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Project name Design of Tete Boreholes, Water Treatment Plant and Pump Stations
Current revision A
Approval
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
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
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.
• Topographical survey
• Geotechnical investigation
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.
3.7 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.
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:
◼ SANS 10160-4: Basis of structural design and actions for buildings and industrial structures Part 4:
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.
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
Existing Boreholes Nhartanda Valley 13 F1; F2; F3; F4; F5; F6; F8; F9; F10; F11;
F13; F14; F15
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
Existing Boreholes 12 F2; F3; F5; F6; F8; F9; F10; F11;
F12; F13; F14; F15
DN400 Steel Pipeline F2; F3; F5; F6; F8; F10; F11
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
Easting Northing
(UTM 36S)
Easting Northing
F1 Nhartanda Valley 35
F2 Nhartanda Valley 35
F3 Nhartanda Valley 35
F4 Nhartanda Valley 35
F5 Nhartanda Valley 35
F6 Nhartanda Valley 35
F8 Nhartanda Valley 50
F9 Nhartanda Valley 35
F10 Nhartanda Valley 35
F11 Nhartanda Valley 35
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
Table 5-9 summarises the design yields established for the new boreholes in the Revubue II Wellfield.
Table 5-11 gives the pump duties for all the pumps in the Revubue I Wellfield as well as the pumps
selected for these duty points.
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
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
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
• 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.
• 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.
• 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.
5.5.1.1 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).
Location
PCH ID Wellfield (UTM 36S)
Easting Northing
PCH-NHT-01 Nhartanda Valley 561561.46 8212738.11
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.
Drawing xx (see Appendix xx) shows the typical site layout of the PCHs and the general arrangement
of the equipment and building.
Approximate
1:100 Flood Level Top of Platform
PCH ID Wellfield Platform Height
(masl) Elevation (masl)
(m)
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.
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
• 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.
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.
Mark No Part
4 Well head consisting of steel cover plate, DN100 steel pipe and stub/sleeve to suit Roxtec
RS31 Seal or similar
7 DN50 Tee
14 DN100 Slanted Seat Check Valve with counterweight and hydraulic damper
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).
• 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.
5.6.4 Pipework
Mark No Part
4 DN150 x 45° Bend welded on both sides to DN150 Straight Steel Pipes (each 500mm F/F)
6 DN150 Straight Ductile Iron Pipe; 500mm F/F (cut from existing Ductile Iron pipe)
8 DN150 Straight Ductile Iron Pipe with variable length (cut from existing Ductile Iron pipe)
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.
• Eight generator sets (genset) to supply a standby generator feed to the eight PCHs.
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
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
NHT-GEN-03 NHT-PCH-03 124.6 250 kVA none
NHT-GEN-04 NHT-PCH-04 100.5 200 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
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:
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.
5.8.1 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.
5.8.2.1 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.
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.
• 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,
• 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.
5.8.7.1 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:
5.8.10 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.
Chlorine Dosing
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.
Number of tanks No 2
Tank depth m 4
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.
Figure 6-2: Filter false floor (left, Basiia Contracting) and Dual parallel lateral (right, Leopold Systems)
Number of filters No 7
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)
Water temperature °C 30
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.
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
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.
Giardia Log Credit Virus Log Credit Giardia Log Removal Virus Log Removal
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.
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.
Water temperature °C 25
Maximum free chlorine dose at disinfection only mg/L 1.5 (awaiting feedback from supplier)
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
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.
• 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.
6.4.4.1 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.
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
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
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
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.
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.
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.
Figure 6-15: WTP 9 m truck reverse movement via entry though the Main 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
6.4.6.6 Ducting
Detailed design to be confirmed in the final Detailed Design Report.
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.
• 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.
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.
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.
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.
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.
6.6.12.1 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
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
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.
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.
6.8.1.1 General
See 5.8.2.1
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.
6.8.8 UPSs
The WTP works shall follow the same philosophy for UPSs as defined in Section 5.8.10.
Figure 6-27: Phase 1 - Decommissioning of existing infrastructure and laying temporary pipes
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.
Cruzeiro DC 804
Matema DC 286
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.
• 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.
• 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
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.
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.
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
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.
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 7-11: 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
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.
7.5.3.6 Ducting
Detailed design to be confirmed in the final Detailed Design Report.
7.7.1 Pumps
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
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
• 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
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.
Mark No Part
4 DN250 Flange Adaptor (DN400/250 eccentric reducer between two flange adaptors)
Mark No Part
4 DN200 Flange Adaptor (DN350/200 eccentric reducer between two flange adaptors)
Table 7-9: Summary of Flow Meter and Scour Chamber Mechanical Installation Parts
Mark No Part
Flange adaptors will be provided as shown on the drawings to cater for misalignment and provide
flexibility for removal of items for future maintenance.
7.7.5 Ventilation
The following ventilation systems are proposed for the different areas of the Pump Station:
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.
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.
7.9.1.1 General
See 5.8.2.1.
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.
The HMIs will have graphics capability and will be set up for display mimic diagrams for monitoring
and control purposes.
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.
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
Reviewer Originator Reviewer
Reference Action Resolution Resolution Client Comments
No. Critical Issue Dwg., Sec., Page Review Comments / Questions
etc. Required Response Date Name
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.
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
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:
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.
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
F4 Nhartanda Valley SP 46-5 F17 (Revubue1_5) Revubue I SP 46-6
F5 Nhartanda Valley SP 46-6 F18 (Revubue1_2) Revubue I SP 46-6
F6 Nhartanda Valley SP 46-5 F19 (Revubue1_4) 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
F11 Nhartanda Valley SP 46-5 Revubue2_2 Revubue II SP 46-4
F13 Nhartanda Valley SP 46-5 Revubue2_3 Revubue II SP 46-4
F14 Nhartanda Valley SP 46-6 Revubue2_4 Revubue II SP 46-4
F15 Nhartanda Valley SP 46-5 Revubue2_5 Revubue II SP 60-6
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
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
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
• From the new Nhartanda 2 (Nh 2) borehole to the Water Treatment Plant (WTP);
• From the existing F14 borehole in Nhartanda Valley (F14_N) to the WTP; and
All results for the waterhammer analysis will be presented along these profiles.
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
Nhartanda Wellfield
Rapid Simultaneous Pump Start
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)
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
0 200 400 600 800 1000 1200 1400
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 87.9 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 3-2: Nhartanda Pressure Profile - Pump Start Event - F1_N to WTP
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400
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
0 200 400 600 800 1000 1200 1400
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 85.7 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 3-3: Nhartanda Pressure Profile - Pump Start Event - F14_N to WTP
Nhartanda Wellfield
Rapid Simultaneous Pump Start
Transient HGL F1_C to WTP
220 `
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000
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: 89.7 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 3-4: Nhartanda Pressure Profile - Pump Start Event - F1_C to WTP
350
300
HGL (m )
250
200
150
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
440
400
360
320
280
Pressure (m)
240
200
160
120
80
40
0
-40 0 500 1000 1500 2000 2500
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
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
400
350
HGL (m )
300
250
200
150
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 293.2 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 3-6: Nhartanda Pressure Profile - Pump trip with normal non-return valves – F1_N to WTP
Nhartanda Wellfield
Simultaneous Pump Trip with Normal Non-Return Valves
Transient HGL F14_N to WTP
400 `
350
300
HGL (m )
250
200
150
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 256.7 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 3-7: Nhartanda Pressure Profile - Pump trip with normal non-return valves - F14_N to WTP
400
350
HGL (m )
300
250
200
150
100
0 500 1000 1500 2000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 342.8 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 3-8: Nhartanda Pressure Profile - Pump trip with normal non-return valves - F1_C to WTP
220
200
HGL (m )
180
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
100
80
60
Pressure (m)
40
20
-20
0 500 1000 1500 2000 2500
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 86.6 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 3-9: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – Nh 2 to WTP
Nhartanda Wellfield
Simultaneous Pump Trip with Rapid-Closing Non-Return Valves
Transient HGL F1_N to WTP
220 `
200
180
HGL (m )
160
140
120
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 80.9 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.0 m Minimum Pressure: -8.7 m Anti-Shock Air Valve: Yes
Figure 3-10: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F1_N to WTP
200
180
HGL (m )
160
140
120
100
0 200 400 600 800 1000 1200 1400
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 200 400 600 800 1000 1200 1400
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 86.3 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.0 m Minimum Pressure: -8.6 m Anti-Shock Air Valve: Yes
Figure 3-11: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F14_N to WT
Nhartanda Wellfield
Simultaneous Pump Trip with Rapid-Closing Non-Return Valves
Transient HGL F1_C to WTP
240 `
220
200
HGL (m )
180
160
140
120
100
0 500 1000 1500 2000
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: 1234.0 m3/h Borehole WL: Static Maximum Pressure: 101.9 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 3-12: Nhartanda Pressure Profile - Pump trip with rapid-closing non-return valves – F1_C to WTP
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500
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 3000 3500 4000 4500
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Static Maximum Pressure: 95.9 m Absolute Roughness: 0.150 mm
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
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
40
20
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Static Maximum Pressure: 101.3 m Absolute Roughness: 0.150 mm
Final Flow: 400.0 m3/h WTP WL: 165.5 m Minimum Pressure: 0.0 m Anti-Shock Air Valves: Yes
Figure 3-14 Revubue I Pressure Profile - Pump Start Event – F15 to Matema DC
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
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 3000 3500 4000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Static Maximum Pressure: 94.8 m Absolute Roughness: 0.150 mm
Final Flow: 400.0 m3/h WTP WL: 165.5 m Minimum Pressure: 0.0 m Anti-Shock Air Valves: Yes
Figure 3-15: Revubue I Pressure Profile - Pump Start Event – F14 to Matema DC
200
180
HGL (m )
160
140
120
100
0 500 1000 1500 2000 2500 3000 3500 4000
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 3000 3500 4000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Borehole WL: Static Maximum Pressure: 91.9 m Absolute Roughness: 0.150 mm
Final Flow: 400.0 m3/h WTP WL: 165.5 m Minimum Pressure: 0.0 m Anti-Shock Air Valves: Yes
Figure 3-16: Revubue I Pressure Profile - Pump Start Event - Rev1_6 to Matema DC
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 400.0 m3/h Borehole WL: Static Maximum Pressure: 186.4 m Absolute Roughness: 0.150 mm
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
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 400.0 m3/h Borehole WL: Static Maximum Pressure: 162.5 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.5 m Minimum Pressure: -9.8 m Anti-Shock Air Valves: Yes
Figure 3-18: Revubue I Pressure Profile - Pump Trip Event – F15 to Matema DC
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
180
130
Pressure (m)
80
30
-20
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 400.0 m3/h Borehole WL: Static Maximum Pressure: 162.7 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.5 m Minimum Pressure: -9.8 m Anti-Shock Air Valves: Yes
Figure 3-19: Revubue I Pressure Profile - Pump Trip Event – F14 to Matema DC
300
250
HGL (m )
200
150
100
0 500 1000 1500 2000 2500 3000 3500 4000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 400.0 m3/h Borehole WL: Static Maximum Pressure: 168.1 m Absolute Roughness: 0.150 mm
Final Flow: 0.0 m3/h WTP WL: 165.5 m Minimum Pressure: -9.8 m Anti-Shock Air Valves: Yes
Figure 3-20: Revubue I Pressure Profile - Pump Trip Event - Rev1_6 to Matema DC
• 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;
All results for the waterhammer analysis will be presented along these profiles.
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 69.9 m Absolute Roughness: 0.600 mm
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
150
140
130
120
110
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 71.5 m Absolute Roughness: 0.600 mm
Final Flow: 900.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -1.0 m Anti-Shock Air Valves: Yes
Figure 3-22: Revubue II Pressure Profile - Pump Start Event – Rev2_5 to Suction Reservoir
Revubue II Wellfield
Simultaneous Pump Start
Transient HGL Rev2_13 to Suction Reservoir
180 `
170
160
150
HGL (m )
140
130
120
110
100
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
100
80
60
Pressure (m)
40
20
-20
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe MAOP Fittings
Initial Flow: 0.0 m3/h Borehole WL: Dynamic Maximum Pressure: 64.3 m Absolute Roughness: 0.600 mm
Final Flow: 900.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -1.0 m Anti-Shock Air Valves: Yes
Figure 3-23: Revubue II Pressure Profile - Pump Start Event – Rev2_13 to Suction Reservoir
It is again worth noting that without anti-shock air valves, the maximum transient pressures are expected to increase
significantly up to 290 m.
Revubue II Wellfield
Rapid Simultaneous Pump Trip
Transient HGL 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)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
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
Initial Flow: 900.0 m3/h Borehole WL: Dynamic Maximum Pressure: 118.5 m Absolute Roughness: 0.600 mm
Final Flow: 0.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -10.0 m Anti-Shock Air Valves: Yes
Figure 3-24: Revubue II Pressure Profile - Pump Trip Event – Rev2_4 to Suction Reservoir
220
200
HGL (m )
180
160
140
120
100
0 200 400 600 800 1000 1200 1400 1600
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
140
120
100
Pressure (m)
80
60
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
Initial Flow: 900.0 m3/h Borehole WL: Dynamic Maximum Pressure: 115.0 m Absolute Roughness: 0.600 mm
Final Flow: 0.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -10.0 m Anti-Shock Air Valves: Yes
Figure 3-25: Revubue II Pressure Profile - Pump Trip Event – Rev2_5 to Suction Reservoir
Revubue II Wellfield
Rapid Simultaneous Pump Trip
Transient HGL Rev2_13 to Suction Reservoir
220 `
200
180
HGL (m )
160
140
120
100
0 100 200 300 400 500 600 700 800 900 1000
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
0 100 200 300 400 500 600 700 800 900 1000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 900.0 m3/h Borehole WL: Dynamic Maximum Pressure: 78.7 m Absolute Roughness: 0.600 mm
Final Flow: 0.0 m3/h Reservoir WL: 144.5 m Minimum Pressure: -10.0 m Anti-Shock Air Valves: Yes
Figure 3-26: Revubue II Pressure Profile - Pump Trip Event – Rev2_13 to Suction Reservoir
150
140
130
120
110
100
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (m)
Transient Pressure
80
60
Pressure (m)
40
20
-20
0 1000 2000 3000 4000 5000 6000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
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
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.
220
200
HGL (m)
180
160
140
120
100
0 1000 2000 3000 4000 5000 6000
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 1000 2000 3000 4000 5000 6000
Chainage (m)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 286.5 m3/h Suction Reservoir WL: 141.0 m Maximum Pressure: 88.2 m Absolute Roughness: 0.600 mm
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
350
300
HGL (m)
250
200
150
100
0 2000 4000 6000 8000 10000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 0.0 m3/h Suction Reservoir WL: 141.0 m Maximum Pressure: 221.5 m Absolute Roughness: 0.600 mm
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
400
350
HGL (m)
300
250
200
150
100
0 2000 4000 6000 8000 10000
Chainage (m)
Invert Level (m) Minimum Hydraulic Grade (m) Maximum Hydraulic Grade (m) Initial Hydraulic Grade (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)
Minimum Pressure (m) Maximum Pressure (m) Initial Pressure (m) MAOP Pipe
Initial Flow: 805.0 m3/h Suction Reservoir WL: 141.0 m Maximum Pressure: 261.0 m Absolute Roughness: 0.600 mm
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
• 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.
• 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.
• 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.
• 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.
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.
• 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.
• 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.
• Soft starters will be used. It is recommended to start and stop the pump over a duration of at least 30
seconds.