ANNEX-3 PROJECT DESCRIPTION
CLASSIFICATION: INTERNAL
TABLE OF CONTENTS
1.
INTRODUCTION.............................................................................................................................. 4
2.
REFERENCE ..................................................................................................................................... 4
3.
ACRONYMS AND DEFINITIONS ..................................................................................................... 4
4.
PLANT DETAILS ............................................................................................................................... 5
5.
PROCESS DESIGN BASIS ................................................................................................................. 6
6.
BRIEF PROCESS DESCRIPTION ..................................................................................................... 10
7.
BATTERY LIMIT CONDITIONS ...................................................................................................... 12
8.
PLANT CONFIGURATION ............................................................................................................. 13
9.
CHEMICALS USED ........................................................................................................................ 14
10.
WASTE DISPOSAL ..................................................................................................................... 17
11.
EQUIPMENT PHILOSOPHY ....................................................................................................... 17
12.
PROCESS SAFEGUARDING ....................................................................................................... 19
13.
LIST OF ASSUMPTIONS ............................................................................................................ 19
14.
PIPING DESIGN BASIS (TSE) ..................................................................................................... 20
15.
ICT ............................................................................................................................................. 24
A.
INTRODUCTION............................................................................................................................ 24
B.
INSTRUMENTATION .................................................................................................................... 24
C.
FINAL CONTROL ELEMENTS ........................................................................................................ 25
D.
PUMPS AND MOTORS ................................................................................................................. 25
E.
VARIABLE FREQUENCY DRIVES ................................................................................................... 25
F.
DRIVES WITH SOFT STARTER OR DIRECT ONLINE STARTER ..................................................... 26
G.
CONTROL VALVES. ....................................................................................................................... 26
H.
ON/OFF VALVES ........................................................................................................................... 26
I.
LOCAL AND REMOTE MODE OPERATION .................................................................................. 27
J.
CABLES .......................................................................................................................................... 27
K.
CONTROL SYSTEM ....................................................................................................................... 28
L.
MISCELLANEOUS ITEMS .............................................................................................................. 29
M.
LIST OF ASSUMPTIONS ............................................................................................................ 30
N.
Scope of work for TSE automation, control System and Low Current Systems: .................... 30
16.
DESIGN BASIS FOR ELECTRIC AND POWER SUPPLY (TSE) ..................................................... 32
A.
ELECTRICAL POWER SYSTEM PHILOSOPHY ............................................................................... 32
B.
MAIN ELECTRICAL EQUIPMENT INCLUDING AUXILIARY SYSTEMS .......................................... 33
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CLASSIFICATION: INTERNAL
C. DESCRIPTION OF MAJOR EQUIPMENT AND SYSTEMS ELECTRICAL EQUIPMENT AND
SYSTEMS, SUCH AS: SWITCHGEARS / TRANSFORMERS / UPS ......................................................... 34
17.
DESIGN
BASIS FOR CIVIL (TSE).......................................................................................... 36
A.
ABBREVIATION ............................................................................................................................. 36
B.
CIVIL WORKS ................................................................................................................................ 36
C.
TANK FOUNDATIONS ................................................................................................................... 39
D.
CIVIL DESIGN CRITERIA ................................................................................................................ 39
E.
SEISMIC PARAMETERS ................................................................................................................. 42
F.
METHOD OF CONCRETE SURFACE PROTECTION ...................................................................... 44
List of Tables
Table 1 References .................................................................................................................................. 4
Table 2 Incoming TSE flow rates ............................................................................................................. 6
Table 3 Design TSE characteristics arrived by blending Appendix-J (PP Performance), Table 3-2 and
Annex-H STP upper plateau Specs, Table 3-3(except for TDS ................................................................ 7
Table 4 Assumed Ionic Balance for RO Design........................................................................................ 8
Table 5 Reference TSE characteristics .................................................................................................... 8
Table 6 Guaranteed quality of Polished TSE ........................................................................................... 9
Table 7 Waste water flow rate.............................................................................................................. 10
Table 8Incoming TSE ............................................................................................................................. 12
Table 9 Polished TSE ............................................................................................................................. 12
Table 10 Waste water disposal to evaporation ponds ......................................................................... 13
Table 11 Chlorine Gas (Cl2) Details ....................................................................................................... 15
Table 12 Coagulant (FeCl3) Details ....................................................................................................... 15
Table 13 Sulphuric Acid Details ............................................................................................................. 15
Table 14 Sodium MetaBiSulphite Details .............................................................................................. 16
Table 15 Caustic Details ........................................................................................................................ 16
Table 16 Polymer Details ...................................................................................................................... 17
Table 17 Structures and Mode of construction for TSE in Lower Plateau ............................................ 37
Table 18 Structures and Mode of construction for TSE plant in Lower Plateau................................... 38
Table 19 Seismic Parameters ................................................................................................................ 42
Table 20 Maximum Chloride ion content for corrosion protection of reinforcement ......................... 42
Table 21 Requirements for concrete exposed to Chloride bearing soil & water ................................. 43
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CLASSIFICATION: INTERNAL
1. INTRODUCTION
The TSE Polishing Plant is designed to treat Raw TSE water of 150 MLD. TSE Plant will receive
the water from tank receiving the Treated sewage from existing NWC Line and also from the
upper plateau STP. Polished TSE is utilized to meet the irrigation demand and cooling water
demand of Qiddiya utility Project
2. REFERENCE
[2]
PERFORMANCE
REQUIREMENTS
QIDDIYA’S TSE POLISHING PLANT
FOR
[3]
PROCESS FLOW DIAGRAM - TSE
ANNEX J(TSE)
QD060100-DAH-D00-DSK-WTR-22T02-00001
Table 1 References
3. ACRONYMS AND DEFINITIONS
The following terms used in this document have the meaning defined below:
EPC CONTRACTOR Alfanar
PACKAGE TSE Polishing Package
PROJECT
Qiddiya Utility Project & Privatization, Riyadh
SCOPE OF WORK The Scope of Work to be performed and services to be rendered in relation
to the realization of the Project.
WORK
Works, tasks and Work to be performed by the sub-contractor as specified in or
to be inferred from the sub Contract, more specifically set out in the Scope of Work which may
be modified by Change Order.
VENDOR Means an Organization that has a Contractual Arrangement with sub-Contractor
or a Prospective Contractual Arrangement with sub- Contractor
PLANT FEED CAPACITY
150MLD
The acronyms used in this document have the meaning defined below:
ATM
Atmosphere
BOD
Biochemical Oxygen Demand
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CLASSIFICATION: INTERNAL
CIP Chemicals In Place
COD
Chemical Oxygen Demand
HP High Pressure
LP Low Pressure
NTU
Nephelometric Turbidity Unit
pH Potential of Hydrogen
SDI Silt Density Index
SMBS
Sodium Meta Bi Sulphite
TDS
Total Dissolved Solids
ERD
Energy Recovery Device
TSS Total Suspended Solids
BW Back Wash
N PIT
Neutralization Pit
TSE Treated sewage effluent
NWC
National Water Company
PFD
Process Flow Diagram
CIP Clean In-Place
CEB
Chemically Enhanced Backwash
4. PLANT DETAILS
Plant Location
:
Site Location
Qiddiya
State/Country
:
Kingdom of Saudi Arabia
Nearest Town/City
:
Riyadh
:
Source of Water
Source
Treated Sewage Effluent
:
Metrological Data
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CLASSIFICATION: INTERNAL
Mean ambient temperature
Minimum 15 °C; Maximum 36.0 °C, Average
25.4°C
Relative humidity
:
Minimum 31%, Maximum - 69%
Average Precipitation
:
25 mm
5. PROCESS DESIGN BASIS
Feed Water Characteristics
TSE Plant will receive the treated sewage from tank receiving the Treated sewage from
existing NWC Line and treated sewage from the upper plateau STP.
Incoming TSE Capacity
Incoming TSE Flow Rate:
Description
Unit
Value
Average hourly flow rate
m³/h
6250
Table 2 Incoming TSE flow rates
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CLASSIFICATION: INTERNAL
Plant Capacities & Inlet TSE Quality
The specified plant output capacity shall be based on the following Reference Inlet Conditions:
Sl.
No
Parameter
Unit
Design Condition Design Condition Design Condition
(Actual)
(+30%)
(-30%)
1.
Inlet TSE Capacity
MLD
150 MLD
150 MLD
150 MLD
(Note-1)
(Note-1)
(Note-1)
142.5 MLD
142.5 MLD
142.5 MLD
(Note-2)
(Note-2)
(Note-2)
2.
Polished TSE Capacity
MLD
3.
pH
-
7.0-8.5
7.0-8.5
7.0-8.5
4.
Total Dissolved Solids
mg/l
1650(Note-3)
2100(Note-3)
1275(Note-3)
5.
Total Suspended Solids
mg/l
15.0
18.0
10.0
6.
Turbidity
NTU
6.0
7.5
4.1
7.
BOD5
mg/l
11.0
14.0
8.0
8.
COD
mg/l
20
27
15.2
Total (TOC)
9.
Organic Carbon
mg/l
4 - 37
5.2 - 44.5
2-8 - 24
10.
Ammonia (NH3-N)
mg/l
1.2
1.5
1.0
11.
Nitrate- NO3
mg/l
9.1
11.8
6.4
Count/
12.
Fecal Coliform
100 ml
1800
2165
1166
13.
Alkalinity
mg/l
100-300
100-300
100-300
Table 3 Design TSE characteristics arrived by blending Appendix-J (PP Performance), Table 3-2 and
Annex-H STP upper plateau Specs, Table 3-3(except for TDS
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CLASSIFICATION: INTERNAL
Table 4 Assumed Ionic Balance for RO Design
Sl.
No
Parameter
Unit
Design Condition
(Actual)
Design Condition
Design Condition
(+30%)
(-30%)
1.
Magnesium
mg/l
48.58
63.15
34.01
2.
Sodium
mg/l
370.00
480.04
258.48
3.
Potassium
mg/l
80.97
105.26
56.68
4.
Calcium
mg/l
56.68
73.68
39.68
5.
Sulphate
mg/l
210
273
147
6.
Chloride
mg/l
592
728
414.4
Notes for Table 3 & Table 4:
The Polished TSE capacity is calculated based on Overall plant recovery of 95%
The Total Dissolved Solids (TDS) at Polishing plant inlet is calculated by blending the Design TDS of
NWC effluent of 1650 ppm and Maximum TDS of treated sewage from Upper plateau STP of 1150
ppm TDS. Margin of (+/-) 30% is considered on TSE inlet from NWC and (+/-)15% is considered
over Treated STP effluent from Upper plateau to arrive at the blending parameters.
For the design of RO system, the minimum and maximum condition temperature considered are
20 °C & 35 °C respectively.
Any other parameters which are not listed down in above table 3 & 4 are assumed to meet the
Treated/ Polished water quality.
The power and chemical consumption indicated is based on the above-mentioned analysis in
Table 3 & Table 4 and it is subjected to changes based on changes in feed analysis.
Reference TSE characteristics
The RO Plant is designed based on the following minimum, maximum and reference conditions
Parameters
Minimum
Maximum
Reference
Temperature (°C)
20
35
20
TDS (mg/l)
1275
2100
1630
TSS (mg/l)
10
19
15
Table 5 Reference TSE characteristics
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CLASSIFICATION: INTERNAL
Notes:
The guarantee performance of TSE plant shall be evaluated based on the reference conditions
specified in above table 5 during commissioning, reliability test and performance guarantee test.
The TSE plant is designed to operate in all conditions between the extreme values given in table
5.
Polished TSE Characteristic
Parameters
Unit
Limit
Overall Plant recovery
%
≥95
Total Dissolved Solids
mg/l
<800
Floatable Materials
-
Absent
TSS
mg/l
5
pH
-
6-8.5
Turbidity
NTU
<2
BOD5
mg/l
<10
COD
mg/l
<50
Oil & Grease
mg/l
Not Detectable
Ammonia Nitrogen
mg/l
<5
Nitrate
mg/l
<10
Free Residual chlorine
mg/l
<0.5
Fecal Coliform
Colony/ 100ml
Not detectable
Egg/L
<1
-
Not Detectable
Helminth
nematodes
Egg/
Colour & Odour
Intestinal
Table 6 Guaranteed quality of Polished TSE
Notes:
The quality of product water shall be guaranteed for the temperature range of 20-35 0C.
Operating conditions shall not defer from design conditions.
Plant shall be operated strictly in accordance with O&M manual supplied along with the plant.
Reliability run and performance guarantee test run to be done at reference design condition
mentioned and correction factor shall be given for complete design temperature range of 20-350C
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CLASSIFICATION: INTERNAL
The parameters which are not specified in feed water analysis are assumed to be compliant to
Polished TSE characteristics.
Actual samples shall be collected, and necessary laboratory testing should be performed to ascertain
the water quality at inlet of TSE Polishing Plant. Analysis provided in the RFP is for indicative purpose
only. No additional cost shall be applicable in case of variation require to be made for plant design.
Waste Water Characteristics
The brine from TSE plant is received in the brine tank. Chemical wastes from the RO CIP is
collected in the Neutralization Pit from where after neutralization, it’ll be transferred to Brine
Tank. The dewatering pits provided in the incoming pumping station and produced water
pumping stations are taken to Brine tank with the help of the dewatering pumps provided at both
the pumping stations.
Combined wastes from the brine tank is then pumped to Evaporation Ponds.
Waste Water from TSE
The waste water stream shall be disposed into the evaporation ponds.
Description
Unit
Value
Waste water Flow Rate- (RO Brine)
m³/h
312.5
Table 7 Waste water flow rate
6.
BRIEF PROCESS DESCRIPTION
Rapid Mixing & Flocculation Tanks
The feed TSE water is received in the raw water buffer tanks wherein it is mixed with the Treated
sewage from upper plateau and pumped to distribution chamber for flocculation Tanks using raw
water transfer pumps. Chlorine is dosed for disinfecting the inlet treated sewage. Static mixer is
provided for rapid mixing in the discharge of raw water transfer pump and coagulant is dosed
and the pH of water is corrected with an acid dosing system. The water then enters the
flocculation chamber distribution basin and to flocculators. Polymer is dosed as an aid to
Coagulated water. Chemical storage, dosing and injection systems are also provided.
Pre-Treatment Section
The Pre-Treatment section shall comprise of Ultrafiltration which will condition the TSE to
produce suitable feed water for the RO trains. It shall reduce the TSS, turbidity, algae, organics
and other contaminants below the desired range from raw water.
Ultrafiltration is provided to remove the TSS and turbidity. The maintenance of these Ultra filters
is ensured by periodic backwashing which includes air scouring, hydraulic backwash with
permeate water, chemical enhanced backwash with Sulfuric acid, Caustic and Sodium
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CLASSIFICATION: INTERNAL
Hypochlorite. The chemical free waste from UF is collected in a sump and is recycled. The chemical
waste is taken to N-Pit wherein it is neutralized and taken back for recycle with N-Pit Transfer/ CEB
recycle Pumps
The CIP waste generated is taken to neutralization pit and further the neutralized waste is
transferred to Brine Tank for disposal.
Recycling of UF Backwash and Chemically enhanced waste is done by passing the water through
a flash mixer, flocculator and Lamella clarifier. Ferric and Polymer are dosed for proper flocculation
before the Lamella. The clarified water is pumped to inlet of Raw water tank Distribution
Chamber. The lean sludge from lamella is discharged into the existing Sewer.
The pretreatment shall also allow for de-chlorination of the pre-treated water. Appropriate
chemical treatment for pH adjustment and control of membrane scaling is also provided.
Filtration of chemicals dosed to RO header is done by cartridge filters at dosing pump discharge
for protecting the RO from any Suspended solids in dosing. The pre-treatment facility is designed
to allow the plant to operate at full capacity during extreme conditions. Chemical storage, dosing
and injection systems are also provided.
Reverse Osmosis:
Reverse Osmosis System is considered for reduction of TDS present in the influent water to meet
the required quality with blending. Considering the net water demand, 6 RO skids of 25MLD
capacity each are provided. Filtered water from filter is fed to the RO skid. Further, skids are
designed to handle 10% additional flow to maximize the availability.
The RO membrane projection result is carried out considering the membrane age as 3 years. The
reverse osmosis system comprises of multiple skid-mounted modules and to achieve higher
recovery, RO-I and RO-II are considered. RO-I consists of three stages and RO-II has a single stage
with ERD (Turbocharger) to recover the energy from Brine. The overall recovery of the RO system
is designed to be ≥ 95%.
Each RO module is configured with one high pressure feed pump and consists of an array of
pressure vessels installed on racks. The pressure vessel is configured for seven (7) spiral-wound
membrane elements. The RO-II concentrate has an ERD (Turbocharger) and reuse it for
pressurization of the RO-II feed water, and consequently save on power consumption.
RO Membrane chemical clean in place systems are provided. The plant is also equipped with
membrane flushing system to take care of RO flushing operation during plant shutdown.
Reject Section
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CLASSIFICATION: INTERNAL
The brine stream generated from RO-II plant is transferred to brine storage tank and further
disposal into evaporation pond.
CIP wastes from RO & UF are taken to 3-Compartment N-Pit and the Neutralized waste is
transferred to Brine tank.
7. BATTERY LIMIT CONDITIONS
Incoming TSE water
The incoming TSE is taken from the raw water buffer tank.
Pressure kg/cm2(g)
Temperature (°C)
Sl. No
Stream Description
Operating
Design
Operating
Design
1
Inlet TSE
ATM
ATM
20-35
20-35
Table 8 Incoming TSE
Polished TSE water
The Polished TSE is collected in Polished TSE buffer tank and is pumped to Polished TSE tank
Sl. No
1
Stream Description
At the outlet of Polished
Transfer Pump
Pressure kg/cm2(g)
Temperature (°C)
Operating
Design
Operating
Design
2.5
3.75
20-35
20-35
Table 9 Polished TSE
Waste Water Disposal
Waste water from TSE plant shall be disposed into the Evaporation Pond and Sludge (0.5%
consistency) to existing sewer line.
Sl. No
1
Stream Description
At the outlet of Brine
Transfer Pump
Pressure kg/cm2(g)
Temperature (°C)
Operating
Design
Operating
Design
2.0
3.5
20-35
20-35
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CLASSIFICATION: INTERNAL
2
Sludge Transfer Pump
2.0
3.5
20-35
20-35
Table 10 Waste water disposal to evaporation ponds
8. PLANT CONFIGURATION
Rapid Mixing & Flocculation Section
7 X 16.67% raw water pumps are provided for Rapid Mixing & Flocculation Tanks
1 x100% Rapid Mixer (Static Type) is provided followed by 6 X 16.67% Flocculation Chambers.
Pre-Treatment Section
7x 16.67% Self-cleaning filters are provided before 13 x 8.34% Ultra filtration Skid to ensure
proper filtration in the per treatment section this leads to sufficient removal of TSS and
Turbidity.
Recycling system includes 1 X 100% Backwash waste collection Sump. 3X 50% Backwash waste
transfer pumps, 2X 75% Flash mixer, Flocculator and Lamella Clarifier. 1X100% Clarified water
sump and 2 X100% transfer pumps to Raw water distribution Chamber. 1X100% Sludge pit
and 2X100% Sludge transfer pumps to sewer.
Reverse Osmosis Section
A set of 6 x 16.67% RO-1 skids are provided to serve the purpose of reducing TDS level from
the feed to make it potable. Similarly, to increase recovery, 6 x 16.67% RO-2 skids are
provided.
RO Reject Section
Two (2) no. of brine tank to collect RO brine from the skids are provided to further transfer
the brine to Evaporation Pond.
2X100% N-Pit Transfer/ CEB recycle Pumps.
Chemical Storage cum Dosing System
All the Chemical tanks and transfer pumps are designed to meet the requirements of PhaseI and Phase-II
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CLASSIFICATION: INTERNAL
Two (2) nos. of Storage cum dosing Coagulant (FeCl3) (40%) Tanks are provided which includes
the chemical requirement of filters and Two (2) nos. of transfer Pump is provided for unloading
of chemicals.
Two (2) nos. of Storage cum dosing Sulphuric Acid (98%) Tanks is provided which includes the
acid requirement for filters and Two (2) nos. of transfer Pumps is provided for unloading of
chemicals.
Two (2) nos. of Storage cum dosing Caustic (25%) tank is provided which includes the caustic
requirement for pH balancing the RO feed. Two (2) nos. of transfer pump is provided to unload
the chemical. Two(2) storage cum dosing tank for Sodium hypochlorite for UF CEB.
Two (2) nos. of dosing tanks are provided for Scale-Inhibitor and Two (2) nos. of dosing tanks
are provided for Sodium metabisulphite,
One number of Chemical preparation tank with 2 Nos. (2 x100%) and 2Nos. of (2 x 100%)
cartridge filters are provided RO CIP operation.
Two (2) nos. Auto poly dosing system for flocculator in Lamella.
9. CHEMICALS USED
The following are the chemicals used
Chlorine gas
Coagulant (FeCl3)
Scale- Inhibitor
Sulphuric Acid (H2SO4)
Sodium MetaBiSulphite (SMBS)
Caustic (NaOH)
Polymer
Chlorine Gas
Description
Value
Purpose
For Pre-Chlorination and Post Chlorination
Available Form
Gas
Commercial grade
100%
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CLASSIFICATION: INTERNAL
Dilution requirement
No, Dosed as chlorine solution
Dosing cum Storage Tank
Tonners Storage in Chlorination Building
Table 11 Chlorine Gas (Cl2) Details
Coagulant (FeCl3)
Description
Value
Purpose
For Coagulation in Raw water & Recycle of waste
Available Form
Liquid
Commercial grade
40%
Dilution requirement
No
Dosing cum Storage Tank
Two No. (2) Coagulant Dosing cum Storage Tanks
Table 12 Coagulant (FeCl3) Details
Sulphuric Acid
Description
Value
Purpose
For pH Correction of incoming TSE & N-pit
Available Form
Liquid
Commercial grade
98%
Dilution requirement
No
Dosing cum Storage Tank
Two Nos. (2) Acid Dosing cum Storage Tanks
Table 13 Sulphuric Acid Details
Scale Inhibitor
Description
Purpose
Available Form
Value
For Scale inhibition, to prevent scaling/fouling of membranes in RO
Membrane
Liquid
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CLASSIFICATION: INTERNAL
Commercial grade
100%
Dilution requirement
No
Storage
Dosing tank
Will be stored in commercially available delivery drums in chemical
building
Two No. (2) Dosing Tanks
Sodium MetaBiSulphite (SMBS)
Description
Value
Purpose
For neutralization of any residual chlorine in RO feed
Available Form
Powder
Commercial grade
65%
Dilution requirement
Yes (35%)
Storage
Dosing tank
Will be stored in commercially available bags of 25-50 kgs in the
chemical building.
Two (2) No. Dosing Tanks
Table 14 Sodium MetaBiSulphite Details
Caustic
Description
Value
Purpose
For pH correction in Polished TSE & N-Pit
Available Form
Liquid
Commercial grade
25%
Dilution requirement
No
Dosing cum Storage tank
Two (2) Nos. of storage tank
Table 15 Caustic Details
Polymer
Description
Value
Purpose
For flocculation of Lamella Sludge
Available Form
Powder
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CLASSIFICATION: INTERNAL
Commercial grade
100%
Dilution requirement
Auto Poly preparation system
Dosing cum Storage tank
Two (2) Nos.
Table 16 Polymer Details
10. WASTE DISPOSAL
RO unit will produce different types of liquid wastes in particular:
-Brine and Neutralized Waste: RO brine and Neutralized waste is collected in the brine tank
and is pumped to Evaporation Tank
-Sludge- The sludge from Lamella will be pumped to nearest Sewer line
11. EQUIPMENT PHILOSOPHY
Equipment philosophy of TSE Package considers the need for maintenance and inspection, as
well as flexibility for operation when group of units are shutdown. Major equipment details
will be as follows based on 150 MLD capacity. For entire equipment details, please refer the
Equipment list:
7 X 16.67% Raw water pumps
1 X 100% Rapid Mixer
6 X 16.67% Flocculation Chambers
2 X 100% Chlorine booster Pump-Pre-treatment
2 No. Coagulant Storage tanks
2 x 100% Coagulant Dosing pumps
2 x 100% Coagulant Transfer pump
2 No. Sulphuric Acid Storage tank
2 x 100% Sulphuric Acid Dosing pumps-Pre
2 X 100% Sulphuric Acid Dosing- N-Pit
2 x 100% Sulphuric Acid Transfer pump
7 x 16.67 Self-cleaning filters
13 x 8.34 % UF Skids
3 x 50 % Air blowers for UF air scouring
3 x 50% Backwash Pump for UF backwash
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CLASSIFICATION: INTERNAL
2 x 100% UF CEB-I-Acid Dosing Tank
2 x 100% UF CEB-II- Caustic Dosing Tank
3 x 50% UF CEB-I-Acid Dosing Pump
3 x 50% UF CEB II-Caustic Dosing Pump
2 x 100% UF CEB-III- Hypo Dosing Tank
3 x 50% UF CEB III-Hypo Dosing Pump
2 x 100% Hypo Unloading Pump
1X100% UF Backwash waste sump
3X50% Lamella Clarifier feed pump
2X75% Flash mixer, Flocculator & Lamella Clarifier
1X100% (3-Compartment) N-Pit
2X100% N-Pit transfer/ CEB Recycle Pump
2 x 50% Sludge Transfer Pump
2 x 100% No. Scale Inhibitor Dosing tanks
2 x 100% Scale Inhibitor Dosing pumps
2 x 100% cartridge filter for Scale inhibitor Dosing
1 x 100% Scale Inhibitor Barrel Pump
2 x 100%. Sodium Metabisulphite Dosing tanks
2 x 100% Sodium Metabisulphite Dosing pumps
2 x 100% cartridge filter for Sodium Metabisulphite Dosing
2 x 100% Caustic Dosing cum Storage tank
2 x 100% Caustic Dosing pumps for Polished TSE
2 x 100% Caustic Transfer pump
2 x 100% Caustic Dosing- N-Pit
7 x 16.67% High pressure pumps for RO-I & RO-II (Store Standby)
7 x 16.67% Inter-stage Booster Pumps for RO-I stage 1 and stage 2 (Store Standby)
7 x 16.67% Energy Recovery device (Store Standby)
6 x 16.67% RO-I & RO-II Skids
2 x 100% CIP Tank
3 x 50% RO CIP Pump
2 x 100% Cartridge filters for RO CIP
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CLASSIFICATION: INTERNAL
2 x 100% RO Flushing pumps
2 x 100% Dewatering pumps each for Chemical Building, DMF Shed & RO Shed
2 x 100% Chlorine booster Pump-Post treatment
3 x 50% Brine transfer Pumps
2 x 100% Air blower for N-pit
2 x 100% Service water pumps
6 x 100% Dewatering pumps in Various Areas
12. PROCESS SAFEGUARDING
ORP, Conductivity & Silt Density Index analyzer are provided at inlet header RO skid. It is the
first priority in the RO plant to safeguard the RO membranes from getting exposed to the free
residual chlorine which oxidizes the membrane and leads to degrade permeate quality with
partial damage or complete damage of membranes if exposed for a longer time. In case ORP
is high, RO feed is dumped in to the raw water buffer tank by opening the valve.
13. LIST OF ASSUMPTIONS
The Inlet TSE parameters as mentioned in Table 3-2 of Annex-J, Polishing Plant Performance
specifications do not indicate any variation in Temperature. The inlet TSE temperatures are
assumed to be 20 Deg C to 35 Deg C. This assumption is based on the temperature variation
of Inlet Sewage to STP. Any variation in above assumed temperature will affect the quality and
performance of the plant.
The Inlet TSE parameters as mentioned in Table 3-2 of Schedule-3, Performance specifications
indicates the TDS level in the inlet water. There is no ionic breakup for the given TDS values.
For designing the RO system at a recovery of ≥95%, ionic balance as per table 4 is assumed.
Any variation in above assumed parameters will affect the quality and recovery of RO system.
The parameters which are not specified in feed water analysis in Table 3-2 of Annex-J,
Polishing Plant are assumed to be compliant to Polished TSE characteristics.
The polished TSE characteristics as mentioned in Table- 7 is as per table 3-3 of Schedule- 3,
Performance specifications are considered for designing of the TSE package and are assumed
to meet the codes & standards as specified Clause 3.3 of Annex-J, Polishing Plant Performance
specifications.
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CLASSIFICATION: INTERNAL
14. PIPING DESIGN BASIS (TSE)
PIPING DESIGN BASIS FOR
MATERIAL OF CONSTRUCTION FOR PIPES:
SI. No
Description
Pipe MOC
1
From Raw Water Buffer Tank to RO High GRP
Pressure pump Suction
(Polyester resin)
SS316L
2
3
4
RO-1 High Pressure discharge (Feed) ,
RO-1 Reject, RO-1 Inter stage Booster
pump discharge(Feed), RO-1 & RO-2
Permeate Skid Piping
RO-1 Inter stage reject and RO-2 High
Pressure pump Discharge (Feed) and
Reject
RO Flushing, RO CIP, RO Permeate
Header, Lime, Treated Water piping &
Service Water
Pressure Rating /
Thickness
PN10
40S Up to DN200
(Seamless up to DN 80 & Welded and 10S for
for DN 100 & above)
DN250 & above
(ASME B36.19M)
Duplex SS (Seamless up to DN 80
&
Welded for DN 100 &
40S (ASME
B36.19M)
above)
GRP
(Polyester resin)
PN10
GRP
5
Low Pressure RO Brine
(Polyester resin)
PN10
SS316L
10S (ASME
B36.19M)
6
Air lines
(Welded Type)
7
Chemical lines
UPVC
SCH 80
Note: 1. GRP Pipe Stiffness 2500 N/m2 for above ground.
2. GRP Pipe Stiffness 5000 N/m2 for below ground.
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CLASSIFICATION: INTERNAL
MATERIAL OF CONSTRUCTION FOR VALVES:
SI.
No
Valve Type
Service
MOC
From Raw Water Buffer Tank to RO High
Pressure pump Suction
Body: DI, Disc: SS316L,
Seat/Seal: EPDM
RO-1 High Pressure discharge (Feed) RO-1 Body: DI, Disc: SS316L,
Reject, RO-1 & RO-2 Permeate Skid Piping Seat/Seal: EPDM
RO-1 Inter
discharge(Feed)
stageBooster
Rating
PN10
PN16
pump
Body & Disc: SS316L
300#
RO-1 Inter stage reject and RO-2 High
Pressure pump Discharge (Feed) and
Body & Disc: Duplex SS 300#
Reject
1
Butterfly
Valves (Wafer
up to DN 600 RO Flushing, RO CIP, RO Permeate Header, Body: DI, Disc: SS316L,
&
Lime, Treated Water piping & Service Seat/Seal: EPDM
PN10
Water
Flanged
above DN600)
Body: DI, Disc: Duplex
SS, Seat/Seal: EPDM
Low Pressure RO Brine
PN10
From Raw Water Buffer Tank to RO High
Pressure pump Suction, RO-1 High
Pressure discharge(Feed) , RO-
2
Dual
Plate
Body & Plate: SS316L 150#
1 Reject, RO-1 & RO-2 Permeate Skid Piping
Check Valves
(Wafer up to RO-1 Inter
stageBooster pump
DN600 and discharge(Feed)
Body & Disc: SS316L 300#
Flanged
above DN600 RO-1
Inter stage reject and RO-2 Body & Plate: Duplex SS
)
High Pressure
pump
300#
Discharge(Feed) and Reject
RO Flushing, RO CIP, RO Permeate Header,
Lime, Treated Water piping & Service
Body & Plate: SS316L
Water
150#
Body & Plate: Duplex SS
Low Pressure RO Brine
150#
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CLASSIFICATION: INTERNAL
From Raw Water Buffer Tank to RO High
Pressure pump Suction, RO-1 High
Pressure discharge(Feed), RO-1 Reject, RO1 & RO-2 Permeate Skid Piping
Body & Ball : SS316L, 150#
Seat: PTFE
RO-1 Inter stage
discharge(Feed)
Booster
pump Body & Ball : SS316L,
Seat: PTFE
300#
RO-1 Reject, RO-1 Inter stage Booster
pump discharge(Feed) & reject and RO-2
Body & Ball : Duplex SS,
High Pressure pump Discharge (Feed) and
Seat: PTFE
Reject
300#
3
Ball Valves
RO Flushing, RO CIP, RO Permeate Header,
Lime, Treated Water piping & Service
Body & Ball : SS316L, 150#
Water
Seat: PTFE
Low Pressure RO Brine
Ball
Valve
4
Body & Ball : Duplex SS,
Seat: PTFE
150#
Chemicals
Body & Ball : UPVC
PN10
Chemicals
Body & Ball : UPVC
PN10
Check
PIPE SIZING CRITERIA:
Velocity in m/s (Max.)
SI. No
Description
1
Pump Suction
1.5
2
Pump Discharge
2.5
3
Chemical Pump Discharge lines
1.8
4
Air Lines
20
5
Gravity lines
1
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CLASSIFICATION: INTERNAL
ASSUMPTIONS:
Butterfly valves shall be concentric design with wafer end up to size DN600 for low pressure
application.
SS316L piping shall be used only for following lines,
RO high pressure lines
Ro Skid permeate piping up to permeate header
Airlines.
SS316L seamless pipe shall be given up to DN80 & Welded pipe shall be given for DN100 & above.
Type of valve shall be followed as per P&ID submitted in the technical offer.
HVAC System & Material Handling:
•
Supply, installation testing and commissioning of HVAC system for all the buildings
which includes electrical and control room buildings, admin building etc.
•
Supply, installation and testing commissioning of ventilation system for all the rooms
as per local standards, OEM recommendations and applicable international standards.
•
Power supply and control works related to HVAC work.
•
Supply and installation of fire alarm detection and fire protection works for the
complete plant as per recommendation of technology providers, international standards,
HCIS and other applicable local standards.
•
Supply and installation of EOT cranes, hoists and other material handling systems as
per recommendations of OEM’s.
•
Complete plumbing, drainage and irrigation networks for the plants usage.
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CLASSIFICATION: INTERNAL
15.
ICT
A. INTRODUCTION
B. INTRODUCTION
This document furnishes the design specification of Control & Instrumentation 150 MLD RO based TSE
for Qiddiya Utility Project. The scope of work includes the necessary monitoring and control
equipment required for the safe and reliable operation of the plant.
Overall Control and monitoring of the plant will be from a PLC based control system with a SCADA
system for monitoring. Operation of facility and treatment processes will normally be from the PLC
located in the Control Room. The Signals from the field instruments shall be terminated in the PLC.
The Proposed PLC system, Automation System Configuration diagram shall be provided with the offer.
C. INSTRUMENTATION
Field Instruments
The following requirements are considered in the selection of Instrumentation and Control:
All electronic transmitters shall be SMART type with (4 – 20 mA conforming to
Protocol, fieldbus technologies- Foundation fieldbus and Profibus DP)
HART
All Motorized Valves shall communicate to PLC through hardwired cables.
All Transmitters shall be with IP–65 enclosure
Wherever standby drives are envisaged, auto start of standby drives shall be provided, when the
running drive is tripped.
Instruments shall be as per the List of Instruments attached with the offer.
Typical Signal Flow Scheme
Single Pair Cable
Junction Box
Multi pair Cable
DCS in Control
Room
Instrument
The following are the common type of instruments envisaged to measure relevant process parameters
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CLASSIFICATION: INTERNAL
Process Parameter
Instrument (PLC monitoring)
Instrument (Local field monitoring)
Pressure
Pressure Transmitter with Local Pressure Gauge
Indicating at field
Differential Pressure
Differential
Pressure
Local indication in Transmitter
Transmitter
with
Local
Indicating at field
Level
Radar Type Level Transmitter
Flow
Electromagnetic Type Flow Rota meter /
Corresponding
Meter / Orifice Type Flow
local indication of the flow
Meter
meters.
Analyzers
pH/Turbidity/ORP/Conductivity All analyzers equipped with local digital
Analyzers
indication at field
Local indication in Transmitter
The interrogation voltage level for the instruments is 24 VDC and the PLC is equipped with a power
supply form the Uninterrupted Power Supply (UPS) of the Plant. The plant is also equipped with local
instruments for monitoring at field such as Pressure gauges, Level gauges and rota meters
The PLC controls the process by means of the Final Control Elements. The final control elements in the
plant include the drives / motors associated with the Pumps, the control valves and the ON/OFF valves.
The Pumps in the plant are either Variable Frequency Driven (VFD) or normal Direct On-Line Starter
(DOL) equipped. The Control valves are motorized control valves and the ON/OFF Valves are either
motor actuated valve.
D. FINAL CONTROL ELEMENTS
The PLC controls the process by means of the Final Control Elements. The final control elements in the
plant include the drives / motors associated with the Pumps, the control valves and the ON/OFF valves.
E. PUMPS AND MOTORS
The Pumps in the plant are either Variable Frequency Driven (VFD) or Soft Starter Driven or normal
Direct On-Line Starter (DOL) equipped. The following are the list of signals and commands available at
the PLC for control of the respective type of drives
F. VARIABLE FREQUENCY DRIVES
FEEDBACK SIGNALS (TO THE PLC)
COMMNADS (FROM THE PLC)
Run Feedback (DI)
Start / Stop Command (DO)
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CLASSIFICATION: INTERNAL
Local / Remote Selector Switch Feedback (DI)
Speed Control Command (AO)
Trip Feedback (DI)
Emergency Stop Feedback (DI)
Speed Feedback (AI)
G. DRIVES WITH SOFT STARTER OR DIRECT ONLINE STARTER
FEEDBACK SIGNALS (TO THE PLC)
COMMNADS (FROM THE PLC)
Run Feedback (DI)
Start Command (DO)
Local / Remote Selector Switch Feedback (DI)
Stop Command (DO)
Trip Feedback (DI)
Emergency Stop Feedback (DI)
H. CONTROL VALVES.
The control valves are pneumatically actuated control valves and serve to control the process and
operate in a closed loop function. The Control valves are suited to adjust opening / closing of the valve
in relation to achieve a suitable value of the process parameter (in most cases, the parameter is
flow rate). The control valve material shall be compatible with the process fluid handled. The control
valves shall be equipped with a SMART positioner.
FEEDBACK SIGNALS (TO THE PLC)
COMMNADS (FROM THE PLC)
Valve percentage Open Feedback (AI)
Valve Open Command (AO)
Valve Fully Open Feedback (DI)
Valve Fully Close Feedback (DI)
I.
ON/OFF VALVES
The ON/OFF valves are pneumatically actuated valves which serve the purpose of isolation and
sequencing of process steps. These valves are either 100% percent open or 100% closed. The ON/OFF
Valves are equipped with 24 VDC based Proximity type limit switches. The Limit Switches are provided
for open and close positions and provide feedback to the PLC of the valve status by means of NO/NC
Contacts. The actuation of the ON/OFF valves is enabled by means of a Solenoid valve which controls
flow of compressed air in the actuator to either close or open the valve. The Solenoid valve shall be a
3/2 Way or 5/2 Way, electrically actuated spring return solenoid valve. The solenoid valves operate
on a voltage level of 24 V DC. The Solenoid valves shall be as per NAMUR standard mounting, i.e.
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CLASSIFICATION: INTERNAL
Solenoid valves shall be mounted on valve body. The Limit switches shall be kept in an enclosure and
mounted on the valve.
FEEDBACK SIGNALS (TO THE PLC)
COMMNADS (FROM THE PLC)
Valve Open Feedback (DI)
Valve Open/Close Command (DO)
Valve Close Feedback (DI)
J.
LOCAL AND REMOTE MODE OPERATION
The drives / motors in the plant shall be operated directly from control room or can also be operated
directly from the field. The following modes of operation of the drives are envisaged for the plant.
I.
Local Mode of Operation
The drives/pumps can be operated directly from the field. Each drive is equipped with a Local Push
Button Station (LPBS). The LPBS is equipped with START and EMERGENCY STOP push buttons to effect
local start/stop of the drive. A Local/Remote Selector Switch (SS) shall be provided. This switch should
be kept in the local mode to enable the local operation of the drive. The local mode of operation of
the drives is provided for maintenance and testing purposes.
II.
Remote Mode of Operation
The remote mode of operation refers to the control of the drives from the PLC. The drives can be
started or stopped from the PLC. The remote mode operation is further classified as follows.
III.
Remote Auto Mode
In this mode, the drive is operated from the PLC according to the built in logic developed in the PLC
System. The operation of the drive is according to the Logic program and is effected only when
necessary process conditions are satisfied.
IV.
Remote Manual Mode
In this mode, the drive can be started or stopped from the PLC by means of Operator command. This
mode is enabled through software configured push buttons by which the operator can start or stop
the respective drives from the control room. The operator can select this mode by clicking on the
Manual mode in the Auto/Manual push button window at the operator screen.
K. CABLES
I.
Signal Cables
The transmitters are wired to junction boxes and further to the PLC by means of pair cables. Pair cables
of 1P, 2P, 6P, 12P or 20P are used in the plant as per requirement. The pair cables shall have an
insulation grade of 600 V. The single pair cables shall be 1.0 Sq.mm conductor size and multipair cable
shall be 1.5 Sq.mm conductor size, made of electrolytic copper. Shield shall be aluminum backed
Mylar / polyester tape bonded together with the metallic side down helically applied with either side
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CLASSIFICATION: INTERNAL
having 25% overlap and 100% coverage. The minimum shield thickness shall be 0.05 mm in case of
single pair / triad and 0.075 mm in case of multipair cable. The cables shall have a primary insulation
of Type C PVC. The inner and outer jacket shall be PVC Type ST-2. All cables shall be twisted and
armored. Armor over inner jacket shall be galvanized steel wire / flat.
II.
Control Cables
The feedback and control signals of ON/OFF valves and drive related signals (from MCC) are wired to
the PLC by means of Control Cables. The Control cable types of 2C, 4C, 12C, 19C, 27C or 37C are used
in the plant as per requirement. The cables shall have an insulation grade of 600 Volts. The core cables
shall have a conductor size of 1.5 Sq.mm made of electrolytic copper conductor. Shield shall be
aluminum backed Mylar / polyester tape bonded together with the metallic side down helically
applied with either side having 25% overlap and 100% coverage. The cables shall have a primary
insulation of Type C PVC. The inner and outer jacket shall be PVC Type ST-2. All cables shall be armored.
The armor over inner jacket shall be galvanized steel wire / flat.
The following standards shall be applicable for signal and control cable design IS-5831, IS-1554 Part I,
IS 8784 and BS 5308. 20% Spare cores or pairs shall be provided in the multi-pair and multi core cables.
Cables shall be laid either in trays or concrete trenches within buildings and shall be directly buried
when laid outside buildings. The cable trays shall be galvanized sheet steel. The cable trays shall be of
perforated type or ladder type. The cable trays shall be 2 mm thick.
L. CONTROL SYSTEM
The TSE plant is equipped with a Programmable Logic Controller (PLC) based central control system
Equipped with Human machine Interface (HMI). The Control System consists of the following:
Dual Redundant Server
Historian Server
Redundant I/O Power Supply
Redundant I/O communication
Non Redundant I/O Modules
2 Nos. Operator Station in control room
1 No Maintenance Laptop (Industrial Grade)
1 No. A4 Laser Printer in control room
All the signals from field /MCC shall be terminated at the marshaling cabinet on the rear side of the
panel.
The signals to the PLC shall be galvanically isolated at the input modules. Power for field transmitters
(24 VDC) and field contact circuits shall be provided from the PLC panel. All digital outputs shall be
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CLASSIFICATION: INTERNAL
through interposing relays mounted on relay boards. The I/O Modules shall have the following channel
configuration
32 Channel Digital Input Modules
32 Channel Digital Output Modules
16 Channel Analog Input Modules
8 Channel Analog Output Modules
M. MISCELLANEOUS ITEMS
I.
Junction Boxes
The instruments from field are wired to the control system through Junction boxes. The Junction
boxes are located at the field representing modular design of the plant. The Junction boxes shall
be IP 65 rated and will have din-rail mounted terminal blocks. The Junction boxes shall have 20%
spare terminals. There shall be in general two types of junction boxes one for analog signals and
one for digital signals. The analog signals comprise of 4-20 mA inputs/outputs and the digital
signals comprises of feedback signals and commands of the Switches & pneumatic valves.
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CLASSIFICATION: INTERNAL
II.
Cable Glands
Cable glands shall be provided for cable entry to instruments, Junction box and panels. Cable
glands shall be double compression type. The material of constructions shall be nickel plated
brass.
III.
Instrument Fittings
Instrument fittings shall be double compression tube fittings. The material of construction of the
fittings shall be SS. Compressed air to the ON/OFF and control valves shall be routed through
suitable pressure rated tubing. This will ensure operation and maintenance flexibility along with
good aesthetic design.
Hart Communicator
A hand-held Hart communicator shall be provided for calibration of all smart instruments.
N. LIST OF ASSUMPTIONS
The Control system for this plant shall be a PLC based System with,
Redundant CPU in Control Room
Redundant power supply module
Redundant Communication module
Non Redundant IO modules
The IO channel density for PLC input Output modules shall be as follows,
Digital Input – 32 Channel
Digital Output – 32 Channel
Analog Input – 16 Channel
Analog Output – 8 Channel
TSE system will have a centralized PLC with SCADA for TSE. The TSE package PLC shall be connected to
SCADA over FOC / communication cable.
O. Scope of work for TSE automation, control System and Low Current Systems:
Each treatment unit shall be controlled and operated automatically through the PLC with SCADA or
DCS system. The Control System (PLC / DCS) is required for control and operation of the TSE; with
provision for remote monitoring from Lower Plateau ICT facility (by Qiddiya);
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CLASSIFICATION: INTERNAL
Parameters measurement shall have local as well as remote visualization.
Each unit can be operated locally through local control panels.
The Plant has been divided in 6 modules and the control logic shall be thought to operate the Plant
from 1 to six modules. Operator shall have the option to operate individual modules from the SCADA
system.
PLC with SCADA system or DCS system shall be proposed in line with the Design Basis outlined in the
RFP. The control system shall be based open standard protocols, scalable, interoperable and vendor
agnostic designed on an open architecture. It shall exchange information with other suppliers’ devices
and platforms via industry standard communications, platforms, and protocols (OPC, Modbus, IEC
61850 protocol etc.) and shall be integrated to any Industry standard application of any vendor.
Contractor shall provide necessary handholding for integration of the control system to any third part
centralized control center platform and required API / SDKs to be provided by the bidder for
integrating the control system to centralized control room.
Operator’s workstations with video display units shall be provided in the central control room. Control
system shall have Local control system interface and interface with Utility command center platform.
Communication requirements for integrating control system with Utility control center (UCC) will be
provided to contractor and contractor has to provide the interface ling to UCC. The control center
application and control equipment shall be compliant for Cybersecurity requirements as per KSA and
International standards ISO 27001, IEC 62443 and ISA S99.
TSE control system shall provide the interface and desired IOs for interfacing with other control
systems such as:
Raw water pumping station for automation of pump operation based on the water levels at TSE
/Pumping station and another requirement.
Treated water pumping station
Control philosophy to be developed by the contractor taking into consideration the HAZOP
recommendations and as instructed by Engineer in charge.
Scope of work also includes the ICT systems as outlined in Annex – J TSE performance specifications.
ICT Systems include Structured cabling for creating state of the art Information communication
network for delivering data, voice and video. Following system shall be considered by the contractor
for TSE:
Telecom network and provision for telecommunication system
Wireless access points inside the manned building area
IP telephony
Addressable Fire Alarm System
Security Surveillance System (Vehicle Screening system, Video Surveillance, Access Control system,
PIDS, etc.)
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CLASSIFICATION: INTERNAL
16.
DESIGN BASIS FOR ELECTRIC AND POWER SUPPLY (TSE)
A. ELECTRICAL POWER SYSTEM PHILOSOPHY
Power System Philosophy for Electrical Power System of Water Treatment Plant (TSE) is elaborated
below:
13.8 kV, 60 Hz, 25 kA for 3 Sec., 630A VCB based Indoor MV Switchboard is proposed with 2 Nos.
Incomers, 1 No. Bus Coupler & 6 Nos. Outgoing Feeders. 4 Nos. Outgoing Feeders are for 4 Nos.
Distribution Duty Outdoor Type Oil Filled Transformers & 2 Nos. as Spare.
Based on 6.2 MVA Max. Operating Demand & taking 10% Future Load Growth Margin as well as max.
90% Loading of each Transformer, 4 Nos. 3150 kVA, 13.8/0.42kV, 60Hz, 8.35%, Outdoor Type
Distribution Transformers has been proposed to step down the 13.8 kV MV to 400 V LV for further
downward distribution.
The Transformers rating has been selected in such a manner that in case of failure of 1 No.
Transformer, remaining Transformers shall take care of entire load.
2 Nos. 2500 kVA 400 V LV DG Set is proposed to take care of 50% of load in case of normal power
outage.
2 Nos. 400 V LV Power Control Centre (PCC) is proposed, each with 3 Nos. Incomer, 2 Nos. Bus Coupler
& required nos. of outgoing feeders.
400V 60 Hz Sandwich Type Copper Bus Duct has been proposed from Transformer Secondary / LV Side
to PCC.
2 Nos. 500 kVAR APFC capacitor banks consisting of automatic power factor correction relay to
improve the power factor from 0.85 to 0.95 has been proposed for each PCC.
Grouping of Motors Loads has been done based on the location of Motors of the respective building
& following 400 V LV Motor Control Centres are proposed. All MCC are being proposed to be housed
in respective building.
MCC for Pump House#1
MCC for Pump House#2
MCC for Pump House#3
MCC for Pump House#4
MCC for Chemical Building
MCC for Chlorination Building
MCC#1 for UF-RO Shed
MCC#2 for UF-RO Shed
MCC#3 for UF-RO Shed
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CLASSIFICATION: INTERNAL
VFD has been considered as per process requirement. All VFDs shall be Low Harmonic Type to achieve
THD at Point of Common Coupling (PCC) in compliance with IEEE-519.
VFD shall be of low harmonics type & VFD rated up to 160 kW shall be installed inside the LV Panels
and above 160 kW shall be Standalone.
Motor Voltage Level Selection Criteria
400 V LV Motors - Motors rated up to 500 kW
13.8 kV MV Motors – Motors rated above 500 kW
Motor Starter Selection Criteria
Up to 5.5 kW – DOL
Above 5.5 kW & Up to 55 kW – Star Delta
Above 55 kW – Soft Starter
Normal Lighting for each building is considered through separate Per Phase isolated Three phase
Distribution Boards to be fed from the respective building LV Panel.
Outdoor Lighting DB based on Astronomical Timer has been proposed for Outdoor Illumination.
Conventional 1 kVA & 2 kVA UPS system with Lead Acid SMF VRLA battery backup is proposed for the
emergency lighting with 30 minutes battery backup. Each building shall have dedicated UPS.
A separate Emergency Lighting DB (EDB) is proposed for feeding the emergency lighting for each
building which in turn shall be fed from UPS.
Single phase power for General Purpose as well as Dedicated Power Outlets for Miscellaneous purpose
is proposed through separate Raw Power DB.
1 No. Aux. DB has been proposed for Electrical Room for UPS, Receptacles, HVAC etc.
1 No. PDB has been proposed for Admin Building for making power provision for UPS, RDB, HVAC DB
etc.
1 No. dedicated RDB & 1 No. HVAC DB has been proposed for Admin Building.
1 No. dedicated DB has been proposed for Workshop.
1 No. DB has been proposed for ICT Loads. All electrical items related to ICT Component has been
considered under ICT Package.
B. MAIN ELECTRICAL EQUIPMENT INCLUDING AUXILIARY SYSTEMS
Electrical System for TSE shall be read with conjunction with typical Single Line Diagrams annexed with
this report and shall include, but is not necessarily limited to, the following Electrical Equipment &
Auxiliary System for TSE in accordance with the latest Standards and Local Power Authority (SEC):
13.8 kV, 60 Hz, 25 kA for 3 Sec., 630A VCB based Indoor MV Switchboard
125 V DC Battery System for 13.8 kV MV Switchboard
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CLASSIFICATION: INTERNAL
13.8/0.42 kV, Dyn11, 3150 kVA, 8.35% ONAN type Distribution Transformers
400 V, 60 Hz Sandwich Type Copper Bus Ducts
400 V, 60Hz Low Voltage Diesel Generator Sets
400 V, 60 Hz Low Voltage Power Control Centres
400 V, 60 Hz Low Voltage Motor Control Centres
Automatic Power Factor Correction Panels
All VFDs shall be Low Harmonic Type to achieve THD at Point of Common Coupling (PCC) in compliance
with IEEE-519.
Lighting & Raw Power Distribution Boards
Emergency Lighting Distribution Boards
Local Push Button Station for Motors
13.8 kV MV Cables & Accessories
LV Power & Control Cables and accessories
Cable Carrier System
Indoor & Outdoor Illumination system
Uninterrupted Power Supply (UPS) system for Emergency Illumination
Earthing and Lightning Protection systems
All Safety Items required for Electrical Rooms
C. DESCRIPTION OF MAJOR EQUIPMENT AND SYSTEMS ELECTRICAL EQUIPMENT AND SYSTEMS,
SUCH AS: SWITCHGEARS / TRANSFORMERS / UPS
a.
Switchgear
13.8 kV Medium Voltage Switchgear:
The Medium Voltage switchgear shall be air insulated metal-clad type with modular design for indoor
service, in accordance with relevant IEC standard and SEC regulations. The switchgear shall be of single
bus bar type and each feeder panel shall consist of bus bar, disconnector, earthing switch, vacuum
circuit breaker, current transformer, voltage transformer, cable compartment, and low voltage
compartment with control devices and protection devices to ensure proper operation. MV SWGR shall
be provided with motorized circuit breakers and necessary interface modules with the SCADA control
system (e.g. through Interposing Relay Panel).
Switchgear shall have a degree of protection against contact with live parts or contact with movable
parts and against external effects of IP 4X for enclosures and IP 2X for partitions/shutters according to
IEC 62271-1 and IEC 60529, when in the connected position. Surge arresters will be provided on each
incoming breaker. Control power supply for MV SWGR shall be a complete system, including main LV
switch, battery charger, batteries, racks and connectors. Batteries shall be heavy-duty nickel cadmium
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CLASSIFICATION: INTERNAL
type of capacity sufficient to supply all MV switchgear auxiliary loads, relays, coils, lamps and alarms
for 10 hours. The battery charger shall be automatic voltage controlled, solid state type, suitable for
float and boost charging. The charger shall have AC voltmeter, DC voltmeter, DC ammeter, main
incoming circuit breakers, pilot lights on AC and DC output, and earth fault detector with alarm
indication.
Within the MV Switchgear each relay shall be provided with an interface data link (IEC 61850 or
equivalent) and adequate number of contacts for tripping annunciation, and interface with SCADA
functions. MV switchgear shall comply with IEC 60947-1, IEC 62271-100, and IEC 62271-200.
LV Switchgear:
400 V, 60 Hz LV Switchboard complete in all respect. The Switchboards shall be totally enclosed, freestanding type, Form 3b to IEC 61439-1, housing the copper busbars and the incoming and outgoing
circuit breakers. Incoming and tie breakers shall be of the withdrawable, air circuit breakers type, fully
rated (100%) with continuous duty at site conditions whereas the outgoing breakers shall be fixed
type, totally enclosed, fully rated (100%) and with a frame size and interrupting capacity to IEC 609472 sequence II. Circuit breakers frame size rated 1250 A and above shall be Air type circuit breakers.
Switchboard will house all needed auxiliaries and interfaces with SCADA system (if any) being provided
in the operational control centre (e.g. through Interposing Relay Panel). The Switchboard shall be
installed in the dedicated low voltage electrical Room with 15% spare breakers provided to allow for
future expansion. The Switchboard shall be designed, manufactured and tested to minimum IP41 for
indoor installations and in compliance with IEC 60529 requirements.
b.
Transformers
Transformer shall be oil type with voltage ratio 13.8/0.42 kV, ONAN, Dyn11 with all accessories as per
IEC60076. Distribution transformers shall be three phase, oil type, with 50°C average winding
temperature rise and 45°C top oil temperature rise limits above ambient. The Transformer cooling
shall be by natural circulation of oil internal to the transformer and external air (ONAN), as per SEC
standards. Transformers shall be fitted with a lockable 5 positions, manual, off load tap changer.
c.
UPS
The UPS will consist of rectifier/charger, static by-pass switch, maintenance switch, protective devices,
accessories, etc. along with all mechanical and electrical devices that will automatically ensure power
transfer within specified tolerances. The batteries shall be SMF VRLA type with autonomy of min. 30
min
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CLASSIFICATION: INTERNAL
17.
DESIGN
BASIS FOR CIVIL (TSE)
A. ABBREVIATION
IBC
- International Building code
PS
- Pumping Station
UTILCO
- Utility Company that will undertake the contracts – Alfanar
SBC
- Saudi Building Code
WTP
- Water Treatment Plant
TSE
- Treated Sewage Effluent
B. CIVIL WORKS
Site preparation, Development and Installation
The Subcontractor will be responsible for site preparation and development. Wherever construction
necessitates the excavation below the natural ground level, the Subcontractor shall assess the
feasibility and safety of open slope excavations and wherever required, temporary excavation
supports and protection systems capable of safely resisting soil pressure, shall be designed, provided,
installed, monitored and maintained for supporting the sides of the excavation, and thereafter
dismantled and removed, in a manner accepted by the Qiddiya and at the Subcontractor’s sole risk
and responsibility.
The Subcontractor shall define the Site class and seismic coefficients based on the findings of the site
investigation campaign, geology of the area, and in accordance with the requirements of the Saudi
Building Code ref. SBC 301 – Chapter 14, UBC/IBC and based on the results of the performed
subsurface investigation campaign.
The TSE and TSE plants are in Lower Plateau area. All the Tanks are of cast-in-situ RCC. The equipment,
pumps, skids are kept on RCC pedestals.
Architectural drawings and shop drawings also shall the scope of contractor.
Food, accommodation, and transportation for the labour shall be in the scope of contractor.
Foundation
For all the Pumping stations, buildings, isolated footing is adopted and for all reservoirs, raft is
adopted. The grade of concrete for footing is C25. A 100mm thick PCC layer of grade C15 is laid below
footing.
Buildings and Structures
There are 14 structures in TSE and 12 structures in TSE plant. They are shown below:
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CLASSIFICATION: INTERNAL
Table 17 Structures and Mode of construction for TSE in Lower Plateau
S.NO.
TSE
MOC
Administration office building
Cast-in-situ RCC
Satellite warehouse/ Workshop
Steel Truss roof with
RCC floors
Guardroom
Cast-in-situ RCC
Staff Rooms
Cast-in-situ RCC
UF & RO Shed
Steel Truss roof with
RCC floors
Pump House - 1 (Raw water Pump
Cast-in-situ RCC
house)
Pump House - 2 (UF feed Pump
Cast-in-situ RCC
house)
Pump House - 3 (Brine transfer
Cast-in-situ RCC
Pump house)
Pump House - 4 (Treated water
Cast-in-situ RCC
Pump house)
Chemical Building
Cast-in-situ RCC
Gas chlorination building
Cast-in-situ RCC
Limestone
Filter
Shed
Limestone storage Area
&
Cast-in-situ RCC
CO2 storage shed
Cast-in-situ RCC
Electrical Building
Cast-in-situ RCC
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CLASSIFICATION: INTERNAL
Table 18 Structures and Mode of construction for TSE plant in Lower Plateau
S.NO.
TSE
MOC
Administration office building
Cast-in-situ RCC
Satellite warehouse/ Workshop
Cast-in-situ RCC
Guardroom
Cast-in-situ RCC
Staff Rooms
Cast-in-situ RCC
UF & RO Shed
Steel Truss roof with
RCC floors
Pump House - 1 (Raw water Pump
Cast-in-situ RCC
house)
Pump House - 2 (UF feed Pump
Cast-in-situ RCC
house)
Pump House - 3 (Brine transfer
Cast-in-situ RCC
Pump house)
Pump House - 4 (Treated water
Cast-in-situ RCC
Pump house)
Chemical Building
Cast-in-situ RCC
Gas chlorination building
Cast-in-situ RCC
Electrical Building
Cast-in-situ RCC
The above building roofs should be capable to withstand the loads of Solar Panels and associated
structures suitable for operating the PV Plant.
The buildings / sheds to be built by contractor shall be in line with the theme works proposed by
Qiddiya to adhere aesthetic look perspective.
Chain Link Fencing to be provided by subcontractor for isolating STP area from other utilities in
Upper Plateau Area.
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CLASSIFICATION: INTERNAL
Site roads, access and parking/loading facilities
A general circulation road is meant to connect all units in the plant. Each treatment unit shall have its
own access for the operation and maintenance purposes to allow entrance and enough maneuvering
space. The minimum requirements to be followed inside TSE are given below:
The design speed should not exceed 30kph.
The minimum lane width for internal roads is 6.0 m. A gap of 5m is left on both sided of the road for
landscaping work.
2 lanes shall be guaranteed.
Shaded parking facility is provided for 8 vehicles in TSE plants.
The longitudinal slopes are flat, due to the nature of the flat topography.
The transverse slopes are designed at 1.5%, to facilitate storm water drainage.
Sidewalks are variable with a minimum width of 0.60 m to ease the circulation of pedestrians within
plant and to protect the adjacent plots.
An adequate turning radius should be provided by the Subcontractor of the plants to facilitate trucks’
movements, such radius shall be a minimum of 5 meters.
C. TANK FOUNDATIONS
For all tanks, raft is adopted. The minimum raft thickness is 300mm. The grade of concrete is C25. A
100mm thick PCC layer of grade C15 is laid below footing.
Security fencing and gates
For lower plateau area, perimeter fencing is of Themed concrete boundary reflecting Qiddiya vision is
proposed. The WTP and TSE area has another boundary fence other than the one in lower plateau.
The plants are to be enclosed by a decorative fence over all height ranging 2-2.5m. The lower 1/3 of
height is to be in solid concrete blocks or concrete with paint on plaster finish while the remaining in
whatever appropriate perforated concrete design. The gates for pedestrian & vehicular access to the
utility area need to match fence design. All necessary fixture & fitting to gates need to be provided to
secure closure at desired times.
D. CIVIL DESIGN CRITERIA
List of Codes and Standards
SBC 304:
SBC 306:
SBC 301:
ACI 318:
Saudi Building Code -Concrete structural requirements
Saudi Building Code -Steel structural requirements
Saudi Building Code -Loading and Forces
Building Code requirements for structural concrete
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CLASSIFICATION: INTERNAL
Geotechnical Report Data
Below mentioned are the data extracted from the Geotechnical report prepared by DAR group and
submitted to Qiddiya Smart City.
According to Chapter 9 of the Geotechnical report, the seismic site classification is Class C.
According to section 7.1.1.1.3 of Geotechnical report, the Safe Bearing Capacity in Upper Plateau is
taken as 600kN/m2 and 200kN/m2 in lower plateau at a depth of 1.5m below the ground level.
The average Unit weight of the soil is 20kN/m3.
The friction angle is 30 degrees.
Dead Load
The dead loads are calculated based on unit weights of materials given in SBC 301.The dead load
considered in the structural design shall consist of the full weight of all known fixed structural and
architectural elements. The weight of fixed service equipment like crane and the weight of all process
equipment including all shall be considered in dead load.
Unless otherwise specified; the unit weight of materials will be used as follows:
Reinforced concrete
24.00 kN/m3
Plain concrete
23.00 kN/m3
Brickwork
21.00kN/m3
Wrought steel
75.50 kN/m3
Water
9.81 kN/m3
Live Load
All the live loads shall be as per SBC 301. In general, following Live load on roof from section 4.9 of the
code shall be used for ordinary flat, pitched or curved roofs.
Lr = 1.0 R1 R2 where, 0.6 ≤ Lr ≤1.0
R1 & R2 are reduction factors
1
For At<18m2
R1=
1.2-0.0111At
For 18 ≤ At ≤54m2
0.6
At≥54m2
At: Tributary area in m2 supported by any structural member
1
For F<4
1.2-0.05F
For 4≤ F ≤12
0.6
F≥12
Where F for a pitched roof = 0.12 x slope, with slope expressed in percentage.
R2=
For a flat roof F=0
Seismic Load
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CLASSIFICATION: INTERNAL
Every buildings and portion thereof, shall be designed and constructed to resist the effects of
earthquakes in accordance with section 9.1.2.2 of SBC 301. The structures are primarily column and
beam framing system. According to section 10.9 of Saudi Buildings Code SBC-301, the total seismic
base shear force V is determined as follows:
V = Cs X W, where
Cs: Seismic coefficient
W: Total weight
V: Base shear
The seismic design coefficient (Cs) shall be determined in accordance with the following equation:
Cs = SDS / (R / I)
SDS: Design spectral response acceleration in the short period range
R: Response modification factor
I: Occupancy importance factor
The value of Cs should be in range of
0.044SD1 I ≤Cs ≤SD1 / [T. (R /I)]
T = 0.1N
Where N = Number of stories
T = Fundamental period of the structure (sec)
Design earthquake spectral response acceleration at short periods, SDS, and at 1-sec period, SD1, shall
be as follows.
SMS= Fa*SS (EQ-1)
SM1= Fv*S1 (EQ-2)
SDS= 2/3*SMS (EQ-3)
SD1= 2/3*SM1 (EQ-4)
SS: the maximum spectral response acceleration at short periods
S1: the maximum spectral response acceleration at a period of 1 sec
Fa: acceleration-based site coefficient
Fv: velocity-based site coefficient
SMS: the maximum spectral response acceleration at short periods adjusted for site class
SM1: the maximum spectral response acceleration at a period of 1 sec adjusted for site class
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CLASSIFICATION: INTERNAL
E. SEISMIC PARAMETERS
Seismic design forces shall be determined based upon the following parameters. These are the factors
which will be constant for all the structures coming in Qiddiya. According to the geotechnical report
Site class C is taken for all the structures. Buildings of different materials of construction and lateral
force resisting systems shall be investigated separately
Table 19 Seismic Parameters
Sr.No
1
2
3
4
5
6
7
8
9
Item
Seismic region
SS
S1
Fa
Fv
SMS
SM1
SDS
SD1
Value
Region 4
0.8
0.2
1.1
1.6
0.88
0.32
0.587
0.214
Reference (SBC 301)
Chapter 9, Fig 9.4.1(a)
Chapter 9, Figure 9.4.1(f)
Chapter 9, Figure 9.4.1(n)
Chapter 9, Table 9.4.3a:
Chapter 9, Table 9.4.3b:
(EQ-1)
(EQ-2)
(EQ-3)
(EQ-4)
Method of corrosion protection for RCC structures
Checking water soluble Chloride ion content
According to SBC 304 section 4.4.1, If the water-soluble chloride ion content, calculated based on
concrete proportions, exceeds those permitted in Table given below, it may be necessary to test
samples of the hardened concrete for water-soluble chloride ion content.
When concrete is tested for water-soluble chloride ion content, the test should be made at an age of
28 to 42 days. The limits in Table are applied to chlorides contributed from the concrete ingredients,
not those from the environment surrounding the concrete.
Table 20 Maximum Chloride ion content for corrosion protection of reinforcement
Maximum water-soluble chloride
ion (cl-) in concrete, percent by
weight of cement*
0.06
Type of Member
Prestressed Concrete
Reinforced concrete exposed to chloride
0.15
in service
Reinforced concrete that will be dry or
1
protected from moisture in service
0.3
Other reinforced concrete construction
* Determined according to ASTM C 1218.
Apply coating on Bars
When reinforced concrete structures are exposed to external sources of chlorides, the watercementitious materials ratio, cementitious materials content, and specified compressive strength of
Table 2 are the minimum requirements that are to be considered. Epoxy- or zinc-coated bars or slag
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CLASSIFICATION: INTERNAL
meeting ASTM C 989 or fly ash meeting ASTM C 618 or silica fume meeting ASTM C 1240 with an
appropriate high-range water reducer, ASTM C 494M, Types F and G, or ASTM C 1017M can provide
additional protection 4.4. When epoxy-coated steel bars are used, they should be according to ASTM
A 775 specifications.
The requirements for minimum concrete cover over the reinforcing steel of 7.7 in conjunction with
7.7.5 should be considered. The requirements for protection of concrete against carbonation are not
provided as it is expected that the use of quality concrete and adequate cover over reinforcing steel,
as specified in the SBC 304, will minimize this problem.
Table 21 Requirements for concrete exposed to Chloride bearing soil & water
Chloride
exposure
Water
soluble
chloride
(cl-) in soil,
percent by
weight
Negligible
Moderate
Up to 0.05
0.05 to 0.1
Severe
Very
Severe
Water
soluble
Cement
chloride
type
(cl-)
in
water, ppm
Up to 500
500 to 2000
2000
to
0.1 to 0.5
10000
More than More than
0.5
10000
Maximum
Watercementitious
materials
ratio
Minimum
cementitious
materials
content,
kg/m3
Minimum
Compressi
ve
strength,
MPa
-
0.50
330
28
I
0.45
350
30
I+
pozzolan+
0.4
370
35
Method of corrosion protection for steel structures
Corrosion Protection System
Cathodic Protection: It is a process that reduces the corrosion rate of metals by maintaining the metal
electrochemical potential in values for which there is immunity to corrosion. This type of corrosion
protection can be obtained by
Impressed current: Current protection provided by external power supply together with relatively
inert anodes.
Sacrificial anodes: Electrical connection to a metal with more negative corrosion potential than that
of steel such as zinc, aluminum and magnesium alloys.
Coating Systems: Non-alloy steel is usually coated with organic coatings (varnish or paint systems),
metallic coatings (e.g. based on zinc or zinc and aluminum coatings), or duplex systems (organic and
metallic coatings).
Surface Preparation: Surface preparation of substrate for coating application provides adhesion and
cleanness by removing corrosion products and other contaminants detrimental to coating to the steel.
This procedure is essential to long-term performance of coating systems, as a poor adhesion may lead
to several defects which result in a reduction of the protection capacity and service life.
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CLASSIFICATION: INTERNAL
F. METHOD OF CONCRETE SURFACE PROTECTION
Plastic shrinkage cracking is usually associated with hot-weather concreting. However, it can occur at
ambient conditions that produce rapid evaporation of moisture from the concrete surface. These
cracks can occur on the surface of freshly placed concrete while it is being finished or shortly
thereafter, if the rate of water evaporation is more than the rate of bleeding. These cracks that appear
mostly on horizontal surfaces can be substantially eliminated if preventive measures are taken.
Precautions to avoid plastic shrinkage cracking may include erecting wind breakers and sunshades,
fog spraying of form and reinforcement, dampening the sub-grade and forms, or placing concrete at
the lowest practicable temperature, and time. After the completion of placing and finishing
operations, concrete should be protected from high temperature, direct sun light, low humidity, and
drying winds. When the rate of evaporation exceeds 1kg/m2 per hour, precautionary measures are
essential. Pozzolanic cement concrete is particularly prone to plastic shrinkage. Therefore, protection
from premature drying is essential for pozzolanic cement concrete even at low evaporation rates.
Following are the surface protection measures that may be taken to minimize or stop the damage to
concrete structures:
Hydrophobation
Painting
Impregnation
Sealers
Coating
Project drawings and diagrams
Structural calculations
The structural calculations for the structures designed are attached as RCDC report in Annexure-5.
Civil works design drawings
NOTE :
Above mentioned sizes are mentioned minimum requirements, Vendor can design and adopt units
sizes as per his design to achieve the process Guarantee.
For design specifications and MOC please refer Annex-J Performance specifications.
For Manufactures details please refer Annexure 5 list of approved makes.
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