TITLE

FEASIBILITY STUDY
AND DESIGNING OF SEWER NETWORK SYSTEM

GRASIM INDUSTRIES LIMITED, CHEMICAL DIVISION

Survey No.1 to 4, Near Kanedu Metta Road, Balabhadrapuram,

East Godavari Dist.-533343 Andhra Pradesh, INDIA

ENGINEERING CONSULTANT
ACE DYNAMICS, Visakhapatnam
www.acedynamics.in
 “Feasibility study and Designing of Sewer network system”

CONTENT

CLAUSE NO. DESCRIPTION PAGE NUMBER

1 Introduction 03
2 Geographical Location 03
3 Objective of the study 05
4 Significance of wastewater re-use 05
5 Source of wastewater generation 05
6 Estimation of total wastewater run-off during the day 08
7 Present wastewater disposal practice 08
8 Suggestion of Ideal Location for Treatment Plant 08
9 Implications of wastewater re-use 10
10 Environmental Concerns 10
11 Analysis of Wastewater Parameter 10
12 Standard parameters set by CPCB for recycle/re-use 10
13 Technologies available for treatment Process and Re-Use 11
14 Design and Schematic drawings of treatment plant 11
15 Detailed BOQ and financial estimates 18
16 Summary 30
17 Wastewater re-use framework Chart 32

1 Annexure-I: Raw water Analysis Report 31

1 Fig.1- Google imagery of the project site 03

2 Fig.2- Location map of the Plant site 04
3 Fig.3- Google Imagery of the Septic Tank & Soak pit (Near 06
Production area)
4 Pic 1- Picture of toilets connected to underground drain-line 07
5 Pic 2- Picture of drain manhole 1 07
6 Pic 3- Picture of drain manhole 2 07
7 Pic 4- Picture of drain manhole 3 08
8 Pic 5- Picture of the Septic Tank 09
9 Pic 6- Picture of the Soak Pit-I 09
10 Pic 7- Picture of the Soak Pit-II 09
11 Fig-5- Schematic diagram of MBBR Process 14
12 Fig-6- SBR operational cycle 15
13 Fig-7- Flow diagram of SBR 17
14 Fig-8- Schematic of Sequential Batch reactor 18

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INTRODUCTION:

Grasim Industries Limited, a flagship company of the global conglomerate Aditya Birla Group, ranks amongst
the top publicly listed companies in India. Incorporated in 1947, it started as a textiles manufacturer in India.
Today, it has evolved into a leading diversified player with leadership presence across many sectors.

Grasim’s chemicals business was set up to manufacture caustic soda for the company’s VSF unit. Today, it is
one of India’s largest caustic soda producers and is a market leader in the chlor-alkali segment. The
Balabhadrapuram unit is intended to manufacture the chlor-alkali sector. Caustic soda is a critical input in the
aluminium sector. Given the expansion plans for the aluminium businesses, it will serve as an excellent sourcing
point for leading aluminium players. The acquisition is in line with Grasim's strategy to strengthen operations
on the East Coast of the country.

The present document is aimed at feasibility study & design considerations of sewer network to transfer the
wastewater from different blocks to the treatment plant. The basic infrastructure of any Industry, mainly the
water supply and sewerage system are vital for urbanization. The wastewater management is a critical issue
in a populated environment. If the wastewater is not properly collected, treated and disposed, the related
effects pose serious threat to the environment.

We all are aware over 70 per cent of our planet is covered with water. This apparent wealth takes on a new
meaning when we consider that only approx. 3 percent is fresh water. From the very beginnings of human
development, this water has meant life to us – both to drink and to water our fields and animals. As technology
advances, we create ever new forms of process water and wastewater. As population grows, water regulations
become stricter, supplies diminish and communities try to expand economic opportunity, the need for water
treatment infrastructure increases. The discharge of untreated effluent in water bodies does not only lead to
eutrophication and human health risks, it also contributes significantly to Greenhouse Gas (GHG) emissions in
the form of nitrous oxide and methane. Emissions from untreated sewage represents three times the emissions
of conventional wastewater treatment.

ACE DYNAMICS is one of the leading Design Engineering Consultant and manufacturing Solutions provider,
offering service to various green field & brown field Industries, to address their Air, Water, Environment, Energy
and Resource management challenges by Innovative & sustainable solutions. The study provides broad
guidance on the design of a sewer line and mapping of sewer network till the treatment plant and to describe
their advantages and constraints so that those involved in the selection, design, construction, operation,
maintenance, and permitting of these facilities can make informed decisions.

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GEOGRAPHICAL LOCATION:

Figure 1. Google Imagery of the project Site

Figure 2: Location Map of the Plant Site

Andhra Pradesh Map

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OBJECTIVE OF THE STUDY:

PLANNING

1. OBJECTIVE:
The objective of a public waste water collection and disposal system is to ensure that sewage or excreta and
sullage discharged from communities is properly collected, transported, treated to the required degree and
finally disposed of without causing any health or environmental problems.

The Sewerage system consists mainly of:-

i) Collection system (sewer, sewer appurtenances)
ii) Conveyance system (pumping station, pumping main etc.)
iii) Treatment plant

The Information for the Sewerage system

i) Data Collection required for designing of domestic sewage collection system
ii) Design of sewage system

2. NEED FOR PLANNING

Planning is required at different levels;
Though the responsibility of various organizations in charge of planning public waste water disposal systems
is different in each case, they still have to function within the priorities fixed by the national and state
governments and to keep in view overall requirements of the area. It is necessary therefore to specify
appropriate standards and design criteria and to avoid different approaches.

BASIC DESIGN CONSIDERATIONS

In designing waste water collection, treatment and disposal systems, planning generally begins from the final
disposal point going backwards to give an integrated and optimum design Co suit the topography and the
available hydraulic head, supplemented by pumping if essential. Once the disposal points are tentatively
selected, further design is guided by the following basic design considerations:

a. Engineering
b. Environmental
c. Process
d. Cost

These considerations are discussed below in detail:

a) Engineering Considerations
Topographical, engineering and other considerations which figure prominently in project design are noted
below:
i) Design period, stage wise population to be served and expected sewage flow and fluctuations
ii) Topography of general area to be served, its slope and terrain. Tentative sites available for treatment
plant, pumping stations and disposal works
iii) Available hydraulic head in the system up to high flood level
iv) Ground water depth and its seasonal fluctuation affecting construction, sewer infiltration, and
structural design (uplift considerations)
v) Soil bearing capacity and type of strata expected to be met in construction
vi) On-site disposal facilities, including the possibilities of segregating the sullage water and sewage and
reuse or recycle sullage water within the households

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b) Environmental Considerations:
The environmental and socio-economic impacts of a sewage treatment plant may prove adverse during the
operation stage. Therefore the following aspects should be considered during design.

i) Surface water Hydrology and Quality

ii) Ground water quality
iii) Coastal water quality
iv) Odour and Mosquito nuisance
v) Public Health and
vi) Land-scaping

c) Process Considerations:
Process considerations involve factors which affect the choice of treatment method, its design criteria and
related requirements such as the following:

i) Waste water flow and characteristics

ii) Degree of treatment required
iii) Performance characteristics
iv) Other process requirements such as land, power operating equipment’s, skilled staff, nature of
maintenance problems, extent of sludge production and its disposal requirements, loss of head through
plant in relation to available head etc.

3. DESIGN PERIOD
Sewerage projects may be designed normally to meet the requirements over a thirty year period after their
completion. The period between design and completion should also be taken into account depending on the
type and size of the project.

4. POPULATION FORECAST
The design population will have to be estimated with due regard to all the factors governing the future growth
and development of the project area in the industrial, commercial, educational, social and administrative
spheres. Special factors causing sudden immigration or influx of population should also be foreseen to the
extent possible.
The tabular consideration is based on the present & future requirement of each block of the plant after
discussion with the management.

Sl No. Block Persons/Day

1 Utility 70
2 Project Admin Building 1, 2, 3 & 4 100
3 UPS room adjacent to Boiler 70
4 Cell House 50
5 Antracite Filter Area 70
6 ZLD 70
7 QC Lab 50
8 MCC/ VAPS 70
9 VAP area near CCU Flake Godown 70
10 G+2 40

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Sl No. Block Persons/Day

11 OHC 30
12 New Canteen 200
13 Canteen washing water 200
14 Security Middle gate 70
15 New Admin Building 100
16 Truck Bay 150
17 Salt Yard (Stand Alone) 0
18 132 KV Yard (Stand alone) 0
19 Covid Quarantine Room (Stand alone) 0
20 Reservoir Pump House (Stand alone) 0

5. ESTIMATION OF WASTEWATER FLOW

There are two types of sewerage systems viz.
i) Sanitary Sewer system, designed to receive domestic sewage and industrial wastes excluding storm water.
ii) Combined sewer system is designed to receive domestic sewage, industrial wastes and storm water. The
combined sewer system though economical initially suffers from several disadvantages and is normally not
recommended.
1. Estimation of Sanitary Sewage:
The Sewer capacity to be provided must be determined from the analysis of the present and probable quantities
expected at the end of design period. The estimation of flow is based upon the contributory population and the
per capita flow of sewage both the factors being guided by design period.

Sl No. Block Persons/Day Sewage Generation @ 40 lt/person

1 Utility 70 2800
2 Project Admin Building 1, 2, 3 & 4 100 4000
3 UPS room adjacent to Boiler 70 2800
4 Cell House 50 2000
5 Antracite Filter Area 70 2800
6 ZLD 70 2800
7 QC Lab 50 2000
8 MCC/ VAPS 70 2800
9 VAP area near CCU Flake Godown 70 2800
10 G+2 40 1600

Sl No. Block Persons/Day Sewage Generation @ 40 lt/person

11 OHC 30 1200
12 New Canteen 200 8000
13 Canteen washing water 200 1200
14 Security Middle gate 70 2800
15 New Admin Building 100 4000
16 Truck Bay 150 6000
17 Salt Yard (Stand Alone) 0 0
18 132 KV Yard (Stand alone) 0 0
19 Covid Quarantine Room (Stand alone) 0 0
20 Reservoir Pump House (Stand alone) 0 0

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 Sl No. Block Persons/Day Sewage Generation @ 40 lt/person Toilets Elevation Lvl(mt.) Routing (Sl.No.) Flow
1 Utility 70 2800 1 mt from EL + 101.400 1 to Header 6 Gravity
2 Project Admin Building 1, 2, 3 & 4 100 4000 0.5 mt from EL + 101.950 2 to Header 1 Gravity
3 UPS room adjacent to Boiler 70 2800 0.5 mt from EL + 102.150 3 to Header 5 Pumping
4 Cell House 50 2000 6 mt from EL + 102.700 4 to Header 5 Gravity
5 Antracite Filter Area 70 2800 0.5 mt from EL + 102.450 5 to Header 5 Gravity
6 ZLD 70 2800 1.0 mt from EL + 101.150 6 to Header 2 Gravity

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7 QC Lab 50 2000 6.0 mt from EL + 101.550 7 to Header 2 Gravity
8 MCC/ VAPS 70 2800 6.0 mt from EL + 101.550 8 to Header 7 Gravity
9 VAP area near CCU Flake Godown 70 2800 0.5 mt from EL + 102.050 9 to Header 7 Gravity
10 G+2 40 1600 6.0 mt from EL + 101.550 10 to Header 7 Gravity

Sl No. Block Persons/Day Sewage Generation @ 40 lt/person

11 OHC 30 1200 0.2 mt from EL + 101.600 11 to Header 7 Gravity
12 New Canteen 200 8000 0.5 mt from EL + 101.500 12 to Header 3 Gravity
13 Canteen washing water 200 1200 0.5 mt from EL + 101.500 13 to Header 3 Gravity
14 Security Middle gate 70 2800 0.5 mt from EL + 101.698 14 to Header 3 Gravity
15 New Admin Building 100 4000 6.0 mt from EL + 101.135 15 to Header 4 Gravity
16 Truck Bay 150 6000 No Construction yet + 100.400 16 to Sump 2 Gravity
“Feasibility study and Designing of Sewer network system”

17 Salt Yard (Stand Alone) 0 0 0 + 99.300

18 132 KV Yard (Stand alone) 0 0 0 + 102.000
19 Covid Quarantine Room (Stand alone) 0 0 0 + 101.382
20 Reservoir Pump House (Stand alone) 0 0 0

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DESIGN OF SEWER AND APPURTENANTS
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 Design of Sewer
 Sewerage system may be classified as sanitary sewers designed to receive domestic sewage excluding
storm water. The design of sewer inertia included estimation of sanitary sewage, hydraulic of sewer;
design of sewer system etc.

Header Design & Overall length

Sl.No. Header - Grid Length of Elevation Levels Overall Gradient
Header (mt.) required (mt.)
1 HEADER 1 (G16 to C16) 200 (+101.850 to +101.332) 1.67
2 HEADER 2 (G14 to C14) 180 (+ 101.550 to + 101.071) 1.50
3 HEADER 3 (J10 to K10) 100 (+ 101.504 to + 101.698) 0.83
4 HEADER 4 (J5 to J4) 50 (+ 101.100 to + 101.070) 0.42
5 HEADER 5 (H20 to H18) 120 (+ 102.690 to + 102.050) 1.00
6 HEADER 6 (C16 to C13) 120 (+ 101.332 to + 101.071) 1.00
7 HEADER 7 (J14 to H14, H14 to J10) 275 (+ 101.850 to 101.698) 2.29
1045
* Header size (Dia) - 200 mm,
* Standard Length - 6 mts, No. of pipes required- 175 (Approx.)
* MOC - HDPE/PVC

 Hydraulics of Sewers
 Flow in sewers is said to be steady if the rate of discharge at a point in a conduit remains constant with
time and if the discharge varies with time it is unsteady. If the velocity and depth of flow are the same
from point to point along the conduit, the steady open channel flow is said to be uniform flow and non-
uniform if either the velocity, depth or both are changing.

 A properly functioning sewer has to carry the peak flow for which it is designed and transport
suspended solids in such a manner that deposits in a sewer are kept to a minimum. The design for
wastewater collection system presumes flow to be steady and uniform. The unsteady and non-uniform
waste water flow characteristics are accounted in the design by proper sizing of manholes.

 Flow friction: The available head in waste water lines is utilized in overcoming surface resistance and
in small part, in attaining kinetic energy for flow. For design purpose, Manning’s formula for open

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channel flow and Hazen William and Darcy-Wcisback formula for closed conduit or pressure flow is
used for working out the head loss due to friction.

 Design criteria: - It is better practice to design sewers with partial full condition to provide ventilation
and keeping sewage in fresh condition. Hence peak factor for design sewer shall range between 2 to
3.5. From consideration of ventilation in waste water flow, sewers should not be designed to run full.
All sewers are designed to flow 80 percent of full ultimate flow. For design of sewer network the slope
and diameter of sewers should be decided to meet the following two conditions:

i. A self-cleansing velocity is maintained at present peak flow

ii. A sewer runs at 0.80 full at ultimate peak flow.

 Self-cleansing velocity: - To ensure that deposition of suspended solids does not take place, minimum
self-cleansing velocities are required to be considered in the design. Hydraulic elements of circular
sewers possess equal self-cleansing properties at all depths.

a. Rate of Water Supply:

Wastewater quantity may be assumed to be 80% of the quantity of water supply. The sewers should be
designed for a minimum of 150 lpcd.

b. Slope/Gradient
Slope depends upon the topography of ground and levels. Slope is also another important parameter because
the rate of flow is depends upon the amount of slope. Velocity of the wastewater is also depends upon it along
with the friction between fluid and pipe.

c. Peak Factor
The peak factor or the ratio of maximum to average flow depends upon contributory population. These peak
factors will be applied to the projected population for the design year considering an average wastewater flow
based on allocation.

d. Velocity
The sanitary sewer is designed to obtain adequate scouring velocities at the average or at least at the maximum
flow at the beginning of the design period for a given flow and slope. Velocity is little influenced by pipe
diameter. The recommended slope for minimum velocity is 0.75 metre/sec. and maximum velocity is 3.00
meter/sec. Here the sewer velocity is 2.1m/sec.

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e. Pipe Size
The pipe size should be decided on the basis of ultimate design peak flow and the permissible depth of flow.
The minimum diameter of public sewer may be 150 mm. In hilly areas, where extreme slope are prevalent, the
size of sewer may be 100 mm. The size of the pipe is calculated by the formula square root of flow rate times 4
divided by 3.14 times velocity.

f. Depth of Cover
01m cover on pipeline is normally sufficient to protect the pipe lines from external damage.

g. Manholes
Manholes are interconnecting between two or more sewers and to provide entry of sewers. Manholes are used
to building connections and junction chambers.

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Sewer Networking BOQ

Sl.No. Item Description Application MOC Qty Flow Pattern
1 Trunk Sewer i.e. Header Pipe (Dia-200 mm) Sewer Transfer HDPE/PVC 1045 mts- 180 Nos (Approx.) Gravity
2 Branching Pipe (Dia- 100 mm) Sewer Transfer HDPE/PVC 315 mts- 55 Nos (Approx.) Gravity
Pipes as per IS:16098 (Part-I); Pipe size OD (mm)- 200
mm- wall thickness (5-6-6.5)mm- Pipe ring Stiffness
(KN/m2)-SN8; Pipe size OD (mm)- 110 mm- Pipe ring
Stiffness (KN/m2)-SN8

3 Pumping Pipe (Dia- 40-50 mm) * Sewer Transfer HDPE/PVC 1645 mts Pumping
* The dia of the pipeline depends on the Suction &
Delivery of the pump

4 Inspection Chambers (315 mm) Sewer Transfer HDPE/PVC 07 Nos Gravity

ULTRA 315 inspection chamber with a provision of
multiple inlet configuration with 110 mm inlet. (Ultra
315- Base-Self invert - 210-305 mm) (Required for
Toilet Outlet).Contractor needs to consider Base &
suitable cover with frame.

5 Inspection Chambers (450 mm) Sewer Transfer HDPE/PVC 14 Nos Gravity

ULTRA 450 inspection chamber with a provision of
multiple inlet configuration with desired reducer to
connect 100 to 200 mm pipe. (Ultra 450- Base-Self
invert - 365-420 mm), Contractor needs to consider
Base, Shaft or' Raiser & suitable cover with frame.
(Required for Toilet Outlet & in the Header line)

6 Intermediate Manholes Sewer Transfer HDPE/PVC 35 Nos Gravity

ULTRA 450 inspection chamber with a provision of
multiple inlet configuration. (Ultra 450- Base-Self
invert - 365-420 mm)-25 Nos; Contractor needs to
consider Base, Shaft or' Raiser & suitable SFRC cover
with frame. (Required for Toilet Outlet & in the Header
25 Nos
line); ULTRA 600 inspection chamber with a provision
of multiple inlet configuration. (Ultra 600- Base-Self
invert - 460-600 mm)-10 Nos.; Contractor needs to
consider Base, Shaft or' Raiser & suitable SFRC cover
with frame. (Required in the Header line).
* Vendor/Contractor needs to confirm whether Ultra 600 is required or' we can use instead Ultra 450…

7 Shaft or' DWC raiser pipe (Length 6 mt.)- 450 mm Sewer Transfer HDPE/PVC 6 Nos (Approx.) Gravity
Shaft or' DWC raiser pipe (Length 6 mt.)- 600 mm Sewer Transfer HDPE/PVC 4 nos (Approx.) Gravity

8 SFRC frame & Cover - 450 mm -10 T Manhole Cover 25 Nos

SFRC frame & Cover - 600 mm -10 T Manhole Cover 10 Nos

9 Rodding Eye
Suitable for 200 mm Header pipe at every 20 mt. to free the clogging MOC- pls specify 40 Nos

SEWAGE WATER PUMPING STATION

Pumping stations handle Sewage water either for lifting the sewage so as to discharge into another gravity
sewer or for treatment/disposal of the Sewage/effluent.

• The capacity of the pumping station has to be based on present and future sewage flow considering a design
period of 15 years. The needs of future expansion need special attention especially in respect of provision of
additional space for replacing the smaller pumping units by larger area, increasing the capacity of the wet well
and constructing new pumping station to cope with the increased flow. The initial flows are generally too small
and the effect of the minimum flow should be studied before selecting the size of the pumps for the project to
be commissioned in order to avoid too infrequent pumping operation and long retention of sewage wet wells.

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• Pumping stations traditionally have two wells, the wet well receiving the incoming sewage and dry well
housing the pumps.
Dry well: The size of the dry well should be adequate to house number of pumps at the desired capacity of
pumping.
Wet Well: The size of the wet well is influenced by the sewage capacity to be provided. The capacity of the well
is to be so kept that with any combination of inflow and pumping the cycle of operation for each pump will not
be less than 5 minutes and the maximum detention time in the wet well will not exceed 30 minutes of average
flow.

• In the wet well baffles should be provided at required places to ensure uniform flow at each pump suction.
• Wherever possible grid removal ahead of pumping should be adopted to increase the life of the pumps.

PUMPS:
The selection of pump is based on many consideration such as the type of pump, the size of pump, the number
of pumps, the capacity or flow rate of each pump range of throttling of each pump, the head of pumping and
others.
• Capacity of the pump shall be adequate to meet the peak rate of flow with 50% stand by. To obtain the least
operating cost, the pumping equipment’s should be selected to perform efficiently at all flow including the peak
flow. Two or more pumps are always desirable at sewage pumping station. The size and number of unit for
larger pumping station, shall be so selected that the variations of inflow can be handled by throttling of the
delivery values or by varying the speed of the pump without starting and stopping the pump too frequently
or necessitating excessive storage.

• The total head of pumping has to be calculated taking note of four factors;
(i) The difference between the static level of the liquid in the suction sump in the wet well and the highest point
on the discharge side i.e. Static head.
(ii) The rate of flow and size of the discharge mouth determine the velocity at the point of discharge (i.e. Velocity
head or kinetic head)
(iii) The difference in the pressure on the liquid in the suction sump and at the point of delivery rate, delivery
pressure will be higher than the atmospheric pressure (i.e. Pressure head)
(iv) The frictional losses across the pipes, values, bend and all such appurtenance (i.e. Frictional loss)
(v) Operation of the pumps—Dry running of pumps should be avoided—the delivery value should be operated
gradually to avoid surges.

Sl.No. Item Description Application MOC Qty Flow Pattern

1 Sump- (Holding Tank -5 m3)- (2.5 x 1.0 x 2.0)(Lx W x D) Sewage HDPE/FRP 5 Nos Underground
* Top opening to dip the cutter pump inside
2 Submersible cutter pump- Make Grundfos-Model SEG Sewer Transfer Impeller & Shaft- SS 316 5 Sets (1w+1s)
i) 5 m3/hr. @ 45 mt. head- (1w+1s)- 02 Nos
ii) 5 m3/hr. @ 30 mt. head- (1w+1s)- 02 Nos
iii) 5 m3/hr. @ 35 mt. head- (1w+1s)- 02 Nos
iv) 5 m3/hr. @ 35 mt. head- (1w+1s)- 02 Nos
v) 5 m3/hr. @ 35 mt. head- (1w+1s)- 02 Nos
3 Desired materials for pipe fitting & accessories

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