2021 03 09 Mechanical Specs

‫جمهورية مصر العربية‬
‫وزارة االسكان والمرافق والمجتمعات العمرانية‬

‫الجهاز التنفيذى لمياه الشرب والصرف‬
‫المقاول العام‬
‫وزارة اإلنتاج الحربي‬
‫الهيئة القومية لإلنتاج الحربي‬
‫شركة قها للصناعات الكيماوية‬
‫(مصنع ‪ 270‬الحربي)‬
‫المقاول الرئيسي‬
‫مدكور جروب‬
‫الميديا للمعالجة البيولوجية‬
‫‪Hawamdeya WWTP Extension, Capacity 20,000 m3/day‬‬
‫‪Mechanical Specifications‬‬
‫استشاري المقاول‬ ‫استشاري المالك‬
‫المكتب االستشاري للهندسة‬ ‫خليفة مهندسون استشاريون‬
‫البيئية والمدنية‬ ‫أ‪.‬د‪ /‬عبد القوى خليفة‬
‫أ‪.‬د‪ /‬خالد زاهر‬
‫مهندسون استشاريون‬
‫‪Mar. 2021‬‬
Civil & Environmental ‫المكــــتب اإلستــــشــارى‬
Engineering Experts ‫للهندسة البيئية والمدنية‬
Infrastructure Studies ‫ خالد زاهر‬.‫د‬.‫أ‬
Consultations, Design & Supervision ‫مهندسون إستشاريون‬
Contents
Part. No. Content Page
no.
Part 1 General conditions of tender 2
Part 2 Detailed technical specification 13
Section 2.1 Screening chamber 14
Section 2.2 The grit extractor (grit chamber) 19
Section 2.3 Biological aeration tank 24
Section 2.4 Equalization Tank 33
Section 2.5 pumping units 37
Section 2.6 Piping system, gates, and valves 40
Section 2.7 isolating gates 45
Section 2.8 Ancillary Equipment 47
Part 3 Tests and trials 51
Part 4 Design data tables 53
Part 5 Guarantee tables 59
Page 1 of 64
Part 1
General conditions of tender
Page 2 of 64
Part 1
General Condition for Tender
1.1. Brief description of works

Hawamdia WWTP is an existing plant with a treatment capacity of 20000 m3/d flow,
which is being upgrade to treat 40000 m3/d sewage flow.
The domestic sewage is collected from the areas through gravitational network and then
pumped through local pumping stations which pump the flow to the treatment plant
Description process treatment
An integrated fixed film activated sludge (IFAS) process, consist of an activated sludge system in
which a material to support attached biomass growth has been added in addition to the suspended
biomass growth in an activated sludge reactor. A variety of synthetic media for attached growth
have been developed for application in activated sludge process. these material may be suspended
in the activated sludge or fixed in the aeration tank. the addition of attached growth to the activated
sludge reactor results in a total equivalent MLSS concentration that may be 1.5 to 2.0 times the
activated sludge MLSS concentration alone. the higher biomass inventory in the aeration tank can
result in an increase in the effective SRT to provide nitrification or an increase in the system
treatment capacity. because the additional solids are form attached growth, the higher MLSS
inventory occurs without an increase in solids loading on the secondary clarifier.
Blower operation
For the two tanks system, the aeration is continuing so that one blower supplies air for
each IFAS tank.
D.O. control
For power savings, a dissolved oxygen (D.O) control system that will automatically
control the blower output will be provided. During periods of low flow or loading, this
system will closely match air supply to process oxygen demand by controlling blower run
time; this will allow a considerable savings in energy usage.
Installation
The bubble aeration system eliminates the need for any mechanical mixers and hoists, jet
aspirators and motive pumps, retrievable diffuser frames or lift-out track ways, etc… the
waste sludge pumps in each tank discharge directly to the thickener
Sludge stability
The sludge generated by the process must be well stabilized, since the process operates
in an aeration mode with a high solids pretension time, over 10 days. Sludge stability in
the basin will be also enhanced as a result of the alternating aerated / non – aerated
environment of the mixed liquor suspended solids (MLSS). This environment allows
significant reduction of sludge volatile compounds and enhances nutrient removal. The
result must be a sludge that settles easily and display a lack of orders. The process control
Page 3 of 64
includes sludge start timers which enable the operator to energize the waste sludge pumps
(allowing optimum solids concentrations to be wasted to the sludge processing facilities).
1.2. Climatic conditions at site
Mean air temperature in shadow 40.0 o C
Maximum recorded summer air Temp. in shadow 45.0 o C
Maximum water temperature 35.0 o C
Average water temperature 15.0 o C
Average water temperature in summer 26.0 o C
Mean barometric reading. 758
Average yearly relative humidity 77 %
Minimum yearly relative humidity 39 %
Average humidity during summer 61.3 %
Average humidity during winter 74.3 %
The air at site is sometimes charged with dust and fine sand.
1.3. Design data
Year 2030
Daily average flow 20000 m3 / day
Hourly average flow 833.33 m3 / hr
Max flow 2083.33 m3 / hr
1.4. Waste water characteristics

Influent water characteristics:
BOD5 500 mg/l

TSS 500 mg/l
PH 6–9
Peaking factor 2.5
NH4 20 mg/l
Effluent water characteristics:
BOD5 60 mg/l
TSS 50 mg/l
The treated effluent should be clear and odorless.

Grit to be removed from sewage water more than 0.2 mm diameter
Page 4 of 64
1.5. Repair of damaged coatings:
N.B: In the case of replace the old pumps with new ones, the parts that were
destroyed by paint (as a result of changing the pumps) are re-painted as follows:
Any damage to the protective coating shall be made good as soon as possible, and shall
not be left until the time of finish painting. Damaged areas shall be cleaned down to bright
metal by power wire brushing or sanding and feathered off the surrounding area. A new
protective system shall then be applied generally following the requirements of the system
originally applied, modified if necessary to comply with the recommendation of the
manufacture of the protective materials used.
1.5.1. Usage for different types of protection.

Unless otherwise specified on the contract drawing the various types of protection shall
be applied as detailed below.
Type a:
(hot – dip galvanized)
All ladders, staircases, guard – rails, guard – rails standards, safety cages and open steel
flooring and small bore pipe work.
All small metalwork such as pipe supports, steel flooring supports and safety chains.
Type b:
(zinc rich epoxy primer and epoxy coal tar)
All steelworks which is in contract with liquid, or is in close proximity to liquid, or is
buried in the ground.
Type c:
(zinc rich epoxy primer)
All steelworks is exposed in buildings or otherwise.
Type d:
(lead primer)
All steelworks which is used in buildings but protected by cladding.
Type e:
All steelworks which is encased in concrete.
1.5.2. Painting general

A) All paints shall be obtained from an approved manufacturer.
B) All materials shall be delivered in sealed containers bearing the manufacture’s
name and description of contents.
C) All paints shall be applied strictly in accordance with the manufacturer’s
instructions.
D) The preparation and painting shall be carried out under dry conditions and on
completely clean and dry surfaces. Painting shall not proceed when the ambient
temperature is 5oC and falling.
Page 5 of 64
1.5.3. Surface drone

The following surface preparation shall be carried out at the protective coatings prior to
painting, together with any additional preparation recommended by the paint
manufacture.
Type “a” protection thoroughly clean and degrease.
Type “b” protection thoroughly clean and

Degrease and wash with
Clean water
Type “c” protection thoroughly clean and degrease where steelworks has been
delivered with zinc rich epoxy primer and has been
allowed to weather,. The primed surface shall be washed
with clean water to remove zinc and allowed to dry.
Type “d” protection thoroughly clean
Bituminous coated thoroughly clean of superficial dirt.
Non- ferrous metal thoroughly clean and degrease
1.5.4. Finishing paint at contractor’s work

All surface of the fabricated steelwork shall be given a first coat of approved finishing
paint in accordance with location. Areas, which will be inaccessible after installation,
shall be given a second coat flooded by a final coat.
1.5.5. Painting at site during installation

Site connection shall be given a second coat and be brought together after being dry.
Where the surface finished has been subjected to damage during transit or installation,
the areas affected shall be cleaned and repaired, generally following the requirements of
the painting system originally applied.
1.5.6. Type of final painting

At site whole of the fabricated steelwork except that to which the final coat was applied
at the contractor’s work will receive a second and final coat of approved shades as
follows:
Type 1:
For surface immersed in water or subjected to splashing. A second coat followed by a
final coat of heavy duty epoxy coat tar will be applied to give a total thickness of 250
microns minimum in the dry film.
Page 6 of 64
Type 2:
For surface neither immersed in water nor subjected to splashing. A second coat followed
by a final coat of approved shade of heavy- duty epoxy enamel will be applied to produce
a minimum dry thickness of 250 microns.
Application will be by airless spray and minimum of 16 hours allowed between coats.
1.5.7. Corrosion protection and painting of other items according to Egyptian code
A) Pipes:
All, ductile and cast iron pipes and fittings 75 mm (diameter) and larger shall be given.
The protection according to low 277 tear 2000 and its appendix (14) for year 2002.
B) Valves:
Corrosion protection shall confirm to the following types:
- Internal protection type b.
- External protection type c
Final painting shall conform to the following types:
- Internally type 1
- Externally type 1 or 2
C) Aluminum:
Corrosion resistant aluminum shall only be used when and where it is specifically
approved by the employer. Where approval is given for its use, it shall not be painted
except for bolt- holes and faces which shall be given one coat of zinc primer paint.
D) Motors, starters, panels, pumps … etc….

The surface of motor, pumps and starters shall be to the manufacturer’s finish according
to location and shall be approved by the employer.
Panels and other similar enclosures shall be stove enameled to a high standard of finish.
Steel conductance’s shall be hot dip galvanized. Switchboard steelwork shall be heated
with a corrosion proofing process. The steelwork shall be degreased, cleaned and
thoroughly rinsed before immersing solution.
Immediately following the heat treatment and drying; in accordance with the process
requirements, the steelworks shall be adequately primed staved, then finished with final
application of stove enamel coats.
Should the bidder’s standard finish differ from the above process, this shall be clearly
indicated in his bid giving full details of the proposed protection.
Page 7 of 64
Part 2
Detailed technical specifications
Page 8 of 64
Part 2
Section 1
Screening Chamber
2.1. General
The technical specification mentioned hereafter shall cover the design, supply, erection,
testing and delivery in good working condition of the mechanical, equipment for the
domestic wastewater treatment plant, subject of this tender.
All equipment shall be designed to withstand the climate and ambient conditions,
corrosive action of sewage and the effect of the flammable sewage gases.
The contractor is requested to take into consideration when choosing his equipment, the
necessary duration in powers of prime-movers, allowance in cross sections of cables,
type of insulation, method of protection, etc.
All equipment asked for in this should be from well-known manufacturers who local
manufacturing, in the absence of it in the Egyptian market, it is imported which have an
international brand name.
This equipment shall comprise section and not limited to the following: -
• Screen equipment
• Pumping unit and their accessories
• Pipes, fitting, special pieces, valves, and penstocks.
• Grit and grease removing equipment.
• Aeration tanks equipment.
• Final sedimentation tanks equipment.
• Chlorination system.
• Gravity thickening tanks.
• Sludge Disposal.
Page 9 of 64
Screen Equipment:
General
The automatically operated mechanically cleaned screens shall be installed in the

concrete channels immediately adjacent to the inlet chamber. The collected screenings
shall be transferred to a screening skip via a chute for later disposal off-site. The
relevant tender documents of this contract show the general arrangement of the
equipment. Five screens shall be required. Four units shall be mechanically operated
screens and one shall be a hand rake screen. The manual screen is provided in case of
power failure. Each unit shall include all accessories and auxiliaries necessary for the
proper control, operation and maintenance of the plant.
The screen shall be provided with the following equipment:
1. Mechanical screens.
2. Manual screens.
3. Control cabinet.
4. Belt conveyor.
5. Screening collection skips.
6. Sliding and sluice gates.
Mechanical coarse screens shall be designed according to the following data:
Mechanical Coarse Screens
Average flow 20,000 m3/day
Peak factor 2.5 -
3
Peak flow 2,083 m /hr
No. mechanical screen 2 duty
flow per each screen 1042 m3/hr
Channel width 1 m
Channel Depth 1.62 m
Space between bars 50 mm
Inclination angle 75 Degree
Bar width 10 mm
Page 10 of 64
Mechanical (Multi Rake type) coarse screen components:
Frame
The frame shall be constructed from stainless steel 304L sections and channels.
The screen bars
The screen shall be of straight bars suitable for inclined installation about (70º- 85º) to
the horizontal. The screen bar shall be formed from st.st. 304 sections. The section is in
rectangular shape with width 10 mm by 40 mm depth, fitted along water stream in a
sense to provide maximum amount of inertia to prevent bending.
The raking mechanism
The cleaning rake mechanism rack shall be of the front cleaned, jam proof type and
shall be formed of several parts of st.st.304 teeth having adequate length and section for
easy replacement.
The teeth parts shall be bolted the rack bars which rotate by using of driving chains and
sprocket wheels of approved alternative.
Screen chains shall be of specified ultimate strength which proper attachment links,
stainless steel pins and rivets.
The sprockets shall be of semi-steel, cast in a chill of specified hardness and with
number of teeth accurately ground to fit the chain. The driving sprocket shall be keyed
firmly to shafts. And the foot shaft sprockets shall be suitable for under water service
under gritty conditions. All shafting shall off stainless steel, straight of sufficient size,
properly keyed to transmit power as required.
The driving unit shall consist of a reduction gear box and an electric motor assembly.
The electric motor shall be of the induction squirrel cage, suitable for electric supply, 3
phase,380 volts, 50 Hz. It shall be totally enclosed weather proof, self-ventilated, fan
cooled, and tropically insulated with class (F) insulation and IP55 enclosure, protected
against gases, dripping water, splash water and moist atmosphere.
The rated output of the motor shall be 20 % in excess than the maximum power
consumed by the raking system, the speed of the motor shall not exceed 1500 r.p.m and
rated for continuous running 24 hours.
Motor starter shall be of direct on line. Automatic contractor type, rated for not less than
15 starters per hours against 100 % full- load torque.
Page 11 of 64
Starter shall be equipped with an adjustable overload time lagged relay to cover the
starting period and an inherent no-voltage release.
Each screen shall be provided with end sprocket and chain for manual operation in
emergency cases.
Rack wiper and dead plate
An automatic rake wiper shall be provided for each screen, designed and placed so that
the screenings do not warp around the rack of the wiper during screenings removal. The
dead plate shall be constructed of at least 4 mm thick st.st 304 sheets and shall be bolted
to the side frame of the screen.
Discharge chute
This part helps captured screenings to drop to a conveyor or a container. It is made of

steel sheet and fixed to the dead plate by bolts or welding.
Roller chains
The multiple rakes are mounted on 100% stainless steel roller chains. The chains are
engineered for continuous, submerged duty without any lubrication and run within
guides on both sides of the screen frame. They are c/w tie rods to prevent chain
movements out of the chain guides.
Drive unit
Drive system is consisting of a motor which has IP 55 class protection as standard and a
gearbox to reduce motor output speed and supply suitable traveling speed for rake
system. It is directly mounted to drive shaft.
Control Cabinet
The control cabinet for screens shall be of the outdoor with IP55, protected against H2S
Gas, weather proof type provided with circuit breakers, contactors, and complete with
selector switches for automatic and manual operation of the screen motors.
Page 12 of 64
Overload protection
If the screen motion was obstructed, it reverses the rotation direction to remove
obstructions. The screen geared motor is equipped with torque switch to stop the screen
in the overload condition to prevent any damage.
Screen operating system:
Our screen works intermittently. Thus, the operation can be adjusted according to timer
controller or the incoming flow. A level sensor is installed in the channel in front of the
screen. The screen starts when a pre-set water level is reached and operates until the
water level is below the pre-set value. The cycle is repeated when the level is reached
again. The belt conveyor starts motion with the start of any screen and stops after a
certain time after the stoppage of the last screen.
Mechanical Fine Step Screens:
General
The automatically operated mechanically fine screens (step type) shall be installed in
the concrete channels immediately adjacent to the inlet chamber. The collected
screenings shall be transferred to a screening conveyor then to a skip via a chute for
later disposal off-site.
The relevant tender documents of this contract show the general arrangement of the
equipment. two screens shall be required. Each unit shall include all accessories and
auxiliaries necessary for the proper control, operation and maintenance of the plant.
Mechanical Fine Screens

Average flow 20,000 m3/day
Peak factor 2.5 -
3
Peak flow 2,083 m /hr
No. mechanical screen 2 nos, duty
flow per each screen 1042 m3/hr
Channel width 1 m
Channel Depth 1.62 m
Space between bars 6 mm
Inclination angle 75 Degree
Page 13 of 64
Bar width 10 mm
Mechanical Fine Screens
Mechanical screens shall have a clear opening between bars of 6 mm. Top and bottom
supports for the screens shall be furnished and shall be suitable for anchorage to the
concrete without vibration.
All screenings shall be disposed of site. Necessary solenoid operated control valve shall
be provided capable of delivering screenings with wash water at an adequate rate.
The fine screens shall be capable of operating intermittently to form a mat of screenings
material to provide maximum trash removal.
When operating, the fine screen shall present a clean filtration surface to the incoming
wastewater at all times.
The screen shall be assembled so that the screen does not need to be removed or pivoted
out from the channel for maintenance purposes.
All bearings to be externally mounted with a life expectancy of 50,000 hours
At normal operating flow conditions, approach velocities should be no less than (0.6
m/s), to prevent settling; and no greater than (1 m/s) to prevent forcing material through
the openings.
Entrance channels should be designed to provide equal and uniform distribution of flow
to the screens.
Design Conditions
A. General
Equipment furnished under this Section shall be suitable for operation in wastewater
from a sanitary sewer system containing domestic wastes.
B. Operation
As the solids accumulate into a mat on the screen, the unit is activated by a timer and
differential level meter. The motor reciprocates the bars incrementally moving the
materials up the bar screen steps. When the solids reach the top they fall off into a bin,
washer or conveyor.
Page 14 of 64
C. Controls
1. General: Each screen shall be provided with a local control panel designed by the
manufacturer. All controls and electrical components shall be suitable for a Class
I, Division I, Group D environment. The control panels shall be provided with
enclosures with NEMA ratings in accordance with the area designations. The
CONTRACTOR shall coordinate all control power.
2. Operating Modes: Each bar screen control panel shall be provided with
HANDOFF-AUTO and REVERSE-FORWARD controls. In automatic mode,
the bar screen shall be activated by timer control with a high differential level
override. Differential level should be ultrasonic type shall be ultrasonic type.
3. Control Stations: Each control panel shall be provided with REMOTE-LOCAL
and REVERSE-OFF-FORWARD switches. REVERSE-OFF-FORWARD switch
shall be lockable in the OFF position. Setting the REMOTE-LOCAL switch to
the LOCAL position shall override all start controls from the control panel.
4. Timer and Head Loss Differential Control: Each mechanically step screen shall
be provided with a time controller designed for variations in operation over a 24-
hour period, adjustable to 5- minute increments. When in the automatic control
mode, a differential controller shall override the timer controller to initiate
operation of the screen.
5. Alarms and Status Lights: Each screen shall be provided with local indicating
lights for alarm and status. Status lights shall be provided to indicate run and
ready conditions. Alarm lights and an alarm buzzer shall be provided to indicate
the following conditions:
a. Screen over torque.
b. Motor high temperature.
c. High channel water level
6. A status output and common trouble alarm output shall be provided for remote
indication and alarm. A dry set of contacts shall be provided for each output and
wired to a labeled terminal within each control panel. The trouble alarm contacts
shall open when any alarm condition occurs and shall close after all alarm
conditions have passed and manual alarm reset button has been depressed.
Manual alarm reset buttons as well as alarm buzzers shall be surface mounted on
each local control panel. Status signal contacts shall close during the run cycle,
Page 15 of 64
maintain closure during the entire run cycle, and open after the cycle is complete
and the drive mechanism is in its normal parked position.
D. Access
The step screen must be completely accessible for manual cleaning in the event of
power outage or other emergency shut down of the mechanical screen. To allow for
manual cleaning, there shall not be any mechanical cross-channel obstructions (such as
support beams, shafts, etc.)
Screening areas shall be provided with stairway access, adequate lighting, and a
convenient and adequate means for removing the screenings
Materials
Moving part Type 304 stainless steel
Stationary part Type 304 stainless steel
Side frame Type 304 stainless steel
Fasteners and hinges Type 304 stainless steel
Construction
The fine screen shall withstand, without deflection, damage or distortion, the loads
imposed by water differential between the upstream and downstream side of the fine
screen at maximum water depth in the downstream channel. The only obstructions in
the channel shall be the bars of the fine screen. All structural supports and fasteners,
except bar rack supports, shall be above the maximum water level to avoid interference
with flow.
Drawings & Documents
The following shall be submitted:

Drawings and descriptive information in sufficient detail to show the kind, size, weight,
arrangements, operation, component materials and devices; external connections,
anchorages, and supports required; performance characteristics; dimensions needed for
installation and correlation with the conveyor.
Electrical data including control wiring.
Information on at least one successfully performing installation of comparable size and
complexity constructed in the recent past including contact name, address, and
telephone number.
Page 16 of 64
Owner's Manual
The following shall be included in the OWNER'S MANUAL:

A. The manufacturer shall provide a written report stating the screens have been
properly installed and tested and each is ready for full-time operation.
B. Complete assembly and maintenance instructions including diagrams, drawings
and parts list.
Manually Cleaned Screen
The manually cleaned bar screen (for standby operation) shall be of bar type set into
position at an inclination of 45º to the horizontal.
The bars shall be fully extended to the floor invert level and shall be extended 75 mm
above the collecting tray.
Gap between the screen frame and side wall shall be sealed with stainless steel baffle
plates welded to the screen frame and bolted to the walls or gasket system manufactured
from a material suitable for permanent emersion in wastewater. The side wall seals shall
ensure that no wastewater in the channel can bypass the screening element.
The screen bars shall be formed of 304 stainless steel sections. The section is
rectangular in shape of at least 10 mm width by 40 mm depth. The space between
bars=50 mm. The screen channel width = 1.00 m.
Belt Conveyor
The belt conveyor shall handle the screenings from the screens with sideways load-
pickup, operated manually and automatically by suitable starters according to the
operating conditions of the screens. The width of the belt conveyor shall be 0.6 m.
The belt shall be made of rubber and canvas of 10 mm thickness two tiles and shall be
carried on rollers to take trough shape. The roller shall be sealed and greased for their
lifetime. The driving motor shall be totally enclosed complete with gear box.
The conveyors shall be fitted with side plates to ensure that the screenings are retained
on the belt and suitable arrangement shall be made to drain the belt of any excess liquid
on the channels. Scrapers shall be fitted to the conveyor to ensure complete removal of
the screenings from the belt.
The drive drum shall be equipped with belt tension device. The belt conveyor starts
motion with the start of any screen and stops after a certain time after the stoppage of
the last screen.
Page 17 of 64
The conveyor belt shall be supplied with emergency stop station to be located in a clear
position. The rollers would be sealed and greased for their life time. The belt conveyor
speed should be of approximately 0.75 m/s.
Drive motor shall be 380 V, 3-phase, 50 Hz, TEFC, IP 55, class F insulation and class B
temperature rise close coupled to a totally enclosed reduction gearbox.
Screening Collection Skips
The Contractor shall supply two skips for collecting screenings material carried by the
conveyor. The skips shall be fabricated from steel sheets of 3 mm thickness coated and
lined with corrosion resistant epoxy. The capacity of skip shall be not less than 1m3. The
collection skip shall be equipped with swivel caster rollers with brake and it shall be
flab type to facilitate screenings removal.
Isolating gates for screening chambers

As specified in section (7)
Page 18 of 64
Part 2
Section 2
The Grit Extractor (grit chamber)
General
This section includes the manufacture, delivery, installation, testing, commissioning,
guarantee and maintenance during the guarantee period of the mechanical and electrical
equipment for the grit extractor complete with all accessories and spares in accordance
with the following clauses:
2.2.1 Brief Description of the Works

Grit and grease shall be removed from the influent in a longitudinal aerated structure
with two treatment streams. It shall be possible for the full flow rate to pass in only two
of the streams at first stage. The distribution of flow should be equalized through each
channel. Means shall be provided for isolating any of the two channels for maintenance.
The sand and grit shall be extracted by from the bottom of the structure by grit removal
pumps.
Removal facilities should be designed to retain particles of a size over 200 microns as
well as floating organic matters.
Grit and sand extracted from the station shall be stored in individual container Extracted
Grease will be concentrated in a separate container for extraction
2.2.2. Tank details

Channel tanks type is to be equipped under this contract. The tank clear dimensions are
as follows:
Q. Design (m3/s ) 0.578

Retention time 3.60
Volume (m3) 63
No. Of chambers 2
Chamber length (m) 10
Width (m) 2.5
Depth of water (m) 2.5
Depth of chamber (m) 3.77
Surface Area (m2) 25
Estimated sand Removal Efficiency: 80% for sand > 0.2 mm
Page 19 of 64
2.2.3. Scraper
Two complete scraper bridge to be installed on both two grit removal channels with the
following specifications:
Bridge structure
For the two grit chambers two cross moving bridges shall be supplied and installed on
both channel from hot dip galvanized steel sections with across and diagonal braces
supported on two end carriages and the bridge shall be able to carry load up to 250
kg/m2.Linear motion of bridge shall be achieved using guide wheels. The bridge shall
have an effective walkway width not less than 1000 mm.
The hand-railing shall be galvanized steel tubular type with double rails set in matching
stanchions and with the top rails 1000-1200 mm above the walkway level.
The bridge shall be supplied complete with grating and walkway side handrails. Two end
stops shall be arranged at each end of the path for security.
Bottom Scraper
The scraper blades shall be connected to the bridge via hinge supporting and shall be
designed to assure effective grit removal to the hopper at the end of the tank. It shall have
continuous contact with tank bottom surface (with its slope) in the backward stroke and
shall be lifted up via lifting mechanism in the forward stroke. Bottom scraper blade shall
be arranged to be fitted with nontoxic type renewable rubber blades. All under water
connections shall be via bolts, washers and nuts.
Surface scraper
The scraper blades shall be connected to the bridge via hinge supporting and shall be
designed to assure effective scum removal to the scum collecting sump at the end of the
tank. Scraper blades shall have continuous contact with water surface in the forward
stroke and shall be lifted up via lifting mechanism in the backward stroke. All under water
connections shall be via bolts, washers and nuts.
Driving system
One driving geared motor with suitable rated power shall be mounted on the scraper
bridge transmitting motion to both end carriages through torque driving shaft. The driving
geared motor shall be squirrel cage induction motor, totally enclosed fan cooled (TEFC),
380 V, 3 ph, 50 Hz, IP 55 and insulation/temperature rise class F/B.
Bottom & surface scraper lifting mechanism:

One lifting geared motor (for each channel) with suitable rated power shall be mounted
on the scraper bridge to lift the bottom scrapers and lower down the surface scraper at the
forward stroke and vice versa at the backward stroke. The geared motor shall be squirrel
cage induction motor, totally enclosed fan cooled (TEFC), 380 V, 3 ph, 50 Hz, IP 55 and
insulation/temperature rise class F/B.
Page 20 of 64
Scrapers Bridge Control Cabinet

Automatic operation is to be time controlled in such a way that the scraper bridge is set
into motion from a\rest position (at the far end of the grit chamber) after expiration of
adjustable preselected time period. The carriage after making a complete scraping stroke
reverses its motion backward to the rest position, upon manual operation the carriage shall
make one complete cycle and stop as described above.
Electric Feeding to the Bridge

This is to be achieved by using of a flexible cable (Festoon type) and, galvanized steel
guide channels and supports or via cable reel mounted on the bridge.
2.2.4. Sand Air lifting pumps

Sand Air Lift pump shall lift the sand and grit from the hoppers to the sand cleaning
equipment or directly to collecting container (sand silo).
Include an air pipe, educator, foot piece, tail pipe, air separator and a vent pipe. Provide
zinc-coated Schedule 40 steel pipe to the educator of adequate size to discharge the
required amount of liquid without excessive pressure drop. Provide globe valve, ball
valve, or plug air control valve on the air pipe for accurate adjustment of the airlift
discharge rate. Ensure tail pipe below the foot piece, the educator pipe, air separator and
vent from it are of zinc-coated steel. Fittings must be of zinc-coated malleable iron or cast
iron. Provide educator with a clean-out above the water level. Two airlift pumps with
discharge capacity for one = 50.24 m3/hr.
* Pump shall deliver the output into a sand cleaning equipment or collecting container.
* The sand silo shall have a volume suitable for average flow rate and shall include: -
- Support scaffolding in profile steel or tubing
- Drip water piping.
- Quick action gate valves.
sand silo
Sand silo sets shall be supplied and erected for the grit and grease removal chamber with total
capacity 5 m3.
The silo shall include the following:
• support scaffolding in profile steel or tubing.
• wash water piping
• Over flow piping.
• Drip-water-piping.
• Quick- action valve.
As disposal of grit shall be done to dump-trucks, enough clearance between the outlet of the
sand silo and finished floor or street level is to be provided.
• wash water system
A sand wash water system shall be supplied and installed for the sand silo to separate the
organic matters to be settled with sand. The separated organic matter with washing water shall
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be returned back to the grit removal chamber. The wash water system shall be complete with all
necessary equipment and pipe work.
This system shall be fed with water from the treated water network at site. The
system should be efficient and reliable.
2.2.5. Aeration equipment

Oxygen requirements generally depend on maximum diurnal organic loading, degree of
treatment, and level of suspended solids concentration to be maintained in the aeration
tank mixed liquor. Aeration equipment shall be capable of maintaining a minimum of 2.0
mg/l of dissolved oxygen in the mixed liquor at all times and providing through mixing
of the mixed liquor. In the absence of experimentally determined values. The required air
blowers are 2 (2 working) each with nominal discharge Q. N of 600 Sm3/hr and 0.5 bar
at 20o C.
2.2.6. Air supply system

Air blowers
A. Air blowers
Blowers: Two (2) lobe type air blowers shall be supplied and erected in a building to be
constructed close to the grit removal chambers blower capacity 770 Sm3/hr for both aeration
and air lift pump. with pressure 0.5 bar at 20o C.
These blowers shall feed process air to the aerated grit removal chambers. The blowers shall be
of the (two or three-lobe) design driven by electric motors through belt drive. The blowers shall
be equipped with all auxiliary equipment such as inlet filter with clog indicator, exhaust valve,
automatic pressure release valve, silencers, check valves, pressure gauge, etc. Each blower shall
be enclosed in a sound proof enclosure to eliminate excessive noise inside and outside the
building. The two of the blowers shall be running. Noise level outside the building shall not
exceed 75 dBA at 3 m around the building. Noise level inside the building shall not exceed 85
dBA.
B. Material
The gears between the driver and driven lobes shall be of nickel cast steel, or other approved,
accurately ground with close clearance to prevent interference between lobes.
The casing shall be of high-grade cast iron adequately ribbed to avoid distortion.
C. Driving Motors:
Each air blower shall be independently driven by directly coupled electric motor or V- belt
type. The motor shall be of induction, squirrel cage three phase, 380 volts totally enclosed,
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weather proof, self-ventilated, fan cooled (IP 54 or IP44) enclosure and tropically insulated
with class (F) insulation, class (B) temp. rise.
The normal output of the motor shall be 20% in excess than maximum power consumed by the
blower. Power factor shall not be less than 0.80. The speed of the motor shall be suitable for the
capacity and type of blower. and the motor shaft shall be carried on the thrust ball or roller
bearing.
D. Starters:
Starters shall be of the automatic Star/Delta; they shall have "Hand-Off-Auto" switches to
permit alternative manual starting and stopping.
Each starter shall be equipped with overload and no – voltage release.
E. Diffusers
Air shall be injected into water using coarse bubble diffusers. The diffusers shall be of the
automatic closing type, manufactured of high-density polyethylene or PVC or equal anti
corrosive material. The diffuser design shall be such that no water is allowed into air pipes in
case of air stopping. Diffusers shall be supplied by well reputed manufactures with well proven
record in similar applications. The performance characteristics of the proposed diffusers shall
be submitted with tender documents by the Contractor. The performance characteristics shall be
verified by independent testing laboratory.
F. Oil and Grease Removing Equipment
The Contractor shall supply Galvanized steel pipe acc. to drawings to be installed across the
width of the grit chamber. The axis of the pipe shall pass through the top water surface in the
chamber.
Part of the pipe wall shall be cut through the whole pipe length to allow for the collection of the
floating oil and grease.
This pipe shall be closed from one end, while the other end shall pass through the wall, and
extended outside to transfer the collected oil and grease to an oil separation chamber. Water
shall be discharged to the site drainage network while oil and grease shall be kept in the
chamber for periodic removal. The pipe shall discharge the oil and grease by gravity. Any
alternative system can be accepted upon approval by the Engineer.
Page 23 of 64
2.2.7. Sand pipes and valves:

Pipes:
Pumps pipes shall be steel conform to ASTM A 36/A 36M hot-dip galvanized in
accordance with ASTM A 123/A 123M or ASTM A 153/A 153M. Submerged steel shall
have a minimum thickness of 6 mm. All pipes shall be protected against the waste water
surrounding atmosphere.
Valves:
Sliding gate valves shall be of the double flanged wedge gate type and to be made of Cast
Iron GGG 50 or GGG 40 and designed according to ISO 2531, they shall have cast iron
bodies and wedges. All sliding gate valves shall have gunmetal or ST.ST. faces, high
grade stainless steel spindles, and shall be complete with hand wheel or extended spindle
and gearing where appropriate.
The valves shall be arranged for clockwise closing by cast iron hand wheel.
Sliding gate valve properly designed to handle heavy polluted water with sand. The
sealing faces to be always in tight contact with gate through the entire stroke, such that
entrance of sand or other foreign matter into the body is impossible.
2.2.8. Isolating gates

Specifications of isolating gates to be furnished are given in (sec. 7)
2.2.9. Schedule of drawings:

- Drawings required with the tender:
General arrangement of plant layout with major loading and leading dimensions.
- Drawings required from the successful tender:
i) Fully dimensioned plant layout.
ii) Foundation details showing all plinths, trenches, holes, etc. required for
accommodation of machinery, pipe work and cabling and confirming all machinery
loading, both static and dynamic.
Page 24 of 64
Part 2
Section 3
Aeration Tanks (IFAS)
2.3.1. General
The aeration process and its various modifications may be used where sewage is amenable
to biological treatment. This process requires close attention and competent operating
supervision, including routine laboratory control. This equipment’s shall be considered
when proposing this type of treatment.
This process requires major energy usage to meet aeration demands.
Energy costs and potential mandatory emergency public power reduction events in
relation to critical water quality conditions must be carefully evaluated.
Capability of energy usage phase-down while still maintaining process viability, both
under normal and emergency energy availability conditions, must be including in design.
2.3.2. Capacities and permissible loading

The size of the aeration tank for any particular adaptation of the process shall be
determined by full scale experience, or rational calculations based mainly on food to
microorganism ratio and mixed liquor suspended solids levels. Other factors such as size
of treatment plant, diurnal load variations, and degree of treatment required shall also be
considered. In addition, temperature, ph, and aeration dissolved oxygen shall be
considered when designing for nitrification.
2.3.3. Number of units
It is requiring to supply, erect and commission the mechanical and electrical equipment
for two aeration tank divided in two sides. The tank dimensions as per drawings.
Total aeration tank volume shall be divided among two units capable of independent
operation, when required by the appropriate reviewing agency to meet applicable effluent
limitations and reliability guidelines.
The capacity of IFAS tanks is 20000 m3/d
Number of IFAS tanks = 2 tanks
Each tank divided to 2 basins
Dimensions of each basin, length= 12.40 m, width= 12.50 m and depth= 5.50 m.
Inlets and outlets for each aeration tank unit shall be suitably equipped with valves, gates,
stop plates, weirs, or other devices to permit controlling the flow to any unit to maintain
reasonably constant liquid level. The hydraulic load to be carried with any single aeration
tank unit out of service. Channels and pipes carrying liquids with solids in suspension
shall be designed to maintain self-cleaning velocities or shall be agitated to keep such
solids in suspension at all rates of flow within the design limits. Adequate provisions
should be made drain segments of channels which are not being used due to alternate flow
patterns. All aeration tanks should have freeboard of not less than 20 inches (50 cm).
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Additional freeboard or windbreaks may be necessary to protect against freezing or

windblown spray.
2.3.4 Aeration Process Control:

Aeration process shall be provided by air blowers and diffusers system. The hydraulic
design of the aerators shall such that complete mixing is achieved of the tank media.
The contractor shall provide all detailed calculations concerning the aeration process
including but not limited to flow rate, media characteristics, tank dimensions, oxygen
capacities, operating parameters, aerators performances.........etc.
The type and the size of the aerator shall be subjected to performance tests under
controlled conditions.
The contractor must present in his tender the oxygen transfers rates and absorbed power
under standard conditions and under actual site conditions. Graphs and tables showing
the relationship between aerator conversions, oxygen transfer rate and mixing efficiency
must also be provided.
2.3.5 Aeration systems

The mechanism shall be designed for the expected conditions in the aeration tank in terms
of the power performance certified testing shall verify mechanical aeration performance.
The design requirements of a mechanical aeration system shall accomplish the following:
1- Maintain a minimum of 2 mg/l of dissolved oxygen in the mixed liquor at all times
through tank or basin.
2- Maintain all biological solids in suspension.
3- Meet maximum oxygen demand and maintain process performance with the largest
unit out of survival.
4- Provide for varying the amount of oxygen transferred in proportion to the load demand
on the plant.
2.3.6. Aeration equipment

Oxygen requirements generally depend on maximum diurnal organic loading, degree of
treatment, and level of suspended solids concentration to be maintained in the aeration
tank mixed liquor. Aeration equipment shall be capable of maintaining a minimum of 2.0
mg/l of dissolved oxygen in the mixed liquor at all times and providing through mixing
of the mixed liquor. In the absence of experimentally determined values. The required air
blowers are 3 (2 working + 1 standby) each with discharge of 9125 Sm3/hr and 0.7 bar
at 20o C.
2.3.7. Tank details

Two aeration tanks whose civil works shall be constructed under other contract.
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2.3.8. Requirements
The following item shall be provided for each aeration tank (deep aeration).
1- Enough no. of air distribution diffusers.
2- Main header pipe line.
3- Air provides units (air blower).
4- Aeration tank inlet gates.
5- Electrical equipment.
N.b.: turbulence velocity of water at any point of the tank shall not be less than
0.3m/sec.
The effect of changing temperature shall to be considered for air blower capacity.
Tenders shall include for any necessary support and fixation material for air distribution
pipe and nozzle.
2.3.9. Air blowers
Each air blower device shall be independently driven by a horizontal air–cooled totally
enclosed squirrel cage induction motor with IP 54 or IP 44 equipped with variable
frequency drive (VFD) to control the quantity of air required for aeration according to
DO and sample analysis.
The motor rated output shall be 10 % in excess of the maximum absorbed power by the
blower. Motor speed shall be suitable for the capacity and type of the blower. Blowers
efficiency shall be not less than 70 %. Number of operation for Motor not less than 10
times/h. Insulation/temperature rise of motor windings shall be class “F/B”, rated voltage
380 V, 50 HZ. The motor winding shall be complete with PTC+PT100 sensors.
Air blower shall be centrifugal or positive displacement rotary type driven by electric
motors. Each electric motor and blower shall be mounted on a combined bed plate of cast
iron or fabricated steel. Anti-vibration mountings and Flexible pipe joints shall be
provided.
Each blower shall be complete with automatic unloading device, dead weight pressure
relief valve, pressure gauge, non-return valve, outlet silencer, inlet filter and silencer and
suitable in every respect for automatic operation.
The drive between the blower and motor shall be through flexible coupling or v-belt of
approved design. The lobes shall be of cast steel, machined to an accurate counter,
together with an integral shaft and shall be statically and dynamically balanced.
The air blower set shall be complete with sound proof housing such that the noise level
at one meter apart from the set in any direction shall not exceed 85 dB.
The blower shall be controlled via the PLC control system.
In the event of duty unit failure an alarm system shall be actuated.
2.3.10. Aeration Pipes and diffuser

The aeration system shall include air blowers, together with local control stations, located
in Blower Building, a single air main delivering to a manifold located on the aeration
tanks walkway and diffusers in the tanks. At the manifold, separate air mains shall deliver
air to diffusers in each aeration tank.
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Air from the main will be supplied from the manifold to the separate longitudinal
secondary air mains, each provided with an actuated control valve. Air shall be separately
supplied to the aeration tanks by these secondary air mains which shall pass along the top
of the partition walls between the tanks. From the secondary air main dedicated for each
aeration tank air will be supplied to 2 or more drop legs (downpipes) to the floor main
manifolds of each tank and distributed via the floor distribution pipes (lateral pipes) to
the diffusers.
General (Important Notes)
The Contractor shall provide pipework, valves and fittings associated with the installation
of aeration plant specified.
The pipework shall form a complete air system consisting of blower room bus main,
delivery air main including buried or overhead run sections, main manifold, longitudinal
secondary air mains, aeration tank drop legs (downpipes), tank floor pipework and
terminating in diffusers, all as specified.
Pipework arrangements shall allow for misalignment of fixed termination points by 25
mm in any direction. All pipework shall be adequately supported and fastened so that
stress is not placed on any plant due to the weight or fixing of the pipework.
All nuts, bolts and washers for fixing shall be stainless steel.
Fixing of pipework to concrete structures shall be by stainless steel resin anchor
bolts.
All pipework shall be galvanized iron (GI) or galvanized mild steel (GMS), except
where otherwise stated. All joints shall be flanged and be rated to PN10.
Flanges shall conform to BS 4504 and drilled in accordance with the appropriate pressure
rating.
Where a pipe passes through a wall, retaining wall or is subject to thrust it shall
incorporate a puddle flange which shall conform to the dimensions stated in BS 4504 but
remain undrilled.
Selection of adapters and couplings shall make due allowance for the thickness of any
pipe coating.
Detachable flexible couplings shall be provided with central register ribs or locations
plugs when so detailed on the Drawings.
Flange adapters shall have flanges as specified for flanged joints.
Sufficient joints shall be provided to allow for expansion and contraction of the pipework
due to the operating temperature.
Air Delivery Main
The delivery main from the blowers to the air supply assemblies shall be Seamless steal
Shc. 20. All buried or exposed main header pipe from external of the blower building to
the aeration tanks shall be Seamless steel Shc. 20, with ball valves to control the flow to
stainless steel dropper feed pipes to individual UPVC or other approved diffuser
distribution pipes which shall be securely fixed to the walls and floors of each aeration
tank.
Page 28 of 64
The delivery main shall be connected via flanged joints to the secondary longitudinal air
mains via flow proportioning valves as described below.
Longitudinal Secondary Air Mains (Header)

The longitudinal branch mains or header shall be of galvanized iron.
Flow proportioning between the air main and longitudinal secondary air mains shall be
effected by flow proportioning valves (butterfly or ball valves) complete with an isolating
guard valve. Flange adapters shall be provided to allow removal of these valves.
The longitudinal secondary mains shall be routed in the manner. Between the flow
proportioning valves and along the aeration tank walkway. Platforms and stairways
(described elsewhere) for personnel access to and adjacent to these mains shall be
provided as part of the Mechanical Works.
Flange adapters shall be provided to allow removal of the valves.
Aeration Tank Downpipes (drop legs)
The downpipes shall be of stainless steel Type 304.

Each drop leg pipe shall be provided with an isolating ball valve and a control ball valve
at walkway level.
The hand railing on the aeration tank walkway shall be provided to suit the Contractor’s
design for the drop leg pipes/longitudinal mains arrangement.
Drop leg pipes shall be connected via flanged joints to the tank floor pipework as
described below.
Aeration Tank Floor Pipework and Diffuser System
Air pipework within the aeration tanks and the diffuser equipment shall be supplied by
one diffused air equipment manufacturer.
The equipment to be supplied shall be complete and shall include all necessary parts,
fittings, etc. to form a complete diffused air system for use in the aeration tanks.
The aeration tank floor pipework from each downpipe shall consist of a floor distribution
manifold and distribution pipes (laterals) not less than 100 mm diameter arranged in a
grid to feed air to the diffusers and be complete with diffusers, spare diffuser connections,
joints, gaskets, pipe stands and moisture blowouts.
The floor distribution manifold shall connect to the downpipe and have sufficient
branches to supply the number of diffuser pipes necessary in each grid. The manifold
shall be fixed to the floor of the aeration tank to prevent flotation. This shall be achieved
by means of stainless steel resin anchor bolts suitable for pipe flanges and straps of similar
material and protection. Pipe supports shall be grade 304 stainless steel.
The pipe shall be uPVC of minimum class D grade treated to prevent degradation by
ultra-violet light or stainless steel and shall be secured to the floor to prevent flotation.
Provision shall be made to adjust the height of the pipe above the floor by a minimum of
25 mm to ensure diffusers are set level in the tank.
Page 29 of 64
Aeration Tank Diffusers
The diffusers. coarse bubble type shall be arranged throughout each aeration tank, in
the manner described below. The quantity of diffusers required shall be determined by
the Contractor to suit the process requirements but in any event to satisfy the installed
blower capacity. The diffusers shall comply to the requirements as given in the latest
edition of AWWA’s Product and Material Specification.
The diffusers shall be mounted horizontally on the pipe such that air distribution is even
over the horizontal surface. Each diffuser shall have a fixed control orifice to regulate the
air supply and assist in providing an even distribution over the tank surface.
Diffusers shall ensure proper mixing of the raw sewage, mixed liquor and provide a
consistent dissolved oxygen concentration throughout each tank as required by the design.
The Contractor shall ensure that the diffusers have a sufficient turn-down capability to
prevent diffuser fouling when only one blower is operating at minimum speed for long
periods.
The entire system shall be designed with sufficient supports and allowance for expansion,
contraction, thrust, uplift, etc. and all forces to be encountered in this operation and at the
depth of water expected.
The complete diffuser assemblies shall consist of a diffuser, diffuser holder, sealing
gasket, air control orifice and retaining device. The diffuser holder shall be factory
welded.
There shall be a minimum clearance of 150 mm between the bottom of the floor pipes
and the tank floor.
Tests shall be according to Egyptian standards.
Valves for Air Pipework

The Contractor shall provide flow proportioning, isolating and non-return valves to the
extent shown in the Drawings (plus further isolating valves required for flow
proportioning valves), and for the pipework system as described in the Specification. Any
valves necessary for the installation that are not covered herein shall be suitably selected
for the particular application.
Valves shall be provided as follows:

a) Non-return valves
Each blower shall be equipped with non-return flap manufactured by blower
manufacturer and assembled with the blower unit.
b) Isolating valves
Valves bodies shall be manufactured from cast iron and have metal faces and seats. Valve
bonnets shall be removable for maintenance by removal of bonnet/body bolts.
All valves shall be suitable for manual operation by hand wheel, either mounted on the
body or at high level (with headstocks) where indicated.
The Contractor can use butterfly valves as isolating valves. Butterfly valves shall in this
case comply with the requirements for flow proportioning valves except that an electric
actuator is not required. Batter fly valves material are cast iron.
Page 30 of 64
Flow proportioning air valves

The flow proportioning air valves fitted between the delivery main and the longitudinal
branch mains shall be butterfly valves. Each valve shall be provided with an electric
actuator suitable for frequent modulating duty where required by design.
Each flow proportioning valve shall be provided with an upstream manually operated
isolating valve. Hand wheels for isolating and flow proportioning valves shall be
positioned at approximately 1000 mm above floor level.
All valves shall be fitted with indicators to show the position of the disc. The body and
disc shall be of grey cast iron.
Flow proportioning valves shall be used to control the proportion of the total air supplied
to each aeration tank (normally equal) to maintain the dissolved oxygen level within the
preset range (s).
2.3.11. Electrical equipment

Starters, relays, fuses, etc. for the air blowers shall be housed in the multi-motor control
panel as detailed in the electrical section. Provision shall be made for additional remote
stop/start of the blower and indication of motors “running / sopped / failed” from the main
PLC in the operating building.
2.3.12. Dissolved Oxygen Meters:

The contractor should include two dissolved oxygen meters (one on the outlet of each
tank) complete with indicators and recorders. These meters shall continuously measure
the dissolved oxygen in the aeration tanks, then the weir penstocks shall be adjusted both
automatically and manually to keep the required DO value.
Each dissolved oxygen meter shall comprise the following equipment:
▪ One dissolved oxygen measuring electrode, filled with aqueous electrolyte, with lead
anode, silver cathode, polyethylene membrane, thermostat temperature
compensation and connecting cable.
One sensor holder made of non- corrosive material.
▪ One amplifier with indicator mounted in a suitable enclosure for outdoor installation,
with automatic electrode calibration check and cleaning, measuring ranges: 0 to15
ppm (mg/1), 0 to 100% saturation, with linear scale, accuracy = 5% of reading,
automatic temperature compensation from 0°C to +40°C, output current 4 to 20 mA,
power supply 220 V, 50 cps.
▪ The contractor shall supply all the necessary installations for the proper operation of
the dissolved oxygen meters.
2.3.13. Schedule of drawings
- Drawings: general layout and hydraulic section.

- Detailed drawings of the air blower units.
- General arrangement of the aeration plant layout with major loading dimensions.
- Fully dimensioned aeration tanks.
- Fully dimensioned aeration plant layout and cross section.
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- Foundation details showing all plinths, trenches, holes …etc. Required for
accommodation of the equipment, pipe work and cabling and confirming all
machinery loading both static and dynamic.
- wiring diagrams to the electrical connection.
Page 32 of 64
Part 2
Section 4
Equalization Tank
General
This section includes the manufacture, delivery, installation, testing, commissioning,
guarantee and maintenance during the guarantee period of the mechanical and electrical
equipment for the equalization tank complete with all accessories and spares in
accordance with the following clauses:
Tank details
Channel tanks type is to be equipped under this contract. The tank clear dimensions are
as follows:
Q. peak (m3/hr ) 2083.33

Volume (m3) 4725
Tank length (m) 36
Tank Depth (m) 6.5
Depth of water (m) 5.25
Width (m) 25
Air supply system

Air blowers
Air blowers
Blowers: Two (2) lobe type air blowers shall be supplied and erected in the Air blowers
building, the equalization tank blower capacity 4200 Sm3/hr with pressure 0.7 bar at 20o C.
These blowers shall feed process air to the equalization tank. The blowers shall be of the (two
or three-lobe) design driven by electric motors through belt drive. The blowers shall be
equipped with all auxiliary equipment such as inlet filter with clog indicator, exhaust valve,
automatic pressure release valve, silencers, check valves, pressure gauge, etc. Each blower shall
be enclosed in a sound proof enclosure to eliminate excessive noise inside and outside the
building. The two of the blowers shall be running. Noise level outside the building shall not
exceed 75 dBA at 3 m around the building. Noise level inside the building shall not exceed 85
dBA.
Page 33 of 64
Material
The gears between the driver and driven lobes shall be of nickel cast steel, or other approved,
accurately ground with close clearance to prevent interference between lobes.
The casing shall be of high-grade cast iron adequately ribbed to avoid distortion.
Driving Motors:
Each air blower shall be independently driven by directly coupled electric motor or V- belt
type. The motor shall be of induction, squirrel cage three phase, 380 volts totally enclosed,
weather proof, self-ventilated, fan cooled (IP 54 or IP44) enclosure and tropically insulated
with class (F) insulation, class (B) temp. rise.
The normal output of the motor shall be 20% in excess than maximum power consumed by the
blower. Power factor shall not be less than 0.80. The speed of the motor shall be suitable for the
capacity and type of blower. and the motor shaft shall be carried on the thrust ball or roller
bearing.
Starters:
Starters shall be of the automatic Star/Delta; they shall have "Hand-Off-Auto" switches to
permit alternative manual starting and stopping.
Each starter shall be equipped with overload and no – voltage release.
Diffusers
Air shall be injected into water using coarse bubble diffusers. The diffusers shall be of the
automatic closing type, manufactured of high-density polyethylene or PVC or equal anti
corrosive material. The diffuser design shall be such that no water is allowed into air pipes in
case of air stopping. Diffusers shall be supplied by well reputed manufactures with well proven
record in similar applications. The performance characteristics of the proposed diffusers shall
be submitted with tender documents by the Contractor. The performance characteristics shall be
verified by independent testing laboratory.
Vertical Pumping Unit:

The pump shall be Vertical pump type with discharge capacity = 420 m3/hr, head=6m,
number of pumps 3 (2 duty + 1 standby).
The pump motor shall be IP54 or IP44, tropically insulated with class “F” insulation and
class “B” temperature rise when the ambient air temperature is 45oC. The electric motor
should be designed to operate with supply voltage of 380 V, 3-phase, 50 HZ. Complete
with electric flexible rubber cable with watertight cable entry and plug. The motor
winding and bearing shall be provided with PTC temperature detectors. The motor excess
Page 34 of 64
power shall be 20% of maximum power absorbed during working range according to
Egyptian code.
Pump casing
The pump casing shall be close grain cast iron GG-25, fitted with renewable high resisting
stainless steel rings to take up the wear (if applicable) between it and the impeller. The
interior surface of the cover shall be shaped to maintain the contours of the internal
surface of casing and bend to which it is attached so as to maintain efficiency and to
prevent the lodging of solids.
Impeller
The impeller shall be made of close grain DI GGG 50 or GGG 40 with special additives
to be able to resist action of sewage gases, sand and silt contained in sewage water. It
shall be carefully statically and dynamically balanced and machined wherever accessible.
It should be channeled impeller and shall be with wide suction waterways with smooth
contours. It shall be fitted with renewable high resisting stainless steel rings
corresponding to those renewable rings fitted to casing.
Shaft and shaft bearings

The pump shaft shall be made of stainless steel. It shall have cross section & number of
bearings enough to avoid having any critical speed occurring at or near the normal speed
and strong enough to absorb any forces at any condition of loading. The bearing life
should be 100 000 hours. Sealing of pump shall be double mechanical seal made of silicon
carbide or tungsten carbide, the space between two mechanical seals shall be filled with
oil.
The velocity at the suction of the pump must not exceed 4 m/s.
Pump accessories
Each pump shall be delivered with all the necessary equipment including, but not limited
to the following:
One set of quick coupling
One discharge elbow
Pump guide bars
All necessary fitting required for successful erection and running
Identification of pumps
Stainless steel name plates shall be attached to each pump. This shall be stamped with the
manufacturer’s name, model number, capacity in liters per second, head in meters, speed,
serial number, and other pertinent data, in English.
Motors
Type of motors
Unless otherwise specified, the driving motors shall be low voltage squirrel cage
induction motors. The motors shall be totally enclosed. The construction of the motors
shall be according to the latest IEC motors specifications with thermal protection for
bearing and coils.
Page 35 of 64
Degree of protection
The degree of motor enclosure protection shall be IP54 or IP44.
Rating
The motor shall be operated at 380V, 3-phase, 50 Hz, in accordance with the requirements.
The motors shall be suitable for minimum 10 starts per hour.
The rated speed shall be equal to the pump speed and not exceeding 1500 rpm.
Power factor shall not be less than 80%.
Constructional features for motor

The pump motor shall be squirrel-cage, induction. The enclosure protection shall be to
the IEC requirements for submersible motor. The stator winding and stator leads shall be
insulated with moisture resistant class “F” insulation with class “B” temperature rise or
class “H” insulation with class “F” temperature rise. The stator shall be dipped and baked
in varnish. The motor shall be designed for continuous duty, capable of sustaining a
minimum of at (10) starts per hour. At the design point the motor shall not draw more
than the nominal KW value at utility supply quality. The junction chamber, containing
the terminal board, shall be sealed from the motor by elastomer compression seal (O-ring)
connection between the cable conductors and stator terminal board and thus perfectly leak
proof. Thermal sensors shall be used to monitor stator and rotor temperatures. The stator
shall be equipped with three (3) thermal sensors, embedded in the end coils of the stator
winding (one in each stator phase). These shall be used in conjunction with and
supplemental to external motor protection and wired to the control panel to trip the motor
under overheating conditions.
Page 36 of 64
Part 2
Section 5
Sludge Pumping Units
2.5.1. General
The required pumps RAS pumps only, the supernatant pumps and WAS pumps are
existing with discharge capacity= 54 m3/hr and head =10m which those can accommodate
the total discharge of existing and extension without change.
The pumps shall be capable of operating under positive static head, to draw sewage from
the aeration tank and discharge it into the sludge holding tank.
2.5.2. Pumping unit

Pumping units shall be designed to operate satisfactorily for long periods with minimum
attendance. Pumping units shall be centrifugal submersible type. The pumps shall be
capable of operating under positive static head. The pumps shall be driven by submersible
electric motor. The pumping sets shall include all controls, accessories and auxiliaries
necessary for proper control and operation of pumps.
Pumps are required to fulfil the performance conditions stipulated in the following
technical data schedule
Description RAS PUMP

No. Of pumps 3 (2 duty + 1 standby)
Output (m3/hr) 420
Total monomeric head (m) 15
Rotating speed (not exceed) rpm 1500
Working range of the pump (m) 12 – 17
Solids dia. (mm) 100
Overall efficiency
40%
(not less than)
Submersible Pumping Unit:

The pump motor shall be IP 68, tropically insulated with class “F” insulation and class
“B” temperature rise when the ambient air temperature is 45oC. The electric motor should
be designed to operate with supply voltage of 380 V, 3-phase, 50 HZ. Complete with
electric flexible rubber cable with watertight cable entry and plug. The motor winding
and bearing shall be provided with PTC temperature detectors. The motor excess power
shall be 20% of maximum power absorbed during working range according to Egyptian
code.
Page 37 of 64
2.5.2.1. Pump casing

The pump casing shall be close grain cast iron GG-25, fitted with renewable high resisting
stainless steel rings to take up the wear (if applicable) between it and the impeller. The
interior surface of the cover shall be shaped to maintain the contours of the internal
surface of casing and bend to which it is attached so as to maintain efficiency and to
prevent the lodging of solids.
2.5.2.2. Impeller
The impeller shall be made of close grain DI GGG 50 or GGG 40 with special additives
to be able to resist action of sewage gases, sand and silt contained in sewage water. It
shall be carefully statically and dynamically balanced and machined wherever accessible.
It should be channeled impeller and shall be with wide suction waterways with smooth
contours. It shall be fitted with renewable high resisting stainless steel rings
corresponding to those renewable rings fitted to casing.
2.5.2.3. Shaft and shaft bearings

The pump shaft shall be made of stainless steel. It shall have cross section & number of
bearings enough to avoid having any critical speed occurring at or near the normal speed
and strong enough to absorb any forces at any condition of loading. The bearing life
should be 100 000 hours. Sealing of pump shall be double mechanical seal made of silicon
carbide or tungsten carbide, the space between two mechanical seals shall be filled with
oil.
The velocity at the suction of the pump must not exceed 4 m/s.
2.5.2.4. Pump accessories

Each pump shall be delivered with all the necessary equipment including, but not limited
to the following:
One set of quick coupling
One discharge elbow
Pump guide bars
All necessary fitting required for successful erection and running
2.5.2.5. Identification of pumps

Stainless steel name plates shall be attached to each pump. This shall be stamped with the
manufacturer’s name, model number, capacity in liters per second, head in meters, speed,
serial number, and other pertinent data, in English.
2.5.2.6. Motors
2.4.2.6.1. Type of motors
Unless otherwise specified, the driving motors shall be low voltage squirrel cage
induction motors. The motors shall be totally enclosed. The construction of the motors
shall be according to the latest IEC motors specifications with thermal protection for
bearing and coils.
2.5.2.6.2. Degree of protection

The degree of motor enclosure protection shall be IP 68.
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2.5.2.6.3. Rating
The motor shall be operated at 380V, 3-phase, 50 Hz, in accordance with the requirements.
The motors shall be suitable for minimum 10 starts per hour.
The rated speed shall be equal to the pump speed and not exceeding 1500 rpm.
Power factor shall not be less than 80%.
2.5.2.6.4. Constructional features for motor

The pump motor shall be squirrel-cage, induction. The enclosure protection shall be to
the IEC requirements for submersible motor. The stator winding and stator leads shall be
insulated with moisture resistant class “F” insulation with class “B” temperature rise or
class “H” insulation with class “F” temperature rise. The stator shall be dipped and baked
in varnish. The motor shall be designed for continuous duty, capable of sustaining a
minimum of at (10) starts per hour. At the design point the motor shall not draw more
than the nominal KW value at utility supply quality. The junction chamber, containing
the terminal board, shall be sealed from the motor by elastomer compression seal (O-ring)
connection between the cable conductors and stator terminal board and thus perfectly leak
proof. Thermal sensors shall be used to monitor stator and rotor temperatures. The stator
shall be equipped with three (3) thermal sensors, embedded in the end coils of the stator
winding (one in each stator phase). These shall be used in conjunction with and
supplemental to external motor protection and wired to the control panel to trip the motor
under overheating conditions.
Page 39 of 64
Part 2
Section 6
Piping system, gates, and valves
2.6.1. General
All pipes, valves and specials pieces shall comply with the requirements of ISO 2531,
ISO 5996 and Egyptian standard specifications of 971 at 1991 with PN 6 or PN10. These
shall be treated internally and externally with an approved anti-corrosive composition and
protected according to ministerial decree number 277 for year 2000 and its appendix
number 14 for year 2002. Also shall be according to approved soil report. Pipes passing
through the walls shall have proper sealed puddle flanged pieces.
2.6.2. Pipe works

The contract shall include for the provision and installation of a complete set of ductile
iron DCI. GGG50 or GGG40 pipe work (k9) & (k12) type for fittings associated with the
equipment, all as generally indicated on the drawings.
The delivery pipe of each pump shall be provided with a non-return valve and a sluice
gate valve with the necessary pipes and special pieces.
The delivery pipe of each Air blowers shall be provided with an elec. actuated butterfly
valve and a dismantling joint with the necessary pipes and special pieces.
After works testing, the pipe work shall be coated inside with an approved bituminous
solution. Bids shall include the provision of a complete set of bituminous materials
including full faced rubber insertion rings, black mild steel bolts, washers and nuts.
All necessary pipe supports shall be included either in the form of hangers, brackets or
stub joints. All pipe-work shall be adequately clamped to the supports by “u” bolts or
similar approved fixings. The pipe-work shall be so designed and installed that no load
wither in the form of hydraulic thrust or dead weight loads are transmitted to the pump
flanges or casing or other machinery. Duck foot bases shall be drilled for holding down
bolts.
Bidders shall ensure that all fittings in the form of pumps, valves, flow-meters, etc. shall
be readily removable without disturbing “built-in” puddle pipes. This shall be achieved
by means of flexible couplings, flange adapters or other approved devices.
The contract shall include for supply of a sufficient number of double flanged and drilled
dismantling pieces to facilitate the removal of all valves, flow meters,…etc. where
specified.
2.6.3. Schedule of pipes

The contractor is responsible to furnish and install all piping, special pieces fittings and
accessories necessary for the plant.
Contractor is responsible for connect all pipes, off-loading, storing on construction site,
transport within the site, trenching, bedding, pipe-laying, jointing and backfilling shall be
the responsibility of the contractor. Any defect found during testing shall be made good
and the test shall be repeated at the expense of the contractor until a successful test is
Page 40 of 64
obtained. The total length of all interconnecting pipes between all units should be
reviewed and measured from the final layout prepared by the contractor.
2.6.4. Valves
The water velocity through valves should not exceed 2 m/s and the contractor shall review
pipe diameters which achieve the required velocity.
A. Sluice valves
Sluice valves shall be of the double flanged wedge gate type with non-rising spindles ,
with working pressure 6 bar and test pressure 10 bar with PN 6 or PN10.
They shall have cast iron DCI GGG 50 or GGG40 body, wedge, bonnet, gland and spindle
made of stainless steel.
Facings on wedge and body shall be of bronze or gunmetal.
The valves shall be arranged for clockwise closing by cast iron GG25 hand-wheel.
Where necessary, overhead valves shall be provided with chain wheels to enable the
valves to be operated from working level.
Extension spindles of mild steel and guide brackets shall be provided where necessary.
Guide brackets shall be “BOLT ON” pattern complete with fixing bolts. Tenderers shall
allow for brackets which provide not less than 150 mm clearance between pipe flange to
valve joint and wall face.
Where head stocks are required these shall be cast iron with guide column mounted on
foot plate brackets and shall incorporate valve position indicators. Hand wheels may be
mounted directly on the valves, and where hand wheels are mounted on spindles they
shall be positioned 150 mm above the coping level or more according to drawings. Key
heads shall be of the removable type and where fitted on spindles they shall be positioned
so the top of the key head is 74 mm below ground or coping level.
The prices for valves and pen-stocks for key operation shall include for the provision of
suitable operating keys.
Mains isolating valves sited within external valve chambers shall be flange coupled to the
rising main in order to retain the static head within the main.
Where valves are installed in horizontal pipe runs, they shall be provided with their own
supports and shall not be supported by the pipe work.
B. Butterfly valves
Butterfly valves shall conform to PN 6 or PN10.
Except where otherwise specified, all butterfly valves shall be resilient seated and shall
give tight closure against unbalanced water pressure in either direction.
The valve seat shall be replaceable and be formed of rubber or other approved resilient
and durable material. The valve seat shall be securely clamped into a machined groove in
the valve body or to the edge of the disc by seat retention members, or other equivalent
retention device, in such a manner as to prevent leakage of water under the seats and to
hold the seat securely in position during opening and closing of the valve disc.
The seat retention members shall be of stainless steel; shall be securely fastened to the
body or disc with stainless steel fasteners.
Disc edges shall be machined with rounded corners and shall be polished to a smooth
finish. The valve disc shall rotate through an angle of 90 degrees from the fully opened
Page 41 of 64
to the fully closed position and the seat shall be of such design as to allow the valve disc
to seat at an angle normal to the axis of the pipe when the disc is in the fully closed
position. Adjustable mechanical stops shall be provided in the valve body or the valve
operating mechanism to prevent over-travel of the valve disc in both the open and closed
positions. These stops shall be capable of absorbing full operating torque with a minimum
design safety factor of five.
The shaft shall be fabricated of stainless steel and may be in one piece or attached as two
stub ends on opposite sides of the disc. The means of attachment of the shaft to the disc
shall be using fixings in a homogeneous corrosion-resistant material of a pattern which
precludes the assembly becoming loose in operational service. Grub screws, pins (parallel
or taper) or clamp will not be acceptable. The shaft and disc fixing shall be capable of
absorbing the full operating torque with a minimum design safety factor of five. Shaft
seals, when used, shall be rubber O-ring type. Packing shall be either rubber O-ring or
self adjusting chevron type.
When all the seat retention members are in place, the finished edges shall fit closely and
the surface shall be smooth with all fastenings set flush in the water passage so as to offer
the least resistance possible to the flow of water through the valve.
Valve seats which extend over the face of the flanges to secure the seat in place, or which
require surface grinding and/or hand fitting of the disc; or designs which require the
adjoining pipe flange to retain the seat in place and resist line pressure, will not be
acceptable.
Operating gear for butterfly valves shall be of the fully enclosed type. Valves shall be
suitable for operation by one man at all pressure conditions that can apply. A valve
position indicator shall be provided, where a hand wheel is used for operating the valve,
the indicator shall be clearly visible from the hand wheel operating position.
All butterfly valves shall be tested at the manufacturer's works in accordance with BS
5155 and under "open end" conditions. The seat test shall be for tight closure under
maximum unbalanced water test pressure in either direction. The maximum permissible
leakage for each valve shall be 0.5 per liter per hour per 100 mm nominal diameter of the
valve.
The contractor shall provide details of the materials of manufacture and design of
butterfly valves, and shall provide evidence to show that the proposed seating materials
and seating designs have given satisfactory performance in similar conditions to those
applying under the contract.
Valves shall carry identification marks and/or plates in accordance with the British
Standard and those for use on process plant shall carry an additional brass plate carrying
valve identification and a brief description of its function.
All nuts and studs subject to vibration shall be fitted with spring washers or locking tabs.
All valves and operating linkage shall be prepared and painted in accordance with the
General Specification for Painting and Protective Coating.
All material used in manufacture of butterfly valves shall conform to the following
minimum standards:
Body and Disc Ductile Cast Iron GGG50 or GGG40
according to ISO 2531.
Shaft Stainless Steel to BS 970 Pt.4
Page 42 of 64
Sealing Ring & Seat Gunmetal to BS 1400 Grade LG2.

Seat surface Stainless steel 304
Rotating ring Stainless steel 304
Sealing ring EPDM
C. Non-Return Valves
These shall be swing type single door valves with an external operating lever. The door
spindles shall be suitable size such that excessive stress is not induced in it when operating
the valve by means of the external lever.
For valves more than DN 400 are with hydraulic damper and the other with arm and
weight.
Gunmetal or bronze facings shall be provided on both door and body. The spindle shall
be sealed by means of a bronze packed gland. Costs of special pieces, fittings and
accessories are included in the unit price and total value of the valves. Working pressure
6 bar and test pressure 10 bar with PN6 or PN10.
Body : Manufactured of ductile cast iron GGG50 or GGG40, of flanged

type.
Disc : Ductile cast iron GGG50 or GGG40 and provided with seal.
Seal bearing : Erected at disc made from rubber or any other material
suitable for operating purposes.
Shaft : Manufactured of high grade stainless steel.
Bearing : It shall bear the internal such as disc and pins, self-greased.
Thrust bearing : for shaft fixation, also for accurate disc position and protection
against displacement due to internal pressure.
Shaft seal : Shall be effected by O-rings.
The valve shall be provided with counter weight.
The valve shall be painted by a suitable epoxy paint (to protect against sewage water) of
quick dry type, adherable with its material and doesn't contain any soluble materials.
Non-return valves shall be mounted horizontally (or vertically if applicable) outside pump
chamber and shall have closing characteristics suitable for the delivery condition
specified and shall fully protect the installation against shock from reversed flow caused
particularly by a sudden power failure.
The disc shall seat at a suitable angle to the axis of the pipe and stops shall be provided
to permit the valve to open to an angle of 30 degree with the axis of the pipe.
The hinge pen shall be of stainless steel and shall be extended on packed glands of
adequate size and shall be extended on one side of the valves through bronze bushed
packed glands of adequate size and shall be fitted with mild steel external levers.
Page 43 of 64
Disc shall be positively secured to the spindles by means of keys, spleens or pins. Flaps
secured only by dimpled sets crews will not be accepted.
2.6.5. Air release valves

Air relief valves shall be DCI GGG 50 or GGG40 of double ball type and of approved
design and make. They shall be installed at the top point and be fitted with stop cocks or
valves to allow repairing without stopping the working of the mains. They shall be
arranged for automatic discharge of air accumulating when the pipeline is working.
These valves shall be capable of working under the actual pressure corresponding to their
places of different section of the project. They shall also be provided with an effective
cover drip tray and drain
2.6.6. Flexible joints

Flexible joints of approved make and design shall be provided for the pipes at the points
where these pipes cross the walls, all flexible joints shall be manufactured from cast iron
(GGG50 or GGG40)
2.6.8. Drawings
Fully dimensioned plant layout.

Foundation details showing all plinths, trenches, holes …etc. Required for
accommodation of the equipment, pipe work, valves and gates and confirming all
equipment loads.
Page 44 of 64
Part 2
Section 7
isolating gates
2.7. Penstocks (isolating gates)

The penstocks required shall be of the following types depending on location and design.
The contractor shall comment on the suitability of the equipment offered to carry out the
duty specified in his specification of plant offered: -
Rising stem, ST.ST. 304 penstocks, Rubber sealing Faces.
1. Gates
Gates shall be fabricated from ST.ST 304 slide gates with stainless steel stem, mounting
embedded in concrete, and furnished with all necessary accessories for a complete
installation, and shall be the latest standard product of manufacturer regularly engaged in
the production of equipment of this type. The same manufacturer shall furnish all slide
gates.
2. Cut-off gates
These shall be stainless steel stem. These gates shall be used on the inlet & outlet, of
screens, grit tank, inlet of aeration tanks, return sludge pumps.
The pen-stocks shall be installed at the entrance of pumping station, the contractor is
responsible for checking the number of gates, pen-stocks required as per tender
documents.
3. Guide frame
The embedded guide frame shall be of ST.ST 304 steel type:
The bearing bars must reduce the coefficient of friction to 0.125 from that of rubber
contact to reduce wear on the gate.
The self-contained guide frames shall be designed for a maximum rigidity and provided
with key-ways to lock the frame into the concrete. Guides for the embedded gates shall
have a weight of not more than pounds per foot, and shall contain bearing bars upstream
and downstream of the gate. The guides shall be sufficiently strong, so that no further
reinforcing will be required where the guides the operating floor.
The yoke to support the operating bench-stand will be formed by two welded at the top
of the guides to provide a one piece rigid frame.
4. Flush bottom invert

The invert of the frame will be stainless steel shall have a sight of not more than 2.5 lbs
per foot, will be provided with key ways to lock it into the concrete, and will be furnished
with a neoprene insert which shall function as a seating surface for the plate.
Page 45 of 64
5. Hand wheel operators

Operation of the gate will be by means of an anti-friction hand wheel bench-stand. The
bronze operating nut will be accurately machined and internally threaded to accept the
rising stem counterpart.
Maximum effort on the hand wheel shall not exceed 40 pounds pull to open or close the
gate.
6. Stem
The operating stem stainless steel will be connected to the plate by means of connector
bolted to the stem and welded to the plate and the top gate.
An adjustable stop collar shall be provided on each stem to limit both upward and
downward travel on gate systems.
7. Full open gate

Each gate system will be designed to open fully above the maximum water level.
Page 46 of 64
Part 2
Section 8
Ancillary equipment
This section includes the manufacture, delivery, installation, testing, putting into
commissioning, guarantee and maintenance (during the guarantee period) of the ancillary
equipment’s complete with all accessories and spares as described in the following
clauses:
2.8.1. Requirements
- Ventilators for the air blowers building.
- Cranes for RAS Pump station and air blowers building.
- Firefighting equipment.
2.8.2. Equipment
2.8.2.1. Ventilators
A- general
Ventilating fans shall be of the type and arrangement indicated on the Hyd. drawings and
specified herein. All fans shall be rated and constructed in accordance with VDE/DIN.
Fans shall be furnished completely with motor, drive equipment, vibration isolators,
supports, appurtenances, and disconnect switches.
Direct driven fans shall have the fan wheel mounted on an extension of the motor shaft.
The motor shall be mounted in a rigid streamlined frame designed to provide vibration
isolation for the motor and so that the wiring can be run to the motor unexposed.
B- Axial fan (wall mounted)

Axial fans shall be supply or exhaust type for high pressure industrial use.
Fans blades shall be designed to ensure low noise high volume of air flow and high
efficiency.
Fans shall be directly coupled with motor and fan and motor assembly shall be supported
by heavy metal frames.
Fans shall be fabricated from galvanized (protected) steel sheets, frame shall be fabricated
from galvanized (protected) steel sheets specified above. The frame, shaft, bolts and nuts
and other parts shall be of stainless steel.
Unless otherwise specified automatic louvers shall be provided with all propeller fans.
An automatic louver shall be gravity shutters and shall be factory fabricated of parallel-
blade type with delicately balanced blades that open automatically when the fan starts and
close by gravity when fan stops. The louver blades shall be fabricated from aluminum
sheets the blades shall be provided with felt or rubber strips to prevent rotating louver
blades shall be supported on aluminum frames and shall be connected to a vertical bar so
all blades open equally.
Page 47 of 64
Fixed louvers of outdoor rain hoods shall be provided fixed louvers shall be parallel-blade
type and fabricated from aluminum sheets.
Supply fans shall be designed to suck fresh air to inside the room and exhaust fans shall
be designed to discharge air from the room.
Motors shall be totally enclosed fan cooled with class b insulation, and rated for an
ambient operating temperature of 45 degree C. Enclosure shall be IP44 or IP54.
Outdoor rain hoods shall be of type 304 stainless steel end shall have sufficient opening
area. Automatic louvers fixed louvers and outdoor rain hoods shall be supplied by the
same manufacture as that of fans.
Equipment and component items when fabricated form ferrous metal they shall be factory
finished with epoxy resin paint of manufacturer’s standard.
E- Requirements
The ventilators shall be capable for changing air according to Egyptian code with air
change rate = 10 times per hour, and the contractor shall be responsible for submitting all
required calculations and detailed drawings for ventilation process. The temperature
inside appointed spaces shall not exceed 5oC over ambient temperature but not less than
the following specifications, and the ventilation of Air blowers building shall be
according to the specifications of the Egyptian code or equivalent.
N.B.
- All fans shall be provided with either integral or supplementary vibration and sound
absorbing mountings.
- Fan wheel and casing inside and outside for the supply and exhaust fans for the pump
station shall be given an acid – resistant coating of eisenheiss, lithcote, heresite or
acceptable equivalent corrosion-resistant coating. The types and numbers of fans to be
installed in the different buildings are shown in the table below:
Location No of units Capacity of each fan

Air blowers Building 4 5000 m3/h
Equalization pump building 2 3000 m3/h
2.8.3. Cranes
Cranes shall be supplied and erected as follows:
Location Type Capacity

Air blowers Building Monorail Crane (6 motions) 5 Ton
Equalization pump building Monorail Crane (6 motions) 2 Ton
RAS Pump Monorail Crane (6 motions) 2 Ton
The capacity of the traveling crane is at least as specified in the technical data schedule
and shall be able to lift complete pumping unit and the heaviest part of the machinery
supplied with safety factor 20% excess load.
Page 48 of 64
The travelling crane shall be complete with rails, stops, fastenings... etc, required for the
construction of the track. The bridge girders shall be one in number and shall be designed
so as to have on permanent set when the crane is subjected to a test-load 20% in excess
of the working load applied at the center of the span.
The two end carriages shall have double flanged travelling wheels of suitable diameter
fitted with ball bearings. The crane shall have electrical lifting and lowering motions, the
remaining possible motions are manual.
There shall be one crab running on rails secured to the top flanges of the bridges and the
travelling wheels of same shall be fitted with ball bearings. The crab shall have hoist of
its capacity and the hoist shall have an automatic brake in its gear to sustain full working
load at any point. The lifting chain shall be of sufficient length to enable lifting equipment
from floor of pump room, and shall be proof tested to75% above the working load. The
lifting hook shall be of forged steel with hardened steel balls under the head.
Electrically Hoisting Equipment

The capacity of the hoist shall be permanently marked in a conspicuous manner. All hooks
shall be safety type.
Hoists shall be factory tested before shipment with a load at least 25% greater than the
rated capacity.
The contractor shall be responsible for prime and finish painting of all metal members
and exposed metal work except for working and lubricated surfaces. Labels, signs or
identification plates shall not be coated.
Hooks shall be of high grade, forged steel and shall have swivel anti friction bearings.
Drums and Hoisting Rope or chain: -

Cable drums shall be all steel, fabricated from heavy wall pipe or tubing. Drums flanges
shall be steel plate or casting and shall act as guards to prevent cable fouling.
Drum flanges shall be of ample capacity. Not less than two complete wraps of rope shall
hook through its rated lift distance. The rope drum pitch diameter should not be less than
18 times the diameter of the rope used. Hoisting cables shall be improved or extra plow
steel with performed strands to reduce load block twist. The rated load divided by the
number of parts of the rope shall not exceed 20 percent of the nominal breaking strength
of the rope. The rope ends shall be attached to the hoist in a manner preventing
disengagement throughout rated hook travel.
Hoist Frame
Hoist frame shall be all steel fabricated, jig milled for accurate alignment of all
components. The hoist frame shall be designed to carry the entire load. Frame shall be
designed so that the static stress, calculated for the rated load shall not exceed 20 percent
of the average ultimate material strength.
Bearings
Roller type thrust bearing shall be used on the hook, all other bearing shall be of the ball
type. All bearings shall be either pressure lubricated or double-sealed lifetime lubricated
except for bearing in the gear case which shall be splash lubricated by the oil reservoir.
Page 49 of 64
Load Break
A self-adjusting mechanical brake of the Weston type multiple disc design shall be
integrated into the hoist mechanism, to control lowering speeds and arrest.
2.8.4 Firefighting Equipment

5 No. Hand portable fire extinguishers, 6 kg capacity dry powder multi-use suitable for
fighting fire of all classes A, B, C, D, E (up to 1000 V).
The extinguishers to be pressure actuated and provided with pressure indicator.
It should comply with Egyptian standard specifications No. 743 issued on 1976.
It should be provided with means for ON and OFF operations during fighting.
It should be capable of controlling fires at the early seconds of setting ON.
The set should fulfill the requirements to the law No. 58 issued on year 1973.
The extinguishers shall be carried on suitable brackets.
Location No Off Weight (kg)

Air blower buildings 3 6 kg
Equalization pump building 2 6 kg
Page 50 of 64
Part 3
Tests and trials
Page 51 of 64
Part 3
Tests and trails
3.1.General
The requirements of special tests on equipment and materials are dealt with below. Unless
clearly stated in these specifications, the nature, procedure and details of these tests shall
be in accordance with the latest standard specifications of the country of manufacture.
All tests shall be carried out in the presence and subject to the control of the owner
delegate at works and the owner engineer at site except in specified or approved cases
where test certificates shall be accepted.
Three copies written in English of all testing standards and procedures shall be submitted
to the owner before execution of tests.
The acceptance of the contractor’s tender including his design, specifications and
drawings shall not bind the owner to accept any of the contract works until they have
passed the tests prescribed and have been approved by owner in writing.
3.2. Expenses
The expenses of all tests carried out during manufacture and at works shall be included
in the prices of the equipment.
3.4. Calibration of instruments

All instruments used for the purpose of testing shall be approved, and shall be calibrated
by a rrecognized official laboratory which must be approved by the owner.
N.B Units of measurements

All units used in the tests shall follow the kilogram-meters second system.
The units shall be those defined in the international standards.
3.5. Tests of materials and machinery at works

The owner’s representative shall have the right to make or cause to be made, either at the
works of the contractor or at the works of any firm which the contractor obtains materials
or machinery to be supplied under this contract, all such tests and trails as may, in his
opinion be necessary to enable him to satisfy himself that the whole material, machinery
and equipment conform with the specifications in all respects and that the guarantee given
by the contractor have been or will be fulfilled two sorts of tests shall be made, namely:
A- type tests to verify the characteristics and performance of equipment and
material.
B- routine tests to eliminate defective equipment and material.
Three copies of all-testing standards procedures and certificates shall be submitted to the
employer.
Page 52 of 64
Part 4
Sample
Design data tables
Page 53 of 64
Part 4
Design data tables
Table no. 1 : screening equipment
Type of screen and make

Width of screen min.
Depth of screen mm.
Clear space between bars mm.
Upstream face width of screen bar mm.
Downstream face width of screen bar mm.
Method of racking
Signature
Page 54 of 64
Table No: 2
a. Pump Data:
- Type of pump ---------------------------------------
- Maker’s name ---------------------------------------
- Rating: pump will discharge at ------------- meters
Manomemtric head ------ lit/sec.
At -------- r.p.m. Absorbing ----- B.H.P. on pump
Shaft with a manometric efficiency -------- percent.
- Diameter of suction opening at pump casing ---- MM.
- Material from which casing is made -----------------
- Inner diameter of impeller -------------------- MM.
- Outer diameter of impeller -------------------- MM.
- Material from which impeller is made ---------------
- Water velocity at end of discharge pipe at maximum discharge ------- m/sec.
- Minimum diameter of impeller shaft ------------ MM.
- Overall length of impeller shaft -------------- MM.
- Material from which impeller shaft is made ---------
- Number of bearing on which pump shaft is supported -------
- Type of bearing and method of lubrication ----------
- Dimensions of protecting sleeves --------------- MM.
- Width of bearing ------------------------------ MM.
- Material from which protecting sleeves are made ----
- Description of staffing boxes used -----------------
- Description of water sealing glands used -----------
- Description of coupling used -----------------------
- Weight of one complete of pump ---------------- kg.
- Weight of water filling of the pump ----------- kg.
b. Pump valves “Data”:

- Marker’s name --------------------------------------
Data Suction / non-
delivery return
* Type of valves
* Number of valves per pump
* Diameter of opening in MM.
* Materiel of facing and sealing.
* Total weight of valves in kg
* Working pressure in atmospheres
N. Test pressure in atmosphere
Disk being open
Disk being closed
Page 55 of 64
c. Pump motor
- Maker’s name ---------------------------------------
- Type of motor --------------------------------------
- Normal output at 100% load of motor --------- B.H.P.
- Speed at full load and discharge of pump ---- R.P.M.
- Percentage slip at 100% --- 75% --- 50% --- load –
- Voltage between terminals ------------------- volts.
- Value of starting current -------------------- amps.
- Current at normal output of pump ------------- amps.
- Efficiency of motor at working load ----------------
- Power factor ---------------------------------------
- Temperature rise of windings and core --------------
- Class of insulation --------------------------------
- Weight of motor complete ---------------------- kg
N.B One H.P. = 0.75 Kw.
Date: / /
Signature of Tenderer
Page 56 of 64
Table No : 3
Submersible pumping units (for each type)
Marker’s name
Type of pump
Rating: ……………………………l/s
Pump will discharge … liters/second of sewage water at total manometic head….m,
and at …. R.p.m consuming ……. b.h.p ………
Number of stages
Inner diameter of impeller ……………………………………. mm
Outer diameter of impeller……………………………………. mm
Width of impeller at periphery……………………………………. mm
Number of impeller vanes……………………………………. mm
Thickness of vanes:
a- At boss ……………………………………. mm
b- At tip ……………………………………. mm
Total weight of pumping units
Enclosure (pump and motor)
Impeller data:
Pump Part Vane Angle Width of passage Water Velocity
between the in met/sec
vanes in mms
Material from which impellers are made ........... ....... ....... ....... ....... ......................
Maximum diameter of solids that can pass through pump ....... ....... ..... ........ mm.
Diameter of impeller shaft:
a) At the impeller ................................ ....... .. .........................................mm.
b) At the bearings ................…………...................................
Page 57 of 64
Table no. 4 :
Design Data for-Air Blower
Blower: type :
makers name :
Type and size of blower :
Type and size of electric motor :
Diameter of blower : mm
Speed of rotation : R.P.M.
Nominal power of impeller : K.W.
Weight : KG.
Type reduction gear :
Gear ratio :
Speed of electric motor : R.P.M.
Type of motor enclosure :
Type of motor insulation :
Nominal motor output power at standard conditions (IEC) HP.
Signature
Page 58 of 64
Part 5
Sample
Guarantee tables
Page 59 of 64
Part 5
Guarantee tables
Table No. 1 : air blower

Make:
Type:
Discharge Sm3/hr
Pressure difference bar
Speed of rotation r.p.m.
Shaft horsepower (at full load) HP.
Power absorbed by the unit (at full load including gear-box and motor losses). If any
N.b.
We guarantee the above performance of the blower unit we are offering, at standard
conditions.
Data: / /
Signature of tender
Page 60 of 64
Table No. 2 : electric motor of air blower
Make:
Type:
Temp. Rise class:
Insulation class:
Protection class:
Volt:
Hertz:
Ampere at nominal discharge:
Power factor:
Efficiency:
Max. Temperature of any part of motor being run as spec:-
Load Percentage % 100 75 50 25 0

Output in B.H.B.
Efficiency %
Input in kW measured on switchboard
Power factor
Current amp
Temperature rise
I H.P = 75 kg.m./sec
N.b.:
We guarantee the above performance of the blowers we are offering, at site
conditions.
Data: / /
Signature of tender
Page 61 of 64
Table No. 3 : pumps
(A)Guarantee table for pumping units
(For each type)
Make and type
Total manometric head (m)

Discharge liters/sec.
Speed of unit r.p.m
Water horsepower
Manometric efficiency of pump %
Shaft horsepower
Efficiency of driving motor %
Input to motor in K.W. measured on the
switchboard.
Overall efficiency of unit percent =
W.H.P.H. 0.746
-----------------------------
K.W.H. at Switchboard
We guarantee the above performance of the motor pumping units we are offering at
site conditions
Date: / /
Tender's Signature
Page 62 of 64
(B) Guarantee table for pump
Make: type:
Manometric head in meters m

Discharge in Lit/sec
Speed of pump
Manometric Efficiency of pump %
Water Horse Power B.HP
Power Absorbed by the pump B.HP metric
(C) Guarantee table for Motor
Make: type:
Motor drive:
Load Percentage % 100 75 50 25 0

Output in B.H.B.
Efficiency %
Input in kW measured on switchboard
Power factor
Current amp
Temperature rise
I H.P = 75 kg.m./sec
We guarantee the above performance of the motor pumping units we are offering at site
conditions
Date: / /
Tender's Signature
Page 63 of 64

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2021 03 09 Mechanical Specs

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‫جمهورية مصر العربية‬

‫وزارة االسكان والمرافق والمجتمعات العمرانية‬

‫الميديا للمعالجة البيولوجية‬

‫‪Hawamdeya WWTP Extension, Capacity 20,000 m3/day‬‬

Part 4 Design data tables 53

Part 5 Guarantee tables 59

1.1. Brief description of works

Description process treatment

1.3. Design data

1.4. Waste water characteristics

BOD5 500 mg/l

Effluent water characteristics:

The treated effluent should be clear and odorless.

1.5. Repair of damaged coatings:

1.5.1. Usage for different types of protection.

1.5.2. Painting general

1.5.3. Surface drone

Type “a” protection thoroughly clean and degrease.

Type “b” protection thoroughly clean and

Type “d” protection thoroughly clean

Bituminous coated thoroughly clean of superficial dirt.

Non- ferrous metal thoroughly clean and degrease

1.5.4. Finishing paint at contractor’s work

1.5.5. Painting at site during installation

1.5.6. Type of final painting

D) Motors, starters, panels, pumps … etc….

The automatically operated mechanically cleaned screens shall be installed in the

Mechanical (Multi Rake type) coarse screen components:

The screen bars

The raking mechanism

Rack wiper and dead plate

This part helps captured screenings to drop to a conveyor or a container. It is made of

Screen operating system:

Mechanical Fine Step Screens:

Mechanical Fine Screens

Mechanical Fine Screens

Drawings & Documents

The following shall be submitted:

The following shall be included in the OWNER'S MANUAL:

Manually Cleaned Screen

Screening Collection Skips

Isolating gates for screening chambers

2.2.1 Brief Description of the Works

2.2.2. Tank details

Q. Design (m3/s ) 0.578

Estimated sand Removal Efficiency: 80% for sand > 0.2 mm

Bottom & surface scraper lifting mechanism:

Scrapers Bridge Control Cabinet

Electric Feeding to the Bridge

2.2.4. Sand Air lifting pumps

2.2.5. Aeration equipment

2.2.6. Air supply system

F. Oil and Grease Removing Equipment

2.2.7. Sand pipes and valves:

2.2.8. Isolating gates

2.2.9. Schedule of drawings:

2.3.2. Capacities and permissible loading

2.3.3. Number of units

Additional freeboard or windbreaks may be necessary to protect against freezing or

2.3.4 Aeration Process Control:

2.3.5 Aeration systems

2.3.6. Aeration equipment

2.3.7. Tank details

2.3.10. Aeration Pipes and diffuser