, process instruments etc. The capacity of
UPS shall be chosen to cater to such loads and to have some spare capacity as well. HP pumps and energy recovery);
The battery bank shall be NI-Cd design, capacity of which shall be chosen to provide
 Administration and Control Building;
adequate backup time. 
 Chemical Dosing Buildings;

 Chlorine Building;

 Workshop;

 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.

Page 122 Page 123

 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.
15.1.2 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.
15.1.3 Lifting Devices
Lifting devices will be included in the design where necessary. These will include
electrically operated Cranes (EOT’s) 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.
15.2 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.
Page 124
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.
15.3 Site Services
All electrical and communication services will be located in suitable underground.
Site pipework will be buried where feasible.
15.4 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.
15.5 Fire Systems
Fire services will be compatible with the requirements of Health, Safety and
Environment and relevant standards.
Page 125
 sufficient distance below the hydraulic grade line, i.e. a certain minimum pressure

16. PRODUCT WATER MAIN is maintained in the pipe. Hence, for closed conduits the hydraulic grade line
slopes according to the head loss.
Sound planning dictates the standard design criteria in the planning and design of
Therefore, pipe sizing is based upon taking consideration of following factors:-
pumping/ transmission mains. Pipelines are designed in accordance with the
 Quantum of flow ( Q in m³/s)
maximum anticipated flow conditions; hence pipelines need to be sized to carry
 Fluid velocity (V in m/s)
water during these events without excessive pressure losses.
 Pressure (m in terms of water column)
 Head loss (m in terms of water column)Pipe material
A water transmission system is the physical works that deliver water from the water
 C-factor (Hazen-Williams coefficient of friction dependent on pipe material)
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 The governing equation is given by,
achieved by way of pumps and motors, water mains, service pipes, storage tanks D= [4*Q/(π*V)] 1/2
or reservoirs, and related equipment, Where,
in a closed system under pressure. D= Internal Dia. Of pipe (m)
The transmission main is normally Q= flow (m³/s)
designed for the carrying capacity V= velocity of fluid (m/s)
needed to supply water demand on
the maximum consumption day at a Transmission by pumping is applied in cases when the water has to be transported
constant rate. All hourly variations in over large distances and/or to higher elevations. The pumping head is the total
the water demand during the day of head, and comprises the static head plus the friction head loss for the design flow
maximum consumption are then rate. The pump to be selected must be able to provide this head at rated flow.
assumed to be evened out by the
service reservoir. The head loss corresponding to the design flow rate can be computed for several
pipe diameters using Modified Hazen William Equation.
A water system has two primary requirements: First, it needs to deliver adequate h = [L (Q / CR) 1.81]/ (994.62*D4.81]
amounts of water to meet consumer consumption requirements plus needed fire CR = pipe roughness coefficient
flow requirements. Second, the water system needs to be reliable; the required D = internal diameter of pipe in m;
amount of water needs to be available 24 hours a day, 365 days a year. h = friction head loss in m;
L = length of pipe in m; and
In a pipe unlike the free-flow, the hydraulic gradient and not the slope of the
Q = flow in pipe in m3 / s
conduit will govern the flow. The hydraulic laws of closed conduit flows, also
Each combination of the pumping head and corresponding pipe diameter should
commonly called pressurized flows, apply in the design of the same. Pressurized
be capable of supplying the required flow rate over the required distance, and up to
pipelines can be laid up- and downhill as needed, as long as they remain at
the service reservoir. Smaller pipe diameters will require a higher pumping head to

Page 126 Page 127

 overcome the increase in head losses, and the other way round. As a result, one
Based on historical performance, life expectancy and durability, the use of cement
pipe diameter will represent the least cost choice taking into account the initial
lined and bitumen lined, and coated DIP and fittings will provide an excellent
costs (capital investment), maintenance costs and the energy costs for pumping.
conveyance mechanism for all segments of the proposed transmission main for the
The total cost, i.e. the capitalized taking both capital and operational cost as the
portions considered for open cut construction.
least and economical, shall be the basis for selecting the most economical pipe
diameter. Therefore, pipe sizing is based upon engineering standards for In selecting the most appropriate pipe material for the said scheme/project the
acceptable energy (i.e. friction loss = loss of pressure) loss related to the intended following consideration shall be made:
use of the pipe transmission main.
 The ground conditions along the pipeline route, mainly conditions such as
For this analysis, the
traffic overload, proximity to sewer lines, and crowded residential areas.
calculated costs for
 The cost and local availability of different types of pipe
different pipe sizes
shall be are plotted  the design pressure in the distribution system

as in a graph shown  assess the performance of the pipe material in terms of

as side. Therefore,
when the capital cost o Durability,
and the operation o Resistance to Chemical Attack,
cost are added the o Corrosion and Abrasion. (Suitable external and internal coating shall be made and
concave up curve is if required cathodic protection).
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 above aspects are considered in conjunction with the cost of procurement and
installation to provide the most economical solution.
The most economical pipe diameter will tend to be large when energy costs are
Ductile iron and steel are the strongest pipe materials, making them the best
high, unit costs of pipe low and capital interest rates low. Nevertheless, it should
choice when very high operating pressures are to be expected. These pipes are
not be forgotten that a larger pipe means lower velocity, i.e. potential water quality
almost impossible to tap without special tools and equipment, which is an
problems. As a preliminary estimate, the range of possible most economic
advantage in cases where illegal connections pose a real threat for the urban local
diameters can be selected based on velocities around 1.0-1.8 m/s.
body. However, the costs of fittings, valves, etc. increase rapidly for higher pipe
The materials of construction available for construction of large diameter water pressure classes and it is therefore often advisable to reduce the maximum internal
transmission main segments include the following alternatives: pipe pressure through the provision of a pressure reducing valve or break-pressure
 Ductile iron pipe (DIP) tank/ intermediate pumping. A break-pressure tank is generally more reliable than
 Pre-stressed Concrete Cylinder Pipe (PCCP) a pressure reducing valve.
 Carbon Steel In spite of higher investment costs, ductile iron pipes are a better alternative than
 High Density Polyethylene pipe (HDPE) cast iron pipes because they have a longer service life, are lighter and more

Page 128 Page 129

flexible and require hardly any maintenance. The pipe is practically corrosion equal to 1.1 m shall be DI with internal CC lining and outside fusion bonded epoxy
resistant due to coatings applied inside and outside. Moreover, this pipe material coating as per IS 8329.
may be subject to scale bursts when tapped without sufficient skill. Alternative
The water pumped from the proposed facility shall be conveyed to existing or new
materials are in this case High-density polyethylene (PE).
ground storage tanks for further distribution in the city. This shall be confirmed in
High-density polyethylene (PE) is a very suitable pipe material for small-diameter the interim stage, when all surveys are in place.
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 Water:
elbows and bends, the flexible PE makes for an ideal pipe material. Polyethylene Product water Mild steel (IS 2062,plate fabricated) with mortar lining
does not deteriorate when exposed to direct sunlight. Conventional jointing of the inside and fusion bonded epoxy /polyurethane/epoxy
PE-pipes may cause leakage and welding is considered to be a better alternative. coatings on exposed surface (above 1100 mm
However PE pipes greater than 1600 mm diameter are not commercial available in diameter of pipe),
the local market, hence is a big constraint in selecting the said pipe material for
Ductile iron pressure pipes and fittings (Class K9)
commercial use when the diameter requirement is above 1600mm OD.
shall comply with IS 8329 and IS 9523 (Upto 1100
To summarize, for pipelines of small-diameter (less than 300 mm) PE may mm Diameter of pipe).
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
large-diameter 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

Page 130 Page 131

16.1 Annexure
option- option- option- option- option- option- option- option- option-
S.No. Particulars Formula/Symbol Unit option-i option- ii option-v option-vii option-x option-xi
iii iv vi viii ix xii xiii xiv xv

16.1.1 Pipe sizing and pump capacity for 550 MLD A 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
Capacity 550.00 MLD
6.37 M³/S 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

Design
LENGTH 60000 M A.4 Td deg.C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Temperature
C 0.8 -
kg/sqcm
TOTAL STATIC HEAD (ΔH) 6 M A.5 Allowable stress Sa 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
(g)
PIPE MATERIAL (MS) IS 2062
Corrosion
A.6 allowance for C 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
carbon steel

Weld joint
A.7 efficiency for J 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
REQUIRED PUMP ERW pipes
ACTUAL STATIC
CALCULATED DIA SELECTED HEAD INCLUDING SELECTED
DESIGN VELOCITY UNIT VELOCITY (Q/C)^1.81 994.62 D^4.81 HEAD
(ø M) DIA (ø M) MINOR LOSS (10 %) PUMP HEAD (M) y factor (as per
(M/S) (ΔH) HEAD IN
IN 'M' A.8 ASME B31.1 table y 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
Kg/Cm² 104.1.2(A))
1 M/S 2.846947987 2.9 0.96 42.69 994.62 167.5461 6 15.37 22.91 23.00 2.346
1.1 M/S 2.714458399 2.8 1.03 42.69 994.62 141.524 6 18.20 26.02 27.00 2.754 Minimum Tc = ((Dp x OD x
1.2 M/S 2.598896054 2.6 1.20 42.69 994.62 99.08817 6 25.99 34.59 35.00 3.57 A.9 calculated pipe 0.1)/(2 x (y x Dp + 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
thickness Sa x J)) + C) x 10
1.3 M/S 2.496938563 2.5 1.30 42.69 994.62 82.05243 6 31.39 40.53 41.00 4.182
1.4 M/S 2.406110204 2.5 1.30 42.69 994.62 82.05243 6 31.39 40.53 41.00 4.182 Mill negative
1.5 M/S 2.324523298 2.4 1.41 42.69 994.62 67.42424 6 38.20 48.02 49.00 4.998 A.10 tolerance for pipe M % 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
thickness
1.6 M/S 2.250710005 2.3 1.53 42.69 994.62 54.94281 6 46.88 57.56 58.00 5.916
1.7 M/S 2.183509431 2.2 1.67 42.69 994.62 44.36629 6 58.05 69.86 70.00 7.14 Minimum required
1.8 M/S 2.121989743 2.2 1.67 42.69 994.62 44.36629 6 58.05 69.86 70.00 7.14 wall thickness T* = Tc / ( 1 -
A.11 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
(after considering (M/100))
1.9 M/S 2.06539315 2.1 1.84 42.69 994.62 35.47111 6 72.61 85.87 86.00 8.772 mill tolerance)
2 M/S 2.013096227 2.1 1.84 42.69 994.62 35.47111 6 72.61 85.87 86.00 8.772
2.1 M/S 1.964580755 2 2.03 42.69 994.62 28.05138 6 91.81 107.00 107.00 10.914 Selected
thickness of pipe
2.2 M/S 1.919411941 2 2.03 42.69 994.62 28.05138 6 91.81 107.00 107.00 10.914 A.12 (based on internal Ts mm 20 20 17.2 17.2 17.2 17.2 16 16 16 16 16 16 16 14.2 14.2
2.3 M/S 1.877221912 1.9 2.25 42.69 994.62 21.9182 6 117.51 135.26 136.00 13.872 load thickness
2.4 M/S 1.837697024 1.9 2.25 42.69 994.62 21.9182 6 117.51 135.26 136.00 13.872 calculation)

Page 132 Page 133

 Capacity 275.00 MLD
3.18 M³/S

LENGTH 60000 M NOTE

C 0.8 - 1 TWO PIPES EACH ACCOMODATING 275 MLD , THE ENTIRE SYSTEM (2 x 275 MLD ) COMPRISING 4W + 2S
TOTAL STATIC HEAD PUMPS. REFER SCHEMATIC DIAGRAM PROVIDED IN THE SHEET.
(ΔH) 6 M
PIPE MATERIAL (MS) IS 2062

REQUIRED PUMP
ACTUAL SELECTED HEAD
CALCULATED SELECTED STATIC HEAD INCLUDING
DESIGN VELOCITY UNIT VELOCITY (Q/C)^1.81 994.62 D^4.81 PUMP IN
DIA (ø M) DIA (ø M) HEAD (ΔH) MINOR LOSS (10 %)
(M/S) HEAD (M) Kg/Cm²
IN 'M'

1 M/S 2.013096227 2.1 0.92 12.18 994.62 35.47111 6 20.71 28.78 29.00 2.958
1.1 M/S 1.919411941 2 1.01 12.18 994.62 28.05138 6 26.18 34.80 35.00 3.57
1.2 M/S 1.837697024 1.9 1.12 12.18 994.62 21.9182 6 33.51 42.86 43.00 4.386
1.3 M/S 1.76560219 1.8 1.25 12.18 994.62 16.89899 6 43.47 53.81 54.00 5.508
1.4 M/S 1.701376842 1.8 1.25 12.18 994.62 16.89899 6 43.47 53.81 54.00 5.508
1.5 M/S 1.643686187 1.7 1.40 12.18 994.62 12.83687 6 57.22 68.94 69.00 7.038
1.6 M/S 1.591492307 1.6 1.58 12.18 994.62 9.589967 6 76.59 90.25 91.00 9.282
1.7 M/S 1.543974326 1.6 1.58 12.18 994.62 9.589967 6 76.59 90.25 91.00 9.282
1.8 M/S 1.500473337 1.6 1.58 12.18 994.62 9.589967 6 76.59 90.25 91.00 9.282
1.9 M/S 1.460453502 1.5 1.80 12.18 994.62 7.030706 6 104.47 120.92 121.00 12.342
2 M/S 1.423473994 1.5 1.80 12.18 994.62 7.030706 6 104.47 120.92 121.00 12.342
2.1 M/S 1.389168374 1.4 2.07 12.18 994.62 5.045171 6 145.59 166.15 167.00 17.034
2.2 M/S 1.3572292 1.4 2.07 12.18 994.62 5.045171 6 145.59 166.15 167.00 17.034
2.3 M/S 1.327396343 1.4 2.07 12.18 994.62 5.045171 6 145.59 166.15 167.00 17.034
2.4 M/S 1.299448027 1.3 2.40 12.18 994.62 3.532381 6 207.94 234.73 235.00 23.97

16.1.2 Pipe sizing and pump capacity for 2 X 275 MLD

Page 134 Page 135
 option- option- option- option- option- option- option- option- option- option- option- option-
S.No. Particulars Formula/Symbol Unit option-i option- ii option-v
iii iv vi vii viii ix x xi xii xiii xiv xv
A Pipe sizing based on internal design pressure
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

Design
A.4 Td deg.C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Temperature
kg/sqcm
A.5 Allowable stress Sa 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
(g)
Corrosion
A.6 allowance for C 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
carbon steel
Weld joint
A.7 efficiency for J 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
ERW pipes
y factor (as per
A.8 ASME B31.1 y 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
table 104.1.2(A))
Tc = ((Dp x OD x
Minimum
0.1)/(2 x (y x Dp
A.9 calculated pipe 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
thickness + Sa x J)) + C) x
10
Mill negative
A.10 tolerance for M % 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
pipe thickness

Minimum
required wall
T* = Tc / ( 1 -
A.11 thickness (after 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
considering mill (M/100))
tolerance)
Selected
thickness of
pipe (based on
A.12 internal load
Ts mm 20 20 17.2 17.2 17.2 17.2 16 16 16 16 16 16 16 14.2 14.2
thickness
calculation)

16.1.3 Pipe size and pump capacity for 400 MLD

Page 136 Page 137

 Capacity 400.00 MLD option- option- option- option- option- option- option-
S.No. Particulars Formula/Symbol Unit option-i option- ii option-v option-vii option-x option-xi option-xii option-xv
4.63 M³/S iii iv vi viii ix xiii xiv

A Pipe sizing based on internal design pressure

LENGTH 60000 M
C 0.8 - A.1 Selected pipe ID ID mm 2500 2400 2300 2200 2100 2000 2000 1900 1900 1800 1800 1700 1700 1700 1600
TOTAL STATIC
HEAD (ΔH) 6 M 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
PIPE MATERIAL
(MS) IS 2062 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
Design
A.4 Td deg.C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Temperature
kg/sqcm
A.5 Allowable stress Sa 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
(g)
REQUIRED
ACTUAL STATIC PUMP HEAD SELECTED Corrosion
CALCULATED DIA SELECTED HEAD IN A.6 allowance for C 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
DESIGN VELOCITY UNIT VELOCITY (Q/C)^1.81 994.62 D^4.81 HEAD INCLUDING PUMP
(ø M) DIA (ø M) Kg/Cm² carbon steel
(M/S) (ΔH) MINOR LOSS HEAD (M)
(10 %) IN 'M' Weld joint
A.7 efficiency for ERW J 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
pipes
1 M/S 2.427885401 2.5 0.94 23.99 994.62 82.052429 6 17.64 25.40 26.00 2.652
y factor (as per
1.1 M/S 2.314897901 2.4 1.02 23.99 994.62 67.424242 6 21.46 29.61 30.00 3.06 A.8 ASME B31.1 table y 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
104.1.2(A))
1.2 M/S 2.216346002 2.3 1.11 23.99 994.62 54.942813 6 26.34 34.97 35.00 3.57
Tc = ((Dp x OD x
1.3 M/S 2.129396361 2.2 1.22 23.99 994.62 44.366288 6 32.62 41.88 42.00 4.284 Minimum
0.1)/(2 x (y x Dp
A.9 calculated pipe 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
1.4 M/S 2.051937677 2.1 1.34 23.99 994.62 35.471112 6 40.80 50.88 51.00 5.202 + Sa x J)) + C) x
thickness
10
1.5 M/S 1.982360129 2 1.47 23.99 994.62 28.051383 6 51.59 62.75 63.00 6.426
Mill negative
1.6 M/S 1.919411941 2 1.47 23.99 994.62 28.051383 6 51.59 62.75 63.00 6.426 A.10 tolerance for pipe M % 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
thickness
1.7 M/S 1.8621031 1.9 1.63 23.99 994.62 21.918197 6 66.03 78.63 79.00 8.058
1.8 M/S 1.809638933 1.9 1.63 23.99 994.62 21.918197 6 66.03 78.63 79.00 8.058 Minimum required
wall thickness T* = Tc / ( 1 -
A.11 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
1.9 M/S 1.761373197 1.8 1.82 23.99 994.62 16.89899 6 85.64 100.20 101.00 10.302 (after considering (M/100))
mill tolerance)
2 M/S 1.716774231 1.8 1.82 23.99 994.62 16.89899 6 85.64 100.20 101.00 10.302
Selected thickness
2.1 M/S 1.675400097 1.7 2.04 23.99 994.62 12.836875 6 112.74 130.01 131.00 13.362
of pipe (based on
2.2 M/S 1.636880004 1.7 2.04 23.99 994.62 12.836875 6 112.74 130.01 131.00 13.362 A.12 internal load Ts mm 17.2 17.2 17.2 16 16 16 16 16 16 16 16 14.2 14.2 14.2 14.2
thickness
2.3 M/S 1.600900225 1.7 2.04 23.99 994.62 12.836875 6 112.74 130.01 131.00 13.362 calculation)
2.4 M/S 1.567193288 1.6 2.30 23.99 994.62 9.5899671 6 150.91 172.00 173.00 17.646

Page 138 Page 139

 Capacity 150.00 MLD
1.74 M³/S

LENGTH 60000 M NOTE

C 0.8 - 1 ONE PIPE ACCOMODATING 150 MLD , THE ENTIRE SYSTEM WILL COMPRISE 3W + 2S PUMPS. REFER
TOTAL STATIC HEAD (ΔH) 6 M SCHEMATIC DIAGRAM PROVIDED IN THE SHEET.
PIPE MATERIAL (MS) IS 2062

REQUIRED
ACTUAL STATIC PUMP HEAD SELECTED
CALCULATED SELECTED DIA
DESIGN VELOCITY UNIT VELOCITY (Q/C)^1.81 994.62 D^4.81 HEAD INCLUDING PUMP
DIA (ø M) (ø M)
(M/S) (ΔH) MINOR LOSS HEAD (M)
(10 %) IN 'M' HEAD IN
Kg/Cm²
1 M/S 1.486770097 1.5 0.98 4.06 994.62 7.030706299 6 34.88 44.36 45.00 4.59
1.1 M/S 1.417579666 1.5 0.98 4.06 994.62 7.030706299 6 34.88 44.36 45.00 4.59
1.2 M/S 1.3572292 1.4 1.13 4.06 994.62 5.045170546 6 48.60 59.46 60.00 6.12
1.3 M/S 1.303983636 1.4 1.13 4.06 994.62 5.045170546 6 48.60 59.46 60.00 6.12
1.4 M/S 1.256550073 1.3 1.31 4.06 994.62 3.532380874 6 69.42 82.36 83.00 8.466
1.5 M/S 1.213942701 1.3 1.31 4.06 994.62 3.532380874 6 69.42 82.36 83.00 8.466
1.6 M/S 1.175394966 1.2 1.54 4.06 994.62 2.403597776 6 102.02 118.22 119.00 12.138
1.7 M/S 1.140300611 1.2 1.54 4.06 994.62 2.403597776 6 102.02 118.22 119.00 12.138
1.8 M/S 1.108173001 1.2 1.54 4.06 994.62 2.403597776 6 102.02 118.22 119.00 12.138
1.9 M/S 1.078616395 1.1 1.83 4.06 994.62 1.581607864 6 155.04 176.54 177.00 18.054
2 M/S 1.051305217 1.1 1.83 4.06 994.62 1.581607864 6 155.04 176.54 177.00 18.054
2.1 M/S 1.025968838 1.1 1.83 4.06 994.62 1.581607864 6 155.04 176.54 177.00 18.054
2.2 M/S 1.002380195 1.1 1.83 4.06 994.62 1.581607864 6 155.04 176.54 177.00 18.054
2.3 M/S 0.98034717 1 2.21 4.06 994.62 1 6 245.21 275.73 276.00 28.152
2.4 M/S 0.959705971 1 2.21 4.06 994.62 1 6 245.21 275.73 276.00 28.152

16.1.4 Pipe size and pump capacity for 150 MLD

Page 140 Page 141
 option- option- option- option- option- option- option- option- option- option-
S.No. Particulars Formula/Symbol Unit option-i option-iii option-iv option-x option-xi
ii v vi vii viii ix xii xiii xiv xv

A Pipe sizing based on internal design pressure

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
Design
A.4 Td deg.C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Temperature
kg/sqcm
A.5 Allowable stress Sa 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
(g)
Corrosion
A.6 allowance for C 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
carbon steel
Weld joint
A.7 efficiency for ERW J 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
pipes

y factor (as per

A.8 ASME B31.1 table y 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
104.1.2(A))

Minimum Tc = ((Dp x OD x
A.9 calculated pipe 0.1)/(2 x (y x Dp + 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
thickness Sa x J)) + C) x 10

Mill negative
A.10 tolerance for pipe M % 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
thickness

Minimum required
wall thickness T* = Tc / ( 1 -
A.11 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
(after considering (M/100))
mill tolerance)

Selected
thickness of pipe
A.12 (based on internal Ts mm 20 20 17.2 17.2 17.2 17.2 16 16 16 16 16 16 16 14.2 14.2
load thickness
calculation)

Page 142 Page 143

17. 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 144
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 145
18. COMMISSIONING PLAN  Describes the structure and necessary requirements of the Commissioning
Documents;

18.1 Purpose of the Plan  Shows how Occupational Health & Safety issues are addressed explicitly within the
Commissioning Work Packs, procedures and work method statements; and
The Overall Commissioning describes the methods and processes to be used by the
contractor during the commissioning phase of the project. The associated activities 18.3 GLOSSARY OF TERMS
include preparation of documentation such as ITPs (Inspection and Test Plan),
Component Smallest element of the plant identified for
procedures, work method statements and ITRs (Inspection and Test records),
commissioning (e.g.: pump, blower)
construction verification, pre-commissioning, commissioning, hand-over and training. CP Commissioning Program
CPU Control Processing Unit
This document covers the whole Desalinated Water Supply System and its constituent
ESS Electrical SCADA System
parts.
FAT Factory Acceptance Test
FD Functional Description
18.2 Objectives
DCMP Design & Construction Management Plan
The objectives of this plan are to ensure that: DRMP Document Records Management Plan
 There are no safety incidents or environmental non-conformances; ITP Inspection and Test Plan
 All aspects of commissioning are planned and prepared in advance; ITR Inspection and Test Record
 The commissioning proceeds in an integrated, planned and organised manner; JSEA Job Safety & Environmental Analysis
 The plant provides water as fast and as efficiently as possible; and MSDS Material Safety Data Sheet
 The Commissioning Test requirements of the Commercial Milestones are PCS Plant Control System
achieved. PMS Plant Management System
SSMS Security Site wide Management System

The Overall Commissioning Plan: Sub-System A collection of Components which act together to effect a
process (eg: a single DMPF including valves, instrumentation
 Defines the organisational structure, roles and responsibilities for the & control, a single RO rack including pumps, valves,
Commissioning team; instrumentation & control)

 Lays out the process for planning, controlling and reporting all commissioning System A collection of Sub-Systems which act together to effect a
process (eg, Pre-treatment Stream 1 consisting of backwash
tasks; system, backwash effluent system, 24 DMPFs, etc)
 Sets out the Work Breakdown Structure to be used for commissioning; V&V Verifications and Validations
 Describes how Quality Assurance documentation (Check Lists, Inspection and Test WBS Work Breakdown Structure
Plans, Non Conformance Reports) will be developed, reviewed, approved,
monitored in progress and completed;
 Gives the format for the various commissioning documents that must be produced
and describes the tasks to be performed: procedures, and ITRs;

Page 146 Page 147

18.4 Organization and Roles

Due to RO Plant size, the commissioning organisation is structured to allow efficient

commissioning of multiple streams of equipment, simultaneously where possible:

 This is certainly possible within the process streams themselves (Pre-treatment and
Reverse Osmosis: Streams 1& 2);

 The HV power supply is treated as a separate asset for commissioning due to its scale
and its non-redundant nature;

18.5 Phased Commissioning Management Structure

The organization of commissioning activities is based on with:

 A preparation phase where dedicated teams develop the Commissioning Work Packs
(all documentation required for the activities to be done after, mainly Commissioning
Procedures, Test.) by process areas (Pre-Treatment, RO, and Potabilization) with
other concurrent preparation tasks handled separately.

 An execution phase where the “stream logic” mentioned above is followed.

18.6 Commissioning Scope: Lifecycle and Interfaces

Before any commissioning task can commence, relevant key activities of Construction
must be completed in the areas relevant to the concerned Components, Sub-Systems or
Systems. Hand-overs between different stages will be the occasion to carry-out thorough
defects inspection, the concept being to have major defects rectified before the next
involved party starts work.

All temporary construction material and equipment will be removed to allow the
Commissioning Team to take over the designated areas/facilities.

The “Commissioning Lifecycle” diagram below illustrates the different phases of

commissioning, outlining on the left the hand-over stages, in the middle the key steps with
their outputs and pre-requisites and on the right, the responsible functions. Commissioning Lifecycle

Page 148 Page 149

 Commissioning stage/
Definition
The following table outlines the various commissioning stages and activities of the activity

commissioning phase: System testing System is described as a number of sub-systems being combined.
From the example above, a system would be the integration of the
two sub-systems to become the ferric sulphate pre treatment
Commissioning stage/
Definition chemical system.
activity
Process commissioning Process commissioning is defined as the integration of the systems
Factory Acceptance Testing of equipment off site at the point of manufacture prior to
contained within a facility or plant area. Using the above example the
Testing delivery to site. The items to be FAT will be nominated in the Scope
ferric sulphate system would be integrated with the other pre
of Work document in the Procurement Package.
treatment chemical dosing systems
Construction Verification Construction verification stage is defined as a series of checks and
Plant integration Plant integration is defined as the integration of all facilities or plant
inspections of all civil structures, mechanical equipment, pipework
areas that make up the desalination plant.
and fittings, electrical equipment, instrumentation and control
equipment to ensure construction and installation is in accordance
with contractual specifications. Testing will include: point to point
tests, pressure and leakage testing of pipework, leak testing 18.7 Commissioning Process & Interfaces Management
vessels/structures. Testing will use temporary hydraulic/electrical
power and temporary seawater and freshwater supply except for
In order to adequately plan the commissioning activities, the Commissioning Manager will
concrete structures that will be tested with potable water. (This work
is performed by the construction team with commissioning monitoring liaise closely with the relevant area / discipline manager during the Construction,
the work) Energisation and Pre-Commissioning stages. Some of the issues to be co-ordinated are
Pre-Commissioning–Dry Pre-Commissioning–Dry stage is defined as activities undertaken to as follows:
test the functionality of all components making up the asset system;
for example, testing motors, pumps, checking valves open and close.
Testing will use installed hydraulic/electrical power  Status of installation, inspection and equipment documentation;
Pre-Commissioning– Wet Pre-Commissioning–Wet stage is defined as operating an asset
 Anticipated components and sub-system work completion dates;
without chemicals in accordance with approved commissioning
sessions to verify the design criteria as detailed in the Engineering  Priorities from commissioning perspective;
Design Report
 Process of acceptance and hand-over of component and area to the Commissioning
Component testing Component testing will be undertaken as part of pre-commissioning Team;
and commissioning and will include supplier factory works testing and
onsite testing and checks. For each component, the commissioning  ‘Permit to Work’ system and requirements;
team will verify that all required checks have been carried out, with
 Defects to be rectified before and after hand-over.
acceptable results. These checks will be carried out prior to system
commissioning. The Commissioning process is an integrated approach between process equipment and
Sub-system testing Sub-system is described as a number of components which interact systems as well as related Control Systems. Those different phases are part of the same
and are connected; mechanically, hydraulically or electrically. An process and cannot be separated. The main phases of the commissioning will correspond
example of this would be the loading system for the ferric sulphate
pre treatment chemical, or the dosing system of the ferric sulphate. A in the Commissioning Lifecycle to the following 4 main steps:
sub-system test demonstrates the interaction of the components.

Page 150 Page 151

 1) Construction/Energisation deliver the below mentioned items fully installed (all piping
(i) Factory Acceptance Testing included) and wired.
‐ All instruments (line mounted, panel mounted, stand pipe mounted...);
Works Flows and Procedures per Systems should reflect the activities and be aligned with
‐ All valves (pneumatic and electrical);
the V&V Plans for PCS, PMS, ESS and SSMS.
‐ All mechanical equipment;
PLC/SCADA Hardware FAT ‐ All panels (fields and rooms);

The panel mounted PCS PLC hardware is subject to FAT prior to issue to site ‐ All field accessories (OLM, I/O racks ...);
construction for installation. This test covers: ‐ All field wiring network cables, FO;
‐ All interconnecting cables including Power.
 Visual inspection of cabinet for finish, labelling, colour;
2) Energisation performs all pre-energisation tests (220 VAC, 24VDC) (continuity, cables
 Power up of the cabinet. Check of power and earthing, and apply power;
isolation/earthing...) to allow the release of the Notice of Energisation.
 I/O testing for each point. Test each hard point by signal injection and monitor it;
Within each energisation ITP, a Commissioning and/or Control System witness point will
 Redundancy testing for each paired device. Run a test program and withdraw the duty
module to confirm fail over to the standby module. be defined.

The Reports of the steps 1 and 2 above should be combined in the Hand-over certificates
PLC/SCADA Software FAT
issued to Commissioning for each item of equipment installed on site. The final state of
The device FAT is a functional test for each I/O point, to confirm the link from the hard I/O any devices, network, Systems.etc should be that all above have been completely
through to the software library block. performed prior to start the Pre-Commissioning activities.

One ITR will be issued per component, tagged with a bar code and inserted in the
The individual PLC/SCADA software is subject to FAT against the Functional Descriptions
Commissioning Management System.
documents. This test is from the I/O software block, through all functions of the logic
described in the Functional Description. (iii) Pre-Commissioning Testing (Site)
 The Pre-Commissioning-Dry corresponds to the final Energisation of components
Following successful individual PLC/SCADA software FAT for each PLC on the system, including Bump Tests, some additional “no Load Run Test” of components and the SAT
the PLC/SCADA system is pre-tested as a complete system down to CPU level prior to activities of the control system such as:

release for site installation. 1) PLC Specifics

‐ Local System Hardware and Communication Network SAT;

(ii) Installed Condition Testing (Site)
‐ I/O SAT;
The Installed Condition Testing includes the hand-over with Construction of each
‐ Devices SAT;
component of the plant. As described in the Lifecycle the hand-over is managed via two
interfaces: Construction for the mechanical scope and Energisation for the electrical ‐ Integration SAT: PCS to Vendor System Test.

scope. 2) Site Wide Specifics

‐ Hardware and Communication Network SAT.

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  The Pre-Commissioning-Wet includes all load tests and verifications described in each
System/ Sub-System ITP (Inspection and Test Plan) as well as the testing of the
automation sequence – SAT (Sequence) - (whether by simulation or in real conditions).
All Pre-Commissioning activities must have been successfully completed for each
relevant system, sub-system and component before commissioning activities are
commenced.
(iv) Commissioning Testing
The Commissioning Testing only occurs once all components are tested; the control
system is operational and mainly consists of putting the plant in operation under normal
process conditions and is called Process Commissioning in the Lifecycle. All tests and
verification to validate the Process Commissioning are described in each System / Sub-
System ITP.
The following schematic explains the above:
Commissioning Work Flows outline the sequence of all activities showing all inputs, outputs, interfaces and
responsibilities.
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18.8 Interface between D&C and O&M
18.8.1 Interface between Commissioning and O&M
The O&M Team shall work closely with the Commissioning Team throughout
commissioning.
Initially, new plant operators will work under the authority of the Commissioning Manager
and attend commissioning activities. As system commissioning progresses, the O&M
team will progressively take over the operation and maintenance of the plant under the
direction of the Commissioning Manager.
The Commissioning Manager and the O&M Plant Manager will determine and agree on
O&M personnel mobilisation and a training program to ensure the continuity of the ramp-
up phase between commissioning and pre-operations.
During Acceptance tests, the Commissioning Team will direct the plant operators on
process issues and be responsible for adequate performance of the tests.
By being involved from the start to the completion of the commissioning and interim-
operation phases, the O&M personnel will receive extensive experience in the range of
activities related to sub-systems and overall systems operation. The O&M team will take a
major role in running the overall plant during the commissioning and interim-operation
periods and until Final Acceptance Test.
Page 155
 system or manually when Check-Points are considered satisfactory by the Commissioning
Engineer in charge of the package.
19. COMMISSIONING MANAGEMENT SYSTEMS
The Management System will allow to link all Commissioning documents (ITPs / ITRs)
19.1 Work Breakdown Structure (WBS)
with the P&IDs tag numbers and to track progress of the commissioning efficiently and
Commissioning activities, for big RO Plant shall be structured into Area, Systems, Sub- accurately.
Systems and Components. Pre-commissioning and commissioning commence at the The Management System can generate commissioning documents automatically per
Component level. A number of commissioned components are brought together and Commissioning System / Sub-Systems using existing templates or manage external
commissioned as a Sub-System. Multiple Sub-Systems are brought together and documents.
commissioned as a System and multiple Systems are brought together and
19.3 DOCUMENTATION
commissioned as an Area.
The above activities will be separate and the WBS divided into two parts:

19.2 Programming  PRE-COMMISSIONING WORK PACKS,

 COMMISSIONING WORK PACKS.
Scheduling of commissioning tasks, tracking and reporting completion of tasks shall be
They shall be organised under exactly the same architecture and will just be the 2 parts of
performed entirely using a detailed commissioning programme.
the same System / Sub-System testing. This should allow better visibility and avoid having
The Commissioning Program shall be developed with sufficient detail to identify individual very large Documentation Packs.
types of resource. Pre-commissioning and commissioning of components, Sub-Systems
and Systems are multidisciplinary. A single Component, Sub-System or System may
19.3.1 PRE-COMMISSIONING DOCUMENTATION
require all the commissioning disciplines at different stages of the commissioning process.
This means that in many areas the programme will break down to tasks which may only i) Pre-Commissioning-Dry
take a few hours. This is necessary to identify the individual resources so that tasks can This phase mainly consists of the hand-over of the COMPONENTS from Construction to
be assigned and tracked. allow Energisation and/or Bump Tests.
Every component has a mechanical input and an electrical input managed through 2
This will provide sufficient detail to track tasks for individual types of resource down to the interfaces, as described in the Commissioning Lifecycle. The Commissioning Team will be
actual day within each commissioning area in charge of checking that the components are ready to be energised or bumped and
receive this information from:
19.2.1 COMMISSIONING MANAGEMENT SYSTEM  CONSTRUCTION: for the mechanical scope. Construction will issue a hand-over
certificate by component where all tasks must be reported as completed, as per
The Core document of the Commissioning Management System is the ITP. There shall be
Commissioning minimum requirements:
one ITP per Sub-System and an overarching ITP per System. The ITP will follow all the
 Anchoring;
steps described in the Commissioning procedure defined for each System and / or Sub-
 Piping Connection;
system.
The ITPs shall be integrated and managed in the Commissioning Management System  Alignment;

either by being automatically updated when an ITR is signed-off and registered in the  Belt tensioning;

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  Greasing (motor / Equipment);  Pre-Energisation checks;
 Lubrication (oil filling);  Receive FAT certificate from supplier;
 Packing / mechanical seal (lubrication system).  Power-up the field panel;
This can be validated through a joint inspection on site and the hand-over certificate,  Verify hardware addressing within the panel.
summarising all Construction Test Sheets and will be scanned and registered in the 3. Network SAT:
Commissioning Management System.  Fiber Optic testing;
 ENERGISATION: for the electrical scope. The Energisation Team is performing all the  DP/PA loop tests (Profibus);
Pre Energisation checks:  software addressing verification;
 Loop Tests / continuity Tests;  NOE registration for the control power of each individual component (on that network);
 Glanding check;  Field control network verification of MCC networks to components (with control power
 Earthing; only);
 Isolation Test (including motor);  Field control network verification for VSDs;
 Motor Connection;  Field control of DP devices network (analysers...);
 Motor Connection tightness;  Field control of PA devices network (Instrumentation...);
 VFD / starter connections (when applicable);  Network redundancy checks.
 Motor Protection setting. 4. Discrete I/O Testing:
Once all verifications are done, the component can be energized and once the  Registration of all components ITRs (= Hand-over certificate).
energisation is achieved, the Commissioning Team becomes the “owner” of the  component information tests back to SCADA (based on I/O list):
equipment. ‐ Components to Field panel;
Each System will have an ITP with all components to be tested, and the ITP will refer to 2 ‐ Field panel to SCADA.
standard Procedures 5. Functionality Tests:
 one for ELECTROMECHANICAL equipment; and  Device functionality tests;
 one for INSTRUMENTATION.  Interlocks Testing.
ii) SAT (I/O)
For each System / Sub-System an ITP will describe all steps and all local system
This part is still a COMPONENT testing phase and will allow validation of all information
hardware/ communication networks and field devices to be tested. ITRs generated by the
and functionalities of a component from the field device up to the SCADA. This activity is
Commissioning Management System or external documents (Suppliers FAT reports) will
closely linked to the Pre-Commissioning-Dry of the components and some steps will
be linked to the steps of the ITP.
require the Pre-Commissioning-Dry to be fully completed and documented.
A standard Procedure for SAT shall describe all test activities among which the main
steps can be summarized as follows:
1. PLC Power-up & associated tests.
2. Field panels Power-up & associated tests:

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19.3.2 COMMISSIONING DOCUMENTATION
i) Pre-Commissioning-Wet & Process Commissioning
20.
Each System described has one or several reference Process Commissioning
20.1
Procedures. Based on the Commissioning Procedures, ITPs are developed for each
System and each Sub-System and shall list all testings or verifications described in the
procedure.
 
Each step can be associated with an ITR in case records of the tests have to be archived
or are just check points that a Commissioning Engineer will validate manually in the
Commissioning Management System.
ii) SAT (Sequence)
The SAT (Sequence) consists of verification of every step of the Functional Descriptions
(FDs), as done during the Control Systems FAT, but in real conditions with all field
components connected, energised and operational.
An ITP will cover those activities to relate all components to the different FDs and
completion will be reported and registered into the Commissioning Management System.
19.3.3 RECTIFICATION OF DEFECTS
At each hand-over step (component hand-over or Area hand-over) a punch list will be
generated by Construction. The punch list will differentiate Major defects (“A” items on the
punch list) and minor defects (“B” items on the punch list).
The Commissioning Team shall review the punch list and agree on the major & minor
items definition. No component or Areas will be accepted with “A” items outstanding.
Punch list “B” items will be registered and monitored in the Commissioning Management
System. Construction will be able to close out “B” items while Commissioning activities
are continuing under a Commissioning work permit
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COMMISSIONING STRATEGY
RO Plant Overall Commissioning Strategy
Unit 1: DMFs & Backwash
The first System to be started will be the DMF area. For this equipment, two main
activities will need to take place as early as possible:
 DMFs media loading (which requires a preliminary bubble test of the filter nozzles);
 Media Backwash (to remove dust and impurities from the media bed and get the
filters ready for production).
These 2 activities are time consuming and their duration cannot be shrunk by adding
resources. Thus it is important to start as soon as possible using temporary arrangements
if necessary.
This operation will require the biggest scope of temporary works, including:
 Temporary power source and electrical panel with equipment starter;
 Temporary blower (at least for bubble Test);
 Temporary Compressed air to operate the valves.
Nevertheless, implementation of temporary means is limited to a certain extent (feasibility/
cost / time) and some minimal requirements have been defined:
 Backwash Tanks & Backwash Effluent Tanks;
 Permanent Backwash pumps; and
 Permanent piping for Backwash Water / Effluent Water / scour air.
Unit 2: DMFs Feed Pumps
The target is to anticipate and complete as many Pre-Commissioning-Wet activities to get
the entire DMFs (including feed) fully operational, when seawater is available from the
Sea Water Lift Pumping Station. Two main actions may be performed with potable water
available from the hydrotest:
 DMFs Feed pump testing;
 DMF Pre-Commissioning-Wet.
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 These 2 units will be wet commissioned when the 1st line of RO is in operation and
For each task, temporary arrangements have been defined and are under development:
process commissioned by still returning water to the outfall.
 Temporary return loop from DMF Feed pumps discharge manifold to Screen & Feed
channel;
Unit 5: Transfer / Disinfection
 Temporary return loop from DMF filtrate to Screen & Feed channel.
Commissioning activities for Treated Pumps Station (TPS) / Treated Water Storage
Unit 3: Seawater / RO / Sludge
Tanks (TWST) will have to be coordinated with Distribution Line activities.
Pre-Commissioning-Wet of the Reverse Osmosis process can only start when Sea Water
TPS and TWST can be commissioned in a closed loop, without needing any temporary
is available, due to both process requirements (risk to the membranes if chlorinated water
arrangements (already included in the design).
is introduced in the racks) and safety (high pressure doesn’t allow work on temporary
arrangements). Beginning of the water pumping through the Pipe distribution will require a detailed and
For the beginning of Pre-Commissioning-Wet of RO racks (including rack flushing and specific procedure validated.
membrane loading) the full loop from seawater inlet to cartridge filters will have to be fully
operational, including: 20.2 Seawater Lift Pump Station
 Seawater lift pumping station; The Seawater Pump Station and associated equipment is commissioned once the entire
 Screening; system is completed and flooded with seawater from the intake. Once the pump station is
 Lamella Settlers flooded, each pump will be commissioned, discharging to the outfall.
 DAF
Once the first pump is satisfactorily tested, the water will be sent to the plant while testing
 DMF feed;
the others. It is then possible to commence process commissioning. The pumps will
 DMFs;
operate automatically to provide feedwater to the process. Testing of automated dosing
 Cartridge filters;
systems with water will also occur.
 Outfall;
 Sludge building.
20.3 Pre-Treatment
As soon as seawater is available the plan is to run the Pre-Treatment to reach water
quality compatible with RO process, returning pre-treated water to the sea. As the DMFs Lamella Settler Construction Verification

will start to produce sludge, the sludge building is necessary in order to treat the waste     Dimensional verification
from the filters.
After construction is finished at least some dimensional checks need to be carry on,
Until Seawater availability, RO Commissioning will progress mainly by simulation tests of
mainly related with the correct levelling of the weirs, the right position of the plates and the
the rack automations.
chain sprocket etc.

Unit 4: Potabilisation     Pre-Commissioning-Dry

This mainly consists of Lime Filters & CO2 as disinfection will only be done just before the
Basically related to all pre-commissioning activities of the ancillary equipments of the
water is ready to be sent through the Distribution Line.
system (sludge penstock, plates, intake value system), including in this phase the I/O test

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 Pre-Commissioning-Wet and Process Commissioning
Once seawater is available, the Settler can be filled to be able to test, mainly the
sequence. One the SAT has been undertaken with positive results and the chemical are
available, the process commissioning will be undertaken. Water quality parameters will be
monitored to ensure correct performance of the settling system.
DAF Construction Verification
    Dimensional verification
After construction is finished at least some dimensional checks need to be carry on,
mainly related with the correct levelling of the weirs, the right position of the nozzles and
the holes size and position in the false floor.
    Pre-Commissioning-Dry
Basically related to all pre-commissioning activities of the ancillary equipments of the DAF
(sludge penstock, pressurization pump, vacuum system), including in this phase the I/O
test
 Pre-Commissioning-Wet and Process Commissioning
Once seawater is available, the DAF can be filled to be able to test, mainly the sequence.
One the SAT has been undertaken with positive results and the chemical are available,
the process commissioning will be undertaken. Water quality parameters will be
monitored to ensure correct performance of the flotation system.
DMF Construction Verification
 Bubble test
Prior to loading of media, all DMF vessels/concrete tanks must have a bubble test
performed to ensure that nozzles are correctly fitted and undamaged.
A bubble test requires that the filter is filled with water to a few centimetres above the top
of the nozzles and air introduced via the air scour system. The escape of air from the
nozzles is observed and should be uniform across all the nozzles. A damaged or
dislodged nozzle will flow far more air and be clearly evident.
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A temporary blower if required will be connected to the existing air scour header to supply
air for the test.
    Media washing (off-site)
The gravel under-bed, sand and anthracite will be pre-washed by the supplier before
drying, grading and packing for shipment.
    Media loading and washing
The filter media will be washed using fresh water or seawater, depending on seawater
availability. Backwash effluent will be collected in the effluent tanks and will be processed
by the sludge line if ready or by temporary sedimentation / filtration plant before being
returned to the backwash tank for reuse. Coagulant will be used in the temporary filtration
plant. The dust and fines will settle in the effluent tanks and will be disposed off site using
a tanker, under the tanker owner’s license.
Once the gravel and sand are loaded, they will need to be backwashed with fluidisation to
remove any residual dust and move the fine at the surface of the filtering bed. Fines at the
surface will then be removed by skimming. It is estimated that around 10 mm of the
filtering bed has to be removed.
Anthracite will be loaded and backwashed with the same arrangements. Suspended
solids will be removed through the backwash effluent drainage, as for a normal DMF
backwash.
Pre-Commissioning-Dry
The electrical and control system commissioning will be performed when the electrical
room is completed and all equipment connected. At this stage each component will be
tested individually.
Pre-Commissioning-Wet
The DMF pump feed tank will be filled with seawater. A bypass pipe will link the DMPF
filtrate outlet to the outfall. Each filter can be individually tested, fed from the DMF feed
pumps and with outlet returned to the DMPF feed pump inlet channel. All individual
components (valves, instruments) will be checked. Backwash equipment will be tested in
automatic mode in accordance with the Functional Description. Each sequence will be
checked to ensure correct operation.
At this stage, DMFs, backwash, maturation and filtration can be tested as a system.
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 Process Commissioning
Once seawater, outfall and pre-treatment chemicals are available, process commissioning
of Pre-Treatment will be undertaken. At this time the sludge system will be available to
receive the backwash effluent.
Once seawater pumps and chemical dosing are available and tested, DMF operation will
be optimised with the filtered water directed to the outfall. Quality parameters will be
monitored and once water quality is suitable for RO and operation is stable, filtered water
will be diverted to the RO. At this stage, a disinfection of the Pre-Treatment components
and RO pipelines through the spiling line will occur using Sodium Hypochlorite.
Meanwhile, Sodium Bisulphite injected at the overflow of the backwash tanks will
neutralise any excess of residual chlorine.
20.4 Reverse Osmosis
Cartridges Filters
Cartridge Filter loading will be carried out as soon as Cartridge Filters have been flushed
with seawater to remove any remaining dust. As soon as the Pre-Treatment water quality
is good enough and stable, the CF will be flushed 2 by 2 until all CF of a stream have
been flushed and are available for cartridge element loading. The Pre-treatment water
quality should be as:
 SDI < 3 – 4 max;
 TOC (mg/l) < 2 mg/l;
 Turbidity (NTU) < 0.2 – 0.5 max;
 Free iron (mg/l) < 20mg/l.
Once the loading of the first 2 CF is complete, the rack flushing can proceed prior to
membrane loading.
The pre-treated water quality should be stable for at least 3 days to allow the following:
 Filter has to be filled up with water and the air released from the casing before opening
the water outlet valve.
 C.F. has to be draining water by the vents for at least 1 hour before opening the water
outlet valve.
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As soon as the Cartridge Filters are in service, time, flow and differential pressure has to
be monitored in order to schedule a replacement of the cartridges inside the casing.
Reverse Osmosis
First, the membrane Flushing sub-system has to be commissioned with clean water
(either de-chlorinated water or demineralised water) from the First pass permeate tank. In
parallel, the CIP sub-system will be commissioned using the same clean water and
recirculating through the pipework. All tanks, pumps and boilers will be individually tested
prior to testing the entire CIP and Flushing process.
The neutralisation tank will be commissioned by recirculating potable water from the
sump, through the pumps and back to the sump.
Prior starting the 1st pass RO HP pump, the cooling water sub-system needs to be
commissioned to provide cooling water for the HP pumps. Potable water will be used on
both sides of the Cooling system until process water is available.
Once process commissioning of the DMF is completed, optimised and stable; pipework
and racks are flushed; loading of the membrane is complete, the Pre-Commissioning-Wet
of the first 1st pass RO rack will start. A number of steps are required to correctly
commission the rack:
 Fill the rack with pre-filtered seawater to verify loading (Low pressure test)
 Pass filtered water at low pressure (without starting the HP pump) across the
membranes for a time long enough to flush out the preservatives.
 Start up the RO rack system and operate with permeate diverted to off spec.;
 Once the permeate quality stabilises, record combined and individual vessel permeate
conductivities. Compare to design data.
The detailed procedure includes the following:
 Pipe and rack flushing;
 Membranes loading;
 Energy recovery devices performance monitoring;
 Booster pumps performance monitoring;
 High pressure pumps performance monitoring;
 Uncoupled motor sequence testing (Tune PID regulation loops);
 Identify PV internal leaks, by checking the Conductivity of each individual pressure
vessel and remedy (Conductivity mapping);
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  Adjust the process to obtain the required performance (Rack/Train performance)
20.5 Potabilisation
The dosing points, instrumentation and associated controls will be initially commissioned
using clean potable water.
It is necessary to sanitise all piping downstream of the hypochlorite dosing points. A
procedure will be developed, setting out how the disinfection will be carried out prior to
use of the pipework. This procedure will describe mainly:
Secondly, the chemical dosing system of the RO will be commissioned: Antiscalant, And
finally, the chemical dosing system for the Potabilisation will be commissioned:
Limestone, CO2, Sodium Hypochlorite, and polymer.
Sludge dewatering system
The sludge treatment system will be wet commissioned with clear water and then process
commissioned when DMF start producing backwash water.
Centrifuges shall be commissioned by the vendor.

 Chemical dosing (contact time, initial concentration, rate of residual chlorine);

20.7 Utilities
 Disposal of water after disinfection (neutralisation if required);
The utilities servicing the entire plant such as:
 Quality water monitoring.
 Compressed air system;

20.6 Rest of Plant  Fire fighting system;

Chemical Dosing Systems  Service water;

Chemical dosing systems will be commissioned using potable water. Since these use  Potable water.
common storage and feed systems, all dosing equipment must be commissioned before Shall be commissioned as standalone units, the energisation of the networks through the
the system is drained, cleaned, dried in some cases, and charged with chemical. Control plant will be developed in conjunction with Construction/ Energisation teams in line with
loops, sequences and regulation will be tested and proved. the readiness of the Plant Systems.

In the specific case of Sulphuric Acid, the calibration cylinder only will be filled with water 20.8 POWER
to commission the system without sending water through the lines. The complete system
20.9 Main Power Supply
will be dried before acid is allowed to be introduced.
General

Chemical dosing pumps will all be commissioned. Dosing delivery pipes will be Commissioning activities shall commence after the completion of the construction

disconnected after the pumps skid and water pumped return to the storage tank. activities including completed QA documentation required for the satisfactory hand-over to

After establishment of appropriate licenses and operating permits and installation of the commissioning team.

suitable barriers to safely segregate the chemical storage and handling facilities, the One of the most import elements is the earthing, earth grid installation and testing to

chemicals tanks will be filled.
First, the chemical dosing system of the Pre-treatment will be commissioned. The
chemical dosing system for the Sludge treatment system will also be commissioned in
order to be ready for the process commissioning of the DMF.
ensure that the installation is in accordance with the design documents and provides the
appropriate level of safety to the personnel and the public when the system is energised
and in service.

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The commissioning process shall be performed in accordance with the procedures,
inspection and test plans and check sheets. All testing and inspection records will be
captured for each step of the process and be recorded in the Commissioning
Management System.
Primary Equipment Testing
The primary testing shall be performed to the various items of equipment in accordance
with the design requirements and the manufacturer’s instructions. These tests will vary
depending on the item of equipment but shall generally involve the following:
 Insulation Resistance Testing;
 Continuity/ Resistance Testing;
 High Voltage With Stand Testing;
 Voltage/ Current Injection Testing;
 Operation, Timing and Function Testing.
Secondary Equipment Testing
The secondary testing shall involve continuity testing of the low voltage protection circuits
and the secondary injection of the protection relays.
The continuity testing of the low voltage protection circuit shall be performed to ensure
that the installation has been installed to the design documents. This also identifies any
faulty connections or design errors in the circuit design.
The secondary injection testing of the protection relays shall be performed to ensure that
each element of the protection has been tested to ensure compliance to the design
documents.
Inter-trip Testing
The inter-trip testing will combine the completed primary and secondary testing to ensure
that the required tripping circuit breakers operation and timing is achieved in accordance
with the design documents.
This testing ensures that a trip from one location operates the appropriate circuit breaker/s
in other locations. This testing will also prove the circuit breaker fail to trip protection.
Page 170
Energisation
Upon the satisfactory testing of the above items and in accordance with the approved
operating protocols the energisation of the system can be achieved. The initial
energisation shall be performed to an approved procedure. At the completion of the
energisation procedure, power will be available at the Wonthaggi Sub-station.
Post Energisation and Load Testing
During and after the energisation process there will be a number of tests performed to
ensure that the system and components are operating satisfactorily and are in-
accordance with the design requirements.
20.10 HV/LV Electrical Systems Energisation
Earthing testing will basically comprise the following:
1. Ensure everything is properly grounded by carrying out earth continuity testing on all
installed earths that are connected prior to power up. For each power up of a system
the Main Earths running from the main MCC/Switchgear to a field device will be
continuity tested either by point to point testing or “meggering” the supply cable. This
test will be conducted from the main point of supply.
2. The final test will be a Earth Loop Impedance Test, where a maximum resistance
reading will be met,
The more detailed framework that the afore mentioned test results will sit in will be as
follows:
The earthing backbone will be terminated to the area being readied, for hand-over to the
energisation team. Prior to hand-over the following steps will take place:
 Earth continuity and resistance checks will be carried on all final sub circuits
requesting to be energised.
 All resistance values per test will be recorded and entered onto a cable check sheet,
signed off by the relevant Installation Supervisor/Project Engineer and entered into the
Systems/Area work pack.
 All Earth Loop Impedance tests to be carried out in the afore mentioned method..
 Lightning Protection testing will be carried out as a point to point test with the
measurement being between the top of the Dynasphere to the down conductor’s
relevant earth stake/ground connection.
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 Lightning protection results will be recorded and entered onto the relevant test sheets
and then entered into the Systems Area work pack.
 All the relevant installation and testing ITPs will be signed off and entered into the
Systems/Area work pack.
 Once the Test Result Sheets and ITPs have been received from Construction the
documentation will then be reviewed and approval by Quality prior to energising.
Page 172
21. OCCUPATIONAL HEALTH AND SAFETY
Management of OH&S risks during commissioning shall be completed in accordance with
the OH&S Management Plan in order to achieve the same standard of safety as during
the other phases of the D&C project.
Risk Assessment & Management shall also follow the same standard in order to:
 Plan and implement hazard identification and risk assessment to ensure all OH&S
risks are identified and assessed;
 Develop and implement control measures that will control or eliminate hazard/risk.
21.1 Access Control
To ensure the safety of all personnel, access to commissioning activities and nearby
areas shall be tightly controlled. Ownership of an area containing components to be
energised or commissioned will transfer to the Energisation or Commissioning Manager
(respectively) upon acceptance of handover from the Area Construction Manager.
This handover will be evidenced by placement of demarcation (clearly labelled fencing,
bunting, tape, etc as deemed appropriate and as agreed by the Construction Area
Manager and Energisation/Commissioning Manager) around the perimeter of the area
handed over.
Post demarcation, a Commissioning Access Permit will be required each day (from either
the Energisation or Commissioning Manager) to enable access within the demarcated
area for that day.
Upon completion of Commissioning, the demarcated area shall be handed over to control
of the O&M Manager.
Specific OH&S procedures will be developed for all high-risk commissioning activities,
including electrical energisation.
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  Site Rules/Requirements Induction Training  Ability to work on site
(O & M Plan)
22. TRAINING  Safety  Work Protocols

 Environment  Training Records

22.1 General
 Vendor Equipment Manuals  Factory Instruction

FAT’s
Training for Commissioning team members, including the O&M team is fundamental to Off
 Vendor Training Documents Special Equipment  Operators
Site
achieving quality test results. Training management and co-ordination is the responsibility Training
 Special Training Equipment  Maintenance Personnel
of the Commissioning Manager. The documenting and recording of the training is the
 Commissioning  Commissioning Records
responsibility of the Commissioning Completions Manager. Documentation

A Training Plan shall be developed for the training of Commissioning (as required on
 Vendor Equipment Manuals Vendor Training Major  Classroom & Field
equipment, control systems, etc) and O&M personnel in the operation and maintenance of Equipment Instruction
 Vendor Training Documents
the plant. This plan will cover the technical and operator training provided by the D&C  Operators

Pre-Commissioning-Dry /
Pre-Commissioning-Wet
 Special Training Equipment
contractor for the commencement of operations.  Maintenance Personnel

 Operation Manuals
The level and extent of training will be dependent on a number of factors and will include: ‘Operational Readiness’  Classroom & Field
 Operation Training Training Instruction
Documents
 Level of competency of operators and maintenance personnel.  Operators
 Commissioning Training
 The maintenance philosophy for the plant (i.e. extent of maintenance to be done by  Maintenance Personnel
O&M personnel and that outsourced to external providers/vendors).  Plant Operating Philosophy

 Control System Navigation  No-load Plan Operation

Simulation Training
 Plant Start/Stop  Operators On Site
22.2 Training Philosophy
 Plant ‘Up-sets’  Ready to Introduce
Training shall be conducted over a number of completion phases of the project including FEED

FATs, pre Pre-Commissioning-Dry, Pre-Commissioning-Wet and Process  Plant Feed  Product

Operational Training
Commissioning. The early mobilisation of operations and maintenance personnel will  Processing Consumables  Ramp-up to 100%

Plant Integration
Training Capacity
enable familiarity with the plant through participation with the commissioning team in the
 Sampling
commissioning and plant start-up phases. This ‘hands on’ training becomes the informal
training whilst the ‘formal’ training will be addressed by the Training Plan and will consist
of both class room and field training. The early mobilisation will also permit the necessary
vendor training to be conducted at the time of commissioning specific equipment.

The development of the Training Plan will require the strategy for the operation and
maintenance of the plant to be understood. This strategy will be developed using the
equipment list and /or the procurement package list and will be recorded in a simple
spreadsheet. This strategy will also be used in the development of the O&M Manual.

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23. APPROACH AND METHOD STATEMENT FOR OPERATION AND 23.1.3 Flow monitoring
MAINTENANCE OF A RO PLANT Various water flow rates will be measured continuously with online flow meters for internal
process operating and contractual purposes. The flow rates that shall be monitored are:
The Methodology to be followed for the Operation and Maintenance Equipment in a Build-  The seawater flow coming from seawater intake pumping station
Design & Operate contracts is based on a procedure that will secure the final results of  The flow located at the inlet of the Reverse Osmosis.
process and assets management of the plant.  The flow measured at the inlet of the permeate tank.

23.1 MOBILIZATION PLAN & START-UP OF THE OPERATION AND MAINTENANCE 23.1.4 Analytical parameters monitoring

The Mobilization Plan will be set in order to ensure that the staff and organization are fully Analytical parameters shall be monitored continuously with online analytical instrument,
ready to take control of the RO Treatment Plant at the Commencement Date. To fulfill the and also over Spot samples. This continuous monitoring will ensure that all performance
objectives the following steps will be achieved. requirements are met and that the RO Plant operation is optimized.

In order to fulfill the analytical monitoring and to perform a suitable operation, the following
23.1.1 Follow-up of the works and plant start-up analysis parameter should be considered (either online either through manual sampling):
 Participation in co-ordination meetings, HAZOP (if any), on-site tests and controls;
 Experience sharing and technical advice to the constructor;  Seawater inlet
 Raw water quality characterization by the laboratory accordingly to a monitoring - Temperature, pH value
control plan; - Conductivity
 Active support in plant commissioning; - Turbidity
 Recruitment of the Operation and maintenance staff; - Hydrocarbons
 Assets inventory and identification; - Residual chlorine
 Collection and classification of the technical documentation including drawings and  Pretreatment
supplier or manufacturer technical documentations. - Turbidity
 Coordination with EPC Contractor for the licenses and permits. - Residual chlorine
 Implementation of the commercial relations with the partners for the supply of - SDI
consumables, by-product evacuation and subcontracted services;  Reverse osmosis inlet
 Definition and organization of the supply chain management with suppliers and clients. - Redox potential
- pH
23.1.2 Process monitoring and follow-up sheets implementation.
A process monitoring schedule shall be implemented and follow-up sheets will allow the - Conductivity

operation staff to follow the variations of every parameter for fast and immediate - Turbidity

interventions and also to insure the effectiveness of the process and the equipments on a - SDI

continuous basis.

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  Remineralisation
- pH
- Conductivity
- Residual chlorine
This analyzing capacity will be completed with all routine analysis necessary for the good
operation of the plant.
23.2 Electric Power Consumption Monitoring
Electrical consumption shall be monitored continuously. The maximum and minimum
instantaneous power demand shall also be recorded.
23.2.1 Chemicals Consumptions Monitoring
The consumptions of the various chemicals on the plant shall be recorded and totalized
on a daily and monthly basis.
23.2.2 Other Monitoring and O&M Log.
As mentioned above, the monitoring program shall be completed with follow-up sheets on
which will be recorded the variations of the most important parameters of the plant. Those
follow-up sheets are going to be configured in order to eliminate the risks regarding
process efficiency degradation and also in order to help the operation team to identify the
causes and remedies of any problematic situations.
A daily O&M log shall also be implemented. This log purpose will be to record the most
important parameters and events over a specific day.
23.3 Industrial start-up and routine operation
23.3.1 Operation and Production
 Determination of the optimum adjustments to achieve the performance levels;
 Treatment of the wastewater in strict compliance with the discharge local standards;
 Treatment of by-products in compliance with environmental regulations;
 Control and analysis of the treated water
 Updating documents and tracking the events and information;
 Staff on duty 24 hours a day, 365-days-a-year on site;
 Remote monitoring and round-the-clock (365-days-a-year) emergency on-call service.
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23.3.2 Maintenance Plan Implementation
A maintenance plan following the manufacturer requirements shall be elaborated and
implemented by a dedicated maintenance team in order to reduce the risk of RO Plant
outage, RO Plant shut down, RO Plant failure and RO Plant dysfunction.
The implementation of the maintenance program will be achieved by the completion of the
following steps:
 Determination of equipment criticality and relevant spare parts to be held in stock,
determination of the spare parts needs and equipment renewal plan,
 Determination of the frequency and the nature of preventive maintenance and editing
of the operating procedures for every equipment
 Implementation of a Computerized Maintenance Management System (CMMS) for
scheduling, optimization and tracking of Maintenance activities of the equipments. The
CMMS shall generate automatically the maintenance task requests in accordance with
the maintenance plan previously elaborated.
 Preparation of the procedures for cleaning, maintenance intervention, painting on
equipment, buildings and works.
23.3.3 Suppliers Chain Assessment and Management Plan
In order to insure the quality and the continuity in supplies, a Suppliers Assessment and
Management Plan shall be implemented before the start of the Operation and
Maintenance period. Although this plan will be applied to all goods and services
purchased, special attention will be given on sensitive purchases like laboratory reagents
and products, materials quality and oil and grease to name a few. This plan shall cover
two main aspects:
 Pre-assessment through a questionnaire of every supplier on the basis of their ability to
meet the requirements in providing quality products or services,
 Continuous monitoring through an annual monitoring based on the supplier or client ability
to guarantee the required level in product quality or services.
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23.4 Communication and Reporting
In addition to the daily O&M log which has been discussed above, the Company shall
also implement the following reporting documents in order to ensure a perfect
transmission of informations between every actor involve in the O&M of the RO plant.
 Monthly activity reports:
These reports summarize the treatment results and noticeable events during the
month taken into account.
 Annual activity report:
Published yearly, this report is a summary review of the twelve monthly activity reports
of the year. It includes a technical part and a financial part. It offers a general view of
the Plant’s operation for a year in order to determine the following year’s orientations
for management and optimization.
 Analytical follow-up reports:
Published regularly, these reports are the result of analyses carried out on the effluent
at the Plant inlet and the outlet and on the sludge produced, and the readings made
through on-line analyzers.
23.4.1 Staff training
Training meeting the needs:
 Training adapted to the level of knowledge, the responsiveness of each category of
personnel and their needs to achieve their tasks as best possible.
 Training for autonomy:
 Training to prepare the replacement of expatriate staff, by incorporating personnel
during the O&M period, until the end of the contract, and make sure they are perfectly
qualified and autonomous in the management and operation of the plant.
 Theoretical but mainly practical training:
 Training to transmit the theoretical bases required for practical application on site, and
to master the approaches and methods specific to the Operation & Maintenance of the
RO plant.
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23.4.2 Implementation of a real Occupational Health & Safety (OHS) policy
 From the design of the Plant to the end of the construction period:
 A plant designed in compliance with occupational health and safety conditions,
ensuring that Plant operating staff is working under the best possible conditions.
 During Start-up and Operation & Maintenance period:
 Implementation of work organization compliant with Quality Assurance procedures,
generating awareness among the personnel of health and safety issues, and
checking that safety recommendations in hazardous areas or on potentially
dangerous machines are steadily observed.
23.5 Staff Mobilization Plan
The staff shall be mobilized in order to insure the smooth and efficient operation of the RO
Plant on the very first day of the Operation and Maintenance. Key elements of the shall
will be mobilized first.
A Job Mobilization Chart shall be issued to show the staff mobilization prior to the starting
of the O&M Period.
23.6 EPC/O&M scope of supply
A scope of supply shall be defined in order to precisely establish the work repartition
between the EPC Contractor and the Operation and Maintenance entity (Operator). Its
purpose is to ensure a smooth transition between the EPC phase and O&M phase and
that all contractual requirements are fulfill. The scope of supply will define, among other,
the provisions regarding:
 The supply of the spare parts,
 The supply of the workshop equipments and tools,
 The supply of the office furniture’s and equipments,
 The supply of the laboratory equipments, reagents and glassware’s,
 The supply of the safety equipments,
 The supply of softwares like SCADA and CMMS,
 The supply of vehicles for EPC and O&M,
 The availability of O&M team during EPC phase,
 The deliverance of various permits and licenses,
 The supply of consumables and chemicals.
This scope of supply is valid only if the EPC Contractor is responsible until the Completion.
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24. OPERATION: TREATED WATER PRODUCTION MANAGEMENT
24.1 General principles
Good production management is strategic for:
 Ensuring constant treatment quality,
 Managing energy consumption and reagents,
 Resuming service in the event of a failure,
 Identifying discrepancies and restoring normal parameters,
 Optimizing the overall operating cost.
Within this perspective, the basic principles to be applied are the following:
The Operational staffs shall take the following measures:
 Define the nature and frequency of operations with the Operation Manager,
 Establish operation procedures and expand them through experience feedbacks,
 Ensure continuous control and maintain a logbook.
 Organize team work to ensure reliable operation;
 Ensure that the contract is respected in terms of all demands relating to operation
and with regard of the expected results for treated water and waste water discharge
quality;
Page 182
 Communicate all operation records.
 Coordinate actions with the maintenance management. These are essential to
ensure constant plant operation in order to achieve the contractual results,
 The Operation Manager (as process engineer) monitors closely the performances of
the various treatment stages and decides new settings or parameters adjustment to
improve the global result.
 Shift teams for round-the-clock operation. These teams managed by a team leader
are in charge of monitoring all treatment areas parameters and operate the facility
outside office hours;
 Several day teams organized by treatment areas and responsible for the production
of their area, by performing day-to-day tasks, such as reagents handling and
removal of by-products, plant preparation for maintenance, routine maintenance and
occasional operations, such as structure drainage. They provide cover to replace
shift absentees, etc.
 The Operation Manager gives the teams, operation instructions. These instructions
are either permanent or updated daily. They are issued as tables for numeric data,
or in the form of messages on the “instructions book”;
 Shift personnel make rounds (organized by the management) in accordance with a
document edited by the Operation Manager, monitor the plant, and note information
either on log sheets, or on the shift report. They are responsible for communicating
information from supervision to all the treatment areas, and occasionally participate
in non-routine interventions.
 All information used to log plant operation is retained either in the form of the log
sheets or in computer format through the monitoring system.
 All operation documents are also archived;
 Any operation problem is recorded on a sheet either for the maintenance service to
carry out corrective work or for the management to undertake whatever corrective
action is required;
 Operation data reviews and event reports are issued monthly, and consolidated in
an annual report;
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  Weekly meetings between operation and maintenance managers are held to adjust
preventive and corrective work in accordance with the operators’ requirements;
We will keep an up-to-date operation log that will contain formatted information production
 Daily briefings are used to highlight the priority actions for each day. and data available at the plant. The main data which will document the daily O&M log are:

 The sampling activities, the results of all analyses from the laboratory.
24.2 Application
 The operating hours of the main equipment like the HP pumps
24.2.1 Work to be carried out
 The daily consumptions of chemicals.
The list of all production-related tasks to be carried out shall be prepared by the plant  Measurement of all gauges and recorders performed.
manager and is known as the Job Plan.  All reports generated by the SCADA system.

 Description of all maintenance and repair works performed during the day.
Plan operation tasks,  Description of all malfunctions, incidents and breakdowns.

The Job Plan defines:
 The tasks to be performed and their frequency;
 Duration of the tasks and the required qualifications of the staff involved.
A methodical and structured examination of the Job Plan ensures a professional approach
to the resources needed to achieve the service required.
24.2.2 Procedures
 Quantities of all materials, products, and substances stored at and removed from the
RO plant.
 The volume of treated water produced daily.
 Staff working hours on site.
The readings and reports are noted on sheets. These sheets are then archived either in
paper format or in computer format in the monitoring system. In this case, important data
will be saved, if necessary, in duplicate, to ensure a permanent record. The data is then
collated manually or by computer to prepare the monthly and annual reports.

During industrial start-up, the plant manager institutes an operating procedure manual.
24.3 Supervision with SCADA System
This manual describes for each piece of equipment:  
Supervision is used to: 
 The operation, the inspection procedures,  
 The potential incidents,  Provide an overall view of all parameters affecting or having affected process in
order to understand the present situation and so optimize operation;
 The measures to be taken in handling these incidents,
 Generate statistics reports.
 The communication route between the different persons involved.

24.2.3 Continuous Supervision and Tracking

Methodic logging of all data.

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 It automatically and autonomously processes data from the control program, recorded by
the operators and laboratory analysis results.
The system has been designed to produce, modify and update reports according to
operators’ desiderata and needs. This program ensures:

 Data acquisition: it exchanges files provided by the controllers, PCs, laboratory

measurement apparatus, remote control units, etc.
 Data processing: the data is first checked against a consistency range, and then new
data is calculated from the data acquired, or entered.
 Data presentation: the data is regrouped in tables or graphs, in Excel format, used to
compile models.
 Report publication at the user’s request.

Navigation in this program is via a user-friendly graphic interface. The program will be
installed on the report PCs and will be parameterized according to the operator’s

The operator’s needs are: requirements. Parameterization consists in defining with the operator:

 To control the process and take action from a control room  The data acquired by the program,
 To collect permanently and automatically store a great amount of data and then be  The data entered and the organization of data entry sheets,
able to edit it accordingly to a redefined frame.  The calculated data,
The site is equipped with a system control and data acquisition (SCADA) for the  Coherence checks to be carried out,
monitoring and the control of the plant. This SCADA system will provide:  Data reporting models,
 Animated mimic charts,  Report models.
 Controls and adjustments,
24.4 Consumables Management
 Events and alarms management (save and acknowledge),
24.4.1 Electricity
 Real time and trends data curves,
 Network communication. Power consumption in a big size Desalination Plant is a major concern in the operating
expenses and therefore requires particular attentions from the operators.
24.3.1 Reports
We will carry out measurements for all electro-mechanical units installed at the plant. The
correct operation of the plant and the achievement of performance in compliance with the
It is contemplated to supply and implement our report edition program, a Long Term Data
required guarantees are subject to a permanent and reliable availability of electricity
Base tool.
supply.
This fully configurable program can compile technical reports for the operators and the
Client.

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24.4.2 Reagents

Sodium hypochlorite will be injected regularly as shock injection to avoid bacteriological

25. MAINTENANCE MANAGEMENT
growth in the seawater intake facilities.
25.1 General Principles
24.4.3 RO Pre-Treatment  The rational management of equipment is the main element in plant reliability. Good
maintenance management is strategic in:
There will be use of the following chemicals
 Ensuring maximum equipment availability,
 Ferric chloride used as coagulant before both Dual Media Filter (DMF) stages.
 Guaranteeing equipment reliability levels,
 Sulphuric acid used as pH adjustment (if necessary)
 Cationic polymer (if necessary) used as coagulant aid before DMF 1st stage.  Re-establishing reliability when a deterioration has occurred,
 Sodium Metabisulphite used to dechlorinate when needed  Identifying equipment whose level of reliability is no longer sufficient,
24.4.4 RO Treatment  Ensuring a sufficient return on investments by increasing equipment lifespan,
 Restraining overall operating costs.
There will be use of the following chemicals

 Antiscalant 25.2 The maintenance philosophy is detailed in Technical information chapter 4.

 DBNPA, Citric acid, caustic soda, used for RO membrane cleaning and flushing.
25.2.1 In our philosophy, the Maintenance Manager is a key role in plant operation
24.4.5 Remineralization
To carry out his tasks, he relies on the full range of technical maintenance.
There will be use of the following chemicals

 Limestone and carbon dioxide (if necessary) for remineralization

MAINTENANCE
 Sodium hypochlorite for disinfection
24.4.6 Water
Preventive Corrective
The plant operation requires the use of permeate or treated water. Generally, the largest
area of water consumption is for the in-line dilution of chemicals and RO membrane
cleaning. Systematic Conditional Forward Palliative Curative

(AFNOR X 60-010 standards)

24.4.7 Other Consumables

These products can be broken down into:

 Oil and grease for equipment and generators, locally available. To organize maintenance management, it is essential to:
 Products and equipment for cleaning premises,
 Define the nature and frequency of the Maintenance Service’s operations,
 Small tools (workshop consumables, bolts, screws, fixtures, hand tools, etc.),
 Define maintenance procedures and then improve them using plant feedback,
 Safety-related consumables (individual and portable safety equipment, such as gloves,
 Ensure continuous supervision and maintain an up-to-date log.
goggles, boots, shoes, earplugs...),
 Small electrical supplies,
 Cleaning and degreasing fluids for electro-mechanical equipment,
 Office consumables.

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 25.2.3 Preventive Maintenance Plan
25.2.2 Preventive Maintenance
Preventive maintenance:
Aims to reduce the probability of failure or deterioration in any piece of
equipment taking into account all the conditions required for its correct
operation as well as its periods of availability.
Preventive maintenance basically includes the following basic operations. This list is not
exhaustive; a complete list will be provided in the works program:
 Lubrication: oil checks (level, quality), oil top-ups, changes, greasing, grease changes;
 Mechanical maintenance: checks (tightness, play, alignment), replace filters, check
service pressures and temperatures, check for vibrations, check belt and chain
tightness, check safety systems, clean and dust, scheduled servicing, check for wear,
replace small parts, check tightness, systematic operations, tests, etc.;
 Electrical and instrumentation maintenance: checks (insulation, stator, rings, brushes,
protections, amperage, heating, position sensors), clean contactors, PLC tests, dust
cabinets, check – maintain – inspect connections, adjust torque limiters, safety checks,
routine calibrations, check data logs, etc.
Page 190
A preventive maintenance plan shall be established mostly upon the manufacturer
specifications. The preventive maintenance is usually established on a time basis
schedule or on running hours marks. This is to say that the equipments that are on a time
basis schedule, which is the most common, have to go thru a maintenance check at a
specific time independently of their running time.
A time basis maintenance schedule is normally setting maintenance at standard
frequencies, which are:
 Weekly: the weekly maintenances are basically consisting in systematic checks and rarely
involve the need for dismantling any component. The weekly maintenances are generally
performed by the operation staff under a checklist system and rarely involve the
maintenance staff. For this reason they are generally not inserted directly in the
maintenance plan.
 Monthly: the monthly maintenances generally involve oil level checks and refilling on
gearboxes and bearing lubrication on some equipment. Proper functioning checks of the
equipments and general cleaning are also usually performed on a monthly basis.
 Quarterly: this frequency generally involves the dismantling of components or heavier
maintenance. Weariness of wearing parts is often checked at this frequency. Quarterly
maintenance can also involve oil changes on specific equipments.
 Semi-annual: this frequency generally involves oil changes and complete lubrication of the
bearings and wearing parts.
 Yearly: this frequency involves the heaviest maintenance as it often requires the
dismantling of equipments for inner parts or submerges components checks. Oil changes
of the bigger equipments are also usually performed at this frequency.
Additional maintenance task on critical or sensitive equipments, like temperature checks
on bearings, motors, gearboxes and vibration measurement checks, are also often added
to the manufacturer maintenance specifications.
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25.2.4 Corrective Maintenance
Corrective maintenance:
Is designed to re-establish the conditions required for the sound operation of a
piece of equipment or set of equipment, after a fault or a deterioration in the
performance achieved with this piece of equipment.
 List all equipment that will require maintenance,
 Compile supplier manuals, and analyze their contents,
 Define tasks and their frequency;
 Define time allocated to each task and the required qualifications;
 Determine the type and quantities of spare parts.

It includes the following operations:

 Equipment disassembly,
 Parts replacement,
 Equipment renewal,
 Replacement of complete assemblies.
These operations can be scheduled for the short or medium term as a function of tests
carried out during preventive maintenance, a set number of service hours for an
apparatus or in response to an alarm (abnormal noise, repeated cut-outs, weakened
insulation...) or in response to an unforeseen failure.

25.2.5 General Maintenance

Plant general maintenance includes a series of activities intended to:
 Limit plant ageing due to its age, climatic conditions and other external factors
irrespective of the actual operation;
 Take care of the external appearance of installation to maintain the aesthetic value of A methodical and structured study of the Maintenance Plan ensures a professional
the plant and ensure a pleasant environment for staff and visitors. approach to the resources necessary to provide the service needed.
A general maintenance plan will be set up; it will list operations to:
 Check civil works, buildings and outside infrastructure, Clean premises; 25.3.2 Procedures
 Maintenance of painted surfaces; Any work on a piece of equipment or group of equipment may have significant impact on
 Repair indoor lights, locks, plumbing, domestic electric installations; the treatment quality, personnel safety or operation of peripheral equipment. It is thus
 Maintenance of site thoroughfares, lamps, fences, and site access gates; essential to communicate with the various people working on site to ensure the
 Maintenance of landscaped areas,
performance levels are never impaired.
 Maintenance of pedestrian paths,
The unifying principle for our entire approach is based on awareness by the Maintenance
25.3 Application
and Production managers of their respective needs and requirements.
25.3.1 Work to be carried out Procedures are also set in place. They govern the transmission of information between
The list of all tasks to be carried out under the maintenance program, is prepared by the
production and maintenance and its tractability, ensure safety of plant and personnel and
Maintenance Manager, and is called the Maintenance Plan.
facilitate productivity.
To author the Maintenance Plan, first:

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 Maintenance procedures basically cover:
 Authoring anomaly sheets, their analysis, processing and archival,
 Authoring corrective and preventive work chits, their processing, closure and archival,
 Planning work chits,
 Authoring work reports and their archival,
 Shutting down and clearing for service a piece of equipment or group of equipment,
 Authoring operation manuals,
 Carrying out the maintenance intervention.
Maintenance operation manuals are authored for each piece of equipment in compliance
with the forms hereafter or theirs equivalent. Once these forms have been filled in, they
are directly entered into the CMMS (Computerized Maintenance Management System).
They make it possible to:
- Detail each operation for each piece of equipment,  
- List the technical specifications of equipment for all installations,
- Plan and check preventive and Corrective maintenance operations,
- Manage staff workloads.
25.4 Computer Resources
The installation of a CMMS (Computerized Maintenance Management System) program
is an important aspect for quality. It is a factor in the rigor with which equipment is
monitored, and contributes to detecting the weak links in a plant.
This tool shall ensures:
 Access to the technical specifications of all the equipment used at the plant;
 Planning and monitoring of preventive and Corrective maintenance operations;
 Management of staff work loads;
 Logging of maintenance operations for each piece of equipment, so that the necessary
action can be taken to limit or prevent failures occurring;
 Statistics are generated for maintenance costs and the reliability of the various pieces
of equipment.

25.3.3 Continuous Control and Tracking

Report information methodically.

The target is to keep an up-to-date equipment log including:

 A description of preventive and corrective maintenance operations,

 The operation time and qualification of staff,
 List of spares used.

The Plant Manager will also have indicators enabling him to assess the efficiency of his
maintenance policy. The ratio of the number of Preventive/Corrective operations is
monitored particularly closely to detect any deterioration.

Maintenance data is recorded in hardcopy format in a file or in softcopy format, in the

supervision system. In the latter case, important data is saved, possibly in duplicate to
ensure a permanent record. The data is then collated manually or by computer to prepare
the monthly and annual reports.

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 26.2 Paint - Protection against Corrosion
26. ASSET MANAGEMENT PLAN
The lifespan of electro-mechanical equipment at the plant as well as civil works
An Asset Management Plan shall be implemented to ensure that all the equipments and
constructions depends, apart from the maintenance aspect, on the way they are protected
installations are maintained at their optimal conditions and performances throughout the
from heat, chemical and atmospheric exposure. The frequent renewal of paint and or anti-
contracted O&M period. An Asset Management Plan can only be successful by:
corrosion coatings is often a factor in guaranteeing a facility’s service life.
 Rigorously following the Preventive Maintenance Plan to prevent any premature
breakdowns, losses of performance or degradations of the equipments and 26.3 Lubricants
installations,
Plant maintenance requires periodic oil changes for engines and electro-mechanical
 Keeping sufficient genuine spare parts and equipments in stock to allow the
equipment and greasing of moving parts. A minimum stock is included of these frequently
completion of corrective maintenances within short delays and to limit the risk of
used products required for the sound operation of electro-mechanical equipment.
machinery breakdowns or losses of performance due to worn parts,
 Keeping provisions for equipment replacement in case of unforeseen breakdowns,
The Maintenance Manager will draw up an exhaustive list of lubricants for each piece of
 Ensuring the renewal of equipments at the end of their life expectancy as specified by
equipment and indicate the lubrication frequency and quantity required. In so far as
each manufacturer,
possible, the types and brands of lubricants shall be kept to a minimum in order to
 Using quality consumables like oil, grease and paint in strict compliance with each
rationalize procurements and usage.
manufacturer specifications,
 Providing a fully equipped maintenance workshop and all the tools necessary to
26.4 Workshop and Stores
perform maintenance task in an efficient and precise way.
The workshop shall be equipped with all necessary means for carrying out all preventive
and corrective maintenance operations. It is forecasted in our approach, a workshop
26.1 Spare Parts and Spare Equipments
equipped with the necessary tooling for maintenance and repair of equipment & civil
works.
Spare parts are broken down as Electrical maintenance and Mechanical & other
A store room is foreseen to store spare parts and equipment in stock.
maintenance.
The Operator may decide to keep in stock certain complete assemblies considered as
26.5 Equipment Renewal Plan
critical, such as non-installed stand-by pumps or long-delivery items. In the event of a
failure, this means rapid action can be taken by installing a complete new assembly
The Equipment Renewal Plan is established in order to define the renewal rates of all
without having to wait for supplies.
equipments over a desired period of time. The Renewal Plan is also defining the required
yearly expenses.

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27. ORGANIZATION OF THE LABORATORY
27.1 General Principles
The laboratory is an essential service for production that provides ongoing monitoring of
water quality at different stages in the treatment process. After analysis of these results,
the process manager determines the parameters adjustment settings and makes sure that
the works are operating properly.
The analyses are carried out at the most appropriate frequency, and always in compliance
with the operation requirements. The results are then examined, taking into account the
change in process parameters over time, and result reproducibility.
The laboratory must above all:
 Prepare its sampling and analysis program,
 Provide reliable results that are directly useable,
 Monitor stocks of reagents and small equipment required for the analyses to ensure it
is in a position to meet any specific demand from the process manager at any point in
time.
Effective laboratory management makes it possible, through careful examination of the
results obtained (critical thresholds, drifts, trends …) to anticipate actions and adjustments
that will thus avoid malfunctions.
For operation monitoring purpose, analyses are performed at different stages of the
treatment process according to a program defined by the Process Manager.
The analysis shall be conducted in accordance with standard methods for the examination
of water along the process line, as specified previously.
Page 198
27.2 Analytical Monitoring
27.2.1 General Principles: Plant monitoring and Environmental monitoring
The aim of analytical monitoring is to provide the operator with all the information required
to optimize structure operation and take action as quickly as possible if needed;
27.2.2 Equipment and Methods
The knowledge of the seawater quality, key date for analytical monitoring requires:
- Continuous flow rate measurement,
- Determination of the treated water quality, either from continuous readings or analyses
of samples.
- The application of a quality analytical monitoring system involves the implementation of
appropriate material and equipment to:
- Measure flow rates under the best possible conditions,
- Take representative samples, and ensure the correct conservation of samples taken,
- Analyze the various pollution parameters necessary to ensure the appropriate
treatment.
The representativeness of the results depends on the judicious installation of
measurement equipment up and downstream from treatment structures.
The equipment and methods used are generally covered by international standards.
A Water Quality Analyses Plan shall be prepared during the commissioning phase
showing a precise framework of what shall be performed.
27.2.3 Analytical Monitoring of final water
 
Samples and Measurement Apparatus
Sampling
Grab samples using adequate bottle (either plastic, glass …) shall be taken at the
entrance of the Product Water Tank.
Additional analyses carried out by O&M team
In addition to contractual analyses, O&M team requires its operators carry out a certain
number of internal analyses, providing more detailed monitoring of the plant’s operation.
Analytical monitoring throughout the treatment line makes it possible to detect any weak
link and to take the required corrective measures as quickly as possible.
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 The type and frequency of these additional analyses will be determined at the beginning 27.5 Consumables
of the Operation and Maintenance period. The frequencies used are, however, indicative
averages and always adapted to the particular plant’s operational requirements. These The Laboratory Technicians must always be able to respond to process analysis

systematic analyses will be extended to include additional analyses as required in requests. He must compile the list of all consumables needed for the proper running of the

response to incidents, such as, storms or sudden changes in seawater pollution.
27.2.4 Analytical Monitoring of Environmental Impact Assessment
Analyses shall be performed on the outfall to verify the compliance with the limit values
according the Local Legislation.
laboratory and manage the necessary stock of reagents and consumables bearing in
mind the following:
 Delivery lead times for each reagent and each type of equipment,
 Reagent storage conditions and notably use-by dates.

27.3 Analytical Means

Operators shall be provided with portable analyzers (pH sensors, analysis kits, etc.) to
carry out routine checks but will rely on the plant laboratory to carry out precise analyses.

The analytical monitoring is carried out in the plant laboratory, equipped in such a way
that it is able to carry out all contractual analyses which have a high frequency of
sampling. Lower frequency analyses for other parameters, will be performed through an
external accredited laboratory.

27.4 Reliability and Traceability of Analysis Results

To be directly useable, laboratory analysis results must be totally reliable.

To guarantee the reliability of these results, a strict quality approach to be applied
includes:
 Sampling procedures and sample conservation,
 Operating methods for each type of analysis,
 A laboratory quality procedure manual,
 Quality control procedures for analysis reagents supplied,
 Control procedures by counter-analyses and quality audits can be organized.

Analysis results are logged on result sheets. These sheets are saved in paper format or in
softcopy format in the monitoring system. In this case, important data is saved or even
duplicated to ensure a permanent record.

Analysis results are then used manually or automatically by the computer system to
prepare analysis monitoring reports, and the monthly and annual reports.

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 28.3 Procurements Reception Inspection Procedure
28. SUPPLY CHAIN MANAGEMENT PLAN
Consumables, notably reagents and spare parts are an essential point for operation as The conditions for checking procurements are set out in the “Inspection of packaged

they concern both the process and the plant’s safety/reliability. goods and reagents” and “Inspection of sub-contracted services” procedures.

It is essential to: All procurements are subject to inspection by the buyer or authorized person.
Inspected goods are used immediately or stored in the designated areas. In the event of
 Rigorously monitor their stock so as never to run out, or simply to ensure orders are
placed with sufficient lead-time, the non-compliance with the order, a “supplier anomaly” sheet is opened and is subject to
 Make sure of the irreproachable quality of these products upstream from the appropriate processing. The anomaly sheets are part of the supplier continuous
procurements procedure itself.
assessment system.

Stock, procurements and delivery acceptance quality monitoring

28.4
procedures.
28.1 Stock Management Procedure
A stock file is written for each product and each type of equipment or spare part. A stock
threshold figure is defined per stock item which triggers product ordering as soon as the
threshold is reached. A regular stocktaking is made to check the real availability of
products.
For reagents, tank storage levels or storage areas will be checked along with daily
consumption levels to predict the appropriate moment for triggering orders at the
supplier’s.
An annual review of spare parts is conducted. It is used to adapt the stock to actual
operation requirements.
An annual review of laboratory reagent consumption conducted. It is used to adapt the
laboratory stock to actual requirements or changes in the context. Concerning imported
products, it is of paramount importance to implement this procedure in order to avoid
shortfall in consumables.
Supplier assessment procedure
The procedure is only applicable to sensitive procurements, that is, those that have a
direct impact on plant operation.
Each site has it own list of sensitive procurements, a copy of which is forwarded to the
head office. New suppliers undergo a preliminary assessment based on:
 A test order,
 An assessment questionnaire.
Before they are added to the plant’s list of approved suppliers,
Suppliers are subject to continuous assessment based on their ability to guarantee the
required level of quality. They are included on the plant’s list of approved suppliers. This
list is reviewed annually on the basis of these assessments, during the plant’s
Management Review.
Usual suppliers, those from the same services are ordered on a regular basis, can be
covered by a procurement agreement, which formalizes certain permanent conditions. At
equal performance and price, the certified suppliers are given precedence.
When the level of risk is justified, procurements may be inspected at the supplier’s

28.2 Procurements Procedure premises prior to shipment.

Also, Operator reserves the right, if necessary, to carry out listing audits of new suppliers
It is possible to use procurements conventions, the Group’s Procurements Department, or
and control audits to assess listed suppliers.
to place direct orders in preference with approved local suppliers.
Order documents must ensure complete traceability of the procurements’ approach, from
its issue through to reception inspection.

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29. HUMAN RESOURCES
The site organization includes:
29.1 Proposed Manpower and Organization
 The analysis of all the tasks to conduct,
The general organization of the manpower during Operation and Maintenance period shall  The aim at maintaining full production capacity at any time,
be kept nearly identical with a structure fragmented into five main sub-organizations,  The notions of safety.
which are: It leads to implementing an organization chart based on:
 The Administration team (including Plant Manager).
 Staff involvement,
 The Operation team.
 Staff adaptability,
 The Maintenance team.
 Treatment areas definition and,
 The Technician team.
 The Occupational health and safety officer.  Specialization.
Staff must have the basic qualifications required for carrying out all tasks: water
Each sub-organization shall be managed by a Head in Charge under the direct
chemistry, process management, electro-mechanical maintenance, instrumentation,
supervision of a Plant Manager. An organization chart shall be included with the general
PLCs, but also financial management in the broadest sense of the term, and human
manpower organization.
resources management.
29.2 Key Personnel Selection

The key personnel (management team) of the organization are the Plant Manager, the
Operation Manager, the Maintenance Manager and the OHS officer. The key personnel
selection shall be made in order to ensure a professional and highly efficient management
by experienced, dedicated and knowledgeable persons.
29.3 Management of Human Resources
The effective management of a plant basically, relies on the organization of human
resources, which must take into account the following parameters to reach an optimum
result:
 Rigorous analysis of the workload, tasks to be carried out, and the level of reliability
required of the installations,
 Ongoing concern, through training, for improving the knowledge of each employee,
 Definition of common objectives,
 Realistic attitude to working conditions which leads to Occupational Health and Safety
measures,
 Ongoing profession levels for all tasks to be carried out,  
The tasks required for monitoring plant operation and maintenance have been defined as:
- Management / Training / Health & Safety / Quality Assurance
The plant is placed under the authority of a Plant Manager who is responsible for all
contractual commitments in terms of plant operation and staff management. This item
also involves staff training, awareness of health and safety and Quality Assurance issues
that are delegated to Quality and OHS officers. The quality officer will be especially in
charge of the coordination of the whole training sessions (safety, technical, financial,
environmental…).
- Production / Control - Monitoring
This item includes all action required to operate the equipment and various processes. It
is, to a large extent, based on analysis of situations and operation parameters to ensure
immediate action.

 Commitment to delegation by managers. - Analytic control

This item includes the analyses required for contractual control and all those required for
The precise definition of the personnel required for the technical, human and financial
the day-to-day monitoring of plant facilities.
management of the plant, takes into account the estimated needs, position-by-position,
and the progressive training of staff.  

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 - Maintenance
Maintenance operations are broken down into preventive and corrective maintenance, in
order to optimize the life span of equipment as well as its maximum availability for
operation.
 
- Service
 Servicing and cleaning structures and equipment.
Particular attention is paid to service operations for equipment requiring specific action in
terms of safety and electro-mechanical instructions. All these tasks have a direct impact
on the sound operation of equipment and contribute to it being maintained in good
condition, and so to increasing its life span.
 Cleaning in technical and administration premises,
 Maintenance of site landscaped areas (if any).
- Administrative management
This item includes personnel management, pay, accounts, supply, stores and sub-
contractors administration and secretariat services. Those tasks will be supervised directly
by the Plant Manager.
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30. COMMUNICATION AND REPORTING
30.1 Operation Log
The Operator shall maintain at the plant an up-to-date operation log, which will include
formatted and sorted production data.
This operation log records all readings made at the plant and all events (major changes to
settings, anomalies, incidents, etc.).
30.2 Activity Reports to the Client
The Operator shall provide to the Client, on a monthly basis and upon specific request,
with reports reflecting all O&M activities during the contract period. As far as possible, the
information shall also be provided and incorporated in electronic format.
30.2.1 Monthly Reports
These reports are a summary of the treatment results for the relevant month.
 They gather all daily results of laboratory analyses, and the plant’s analytical
monitoring their interpretation, and process analytical calculations used for plant
settings, as well as the main maintenance events;
 Using didactic curves, these reports reflect any changes at the plant, quality of the raw
and treated water, and so are used to decide whether any changes or improvements
need to be made at the plant, as a function of contextual changes (variations in raw
water quality, changes to standards to be respected at the plant outlet, etc.);
 They even contain a chart monitoring the yield from each major structure (inflow and
outflow rates, power consumption, reagent consumption, etc.). The yield survey is
used to decide whether to modify or reset equipment adjustment parameters,
thresholds or workloads.
 They are listing the spare parts used during the month.
 They are providing the staff time sheets and resources used.
 They summarize all the emergency events and the corresponding reactive actions
taken.
 They summarize the faults and the corresponding correctives measure taken.
 They underline the failure rates and down times as well as other key performance
indicators.
 They list the prediction of the following month major activities.
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 31.
30.2.2 Annual Report
Each year, the Operator produces an annual report that summarizes the twelve monthly
reports. In particular, this report includes statements tracking all operations related to the
provision of the contractual services.
This annual report gives a global view of the plant’s operation over a twelve-month period.
It is used as a basis to fix plant operation guidelines and potential for improvement for the
year ahead.
The technical report:
 Is preceded by a summary listing the facts, figures and notable changes;
 Regroups qualitative and quantitative data relative to analytical monitoring, measures
taken;
 Analyses technical indicators in the form of processed statistical data, that is
correlated, interpreted and compared with that of the previous year;
 Lists malfunctions, main work carried out, and renewal operations;
 States operation conditions, measures taken with a view to optimizing treatment;
 In general terms, compile all the date and information required per tender document
and relevant to the elapsed year.
31.1
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INCIDENT MANAGEMENT PLAN
The implementation of an Incident Management Plan (IMP) shall permit to respond to
unforeseen incidents including accidents, spills, weather-related emergency situations,
abnormal conditions, threats to plant security and other contingencies. The management
plan shall be configured to provide means of anticipating and managing situations with
potentially harmful impact on the RO Plant and its staff. The plan will provide the required
tools to ensure that the on site staff is able to:
 Alert the appropriate individuals immediately after the occurrence of any serious
incident or situation.
 Master the capacity to analyze an emergency situation and decide of immediate
appropriate actions to engage.
 Know how to quickly mobilize adequate resources in order to control the crisis as best
as possible and to provide any operational entity the best support they may require.
The IMP shall be elaborated in a way to define the procedure to be followed, from the
identification of an emergency or crisis situation, up to its final management, in
conjunction with the existing IMP of the Client.
Identification of an Emergency Situation
The gravity of any incident is determined based on the significance of its consequences. A
serious incident is likely to generate significant consequences on employees or other
individuals like Client, subcontractors and visitors, on the environment, on the property or
the RO Plant and even on the quality of services. The following events, to name a few, will
be considered as an emergency situation:
 Accident resulting in life fatalities or life-threatening situation,
 Serious injuries,
 Significant damage to property or the environment,
 Significant security or safety issues,
 Cause of Force Mayor as earthquake, tsunami and flood,
 Terrorism acts or threatening,
Page 209
  Fire and explosions, 32. SAFETY, HEALTH, WORKING CONDITIONS AND ENVIRONMENT
 Any serious incident involving the local police, emergency services or authority.
32.1 Safety, Health and Working Conditions Considered in the Plant’s Design
31.2 Alert and Information Transmission

Any witness of an emergency situation will be requested to immediately call and forward
the information to a main Standby Safety Coordinator available around the clock at any
time to receive all alerts. In order to insure that the witness is able to get immediate
assistance all the time, an alternate Standby Safety Coordinator will also be available.
The phone number of the two coordinators will be programmed in every phone set. In
addition the phone numbers will also be posted in numerous locations on a standard
formats the example shown here after.
The witness will then be requested by the coordinator to provide all the preliminary
information available, including:
 The name, position and telephone number of caller,
It is Operator’s policy to take into account all standards relating to occupational health,
safety and working conditions right from the very early stages in plant design. This is the
principle of Integrated Prevention that aims to avoid the occurrence of risks (mechanical,
electrical, drowning or falling, chemical, explosion or fire, and all nuisances caused by
noise and excessively high or low temperatures), by eliminating them at the source.
Further, the operator must, when taking over operation of the plant, implement a work
organization program in compliance with Quality Assurance procedures, make staff aware
of health and safety issues, and make sure that safety rules and work procedures in risk
areas or on dangerous machinery are scrupulously adhered to.

 Nature, location and date of incident,

32.2 General Principles of Health and Safety for Plant Operation
 Number of injuries and property or environmental damages,

 Involvement of third parties like Client, neighbors and emergency services,
 Evolution of the criticity in time (stabilized or not),
 Additional assistance required or not,
 The impact on the RO Plant.
After gathering the witness information, the Safety Coordinator will be requested to
establish a preliminary assessment of the gravity of the incident in order to evaluate the
needs or requirements for immediate assistance. In any case the Safety Coordinator will
have to advise the Operator‘s share holders Senior Management as well as Operator‘s
share holders Safety Department.
Health and safety considerations for operating water treatment plants are very important
issues because of the diversity of potential risks: rotating machines, automatic machines,
electricity, use of chemicals, work in tanks, in confined spaces, dangerous atmospheres
(asphyxia, explosion, etc.), near heat units, risk of infection and bacteriological risks, etc.
The main divisions in the Operator‘s share holders Safety Action Plan are as follows:
 A safety manager based at head office and available to assist sites,
 A central Health, Safety Working Conditions Committee,
 An in-house safety brochure (3rd edition) distributed and discussed with each staff
member,

 Specific training and information and regular awareness meetings,

31.3 Final Incident Assessment Report
 Attentive medical prevention.
The Client shall be informed and updated at all time during the management of the
emergency. A final Emergency Assessment Report shall be produced and provided to the
Client. This report will evaluate the efficiency of the Emergency Management Plan and will
revise as needed.

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32.3 Health and Safety
Importance of safety and health at a water treatment site is paramount. Operator will
implement, in addition to the training already mentioned, strict safety rules and a
prevention plan designed to generate awareness among operation staff of the risks
inherent in their activity and to take the measures required to guarantee a pleasant and
healthy, and efficient, working environment.
The health and safety program includes the following actions:
A conventional RO Plants have a certain number of apparatus and tools that require
regular checks by authorized inspection agencies.
For reference:
 Lifting apparatus, hoists and jibs;
 Electricity cabinets and associated circuitry,
 Pressurization tanks (if applicable), compressors.
- As well as mandatory legal formalities relative to the operation of RO Plant.

 Appointment of the plant occupational Health & Safety officer, The following action plans and rules will also be implemented and commented to the
staff:
 Creation of a Safety, Health and Working Conditions Surveillance Committee,
- “Crisis situation” action plans, relevant procedures and means to be applied in the
 Risk mapping study,
event of a crisis (explosion, pollution, emanation of toxic gas, serious accidents, etc.),
 Notices and signs in risk areas,
compiled in liaison with the local Emirati services involved in crisis management,
 Noise pollution awareness and mitigation measures,
- “Fire protection and fighting” rules, and relevant checks and procedures,
 Environmental awareness and CDR Health & Safety regulations application,
- “Anti-intrusion and anti-vandalism” rules, and relevant checks and procedures.
 Availability of essential standard safety equipment,

 Supply staff with uniforms and Personal Protective Equipment (work clothes, safety
shoes, ear muffs, gloves, goggles, gas sensors if necessary, etc.),

 Work clothes are cleaned and maintained by the company. This task is outsourced to
a specialized company. In this way, perfect health and safety conditions are respected
both at work and at home.

 Installation at strategic points of safety equipment (safety shower, handrail, non-slip

coating, buoys),

 Implementation and presentation of the “health and safety” regulations, procedures

and relevant checks,

 Each staff member is given his or her own copy of the safety booklet specific to our
profession. They also receive training in health and safety from the site Health &
Safety Responsible.

 Analysis of any accidents that occur and measures taken to avoid their recurrence,

 Systematic medical visits and legal or recommended vaccinations for staff,

 Mandatory periodic checks

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33. THE QUALITY APPROACH - Maintenance
- Safety
33.1 Quality Objectives and Approach
- Administration
Under its General Quality Policy, Operator is committed to providing their customers - Purchase
plants and services compliant with their expectations and needs in the most efficient and
economic manner possible.
Operator’s Quality Commitment involves the entire management team and all employees,
each person being guided in their day-to-day activities by the quest for transparency and
performance.
The Quality Approach implemented by O&M Contractor follows a strategy aimed at:

=> Meeting the customer’s needs, focusing on the transparency of our acts,

=> Capitalizing on and perpetuating our know-how,

=> Optimizing working methods and organization, by implementing a strong,

flexible and responsive structure,

=> Improving staff confidence by providing them with training and promoting
initiative and innovation,

=> Reducing and preventing deficiencies.

The application of this Quality Approach is based on an organizational structure,

responsibilities and procedures defined and written in the Quality Assurance Manual.

The application of this Quality Policy results, in terms of operation, in precise procedures,
in the areas of production organization, maintenance organization and laboratory
organization.

33.2 Certification
Based on a general documentary structure issue from sites experience, a set of
procedures and instructions specific for the RO Plant will be authored. These
organizational procedures will cover the following topics:

- Laboratory
- Production

Page 214 Page 215

 time. Economics – including both the cost of the water produced and the complex
financial arrangements needed to develop a project – are key factors that will determine
34. Project Financials
the ultimate success and extent of the said desalination facility.
Therefore to mitigate the above, the proposed plant delivery method is Design-Build-
The primary cost components of a seawater desalination plant are commonly divided into
Operate (DBO) Model.
two major categories: capital costs and operation and maintenance (O&M) costs. Capital
costs include those costs incurred during the construction of the project and include
Capital costs include those costs incurred during the construction of the project and
expenses associated with planning, permitting, designing, and constructing the project.
include expenses associated with planning, permitting, designing, and constructing the
Other capital costs include the expenses associated with buying or leasing equipment,
project. Other capital costs include the expenses associated with buying or leasing
purchasing the site, and mitigating environmental impacts.
equipment and mitigating environmental impacts. The cost also includes cost of
34.1 Capital Cost approximately 60 km of product water main. The capex stated below is exclusive of
custom and excise duty, since this being a Drinking Water Plant. The Capex brief is as
Infrastructure projects are complex, capital intensive, and have long gestation periods that below:
involve multiple and often unique risks to project financiers. Due to its non-recourse or
limited recourse financing characteristic (i.e., lenders can only be repaid from the
revenues generated by the project), and the scale and complexity, infrastructure financing
requires a complex and varied mix of financial and contractual arrangements amongst
multiple parties including the project sponsors, commercial banks, domestic and
international financial institutions (FIs), and government agencies.

Further, specifically sea water desalination projects create long-lived assets, with cash
flows that grow slowly, financing requires debt structures with long maturities. The limited
ability and willingness of consumers to pay also requires that debt be amortized over long
periods (15to 25 years) to help minimize annual debt repayments and reduce the
necessity to increase tariffs.

The construction of a desalination plant is expensive and requires considerable up-front

capital investment. To cover these costs, project developers often rely heavily on debt
financing, which involves borrowing money from a lender with the intent of repaying the
principal of that debt and interest.

A life-cycle view helps to get better ‘buy in’ from all parties involved. It also provides a
framework for evaluating whether the solution is the most appropriate for the public over

Page 216 Page 217

Description INR US$ Instrumentation, Instruments including all
Controls 58,32,000
Engineering Cost 50,00,000
Cost for Insurances, Guarantees 25,00,00,000
Intake through Pipe Jacking 1,05,06,98,094 71,98,700
Total E&M 10,56,04,51,474 17,03,87,632
Intake Pump Station and Intake Screens 19,03,95,390 71,78,396
Total Civil 8,54,60,32,914
Lamella along with Chemical Dosing 1,81,80,000 Description INR US$

Dissolved Air Floatation 2,75,40,000 Add Contingences @3% 57,31,94,532 51,11,629

Dual Media Gravity Filters 1,02,02,60,880 Total of Civil and E&M 19,67,96,78,919 17,54,99,261
Reverse Osmosis (RO) 9,61,55,680
Testing,Erection, Commissioning, etc. @ 10% 1,02,27,26,502 1,75,49,926
Potabalization 32,88,88,800 6,02,857
Product water pumps and Disinfection Total E&M and Civil 20,70,24,05,421 19,30,49,187
system 8,55,95,526
Product Water Main inc. all crossing, Contractor Profit and OH 2,07,02,40,542 1,93,04,919
pedestal , intermedite Pumping Station and
6,12,44,95,909
civil works Total of Works 22,77,26,45,963 21,23,54,106
All mixing equipment's and dosing
equipment's including Valves for dosing etc. 40,11,01,875 27,00,000 Freight and Packing, Insurance @ 3% 31,68,13,544.21 52,64,978

Electrical SS 110/11 KV Inc. MRSS 26,45,90,000 Add CST/VAT @ 14.5% 1,57,72,03,427.61

Electrical and cabling 84,44,25,000 Grand Total 24,66,66,62,935 21,76,19,084

Page 218 Page 219

 SWRO Membrane
3 Replacement 9,10,913.35 4.65% 2.28
Grand Total In INR 38,27,87,36,642
4 Cartridge Filter Replacement 1,06,557.38 0.54% 0.27

5 Filter Media Replacement 500 26,974.11 0.14% 0.07

Add for EB Substation and Miscellaneous
6 Anthracite Replacement 500 67,435.27 0.34% 0.17
(Provisional Sum) 1,50,00,00,000
7 Chemicals 41,68,953.17 21.28% 10.42

1% of Civil and
Total- Grand Inc EB Substation 39,77,87,36,642 3.0% of Project
Value Every Year
Inc. Product Water
US$:INR @ 62.55 8 Maintenance, Insurance etc. main 22,46,575.34 11.47% 5.62

Including Product
9 Depreciation water main 44,15,525.11 22.54% 11.04

Total O&M per day 1,95,88,282.31 100.00% 48.97

Water Cost per Kl in INR 48.97

 Doesn’t include cost of bowering money.

Break up of O&M Cost

34.2 Operational Cost

O&M costs represent the ongoing costs required to operate the plant, including expenses
associated with replacement membranes, chemicals for pre- and post-treatment, energy
to run the plant, environmental monitoring, and labor for plant operators. Some O&M
costs, such as labor, are fixed, e.g., they do not vary with respect to the amount of water
produced. Other O&M costs, such as for energy and chemicals, are variable and thus
change in response to the amount of water produced. Capital costs are reported as one
time, fixed costs. O&M costs, by contrast, are typically reported as annual costs.

Summary O&M Cost

% to Total in
S.N. Description Qty. Cost INR/day Cost INR/KL

1 Power @ INR 4.5 per unit 1663556.514 74,86,004.31 38.22% 18.72

2 Manpower 1,59,344.26 0.81% 0.40

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