Process Design WTP

PROCESS DESIGN
1 Process Design Basis

2 Treatment Units
Description and Design Parameters of various Units of Water
3 Treatment Plant
4 WTP Process Design Calculations
5 Water Treatment Plant Layout
6 Hydraulic Design Calculations
7 Hydraulic Flow Diagram
1 Process Design Basis
The Water Treatment Plant of 4 MLD (16 hours operation)

capacity has been designed as a conventional one, based on
Cascade aeration, primary settling, coagulation, flocculation and
clarification followed by Rapid Gravity filters, as per the
guidelines of CPHEEO manual.
Design Flow:
The design flow of WTP has been considered as detailed below

WTP Capacity = 2 MLD
Pumping Hours = 24 hr
Normal Flow Rate = 83.33 m3/hr
Losses in Water Treatment Plant, assumed = 5%
Total designed flow rate of raw water = 87.50 m3/hr
Hydraulic Overloading @ 20 %
Flow rate with hydraulic overloading = 105.00 m3/hr
All Inter connecting Channels has been designed for a hydraulic
overloading of 20% over the design flow. All the process
parameters has been adopted as per the guidelines of CPHEEO
manual and as per our assumptions based on standard
engineering practices.
2 Treatment Units
The main Treatment units for the water treatment plant are as
detailed below:
i Cascade Aerator
ii Raw Water Channel with Parshall Flume
iii Flash Mixer
iv Clariflocculator
v Gravity Sand Filters (Variable Declining Rate)
vi Chemical House & Filter Annex Building
vii Central Sludge Sump
viii Chlorine Building
ix Clear Water reservoir
x Pure Water Pump House
3 Description and Design Parameters of various Units of Water Treatment Plant
3.1 Cascade Aerator
The cascade aerator is a reinforced cement concrete structure

with central inlet with bell mouth opening at top and peripheral
collection channel at bottom.
Design Parameters
Design Flow 87.50 m3/hr

Surface Loading Rate 600 lpm/sqm
36 m3/hr/sqm
No of cascades 4 nos.
Rise of cascade 0.3 m
3.2 Raw Water Channel with Parshall Flume:
From the Cascade aerator peripheral channel the water

overflows into raw water channel, which is an R.C.C. open
channel having Parshall flume for flow measurement. The
measurement of flow will be done by float operated weather
proof pedestal type open channel transmitter with level
indicator.
Alum and lime dosing arrangements will be provided in flume

section of the Parshall flume
Design Parameters
Design Flow, with 20% hydraulic overloading 105.00 m3/hr

Number 1 no.
Hydraulic Overloading 20 %
Type of Flow meter: Float operated Open channel transmitter
Type of Flume: Parshall Flume
Free Board 300 mm
Material of Construction: R.C.C. - M25
3.3 Flash Mixer:
Flash mixer chamber is of conventional type and equipped with

electrically driven propeller type, high-speed mixer. The top of
the Flash mixer units will be accessible by the general walkway
along the measuring channel for proper inspection.
Design Parameters

Number 1 no.
Material of Construction: R.C.C. - M25
Free Board 300 mm
Detention Time 60 sec
Velocity Gradient (300-600) 300 per sec
Number of Agitators 1 no.
Ratio of Tank Height to Dia. 1.43
Ratio of Impeller Dia to Tank dia
3.4 Clariflocculator
The Conventional type clariflocculator with an arrangement of

central feed and flocculation and clarification, has been
adopted. Clariflocculator is of a circular reinforced cement
concrete structure having a central area for coagulation and
flocculation and outer area for settling. The flocculation zone
and the sedimentation zone will be separated by a circular
isolation wall.
A mechanical scraper arrangement is provided. The bottom of
the clarifier bottom slope of 1:12 for efficient removal of the
sludge into the sludge pit from where it will be drained to
underground drainage system.
The independently driven paddle agitators for slow mixing of
the incoming raw water in the central unit will be provided.
The sludge from sludge collection pit will be drained to sludge
sump by Hydrostatic pressure with telescopic arrangement for
constant bleeding.
Design Parameters
Design flow 87.50 m3/hr

No. of units 1
Velocity of Water in central shaft 0.65 m/sec
Clarifier Side water Depth 3m
Free Board 500 mm
Velocity gradient (20 – 75) 40 per sec
Detention period in flocculator 30 min
Detention period in Clariflocculator 2.5 hr
Surface over flow rate (20-40) 30 cum/sqm/day
Weir Loading <300, 300 cum/m/hr
Velocity of water below the partition wall 0.3 m/min
Bottom Slope provided 1 in 12
3.5 Chemical House, Filter Annex Building & Chlorine Building
a) Chemical House
The chemical house along with necessary storage space for 90

days requirement of chemicals and weighing arrangements etc
will be provided, with a calculated floor area as per
requirement.
Chemical house is a two storied (GF + FF) building,
Ground Floor:
Chemical store
Toilet block
Stair case
First Floor:
Alum Solution tanks (1 no. for preparation, 1 no. for Dosing and
1 no. Standby) 3 nos.
Lime Solution tanks (1 no. for preparation, 1 no. for Dosing and
1 no. Standby) 3 nos.
Laboratory – For measuring Dose of alum as per raw water
turbidity condition Stair case

Chemical Dosing Rates:
Following general dosage rates for various chemicals have been
considered depends upon turbidity condition:
Alum 30 mg/l
Lime 10 mg/l
Post Chlorination 5 ppm
b) Filter House Annex building

Filter house annex building is consisting of:
Office cum Control Room
Air Blower Room
Lobby
c) Chlorine Building
Chlorine Building Consisting of:
Chlorine Tonner Yard to accommodate 2 Chlorine Tonners with
Neutralization Pit
Chlorinator Room, Emergency Bleaching powder tanks with
Storage Room
3.6 Rapid Sand Gravity Filters:

Clarified water or bypassed raw water through a common
collection channel enters into filter inlet channel, from where it
will be overflows on to the filter beds.
The filter beds have been considered as Twin bed type of 6 Nos,
and are with covered roof. Distribution channels, pipe gallery
with clear water channel and sump, control gallery, observation
platforms, walkways, stairs, railings, back wash water tank,
recycling tank & pumps has been considered as per the
specification. The filters shall be of the declining flow and rising
water level type. All filters will be identical in internal
dimensions.
Design Parameters
Rate of flow 87.50 m3/hr

Hydraulic Overloading 20 %
No of Twin Bed Filter Beds 6 nos.
Filtration Rate 4.8 cum/sqm/hr
Height of water over the filter bed 1.8 m
Free board 0.5 m
Rate of back wash 600 l/sqm/min
No of filters washed at a time 1 no.
Duration of wash 12 min
Velocity of flow across channels 1 m/s
Velocity at Filter inlet Gate 0.6 m/s
Velocity at Filter outlet 0.8 m/s
Velocity in wash water inlet Pipe 1.8 m/s
Velocity in wash water outlet Gate 0.75 m/s
Air scouring rate 36 cum/m/hr
All valves for filter beds are operated by actuator operation and
will be operated from Operating platform of filter house.
Backwash Reservoir
The backwash reservoir is a RCC Structure located on top of the
filter gallery at a staging height of 12m or fixed according to the
requirement of the backwash pressure whichever is higher. The
capacity of the reservoir so calculated will be sufficient to
provide for quantity of water required for back-washing of one
full filter bed , water Required for Chemical preparation and
10% additional Margin for, service/drinking water
requirements.
It will have a minimum free board of 30 cm.
The backwash reservoir filling pumps will be located in pure
water pump house and draw the water from clear water sump.
3.7 Clear Water Sump:

Clear water Sump (RCC structure) will be provided in close
vicinity of chlorine contact tank, chlorination room and
backwash pump house. 500 cum
A sump will be constructed within the Clear Water Sump of
depth 0.75m width 1.2m to minimize the dead storage of the
sump.
Design Parameters
A clear gap of 1500 mm will be maintained between Clear
Water Sump wall and Pure Water pump house. All pumps will
be housed in one pump house and drive way to be attached to
pump house for entry of truck loaded with pumps.
3.8 Sludge Sump:

The sludge drain from clarifloculator, backwashed wastewater
from filter beds and wastewater from all units of WTP will be
collected in sludge collection sump by gravity. From sludge
collection sump, sludge will be disposed off to nearby natural
drain (nallah).
3.9 Bypass Arrangements:

Following Bypass arrangement has been made in the Water
treatment Process:
· By pass pipe line for Flash Mixer and Clariflocculator
· By pass pipe line for Flash mixer, Clariflocculator and
Filter Beds.
Sump Volume 250 cum
Side water depth 3m
Material of Construction: R.C.C.

Free Board 450 mm
1 Cascade Aerator 1 no.

Dia. 3.5 m
No. of steps 4
Rise 0.3 m
Tread 0.525 m
Free board 0.3 m
2 Raw Water Channel With Parshall flume 1 no.

0.5m Wide x 0.45 m Liquid depth x 0.95m Long
3 Flash mixer 1 no.

2 m Dia. x 2 m SWD
4 Sluice gate at inlet of Flash Mixer - 0.35 m x 0.35 m
5 Clariflocculator - 1 no.
19 m dia x 3 m SWD + 0.5 m FB
6 Filters (Rapid sand gravity filters) - Twin Type 6 nos.

3.5m x 5.2m
7 Back Wash Water Tank 100 cum

On top of the Filter Gallery
8 Clear Water Sump 1 no.

14m x 9m x 4m SWD + 0.45m FB
9 Alum Solution Tanks 3 nos.

0.85m x 0.85m x 1.2m SWD + 0.3m F.B.
10 Lime Solution Tanks 3 nos.

1.05m x 1.05m x 1.2m SWD + 0.3m F.B.
NOTE:
The Sizes calculated for various Units of WTP are subject to get
optimized with respect to the associated electro-mechanical
equipment.
DESIGN BASIS
Water Treatment Plant capacity 2 MLD
Pumping Hours 24 hr
Normal Flow Rate 83.33 m3/hr
Losses in Water Treatment Plant 5%
Total Designed flow rate of raw water 87.50 m3/hr
1 Cascade Aerator
Design Criteria
Surface Loading Rate 600 lpm/sqm
36 m3/hr/sqm
Rise of cascade 0.3 m
Sizing Calculation
Surface area required = design flow / surface loading rate
2.43 sqm
Dia of inlet pipe to the Aerator, assumed 0.3 m
Ratio of Cascade aerator Lip diameter to inlet shaft diameter
(1.4-1.5) 1.5 m
Bell mouth Diameter = 0.3 x 1.5 m
0.45 m
Provide Bell mouth diameter 0.45 m
Bell mouth area 0.16 sqm
Total area required for cascade aerator = 7.29 + 0.16 sqm
2.59 sqm
Dia. of lowest cascade = 2 x √(7.45/π) m
1.82 m
Say, 3.20 m
Tread of each cascade 0.525 m
Provide Tread of each Cascade 0.525 m
Provide Actual dia. of Lowest cascade 3.20 m
Dia. of Fourth Cascade 3.20 m
Dia. of Third Cascade = 3.10 - (0.525 x 2) m
2.15 m
Dia. of Second Cascade = 2.05 - (0.525 x 2) m
1.10 m
Dia. of First Cascade = 1.00 - (0.525 x 2) m
0.05 m
Rise of cascade = 0.30 m
Total drop over cascade = 0.3 x (4 - 1) m
= 0.90 m
Peripheral Collection Chamber
Peripheral Collecting Half Channel Flow = 328.95/2 cum/hr
= 164.47 cum/hr
Velocity in the channel = 0.80 m/sec
Area of c/s of channel = 164.47/3600/0.8 sqm
= 0.06 sqm
Width of channel = 0.75 m
Depth of channel = 0.06/0.75 m
= 0.08 m
Freeboard = 0.30 m
Free fall from last step to channel = 0.20 m
Depth of Channel wall = 0.08 + 0.3 + 0.2 m
= 0.58 m
Provide Depth of Channel Wall = 0.60 m
Total diameter of cascade aerator excluding peripheral channel = 3.5 + 0.25 m
= 3.75 m
Size of Peripheral Collection Channel - 0.75m x 0.60m deep
2 Raw Water Channel With Parshall flume
Design Criteria
Design flow = 328.95 cum/hr
Hydraulic Overloading = 20 %
= 394.74 cum/hr
Sizing Calculation
a Approach Channel to Parshall Flume
Velocity across channel, V = 0.60 m/sec
Cross-sectional area of the channel = 394.74/3600/0.6 sqm
= 0.18 sqm
Head rise over throat at 20% overload = 0.18 / 1 m
= 0.18 m
Free board = 0.30 m
Parshall Flume No. (as per IS:14371:1996) = 3
For the given discharge as per Table No.3
Throat Width, b, for Flume as per Table No.3 = 0.30 m
Length of Approach Channel, 10 times the Head Rise = 1.83 m
Check for Froude Number for Subcritical flow,
F = Qmax/A√ghmax = 0.45
< 0.5 or 0.7
Hence, OK
Saraikela Water Supply Scheme: Engineering Design Page 67
PROCESS DESIGN
SARAIKELA WATER SUPPLY SYSTEM: WATER TREATMENT PLANT
b Flume Structure
Flume Dimensions as per Fig-1 (IS 14371:1996)
Throat
Width, b = 0.30 m
Length, l = 0.60 m
Height of Flume Crest, hp1 = 0.23 m
Entrance Section
Width, b1 = 0.84 m
Length, l1 = 1.35 m
Slant wall length, le = 1.377 m
Exit Section
Width, b2 = 0.60 m
Length, l2 = 0.92 m
hp2 = 0.072 m
c Downstream Channel to Parshall Flume
Velocity, V = 0.54 m/sec
Cross-section area of the channel = 394.74/3600/0.54 sqm
= 0.20 sqm
Depth of flow = 0.20 / 0.5 m
= 0.41 m
Say, = 0.45 m
Free board = 0.30 m
Length of Channel, 5 times of head rise ~ 0.95 m
Type of flow meter: Float Operated Open Channel Transmitter
Measurement of Head
For free flow condition, the discharge through Parshall Flume is
determined by measuring the head, ha in the entrance
3 Flash mixer
Design Criteria
No .of mixers = 1 No.
Detention time = 60 Sec
Free board = 0.30 m
Side water depth = 2.00 m
Sizing Calculation
Volume of tank = 328.95 x 60 / 3600 cum
= 5.48 cum
Volume of tank provided = 5.5 cum
Area of Chamber = 5.5 / 2 cum
= 2.75 sqm
Size of the Raw Water Channel: 0.5m Wide x 0.45 m Liquid depth x 0.95m Long
Saraikela
Dia. Of Chamber = √(4 x 2.75 / π) m
= 1.87 m
Provide diameter of Chamber = 1.9 m
Say = 2.0 m
Size of the tank 2 m Dia. x 2 m swd
Ratio of Tank Height to Dia. = 2 / 1.9
1.05
<3
Hence, OK
Ratio of Impeller Dia. to Tank dia. = 0.3
~ 0.2 - 0.4
Impeller diameter, dimp = 1.9 x 0.3 m
= 0.57 m
Say, = 0.6 m
Provide Impeller of Dia 0.6 m
Agitator Power Requirement
Velocity Gradient, G = √P/μV 300 sec-1
G = Temporal Mean Velocity Gradient (sec-1)
P = Total Input of Power in Water, Watts
μ = Absolute viscosity of water, N.s/m2 (0.798 x10-3) @ 30°C
V= volume of water to which power is applied, m3
Input Power = (5.48 x 0.798 x 10¯³) x 300² W
= 393.75 W
Provide Agitator Motor = 393.75 x 1.5 / 1000 kW
= 0.6 kW
However the actual motor rating shall be as recommended by
Agitator manufacturer
Shaft speed, N, assumed = 125 rpm
Peripheral Velocity = πdimpN/60 = π x 0.6 x 125/60 m/sec
= 3.93 m/sec
> 3 m/msc
Hence, OK.
4 Sluice Gate at Inlet of Flash Mixer
Flow at Inlet of Flash Mixer = 328.95 cum/hr
Velocity = 0.75 m/s
C/s Area required for gate = 328.95/3600/0.75 sqm
= 0.12 sqm
Width of Gate = 0.35 m
Height of Gate = 0.35 m
Provide Sluice gate of 0.35 m x 0.35 m at Inlet of Flash Mixer
PROCESS DESIGN
5 Pipe from Flash mixer to central column of Clariflocculator
Design flow, with 20% hydraulic overload = 394.74 cum/hr
No .of Clariflocculators = 1 No.
Velocity = 0.90 m/s
Flow through each Clariflocculator = 394.74 cum/hr
C/S area of pipe = 0.12 sqm
Dia. of the pipe = 0.39 m
~ 400 mm
Provide pipe of 400 mm dia
6 Clariflocculator
Design Criteria
No. of units = 1 no.
Velocity of Water in central shaft = 0.65 m/sec
Side water Depth = 3 m
Free Board = 500 mm
Velocity gradient, 40 to 60 = 40 sec-1
Detention period in flocculator, given = 30 min
Detention period in Clariflocculator, given = 2.5 hr
Surface over flow rate, given = 30 cum/sqm/day
Weir loading, given = 300 cum/m/day
Velocity of water below the partition wall = 0.3 m/min
Bottom Slope provided 1 in 12 as per CPHEEO Manual
a) Flocculator
Rate of flow/unit = 328.95 cum/hr
Central Shaft
Dia. of shaft = 0.4 m
Assume thickness of wall = 0.2 m
Therefore, outside dia of central shaft = 0.4 + 2 x 0.2 m
= 0.8 m
No. of Ports on Central Shaft
No. of Ports in central shaft provided = 4 nos.
Assume velocity through Ports = 0.40 m/sec
Total area of Ports, A = Q/V = (328.95/3600)/0.4 sqm
= 0.23 sqm
Area of each port = 0.23 / 0.4 sqm
= 0.06 sqm
Width of each port taken = 0.50 m
Depth of port opening = 0.06 / 0.5 m
= 0.11 m
Size of each port opening 4 Nos., 0.5 m W x 0.11 m H
PROCESS DESIGN
Volume of flocculator tank = Design Flow x Detention Time = (328.95/60) x 30 cum
= 164.47 cum
Area of flocculator tank = Tank Volume / Side Water Depth = 164.47 / 3 sqm
= 54.82 sqm
Diameter of Flocculator tank = 8.35 m
Say, 8.5 m
Size of flocculator tank: 8.5 m dia. x 3 m SWD
Area of flocculator tank, provided = 56.75 sqm
Material of construction: R.C.C
Assume thickness of wall = 0.25 m
Flocculation Tank dia. including wall thickness = 9 m
Bottom opening for Flocculator Partition Wall
Velocity of water below the partition wall, V = 0.3 m/min
Opening Area Required, A = Q/V = 328.95/(0.30 x 60) sqm
= 18.27 sqm
Depth below partition wall = 18.27/(π x 8.5) m
= 0.68 m
Depth with 25% allowance for sludge = 0.75 m
Total depth of tank at the partition wall = 0.5 + 3 + 0.68 + 0.75 m
= 4.93 m
Say, 5.00 m
Length of opening = 18.27/5.00 m
= 3.65 m
Say, 3.70 m
b) Clarifier - Circular
No. of units = 1 no.
Volume of Tank = Design Flow x Detention Time = 328.95 x 2.5 cum
= 822.37 cum
Side water depth = 3 m
Surface Area of Clarifier = Volume of Tank / Side Water Depth = 822.37 / 3 m2
= 274.12 m2
Diameter of Clarifier, Dcf = √(4 x 274.12 / π) m
= 18.68 m
Say, 19 m
Free Board = 500 mm
Size of Clarifier: 19 m dia x 3 m SWD + 0.5 m FB
Slope provided (Suitable for mechanical scrapper), 1 in 12 ~ 8 %
c) Calculation Of Surface overflow Rate
Normal Flow rate through clarifier = 328.95 x 16 cum/day
= 5263.16 cum/day
Internal launder area, Ala = 35.19 sqm
Flocculator zone area, Afl = 63.62 sqm
Effective surface area of clarifier zone = Acf - Ala - Afl = (π 19²/4) - 35.19 - 63.62 sqm
= 184.72 sqm
Surface loading Rate = 28.49 cum/sqm/day
< 30 cum/sqm/day
PROCESS DESIGN
Hence, OK
d) Calculation Of Weir Loading Rate
Provide 90° V-Notches of 50mm Depth @ 200mm C/C
Length of Weir = π x Dcf = π x 19 m
= 59.69 m
Weir Loading = Design Flow / Weir Length = 328.95 x 16 / 59.69 cum/m/hr
= 88.17 cum/m/hr
< 300 cum/m/hr
Hence, OK
PROCESS DESIGN
e) Outlet collection channel
Velocity = 0.9 m/s
Free Board = 0.3 m
C/S Area of channel = 0.10 sqm
Depth of flow = 0.4 m
Say, 0.3 m
Channel size: 0.3 m W x 0.4 m SWD + 0.3 m FB
Slope of Channel, V = 1/n x R3/2 x S1/2 = 0.04
0.04
f) Sludge Collection Pit (Below Clariflocculator):
Sludge will be collected in the centrally located circular pit of
0.75m depth with 3m dia (approx.) and will be drained by
300mm dia. drain pipe.
g) Sludge Bleeding Arrangement
The sludge from sludge collection pit will be will be drained to
sludge sump by Hydrostatic pressure with Telescopic valve
arrangement for constant bleeding.
7 Chemical Storage Area & Chemical Solution Tanks
Design Criteria
Alum dosage, assumed = 30 mg/lt
No. of days for Alum Storage, given = 90 days
Strength of Solution = 10 %
No. of Alum Solution Tanks = 3 nos.
Maximum dosing hours for each tank = 8 hr
Lime dosage, assumed = 10 mg/lt
No. of Days for Lime Storage, given = 90 days
No. of Lime Solution Tanks = 3 nos.
a) Chemical Storage Area
Design Flow = 328.95 cum/hr
Alum dosage = 30 mg/lt
Total Alum required per day = 236.84 kg/day
No. of days for Alum Storage = 90 days
Alum quantity required = 21.32 MT
Storage area required for 180 Kg of Alum = 0.1 sqm
Storage area required for total alum quantity = 11.84 sqm
Add 15% for voids = 13.62 sqm
Add 25% of work space = 17.02 sqm
Say, 20.00 sqm
Provide space for alum storage 20 sqm
PROCESS DESIGN
Lime dosage = 10 mg/lt
Total Lime required per day = 78.95 kg/day
No. of days for Lime Storage = 90 days
Lime quantity required = 7105.26 kg/day
= 7.11 MT
Lime 1 ton occupies 1.35 cum
Volume of storage space required = 9.59 cum
Staking Height = 1 m
Area required for Lime storage = 9.59 sqm
Add 15% for voids = 11.03 sqm
Add 25% of work space = 13.79 sqm
Say, 15.00 sqm
Provide space for alum storage 15 sqm
Provide Storage Area for Alum & Lime 35 sqm
b) Alum Solution Tanks
Total Alum required per day = 236.84 kg/day
Total Alum required per hour = 9.87 kg/hr
Alum solution required per hour = 98.68 lt/hr
No. of Alum Solution Tanks = 3 nos.
Alum Tank capacity = 789.47 litres
Area of Alum tank = 0.66 sqm
Considering Free board = 0.30 m
Depth of the Tank = 1.50 m
Side of tank = 0.81 m
Say, 0.85 m
Provide 3 Nos. Tanks of size 0.85m x 0.85m x 1.2m SWD +
0.3m F.B.
c) Lime Solution Tanks
Total Lime required per day = 78.95 kg/day
Total Lime required per hour = 3.29 kg/hr
Lime solution required per hour = 164.47 litres/hr
No. of Tanks = 3 nos.
Each Tank capacity = 1315.79 litres
Area of Lime tank = 1.10 sqm
Considering Free Board = 0.3 m
Depth of the Tank = 1.5 m
Side of the Tank = 1.05 m
Say, = 1.05 m
Provide 3 Nos. Tanks of size 1.05m x 1.05m x 1.2m SWD +
0.3m F.B.
PROCESS DESIGN
8 Post Chlorination
a) Chlorinators
Post chlorination
Rate of Dosing = 5 ppm
Rate of flow = 328.95 cum/hr
Dosing capacity of chlorinators = 1.64 kg/hr
Say, 0-5 kg/hr
Provide 2 Nos. Vacuum Type Chlorinators (1Working + 1
Standby) of each capacity 0-5 Kg/Hr
b) Emergency Bleaching Powder Tank & Store Room
Rate of Dosing = 3 ppm
Percentage of available chlorine in bleaching powder = 25 %
Requirement of Bleaching Powder per day = 94.74 Kg/day
Requirement of Bleaching Powder per Hour = 3.95 Kg/hr
Bleaching Powder Storage Area
Storage of Days = 7 Days
Bleaching Powder Quantity for 7 days = 663.16 Kg
No. of Bags (25Kg) ~ 27 nos.
Stacking Height = 1.75 m
Height of each bag, approx. = 0.25 m
No. of bags per stack = 7 nos.
No. of stacking required = 4 nos.
Size of each bag 0.6m x 0.4m Approx. = 0.24 sqm
Area required for Stacking = 0.96 sqm
Say, = 1 sqm
Provide space for Bleaching Power storage 1 sqm
TCL Solution Tanks
No. of Tanks = 2 Nos.
No. of Dosing Hours per tank = 4 hr
Quantity of water required for 1 kg of bleaching powder = 40 litres
Capacity of each tank = 1.5 cum
Provide capacity of each tank = 2 cum
Tank Side Water Depth = 1.4 m
Freeboard = 0.3 m
Area of each tank = 1.43 sqm
Shape of tank : Square
Side width of tank = 1.20 m
Say, 1.20 m
Provide tank of size 1.2m x 1.2m x 1.4m SWD, 0.3m FB.
PROCESS DESIGN
9 Filters (Rapid sand gravity filters)
Design Criteria
No. of Twin Bed Filter Beds, given = 6 nos.
Filtration Rate, given = 4.8 cum/sq m/hr
Height of water over the filter bed = 1.8 m
Free board = 0.5 m
Rate of back wash, given = 600 l/sq m/min
No of filters washed at a time = 1 no.
Duration of wash, given = 12 min
Velocity of flow across channels = 1 m/sec
Velocity at Filter inlet = 0.6 m/s
Velocity at Filter outlet = 0.8 m/s
Velocity in wash water inlet = 1.8 m/s
Velocity in wash water outlet Gate = 0.75 m/s
Air scouring rate = 36 m3/m2/hr
Sizing Calculation
No of Twin Bed units = 6 nos.
Area required for filter beds = 68.53 sqm
Area required per each twin bed = 11.42 sqm
Area required for half portion of twin bed = 5.71 sqm
Length = 3.50 m
Width = 1.63 m
a) Size of Half Portion of Each Twin bed
Provide size of the half portion of Twin Filter bed
Length = 3.50 m
Width = 1.75 m
Actual rate of filtration = 4.48 cum/sqm/hr
> 4.8 cum/sqm/hr
Err:509
Height of water over the filter bed = 1.8 m
Free board = 0.5 m
b) Filter inlet channel
Design Flow, with 20% hydraulic overload = 394.74 cum/hr
Velocity of flow taken = 0.6 m/sec
Cross sectional area of Channel = 0.18 sqm
Width of channel considered = 0.5 m
Free board = 0.3 m
Depth of channel = 0.70 m
Provide Channel of size 0.5m W x 0.4m SWD + 0.3m FB
PROCESS DESIGN
c) Filter Media
Sand Bed
Estimation of Sand Depth
Uniformity Coefficient = 1.5
Effective size of sand, 0.45 - 0.7mm = 0.7 mm
Hudson Formula: Qd³h/l = B x 29323
Q = Rate of Filtration Maximum = 6 m3/m2/h
d = Size of sand = 0.7 mm
H = Terminal Loss of Head, assumed = 4 m
B = Breakthrough Index, assumed (4x10-4 - 6x10-3) = 0.0004
l = Depth of Sand bed = 0.70 m
~ 0.7 m
Depth of filter sand provided 0.7 m
0.6 to 0.75m
Supporting Gravel
Gravel depth, provided = 0.45 m
Size of gravel at top - 2.5 to 6 mm
Size of gravel at bottom layers = 50 mm
Filter box height (including Free Board) = 3.45 m
d) Back Wash Water Tank
Rate of back wash = 600 l/sqm/min
Wash water rate/unit = 6853.07 l/min
No of filters washed at a time = 1 no.
Duration of wash = 12 min
Water requirement for one Filter Back Wash = 82.24 cum
Water Requirement for other than the Filter Back Wash
Water requirement for Alum preparation = 1578.95 litres
Water requirement for Lime preparation = 2631.58 litres
Water requirement for Chlorination = 526.32 litres
Total water requirement = 4736.84 litres
~ 5.0 cum
Total Water Requirement = 87.24 cum
Adding 10% extra for other utilities = 8.72 cum
Capacity of Backwash water tank = 95.96 cum
Say, 100 cum
Location of Tank: On top of the Filter Gallery
Velocity for wash water inlet = 1.8 m/s
C/S area of wash water pipe = 0.05 sqm
Dia. of wash water main = 0.25 m
Dia. of wash water main provided = 300 mm
Saraikela Water Supply Scheme: Engineering Design
Length of the pipe = 40 m
Velocity in the pipe = 1.8 m/s
Head required over under drain system = 9 m
Frictional head losses, Hf = 0.47 m
Total head loss = 0.48 m
Say, 0.5 m
Actual head required = 9.5 m
Provide total head for Back Wash 12 m
e) Wash Water Pump Calculations (Pump Location: Pure Water Pump House)
Duration of filling time of wash water tank = 1 hr
No. of Pumps provided, = 2 Nos.
Standby = 50 %
Total no. of Pumps (2 W + 1 S) = 3 Nos.
Rate of Pumping = 100 cum/hr
Capacity of each pump = 50 cum/hr
Head Requirement
Height of Back wash tank bottom = 12 m
Back wash water tank Height = 2.5 m
Suction head = 0.3 m
Total Head required, with 10% transmission losses = 16.28 m
Assuming Velocity in the pipe = 1.8 m/sec
Hence, pipe dia = 0.05 m
~ 100 mm
Maximum Pipe Length, assumed = 50 m
By using Modified Hazen William's formula, Frictional Loss in
the pipe = 2.10 m
Total Operating Head on Pump = 18.38 m
Say, = 19.00 m
Efficiency of Pumping = 75 %
Safety on Motor = 15 %
Input power of pump = 5.40 HP
~ 10.00 HP
However the actual motor rating shall be as recommended by
pump manufacturer.
Hence provide 3 Pumps of 10 HP (2 Working, 1 Standby)
Type of Pump: CI, Horizontal Centrifugal
Summary: Wash Water Pump
Duration filling time of wash water tank = 1 hr
Total no. of Pumps (2 W + 1 S) = 3 nos.
Capacity of each pump = 50 cum/hr
Head Required = 19.00 m WC
Type : CI, Horizontal Centrifugal
PROCESS DESIGN
f) Pure water channel
Design Flow (with 20% hydraulic overloading) = 394.74 cum/hr
Velocity of flow taken = 1 m/sec
Cross sectional area of Channel = 0.11 sqm
Width of channel considered = 0.40 m
Free board = 0.30 m
Depth of channel = 0.57 m
Dimensions of Channel: 0.40m x 0.27m SWD + 0.30m F.B.
g) Wash water collection and Disposal
Design of Cross Troughs
Wash water rate/unit = 6.85 cum/min
Spacing of trough = 1.8 m
Longer dimension filter Unit = 4 m
No. of cross Troughs/bed, half on either side of central gullet = 6 nos.
Rate of flow per Trough = 1.14 cum/min
Width of trough = 0.8 m
Depth of water in trough, Q = 1.376 x b x h3/2 = 0.22 m
Say. 0.3 m
F.B. 0.2 m
Size of cross trough
Depth = 0.5 m
Width = 0.8 m
h) Design of Gullet
Wash water rate/unit = 6853.07 l/min
Width of Gullet = 0.9 m
Minimum Depth of Gullet Required = 0.20 m
Depth Required for Gullet = 0.7 m
However the Gullet will be provided up to filter bottom with
Free fall condition
Length of Lateral travel of water in Central Gullet = 0.92 m
< 1.4
Hence, OK.
Length of Twin Bed Filter Unit = 3.50 m
Width of Twin Bed Filter Unit = 5.2 m
Provide Twin Bed Filter Unit of 3.5m x 5.2m
i) Filter port Sizes
Filter inlet Gate
No of filter inlets per bed = 1 no.
Rate of flow per inlet, with 20% hydraulic overloading = 54.82 cum/hr
Velocity at inlet = 0.8 m/s
Area of opening required = 0.02 sqm
Size of Gate required = 0.14 m
~ 200 mm
Size of Gate provided 200 x 200 mm
PROCESS DESIGN
Filter outlet Pipe
No. of filter outlets per bed = 1 no.
Rate of flow per outlet, with 20% hydraulic overloading = 54.82 cum/hr
Velocity at outlet = 0.8 m/s
Area of opening required = 0.02 sqm
Dia. of pipe required = 0.16 m
~ 200 mm
Dia. of pipe provided 200mm
Wash water inlet and outlet
Velocity in wash water inlet = 1.8 m/s
Velocity in wash water outlet Gate = 0.75 m/s
Quantity of wash water = 6.85 cum/min
Area of opening reqd. at wash water inlet = 0.06 sqm
Dia. of wash water inlet = 0.28 m
~ 300 mm
Provide pipe of dia 300mm
Area of opening reqd. at wash water outlet = 0.15 sqm
Size of wash water outlet Gate = 0.39 m
~ 400 mm
Provide wash water outlet Gate size 400mm x 400mm
j)
Design of Filter under drain system (for half portion of
Filter Bed) as per IS 8419 (Part-2) -1984
Plan Area of each half portion of Twin Bed filter = 9.1 sqm
Area of orifices to Laterals, 0.3% of filter bed area = 0.03 sqm
Size of perforations: 5mm to 12mm, as per CPHEEO Manual. = 10 mm
Area of one perforation = 0.000079 sqm
Total no. of perforations = 347.59 nos.
~ 350 nos.
Area of laterals, 2 times the area of orifices = 0.0546 sqm
Area of manifold 1.5 times the area of laterals = 0.0819 sqm
No. of manifolds for half Portion of Twin Bed = 1 no.
Size of each manifold pipe = 0.4 m
Spacing of laterals (max 0.30 m) = 0.2 m
No of laterals per half portion of twin bed filter = 5.83 nos.
Area of each lateral pipe = 0.0087 sqm
Dia. of laterals = 0.11 m
~ 150 mm
Provide laterals of dia 150mm
Length of each lateral, to be made in to two equal halves to
accommodate on either side of each manifold while execution = 2.6 m
No. orifices/lateral = 50 nos.
Spacing of orifices = 0.105 m
PROCESS DESIGN
Ratio of area of orifices to area of laterals = 0.5
Ratio of length to dia. of laterals = 20
< 60
Hence, OK.
Ratio of area of manifold to area of laterals = 1.5
Minimum Depth of under drain system = 0.48 m
Orifice Location- Located downward with successive holes
staggered
k) Air Scouring Blower
Air scouring rate = 36 m3/m2/hr
Area of each twin bed filter = 12.25 m2
Air flow rate required = 441 m3/hr
Air Blower capacity considered = 1000 m3/hr
Head of Blower, provided = 4000 mm WC
No. of Air blowers required, (1 W + 1 S) = 2 nos.
Capacity of each Blower = 1000 m3/hr
Air velocity through pipe = 20 m/sec
Air Pipe dia. for each filter = 0.13 m
Say, = 200 mm
10 Pipe from Pure Water Channel to Clear Water Sump
Design flow, with 20% overloading = 394.74 cum/hr
Velocity = 0.9 m/s
Provide dia. of the pipe = 400 mm
11 Clear water sump
Design Criteria
Capacity = 500 cum
No. of Clear Water Sumps = 1 No.
Side water depth = 4 m
Free Board = 0.45 m
Shape of sump: Rectangular
Sizing Calculation
Total Volume of sump = 500 cum
Area of sump = 125.00 sqm
Length of sump = 14 m
Width of sump = 8.93 m
~ 9.00 m
Size of Clear Water Sump 14m x 9m x 4m SWD + 0.45m FB
PROCESS DESIGN
12 Bypass arrangements
a
Bypass pipe line from Flash Mixer inlet to clariflocculator outlet
channel
b
Bypass pipe line from filter inlet channel to clear water sump
inlet
Dia. of each Bypass pipe
Design flow, with 20% overload = 394.74 cum/hr
Velocity = 0.9 m/s
Provide pipe of dia. = 400 mm
Formulae used
Hazen Williams Formula
Head Loss in Straight circular pipes (in m), Hf =
Where, L = length of the pipe (in m)
Q = discharge volume (in m3/s)
C = Pipe roughness coefficient
D = internal diameter of pipe (in m)
Manning's Formula
Velocity in pipe (in m/sec), V =
R = hydraulic radius of conduit, (in m)
S = slope of hydralic gradient = Hf/L
n = Manning's coefficient of roughness
S = Hf/L
Hf = headloss in conduit
L - length of conduit
(As per CPHEEO Manual, 6.2.1, Pg. 104)
Basic Formula
Head Loss in Specials and Appurtenances, h = KLV2/2g
Where, KL = constant for different fittings
V = velocity in pipe
g = accelaration due to gravity
(As per CPHEEO Manual, 6.2.9, Pg. 115 and Water Supply
Engineering, S. K. Garg, Pg. 276)
Discharge through a rectangular notch, Q =
Where, be = effective width
H = effective head
g = acceleration due to gravity (in m2/s)
Ce = varies from 0.58 to 0.7
(As per CPHEEO Manual, 4.2.1.1, Pg. 39)
Discharge through 90 ° V-Notch, Q = 2.362 Ce H2.5
Ce ranges from 0.603 to 0.686
h, measured head in m
1 Clear Water Sump
Design Flow = 394.74 m³/hr
= 0.11 m³/sec
FSL of Clear Water Sump (as per Site Survey) = 95.5 m
HYDRAULIC DESIGN
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HYDRAULIC DESIGN
Pipe from Clear Water Channel to Clear Water Sump
Pipe Entry Losses (using Basic formula)
KL = 0.5
V = 0.9 m/sec
D = 0.4 m
Accelaration due to gravity, g = 9.806 m²/sec
Minor Loss = KL (V2/2g)
= 0.5 x (0.9²/2 x 9.806) m
= 0.0207 m
Pipe Losses (using Hazen Williams)
Pipe Length, L = 22 m
Velocity in pipe, V = 0.9 m/sec
Diameter of Pipe, D = 0.4 m
Roughness coefficient = 120
Head loss, using Hazen Williams formula = 0.0485 m
Losses in Bends (using Basic formula)
For 45° Bends
KL = 0.6
V = 0.9 m/sec
Minor Loss = 0.6 x (0.9²/2 x 9.806) m/sec
= 0.0248 m
No. of Bends = 0
Total loss for 45° Bends = 0 m
For 90° Bends
KL = 1.08
V = 0.9 m/sec
= 0.0446 m
No. of Bends = 2
Total loss for 90° Bends = 0.0892 m
Pipe Exit Losses (using Basic formula)
KL = 1
V = 0.9 m/sec
Minor Loss = 1 x (0.9²/2 x 9.806) m/sec
= 0.0413 m
Total Head Loss = 0.1997 m
Say, 0.20 m
Water Level in Pure Water Channel = 95.70 m
HYDRAULIC DESIGN
2 Filtered Water Outlet Chamber
Pure Water Channel Width = 0.40 m
Water depth = 0.27 m
Hydraulic radius, R = 0.4 x 0.27/(2 x 0.27 + 0.4) m
= 0.115 m
Velocity in channel, V = 1 m/sec
n for smooth concrete = 0.013
Slope of hydraulic gradient, S (using Manning's) = 0.0030 m/m
Length of the Channel, L = 45 m
Head loss = S x L = 0.1362 m
Weir free fall = 0.1200 m
Weir length = 0.9 m
Ce = 0.6
be = 1.1
Water head above weir, H = 0.1468 m
Say, 0.50 m
Weir Crest Level = 96.053 m
Water Level in Filter Outlet Chamber = 96.20 m
3 Rapid Sand Gravity Filters
Head loss across filter bed = 1.8 m
(as per CPHEEO Manual)
Water Level in Filter Bed = 98.00 m
Minimum water height above sand bed = 0.2 m
Top level of sand = 98 - (1.8 + 0.2) m
= 96.00 m
Media height = 0.7 m
Filter bottom level = 96 - 0.7 m
= 95.30 m
HYDRAULIC DESIGN
Manifold dia = 0.4 m
Lateral dia = 0.15 m
Clearance for drain valve = 0.5 m
Floor level of Filter Gallery = 95.3 - (0.4 + 0.15 + 0.5) m
= 94.25 m
4 Filter Inlet Channel
Inlet Gate size = 0.25m x 0.25m
Velocity in channel, V = 0.6 m/sec
No. of Gates = 6
K=1
Head loss (using basic formula) = 0.0184 m
Total head loss = 6 x 0.0184 m
= 0.1101 m
Filter Inlet Channel width = 0.5 m
Water depth = 0.4 m
= 0.154 m
Say, 0.15 m
Water Level in Filter Inlet Chamber = 98.15 m
5 Clariflocculator Outlet Collecting Trough
Clarifier Outlet Channel width = 0.3 m
Water depth = 0.4 m
= 0.109 m
HYDRAULIC DESIGN
Say, 0.10 m
Water Level in Clariflocculator Outlet Trough = 98.25 m
Clarifier Diameter = 19 m
Collecting trough slope = 0.0026 m/m
Head loss = 19 / 2 x 0.0026 m
= 0.0249 m
Weir Length = 60.00 m
Number of notches = 2 per m
= 2 x 60 Nos.
= 120 Nos.
Width of notch = 0.1 m
Height of notch = 0.05 m
Flow per notch = 0.000914 m3/sec
Head loss at notch, h (using equation for 90° V-Notch) = 0.0528 m
Say, = 0.2 m
Water Level in Clariflocculator = 98.45 m
6 Pipe from Flash Mixer Chamber to Clariflocculator
Pipe Entry Losses
K=1
Diameter of pipe, D = 0.4 m
HYDRAULIC DESIGN
Pipe Losses
Pipe Length, L = 25 m
Velocity in pipe, V = 0.90 m/sec
Diameter of Pipe, D = 0.4 m
Roughness coefficient = 120
Head loss, using Hazen Williams formula = 0.0552 m
Losses in Bends
For 45° Bends
KL = 0.6
V = 0.90 m/sec
= 0.0248 m
No. of Bends = 2
For 90° Bends
KL = 1.08
V = 0.9 m/sec
= 0.0446 m
No. of Bends = 2
Pipe Exit Losses
KL = 1
V = 0.9 m/sec
Minor Loss = 1 x (0.9²/2 x 9.806) m/sec
= 0.0413 m
Valve Losses
KL = 0.7
V = 0.9 m/sec
= 0.0289 m
Say, = 0.35 m
Water Level in Flash Mixer Chamber = 98.80 m
HYDRAULIC DESIGN
7 Raw Water Channel with Flume
Flash mixer inlet sluice gate size = 0.35m x 0.35m
Velocity through gate, V = 0.60 m/sec
K=1
No. of Gates = 1
Flume downstream channel width = 0.50 m
= 0.161 m
Length of the Channel, L = 0.95 m
Say, 0.20 m
Water Level in Flume Exit Channel = 99.00 m
Flume upstream channel width = 1.00 m
Hydraulic radius, R = 1 x 0.18/(2 x 0.18 + 1) m
= 0.132 m
Length of the Channel, L = 1.83 m
Height of Flume Crest = 0.23 m
Height of Exit Section = 0.072 m
Total head loss over Flume = 0.23 - 0.072 m
= 0.16 m
Say, 0.20 m
Water Level in Flume Approach Channel = 99.20 m
HYDRAULIC DESIGN
7 Cascade Aerator
Total vertical drop over cascades = 0.90 m
Freefall = 0.20 m
Freeboard = 0.30 m
Total head loss in Cascade Aerator = 1.40 m
Water Level at Cascade Aerator Top = 100.60 m

Process Design WTP

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Process Design WTP

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PROCESS DESIGN

1 Process Design Basis

1 Process Design Basis

The Water Treatment Plant of 4 MLD (16 hours operation)

The design flow of WTP has been considered as detailed below

3.1 Cascade Aerator

The cascade aerator is a reinforced cement concrete structure

Design Flow 87.50 m3/hr

3.2 Raw Water Channel with Parshall Flume:

From the Cascade aerator peripheral channel the water

Alum and lime dosing arrangements will be provided in flume

Design Flow, with 20% hydraulic overloading 105.00 m3/hr

3.3 Flash Mixer:

Flash mixer chamber is of conventional type and equipped with

Design Flow 87.50 m3/hr

The Conventional type clariflocculator with an arrangement of

Design flow 87.50 m3/hr

3.5 Chemical House, Filter Annex Building & Chlorine Building

The chemical house along with necessary storage space for 90

Chemical house is a two storied (GF + FF) building,

turbidity condition Stair case

b) Filter House Annex building

3.6 Rapid Sand Gravity Filters:

Rate of flow 87.50 m3/hr

3.7 Clear Water Sump:

3.8 Sludge Sump:

3.9 Bypass Arrangements:

Material of Construction: R.C.C.

1 Cascade Aerator 1 no.

2 Raw Water Channel With Parshall flume 1 no.

3 Flash mixer 1 no.

4 Sluice gate at inlet of Flash Mixer - 0.35 m x 0.35 m

6 Filters (Rapid sand gravity filters) - Twin Type 6 nos.

7 Back Wash Water Tank 100 cum

8 Clear Water Sump 1 no.

9 Alum Solution Tanks 3 nos.

10 Lime Solution Tanks 3 nos.

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