CCG Design Engineering Services

Document Front Page

Issue Made Chk’d Appr.

Proj. rev. Date Reason for issue by by by
P.O. Number Package Title

PRIMARY TREATING FACILITIES

Tag No.(s)

Supplier: CCG Design Engineering Services. For Project use only:

Edisonstraat 12 1 2A 2 3 4
Paramaribo, Surinam Date Sign.
Supplier Job No.: 202511CCG01
Supplier Document Number

Originator Code Area/Location System Code

SOM AREA

Project No. Contract No.:

Document title

OWT SPECIFICATION
FOR
PRIMARY TREATMENT FACILITIES
VDR Code(s) SOM doc/dwg type Code

Project Document Number Page

Proj. no. Origin code Disc. Doc. Type Sequence No.
Code
1 of 8
TA - CCG - PE - C S - 0 0 0 1

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LIST OF CONTENTS

1. CONSTRUCTION MANAGEMENT PRINCIPLES

2 MATERIALS

3. FABRICATION AND INSTALLATION

4. INSPECTION

5. PREPARATION FOR ERECTION

6. CLEANING

7. PRESSURE TESTING
1 PURPOSE

This treatment system is designed to process oily wastewater and industrial

effluents containing oil, suspended solids, and biodegradable organic matter.
It combines physical separation (CPI), biological treatment (biofilm reactor),
and modular control to achieve compliant discharge or reuse-quality water.
The system is engineered for modular expansion and low chemical
dependency, making it suitable for remote or environmentally sensitive
locations.

Codes and Standards

The requirements for fabrication, assembly and erection of piping systems

shall be in accordance with the
following ANSI/ASME B31.3 "chemical Plant and Petroleum Refinery Piping".
 Chapter I - Scope and Definitions
 Chapter V - Fabrication, Assembly and Erection
 Chapter VI - Examination, Inspection and Testing

Scope of Work

1. Inlet Buffer Tank (Equalization)

 Volume: 35 m³
 Function: Temporarily stores incoming wastewater to stabilize flow and
concentration fluctuations.
 Features: PE construction, underground placement, fitted with level
sensors and controlled feed to CPI.

2. Corrugated Plate Interceptor (CPI)

 Function: Separates free oil and settleable solids using inclined
corrugated plates.
 Efficiency: Removes 90–95% of free oil based on gravity separation
principles.
 Operation: Passive; no power or chemicals required. Periodic manual
or automatic skimming is included.

3. Biological Treatment – Fixed-Bed Biofilm Reactor

 Volume: 35 m³ (Phase 1)
 Function: Aerobic treatment of biodegradable organics using biofilm
growing on submerged plastic media.
 Aeration: Fine bubble diffusers powered by an external blower.
 Monitoring: DO (dissolved oxygen), temperature, and flow sensors
managed via PLC.

4. Secondary Settling Tank

 Volume: 6 m³
 Function: Allows biomass (sludge) to settle after biological treatment.
 Features: Sloped base for sludge collection; overflow directed to
effluent system.

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5. Sludge Holding Tank
 Volume: 2–3 m³
 Function: Stores excess biological sludge prior to removal or
dewatering.
 Maintenance: To be emptied weekly or based on sludge level sensors.

6. Effluent Outlet / Polishing (Optional)

 Options: Sand or carbon filtration + UV disinfection for reuse
 Discharge Quality:
o Oil & Grease: < 10 ppm
o COD: < 100 mg/L
o TSS: < 30 mg/L
o pH: 6.5–8.5

7 System Control
 Control Panel: PLC with HMI touchscreen
 Remote Monitoring (Optional): Integration into SCADA or online
dashboard
 Alarms: High sludge level, aeration failure, overflow detection
 Automation: Pump control, aeration cycles, tank levels

System Benefits
 Modular & expandable to 8–12 m³/h
 Minimal chemical use (Phase 1 operates chemical-free)
 Underground installation minimizes footprint and odor
 Safe, automated, and environmentally compliant

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� Process Description & Design Basis
Hybrid Wastewater Treatment System
Designed Capacity: 4–8 m³/h
Application: Oily and industrial wastewater from offshore or industrial facilities

1. � System Objective
This hybrid treatment system is designed to manage wastewater streams contaminated with oil,
suspended solids, and biodegradable organics. It ensures:

 Oil and grease reduction to <10 ppm

 COD reduction to <100 mg/L

 TSS reduction to <30 mg/L

 Safe discharge or reuse as process or irrigation water

2. � Process Overview
The system consists of multiple integrated treatment steps, each with a specific function:

A. Inlet Equalization Tank (35 m³)

 Provides buffer capacity to absorb inflow variations

 Equalizes flow and concentration peaks before downstream treatment

 Retention time: 4 hours @ 8 m³/h

B. Corrugated Plate Interceptor (CPI)

 Gravity-based separator using inclined plates

 Removes free-floating oil based on Stokes’ Law

 Typical oil droplet removal: >90% for droplets >100 µm

Design Calculation
Vs=g(ρw−ρo)⋅d218μV_s = \frac{g(\rho_w - \rho_o) \cdot d^2}{18 \mu}
Where:

 g=9.81 m/s2g = 9.81 \, m/s^2 (gravity)

 ρw=1000 kg/m3\rho_w = 1000 \, kg/m^3, ρo=850 kg/m3\rho_o = 850 \, kg/m^3

 d=100 μm=0.0001 md = 100 \, \mu m = 0.0001 \, m

 μ=0.001 Pa⋅s\mu = 0.001 \, Pa \cdot s (viscosity of water)

Resulting velocity:
Vs≈0.0087 m/sV_s \approx 0.0087 \, m/s

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Required CPI surface area:
A=QVs=8/36000.0087≈0.26 m2A = \frac{Q}{V_s} = \frac{8/3600}{0.0087} \approx 0.26 \, m^2
Using a plate angle of 45° and a 70% effective projection, real plate area ≈ 0.37 m²

� Reference: Frank M. White – Fluid Mechanics (9th Edition), Chapter 9: Differential Analysis of
Fluid Motion

C. Biological Treatment – Fixed-Bed Biofilm Reactor (Delphin Technology)

 Aerobic reactor with submerged fixed media

 Degrades dissolved organic matter (COD, BOD)

 Filled with structured PE carriers (150 m²/m³ specific surface)

Design Load:
COD load=8 m3/h×200 mg/L=1.6 kg/h\text{COD load} = 8 \, m^3/h \times 200 \, mg/L = 1.6 \, kg/h
Assuming 0.8 kg COD/m³·day → Required reactor volume:
V=1.6×240.8=48 m3V = \frac{1.6 \times 24}{0.8} = 48 \, m^3
Actual tank volume with headspace: 60–70 m³

D. Secondary Clarifier + Sludge Handling

 Settles biomass and suspended solids from the biological effluent

 Sludge collected in conical bottom and pumped to a 2–3 m³ sludge tank

 Expected dry solids production: ~15 kg/day

E. Optional Polishing and Disinfection

 Sand or activated carbon filtration for TSS, odor, and trace oil

 UV disinfection or chlorine for safe reuse

 Filter backwash requirement: 1.5 m³/day

3. � Instrumentation and Control

 PLC-controlled process logic with sensors for:

o Flow, level, pH, DO (optional)

 Modular I/O for future expansion (e.g., DAF, chemical dosing)

 Remote monitoring possible via SCADA interface

4. � Theoretical References
Topic Theory/Source
Stokes’ Law for CPI sizing Frank M. White – Fluid Mechanics, Ch. 9

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 Topic Theory/Source
COD loading and biofilm design Metcalf & Eddy – Wastewater Engineering, Ch. 14
Air distribution and retention Droste – Theory and Practice of Water and Wastewater
time Treatment
Sludge production Henze et al. – Biological Wastewater Treatment

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2 MATERIALS

Materials shall be as follow

.

8 FABRICATION AND INSTALLATION

Piping 2" and smaller shall be fabricated after checking routing and
dimensions in the field.

At Field Fit-up Weld locations heat number shall be at least 250 mm from the
plain end part, if field fit-up pipe length is 100 mm, to prevent that this info will
be cut-off during fit-up and welding. If more additional length is required the
location of the heat numbers should be at least 150 mm from the exact
dimension as indicated on isometric. Field Welds and/or Field Fit-up welds

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shall be kept to a minimum and shall be located by the contractor to suit
transport and/or erection conditions.

Fabrication and installation shall be according to isometrics released for

construction.

Welding, weld examination and weld heat treatment shall be in strict

accordance with the applicable welding specification.

All joints to be field welded shall be shaped or bevelled, except for Field Weld
for field Fit-up purposes connection of which only one side shall be shaped or
bevelled and the end executed with no bevel and established by adding
100mm to the required pipe length.

Welded Pipe: Longitudinal welds of succeeding piping shall be staggered with

minimum distance between the welds according to welding specification

Welds shall not be positioned at the underside of horizontal lines, and shall
not interfere with branches, pads or saddles.

Fabricated piping shall be fabricated in as few pieces as possible, to minimize

field welding.

The clear distance between centrelines of adjacent girth butt welds shall be
as per welding specification

Taper pipe threads (NPT) per ANSI B2.1 shall be used for all threaded pipe
joints.

Flange joints shall be with clean gaskets. The use of gasket sealing
compounds or sealing agents is prohibited.

Flat face flanges shall be installed against flat face cast iron valves and
equipment.

Valve bodies with a flow arrow shall be installed in the direction of the flow
indicated on the drawings, except otherwise indicated.

Stems of small-bore valves (e.g. vent, drains, pressure connections etc.) not
indicated on Piping drawings shall be orientated perpendicular to pipe run and
in the best operable direction if not indicated on the isometric.

Welded branch connections shall be executed as weld-on pressure

connections in accordance with ANSI-B31.3, Fig. 327.4.4A, B, C and 4D
sketch 1 and 3.

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Do not use thread compound or Teflon tape on joints to be seal welded, all
cutting oil shall be removed.

Seal welding shall be done with electrodes not to exceed 3.2 mm. Using low
range amperage

Non-pressure attachments shall be installed in accordance with details,

sheets as provided in standard fabrication and installation detail packages.
The material for non-pressure attachments shall be in accordance with those
fabrication details.

Pipe shoes, which are field welded to pipe, shall be centred over pipe
supports in the cold position, unless otherwise specified. Shoes shall
preferably be located and attached after the line is installed.

Execution of hottapping to lines in service and the installation of nozzle and

block valve shall be made in accordance with SOM plant procedures.

Ultra sonic examination has to be executed on existing piping systems for wall
thickness measurements, before cutting for tie-in installation.

9 INSPECTION

Inspection shall be carried out according to the applicable requirements by

SOM

Inspection by SOM does not relieve the Contractor of his obligation to provide
his own quality control and inspection to assure himself that the Contract
requirements are met.

Neither does such inspection relieve the Contractor of this responsibility.

Operation & Maintenance Summary

Task Frequency
Check inlet pump and level Daily
Monitor aeration system Daily
Clean CPI (if needed) Weekly
Check sludge level and drain Weekly
Inspect control panel &
Weekly
sensors
Full system inspection Monthly

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10 PREPARATION FOR ERECTION

Remove all burrs, spatter, loose scale and welding slugs. Clean pipe in and
out. Apply paint as specified.

After inspection, all fabricated carbon steel pipe shall be protected as follows:

The open ends of pipe shall be protected with weatherproof closures.

11 CLEANING

Special mechanical or chemical cleaning of piping shall be done after

pressure testing.

All such piping shall be protected to ensure that it will be free and clear from
all rust and corrosion during storage until installed.

Field cleaning of Piping

Fabricated piping shall be sufficiently cleaned to dislodge rust before

installing. The material inside the piping can be removed by lifting one end
with a crane and hammering lightly to remove the rust and dirt. Air, when
available, can be used to blow the dislodged debris out. Only slight
hammering with a wooden or rubber hammer may be done, to avoid any
plastic deformation.

Before installation, the fabricated piping shall be inspected to ensure that all
foreign matter has been removed.

Piping materials shall be stored at the worksite in a manner that minimum

contact and exposure to dirt, debris, etc. is achieved.

After installation, lines shall be flushed to ensure that no debris is left in the
lines.

12 PRESSURE TESTING

Pressure testing shall be performed on the worksite after erection; pipe

spools, which have to be chemically cleaned, shall be tested before erection.

Testing, if required on special piping, is noted on the isometric, with the

required test pressure.

Hydro testing points (hold) shall be in accordance with the applicable

specification.

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Oily water system - Process description
Table of contents
(D) OILY WATER SYSTEM - PROCESS DESCRIPTION .............................. 1
1 SCOPE AND RELATED DOCUMENTS ................................................... 2
2 ABBREVIATIONS .................................................................................... 2
3 OILY WATER SYSTEM ........................................................................... 2
3.1 OILY WATER COLLECTION ..................................................................... 3
3.2 OILY WATER SUMPS NO. 1-3 ......................................................... 4
3.3 OILY WATER TRANSFER PUMP UNITS DAD 901-903 ................... 4
3.4 OILY WATER BUFFER TANK DAB 901 .......................................... 5
3.5 OILY WATER TREATMENT UNIT DBB 901 AND OW FEED PUMP
UNIT DAD 904 ............................................................................................... 6
3.6 EXISTING SLUDGE TANK HT002 (CUSTOMER SCOPE) ............................... 6

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 1 Scope and related documents
This document describes the basic control and functionality of the oily water
treatment system. It is to be read in conjunction with the latest revision of main
flow diagrams listed in table 1.
Table 1. Reference documents
Document number Title, main flow diagram
(D) Oily water treatment system
DBAC149318 1(2)
(D) Oily water treatment system
DBAC149319 2(2)
DAD 901-903 OW transfer
4V76F5086 pump unit
DAAB419530 DAD 904 OW feed pump unit
SP2100-P&I DBB 901 OW treatment unit

2 Abbreviations
CBU Compact Booster Unit
HFO Heavy Fuel Oil
OW Oily Water
PLC Programmable Logic Controller

3 Oily water system

Main equipment in oily
water treatment DAD 901-903 DAB 901
system: Equipment Code
DAD 904 DBB 901
HT002 (customer scope)
Oily water transfer
pump units Oily water buffer tank Oily water feed pump unit Oily water
treatment unit Existing sludge tank
Oily water system comprises of OW collection, storage, pumping and
treatment. OW is collected into the OW sumps and further to the OW buffer
tank or directly to the existing sludge tank (if necessary) by the OW transfer
pumps. The choice is made by the manual operated 3-way valve DAD 900
V001.
A feed pump unit transfers oily water from the buffer tank to the treatment unit.
A three-way valve (DAD 900 V005) on the outlet side of the pump allows the
oily water from the buffer tank to be pumped to the existing sludge tank HT002
if necessary. Oily water is treated in oily water treatment unit and sludge is led
to the existing sludge tank HT002.

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The contents of the work shop sump are emptied directly to the existing sludge
tank HT002. The reason for keeping this OW separate from the rest of the
system is that the OW from the workshop contains surfactants. The
surfactants can emulsify oil making the separation process in the oily water
treatment unit difficult and inefficient.

3.1 Oily water collection

Oily water is collected in the sumps from the following locations/consumers in
the power plant area:
• drain from the power house
• drain from fuel treatment house
• drain from compressor room
• drain and overflow from storage tank area
• drain from work shop
Oily water is also collected from separate sludge tanks in the following units:
• Lube oil separator units
• Dirty leak tank in compact booster units
• HFO separator unit PBB 901
The drainage from the different sources flows by gravity to the oily water
sumps around the site.

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The storage tank area has separate drainage channels for rain water. Clean
rainwater is lead to rain water drainage. The valves on the piping for rain water
drain are to be kept closed and only opened under supervision.
All drain valves from the tank area are to be kept closed and only opened under
supervision. This is due to the large potential flow of fluids in case of
emergency. If the valves were open the OW sumps would quickly be overfilled.

3.2 Oily water sumps No. 1 -3

The oily water sumps are underground cast concrete sumps.
OW sumps are equipped with multi-level level switch for controlling oily water
transfer pump units DAD 901-903. The OW pump is controlled by the high and
low level switch in the sump. The pump is automatically started when the high
level is achieved. The pump will be stopped when the low level is reached.
The sumps are also equipped with a strainer for pump protection from debris
and other bigger solids.

3.3 Oily water transfer pump units DAD 901 -903

The transfer pump is an air-driven diaphragm pump. The liquid line includes an
inlet valve, an outlet valve) and a non-return valve for preventing backflow. A
pressure gauge is installed at the outlet of the pump.
The operating air flow to the pump is controlled by a solenoid valve. The pump
is in operation when the solenoid valve is open. The compressed air line to the
pump also includes a pressure reducer with an integrated filter, as well as a
flow adjustment valve. The pump should normally be run at the minimum flow
and pressure required for proper operation, to avoid an excessive use of
compressed air.

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PRIMARY TREATMENT FACILITIES

The oily water transfer pump units are equipped with a control panel. The
control is normally set to “auto” mode, which means that the pumps start and
stop automatically according to the low and high level signals from the level
switch in the corresponding oily water sump.
The pumps can also be used manually in case a sump needs to be emptied.
This operation needs to be supervised by an operator.
The OW transfer pump unit control actions are summarized in table 1.
Table 1 OW transfer pump functions and actions.
Function Actions
Automatic start High level in corresponding oily water
sump.
Automatic stop Low level in corresponding oily water
sump.
Manual start/stop HIGH HIGH unit
From pump levelcontrol
in OWpanel.
buffer tank.

Pump running status Remote monitoring of pump running

status.

3.4 Oily water buffer tank DAB 901

The OW buffer tank is insulated and has a capacity of 50 m3. The tank serves
as an intermediate storage for OW and also allows for some homogenisation.
The temperature of 50°C (40-60°C) in the insulated OW buffer tank is kept by a
steam heating coil. The steam heating coil should remain submerged in liquid
at all times. The steam flow to the coil is controlled by a self-acting thermostatic
valve. The tank is insulated.
The tanks are equipped with three level switches that are used for controlling
the oily water treatment unit and for alarms. In case of a high-high level alarm in
the oily water buffer tank all oily water transfer pumps will be automatically
stopped. OW feed pump DAD 904 is automatically stopped if low level in the
tank.
The tank is also equipped with local level and temperature indicators.
Water can and should be drained from the OW buffer tank manually in order to
remove free water. The tank shall not be emptied totally nor without appropriate
supervision since the heating coil shall be kept under the liquid level.
The OW buffer tank control actions are summarized in table 2.

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Table 2 OW buffer tank instruments and actions.

Tank Type Signal Actions
nozzle
X4 LS HIGH HIGH Alarm. All OW transfer pumps are
level stopped.
X2 LS HIGH level Alarm.
X3 LS LOW level Alarm. OW feed pump is stopped.
Ac LT Continuous High/low level alarm. Remote monitoring
level of actual tank level
Y TS - Self-acting mechanical thermostat for
temperature control in tank. Set point is
50°C (40-60°C).
Aa1 TI - Local temperature indication
X1 LI - Local level indication

3.5 Oily water treatment unit DBB 901 and OW feed pump unit DAD 904
The oily water treatment unit consist of pumps, two flotation tanks, chemical
dosing system, filter and sludge collecting tank. The sludge from the unit is
pumped to the existing sludge tank HT002 by a built in sludge pump while the
treated water is disposed to drain. For closer information on the control and
function of the OWT unit please refer to the supplier’s manual.
The OW feed pump unit DAD 904 consists of a screw pump with a built in
spring loaded mechanical pressure relief valve and shut off valves on both
sides of the pump. The delivery pressure can be read from the pressure
indicator. The oily water feed pump is controlled manually or automatically from
the OWT unit. DBB 901 is normally in MANUAL mode. The operator monitors
the level of the OW buffer tank. When it is time to empty the OW buffer tank,
operator starts the feed pump from the local control panel of DBB 901. Start is
manual, but the stop is automatic (low level in OW buffer tank DAB 901 or high-
high level in existing sludge tank HT002).
In AUTO mode; the feed pump is controlled by the PLC in the OW treatment
unit and stopped when LSL (low level) is activated in OW buffer tank or when
LSHH (high-high level) is activated in the existing sludge tank HT002. If the
ready signal from OWT unit goes to OFF mode, something is wrong and the
feed pump is stopped.

3.6 Existing sludge tank HT002 (customer scope)

Following tank instrumentation is required in order to get well working entity of
oily water system on Wartsila supplied equipment.
The temperature and the level of the fuel in the existing sludge tank should be
possible to read locally from the thermometer and level indicator. The
temperature in the tank should be kept at 50°C (40-60°C). The level transducer

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is used to measure the tank level and level information to be sent to the control
room.
The customer sludge tank HT002 should be equipped with three level switches.
When the high level switch is activated the alarm indicates that it is time to
empty the tank. The high-high level alarm stops the OWT unit and OW feed
pump. High-high level alarm warrants immediate attention from the operators
as the OW buffer tank will not be emptied. When the high-high alarm in the OW
buffer tank is activated the OW transfer pumps stops. If the OW transfer pumps
are stopped the OW sumps will overflow. Due to the large volumes in the
system this chain of events will take some time to build up but it can easily be
avoided by emptying the existing sludge tank in time.
Recommended sludge tank control actions are summarized in table 3.
Table 3 Sludge tank instruments and actions.
Type Signal Actions
LS HIGH HIGH Alarm. Stop signal to OWT unit and OW feed pump.
level
LS HIGH level Alarm. Sludge tank emptying to be started.
LS LOW level Alarm. Sludge tank emptying to be stopped.
LT Continuous High/low level alarm. Remote monitoring of actual
level tank level
TS - Temperature switch for heating coil control. Set point
is 50°C (40-60°C).
TI - Local temperature indication
LI - Local level indication

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