TECH
T
NICAL
L
SPAN TS
T 1402::2016
SPEC
S
IFICAT
TION
SEWA
S
GE TR
REATM
MENT S
SYSTEM
Standa
S
rd Sew
wage Tre
eatmen
nt Plantt
Part
P
1 - Extend
ded Aeration ((150 - 5000
5
PE
E)
Sewera
age Regula
atory Depa
artment
SPAN TS 1402:2016
CONTENTS
Page
1.0 Scope ....................................................................................................... 8 2.0 Normative Reference ............................................................................. 8 3.0 Terms and Definitions .............................................................................. 8 3.1 biochemical oxygen demand, BOD .................................................... 8 3.2 chemical oxygen demand, COD......................................................... 8 3.3 design capacity ...................................................................................... 8 3.4 effluent ..................................................................................................... 8 3.5 equipment ............................................................................................... 9 3.6 population equivalent (PE) .................................................................... 9 3.7 performance requirements ................................................................... 9 3.8 regulatory authority ................................................................................ 9 3.9 scum ......................................................................................................... 9 3.10 sewage..................................................................................................... 9 4.0 Sewage Treatment Plant (STP) Drawings ........................................... 10 4.1 General Requirements ......................................................................... 10 4.2 Layout ..................................................................................................... 10 5.0 Civil and Structural (C&S) Requirements ........................................... 11 5.1 Reference Standards ........................................................................... 11 5.2 Soil and Hydraulics ................................................................................ 12 5.3 Concrete................................................................................................ 13 5.4 Reinforcement....................................................................................... 14 5.5 Coating for Steel ................................................................................... 14 5.6 Water Supply ......................................................................................... 15 5.7 Roads and Access ................................................................................ 16 5.8 Perimeter Drain...................................................................................... 16 1
SPAN TS 1402:2016
5.9 Effluent Discharge ................................................................................. 17 5.10 Fibre Reinforced Plastic (FRP) .............................................................. 17 5.11 Aluminium .............................................................................................. 19 5.12 High Density Polyethylene (HDPE) ...................................................... 19 5.13 Marine Corrosive Environment ............................................................ 19 6.0 Mechanical and Electrical Requirements ......................................... 20 6.1 Mechanical Design Consideration ..................................................... 20 6.2 Mechanical Installation Considerations............................................. 20 6.3 Noise ....................................................................................................... 22 6.4 Odour Control ....................................................................................... 22 6.5 Motors, Controllers and Motor Starters ............................................... 23 6.5.1 Motors .......................................................................................... 23 6.5.2 Controllers ................................................................................... 23 6.5.3 Motor Starters.............................................................................. 23 6.6 Power Supply Systems .......................................................................... 23 6.7 Switchgear and Control Gear Assemblies......................................... 24 6.8 Control Room and Cabinets ............................................................... 25 6.9 Control Requirements........................................................................... 26 6.9.1 Manual Control .......................................................................... 26 6.9.2 Drive Systems .............................................................................. 26 6.10 Early Warning System (EWS)................................................................. 26 6.11 Instrumentation ..................................................................................... 26 6.12 Cables and Cabling Installation ......................................................... 27 6.12.1 General ....................................................................................... 27 6.12.2 Instrumentation .......................................................................... 27 6.12.3 Buried Cables ............................................................................. 27 6.12.4 Underground Ducts ................................................................... 27 2
SPAN TS 1402:2016
6.12.5 Conduits ...................................................................................... 28 6.12.6 Cable Support Systems ............................................................. 28 6.13 Earthing and Lightning Protection ...................................................... 28 6.13.1 General Purpose Power ............................................................ 29 6.13.2 Manuals and Labelling .............................................................. 29 7.0 Process Design Requirements ............................................................. 30 7.1 Design Influent and Effluent Values .................................................... 30 7.2 Inlet Chamber ....................................................................................... 31 7.3 Primary Screens ..................................................................................... 31 7.4 Pump Stations ........................................................................................ 32 7.5 Secondary Screen Chamber .............................................................. 33 7.6 Grit and Grease Chamber .................................................................. 33 7.7 Anoxic Tank ........................................................................................... 34 7.8 Aeration Tank ........................................................................................ 35 7.9 Blower Room.......................................................................................... 36 7.10 Secondary Clarifier ............................................................................... 37 7.10.1 General ....................................................................................... 37 The design requirements shall include: .............................................. 37 7.10.2 Weirs............................................................................................. 37 7.10.3 Square Clarifiers.......................................................................... 38 7.11 Disinfection Tank ................................................................................... 38 7.11.1 Disinfection with Hypochlorite .................................................. 39 7.12 Flow measurement ............................................................................... 40 7.13 Sludge Holding Tank ............................................................................. 40 7.14 Sludge Drying Bed (If Applicable) ...................................................... 41 7.15 Sludge Storage Hut (If applicable) ..................................................... 42 7.16 Control Room ........................................................................................ 42 3
SPAN TS 1402:2016
7.17 Ancillary Requirement .......................................................................... 43 7.18 Yard Lighting .......................................................................................... 44 7.19 Handrail, Safety Chain, Staircase, Grating and Chequered Plate 45 7.20 Toilet........................................................................................................ 46 7.21 Lifting Facility ......................................................................................... 46 7.22 Ventilation .............................................................................................. 47 7.23 Painting for Pipe Works ......................................................................... 49 7.24 Plumbing Works ..................................................................................... 49 7.25 General Mechanical and Electrical ................................................... 50 8.0 Reporting Format .................................................................................. 52 9.0 Construction and Installation .............................................................. 52 10.0 9.1 General .................................................................................................. 52 9.2 Quality control ....................................................................................... 52 9.3 Health and safety requirements ......................................................... 52 9.4 Inspection .............................................................................................. 54 Testing and Commissioning ................................................................. 54 4
SPAN TS 1402:2016
TABLES
Table 1 Range of PE .............................................................................................................. 10 Table 2 Design Influent Values ............................................................................................. 30 Table 3 Design Effluent Values ............................................................................................. 30 Table 4 Inlet Chamber Requirements ................................................................................. 31 Table 5 Primary Screen Requirements ................................................................................ 31 Table 6 Pump Station Requirements ................................................................................... 32 Table 7 Secondary Screen Chamber Requirements ........................................................ 33 Table 8 Grit Chamber Requirements .................................................................................. 33 Table 9 Grease Chamber Requirements ........................................................................... 34 Table 10 Grit and Grease Sand Bed Requirements .......................................................... 34 Table 11 Anoxic Tank Requirements ................................................................................... 34 Table 12 Aeration Tank Requirements ................................................................................ 35 Table 13 Blower Room Requirements ................................................................................. 36 Table 14 Secondary Clarifier Requirements ....................................................................... 38 Table 15 Chlorination Chamber Requirements ................................................................. 39 Table 16 Flow Measurement Requirements ....................................................................... 40 Table 17 Sludge Holding Tank Requirements..................................................................... 40 Table 18 Sludge Drying Bed Requirements ........................................................................ 41 Table 19 Sludge Storage Hut Requirements ...................................................................... 42 Table 20 Control Room Requirements ................................................................................ 42 Table 21 Anti-Climb, Brick Wall Fencing Requirements .................................................... 43 Table 22 Sliding Gate Requirements ................................................................................... 43 Table 23 Yard Lighting Requirements ................................................................................. 44 5
SPAN TS 1402:2016
Table 24 Handrail, Staircase, Grating and Chequered Plate Requirements ................ 45 Table 25 Toilet Requirements ............................................................................................... 46 Table 26 Lifting Requirements .............................................................................................. 46 Table 27 Common Ventilation Rates .................................................................................. 48 Table 28 Plumbing Work Requirements .............................................................................. 50 Table 29 Bolt and Nut Requirements .................................................................................. 50 Table 30 Piping Works Requirements .................................................................................. 50 Table 31 Emergency Shutoff Switch, Junction Box & Electrical Services Requirements
.................................................................................................................................................. 51 6
SPAN TS 1402:2016
ANNEXES
ANNEX A: REFERENCES .......................................................................................................... 55 ANNEX B: STANDARD STP DRAWINGS ................................................................................. 62 ANNEX C: INSPECTION GUIDE & TYPICAL LIST OF DEFECTS............................................... 67 ANNEX D: MASS BALANCE AND HYDRAULIC PROFILE ...................................................... 89 ANNEX E: PROCESS DESIGN CALCULATION ......................................................................... 1 7
SPAN TS 1402:2016
1.0 Scope
The Technical Specification of Sewage Treatment Systems: Standard Sewage
Treatment Plant, Part 1 - Extended Aeration (150 PE - 5000 PE) covers the following
requirements:
a)
Section 1: Layout and Design
b)
Section 2: Construction and Installation
c)
Section 3: Testing and Commissioning
2.0 Normative Reference
The documents and publications that are requisite for application of this
specification are listed in ANNEX A. For undated references, only the edition cited
and the latest edition of the referenced document (including any amendments)
applies.
3.0 Terms and Definitions
For the purpose of this specification, the following terms and definitions apply:
3.1
biochemical oxygen demand, BOD
The concentration of dissolved oxygen consumed under specified conditions (5
days at 20°C with or without nitrification inhibition) by the biological oxidation of
organic and/or inorganic matter in water
3.2
chemical oxygen demand, COD
The concentration of oxygen equivalent to the amount of dichromate consumed
when a water sample is treated with that oxidant under defined conditions
3.3
design capacity
Maximum flows and loads of the sewage the facilities are designed for, which
conform to the specified consent effluent standard
3.4
effluent
The liquid discharged from a sewage treatment process
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SPAN TS 1402:2016
3.5
equipment
Any component which is installed in, mounted on, attached to, or operated on
structures in the performance of their intended function
3.6
population equivalent (PE)
The equivalent, in terms of fixed population of a varying or transient population or
other activity (e.g. industrial, commercial contributing flow to the sewerage system)
3.7
performance requirements
The functions that a system has to perform in order to operate as required
3.8
regulatory authority
The authority which is empowered by statute to be responsible for regulating
sewerage industry
3.9
scum
The floating mass of sewage solids buoyed up by entrained gas, grease or other
substances which form an accumulating layer on the liquid surface inside the tank.
3.10 sewage
Any liquid discharges containing human excreta, animal or vegetable matters in
suspensions or solution derived from domestic activities and being generated from
household, commercial, institutional and industrial premises including liquid
discharges from water closets, basins, sinks, bathrooms and other sanitary
appliances but excluding rain water and prohibited effluent.
9
SPAN TS 1402:2016
4.0 Sewage Treatment Plant (STP) Drawings
4.1
a)
General Requirements
This technical specification shall be read in conjunction with the typical
drawings in Annex B;
b)
All dimensions shown in the drawings are in millimeters (minimum) unless
otherwise stated and shall be checked on site before commencement of
works;
c)
The drawings are scaled to suit A3 paper size;
d)
The drawing code is to be read as follows:
AAA/BBB/CCC/1234
whereby;
Example: SPAN TS 1402/Type A/LP/01
AAA
- Technical Specification Title
BBB
- PE Range
CCC - Drawing Title
1234
4.2
- Drawing No.
Layout
The typical layout of the system shall be in accordance with drawings as stipulated
in Annex B that varies in PE ranges as listed below;
Table 1 Range of PE
PE range
Drawing No.
150 ≤ PE ≤1000
SPAN TS 1402/Type A/LP/01
1000 < PE ≤ 3000
SPAN TS 1402/Type B/LP/01
3000 < PE ≤ 5000
SPAN TS 1402/Type C/LP/01
10
SPAN TS 1402:2016
5.0 Civil and Structural (C&S) Requirements
5.1
Reference Standards
All elements are to be designed to the Competent Person’s requirements complying
with the specified standards, other appropriate standards and current standards.
The references are as listed below:a)
Structural elements - BS EN 1990+A1, BS EN 1992+A1, BS EN 1992-3, MS 1195 Part
2;
b)
Composition, specifications and conformity criteria for common cement - BS
EN 197-1
c)
Cement to be used to resist sulphate attack - MS 1037, BS EN 15743+A1;
d)
Pulverized-fuel ash - MS 1226: Part 1;
e)
Ground granulated blast furnace slag - MS EN 15167 Part 1 and 2;
f)
Aggregates - MS EN 12620;
g)
Steel:
i)
Steel reinforcement - BS 4449+A2;
ii)
Cold reduced mild steel wire and steel fabric - MS 144, MS 145;
iii)
Hot rolled steel bars and sections - MS 146, EN 10210;
iv)
Welding of steel reinforcement - BS EN ISO 17660-1, BS EN ISO 17660-2;
v)
Structural steel sections - BS 4-1;
vi)
Cold rolled steel sections - EN 10162;
vii)
Weldable structural steel and minor structural steelwork - EN 10025;
viii)
Steel tube- EN 10296, EN 10297, EN 10305;
ix)
Structural steel in building and all other steelwork - MS 415;
h)
Admixtures - MS 822, MS EN 934, BS EN 934-2;
i)
Waterstops for sealing joints in concrete - MS 1292;
j)
Ultra high-build paint- AS/NZS 3750.2;
k)
Alkyd/micaceous iron oxide- AS/NZS 3750.12;
l)
Hot dip galvanized coating - MS 740;
m)
Sealed sprayed zinc coating - EN ISO 2063;
n)
Other coatings - Table 3 Part 8 of BS 5493;
o)
Steel substrates - BS 7079;
p)
Other corrosion protection coating for steelwork - BS 5493 or AS/NZS 2312.1;
q)
Nuts, bolts, screws and washers in contact with sewage shall be stainless steel
of Grade 316S31 steel in accordance with BS EN 10088 Part 1and 3 or EN 10029
and EN ISO 9445;
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SPAN TS 1402:2016
r)
Bolts, nuts, screws, fasteners and washers other than stainless steel shall conform
to MS 739 and BS 4921;
s)
FRP:
i)
All other FRP products - ASTM C582 for FRP laminates;
ii)
Fire rating - ASTM E84, BS 476;
iii)
Unsaturated polyester resins - Type B or C of BS 3532;
iv)
E glass and E-CR glass -BS EN 14118 Part 1, 2 and 3, BS 3396-1, BS 3749;
v)
Textile glass rovings - EN 14020;
vi)
FRP water tanks - MS 1241 where not constructed of FRP panels, MS 1390
where constructed of FRP panels;
t)
Anodic oxidation coating on aluminium-BS EN ISO 3210;
u)
Structural design, materials, workmanship and protection of aluminium BS EN 1999-1-4+A1; BS EN 1999-1-3+A1; BS EN 1999-1-1+A2;
v)
w)
Wrought aluminium and aluminium alloys:
i)
BS 1161 for structural purposes;
ii)
BS EN 485 for sheet,strip and plate;
iii)
BS EN 754 for drawn tube;
iv)
BS EN 755 for extruded rod/bar, tube and profiles;
v)
BS EN 1676 for ingots and castings;
vi)
BS 4868 for profiled sheet;
Marine corrosive environment:
i)
Concrete resistant to all chemical attacks - BS EN 1990;
ii)
Structural steelwork shall be thoroughly descaled to second quality - BS
7079.
5.2
Soil and Hydraulics
a)
Soil bearing capacity to be taken as minimum 100kN/m2;
b)
Soil bearing pressure for brickwork fencing is to be taken as more than 50kN/m2.
c)
Soil investigation is required to determine soil condition and requirement of
piling;
d)
All sub-grade compaction shall be determined by geotechnical results;
e)
Hydraulically shall be 50mm drop from component to component;
f)
Actual levels shall be determined from hydraulic calculation of actual plant
design and actual site survey;
g)
Minimum openings are as stated in the drawings but should be designed
according to hydraulic needs;
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SPAN TS 1402:2016
h)
Freeboard shall be 500mm for process tank;
i)
The emergency overflow pipe shall be located at inlet chamber whereby the
level shall be lower than the lowest manhole ground level;
j)
Competent Person is allowed to propose overflow pipe at lowest cast manhole
ground level which shall not create public nuisance;
k)
Flap gate shall be provided to avoid back flow from the river/ main drain;
l)
Plant hydraulic must be designed properly to ensure the discharge head is
adequate to open the flap valve at any circumstances.
5.3
Concrete
a)
Unless otherwise stated, the design working life of all concrete structures shall
be 50 years;
b)
Concrete for structures retaining sewage shall be designed for buoyancy due
to ground condition;
c)
Concrete for structures retaining sewage shall be of grade 35A;
d)
Concrete for all other structures (except for fencing) shall be of grade 35;
e)
Concrete for fencing shall be of grade 25/20;
f)
Mass concrete for benching shall be of grade 35A;
g)
Mass concrete and lean concrete for fencing shall be of grade C20;
h)
Concrete structures retaining sewage shall be lined with high alumina cement
mortar of 20mm thickness;
i)
All concrete shall be sufficiently vibrated;
j)
Concrete and cement mortar exposed to soils or groundwater, cement
suitably resistant to sulphate attack shall be used for the entire structure;
k)
Cement to be used to resist sulphate attack shall be:
l)
Sulphate-resisting Portland cement;
m)
Portland pulverized fuel ash cement;
n)
Ground granulated blast furnace slag;
o)
High silica content Portland cement;
p)
Super sulphated cement;
q)
Approval for admixtures shall be obtained prior to inclusion in the concrete mix;
r)
All bottom of tank shall be chamfered to avoid dead zones.
s)
The water used for mixing and curing shall be fresh, clean and not contain any
organic matter, sulphate or other impurities in sufficient quantities to reduce the
strength of the concrete or attack the concrete of the reinforcement;
t)
The building area / compound shall be of mass concrete;
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SPAN TS 1402:2016
5.4
Reinforcement
a)
Minor structural steelwork shall be Grade 43A;
b)
Stirrups / links shall be of mild steel;
c)
Bar lap length shall be of 50 times the diameter of bar;
d)
Open type flooring:
i)
where cut outs are required in flooring around pipework or other
obstruction, a continuous nosing bar shall be fully welded to all bearing
bars around the cut out;
ii)
maximum weight is 40kg;
iii)
superimposed loading is 5kN/m2;
iv)
deflection shall not exceed span/200 or 10mm whichever is lesser when
fully loaded;
v)
clearance around the obstruction shall not exceed 30mm.
5.5
Coating for Steel
a)
Steelwork that may be in contact with sewage through immersion, splash or
spray, or that is over tanks containing sewage, shall be protected against
corrosion using one of the following coating systems:
i)
high build tar epoxy system shall be applied in two or more coats to
give a total dry film thickness of not less than 200µm;
ii)
high build micaceous iron oxide pigmented epoxy system shall be
applied in two or more coats to give a total dry film thickness of not less
200µm;
b)
iii)
hot dip galvanized coating of 140µm nominal thickness;
iv)
sealed sprayed zinc coating of 150µm nominal thickness;
Other coatings providing 10 to 20 years’ service, before first maintenance shall
be considered for approval by the Commission;
c)
Steelwork that is exposed to the external atmosphere, except severe
marine atmospheres, shall be protected against corrosion using one of the
following coating systems;
d)
Steelwork that is exposed to the external atmosphere, except severe
marine atmospheres, shall be protected against corrosion using one of the
following coating systems:
i)
a prime coat of a two pack polyamide cured epoxy zinc phosphate of
dry film thickness 60 to 80µm with a finishing coat of a high build
14
SPAN TS 1402:2016
micaceous iron oxide chlorinated rubber paint, spray applied to a dry film
thickness of 60 to no more than 80µm;
ii)
hot dip galvanized coating of 85µm nominal thickness;
iii)
sealed sprayed zinc coating of 150µm nominal thickness;
e)
Steel substrates shall be prepared before application of coatings;
f)
Other corrosion protection coating systems for steelwork (for tropical
atmospheres), provide 20 or more years to first maintenance;
g)
Unprotected steelwork in contact with sewage shall be stainless steel grade
316L;
h)
Successive coatings of the one component shall be tinted a different colour to
facilitate over coating and inspection;
i)
All coatings shall be applied strictly in accordance with the coating
manufacturer’s printed instructions;
j)
Bolts, nuts, screws and other fasteners shall have either hot dip galvanized,
sherardized zinc or electro plating coating;
k)
Washers and other small components shall have either hot dip galvanized, or
sherardized zinc coating;
l)
Fasteners of incompatible material to the component being fastened shall
have suitable isolating washers and sleeves.
5.6
Water Supply
a)
Water shall be connected to potable supply that provides a minimum pressure
of 20m head across the site;
b)
Water tank of at least 445 liter storage capacities or one day water usage or
whichever is higher shall be provided;
c)
Double backflow prevention shall be provided in all cases to prevent
contamination of any potable water service, including the incoming supply
line;
d)
The water supply system shall be sized to meet the following cases:
i) firefighting demand as instructed by the local regulations and any essential
plant water demands;
ii) all potentially simultaneous process uses, equipment uses and a for plant
cleansing;
e)
All water supplies and its installation (piping, tanks, air conditioning drainpipes,
gutters and etc.) must be totally isolated from all potential contact of electrical
system;
15
SPAN TS 1402:2016
f)
Where required, wash water shall be equipped with booster pump and where
possible, obtain from reclaimed water.
5.7
Roads and Access
a)
Earth formation to be compacted or reinforced concrete road and withstand
a load of at least 15 tonnes;
b)
Construction shall comply with Public Works Department requirements;
c)
On-site road shall be able to provide safe and convenient access for trucks or
other machinery equipment used for maintenance purposes;
d)
Minimum width of the road shall be 4m;
e)
Where vehicles need to pass frequently or parking is required along the road,
the minimum width shall be 6m;
f)
Corner of junction for perimeter internal road for tankers or trucks access shall
have a minimum inside radius of 6m;
g)
Inside radius for perimeter road not intended for tankers or trucks access shall
be not less than 4m;
h)
Where roads for maintenance vehicles or machineries are not required,
concrete or hard surfaced walkways of at least 900mm width shall be provided
between each process unit;
i)
Concrete hardstanding area can be laid where storage bins are located;
j)
The use of steps shall be avoided, where possible;
k)
Where the ingress or egress of the treatment plant is near a junction of a public
road, an adequate acceleration and deceleration lane must be made
available between the access road and the junction for vehicles to safely
enter and leave the treatment plant;
l)
Slope area within the treatment plant reserve shall be premixed.
5.8
Perimeter Drain
a)
Drainage shall conform to local authority standard requirements and shall be
of 225mm half round salt glaze ware drain (HRSGW);
b)
Velocity shall be on range of 0.8 m/s to 4.0 m/s;
c)
Reinforced concrete cover shall be provided for drain depth >1000mm;
d)
Drainage sump of 300mm x 300mm to be provided when there is a change of
flow direction;
e)
Heavy duty mild steel grating shall be used for drainage sump;
16
SPAN TS 1402:2016
f)
Any cleaning or maintenance process wash water must be returned to the inlet
works via a separate drainage system;
g)
External drainage facilities must be provided for treatment plant along the
slope area;
h)
Cut off drainage at the entrance must also be provided;
i)
Drainage routing shall be adjusted to suit the site condition;
j)
Location of perimeter drainage discharge shall be determined by on site
condition.
5.9
Effluent Discharge
a)
Flap gate shall be provided to avoid back flow from the river/ main drain;
b)
Plant hydraulic must be designed properly to ensure the discharge head is
adequate to open the flap valve at any circumstances;
c)
Effluent discharge shall be directed to the main drain or river to avoid
discharging effluent into a drain within the residential area;
d)
Discharge to a retention pond is not allowed unless prior approval has been
granted;
e)
The receiving drain/watercourse shall have sufficient capacity to accept the
run-off from the plant as well as the effluent discharge from the treatment
plant.
5.10 Fibre Reinforced Plastic (FRP)
Only FRP products approved by the Commission shall be used and FRP products
shall not be used for access purposes. The thickness of the structural section of the
FRP wall shall not be less than 10mm. Notwithstanding any other requirements in
standards, all FRP products, including FRP tanks and vessels for sewage treatment
processes, shall conform to the following material requirements:
a)
FRP properties shall be as determined by design but shall not be less than the
following values:
i)
Tensile strength - 80 MPa
ii)
Tensile modulus - 7000 MPa
iii)
Flexural strength - 140 MPa
iv)
Flexural modulus - 6000 MPa
v)
Water absorption-≤ 0.75 %
vi)
Barcol hardness - 40
vii)
Operating temperature is -40°C to +50°C
17
SPAN TS 1402:2016
viii)
ix)
b)
Specific gravity - ≥ 1.5
Fire rating - < 25s or Class 1
Unsaturated polyester resins shall be used but shall only be isophthallic,
bisphenol A fumurate or terephthalic polyester resins;
c)
All surfaces shall have a resin rich layer, gel coat;
d)
Surfaces in contact with sewage, water or any moisture shall comprise of a
resin rich layer at least 1 mm thick;
e)
All other surfaces shall comprise of a resin rich layer at least 0.25 mm thick up to
10% by mass of corrosion resistant glass fibres, (that is, C-glass or E-CR glass),
polyester fibres or acrylic fibres may be used in the surface layer;
f)
A barrier layer shall be provided behind the surface layer and shall be at least
1.5 mm thick;
g)
The barrier layer shall comprise of 70to 80% by weight resin with the remainder
by weight being E glass or E-CR glass;
h)
The structural layer shall comprise resin impregnated layers of E glass or E-CR
glass and shall comprise at least 25 % E glassor E-CR glass. Aggregate and filler
may be included;
i)
E glass and E-CR glass shall be of glass rovings, chopped strand mat woven
fabric or woven roving fabric;
j)
Glass fibres shall have a surface treatment compatible with the manufacturing
process to ensure bonding to the resin;
k)
Aggregates shall only be used in FRP structural layers and external layers.
Aggregates shall be clean, washed, high grade silica sand containing not less
than 95% silica;
l)
Aggregates shall be of a size not greater than 20% of the thickness of the FRP
structural layer with a particle size not less than 0.05 mm and not greater than
5mm;
m)
Fillers shall only be used as a resin extender and shall comprise of clean inert
material, for example, silica, with particle size less than 0.05 mm;
n)
Surfaces exposed to sunlight shall incorporate provisions to minimize ultraviolet
degradation, such as, ultraviolet inhibitors, screening agents or pigment in the
outer resin rich layer;
o)
Pigments and dyes shall not normally be required, but where required by the
Commission, shall be of a type and colour specified by the Commission.
18
SPAN TS 1402:2016
5.11 Aluminium
a)
Aluminium is found primarily as the ore bauxite and is remarkable for its
resistance to corrosion (due to the phenomenon of passivation) and its light
weight;
b)
Structural components made from aluminium and its alloys are very important
in which light weight, durability, and strength are needed.
5.12 High Density Polyethylene (HDPE)
a)
High density polyethylene (HDPE) is the high density version of PE plastic;
b)
Its molecules have an extremely long carbon backbone with no side groups;
c)
As a result, these molecules align into more compact arrangements,
accounting for the higher density of HDPE;
d)
HDPE is stiffer, stronger, and less translucent than low-density polyethylene;
e)
HDPE is lighter than water, and can be moulded, machined and joined
together using welding;
f)
High density polyethylene shall comply to the following physical properties:
i)
Tensile Strength0.20 - 0.40 n/mm2;
ii)
Notched Impact Strength no break kJ/m2;
iii)
Thermal Coefficient of expansion100 - 220 x 10-6;
iv)
Max Cont use Temp650°C;
v)
Density0.944 - 0.965g/cm3;
vi)
Minimum required strength 8.0 MPa.
5.13 Marine Corrosive Environment
a)
All areas within 5 km from the coast line or salt water bodies shall be classified
as marine environment;
b)
Sewerage facilities in marine and corrosive environment e.g. where the
atmosphere or soil contains high levels of chloride, sulphates and corrosive
chemical elements or compounds shall be adequately designed to withstand
the corrosive actions of the chemicals prevalent in the environment;
c)
Necessary protections shall be provided against all corrosive actions of the
environment;
d)
Design requirement for facilities in marine and corrosive environment shall
include two coats of sodium silicate that shall be applied to all external
surfaces of concrete structures;
e)
Exposed metal shall be of corrosion resistant and of marine grade;
19
SPAN TS 1402:2016
f)
Proper smooth surface finishing shall be provided for the metal;
g)
Unprotected metals acceptable for SS316L, aluminium alloy or materials
suitable for use in corrosive environment acceptable by the Commission;
h)
All structural steelwork shall be painted with 2 coats of two pack epoxy based
red lead primer before leaving the manufacturer ’s works;
i)
In addition, all structural steelwork shall be provided with protective paint
for chloride, sulphate or the prevailing chemicals in the site after installation;
j)
Cathodic protection shall be provided for all load bearing steel structures in
marine environment for a minimum life of 50 years.
6.0 Mechanical and Electrical Requirements
6.1
Mechanical Design Consideration
a)
The design shall simplify the equipment required, control system, maintenance
and operational procedures, while fulfilling the intended performance and
standard of service;
b)
The brand and models of major drive equipment (e.g.: pumps, blowers,
aerators, clarifier scrappers, etc.) shall be those approved by the Commission;
c)
The types and makes of equipment provided throughout the facility shall be
standardized, whenever possible;
d)
Only new and genuine equipment shall be provided;
e)
Equipment sizing and selection shall minimize energy and other consumables /
costs;
f)
The minimum economic life of equipment;
g)
Material selection shall be in accordance with the Commission specifications
or/and other relevant international standards;
h)
Components shall be robust and suitable for use. Where thin metal sheeting is
used, it shall be stiffened to minimize distortion;
i)
Water storage tanks shall not be placed on the roof top of any control room; all
water supply system shall be homed with separate entrance.
6.2
Mechanical Installation Considerations
a)
The base frame of rotational equipment or any equipment that may induce
vibration shall be provided with anti-vibration mount;
b)
All revolving parts shall be properly balanced both statically and dynamically
so that there shall be no undue vibration anywhere in the machine or
transmitted to the adjacent structure;
20
SPAN TS 1402:2016
c)
The criteria adopted for vibration severity shall be the RMS value of the
vibration velocity in millimeters per second;
d)
Where rotational equipment or equipment which may induce vibration is
connected to piping, then vibration isolator shall be provided;
e)
All moving parts shall be designed and installed in a manner that is inherently
safe to operate;
f)
Foundations shall be adequately designed to include all dynamic load and
anchored to withstand all loads imposed by the equipment;
g)
Equipment shall be accurately located, levelled and secured by holding down
bolts;
h)
Non-shrink grout shall then be used to complete the foundation. In some cases,
a resilient connection to the foundation is required, in which case, the
manufacturer’s instructions shall be followed;
i)
Puddle collar is required for all pipe passing through all walls;
j)
Appropriate joints shall be provided in all pipe works to facilitate the removal of
equipment, meters, valves and other special items without dismantling the
entire pipeline;
k)
Valves shall be provided for isolation purpose;
l)
Outdoor and dry installation pump shall be provided with housing;
m)
Competent Person must ensure that the unit processes are arranged in such a
way to prevent/reduce criss-crossing of piping works, unnecessary bends,
choking of interconnected pipe and excessive hydraulic losses through the
system;
n)
The platform level of mechanical equipment and electrical control system of
any process unit shall be located above design flood level;
o)
Silencers and acoustic enclosures shall be provided as required to achieve
noise level reduction;
p)
Enclosures used to achieve these noise reductions shall permit ready access to
the equipment for routine maintenance;
q)
Adequate air ventilation shall be provided to allow cooling of the enclosure to
prevent overheating of the equipment/motors;
r)
The fixing and co-ordination by exact position of service to and from sanitary
fitting shall be the responsibility of contractor.
21
SPAN TS 1402:2016
6.3
Noise
a)
Noise level measurement in dB (A) shall be made with a sound level meter
which complies with BS EN 61672 Part 1, 2 and 3;
b)
Noise level for all electronically operated electrical device such as soft starters,
variable speed drives and others shall conform to IEC and EN. Thus it shall fulfill
all EMC Immunity requirements complying with BS EN 61000-6 Part 1 and 2;
c)
Noise level generated shall comply with the requirements stipulated in
Factories and Machinery (Noise Exposure) Regulations 1989, The Planning
Guidelines for Environmental Noise Limits and Control by Department of
Environment.
6.4
Odour Control
Odour control requirements shall be applied upon condition set during planning
stage as follow:
a)
Isolate odorous gases from general ventilation by containing identified odour
generating sources with a separate local exhaust system;
b)
Containment of the odour sources shall be by installing lightweight and
corrosion resistant covers/enclosures designed for practical operation and
maintenance works;
c)
Local exhaust rates for containment shall be designed to provide a negative
pressure preventing buildup of toxic, corrosive or explosive gases and to
include provision for process air or air displaced by changes in the level of
liquid inside the covered space;
d)
The odorous air in the local exhaust system shall be conveyed through well
designed and balanced ductworks by a centrifugal fan to an effective odour
treatment system;
e)
Odour treatment equipment shall be selected such that odour is reduced to
the lowest possible level and in compliance to the EQA;
f)
In situation where specific gases such as hydrogen sulphide and ammonia are
significantly present, provide a pre-scrubber unit upstream of the main odour
treatment equipment;
g)
Containment, exhaust and treatment shall be designed as an integrated
package;
h)
Consideration must be given to the life span of the odour control system and
associated costs in operating and maintaining such a system.
22
SPAN TS 1402:2016
6.5
Motors, Controllers and Motor Starters
6.5.1 Motors
a)
Provide readily replaceable anti-condensation heaters for motors that do not
require frequent operation.
b)
At least three thermistors to be provided for motors which are >50 kW.
c)
Electrical motors should be rated as continuous run.
d)
Motors > 22kW shall be protected with soft starter or variable speed drive.
e)
Where water hammer prevails, frequency inverter shall be provided.
f)
The appropriate cooling system based on the requirements of the equipment
shall be provided.
6.5.2 Controllers
a)
Start push buttons to be green and recessed
b)
Stop push buttons to be red and recessed
c)
Emergency stop push button to be red and mushroom head type
d)
ON signal lamps to be green
e)
OFF signal lamps to be red
f)
Trip signal lamps to be amber
6.5.3 Motor Starters
a)
Up to 3.7 kW - Direct-On-Line starters
b)
Above 3.7 and up to 7.5 kW - Star/Delta starters
c)
Above 7.5 and up to 22 kW - Auto-transformer starters
d)
More than 22 kW - Soft starter
e)
Above 50 kW - Variable speed drive is preferred
Soft starting of motors above 30kW or greater in size is necessary to minimize power
disturbances (e.g. power surge) and process disturbances (e.g. water hammer).
Variable speed drive shall be considered at application where variable capacity
maybe need to enhance the process flexibility, for example, aeration device and
blowers.
6.6
Power Supply Systems
a)
All matters relating to electricity shall comply with Energy Commission Law and
any other subsidiary regulations;
23
SPAN TS 1402:2016
b)
The power supply provided shall be single incomer with properly design control
overflow system during power failure (all electrical control system shall be
located above design flood level);
c)
No direct tapping of power is allowed from distribution board (DB). Proper
protection shall be provided for any direct connection from switchboard;
d)
Earth leakage current breaker (ELCB) shall be provided for DB;
e)
The power system distribution shall be designed to achieve a minimum power
factor of 0.9;
f)
For phase development, the plant and power system distribution shall be
designed for maximum load and installed in appropriate modular unit to
ensure that the minimum power factor is achievable at all phases of operation;
g)
Equipment shall be protected by either moulded case circuit breaker (MCCB)
or miniature circuit breaker (MCB) based on its suitability;
h)
Every control circuit shall be protected with separate MCB;
i)
TNB meter panels shall be installed close to the site entrance or adjacent to but
physically separated from the main switchboard;
j)
Suitable flexible steel conduit with approved adaptors shall be supplied and
fitted between the main switchboards;
k)
All metering panel shall be located flush with the fence and door opening from
outside to enable TNB inspector to read the kWh and kVAhr reading;
l)
Provide earthing connected with Current Transformer (CT) for Large Power
Consumer (LPC) (i.e. consumption with more than 100A or 10kW);
m)
To provide earthing connected to ELCB/RCCB/ELR or Over Current & Earth
Fault relay to protect overcurrent and surge current to all wiring connected to
TNB metering panel for Large Power Customer (LPC) or Ordinary Power
Customer (OPC);
6.7
Switchgear and Control Gear Assemblies
a)
Supply Authority Metering separated from the main switchboard;
b)
Electro galvanized plates to be used to protect materials against corrosion due
to high humidity;
c)
Panel isolators and door locks to be capable of padlocking open with 6 mm hasp padlock;
d)
Separate panel boards to be used for general purpose light and power;
e)
All motor starting equipment for an area to be grouped into multi-motor, starter
control board;
24
SPAN TS 1402:2016
f)
Cabinets are to be constructed to prevent the ingress of insects and vermin;
g)
For all incomer above 400A, over current and earth fault protection to be
provided on all starter circuits in excess of 200A;
h)
Where a circuit has a main and standby supply, an isolator in each supply
circuit to be provided;
i)
Junction boxes for submersible pumps and float controls shall be above the
floor or any possibility of flood level and must not be located in the wet well.
6.8
Control Room and Cabinets
a)
Provide 900mm minimum clearance between an open door and any fixed
object;
b)
Provide 900mm clearance between open cabinet doors of facing cabinets;
c)
Front access cubicles to have the electrical clearance distances between
doors mounted equipment and gear tray mounted equipment as specified in
the regulations;
d)
Main supply bus bars shall extend the full length of panels, and the panel
casings shall be effectively earthed;
e)
Mount all equipment inside cabinets on gear trays;
f)
All control panels shall be provided with phase sequence relay;
g)
All cabinets to have a base frame, at least 50mm high;
h)
All control rooms shall be isolated from invasive environment of the sewerage
system, where carbonization, corrosion or condensation may occurs that lead
to short-circuiting;
i)
Height to be no greater than 1600mm internally;
j)
Mount cabinet on reinforced concrete plinth, 200mm minimum above floor;
k)
Provide reinforced concrete paved area for the full width of the cabinet and
extending 1m in front of the cabinet doors, when they are opened;
l)
Natural ventilation is suitable for direct-on-line, star-delta and auto transformer
starters;
m)
The minimum acceptable IP rating and tests required shall be clearly specified;
n)
Cable entry from the bottom only.
25
SPAN TS 1402:2016
6.9
Control Requirements
6.9.1 Manual Control
a)
Interlocks shall be provided to prevent damage to the equipment during
equipment start up, for example, bearing overload, overheated, temperature,
loss of cooling water, no flow when operating;
b)
Selector switches to be provided at one location so that equipment can be
manually operated from that location.
6.9.2 Drive Systems
a)
Each drive must be independently provided with the following features:
i)
ON-starts and runs drive;
ii)
OFF-stops drive;
iii)
AUTO-operates the drive in accordance with automatic control system;
b)
Indicate operation by an ammeter;
c)
Record running hours with local indicator;
d)
Local annunciation on motor starter of each fault condition;
e)
Record kilo-Watt-hour (kWh) of major drive equipment.
6.10 Early Warning System (EWS)
a)
For sewage treatment plants designed to comply with Standard A/B effluent
discharge and located upstream of the water intake point, EWS shall be
provided and comes with computer (monitoring) or data logger;
b)
The EWS is used to monitor raw sewage pumps and blowers trip signals, high
water level, incoming power supply failure and RTUs health status;
c)
EWS system shall be able to transmit digital and analog values via Short
Messaging Service (SMS), e-mail or via other telecommunication mean in text
mode to technical staff for the fast recovery of the treatment system;
d)
The modules shall be able to interpret SMS message from the operator to
activate or deactivate long distance machine (remote control);
e)
For public system, the EWS shall be integrated into a centralized monitoring
system.
6.11 Instrumentation
Provision for instrumentation shall be as follows:
a)
Inlet Pump Station
-
Level;
b)
Blower
-
Pressure;
26
SPAN TS 1402:2016
c)
Effluent
-
Flow Measurement;
d)
Electrical Drive
-
Amp/Volt/HR/kW/Power Factor meter;
e)
Disinfection
-
Outlet water level indicator;
Instruments shall be installed in such a way that they can be removed for
maintenance without interrupting the process.
6.12 Cables and Cabling Installation
6.12.1 General
a)
b)
Segregate cables into the following categories:
i)
Power (less than 1000 V phase to phase);
ii)
Instrumentation / telemetry;
iii)
Control;
Wherever possible, use a separate cable-support system for each cable
category;
c)
Separate such cable support systems by minimum clear distances of 300mm;
d)
When one cable support system has to be used, separate cable categories by
minimum clear distances of 150mm;
e)
Secure cable at 900mm intervals for horizontal runs and 300mm for vertical runs;
f)
Cable ties shall be made of non-corrosive material and if exposed to the
environment, shall have UV protection;
g)
All cables shall be at least of double PVC protection, and if exposed to the
environment then armoured cable shall be provided.
6.12.2 Instrumentation
a)
Use separate cables for digital and analog signals;
b)
Marshal cables in a process or geographical area into junction boxes;
c)
Use multi-pair cables between areas.
6.12.3 Buried Cables
a)
Install cables without trees or through joints, unless approved;
b)
All buried cables shall be laid in ducts.
6.12.4 Underground Ducts
a)
Construct road crossings from uPVC conduit of minimum 100mm diameter with
900mm cover and encased on all sides with 150mm concrete;
27
SPAN TS 1402:2016
b)
All other ducts to be PVC conduit laid with a minimum cover of 600mm. Ducts
to be bedded in 75mm sieved sand;
c)
Provide draw strings in all ducts;
d)
Provide cable pits to suit cabling layout and to allow drain-in of cables through
the duct work;
e)
Cable pits shall be provided no greater than 100m apart. They shall be fitted
with trafficable cast iron covers and equipped with drainage;
f)
Seal ducts into buildings with approved systems providing a fire rating of 30
minutes.
6.12.5 Conduits
a)
All cabling within buildings or structures where cable trays are not permitted,
and in all external locations, shall be installed within conduits;
b)
Conduits installed externally shall be arranged to minimize their length and
exposure;
c)
PVC heavy duty conduit is permissible, where it is protected from physical
damage and UV, otherwise, metal or flexible conduits shall be used;
d)
Use flexible steel reinforced conduit for connections, where relative movement
and removal for maintenance has to be considered.
6.12.6 Cable Support Systems
a)
Ensure cable support systems in electrical switch rooms, equipment (for
example, pump) rooms and service galleries;
b)
When run in common service galleries, ensure cables are not adjacent to hot
services.
6.13 Earthing and Lightning Protection
a)
2W UTX for earthing system / manhole with sufficient diameter size and number
of pipe(s) shall be allocated / separated for earthing conductor / tape and
electrical cable/wiring services;
b)
Lightning arrestor material shall be of copper and embedded in the wall;
c)
Provide earthing and lightning protection to meet local regulations;
d)
Use a specialist inspector to verify the installation;
e)
Earthing test results shall be submitted and results shall be below or equal to 1
Ohm;
28
SPAN TS 1402:2016
f)
Lightning arrestor test results shall be submitted and results shall not more than 5
Ohms;
g)
Earthing and lightning arrestor chamber shall be of pre-cast material.
6.13.1 General Purpose Power
Provide general purpose power socket outlets as follows:
a)
Single phase outlet rated at 10A adjacent to, or inside each control cabinet
and within 10 in of all equipment installations;
b)
Three phase outlet rated at 50A within 20 in of every screen, sludge scraper,
clarifier rake, grit collector and conveyor;
c)
Three (3) phase (with neutral) outlet rated at 50 Amp shall be provided at an
interval of at least 20 in;
d)
These outlets shall be water proofed industrial type switch socket outlets (SSO).
6.13.2 Manuals and Labelling
These items below shall be prepared and submitted to the plant operator or owner:
a)
Provide plant function diagrams, electrical system, electrical circuit, Process
and Instrumentation Diagram (P&ID), instrument loop diagrams and single line
diagrams with endorsement by qualified person, before the plant is precommissioned;
b)
All plant and equipment are to be provided with inscriptions and labels to
facilitate understanding and safe operation and to satisfy the requirements of
any standards and regulations applying to the works. Labelling includes:
i)
Inscriptions on equipment, cubicles, instruments, process controllers and
on small equipment such as relays, control switches, indicating lights, etc.;
ii)
Identification of cables at both ends and along their lengths;
iii)
Identification of terminations for cable cores and cubicle wiring in
accordance with the circuit diagrams.
29
SPAN TS 1402:2016
7.0 Process Design Requirements
The detailed process design calculation is as shown in Annex E. The minimum design
requirements shall be as stated below.
7.1
Design Influent and Effluent Values
Treated sewage effluent requirement is to achieve Environmental Quality (Sewage)
Regulations 2009 and any other related subsidiary law prescribed by Department of
Environment (DOE). The effluent E.Coli compliance is subject to the sensitivity of the
receiving watercourse and as directed by the Department of Environment (DOE).
Table 2 Design Influent Values
Item
1
2
3
4
5
6
7
Process
Biochemical Oxygen Demand (BOD5)
Suspended Solids (SS)
Chemical Oxygen Demand (COD)
Total Nitrogen (TN)
Ammoniacal nitrogen (AMN)
Total Phosphorus (TP)
Oil and Grease (O&G)
Value
(g/capita.day)
56
68
113
11
7
2
11
Value (mg/l)
250
300
500
50
30
10
50
Table 3 Design Effluent Values
Parameter
BOD5
SS
COD
AMN
Nitrate
Nitrogen
Total
Phosphoru
s
O&G
Effluent Discharge to Rivers /
Stream
Effluent Discharge to Stagnant
Water Bodies*
Standard A
Standard A
Standard B
Standard B
Absolute
Design
Absolute
Design
Absolute
Design
Absolute
Design
20
50
120
10
10
20
60
5
50
100
200
20
20
40
100
10
20
50
120
5
10
20
60
2
50
100
200
5
20
40
100
2
20
10
50
20
10
5
10
5
N/A
N/A
N/A
N/A
5
2
10
5
5
2
10
5
2
2
10
5
* Stagnant Water Bodies refer to enclosed water bodies such as lakes, ponds and slow
moving watercourses where dead zone occur.
30
SPAN TS 1402:2016
7.2
Inlet Chamber
Table 4 Inlet Chamber Requirements
Item
1
2
3
7.3
Description
Penstock (Manual)
- Size
- Rising stem
- Spindle
Emergency overflow
pipe
Fixed Screen
Requirement
Water tight – 1 no.
225mm min. depending on the sewerline sizing
Ductile iron
Stainless steel
Vitrified clay pipe;
Equivalent to incoming sewer pipe
Non-corrosive material;
Spacing: 50mm clearance
Primary Screens
Screens must be designed to withstand flushing velocity. In the event of the manual
bypass screen being blocked, sewage must be able to flow over the top of the
screen without causing excessive backup flooding or overflows.
Table 5 Primary Screen Requirements
Item
1
2
3
4
5
6
7
8
Process
Screen clear spacing
Slope
Approach velocity at
feed channel
Flow through velocity at
the screen face
Approach & flow through
velocity at 50% blockage
Estimate screenings per
volume of sewage
Screenings skip storage
capacity
Overflow opening
between channel
9
Coarse screen
10
11
12
13
Opening to pump sump
Spotlight
Perforated Tray
Screening Bin
Overflow pipe within
chamber
Standpipe
14
15
Requirement
Max. clearance, 25 mm
30° to vertical or 60° to horizontal
Max. 1.0 m/s
Max. 1.0 m/s
Min. 150mm freeboard shall be provided to
prevent the approached channel from
overflowing
20m3/106 m3 at average flow
7 days
Invert level shall be with 50% blockage and
150mm freeboard
Static, Fibre reinforced plastic (FRP);
2 nos. (2 duty);
Min. width: 500mm; Spacing: 25mm
Min. 300mm x 300mm
Adjustable weather proof
Fibre reinforced plastic (FRP)
High Density Polyethylene (HDPE)
Min. 200mm uPVC pipe
Located within 3m
31
SPAN TS 1402:2016
Item
17
7.4
Process
Requirement
Fibre reinforced plastic (FRP)
Stop log
Pump Stations
Table 6 Pump Station Requirements
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Hydraulic Retention Time
at Qavg
Pumping Cycle
Raw sewage pump
Guide rail of RSP
Cat ladder
Check and gate valve
Spot light
Force main and filtrate
return pipe
Staircase
Float switch
Check valve
Slope of benching
Internal width of pump
sump
Difference between
pump Stop Level and
pump Start Level
Difference between
pump Low Level Alarm
and pump Stop Level
Difference between
pump Start Level and
pump High Level Alarm
Requirement
Max. of 30min detention at Qavg(min)
6 - 15 (start/hour)
2 nos. (1 duty, 1 standby)
Double
Stainless Steel, Fixed type
Ductile iron
Adjustable weather proof
Ductile iron
Head clearance at least 2.1m
Heavy duty non-mercury type
Swing check type with anti-slam
60º (surrounding internal of tank)
Min. 2m
Min. 450mm, Max. 900mm
Min. 150mm
Min. 150mm
Additional criteria for pumps:
a)
Shall operate within their best efficiency range at normal operating condition;
b)
Equipped with an auto restart mechanism in the event of power failure;
c)
Equipped with cutting or macerating facilities are not acceptable.
32
SPAN TS 1402:2016
7.5
Secondary Screen Chamber
Table 7 Secondary Screen Chamber Requirements
Item
1
2
3
4
5
6
7
8
9
10
7.6
Description
Filtrate return pipe
Ramp
By-pass overflow pipe
Fine screen (static)
Kerb
Screen clear spacing
Estimate screenings per
volume of sewage
Perforated Tray
Stop Log
Screening Bin
Requirement
Ductile Iron (Above ground); VCP (Buried)
Reinforced concrete
UPVC - 200mm dia.
Fibre reinforced plastic – 2 units duty
500mm width; 12mm spacing
100mm (H) x 100mm (W) x 500mm (L)
Max clearance, 12mm
37m3/106 m3 at average flow (minus the rubbish
removed by primary screen)
Fibre reinforced plastic (FRP)
Fibre reinforced plastic
High Density Polyethylene (HDPE)
Grit and Grease Chamber
Table 8 Grit Chamber Requirements
Item
1
2
3
4
5
6
7
8
9
10
Process
Chamber unit at Qpeak
Chamber type
Hydraulic Retention Time
at Qpeak
Maximum gravity flow
through velocity at Qpeak
Estimated grit quantity
Check valve
Gate valve with T plain
end
Grit removal pipe
Channel ratio
Side slope degree
Requirement
1 units duty; 1 unit standy
Rectangular
3 min
0.20m/s
~ 0.03m3 / 103 m3 of sewage
Ductile iron
Ductile iron
Ductile iron - 100mm dia.
Gradient 1 : 75
Depth : width 1 : 2
Length : width 2 : 1
30°
33
SPAN TS 1402:2016
Table 9 Grease Chamber Requirements
Item
1
2
3
4
5
6
7
8
9
10
11
Process
Chamber unit at Qpeak
Chamber type
Hydraulic Retention Time
at Qpeak
Estimated grease quantity
Concentration of grease
in the water
Grease removal pipe
Gate valve
Stop Log
Feeding to Anoxic
Grease skimmer
Gradient of grease buffer
wall
Requirement
1 units duty; 1 unit standy
Horizontal flow
3 min
~0.03 m3/103m3 of sewage
0.1 kg/m3
Ductile iron - 100mm dia.
Cast iron
Fibre reinforced plastic (FRP)
Free flow with opening
Fixed & adjustable
5°
Table 10 Grit and Grease Sand Bed Requirements
Item
1
2
3
4
5
6
7
8
7.7
Process
Retention Time
Screed to fall
Depth of grit and grease
feed
Perforated& overflow pipe
Filtrate return sump
Filtrate return pipe
Splash pad
Sand layer
Requirement
30 days
1:200
350mm
uPVC /VCP
Min. 450mm depth
Ductile Iron (above ground); VCP (buried)
500mm x 500mm x 100mm thk.
200mm coarse sand;
300mm aggregate (Grade 28mm to 40mm)
Anoxic Tank
Table 11 Anoxic Tank Requirements
Item
1
2
3
4
5
6
7
Process
Number of tanks
Mixed Liquor Suspended
Solids (MLSS)
Internal Recycle
Location
Mixing power
No. of mixer
Feeding to aeration
Requirement
1 (Type A); 2 (Type B and C)
2000 -4000 mg/l
2 to 6 (MLSS recirculation ratio)
Head of aeration tank
3 w/m3 - 8 w/m3
2 nos. (1 duty, 1 standby)
Overflow design with opening
34
SPAN TS 1402:2016
The Competent Person shall take all necessary consideration in the design in relation
to the specific requirements of the receiving water in determining the actual nutrient
removal requirement on a case by case basis. The selection of mixer shall also
referring to the thrust which refer to the geometry of the tank. The actual position of
mixer shall refer to manufacturer recommendation.
7.8
Aeration Tank
Table 12 Aeration Tank Requirements
Item
1
4
5
6
Process
Number of tanks
Hydraulic Retention Time
(HRT)
Mixed Liquor Suspended
Solids (MLSS)
F/M Ratio
Organic loading
Sludge age
7
Sludge yield
2
3
11
Dissolved oxygen (DO) in
the tank
Total air provided for
organic removal
Total air required for
mixing
Type of diffuser
12
Diffuser installation
8
9
10
13
14
15
16
17
18
19
20
Material at air and purge
line pipe
Air required for blower
selection
MLSS recycle ratio
Return activated sludge
(RAS) flow, QRAS
IR pump
Guide rail of IR pump
Tank dimension length to
width ratio
Water depth
Requirement
2
18 - 24 hrs (typical 20 hrs)
2000 - 4000 mg/l
0.05 ~ 0.1d-1
0.1 - 0.4 kg BOD5/m3.day
> 20 days
0.4 (at 24 hrs HRT) sludge produced / kg BOD5
consumed
0.6 kg (at 18 hrs HRT) sludge produced / kg
BOD5 consumed
≥ 2.0 mg/l
Safety factor 20% for blower selection at
suction
Diffuser grid arrangement, 10-15 m3/103m3.min
complete with purge line
Fine bubble disc type
Top of diffuser to be installed at max. of 0.3m
from tank floor
Hot dipped galvanized iron
Highest among total air required for organic
removal and mixing requirement
4 - 6 times of Qavg
Equal to Qave (if MLSS = 4000 mg/L and
underflow concentration, Cu = 8000 mg/L)
2 nos. (1 duty, 1 standby)
Double
Type A ( > 2.5:1 ) / Type B ( 3:1 ) /
Type C ( 2:1 )
Min. 3m (Type A);
Min. 3.5m (Type B and Type C)
35
SPAN TS 1402:2016
7.9
Blower Room
Table 13 Blower Room Requirements
Item
1
2
Description
Distance
Main door
Requirement
1000mm (between blower and wall)
Acoustic door with engineering design soundproof (Sound
Transmission Class 40)
2400mm (W) x 2700mm (H)
Monolithic structures; Heavy duty
12mm deep groove at ramp 200mm dia. pipe header
Horizontal
Min. 2 times the blower discharge pipe dia.
Hot dipped galvanized iron
Cast iron
To aeration tank;
Individual air pipe tapping
To sludge holding tank;
from air header in blower
To scum skimmer;
house
Min. 3 nos. air flow female tapping
Mineral wool
Plastering to HDGI air pipe
To be provided with the blower
3
Ramp & floor slab
4
5
Outlet silencer
Pipe header
6
7
Gate & check valve
HDGI Air pipe
8
9
Sampling point
HRC acoustic
plastering
Safety valve
External compound
Beacon light
lighting
Roof
RC flat slab (screed to fall with water proofing)
Throating size - 10mm wide
Mortar for brickwork 1:1:5 Cement-Lime-Sand mortar;
Plastering and
20mm thk. with 1:3 cement-sand mortar
rendering
Concrete Plinth
Min. 100mm
Blower selection
Discharge temp.: 25°C-120°C;
Ambient temp.: 40°C;
Relative humidity: 85% blower capable of operating at
partial load condition of at least 60% of the rate speed at
continuous operation
Dampener of
Spring type
blower
Lifting device
Mobile A-Frame
Exhaust fan
Shall be provided inlet and out c/w acoustic treatment
10
11
12
13
15
16
17
18
19
20
The Competent Person shall take all necessary consideration in the design where
vibration from blower and piping shall be dampened adequately to avoid
transmitting to the floor and wall of control room. Shall provide signage for mobile
A-Frame not to bring out from the blower room.
36
SPAN TS 1402:2016
The design of roof shall be considered from the following:
i)
Suitable material for roof (flat or slope) including colour;
ii)
Adequate air for ventilations;
iii)
Enough height for lifting facilities, access and headroom;
iv)
Type of insulation;
v)
Acoustic treatment where applicable;
7.10 Secondary Clarifier
7.10.1 General
The design requirements shall include:
a)
Minimum retention time for settlement;
b)
Maximum settling velocity for settlement;
c)
Sludge hopper to collect settled sludge;
d)
For square clarifiers with 60º slope (from horizontal), minimum 1m side water
depth shall be provided;
e)
The 60º slope (from horizontal) shall be cast in reinforced concrete structure;
f)
All clarifiers must be equipped with scum skimmer to remove scum from the
surface. The scum collected must be drained (where necessary) and
disposed to sludge holding tank. Returning the scum to the preliminary system
or the biological system is not permitted;
g)
Multiple hopper are not permitted;
h)
Stilling basin to prevent hydraulic shock circuiting;
i)
Facilities to dispose scum and sludge;
j)
Appropriate feed and outlet pipe with hydraulic consideration;
k)
Proper maintenance access to all components.
7.10.2 Weirs
a)
If insufficient length is available, then considerations shall be given for the use
of double weir;
b)
Cascading V-notch is preferred over rectangular weirs;
c)
Broad crested weirs are not encouraged;
d)
Slots in the weir shall be provided to allow for level adjustment during the
installation stage;
e)
All parts of the weirs must be visible and accessible for regular cleaning.
37
SPAN TS 1402:2016
7.10.3 Square Clarifiers
Table 14 Secondary Clarifier Requirements
Item
1
2
4
Process
Number of tanks
Type of configuration
Hydraulic Retention Time
(HRT) at Qpeak
Surface overflow rate
5
Solids loading rate
6
7
8
Weir loading rate
Feeding
Stilling box
9
10
11
12
13
14
15
Return sludge rate,
Scum skimmer
Scum pipe
Maintenance platform
Air pipe
Weir plate
Effluent channel
surrounding
Effluent channel finishing
RAS/WAS pump
3
16
17
18
19
20
Requirement
1 nos. (Type A) / 2nos. (Type B) / 4 nos. (Type C)
Square with 60° slope, min. 1.0 side water depth
≥ 2 hrs
≤ 30 m3/d/m2 (Qpeak)
< 150 kg/d/m2 (Qpeak)
< 50 kg/d/m2 (Qave)
< 180 m3/day/m (Qpeak)
Centre
Non-corrosive Metal or FRP 10mm thickness;
Length to be extended top at max. 1.5m from
bottom level
Diameter min. 1.0m
0.5 - 1.0 (QRAS/ Qinflow)
Adjustable air lift
Ductile iron or 3 layer mPVC
Reinforced concrete - 1000mm width
Hot dipped galvanized with ball valve
Fibre reinforced plastic
4 sides
White glazed tile entirely (all internal surfaces)
2 nos. (1 duty, 1 standby) for Type A ;
4 nos. (2 duty, 2 standby) For Type B;
5 nos. (4 duty, 1 spare pump) for Type C
Guide rail of RAS/WAS
Double
pump
RAS/WAS pipe
Ductile iron or 3 layer mPVC – min. 80mm dia.
Check and gate valve
Ductile iron
7.11 Disinfection Tank
Continuous disinfection is required for those areas where the discharge from the
sewage works will cause detrimental effect onto the receiving water course, such as
bathing beaches, lakes, etc. The Commission reserves the right to determine the
need for the provision of a continuous disinfection facility. Only liquid or solid
hypochlorite (sodium or calcium) shall be used.
38
SPAN TS 1402:2016
7.11.1 Disinfection with Hypochlorite
a)
The dosage rate is affected by the suspended solids and ammonia present in
the effluent, mixing employed, contact time and the control strategies used
for dosing;
b)
Proper mixing is important for effective disinfection;
c)
Circular chambers for disinfection are not acceptable;
d)
For continuous disinfection, liquid or solid hypochlorite (sodium or calcium)
shall be used;
e)
For intermittent disinfection, only liquid hypochlorite (sodium or calcium) shall
be used;
f)
A bypass around the chlorine contact chamber shall also be provided to
enable flows to be bypassed during maintenance or servicing. There shall be
penstocks upstream and downstream of the chlorine contact chamber for
isolation purposes;
g)
By pass channel to be constructed at higher level to avoid sludge settlement
in the channel;
h)
Adequate access with sufficient turning radius for the vehicle to carry in the
chemicals to the disinfection system shall be provided;
i)
Benching shall be provided for all corners to enable smooth flow and
minimize solids deposition.
Table 15 Chlorination Chamber Requirements
Item
1
Process
Dosage
2
Chlorination tube
3
4
Contact period
Maximum water depth
Ratio
5
6
7
8
Requirement
6 - 10 mg/l
Portable type
Non-corrosive material
15 minutes at Qpeak
3m
depth: width (2 : 1);
length to width at each pass (6 : 1);
wetted depth: width (< 2 : 1)
Minimum no. of passes
4
Stop Log
Washing bay
Fibre reinforced plastic
One stand pipe complete with concrete kerb
39
SPAN TS 1402:2016
7.12 Flow measurement
Table 16 Flow Measurement Requirements
Item
1
2
3
4
5
Process
Location of flow meter
Type of flow measurement
Type of flow meter
Method of measurement
Measurement times
Requirement
Outlet
Open Channel
V- notch
Manual measurement using staff gauge to
measure height of crest with calibration
curves / tables
Intermittent
7.13 Sludge Holding Tank
Table 17 Sludge Holding Tank Requirements
Item
1
2
3
4
5
6
7
8
9
10
11
12
Process
Retention Time Required
Mixing requirement
Slanted floor
Safety ramp (top of tank)
Air and purge line pipe
Looping pipe
Air diffuser
Sludge drawn out / Sludge
Transfer Pipe
Female coupling (without
SDB)
Sludge Transfer Pump
Guide rail of sludge
transfer pump
Splash pad
Requirement
30 days
20m3 air / min./1000m3 tank
1:50
Hot dipped galvanized mild steel
Min. 600mm
Hot dipped galvanized iron
Hot dipped galvanized iron - 50mm dia.
Coarse bubble disc type
Ductile iron or 3 layer mPVC
Ductile iron
1 Duty, Submersible Type
Double
500mm x 500mm x 100mm (located below
sludge drawn out pipe for tanker)
40
SPAN TS 1402:2016
7.14 Sludge Drying Bed (If Applicable)
Table 18 Sludge Drying Bed Requirements
Item
1
2
3
4
5
9
10
11
12
13
Description
Retention Time
Free board
Roofing
Column, Truss
Min. clearance between
roof truss & top of ramp
Min. eave length
Max. allowable depth of
sludge feed.
Screed to fall (floor)
Concrete
Perforated pipe
Gate valve
Sludge transfer pipe
14
15
16
Filtrate return sump
Splash pad
Ramp
17
Sand layer
6
8
Requirement
28 days
100mm from top of sludge feed
1:15 gradient metal roofing sheet
Structural Steel
2.1m
300mm
450mm
1:200
Min. grade 25
uPVC / VCP
Ductile Iron
Ductile Iron
Min. 80mm – Type A & Type B
Min. 100 – Type C
Brickwall c/w 150mm dia. interconnected pipe
500mm x 500mm x 100mm
Reinforced concrete;
600mm width;
1:10 slope with min. length of 1m
200mm coarse sand (from 2mm-4.7mm);
300mm aggregate (Grade 28mm to 40mm)
The actual quantity of sludge from the upstream unit processes needs to be
computed before sizing the bed. Each bed may be designed to handle a maximum
of 7 days continuous feed. The next feed to the same bed shall only be after a
minimum of 21 days from the last feed. A one-third (1/3) reduction in actual land
area requirement will be acceptable if fully covered drying beds are provided.
Reduction shall only apply to the total surface area of drying bed.
41
SPAN TS 1402:2016
7.15 Sludge Storage Hut (If applicable)
Table 19 Sludge Storage Hut Requirements
Item
1
2
3
4
5
6
Description
Roofing
Column, Truss
Min. clearance between
roof truss & top of ramp
Min. eave length
Concrete
Ramp
Requirement
1:15 gradient metal roofing sheet
Structural Steel
2.1m
300mm
Min. grade 25
Reinforced concrete;
600mm width;
1:10 slope with min. length of 1m
7.16 Control Room
Table 20 Control Room Requirements
Item
1
Description
Main door
2
3
Window
Control panel box
4
5
6
7
8
9
Mounting
Fire extinguisher
First aid box,
emergency sign &
equipment labeling
Rubber mat
Exhaust fan
Notice board
10
Roof
Requirement
Single leaf metal door with 2 layers anti rust epoxy coating
900mm (W) x 2100mm (H)
Louvered window
Front 2.0mm thk. mild steel sheet;
Rear/Side/Top 2.0 mm thk. mild steel sheet ;
Light grey powder coated paint
≤ 100A : Wall mounted; ≥ 100A : Floor mounted
CO2 type
To be provided
12mm thk. (min.)
To meet the room air exchange requirement
Single line diagram; Artificial respiration chart, process flow
diagram
RC flat slab (screed to fall with water proofing);
Throating size - 10mm wide
The design of roof shall be considered from the following:
i)
Suitable material for roof (flat or slope) including colour;
ii)
Adequate air for ventilations;
iii)
Enough height for lifting facilities, access and headroom;
iv)
Type of insulation;
v)
Acoustic treatment where applicable.
42
SPAN TS 1402:2016
7.17 Ancillary Requirement
Table 21 Anti-Climb, Brick Wall Fencing Requirements
Item
1
2
3
4
5
Description
Gate wire mesh
Cover to reinforcement
Mortar
Plastering and rendering
Weld thickeners
Requirement
10SWG / 13SWG (for anti-climb fencing only)
25mm
1:1:5 Cement-Lime-Sand mortar
20mm thk. with 1:3 cement-sand mortar
6mm fillet
Table 22 Sliding Gate Requirements
Item
1
2
Description
Type
Weld thickeners
Requirement
6m wide double rail
6mm fillet
Brick walls shall be anchored to concrete faces using galvanized fishtail anchors to
lap in with the brick reinforcement at every fourth course commencing two courses
above ground beam level. All exposed wall shall be painted with (1) one undercoat
of approved resisting primer sealer and (2) two coats of approved weather resistant
emulsion paint.
All bricks used shall be first quality cement / sand bricks. Brickwork shall be reinforced
with expanded metal or “exempt” at every fourth course commencing two courses
above ground beam level.
43
SPAN TS 1402:2016
7.18 Yard Lighting
Table 23 Yard Lighting Requirements
Item
1
2
Description
Type A
Type B
Type C
4
5
6
7
Type
Supplier/manufacturer &
galvanizer of the column
Column design
Steel column material
Steel accessories
Column seam building
8
Column material
9
10
11
12
13
Panel
Material
Thickness
Painting Finish
Colour
3
Requirement
Min. 1 no at inlet works or entrance
Min. 2 nos. at inlet works and treatment process unit
Min. 4 nos. at every internal corner of STP boundary
and nearby to inlet works and treatment process unit
LED
ISO 9001:2000
BS 5649
Steel BS-EN10025 fe 430C or fe 510C
Fe 360
BS 5135
Hot dipped galvanized BS 729 (average coating
weight 460gm/m)
Outdoor type (floor standing)
Electro galvanized sheet
2.3mm
Epoxy powder paint
Light grey
Sufficient lighting shall be provided at strategic location such as entrance gate, inlet
works and necessary areas. All lightings shall be installed above emergency overflow
level.
44
SPAN TS 1402:2016
7.19 Handrail, Safety Chain, Staircase, Grating and Chequered Plate
Table 24 Handrail, Staircase, Grating and Chequered Plate Requirements
Item
Handrail
Description
1
Material
2
Size
3
4
At platform, walkways and
landing
Above pitch pitch line on stairs
5
Joint
6
Finishing
7
Kicker plate
Staircase
1
Type
2
Thread and riser
3
Landing length
Grating
1
Material
2
Weight
Chequered plate
1
Material
2
Weight
Guide rail
1
Material
Requirement
Hot dipped galvanized mild steel (above
ground level and dry well area);
Stainless steel 304 (wet well area and area that
come in contact with sewage)
38mm dia. tubular rails;
Top and intermediate rails at 550mm center
1100mm (H)
900mm to 1000mm
Handrail joint to be located on center line of
handrail standards
All rough edges and burrs to be removed;
Welds to be 6mm thk. fillet weld (neat and
ground smooth)
Hot dipped galvanized mild steel (above
ground level and dry well area);
Reinforced concrete- anti skid
Thread : 250
Riser : 200
1000mm
Fibre reinforced plastic or Hot dipped
galvanized steel;
≤ 16kg / piece
Hot dipped galvanized steel
≤ 16kg / piece
Stainless steel filled with cement
Safe access and walkways shall be provided at all process units and equipment
(valves, penstocks, aeration tanks, etc.) that require service and maintenance.
Safety handrails shall also be installed at walkways and other working areas with a
fall greater than 2 m.
45
SPAN TS 1402:2016
Provision for fire detection, alarm and firefighting equipment shall be complying with
the latest requirements in the Uniform Building Bylaws, the Institute of Electrical
Engineers (IEE) guidelines and other statutory requirements. All tanks shall not exceed
1.2 m above ground. Staircase and ladder exceeding 1.2 m shall be provided with
handrail. All plants located adjacent to earth slopes shall be provided with proper
slope protection structures. The slope protection design must be certified by
Competent Person.
7.20 Toilet
Table 25 Toilet Requirements
Item
1
2
3
4
5
6
Description
Floor and Wall
Window
Washing bay
Door
Water closet
Water tank
Requirement
Ceramic tiles
Hollow ventilation block
One stand pipe complete with concrete kerb
PVC ; 900mm (W) x 2100mm (H)
Squatting type
100 gallon
7.21 Lifting Facility
Table 26 Lifting Requirements
Item
1
Description
Weight < 16kg
16 kg ≤ Weight ≤ 250 kg
2
Weight > 250 kg
3
4
Safety chain
Requirement
Manual lifting
A davit or ‘A’ frame shall be arranged to allow
items lifted by using manual chain hoist to be
projected on a 1.2m truck tray and positioned
at 2m above road level. In the pump station,
motorized hoist is required for lifting weight
exceeding 100 kg
A gantry with motorized hoist shall be arranged
to allow items to be projected on a 1.2 m truck
tray and positioned at 2m above road level
truck tray
Min. 6mm dia. long link smooth welded
complete with fixings including ‘S’ hooks and
‘D’ shackles stainless steel
Lifting equipment shall be subjected to DOSH approval standards and guidelines.
Safe Working Load with approved method of installation shall be rated, indicated
and printed for all lifting facilities. Height and lifting method must be considered in
the design for Safe Working Load of lifting facilities. All portable motorized hoist shall
46
SPAN TS 1402:2016
be of 230 V operating voltage and fixed electrical hoist shall be of 415 V operating
voltage.
All fixed 3 axis type gantry shall come with additional safety features such as travel
stop limit switch, hoist over run limit switch, slow & fast speed mode and emergency
stop (for all type of hoist). All fixed type outdoor lifting facility futures shall comprise of
hoist parking bay with shade. All fixed type lifting facility shall come with working
platform and excess ladder.
7.22 Ventilation
Ventilation can be achieved naturally or mechanically:
i)
Natural ventilation uses the force of nature such as air currents, breezes,
thermal gradients and pressure differences to move airing and out of the
space;
ii)
Mechanical ventilation uses fans and blowers to force air through space. It is
also sometimes called forced ventilation.
Particular requirements are:
i)
Ventilation shall be intrinsically safe with respect to explosive gases (such as
methane) where such gases may be present;
ii)
Ventilation shall be designed to deal with the different densities of the various
gases;
iii)
Ventilation fans shall be located outside the enclosed space to induce forced
air into the plant. Intake locations shall be such that only fresh air is drawn into
the system and not air recirculated from the exhaust;
iv)
Mechanical ventilation shall be used if the system is required to remove
contaminants;
v)
Ventilation exhaust shall be directed to a suitable location for discharge and it
shall not be adjacent to the intake point;
vi)
Ventilation at rooms where heat generation may take place must be
adequate to dissipate the heat generated to ensure a comfortable making
ambient for the equipment and the operator;
vii)
Noise levels associated with operating fans and blowers, particularly in a
confined space, shall conform to the requirements in Section5.7 and other
stationary requirements;
viii)
ix)
Optimize recurring cost for operation, maintenance and replacement;
Regular testing and inspection of the equipment;
47
SPAN TS 1402:2016
x)
Visible warning shall be provided at all entry points. This shall automatically
operate if the fan fails;
xi)
Where natural or forced ventilation is provided, it shall be installed in such a
manner so as to avoid any ingress of water due to rain or other sources;
xii)
In areas with routine entry by personnel, the ventilation strategy shall
emphasize adequate control of contaminants and the ventilation system shall
be continuously operated.
Table 27 Common Ventilation Rates
Item
Wet-Well
Dry-Well
Grit Removal/Screen
Area
Digester Gas Control
Room
Sludge Gas Compressor
Room
Enclosed Grit Loading
Areas
Enclosed Primary
Sedimentation Tanks
Scum Concentration
Tank
Description
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
30 intermittent
12 continuous
Chlorine and Sulphur
Dioxide Rooms
60 intermittent
12 continuous
Filter/Dewatering Area
12 continuous
All other enclosed unit
processes not
mentioned elsewhere
30 intermittent
12 continuous
Requirement
Use 100% outside air.
Step up to 24 ac/hr if hazardous gases are
detected.
Consider odour control, where warranted
Same as wet well
Same as wet well
Same as wet well
Same as wet well
Same as wet well
Same as wet well
Hazardous areas, toxic fumes, floor level
exhaust required. Interlock fans with manual
switches located at each entrance. Also
interlock fans with chlorine and Sulphur
dioxide detection. Use 100% outside air
Consider odour control for exhaust air from
dewatering area, where warranted
In particular at blower room, high tension
room, low voltage room, switchboard and
control panel rooms, where there are
tendency of heat generation
48
SPAN TS 1402:2016
7.23 Painting for Pipe Works
Painting shall include all plant and machinery inside buildings, including pipework,
grating, hand railing, internal walls below ground level and all metal work including
machinery. The conduits and piping shall be appropriately named and labeled
indicating flow directions and painted with the following colour codes for easy
identification:
i)
Chlorine line - yellow with double green bands;
ii)
Compressed air line - green;
iii)
Fuel gas line - orange;
iv)
Potable water supply line - blue;
v)
Raw sewage line - black;
vi)
Final effluent line - grey;
vii)
Sludge line - brown;
viii)
Non-potable water line - blue with double black bands;
ix)
Other disinfectant lines - yellow with double red bands;
x)
Biogas line - yellow;
The labels shall be stenciled on the piping in a contrasting colour with the colour
coded bands, if any, located at appropriate and strategic points. Colour codes
selected for general equipment, building and others items in a sewage treatment
plant shall be adhered to. The types of paint and surface preparation used shall be
as recommended by the paint manufacturer.
7.24 Plumbing Works
Plumbing works and fire protection to follow local authorities’ requirements.
Inspection and cleaning access shall be provided at all bends and junction of soil
and waste pipes.
49
SPAN TS 1402:2016
Table 28 Plumbing Work Requirements
Item
Description
1
Piping material
2
Gradient
3
Waste piping from
basin/sink
4
Floor traps
5
6
Soil pipes under
carriageway
Manholes cover on
carriageway
Requirement
UPVC BS 4514, BS 5255 and MSD 15 (above
ground soil, waste and vent)
UPVC BS 4660 (underground soil & waste pipes)
32mm dia. - (1:12.5); 40mm dia. – (1:15.0);
50mm dia. – (1:20.0); 75mm dia. – (1:30.0);
100mm dia. – (1:40.0); 150mm dia. – (1:60.0)
50mm dia. and below; shall be chased in brick
wall wherever possible
100mm dia. and complete with stainless
grating and access for cleaning
To be encased in min. 150mm concrete and
reinforced with one layer BMC A7
Heavy duty type
7.25 General Mechanical and Electrical
Table 29 Bolt and Nut Requirements
Item
Description
Bolt and Nut
1
Material
Holding down bolts
1
Materials
Requirement
J-bolt OR Chemical grouting
Stainless steel Grade 316 if contact with sewage or
Chemical grouting.
Table 30 Piping Works Requirements
Item
Description
Pipe works
1
Material
Pipe support/ bracket
1
Material
2
Clearance
Pipe support bracket
Pipe joint
Requirement
Ductile iron with cement lining or mPVC 3-layer
Stainless steel 304
100mm from floor concrete slab to flange;
3m interval for ductile iron and 1m for 3 layer mPVC;
Pipe per length shall be jointed at every 6m
Flexible coupling shall be provided for 3 layer mPVC
pipe
Additional requirement for pipe works:
i)
External surface of pipework (D.I. type) in chambers and wells shall be epoxy
coated;
ii)
Buried ductile iron pipe shall have polyethylene sleeving;
50
SPAN TS 1402:2016
iii)
Pipe within wells and pits shall have flanged joints, while pipe laid in the
ground shall have spigot and socket joints;
iv)
Pipe work shall be adequately supported on concrete plinths or steel
structural supports;
v)
Flanges shall be located at least 150 mm away from structures;
vi)
Dismantling joints such as bends shall be provided;
vii)
Pumping thrust shall be resisted using pipe supports inside chambers and by
mass concrete thrust blocks poured against undisturbed soil in the ground
outside chambers;
viii)
No welding joints are allowed.
Table 31 Emergency Shutoff Switch, Junction Box & Electrical Services Requirements
Item
Description
Emergency shutoff switch
1
Switch
2
Type
Junction box
1
Enclosure
2
Temperature
3
Resistance
4
Mounting type
Electrical Services
1
GI conduit (Exposed)
2
UPVC conduit
(Concealed)
3
Final combined earthing
system resistance
Earth resistance
4
5
Protective conductor
- Cross-sectional area of
protective conductor
Auto restart facilities
Requirement
For every motorised equipment/ machines
Mushroom
IP66 dust damp proof according to IEC 529
Up to 75 deg. C
To chemical, detergent solvent, grease and oil;
Watertight surface
Heavy gauged (class B) hot dipped galvanised,
threaded;
20mm dia. & 1.52mm thickness;
Location at M&E plant room; Machinery plant;
Substation / switch room
High impact rigid conduit;
20mm dia. & 1.80mm thickness;
Not exceeding 1 ohm
Electrical system < 5 ohms each chamber
2 lightning protection system < 10 ohms each
chamber
S<16mm2 - Smm2
16≤S<35mm2 - 16mm2
S>35mm2 - S/2mm2
Equipped for all electrical items for quick reoperation in the event of power failure
51
SPAN TS 1402:2016
8.0 Reporting Format
Competent Person is to submit the Summary of Design Declaration form and
endorsed Mass Balance and Hydraulic Profile calculation sheet as stipulated in
Annex D.
9.0 Construction and Installation
9.1
General
The construction and installation works shall be executed in compliance with the
relevant statutory and legislative regulations of Malaysia.
The complete installation construction and material stated shall comply with the
current rules and requirement of local authority and any other relevant authorities
having jurisdiction over the installation.
9.2
Quality control
Before commencement of the construction works, a quality control program shall be
developed, implemented and maintained consistent with the requirements of the
works. Quality shall be maintained in all areas of work.
9.3
Health and safety requirements
The following shall be considered throughout the construction and installation period
to ensure safe working conditions for workers and ensure protection of adjoining
properties and the public: a)
Site layout;
b)
Provision of welfare facilities;
c)
Safe access and egress;
d)
Requirement of competent/designated persons;
e)
Earthworks;
f)
Temporary working platforms;
g)
Piling and excavation works;
h)
Working at height;
i)
Permit to work;
j)
Working in confined space;
k)
Lifting appliances and method;
l)
Registration of plant/equipment;
52
SPAN TS 1402:2016
m)
Machine guarding;
n)
Safe use of portable tools;
o)
Site tidiness/housekeeping;
p)
Accident reporting and investigation;
q)
Emergency prevention, preparedness and response;
r)
Compliance to Environmental Quality Act 1974, Occupational Safety and
Health Act 1994 and Factories and Machinery Act 1967 requirements
s)
Health and Safety Audits;
t)
The plant shall also be designed to comply with other related legislations such
as IEE, Akta Bekalan Elektrik 1990 (Akta 448) and Peraturan-Peraturan Elektrik
1994 and the relevant IEEE Standards;
u)
Safety level for all electronically operated electrical device such as soft
starters, variable speed drive and others shall conform to IEC, EN, UL, NFC and
VDE. Thus it shall fulfill EN 50178, EN 60204, BS EN 60950, IEC 61800;
v)
Where appropriate, IEE and Akta 448 (1990) and Peraturan Elektrik 1994 must
be complied within all electrical installation;
w)
The following shall be provided:
i)
All moving parts shall be protected by suitable guards. Where inspection
is required, an open mesh with frame and suitably supported maybe
used. The maximum aperture of the mesh shall be 6 mm;
ii)
All guards shall be readily removable and replaceable to the correct
orientation only. However the guard shall be designed with features to
prevent accidental dislocation from its' original position. The fasteners
when dropped during dismantling, must be easily retrievable and should
not damage any equipment or endanger personnel, else fixed fasteners
shall be used;
iii)
An emergency stop button, preferably of mushroom head type shall be
located adjacent to all equipment. More than one emergency stop
button shall be used, if access around the item is restricted;
iv)
Long items, such as conveyor belts, shall have an emergency lanyard
applied to each accessible length of conveyor;
v)
Surfaces which are greater than 50°C shall be guarded;
vi)
Permanent warning signs shall be posted at visible location tall
dangerous areas and shall clearly indicate the nature of risk at that
area. This includes warning signage at digesters area, high tension room,
low voltage room, generator room and other hazardous areas;
53
SPAN TS 1402:2016
vii)
Automatic CO2discharge triggered by heat and smoke sensors shall be
installed in high voltage switch room, transformer room, low voltage
switch room and generator room;
viii)
High tension room shall have signage to clearly indicate the purpose of
the room and also safety signage to prevent unauthorized entry.
Calcium and sodium hypochlorite are hazardous chemicals to handle and use.
Calcium hypochlorite is classified as a corrosive agent. Eye protection, access to an
emergency eyewash system and showers must be made available to the operators.
Also, direct contact with the undiluted hypochlorite is likely to cause burns to the skin
and clothing. Therefore, it is imperative that protective clothing which includes
rubber gloves, must be worn by operators when working with these chemicals. When
calcium hypochlorite is being transported in the powder form and mixed in water to
form solutions, the operator should always wear eye protection and dust masks. All
areas exposed to hypochlorite should be washed thoroughly.
9.4
Inspection
For the purpose of inspection, a guide has been prepared but is not limited to Annex
C. This guide comprises common components as well as a typical defect list that
shall be referred to by the CP during the inspection exercise. The inspection guides
including all relevant test records are not required to be submitted but has to be
kept properly by the CP and made available upon request.
10.0
Testing and Commissioning
All testing and commissioning (T&C) shall be carried out in accordance with the
relevant operation and maintenance manual witnessed and endorsed by CP.
Records of pre-commissioning tests and commissioning tests should be properly
maintained by CP and made available upon request. The functionality test shall be
carried out on the following but not limited to:a) Inlet Chamber - Manual Screen Test;
b) Pump Sump - Raw Sewage Pump;
c) Secondary Screen Chamber - Manual Screen Test;
d) Aeration Tank - Diffuser Test;
e) Clarifier Tank - RAS / WAS Pump;
f)
Sludge Holding Tank - Diffuser Test;
g) Blower Room - Blowers, Main Control Panel.
54
SPAN TS 1402:2016
ANNEX A: REFERENCES
Malaysian Standards
• MS 144
Steel wire for the reinforcement of concrete products – specification
• MS 145
Steel fabric for the reinforcement of concrete – specification
• MS 146
Steel for the reinforcement of concrete - weldable reinforcing steel - bar, coil and
decoiled product – specification
• MS 415
Code of practice for composite construction in structural steel and concrete
• MS 739
Specification for hot-dip galvanized coatings on iron threaded fasteners
• MS 740
Specification for hot-dip galvanized coatings on iron and steel articles
• MS 822
Specification for sawn-timber foundation piles
• MS 1037
Specification for sulphate-resisting portland cement
• MS 1195: Part 2
Code of practice for structural use of concrete: Special circumstances
• MS 1226: Part 1
Pulverized-fuel ash: Specification for pulverized-fuel ash for use as a cementitious
component in structural concrete
• MS 1241
One-piece glass fibre reinforced polyester (GRP) water tanks - nominal capacity of
100 000 litres and below – specification
• MS 1292
Rubber seals - water stops for sealing joints in concrete - specification of materials
• MS 1390
Glass-fibre reinforced polyester panels and panel water tanks – specification
55
SPAN TS 1402:2016
• MS EN 934
Admixtures for concrete
• MS EN 12620
Aggregates for concrete
• MS EN 15167-1
Ground granulated blast furnace slag for use in concrete, mortar and grout - part 1:
Definitions, specifications and conformity criteria
• MS EN 15167-2
Ground granulated blast furnace slag for use in concrete, mortar and grout - part 2:
Conformity evaluation
British Standards
• BS 4-1
Structural steel sections. Specification for hot-rolled sections
• BS 476
Fire tests on building materials and structures
• BS 1161
Specification for aluminium alloy sections for structural purposes
• BS 3396-1
Woven glass fibre fabrics for plastics reinforcement. Specification for loom-state
fabrics
• BS 3532
Method of specifying unsaturated polyester resin systems
• BS 3749
Specification for E glass fibre woven roving fabrics for the reinforcement of polyester
and epoxy resins systems
• BS 4449+A2
Steel for the reinforcement of concrete. Weldable reinforcing steel. Bar, coil and
decoiled product. Specification
• BS 4514
Unplasticized PVC soil and ventilating pipes of 82.4 mm minimum mean outside
diameter, and fittings and accessories of 82.4 mm and of other sizes. Specification
56
SPAN TS 1402:2016
• BS 4660
Thermoplastics ancillary fittings of nominal sizes 110 and 160 for below ground gravity
drainage and sewerage
• BS 4868
Specification for profiled aluminium sheet for building
• BS 4921
Specification for sherardized coatings on iron or steel
• BS 5255
Specification for thermoplastics waste pipe and fittings
• BS 5493
Code of practice for protective coating of iron and steel structures against corrosion
• BS 7079
General introduction to standards for preparation of steel substrates before
application of paints and related products
• BS EN 197-1
Cement. Composition, specifications and conformity criteria for common cements
• BS EN 485
Aluminium and aluminium alloys. Sheet, strip and plate
• BS EN 754
Aluminium and aluminium alloys. Cold drawn rod/bar and tube
• BS EN 755
Aluminium and aluminium alloys. Extruded rod/bar, tube and profiles
• BS EN 934-2
Admixtures for concrete, mortar and grout. Concrete admixtures.
• BS EN 1676
Aluminium and aluminium alloys. Alloyed ingots for remelting. Specifications
• BS EN 1990+A1
Eurocode. Basis of structural design
• BS EN 1992-1-1+A1
Eurocode 2: Design of concrete structures. General rules and rules for buildings
57
SPAN TS 1402:2016
• BS EN 1992-3
Eurocode 2: Design of concrete structures. Liquid retaining and containing structures
• BS EN 1999-1-1+A2
Eurocode 9: Design of aluminium structures. General structural rules
• BS EN 1999-1-3+A1
Eurocode 9: Design of aluminium structures. Structures susceptible to fatigue
• BS EN 1999-1-4+A1
Eurocode 9: Design of aluminium structures. Cold-formed structural sheeting
• BS EN 10088-1
Stainless Steels. List of Stainless Steels
• BS EN 10088-3
Stainless steels. Technical delivery conditions for semi-finished products, bars, rods,
wire, sections and bright products of corrosion resisting steels for general purposes
• BS EN 14118-1
Reinforcement. Specifications for textile glass mats (chopped strand and continuous
filament mats). Designation
• BS EN 14118-2
Reinforcement. Specifications for textile glass mats (chopped strand and continuous
filament mats). Methods of test and general requirements
• BS EN 14118-3
Reinforcement. Specifications for textile glass mats (chopped strand and continuous
filament mats). Specific requirements
• BS EN 15743+A1
Supersulfated cement. Composition, specifications and conformity criteria
• BS EN 60950
Information technology equipment. Safety
• BS EN 61000-6-1
Electromagnetic compatibility (EMC). Generic standards. Immunity for residential,
commercial and light-industrial environments
• BS EN 61000-6-2
Electromagnetic compatibility (EMC). Generic standards. Immunity for industrial
environments
58
SPAN TS 1402:2016
• BS EN 61672-1
Electroacoustics. Sound level meters. Specifications
• BS EN 61672-2
Electroacoustics. Sound level meters. Pattern evaluation tests
• BS EN 61672-3
Electroacoustics. Sound level meters. Periodic tests
• BS EN ISO 3210
Anodizing of aluminium and its alloys. Assessment of quality of sealed anodic
oxidation coatings by measurement of the loss of mass after immersion in phosphoric
acid/chromic acid solution
• BS EN ISO 17660-1
Welding. Welding of reinforcing steel. Load-bearing welded joints
• BS EN ISO 17660-2
Welding. Welding of reinforcing steel. Non load-bearing welded joints
European Standards
• EN 10025
Hot rolled products of structural steels
• EN 10029
Hot-rolled steel plates 3 mm thick or above - Tolerances on dimensions and shape
• EN 10162
Cold-rolled steel sections - Technical delivery conditions - Dimensional and crosssectional tolerances
• EN 10210
Hot finished structural hollow sections of non-alloy and fine grain steels
• EN 10296
Welded circular steel tubes for mechanical and general engineering purposes Technical delivery conditions
• EN 10297
Seamless circular steel tubes for mechanical and general engineering purposes Technical delivery conditions
• EN 10305
Steel tubes for precision applications - Technical delivery conditions
59
SPAN TS 1402:2016
• EN 14020
Reinforcements - Specification for textile glass rovings
• EN 50178
Electronic equipment for use in power installations
• EN 60204
Safety of machinery - electrical equipment of machines
• EN ISO 2063
Thermal spraying - metallic and other inorganic coatings - Zinc, aluminium and their
alloys
• EN ISO 9445
Continuously cold-rolled stainless steel - Tolerances on dimensions and form
ASTM Standards
• ASTM C582
Standard specification for contact-molded reinforced thermosetting plastic (RTP)
laminates for corrosion-resistant equipment
• ASTM E84
Standard test method for surface burning characteristics of building materials
AS Standards
• AS/NZS 2312.1:2014
Guide to the protection of structural steel against atmospheric corrosion by the use
of protective coatings - Paint coatings
• AS/NZS 3750.2
Paints for steel structures - Ultra high-build paint
• AS/NZS 3750.12
Paints for steel structures - Alkyd/micaceous iron oxide
IEEE Standard
• IEC 61800
Adjustable speed electrical power drive systems
60
SPAN TS 1402:2016
Other Reference Materials
Environmental Quality Act 1974 (Act 127)
Factories and Machinery Act 1967 (Act 139)
Electricity Supply Act 1990 (Act 447)
Electricity Supply (Successor Company) Act 1990 (Act 448)
Occupational Safety and Health Act 1994 (Act 514)
Water Services Industry Act 2006 (Act 655)
Electricity Regulations 1994
Environmental Quality (Sewage) Regulations 2009
SPAN. 2009. Malaysian Sewerage Industry Guidelines. National Water Services
Commission Malaysia.
DOE. 2012. Guidelines for Siting and Zoning of Industry and Residential Areas.
Department of Environment Malaysia.
61
SPAN TS 1402:2016
ANNEX B: STANDARD STP DRAWINGS
62
SPAN TS 1402:2016
SEWAGE TREATMENT SYSTEM:
STANDARD STP, PART 1 -EXTENDED AERATION
(150 - 5000 PE)
STANDARD STP DRAWINGS
TYPE A (150 - 1000 PE)
63
SPAN TS 1402:2016
SEWAGE TREATMENT SYSTEM:
STANDARD STP, PART 1 - EXTENDED AERATION
(150 - 5000 PE)
STANDARD STP DRAWINGS
TYPE B (1001 - 3000 PE)
64
SPAN TS 1402:2016
SEWAGE TREATMENT SYSTEM:
STANDARD STP, PART 1 - EXTENDED AERATION
(150 - 5000 PE)
STANDARD STP DRAWINGS
TYPE C (3001 - 5000 PE)
65
SPAN TS 1402:2016
SEWAGE TREATMENT SYSTEM:
STANDARD STP, PART 1 - EXTENDED AERATION
(150 - 5000 PE)
STANDARD STP DRAWINGS
TYPICAL DETAILS
66
SPAN TS 1402:2016
ANNEX C: INSPECTION GUIDE & TYPICAL LIST OF DEFECTS
67
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Reinforcement
Location
:
Designation
:
Checklist No. ___________________________
Item
Yes
Description
No
Remarks by Engineer
FIXED REINFORCEMENT
1 Main Re-Bar
1.1 Grade
1.2 Bar size ………………..………… mm
1.3 Spacing ………………………….. mm
1.4 Lapping length ……...…………… mm
1.5 Final Inspection for this item
2 Secondary Re-Bar
2.1 Grade
2.2 Bar size ………………..………… mm
2.3 Spacing ………………………….. mm
2.4 Lapping length ……...…………… mm
2.5 Final Inspection for this item
3 Reinforcement
3.1 Minimum cover achieved
3.2 Free from mud, oil, grease, etc.
3.3 Cleanliness of re-bars (free from excessive rust)
3.4 Starter bars & dowel bars installed properly
3.5 Position of re-bars around openings as required based as per drawings
3.6 Tying wire and supports (sufficient number of spacers and chairs)
3.7 Others …………………………….
3.8 Final Inspection for this item
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
68
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Formwork
Location
:
Designation
:
Checklist No. ___________________________
Description
Item
Yes
No
Remarks by Engineer
FORMWORK
1 Forms
1.1 Levels and chambers
1.2 Closeness and joints
1.3 Forms are adequate for required class of surface finish (F1, F2, F3, ……)
1.4 Alignment and plumb
1.5 Application of form oil
1.6 Free from ponding of water
2 Openings and Penetrations
2.1 Dimensions as per drawings
2.2 Position as per drawings
2.3 Embedment plates installed
2.4 Fixings and supports
2.5 Cast-in pipe and conduits
2.6 Chamfers installed
3 Wall and Column Forms
3.1 Type of form (steel, timber, other, ………)
3.2 Tie bolts (number, location, etc)
3.3 Fixings and supports
3.4 Concrete cover (…………mm)
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
69
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Cast In-Situ Reinforced Concrete Concreting
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
FINAL CHECK PRIOR TO CASTING
1
Inspection of formwork (dimensions, plumb, level, alignment, rigidity).
2
Cleanliness of forms (mould oil applied)
3
Construction joints (cleanliness, position, preparation, properly secured)
4
Inspection of reinforcement (cover, size, numbers, spacing, cleanliness
laps, links, stirrups)
5
Mechanical (opening for duct & pipe sleeve, trimming bars, inserts, rigidity)
6
Electrical (conduit and box earthing conductor, opening for equipment
rigidity)
7
Slump test recorded (at the batch plant……….mm; on site…………mm)
8
Mix acceptable (concrete grade as required) check D/O for night grade
9
Testing laboratory notified and required number of cubes taken
10 Vibrators and stand-by vibrators available
11 Weather condition acceptable (good, fair, rain)
12 Time limitation 120 min. (time measured from batching to fully discharged
concrete time)
13 If in-use concrete pumps clean and ready
14 Mobile cranes & concrete hoppers available as means of concrete
placement
15 Concrete free fall not more than 1.6m
16 Safety measures covering this activity are adequate (barricades,
platform, etc.)
17 Dowel bars, waterstop, joint filter installed as required
18 Others
19 Final inspection for this item
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
70
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Cast In-Situ Reinforced Concrete Concreting
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
INSPECTION DURING CASTING AND POST-CASTING
1 Compaction in horizontal layers of less than 450mm
2 Thoroughly worked between forms and reinforcement
3 Pouring time START…………………..FINISH………………….
4 Alignment, elevations and supports checked during pouring
5 Construction joints (horizontal) in required position
6 Finish of concrete as specified (type/ class of finish…………………….)
7 Concrete curing applied as specified (type of curing…………………….)
8 Amount of concrete poured…………………m 3
9 Others
10 Final inspection for this item
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
71
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Installation of Penstock
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
1 Approved material : _______________________________________
2 Correct bolt holes depth, position and spacing
3 Bolting (chemical anchor bolt) penstock to wall
4 Correct vertically
5 Correct horizontally
6 Correct spindle alignment
7 Grouting of penstock frame
8 Headstock and actuator installed
9 _______________________________________________
10 _______________________________________________
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
72
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Installation of Pumpset
Location
:
Designation
:
Checklist No. ____________________________
Item
Yes
Description
No
Remarks by Engineer
1 Approved handling and working method
2 Correct pump plinth and/ or motor pedestal footing setting out
3 Correct hold down bolt type & size for pump/ motor pedestal/ shaft
pedestal
4 Correct pump level and alignment
5 Correct motor level and alignment
6 Correct shaft alignment - pump, motor, intermediate shaft (attach results)
7 Bolting and gasket at flange joint
8 Grouting of pump foot/ shaft pedestal/ motor pedestal
9 Auxiliary piping installed
10 All damaged surface made good
11 _______________________________________________
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
73
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Cast In-Situ Reinforced Concrete Concreting
Location
:
Designation
:
Item
Checklist No. ____________________________
Description
Yes
No
Remarks by Engineer
1 Correct chamber level and opening size
2 Correct vertically and horizontality - Bottom section
3 Correct vertically and horizontality- Intermediate section
4 Correct vertically and horizontality - Upper intermediate section
5 Bolting and grouting of frame sections to wall
6 Correct vertically and horizontality - Head section
7 Scarificial anodes installed correctly
8 Assembly of equipments at head section in order
9 Correct installation of roler chain and mesh panel
10 Wash water system installed correctly
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
74
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Installation of Valve
Location
:
Designation
:
Checklist No.
Description
Item
Yes
1
Correct plinth dimension and level
2
Flange dimension comply to Appendix 3.1 (Specification)
3
Correct J-bolt installed
4
Correct valve level
5
Correct vertically, horizontality and orientation (flow direction)
6
Correct bolts and gasket as flange joint
7
Correct bolt tightening torque
8
Correct alignment of extendd spindle
9
Headstock and/or actuator installed
10
Grouting at plinth
11
All damaged surface make good
Inspected by :
No
Signature :
Remarks by Engineer
Date:
(Name)
Remarks by Engineer :
The Contractor is :
NOT ALLOWED to proceed with the works.
ALLOWED
Nonconformance raised during inspection /re-inspection?
Inspected by :
Signature :
YES
NO
NCR No.:
Date:
(Name)
Please √ off w here appropriate
75
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Installation of Submersible Equipment
(e.g VERTICAL MIXERS / SLUDGE MIXERS / SUBMERSIBLE PUMPS)
Location
:
Designation
:
Checklist No.
Item
Yes
Description
1
Correct level (tank/sump….etc)
2
Approved submerged part material
3
Correct alignment of guide rail (sub. pump)
4
Drive unit secured to position
5
Correct alignment of rotatiing shaft (ver. mixer)
6
Lifting equipment installed (i.e slewing jib, hoisting chain)
7
_________________________________________________
8
_________________________________________________
9
_________________________________________________
10
_________________________________________________
Inspected by :
No
Signature :
Remarks by Engineer
Date:
(Name)
Remarks by Engineer :
The Contractor is :
NOT ALLOWED to proceed with the works.
ALLOWED
Nonconformance raised during inspection /re-inspection?
Inspected by :
Signature :
YES
NO
NCR No.:
Date:
(Name)
Please √ off w here appropriate
76
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Cast In-Situ Reinforced Concrete Concreting
Location
:
Designation
:
Item
Checklist No. ____________________________
Description
Yes
No
Remarks by Engineer
1 Approved pipe material & size : ______________
2 Piping layout, level and alignment as per approved drawing
3 All valves, fittings and etc in order
4 Correct piping jointing
5 Approved pipe support and brackets
6 Approves surface coating at site : __________________
7 _________________________________________________
8 _________________________________________________
9 _________________________________________________
10 _________________________________________________
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
77
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Checklist
Pump Performance Test
Location
:
Designation :
Checklist No. : ___________________________
Pump Make/ Model :_______________________________
Pump Serial No : _________________________________
Motor Rating : ____________________kW,
Voltage : ________________
Motor Make/ Model :_______________________________
Motor Serial No : _________________________________
Pumpset No : ___________________________________
Specified Pump Duty : Flow : ______________________
Total head : ___________________
Speed : ______________________
Suction pipe diameter : _______________________
Discharge pipe diameter : ________________________
Suction gauge elevation above pump C/L suction : ____________________ Discharge : __________________
No
Description
1
2
3
4
5
6
7
8
9
10
11
12
Flowrate (
)
Delivery Head (m)
Suction Head (m)
Current (A)
Voltage (V)
Motor Input power (kW)
1
2
3
4
Valve fully
closed
Duty
Point
1
Duty
Point
2
Duty
Point
3
5
6
Intermediate Valve fully
Point
open
Test date : _______________
Time start : ____________
Recorded by : _______________
(Contractor)
Name : _______________________
Inspected by : _______________
(Consultant)
Name : _______________________
Witnessed by : _______________
(Employer)
Name : _______________________
Remarks
Time finish : _____________________
Please √ off w here appropriate
78
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Inspection of Lifting Equipment
(OVERHEAD CRANE / PORTAL CRANE / MONORAIL / SLEWING JIB)
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
1 Approved beam/girader launching method
2 Correct level of corbel ; with shim if necessary (overhead crane) /
floor (portal crane or slewing jib) / beam (monorail)
3 Correct plates, beam and girder dimension
4 Correct span of runway
5 Correct anchor bolts size and spacing
6 Grouting of anchor bolt pocket
7 Runway beam / jib standard bolted to structure
8 Tie member bolted to column & welded to runway beam
overhead crane
9 All members bolted correctly (portal crane)
10 Stooper plate installed
11 All damage surface make good
12 End carriage / hoist / electrical festoon installed
13 Saftey feature & sinage installed (buzzer, etc.)
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
79
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Inspection of Ventilation Fan
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
1 Correct opening size
2 Correct fan type, make, capacity and spec.
3 Correct fan orientation
4 Correct fan level and alighment
5 Fan assembly bolted correctly to wall / plinth
6 Correct duct size
7 Correct duct alighment
8 Sufficient fan and duct support
9 Duct insulated (for pump motor exhaust)
10 Opening gap sealed
11 Grouting of pllnth
12 All damage surface make good
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
80
SPAN TS 1402:2016
Standard STP - Extended Aeration (EA)
Inspection Guide
Installation of Equipment on Plinth
Location
:
Designation
:
Checklist No. ____________________________
Description
Item
Yes
No
Remarks by Engineer
1 Approved type, make, model and capacity
2 Correct plinth dimensions
3 Assembly in order
4 Correct level (skims if necessary)
5 Correct alighment and orientation (flow)
6 Correct bolt type, size and tightening
7 Grouting of plinth (if necessary)
8 Auxilary piping and fixing installed
9 ____________________________________
10 ____________________________________
Inspected by :
Signature :
Date:
(Name)
Remarks by Engineer :
The Contractor is :
ALLOWED
NOT ALLOWED to proceed with the works.
Non-conformance raised during inspection / re-inspection?
Inspected by :
Signature :
YES
NCR No.:
NO
Date:
(Name)
Please √ off w here appropriate
81
SPAN TS 1402:2016
Guidance on List of Defects (not limited to)
82
SPAN TS 1402:2016
ITEM
DEFECTS
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
A
General
1
Clean Site compound
Visual
Minor
2
Clean perimeter drain
Visual
Minor
3
Clean inner channel
Visual
Minor
4
Clean inspection/valve chambers
Visual
Minor
5
Clean debris from site
Visual
Minor
6
Soil settlement at site
Civil
Major
7
Site flooded
Civil
Major
8
Premix to internal road
Maintenance
Minor
9
Provide internal drains
Maintenance
Minor
10
Repair perimeter drain
Maintenance
Minor
11
Repair Fencing
Maintenance
Minor
12
Repair kerbs
Maintenance
Minor
13
Repair fencing posts/gates
Maintenance
Minor
14
Replace RC slab/grating cover
Material
Minor
15
Penstock not installed
Equipment
Major
16
Penstock leaking
Equipment
Minor
17
Tank leaking
Structural
Major
18
Repair RC crack to structures
Structural
Major
19
Provide hand railing
Minor
20
Paint hand railing yellow
Safety
Visual
21
Re-paint hand railing
Visual
Minor
22
Paint RC walls
Visual
Minor
23
Provide grating for opening
Screening plants surrounding fencing
Safety
Visual
Minor
24
25
Trim grass up to 5 ft outside fencing
Visual
Minor
26
Landscaping
Visual
Minor
27
Provide warning signboard
Safety
Minor
28
Provide water supply
Maintenance
Minor
29
Provide toilet facility with wash basin
Operation
Minor
30
Provide stop log
Equipment
Minor
31
Rectify effluent channel
Civil
Minor
Minor
Minor
32
Access road to STP
Access
Major
33
Stainless steel nuts & bolts
Material
Minor
B
Screen & Chambers
1
Lifting chain for basket screen to be SS
Operation
Minor
2
Electric chain hoist for basket screen
Operation
Minor
3
Guide rails for basket screen
Operation
Minor
4
Working platform for static screen
Access
Minor
83
SPAN TS 1402:2016
ITEM
DEFECTS
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
B
Screen & Chambers (continued)
5
Platform for mechanical screen
Access
Minor
6
Clear access to stairway etc
Access
Minor
7
Provide perforated screenings bin
Equipment
Minor
8
Relocate electrical cable for screen
Maintenance
Minor
9
Bar screen to be removable
Maintenance
Minor
10
Clean screen chamber
Maintenance
Minor
C
Pump Station
1
Cracked wall
Structural
Major
2
Provide SS guide rails
Material
Minor
3
Provide SS lifting chain
Material
Minor
4
Clear pump sump
Maintenance
Minor
5
Provide overflow pipe
Operation
Minor
6
Leaking gate valve
Equipment
Safety
Minor
7
Provide hand railing around pump sump
8
Grating for pump opening
9
Minor
Safety
Minor
Label all pumps
Operation
Minor
10
Noisy pump –vibrating
Equipment
Major
11
Adjust level regulator-floats
Operation
Minor
12
Isolation switch for pumps
Safety
Major
13
Re-install guide rails
Maintenance
Minor
D
Pipework & fittings
Minor
1
Repair pipe leaks
Pipe/fitting
2
Label pipes with flow direction
Operation
Minor
3
Noisy check valve
Pipe/fitting
Minor
Maintenance
Minor
Minor
4
Provide valve chamber
5
Provide extension spindle for gate valve
6
Provide valves for diffuser pipes
Operation
Pipe/fitting
7
Valve leaking
Pipe/fitting
Minor
8
Force main to be properly secured
Maintenance
Minor
9
Replace GI pipes with DI
10
Relocate pipe works
Minor
Material
Minor
Maintenance
Minor
11
Paint pipe work to colour codes
Operation
Minor
12
Incorrect pipe size
Pipe/fitting
Major
E
Grit Removal
1
Provide grating
2
Provide collection bin
Safety
Minor
Equipment
Minor
3
Filtrate return to sump
Operation
Minor
4
Provide stop log for distribution channel
Equipment
Minor
84
SPAN TS 1402:2016
ITEM
DEFECTS
E
Grit Removal (continued)
5
Provide access ramp and platform
6
Leaking sand classifier
F
Oil & Grease Removal
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
Access
Minor
Equipment
Minor
1
Provide access platform
Access
Minor
2
Provide hand railing
Safety
Minor
3
Provide baffles
Operation
Minor
4
Skimmer pipe to be non-corrosive
Material
Minor
5
Paint belting cover
Maintenance
Minor
G
Mechanical
1
Screen conveyor overload
Blower motor burnt
Electrical
Equipment
Major
2
3
Noisy check valve
Equipment
Minor
Major
4
To provide spare parts
Maintenance
Minor
5
Label all equipment
Maintenance
Minor
6
Set equipment working on timer
Grease all bearings & chains
Operation
Maintenance
Minor
7
8
Install all equipment 1 m from wall
Maintenance
Minor
9
Ventilation system in dry well/chamber malfunction
Safety
Major
H
Electrical
Minor
1
Rectify timer
Electrical
Minor
2
Repaint switchboard panel
Electrical
Minor
3
Check efficiency of capacitor
Electrical
Minor
4
Beacon light not functioning
Electrical
Minor
5
Re-calibrate current overload
Electrical
Minor
6
Provide rubber mat at control room
Safety
Minor
7
Replace non-functioning indicator lights
Electrical
Minor
Equipment
Major
8
Aerator trip
9
Replace capacitor/contactor
Electrical
Minor
10
Provide individual isolator switch
Electrical
Major
11
Repair junction box
Electrical
Major
12
Exposed electric cable
Electrical
Major
Minor
13
Replace PVC conduits with GI
Electrical
14
Incoming cable sizing not correct for amps
Electrical
Major
15
Replace single MCB with 3-phase
Electrical
Major
16
Provide spot light for wet well
Electrical
Minor
17
Junction box to complete with isolator
Electrical
Minor
Minor
18
Provide 3-pin outlet socket
Maintenance
19
Calibrate earth fault relay
Electrical
Major
20
Replace malfunctioned light fittings
Maintenance
Minor
85
SPAN TS 1402:2016
ITEM
DEFECTS
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
H
Electrical (continued)
21
Ammeter non functioning
Electrical
Minor
22
Hour-meter non functioning
Electrical
Minor
23
Replace auto-trans for pump
Electrical
Major
24
Check incoming cable to MCCB
Electrical
Minor
25
Switchboard to comply to specs
Electrical
Minor
26
Indicate MCB rating for mechanical screen
Electrical
Minor
27
Indicate MCB rating for belt press
Electrical
Minor
28
Provide compound light
Electrical
Minor
29
Relocate junction box
Electrical
Minor
30
Cover bus-bar
Safety
Major
31
Junction box to be weather proof
Electrical
Minor
32
Sand fill & concrete cover for incoming trench
Electrical
Major
33
Outdoor cable tray to be GI
Material
Minor
34
Replace damaged cable trunk
Electrical
Major
35
Replace power factor regulator
Electrical
Major
36
Replace malfunctioned starter
Electrical
Major
37
Carry out impedance test
Electrical
Minor
38
Provide earthing chamber
Safety
Minor
39
Provide fire extinguisher
Safety
Minor
40
Provide electrical line diagram
Electrical
Minor
41
Provide first aid kit
Safety
Minor
Safety
Minor
I
Blower Room
1
Provide sound proofing
2
Provide ventilation
Safety
Minor
3
Provide acoustic doors
Safety
Minor
4
Provide silencer for blowers
Safety
Major
Pipe/fitting
Minor
Safety
Minor
Major
5
Replace piping & check valve
6
Carry out sound test
7
Oil leakage at pressure gauge
Maintenance
8
Nuts & bolts for blower frame
Material
Minor
9
Repair cracks in blower room walls
Structural
Major
10
Blower not functioning
11
Provide lifting device for blower
12
Blower undersized
13
Provide cover for belt drive
Equipment
Major
Maintenance
Minor
Equipment
Major
Safety
Minor
Equipment
Major
J
Aeration Tank
1
Noisy aerator
2
De-silt tank
Maintenance
Minor
3
Structural cracks
Structural
Major
4
Aerator malfunction
Equipment
Major
86
SPAN TS 1402:2016
ITEM
DEFECTS
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
J
Aeration Tank (continued)
5
Diffuser imbalances air
Pipe/fitting
Minor
6
Surface aerator vibrating
Equipment
Major
7
Access to aeration tank
Access
Minor
8
Replace slabs with grating at openings
Material
Minor
9
Metal stairway corroded
Access
Minor
Operation
Minor
Access
Minor
Operation
Minor
10
Adjust surface aerator submergence
11
Access to discharge channels
K
Secondary Clarifier
1
Scum skimmer adjustment
2
Repaint sludge scraper bridge
General
Minor
3
Adjust level of scum box
Operation
Minor
4
Adjust overflow weir plate
Operation
Minor
5
Access to bridge
Access
Minor
6
Clean launder
Maintenance
Minor
7
Clear rubbish from scum box
Maintenance
Minor
8
Provide safety grating for opening
Safety
Minor
9
Skimmer pipe leaking
Pipe/fitting
Minor
10
Hand railing for bridge
Safety
Minor
11
Noisy motor
Equipment
Major
12
Provide water tap for maintenance
Maintenance
Major
13
RAS pump malfunction
Maintenance
Major
14
Check for equal distribution
Operation
Major
15
Provide access for sludge collection chamber
Access
Minor
16
Clarifier scraper malfunction
Equipment
Major
17
Clarifier tank leaking
Structural
Major
L
Lifting Devices
1
Provide 1 ton chain block
Maintenance
Major
2
Provide lifting davit
Maintenance
Minor
3
Adjust height/location I-beam
Maintenance
Minor
4
Safe working load for I-beam to comply to DOSH
Safety
Major
5
SWL painted on davit
Safety
Minor
6
Electrically operated lifting device
Maintenance
Minor
7
Lifting chain to be stainless steel
Maintenance
Minor
M
Flow Measurement
1
Calibrate flow measurement equipment
Maintenance
Minor
2
Hard-standing / concrete working area
Maintenance
Minor
3
Test & certify flow recorder
Maintenance
Minor
4
Hand railing for parshall flume
Safety
Minor
5
Flow meter device not provided
Instrument
Minor
87
SPAN TS 1402:2016
ITEM
N
DEFECTS
TYPE OF
DEFECTS
CATEGORY OF
DEFECTS
Holding Tank
1
Provide desludging pipe
Operation
Minor
2
Provide overflow pipe to inlet
Operation
Minor
3
Repair desludging pipe
Pipe/fitting
Minor
4
Provide stairway and extended platform
Access
Minor
5
Provide cover for opening
Safety
Minor
6
Provide SHT mixer
Equipment
Major
88
SPAN TS 1402:2016
ANNEX D: MASS BALANCE AND HYDRAULIC PROFILE
89
SPAN TS 1402:2016
HYDRAULIC PROFILE
18
16
Top Water Level (m)
14
12
10
8
EXAMPLE
6
4
2
0
Inlet Chamber
Primary Screen Chamber
Pump Sump
Secondary Screen Chamber
Grit Chamber
Grease Chamber
Anoxic Tank
Aeration Tank Clarifier Tank Chlorination Sludge Chamber
Holding Tank
Process Unit
Top Water Level (TWL) m
Signature
&
Endorsement:
Ground Level
Company
Stamp:
90
SPAN TS 1402:2016
EXAMPLE
Signature
&
Endorsement:
Company
Stamp:
91
SPAN TS 1402:2016
ANNEX E: PROCESS DESIGN CALCULATION