ABU DHABI SEWERAGE SERVICES COMPANY

(ADSSC)

GENERAL SPECIFICATION FOR MECHANICAL

WORKS

DIVISION 15 MECHANICAL

SECTION 15180 SLUDGE DIGESTION

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description / Purpose of Issue

01 April 2008 First Issue.

02 Jan. 2011 ADSSC new logo

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

TABLE OF CONTENTS

1. DIGESTERS .................................................................................................... 5
1.1 GENERAL ............................................................................................ 5
1.2 SLUDGE INLET AND OUTLET ............................................................ 5
1.3 HIGH LEVEL OVERFLOW ................................................................... 5
1.4 GRIT REMOVAL, AND EMERGENCY DRAIN & GUARD VALVE ........ 5
1.5 SCUM CONTROL ................................................................................ 6
1.6 INSULATION........................................................................................ 6
1.7 DIGESTER ROOF................................................................................ 6
1.8 GAS COLLECTION .............................................................................. 6
1.9 VIEWING PORTS ................................................................................ 7
1.10 DIGESTER ACCESS HATCHES ......................................................... 7
1.11 TEMPERATURE SENSING ................................................................. 7
1.12 PH MEASUREMENT............................................................................ 7
1.13 ACCESS STAIRCASE ......................................................................... 7
1.14 SLUDGE MIXING ................................................................................. 8
2. DIGESTED SLUDGE STORAGE TANK .......................................................... 8

3. GAS SYSTEM.................................................................................................. 8
3.1 GENERAL ............................................................................................ 8
3.2 GAS BLOWERS ................................................................................... 8
3.3 PIPEWORK .......................................................................................... 9
3.4 FLAME ARRESTORS .......................................................................... 9
3.5 CONDENSATE TRAPS........................................................................ 9
3.6 FLUE SYSTEMS ................................................................................ 10
4. LIQUID PETROLEUM GAS (LPG) ................................................................ 10

5. GAS HOLDER AND WASTE GAS BURNING SYSTEM ............................... 10

5.1 GENERAL .......................................................................................... 10
5.2 PRESSURE AND VACUUM RELIEF ................................................. 11
5.3 GAS BELL POSITION MONITOR ...................................................... 11
5.4 WASTE GAS BURNERS .................................................................... 11
6. PUMPS .......................................................................................................... 11
6.1 GENERAL .......................................................................................... 11
6.2 INSTRUMENTATION ......................................................................... 12
7. SCADA .......................................................................................................... 12

8. SAMPLING POINTS ...................................................................................... 12

9. POTENTIALLY EXPLOSIVE ATMOSPHERES ............................................. 13

10. INSPECTION AND TESTING ........................................................................ 13

10.1 GENERAL .......................................................................................... 13
10.2 DIGESTER & GAS BELL ................................................................... 13
10.2.1 GAS HOLDER .................................................................................... 14

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

10.2.2 INITIAL START-UP ............................................................................ 14

10.2.3 PROCESS ACCEPTANCE AND COMPLETION OF TESTS.............. 14
10.2.4 AUTOMATION AND PLC SYSTEM TESTING ................................... 15
10.2.5 OPERATOR TRAINING ..................................................................... 16

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

1. DIGESTERS

1.1 GENERAL

a) Digesters shall be of concrete or glass coated steel, as defined in the

particular specification.

b) Glass coated steel tanks shall comply with Section 15200: Sectional
Storage Tanks. The life expectancy of the tanks shall be in excess of 25
years.

c) The temperature of the digester contents shall be maintained using

closed loop control from a resistance thermometer. Mixing of the tank
contents shall be achieved not less than six times a day using re-cycled
digester gas.

d) Egg shaped digester tanks may be considered.

e) All equipment to be in accordance with Section 15004: Corrosion

Protection.

1.2 SLUDGE INLET AND OUTLET

a) The digester vessel shall be fed by thickened sludge transfer pumps

which shall intermittently feed the digester under normal conditions.
Sludge shall be fed to the digester via a vertical, central pipe which shall
terminate not less than 0.5m below top sludge level. Provision shall be
made for an external rodding point at the point of penetration through the
tank roof.

b) There shall be gravity flow out of the digester into the digested sludge
holding tanks. The sludge outlet shall be via an overflow weir and outlet
pipe. A rodding point and mobile compressor connection shall be
provided at this point. Also a high level probe to inhibit operation of the
thickened sludge transfer pumps.

c) Centrifugal pumpsets shall be used to mix the entire Digester contents

once every 8 hrs.

1.3 HIGH LEVEL OVERFLOW

An overflow shall be provided at maximum sludge level. The overflow shall

be in the form of a bell mouth of not less than 150mm diameter and shall
direct excess sludge to the digested sludge holding tank(s).

1.4 GRIT REMOVAL, AND EMERGENCY DRAIN & GUARD VALVE

An emergency drain shall be provided in the digester base comprising a

central bell mouth and drainage pipe back to the Sludge reception tank. A
handwheel operated guard valve shall be provided on the digester bottom

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

outlet immediately adjacent to the Digester. A 100mm Female Bauer

coupling shall be provided on the drainage main for mobile tanker
connection when grit is discharged under hydrostatic conditions. The tanker
connection and manual digester control and isolation valves shall be in
addition to the guard valve.

1.5 SCUM CONTROL

a) Scum control will be provided in the form of a Rootes type blower and
grade 316L stainless steel air delivery pipework system.

b) Blowers will be belt driven by flameproof motors.

c) Blowers to be in accordance with Section 15100: Compressed Air

Systems

1.6 INSULATION

The roof and walls of the tank shall be insulated with proprietary insulating
panels, fixed to the steel tank section with fixing bolts. The panels shall be
capable of being removed individually.

1.7 DIGESTER ROOF

a) The digester roof shall be of a proven design and capable of supporting

all conditions of loading including maximum operating pressure and
dead loads. The roof shall be designed in accordance with BS 6399
Part 1 or equivalent of CP3 Ch. 5 to accommodate superimposed loads
including pedestrian access.

b) The roof shall also be provided with handrailing to provide access to all
points requiring access for operation and maintenance.

c) All roof segments shall be sealed internally and fixing bolts shall be
stainless steel and fitted external to the dome.

1.8 GAS COLLECTION

a) Gas collection shall take place in the digester roof dome. The design of
the gas take-off shall prevent carry over of foam into the gas system.
The gas take-off shall rise vertically from the digester roof to ensure
condensate drainage back into the digester and incorporate a lockable
isolation valve.

b) The gas collection/digester roof dome shall incorporate at least, two in

number, pressure relief/vacuum relief valves. The relief valve
connections shall incorporate a tamper-proof isolation valve, test
pressure connection, purging connection and drip leg drain. The design
of the relief valves shall take into account the exposed nature of desert
conditions. All Flanges to be to BS4504.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

1.9 VIEWING PORTS

Two number viewing ports shall be provided adjacent to each other in the
digester roof. Provision shall be made for internal cleaning of the viewing
ports by externally operated wipers. The wiper system shall be gas tight and
each point shall also be covered with a hinged lid to prevent the formation of
algae on the viewing point.

1.10 DIGESTER ACCESS HATCHES

2 No 750mm x 750mm diameter manways complete with bolted covers shall

be mounted in the tank side wall at ground level with a further unit to be
mounted in the roof of the tank adjacent to the access ladder. Nuts, bolts,
washers removed for maintenance activities on a routine basis shall be
grade 316L stainless steel.

1.11 TEMPERATURE SENSING

a) Not less than three number Temperature measuring points shall be

provided on the digester for temperature control and local indication (top,
bottom and mid-height). The lowest shall be located on the periphery at
a height not more than 1.5m above ground level. Temperature sensing
pockets more than 1.5 m above ground level shall be accessible from
maintenance platforms.

b) Temperature sensing pockets shall extend in to the digester and/or

sludge by not less than 1.0m.

c) Temperature sensing units to be in accordance with Section 16600:

Instrumentation.

1.12 PH MEASUREMENT

a) pH measurement shall be included at one point within the digester. The

measurement probe shall be located adjacent to the digester outlet so
that maintenance can be readily carried out with the digester full, and
also such that the sample is representative of the whole digester
contents. Where required, access ladders and platforms shall be
supplied to ensure safe access for maintenance and operation.

b) The pH system including its location, enclosure requirements etc shall

comply with Section 16600: Instrumentation.

1.13 ACCESS STAIRCASE

a) Access to the digester tank roof shall be via a single galvanised steel
staircase. Alternative GRP construction staircases may be submitted for
approval by the ADSSC. At the top of the staircase an access platform
shall be provided on the tank roof for access to the viewing ports, gas
take-off pressure/vacuum relief valves and the access hatch. Galvanised

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

handrailing 1.5m high shall be supplied. The area between the upper rail
and the toe board will be filled with robust galvanised steel mesh.

1.14 SLUDGE MIXING

a) Sludge mixing shall be actioned by one of the following methods:-

b) Gas Mixing.

c) Mechanical pump mixing.

d) Mechanical vertical shaft mixing.

2. DIGESTED SLUDGE STORAGE TANK

a) The digested sludge storage tank shall be provided as an open topped

conical bottom tank fitted with a decanting manifold.

b) A multiple valve decanting manifold shall be provided for supernatant

water draw off. This shall comprise chain-operated 100mm sluice valves
mounted on the tank at 1.0m intervals with the uppermost acting as the
high level overflow. Discharge shall be into an adjacent chamber.

c) Sludge shall be drawn from a central bellmouth by the road tanker via
the sludge outlet valve and road tanker connection. A rodding point and
compressor connection shall be provided at the periphery of the tank
base.

d) A 100mm drain shall be provided at the tanker loading point to return

spillage and wash down water to the works inlet.

e) The sludge outlet valve shall be a lockable knife edge valve.

3. GAS SYSTEM

3.1 GENERAL

Unconfined gas mixing shall be achieved by not less than three in number,
gas nozzles. Re-cycled gas shall totally mix the sludge, maintaining uniform
sludge temperature; preventing water/sludge banding, minimising grit
settlement and inhibiting scum/foam build up. Each gas nozzle shall
incorporate an integral "non-clog" non-return valve and an isolating valve.
The non-return valves shall be mounted on the gas supply pipes external to
the tank.

3.2 GAS BLOWERS

a) The gas blower shall be a packaged units in accordance with Section

15100: Compressed Air and shall be provided on a continuous/duty
standby arrangement for each digester. The blower shall be suitable for

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

use with sludge gas, and bearing materials, seals, etc shall take into
account the nature of sludge gas and associated moisture related
corrosion products. The unit shall be capable of automatic operation,
unattended with the minimum of maintenance. A flow failure switch shall
be fitted to the blower.

b) Each blower shall discharge into a common gas supply manifold of 316L
stainless steel via a non-return valve and an isolating valve. Each
blower discharge shall incorporate a pressure relief valve and a pressure
operated under pressure switch which shall trip the blower on loss of gas
supply. A discharge pressure gauge shall be provided on the delivery
branch of the air supply manifold.

3.3 PIPEWORK

a) All gas handling pipework shall be in stainless steel and run at high
level. The pipework shall include a condensate trap.

b) The gas supply to the blower shall be direct from the gas holder.
Branched connections on the digester/gas holder gas main shall not be
acceptable.

c) All gas valves shall be quarter-turn, lever operated, firesafe valves

approved by Abu Dhabi Gas.

d) Connections shall be butt welded where possible otherwise compression

fittings shall be provided.

3.4 FLAME ARRESTORS

Flame arrestors shall be fitted on the upstream and downstream of the gas
pipework in association with the blower isolation valves.

3.5 CONDENSATE TRAPS

a) Condensate traps shall be automatic in operation and be arranged such

as to prevent gas escape, or air entry into the system under all operating
pressure conditions, including vacuum. Each trap shall have gas
isolation valves.

b) Condensate traps shall be installed on horizontal lines immediately

following any vertical section.

c) Dip pipes may be of ABS or uPVC be of full pipeline diameter and shall
drain into the supernatant return chamber.

d) In the event of high gas holder volumes the waste gas burner shall be
brought on line to consume excess gas. Facilities will be provided for
taking off and burning the gas yield from the digesters, through a waste

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

gas burner "Flare Stack", at the rate specified in the particular

specification.

e) Under normal operating conditions the source of heat may be provided

by utilising sludge digester gas. Under initial start up conditions the
secondary fuel shall be utilised from an L.P.G bulk storage tank,
provided bt the Contractor.

3.6 FLUE SYSTEMS

a) A stainless steel flue system shall be provided and incorporate a stack

condensate drain on vertical flue sections.

b) Roof/Wall penetrations shall be provided with penetration flashings and

the stack shall terminate in a rain/draught cowl.

c) Flues shall terminate not less than 1m above roof level or in accordance
with local Building regulation requirements whichever is the greater.

4. LIQUID PETROLEUM GAS (LPG)

a) As an alternative fuel source for initial start up and emergency, the

Contractor shall provide a bulk storage tank for LPG. The tanks shall
have a nominal capacity, equivalent to the volume of LPG required to
satisfy the heating requirements of the digester for a period of 1 month.
The bulk LPG installation shall incorporate the following:

i. Bulk tank filter, vent and isolation valves.

ii. Tank level gauge.
iii. Fill alarm and low level cut out/alarm.
iv. Sheathed copper feed pipework to the boiler room.
v. All necessary valves and fittings, including a fire check shut-off
valve, required to complete the installation.

b) The Contractor shall provide the first fill and shall use what fuel he
requires for the test before completion and extending operating tests.

5. GAS HOLDER AND WASTE GAS BURNING SYSTEM

5.1 GENERAL

a) A gas storage system shall be provided for each digester, sized in

accordance with the particular specification.

b) Gas storage bells and gas bag units with an internal bladder type
storage unit may be considered.

c) Hand rails and panels will be installed as outlined in the particular

specification.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

d) The gas pressure shall be thrown by the self weight of the bell. Where
trimming is required then the ballast shall be mounted external to the
bell.

e) The bell shall be guided to prevent jamming on ascent or descent such

that the bell movement is always balanced.

f) The bell shall be capable of being locked in its uppermost position to

allow maintenance inspection of the gas holder. Inspection access
hatches shall be provided for this purpose.

5.2 PRESSURE AND VACUUM RELIEF

Not less than two in number pressure relief/vacuum relief valves shall be
provided in the gas bell dome. Each shall be fitted directly to the gas bell via
a lockable isolation valve. The locking device shall incorporate a mechanical
interlock that shall ensure that one of the isolating valves will always be
open.

5.3 GAS BELL POSITION MONITOR

An ultrasonic device shall be installed to monitor gas bell position. The

generated signal shall be used for alarm/indication functions. The waste gas
burner initiation high level shall be via a separately mounted proximity switch
sensing a high gas bell level.

5.4 WASTE GAS BURNERS

a) The Contractor shall supply a minimum of 2 no. waste gas burner units.
These units shall operate on a duty/ standby basis.

b) Each gas burner shall be sized to operate at a maximum of 200% of

maximum gas production.

c) Waste gas and gas not used to fire the digester heating boilers shall be
pumped to the water gas burners for burning.

6. PUMPS

6.1 GENERAL

a) All pumps shall be provided on a duty/standby configuration, and shall

comply with Section 15030: Pumps and associated equipment and
Section 15280: Posive Displacement Sludge Pumps.

b) The pumping equipment to be provided shall be as follows

i. Positive Displacement Sludge Pumps

 Raw Sludge Transfer.
 Thickened Sludge Transfer.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

 Digested Sludge Transfer.

ii. Centrifugal Water Pump

 Wash Water Booster Pump.

iii. Supernatant Recovery

i. Pumps shall be submersible pumps in accordance with the
Centrifugal Pump specification and provided on a duty/standby
basis.

6.2 INSTRUMENTATION

a) Instrumentation shall comply with Section 16600 : Instrumentation and

the following instrumentation shall be provided for process monitoring:

i. Compressed Gas Pressure Indicator.

ii. Sludge Flow Metering. Gas Flow Metering.
iii. Gas Methane Content Metering.
iv. Sludge "Dialog" Units (Import & Export).
v. Supernatant Flow Metering.

7. SCADA

a) The following SCADA screens shall be provided for the plant:

i. Sludge Flow.
ii. Gas Flow.
iii. Water Flow.
iv. Overall Flow.
v. Alarms.
vi. Supernatant Plant.
vii. Sludge Pressing Plant (Where Applicable).
viii. Digester Temperature.
ix. Digester Plant Retention (Auto calculation from daily flow &
hydraulic capacity).

8. SAMPLING POINTS

a) Sampling points shall be provided at the following process points:

i. Raw Sludge Inlet - Indigenous and imported (where applicable).

ii. Raw Sludge Thickener Feed.
iii. Raw Sludge Thickener Supernatant Return.
iv. Digester Feed.
v. Digester Outlet.
vi. Digested Sludge Storage Supernatant Return.
vii. Gas Analysis Points -each digester.
viii. Gas Bell to Gas Mixers.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

All sample points shall be 50mm diameter and incorporate isolation

valves.

9. POTENTIALLY EXPLOSIVE ATMOSPHERES

To be in accordance with Section 16680: ATEX Guidelines

10. INSPECTION AND TESTING

10.1 GENERAL

All tanks, including digesters shall be subject to leak tests before the
introduction of the stored medium. The tank tests shall be in the form of a
"Drop Test". All tanks shall be filled with final effluent at a rate approved by
the ADSSC After allowing a period of seven days or such other period as
ADSSC may decide for absorption, the water level shall be recorded by a
hook gauge with vernier attachment or by other approved means and the
water shall be allowed to stand for a period of seven days during which the
time the maximum permissible drop shall not exceed 1/500 of the average
water depth of the full tank or 2mm whichever is the less.

10.2 DIGESTER & GAS BELL

a) The digester and gas bell shall be water tested in accordance with Tank
Site Installation Test prior to the installation of insulation cladding.

b) The digester roof and the gas bell shall be tested by water or air
pressure and the relief valve operation/setting confirmed.

c) All gas lines, including the digester roof, gas bell and blowers shall be
tested in accordance with Abu Dhabi Gas Testing Procedures for
Industrial and Commercial Gas Installations".

d) Test pressure shall be 1.5 times the maximum pressure likely to be

experienced.

e) Purging All pipework and vessels which will ultimately contain sludge
gas shall be purged of air prior to commencing sludge feeding. The
purging shall be carried out in an approved systematic manner using the
atmospheric pressure method for nitrogen. Digester purging shall apply
to the whole of the vessel. Purging shall continue until the oxygen level
is less than 3% in accordance with BOC Nitrogen process data sheet
002. Sufficient gas shall be left in the gas holder so that the gas
recirculation mixing system can be started as soon as the digester is
sealed. The digester shall then be brought up to process temperature
whilst containing the static volume of final effluent used for testing.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

10.2.1 GAS HOLDER

a) Before gas storage is initiated the gas holder shall be tested for
soundness.

b) The gas tank shall be filled to the top gas level and allowance to stand
for 48 hours.

c) A level check shall then be carried out and the tank left for a further 5
days during which no loss of water shall be acceptable.

d) On satisfactory completion of the water test the gas bell shall be run
from bottom limit to top limit using air to set up the level control
equipment, the guide rail carriages and to prove the pressure relief
valves.

e) The gas bell shall be left at its uppermost limit under air pressure. After
not less than 10 minutes the air pressure shall be noted and a gas
soundness test carried out for not less than one hour during which time
the pressure shall not decrease.

f) Finally the gas bell shall be "purged" of air before testing of the
associated gas, heat and power systems are carried out.

10.2.2 INITIAL START-UP

As soon as the plant is functioning on gas produced and is functioning on

100% raw sludge feed at current works loadings (existing population and
sludge quality), the works shall be tested for a period of 60 days by the
Contractor. If the plant fails, the testing procedure shall be restarted and the
Tests before Completion period shall recommence.

10.2.3 PROCESS ACCEPTANCE AND COMPLETION OF TESTS

During the period of the Tests before Completion the ADSSC will take
regular tests on:

a) Feed sludge

i. dry solids content.

ii. % volatile matter.
iii. % non-volatile matter.
iv. temperature.

b) Digested sludge

i. % volatile matter destroyed.

ii. % non-volatile matter reduction.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

c) Sludge gas

i. % methane.
ii. net calorific value.

d) Monitor acids vs total alkalinity.

e) Thickened sludge

i. dry solids content.

ii. % volatile matter.
iii. % non-volatile matter.
iv. Temperature.

f) Where a fundamental process or automatic failure occurs during the 60

day test then the period shall be restarted. A 'one off' failure shall not
constitute a fundamental process or automatic operation failure. The
significance of the failure shall be entirely at the discretion of the ADSSC
who shall consult with the Contractor over the failure before declaring
that the Tests before Completion shall be stopped.

g) The excessive use of L.P.G. without valid explanation or reason shall

constitute a fundamental failure.

h) The works shall have passed the tests before completion with respect to
treatment if during 60 days of continuous operation the guaranteed
reduction in volatile solids within the digesters has been achieved.

i) The works shall be deemed to have passed the tests before completion
with respect to operating costs (power consumption/manpower
requirements/sludge disposal costs) if after 60 days continuous
operation the overall performance has been equal to or better than
that guaranteed. Where the Contractor considers that the works is
unlikely to achieve the guaranteed performance, modifications may be
carried out as agreed by ADSSC.. In this case the 60 day test period
shall be restarted after completion of the modifications. If the
guaranteed performance has not been achieved within a period of 180
days from the date of the start of the tests before completion the Tests
before Completion shall be terminated and it shall be deemed that a
fundamental failure has occurred.

10.2.4 AUTOMATION AND PLC SYSTEM TESTING

a) The works shall operate in automatic mode for the whole period of the
Tests before Completion.

b) Where the automatic operation of the works is interrupted by plant failure

then the tests will be stopped subject to agreement on whether the
failure constitutes a recurring or a fundamental fault. Either failure will
result in suspension of the Tests before Completion.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

c) Further to testing requirements of the PLC Specification the system shall

only be accepted after the satisfactory operation of the full system for a
continuous period of not less than 60 days.

10.2.5 OPERATOR TRAINING

a) The Contractor shall provide Operator Training in the form of:

i. "Hands on" experience when the plant is being commissioned.

ii. One day seminar to explain the principles of the works design and
detailed examination of the process schematic.
iii. One day seminar and introduction to the plant hardware and
familiarisation with the equipment installed.

b) This training shall be a pre-requisite to commencement of the Tests

before Completion.

c) The Contractor shall make allowance for instruction of the following

personnel.

i. 2 No Assistant Engineers.
ii. 1 No Supervisor.
iii. 3 No Plant Operators.
iv. 6 No Mechanical, Electrical and Instrumentation Craftsmen.
v. 3 No Others.

END OF SECTION

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