COVER SHEET

REV. NO.

PREPARED BY

DESCRIPTION

DATE

INTLS.

SIGN.

APPROVED BY
INTLS.

21.01.15

FOR FIRST SUBMISSION

SSJ

SSJ

MBS

18.08.15

REVISED AS PER NTPC COMMENTS

KR

KR

SSR

OWNER:

KR

CHECKED BY:

SSJ

APPROVED BY:

MBS

DATE:

CHECKED BY
INTLS.

PROJECT:

PREPARED BY:

SIGN.

18.08.15

OWNERS
CONSULTANT:

SCCL COAL BASED THERMAL POWER PLANT (2X600 MW)

THE SINGARENI COLLIERIES COMPANY LTD.

NTPC LIMITED
(A GOVERNMENT OF INDIA ENTERPRISE)
CONSULTANCY WING

CONTRACTOR:
CONSORTIUM PARTNER

THIS DOCUMENT IS PROPERTY OF MBE AND MUST NOT BE

USED EXCEPT IN CONNECTION WITH WORK OF MBE.
REPRODUCTION, USE OR DISCLOSURE OF THE
CONTENTS OF THIS DOCUMENT TO THIRD PARTY/IES
WITHOUT EXPRESS / WRITTEN PERMISSION OF MBE IS
STRICTLY PROHIBITTED.

SIGN.

McNally Bharat Engineering Company Limited

ION EXCHANGE INDIA LIMITED

R-14, TTC MIDC INDL AREA,
RABALE, NAVI MUMBAI, 400701

MBE JOB NO.:

DOCUMENT TITLE:

BP05
PROCESS CALCULATION FOR STP (TOWNSHIP AND PLANT)

NTPC DOC. NO.:

9661-520-PVM-U-001

MBE DOC. NO.:

2-BP05-VDLET-1-013
A4-A40197-12-160

IEIL DOC. NO.:

ECOSPACE

BUSINESS PARK,
CAMPUS-2B, NEW TOWN, RAJARHAT, KOLKATA-700156

NO. OF SHEETS

REV.
NO.

1
15

1
1

Design Basis reference for process calculation

SN Design Paramaters
Unit
1 Average flow
mld
2 Average daily flow
m3/d
3 Average hourly flow
m3/h
4 Average flow
m3/s
5 Peak factor
ratio
6 Peak flow
mld
7 Peak flow
m3/d
8 Peak flow
m3/h
9 Peak flow
m3/s
10 Biochemical Oxygen Demand (BOD5 )
mg/l
11 Chemical Oxygen Demand (COD)
mg/l
12 Total Suspended Solids (TSS)
mg/l
13 TKN as N
mg/l
14 Phosphorus
mg/l
15 Total Ammonical Nitrogen
mg/l
16 Design temperature
oC
17 Min. temparature of sewage
oC
18 Max. temparature of sewage
oC
19 Sulphate
mg/l
20 Fecal Coliform
21 DO in aeration tank
22 Elevation
23 Oxygen transfer efficiency
24 Operating Hr/day

MPN/100ml
ppm
m
%
Hr

gn Basis reference for process calculation

Raw sewage
0.60
600.00
27.27
0.01
2.25
1.35
1350.00
61.36
0.017
400.00
600.00
450.00
10.00
6.00
17.00
25.00
25.00
35.00
0.00
2 x 107
2.00
15.00
35.00%
22.00

Treated Sewage
0.60
600.00
27.27
0.01
2.25
1.35
1350.00
61.36
0.02
30.00
250.00
100.00
0.50
2.00
5.00
25.00
25.00
30.00
0.00
10000.00
2.00

WATER BALANCE
Note

All flowes are in m3/hr unless specified

Air Blower

Centrifuge/sludge bed

Capacity = 680.65 m/hr @

0.45 kg/cm2

Capacity = 0.32 m/hr

Recirculation Flow

Inlet Bar screen

Inlet Sewage
Avg. Flow
27
Peak Flow
61
COD 600.00
BOD 400.00
TSS 450.00
Operating
22.00
Hr

No of unit - 1
Peak Flow 61
COD 600.00
BOD 400.00
TSS 450.00

L= 13.33 , W= 13.33 , H= 3.49

waste sludge
0.32
Flow
Secondary settling tank (Lamellar
Clarifier)
No of unit - 1

Extended aeration based aeration Tank

No of unit- 1
L= 1.5 , W=0.7 , H=0.79

17.23

Avg. Flow 44.83

COD 250.00
BOD 30.00
TSS 4000.00

L = 3 ,W = 2.5 , SWD= 4
Avg. Flow
COD
BOD

27
250.00
30.00

TSS
100.00
Clarified cum Chlorination Tank
No of unit - 1
Avg. Flow
COD
BOD
TSS

27

L= 4 , W= 3 , H= 2.5

250.00
30.00
100.00
Hypo-Chloride Dosing
Capacity = 20 LPH @ 20 m head

Bar Screen
Total Flow
No of screens
Flow per screen
Velocity at peak flow, V
Clear area of opening
Assume LD
Angle of Inclination of screen with horizontal
Projected depth of the screen

m3/sec
no
m3/sec
m/s
m2
m
deegree

Clear width of openings through racks

Clear spacing between the bars

m
mm
m
mm
m

0.148
10.000
0.010
3.000
0.003

no

13.76
14.000
15.000
16.000

Flat thickness

0.017
1.00
0.017
1.000
0.017
0.10
60.00
0.12

No of bars
say
No of Openings
say
Width of the screen

no

m
say
Velocity through screen chamber, v

0.017
1.00
0.017
1.000
Flow per screen / Velocity at peak flow, V
0.10
60.00
Assume LD / SIN (Angle of Inclination of screen with horizontal)
Clear area of opening / Projected depth of the screen
10.000
0.010
3.000
0.003
(Clear width of openings through racks / Clear spacing between the bars)-1

14.000
No of bars+1
16.000
(No of bars*Flat thickness)+(No of Openings*Clear spacing between the
bars)
0.202
0.700
0.700

Free Board

m/s
m

0.244
0.40

Length of channel required on downstream

0.937

Length of channel required on upstream

Total Length

Total Flow / ( Width of the screen*Assume LD) / No of screens

0.40
Assume LD+(Free Board/TAN(Angle of Inclination of screen with
horizontal))+(3*Width of the screen)
0.500
0.500
Length of channel required on downstream +Length of channel required on
1.437
upstream

Head loss through bar screen

For clean condition
HL= 1 /C [ V2 - v2 ] / 2g
Where
Emperical discharge coefficient for clear condition, C
V
v
therefore ,

HL

For 50% clogged condition

Emperical discharge coefficient for clear condition, C
V
v
Therefore ,

HL

Provided Length
Provided Width
Provided Height

m/s
m/s

0.600
1.000
0.244

0.080

m/s

0.700
2.000

0.700
Velocity at peak flow, V / 0.5

m/s

0.244

Total Flow / ( Width of the screen*Assume LD) / No of screens

0.287

m
m
m

1.50
0.70
0.79

0.600
1.000
Total Flow / ( Width of the screen*Assume LD) / No of screens

1.50
0.70
0.79

Extened Aeration p
0.00%

Reduction due to primary treatment

Biodegradable COD

ppm

Non Biodegradable COD

ppm

Soluble BOD

ppm

Soluble COD

ppm

effluent soluble COD

ppm

40.00

Non Biodegradable VSS

ppm

127.50

Total volatile particle, VSS

MLSS

ppm
ppm

382.50
4000.00

Growth kinetics constant only for Hetrophylic bacteria at 20oC

K
Y
Kd
Ks
Fd
Um
SRT
value
Um.
Kd.
Ks.
Um at working temperature
Kd at working temperature
Growth kinetics constant only for nitrification bacteria at 20oC
Umn
Kn

g bCOD/m3
g VSS/gbCOD
g vss/g vss.d
g bCOD/m3
unitless
g VSS/gVSS .d
Day

640.00
40.00
200.00
360.00

20.00
0.40
0.10
30.00
0.15
5.00
60.00

g/g.d
unitless
unitless
g/g.d
g/g.d

1.07
1.04
1.00
7.01
0.12

g vss/gvss.d
g NM4-N/m3

0.75
0.74

Yn
kdn
Ko

g vss/g NH4-N
g vss/gvss.d
g/m3

0.12
0.08
0.50

value
Um
Kn
kdn

Unitless
Unitless
Unitless

1.07
1.05
1.04
1.05
0.10
0.96

Um at working temperature
kdn at working temperature
Kn at working temperature

Specific growth rate Un

g/g.d

0.19

SRT
Design SRT (peak TNK/Avg TNK)
Design SRT

Day

5.23
1.00
5.23

g bCOD/m3

Solid production rate in term of Suspended particle

Heterotropic Biomass , A
kg/d
Cell debris, B
kg/d
Nitrifying bactetia biomass, C

1.09

77.71
11.34
0.40

Non bio degradable VSS in influent, D

Kg/d
kg/d

76.50

Px,tss

kg/d

222.24

Px,vss

kg/d

165.95

No of aeration tank
Volume of the Aeration tank
Liquid depth
(C/s Area of the tank)
(Length / width ratio)

no
m3
m
m2
m

1.00
444.48
2.50
177.79
1.00

width
Length
Free board

m
m
m

Retainsion time

Hr

MLVSS in aeration tank

ppm

F/M Ratio

kg/kg.d

13.33
13.33
0.50
16.30
2986.94
0.18

Oxygen requirment

Kg/day

282.30

Air requirment for mixing

Total air requirment for mixing

Kg/hr
Kg/hr
M3/hr
M3/hr/m3 of tank volume
m3/hr

12.83
36.66
30.30
1.20
680.65

Provide the Air blower of capacity

m3/hr

680.65

Air requirment

Air requirement
Relative pressure at elevation
1.00

Pb/Pa
Oxygen Saturation value at operating temperature

ppm

Oxygen Concentration at operating temperature and altutude

ppm

Sp. Wt at working temperature

KN/m3

Atm press. At working elevation and temperature

% conc of oxygen in air leaving aeration tank

m of water
%

Oxygen Concentration at operating temperature and altutude in

aeration tank

ppm

Fouling factor

8.24
8.22
9.77
10.35
19.00

8.21

0.65
0.95
0.90

SOTR

Kg/h

Air flow rate

m3/hr

Provide the air blower of capacity

m3/hr @ .5kg/cm2

Retainsion time during peak flow

Hr

Ht required to accoumodate the peak flow

Free board

m
m

Volume of the tank

m3

Waste sludge production

m3/day

Diffusers requirment
Area covered by diffusers
Total area to be coverd
No of diffusers required

m2/diffuser
m2
No

Air flow through each diffusers

m3/hr/diffusers

26.91

270.68
680.65

2.00
0.69
0.30
567.21
7.11

2
177.79
88.90
7.66

Extened Aeration process

0.00%
1.6* Biochemical Oxygen Demand (BOD5 )*(1-Reduction due
to primary treatment)
Chemical Oxygen Demand (COD)*(1-Reduction due to
primary treatment)-Biodegradable COD
Biochemical Oxygen Demand (BOD5 )*0.5* (1-Reduction due
to primary treatment)
Chemical Oxygen Demand (COD)*0.6*(1-Biodegradable COD)
Soluble COD-1.6*Soluble BOD
(1-1.6*(Biochemical Oxygen Demand (BOD5 )-Soluble BOD)/
(Chemical Oxygen Demand (COD)-Soluble COD))*Total
volatile particle, VSS
0.85*Total Suspended Solids (TSS)
4000.00

20.00
0.40
0.10
30.00
0.15
5.00
60.00

range
range
range
range
range
range

1.07
1.04
1.00
Um*Um.^(Design temperature-20)
Kd*Kd.^(Design temperature-20)

range 1.03 - 1.08

range 1.03 - 1.08
range 1-1

0.75
0.74

Range .2 - .9
range .5 - 1

5 - 40
0.3-0.5
0.06-0.20
5 - 40
0.08 - 0.2
3.0 - 13.2

Table
Table
Table
Table
Table

no
no
no
no
no

8.10
8.10
8.10
8.10
8.10

metcaff
metcaff
metcaff
metcaff
metcaff

Eddy
Eddy
Eddy
Eddy
Eddy

0.12
0.08
0.50

range 0.1- .15

range 0.05 - .15
range 0.4 - 0.6

1.07
1.05
1.04

range 1.06 - 1.123

range 1.03 - 1.123
range 1.03- 1.08

Umn*Um^(Design temperature-20)
kdn*kdn^(Design temperature-20)
Kn*Kn^(Design temperature-20)
(Um at working temperature*TKN as N/ (TKN as N+Kn at
working temperature))*(DO in aeration tank/(DO in aeration
tank+Ko))-kdn at working temperature
1/Specific growth rate Un
1.00
SRT*Design SRT (peak TNK/Avg TNK)

Say

(Ks*(1+Kd at working temperature*Design SRT ))/(Design SRT

*(Um at working temperature-Kd at working temperature)-1)
(Y*(Biodegradable COD-S)*Average daily flow/(1+Kd at
working temperature*Design SRT )/1000
(Heterotropic Biomass , A*Fd*Kd at working
temperature*Design SRT
(Average daily flow*Yn*TKN as N/(1+kdn at working
temperature*Design SRT )/1000
(Average daily flow*Non Biodegradable VSS/1000
Heterotropic Biomass , A/0.85+Cell debris, B/0.85+Non bio
degradable VSS in influent, D+Average daily flow*(Total
Suspended Solids (TSS)-Total volatile particle,
VSS)/1000+Nitrifying bactetia biomass, C/0.85
Heterotropic Biomass , A+Cell debris, B+Non bio degradable
VSS in influent, D+Nitrifying bactetia biomass, C
1.00
Px,tss*Design SRT /MLSS*1000/No of aeration tank
2.50
Volume of the Aeration tank/Liquid depth
1.00
Squire root of ((C/s Area of the tank)/(Length / width ratio))
width*(Length / width ratio)
0.50
Volume of the Aeration tank/Average daily flow*Operating
Hr/day*No of aeration tank
Px,vss / Px,tss*MLSS
Average daily flow*Biochemical Oxygen Demand (BOD5 ) / MLVSS in
aeration tank / Volume of the Aeration tank / No of aeration tank

Average daily flow*(Biodegradable COD-S)/10001.42*(Heterotropic Biomass , A+Cell debris, B+Nitrifying

bactetia biomass, C)+4.33*Average daily flow*TKN as N/1000
Oxygen requirment / Operating Hr/day
Oxygen requirment /Oxygen transfer efficiency
Air requirment/1.21
1.20
Volume of the tank*Air requirment for mixing

EXP(-9.81*28.97*(Elevation-0)/(8314*(273+Min. temparature
of sewage)))
-9*10^(-5)*Min. temparature of sewage^3+0.0083*Min.
temparature of sewage^2-0.4055*Min. temparature of
sewage+14.594
Pb/Pa*Oxygen Saturation value at operating temperature
-4*10^(-5)*Min. temparature of sewage^2-0.0007*Min.
temparature of sewage+9.8126
Pb/Pa*101.325/Sp. Wt at working temperature
19.00
Oxygen Concentration at operating temperature and
altutude/2*((Atm press. At working elevation and
temperature+Kn at working temperature)/Atm press. At
working elevation and temperature+% conc of oxygen in air
leaving aeration tank/21)
0.65
0.95
0.90

Cell debris, B*9.08*1.024^(20-Min. temparature of sewage)/

(*Fouling factor*(*Oxygen Concentration at operating
temperature and altutude-DO in aeration tank))
SOTR/ Oxygen transfer efficiency/0.27*100/Um at working
temperature
maximum between Air flow rate and Total air requirment for mixing

2.00
Peak flow / (C/s Area of the tank)*Retainsion time during peak
flow
0.30
(Liquid depth + Ht required to accoumodate the peak flow )
*(C/s Area of the tank)
Volume of the Aeration tank/SRT

2
(C/s Area of the tank)*No of aeration tank
Total area to be coverd/Area covered by diffusers
Provide the air blower of capacity / No of diffusers required

1mtr long tubular diffisers

Secondry Setling tank (Lamella Clarifier)

No of tanks
In flow(avg.)
Total Inlet flowrate (Flow + return sludge)
Plate length
Plate width
Plate thickness
Plate inclination from horz.( 55 deg)
Surface Over flow rate

no.
m3/d
m3/hr
m
m
m
Radian
m/m/day

1.00
600.00
44.83
2.40
1.20
0.01
0.96
24.00

Area required/unit

m2

41.09

Area of each plate

m2

2.88

Projected area (at inclination of 55O from horz.)

m2

1.65

Assuming plate efficiency ( Actual Emersed area in water for functional requirement)

0.85

Available Projected area of each plate

m2

1.40

([Link] plate reqd./unit)

nos.

29.27

say
Assuming no. of rows

nos.
nos.

30.00
1.00

Plates provided on each row

nos.

30.00

Distance between Lamella Plates

mm

50.00

Total distance between lamella plates

1.45

Total thk. of plates in a row

0.15

Space left because of inclination

1.38

Length of Lamella

2.98

say

3.00

SIDE CHANNEL (Q)

m3/hr

26.90

Considering velocity through channel

m3/s
m/s

0.01
0.60

C/S area required

m2

0.01

Channel width Provided

0.50

Liquid depth in Channel calculated

0.02

Provided Liquid Depth

Free board considered in Channel

m
m

0.10
0.20

Total Depth of Channel

0.30

mXm

0.5 & 0.3

Width of Lamella unit calculated excluding Wall Thickness

2.30

Total Width of Lamella unit

2.50

Length
Width Selected
Side water Depth considered

m
m
m

3.00
2.50
4.00

m3/d
m3/s
m3/s
ppm
%
ppm

7.11
0.00
0.01
100.00
1.00%
10000.00

Width & Depth of channel Considered

Return sludge calculation

Waste sludge produced
Outlet from the Secondary Clarrifier
TSS concentration in it
Return sludge Consitancy
Return sludge TSS conc.

Return sludge Flow rate

Recirculation Ratio

m3/s

0.00

m3/d

379.14
0.63

y Setling tank (Lamella Clarifier)

Refernce
1.00
600.00
44.83
2.40
1.20
0.01
0.96
24.00
Total Inlet flowrate (Flow + return
sludge)/Surface Over flow rate*Operating
Hr/day
Plate length*Plate width
Area of each plate*COS(Plate inclination from
horz.( 55 deg))
0.85
Projected area (at inclination of 55O from
horz.)*Assuming plate efficiency ( Actual
Emersed area in water for functional
requirement)
Area required/unit/Available Projected area of
each plate
30.00
1.00
([Link] plate reqd./unit)/Assuming no. of rows
50.00
(Plates provided on each row-1)*Distance
between Lamella Plates/1000
Plates provided on each row*Plate thickness

30

15-30

CPHEEO manual table no 12.1 Secondary

settling tank overflow rate for Activated sludge
process

Plate length*COS(Plate inclination from horz.

( 55 deg))
Total distance between lamella plates+Total thk.
of plates in a row +Space left because of
inclination
3.00
Total Inlet flowrate (Flow + return
sludge)/2)*1.2
0.60
SIDE CHANNEL (Q)/Considering velocity
through channel
0.50
C/S area required/Channel width Provided
0.10
0.20
Provided Liquid Depth+Free board considered
in Channel
0.5 & 0.3
(Plate width+0.1)*Assuming no. of rows)+
(Channel width Provided*2)
Width of Lamella unit calculated excluding Wall
Thickness+0.2
3.00
2.50
4.00

100.00
1.00%
10000.00

(Waste sludge produced *Return sludge TSS

conc.+Outlet from the Secondary Clarrifier*TSS
concentration in it-MLSS*Outlet from the
Secondary Clarrifier)/(MLSS-Return sludge TSS
conc.)

Return sludge Flow rate*3600*Operating Hr/day

Return sludge Flow rate / Outlet from the
Secondary Clarrifier

No. of tanks
Incoming flow (avg)
Retainsion time
Volume required
Assume the L.D.
C/S area
W:L ratio
Width
length
Volume of the Tank
Free board
Provide Length
Width
Height

Clarifier cum Chlorine contact Tank

no.
1.00
m3/day
600.00
hr.
1.00
m
25.00
m
m
m
m
m
m
m
m
m

2.00
12.50
1.00
3.54
3.54
25.00
0.50
4.0
3.0
2.5

Clarifier cum Chlorine contact Tank

1.00
600.00
1.00
Incoming flow (avg)/ 24 * Retainsion time / No. of
tanks
2.00
Volume required / Assume the L.D.
1.00
Squar Root of ( C/S area / W:L ratio)
Width * W:L ratio
Assume the L.D.*Width * length
0.50
4.0
( C/S area ) / Provide Length
Assume the L.D. + Free board

Sl no
1

Description

2
3
4
5
6

Flow rate
Number of Working dosing system
Chemicals to be dosed
Conc of Chem solution to be prepared
Dosing rate (100%)
Purity of Chemical considered
Dosing rate

Dosing rate required

8
9
10

Pump Capacity provided

Pump Head required / provided
Number of Dosing Pumps

11

Unit
m3/h

Hypo chlorite
dosing system

mg/l
% w/v
kg/h
% w/w
kg/h

27.3
1.0
4.0
5.00%
0.11
18
0.11

lph

12.1

lph
mwc
Nos

20
20
1W+1S

Storage Capacity

12

12

Volume of the tank required

m3

0.145

13

Design margin

20

14

Volume of the tank calculated

m3

0.175

15

Tank Type

Vertical Cylindrical

27.3
1.0
4.0
5.00%
Flow rate*Chemicals to be dosed / 1000
18
Flow rate * Chemicals to be dosed /1000
(Dosing rate* 1000 ) / (Conc of Chem solution to be prepared* 10) /
Number of Working dosing system/100 /( Purity of Chemical
considered/100)
20
20
1W+1S
12
Dosing rate required*Storage Capacity*Number of Working dosing
system/1000
20
Volume of the tank required* (1+(Design margin/100))
Vertical Cylindrical

Sludge druing bed

Sludge consitancy
Total waste sludge genrated from STP
Sludge quantity
Drying time
quantume of sludge genrated during this period
depth of sludge on SDB

%
kg/hr
m3/day
day
m3
m

Surface area required

Length of bed
Width of bed

m2
m
m

No of bed required

No

sludge consitancy after dying

Quantume of dried sludge

m3/hr

Filtrate from the SDB

m3/hr
M3/day

Sludge druing bed

1.00
3.23
7.11
7.00
49.76
0.30
165.85
4.50
4.50
8.19
40.00%

1.00
3.23
7.11
7.00
Sludge quantity*Drying time
0.30
quantume of sludge genrated during this
period /depth of sludge on SDB
4.50
4.50
(Surface area required/(Length of bed*Width
of bed)
40.00%

0.01

Total waste sludge genrated from STP/

(sludge consitancy after dying*10*100)

0.32

Sludge quantity-Quantume of dried sludge

7.00

Filtrate from the SDB*Operating Hr/day

Line Size Criteria

Sr.

FROM

TO

No.

1
2
3
4
5
6

Bar Screen
Collection cum FMR tank
Collection cum FMR tank
Secondary settling tank
Secondary settling tank
Secondary settling tank

Collection cum FMR tank

Secondary settling tank
Secondary settling tank
Clorine contact tank
Collection cum FMR tank
Sludge drying bed

FLOW

Velocity of flow (M/Sec)

M3/Hr

Gavity

65
45
45
27
18
18

0.6

Suction

Discharge

1.8
2
0.6
0.6
0.6

DIA Required

DIA Selected

Actual Vel.

MM

MM

M/Sec

196
94
89
126
103
103

200
100
100
200
100
100

0.58
1.59
1.59
0.24
0.64
0.64

Air line

Air blower

Collection cum aeration tank (main

header)

700

15

128

150

11.01

Collection cum aeration tank

(main header)

Collection cum aeration tank (Latterals

branches - 7 branches)

100

15

49

50

14.15

Formula used for dia required = square root of (Flow*4/(velocity of flow*Pi))