0000 REP JJ 0003 - Detailed Design Report & Appendices

Contract No FIPAG/
WASIS II/CON 15A/18
Design of Tete Boreholes,

Water Treatment Plant and
Pump Stations
Draft Detailed Design Report
Fundo de Investimento e Património do

Abastecimento de Água (FIPAG)
Submission date: 2021/09/30
Document
Reference: number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30
1001069-0000-REP-JJ-0003 1
Revision: A
Document control record
Document prepared by:
Zutari (Pty) Ltd
Reg No 1977/003711/07
Riverwalk Office Park, 41 Matroosberg Road,
Ashlea Gardens, Extension 6, Pretoria
South Africa
PO Box 74381, Lynnwood Ridge 0040
T +27 12 427 2000

F +27 86 556 0521
E tshwane@zutari.com
A person using documents or data accepts the risk of:

Using the documents or data in electronic form without requesting and checking them for accuracy against the original hard
copy version.
Using the documents or data for any purpose not agreed to in writing by.
Document Control
Project name Design of Tete Boreholes, Water Treatment Plant and Pump Stations
Document number 1001069-0000-REP-JJ- Project number 1001069

0003
Client Fundo de Investimento e Património do Abastecimento de Água (FIPAG)
Client contact Adelaide Carlos Client reference FIPAG/WASIS II/CON-15A/18
Rev Date Revision details/status Author Reviewer Verifier Approver

(if required)
A Draft for client review J Calitz P. Lehener S. Kleynhans

I van der Junior
Merwe B
S Edlmann Theunissen
L Ingle
J Daniels
K O’kennedy
Current revision A
Approval
Author signature Approver signature
Name John-Bert Calitz Name Stephan Kleynhans
Title Associate Title Technical Director
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 i

Executive Summary
The Executive Summary will be completed as part of the final Detailed Design Report.
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 ii

Editorial Note
In terms of the Request for Proposal document, a draft (interim) and final Detailed Design Report must
be submitted as deliverables. This report is the draft Detailed Design Report, which is updated as
progress is made with the detailed design. As such, some sections in the report are still in draft or
incomplete. Where this is the case, a comment has been inserted in blue text.
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 iii

Contents
1 Introduction ........................................................................................................................................1
1.1 Background ....................................................................................................................1
1.2 Project Scope and Deliverables .....................................................................................1
1.3 Project Area ....................................................................................................................1
1.4 Structure of Report .........................................................................................................2
2 Preliminary Design Report Decisions .............................................................................................3

3 Site Investigations and Development..............................................................................................4
3.1 Site Investigations ..........................................................................................................4
3.2 Bulk Earthworks ..............................................................................................................4
3.3 Roads and Paving ..........................................................................................................4
3.4 Stormwater .....................................................................................................................5
3.5 Water Network ................................................................................................................5
3.6 Sewer System ................................................................................................................5
3.7 Ducting ...........................................................................................................................5
3.8 Boundary Walls and Fencing .........................................................................................6
4 Detailed Structural Design ...............................................................................................................7

4.1 Structural Design Codes.................................................................................................7
4.2 Design Loadings .............................................................................................................8
4.3 Key Design Criteria .........................................................................................................9
4.4 Special Design Considerations for Reservoir .............................................................. 10
4.5 Concrete Materials ...................................................................................................... 10
4.6 Concrete Cover to Reinforcement ............................................................................... 11
4.7 Reinforcement ............................................................................................................. 11
4.8 Structural Steel ............................................................................................................ 12
4.9 Design Working Life .................................................................................................... 12
4.10 General Building Items ................................................................................................ 12
5 Wellfields ......................................................................................................................................... 13
5.1 Wellfield Configuration................................................................................................. 13
5.1.1 Nhartanda Wellfield ...................................................................................... 13
5.1.2 Revubue I Wellfield....................................................................................... 14
5.1.3 Revubue II Wellfield...................................................................................... 15
5.2 Borehole Safe Yields ................................................................................................... 16
5.3 Pump Duties ................................................................................................................ 18
5.4 Waterhammer Analysis ............................................................................................... 22
5.4.1 Nhartanda Wellfield ...................................................................................... 22
5.4.2 Revubue I Wellfield....................................................................................... 23
5.4.3 Revubue II Wellfield...................................................................................... 23
5.5 Civil Design .................................................................................................................. 23
5.5.1 Pump Control Houses .................................................................................. 23
5.5.2 Boreholes ..................................................................................................... 26
5.5.3 Fencing ......................................................................................................... 28
5.6 Mechanical Design ...................................................................................................... 29
5.6.1 Equipment Arrangement............................................................................... 29
5.6.2 Pumps........................................................................................................... 30
5.6.3 Riser pipes .................................................................................................... 31
5.6.4 Pipework ....................................................................................................... 31
5.6.5 Valves ........................................................................................................... 33
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 iv

5.6.6 Flow Meter .................................................................................................... 34
5.6.7 Pressure Gauges .......................................................................................... 34
5.6.8 Flow Control ................................................................................................. 35
5.7 Electrical Design .......................................................................................................... 35
5.7.1 Electrical Scope of Work .............................................................................. 35
5.7.2 Electricity Supplies ....................................................................................... 35
5.7.3 Motor Control Centres .................................................................................. 37
5.7.4 MV and LV Cables ........................................................................................ 37
5.7.5 Earthing and Lightning Protection ................................................................ 38
5.7.6 Electrical Building Services .......................................................................... 38
5.8 Control and Instrumentation ........................................................................................ 38
5.8.1 General ......................................................................................................... 38
5.8.2 Control Narrative .......................................................................................... 39
5.8.3 Overall Control Network Architecture ........................................................... 41
5.8.4 Communication ............................................................................................. 42
5.8.5 Borehole Control and Instrumentation (C&I) Scope of Work ....................... 43
5.8.6 PLCs and HMIs ............................................................................................ 43
5.8.7 Field Instrumentation .................................................................................... 43
5.8.8 Radio Telemetry ........................................................................................... 44
5.8.9 Earthing and Surge Protection ..................................................................... 45
5.8.10 UPSs............................................................................................................. 45
5.8.11 HMI ............................................................................................................... 45
5.9 Sequencing of wellfield infrastructure .......................................................................... 45
5.9.1 Nharthanda wellfield sequencing ................................................................. 46
5.9.2 Revubue I wellfield sequencing .................................................................... 46
5.9.3 Revubue II wellfield sequencing ................................................................... 47
6 Water Treatment Works ................................................................................................................. 48

6.1 Water Quality ............................................................................................................... 48
6.1.1 Raw Water Characterisation ........................................................................ 48
6.1.2 Treatment objectives .................................................................................... 48
6.2 Flow and Treatment Capacity ..................................................................................... 49
6.3 Process Design ........................................................................................................... 49
6.3.1 Aeration ........................................................................................................ 50
6.3.2 Sedimentation ............................................................................................... 50
6.3.3 Filtration ........................................................................................................ 51
6.3.4 pH Adjustment .............................................................................................. 54
6.3.5 Disinfection ................................................................................................... 55
6.3.6 Future process enhancements ..................................................................... 58
6.4 Civil Design .................................................................................................................. 58
6.4.1 Operator-Centric Design Approach .............................................................. 58
6.4.2 General Design Requirements ..................................................................... 59
6.4.3 Architecture design ....................................................................................... 59
6.4.4 Structures and Buildings............................................................................... 61
6.4.5 Interconnecting Pipework ............................................................................. 68
6.4.6 Site Development ......................................................................................... 68
6.5 Structural Design ......................................................................................................... 72
6.5.1 Filtration and Sedimentation Structure ......................................................... 72
6.5.2 Machine Room Building................................................................................ 73
6.5.3 Chlorine Contact Tank .................................................................................. 73
6.6 Mechanical Design ...................................................................................................... 73
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 v

6.6.1 Introduction ................................................................................................... 73
6.6.2 Aeration ........................................................................................................ 73
6.6.3 Plate settlers ................................................................................................. 74
6.6.4 Filter equipment ............................................................................................ 74
6.6.5 Treated Water Pumpsets.............................................................................. 74
6.6.6 Backwash Pumps ......................................................................................... 75
6.6.7 Backwash Blowers ....................................................................................... 77
6.6.8 Pipework Sizing, Materials & Corrosion Protection ...................................... 77
6.6.9 Valves ........................................................................................................... 77
6.6.10 Lifting Equipment .......................................................................................... 78
6.6.11 Ventilation Systems ...................................................................................... 78
6.6.12 Chemical handling and storage .................................................................... 78
6.7 Electrical Design .......................................................................................................... 80
6.7.1 Electrical Scope of Work .............................................................................. 80
6.7.2 Electricity Supplies ....................................................................................... 80
6.7.3 Motor Control Centres .................................................................................. 81
6.7.4 MV and LV Cables ........................................................................................ 81
6.7.5 Earthing and Lightning Protection ................................................................ 82
6.7.6 Electrical Building Services .......................................................................... 82
6.7.7 Area and Road Lighting ................................................................................ 82
6.8 Control and Instrumentation ........................................................................................ 82
6.8.1 Control Narrative .......................................................................................... 82
6.8.2 WTP Control and Instrumentation (C&I) Scope of Work .............................. 83
6.8.3 PLCs and HMIs ............................................................................................ 84
6.8.4 Field Instrumentation .................................................................................... 84
6.8.5 Radio Telemetry and Networking ................................................................. 84
6.8.6 Control, Instrumentation and Data Cables ................................................... 85
6.8.7 Earthing and Surge Protection ..................................................................... 85
6.8.8 UPSs............................................................................................................. 85
6.8.9 SCADA and Reporting.................................................................................. 85
6.9 Sequencing of WTP Infrastructure .............................................................................. 87
7 Revubue II Pump Station and Reservoir ...................................................................................... 91

7.1 Design Flows ............................................................................................................... 91
7.2 Pump Duties ................................................................................................................ 91
7.3 Waterhammer Analysis ............................................................................................... 93
7.3.1 DN350 to Matema DC .................................................................................. 93
7.3.2 DN400 to Cruzeiro DC.................................................................................. 93
7.4 Suction Reservoir ........................................................................................................ 94
7.4.1 Layout ........................................................................................................... 94
7.4.2 Structural design ........................................................................................... 96
7.4.3 Inlet, Outlet, Scour and Overflow Pipework.................................................. 96
7.4.4 Chlorination system ...................................................................................... 97
7.5 Civil Design .................................................................................................................. 97
7.5.1 Pump Station Layout .................................................................................... 97
7.5.2 Building finishes ............................................................................................ 99
7.5.3 Site Development ....................................................................................... 100
7.6 Structural Design ....................................................................................................... 103
7.7 Mechanical Design .................................................................................................... 104
7.7.1 Pumps......................................................................................................... 104
7.7.2 Equipment Arrangement............................................................................. 108
7.7.3 Pipework ..................................................................................................... 111
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 vi

7.7.4 Valves ......................................................................................................... 112
7.7.5 Ventilation ................................................................................................... 113
7.7.6 Lifting equipment ........................................................................................ 113
7.8 Electrical Design ........................................................................................................ 114
7.8.1 Electrical Scope of Work ............................................................................ 114
7.8.2 Electricity Supplies ..................................................................................... 114
7.8.3 Motor Control Centres ................................................................................ 114
7.8.4 MV and LV Cables ...................................................................................... 115
7.8.5 Earthing and Lightning Protection .............................................................. 115
7.8.6 Electrical Building Services ........................................................................ 115
7.8.7 Area and Road Lighting .............................................................................. 115
7.9 Control and Instrumentation ...................................................................................... 115
7.9.1 Control Narrative ........................................................................................ 115
7.9.2 Revubue II Pump Station Control and Instrumentation (C&I) Scope of Work
.................................................................................................................... 117
7.9.3 PLCs and HMIs .......................................................................................... 118
7.9.4 Field Instrumentation .................................................................................. 118
7.9.5 Radio Telemetry ......................................................................................... 118
7.9.6 Control, Instrumentation and Data Cables ................................................. 119
7.9.7 Earthing and Surge Protection ................................................................... 119
7.9.8 UPSs........................................................................................................... 119
7.9.9 HMI ............................................................................................................. 119
8 Authorisation Processes ............................................................................................................. 120

9 Financial Considerations ............................................................................................................. 121
10 Project Programme ...................................................................................................................... 122
11 Conclusions and Recommendations ......................................................................................... 123
Appendices
Appendix A: Table of Comments – Preliminary Design Report
Appendix B: Waterhammer Analysis Report
Appendix C:
Appendix D:
Appendix E:
Appendix F:
Figures
Figure 1-1: Tete - Moatize Locality Map (adapted from https://www.bing.com/maps) .............................2
Figure 3-1: 10 ton, 9 m Long design vehicle (left) and typical road layer works ......................................5
Figure 5-1-: System Curve of Borehole Nhartanda 2 in Nhartanda Valley Wellfield ............................. 19
Figure 5-2: Isometric view of PCH ......................................................................................................... 24
Figure 5-3: Site layout for PCH-NHT-01 ................................................................................................ 25
Figure 5-4: Detail of watertight borehole installation (and well head) ................................................... 27
Figure 5-5: Roxtec Watertight Seal ....................................................................................................... 27
Figure 5-6: Proposed fencing at boreholes ........................................................................................... 28
Figure 5-7: Borehole Equipment Arrangement ...................................................................................... 29
Figure 5-8: Grundfos Multi-Stage Borehole Pump ................................................................................ 30
Figure 5-9: Proposed tie-in details of borehole pipework ...................................................................... 32
Figure 5-10: Proposed mechanical flow meter with opto-electronic sensor .......................................... 34
Figure 5-11: Bourdon type pressure gauge ........................................................................................... 34
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 vii

Figure 5-12: Typical MCC General Arrangement (NHT-MCC-01) ........................................................ 37
Figure 5-13: Tete BWS Control Architecture Overview ......................................................................... 42
Figure 5-14: Wellfield Control Architecture ............................................................................................ 45
Figure 6-1: Process configuration.......................................................................................................... 49
Figure 6-2: Filter false floor (left, Basiia Contracting) and Dual parallel lateral (right, Leopold Systems)
..................................................................................................................................... 52
Figure 6-3: pH Adjustment of Water ...................................................................................................... 55
Figure 6-4: Calcium Hypochlorite Chip Feeder Dosing System – 35 kg left and 200 kg right .............. 56
Figure 6-5: Scaling Inhibitor Prevention Mechanism ............................................................................. 58
Figure 6-6: Aeration structure isometric view ........................................................................................ 61
Figure 6-7: Sedimentation tank isometric view ...................................................................................... 62
Figure 6-8: Filtration structure plan view ............................................................................................... 63
Figure 6-9: Filtration structure isometric view ........................................................................................ 63
Figure 6-10: Chlorine contact tank isometric view................................................................................. 64
Figure 6-11: Administration building, new expansion shown in red on the right side ........................... 66
Figure 6-12: Administration building, new expansion with areas to be demolished shown in red ........ 67
Figure 6-13: WTP road layout ............................................................................................................... 69
Figure 6-14: WTP 9 m truck movement through the Site ...................................................................... 70
Figure 6-15: WTP 9 m truck reverse movement via entry though the Main Access Gate .................... 70
Figure 6-16: WTP 9 m truck reverse movement via entry though the Secondary Access Gate ........... 71
Figure 6-17: WTP 18 m truck reverse movement via entry though the Main Access Gate .................. 71
Figure 6-18: WTP Backwash Channel and Pipe ................................................................................... 72
Figure 6-19: Example of a horizontal split case pump configuration..................................................... 74
Figure 6-20: System and Pump Curves for Treated Water Pumps ....................................................... 75
Figure 6-21: System and Pump curves for Backwash Pumps .............................................................. 76
Figure 6-22: Example of Onsite forklift (Left) & Intermediate Bulk Container (IBC) (Right) .................. 79
Figure 6-23: Tete WTP Electrical Supply Block Diagram ...................................................................... 81
Figure 6-24: Tete WTP Control Architecture Diagram .......................................................................... 84
Figure 6-25: SCADA Process Overview Example ................................................................................. 86
Figure 6-26: Reporting Dashboard Example ......................................................................................... 86
Figure 6-27: Phase 1 - Decommissioning of existing infrastructure and laying temporary pipes ......... 87
Figure 6-28: Phase 2 - Construction of new structures / buildings ........................................................ 88
Figure 6-29: Phase 3 - Installation of new pipework ............................................................................. 89
Figure 6-30: Phase 4 - Construction of new structures / buildings ........................................................ 90
Figure 7-1: Revubue II Pump Station to Cruzeiro DC System Curves.................................................. 92
Figure 7-2: Revubue II Pump Station to Matema DC System Curves .................................................. 92
Figure 7-3: Isometric view of suction reservoir with chlorination building ............................................. 95
Figure 7-4: Isometric view of suction reservoir (roof not shown) ........................................................... 95
Figure 7-5: Operating level in suction reservoir ..................................................................................... 97
Figure 7-6: Isometric view of Revubue II pump station (View 1) ........................................................... 98
Figure 7-7: Isometric view of Revubue II pump station (View 2) ........................................................... 98
Figure 7-8: Revubue II Pumpstation Typical Bulk Earthworks Section ............................................... 100
Figure 7-9: Revubue II Pump Station Road Layout............................................................................. 101
Figure 7-10: Revubue II Pumpstation 9m Truck Movement to Northern end of Site .......................... 102
Figure 7-11: Revubue II Pump Station 9m Truck Movement into Pump Station's Access Door ........ 102
Figure 7-12: Revubue II Pump Station Stormwater Elements ............................................................ 103
Figure 7-13: Revubue II to Cruzeiro DC Pump Curves ....................................................................... 105
Figure 7-14: Revubue II to Matema DC Pump Curves ....................................................................... 105
Figure 7-15: Multi-Stage Pump Configuration ..................................................................................... 107
Figure 7-16: End-Suction Pump Configuration .................................................................................... 107
Figure 7-17: Cruzeiro DC Pump Arrangement .................................................................................... 108
Figure 7-18: Matema DC Pump Arrangement ..................................................................................... 109
Figure 7-19: Flow Meter and Scour Chamber Equipment Arrangement ............................................. 110
Figure 7-20: RVBIIPS-MCC-01 General Arrangement ....................................................................... 115
Figure 7-21: Revubue II Pump Station Control Architecture ............................................................... 118
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 viii

Tables
Table 5-1: Nhartanda Wellfield Configuration ....................................................................................... 13
Table 5-2: Nhartanda Borehole Position and Elevation ........................................................................ 13
Table 5-3: Revubue I Wellfield Configuration ........................................................................................ 14
Table 5-4: Configuration between Pipelines and Boreholes ................................................................. 15
Table 5-5: Revubue I Borehole Position and Elevation ......................................................................... 15
Table 5-6: Revubue II Borehole Position and Elevation ........................................................................ 16
Table 5-7: Nhartanda Wellfield Safe Yields ........................................................................................... 16
Table 5-8: Revubue I Wellfield Safe Yields ........................................................................................... 17
Table 5-9: Revubue II Wellfield Safe Yields .......................................................................................... 18
Table 5-10: Nhartanda Wellfield Borehole Pump Duties ....................................................................... 19
Table 5-11: Revubue I Wellfield Borehole Pump Duties ....................................................................... 20
Table 5-12: Borehole Pump Selection for Revubue II Wellfield ............................................................ 21
Table 5-13: Summary of Borehole Pumps for All Wellfields ................................................................. 21
Table 5-14: Positions of Pump Control Houses .................................................................................... 24
Table 5-15: Raised Platform Heights for Pump Control Houses ........................................................... 24
Table 5-16 Building finishes and materials for Pump Control Houses .................................................. 26
Table 5-17: Summary of Borehole Mechanical Installation Parts ......................................................... 30
Table 5-18: Summary of Borehole Pipework Parts for tie-in ................................................................. 32
Table 5-19: Maximum Demand and Transformer Sizes for the Wellfields ............................................ 35
Table 5-20: Standby Generator Sizes for the Wellfields ....................................................................... 36
Table 6-1: WTP flow volumes................................................................................................................ 49
Table 6-2: Sedimentation Design Criteria ............................................................................................. 51
Table 6-3: Filter Design Criteria............................................................................................................. 54
Table 6-4: Disinfection Target Log Removals ....................................................................................... 56
Table 6-5: Disinfection Design Criteria .................................................................................................. 57
Table 6-6: Tete WTP Chlorine Summary .............................................................................................. 57
Table 6-7 Building finishes and materials for Tete WTP buildings ........................................................ 60
Table 6-8: WTP Interconnecting Pipework ............................................................................................ 68
Table 6-9: WTP Internal Pipework ........................................................................................................ 77
Table 6-10: Chemical Storage and Dosing Supply ............................................................................... 79
Table 6-11: Chemical Dosing Piping ..................................................................................................... 80
Table 7-1: Revubue II Pump Station Design Flows............................................................................... 91
Table 7-2: Revubue II Pump Station Design Pump Duties ................................................................... 91
Table 7-3: Building finishes and materials for Revubue II Pump Station .............................................. 99
Table 7-4: Revubue II Pump Station Pump Selection ......................................................................... 104
Table 7-5: Expected Flow Ranges for Revubue II Pump Station ........................................................ 104
Table 7-6: Revubue II Pump Station Motor Sizes ............................................................................... 106
Table 7-7: Summary of Cruzeiro DC Pumps Mechanical Installation Parts ........................................ 108
Table 7-8: Summary of Matema DC Pumps Mechanical Installation Parts ........................................ 109
Table 7-9: Summary of Flow Meter and Scour Chamber Mechanical Installation Parts..................... 110
Table 7-10: Revubue II Pumpstation Pipework Pressure Ratings ...................................................... 111
Table 7-11: Revubue II Pump Station Pipe and Valve Sizing ............................................................. 111
Table 7-12: Ventilation Systems .......................................................................................................... 113
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 ix

List of Abbreviations
BWL bottom water level
DC Delivery Centre
DN nominal diameter
CML cement mortar lined
FIPAG Fundo de Investimento e Património do Abastecimento de Água
GA General Arrangement
GoM Government of Mozambique
ID internal diameter
km kilometre
m metre
masl metres above sea level
mbgl metres below ground level
MCC Motor Control Centre
m3/h cubic metre per hour
MD Ministry Diploma
Mℓ/d megalitre per day
NGL natural ground level
OD outer diameter
PFD process flow diagram
PLC Programmable Logic Controller
RFI Request for Information
SCADA Supervisory Control and Data Acquisition
SLD Single Line Diagram
TWL top water level
UPS Uninterruptible Power Supply
VSD Variable Speed Drive
WASIS Water Services and Institutional Support Project
WTP Water Treatment Plant
WTW Water Treatment Works
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 x

1 Introduction
1.1 Background
The International Development Association provided the Government of Mozambique (GoM) with
funding for the Water Services and Institutional Support Project II (WASIS II), with the objective of:
(i) Improving the performance, sustainability and coverage of water supply services in the
five cities of Beira, Dondo, Tete, Moatize and Pemba; and
(ii) Strengthening institutional and regulatory capacity for water supply services in the
Northern, Central and Southern Regions of Mozambique.
Part of the WASIS II funding was allocated to Contract No.: FIPAG/WASIS II/CON-15/18) for the
‘Design and Supervision of Rehabilitation and Construction of Electro-Mechanical Equipment
of Boreholes, Water Treatment Plant and Pumping Stations, Tete. Fundo de Investimento e
Património do Abastecimento de Água (FIPAG) appointed Zutari (Pty) Ltd / Aurecon Mozambique Lda
(the Consultant) for this Contract.
1.2 Project Scope and Deliverables

The GoM aims to reform the urban water supply system through investments in rehabilitation and
extension of the existing systems. This contract, which forms part of the WASIS II project, comprises
the following:
(i) Supply and installation of electromechanical equipment at new boreholes;
(ii) Inspection and refurbishment of electromechanical equipment at existing boreholes; and
(iii) Rehabilitation and expansion of the existing water treatment works (WTW) and pumping
stations.
The Consultant is responsible for the preliminary design, detailed design, preparation of the bidding
documents and tender evaluation for the works noted above. The following deliverables for part of the
Contract:
◼ Inception Report;
◼ Preliminary Design Report;
◼ Draft Detailed Design Report;
◼ Final Detailed Design Report; and
◼ Bidding Documents.
This report is the Draft Detailed Design Report deliverable.
1.3 Project Area

The City of Tete is the provincial capital of Tete Province, with a population of approximately 298,581.
Tete is located on both sides of the Zambezi River, with the Revubue and Mupuno Rivers providing
natural borders in the east, while it is bordered by the Quiro River in the south-east and the Zambezi
River in the north-east and south. Tete is conveniently located at the Zambezi River crossing, by the
supply routes for goods from the inland countries to the Mozambican harbours of Nacala and Beira.
Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 1

Moatize town, also in Tete Province, has a population of approximately 54,446 people. The town is
located along a branch of the Revubue River, near the Tete city and the Zambezi River. The town is
known for its mining projects. There is a railway that links Malawi to the seaport at Nacala coal
terminal. Figure 1-1 shows a locality map of the project area.
Figure 1-1: Tete - Moatize Locality Map (adapted from https://www.bing.com/maps)
1.4 Structure of Report

The Detailed Design Report is structured as follows:
Chapter 1 presents the background and scope of the study;
Chapter 2 provides an overview of the outcomes of the Preliminary Design Phase;
Chapter 3 details the site development designs adopted for the project;
Chapter 4 deals with the detailed structural design considerations;
Chapter 5 presents the design of the boreholes in the wellfields;
Chapter 6 deals with the design of the Water Treatment Works;
Chapter 7 discusses the design of the Revubue II Pump Station and Reservoir;
Chapter 8 describes the control and operation of each water supply system;
Chapter 9 addresses the authorisation processes;
Chapter 10 details the financial considerations;
Chapter 11 presents the programme for the remainder of this contract; and
Chapter 12 provides conclusions and recommendations.

2 Preliminary Design Report Decisions
The final Preliminary Design Report (reference 1001069-0000-REP-JJ-0002) was submitted in August
2021. The following is a summary of the key decisions taken by FIPAG that must be considered
during the detailed design phase:
Wellfields:
◼ The safe design yields of the Nhartanda, Revubue I and Revubue II wellfields are 1050 m3/h, 820
m3/h and 875 m3/h, respectively;
◼ The updated borehole equipment arrangement was acceptable;
◼ Flood protection of the pump control houses will be by means of raised platforms;
◼ The flood protection of the borehole installations will be by means of a watertight seal that will
prevent water ingress into the boreholes; and
◼ Flow control at the boreholes will be achieved by throttling the discharge isolation valve. Provision
will be made in the pipework to install variable orifices should this be required in future.
Water Treatment Plant:
◼ The Tete Water Treatment Plant (WTP) will be upgraded to a capacity of 30 ML/d using a
conventional treatment process with sedimentation (Option 2D); and
◼ The upgrading of the WTP will take place on the existing site.
Revubue II Pump Station:
• Multi-stage pumpsets will be used for the Cruzeiro DC pumping system, whereas end-suction
pumpsets will be used for the Matema DC pumping system;
• The pipework layout of the pumpsets was accepted; and
• The sizing of the suction reservoir was accepted.
Control and Operation:
• The proposed Control and Operation of the scheme was accepted.
General:
• All motors larger than 10 kW must be fitted with soft-starters.

The comments received from FIPAG on the Preliminary Design Report, Zutari’s response and the final
remarks by FIPAG are included as Appendix A.

3 Site Investigations and Development
The section provides a general overview of the design principles adopted for the site development of
the various project sites. Specific details on site development for the Tete Water Treatment Plant
(WTP) and Revubue II Pump Station & Reservoir can be found in Section 6 and 7 respectively.
3.1 Site Investigations

The following site investigations were undertaken during the Preliminary Design phase of the project:
• Topographical survey
• Geotechnical investigation
• Water quality testing
• Laboratory analysis on pipe scale

Details of the site investigations are contained in Section 4 of the Preliminary Design Report and are
not repeated in the Detailed Design Report.
3.2 Bulk Earthworks

A geotechnical investigation was carried out at the Revubue II Pump Station and Tete Water
Treatment Plant (WTP) sites in April 2021 by Grupo de Materias Geotecnicos (GMG) on behalf of
FIPAG. The geotechnical investigation comprised of 14 test pits at the Pump Station site and 6 test
pits at the WTP site. The test pits were excavated using a 20-tonne excavator to a depth of 5 m or until
refusal conditions were met. The geotechnical report (refer to Appendix A of the Preliminary Design
Report) provided sufficient details to plan and design the bulk earthworks activities in preparation for
construction. A foundation solution, based on the results of the geotechnical investigation, was used
as a guide to develop the bulk earthworks design.
3.3 Roads and Paving

The road layout on site is dictated by the locations of the buildings, which were positioned for optimal
operational use. The roads allow for access to all buildings/structures for offloading of chemical
products and maintenance and operation of the plants. The road layouts have been designed to
accommodate the movement of 9 m long trucks with a 10-tonne load capacity. Figure 3-1 illustrates
the vehicle that was in vehicle movement assessment to design the various road layouts.
The road layer works have been designed to carry vehicles with a 10-tonne load capacity. A cross
section indicating the typical layer works design is shown in Figure 3-1, which is applicable for both
sites.
The roads will all have a vertical grade that is equal to or greater than a minimum grade of 0,5%. The
gradients were chosen with due consideration to the access doorways into the buildings/structures,
overland stormwater flow and other structural and process requirements.

Figure 3-1: 10 ton, 9 m Long design vehicle (left) and typical road layer works
3.4 Stormwater
The two sites, located in Tete, have different topographies but both follow the same principle of
overland stormwater drainage which is predominantly found throughout the city. Rainwater is
discharged from the buildings onto the roads, paved areas and some landscaped areas. The grade of
the roads, paved areas and landscaped areas around the structures are designed to ensure that water
which falls within the site will be directed offsite.
3.5 Water Network

The water reticulation on each site is fed from an existing water supply point after which the on-site
reticulation will be split into two mains to supply potable and fire water respectively. The split of potable
and fire water will be confirmed in the final Detailed Design Report.
Potable water will be provided to the required connection points at buildings via branches that tee off
from the potable water main. Fire water will be provided to hydrants that will tee off from the fire water
main. The fire water main will have a booster connection point to ensure that sufficient water pressure
can be obtained during firefighting operations. The requirement for a booster connection will be
confirmed in the final Detailed Design Report.
3.6 Sewer System

The sewer system on each site will drain to a septic tank via an underground pipe system comprising
of 110 or 160mm diameter uPVC Class 34 pipes. There will be either a rodding eye or a manhole
where the pipe route is required to bend when flowing to the septic tank. Rodding eyes will be used for
bends in non-trafficable areas and manholes in trafficable areas.
The tanks are to be emptied by an external service provider using a honeysucker vehicle. The tanks
have been sized to accommodate sewerage for a minimum period of 2 weeks, however, this is to be
confirmed with the final Detailed Design Report.
3.7 Ducting
Ducting for electrical and instrumentation cables will be installed across the sites in line with the
electrical engineers' design requirements, i.e. the size and number of ducts. PVC ducting is to be used
with manholes at all changes in direction.

3.8 Boundary Walls and Fencing
The perimeter of each site will be closed off using boundary walls or fences as applicable and access
to the site will be through dedicated access gates.

4 Detailed Structural Design
This section of the report sets out the structural design statements adopted during the preliminary
design and which form the basis for the detailed design stage. It is applicable to all structural elements
in the project.
4.1 Structural Design Codes

Structural designs will be carried out to meet the minimum requirements set out in the following codes
(and in compliance with relevant/applicable FIPAG regulations):
Eurocode
◼ SANS 10160-1: Basis of structural design and actions for buildings and industrial structures Part 1:
Basis of structural design.
Self-weight and imposed loads.
Wind actions.
Basis of geotechnical design and actions.
Actions induced by cranes and machinery.
◼ SANS 10100-1: The structural use of concrete Part 1: Design.
◼ SANS 10100-2: The structural use of concrete Part 2: Materials and execution of work.
◼ SANS 10162-1: The structural use of steel Part 1: Limit-state design of hot-rolled steelwork.
◼ SANS 10162-2: The structural use of steel Part 2: Cold-formed steel structures.
Where applicable/deemed necessary for some of the structures on the water treatment plant, as well
as reservoir and booster pump station, seismic requirements will need to comply with the following
code:
Seismic actions and general requirements for buildings.
Furthermore, where deemed suitable, structural design will also be guided by the following codes:
◼ Regulamento de Estruturas de Betão Armado e Pré-esforçado (Code for reinforced and
prestressed concrete structures).
◼ Regulamento de Estruturas de Aço para Edifícios (Code for steel structures for buildings).
◼ Regulamento de Segurança e Acções para Estruturas de Edifícios e Pontes (Safety regulations
and actions for building structures and bridges).
◼ BS-EN 1990: Eurocode 0 – Basis of Structural Design.
◼ BS-EN 1991: Eurocode 1 – Actions on Structures.
◼ BS EN 1992: Eurocode 2 – Design of Concrete Structures.
◼ BS-EN 1993: Eurocode 3 – Design of Steel Structures.
◼ BS-EN 1996: Eurocode 6 – Design of Masonry Structures.

◼ BS-EN 1997: Eurocode 7 – Geotechnical Design.
◼ BS-EN 1998: Eurocode 8 – Design of Structures for Earthquake Resistance
In addition to the above, structural design of water-retaining/water-excluding reinforced concrete

structures shall comply with the following:
◼ Water-retaining and water-excluding elements shall be designed in accordance with BS 8007:1987.
Updated cementitious binder hydration temperatures and further guidance in design will be
obtained from CIRIA C766 – Early-age Thermal Crack Control in Concrete.
◼ Water-retaining structures shall be designed generally adopting a design crack-width of 0.2mm.
4.2 Design Loadings

The design loadings will be as per the minimum requirements set out in BS-EN 1990 and BS-EN
1991, with the following applying where these are found to be more onerous than the minimum
requirement:
◼ Additional dead loads – concrete structures
o Services suspended from slabs: 0.5 kPa
o Office partitions and dividing walls: 2.5 kPa
o Screed to gutters and roof slabs: 3.0 kPa
o Brick / Block walls (double skin): 5.1 kPa / m height
o Plant / MCC rooms with permanent plant: 5.0 kPa minimum
◼ Additional dead loads – structural steel structures
o Str. Steel Roofs (incl. Services, sheeting, insulation and ceiling) 0.5 kPa
◼ Imposed (Live) loads
o General Office Areas and Reception: 3.0 kPa
o Accessible roofs / gutters (No plant): 2.0 kPa
o Structural Steel Roofs (no solar panels): 0.60 kPa
o Structural Steel Roofs (incl. Solar panels): 0.75 kPa
◼ Design Loads specific to water-retaining/water-excluding structures (buried structures) and
reservoirs:
o Hydrostatic water pressure of 10 kN/m³
o Earth pressure (saturated conditions) of 20 kN/m³ in unfavourable conditions (lateral
loading on tank/reservoir walls, vertical loading on tank/reservoir bases).
o Earth pressure (saturated conditions) of 18 kN/m³ in favourable conditions (uplift
check on structures).
o Additional dead load of 100mm layer of coarse aggregate on reservoir roof slab.
o Imposed (live) load of 2 kPa on reservoir roof slabs.
Design wind loads considered will be for the worst case of the following:
◼ Wind loads will be based on a 50 year return period, taking into account terrain exposure
conditions and allowing for a fundamental basic wind velocity of 46 m/s (equivalent to 165 km/h) for
a 3-second gust. The wind loads will also comply with the more stringent criteria/requirements of
SANS 10160-3 or BS-EN 1991.

◼ Terrain Category D will be considered (area in which at least 15% of the surface is covered by
buildings and their average height exceeds 15m).
Design seismic loads considered will be as follows:

◼ According to the Mozambique Seismic Hazard Distribution Map published by the World Health
Organisation in 2010, Tete falls within a Seismic Hazard Zone ranging between 0.2 and 0.8 PGA
(peak ground acceleration), equivalent to between 0,02g to 0,08g. A worst-case design value of
0,1g shall therefore be used in design.
◼ The reinforcing detailing guidelines of SANS 10160-4 will be incorporated into the detailed
structural design.
◼ The general principal is to use a ground acceleration that corresponds to a seismic event with a
return period of 475 years and 10% exceedance probability in a 50 year period. The Static Lateral
Equivalent Force Procedure as indicated by the code will be followed with a simplified design base
shear to calculated lateral seismic loads.
Design loadings for the final lifting equipment selected for each relevant structure at the Water
Treatment Plant and Revubue II Pumpstation will also be taken into account. These are described in
more detail in the relevant sections of this report.
4.3 Key Design Criteria

◼ Structures will be designed with the minimum loadings given in BS-EN 1990 and 1991 unless other
loads are otherwise specified/agreed.
◼ Foundation bearing pressures will be limited by the bearing capacity values provided in the
geotechnical report, with minimum requirements for safe design bearing pressures (unfactored)
envisaged to be in the region of:
o 250 kPa for the WTP structures.
o 150 kPa for the reservoir raft slab
o 200 kPa for the booster pumpstation pad foundations.
o 75 kPa for the booster pumpstation unreinforced strip footings
o Where in-situ conditions do not meet the above requirements, design will take into
consideration the necessary soil improvement measures to be undertaken to achieve the
required bearing pressures and ensure uniformity of founding material, so as to mitigate
the adverse effects that differential movement will have on foundations of water-retaining
structures.
◼ Special design measures will be taken where differential settlements may occur due to unequal
founding conditions or unequal loading.
◼ Water-retaining / excluding structures shall be designed for serviceability limit state (SLS) for the
following conditions:
o Normal operating conditions e.g. water-retaining structure full to TWL or buried/buoyant
water-excluding structure (empty and submerged).
◼ Water-retaining structures shall be designed for ultimate limit state (ULS) for the following
conditions:
o Faulted conditions e.g. overspill in water-retaining structures.
o Buoyancy load case e.g. empty water-retaining structures with buoyant underground
pressure.

◼ For the buoyancy load case, submerged structures will be designed to achieve an overall factor of
safety against buoyancy of 1.1 for the SLS case (global uplift check). Water-table levels for
buoyancy design will be determined as final ground level, or the rational high water level in the
ground if this can be determined. Design water-levels will be provided on the drawings.
◼ Where it is deemed uneconomical to size a structure for global stability against buoyancy, special
design measures (overflows, underdrainage etc.) will be considered to make the overall design
more economical.
◼ Retaining walls will be designed to achieve an overall factor of safety of 1.2 against sliding and 1.5
against overturning based on soil parameters provided by the geotechnical report and the
maximum operational water levels / maximum water tables possible.
4.4 Special Design Considerations for Reservoir

For the reservoir structure, the following additional design considerations will be made (depending on
the findings of the geotechnical investigation):
◼ To mitigate the adverse effects of possible localised outcrops of unsuitable in-situ founding and
achieve uniformity of founding throughout the reservoir footprint, an engineered fill platform may be
used with imported material (G5 to G7 quality) OR mass concrete that extends to an adequate
minimum depth below design founding depth across the entire footprint of the reservoir.
◼ If made up of G5 to G7 material, the engineered fill platform is to be added in layers not exceeding
150mm, with each layer being compacted to at least 95% MOD AASHTO.
◼ If the reservoir site is in close proximity to existing structures, it is imperative that suitable retaining
structures be implemented to achieve overly steep excavation slopes between adjacent properties
and the reservoir platform.
◼ In the case of jointed construction, joints along reservoir floors, walls and roof slabs will be as per
the details on the relevant drawings. These joints will be sealed by means of a flexible bandage
joint-sealing system that will cater for differential movement occurring at the joint.
4.5 Concrete Materials

◼ Watertight concrete shall be 35 MPa and have a 19mm nominal coarse aggregate size (annotated
as “Grade 35/19 Watertight”) where member thicknesses are less than 400mm.
◼ Watertight concrete shall be 35 MPa and have a 27mm nominal coarse aggregate size (annotated
as “Grade 35/27 Watertight”) where member thicknesses are equal to or greater than 400mm.
◼ Normal Strength concrete (non-water-retaining) shall be 30 MPa and have a 19mm nominal coarse
aggregate size (annotated as “Grade 30/19”).
◼ Where the possibility/likelihood of a particular structure exists of having both watertight and non-
watertight concrete (e.g. buried clearwell/sump/pumpstation with reinforced concrete (RC)
superstructure above ground), watertight concrete shall be adopted throughout.
◼ All concrete shall be specified using coarse aggregate that aims to reduce the thermal expansion of
concrete and reduce the risk of alkali silica reaction.
The use of ground-granulated blastfurnace slag (GGBS – industrial by-product of the steel –smelting
process) or fly-ash (FA – industrial by-product of coal combustion) will be required as a cementitious
binder to improve concrete durability and reduce the cement content in the following proportions:
◼ GGBS – between 30 and 50% replacement of cement. Exceptions such as internal surface beds or
trafficable slabs will be limited to 15%.
◼ FA – between 20 and 30% replacement of cement. Exceptions such as internal surface beds or
trafficable slabs will be limited to 15%.

Durability will be further achieved by implementing adequate concrete cover, immediate protection and
curing methods, limiting shrinkage (300 microstrain), minimum waiting time before stripping/removal of
formwork and stringent concrete mix design criteria such as a minimum coarse aggregate fraction and
a maximum water-binder ratio in accordance with the relevant exposure conditions as classified in
SANS 10100-2, SANS 1200G, as well as the project specification.
Concrete protection will be provided on concrete surfaces of structures that would otherwise be in
contact with aggressive substances/chemicals that will cause concrete deterioration or corrosion of
steel reinforcement. Depending on the aggressiveness of the environment in contact with the concrete
surface, protection will typically include one of the following, also depending on locally availability of
products and skills/expertise of applicators:
◼ Epoxy-cement sealing mortars.
◼ Chemically resistive epoxy coatings.
◼ Concrete protective HDPE linings.
◼ Increased concrete cover to reinforcement on the submerged sides of RC elements.
◼ Chemically resisting concrete admixtures.
4.6 Concrete Cover to Reinforcement

Concrete cover requirements shall comply with the more onerous of the following:
◼ Minimum requirements with relation to the relevant exposure conditions as classified in SANS
10100-2, SANS 1200 G and the project specifications.
◼ The following minimum concrete cover to reinforcement values:
o Normal Strength Concrete
▪ Foundations 50mm top & bottom (with blinding); 75mm sides
▪ Columns 40mm to stirrups
▪ Slabs 40mm top, bottom & sides
▪ Beams 40mm top, bottom & sides to stirrups
▪ Surface Beds 50mm bottom (with blinding); 40mm top & sides
▪ Retaining Walls 40mm
o Watertight Concrete
▪ Foundation Rafts/Slabs 50mm top & bottom (with blinding); 75mm sides
▪ Columns in tanks 40mm
▪ Slabs 40mm
▪ Beams 40mm
▪ Tank internal floor/surface bed panels 50mm
▪ Retaining Walls 40mm
4.7 Reinforcement
Reinforcement steel design strength (fy) will conform to the following:
◼ High tensile reinforcement (Y): 450 MPa
◼ Mild steel reinforcement (R): 250 MPa

4.8 Structural Steel
Hot-rolled structural steel shall be Grade S355JR and shall have a minimum design yield strength (f y)
of 460 MPa. Cold-formed structural steel shall have a minimum design yield strength (fy) of 200 MPa.
Corrosion protection of structural steelwork will be done in accordance with BS EN ISO 12944, based
on exposure environment and the required durability range. The following requirement shall be
complied with:
◼ Atmospheric Corrosivity Category (Environment Classification):
o External – C3 (Medium – Urban and Industrial Area)
o Internal – C2 (Low – some occasional condensation may occur)
◼ Durability Range
o Medium (5 – 15 years)
Stemming from the above, the minimum requirements for corrosion protection of structural steelwork
will comply with the following:
◼ Hot-dip Galvanising and high-spec protective paint for aggressive internal environments and
externally exposed members. Protective paint will be done after steel members have been
adequately de-greased and will comprise of a minimum of a duplex coating, preceded by a
proprietary primer.
◼ Hot-dip Galvanising for other exposure environments. Cold-formed members will be from pre-
galvanised plates.
◼ Electroplating will not be acceptable.
4.9 Design Working Life

All new structures in the water treatment plant, reservoir and booster pumpstation shall be designed
with a design working life of 50 years, in accordance with Category 34 (Building structures and other
common structures) as described in SANS 10160-1.
Structures shall be designed such that any deterioration over their design working life shall not impair
the performance of the structures below that which is intended, having due regard to the exposure
environment and anticipated level of maintenance.
4.10 General Building Items

New water-retaining process tanks/structures will consist of Reinforced Concrete construction.
Reinforced concrete raft foundations will support reinforced concrete walls, with super structure
consisting of reinforced concrete columns and beams/suspended slabs where applicable. External
cladding will consist of brickwork that will be finished to match existing structures on the site.
The roof options for the different structures will consist of one or more of the following:
◼ Structural Steel Roofing
◼ Timber Roof
◼ Reinforced Concrete Roof

5 Wellfields
5.1 Wellfield Configuration
5.1.1 Nhartanda Wellfield

The Nhartanda Wellfield comprises all the boreholes in the Nhartanda Valley and Canongola
wellfields. Drawing 1001069-0000-DRG-JJ-0001 (see Appendix XX for all wellfield-related drawings)
provides a locality plan of the Tete water supply system and also shows the location of the Nhartanda
Wellfield. Drawing 1001069-0000-DRG-JJ-0002 shows a site layout of the Nhartanda Wellfield.
There are 27 boreholes in total in the wellfield, of which 21 are in the Nhartanda Valley Wellfield and 6
in the Canongola Wellfield. Out of the 27 boreholes, 19 are existing boreholes, and 8 are newly drilled
boreholes of which 6 boreholes are still unequipped. Table 5-1 provides further details of the
boreholes.
Table 5-1: Nhartanda Wellfield Configuration
Borehole Wellfield Total Number Borehole ID

Description of Boreholes
Existing Boreholes Nhartanda Valley 13 F1; F2; F3; F4; F5; F6; F8; F9; F10; F11;
F13; F14; F15
Existing Boreholes Canongola 6 F1; F2; F3; F4; F5; F1_OLD
New Boreholes Nhartanda Valley 2 F16; F17

(Equipped)
New Boreholes Nhartanda Valley 6 Nhartanda_2; Nhartanda_4; Nhartanda_5;

(Unequipped) Nhartanda_6; Nhartanda_7; Nhartanda_8
Currently some of the Nhartanda Valley boreholes pump directly to the Tete WTP, whereas other
Nhartanda Valley and all the Canongola boreholes pump directly into the reticulation network and
distribution reservoirs. All the boreholes in the Nhartanda Valley and Canongola wellfields will be
reconfigured to pump directly to the upgraded WTP. The design of the transmission pipelines,
connecting the boreholes to the WTP, is done by others under contract FIPAG/WASIS II/W-9/15.
Information on the wellfield (e.g. borehole name, pipe details, etc.) have been summarised on a
process flow diagram presented in drawing 1001069-2000-DRG-WW-0320 (see Appendix XX).
The Nhartanda Wellfield borehole positions are shown on drawings 1001069-2000-DRG-JJ-0300 and
1001069-2000-DRG-JJ-0301 (see Appendix XX). Table 5-2 provides an overview of the position and
NGL of each borehole in the wellfield.
Table 5-2: Nhartanda Borehole Position and Elevation
Borehole ID Wellfield Location NGL (m)

(UTM 36S)
Easting Northing
F1 Nhartanda Valley 561445.06 8213152.8 127.0

Borehole ID Wellfield Location NGL (m)
(UTM 36S)
Easting Northing
F16 (Nhartanda 1) Nhartanda Valley 561331.78 8213046.14 127.6
F17 (Nhartanda 3) Nhartanda Valley 560880.97 8214036.86 127.4
Nhartanda 2 Nhartanda Valley 560755.4 8214240.04 127.8
F1 Canongola 562701.88 8211763.14 124.5
F2 Canongola 562657.4 8211787.06 124.6
F3 Canongola 562590.56 8211733.11 124.6
F4 Canongola 562593.18 8211811.08 124.7
F5 Canongola 562735.75 8211836.22 124.5
F1_OLD Canongola 562657.48 8211727.80 124.5
5.1.2 Revubue I Wellfield

The Revubue I Wellfield consists of 18 boreholes – 12 existing boreholes, and 6 newly drilled
boreholes of which 2 are still unequipped. Table 5-3 provides a summary of the boreholes as
described above and drawing 1001069-0000-DRG-JJ-0001 (see Appendix XX for all Revubue I
wellfield-related drawings) shows the locality plan of the overall Tete water supply system, as well as
the position of the Revubue I Wellfield.
Table 5-3: Revubue I Wellfield Configuration
Borehole Description Total Number of Boreholes Borehole ID
Existing Boreholes 12 F2; F3; F5; F6; F8; F9; F10; F11;
F12; F13; F14; F15
New Boreholes (Equipped) 4 F16; F17; F18; F19
New Boreholes (Unequipped) 2 Revubue1_3; Revubue1_6

All the boreholes in the Revubue I Wellfield will supply water to the Matema DC via three transmission
mains. Table 5-4 summarises these three transmission mains with the boreholes connecting to each
of these mains.
Table 5-4: Configuration between Pipelines and Boreholes
Transmission Main Borehole ID
DN400 Steel Pipeline F2; F3; F5; F6; F8; F10; F11
DN315 PVC Pipeline F9; F12; F13
DN350 Ductile Iron Pipeline F14; F15; F16; F17; F18; F19; Revubue1_3;
Revubue1_6
The positions of the boreholes were verified with the topographical survey and are shown on drawing
1001069-3000-DRG-JJ-0500 (see Appendix XX). Table 5-5 provides an overview of the position and
NGL of each borehole in the wellfield.
Table 5-5: Revubue I Borehole Position and Elevation
Borehole ID Location NGL (m)

(UTM 36S)
Easting Northing
F2 568547.94 8213222.9 127.3
F3 568572.81 8213256.57 127.7
F5 568627.17 8213363.63 127.9
F6 568659.15 8213435.35 128.3
F8 568637.84 8213537.54 128.5
F9 568703.04 8213698.16 128.6
F10 568625.09 8213495.55 128.6
F11 568692.23 8213545.79 128.2
F12 568646.19 8213607.45 128.1
F13 568673.87 8213657.81 128.4
F14 568720.33 8213650.31 128.3
F15 568619.64 8213416.51 128.8
F16 (Revubue1_1) 568524.63 8213167.78 126.8
F17 (Revubue1_5) 568768.55 8213596 126.6
F18 (Revubue1_2) 568755.58 8213742.26 127.3
F19 (Revubue1_4) 568798.48 8213695.33 127.0
Revubue1_3 568500.09 8213115.81 126.2
Revubue1_6 568797.93 8213814.24 127.3
5.1.3 Revubue II Wellfield

The Revubue II Wellfield consists of 15 newly drilled boreholes that are still unequipped. These
boreholes will pump to the new Revubue II Pump Station, which will supply water to Cruzeiro DC and
Matema DC. Drawing 1001069-0000-DRG-JJ-0001 (refer to Appendix XX for all Revubue II wellfield-
related drawings) provides a locality plan of the Tete water supply system and also shows the location
of the Revubue II Wellfield.

The positions of the boreholes were verified with the topographical survey. The Revubue II borehole
positions are shown on drawing 1001069-4000-DRG-JJ-0700 (see Appendix XX). Table 5-6 shows the
position and NGL for each borehole.
Table 5-6: Revubue II Borehole Position and Elevation
Borehole ID Location NGL (m)
(UTM 36S)
Easting Northing
Revubue2_1 569675.03 8217899.1 131.1
Revubue2_2 569647.42 8217817.88 131.3
Revubue2_3 569572.12 8217709.18 131.3
Revubue2_4 569439.54 8217186.18 130.2
Revubue2_5 569474.09 8217269.01 130.3
Revubue2_6 569566.85 8217357.65 131.2
Revubue2_7 569629.23 8217452.51 131.2
Revubue2_8 569722.2 8217952.71 130.9
Revubue2_9 569795.28 8218003.9 131.6
Revubue2_10 569809.1 8217589.57 130.7
Revubue2_11 569844.14 8217772.17 131.9
Revubue2_12 569869.07 8217901.56 131.8
Revubue2_13 569722.07 8217738.75 131.7
Revubue2_14 569660.35 8217649.21 131.1
Revubue2_15 569626.02 8217561.84 131.5
5.2 Borehole Safe Yields

The safe yields for the boreholes were determined through a collaborative process between FIPAG
and Zutari as noted in the Preliminary Design Report. Table 5-7 summarises the safe design yields for
the existing and new boreholes in the Nhartanda Wellfield.
Table 5-7: Nhartanda Wellfield Safe Yields
Borehole ID Wellfield Safe Yield

(m3/h)
F1 Nhartanda Valley 35

Borehole ID Wellfield Safe Yield
(m3/h)

F16 (Nhartanda 1) Nhartanda Valley 40
F17 (Nhartanda 3) Nhartanda Valley 50
Nhartanda 2 Nhartanda Valley 50
F1 Canongola 35
F2 Canongola 35
F3 Canongola 35
F4 Canongola 35
F5 Canongola 35
F1_OLD Canongola 35
Total safe design yield (m3/h) 1050
Table 5-8 summarises the safe design yields for the existing and new boreholes in the Revubue I
Wellfield.
Table 5-8: Revubue I Wellfield Safe Yields
Borehole ID Wellfield Design Yield (m3/h)

F2 Revubue I 40
F3 Revubue I 40
F5 Revubue I 60
F6 Revubue I 40
F8 Revubue I 40
F9 Revubue I 40
F10 Revubue I 60
F11 Revubue I 60
F12 Revubue I 40
F13 Revubue I 40
F14 Revubue I 60
F15 Revubue I 40
F16 (Revubue1_1) Revubue I 50
Table 5-9 summarises the design yields established for the new boreholes in the Revubue II Wellfield.

Table 5-9: Revubue II Wellfield Safe Yields
Borehole ID Wellfield Design Yield (m3/h)

Revubue1_3 Revubue I 40
Revubue1_6 Revubue I 40
Revubue2_1 Revubue II 65
5.3 Pump Duties

System characteristic curves were developed for each of the boreholes, which informed the duty point
for each of the borehole pumps based on the safe yields as noted in Section 5.2 (also refer to Section
5.3.3 in the Preliminary Design Report). As an example, Figure 5-1 shows the minimum and
maximum system curves for borehole Nhartanda 2 in the Nhartanda Valley Wellfield, as well as the
safe design yield of 50 m3/h.
The duty points were taken as the pumping head for the maximum system curve given the fact that the
pumps will be fitted with soft starters, i.e. it would not be possible to increase the pump speed to
achieve higher flow rates. This approach will ensure that the pumps will deliver at least the safe
design yields under all operating conditions, but might require the discharge isolation valve to be
throttled if the pumped flow rate is much higher than the safe yield.
The Terms of Reference, Clause 3.2.1.3, states that “FIPAG aims to standardize on a limited number
of makes of pumps in order to be more effective in keeping spare parts and doing maintenance, the
pumps specified should be Grundfos SP or approved equal.” As such, the pump selection was based
on Grundfos SP pumps, although a number of other reputable pump suppliers are available, e.g. C.R.I
Pumps.
Table 5-10 gives the pump duties for all the pumps in the Nhartanda Wellfield as well as the pumps
selected for these duty points.

Figure 5-1-: System Curve of Borehole Nhartanda 2 in Nhartanda Valley Wellfield
Table 5-10: Nhartanda Wellfield Borehole Pump Duties
Wellfield Duty Point Pump Selection

Borehole ID Duty Flow Duty
(m3/h) Pressure (m)
F1 Nhartanda Valley 35 65.2 SP 46-7
F16 (Nhartanda 1) Nhartanda Valley 40 51.3 SP 46-6
F17 (Nhartanda 3) Nhartanda Valley 50 55.3 SP 46-8
Nhartanda 2 Nhartanda Valley 50 58.5 SP 46-8

Wellfield Duty Point Pump Selection
Borehole ID Duty Flow Duty
(m3/h) Pressure (m)
F1 Canongola 35 61.3 SP 46-7
F1_OLD Canongola 35 59.4 SP 46-6
Table 5-11 gives the pump duties for all the pumps in the Revubue I Wellfield as well as the pumps
Table 5-11: Revubue I Wellfield Borehole Pump Duties
Duty Point
Borehole ID Design Yield Pump Selection
Duty Pressure (m)
(m3/h)
F2 40 71.3 SP 46-8
F3 40 73.4 SP 46-8
F5 60 70.9 SP 60-10
F6 40 72.5 SP 46-8
F8 40 74.1 SP 46-8
F9 40 56.3 SP 46-7
F10 60 71.6 SP 60-10
F11 60 66.8 SP 60-9
F12 40 63.1 SP 46-7
F13 40 59.6 SP 46-7
F14 60 61.2 SP 60-9
F15 40 62.0 SP 46-7
F16 (Revubue1_1) 50 59.6 SP 46-8
F17 (Revubue1_5) 40 60.1 SP 46-7
F18 (Revubue1_2) 40 60.5 SP 46-7
F19 (Revubue1_4) 50 58.8 SP 46-8
Revubue1_3 40 64.1 SP 46-7
Revubue1_6 40 63.3 SP 46-7

Table 5-12 gives the pump duties for all the pumps in the Revubue II Wellfield as well as the pumps
Table 5-12: Borehole Pump Selection for Revubue II Wellfield
Duty Point Pump Selection

Borehole ID Design Yield Duty Pressure (m)
(m3/h)
Revubue2_1 65 29.0 SP 60-5
Revubue2_2 45 29.7 SP 46-4
Revubue2_3 45 31.9 SP 46-4
Revubue2_4 45 35.3 SP 46-5
Revubue2_5 65 40.9 SP 60-7
Revubue2_6 45 49.3 SP 46-6
Revubue2_7 65 34.7 SP 60-6
Revubue2_8 65 29.2 SP 60-5
Revubue2_9 65 30.5 SP 60-5
Revubue2_10 45 40.5 SP 46-5
Revubue2_11 65 30.9 SP 60-5
Revubue2_12 65 28.4 SP 60-5
Revubue2_13 65 31.4 SP 60-5
Revubue2_14 65 32.2 SP 60-6
Revubue2_15 65 33.0 SP 60-6
Table 5-13 shows a summary of the pump models proposed for the Nhartanda, Revubue I and
Revubue II wellfields.
Table 5-13: Summary of Borehole Pumps for All Wellfields
Grundfos Number of Pumps

SP Pump
Model Nhartanda Revubue I Revubue II All Wellfields (Total)
SP 46-4 - - 2 2
SP 46-5 - - 2 2
SP 46-6 14 - 1 15
SP 46-7 7 8 - 15
SP 46-8 6 6 - 12
SP 60-5 - - 6 6
SP 60-6 - - 3 3
SP 60-7 - - 1 1
SP 60-9 - 2 - 2
SP 60-10 - 2 - 2

5.4 Waterhammer Analysis
Waterhammer analyses were conducted on the following pipelines within Tete’s bulk water supply
systems:
• Nhartanda Wellfield: All pipelines from the wellfield to the Tete WTP
• Revubue I Wellfield: The new DN350 ductile iron main for the wellfield to Matema DC
• Revubue II Wellfield: All pipelines from the wellfield to the suction reservoir of the Revubue II
Pump Station
Waterhammer analyses were not conducted for the existing DN400 steel and DN315 PVC mains from
Revubue I Wellfield to Matema DC. There are currently no waterhammer problems experienced along
these pipelines. Furthermore, the flows through these pipelines will be reduced during the upgrading
of the wellfield, which will reduce the waterhammer pressures. The equipment selection for these
boreholes will therefore be done to match the current installations, i.e. all pipework, fittings and valves
are PN16 rated.
The objective of the waterhammer analysis was to investigate operational factors that lead to transient
flow conditions. Any operational procedure that causes the flow in a pipeline to change from steady to
unsteady will induce transient pressures. Depending on the specific operation, the resulting transient
pressures will range from low to severe. The following main operational events were analysed to
obtain minimum and maximum transient pressure envelopes:
• Pump start-up (i.e. normal start);
• Pump shutdown (i.e. normal stop); and
• Pump failure/trip (i.e. power outage).

Although the larger motors (i.e. 10 kW and larger) are fitted with soft-starters, a 2 second period was
used for pump start-up. The results obtained from the waterhammer analysis were used to determine
the pressure ratings of the fittings at the borehole installations and the Revubue II Pump Station.
A detailed write-up of the waterhammer analysis undertaken for each of the above pumping systems is
contained in Appendix B. A summary of the results is presented below.
5.4.1 Nhartanda Wellfield

It can be concluded from the water hammer analysis that the transient pressures in the Nhartanda
Wellfield are not expected to exceed 110 m with the assistance of anti-shock air valves and fast-
closing non-return valves. The maximum transient pressure will increase to approximately 350 m
without the use of fast-closing non-return valves at the borehole installations. It was also found that the
system will be prone to vacuum conditions, however, the proposed ductile iron pipeline will not buckle
under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Nhartanda
Wellfield:
• The pressure class of all valves and fittings to be at least PN16.

• The check valves at the borehole installations to be slanted-seat valves fitted with counterweights
and hydraulic dampeners.
• All air valves to have an anti-shock mechanism.

• In starting and stopping successive pumps, it is good practice to allow the system to stabilise
between these pump stops or starts. It is recommended that at least one minute be allowed between
successive pump stops or starts.

5.4.2 Revubue I Wellfield
In the DN350 ductile iron main and connecting pipework, the maximum transient pressures are not
expected to exceed 190 m with the assistance of anti-shock air valves and fast-closing non-return
valves. The maximum transient pressure will increase significantly to approximately 300 m without the
use of anti-shock air valves. It was also found that the system will be prone to vacuum conditions,
however, the proposed ductile iron pipeline will not buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Revubue I
Wellfield:
• The pressure class of all valves and fittings to be at least PN16. The rated pressure of the PN16
valve will be exceeded during a pump trip event with expected transient pressures up to 190 m,
however, for such instantaneous transient pressures, the valve will be able to withstand up to
25% more than its rated pressure (i.e. surge pressures should be lower than 192 m). Steady-
state pressures will also not exceed the rated pressure of a PN16 valve as the maximum steady-
state pressure for this wellfield is below 100 m.
• The check valves at the borehole installations to be slanted-seat valves fitted with
counterweights and hydraulic dampeners.
between these pump stops or starts. It is recommended that at least one minute be allowed
between successive pump stops or starts.
5.4.3 Revubue II Wellfield

In the DN350 ductile iron main and connecting pipework, the maximum transient pressures are not
expected to exceed 120 m with the assistance of anti-shock air valves. The maximum transient
pressure will increase significantly to approximately 300 m without the use of anti-shock air valves. It
was also found that the system will be prone to vacuum conditions, however, the proposed ductile iron
pipeline will not buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Revubue II
Wellfield:
between these pump stops or starts. It is recommended that at least one minute be allowed
between successive pump stops or starts.
5.5 Civil Design
5.5.1 Pump Control Houses
5.5.1.1 Layout
The number of pump control houses (PCHs) in each wellfield, as well as the location of each, were
based on the positions of the existing PCHs and the maximum length of the low-voltage power supply
cables between the PCHs and boreholes. The locations of the PCHs are summarised in Table 5-14.
The locations of the PCHs are also shown on the wellfield layout drawings (see drawings xx in
Appendix xx).

Table 5-14: Positions of Pump Control Houses
Location
PCH ID Wellfield (UTM 36S)
Easting Northing
PCH-NHT-01 Nhartanda Valley 561561.46 8212738.11
PCH-CNG-01 Canongola 562740.38 8211710.16
PCH-RVBI-01 Revubue I 568592.96 8213311.38
PCH-RVBI-02 Revubue I 568665.45 8213548.52
PCH-RVBII-01 Revubue II 569548.33 8217501.78
PCH-RVBII-02 Revubue II 569766.03 8217898.80
All the PCHs in each wellfield shall have a MCC room, generator, office, and an ablution facility.
Figure 5-2 shows an isometric view of the PCHs.
Figure 5-2: Isometric view of PCH
Drawing xx (see Appendix xx) shows the typical site layout of the PCHs and the general arrangement
of the equipment and building.
5.5.1.2 Raised Platform

All the pump control houses will be positioned on a earthworks platform to protect it against flooding.
The platform level is based on the 1:100 year flood water level with a freeboard allowance of 0.5 m.
Table 5-15 provides the platform level and approximate platform height for each PCH.
Table 5-15: Raised Platform Heights for Pump Control Houses
Approximate
1:100 Flood Level Top of Platform
PCH ID Wellfield Platform Height
(masl) Elevation (masl)
(m)
PCH-NHT-01 Nhartanda Valley 128.5 129.0 3.30
PCH-CNG-01 Canongola 127.1 127.6 3.52
PCH-RVBI-01 Revubue I 128.6 129.1 1.40

Approximate
1:100 Flood Level Top of Platform
PCH ID Wellfield Platform Height
(masl) Elevation (masl)
(m)
PCH-RVBI-02 Revubue I 128.8 129.3 0.60
PCH-RVBII-01 Revubue II 132.2 132.7 2.40
PCH-RVBII-02 Revubue II 132.5 133.0 3.30
The access ramp to the top of the platform will have a maximum grade of 10%. The side slopes of the
platforms will be limited to a minimum slope of 1:2.
A site layout drawing, which also contains the setting-out detail of the PCH and platform, has been
developed for each PCH – refer to drawings xx to xx in Appendix xx. Figure 5-3 shows the site layout
for PCH-NHT-01.
Figure 5-3: Site layout for PCH-NHT-01
5.5.1.3 Access to PCHs

Access to each of the PCHs will be along existing access roads. A ramp, constructed at a slope of
1:10, will be provided at each platform for vehicle access to the top of the platform. The vehicle
access will be required to install the generator and MCC panels, and for the subsequent refuelling the
generator.
5.5.1.4 Building finishes

Drawing xx (refer to Appendix xx) shows the structural footing detail applicable to the PCH building.
The building finishes will match that of the current PCHs and are summarised in Table 5-16.

Table 5-16 Building finishes and materials for Pump Control Houses
Building Component Description of materials

General
External Doors Timber (meranti) door and frame. MCC double door to contain louvres
Internal Doors Steel door, powder coated
Floors Concrete, tiled finish
Ceilings Gypsum RhinoBoard
Roof Steel IRB roof sheeting on wooden truss system
Roof insulation Cellulose fibre insulation
Windows Aluminium frames with tinted glass. Opaque windows for bathroom
External Burglar Bars No burglar bars
Walls Brick, plaster and paint (internal and external)
Ablution facilities
Toilets and Sundries Porcelain, Seats and Flush mechanisms accessible with
interchangeable parts.
Basins Porcelain
Mixers and Taps Chrome plated brassware
Showers Chrome plated brassware, accessible traps
Hot Water Cylinders Hot Water Cylinder
The generators will be installed on a concrete slab. A steel structure with IBR roof sheeting will be
erected over the generator to provide protection against the natural elements.
5.5.2 Boreholes
5.5.2.1 Flood protection

The following flood protection measures, applicable to the boreholes, were agreed to during the
Preliminary Design Phase:
• Instrumentation: All instrumentation such as the flow meter and pressure gauges will be
specified to have an IP68 waterproof rating.
• Electrical Equipment: The electrical equipment and switchgear will be pole mounted and
located above the flood level. A small soil berm will be constructed to provide access to the
electrical equipment if located too high above the NGL.
• Ingress into the borehole casing: Ingress of flood water through the top of the borehole casing
will be prevented by installing watertight seals (e.g. Roxtec or similar) at all cable entries. The
existing concrete plinth will also be raised to provide a flat surface to which a cover plate can
be attached. Figure 5-4 shows the proposed arrangements to ensure a watertight installation.
Figure 5-5 shows the details of the Roxtec seal.

Figure 5-4: Detail of watertight borehole installation (and well head)
Figure 5-5: Roxtec Watertight Seal
In terms of the Roxtec (or similar) watertight seals, it is worthwhile noting the following:
• It is a split unit that is fitted over the cable and pushed into a sleeve/stub welded onto the cover
plate, as shown in Figure 5-5. The bolts on the Roxtec seal are thereafter tightened with an allen/hex
key which compresses the seal against the cable and sleeve to achieve a watertight joint.
• The seals can withstand differential water pressures of up to 4 bar.

• The seals are UV resistant and can be installed in an external environment
• The seals are fire rated and rodent resistant.
• Once the seals are installed and tightened, no maintenance is required.

• If required, removal of the seals is simple – the seal is removed by loosening the bolts with an
allen/hex key, whereafter the two halves of the seal are slided out from the sleeve/stub on the cover
plate.
5.5.2.2 Access to boreholes

Access to the boreholes will be along the existing gravel roads.

5.5.3 Fencing
The fencing at the existing and new borehole installations will match the existing fencing as shown in
Figure 5-6.
Figure 5-6: Proposed fencing at boreholes

5.6 Mechanical Design
5.6.1 Equipment Arrangement

The proposed borehole equipment arrangement is shown in Figure 5-7.
Figure 5-7: Borehole Equipment Arrangement

Table 5-17 provides a description of the items tagged in Figure 5-7. The main components are
discussed in further detail below.
Table 5-17: Summary of Borehole Mechanical Installation Parts
Mark No Part
1 Submersible Multi-Stage Groundwater Pump
2 DN100 Polyester Reinforced Polyurethane Flexible Rising Main Hose
3 PVC Borehole Casing
4 Well head consisting of steel cover plate, DN100 steel pipe and stub/sleeve to suit Roxtec
RS31 Seal or similar
5 DN100 x 90° Bend
6 DN100 Straight Steel Pipe
7 DN50 Tee
8 DN50 Full Port Ball Valve
9 DN50 Air Valve (with anti-shock mechanism)
10 DN25 Full Port Ball Valve for connection of pressure transducer/gauge
11 DN100 Woltman Type Mechanical Flow Meter with opto-electronic sensor
12 DN100 Spool Piece (Frese Alpha orifice)
13 DN100 Dismantling Joint
14 DN100 Slanted Seat Check Valve with counterweight and hydraulic damper
15 DN100 Metal Seat Wedge Gate Valve
16 DN150/100 Concentric Reducer
17 DN150 x 45° Bend
18 Steel Pipe Support
19 DN150 Straight Steel Pipe
5.6.2 Pumps
The Terms of Reference, Clause 3.2.1.3, states that “FIPAG aims to standardize on a limited number
of makes of pumps in order to be more effective in keeping spare parts and doing maintenance, the
pumps specified should be Grundfos SP or approved equal.” As such, the pump selection was based
on Grundfos SP pumps, although a number of other reputable pump suppliers are available, e.g. C.R.I
Pumps. The Grundfos SP is a multi-stage submersible borehole pump (see Figure 5-8).
Figure 5-8: Grundfos Multi-Stage Borehole Pump

The borehole pump selection, based on the duty point for each borehole, is presented in Section 5.3.
The following materials are proposed for the pumpset:
• Pump and motor casing: Grade 1.4301 (Grade 304) stainless steel
• Impellers: Grade 1.4301 stainless steel
• Inlet strainer: Grade 1.4301 stainless steel
• Pump and motors shafts: Grade 1.4057 stainless steel
The pumps are fitted with built-in non-return valves. Non-return valves are, however, also proposed
above-ground as slanted seat non-return valves are preferred to mitigate the risk of excessive surge
pressures.
5.6.3 Riser pipes

For all the boreholes, a Polyester Reinforced Polyurethane Flexible Rising Main (FRM) hose will be
used as riser pipe, with an internal diameter (ID) of 102 mm to connect to the pump outlet, and a
minimum pressure rating of PN16. The couplings with clamps shall be manufactured from Grade 316
stainless steel.
The connection between the Grundfos pump and riser pipe shall be a threaded connection.
5.6.4 Pipework
5.6.4.1 Pipework Properties

All the above ground pipework will be galvanised carbon steel in accordance with SANS 62 (medium
duty).
The minimum and maximum flow rate of the boreholes is 35 m3/h and 65 m3/h, respectively. A
minimum velocity of 0.7 m/s must be achieved to ensure the non-return valve is fully open. All above
ground pipework will therefore be DN100.
All pipework (pipes and fittings), other than those conforming to SANS 62, will have a minimum wall
thickness of 4.5 mm.
Pipe flanges will be in accordance with EN 1092 Type B (Raised Face).
A pressure rating of PN16 will apply to all pipework.
Flange adaptors will be provided as shown on Figure 5-7 to cater for misalignment and provide
flexibility for removal of items for future maintenance.
5.6.4.2 Well Head

Figure 5-4 shows the details of the well head. The pipework properties provided in Section 5.6.4.1 will
also apply for the well head. The well head will consist of a vertical DN100 steel pipe welded to a
cover plate that is bolted on top of a concrete plinth. The DN100 steel pipe will have a threaded
internal surface on the one side to allow for coupling with the riser pipe. There will be two openings in
the cover plate for the water level sensor and electrical pump cable to enter the borehole.
5.6.4.3 Pipe Supports

A pipe support will be installed at each borehole as shown in Figure 5-7. The supports will be made of
prefabricated mild steel and be hot dip galvanised. It will be bolted to the flange of the pipe located

downstream of the wedge gate valve and will have adjustable bolts into the concrete base that will
allow for any misalignment. The bases of the pipe supports will be grouted once in its final position.
5.6.4.4 Tie-in to existing pipework

The pipework of the existing and new boreholes must tie into the underground transmission pipelines
installed by others. At the new boreholes (e.g. Revubue II wellfield), it is unsure whether the borehole
will be completed before the transmission pipeline or vice versa. The design of the borehole pipework
must therefore be flexible to allow the tie-ins to be completed with minimal efforts.
Figure 5-9 shows the detail proposed for the tie-in to the existing transmission pipelines with Table
5-18 describing the details of the various parts. The thrust block at Item 4 has been omitted for clarity.
Figure 5-9: Proposed tie-in details of borehole pipework
Table 5-18: Summary of Borehole Pipework Parts for tie-in
Mark No Part
1 DN150 x 45° Bend
2 DN150 Loose Flange
3 DN150 Straight Steel Pipe with variable length
4 DN150 x 45° Bend welded on both sides to DN150 Straight Steel Pipes (each 500mm F/F)
5 DN150 Flange Adaptor
6 DN150 Straight Ductile Iron Pipe; 500mm F/F (cut from existing Ductile Iron pipe)
7 DN150 Coupling (dismantling joint)
8 DN150 Straight Ductile Iron Pipe with variable length (cut from existing Ductile Iron pipe)
The following installation methodology will be applicable at the existing boreholes:

- Expose the existing transmission pipeline below ground to determine the position and invert
level;
- The flange above the well head is a loose flange, which allows the above-ground pipework to
be rotated through any angle in order to be aligned with the transmission pipeline;
- Once the invert level and height of the borehole is confirmed, the length of Item 3 in Figure 5-9
can be determined;
- The borehole pipework is then installed from the borehole up to Item 5 (ductile iron flange
adaptor);

- The existing ductile iron pipe is then cut to create Items 6 and 8. If the misalignment is
considered negligible, it would be possible to omit Items 6 and 7 (one of the couplings) and
connect Item 8 directly to Item 5;
- Provision is made for installing two dismantling joints (couplings) to allow for minor
misalignment; and
- Once the pipeline connections have been completed, the thrust block at Item 4 must be cast.
The borehole can be commissioned seven (7) days after casting of the thrust block.
5.6.5 Valves
The valves discussed in this section will be installed at each borehole, as shown in the equipment
arrangement on Figure 5-7. All valves will have a pressure rating of PN16.
5.6.5.1 Non-Return Valve

A DN100 slanted seat check valve will be used with a counterweight and hydraulic damper.
The condition of existing non-return valves would need to be assessed during the construction phase.
Valves in a good condition and with a pressure rating of PN16 will then be removed, serviced and kept
as spares.
5.6.5.2 Isolation Valves

DN100 Isolation Valve
A flanged DN100 metal seated wedge gate valve will be installed at each borehole to isolate the
borehole and above ground pipework for maintenance purposes. A hand wheel will be fitted to the
valve to allow for manual operation.
A metal seated valve is preferred above a resilient seal gate valve as the isolation valves might also
be throttled as a flow control measure. The metal seated valves are less prone to cavitation and
higher velocities through the valve could damage the seals of the resilient seal gate valves.
DN50 Isolation Valve

A DN50 full port ball valve will be installed below the air valve as shown on the equipment
arrangement in Figure 5-7. The main purpose of the valve is to isolate the air valve for maintenance
purposes.
A full port ball valve is chosen as it will allow for a straight flow path to the air valve, i.e. there is no
reduction of flow as the water travels through the valve. This will allow for effective functioning of the
air valve.
An additional DN50 full port ball valve will be installed on the tee-section as shown on the equipment
arrangement, to allow for water sampling and to serve as an air bleed valve.
5.6.5.3 Air Valve

Three stage air valves with a double orifice and anti-shock orifice mechanism should be installed as
part of the surge mitigation measures. Vent-O-Mat RBX, Variant, Vacuvent, etc. are all examples of
suitable manufacturers. The air valves will be standardised to DN50, which is suitable according to the
waterhammer analysis and agrees with what is currently used at the boreholes.
The conditions of the air valves at the existing installations will be inspected when construction
commences. Where these air valves are still in good working condition, they will be kept as spares.

5.6.6 Flow Meter
A DN100 Woltman type mechanical (turbine) flow meter will be used with an opto-electronic sensor as
shown in Figure 5-10. The flow meter will be flanged with a pressure rating of PN 16.
Figure 5-10: Proposed mechanical flow meter with opto-electronic sensor
5.6.7 Pressure Gauges

Bourdon type pressure gauges, as shown in Figure 5-11, will be installed on the borehole pipework.
Each pressure gauge will be fitted with a ball valve to isolate the pressure gauge for maintenance
purposes.
The pressure gauges shall be selected such that the operating pressure is approximately in the middle
of the gauge’s display rating, e.g. a 10 bar gauge will be installed if the operating pressure is 5 bar
whereas a 6 bar gauge will be installed for an operating pressure of 3 bar.
Figure 5-11: Bourdon type pressure gauge

5.6.8 Flow Control
Flow control options were discussed in Section 5.4 of the Preliminary Design Report, where maximum
and minimum system curves were plotted to illustrate the likely variation in flows that could be
expected due to fluctuating water levels within the boreholes.
It was agreed during the Preliminary Design phase that flow control at the boreholes will be achieved
by throttling the discharge isolation valve located downstream of the pump. The isolation valve will
effectively demolish surplus pressure (head) that will cause a reduction in the flow rate. To minimise
the risk of cavitation at the isolation valve, the ratio between the upstream and downstream pressure
should not exceed 3:1, e.g. if the upstream pressure is 60 m, the downstream pressure should be at
least 20 m or higher to avoid cavitation.
It was also agreed that a spool piece be installed as part of the borehole pipework, which can in future
be replaced by a variable orifice, should it be required. This is Item 12 as shown in Figure 5-7.
5.7 Electrical Design
5.7.1 Electrical Scope of Work

The electrical scope of work will comprise the following at the wellfields:
• Overhead line from EDM point of connection to transformer

• Eight 33/0.4 kV transformers (incl. distribution boards) to supply the eight new pump control
houses (PCH).
• Eight generator sets (genset) to supply a standby generator feed to the eight PCHs.
• Eight Motor Control Centres, including PLC cabinets.
• Remote I/O panels at the Matema DC and Cruzeiro DC reservoirs

• MV and LV cables and support systems,
• Earthing and lightning protection,
• Electrical building services comprising lighting and power outlets, and
• Area and road lighting.
5.7.2 Electricity Supplies

The maximum demand for each MCC in the wellfields are shown in Table 5-19.
Table 5-19: Maximum Demand and Transformer Sizes for the Wellfields
Selected
Transformer Maximum State of Existing
PCH Transformer Size
Name Demand (kVA) infrastructure
(kVA)
Nhartanda Wellfield
NHT-TRF-01 NHT-PCH-01 98.5 200 Existing
NHT-TRF-02 NHT-PCH-02 123.8 200 Existing 250 kVA TFR
NHT-TRF-03 NHT-PCH-03 124.6 200 None
NHT-TRF-04 NHT-PCH-04 100.5 200 None
Canongola Wellfield

CNG-TRF-01 CNG-PCH-01 157.2 315 Existing 250 kVA TRF
to be decommissioned
as reused if possible
Revubue I Wellfield
RVBI-TRM- RVBI-PCH-01 199.2 315 Existing 200 kVA TRF
01 to be decommissioned
as reused if possible
RVBI-TRM- RVBI-PCH-02 211.6 315 Existing
02
Revubue II Wellfield
RVBII-TRF- RVBII-PCH- 118.9 200 None
01 01
RVBII-TRF- RVBII-PCH- 152.3 315 None
02 02
An existing 33kV overhead line runs through or adjacent to all the wellfields Where new transformers
will be installed, new overhead lines will be constructed from the nearby overhead line to supply power
to the new transformers. The available MV supply capacity will be confirmed with EDM at the end of
the detail design phase.
Each MCC in the wellfields will have a dedicated genset providing backup power to the borehole
pumps in the event of load shedding or network outages. The estimated genset sizes are populated
below in
Table 5-20. The generators are sized to provide the motor start-up current required by the boreholes
pumps; as such, they are typically sized above the transformer rating. The standby generators shall
only be used for emergency cases in the event of a main power network failure for a maximum of 500
hours per year. In the event of a power outage, the generator shall come online and shall be capable
of restarting each borehole sequentially to ease the start-up transient current supplied by the
generator.
Table 5-20: Standby Generator Sizes for the Wellfields
Selected Genset
Maximum Size (kVA) (Prime State of Existing
Genset Name PCH
Demand (kVA) Rate) (preliminary infrastructure
sizing)
Nhartanda Wellfield
NHT-GEN-01 NHT-PCH-01 98.5 200 kVA Existing 550 kVA to
be relocated
NHT-GEN-02 NHT-PCH-02 123.8 250 kVA none
Canongola Wellfield
CNG-GEN-01 CNG-PCH-01 157.2 250 kVA none
Revubue I Wellfield
RVBI-GEN-01 RVBI-PCH-01 199.2 300 kVA Existing 550kVA

RVBI-GEN-02 RVBI-PCH-02 211.6 300 kVA none
RVBII-GEN-01 RVBII-PCH-01 118.9 200 kVA none
RVBII-GEN-02 RVBII-PCH-02 152.3 250 kVA (TBC) none
5.7.3 Motor Control Centres

All eight new pump control houses shall be fitted with new 400 V Motor Control Centres (MCC). Each
MCC shall house the switchgear and controlgear for all LV motor loads. Each MCC shall also provide
power to the building electrical services.
A typical general arrangement of each MCC is shown in Figure 5-12. Each MCC shall house three
sections. The first section is dedicated to the utility incomer, generator incomer, metering, generator
control, and a distribution section for small power and lighting. The second section is dedicated to
buckets housing each borehole’s motor starters and supply. The final section is reserved for the PLC
cabinet, which will house the PLC, communications and control equipment. Spare buckets shall be
made available for any future upgrades and were sized for 10 – 20 % of the borehole section.
Figure 5-12: Typical MCC General Arrangement (NHT-MCC-01)
5.7.4 MV and LV Cables

Electrical cables schedules have been drawn up from the equipment load lists and cable load
calculations, taking into consideration maximum allowable volt drop, installation method and derating
factors in accordance with SANS 10142.
MV cables will be 3-core copper conductor XLPE cables with steel wire armouring and a voltage rating
to suit the system voltage (i.e. 33 kV or 11 kV). Cable size will be selected to serve the load,
installation conditions and method, and supply system fault level. Cable terminations will be of the
heat-shrink type.
LV cables used within the PCH will be multicore copper conductor, PVC-insulated cables with steel
wire armouring. LV cables used for reticulation to the boreholes shall follow the same philosophy of
existing infrastructure and employ aluminium aerial bundle conductors (ABC). All cable sizes are
selected to suit the load, installation conditions and methods, voltage drop limits and installation fault
levels.
Cable support systems within the PCH will be hot-dipped galvanised cable ladder and wire-mesh tray
for large and small cables, respectively.

5.7.5 Earthing and Lightning Protection
An integrated earthing system will be provided for:
• Systems earthing i.e. earthing of transformer neutrals
• Equipment earthing i.e. earthing of exposed conductive part of LV equipment

• Lightning protection i.e. earthing of building LP down conductors
• Bonding of exposed and extraneous conductive parts
A single building foundation earth electrode will be provided at each PCH and shall be extended if
required to provide an earth resistance of a maximum 1 Ω to allow LV earthing. This earth electrode
will then also meet the requirements for lightning protection Type B earthing and will be designed in
accordance with SANS 1019: Design and Installation of Earth Electrodes.
It is considered prudent to provide lightning protection for the PCHs for the following reasons:
• The lightning ground flash density in the area is very high (approximately 16 flashes/km2/year)
• Loss of a PCH will cause loss of an essential service and economic loss
• The PCH will contain electronic equipment which is susceptible to lightning damage.
Lightning protection will be designed in accordance with the following parts of IEC 62305: Protection
against lightning:
• Part 3: Physical damage to structure and life hazard
• Part 4: Electrical and electronic systems within structures
Based on a preliminary lighting risk assessment, all PCHs shall be fitted with Class I protection
measures and coordinated surge protection devices to protect the structure against direct and indirect
lightning strikes. Air termination rods will be provided to connect to the down conductors in intervals
and locations required by the detailed design of a Class I protected system.
5.7.6 Electrical Building Services

Each MCC shall be equipped with a distribution section that shall provide power to all small power and
lighting equipment within and around the PCH. Interior and exterior lighting will be provided in the form
of a wall- or ceiling-mounted, corrosion protected luminaires with LED lamps. Emergency (battery
back-up) lighting will be provided at exits. Single-phase switched socket outlets will be provided in all
rooms as required.
5.8 Control and Instrumentation
5.8.1 General
The design approach for the control and instrumentation works is to achieve the following:
• Design a centralised SCADA with distributed PLC control system that will allow easy and
convenient operation of the scheme
• Safe design to ensure equipment and persons are adequately protected from possible faults
and hazards.
• Allow spare capacity to accommodate future extensions and or modifications of the scheme.

5.8.2 Control Narrative
5.8.2.1 General
The scheme will have one integrated control system with the master SCADA located in the control
room at the WTP. The control system aims to provide a comprehensive monitoring system that
includes the status and performance of the scheme’s wellfield equipment, pump stations, reservoirs,
and WTP. The operator will be notified of operational disturbances, equipment failure or prompted for
input when manual intervention is required.
The scheme will be monitored from the Master SCADA station located in the control room at the Tete
WTP or from the remote view node at the Matema DC. The scope includes all boreholes at the
Nhartanda, Revubue I and Revubue II wellfields, the WTP, the Revubue II pump station, and the
Matema DC reservoirs.
All boreholes can be started and remotely monitored from the control room located at Tete WTP. Each
MCC powering and controlling a subset of the boreholes can also be locally controlled at the MCCs
Human Machine Interface (HMI). A local switch-disconnector is provided at each borehole pump
station for isolation of the pump from electrical supply.
Automation will be limited to automatic duty change over, simple level stop-start control of pumps and
some pump protection functions. Every MCC will have a programmable logic controller (PLC) that will
monitor and control equipment and relay signals to the larger control i.e. to the SCADA or other PLCs.
The control system will monitor the following main signals:
• Flows from each borehole and the pump stations
• Water levels at each borehole
• Electronic pressure transducers at boreholes

• Level of reservoirs
• Flows at the WTP
• Level of reservoirs and sumps at the WTP
• Electrical consumption of load centres
• Equipment status (running, stopped, faults)

• Critical Alarms
All valves for the wellfields, treatment plant and pump stations will be operated manually, i.e. no
electrical actuation will be provided.
5.8.2.2 Operating Modes

The scheme will have the following main operating modes:
◼ Auto
◼ SCADA Manual
◼ Manual or Field control mode
◼ Off
Each MCC compartment that supplies mechanical equipment will have an auto/off/manual selector
switch that will be used to select the desired mode. SCADA manual will be selected on the SCADA
when the selector switch is in auto.

5.8.2.3 Auto Mode
In “Auto” mode, the control system will control the scheme automatically as detailed control narrative
chapter of each respective control system. This will be the default setting of the scheme. For
equipment to operate in “auto” mode, the MCC selector switch shall be in the auto position, allowing
PLC and SCADA control. All protection is active in this mode.
5.8.2.4 SCADA Manual Mode

In “SCADA manual” mode, the SCADA operators will be able to control the equipment manually from
the SCADA, e.g. stopping and starting of borehole pumps. This mode will also require the MCC
selector switch to be in ‘Auto”, but “SCADA manual” mode will be selected on the SCADA. All
protection is active in this mode.
5.8.2.5 Manual Mode

In “Manual” mode, individual equipment will be controlled from the local MCC or the field stop/start
stations. In “Manual” mode MCC selector switch shall be in the “Manual” position. In “Manual” mode,
the equipment cannot be controlled by the PLC or the SCADA. Only safety interlocks are active in this
mode, such as motor and pump protection, e.g. low level and electrical protection.
5.8.2.6 Nhartanda Wellfield

The boreholes in the Nhartanda Wellfield, comprising boreholes in Nhartanda Valley and Canongola,
will all discharge to the Tete WTP.
In “Auto” mode, the boreholes will be stopped and started automatically by the control system at the
Tete water treatment plant (WTP) based on the inflow required to the Tete WTP.
An alarm will sound if the flow meter registers flow outside the set parameters but will not switch off
the borehole pump. An alarm will also sound if the water level in the borehole reaches a low level. If
the water level sensor detects a low-low water level, the borehole pump will be stopped irrespective of
whether operating in “Auto” or “Manual” mode.
In “SCADA Manual” mode, the SCADA operator will be able to manually switch each borehole pump
on and off based on the total inflow required to the WTP at the SCADA.
The following instrumentation will be used for the wellfield’s control:
• Water level sensors at the boreholes

• Flow meters at boreholes and the WTP inlet
• Electronic pressure transducers at boreholes
5.8.2.7 Revubue I Wellfield

The Revubue I Wellfield will discharge to the Matema DC storage reservoirs. The control for the
Revubue I Wellfield will be automated based on the level in the Matema DC reservoirs. The wellfield
will be monitored and controlled from the WTP SCADA or the SCADA view node at the Matema DC.
In “auto” mode, the pumps in the Revubue I Wellfield will be controlled to keep the water level of the
Matema DC reservoirs between the operating level (OL) and high level (HL). Under normal operation,
the operating level will be defined as the minimum desired water level (e.g. 70%). The high level is
defined as the level at which intervention is required to reduce the flow before the reservoir reaches
full capacity (e.g. 90%). The boreholes in the Revubue I Wellfield will be assigned a rotating sequence
number to determine the pumps’ starting/stopping order.

The water level sensor will send a signal to the control system if the water level in the reservoir drops
below a pre-set level (e.g. 80%). When this level is reached, the control system will automatically
switch on additional pumps at set intervals and in accordance with the pre-set sequence until the
water level rises in the reservoirs. The water level will then be allowed to rise until it reaches the high
level (90%). At this level, the control system will start to switch off pumps until the level starts to drop.
The water level will then be allowed to drop until the preset operating level is reached. This cycle will
continuously repeat while in automatic mode.
The pump set at the Revubue II Pump Station supplying the Matema DC will also be controlled based
on the Matema DC reservoir level. This pump station will be operated in the same manner as the
borehole pumps, but at a lower priority level i.e., it will only be used when more water is required than
can be delivered by all the Revubue I boreholes. Once the demand drops, the Revubue II pump will be
switched off first before the boreholes are switched off.
In SCADA manual mode, the SCADA operator will have full control to switch each borehole pump
manually and the Revubue II pump sets to Matema DC on and off to manually maintain the desired
reservoir level. The sequence determined for the automatic operation above will still guide the
operator, but it can be overridden in this mode.
High Level (HL) and Low Level (LL) alarms will sound during manual operation mode to prompt the
operator to take the necessary action. In the case that the reservoirs reach the High-High Level
(HHL), all the pumps supplying the reservoir will be automatically switch off to prevent it from
overflowing.
The following instrumentation will be used for the Revubue I control:
• Water level sensors at Revubue I Boreholes and Matema DC reservoirs

• Flow meters at the Revubue I boreholes
• Electronic pressure transducers at Revubue I boreholes
5.8.2.8 Revubue II Wellfield

Revubue II’s control narrative is described in conjunction with the Revubue II pump station in Chapter
7.9.1.2.
5.8.3 Overall Control Network Architecture

The complete control network architecture is shown graphically in Figure 5-13. At the field instrument
control level, all boreholes will communicate to their respective MCCs through a low powered radio
communication link. This will ensure a reliable connection to monitor the borehole’s instruments (flow,
level and pressure) without the need to lay and trench additional power and/or communication cables.
All boreholes shall be controlled via a PLC within the respective MCC at a process control level. A
generator control unit (GCU) is required to safely monitor and interlock the genset to the MCC. All
MCCs will be equipped with a local HMI to monitor the performance and alarms of the MCC’s
equipment.
The MCCs in the field shall provide communication to the central control room at the Tete WTP via a
radio communication link supported in a star network to allow optimal routing. This inter-PLC radio
communication link will be done via WAN network gateways. All PLCs in the Tete WTP will
communicate to the central control room through a direct fibre link, as shown in Figure 5-13. The
supervisory control level includes a remote viewing node for the client and will be accessible via a
secure internet connection to the control room.

Figure 5-13: Tete BWS Control Architecture Overview
5.8.4 Communication
An event-based (change of state) control system rather than the traditional polling-based system will
be provided to optimize the network hardware, bandwidth and allow a more responsive control and
monitoring system. All communication from the control level to the SCADA will be done using the
MQTT protocol (am open and low-bandwidth protocol) over ethernet.
The following communication protocols are proposed for the scheme:
◼ PLC to Soft Starters: Industrial Ethernet
◼ PLC to MCC Power Meter: Industrial Ethernet
◼ PLC to HMI: Industrial Ethernet
◼ PLC to SCADA: MQTT over ethernet via Fibre optic cable or copper (Cat 6)
◼ PCH Telemetry to SCADA: MQTT over ethernet UHF
◼ Borehole low powered telemetry to PCH: LoRaWAN
◼ Instruments to low power telemetry: Hardwired pulses or 4 – 20mA
◼ Fieldbus communication to analogue field instruments will not be required.

5.8.5 Borehole Control and Instrumentation (C&I) Scope of Work
The C&I scope of work will comprise the following at the wellfields:
• Programmable logic controller (PLC) and associated human machine interface (HMI) at each
of the MCCs,
• Field instrumentation at each borehole,
• The Wide Area Network (WAN) Radio telemetry linking each borehole pump to their
respective MCC,
• The backhaul radio network connecting each MCC to the control room at Tete WTP,
• Control-, instrumentation- and data cables,

• Earthing and surge protection, and
• Uninterruptible power supplies (UPSs)
5.8.6 PLCs and HMIs

PLCs will be provided for the automatic control of the boreholes supplied by each respective MCC.
The PLCs will also provide process interlocking and protection functionality and serve as interfaces
with the central SCADA.
Associated with each PLC will be an HMI which will be provided to serve as the operator’s local
interface for the following:
• Monitoring of equipment status/conditions

• Monitoring of process variables (levels and flow rates)
• Monitoring of alarm and trip events

• Logging and trending of selected information
• Adjustment of process control, alarm and protection setpoints
• Generator controller
• Motors starters (direct-on-line and soft starters)
The HMIs will have graphics capability and will be set up for display mimic diagrams for monitoring
and control purposes.
5.8.7 Field Instrumentation
5.8.7.1 General
The scheme will have a basic level of instrumentation and will include the following main types of
online instrumentation. Signals from these instruments will be relayed and displayed on the SCADA:
5.8.7.2 Flow measurement

Electromagnetic flowmeters will do flow measurement at the water treatment works and Revubue II
Pump Station. Flow measurement at the boreholes will be done with mechanical turbine flowmeters
with opto-electronic outputs to the control system.

5.8.7.3 Pressure measurement
In addition to conventional pressure gauges, online pressure transducer will be provided at pressure
monitoring points.
5.8.7.4 Level Measurement

Level measurement will be done with hydrostatic level sensors which are more robust and cost-
effective than ultrasonic level meters. Where non-contact level measurement is required, ultrasonic
level meters will be provided.
5.8.7.5 Borehole Instrumentation

Each borehole shall be fitted with a dedicated flow meter, pressure transducer and level sensor, which
will replay the information via a low powered radio link back to the PLC that controls its pump. The
borehole shall also be fitted with an integrated temperature sensor to monitor the motor temperature
and send it out to the Groundfos MP 204 Motor Protection units over the Power Line Carrier. The
respective PLC shall then read the temperature signal via the motor protection units within the MCC.
All field instruments (excluding the integrated temperature sensor) shall be fitted with a remote radio
antenna and a backup battery system to reduce the cost of laying additional communication and
power cables to each borehole.
5.8.8 Radio Telemetry

Low Power Wide Area Networks (LPWANs) provide long-range communication on small, inexpensive
batteries that last for up to 10-15 years. They are purpose-built to support large-scale networks
sprawling over vast areas, comfortably providing connectivity for ranges of up to 10 km. LPWANs have
a low data transfer rate and are better suited for use cases that don’t require high bandwidth. In the
case of the wellfield, since an event-based control system is proposed, LPWAN is well-suited to the
application.
The WAN network shall provide a low-powered IIoT communication network link between the
boreholes and the PLCs in the field. The instruments shall communicate directly to their respective
PLC, which will communicate directly with the control room over IIoT LoRaWAN enabled gateways as
shown in the wellfield control architecture drawing 1001069-0000-DRG-II-0251 and Figure 5-14 below.
LoRaWAN network architecture is deployed in a star-of-stars topology in which gateways relay
messages between end-devices and a central network server. The gateways are connected to the
network server via standard IP connections and act as a transparent bridge, simply converting RF
packets to IP packets and vice versa. The wireless communication takes advantage of the long-range
characteristics of the LoRa physical layer, allowing a single-hop link between the end-device and one
or many gateways. All modes are capable of bi-directional communication.

Figure 5-14: Wellfield Control Architecture
5.8.9 Earthing and Surge Protection

Surge protection devices will be specified for all power and signal circuits of electronic equipment.
Functional and protective earthing will be provided as required to all electronic equipment.
5.8.10 UPSs
Uninterruptible power supplies (UPSs) will be provided to condition the power supply and provided
backup power to the PLCs and HMIs. The UPSs will be specified to be of the single-phase type with
an isolation transformer and a bypass to mains. Rated stored energy time will be standard in the 30
minutes range.
5.8.11 HMI
Each MCC will be provided with a Human Machine Interface (HMI) to monitor and control the
equipment of the respective MCC locally.
5.9 Sequencing of wellfield infrastructure

It is an important requirement of the upgrading of the wellfields that the current water supply not be
interrupted for extended periods. As such, the sequencing of the wellfield infrastructure is a critical
aspect of the planning process to minimise the disruption to the water supply. The following
sequencing is proposed for each of the wellfields under consideration.

5.9.1 Nharthanda wellfield sequencing
The existing Nharthanda Valley wellfield supplies the Tete WTP with some boreholes linked directly
with the reticulation network. The Canongola wellfield supplies directly to the reticulation network.
After the upgrading of the wellfields, all boreholes will feed to the Tete WTP from where water will be
supplied to the reticulation network. The following phased approved is suggested for the Nhartanda
wellfield:
- Phase 1: Ensure that all pipeline links are completed between the Tete WTP and the
reticulation network so that the boreholes that supply directly into the reticulation network can
be connected to the Tete WTP.
- Phase 2: Construct the new Pump Control Houses (PCHs) adjacent to the existing PCHs so
that the existing PCHs can remain operational. Once the new PCHs are complete and the
MCC panels installed, switch the power over to the new PCHs to continue operation of the
wellfields.
- Phase 3: It is assumed at this stage that all the collector pipelines between the boreholes and
the Tete WTP would be completed. All new boreholes (i.e. those currently unequipped) in
Nhartanda Valley must be equipped and commissioned, which will increase the flow to the
Tete WTP and enable Phase 4 to proceed.
- Phase 4: Upgrade all the Canongola (Phase 4A) and Nhartanda Valley (Phase 4B) boreholes
that are linked to the DN 500 transmission main. The upgrade must be planned to only take
four boreholes offline at a time while keeping the existing boreholes operational. Once these
four boreholes have been upgraded, the next four boreholes can be taken offline.
- Phase 5: Upgrade all the Nhartanda Valley boreholes linked to the DN 350 transmission main.
5.9.2 Revubue I wellfield sequencing

The Revubue I boreholes are linked to the existing DN 315 and DN 400 pipelines with a new DN 350
ductile iron transmission main being constructed by others. The following phased approach is
suggested for the Revubue I wellfield:
- Phase 1: Construct the new Pump Control Houses (PCHs) adjacent to the existing PCHs so
that the existing PCHs can remain operational. Once the new PCHs are complete and the
MCC panels installed, switch the power over to the new PCHs to continue operation of the
boreholes.
- Phase 2: It is assumed at this stage that the DN 350 transmission main would be completed.
All new boreholes (i.e. those currently unequipped) must be equipped and commissioned,
which will increase the flow to the Matema DC.
- Phase 3: Upgrade all the existing boreholes linked to the new DN 350 transmission main.
The upgrade must be planned to only take four boreholes offline at a time while keeping the
existing boreholes operational. Once these four boreholes have been upgraded, the next four
boreholes can be taken offline.
- Phase 4: Upgrade all the existing boreholes linked to the DN 315 transmission main (i.e. three
boreholes).
- Phase 5: Upgrade all the existing boreholes linked to the DN 400 transmission main (i.e.
seven boreholes). The upgrade must be planned to only take four boreholes offline at a time
while keeping the existing boreholes operational. Once these four boreholes have been
upgraded, the remaining three boreholes can be taken offline.

5.9.3 Revubue II wellfield sequencing
None of the Revubue II boreholes is equipped. In terms of sequencing, it would be important that:
- The Revubue II pump station be completed and commissioned by the time that the Revubue II
wellfield can supply water; and
- The two transmission mains to Cruzeiro DC and Matema DC be completed by the time that
the Revubue II pump station is commissioned.

6 Water Treatment Works
6.1 Water Quality
6.1.1 Raw Water Characterisation

The Preliminary Design Report reports on the water quality of the groundwater abstracted from the
Nhartanda and Canongola wellfields. To characterise the applicable water quality, a comprehensive
analysis of the raw water from each borehole was commissioned including the analysis of historical
water quality from January 2019 to December 2020 provided by FIPAG.
The influent raw water at Tete water treatment plant (WTP) can be broadly classified as:
◼ being low in turbidity;
◼ having a pH above neutral;
◼ iron and manganese exceeding regulatory limits;
◼ containing a low amount of dissolved organic matter;
◼ containing faecal coliforms in some borehole samples;
◼ of acceptable salinity;
◼ ‘hard water’ (i.e., falls within 150 – 300 mg/l CaCO3 range);
◼ being well buffered;
◼ scaling or protective waters.
The results and discussion of the applicable water quality can be found in the Preliminary Design Report.
The water quality analysis revealed the following with regards to any increased in future supply from
Canongola and remarks on why the aquifer should be protected.
◼ The inclusion of Canongola wellfield raises average concentration of iron, salinity, turbidity,
hardness, alkalinity of WTP raw water. It is therefore recommended that further Canongola wellfield
development to supply Tete WTP should not be considered and that the additional supply to the
WTP be sourced elsewhere.
◼ It is recommended that a deliberate programme be developed to manage the wellfield catchment
area to ensure that the water quality is appropriate for process design. Faecal pollution has been
noticed in the borehole samples which will continue to increase if not deliberately addressed.
6.1.2 Treatment objectives

From the raw water characterisation, the following treatment objectives were formulated to design the
process able to treat the raw water:
◼ Precipitation of dissolved Iron and Manganese is required and removal of precipitated metals to
acceptable levels.
◼ It has been demonstrated on the Preliminary Design report that the turbidity of the raw water is
attributed to the metals in the water, therefore turbidity reduction will be addressed when metals
are removed.
◼ Removal and destruction of pathogens is required to protect public health.
◼ Implementing pH adjustment to mitigate scaling in reticulation pipes and tanks.

6.2 Flow and Treatment Capacity
The WTP must be able to treat the incoming raw water to supply 30 ML/d of treated water.
The available safe yield supply from the wellfields at the present time is only 25.20 ML/d. An additional
6 - 7 ML/d must be sourced in future to meet the full capacity of the plant.
The civil, mechanical and electrical components of the WTP shall be designed to accommodate 30
ML/d with no interim phasing. Treating 24 ML/d until the future additional supply is provided will mean
that the filters will operate at a lower level and that the runtimes of the treated water pumpsets will less
compared to treating 30 ML/d. No capacity upgrade beyond 30 ML/d is possible.
The plant shall have the capacity to turn-down operations to a minimum of 12 ML/d after which any
lower quantum will affect the operation of the filters negatively, should all of the filters be in operation.
The wasteflow of the plant is between 3 – 5% based on the treatment volume. The variation of
wasteflow will depend on how the plant is operated. The design wasteflow is set at 5% for the plant.
As a result, the raw water inflow is set at 31.58 ML/d to achieve a 30 ML/d treatment volume, while
accounting for the plant 5% wasteflow.
Consequently, the present available raw water supply of 25.20 ML/d would enable the production of
23.94 ML/d of treated water given a 5% wasteflow.
Table 6-1 below summarises the applicable flow volumes for Tete WTP.
Table 6-1: WTP flow volumes
Description Flow Volume (ML/d)

Maximum treatment capacity 30.00
Minimum treatment capacity 12.00
Wasteflow 1.58
Raw water inflow 31.58
Upgradable ultimate capacity Cannot upgrade further
Present available supply 25.20
Present maximum treatment capacity 23.94
6.3 Process Design

The process is based on an oxidation and precoat filtration configuration with the addition of a
sedimentation step upstream of filtration and pH adjustment to lower the pH. This process does not
reduce water hardness but is able to reduce the pH to mitigation scaling.
The process configuration shall be as follows:
Aeration – sedimentation – filtration – pH adjustment – disinfection
Chlorine Dosing
Figure 6-1: Process configuration

6.3.1 Aeration
The aeration process introduces oxygen into water for oxidation of dissolved metals, mostly iron. The
oxidation of manganese using oxygen is a slow process that cannot be accommodated within the
aeration step; therefore the process allows for the precipitation of this metal in the filters using media
precoated with manganese dioxide.
Water is pumped directly from the wellfields to the top of the aeration structure where the raw water
falls over a series of weirs to introduce the desired oxygen concentration of 4 mg/L which also allows
for most of the dissolved carbon dioxide to escape.
The release of carbon dioxide from the raw water supply reduces the acidity of the water which then
raises the pH. The potential for calcium carbonate to precipitate on surfaces is increased when the pH
is raised.
6.3.2 Sedimentation
6.3.2.1 General
Sedimentation using plate settlers was chosen due to the space limitation on site. Plate settlers, even
though a static mechanical technology, allows for a significant reduction in space required for settling
in comparison to horizontal settlers. Plate settlers increase the surface area and optimise hydraulic
distribution leading to higher upflow rates.
The added benefit of plate settlers is that it can allow for a range of plate sizes which does not limit the
sedimentation tank sizing. Suppliers are able to retrofit plates in most horizontal tanks.
6.3.2.2 Design and operation

Aerated water drops directly into the sedimentation basin below. The sedimentation tank is divided into
two parts, 1) the inlet basin and 2) the plate settle basin, which is separated by a baffle wall. The baffle
wall is designed with specific size orifice holes to facilitate vertical and horizontal flow distribution
across the tank to the plate settles. An opening at the bottom of the baffle wall was introduced to
enable access to both basins for cleaning which will allow the majority of the flow to move to the
bottom of the tank when entering the plate settling basin.
For plate settlers to operate efficiently, the influent and effluent hydraulics must be carefully assessed.
High approach velocities to the plate settlers does not allow equal loading on the plates and may also
shear the solids settling from the plates, allowing solids to be resuspended and carried back to the
plate openings.
The upflow rates are also an important parameter. Given the site space limitation, a 5.8 m/h upflow
velocity is achieved for the plate settlers. This is on the upper spectrum for plate settlers, however,
bearing in mind that the sedimentation basin is necessarily required from a process point of view
based on the observed water quality data (the tank adds robustness to the design), and knowing that
the currently settling tank operates at 5.93 m/h without plate settlers (i.e. it operates as a horizontal
settling tank), this upflow rate is acceptable.
The baffle was introduced to control the hydraulics of the influent to the plate settling basin. Orifices or
launders will be used above the plate settlers to control the effluent distribution to the plates, ensuring
equal loading across the tank. Clarified water is collected in overflow launders.
Heavy solids will be able to settle in the inlet basin and accumulate in the hopper provided. Solids
settling from the plate settles will accumulate on its respective floor until the basin is emptied and
cleaned. All solids from the plate settling area are directed to the inlet basin hooper during the
cleaning process which is then removed by the installed pipe to the waste channel. The hopper is
placed at the inlet as theoretically 20-30% of the solids settle in the inlet zone.

6.3.2.3 Design criteria
The sedimentation process design criteria are summarised in Table 6-2.
Table 6-2: Sedimentation Design Criteria
Description Unit Design Value
Number of tanks No 2
Flow per sedimentation tank m3/h 625
Upflow velocity m/h 5.8
Sedimentation type Plate Settlers
Plan size per tank m 15.3 long x 7.1 wide
Sedimentation Area per tank m2 110
Tank depth m 4
Retention time min 50
Length to width ratio 2.1
Weir loading L/day/m 245,000 (awaiting feedback from supplier)
6.3.3 Filtration
6.3.3.1 General
The filters are designed as rapid gravity filter with a relatively coarse single grade media, using silica
sand. This rapid gravity sand filtration process involves the removal of solids by attachment in a bed of
filter media including the absorption of soluble manganese (Mn2+) to the media that is precoated with
manganese dioxide.
Chlorine is dosed upstream of filters to maintain free chlorine residual across the filters for oxidation of
absorbed Mn2+. The oxidation of Mn2+ with chlorine only is a slow process; however, it is accelerated
by coating the filter media with manganese dioxide. The absorbed Mn2+ is oxidised by the available
free chlorine to manganese dioxide whereafter the precipitate is removed from the filter during
backwashing.
A relatively coarse media of 0.95 effective size (ES) was selected to provide a greater storage space
for particles to increase filter run times, leading to fewer backwashes over time. A bed depth of 1000
mm was chosen to maintain a L/de ratio > 1000. No support media or gravel layer is required.
It should be noted that the existing filters for Tete WTP shall be decommissioned for the plant
upgrade, therefore no refurbishment is applicable for the existing filter system.
6.3.3.2 Hydraulic control

The preliminary design allowed for two types of filter hydraulic control, namely inlet flow split, variable
level (IFSVL) or variable level declining rate (VLDR). The Tete WTP filters are designed to be
controlled as VLDR filters, which allows each filter to transmit (within limits), the flow that matches the
degree of clogging (i.e. flow reduces in filter as clogging increases) of the individual filter. VLDR
filtration offers the following advantages:
◼ Filters controlled with this system can generally be expected to produce a comparatively better
effluent quality than an otherwise equivalent equal rate filter system. This is because the flow
through any filter declines proportionately and gradually as the filter clogs (i.e. the filtration rate is
the highest in the cleanest bed and lowest in the dirtiest bed). There is thus a natural equilibrium
between degree of clogging and flow rate, which limits the velocities through the shrinking voids

between media grains and in turn controls wash-through of particles entrapped in the filter media
bed.
◼ Submerged filter inlets and a deep inlet channel result in nearly equal water level in all filter boxes,
which varies in response to plant flow rate and degree of media clogging.
◼ Total operating head loss at any instant is the same for all on-line filters, so the cleanest filter
operates at the highest flow rate and the dirtiest filter at the lowest flow rate. Flow rate in a filter
declines in a step-wise manner as other filters are progressively backwashed.
◼ The clogging head to be allowed for the VLDR filter system (i.e. the head loss allowed for the
clogging of filters as they accumulate solids through a filtration cycle) is typically about 30% lower
than for an otherwise equivalent equal rate filter system. This is because the head (i.e. energy) is
consumed as turbulent head losses in the piping under-drains at higher flow rate near the
beginning of the filter cycle which becomes available for as a clogging head loss as the flow rate
declines during the cycle. In other words, turbulent head loss is reallocated to laminar clogging
head loss as the filter cycle progresses from clean to dirty.
◼ Less control equipment is required than for equal rate systems. The filters are thus simple to
operate, and do not require automated hydraulic controls.
◼ Water level is monitored at a single location in the inlet channel for backwash initiation. Simply, the
filter with the most hours of service is backwashed.
All filters operated at nearly equal level all the time, therefore after a filter is backwashed the water
level rises to match the adjacent filters, which will result in a very high filtration rate that might lead to
turbidity breakthrough. A fixed flow restrictor is therefore required on the effluent line of each filter to
limit the starting filtration rate on a clean filter. An orifice plate is provided for each the filters at Tete
WTP.
During a filter backwash, the water level in the remaining duty filters rise to accommodate the
additional flow load. The filter structure is designed to accommodate this increased water level.
6.3.3.3 Underdrainage system

The filter under-drainage system serves to collect filtered water that has passed through the filter
media, and to distribute filter backwash water and air scour evenly across the filter bed. This
component is very important for the proper functioning of the filter. Improper designs or improper
construction of filter floors can compromise the performance or even lead to total failure of filter.
The design of the Tete WTP filters is based on the use of a false floor with nozzles for the
underdrainage system. Dual parallel laterals were evaluated but not considered for Tete WTP due to
the potential risk of calcium carbonate closing the slots available for drainage. Once the slots are
scaled closed, the system needs to be broken out and be replaced. With a nozzle system, the nozzles
can be replaced as needed without affecting the false floor.
Figure 6-2: Filter false floor (left, Basiia Contracting) and Dual parallel lateral (right, Leopold Systems)

The false floor is placed 1000 mm above the base of the filter. The filter nozzles are fitted into the false
floor. Filtered water passes through filter nozzles into the under-floor plenum and then via a collection
pipe to the filter outlet box. Access is provided to the plenum to facilitate cleaning and inspection.
False floor systems may either be pre-cast reinforced concrete slabs or cast in situ. Pre-cast slabs
have the disadvantage that they are bolted down and the joints between the slabs must be sealed.
Experience has shown that the seals generally require replacing at 10 to 15 year intervals. The life of
a cast in situ floor slab should be similar to that of the concrete structure.
Filter nozzles serve to collect the filtered water and distribute the washwater and air scour evenly over
the filter bed area. They generally comprise a nozzle cap having accurately sized slots, and a nozzle
stem. The nozzle stem has an air slot near the bottom and air release hole near the top of the stem.
The filter nozzles are fitted into the false floor. For accurate distribution of washwater, and in particular
air scour, the nozzles must be accurately levelled to a tolerance of plus/minus 2 mm. Where no
adjustment of the filter nozzles is possible, the floor system must be constructed to this tolerance.
6.3.3.4 Backwash system

The filters will be cleaned using a combination of air scour and water backwash in the following high-
level sequence:
◼ Inlet sluice gate is closed, and filter allowed to drain to a set level just above the media.
◼ Necessary outlet valves opened and closed.
◼ Only air scour is started.
◼ This is followed by combined air-and-water backwash at sub-fluidisation flow (known as collapse-
pulsing backwash) on rising level to 100mm below overflow crest where air and water flow is then
stopped.
◼ Air is allowed to escape filter after collapse-pulse cycle and before rinse backwash is started.
◼ Finally, a rinse backwash is initiated an increased rate to rinse loosened solids from the filter bay.
◼ Necessary outlet valves opened and closed, and inlet sluice gate opened to put filter back into
operation.
This system is designed to achieve collapse-pulsing conditions that have been shown to provide for
most effective filter cleaning. The backwash water will be drawn from the chlorine contact tank (CCT)
into which the filtered water flows. For Tete WTP, the chlorinated backwash water will not have an
adverse effect on the filters as chlorine is already dosed upstream of the filters for the oxidation of
Mn2+. The CCT tank provides dedicated water for filter backwash.
The filters are designed to minimize water loss during backwash. The overflow crest of the filters is set
at 750 mm above the filter media which results in a total loss of water which is less than 5% of plant
treatment capacity. The filters have the option of being equipped with washout troughs, however, due
to the short filter bay width of 3.7m, the troughs may be omitted and has subsequently not been
included in the detailed design.
6.3.3.5 Chlorination at Filters

Chlorine shall be dosed upstream for the oxidation of the Mn2+. The chlorine chemical and dosing
apparatus shall be the same as used for disinfection. Refer to Section 6.3.5. The maximum dosing
rate is calculated at 1.5 mg/L of calcium hypochlorite, producing a free chlorine concentration of
approximately 0.91 mg/L.

6.3.3.6 Design Criteria
The design criteria are summarised in the Table 6-3.
Table 6-3: Filter Design Criteria
Number of filters No 7
Nominal filtration rate m/h 5.98
Nominal filtration rate (N-1) m/h 6.97
Nominal filtration rate (N-2) m/h 8.37
Total system head allowed m 2.40
Nominal clean bed head (with orifice plate) m 1.14
Clogging head allowed m 1.40
Maximum operating water level in filter m 2.31 above filter media (VLDR Level 4)
Minimum operating water level in filter m 1.61 above filter media (VLDR Level 2)
Plan size m 8.5 x 3.7
Filter area m² 31.45
Height control weir above filter media m 0.75
Media effective size mm 0.95
Coefficient of uniformity 1.4
Media bed depth mm 1000
Air scour rate m/h 75
Backwash rate (combined air scour) 15
Backwash rate (rinse) m/h 24
Backwash water volume m³ 180
Backwash water compared to total treatment volume % 5.0
Water temperature °C 30
Maximum upstream calcium hypochlorite dose mg/L 1.5
Maximum upstream free chlorine dose mg/L 0.9
Gravity chip feeder system No 3 duty, 1 standby (awaiting feedback from

supplier)
6.3.4 pH Adjustment
The raw water that enters the WTP is considered ‘hard’ with a calcium carbonate precipitation
potential (CCPP) values exceeding 30 mg/L (as CaCO3), indicating that there is a high risk that the
water would scale within pipes and water reservoirs. Scaling in pipelines have been observed at Tete.
Various methods were analysed in the Preliminary Design process to eliminate or mitigate scaling.
The adjustment of the pH was selected as the preferred approach to mitigate water scaling.
Reducing the pH increases the saturation concentration and reduces concentration of the carbonate
species in solution available for reaction, which in turn, lowers the possibility of scale formation. These
two phenomena effectively reduce the CCPP value. Ideally, the CCPP should be slightly positive (4 to
8 mg/L as CaCO3). This method does not reduce water hardness or alter the taste of the water.

Figure 6-3 provides an illustrative overview of the change in CCPP and pH across the WTP when
dosing a sulphuric acid to lower the pH. The results indicate that the CCPP and pH increases after the
aeration step. The addition of calcium hypochlorite has a minimal effect on pH and CCPP during the
process. By dosing sulphuric acid, the pH is reduced including the CCPP value.
100 9.00
90 8.80
Raw Water Aerated Water Filtered Water Final Water
80 (Dose Acid)
CCPP (mgCaCO3/L)
8.60
70
60 8.40
pH
50 8.20
40 8.00
30
7.80
20
10 7.60
0 7.40
CCPP pH
Figure 6-3: pH Adjustment of Water
The design is based on the dosing 20 mg/L of sulphuric acid at a concentration of 98%. The applicable
dosing rate would depend on the raw water quality, which may differ slightly for different seasons. The
equipment shall be designed to achieve the necessary operating range.
The acid is to be dosed directly upstream of the CCT to increase the speciation concentration of the
hypochlorous acid (HOCl) for more effective pathogen inactivation and also to reduce the contact time
required for the disinfection step. The dosing point shall be either within the pipe leading to the CCT or
within the inlet chamber of the CCT where water flows over a weir. Dosing at the inlet chamber is
preferred as the equipment is more accessible.
It is to be noted that the dosing of an acid only still carries the risk that scale could form when the
temperature of the water is increased, leading to the saturation concentration being reduced. The
systems effected are hot water systems such as kettles and geysers.
6.3.5 Disinfection
6.3.5.1 General
A disinfection step must be provided to inactivate and destroy the pathogens entering the system. It
has been shown that faecal bacteria were detected in the boreholes, posing a health and safety risk to
the public receiving the water.
The overall treatment process is designed to achieve a 3 log removal of Giardia, and a 4 log removal
of viruses, in accordance with international practise. A credit of 2,5 log for Giardia and 2 log for viruses
is accepted as an industry standard for conventional treatment (coagulation – flocculation –
sedimentation – filtration - disinfection) and the balance must be achieved by the disinfection step.
However, for the Tete WTP, process log removal credits associated with direct filtration was adopted
due to the process not involving coagulation and flocculation upstream of sedimentation.
The process log removal credits available for direct filtration is shown in Table 6-4 including the
remaining log removals that must be achieved by disinfection.

Table 6-4: Disinfection Target Log Removals
Process Log Removal Credit Log Removal Remaining for Disinfection
Giardia Log Credit Virus Log Credit Giardia Log Removal Virus Log Removal
2.0 1.0 1.0 3.0
The accepted credited log removals are based on the filters achieving a turbidity of <0.3 NTU for 95%
of the time. If the turbidity goal is not achieved for the time required, the total credit cannot be claimed.
The target log removals provide a good guideline for the authority to ensure that the water produced is
safe for public consumption.
Chlorine is dosed upstream of the filters to maintain a free chlorine residual across the filters for the
oxidation of the manganese. The chlorine that remains in solution post filtration will also contribute to
the free chlorine concentration required for disinfection, hence reducing the chlorine to be dosed at the
CCT.
6.3.5.2 Disinfection System

Calcium hypochlorite is to be dosed as the disinfection chemical. A gravity feeder system shall be
used for dosing the disinfection chemical. The dosing system was selected to prevent the fouling of
dosing lines associated with pumped dosing systems including the ease at which the chip feeders are
operated. The operator only has to ensure that the chlorine hoppers remain full of chlorine chips. No
electrical power is required. Calcium hypochlorite must be supplied as chips for the gravity feeder
system.
The HTH Scientific 35 kg chip feeder is the selected dosing apparatus. Two to three (awaiting
feedback from supplier) duty feeders are required with a standby should one need to be taken offline
for maintenance. The 35 kg system has a total height of 720 mm which is easily accessible by the
operator to fill the feeder, whereas the 200 kg system has a height of 1850 mm, which necessitates an
additional platform for the operator to fill the tank. Considering the height of where the tanks will be
installed including the applicable dosing rate, the 35 kg is more suited for Tete WTP.
Figure 6-4: Calcium Hypochlorite Chip Feeder Dosing System – 35 kg left and 200 kg right
The water enters the feeder system via the inlet valve. The water then enters the base of the chip
hopper, the bottom drum, where it flows into the chip bed. The chlorinated solution is then discharged
to the preferred dosing point.
The concentration of chlorine dosed is determined by the flow rate into the feeder system. A controller
is used to regulate the flow into the system, hence controlling the chlorine concentration dosed. An
inlet water pressure of 1 - 2 bar will be provided from the service water system.

The chlorine contact tank is sized for a retention of 25 min at 30 ML/d. The tank is a concrete tank with
an inlet and outlet weir to secure the 25 min required retention time. Baffle walls are provided to
increase the baffling factor in order to reduce the footprint of the tank.
6.3.5.3 Design Criteria

The dosing rate was calculated using a conservative water temperature of 25°C instead of the
adopted 30°C as there could be certain times in the year where colder water temperature prevail.
The design also allows for a large pH range, considering that pH is adjusted in the process. The
equipment is designed accommodated the applicable pH should the acid dosing system fail. The
dosing rate can be adjusted upwards in such an event. The design allows that water remains safe for
public use even if the pH adjustment process should fail for whatever reason.
The design criteria are summarised in the Table 6-5.
Table 6-5: Disinfection Design Criteria
Giardia removal required Log 3
Giardia credit for direct filtration Log 2
Giardia removal required by disinfection Log 1
Virus removal required Log 4
Virus credit for direct filtration Log 1
Virus removal required by disinfection Log 3
Water temperature °C 25
pH range pH 7.5 – 9.0
Average calcium hypochlorite dose mg/L 0.5
Average free chlorine dose mg/L 0.3
Expected free chlorine remaining post filtration mg/L 0.6 – 0.9
Total available free chlorine mg/L 0.9 – 1.2
Maximum free chlorine dose at disinfection only mg/L 1.5 (awaiting feedback from supplier)
Contact time required min 25
Volume of contact tank m³ 521
Baffling factor adopted - 0.7
Gravity chip feeder system No 2 duty, 1 standby (awaiting feedback

from supplier)
Inflow pressure feed to gravity chip feeder bar 1.0 - 2.0
The two chlorination systems at Tete WTP, one at the filters and one at the CCT, both utilise the same
chemical and equipment. Table 6-6 describes the total chlorine requirements for Tete WTP.
Table 6-6: Tete WTP Chlorine Summary
Average filter calcium hypochlorite dose mg/L 1.5
Average CCT calcium hypochlorite dose mg/L 0.5
Total calcium hypochlorite dose mg/L 2.0

Total daily usage kg/d 60
Total monthly usage kg/m 1815
Filter gravity chip feeder system No 3 duty, 1 standby (awaiting feedback

from supplier)
CCT gravity chip feeder system No 2 duty, 1 standby (awaiting feedback

from supplier)
6.3.6 Future process enhancements

The use of scale inhibitor does not reduce water hardness, but rather interrupts chemical scaling
process to lower the possibility of scaling as shown in Figure 6-5. Scale inhibitors are commonly used
for industrial applications such as boilers and reserve osmosis plants and certain product has been
certified for drinking water. Scaling inhibitors are propriety products with specific conditions for
application. The dosing of a sequestering agent (scaling inhibitor) can also be implemented to disrupt
the scaling process should an additional protection be required or if the acid dosing is to be lowered.
Figure 6-5: Scaling Inhibitor Prevention Mechanism
Discussions with a leading supplier of inhibiting agents confirmed that are products available that is
suited for the Tete water quality and safe for human consumption. These products can provide
protection against scaling up to 80% effectiveness for waters reaching temperatures of 90- 100°C,
providing protection for hot water systems such as kettles and geysers.
The chemical is expensive, however there could be cheaper alternatives available in future. Should
the cost of this chemical become more feasible in future, it could be considered for an enhanced
mitigation of scaling, also protecting hot water systems and not only the reticulation network
No scaling dosing systems is provided for Tete WTP; however allowance is made in the MCC room for
the control of this equipment should this be considered in future.
6.4 Civil Design
6.4.1 Operator-Centric Design Approach

Zutari recognises that a WTP will only function successfully if it has a staff compliment who are
competent and engaged in operating it. Consequently, Zutari has adopted an operator-centric
approach to the design of the works and capacity building of the operational staff. This includes the
following features:
• Aspects such as the flow and circulation within the works, as well as security, protection from the
elements, etc. are considered to encourage the operator to walk around his plant.

• Ready access to all areas of the works that require regular visiting is allowed to ensure that the
operator is able to access and maintain all areas of the plant.
• In our experience, if the design takes the operator’s needs into account, then they tend to take
more interest in, and ownership of the plant and make more effort to maintain it and operate it. If
they are not considered, then they tend to lose interest in operating/maintaining the plant.
• This approach drives the spatial layouts and aims to encourage active engagement between
operators and their duties, and between operators and the building itself. Ensuring safe,
transparent and ready access to all areas of the works and engendering a sense of ownership of
the plant will increase staff morale and performance efficiency.
6.4.2 General Design Requirements

In order to house the processes and supporting infrastructure for the WTP, two buildings and a
number of structures are required. The layout of the buildings and structures were defined by the site
constraints, the process and operator requirements. This section of the report discusses each of the
structures to provide more detail on the specific civil design considerations and how these have been
accommodated. Supporting imagery is provided to illustrate the building and/or structure to the reader.
The design of the buildings and structures typically accommodates the following requirements which
are discussed in more detail where required:
• Connections to and associated hydraulics of existing Tete WTP infrastructure.
• Process requirements in terms of volumes and hydraulic levels.
• Founding and minimum operating level of the adjacent structures.
• Geotechnical founding conditions and prevailing water table.
• Installed equipment requirements and associated pipework.
• Access requirements for operators, maintenance staff and vehicle deliveries.

• Electrical infrastructure and cable requirements.
• Ventilation of structures, where relevant.
• Natural drainage of structures including the maintenance and cleaning requirements.

• Practical constructability requirements and material cost considerations.
6.4.3 Architecture design

The architectural language of the buildings is aesthetically pleasing and appropriate for the
environment, reflecting an aesthetic derived as a consequence of good design practice and spatial
considerations appropriate to the function and use of the buildings.
The building structures are designed to be long-lasting and economical. The reinforced concrete
elements are reflected, expressed, and celebrated in the overall aesthetic of the building.
6.4.3.1 Building Services

Building services will be integrated with the overall architectural strategy of the Tete WTP site to
reduce the reliance and demand on artificial lighting, ventilation, and heating and cooling.
Natural lighting and ventilation are encouraged through large sections for fixed and openable windows
in all areas. The building envelope is designed to minimise solar heat gain and reduce reliance on
artificial heating and cooling.

6.4.3.2 Building Finishing
Building finishes have been selected in terms of their appropriateness to the operations they serve; to
be durable, long lasting, to require low maintenance, and based on preference from FIPAG. The below
schedule provides an overview of the finishes.
The sanitary fixtures are selected to be durable, require low maintenance, and have reliable support
from local suppliers and installers.
Joinery is designed to be fit for purpose of materials that are selected to be durable with hardware that
requires low maintenance and available locally.
Table 6-7 Building finishes and materials for Tete WTP buildings

General
External Doors Aluminium door and frame with clear windows
Internal Doors Aluminium door and frame with clear windows.
Windows Aluminium frames with tinted glass
Walls Brick, plaster and paint, plastered and painted
Machine Room Building
Service door Machine room: Roller shutter
MCC & Blower rooms: Steel door, no windows, powder coated (design
still to be finalised)
Floors Modified polyurethane or epoxy screeds (design still to be finalised)
Louvres Powder-coated aluminium with vermin proof mesh
Ceilings Sisalation suspended below steel roof (design still to be finalised)
MCC & Blower rooms: Off-shutter concrete
Roof Machine room: Steel IRB roof sheeting on steel truss system
MCC & Blower room: Concrete roof
Administration Building
Internal Doors Aluminium door and frame with clear windows. Opaque windows for
kitchen and bathroom
Floors Tiling
Ceilings Gypsum Plasterboard (Rhino Board type)
Roof insulation Cellulose fibre insulation
Roof Steel IRB roof sheeting on wooden truss system
Basins Porcelain
Hot Water Cylinders Hot Water Cylinder with Heat Pump

6.4.4 Structures and Buildings
6.4.4.1 Aeration
Aeration is achieved through an elevated concrete structure above the sedimentation tanks. Water is
received from the boreholes through DN 600 pipeline which splits the flow into two streams, entering
the two aeration structures as shown in Figure 6-6. This allows operators to isolate one stream in the
event a sedimentation tank needs to be serviced or drained.
The new aeration structure is similar in design to the existing aeration structure where water cascades
through a series of channels before draining into the sedimentation tank. Access to the top of the
structure has not been provided as there is no equipment in the structure and concrete will be the
material of choice.
Figure 6-6: Aeration structure isometric view
6.4.4.2 Sedimentation Tank

Following the two-stream aeration, two sedimentation tanks are provided to aid in settling out iron
oxide and other constituents from the raw water. The tanks will be equipped with plate settlers
designed and installed by the contractor. In-order to ensure even distribution of flow, the tanks are
fitted with a baffle wall with DN 200 openings. The baffle wall is open from the bottom to allow for
sludge to collect in a hopper as shown in Figure 6-7.
The sludge collection hopper is placed at the inlet zone as theoretically, 20-30% of sludge is settled at
the inlet (this can vary depending on water quality and treatment objective). The tank floor is benched
at a 1:75 slope to assist in sludge transport to the hopper. This method is not as effective as having
hoppers along the whole floor or mechanical sludge scrappers, both which are expensive additions
while increasing maintenance requirements, therefore the tank will need to be drained periodically as a
sludge blanket forms at the bottom. This operation method is acceptable as the water is not very turbid
and low sludge volumes are expected. The currently practice of cleaning the sedimentation tanks once
a month seems to be appropriate for the new settling tanks but would need to be monitored. Sludge is
drained from the hoppers using stainless steel pipes with orifices. The sludge collects in a pipeline and
discharges into the main site waste channel.
Settled water is collected in an effluent channel where chlorine is dosed using a pipeline placed above
the weir for adequate mixing. The chlorine solution is prepared in the as described in Section 6.3.5.
The chlorine dosing equipment is placed on the walkway allowing direct operator access when refilling
the drums. Since the drums are plastic, the filter control room is extended over the walkway. The
channel connects to the filter inlet channel.

Plant overflow from the sedimentation tanks drain in the effluent channel, which is then directed to the
overflow point, located within the filter inlet channel. This overflow also serves to as the overflow point
for the filters.
Each tank can be isolated by closing off the flow the respective aeration structure. The weir upstream
of the effluent channel is located above the filter inlet channel overflow, which protects the personnel
working in the isolated tank whilst normal operation continues in the adjacent tank. No isolation is
required for the effluent channel.
Since the structure proud out of the ground, access from ground level is provided through the use of a
concrete staircase and a central walkway. The plate settlers can be designed to allow operators to
walk on them for inspection and cleaning. The walkway also connects to the filtration structure and the
filter control room giving the operators complete circular access. The tanks are not covered with a
steel roof as the existing structures as this hampers access to install the lamella plates. Furthermore,
the roof is not required to protect the quality of the water. The roof covering from the filter building
control room has been extended over the chlorine feeders to shield the operator when filling the drums
with chlorine. A steel canopy roof similar to the existing roof over the sedimentation tanks can be
designed for if requested by FIPAG.
Figure 6-7: Sedimentation tank isometric view
6.4.4.3 Filter Building

Settled water will flow from the sedimentation tanks effluent channel into the filter inlet channel. Since
the filter control is based on VLDR control, each filter is fed from a submerged inlet equipped with a
sluice gate
The structure comprises of two elements, the concrete structure which houses the filter inlet and bays,
and a brickwork structure adjacent to the filters which houses the pipework, filter outlet boxes and the
filter control room. The filters are not covered with a roof while the control room is covered by a steel
roof. The control room is placed on the northern side of the structure instead of the southern side to
allow for the spent backwash channel to connect to the existing site waste channel.

Figure 6-8: Filtration structure plan view
Figure 6-9: Filtration structure isometric view
The filters are gravity filters with a conventional monolithic filter false floor. The media bed depth is 1.0
m deep. The minimum water level in the filters is driven by the throttling of the filter outlet valves and
the downstream hydraulic control which is a set weir in the filter outlet box. The top water level allows
for adequate clogging head. The maximum top water level is set by the level of the overflow weir
placed within the filter inlet channel.
The bulk of the pipework in the building is contained in the lower filter gallery to limit the sense of
clutter in the upper galleries however the air scour pipe is located below the upper filter gallery at the
intermediate level. Access to the lower filter gallery is from ground level. Access into the filter
underdrainage is provided using a 600 mm diameter access manway for each filter. The access

manway dimensions are limited by the available depth of the filter plenum and outlet pipework
configuration.
Filter outlet boxes are accessible using a staircase from the lower filter gallery. The outlet boxes
provide the operators a visual feel of the filtered water and also sets the hydraulic level from the filters
to the CCT. The outlet box allows the operators to quickly deduce if the filtration step is achieving
filtrate quality required using visual inspection and also allows easy access to sample flow from each
filter. Filtered water overflows the outlet box and enters into a channel below the structure.
The upper filter gallery houses the backwash controllers. Also, the outlet, backwash, waste and air
scour valves can all be opened or closed using spindles leading to the upper filter gallery. The gallery
also allows operators to see the level of water in the filters and the water in the outlet box. The upper
filter gallery connects to the filters top level through walkways giving access to the sedimentation
structure as well (see Figure 6-9).
During a backwash cycle the washwater overflows into a side channel leading the water into a lower-
level channel from which the spent backwash water flows to the main site waste channel. No run-to-
waste pipework is provided. In the event of filter media or nozzle replacement, the filters can be
isolated by closing the inlet sluice gate and allowing the filter to drain into the pipe outlet. The
remaining the water within the media is drained by opening a DN 200 drainpipe that discharges into
the waste channel.
The media can be loaded into the filters from the top given the very infrequent need to replace media.
Abiding by the philosophy of keeping the plant simple to ensure operational robustness, a fixed crane
is not specified, and the operators would either need to carry up media bags, or better yet, a mobile
crane can be brought into site when media needs to be replaced.
6.4.4.4 Chlorine Contact Tank

Filtered water is received in the CCT over an inlet weir. The weir allows for the addition of chlorine.
The structure contains baffle walls reducing dead zones and providing effective mixing. The structure
is also covered using a concrete roof.
Disinfected water overflows an outlet hydraulic control weir and is piped to the reservoir. Overflow for
the tank is near the outlet weir and drains to the main site waste channel. The overflow will only be
activated in the event that all the reservoir inflow valves are closed. The tank also allows for backwash
water draw-off upstream of the outlet weir.
Figure 6-10: Chlorine contact tank isometric view

6.4.4.5 Machine Room Building
The Machine Room Building comprises of the Pump Room, the blower room, and the electrical room.
Each of the components will be discussed in turn. An illustration of the building will be provided in the
final Detailed Design Report.
6.4.4.5.1 Pump room

The Pump Room is a large pumping hall which houses the treated water pumps, and the filter
backwash pumps. The room has a floor level approximately 2.4 m below FGL in order to enable a
flooded suction condition from the chlorine contact tank and existing reservoirs. The pumps are
located on plinths which are integral with the floor slab. Isolation of the plinths from the floor slab is
considered unnecessary due to the room being below ground level with minimum risk of vibrations to
the structure that would increase noise transmission.
Access is provided to each of the pump sets via a mezzanine walkway at 157.400 and associated
steel stairways. The pumpstation accommodates a motorised traveling gantry crane lifting equipment.
The gantry crane can be accessed using a cage ladder from the loading bay. A loading bay is
provided within the pumpstation. This allows for ease of equipment loading and offloading into the
pump room. Furthermore, the room has forced cross flow ventilation.
Sub-surface drainage has not been allowed for below the pumpstation as the floor level is lower than
the waste main invert level. Instead, the pumpstation is designed to withstand buoyancy. A dedicated
floor drain collects potential spillage, and daylights to the low point on site which has a ground level
lower than the drain (to be confirmed in the final Detailed Design Report).
The pump room walls will be constructed using both concrete and brickwork. Concrete walls will be
used below ground level and brick walls above it. The structure will also have a steel roof covering the
pumproom.
6.4.4.5.2 Electrical and Blower Room

Adjoining the Pump Room to the North are two rooms, the electrical room which houses the pump and
blower MCCs, and secondly the blower room which houses blowers for the filter air scour. The rooms
are located at ground level and are laid out in accordance with the needs of the infrastructure they
house. Ready access has been provided to access and service all equipment.
The ventilation system for the Pump Room is located on the roof of the electrical rooms, therefore a
concrete roof was chosen for the rooms. The ventilation equipment is accessible by a ladder from
ground level.
6.4.4.6 Reservoirs
In the Prelim Design it was determined that the internal condition of the reservoir walls and floors are
satisfactory and in no need of any significant refurbishments. The reservoir roof slabs and the
roof/cover slab of the pump area in-between the reservoirs were however found to be in a very
deteriorated condition. The general proposal for these two elements will be as follows:
◼ The roof area covering the pump rooms between the four reservoirs will be demolished and
removed so that the brick walls that are constructed onto the edges of each reservoir roof can be
removed.
◼ The roof slab and beams of each reservoir will be demolished/removed and replaced by new
reinforced concrete elements including new air vents, access manhole cover and ladder
◼ The roof covering the internal spaces of the reservoirs will be replaced to ensure that stormwater
runoff does not accumulate between the reservoir and within the pipe trenches. The new roof
covering over the internal spaces of the reservoirs will consist of a lightweight (HDG structural

steel) roof structure, with reinforced concrete slabs with handrailing on each edge to provide safe
access between each of the reservoir roof slabs.
◼ Care must be taken by the Contractor to carry out the demolition works in such a sequence and
manner such that minimal disruption is experienced by the existing structures and that continuous
operation of the plant is possible during construction.
◼ It is proposed to take two reservoirs out of operation and remove and replace existing roof slabs.
The roof covering the internal spaces is also to be removed during this process. Once the two roofs
have been replaced and the reservoir refurbished, the next two reservoirs will be refurbished.
Finally, the roof covering the internal spaces will be replaced.
The pipework between and built into the reservoirs will also be replaced with the same diameters. The
bottom DN 300 outlet will be converted to a bi-directional inlet and outlet pipe (refer to Section 6.4.5).
The existing top water inlet pipe is to be converted to overflow pipes however the detailed design is
still to be confirmed with the final report.
6.4.4.7 Administration Building

The existing administration building will be expanded to the eastern side, which would require the
demolition of the existing residential building east of the administration building. The site slopes
downward to the eastern side, therefore the building extension would be stepped to a lower level
complete with a separate roof that will be located at a lower level than that of the existing building.
The new extension allows for the following:
◼ A large 8-seater meeting room.
◼ Control and server room to monitor and control the operations of the WTP and wellfield .
◼ Shower and dressing room
◼ Separate toilet with wash basin
◼ Kitchen and dining
◼ Rest area which can also be converted to a storeroom.
Figure 6-11: Administration building, new expansion shown in red on the right side
This building is both where the operators will be performing most of the operational work and the first
building with which any visitors to the site will engage. With this in mind, the new expansion has been

critically designed so that the different operational rooms are situated close together, making it easier
for the operators to do their work and to communicate with each other, and other various stakeholders,
efficiently.
The existing part of the administration building will not be altered or refurbished as the condition is
considered satisfactory. Demolition of the western side of the building Is required for the new access
road including the current storeroom to provide access to the new expansion. The areas to be
demolished is shown in red in Figure 6-12.
Figure 6-12: Administration building, new expansion with areas to be demolished shown in red
The plumbing of the new expansion will all drain to the north-eastern corner of the building after where
it will drain to the eastern part of the site into a new septic tank. Drainage plumbing from the existing
part of the building will also be directed to the new septic tank and the existing one decommissioned.
The new kitchen and bathroom drainage pipes are at a lower level of the existing septic tank including
that the new access road may influence the existing septic tank, hence the reason to decommission
the existing and allow all sewer to drain towards the new tank.
6.4.4.8 Laboratory Building

The existing laboratory building is to be retained. The condition of the building does not require any
refurbishment.
The equipment within the laboratory was also found to be adequate for the purposes of operating the
existing and upgrade Tete WTP. No additional equipment is suggested unless there are specific
requests from FIPAG.
The drainage line of the building will be directed to the new septic tank.
6.4.4.9 Guardhouse Building

The optional guardhouse building indicated close to the main entrance gate for the Preliminary Design
has been omitted in the detailed design. The site visit revealed that the entry to the site is not
monitored closely with dedicated access control.
The space that this building would have occupied is now rather available for additional vehicle parking
and allows more freedom for large vehicles to manoeuvre on the site.

6.4.5 Interconnecting Pipework
Interconnecting pipelines are required to connect the different process structures including the
Machine Room Building, existing Reservoirs and Elevated Tank.
The applicable pipework diameters range from 300 to 700 mm.
Steel and HDPE materials shall be used, application depending on the size and application.
Mild steel shall be hot-dip galvanised carbon steel grade C in accordance with SANS 719 (>DN 150).
Pressure range of the pipes shall vary in accordance with the application. Stainless steel grade 316
puddle pipes shall be used where pipes are cast into concrete structures.
The different pipelines including material and operating properties are shown below.
Table 6-8: WTP Interconnecting Pipework
Pipeline Size Material and PN Flow Velocity
Inlet pipeline to aeration structure DN 600 HDG steel, PN 10 0.37 m³/s 1.30 m/s
Filter structure to CCT pipeline DN 800 HDG steel, PN 10 0.37 m³/s 0.73 m/s
CCT to Reservoirs pipeline DN 700 HDG steel, PN 10 0.35 m³/s 0.90 m/s
CCT to Machine Room Building: Treated water DN 700 HDG steel, PN 10 0.35 m³/s 0.90 m/s
CCT to Machine Room Building: Backwash water DN 500 HDG steel, PN 10 0.18 m³/s 0.90 m/s
Filter backwash rising main DN 450 HDPE 450, PN 6 0.18 m³/s 1.29 m/s
Treated water rising main DN 500 HDG steel, PN 10 0.35 m³/s 1.77 m/s
A pipeline corridor was identified for the inlet, filter backwash and air pipeline along the western
boundary wall. The inlet pipeline will be installed above ground, as close as possible to the wall to
create space for the other pipelines. In order not to undermine the boundary wall, the pipeline will be
installed above ground (final design shall be confirmed in final Detailed Design Report). Concrete
pedestals will support the pipes. Where the pipeline crosses the road, it will be buried and continue
below ground to the aeration structure. The filter backwash and air pipelines will be installed below
ground.
A large DN 700 steel pipe will connect to the existing reservoir outlet pipework, which tapers from DN
500 to DN 300 steel pipe at the bottom for each reservoir. The new supply and draw from the
reservoirs will be from the same bottom DN 300, which currently serves as the reservoir outlet only.
The existing top water inlet pipe for each reservoir will not be used as the hydraulic control for the
WTP is provided upstream at the CCT outlet weir. The water level in all in the reservoirs will operate in
unison as the level rises and falls within the structures.
6.4.6 Site Development
6.4.6.1 Bulk Earthworks

Given the existing and contained nature of the WTP site, the bulk earthworks design is heavily
dependent on existing boundary conditions and the final site layout taking into account new and
existing structures’ locations and depths. The bulk earthworks design will be described in the final
Detailed Design Report once the final footprint of all the buildings have been confirmed.

6.4.6.2 Road Layout
Figure 6-13 illustrates the road layout for the WTP site. Parking is provided at the lower administration
building level. Vehicles will access the site via an existing gravel through road that comes off from
Avenida 25 de Junho road.
There are two existing access gates to the site. The main gate is accessed via an existing concrete
ramp. The roads design for the WTP allows comfortable site access for a 9 m long truck through the
main gate and looping around the site and to exit via the secondary gate.
Vehicles larger than 9 m but less than 18 m can access the site and the layerworks is designed to
accommodate larger vehicles, however the movement through the secondary access point can only
accommodate a 9 m vehicle or less due to the site restrictions.
Figure 6-13: WTP road layout
This movement of the 9 m truck is shown in Figure 6-14. To allow for such a vehicle to complete this
movement, several adjustments and upgrades to the existing site will take place. These upgrades and
adjustments include:
◼ Reducing the size of the circular island on the lower level.
◼ Introducing a ramp from the lower level at the administration building to the higher level at the
existing reservoirs.
◼ Construction of a retaining wall along the south-eastern face of the administration building to allow
for the ramp and higher paving levels on the one side and a sidewalk around this building on the
lower side.
◼ Shifting of the reservoir retaining wall to create more space for the 9 m truck to move up the new
ramp.
◼ Resizing and realignment of the secondary access gate.

◼ Formalisation of the secondary access road from the existing gravel through road including the
hairpin bend and embankment protection between the access road and the existing gravel road.
Figure 6-15 and Figure 6-16 show the movements of the 9 m truck reversing to the MCC building after
entering the site via the main access gate and the secondary access gate respectively. The forward
movement of the trucks is shown in black and reverse movements in colour. This modelling was done
to showcase that a 9 m and smaller vehicle is able to access only through one entry point to make the
necessary deliveries. This is an advantage should only the main gate be accessed, and the truck is
able to reverse into where it required and access the site again.
Figure 6-14: WTP 9 m truck movement through the Site
Figure 6-15: WTP 9 m truck reverse movement via entry though the Main Access Gate

Figure 6-16: WTP 9 m truck reverse movement via entry though the Secondary Access Gate
Figure 6-17 illustrates the movement for a vehicle larger than 9 m but less than 18 m. A vehicle larger
than 9 m is able to manoeuvre within the site for large deliveries. However, access of any vehicle
larger than 9 m is subject to the type of vehicle accessing the site and whether the driver is
comfortable with manoeuvring in the tight space.
Figure 6-17: WTP 18 m truck reverse movement via entry though the Main Access Gate

6.4.6.3 Stormwater
The site is situated on hill. Stormwater runoff will drain across the roads and offsite through the two
site access points as shown in Figure 6-18. An existing drainage channel for backwash water is
located on the site. Runoff which enters the channel will flow through the channel and into a pipe
which carries water offsite and across the city before entering the Zambezi River. The channel and
pipe are also indicated in Figure 6-18 together with black arrows that indicate the general overflow
directions.
Figure 6-18: WTP Backwash Channel and Pipe
6.4.6.4 Water Network

Detailed design to be confirmed in the final Detailed Design Report.
6.4.6.5 Sewer Network

6.4.6.6 Ducting
6.5 Structural Design

The general structural items relating to the WTP have been addressed in Section 4. This section deals
with items that are specific to the current WTP site.
6.5.1 Filtration and Sedimentation Structure

The geotechnical investigation carried out at the WTP site revealed that competent hard rock can be
expected from around 0.75 to 1.0 m depth below NGL.
The proposed footprint and location for the filtration and sedimentation building is such that the south-
western end of the structure has a global top of concrete (TOC) for raft footing which is close to the
natural ground level (NGL). The south-western end of the structure will hence require a limited amount
of fill material after excavations to competent in-situ material have been carried out. The NGL on site
dips from the south-western direction towards the north-eastern end of the structure, resulting in the
TOC of raft footing being higher than NGL at the north-eastern end. This specific end of the structure
would then require a substantial amount of fill material before the raft of the sedimentation tank can be
constructed. This could lead to differential settlement between the filtration and sedimentation
structures.
In order to mitigate possible differential settlement, it is proposed that the rafts for the filters and
sedimentation structures be constructed on a combination of mass concrete platform (founded on the
competent in-situ founding), which is overlain by an engineered fill platform that will extend up to
underside of blinding layer. The mass concrete platform will be thickest at the north-eastern end of the
site beneath the sedimentation tanks (where the NGL is lowest). Underneath the filtration tanks,
depending on NGL, the mass concrete platform will either reduce in thickness or be omitted
altogether, with only engineered fill platform needed towards the south-eastern end of the site (where
the NGL is highest).
6.5.2 Machine Room Building

The pump room for this structure is buried at bout 2-3 m underground. With competent in-situ founding
very likely consisting of hard rock from about 1 m below NGL, this means that a portion of excavation
of up to 2 m could consist of hard rock excavation. The methods of excavations adopted by the
Contractor must therefore take this into account, given the proximity of this structure to adjacent
existing structures in the WTP, inclusive of water retaining structures Highly disruptive methods such
as blasting will not be permitted which also carries a safety risk to the Tete residents bordering the site
boundary. Hardrock excavations methods such as hydraulic drilling or mechanical / chemical splitting
is required.
6.5.3 Chlorine Contact Tank

The floor level of the tank is similar to the Machine Room Building. Hardrock excavation will therefore
also be required to the same prescribed conditions required for the Machine Room Building.
6.6.1 Introduction
The mechanical design is largely dictated by the process design and provides the mechanical
equipment required for each process step, thus ensuring that the process can take place as intended.
Close cooperation with the electrical design is required to ensure that the various systems function
correctly.
Mechanical design responsibilities are such that the concept, engineering and layout designs to tender
stage are completed by the Employer and Engineer, however, the contractor will be responsible for the
detailed design of the works and final equipment selection in accordance with those requirements.
The design life of installed equipment is typically 15 years if correctly designed, installed, operated and
maintained.
6.6.2 Aeration
Only the pipework that feeds into the aeration structure inclusive of the isolation valves will form part of
the mechanical scope for the aeration structure.

6.6.3 Plate settlers
The plate settler equipment will be of EN Grade 1.4401 (316) stainless steel. The rigid material
ensures durability for the operating environment and enables access for the operator on top of the
plates for inspection and cleaning.
An alternative to stainless steel is a hydrophobic high-density polyethylene material (HDPE) that
requires less cleaning, is a lighter material which requires fewer supporting structures and may also be
a cheaper alternative to steel.
For both materials, durability is the main driver for the choice in the final design. Feedback is still
pending from suppliers on the HDPE material system.
6.6.4 Filter equipment

The filter underdrain system will be false floors with nozzles for even distribution of water during
filtration and backwashing.
A DN 400 outlet pipe with an isolation valve to the filter outlet box is provided for each filter, including a
DN 400 connection from the DN 400 backwash manifold pipe. The backwash pipe is also isolated with
valve. The backwash pipework will include a standpipe that will extend to a level that protects the filter
floor from over pressurisation during backwash. A plan view of the pipework is shown in red for Figure
6-9.
An orifice plate will be provided in each filter outlet pipework to restrict the filtration rate through a
clean filter bed after backwash.
The outlet pipe will extend into the filter plenum with orifices spaced along the pipe. The pipe
extension is not required for the filter outlet flow distribution, but for flow distribution during the
backwash. Similar extension is provided for the air scour pipe. A connection to each filter from the air
scour manifold is provided. Each connection can be isolated.
6.6.5 Treated Water Pumpsets

Horizontal split case pump(s) is the preferred pump type for this application. The design of this pump
allows the pipework to remain horizontal, inline and remain close to the floor level which results in
smaller pipe supports and eliminates any potential vertical forces acting on the pump casing.
Horizontal split case pumps enable the operator to remove the impeller, shaft, seals, bearings, etc.
without the need to disconnect the pump from the pipeline or plinth. This reduces maintenance time,
downtime, and possible misalignment problems.
Figure 6-19 is an example of the horizontal split case pump configuration.
Figure 6-19: Example of a horizontal split case pump configuration

The pump selection must be evaluated based on the hydraulics of the feed and discharge pipes to and
from the pumps, especially because no variable speed drives are utilised. The two operating scenarios
producing the minimum and maximum pump heads were investigated for the pump selection, which is
described below.
The pumpset configuration shall be 2 duty, 1 standby. The pump station shall pump directly to the
elevated tank.
• Minimum pump head: One pump operating and the treatment plant operating at 50% capacity,
thus producing 15 ML/d.
• Maximum pump head: Two pumps operating and the treatment plant operating at 100%
capacity, thus producing 30 ML/d.
Due to the varying hydraulic levels a workable pumpset was selected to satisfy the average differential
pumping head for 30 ML/d. The Grundfos LS 250-200-305C horizontal split case pump was selected
to demonstrate a workable solution for the system. The system and pump curves are shown in Figure
6-20. With one pump operating, approximately 720 m3/h (17.28 ML/d) will be produced.
Figure 6-20: System and Pump Curves for Treated Water Pumps
The pumps will be driven by 4-pole (1500 rpm), low-voltage cage induction motors, horizontally
mounted and direct-coupled to the pumps. The motors will be specified for compliance with the
relevant parts of SANS 60034: Rotating electrical machines in accordance with the guidelines in SANS
1804: Induction motors – Part 1: IEC requirements.
The motors will be rated to provide a 30% safety/design contingency margin above the calculated
pump absorbed power at the duty point to allow for system and pump characteristic variances. This
results in anticipated 55 kW motor per pump and a total installed capacity of 165 kW.
The pumpsets will be mounted on steel base plates that are bolted to reinforced concrete plinths.
6.6.6 Backwash Pumps

It was established during the detailed design that two different pump types can satisfy the refined duty
backwash rates for the filter backwash; namely, end suction and horizontal split case centrifugal
pumps. Both pump types result in similar motor sizing, operating speeds, NPSH requirements and

operational flexibility. However, horizontal split case pumps are recommended for the following
reasons:
◼ Uniformity: Keep the pump type uniform in the pump room, as the treated water pumps are
horizontal split case pumps.
◼ Simplified: The design of this pump allows the pipework to remain horizontal, inline and remain
close to the floor level which results in smaller pipe supports and eliminates any potential vertical
forces acting on the pump casing
◼ Improved maintenance aspects: Enables the operator to remove the impeller, shaft, seals,
bearings, etc. without the need to disconnect the pump from the pipeline or plinth. This reduces
maintenance time, downtime, and possible misalignment problems.
For the required backwash water rate during collapse-pulse backwash (15 m/h), the KSB Omega 300-
300 B horizontal split case pump was selected to demonstrate a workable solution for the system.
The system and pump curves are shown in Figure 6-21. With two pumps operating, approximately 24
m/h rinse rate for filter backwash will result, which is acceptable for the backwash procedure and time
required for backwash. It is shown that three pumps operating will not increase the rinse rate much
further. However, a third pump will be provided as standby.
Furthermore, this pumpset was selected with an impeller diameter less than maximum diameter to
allow for further flexibility and system variances.
Figure 6-21: System and Pump curves for Backwash Pumps
The pumpsets will likely operate at speeds lower than 1500 rpm. The motors will be rated to provide a
30% safety/design contingency margin above the calculated pump absorbed power at the duty
point(s) to allow for system and pump characteristic variances. This results in anticipated 11 kW
motor per pump and a total installed capacity of 33 kW.
The pumpsets will be mounted on steel base plates that are bolted to reinforced concrete plinths.
The backwash pump discharge pipework will include a standpipe that will extend to a level that
protects the filter floor from over pressurisation during backwash.

6.6.7 Backwash Blowers
One duty and one standby blower will be installed in the Blower Room. Each blower will be sized for
the air flow rate requirement for backwashing the filters; i.e. 2358.75 m3/h for an air scour rate of
75 m/h.
The blowers will be acoustically enclosed units with removable covers.
The Blower Room will be provided with acoustic louvres sized and positioned to allow for installation of
the blowers through the louvre openings, and to prevent water ingress by limiting the velocity through
the louvres to 2 m/s.
Permanent lifting equipment is not provided as the units will be rolled and lifted into position during
installation. Future maintenance will require the removal of components within the units with the
assistance of the suppliers.
Pressure relief valves will be provided to protect the floor from over pressurisation during backwash.
Furthermore, the blower pipework will be provided with a high loop above the water level in the filters
to prevent water from getting to the blowers and causing damage.
6.6.8 Pipework Sizing, Materials & Corrosion Protection

All pipework above and below ground level will be hot-dip galvanised (HDG) carbon steel unless
otherwise stated. Puddle pipes and pipework below water level will be EN Grade 1.4401 stainless
steel (316) due to the increased corrosivity and/or complexities in future replacement.
The pressure rating will be a minimum of PN 10.
Table 6-9 provides a summary of the proposed mechanical pipework within buildings at the WTP.
Table 6-9: WTP Internal Pipework
Pipe Designation Size Material and PN rating Flow Velocity
Treated Water Pumps Suction Manifold DN 700 HDG carbon steel, PN 10 0.35 m3/s 0.9 m/s
Treated Water Pump Suction Pipe DN 400 HDG carbon steel, PN 10 0.17 m3/s 1.4 m/s
Treated Water Pump Discharge Pipe DN 400 HDG carbon steel, PN 10 0.17 m3/s 1.4 m/s
Treated Water Pump Discharge Manifold DN 500 HDG carbon steel, PN 10 0.35 m3/s 1.8 m/s
Backwash Pumps Suction Manifold DN 500 HDG carbon steel, PN 10 0.21 m3/s 1.1 m/s
Backwash Pumps Suction Pipe DN 350 HDG carbon steel, PN 10 0.13 m3/s 1.4 m/s
Backwash Pumps Discharge Pipe DN 300 HDG carbon steel, PN 10 0.13 m3/s 1.8 m/s
Backwash Pumps Discharge Manifold DN 400 HDG carbon steel, PN 10 0.21 m3/s 1.7 m/s
Air pipework within Blower Room DN 250 HDG carbon steel, PN 10 0.66 m3/s 13.3 m/s
6.6.9 Valves
All isolation valves will be manually operated, flanged butterfly valves due to it being an economical
option and suited to the applications of this design, unless otherwise stated. This includes for blower
and pump discharge isolation as well as all filter isolation valves and the suction pipework isolation
valves from the CCT and Reservoirs.
Gate valves will be installed on the suction pipe of each pump for isolation purposes only. This is the
recommended type of valve to ensure full bore flow and minimising turbulence at the pump inlet,
particularly when the suction pipework lengths are short due to site space constraints.
All handwheels will be clockwise closing.

Slanted seat check valves are recommended for the backwash pumps and treated water pumps, with
levers and counterweights for visual position indication and assisted closure.
6.6.10 Lifting Equipment

Permanent lifting equipment will be provided in the pump room due to installation and maintenance
requirements of the pump systems.
The heaviest load in the pump room is anticipated to be the pumpsets. The Contractor would align the
pump and motor on site and the likelihood of lifting the pumpset in future is low. Therefore, the Safe
Working Load (SWL) for the overhead traveling crane is based on lifting the individual pump or motor
whichever is anticipated to be heavier plus 30% safety margin.
The anticipated weights for the pump and motor are 1000 – 1100 kg and 350 – 400 kg respectively,
thus the proposed SWL for the permanent lifting equipment is 1500 kg (1.5 ton).
6.6.11 Ventilation Systems

The following ventilation systems are proposed for the different areas of the WTP:
Section Type of ventilation
Machine Room Forced Ventilation – To deal with mechanical heat loads generated within the pump
room, allowing for a temperature increase of 50C or allowing 5 air changes per hour,
whichever one of the two bears the greatest airflow requirement.
Blower Room Natural Ventilation allowing sufficient air into the room for consumption during
backwashing without rain entrainment.
MCC Room Air Conditioning
Offices Air Conditioning
Laboratory Air Conditioning
Two duty fans will be situated on the outside of the Machine Room Building on top of the concrete roof
covering the MCC and Blower rooms, forcing ambient air into the room via a main ventilation duct. The
two fans will be sized to have a combined duty required to remove the heat loads during maximum
equipment operation, namely two Treated water pumps and tow Backwash pumps operating at full
capacity.
The main ventilation duct will run along the length of the room underneath the walkway and at a low
level. The main duct will have six take-off ducts with louvres, each facing the corresponding equipment
i.e., each pumpset will have a take-off duct and louvre directing air across it.
The main duct and take-off ducts will be designed to meet the required air volume and velocity to
remove the heat load generated by the equipment. It is recommended to keep the velocity below 10
m/s in the main duct to mitigate noise levels.
Outlet louvres will be positioned at a higher level in the machine room and on the opposite wall of the
main duct. This will result in an affective cross flow over the mechanical equipment, thus removing the
heat load from the equipment and building.
6.6.12 Chemical handling and storage
6.6.12.1 General
The design allows for sulphuric acid being delivered to site by means of Intermediate Bulk Containers
(IBCs). Site constraints only allows for a 10 ton truck (5 IBCs) to deliver at the storage area on site, or

if needed, bigger trucks (< 20 ton) can deliver outside of the site, however the IBCs will have to be
transported with an onsite forklift to the storage area.
It has been shown that a 20 ton truck can enter and manoeuvre within the site, effectively increasing
the number of IBCs that can delivered in a single load. The access for this type of truck or less would
be dependent on the truck.
Figure 6-22: Example of Onsite forklift (Left) & Intermediate Bulk Container (IBC) (Right)
Due to the delivery method and system design, there will be no need for big storage/day tanks on site.
A storage area and dosing area have been allocated for a 1-month dosing supply.
Table 6-10: Chemical Storage and Dosing Supply
Chemical Storage and Dosing Supply

Chemical Volume of Number of IBCs required Number of IBCs Number of IBCs at
IBC (m3) for 1-month dosing at storage area dosing area
supply
Sulphuric Acid
1 10 5 5
(98%)
The IBCs will be transported from the storage area to the dosing area and vice versa with an onsite
forklift. Due to the constant rotation of IBCs there will be no need to clean and maintain the containers
from sludge as the empty containers will be swapped for full containers with each delivery.
The design and layout of the chemical dosing area minimises unnecessary handling of the chemical
which reduces the safety risks to the plant operators.
Five IBCs will be connected via flexible hoses to a manifold that feed the dosing pumps. The
containers can be set as all-duty or duty/standby to ensure an uninterrupted flow while empty
containers are being replaced with full containers from the storage area.
6.6.12.2 Safety Requirements

The civil infrastructures that accommodate the storage tanks and dosing tanks includes covering as
well as bunded areas with chemical resistance coatings. The bunded areas are designed to
accommodate 110% of the volume of a single container. Further to this they have been designed such
that the operators will be able to safely access the isolation valves from each container and can easily
connect, disconnect, and replace the containers with the onsite forklift as they reach their minimum
level.
The storage and dosing areas are open to atmosphere and therefore well ventilated to prevent any
build-up of hazardous fumes and a safety shower is positioned nearby.

6.6.12.3 Chemical dosing piping
The design and position of the dosing area minimises the length of dosing pipes required and will run
above ground from the dosing pumps to the dosing point. Any potential leaks will be spotted, thus
eliminating the need for double wall containment pipework. The piping specification for the chemical
being dosed is indicated in Table 6-11.
Table 6-11: Chemical Dosing Piping
Chemical dosing piping

Chemical Rating (PN) Pipe & Fittings Material
Sulphuric Acid (98%) 10 Polyvinylidene fluoride (PVDF)

The electrical scope of work will comprise the following at the WTP:
◼ One 33/0.4 kV transformer (incl. distribution boards) to provide the main supply to the WTP.
◼ One containerized generator set (genset) to supply a backup power feed,
◼ Two Motor Control Centre and control gear assemblies, supplied by one Main distribution board
(MDB),
◼ Overhead line from EDM point of connection to transformer
◼ MV and LV cables and support systems,
◼ Earthing and lightning protection,
◼ Electrical building services comprising lighting and power outlets, and
◼ Area and road lighting.

The WTP shall be supplied via a spur connection of a nearby overhead line energizing a new 33/0.4
kV transformer. The WTP will be sized to meet the notified maximum demand of the plant, which is
centralised at the Main Distribution Board (MDB). The available MV supply capacity will be confirmed
with EDM at the end of the detail design phase.
A containerised standby rated generator set is required to provide backup power to the site in the
event of load shedding or network outages and shall be centralised at the MDB. A complete view of
the electrical supply equipment is shown in Figure 6-23.
The diesel generator set will be equipped with a fuel tank sized with the capacity to supply 8 hrs of
continual operation of the whole plant. In the case of a power failure, there will be an automatic
changeover to generator power. In this power outage, the generator shall come online and be capable
of restarting each pump sequentially to ease the start-up transient current supplied by the generator.

Figure 6-23: Tete WTP Electrical Supply Block Diagram

Two separate MCC shall control the WTP, fed from a centralised MDB, as shown in Figure 6-23. The
MDB shall be responsible for the electrical changeover in the event of a loss in the main supply. The
treated water MCC is responsible for powering and controlling the three treated water pumps and shall
be equipped with soft-starters to limit the in-rush currents of the motors to three times the nominal
current.
The Filtration and Dosing MCC is dedicated for powering and controlling the filtration and dosing
equipment (backwash pumps included) as well as the remainder of the site’s small power and lighting
loads. Mechanical pumps less than 10 kW shall be equipped with Direct-on-Line (DOL) starters,
whereas mechanical pumps larger than 10 kW shall be equipped with soft-starters to limit the in-rush
currents of the motors.

Electrical cables schedules have been drawn up from the equipment load lists and cable load
calculations considering maximum allowable volt drop, installation method, and derating factors
according to SANS 10142.
MV cables will be 3-core copper conductor XLPE cables with steel wire armouring and a voltage rating
to suit the system voltage (assumed to be 33 kV for this installation).
LV cables used within the pump station will be multicore copper conductor, PVC-insulated cables with
steel wire armouring, and all cables will be labelled. All cable sizes will be selected to suit the load,
installation conditions and methods, voltage drop limits and installation fault levels. Cable support
systems within the WTP will be hot-dipped galvanised cable ladder and wire-mesh tray for large and

small cables, respectively. The cable sizes will be restricted within the range of 4C x 2.5mm² to 4C x
185mm² to allow for the most practical installation.

The WTP works shall follow the same philosophy for earthing and lightning protection as defined in
Section 5.7.5, replacing the term ‘PCH’ with ‘WTP’.

The WTP works shall follow the same philosophy for electrical building services as defined in Chapter
5.7.6, replacing the term ‘PCH’ with ‘WTP’.
6.7.7 Area and Road Lighting

Area lighting shall be provided to illuminate the exterior of the WTP enough to meet the minimum lux
(lighting level) requirements as defined in SANS 10142. All exterior lighting shall use IP rated, LED
lighting fixtures and pole or surface mounted depending on the final lighting design.
6.8.1.1 General
See 5.8.2.1
6.8.1.2 Tete WTP

In “Auto” mode, the process controller will enter the flow rate at which the WTP must operate, e.g.
20 ML/d. Each borehole will be assigned a starting priority and will have a safe design yield. The
control system will then start the required number of pumps to deliver a flow of 20 ML/d.
The flow meter at the inlet to the WTP will measure the total inflow to the WTP and will sound an alarm
if the inflow varies by more than ±5% of the set value. If the measured flow at the WTP exceeds the
set point, the PLC will automatically switch off the last pump that was started. If the measured flow at
the WTP is lower than the set point, the control system will automatically switch on the next pump
based on the pre-programmed starting sequence.
In “Auto” mode, the treated water pumps will start when a low-level signal is received from the level
sensor in the elevated tank, and the pump(s) shall stop when a high-level signal is received. In
“Manual” mode, the process controller can manually stop and start the pumps from the local control
panel.
The filters will not be backwashed automatically but will be provided with a push-button type control
panel at the filters that allows the operator to stop and start the backwash equipment from the filters.
All valves will be operated manually i.e. no electrical actuation will be provided. It is recommended that
each filter be backwashed based on specific time intervals i.e. once every day. The time between filter
backwashes shall be sufficient to ensure that the backwash storage tank (CCT) is replenished for the
next filter backwash, especially when the production flow of the plant is low.
If the process controller adjusts the flow rate to be treated, e.g. reduce it to 15 ML/d, the control
system will automatically switch off boreholes until the total inflow is reduced to the new set point.

In “SCADA Manual” mode, the SCADA operator will be able to switch on and of the WTP equipment
manually.
The following instrumentation will be used for the WTP’s control:
◼ Water level sensors for the Nhartanda Boreholes, WTP filters, storage reservoirs and elevated
tank.
◼ Flow meters at the Nhartanda boreholes.
◼ Pressure meters at Nhartanda boreholes.
◼ A flow meter at the inlet to the Tete WTP to measure the combined inflow.
◼ A flow meter at the discharge manifold of the treated water pumps to measure flow to the elevated
tank.
◼ A flow meter at the discharge manifold of the backwash water pumps to monitor flow to the filters.
◼ A flow meter on the air piping from the filter blowers.
◼ A flow measuring device to set the dosing of acid into the system.
The instrumentation will also be used to generate alarms, e.g.:

◼ If the measured inflow is ±5% of the set point of the WTP.
◼ High or low water levels in the storage reservoirs, elevated tank and filters.
◼ Pump and motor protections on the pump sets.
◼ Any boreholes not starting or stopping via the PLC.
◼ Any fault signals received directly from the boreholes (e.g. low level at the borehole itself)
6.8.2 WTP Control and Instrumentation (C&I) Scope of Work

The C&I scope of work will comprise the following at the WTP:
◼ Programmable logic controller (PLC) and associated human machine interface (HMI) at the two
MCC at the WTP,
◼ Field instrumentation,
◼ Radio telemetry linking the WTP to all of the PCH and Revubue II pump station gateways,
◼ Control-, instrumentation- and data cables,
◼ Earthing and surge protection,
◼ Uninterruptible power supplies (UPSs), and
◼ A supervisory, control and data acquisition (SCADA) system.
◼ Historian and Reporting software

Figure 6-24: Tete WTP Control Architecture Diagram
6.8.3 PLCs and HMIs

PLCs will be provided for the automatic control of the WTP. The PLCs will also serve to provide
process interlocking and protection functionality and to serve as interfaces with SCADA systems.
Associated with each PLC will be an HMI which will be provided to serve as an operator interface with
the PLC for the following:
◼ Monitoring of equipment status/conditions.
◼ Monitoring of process variables (reservoirs and filter levels including pump flow rates).
◼ Monitoring of alarm and trip events.
◼ Logging and trending of selected information.
◼ Adjustment of process control, alarm and protection setpoints.

Conventional 4-20 mA current loops will be used for continuous measurement, and 24V DC or
potential-free contacts for discrete measurement.
6.8.5 Radio Telemetry and Networking

A radio telemetry system will be provided to communicate to all remote sites, which are defined as all
wellfield MCCs, Matema DC remote I/O, Cruzeiro DC Remote I/O and the Revubue II pump station
MCC.

The radio telemetry system is designed using industry-standard UHF WAN architecture, distributed
network protocols and frequency bands approved by the national telecommunications authority. The
two PLCs at the WTP shall not be connected via radio telemetry and instead communicate via a fibre
ring on site.
6.8.6 Control, Instrumentation and Data Cables

Control cables will be provided as required for the control circuitry of all controlled equipment and
remote-controlled devices. The following list defines the necessary data and communication cables,
depending on their application.
◼ Control cables will be 600/1000V multicore 1,5mm2 minimum copper conductor, PVC-insulated
cables with galvanised steel wire armouring and PVC serving.
◼ Instrumentation cables will be provided as required for all instrumentation signals where the
instrumentation is not equipped with an integral cable long enough to reach the termination point.
◼ Instrumentation cables will be a minimum 1 mm2 twisted-pair, copper conductor, individually and
overall screened, PVC-insulated with galvanised steel wire armouring and PVC serving.
◼ Data cables for linking the HMIs, UPSs and pump motor starters will be industrial Cat5/6e UTP
Ethernet cable or of a type suitable for the equipment supplied by the contractor.
◼ The PLCs at the WTP shall be connected via a fibre ring to ensure network redundancy, as shown
in Figure 6-24.

The WTP works shall follow the same philosophy for earthing and surge protection as defined in
Section 5.8.9.
6.8.8 UPSs
The WTP works shall follow the same philosophy for UPSs as defined in Section 5.8.10.
6.8.9 SCADA and Reporting

The control room will house the Master SCADA system at the WTP. The SCADA servers, located in a
dedicated server room, will have a hot standby arrangement to allow for redundancy with remote view
SCADA PCs that will connect to the SCADA servers. The SCADA PC will provide an overview of the
complete water distribution system.
The SCADA software will serve as the user interface to the whole scheme and as the single point of
truth for operational data. It is, therefore, a critical aspect to consider. Although it is usually a fraction of
the cost of the overall scheme, it can become a sore point and frustration to the scheme operators if
not well designed.
The SCADA software package will be chosen based on the following criteria:
◼ Flexibility to customise software
◼ Availability of certified system integrators to support the software
◼ Web and mobile functionality
◼ Supporting open protocols, e.g. MQTT
◼ Licensing costs, i.e. are renewal licenses required
◼ Scalability.

All data points monitored by the SCADA will be stored into an industrial historian. Additionally, the
SCADA system will make allowance for the capturing of manual data such as lab samples and storing
this data into the database.
A reporting software package will be provided that will allow for automated reports on the scheme or
subsystem’s most important indicators.
Figure 6-25: SCADA Process Overview Example
Figure 6-26: Reporting Dashboard Example

6.9 Sequencing of WTP Infrastructure
The site of the upgrade of the Tete WTP is severely restricted, as was demonstrated in the Preliminary
Design. The main objective of the WTP construction is to upgrade the existing plant while the plant
remains operational to feed potable water to the town of Tete.
Certain temporary connections and short term interruption (less than 24 hours) will be inevitable during
construction, nonetheless the site was design to prevent major disruptions.
The following sequence of infrastructure development is planned for Tete WTP, which is illustrated in
the various figures below. Certain details of the phasing proposed may be changed for the final
Detailed Design Report, depending on how the design is developed.
The construction and commissioning process described below would take longer to complete
compared to a WTP constructed on a greenfield site. The reason is to maintain the water supply of the
existing while upgrading.
Figure 6-27: Phase 1 - Decommissioning of existing infrastructure and laying temporary pipes
Phase 1: Decommissioning on existing infrastructure and laying temporary pipes

◼ The first action would be to install the temporary pipes as represented by the blue lines in Figure
6-27. The pipework is temporary and would most likely be installed above ground with certain
sections below ground as required for construction vehicle access.
◼ The existing aeration and sedimentation structure will be decommissioned along with all the other
buildings shown in the red blocks.
◼ As the aeration step is temporarily omitted, chlorine is to be dosed at the purple point to assist with
the oxidation of iron. The dosing line would be extended from the current dosing point to the one
shown in purple.

Figure 6-28: Phase 2 - Construction of new structures / buildings
Phase 2: Construction of new structures / buildings

◼ Space would now be available to construct the majority of the structures. The critical structures to
be constructed would be the new aeration-sedimentation-filtration superstructure and the Machine
Room Building.
◼ During this time, the reservoir refurbishment would also commence, subject to not more than two
reservoirs taken out of operation at the same time. Care would be taken when refurbishing the
reservoirs to protect the existing backwash and treated water pumps to ensure continuous
operation.

Figure 6-29: Phase 3 - Installation of new pipework
Phase 3: Installation of new pipework

◼ Phases 2 and 3 would overlap for certain periods.
◼ New pipework must be installed to service the filters and the elevated tank. Once all the pipework
is installed, the filters will be commissioned with the Machine Room Building equipment.
◼ The new inlet pipe will be installed (shown in yellow)
◼ The backwash rising main and air scour pipelines will be installed along with the treated water
rising main (shown in red dashed line)
◼ The suction line from the reservoir to the treated water pumps will be connected (shown in light
green). The backwash suction will connect to the treated water suction manifold temporarily until
the CCT is constructed. The treated water pumps will need to shut down when a backwash cycle is
started.
◼ A temporary line from the new filters will be installed (shown in purple) to the temporary pipeline in
order to feed the reservoirs.
◼ Once the new filters are feeding the reservoirs, the existing filter structure may be
decommissioned.
◼ The upstream chlorination at the new filters will provide the necessary temporary disinfection until
the CCT is constructed and commissioned.

Figure 6-30: Phase 4 - Construction of new structures / buildings
Phase 4: Construction of CCT and final pipework

◼ The existing filtration structure is decommissioned, and the temporary pipework removed, except
for the new filter feed to the reservoirs.
◼ The CCT is then constructed including the pipelines between this structure, the filters and the
backwash pump suction manifold (dark blue pipelines).
◼ The temporary pipeline from the filters to the reservoir may now be removed.
◼ The acid and chlorine dosing systems are installed.
◼ The process can now be operated as designed for the upgrade.
Phase 5: Shaping of site, final road construction and completions site services
◼ The final phase would be to wrap up the remaining work for the WTP.
◼ The reminder of the work would mostly be the final shaping of the site, completing the road
construction where required and finishing of the site services that was not essential to the process
operation.
◼ Final painting, installation of ancillaries and handing over the site shall be done.

7 Revubue II Pump Station and Reservoir
7.1 Design Flows

Table 7-1 shows the design flows for the Revubue II Pump Station, which are based on the flows
recommended in the Preliminary Design Report (prepared for Contract No FIPAG/WASIS II/W-9/15) to
satisfy the 2038 demands.
Table 7-1: Revubue II Pump Station Design Flows
Distribution Centre Flow (m3/h)
Cruzeiro DC 804
Matema DC 286
7.2 Pump Duties

The hydraulic design for the Revubue II pumps is detailed in the Preliminary Design Report. Table 7-2
summarises the pump duties for the two pumping mains. The duty points given in Table 7-2 were
selected on the maximum system curve to ensure that the pump station will be able to achieve, as a
minimum, the design flows under all operating conditions.
Table 7-2: Revubue II Pump Station Design Pump Duties
System Flow (m3/h) Head (m)
To Cruzeiro DC 804 177
To Matema DC 286 39
Figure 7-1 and Figure 7-2 shows the system curves for pumping to the Cruzeiro and Matema
Distribution Centres respectively. Besides selecting and configuring the pumps for the Cruzeiro and
Matema pumping systems to meet the duty points given in Table 7-2, cognisance must also be taken
to ensure that the pump curves intersect the minimum and maximum system curves during all modes
of operation.

Figure 7-1: Revubue II Pump Station to Cruzeiro DC System Curves
Figure 7-2: Revubue II Pump Station to Matema DC System Curves

7.3 Waterhammer Analysis
Waterhammer analyses were conducted for the DN350 ductile iron pipeline from Revubue II Pump
Station to Matema DC, as well as for the DN400 ductile iron pipeline from Revubue II Pump Station to
Cruzeiro DC. The objective of the waterhammer analyses was to investigate operational factors that
lead to transient flow conditions. Any operational procedure that causes the flow in a pipeline to
change from steady to unsteady will influence the steady state pressures. Depending on the specific
operation, the resulting surge pressures will range from low to severe. The following main operational
events were analysed to obtain minimum and maximum surge pressure envelopes:
• Pump start-up;
• Pump shut-down/trip;
The results obtained from the waterhammer analyses were used to determine the pressure ratings of
the fittings at the Revubue II Pump Station, if any waterhammer mitigating equipment is required and
to establish good operating practices for the pump station.
This section provides a summary of the conclusions and recommendations for the waterhammer
analyses. More information on the input parameters and results can be found in Appendix B. Note
that it was assumed that all the air valves to be installed on the pipeline project will have an anti-shock
function. Also note that if the air valve dimensions vary from what is used in the waterhammer
analyses, it will have an influence on the surge pressures.
7.3.1 DN350 to Matema DC

It can be concluded from the waterhammer analysis that the transient pressures in the Revubue II to
Matema DC system are not expected to exceed 90 m with the assistance of anti-shock air valves. The
maximum transient pressure will increase to approximately 150 m without the use of anti-shock air
valves. It was also found that the system will be prone to vacuum conditions, however, the proposed
ductile iron pipeline will not buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is proposed for this pumping system:
• According to the transient pressures, pressure class PN10 would be sufficient for the valves
and fittings. However, as PN16 is used for all the wellfields, it is proposed to also use PN16
valves and fittings at the Revubue II Pump Station to standardise what is used.
• All air valves must have an anti-shock mechanism.
• It is advised to install a slanted seat check valve at the pump that is fitted with a counterweight
and hydraulic dampener, or a nozzle check valve, to prevent reverse flow and large positive
pressure spikes.
• A soft starter will be used. It is recommended to start and stop the pump over a duration of at
least 30 seconds.
7.3.2 DN400 to Cruzeiro DC

It can be concluded from the waterhammer analysis that the transient pressures in the Revubue II to
Cruzeiro DC system are not expected to exceed 265 m with the assistance of anti-shock air valves.
The maximum transient pressure will increase to approximately 305 m without the use of anti-shock air
valves. It was also found that the system will be prone to vacuum conditions, however, the proposed
ductile iron pipeline will not buckle under vacuum conditions.
• According to the steady state and transient pressures observed in the system, pressure class
PN25 is recommended for all valves and fittings. PN25 is suitable, as this pressure class is
expected to withstand 25% more than its specified head of 250 m for instantaneous transient

pressure spikes. Thus, it will suffice for a simultaneous pump trip event and for a shutdown
event under normal operation.

• In response to the high transient pressures observed in the system, it is advised to install slanted
seat check valves or nozzle-type check valves at the pumps to prevent reverse flow and large
positive pressure spikes.
• Pumps should be started sequentially with a minimum time of 5 minutes between pump starts
to allow the system to stabilise.
• Pumps should be turned off simultaneously.

• Soft starters will be used. It is recommended to start and stop the pump over a duration of at
least 30 seconds.
7.4 Suction Reservoir
7.4.1 Layout
The Revubue II Pump Station will have a 500 m3 suction reservoir to balance the supply from the
wellfield with the downstream demand of the two DC’s being supplied by the pump station. The
suction reservoir will also be used for the chlorination required to disinfect the raw water supplied from
the wellfield.
The suction reservoir will be a rectangular reservoir that is constructed as an extension of the pump
station building i.e., a wall will be shared between the pump station and reservoir. Each pump within
the pump station will draw water directly from the reservoir through the shared wall.
A chlorination facility will be constructed on the roof of the reservoir. Chlorine dosing will happen at the
inlet pipe and baffle walls will be used inside the reservoir to ensure thorough mixing after chlorination.
An external staircase provides access to the chlorination facility on the reservoir roof. Depending on
the size of the chlorination chips, it can be offloaded with a mobile crane truck onto the roof or be
carried up the stairs.
The roof of the reservoir will be accessed through a door at the back of the chlorination facility. From
the reservoir roof, each internal compartment in the reservoirs can be accessed through an access
manhole with a cat ladder.
Figure 7-3 and Figure 7-4 shows isometric views of the suction reservoir and chlorination building on
top of the reservoir.

Figure 7-3: Isometric view of suction reservoir with chlorination building
Figure 7-4: Isometric view of suction reservoir (roof not shown)

7.4.2 Structural design
The general structural items relating to the Suction Reservoir have been addressed in Section 4. This
section deals with items that are specific to the suction reservoir structure and the current proposed
site.
The bearing capacity required for the reservoir RC raft is in the order of 150 kPa. According to the
geotechnical investigation carried out, the in-situ material should be sufficiently competent to cater for
this. This will be verified on site once excavations have commenced.
Because the RC raft is founded close to NGL and competent in-situ material is expected at
approximately 1m – 1.5m below NGL, it is proposed that an engineered fill platform be used to bring
the suction reservoir founding level up from excavation level to design founding level. The engineered
fill platform will be such that it can cater for the expected bearing pressure from the RC raft.
Because the reservoir is envisaged to be constructed from monolithic construction (no
movement/expansion joints in the RC raft) and because the reservoir raft TOC level is very close to
NGL, any possible issues relating to groundwater pressure build-up or water leaking out of the
reservoir are not at all deemed likely. Hence there will be no requirement for a free-draining platform or
sub-soil layer to allow for groundwater pressure relief and or leak detection.
The roof of the reservoir will be covered by a layer of clean 19mm stone, which will serve as an
insulation layer for the roof while also helping to better control the thermal behaviour
(expansion/contraction) of the concrete slab.
7.4.3 Inlet, Outlet, Scour and Overflow Pipework

The size of the reservoir’s inlet pipe will be DN400. This was sized in accordance with the size of the
transmission main from the Revubue II Wellfield. The reservoir will have a top inlet to prevent the
reservoir from draining in the event of a pipe burst in the transmission pipeline. The top inlet also
means that no inlet valve chamber will be required.
The reservoir will not have a single outlet as each pump will draw water directly from the reservoir
through a dedicated suction bellmouths. The outlet/suction pipes will DN350 for the Matema DC
Pumping System and DN400 for the Cruzeiro DC Pumping System as per Section 7.7.3.2. The critical
submergence has been calculated as 1.0 m and 0.8 m for the two suction inlets.
The top of the pump casing is approximately 1.2 m higher than the floor level of the suction reservoir.
In order to ensure flooded suction conditions, the minimum operating water level (MOWL) of the
suction reservoir must be 1.2 m higher than the floor level as shown in Figure 7-5.

Figure 7-5: Operating level in suction reservoir
The reservoir will have a DN300 overflow pipe with a DN 600 upward facing inlet bellmouth. The top of
the overflow pipes inlet bell will be 100 mm above the reservoir top water level. The overflow pipe and
its inlet bell were sized to ensure that, at the maximum inflow rate of 875 m3/h, the reservoir’s water
level will not rise more than 200 mm above the overflow level. The underside of the reservoir roof is
400 mm higher than the top of the overflow pipe, therefore providing a freeboard of 200 mm.
The reservoir will have a DN150 scour pipeline which will drain the reservoir through a sump in the
reservoir floor. If the reservoir needs to be emptied, most of the water will be pumped out by using the
pumps in the Revubue II Pump Station. The scour pipeline will only be used to drain the water that
remains in the reservoir below the minimum operating level. The scour pipeline will be isolated by a
gate valve that will be located in a separate chamber next to the reservoir.
The reservoir’s scour and overflow pipes will discharge to a stilling basin within the site. The stilling
basin will overflow into the environment.
7.4.4 Chlorination system

The chlorination system will be the same as will be implemented at the Tete WTP and as detailed
under Section 6.3.5.2. Further comments on the preferred gravity chip feeder equipment will be
confirmed in the final Detailed Design Report.
7.5 Civil Design
7.5.1 Pump Station Layout

The pump station building will have a shared wall with the suction reservoir and will consist of a pump
room, loading bay, LV Motor Control Centre, storage room, office, and an ablution facility. The flow
meters will be in a separate chamber outside the pump station. Figure 7-6 and Figure 7-7 shows two
isometric views of the pump station building.

Figure 7-6: Isometric view of Revubue II pump station (View 1)
Figure 7-7: Isometric view of Revubue II pump station (View 2)
The pump room contains the pumping assembly and the discharge manifold. Due to the shared wall
between the pump station and reservoir, no suction manifold will be required, and the pumps can draw
water directly from the reservoir. A drainage channel will be constructed along the shared wall
between the reservoir and pump station to drain any water leakages from either the reservoir or the
pumping assemblies.
The loading bay provides vehicle access into the pump station through a single roller shutter door.
Due to space restrictions on the site, the purpose of the loading bay is for the loading and offloading of

equipment for maintenance purposes. The loading bay and entire pump room will be serviced by an
overhead travelling crane to facilitate the installation and removal of equipment.
The LV Motor Control Centre (MCC) will be located in a separate room on a raised platform behind the
pump room. The raised floor is to create a false floor compartment (or void) below the MCC to allow
cables to be installed on cable trays rather than providing cable trenches in the floor. The MCC room
will be accessed through stairs leading to an internal double door.
The storage room will be located next to the loading bay and allows for the storage of spare parts and
tools.
An office will be provided to be used by operational staff.
The ablution facility will have a toilet, hand wash basin and shower as per standard practice in
FIPAG’s existing pump control houses in the wellfields.
The pump station has a concrete roof that will be covered by a layer of clean 19mm stone, which will
serve as an insulation layer for the roof while also helping to better control the thermal behaviour
(expansion/contraction) of the concrete slab.
7.5.2 Building finishes

The building finishes proposed for the Revubue II pump station are noted in Table 7-3.
Table 7-3: Building finishes and materials for Revubue II Pump Station

General & Pump Room
External Doors Steel door, powder coated
Internal Doors Timber (meranti) door and frame. MCC double door to contain louvres
Floors Concrete
Ceilings N/A
Roof Concrete
Windows Aluminium frames with tinted glass. Opaque windows for bathroom
Walls Concrete, brick, plaster and paint (internal and external)
Office
Floors Concrete, tiled finish
Ceilings N/A
Roof Concrete
Store room
Floors Concrete
Ceilings N/A
Roof Concrete
MCC Room
Doors Timber (meranti) door and frame with louvres
Floors Concrete, epoxy painted

Ceilings N/A
Roof Concrete
Ablution facilities
Basins Porcelain
Hot Water Cylinders Hot Water Cylinder
7.5.3 Site Development
7.5.3.1 Bulk Earthworks

The foundation recommendations which dictated the bulk earthworks decision was that the soil up to a
depth of 1m below the natural ground level was not suitable for founding. To ensure that the raft slab
of the reservoir and pad footings of the pumpstation are founded on suitable material, a minimum
excavation of 1 meter below the natural ground levels will take place.
Structural and operational requirements in the form of leak detection from the reservoir and weephole
requirements at the pumpstation make the grade of the existing ground from the east to the west of
the site too steep. For this reason, the site will be reshaped to ensure a less steep grade of external
ground levels along the Southern and Northern faces of the structure. The red dashed line in the
section shown in Figure 7-8 shows the existing ground levels, while the blue line shows the less steep
reshaped finished ground level. The selected bulk earthworks building platform ensures that the
minimum depth of 1m is excavated along the full length of the building with a depth of exactly 1m of
unsuitable material removed from the lower end of the site along the southern face of the reservoir.
The bulk earthworks building platform also allows for a 1m wide working space along the perimeter of
the building and its foundations.
Figure 7-8: Revubue II Pumpstation Typical Bulk Earthworks Section
After the compaction of the bulk earthwork’s platform, a cast and fill operation will take place to fill the
gap between the bulk earthwork’s platform and the underside of the structure. The gap will be filled
and compacted in a controlled manner, using imported material of minimum G7 quality.

Additional bulk earthworks will include for the box cut required for the new roads. All excavated
materials are deemed unsuitable for re-use on this site and must therefore be spoiled off-site.
7.5.3.2 Roads Layout

Figure 7-9 illustrates the road layout for the pump station site. Vehicles will access the site via the
existing surfaced road. A single access gate will be used to enter and exit the site. The access gate
and bell mouth at the access gate have been designed to allow a 9m truck to make deliveries to the
Northern End of the site.
For deliveries and maintenance, the 9m truck is required to access the Northern end of the site and to
be able to reverse into the main structure through the structure’s access door at its southern end.
Figure 7-10 and Figure 7-11 show these movements respectively with the forward movement of the
trucks shown in black and reverse movements in colour. When testing vehicle movements,
consideration was given to the potential future upgrades of the existing surfaced road from a 2-lane
road to a 6-lane road.
Allowance for the parking of two (2) regular sized vehicles has been catered for.
Figure 7-9: Revubue II Pump Station Road Layout

Figure 7-10: Revubue II Pumpstation 9m Truck Movement to Northern end of Site
Figure 7-11: Revubue II Pump Station 9m Truck Movement into Pump Station's Access Door
7.5.3.3 Stormwater
The existing ground levels on and around the site fall from East to West at a grade of approximately 3
to 4%. A berm will be installed along the eastern site boundary as shown in Figure 7-12. The berm will
serve to prevent overland drainage originating outside of the site from passing through the site by

diverting the flow around the site to the north and south utilising the natural slope of the external
ground levels. The black arrows shown in Figure 7-12 indicate the general overland flow directions.
Figure 7-12: Revubue II Pump Station Stormwater Elements
A grass lined channel along the eastern building apron perimeter will prevent stormwater that falls
within the site from pooling along the Eastern facade of the structure. The channel will carry runoff
around the corners of the structure and will discharge overland within the site before following the
designed roadways and general overland grade out of the site.
7.5.3.4 Water Network

7.5.3.5 Sewer System

7.5.3.6 Ducting
7.6 Structural Design

The general structural items relating to the Pump Station have been addressed in Section 4. This
section deals with items that are specific to the Pump Station structure and the current proposed site.
The bearing capacity required for the RC pad footings raft is in the order of 200 kPa. According to the
geotechnical investigation carried out, the in-situ material should be sufficiently competent to cater for
this. This will be verified on site once excavations have commenced.

It is proposed that the RC pad footings be constructed directly onto competent in-situ material at
approximately 1m – 1.5m below NGL, with an engineered fill platform used to bring the level up from
excavation level to design founding level of unreinforced strip footings and surface bed.
Design loads considered for the RC pad footings will include the safe working loads for the overhead
crane inside the pump station building.
7.7.1 Pumps
7.7.1.1 Pump Selection
The pump option analysis and selection, based on the duties given in Table 7-2, were completed
during the Preliminary Design Phase. Table 7-4 below summarises the outcome of the pump selection
processes.
Table 7-4: Revubue II Pump Station Pump Selection
Pump System to Cruzeiro Pump System to

DC Matema DC
Pump Type Multi-Stage Centrifugal End-Suction Centrifugal
Configuration 2 duty, 1 standby 1 duty, 1 standby

3
Total Duty Flow (m /h) 804 286
Duty Flow per pump

402 286
(m3/h)
Duty Head (m) 177 39
Hydraulic efficiency 82% 81%
Maximum Pump Speed 1500 RPM 1500 RPM

[1]
Make and Model KSB Multitec 200-4 KSB Etanorm 200-150-400
[1] – Make and model only given as example of workable pump option. Other options are available for selection during tender
phase.
Figure 7-13 and Figure 7-14 show the pump curves of the workable pump options given in Table 7-4
against the system curves for each of the Cruzeiro DC and Matema DC pumping systems. It should be
noted that besides meeting the duty points, these pump curves must also intersect the minimum and
maximum system curves (i.e. when only one of the duty pumps or both duty pumps are pumping to the
Cruzeiro DC).
The expected flow ranges for the Revubue II pump station can be obtained from Figure 7-13 and
Figure 7-14 and are summarised in Table 7-5.
Table 7-5: Expected Flow Ranges for Revubue II Pump Station
Minimum Maximum
Flow Flow
Matema DC Pumping System 286 m3/h 345 m3/h
Cruzeiro DC Pumping System (1 pump running) 580 m3/h 640 m3/h
Cruzeiro DC Pumping System (2 pumps running) 804 m3/h 925 m3/h

Figure 7-13: Revubue II to Cruzeiro DC Pump Curves
Figure 7-14: Revubue II to Matema DC Pump Curves

7.7.1.2 Motors
The pumps will be driven by 4-pole (1500 RPM), low-voltage (400 V) cage induction motors which will
be horizontally-mounted and direct-coupled to the pumps. The motors will be specified for compliance
with the relevant parts of SANS 60034: Rotating electrical machines in accordance with the guidelines
in SANS 1804: Induction motors – Part 1: IEC requirements.
The motors will be rated to provide a 20% safety/design contingency margin above the calculated
pump absorbed power at the design duty point or a 10% safety/design contingency margin above the
selected pump’s runout point, whichever is greater. This safety/design contingency margin is to allow
for system and pump characteristic variances. Table 7-6 shows the required motor sizes for the
Revubue II Pump Station based on the required safety/design contingency margin.
Table 7-6: Revubue II Pump Station Motor Sizes
Pumping System to Cruzeiro DC Pump System to Matema DC

Motor Size 315 kW 45 kW
Total Installed Capacity 945 kW 90 kW
Specific requirements which will be specified are as follow:
• Cooling method: IC411 (refer next item)

• Protection rating: IP55 (formerly referred to as “totally enclosed, fan cooled”)
• Efficiency class: IE2 (high efficiency i.e. one better than standard)
• Insulation class: Class F but designed for Class B temperature rise to prolong motor life
• Integral protection: PT100 RTDs in windings and on bearings for temperature monitoring
• Bearings: long-life re-greasable rolling-element bearings.

The motors will be started with solid-state soft starters to avoid damage due to over-pressure and
waterhammer during starting and stopping respectively.
7.7.1.3 Pump and Motor Configuration

The multi-stage centrifugal pumps to be used for the Cruzeiro DC pumping system will be horizontal
ring-section pumps. The pump will be configured with the suction nozzle on the left and the discharge
nozzle at the top. The suction nozzle will be located on the end of the pump closer to the motor. Figure
7-15 shows the configuration of the multi-stage pumps as explained above.

Figure 7-15: Multi-Stage Pump Configuration
The end suction pumps for the Matema DC pumping system will have a standard horizontal
configuration with an axial suction and top discharge. Figure 7-16 is an example of the end-suction
pump configuration.
Figure 7-16: End-Suction Pump Configuration
7.7.1.4 Pump Plinths

The pump and motor set will be mounted on steel base plates as shown in Figure 7-15 and Figure
7-16. The base plates will be bolted to reinforced concrete plinths. The combined mass of the pump
plinth and floor slab will be sufficient to dampen the vibrations from the pump and motor set.
The decision to separate the plinths from the floor to minimize risks of vibration transfer between
pumpsets and noise transmission to the environment is still being considered for the final design–
does FIPAG have any comment on this at this stage?
The concrete plinths will be sized to have a minimum clearance of 200 mm around the base plate of
the pump and motor sets. The concrete plinths will have a minimum height of 150 mm above the pump
room floor, but the exact height will be driven by the clearance required by the suction bell above the
suction reservoir floor.
The bolts into the concrete plinths will be adjustable to allow for any misalignment. Once in final
position, the gap between the base plates and concrete plinths will be grouted with a non-shrink grout.

7.7.2 Equipment Arrangement
7.7.2.1 Cruzeiro DC Pumps

The equipment arrangement for the Cruzeiro DC pumps is shown in Figure 7-17. Table 7-7 provides a
summary of the main mechanical installation parts for the pumps.
Figure 7-17: Cruzeiro DC Pump Arrangement
Table 7-7: Summary of Cruzeiro DC Pumps Mechanical Installation Parts
Mark No Part
1 DN400 Suction Bellmouth
2 DN400 Butterfly Valve
4 DN250 Flange Adaptor (DN400/250 eccentric reducer between two flange adaptors)
5 Horisontal Ring Section Multi-Stage Pump
6 DN300 Silent or Nozzle Check Valve
7 DN300 Resilient Seated Gate Valve
8 DN300 Restrained Flange Adaptor

Mark No Part
10 DN50 Double Action Air Valve (with Anti-Shock mechanism)
7.7.2.2 Matema DC Pumps

The equipment arrangement for the Matema DC pumps is shown in Figure 7-18. Table 7-8 provides a
summary of the main mechanical installation parts for the pumps.
Figure 7-18: Matema DC Pump Arrangement
Table 7-8: Summary of Matema DC Pumps Mechanical Installation Parts
Mark No Part
1 DN350 Suction Bellmouth
2 DN350 Butterfly Valve
4 DN200 Flange Adaptor (DN350/200 eccentric reducer between two flange adaptors)
5 End Suction Pump
6 DN250 Silent or Nozzle Check Valve

Mark No Part
10 DN50 Double Action Air Valve (with Anti-Shock mechanism)
7.7.2.3 Flow Meters and Scour Isolation Valve

The equipment arrangement for the flow meter and scour chamber is shown in Figure 7-19. Table 7-9
provides a summary of the main mechanical installation parts for the chamber.
Figure 7-19: Flow Meter and Scour Chamber Equipment Arrangement
Table 7-9: Summary of Flow Meter and Scour Chamber Mechanical Installation Parts
Mark No Part
1 DN400 Electro-Magnetic Flow Meter (to Cruzeiro DC)
4 DN250 Electro-Magnetic Flow Meter (to Matema DC)
7 DN150 Resilient Seated Gate Valve (scour outlet)

7.7.3 Pipework
7.7.3.1 Pipework Properties

All pipework will be galvanised carbon steel Grade C in accordance with SANS 719 for pipe diameters
larger than DN 150 and SANS 62 medium duty for pipe diameters up to and including DN 150.
All pipework (pipes and fittings) will have a minimum wall thickness of 4.5 mm.
Pipe flanges will be in accordance with EN 1092 Type B (Raised Face).
The pressure rating of flanges will be as shown in Table 7-10 below:
Table 7-10: Revubue II Pumpstation Pipework Pressure Ratings
Pipework Segment Pressure Rating

All suction pipework PN10
Matema DC pumps discharge pipework PN16
Cruzeiro DC pumps discharge pipework PN25
Flange adaptors will be provided as shown on the drawings to cater for misalignment and provide
flexibility for removal of items for future maintenance.
7.7.3.2 Pipework Sizing

The sizing of the pipework was done to maintain velocities in suction and discharge pipework below
1.5 m/s and 2.5 m/s, respectively. Table 7-11 gives the maximum and minimum expected velocities in
the Revubue II Pump Station Pipework.
Table 7-11: Revubue II Pump Station Pipe and Valve Sizing
Minimum Minimum Maximum Maximum

Segment of Pipework Size Flow [1] Velocity Flow [1] Velocity
(m3/h) (m/s) (m3/h) (m/s)
Cruzeiro DC pumps’ suction DN400 402 0.9 640 1.4
Cruzeiro DC pumps’ discharge DN300 402 1.6 640 2.5
Matema DC pumps’ suction DN350 286 0.8 345 1.0
Matema DC pumps’ discharge DN250 286 1.6 345 2.0
Discharge Manifold to Cruzeiro DC DN400 580 1.3 925 2.0
Discharge Manifold to Matema DC DN250 286 1.6 345 2.0

[1] – Maximum and minimum flows may vary depending on the final pump selected during construction phase
7.7.3.3 Pipe Supports

The suction pipework will be supported at the shared wall between the reservoir and pump station,
and at an additional pipe support at the reducer before the pump’s suction nozzle. The additional pipe
support before the suction nozzle will ensure that no additional moments are transferred to the pump
casing. The supports will be prefabricated steel supports that will be bolted to the flanges of the pipes
and will have adjustable bolts into the concrete base that will allow for any misalignment. The bases of
the pipe supports will be grouted once in final position.
The discharge pipework will be supported from the shared wall between the pump station and
reservoir. The supports will be prefabricated steel supports that will be bolted to the concrete walls.

7.7.4 Valves
Each pump will be equipped with an isolating valve on the suction pipework, as well as a check valve
and isolating valve on the discharge pipework. Air valves will be installed on both discharge manifolds
at the high points after they exit the pump station. Each discharge manifold will have a flow meter and
isolation valve in a separate chamber outside the pump station
The pressure ratings of the valves will be in accordance with Table 7-10.
7.7.4.1 Suction Isolating Valves

Flanged butterfly valves will be used as the suction isolation valves. The valves will be fitted with a
hand wheel that will allow for manual operation. The main purpose of the valve is to isolate the suction
reservoir for maintenance purposes.
As the diameters of the suction pipework are relatively large, the butterfly valves are preferred above
resilient seated gate valves as a more economical and space-friendly option.
7.7.4.2 Discharge Check Valves

Silent (or nozzle) check non-return valves will be installed vertically on top of the reducers that sit on
the pump discharge. This configuration means that all the thrust forces will be transferred to the pump
plinth through the pump casing and, therefore, no additional restraining of the check valve will be
required.
Silent check valves were selected as they remain effective in a vertical installation and their quick and
smooth closing action which will assist in reducing vibrations and excessive waterhammer pressures.
7.7.4.3 Discharge Isolating Valves

The discharge isolating valves will be resilient seated gate valves. The isolation valves will be installed
in a horizontal position above the check valve to provide easier access to the valves. The valves will
be operated manually by means of a handwheel. The valve will be open during normal operation and
will only be closed for maintenance purposes.
7.7.4.4 Air Valves

A double action air valve with an anti-shock mechanism will be installed on each discharge manifold
just after they exit the pump station. Isolating valves will be provided at each air valve for maintenance
purposes.
The air valves will be accessible from the landing platform that is used for access to the chlorination
building.
7.7.4.5 Flow Meters

Electromagnetic flow meters will be installed on each of the two rising mains.
7.7.4.6 Flow Meter Isolation Valve

The flow meter isolation valves will be resilient seated gate valves. The valves will be operated
manually by means of a handwheel as they will only be used when maintenance is required on the
flow meter. The valve will be open during normal operation and will only be closed for maintenance
purposes.
To limit the size of the overall flow meter chamber, the flow meters will only have isolation valves on
the downstream side. During maintenance, the water in the pipes on the upstream side will drain into

the flow meter chamber. This will have to be pumped out through a sump that will be provided in the
flow meter chamber.
7.7.5 Ventilation
The following ventilation systems are proposed for the different areas of the Pump Station:
Table 7-12: Ventilation Systems
Section Type of ventilation
Pump Room Forced Ventilation – To deal with mechanical heat loads generated within the pump
room, allowing for a temperature increase of 50C or allowing 5 air changes per hour,
whichever one of the two bears the greatest airflow requirement.
MCC Room Air Conditioning
Office Air Conditioning
Two duty fans will be situated on the outside of the Pump Station building on top of the concrete roof
covering the pump room, forcing ambient air into the room via a main ventilation duct. The two fans
will be sized to have a combined duty required to remove the heat loads during maximum equipment
operation, namely two pumps pumping to Cruzeiro DC and one pump pumping to Matema DC while
operating at full capacity.
The main ventilation duct will run along the length of the room, against the wall and between the
suction and discharge pipework of the pumps. The main duct will have five take-off ducts with louvres,
each facing the corresponding equipment i.e., each pumpset will have a take-off duct and louvre
directing air across it.
The main duct and take-off ducts will be designed to meet the required air volume and velocity to
remove the heat load generated by the equipment. It is recommended to keep the velocity below
10 m/s in the main duct to mitigate noise levels.
Outlet louvres will be positioned at a higher level in the pump room and on the opposite wall of the
main duct. This will result in an affective cross flow over the mechanical equipment, thus removing the
heat load from the equipment and building.
7.7.6 Lifting equipment

Permanent lifting equipment will be provided in the pump station due to installation and maintenance
requirements of the pump systems.
The heaviest load in the pump room is anticipated to be the pumpsets. The contractor would align the
pump and motor on site and the likelihood of lifting the pumpset in future is low. Therefore, the Safe
Working Load (SWL) for the overhead traveling crane is based on lifting the individual pump or motor
whichever is anticipated to be heavier plus 30% safety margin.
The anticipated weights for the pump and motor are 3200 – 3300 kg and 1500 – 1900 kg respectively,
thus the proposed SWL for the permanent lifting equipment is 5000 kg (5 ton).
Due to the weight of the equipment, it is proposed that an electric hoist be provided.


The electrical scope of work will comprise the following at the wellfields:
◼ Overhead line from EDM point of connection to transformer
◼ One 33/0.4 kV 1250 kVA transformers (incl. distribution boards) to provide the main supply
to the pump station.
◼ One containerized generator set (genset) to supply a backup power feed,
◼ One Motor Control Centre and control gear assemblies.
◼ MV and LV cables and support systems,
◼ Earthing and lightning protection,
◼ Electrical building services comprising lighting and power outlets, and
◼ Area and road lighting.

The pump station shall be supplied via a spur connection of a nearby overhead line energizing a new
1250 kVA 33/0.4 kV transformer. The Revubue II PS transformer was sized to meet the plant's notified
maximum demand, which is centralised at the pump station’s MCC. An existing 33kV overhead line
runs adjacent to the pump station. An application to EDM, the supply authority, on behalf of FIPAG is
required to secure the MV bulk capacity.
A containerised 1100 kVA rated standby generator set is required to provide backup power to the site
in the event of load shedding or network outages. The diesel generator set will be equipped with a fuel
tank sized with the capacity to supply 8 hours of continual operation of essential equipment.
In the case of a power failure, there will be an automatic changeover to generator power. In this power
outage, the generator shall come online and shall be capable of restarting each pump sequentially to
ease the start-up transient current supplied by the generator.

A new 400V RVBIIPS-MCC will supply, control and monitor all mechanical and building loads of the
pump station. A general arrangement of the MCC is shown in Figure 7-20. All mechanical pumps will
be provided with soft starters to limit the start-up current of the motors and prevent oversizing the
generator.

Figure 7-20: RVBIIPS-MCC-01 General Arrangement

The WTP works shall follow the same philosophy for MV & LV cables as defined in Chapter 6.7.4,
replacing the term ‘WTP with ‘pump station’.

The pump station works shall follow the same philosophy for earthing and lightning protection as
defined in Chapter 5.7.5, replacing the term ‘PCH’ with ‘pump station’.

The pump station works shall follow the same philosophy for electrical building services defined in
Chapter 5.7.5, replacing the term ‘PCH’ with ‘pump station’.
7.8.7 Area and Road Lighting

The pump station works shall follow the same area and road lighting philosophy as defined in Chapter
6.7.7, replacing the term ‘WTP with ‘pump station’.
7.9.1.1 General
See 5.8.2.1.
7.9.1.2 Revubue II Wellfield and Pump Station

The Revubue II wellfield and pump station will discharge to the Matema DC or the Cruzeiro DC
reservoirs. Control of the boreholes will be automated based on the Revubue II Pump Station suction
reservoir level. The Revubue II pump station will then, in turn, pump the water to Matema and Cruzeiro

DC reservoirs, based on the levels in the suction reservoir, Matema and Cruzeiro DC reservoirs. The
wellfield and pump station can be monitored and controlled from the WTP SCADA or the SCADA view
nodes at the Matema DC and Cruzeiro DC.
Operation between Revubue II Wellfield and Suction Reservoir
The required flow from the Revubue II Wellfield is dependent on the water level of the Revubue II
pump station suction reservoir. As such, the water level in the suction reservoir will drive the operation
of the Revubue II Wellfield.
In “Auto” mode, the pumps in the Revubue II Wellfield will be controlled to keep the water level of the
Revubue II suction reservoir between the operating level (OL) and high level (HL). Similar to the
Revubue I Wellfield, the Revubue II Wellfield boreholes will be assigned a rotating sequence number
to determine the pumps’ starting/stopping order.
The water level sensor will send a signal to the control system if the water level in the suction reservoir
drops below the operating level (e.g. 70%). When this level is reached, the control system will
automatically start to switch on additional pumps in the wellfield at set intervals and in accordance with
the sequence. This process will continue until the water level starts to rise in the suction reservoir. The
water level will then be allowed to rise until it reaches the high level (e.g. 85%). At this level, the
control system will start to switch off pumps until the level starts to drop. The water level will then be
allowed to drop until the operating level is reached. This cycle repeats itself continuously while in
automatic operation mode.
In “SCADA manual” mode, the operator will have full control to manually switch on/off each borehole
pump by considering the suction reservoir water level. The sequence determined for the automatic
operation above will still serve as a guide to the operator, but it can be overridden.
High Level (HL) and Low Level (LL) alarms will sound during manual operation mode to prompt the
operator to take the necessary action. If the required action is not taken for the HL alarm and the
reservoir reaches the High-High Level (HHL), all the pumps supplying the reservoir will be
automatically switched off to prevent the reservoir from overflowing.
Operation of Revubue II Booster Pumps Supplying to Cruzeiro DC
The Revubue II Cruizero DC booster pumps are controlled based on the water level of the Cruzeiro
DC reservoirs, as well as the water level of the Revubue II suction reservoir.
In “auto” mode, the booster pumps will be controlled to keep the water level of the Cruzeiro DC
reservoirs between the operating level (OL) and high level (HL). The water level sensor in the Cruzeiro
DC reservoirs will send a signal to the control system if the water level drops below the operating level
(e.g. 70%). When this level is reached, the control system will first confirm the water level in the
Revubue II suction reservoir via a signal sent by the water level sensor in the suction reservoir.
If the water level in the suction reservoir is equal to or more than the operating level (e.g. 70%), the
control system will automatically switch on the first booster pump. The second booster pump will be
switched on automatically at a set interval if the water level continues to drop with one pump
operating. The water level in the reservoirs will then be allowed to rise until it reaches the high level
(e.g. 85%), after which a signal will be sent to the control system to reduce supply. The pumps will
automatically be switched off until the water level in the Cruzeiro DC reservoirs starts to drop. The
water level will then be allowed to drop until the operating level is reached. This cycle repeats
continuously while in automatic operation mode.
Suppose the water level in the suction reservoir is below the operating level. In that case, the booster
pumps will remain switched off until a signal is sent confirming that the operating level is satisfied in
the suction reservoir. In addition to this check, the control panel will determine whether the Cruzeiro
DC reservoirs still require a water supply. The cycle mentioned above is then repeated if the water
supply is still needed.
When the water level in the suction reservoir reaches the low-low level (LLL), a signal will be sent to
the control panel, and all booster pumps will automatically be switched off.

In “SCADA manual” mode, the SCADA operator will have full control to manually switch on/off each
booster pump by considering the water level in the Cruzeiro DC reservoirs and the Revubue II suction
reservoir.
High Level (HL) and Low Level (LL) alarms will sound for the Cuzeiro DC reservoirs during manual
operation mode to prompt the operator to take the necessary actions. If the required action is not
taken for the HL alarm and the Cruzeiro DC reservoirs reach the High-High Level (HHL), all the
booster pumps will be automatically switched off to prevent the reservoirs from overflowing.
When the LL alarm sound for the suction reservoir, the operator will be prompted to take action. If the
required action is not taken and the suction reservoir reaches the Low-Low Level (LLL), all the booster
pumps will automatically be switched off for protection.
The following instrumentation will be provided for control purposes:
1) Water level sensors at the Revubue II boreholes, Revubue II suction reservoir, Matema and
Cruzeiro DC storage reservoirs.
2) Flow meters at the Revubue II boreholes and Revubue II pump station
3) Pressure gauges at the Revubue II boreholes and Revubue II pump station
7.9.2 Revubue II Pump Station Control and Instrumentation (C&I)

Scope of Work
The C&I scope of work will comprise the following at the pump station:
◼ Programmable logic controller (PLC) and associated human machine interface (HMI) at the pump
station.
◼ Field instrumentation
◼ Radio telemetry linking the pump station to the Master SCADA
◼ Control-, instrumentation- and data cables,
◼ Earthing and surge protection, and
◼ Uninterruptible power supplies (UPSs).
The control architecture at the Revubue II pump station is shown in Figure 7-21. The PLC shall be
interfaced directly with all instruments, the generator controller unit (GCU) and the gateway to
communicate back to the Master SCADA.

Figure 7-21: Revubue II Pump Station Control Architecture
7.9.3 PLCs and HMIs

The pump station’s PLC will be provided for the automatic control of the pump station. The PLCs will
also serve to provide process interlocking and protection functionality and to serve as interfaces with
SCADA systems. The PLC shall be interfaced via a local HMI on the MCC, which will allow the
operator to monitor and control the following:
◼ Monitoring of equipment status/conditions
◼ Monitoring of process variables (reservoirs levels and pump station flow rates)
◼ Monitoring of alarm and trip events
◼ Logging and trending of selected information
◼ Adjustment of process control, alarm and protection setpoints

The pump station works shall follow the same philosophy for field instruments as defined in Chapter
6.8.4.
7.9.5 Radio Telemetry

The pump station shall utilise the backhaul radio network to communicate directly with the Master
SCADA at the Tete WTP control room.
7.9.6 Control, Instrumentation and Data Cables
The pump station works shall follow the same philosophy for control, instrumentation and data cables
as defined in Chapter 6.8.65.8.9.

The pump station works shall follow the same earthing and surge protection philosophy as defined in
Chapter 5.8.9.
7.9.8 UPSs
The pump station works shall follow the same philosophy for UPSs as defined in Chapter 5.8.105.8.9.
7.9.9 HMI
The Revubue II pump station MCC will be provided with a Human Machine Interface (HMI) to monitor
and control the equipment of the pump station locally.

8 Authorisation Processes
To be completed in the Final Detailed Design Report.

9 Financial Considerations

10 Project Programme
The latest project programme is included in Appendix xx. In terms of the programme, the following
key dates are applicable:
- Submission of draft Detailed Design Report = 30 September 2021
- Submission of final Detailed Design Report = 4 November 2021
- Submission of Bidding Documentation = 25 November 2021
In addition to the above key dates, it is also proposed that the detailed design and tender drawings be
submitted in a phased manner to allow sufficient time for FIPAG to review and comment on the
drawings before the bidding documentation is finalised. The following key dates are proposed:
- Submission of 1st batch of drawings (60% of the drawings) = 21 October 2021
- Receive FIPAG’s comments on drawings = 29 October 2021
- Submission of 2nd batch of drawings (remaining 40% of drawings) = 4 November 2021
- Receive FIPAG’s comments on drawings = 12 November 2021
- Submit tender drawings = 25 November 2021

11 Conclusions and Recommendations

Appendix A: Table of Comments – Preliminary Design Report

DESIGN OF REHABILITATION AND CONSTRUCTION OF ELECTRO-MECHANICAL EQUIPMENT OF BOREHOLES, WATER TREATMENT PLANT AND PUMPING
STATIONS, TETE – FIPAG/WASIS II/CON‐15A/18
Comments on Preliminary Design Report Rev. 0
Comments
Reviewer Originator Reviewer
Reference Action Resolution Resolution Client Comments
No. Critical Issue Dwg., Sec., Page Review Comments / Questions
etc. Required Response Date Name
1 General comments
In general, we note that the PDR addressed all aspects foreseen in The revised PDR is
the TOR, thus it is acceptable subject to the incorporation of acceptable.
comments below. Please ensure that all
activities that were
postponed for the detailed
design phase are
considered.
1.1 Control System 11. 149 to Include On design phase, to include the provision of back up of the Noted. Will be addressed as part of the Detailed Design 27 August 2021 Zutari Accepted.
and Electronic 152 programmed software for the SCADA, in a spare Hard Disk to Phase and included as a requirement in the Bidding Issue to be discussed under
Design be hand over to the Client. Documents. DDR phase.
1.2 On the design phase, please provide Cause and Effect Chart on Noted. Will be addressed as part of the Detailed Design 27 August 2021 Zutari Accepted.
the system when analyzing the P&ID, to ensure quick action Phase. Issue to be discussed under
safety device and alarms. DDR phase.
1.3 Consider Energy efficiency for the operations, especially for pumps drives Noted. Detailed Design will be based on optimising 27 August 2021 Zutari Accepted.
start-stop must be considered soft starters. energy efficiency in order to minimise operatational
costs.
Pump drives for the borehole pump motors will be fitted
with variable speed drives (subject to response to Item
2.2 below). All large motors ( >30kW) will be fitted
with soft starters.
1.4 Process Design 6.3 74 to Revise Based on the results of laboratory analysis, one of the major The request to evaluate a second option for Iron and 27 August 2021 Zutari Accepted.
83 problems that Tete system faces is high levels of iron and Manganese removal is addressed in Section 6.3.1.7 of
manganese in raw water. Although there is an indication of water the revised Preliminary Design Report.
with hardness, but it is within the maximum admissible limit in
the Water Quality regulation.
Therefore, we agree with the option given by the consultant,
namely, oxidation and precoat filtration with pH adjustment
(option 2C - conventional treatment).
However, is suggested a second option for Iron and Manganese
removal, so that the consultant can evaluate, namely:
Aeration - Filtration 1 - Alkalinization - Filtration 2 -
Disinfection.
Filtration 1 aims to remove all insoluble iron derived from the
aeration process. To remove manganese, we have to increase the
pH from 9 to 11 to allow the formation of insoluble manganese
and, this in turn will be removed in the second filtration.
1.5 Flood Protection 5.6 39 to Consider We have no objection to your recommendation for flood Noted. The flood protection will be applicable to the 27 August 2021 Zutari Accepted.
51 protection of boreholes and pump control house that shall be Nhartanda Valley, Canongola, Revubue I and Revubue
considerate in all wellfields. In this regard, the Consultant shall II wellfields as reflected in the Preliminary Design
proceed with detailed design considering option 2 for boreholes. Report.
However, all related risk shall also be assessed and addressed in
the report.
Comments
2 Specific comments
2.1 Design Loadings 3.1 6 Revise/ No reference is made to design load for Overhead Travelling The estimated safe working loads for the overhead 27 August 2021 Zutari Accepted.
Include Crane at pump station. Please provide travelling cranes have been included in Sections 6.4.3.9
and 9.4.4 of the Preliminary Design Report and
referenced in Section 3.1.
2.2 Flow Control 5.4.3 36 and Consider Wellfields - it is recommended to control the flow at the Variable speed drives (VSDs) are sophisticated power 27 August 2021 Zutari Noted.
37 boreholes by using variable speed drive (option iii). electronic components. Zutari is in agreement that the After FIPAG’s evaluation
VSDs will allow better control of pumps, but it will also 2 September 2021 considering Consultant’s
introduce additional complexity and possible negative latest clarification, we do
side effects. It is proposed that FIPAG consider the agree with your
following: recommendation to
1. The long cable runs to the borehole pumps disregard the VSD’s
will require special sine wave filters that option.
will require specialist maintenance and
additional spare holding. However, we recommend
2. The VSDS and filters will generate the use of soft-starters for
significant heat and special cooling will be motors above 10kW, as
required in the Control Panel Rooms. well as the protection of
3. VSDs being power electronic components pump motors with
introduce harmonics into the electricity protective devices against
system that may affect other equipment and phase loss, overvoltage,
customers. Power quality studies are overcurrent and
normally required to confirm that the undercurrent.
harmonics produced by the VSDs are within
acceptable limits according to international
standards and equipment compatibility
levels (e.g., IEEE 519).
4. The VSDs will be more sensitive and
susceptible to power quality issues on the
existing EDM network than the equipment
proposed currently in the PDR.
5. The additional costs associated with the
VSDs is approximately USD 1,044,000
including the need to expand the pump
control house structures.
FIPAG confirmed cost to clean a borehole (linked to

over-abstraction) to be approximately USD 6,000. The
cost to repair a pump is approximately USD 1,000. The
total cost associated with every cleaning of a borehole is
therefore USD 7,000.
Assuming no maintenance or replacement costs for the

VSDs, it will be possible to clean 149 boreholes (i.e.
USD 1,044,000 / USD 7,000) to break even in terms of
capital costs. If over-abstraction is experienced at 5
boreholes that require cleaning annually, it will take 30
years to break even with the costs to install VSDs. The
break-even period will be even longer than 30 years, as
the VSDs do break and will require maintenance and
replacement.
Comments
Based on the above cost-benefit analysis, it appears that
the VSDs will not be an economical solution.
It would be appreciated if FIPAG can consider the above

factors and then confirm whether the Detailed Design
should still be based on the use of variable speed drives
(VSDs). Should this be the case, the control philosophy
will also be amended based on the use of VSDs.
2.3 Watertight Seals 5.6.2 42 and Consider Wellfields - For flood protection, it is recommended to use the Noted – the Detailed Design will be based on the use of 27 August 2021 Zutari Accepted.
43 watertight seals. the watertight seals. Details on the operational and
maintenance aspects of the seals will be included as part
Therefore, the consultant shall provided the associated risks for
of the Detailed Design Report.
the operational component.
2.4 Pump station - 9.4.1 137 to Revise/ Revuboé II Pump Station arrangement– please consider the The layout has been updated in the Preliminary Design 27 August 2021 Zutari Accepted.
Layout 139 Improve Report to change the bends on the suction pipework
possibility to rotate the pump sets by 45 degree to avoid 90-
degree bend on suction pipe. from 90-degrees to 45-degrees – refer to Figure 9.6 and
the drawings included in Annexure C.
2.5 Clarify Please ensure that the pumps work in a flooded way (positive This was addressed in Section 9.5.2 of the Preliminary 27 August 2021 Zutari Accepted.
Figure 9-6 suction head), therefore, the minimum level for operation of the Design Report. A figure has been added in the
reservoir is requested. Preliminary Design Report (see Figure 9.9) to show the
minimum operating level in the suction reservoir.
2.6 Revise The consultant shall consider the inclusion of a hydraulic shock Refer to Section 9.4.2 of the Preliminary Design Report. 27 August 2021 Zutari Accepted.
absorber or other fittings in order to ensure proper management The design is based on using nozzle check or slanted
of water hammer and safety operation of the system in case of seat non-return valves, as well as soft starters for the
sudden power outage. starting and stopping of the pumpsets. The slanted seat
non-return valves will be fitted with a hydraulic
dampener and external lever to assist with reducing
surge pressures.
2.7 We recommend to include supports for the inlet and outlet pipe in Noted. This will be addressed as part of the Detailed 27 August 2021 Zutari Accepted.
order to protect the pump system. Design phase and when preparing construction
drawings. Issue to be reviewed and
discussed in DDR.
2.8 9.4.3 Electromagnetic flowmeters to be of same brand as existing in Noted. 27 August 2021 Zutari Closed.
other locations of FIPAG systems. Thus we propose SIEMENS.
2.9 9.4.4 Improve Revubue II Pump Station - OT Crane must be designed in the Noted. Section 9.4.4 of the Preliminary Design Report 27 August 2021 Zutari Accepted.
pump station. has been updated to reflect an overhead crane.
2.10 Control and 10 144 Consider Control and Operation of the Scheme is acceptable Noted. 27 August 2021 Zutari Closed.
Operation
2.11 Control System 11.5 151 Improve/ Due to power instability, consider small UPS and Automatic Noted. Will be incorporated as part of the Detailed 27 August 2021 Zutari Accepted.
Voltages Include Power Supply Voltage Regulator Stabilizer to all computer Design phase.
hardware. Issue to be discussed in
DDR stage.
2.12 Tete WTW 13.1.2 156 Consider During preparation of specifications, please include list of spares Noted. Will action when preparing the bidding 27 August 2021 Zutari Accepted.
Upgrade parts and special tools required for the systems. documents.
Issue to be reviewed and
discussed in Bidding
Documents.
2.13 Environmental 12.1 153 Revise The WASIS II project has already the Environmental License for Noted. Section 12.1 of the Preliminary Design Report 27 August 2021 Zutari Noted.
Authorisation and the proposed activities in Tete and Moatize. has been updated to reflect the current authorisations.
154 We expect to receive this
component with
observation of all measures
Comments
In this case an Environmental and Social Management Plan of mitigation of all impacts
(ESMP) will need to be prepared during subproject design phase, of the project.
including a Health and Safety Plan (HSP).
The ESMP produced shall respond to the TOR and World Bank
requirements as well as all environmental and social instruments
prepared such as ESMF and RPF.
The ESMP shall look to the all approved technical options in all
components that are part of this contract and propose the
mitigation measures of its impacts.
Nevertheless, as per the TOR, the Consultant shall produce for
review and approval a simplified resettlement action plan, when
required, in compliance with the World Bank policies and
procedures.
2.14 WTP layout 6.9 102 to We choose the recommend option 2C (Conventional treatment Layout Option 2D has been created to accommodate the 27 August 2021 Zutari Accepted.
option and Table 6- 105 with sedimentation) to be developed in the next phase (detailed 30 ML/d flow, which is based on the Layout Option 2C
24 design). configuration.
The associated impact for the increased throughput is
However, due to the projected water demand as well as aquifer
reported in Section Error! Reference source not
capacity we would like to request the Consultant to design the
found. and the details of layout is presented in Section
WTP that can be upgradable to ultimate capacity of 30 ML/d.
Error! Reference source not found. of the updated
Preliminary Design Report.
Appendix B: Waterhammer Analysis Report

T +27 21 526 9400 E capetown@zutari.com
A 1 Century City Drive, Waterford Precinct,

Century City, Cape Town, 7441
P PO Box 494, Cape Town 8000
zutari.com
Technical Memorandum
Project number 1001069 Date 2021-09-27
Design of Tete Boreholes, WTW and
Project name From Stephan Kleynhans
PS
Reference 1001069-0000-MEM-WW-0006
Total pages 27
number Waterhammer Analysis
Copy
Name Organisation Contact details

To
 ☐ Mr Anselmo Matavel FIPAG Anselmo.matavel@fipag.co.mz

☐ ☐
☐ ☐
☐ ☐
1 Introduction
Waterhammer analyses were conducted on the following pipelines within Tete’s bulk water supply systems:
• Nhartanda Wellfield: All pipelines from the wellfield to the Tete WTP.
• Revubue I Wellfield: The new DN350 ductile iron main for the wellfield to Matema DC.
• Revubue II Wellfield: All pipelines from the wellfield to the suction reservoir of the Revubue II Pump Station.
• Revubue II Pump Station: The DN350 ductile iron main from the pump station to Matema DC.
• Revubue II Pump Station: The DN400 ductile iron main from the pump station to Cruzeiro DC.
Waterhammer analyses were not conducted for the existing DN400 steel and DN315 PVC mains from Revubue I
Wellfield to Matema DC. There are currently no waterhammer problems experienced along these pipelines.
Furthermore, the flows through these pipelines will be reduced during the upgrading of the wellfield, which will
reduce the waterhammer pressures. The equipment selection for these boreholes will therefore be done to match
the current installations, i.e. all pipework, fittings and valves are PN16 rated.
The objective of the waterhammer analysis was to investigate operational factors that lead to transient flow
conditions. Any operational procedure that causes the flow in a pipeline to change from steady to unsteady will
induce transient pressures. Depending on the specific operation, the resulting transient pressures will range from
low to severe. The following main operational events were analysed to obtain minimum and maximum transient
pressure envelopes:
• Pump start-up (i.e. normal start);
• Pump shutdown (i.e. normal stop);
• Pump failure/trip (i.e. power failure)

The results obtained from the waterhammer analysis were used to determine the pressure ratings of the fittings at
the borehole installations and the Revubue II Pump Station.
2 System Characteristics
The characteristics of a system that are important to consider for a waterhammer analysis include the pipeline
properties, pump details and the air valves.
Project number 1001069, 1001069-0000-MEM-WW-0006 - Waterhammer Analysis.docx, 2021/09/27 1

2.1 Pipeline Properties
Besides the normal pipeline properties considered in a hydraulic analysis, the wave celerity of a pipeline also needs
to be considered when conducting a waterhammer analysis. The wave celerity is the speed at which a pressure
wave moves through a pipeline, and is dependent on the pipe material, diameter and wall thickness. The wave
celerity and other properties of the different types of pipes found in the systems analysed are given in Table 2-1.
Table 2-1: Pipeline Properties
Wall Lining Pipe Wave

Material Pipe DN Pipe OD Pressure MAOP MASP
Thickness Thickness ID Celerity
Type (mm) (mm) Class (m) (m)
(mm) (mm) (mm) (m/s)
150 167.1 C40 3 4 153.1 400 480 1300

200 219 C40 3.1 4 204.8 400 480 1250
250 270.9 C40 3.9 4 255.1 400 480 1250
Ductile
300 322.7 C40 4.6 4 305.5 400 480 1250
Iron
350 374.6 C30 4.7 5 355.2 300 360 1200
400 425.5 C30 4.8 5 405.9 300 360 1200
500 528.2 C30 5.6 5 507 300 360 1150
150 165.1 - 4.2 - 156.7 790 1190 1350
300 323.9 - 6 - 311.9 425 640 1300
Steel 350 355.6 - 6 - 343.6 385 580 1300
400 406.4 - 6 - 394.4 335 505 1250
800 813 - 8 - 797 295 445 1150
MAOP = maximum allowable operating pressure
MASP = maximum allowable surge pressure
2.2 Pump Characteristics

To obtain accurate results during a waterhammer analysis, it is important to model the various pumps as accurately
as possible. The pump characteristics that are significant for a waterhammer analysis are the pump curve and the
inertia generated by the pump and its motor.
Each of the borehole pumps in the systems analysed was assigned a pump curve based on the pump selection
done during the Preliminary Design Phase. Table 2-2 below shows the Grundfos SP pump models of which the
corresponding pump curves were used in the waterhammer analysis.
Table 2-2: Pump Curves
Grundfos Grundfos
SP Pump SP Pump
Borehole ID Wellfield Borehole ID Wellfield
Curve Curve
Used Used
F1 Nhartanda Valley SP 46-6 F14 Revubue I SP 60-8
F2 Nhartanda Valley SP 46-6 F15 Revubue I SP 46-7
F3 Nhartanda Valley SP 46-5 F16 (Revubue1_1) Revubue I SP 46-8
F8 Nhartanda Valley SP 46-7 Revubue1_3 Revubue I SP 46-7
F9 Nhartanda Valley SP 46-5 Revubue1_6 Revubue I SP 46-7
F10 Nhartanda Valley SP 46-5 Revubue2_1 Revubue II SP 60-5

Grundfos Grundfos
SP Pump SP Pump
Borehole ID Wellfield Borehole ID Wellfield
Curve Curve
Used Used
F16 (Nhartanda 1) Nhartanda Valley SP 46-6 Revubue2_6 Revubue II SP 46-5
F17 (Nhartanda 3) Nhartanda Valley SP 46-7 Revubue2_7 Revubue II SP 60-5
Nhartanda 2 Nhartanda Valley SP 46-8 Revubue2_8 Revubue II SP 60-5
F1 Canongola SP 46-6 Revubue2_14 Revubue II SP 60-5
F2 Canongola SP 46-6 Revubue2_15 Revubue II SP 60-5
F3 Canongola SP 46-5
F1_OLD Canongola SP 46-6
The combined pump and motor inertia is another important pump parameter that must be considered during a surge
analysis. The inertia of the pump and motor has a significant influence on the water column deceleration rate during
a pump trip/shut-down event as well as the likelihood of reverse flow through the pump. The inertia of a pump and
motor can be determined from the motor speed as well as the flow, head and efficiency at the pump’s best efficiency
point (BEP). Table 2-3 gives the pump and motor inertia calculated for each type of borehole pump found in
Table 2-2.
Table 2-3: Pump Inertia Borehole Pumps
SP46-4 SP46-5 SP46-6 SP46-7 SP46-8 SP60-5 SP60-6 SP60-8

Flow at BEP (m3/h) 46 46 46 46 46 60 60 60
Head at BEP (m) 34.2 43.0 51.3 60.0 69.3 38.7 46.1 62.3
Efficiency at BEP 72.1% 72.9% 73.5% 73.9% 74.1% 72.7% 73.7% 74.9%
Motor Speed (RPM) 2900 2900 2900 2900 2900 2900 2900 2900
Pump & Motor
0.0222 0.0290 0.0360 0.0440 0.0530 0.0358 0.0441 0.0640
Inertia (kg·m2)
The pumps for the Revubue II Pump Station (PS) were also modelled according to the pump selection done during
the Preliminary Design Phase. The recommended installation for the Revubue II to Matema DC system, is to use
end-suction centrifugal pumps with a 1 duty and 1 standby configuration. The KSB Etanorm 200-150-400 end
suction pump was used to perform the waterhammer analysis, as it is an example of a workable option for this
system. The recommended installation for the Revubue II to Cruzeiro DC system, is to use multi-stage centrifugal
pumps with a 2 duty and 1 standby configuration. The KSB Multitec 200-4 multi-stage pump was used to perform
the waterhammer analysis, as it is an example of a workable pump option for this system.
Table 2-4 below summarises the pump models used in the two pumping systems, and the estimated inertia of these
pumps with their motors.
Table 2-4: Pump Inertia Revubue II Pumps
Revubue II to Matema DC Revubue II to Cruzeiro DC

Pump Model KSB Etanorm 200-150-400 KSB Multitec 200-4
Flow at BEP (m3/h) 363.6 500.4
Head at BEP (m) 35.5 157
Efficiency at BEP 84.5% 83%
Motor Speed (RPM) 1475 1490
Pump & Motor Inertia (kg·m2) 1.0369 11.2286

2.3 Air Valves
It is important to include air valves in a waterhammer analysis as the operation of air valves has a significant effect
on the waterhammer pressures that develop in a system (e.g., it reduces negative pressures by allowing for air
intake, it can create additional positive pressure spikes when the air valve closes, etc.). The air valves shown in
Table 2-5 were included in the waterhammer analysis. The size and position of these air valves were obtained from
detail design drawings of Contract FIPAG/WASISII/W-8/18. All modern air valves have an anti-shock function that
limits the air outflow by having a reduced orifice for air outflow and thereby reducing the waterhammer pressures
that are induced when the air valve closes. It was assumed that all the air valves to be installed on the pipeline
project will have this anti-shock function. The inlet and outlet orifice diameters for the air valves were based on data
published by DFC for the Vent-O-Mat range of air valves. It should be noted that if the air valves to be installed/used
on site have larger anti-shock outlet sizes, the surge pressures will most likely increase and the waterhammer
analyses need to be repeated.
The waterhammer analysis also included the DN50 anti-shock air valves to be installed upstream of the non-return
valve at each of the borehole installations as per the borehole equipment design. At the Revubue II Pump Station,
an anti-shock air valve will also be installed downstream of each pumpset as per design (refer to the air valves
named AV-PMP in Table 2-5).
Table 2-5: Air Valves
Location Inlet Outlet

Air Valve (UTM 36S) Elevation
Description Pipeline Size Size
Size (m)
Easting Northing (mm) (mm)
Nhartanda Wellfield
AV-C1-01 DN80 Line C1 561,364.0 8,213,095.2 127.7 80 14
AV-C4-01 DN80 Line C4 562,203.6 8,212,251.7 125.5 80 14
AV-C4-02 DN80 Line C4 561,756.4 8,212,790.2 126.9 80 14
AV-T2-01 DN80 Line T2 562,072.2 8,213,139.2 144.0 80 14
AV-T1-01 DN100 Line T1 562,072.6 8,213,138.5 143.9 100 17
Revubue I Wellfield (New DN350 DI Main)
AV-R1-C1-1 DN80 Line R1 C1 568,616.5 8,213,438.9 129.2 80 14
AV-R1-C2-0 DN80 Line R1 C2 568,708.4 8,213,685.3 129.4 80 14
AV-T3-01 DN80 Line T3 568,604.7 8,214,458.2 131.9 80 14
AV-T3-02 DN80 Line T3 568,521.5 8,214,932.8 136.7 80 14
AV-T3-03 DN80 Line T3 568,045.4 8,215,115.5 150.2 80 14
AV-T3-04 DN80 Line T3 567,777.1 8,215,327.0 153.9 80 14
AV-R2-C1-1 DN80 Line R2 C1 569,605.4 8,217,639.9 132.6 80 14
AV-R2-C1-2 DN100 Line R2 C1 570,076.6 8,217,968.5 138.3 100 17
Revubue II Pump Station to Matema DC
AV-PMP DN80 Line T4 570,178.8 8,218,205.6 144.0 80 14
AV-T4-1 DN80 Line T4 570,126.6 8,218,437.9 137.3 80 14
AV-T4-2 DN80 Line T4 569,364.1 8,218,646.6 138.8 80 14
AV-T4-3 DN80 Line T4 568,820.0 8,218,118.7 136.5 80 14
AV-T4-4 DN80 Line T4 568,464.3 8,217,761.7 137.9 80 14
AV-T4-5 DN80 Line T4 567,873.7 8,217,169.4 136.4 80 14
AV-T4-6 DN80 Line T4 566,504.9 8,216,261.4 160.0 80 14
Revubue II Pump Station to Cruzeiro DC
AV-PMP DN100 Line T5 570,178.3 8,218,201.7 144.0 100 17
AV-T5-1 DN100 Line T5 570,343.9 8,218,580.1 140.9 100 17
AV-T5-3 DN100 Line T5 570,874.1 8,219,057.4 138.5 100 17
AV-T5-4 DN100 Line T5 571,531.0 8,218,997.1 140.7 100 17
AV-T5-5 DN100 Line T5 572,305.0 8,218,796.9 142.9 100 17
AV-T5-6 DN100 Line T5 573,028.2 8,218,598.1 149.7 100 17
AV-T5-7 DN100 Line T5 573,702.7 8,218,411.1 153.0 100 17
AV-T5-8 DN100 Line T5 574,557.7 8,218,175.2 159.2 100 17
AV-T5-9 DN100 Line T5 575,010.9 8,218,050.6 161.6 100 17

AV-T5-10 DN100 Line T5 575,666.6 8,217,870.2 164.1 100 17
AV-T5-11 DN100 Line T5 576,406.5 8,217,810.6 171.8 100 17
AV-T5-12 DN100 Line T5 577,153.2 8,217,880.8 177.1 100 17
AV-T5-13 DN100 Line T5 577,741.6 8,217,514.4 182.8 100 17
AV-T5-14 DN100 Line T5 578,022.2 8,217,212.1 183.0 100 17
AV-T5-15 DN100 Line T5 578,299.0 8,216,976.1 183.5 100 17
AV-T5-16 DN100 Line T5 578,366.8 8,216,687.7 184.0 100 17
2.4 Scenarios analysed

Each pumping system was analysed for pump-start and pump-trip conditions. A pump-start up time of 2 seconds
was used in the analysis. This is conservative as the larger pumpsets (i.e. with motor sizes greater than 10 kW)
will be fitted with soft-starter that will allow longer starting times.
The pump-trip conditions, i.e. during a power failure, will also result in more severe surge pressures compared to
a normal pump stop condition since the soft-starters will allow the pump speed to be reduced over time. As such,
only the results of the pump-trip conditions are discussed in the report.
3 Presentation of Results
3.1 Nhartanda Wellfield

The waterhammer analysis done for the Nhartanda Wellfield calculated the maximum and minimum pressure
envelopes for a pump start and pump trip/stop event. To get an overall view of the waterhammer pressures in the
wellfield, the waterhammer pressures were calculated along four pipeline profiles/routes, namely:
• From the new Nhartanda 2 (Nh 2) borehole to the Water Treatment Plant (WTP);
• From the existing F1 borehole in Nhartanda Valley (F1_N) to the WTP;
• From the existing F14 borehole in Nhartanda Valley (F14_N) to the WTP; and
• From the existing F1 borehole in Canongola (F1_C) to the WTP.
All results for the waterhammer analysis will be presented along these profiles.
3.1.1 Pump Start Event

The analysis for the pump start event evaluated the waterhammer pressures that will be induced when all the
borehole pumps are started simultaneously. Although it is recommended that the borehole pumps are started
sequentially with a delay between each pump start, a simultaneous pump start was modelled as a worst-case
scenario approach as this might be the case when power is restored to an entire wellfield. The maximum
waterhammer pressures obtained across all profiles analysed for the pump start event is 95 m. Figure 3-1 to
Figure 3-4 give the minimum and maximum pressure envelopes for a pump start event.

Nhartanda Wellfield
Rapid Simultaneous Pump Start
Transient HGL Nh 2 to WTP
220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 94.5 m Absolute Roughness: 0.600 mm
Final Flow: 992.0 m3/h WTP WL: 165.0 m Minimum Pressure: 0.0 m Anti-Shock Air Valve: Yes
Figure 3-1: Nhartanda Pressure Profile - Pump Start Event - Nh 2 to WTP
Nhartanda Wellfield
Transient HGL F1_N to WTP
200 `
190
180
170
160
HGL (m )
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-2: Nhartanda Pressure Profile - Pump Start Event - F1_N to WTP

Nhartanda Wellfield
200 `
190
180
170
160
HGL (m )
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-3: Nhartanda Pressure Profile - Pump Start Event - F14_N to WTP
Nhartanda Wellfield
Transient HGL F1_C to WTP
220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500
Chainage (m)
Figure 3-4: Nhartanda Pressure Profile - Pump Start Event - F1_C to WTP

3.1.2 Pump Trip Event
This waterhammer analysis looked at the transient pressures that would be induced by a simultaneous pump trip
event in the Nhartanda Wellfield. A simultaneous pump trip event would occur for example when the power supply
to the wellfield fails/trips.
Since the Nhartanda Valley and Canongola wellfields have a combined total of 27 pumps that supply the WTP,
stopping all these pumps simultaneously induces substantial transient pressures in the system. It was also found
that the type of non-return valve installed at the borehole installations will have a significant effect on the magnitude
of the transient pressures. The pump trip waterhammer analysis was initially done for a system that has normal
single door swing type non-return valves installed. Thereafter, the analysis was repeated with the use of faster
closing, single door slanted seat type non-return valve, fitted with a counterweight and hydraulic dampener.
3.1.2.1 Normal (Single Door) Non-Return Valves

Transient pressures up to 342 m were obtained for a simultaneous pump trip event where the system has normal
swing-type non-return valves installed. Full vacuum conditions also occurred along most of the pipelines. Figure 3-5
to Figure 3-8 show the minimum and maximum transient pressure envelopes obtained for this analysis.
It can be seen on these figures that the maximum allowable operating pressures (MAOP) of the pipelines are never
exceeded. The ductile iron pipelines will also be able to withstand full vacuum without buckling. Although the
pipelines’ MAOP are not exceeded, the high internal pressures observed are a safety concern. It also means that
high pressure fittings and valves (> PN25) will be required for the borehole installations and the pipelines. These
fittings are expensive and not always readily available.
Nhartanda Wellfield
Simultaneous Pump Trip with Normal Non-Return Valves
400 `
350
300
HGL (m )
250
200
150
100
0 500 1000 1500 2000 2500
Chainage (m)
Transient Pressure
440
400
360
320
280
Pressure (m)
240
200
160
120
80
40
0
-40 0 500 1000 1500 2000 2500
Chainage (m)
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 226.4 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.0 m Minimum Pressure: -10.0 m Anti-Shock Air Valve: Yes
Figure 3-5: Nhartanda Pressure Profile - Pump trip with normal non-return valves - Nh 2 to WTP

Nhartanda Wellfield
450 `
400
350
HGL (m )
300
250
200
150
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
440
400
360
320
280
Pressure (m)
240
200
160
120
80
40
0
-40 0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-6: Nhartanda Pressure Profile - Pump trip with normal non-return valves – F1_N to WTP
Nhartanda Wellfield
400 `
350
300
HGL (m )
250
200
150
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
440
400
360
320
280
Pressure (m)
240
200
160
120
80
40
0
-40 0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-7: Nhartanda Pressure Profile - Pump trip with normal non-return valves - F14_N to WTP

Nhartanda Wellfield
500 `
450
400
350
HGL (m )
300
250
200
150
100
0 500 1000 1500 2000
Chainage (m)
Transient Pressure
440
400
360
320
280
Pressure (m)
240
200
160
120
80
40
0
-40 0 500 1000 1500 2000 2500
Chainage (m)
Figure 3-8: Nhartanda Pressure Profile - Pump trip with normal non-return valves - F1_C to WTP
3.1.2.2 Fast-Closing (Slanted Seat) Non-Return Valves

With the use of faster closing, slanted seat swing check valves fitted with counterweights and hydraulic dampeners,
the maximum transient pressure for a pump trip event is significantly reduced to 102 m. Full vacuum conditions will
still occur in sections of the pipeline. Figure 3-9 to Figure 3-12 show the minimum and maximum pressure envelopes
obtained for this analysis.

Nhartanda Wellfield
Simultaneous Pump Trip with Rapid-Closing Non-Return Valves
240 `
220
200
HGL (m )
180
160
140
120
100
0 500 1000 1500 2000 2500
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 500 1000 1500 2000 2500
Chainage (m)
Figure 3-9: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – Nh 2 to WTP
Nhartanda Wellfield
220 `
200
180
HGL (m )
160
140
120
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-10: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F1_N to WTP

Nhartanda Wellfield
220 `
200
180
HGL (m )
160
140
120
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Figure 3-11: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F14_N to WT
Nhartanda Wellfield
240 `
220
200
HGL (m )
180
160
140
120
100
0 500 1000 1500 2000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500
Chainage (m)
Figure 3-12: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F1_C to WTP

3.2 Revubue I Wellfield
The waterhammer analysis done for the new DN350 ductile iron main and connecting pipelines calculated the
maximum and minimum pressure envelopes for a pump start and pump trip/stop event. To get an overall view of
the waterhammer pressures in the wellfield, the waterhammer pressures were calculated along four pipeline
profiles/routes, namely:
• From the new Revubue 1_3 (Rev1_3) borehole to Matema DC;
• From the existing F15 borehole to Matema DC;
• From the existing F14 borehole to Matema DC; and
• From the new Revubue 1_6 (Rev1_6) borehole to Matema DC.


For a simultaneous pump start of all the borehole pumps connected to the DN350 ductile iron main, a maximum
transient pressure of 102 m is expected. Figure 3-13 to Figure 3-16 give the minimum and maximum pressure
envelopes for a pump start event.
Revubue I Wellfield - DN350 Ductile Iron Main
Transient HGL Rev1_3 to Matema DC
220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Final Flow: 400.0 m3/h WTP WL: 165.5 m Minimum Pressure: 0.0 m Anti-Shock Air Valves: Yes
Figure 3-13: Revubue I Pressure Profile - Pump Start Event - Rev1_3 to Matema DC

Transient HGL F15 to Matema DC
220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
40
20
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-14 Revubue I Pressure Profile - Pump Start Event – F15 to Matema DC

220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-15: Revubue I Pressure Profile - Pump Start Event – F14 to Matema DC

220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-16: Revubue I Pressure Profile - Pump Start Event - Rev1_6 to Matema DC

In case of a failure in the electricity supply to the Revubue I Wellfield, all the borehole pumps connecting to the
DN350 main will trip simultaneously. Transient pressures up to 187 m are expected for such a pump trip event
where anti-shock air valves and fast-closing non-return valves are used. Figure 3-17 to Figure 3-20 show the
minimum and maximum transient pressure envelopes obtained for this analysis.
As in the case for a pump trip event in the Nhartanda Wellfield, full vacuum conditions are also expected along most
of the pipelines, however, the ductile iron pipelines proposed for this system will not buckle under vacuum
conditions.
The faster closing non-return valves does not have such a big impact in this system as at the Nhartanda Wellfield.
The maximum transient pressures are expected to increase to 200 m if normal non-return valves are used. It is also
worth noting that without anti-shock air valves, the maximum transient pressures are expected to increase
significantly up to 290 m.

Simultaneous Pump Trip
350 `
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Final Flow: 0.0 m3/h WTP WL: 165.5 m Minimum Pressure: -9.8 m Anti-Shock Air Valves: Yes
Figure 3-17: Revubue I Pressure Profile - Pump Trip Event - Rev1_3 to Matema DC

350 `
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-18: Revubue I Pressure Profile - Pump Trip Event – F15 to Matema DC

350 `
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-19: Revubue I Pressure Profile - Pump Trip Event – F14 to Matema DC

350 `
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Transient Pressure
200
180
160
140
Pressure (m)
120
100
80
60
40
20
0
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Figure 3-20: Revubue I Pressure Profile - Pump Trip Event - Rev1_6 to Matema DC

3.3 Revubue II Wellfield
The waterhammer analysis done for the Revubue II Wellfield calculated the maximum and minimum pressure
envelopes for a pump start and pump trip/stop event. To get an overall view of the waterhammer pressures in the
wellfield, the waterhammer pressures were calculated along three pipeline profiles/routes, namely:
• From the new Revubue 2_4 (Rev2_4) borehole to the suction reservoir of the Revubue II Pump Station;
• From the new Revubue 2_5 (Rev2_5) borehole to the suction reservoir of the Revubue II Pump Station;
and
• From the new Revubue 2_13 (Rev2_13) borehole to the suction reservoir of the Revubue II Pump
Station;

The maximum transient pressure expected for a rapid simultaneous pump start in the Revubue II Wellfield is 72 m.
Figure 3-21 to Figure 3-23 shows the minimum and maximum transient pressure envelopes for a pump start event
in the Revubue II Wellfield.
Simultaneous Pump Start
Transient HGL Rev2_4 to Suction Reservoir
190 `
180
170
160
HGL (m )
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe MAOP Fittings
Final Flow: 900.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -1.0 m Anti-Shock Air Valves: Yes
Figure 3-21: Revubue II Pressure Profile - Pump Start Event – Rev2_4 to Suction Reservoir

190 `
180
170
160
HGL (m )
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
180 `
170
160
150
HGL (m )
140
130
120
110
100
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)

In case of a failure in the electricity supply to the Revubue II Wellfield, all the borehole pumps in the wellfield will
trip simultaneously. Transient pressures up to 119 m are expected for such a pump trip event. Figure 3-24 to
Figure 3-26 show the minimum and maximum transient pressure envelopes obtained for such a pump trip event.
As in the case for a pump trip event in the other wellfields, full vacuum conditions are also expected along most of
the pipelines, however, the ductile pipelines proposed for this system will not buckle under vacuum conditions.
It is again worth noting that without anti-shock air valves, the maximum transient pressures are expected to increase
significantly up to 290 m.
Rapid Simultaneous Pump Trip
260 `
240
220
200
HGL (m )
180
160
140
120
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
40
20
-20
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Figure 3-24: Revubue II Pressure Profile - Pump Trip Event – Rev2_4 to Suction Reservoir

260 `
240
220
200
HGL (m )
180
160
140
120
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
40
20
-20
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
220 `
200
180
HGL (m )
160
140
120
100
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)

3.4 Revubue II Pump Station

The waterhammer analysis results for the pipeline from Revubue II Pump Station to Matema DC provides maximum
and minimum pressure envelopes for a pump start and pump trip/stop event.
3.4.1.1 Pump Start Event

Through the analysis, the waterhammer pressures were evaluated when the pump at Revubue II Pump Station
starts to pump water to Matema DC. The maximum waterhammer pressure obtained along the pipeline profile is
58.9 m. Figure 3-27 gives the minimum and maximum pressure envelope for the pump start event.
Revubue II Pump Station

Revubue II PS to Matema DC
Transient HGL Pump Start
200 `
190
180
170
160
HGL (m)
150
140
130
120
110
100
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Transient Pressure
80
60
Pressure (m)
40
20
-20
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Initial Flow: 0.0 m3/h Suction Reservoir WL: 144.5 m Maximum Pressure: 58.9 m Absolute Roughness: 0.150 mm
Final Flow: 342.2 m3/h Matema Reservoir WL: 165.5 m Minimum Pressure: 0.0 m Anti-Shock Air Valve: Yes
Figure 3-27: Pressure Profile - Rapid Pump Start – Revubue II Pump Station to Matema DC
3.4.1.2 Pump Trip Event

This waterhammer analysis looked at the transient pressures that would be induced by a pump trip event. A pump
trip event would occur for example when the power supply to the Revubue II Pump Station fails/trips.
Transient pressures up to 88.2 m were obtained for a pump trip event. Figure 3-28 shows the minimum and
maximum transient pressure envelope obtained for this analysis. The maximum allowable operating pressure
(MAOP) of the pipeline is not exceeded. Full vacuum conditions are expected to occur along the majority of the
pipeline; however, the ductile iron pipeline will not buckle under vacuum conditions.
It is also worth noting that if it is opted not to install anti-shock air valves in this pumping system, the maximum
pressures induced during a pump trip event would increase to 148.5 m.

Revubue II PS to Matema DC
Transient HGL Pump Trip
240 `
220
200
HGL (m)
180
160
140
120
100
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Transient Pressure
120
100
80
Pressure (m)
60
40
20
-20
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Final Flow: 0.0 m3/h Matema Reservoir WL: 165.5 m Minimum Pressure: -10.0 m Anti-Shock Air Valve: Yes
Figure 3-28: Pressure Profile - Pump Trip – Revubue II Pump Station to Matema DC

The waterhammer analysis results for the Revubue II to Cruzeiro DC system provide maximum and minimum
pressure envelopes for a pump start and pump trip/stop event.
3.4.2.1 Pump Start Event

The analysis for the pump start event evaluated the waterhammer pressures that will be induced when both duty
pumps are started simultaneously to supply water to Cruzeiro DC. Although it is recommended that the pumps are
started sequentially with a delay between pump starts, a rapid simultaneous pump start was modelled as a worst-
case scenario approach. The maximum waterhammer pressure obtained along the pipeline profile is 221.5 m.
Figure 3-29 gives the minimum and maximum pressure envelope for the pump start event. It can be seen that the
maximum allowable operating pressure (MAOP) of the pipeline is not exceeded.

Revubue II PS to Cruzeiro DC
Transient HGL Rapid Simultaneous Pump Start
400 `
350
300
HGL (m)
250
200
150
100
0 2000 4000 6000 8000 10000
Chainage (m)
Transient Pressure
340
320
300
280
260
240
220
Pressure (m)
200
180
160
140
120
100
80
60
40
20
0
-20
0 2000 4000 6000 8000 10000
Chainage (m)
Final Flow: 805.0 m3/h Cruzeiro Reservoir WL: 229.0 m Minimum Pressure: -10.0 m Anti-Shock Airvalves: Yes
Figure 3-29: Pressure Profile – Rapid Simultaneous Pump Start – Revubue II Pump Station to Cruzeiro DC
3.4.2.2 Pump Trip Event

This waterhammer analysis looked at the transient pressures that would be induced by a simultaneous pump trip
event. A simultaneous pump trip event would occur for example when the power supply to the Revubue II Pump
Station fails/trips.
Figure 3-30 shows the minimum and maximum transient pressure envelope obtained for this analysis. Transient
pressures up to 261 m were obtained for a pump trip event. Full vacuum conditions occurred along most of the
pipeline.
It can be seen that the maximum allowable operating pressure (MAOP) of the pipeline is not exceeded. The ductile
iron pipeline will also be able to withstand full vacuum without buckling. It is also worth noting that if it is opted not
to install anti-shock air valves in this pumping system, the maximum pressures induced during a pump trip event
would increase to 303.2 m, which slightly exceeds the MAOP of the pipeline.

Revubue II PS to Cruzeiro DC
Transient HGL Simultaneous Pump Trip
450 `
400
350
HGL (m)
300
250
200
150
100
0 2000 4000 6000 8000 10000
Chainage (m)
Transient Pressure
340
320
300
280
260
240
220
Pressure (m)
200
180
160
140
120
100
80
60
40
20
0
-20
0 2000 4000 6000 8000 10000
Chainage (m)
Final Flow: 0.0 m3/h Cruzeiro Reservoir WL: 229.0 m Minimum Pressure: -10.0 m Anti-Shock Airvalves: Yes
Figure 3-30: Pressure Profile – Simultaneous Pump Trip – Revubue II Pump Station to Cruzeiro DC

4 Conclusion and Recommendations
4.1 Nhartanda Wellfield

It can be concluded from the water hammer analysis that the transient pressures in the Nhartanda Wellfield are not
expected to exceed 110 m with the assistance of anti-shock air valves and fast-closing non-return valves. The
maximum transient pressure will increase to approximately 350 m without the use of fast-closing non-return valves
at the borehole installations. It was also found that the system will be prone to vacuum conditions, however, the
proposed ductile iron pipeline will not buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Nhartanda Wellfield:
• The check valves at the borehole installations to be slanted-seat valves fitted with counterweights and
hydraulic dampeners.
• In starting and stopping successive pumps, it is good practice to allow the system to stabilise between
these pump stops or starts. It is recommended that at least one minute be allowed between successive
pump stops or starts.
4.2 Revubue I Wellfield

In the DN350 ductile iron main and connecting pipework, the maximum transient pressures are not expected to
exceed 190 m with the assistance of anti-shock air valves and fast-closing non-return valves. The maximum
transient pressure will increase significantly to approximately 300 m without the use of anti-shock air valves. It was
also found that the system will be prone to vacuum conditions, however, the proposed ductile iron pipeline will not
buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Revubue I Wellfield:
• The pressure class of all valves and fittings to be at least PN16. The rated pressure of the PN16 valve will
be exceeded during a pump trip event with expected transient pressures up to 190 m, however, for such
instantaneous transient pressures, the valve will be able to withstand up to 25% more than it’s rated
pressure (i.e. surge pressures should be lower than 192 m). Steady-state pressures will also not exceed
the rated pressure of a PN16 valve as the maximum steady-state pressure for this wellfield is below 100 m.
• The check valves at the borehole installations to be slanted-seat valves fitted with counterweights and
hydraulic dampeners.
4.3 Revubue II Wellfield

In the DN350 ductile iron main and connecting pipework, the maximum transient pressures are not expected to
exceed 120 m with the assistance of anti-shock air valves. The maximum transient pressure will increase
significantly to approximately 300 m without the use of anti-shock air valves. It was also found that the system will
be prone to vacuum conditions, however, the proposed ductile iron pipeline will not buckle under vacuum conditions.
Based on the results of the waterhammer analysis, the following is recommended for the Revubue II Wellfield:

4.4 Revubue II Pump Station

It can be concluded from the waterhammer analysis that the transient pressures in the Revubue II to Matema DC
system are not expected to exceed 90 m with the assistance of anti-shock air valves. The maximum transient
pressure will increase to approximately 150 m without the use of anti-shock air valves. It was also found that the
system will be prone to vacuum conditions, however, the proposed ductile iron pipeline will not buckle under vacuum
conditions.
• According to the transient pressures, pressure class PN10 would be sufficient for the valves and fittings.
However, as PN16 is used for all the wellfields, it is proposed to also use PN16 valves and fittings at the
Revubue II Pump Station to standardise what is used.
• It is advised to install a slanted seat check valve at the pump that is fitted with a counterweight and
hydraulic dampener, or a nozzle check valve, to prevent reverse flow and large positive pressure spikes.
• A soft starter will be used. It is recommended to start and stop the pump over a duration of at least 30
seconds.

It can be concluded from the waterhammer analysis that the transient pressures in the Revubue II to Cruzeiro DC
system are not expected to exceed 265 m with the assistance of anti-shock air valves. The maximum transient
pressure will increase to approximately 305 m without the use of anti-shock air valves. It was also found that the
system will be prone to vacuum conditions, however, the proposed ductile iron pipeline will not buckle under vacuum
conditions.
• According to the steady state and transient pressures observed in the system, pressure class PN25 is
recommended for all valves and fittings. PN25 is suitable, as this pressure class is expected to withstand
25% more than its specified head of 250 m for instantaneous transient pressure spikes. Thus, it will suffice
for a simultaneous pump trip event and for a shut down event under normal operation.
• In response to the high transient pressures observed in the system, it is advised to install slanted seat
check valves or nozzle-type check valves at the pumps to prevent reverse flow and large positive pressure
spikes.
• Pumps should be started sequentially with a minimum time of 5 minutes between pump starts to allow the
system to stabilise.
• Pumps should be turned off simultaneously.
• Soft starters will be used. It is recommended to start and stop the pump over a duration of at least 30
seconds.

Appendix C:

Appendix D:

Appendix E:

Appendix F:

In diversity there is beauty
and there is strength.
MAYA ANGELOU
Document prepared by:

Zutari (Pty) Ltd
Reg No 1977/003711/07
Riverwalk Office Park, 41 Matroosberg Road,
Ashlea Gardens, Extension 6, Pretoria
South Africa
PO Box 74381, Lynnwood Ridge 0040
T +27 12 427 2000

F +27 86 556 0521
E tshwane@zutari.com

0000 REP JJ 0003 - Detailed Design Report & Appendices

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

0000 REP JJ 0003 - Detailed Design Report & Appendices

Uploaded by

Copyright:

Available Formats

Contract No FIPAG/

WASIS II/CON 15A/18

Design of Tete Boreholes,

Fundo de Investimento e Património do

T +27 12 427 2000

A person using documents or data accepts the risk of:

Document number 1001069-0000-REP-JJ- Project number 1001069

Client Fundo de Investimento e Património do Abastecimento de Água (FIPAG)

Client contact Adelaide Carlos Client reference FIPAG/WASIS II/CON-15A/18

Rev Date Revision details/status Author Reviewer Verifier Approver

A Draft for client review J Calitz P. Lehener S. Kleynhans

Author signature Approver signature

Name John-Bert Calitz Name Stephan Kleynhans

Title Associate Title Technical Director

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 i

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 ii

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 iii

2 Preliminary Design Report Decisions .............................................................................................3

4 Detailed Structural Design ...............................................................................................................7

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 iv

6 Water Treatment Works ................................................................................................................. 48

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 v

7 Revubue II Pump Station and Reservoir ...................................................................................... 91

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 vi

8 Authorisation Processes ............................................................................................................. 120

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 vii

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 viii

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 ix

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 x

1.2 Project Scope and Deliverables

1.3 Project Area

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 1

Figure 1-1: Tete - Moatize Locality Map (adapted from https://www.bing.com/maps)

1.4 Structure of Report

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 2

• All motors larger than 10 kW must be fitted with soft-starters.

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 3

3.1 Site Investigations

• Water quality testing

• Laboratory analysis on pipe scale

3.2 Bulk Earthworks

3.3 Roads and Paving

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 4

3.5 Water Network

3.6 Sewer System

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 5

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 6

4.1 Structural Design Codes

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 7

In addition to the above, structural design of water-retaining/water-excluding reinforced concrete

4.2 Design Loadings

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 8

Design seismic loads considered will be as follows:

4.3 Key Design Criteria

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 9

4.4 Special Design Considerations for Reservoir

4.5 Concrete Materials

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 10

4.6 Concrete Cover to Reinforcement

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 11

4.9 Design Working Life

4.10 General Building Items

Document number 1001069-0000-REP-JJ-0003, Revision number A, Date 2021/09/30 12