INSPECTION REPORT ON 450? KLD STP SOBHA CHRYSANTHEMUM APARTMENTS THANISANDRA MAIN ROAD

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1 INSPECTION REPORT ON 450? KLD STP SOBHA CHRYSANTHEMUM APARTMENTS THANISANDRA MAIN ROAD Dr. Ananth S. Kodavasal June 13, 2012 Ecotech Engineering Consultancy Pvt. Ltd. Bangalore ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 1

2 A. MECHANICAL EQUIPMENTS: STP INSPECTION REPORT SOBHA CHRYSANTHEMUM Flats (190 Occupied) Sl. Name of Equipment & Specifications Qty Status Remarks Recommendations No. 1 Raw sewage transfer pumps - Submersible Make: Details not Known 2 No W -Presently Ok -Submersible pumps are not recommended for this duty - Replace these pumps by Kirloskar or Johnson pumps for the long term. See Note 1 Justifications. 2 Air blowers Make: Everest Model: 67 ES Capacity: 500 cum/hr Motor: 15 HP, Kirloskar 2 No W Equipment working Ok 3 Secondary Clarifier Mechanism Make: Elecon Type: 3SNU Motor : 1.0 HP 4 Sludge recirculation pumps Model: 12B-5 Motor: 2.0 HP, CG 5 Filter feed pumps Model: CN G1S2L1 Capacity: 73.0 cum/hr Motor: 7.5 HP, CG 6 Pressure Sand filter 1.6 m Dia x 2.0 m HT 1 set W Equipment working Ok - Have to check condition of bottom arms /blades / squeegees after emptying tank - Also need to check floor condition, corner slopes 2 No W Equipment working Ok 2 No W Equipment working Ok 1 No W Equipment working Ok Filter media life to be checked and replaced if necessary ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 2

3 7 Activated Carbon filter 1 No W Equipment working Ok Filter media life to be checked and replaced 1.6 m Dia x 2.0 m HT if necessary 8 Chlorine Dosing System Not available at site This system is required for disinfection. 9 Filter press system 610 mm x 610 mm x 23 plates 10 Filter press feed pumps Make: Roto Flow Model: RDAA551-R2CDID Discharge: 2.5 cum/hr Motor: 5.0 HP, Kirloskar 1 set NW -Air line & bypass line not provided -Hydraulics jammed - Filtrate line is not connected -Air line is to be provided for faster drying of sludge and bypass line to be provided. -Hydraulic system needs to be serviced. - Filtrate line has to be connected to Eq. tank. 1 No NW Not working, Pump is jammed Need to service the pump with necessary spares 11 Polymer Dosing System Not available at site This system is to be provided for sludge conditioning and dewatering. (Later) 12 Drain pump Details not known 13 Ultra Filtration system Model: KOCH Cartridge: 2 Nos. 14 UF Feed pump Model: CBR R6 Capacity: 19.0 cum/hr Motor: 3.0 HP 15 UF flush pump Model: CBR R6 Capacity: 75.0 cum/hr Motor: 5.0 HP 1 No NW Sent for service To be checked after servicing 1 set W Equipment working Ok 2 No W Equipment working Ok 2 No W Equipment working Ok ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 3

4 16 UF Backwash pump Model: CBR R6 Capacity: 29.0 cum/hr Motor: 3.0 HP 2 No W Equipment working Ok Sl. No. B. CIVIL UNITS Name of Tank & Dimensions Qty Status Remarks Recommendations 1 Bar screen chamber 1.0 x 0.75 x 0.6 m TD 2 Oil & grease chamber 3.75 x 0.75 x 0.6 m TD 3 Equalization tank 4.0 x 15.0 x 3.8 m SWD 4 Aeration tank 4.8 x 17.7 x 3.5 m SWD 20 sets of diffusers provided, specs not known 5 Secondary Clarifier 5.0 x 5.0 x 2.6 m SWD 6 Clarified water tank 5.0 x 11.0 x 2.5 m TD 1 No Ok Ok 1 No Ok Ok Typically in Res. Complexes, no free O&G can be collected/ removed 1 No Not Ok 1 No Not Ok -Tank contains lots of solids -No aeration is being given as the air header line is broken in the tank (Fixed type diffusers provided) - Tank is oversized -MLSS is very high in the tank due to non functioning of filter press -3 sets of diffusers disconnected 1 No Ok - Sludge is floating all over the tank and Water quality is very poor because of high MLSS 1 No Not Ok -Tank contains lot of sludge -No aeration ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 4 - Tank needs to be cleaned - Diffusers to be checked when tank is cleaned. - Operate the plant scientifically - Diffusers to be checked when tank is cleaned. - Reconnect the 3 sets of diffusers - Replace damaged diffusers - Need to check floor slope and corner slopes after emptying tank - Operate the plant scientifically - Tank needs to be cleaned - Aeration is to be introduced by means of coarse bubble diffusers

5 7 Sludge holding tank 5.0 x 2.0 x 3.8 m TD 8 Final tank - 1 (Garden) 10.7 x 5.4 x 3.5 m TD 9 Final tank 2 (Flushing) 4.0 x 5.4 x 3.5 m TD 1 No Ok -No aeration - Aeration is to be introduced by means of coarse bubble diffusers 1 No Ok -Tank contains lot of muck -No aeration - Tank needs to be cleaned. - Aeration cannot be introduced due to air blower capacity constraint 1 No Ok -No aeration - Aeration cannot be introduced due to air blower capacity constraint Highlights: 1. Proper operation of the plant has to be done to get good results. 2. Proper maintenance not being carried out. 3. MLSS is very high in the Aeration tank. 4. Filter press has to be commissioned to dewater the excess sludge. 5. Lot of waste material/ sediment/ muck accumulated in all the tanks due to poor operational practices in the past. 6. All the tanks are to be cleaned one time at the start of operations. 7. Introduce aeration / mixing system in clarified water tank, final tank (Later) and sludge tank to reduce manual cleaning. 8. Chlorine dosing system needs to be provided for disinfection Mukhtar/Hidayath Date: Dr. Ananth S Kodavasal Director Ecotech ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 5

6 TECHNICAL JUSTIFICATIONS NOTES: 1. JOHNSON/ KIRLOSKAR PUMPS IN PLACE OF SUBMERSIBLE PUMPS: We are making this strong recommendation based on our 25 years of design, engineering and operation experience in treatment plants on the following grounds: 1. Submersible pump (without cutter option) is not the correct choice for raw sewage duty and application. 2. Johnson pump is robust for this application and failure rate/ frequency is very low. 3. Johnson pumps are rated to handle solids up to 11 mm size for this model of 11-4 with an open impeller design, whereas Grundfos is closed impeller design with smaller opening. 4. Johnson pumps are less expensive than Grundfos/ KSB pumps 5. Repair/ servicing costs for Johnson pumps are negligible compared to KSB/ Grundfos submersible pumps servicing 6. Johnson pumps may be serviced at site itself within a few hours with readily available spares and consumables. 7. Submersible pumps have to be sent to their service centre/ factory for any repairs, and the time required is not less than 2 weeks. 8. Once a submersible pump goes for repair, it never recovers 100 % efficiency, and failures start occurring periodically (AS per our experience, these pumps are for use and throw duty only) 9. Guarantees/ warranties on repaired units are available, only if sent to the respective factories. ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 6

7 STP LAYOUT: BSC AERATION TANK FINAL TANK - 1 O&G TRAP EQ. TANK CLARIFIED WATER TANK SLUDGE HOLDING TANK SECONDARY CLARIFIER FINAL TANK - 2 PUMP ROOM ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 7

8 SPECIFICATIONS AND QUOTATION Sl. Name of Equipment - Existing SPECIFICATIONS QTY RATE, Rs. AMOUNT Rs. A MECHANICAL EQUIPMENTS 1 Raw sewage transfer pumps Johnson/ Kirloskar pumps LATER 2 No 00=00 Submersible Make: Details not Known 2 Air blowers Make: Everest Model: 67 ES Capacity: 500 cum/hr Motor: 15 HP, Kirloskar Equipment working Ok 2 No 00=00 3 Secondary Clarifier Mechanism Make: Elecon Type: 3SNU Motor : 1.0 HP 4 Sludge recirculation pumps Model: 12B-5 Motor: 2.0 HP, CG 5 Filter feed pumps Model: CN G1S2L1 Capacity: 73.0 cum/hr Motor: 7.5 HP, CG 6 Pressure Sand filter 1.6 m Dia x 2.0 m HT - Check entire underwater items / engineering 1 set 00=00 Equipment working Ok 2 No 00=00 Equipment working Ok 2 No 00=00 - Check condition of filter media 1 No 00=00 ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 8

9 7 Activated Carbon filter 1.6 m Dia x 2.0 m HT 8 Chlorine Dosing System Not provided 9 Filter press system 610 mm x 610 mm x 23 plates 10 Filter press feed pumps Make: Roto Flow Model: RDAA551-R2CDID Discharge: 2.5 cum/hr Motor: 5.0 HP, Kirloskar 11 Polymer Dosing System - Provide LATER for sludge conditioning 12 Drain pump Details not known 13 Ultra Filtration system Model: KOCH Cartridge: 2 Nos. 14 UF Feed pump Model: CBR R6 Capacity: 19.0 cum/hr Motor: 3.0 HP 15 UF flush pump Model: CBR R6 Capacity: 75.0 cum/hr - Check condition of filter media 1 No 00=00 - Provide 200 L LDPE tank - Provide 0-6 LPH electronic dosing pump 1 set 30,000=00 30,000=00 - Provide air line 1 set 25,000=00 25,000=00 - Provide by sludge bypass line - Service Hydaraulic system - Connect filtrate line to Eq. tank - Service pump with necessary spares 1 No 12,000=00 12,000=00 1 set 00=00 - To be checked after return from 1 No 00=00 service Equipment working Ok 1 set 00=00 Equipment working Ok 2 No 00=00 Equipment working Ok 2 No 00=00 ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 9

10 Motor: 5.0 HP 16 UF Backwash pump Model: CBR R6 Capacity: 29.0 cum/hr Motor: 3.0 HP B CIVIL UNITS 1 Bar screen chamber 1.0 x 0.75 x 0.6 m TD 2 Oil & grease chamber 3.75 x 0.75 x 0.6 m TD Equipment working Ok 2 No 00=00 1 No 00=00 1 No 00=00 3 Equalization tank 4.0 x 15.0 x 3.8 m SWD 4 Aeration tank 4.8 x 17.7 x 3.5 m SWD 20 sets of diffusers provided, specs not known 5 Secondary Clarifier 5.0 x 5.0 x 2.6 m SWD 6 Clarified water tank 5.0 x 11.0 x 2.5 m TD - Clean tank - Check diffusers - Repair air line to recommission mixing after checking damage - Convert to Retrievable type LATER - Check diffusers condition and replace damaged membranes Membranes charged on usage basis Rs. 2500=00 for 90 OD x 1000 L Rs. 1,500=00 for 90 OD x 500 L - Check underwater parts - Check tank engineering - Clean tank - Provide mixing with 10 sets ( 20 Nos) CBD each 90 OD x 800 L LOT 00=00 00=00 LOT 00= ,000=00 100,000=00 ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 10

11 7 Sludge holding tank 5.0 x 2.0 x 3.8 m TD 8 Final tank - 1 (Garden) 10.7 x 5.4 x 3.5 m TD 9 Final tank 2 (Flushing) 4.0 x 5.4 x 3.5 m TD - Clean tank - Provide air mixing with 04 sets ( 08 Nos.) CBD each 90 OD x 800 L 08 5,000=00 40,000=00 - Clean tank LOT 00=00 - Clean tank LOT 00=00 A+B TOTAL MATERIALS 207,000=00 C SERVICES 1. One time cleaning of tanks Cleaning LOT 60,000=00 60,000=00 specified above 2. Labour, Supervision of all works in Section A & B above LOT 30,000=00 30,000=00 C TOTAL SERVICES 90,000=00 D TAXES 5 % ( 177,000) 8,850=00 14 % ( 30,000) 4,200=00 Service Tax not applicable for Services in residential STP s 00=00 D TOTAL TAXES 9,250=00 GRAND TOTAL A+B+C+D 306,250=00 ( Rupees Three lakh six thousand two hundred fifty only) COMPLETION PERIOD weeks from date of work order along with advance. PAYMENT TERMS ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 11

12 - Rs. 100,000 =00 advance with order - Rs. 107,000=00 Plus applicable VAT on delivery of all materials to site - Balance after completion of works WORKING OF STP DURING UPGRADATION WORKS Ecotech will ensure minimum disruption to normal working of the STP for the entire duration of the rectification works, expected to last for 3-4 weeks. EXCLUSIONS 1. Since this is working STP, not all deficiencies may have been captured in the above report/ quote. Other deficiencies/ improvements to be made, that may be uncovered later during execution/ operation of the STP may be mutually agreed and completed. 2. Any and all items of works not specified and included above, incl. Civil works ( except for settling tank modifications) 3. Any and all electrical works. (If electrical works are necessitated, same will be carried out at cost + 30 %) 4. Damaged membranes in aeration tank shall be charged on usage basis as per rates specified 5. Some defects/ deficiencies/ lacunae which are not immediately apparent, can only be uncovered when we empty the tanks/ start operations. It is therefore understood and agreed by both parties that our responsibility at present is to complete the works as per specifications and our quotation only. CONDITIONALITY - Our Company is geared and structured to take up STP Upgradation works only for our AMC clients. Our AMC proposal is forwarded separately. - Likewise, it is also a condition that we will start AMC operations only upon getting work order for upgradation works as above simultaneously. Dr. Ananth S Kodavasal Director June 14, 2012 ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 12

13 Ecotech Engineering Consultancy Pvt. Ltd. Tel/Fax : , Dodsworth Enclave Mobile : Whitefield, Bangalore kodavaas@bgl.vsnl.net.in ECOTECH 25 YEARS AN D MORE OF EXCELLENCE AND INTEGRITY 13

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