PRE -FEASIBILITY REPORT - Welcome to...

Pyujjfjdlfkgjndgh PRE-FEASIBILITY REPORT

OF

PROPOSED 5 MLD COMMON EFFLUENT TREATMENT PLANT (CETP)

AT

BELA INDUSTRIAL AREA, DISTRICT MUZAFFARPUR, BIHAR

BY

M/S. BIHAR INDUSTRIAL AREA DEVELOPMENT AUTHORITY (BIADA)

GOVERNMENT OF BIHAR

EIA Consultant

SMS Envocare Ltd

301, Pentagon P3, Magarpatta City, Hadapsar, Pune, 411028 MS Phone No.: 020-66801111, Fax No. 020-66801100

Web: www.smsenvocare.co.in

Draft Detailed Project Report for Establishment of CETP in BELA Industrial Area, MUZAFFARPUR

SMS Envocare Ltd. 1

INDEX

SR. NO. PARTICULAR PAGE NO.

CHAPTER 1- INTRODUCTION

1.1 BACKGROUND OF THE PROJECT 1 1.2 SCOPE OF WORK 2 1.3 METHODOLOGY ADOPTED 3 1.4 COLLECTION/ CONVEYANCE OF WASTEWATER 5 1.5 ASSUMPTIONS MADE DURING PREPARATION OF DETAILED PROJECT

REPORT 5

1.6 JUSTIFICATION FOR REQUIREMENT OF CETP 6 CHAPTER 2- PROFILE OF MUZAFFARPUR

2.1 CITY PROFILE OF MUZAFFARPUR 7 2.2 LOCATION & GEOGRAPHICAL AREA 7 2.3 TOPOGRAPHY 8 2.4 CLIMATE & RAINFALL 8 2.5 DEMOGRAPHY 11 2.6 ECONOMY 11 2.7 TRANSPORT 11 2.8 HISTORY & CULTURE 12

CHAPTER 3- PROFILE OF BELA INDUCTRIAL AREA

3.1 BELA INDUSTRIAL AREA 16 3.2 INVENTORY OF INDUSTRIES 17 3.3 INDUSTRIAL SECTORS IN MUZAFFARPUR 21 3.4 PRESENT SCENARIO OF WASTEWATER GENERATION 24 3.5 FUTURE PROJECTIONS OF WASTEWATER QUANTITY 25 3.6 CATEGORIZATION OF INDUSTRIES (RED, ORANGE AND GREEN) 26 3.7 MAJOR INDUSTRIES LOCATED IN BELA, INDUSTRIAL AREA 27

CHAPTER 4- PRODUCTION PROCESS

4.1 PRODUCTION PROCESS 30 CHAPTER 5- QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/EFFLUENTS

5.1 ASSUMPTIONS IN CALCULATION OF WATER CONSUMPTION AND EFFLUENT GENERATION

44

5.2 WATER CONSUMPTION AND EFFLUENT GENERATION 44 5.3 DESIGN CAPACITY OF PROPOSED CETP 46 5.4 CHARACTERISTICS OF WASTE WATER 46 5.5 CHARACTERISTICS OF TREATED WASTE WATER 47

CHAPTER 6- CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/SCHEMES

6.1 ACTIVATED SLUDGE PROCESS 48 6.2 SEQUENTIAL BATCH REACTOR (SBR) 49 6.3 MOVING BED BIO-REACTOR (MBBR) 50 6.4 RECOMMENDED TECHNOLOGY 53

CHAPTER 7- PROPOSED SCHEMES

7.1 PROPOSED TREATMENT SCHEME 54 7.2 DETAILED TREATMENT SCHEME 56 7.3 SLUDGE HANDLING SYSTEM 61

CHAPTER 8- DESIGN SPECIFICATION OF TREATMENT UNIT

8.1 SPECIFICATIONS FOR CIVIL UNITS 62 8.2 SPECIFICATION FOR MECHANICAL EQUIPMENTS AND WORKS 67

Draft Detailed Project Report for Establishment of CETP in BELA Industrial Area, MUZAFFARPUR

SMS Envocare Ltd. 2

8.3 SPECIFICATION FOR ELECTRICAL & INSTRUMENTATION WORKS 74 8.3.1 Automatic Power Factor Control Panel 74 8.3.2 Electr ical Panel 75

8.4 INSTRUMENTATION 76 8.4.1 The Aerat ion System Shall be PLC Controlled for Automatic Operation

through SCADA 76

8.4.2 Online Real Time CETP Water Quality Monitor ing 78 8.5 ELECTRICAL LOAD 78

CHAPTER 9- ENVIRONMENTAL MANAGEMENT PLAN (EMP)

9.1 ENVIRONMENTAL MANAGEMENT PLAN (EMP) 80 9.2 ENVIRONMENTAL MANAGEMENT DURING OPERATION OF CETP 83

CHAPTER 10- CONCLUSION

10.1 CONCLUSION 87

LIST OF TABLES

TABLE. NO. PARTICULAR PAGE NO.

CHAPTER 2- PROFILE OF MUZAFFARPUR

2.1 Rainfall intensities (month wise) from Meteorological Depar tment 9 CHAPTER 3- PROFILE OF BELA INDUCTRIAL AREA

3.1 Summary of Distr ibution of Industr ies & Plot area 18 3.2 Categor ization of Industr ies 19 3.3 Distr ibution of industr ial clusters in BELA, MUZAFFARPUR Region 22

CHAPTER 5- QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/EFFLUENTS

5.1 Distr ibution of industr ial clusters in BELA, MUZAFFARPUR Region 45 5.2 Average Character istics of Combined Untreated Effluent for Design 47

5.3 Character istics of Treated Water as per CPCB/ SPCB

CHAPTER 6- CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/SCHEMES

6.1 Comparative of Mer its and Demer its of ASP, SBR and MBBR technologies

52

CHAPTER 7- PROPOSED SCHEMES

7.1 Expected Character ist ics of Effluent after Physico-chemical treatment

56

7.2 Expected Character istics of tr eated Effluent after Biological Treatment

58

7.3 Expected Character istics of final treated effluent after Ter tiary treatment

59

CHAPTER 8- DESIGN SPECIFICATION OF TREATMENT UNIT

8.1 Details of CETP Units and BOQ of Civil work 63 8.2 Pipe Details 67 8.3 Mechanical Items Details 68 8.4 Electr ical Load Sheet 78

Draft Detailed Project Report for Establishment of CETP at Bela Industrial Area, Muzaffarpur

SMS Envocare Limited Page 1 of Chapter 3

CHAPTER -1

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

The enhanced pace of developmental activit ies and rapid urbanizat ion have resulted in stress on natural resources and quality of li fe. In the present scenar io of increasing

urbanizat ion, vast amount of industr ial, vehicular as well as water pollution occurs due to discharge of effluents without conforming to the environmental norms and standards, the

concern for environmental quality has become an issue of worry. The trend of increasing pollut ion in var ious environmental media is evident from the deter iorating quality of water , air , soil etc.

Small Scale Industr ial units (SSIs) have a very impor tant role in industr ial development in

the country. Government actively promotes growth of SSI units to induce a balanced economic growth and distr ibute the benefits of industr ial development in an equitable

manner . SSI units generally find it difficult to establish and operate individual Effluent Treatment Plant (ETP) due to their limited plot size and scale of operat ions. However , SSI

units are generally located as clusters in industr ial areas/ estates; the concept of Common

Effluent Treatment Plant (CETP) for the ent ire effluent from the industr ial area has been developed to achieve sat isfactory treatment through their collective effor ts. The

monitor ing and enforcing a CETP as a single pollut ing source also becomes easier for regulatory agencies as compared to monitor ing a large number of SSI units individually.

The cont inuous discharge of par tially/ un-treated industr ial wastewater from the industr ies

leads to contaminat ion of sur face and ground water . Most of the industr ial estates in Bihar are located at the Bank of River “Ganga”. Ganga is no more pure for direct dr inking

purpose. Government of India as well as var ious states has taken init iatives to pur ify the r iver Ganges. Present ly Government has come up with the scheme of “Namami Ganga” to pur ify r iver Ganga upto 2020. In line with this, State Pollut ion Control Board has taken

initiat ive under the direct ion of Nat ional Green Tr ibunal to establish Common Effluent Treatment Plant (CETP) in the Industr ial Estate to treat the wastewater to meet sur face

discharge norms. Subsequently, Bihar Industr ial Area Development Author ity (BIADA) has floated tender for gett ing Consultancy Services for the Preparat ion of Detailed Project Repor t (DPR) for Establishment of Common Effluent Treatment Plant (CETP). SMS

Envocare Limited (SMSEL) being pioneer in the field of Environmental Consultancy in India had par ticipated in the Tender and qualified technically and financially and eventually was

awarded the work for the same in the month of August 2015.



After receipt of the work order and execut ion of agreement for the conduct ion of study for the preparation of DPR for establishment of CETP in the five industr ial areas, viz- ( i)

Patliputra Industr ial Area, ( ii) Hajipur Industr ial Area, ( ii i) Bela, Muzaffarpur Industr ial Area, ( iv) Barar i, Bhagalpur Industr ial Area and (v) Fatuha Industr ial Area; the team of

SMSEL conducted field studies in the month of August –September 2015 and prepared the Feasibi lity Repor t . Subsequent ly, a presentation has been made before the officials of BIADA under the chairmanship of Managing Director , BIADA. The feedback/ suggest ion

received on the feasibility repor ts has been incorporated in draft DPR.

This Draft Detailed Project Repor t is per taining to Bela Industr ial area, Muzaffarpur

1.2 SCOPE OF WORK

As per NIT/ Tender document/ contract agreement, the following scope of work has

been envisaged:

1. Ident ify the type of Industr ies with numbers and categor ies in each Industr ial Area. 2. Undertake detai led pr imary as well secondary surveys to quant i fy the d ischar ge

and determine the character ist ics of discharge in terms of influent and effluent

from each unit w ithin the Industr ial Area.

3. Determine the total cur rent discharge and the type and character istics of discharge

from a par ticular Industr ial Area and categor ize the industr ies into pollut ing and ser iously polluting industr ies.

4. Just ifying the Need for sett ing up of the CETP.

5. Suggest and ident ify the most suitable land in consultation with BIADA for setting

up of the CETP.

6. Topographical survey and geotechnical investigat ion of the identified land. 7. Based on the present and future discharge, capacity planning of the CETP and

adopt best pract ices in terms of technology while following all norms and specificat ions.

8. Detailed Engineer ing Design of the CETP, Detailed Plan Drawings showing the

Co- Ordinates , Engineering Drawings with Detailed Quantity and Cost Est imate (cost estimate shall be prepared as per latest schedule of rates of Govt. of Bihar) .

9. Technical and Financial sustainabili ty analysis and implementat ion of framework. 10. Obtain Approval/ clearances on behalf of BIADA from all concerned Author it ies

like, Bihar State Pollut ion Control Board, National Green Tr ibunal etc as may be

required for smooth implementation of the project.



1.3 METHODOLOGY ADOPTED

Following methodology has been adopted in the Preparation of Draft DPR:

Kick –off meeting: Immediately after receipt of the work order , kick off meet ing has been made in the Head office of BIADA at Patna. The methodology for the

conduction of study has been discussed with the Secretary, concerned Execut ive

Engineer & Asst Engineer of BIADA.

Getting Authorization Letter: Dur ing the meeting, i t has been felt that an Author izat ion letter need to be issued from the office of BIADA to meet with the Entrepreneurs of the Industr ial Area, Industry’s Associat ion, Bihar State Pollut ion

Control Board and other Government offices/ inst itutions in gett ing the available information. The head office of BIADA issued letter to all concerned officers of

Industr ial areas like Execut ive Director , Executive Engineer , Asst Engineer , Junior

Engineer , Area-In-Charge etc. The respective Area In-Charge fur ther issued Author izat ion letter to SMSEL for the easy access to the industr ies. They have

communicated at their end to all the industr ies to extend cooperat ion in gett ing valuable information by SMSEL. A copy of let ters are enclosed in Annexure-I

Collection of Available Secondary Data: The available data with the BIADA office

has been collected by the team of SMSEL like Layout Plan of the Industr ial Area, Updated list of the industr ies with plot size and type of product/ manufactur ing. The data of operational, closed, under construction, vacant plot also have been collected.

Preparation of Questionnaire for survey: A quest ionnaire has been prepared for

the collection of data per taining to Production Capacity, Product(s) , water consumption, wastewater generat ion, quality of wastewater , existence of ETP,

future expansion in the product ion capacity etc to arr ive at the design wastewater quant ity and character ist ics. A copy of quest ionnaire is placed at Annexure-II.

Conduction of field survey: Team of exper ts from SMSEL conducted field survey to collect information door-to-door from all the operat ional units in the industr ial area.

The schedule of visit to the industr ies has been communicated to the concerned

Executive Director as well as Area In-Charge. They were communicated and br iefed in advance to all the industr ies about the field survey work and data collect ion for CETP work. Dur ing the survey, the representatives of BIADA along with the team of

SMSEL visited to the industr ies.

Inventory of Industries: Inventory of industr ies/ inst itut ions with detai ls of address, plot size, types of product, daily production, man-power strength, quantity

of process water consumption, existence of ETP etc was studied through door to door survey of the exist ing plots.



Collection of Representative samples: The necessary wastewater samples have been collected to represent all possible industr ial sectors. The wastewater samples

have been analyzed in the field through test kits and also analyzed in the Environmental Laboratory of SMSEL/ NABL accredited laboratory.

Meeting with the officials of Bihar State Pollution Control Board (BSPCB): The

exper ts from SMSEL met the Member Secretary of BSPCB and Regional officers looking after the Industr ial Estate. The Regional Officers and their colleagues ident ified the major water pollut ing industr ies located in the industr ial areas who

are the major contr ibutors of wastewater generated from the industr ial area.

Literature Survey: The team of SMSEL has gone through the relevant li terature

available in the Books, Journals, Internet Web-sites, and Publication of CPCB etc. The

ear lier prepared repor ts by CPCB, NPC, MoEF, Wor ld Bank, UNIDO, and USEPA etc have been referred for gett ing specific wastewater generation from all possible type

of industr ial sectors located in the industrial area. The relevant wastewater character istics available from the reputed literature for the different industr ial

areas/ industr ial processes have been referred to arr ive at composite and combined

wastewater character istics.

Quantification and Characterization of wastewater: The design flow and character istics have been arr ived based on the estimated wastewater flow and

character istics from the individual operat ional industr ies dur ing the survey per iod

and projection for closed, under-construction and vacant plots. Specific water

consumption figures in var ious sectors of industr ies were taken as per CPCB guidelines, experience of the consultant. For domestic wastewater , CPHEEO Manual was followed. The weightage average value of BOD of combined effluent for CETP

design was calculated by mult iplying est imated daily flow (quant ity) and BOD value

of individual industry.

Estimation of Design flow & characteristics: The design flow and character istics have been arr ived based on total est imated industr ial and domestic wastewater generated from the operating industr ies and fur ther projection for closed, under

construct ion and vacant plots. The combined wastewater characterist ics have been

evolved based on summation of BOD load from all the operational units and

projected BOD load from closed, under construction and vacant plots.

Identification of proposed land for CETP: With the help of concerned Execut ive Director and Area In-charge, the proposed available site(s) of land for CETP have

been seen by the exper t of SMSEL. The same has been cr itically examined for the feasibili ty of setting up of CETP. It has been discussed with the senior officials of

BIADA before finalization of DPR.



Preparation of Feasibility Report: Based on the design flow and character ist ics, the var ious possible treatment schemes have been evolved and discussed. The sizes

of var ious treatment units were calculated based on design flow and characterist ics. The comparative analysis of specificat ion of Civi l, Electro-mechanical par ts,

Operation & Maintenance and Power requirement have been made with the latest

t reatment technologies and discussed in the repor t . Out of alternate treatment schemes suggested in Feasibili ty Repor t, one best suited treatment scheme has been

selected after discussing with the BIADA officials. After necessary changes or correct ion the Draft Detailed Project Repor t has been prepared for Submission.

Preparation of Draft DPR: - After receipt of comments on feasibi li ty repor t and

finalization of land for the proposed CETP the detai led Topographic & Geo-Investigation survey have been carr ied out for the proposed CETP site. Based on actual ground condit ion detai led costing of Civi l & Electro-Mechanical i tems have

been made based on rear ranged CETP components or layout.

1.4 COLLECTION /CONVEYANCE OF WASTEWATER

Present ly the wastewater is being discharged outside/ inside the premises. There is no existence of conveyance system. As per discussion with BIADA, the same is in process of implementat ion.

There is no storm water drainage system existing in the industr ial areas. Dur ing rainy season, the Storm water gets mixed with the trade & domest ic waste water of

the industr ies. Most of the time, i t leads to flooding in the industr ial area due to

absence of drains.

Dur ing the presentation of Feasibi li ty Repor t, it has been clear ly mentioned that there should be separate conveyance system for storm water , domestic and trade

effluent for the proposed site of CETP. It has been accepted by the BIADA officials.

1.5 ASSUMPTIONS MADE DURING PREPARATION OF DETAILED PROJECT REPORT

Following assumptions have been followed for the estimat ion of wastewater flow and character istics to design suitable Treatment Scheme for sett ing up of CETP:

The door to door visit has been made in the operational units.

The estimation of flow has been made based on repor ted figures from the representative of industr ies dur ing the field survey, exper ience of SMSEL exper ts in

the same industr ial sectors and authent ic data on specific wastewater generat ion and pollut ion load from the literature/ repor ts and monitored/ est imated value

dur ing survey.

The value for closed and under-construct ion units have been made based on the Production Capacity/ Product(s) .



The est imated wastewater from the vacant plot has been made for the prominent industr ies available in the industr ial area.

The pre-treatment has been suggested to industr ies those who are generat ing excess quant ity of Oil/ grease, Total Suspended Solid (TSS), highly Acidic or Highly Alkaline in nature and Tannery wastewater .

There is no conveyance system present in the industr ial areas for carrying out the industr ial wastewater generated from individual units. Therefore, i t was assumed that based on the flow from the individual units, the BIADA will construct suitable

conveyance system with gravity flow ( to extent possible) which leads to proposed site of CETP.

The Storm water drain should be separately constructed by BIADA for the

conveyance of Rain water .

Present ly, there is no Hazardous Waste Treatment, Storage and Disposal Facility (TSDF) available in Bihar . After commissioning of CETP, the CETP sludge as

hazardous waste would be disposed in the TSDF facili ty as per Hazardous Waste (Management and Handling) Rules. The BIADA has to plan in setting up of TSDF.

The industry designated for “Zero Discharge Limit” has been considered to

discharge only domestic wastewater into the common drain leading to CETP.

The battery limit of Treated water disposal at the CETP point. The BIADA has to ident ify the disposal point for the discharge of treated wastewater from the CETP. It

could be discharged into nearby r iver , municipal drain or reuse in the agr iculture

field.

1.6 JUSTIFICATION FOR REQUIREMENT OF CETP

The industr ies and institutes generate waste water from the production process, toi lets

(domestic) and laborator ies etc. Such wastewater has pollutants concentrat ion levels much above the permissible limits prescr ibed by the State Pollut ion Control Boards. Few big

industr ies has installed Effluent Treatment Plants (ETP), however , most of the industr ies discharge their untreated effluent in nearby open land/ drain leading to r iver .

In view of direct ions from the Central and State Pollut ion Control Boards, BIADA has decided to install a Common Effluent Treatment Plant (CETP) for proper treatment of

untreated wastewater likely to be generated from industr ies. The proposed CETP will help in achieving end-of-pipe treatment of combined wastewater of all par ticipat ing industr ies at lower O&M cost and also facili tate better monitor ing by the State Pollut ion Control

Board.

*****



CHAPTER-2

PROFILE OF MUZAFFARPUR

2.1. CITY PROFILE OF MUZAFFARPUR

Muzaffarpur town lies in the centre of Muzaffarpur distr ict . The city of Muzaffarpur is famous for its exotic fruit Litchi. Muzaffarpur is a thr iving wholesale business place and has a number of reputed educat ional institutions. The pr incipal communicat ion routes of the

distr ict pass through Muzaffarpur town.

Future growth potent ial is towards nor th, west and southwest direct ions. Despite this and its good transpor t connect ivity, the town has not developed as a major industr ial centre. In

addition, economic growth in the town has been affected by the poor power supply situation and water logging. The core commercial areas are overcrowded and

unorganized contr ibuting to the haphazard traffic situation on the roads.

2.2. HISTORY & CULTURE

According to the Ramayana, King Janaka, the father of Sita ruled Videha, which is a traditional name for the entire region including eastern Nepal and nor thern Bihar .

Sitamarhi, a town in this region, ascr ibes to the Hindu mythological belief

where Sita sprang to li fe out of an earthen pot at nearby Punaura dham, while Rajarshi Janak was t illing the land from haleshwar to westwards.

As per recorded history the Vajji Republic was a confederat ion of eight clans of which the Licchavis were the most powerful and influential. Even the powerful kingdom of Magadha had to conclude matr imonial alliances in 519 B.C. w ith the neighbor ing estates of

the Licchavis.

2.3. LOCATION & GEOGRAPHICAL AREA

Muzaffarpur is located at 25°54′- 26°23′N and 84°53’ -85°45’E. It has an average elevat ion

of 170 metres (557 feet) . The geographical area of Muzaffarpur is 3,17,591 Hectare.

Muzaffarpur is surrounded by distr ict Sitamarhi & East Champaran in the Nor th, distr ict

Darbhanga & samastipur in the east, distr ict Vaishali & Saran in the south and distr ict Saran & Gopalganj in the west.

Muzaffarpur distr ict gives a way to many impor tant r ivers like Bagmati, Gandak, Burhi Gandak and Lakhandeyee which leaves a highly fer t ile land (Alluvial soil). Being strategic in



situat ion Muzaffarpur is claimed to be the commercial capital of Bihar . It is the distr ict headquar ters and head quar ter of the Tihut Division too.

2.4. TOPOGRAPHY

In general the distr ict exhibits a flat topography with few gentle undulat ions. The drainage system of the distr ict is controlled by the r iver Burhi Gandak which is perennial. The

distr ict is also threatened by the flood dur ing the rainy season. The town lies in the highly seismic zone of India. Muzaffarpur is one of the largest commercial and educational centers

of Mithi la.

Fig 2.1: Map showing topographical distribution



2.5. CLIMATE

It has a sub-tropical climate.

Table 2.1: Rainfall intensities (Month wise) from Meteorological Department

S. N

o.

Ye

ar

Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec

R

/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

1

20

11

3.4

-75

7.8

-12

8

10

28

.3

11

3

10

5.1

95

26

0.8

62

27

9

-14

24

7

-15

42

5

11

0

21

-67

0

-10

0

0

-10

0

2

20

12

26

.8

10

0

0

-10

0

8.7

19 6

-55

18

.7

-65

27

.4

-83

32

0

-2

27

5

-6

31

2

54

23

.1

-64

0

-10

0

0

-10

0

3

20

13

16

.1

20

43

.9

39

3

0

-10

0

25

88

14

9.5

17

7

16

1.1

0

79

.9

-75

12

3

-58

89

.4

-56

23

0.7

26

1

0

-10

0

0

-10

0

Note:

1. The Distr ict Rainfall in millimeters (R/ F) shown below are the arithmetic averages of Rainfall of Stations under the Distr ict .

2. % Dep. is the Depar tures of rainfall from the long period averages of rainfall for the Distr ict .

3. Blank Spaces show non-availability of Data.



0

50

100

150

200

250

300

350

400

450

Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec

Ra

Months

Graph 2.1: Arithmatic Averages of Rainfall

2011 2012 2013

-200

-100

0

100

200

300

400

500

Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec%

D

Months

Graph 2.2: % Dep. are the Departures of Rainfall from Long

period averages of Rainfall

2011 2012 2013



2.6. ADMINISTRATIVE SETUP

Muzaffarpur was created in 1875 for the sake of administrative convenience by split t ing up the ear lier distr ict of Tirhut. The present distr ict of Muzaffarpur came to its existence in the 18th century and named after Muzaffar Khan, an Amil (Revenue Officer) under Br it ish Dynasty. Purbi Champaran and Sitamarhi distr icts on Nor th, on the South Vaishali and Saran distr icts, on the East Darbhanga and Samastipur distr icts and on the West Saran and Gopalganj distr icts surround Muzaffarpur .

Muzaffarpur is the distr ict headquar ter along with the commissionaire headquar ter of

Tirhut Division also. From administrative point of view it has two (2) sub divisions namely -Muzaffarpur East and Muzaffarpur West. Muzaffarpur i tself a Municipal corporation and

two Nagar Panchayat. The Muzaffarpur city is divided into 49 wards for which elections are held every 5 years.

Muzaffarpur Municipal Corporat ion has total administrat ion over 65,870 houses to which it supplies basic amenit ies like water and sewerage. It is also author ize to build roads within Municipal Corporation limits and impose taxes on proper t ies coming under i ts jur isdict ion. 2.7. DEMOGRAPHICS

According to the 2011 census, Muzaffarpur distr ict has a population of 4,778,610. This gives it a ranking of 24th in India (out of a total of 640) . The distr ict has a populat ion density of 1,506 inhabitants per square kilometer (3,900/ sq tm). Its populat ion growth rate over the decade 2001-2011 was 27.54%.

The Muzaffarpur Municipal Corporat ion has population of 354,462 of which 187,564 are

males while 166,898 are females as per repor t released by Census India 2011. Populat ion of Children with age of 0-6 is 44280 which are 12.49% of total populat ion of Muzaffarpur

town. In Muzaffarpur Municipal Corporation, Female Sex Ratio is of 890 against state

average of 918. Moreover Child Sex Ratio in Muzaffarpur is around 902 compared to Bihar state average of 935. Literacy rate of Muzaffarpur city is 83.07% higher than state average

of 61.80%. In Muzaffarpur , Male li teracy is around 86.42% while female li teracy rate is 79.29 %.

2.8. ECONOMY

In 2006 the Ministry of Panchayati Raj named Muzaffarpur one of the country's 250 most backward distr icts (out of a total of 640) . It is one of the 36 distr icts in Bihar current ly receiving funds from the Backward Regions Grant Fund Programme (BRGF).

The land use around Muzaffarpur is mainly agr icultural and hor t icultural. While li tchi and

mangoes are abundant ly grown, pr incipal crops are r ice, wheat, pulses, and jute, maize and

oil seeds. Vegetables like cauliflower , cabbage, onion, tomato, radish, car rot, beetroot,



among others, are also grown. Sugar cane, potato and bar ley are some of the non-cereal crops grown.

The main livestock of the town are cows, buffalo, goats, and poultry. Muzaffarpur City has several industries, big and small. The rai lway wagon industry is one of the City landmarks. Muzaffarpur is an impor tant centre for the wholesale cloth trade.

2.9. TRANSPORT

Muzaffarpur is connected by NH-28, NH-57, NH-77 and NH-102. The total road network of Muzaffarpur city is approximately 72.17 km joint ly managed by Muzaffarpur Municipal Corporat ion (38 km), Public Works Depar tment (17.12 km) and the Distr ict Council (16.69

km). Approximately99% of the roads under the jur isdict ion of the corporat ion are pucca roads. The town has two Intercity bus stands one under BSRTC and the other for pr ivately

owned buses.

ROADS Nat ional Highway 57 ( India) comes via Gorakhpur , Motihar i and crosses Muzaffarpur and National

Highway 57 ( India) goes to Darbhanga, Purnia. The

EAST-WEST CORRIDORS crosses Muzaffarpur thus

connecting it to all the major towns and cities in India. The National Highway 77 ( India) star ting from Hajipur passes through Muzaffarpur and

connects Muzaffarpur to Sitamarhi. Recently, the

Nat ional Highway 102 ( India) has been constructed

which connects Muzaffarpur to Chhapra. The Nat ional Highway 28 (India) connects Muzaffarpur to Barauni.

RAILWAYS

Muzaffarpur is amongst the top hundred booking stations of Indian Railway.It handles over

150 trains and about 1,00,000 passengers daily Muzaffarpur Railway Stat ion is a main

railway junction, w ith two suburban stations, Ram Dayalu Nagar and Narayanpur Anant (Sherpur). It is well connected to major cities of Bihar like Patna, Bhagalpur , Gaya,

and Darbhanga.

The Muzaffarpur Junct ion railway stat ion is well connected to most of the major cities in India by the railway network and serves the city w ith numerous numbers of trains. Muzaffarpur is well connected to Patna, New Delhi, Mumbai, Kolkata, Howrah, Chennai, Bangalore, Ajmer, Kanpur , Guwahati, Surat, Lucknow, Chandigarh, Jamu, Vishakhapatnam, Raipur , Allahabad, Ranchi, Gwalior , Ahmedabad, Rajkot, Jaipur Porbander , Kochi and other cit ies

*****



CHAPTER-3

PROFILE OF MUZAFFARPUR INDUSTRIAL AREA

3.1. MUZAFFARPUR INDUSTRIAL AREA

The BIADA is responsible for promoting and assist ing the rapid development of industr ies

in the industr ial areas and estates of Bihar . Operations of BIADA are divided in four regions –Patna, Muzaffarpur , Darbhanga and Bhagalpur–to faci li tate quick services to trepreneurs.

FIG 3.1 MAP SHOWING LOCATION OF MUZAFFARPUR INDUSTRIAL AREA



Fig 3.2: Google Image of Muzaffarpur Industrial Area Phase-1

Fig 3.3: Google Image of Muzaffarpur Industrial Area Phase-2



3.2. INVENTORY OF INDUSTRIES

Muzaffarpur distr ict is the centre of several industr ies. In the south-western par t of Muzaffarpur city, Bela Industr ial Area is spread in around 379.53 acres, in which 206.53 acre for Phase I and 173 acre for Phase II. Out of total area, 268 acres are occupied by Working, under construction, Closed and Cancelled units, and 24.41 acre are vacant which has to be allotted. Out of 24.41 acre, 11 acres are reserved for Leather cluster . As per information collected dur ing the survey, it was found that most of the industr ies located in this region are small and medium scale type. Distr ibut ions of industr ies with respect to the plot area are summar ized in Table 3.1



Table 3.1 Plot Area Wise Distribution of Industries

Summary: Total working or functional plot area= 5668483 (sq. ft)=_____________________________130.13 (Acre)

Total under construction plot area = 1136630 (sq.ft) =_____________________________ 260.9 (Acre)

Total closed units plot area = 4899393 (sq.ft)=____________________________112.47 (Acre)

Total plot area =11704506 9sq.ft)=__________________________268.70 (Acre)

MUZAFFARPUR INDUSTRIAL AREA

Working or Functional Under Construction Closed

Total no. of

Industries

Total Plot

Area (sq.ft)

No

. of

Ind

us

trie

s

To

tal

Plo

t

ar

ea

(Sq

.ft)

% o

f P

lot

Are

a

No

. of

Ind

us

trie

s

To

tal

Plo

t

ar

ea

(Sq

.ft)

% o

f P

lot

Are

a

No

. of

Ind

us

trie

s

To

tal

Plo

t

ar

ea

(Sq

.ft)

% o

f P

lot

Are

a

Less than 0.25 Acres

(10,890 sq. ft) 112 537,342 9.5 30 171,228 15.1 8 44,785 0.9 150 753,355

From 0.251 to 0.50 Acres

(21,786 sq. ft) 30 549,906 9.7 2 42,080 3.7 3 47,383 1.0 35 639,369


(43,573 sq. ft) 18 736,580 13.0 9 337,036 29.7 3 100,567 2.1 30 1,174,183


(65,360 sq. ft) 15 895,114 15.8 1 62,913 5.5 1 65,340 1.3 17 1,023,367

Above 1.5 Acres (Above 65,361 sq.

ft) 19 2,949,541 52.0 5 523,373 46.0 10 4,641,318 94.7 34 8,114,232

TOTAL 194 5,668,483 100.0 47 1,136,630 100.0 25 4,899,393 100.0 266 11,704,506

Total % of Plot

Area 48.43

9.71

41.86



Due to lack of power supply and the problem of water logging in the estate, many units have closed down. Dur ing field survey and consultation with var ious entrepreneurs, i t is observed that there is problem of water logging in Bela Industr ial area due to drain coming from municipal area, this drain should be intercepted to municipal conveyance system to avoid intermixing of Municipal waste water w ith industr ial waste water . Graphical and Tabular representation of Industr ial unit distr ibut ion in Bela Industr ial area has been discussed below in Table 3.2 and Graph 3.1:

Table 3.2 Categorization of Industries

-

10,00,000.00

20,00,000.00

30,00,000.00

40,00,000.00

50,00,000.00

60,00,000.00

Working Under Construction Closed Vacant

Ar

Distribution of Industries

Graph 3.1: Current Scenario of Plot Area wise Industrial Categorization

194

47

25

20

S. No Types of plots Numbers

1 Working or Functional 194

2 Under construct ion or construct ion to be star ted 47

3 Closed 25

4 Total number of occupied Industries 266

5 Total number of vacant Plot 20



In below mentioned Graph, total number of industr ies distr ibuted under 0.25, 0.50, 1.0, 1.5 acre and above has been discussed respectively. The graph shows that maximum number

of industr ies around 150 are located under 0.25 acres, followed by 35, 30, 17 and 34 numbers are distr ibuted among 0.50, 1.0, 1.5 and above 1.5 acres of plot area respect ively

in Bela, Muzaffarpur Industr ial area.

On the basis of the above graph, a pie char t has been prepared wherein the percentage of total plot area occupied with respect to the industr ial categor ies i.e. working, under construct ion, closed and vacant plots have been discussed. Out of the four categor ies maximum plot area has been covered by working industr ies i.e. 44.4% followed by closed industr ies of 38.3% plot area, 8.9% is under construction or allotted plots in which construct ion is yet to be star ted and 8.3% vacant plots.

0

20

40

60

80

100

120

140

160

Less than 0.25Acres

From 0.251 to0.50 Acres



Above 1.5Acres

150

3530

17

34Nu

Areawise distribution of Plots

Graph 3.2: Areawise Distribution of Industrial units



3.3. INDUSTRIAL SECTORS IN MUZAFFARPUR

Major industr ial sectors located in Muzaffarpur region on the basis of numbers are of Agro-based or Food processing and engineer ing type followed by other industr ial sectors like Plastic, chemical, inst itut ion, Poultry. Information collected from each industry dur ing survey coming under Bela, Muzaffarpur area has been discussed in Table 3.3. In this, we have distr ibuted each industry in

par t icular sector and on that basis we have appraised total wastewater generat ion from domestic plus industr ial activity. Also, we have discussed that how much area is covered

by each industr ial sector .

44.40

8.90

38.37

8.33

Graph 3.3: % of Total Plot Area Occupied

Working

Under Construction

Closed

Vacant



Table 3.3 Distribution of industrial clusters in Bela, Muzaffarpur

DWW- Domestic waste water, PWW-Process waste water,

PDWW- Projected Domestic Waste water, PPWW- Projected Process Waste water.

NOTE: 1. Above mentioned BOD is taken for the wastewater generated from Process only. 2. *Textile: 2MLD wastewater estimated for Tanner ies by consider ing vacant plot/ future expansion under Tannery Cluster . 3. *Tannery: These units produce Hosiery Goods & Garments and there is no use of water in production. Therefore, Process wastewater generation

not considered

BELA, MUZAFFARPUR – SECTORWISE INDUSTRIAL DISTRIBUTION

Industrial

Group

No of

Industry Functional Closed U/C Cancelled

DWW

(lit/day)

PWW

(lit/day)

BOD

(mg/l)

PDWW

(lit/day)

PPWW

(lit/day)

Plot Area

in Sq.ft

*Tannery 8 5 1 2 0 5,625 600,000 1000 9,000 2,000,000* 964,592

Chemical 29 28 1 0 0 16,250 130,950 350 16,830 135,627 591,648

Engineering 45 31 6 8 0 20,715 32,050 250 30,070 46,524 1,151,667

Food 58 41 4 13 0 70,170 628,700 600 99,265 889,380 1,388,841

Insti tution 21 15 3 3 0 58,165 - 0 81,431 - 2,323,680

Mineral Water 3 3 0 0 0 1,170 40,000 100 1,170 40,000 17,300

Others 37 28 4 5 0 19,735 49,700 250 26,078 65,675 1,219,762

Phar maceutical 3 2 1 0 0 2,115 6,500 400 3,173 9,750 2,861,780

Plastic 41 27 3 11 0 16,380 16,100 250 24,873 24,448 505,538

Poultry 14 9 1 4 0 22,410 60,500 500 34,860 94,111 630,809

Pr inting 3 2 0 1 0 3,420 6,000 250 5,130 9,000 33,000

*Textile 4 3 1 0 0 900 - 500 1,200 - 15,890

266 194 25 47 0 237,055 1,570,500 4450 333,081 3,314,516 11,704,507

Total Estimated

Value 1,807,555 3,647,596



In Muzaffarpur distr ict , we have categor ized each surveyed industry into 12 categor ies. Of these categor ies it can be seen from the graph that maximum plot area in the region has

been covered by Pharmaceuticals and institutional setups like Malls, Govt. Offices, colleges

etc. Apar t from that Food, Engineer ing, Tannery, Poultr y, Plast ic and chemical has average value while minimum area is covered by industr ies like Pr int ing, Mineral water , Texti le and

other small units. Details of the same are shown in Graph 3.4.

On the other hand in Graph 3.5, we have discussed about the number of industries with respect to the each industr ial sectors. As it is clear ly indicated in the below mentioned graph

that maximum number of industr ies are of food processing type that includes Juices, flour ,

Biscuits, Snacks, Jam & Jelly, Spices, Dal Besan, Rice mills etc. Subsequently, Engineer ing, Plastic, Chemicals, Inst itut ions, Poultry are distr ibuted. Very few units are of Mineral water ,

pr inting and texti les. Also Tanner ies are also present in good numbers in the region.

-

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

30,00,000Are

Industrial Sectors

Graph 3.4: Industrial Sector wise plot Area Distribution



Other industrial units include Card Board box, Paraffin wax, Cold storage, cement, Paper ,

Hume pipes and Aluminium utensils are also in significant numbers.

3.4. PRESENT SCENARIO OF WASTEWATER GENERATION

With all the information/ data collected dur ing the survey, we have appraised present scenar io of wastewater quantity generated from domestic and industr ial processes. The

same has been discussed in Graph 3.6.

8

29

45

58

21

3

37

3

41

14

3 4Nu

Industrial Sectors

Graph 3.5 Industrial Sector wise numbers of

Industry



While analyzing the above mentioned graph, i t is apparent that out of total 12 categor ies of

var ious industr ial clusters, maximum process wastewater is generated from Tanner ies followed by Food sector . On the other hand, domest ic wastewater generat ion is maximum for inst itut ional setups and Food sector . Sectors like Chemical, Engineer ing, Mineral water

and Poultry produced average quant ity of wastewater from the process. Other sectors like

Pr inting, Texti le, Plastic, Pharmaceuticals are the minor contr ibutors of wastewater .

3.5. FUTURE PROJECTIONS OF WASTEWATER QUANTITY

To evaluate the capacity of CETP, we have made few projections on the basis of product

manufactur ing and water consumption in domest ic and industr ial processes discussed in Graph-3.7.

-

1,00,000

2,00,000

3,00,000

4,00,000

5,00,000

6,00,000

7,00,000W

a

Industrial Sectors

Graph 3.6 Current Scenerio of Waste Water Generation

DWW (lit/day) PWW (lit/day)



Tannery industry located in the region has been considered as the major contr ibutor for

process wastewater generation approx. 2 MLD; as the process consumes substant ial amount of water consumption in each of i ts process and hence produce more wastewater . After that

food industry may produce wastewater major ly from process and domest ic activity. Inst itut ional setups are also major contr ibutor of domest ic wastewater . Other sectors like Chemicals, Poultry, Mineral, Pr inting, Plast ic and Engineer ing will contr ibute less compared

to Tannery and Food industry.

3.6. CATEGORIZATION OF INDUSTRIES (RED, ORANGE AND GREEN)

Out of the ent ire Working, Under construction and Closed industr ies covered dur ing industr ial survey are fur ther classified into Red, Orange and Green on the basis of pollution

load as per schedule VIII norms st ipulated by Ministry of Environment & Forests, Govt. of

India (Annexure-IV) which is shown in below mentioned Char t.

-

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000Pro

Industrial Sectors

Graph 3.7 Projected Waste Water Generation

PDWW (lit/day) PPWW (lit/day)



It can be clear ly seen that maximum numbers of industr ies covered as per the list dur ing the

survey provided by BIADA falls under Green category which is around 60% that contributes

less to the pollut ion load followed by Orange Category (31%) while Red category industr ies are only 9% that include sectors like Tanner ies and Chemical.

3.7. MAJOR INDUSTRIES LOCATED IN MUZAFFARPUR AREA

Based on the survey done by our team in Bela Industr ial Area, Muzaffarpur major

contr ibutor of wastewater generation belongs to Tannery, Biscuit , Rice Mill, Flour Mill,

Fer t ilizer and Agro-based sectors. Name of few industr ies are mentioned below:

S.

No

Name of Industry Address Projected

Wastewater

Sector Category

1 M/ s Espana Tanner ies C-22P 120,900 Tannery Red 2 M/ s Saba Tannery C-25 120,900 Tannery Red 3 M/ s Alpha Leather industry C-28 120,900 Tannery Red 4 M/ s Green Leather industry C-24 120,900 Tannery Red 5 M/ s Nor th Bihar leather

industry C-23

120,900 Tannery Red

6 M/ s Lavanya Finvest Pvt. Ltd.

N.S-10 P N.S-10 P

30,350

Food Orange

7 M/ s Hentech Agrovat Pvt. Ltd.

NS1, NS2P NS-2

60,900

Poultry Feed

Orange

8 M/ s Lavanya Pure Food Pvt. Ltd.

Shed- B-11

256,750

Food Orange

9 M/ s Venkey's India Ltd. A8, A7P 31,125 Poultry Orange 10 M/ s Litchica International Shed B-9 100,225 Food Orange 11 M/ s Shashi Bhushan Agro B 16 26,125 Food Orange

Red, 25, 9%

Orange

81

31%Green, 160, 60%

Chart 3.8: Category wise distribution of Industries

Red

Orrange

Green



CHAPTER-4



PRODUCTION PROCESS

4.1. PRODUCTION PROCESS Major ity of industr ies in industr ial area are food processing such as Rice Mills, Flour Mill,

Dal Mill, Besan & Sattu; Juice, Bakery, Ice Cream; Tannery, Poultry feed which generate biodegradable wastewater . Few industr ies such as packaging, engineer ing, plastic etc.

generate small / negligible wastewater . The flow char ts for var ious products of industr ies are shown in the following pages. It w ill

also indicate the major sources of process wastewater generat ion.

Tannery

Raw Rice Product ion

Rice Product ion

Dal & Besan Mill

Bakery

Paint

Flour Mill

Pest icides

Newspaper Pr inting

Hatchery

Dry Type Wheat Flour Mill

Syrup Manufactur ing

Wet Type Flour Mill

Milk

Ice Cream

Detergent

RCC/ Cement Pipe

PVC Pipe

Pharmaceuticals

Mineral Water



CHAPTER-5



QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/ EFFLUENTS

5.1. ASSUMPTIONS IN CALCULATION OF WATER CONSUMPTION AND EFFLUENT

GENERATION

A minimum quantity of 500 li tres, 1000 li tres and 2000 li tr es have been considered for

small, medium and large sized plots respect ively, which either did not repor t the figures or their products (e.g. packaging and plastic goods) do not require water .

Domestic water consumption for residents of institutes and industries is taken @125

LPCD.

Domestic water consumption for manpower of food processing industr ies is taken @45 to 100 LPCD including for quality testing laboratory and hand wash.

Domestic water consumption for students and staff of inst itutes is taken @25 LPCD.

5.2. WATER CONSUMPTION AND EFFLUENT GENERATION

Dur ing survey, i t was observed that industr ies have neither water meters for measurement

nor awareness on cor rect figures of water consumption and waste water generat ion. Except few, most of the industr ies and inst itutes had repor ted arbitrary figures of water

consumption and waste water generat ion. In some cases, the data was not even repor ted.

This is shown in Annexure-III.

Foods processing such as Beverages (soft drink and juice), Biscuits, Bread, Rice Mills, Ice-

cream, Dairy & Agro products, RO package water industr ies are water intensive, therefore, consume significant quant ity of water due to frequent clean-in-process (CIP) requirement.

Accordingly, these units generate huge quantity of biodegradable wastewater . The Tannery sector contr ibutes 40% of the effluent from the industr ial area. As per

discussion with the management, the estimated wastewater generation from funct ional,

vacant plots and keeping provision for future product ion expansion, is 2000 KLD.

Industr ies such as engineer ing, chemicals manufactur ing generate moderate quant ity of wastewater .

Few industr ies such as packaging, plastic etc. use and generate small/ negligible

quant ity of wastewater .

Inst itutes, warehouses, offices and service providers consume water for domest ic use, laborator ies and gardening etc. The waste water is generated in the form of

sewage. As per the calculat ion of waste water generation (shown in Annexure-III) the total quant it ies are tabulated below:



Table 5.1 Details of Wastewater Generation from Domestic and Process Activities

Industrial

Group

No of

Industry Functional Closed U/C

Cancell

ed

DWW

(lit/day)

PWW

(lit/day)

BOD

(mg/l)

PDWW

(lit/d)

PPWW

(lit/day)

Plot Area

in Sq.ft

*Tannery 8 5 1 2 0 5,625 600,000 1200 9,000 2,000,000* 964,592

Chemical 29 28 1 0 0 16,250 130,950 350 16,830 135,627 591,648

Engineer ing 45 31 6 8 0 20,715 32,050 250 30,070 46,524 1,151,667

Food 58 41 4 13 0 70,170 628,700 600 99,265 889,380 1,388,841

Institut ion 21 15 3 3 0 58,165 - 0 81,431 - 2,323,680

Mineral Water 3 3 0 0 0 1,170 40,000 100 1,170 40,000 17,300

Others 37 28 4 5 0 19,735 49,700 250 26,078 65,675 1,219,762

Pharmaceutical 3 2 1 0 0 2,115 6,500 400 3,173 9,750 2,861,780

Plastic 41 27 3 11 0 16,380 16,100 250 24,873 24,448 505,538

Poultry 14 9 1 4 0 22,410 60,500 500 34,860 94,111 630,809

Pr int ing 3 2 0 1 0 3,420 6,000 250 5,130 9,000 33,000

*Textile 4 3 1 0 0 900 - 500 1,200 - 15,890

266 194 25 47 0 237,055 1,570,500 4650 333,081 3,314,516

1,807,555 694 3,647,596 11,704,507

Note: DWW-Domestic Wastewater ; PDWW-Projected Domestic Wastewater

PWW-Process Wastewater ; PPWW-Projected Process Wastewater

U/ C-Under Construct ion

*Tannery: 2MLD* wastewater estimated for Tanner ies by consider ing vacant plot/ future expansion under Tannery cluster. *Textile: These units produce Hosiery goods & Garments and there is no use of water in production. Therefore, Process wastewater generation not considered.

Draft Detailed Project Report for Establishment of CETP at Bela Industrial Area,

Muzaffarpur

SMS Envocare Limited Page 50 of chapter 6

Hence, it is evident from the Table 5.1:

The total domestic wastewater generation from operational units =237,055 l/ d

The total process wastewater generation from operational units = 1,570,500 l/ d

The total effluent from operational units = 1,807,555 l/ d

The projected domestic wastewater = 333,081 l/ d

The projected process wastewater = 3,314,516 l/ d

The total projected effluent = 3,647,596 l/ d 5.3. DESIGN CAPACITY OF PROPOSED CETP

As per the estimated wastewater generation from industr ies, it is proposed to install a Common Effluent Treatment Plant (CETP) of 5.0MLD (5000KL/ day) capacity for

treatment of industr ial and domestic effluent likely to be discharged by the exist ing industr ies, institutes and Tanner ies including provision for vacant plots. The higher capacity has been designed keeping in mind the future expansion in the production

process.

5.4. CHARACTERISTICS OF WASTE WATER

The wastewater from Food processing industr ies; such as Rice Mills, Flour Mill, Dal Mill,

Besan & Sattu; Juice, Bakery, Ice Cream; Tannery etc.; contains high BOD, COD, TSS and oil/ grease/ fats. However , wastewater is easily biodegradable; and it w ill require biological treatment.

Wastewater from Textile, engineer ing, Pr inting and chemicals manufactur ing

industr ies contains mainly COD, TSS, oil/ grease and less BOD. Hence, it is less biodegradable and it w ill require physico-chemical treatment.

The BOD of composite wastewater (process and washing/ cleaning) has been worked

out to be 694 mg/ l in Table 5.1.

The combined character ist ics of wastewater for design purpose has been shown in Table 5.2


Muzaffarpur


Table-5.2: Average Characteristics of Combined Untreated Effluent for Design

S. No. Parameters Units Values

1 pH value - 6.0 ~ 8.5

2 Total Suspended Solids (TSS) mg/ l 400~ 500

3 Chemical Oxygen Demand (COD) mg/ l 2000

4 Biochemical Oxygen Demand (BOD, 3 days,

27 0C)

mg/ l 700-750

5 Oil and Grease mg/ l 40~ 50

Design Flow for Proposed CETP: 5000 KLD = 5 MLD

5.5. CHARACTERISTICS OF TREATED WASTE WATER

The treated water from the CETP will meet the stipulated norms of sur face water discharge

standard and is placed below:

Table-5.3: Characteristics of Treated Waste Water as per CPCB/SPCB


1 pH value - 6.5 ~ 8.5

2 Total Suspended Solids (TSS) mg/ l <100

3 Chemical Oxygen Demand (COD) mg/ l <250

4 Biochemical Oxygen Demand

(BOD, 3 days, 27 0C)

mg/ l <30

5 Oil and Grease mg/ l <10

*****

CHAPTER-6


Muzaffarpur


CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/ SCHEMES

Dur ing the preparation of Feasibility Repor t, var ious options have been cr itically

examined for the consideration of best technologies suitable for the establishment of CETP in industr ial area.

The objective of wastewater treatment technology selected for the treatment of effluent

generated from the industr ial area is to provide: 1. Discharge water quality standards by regulatory bodies. 2. Cost Economic. Less Capital and Operating Cost. 3. Complete CETP system built-in in the available land area i.e. Minimum area

requirement. 4. Trouble-free in operation of CETP i.e. simple and reliable maintenance. 5. Consistent delivery of treated wastewater . 6. Withstand var iations in pollut ion and hydraulic load. 7. Recycling/ reuse of the treated effluent for hor t iculture purpose.

Var ious treatment technologies available for wastewater treatment are discussed below to meet the above mentioned objectives and to opt the appropr iate one for

Muzaffarpur Industr ial area:

6.1 ACTIVATED SLUDGE PROCESS (ASP)

It is a biological wastewater treatment process is w idely used by large communities where large volumes of waste water to be treated economically.

Fig: 6.1 Schematic Diagram of a Conventional Activated Sludge Process

Activated Sludge Process (ASP) is a suspended growth aerobic process. It is provided

with pr imary clar ifier to reduce the organic load in biological reactor (aeration basin).

About 40% of organic load is intercepted in pr imary clar ifier in the form of sludge, decreasing the loading in the aeration tank. After aeration tank, the mixed liquor is

sent to secondary clar ification where sludge and liquid are separated. A major

Excess Sludge Returned Sludge

Effluent Secondary

Clarifier

Aeratio

n

Tank

PST

Influent


Muzaffarpur


por tion of the sludge is re‐circulated and excess sludge is sent for the disposal.

Merits

Good process flexibility Reliable operation Proven track record in all plant sizes Low odor emission Energy production Ability to w ithstand nominal changes in water character ist ics

Demerits

High energy consumption Skilled operators needed Uninter rupted power supply is required Requires sludge digestion and drying Less nutr ient removal

6.2 SEQUENTIAL BATCH REACTOR (SBR)

It is a fi ll and draw activated sludge system for waste water treatment. Equalization, aeration & Clar ification can all be achieved using a single Batch Reactor . SBR systems

have been successful for large industr ial effluents. The SBR typically eliminates the need for secondary clar ifier .

Fig: 6.2 Schematic Diagram of SBR


Muzaffarpur


Although SBR has shown more maintenance in operation since the process is PLC

based, it shows higher efficiency and less area requirement for the CETP. It is a fi ll‐and‐draw batch aerobic suspended growth (Activated Sludge) process incorporating all the features of extended aeration plant. After screening and de‐gritting, effluent is fed to the batch reactor. Reactor operation takes place in certain sequence in cyclic order and in each cycle, following operations are involved:

Anoxic Filling tank Aeration Sedimentation/ clar ification Decantation Sludge withdrawal

Merits

Excellent effluent quality Smaller footpr int because of absence of secondary clar ifiers and digester Recent track record available in large applications in India also Biological nutr ient (N&P) removal High degree of coliform removal Less chlor ine dosing required for post disinfection Ability to w ithstand hydraulic and organic shock loads

Demerits

Comparatively high energy consumption To achieve high efficiency, complete automation is required Highly skilled operators needed No energy production Uninter rupted power supply required

6.3 MOVING BED BIO-REACTOR (MBBR)

Moving Bed Biofi lm Reactor is an aerobic attached biological growth process. It does not require pr imary clar ifier and sludge recirculation. Raw sewage, after screening

and de‐ gritting, is fed to the biological reactor.

In the reactor , floating plastic media is provided which remains in suspension. Biological mass is generated on the sur face of the media. Attached biological mass consumes organic matter for their metabolism. Excess biological mass leaves the

sur face of media and it is sett led in clar ifier .


Muzaffarpur


Fig: 6.3 Schematic Diagram of a Moving Bed Bio‐Reactor

MBBR is mostly preferred for the small effluent flow rates. In large plant, media quantity is very high and it requires long shut down per iod for plant maintenance. In fact, it may not be successful for large capacity plants.

Merits

Moving Bed Biofi lm Reactor needs less space Ability to w ithstand shock load with equalization tank option High operator oversight is not required

Demerits

High operating cost due to large power requirements Not much exper ience available with larger capacity plants (>1.5 MLD) Skilled operators needed No energy production Much less nutr ient removal

The comparative of technologies are discussed subsequently for better selection of suitable treatment technology:

Excess Sludge Air Blower

Effluent Secondary

Clarifier

MBBR II MBBR I Influent



Table 6.1: Comparative of Merits and Demerits of ASP, SBR and MBBR technologies

S.

No.

Defining

Parameters

ASP SBR MBBR/ FAB

1 Type of treatment/ Process

Continuous suspended growth Tr eatment

Fill and Draw regime Continuous Attached growth Treatment

2 System

Descr iption (component w ise)

Pr imary treatment-

Effluent collection and pumping- Bioreactor w ith Air distr ibution

gr id- Settling Tank- Disinfection - Fi ltr ation with DMF-ACF. Sludge

removal- Sludge digester tank- Dewater ing of sludge.

Pr imary treatment-

Effluent collection and pumping- Bioreactor w ith Air distr ibution

gr id & Decanter - Disinfection. Sludge removal - Sludge

dewater ing

Pr imary

treatment-Effluent collection and pumping -

Bioreactor w ith MBBR media & Air distr ibution gr id-

Tube settler - Disinfection- Fi ltr ation with

DMF-ACF. Sludge removal - Sludge digester tank- Dewater ing of sludge.

3 Sludge handling system requirement

Yes with Suitable mechanism



4 Advantages Suitable for Bigger plant capacity. Conventional treatment.

Batch process involves par tial nitr i fication of wastewater . Suitable for

small plant & Big Plants along with Automatic Operation (PLC Based)

Attached growth pr ocess. Compact plant w ith

resistance to shock load. Easy for installation. With Bio-digested sludge.

5 Disadvantage High Power & Maximum

Space Required, MLSS to be maintained and Continuous sludge

recirculation required. Susceptible to sock loads. Comparatively

high AMC cost

High Capital Cost. MLSS

to be maintained. Higher degree of automation & contr ol.

Tedious operation needs trained site person. Comparatively

high AMC cost

Maintenance of air

gr id in MBBR Tank is Cr it ical. Possibili ty of

loss/ car ryover of media. Annual make up of media

requir ed.



S.

No.

Defining

Parameters

ASP SBR MBBR/ FAB

6 Installation Entire Electr o-Mechanical er ection take place at site, hence takes more time

Entire Electr o-Mechanical er ection take place at site, hence takes more time

Less Time for MS Package System / Electro-Mechanical almost 4-6 weeks

7 Capital Cost Least High Cost Medium cost 8 Civil Cost High Cost Least Medium cost 9 Electro-

Mechanical Cost Least High Cost Medium cost

10 Daily Power Cost Medium Least Maximum 11 Area Requirement Maximum Normal Normal 12 Annual

Maintenance cost Maximum Least Normal

13 Operation Easy but requires a continuous observation

Easy but requires a continuous observation

Easy and System operate on i ts own

with Simple Automation

14 Manpower Semiski lled for

continuous basis Skilled for continuous

basis Semiski lled not on

continuous basis 15 Automation Not required As per requirement Not required

6.4 RECOMMENDED TECHNOLOGY

Based on the above discussed treatment technologies and appraising present area

availabili ty and type of wastewater generated from different industr ial sectors, i t has been suggested to setup CETP based on Activated Sludge Process. Detailed descr ipt ion of the proposed treatment scheme based on ASP has been discussed in Chapter -7

******



CHAPTER -7

PROPOSED TREATMENT SCHEME

Based on the character ist ics of combined wastewater mentioned in Table 5.2, the

wastewater contains significant suspended solid (TSS), BOD, COD and Oil & Grease. This requires preliminary treatment (Screen, Oil & Grease and Gr it Removal, Equalizat ion),

Physico-chemical t reatment for removal of TSS and par t ial removal of BOD and COD;

Biological treatment to achieve BOD level upto 30mg/ l followed by ter t iary treatment (Chlorination followed by Filtrat ion) to achieve the prescr ibed norms for disposal into

inland sur face water , reuse in hor ticulture and par tial reuse into industr ial process like Automobile Service Stations.

7.1 PROPOSED TREATMENT SCHEME

The Proposed CETP treatment units consist of all sub-units necessary for three stage

treatment i .e., Pr imary, Secondary and Ter tiary as mentioned below. Based on the

availabili ty of land and type of industry in the industr ial area, Extended Act ivated Sludge Process has been proposed for Common Effluent Treatment Plant of capacity 5 MLD or

5000 m3/ day.

The combined effluent has moderate values of parameters-TDS, BOD, COD, and Oil &

Grease. It is compulsory for each/ individual industry to install a screen for trade effluent and a septic tank for domest ic wastewater before connecting in to the sewer / drain leading

to CETP.

The treatment scheme consists of:

1. Pr imary Treatment (Screening, Oil/ grease skimmer & gr it removal tank, Equalizat ion)

2. Physico-chemical treatment (Chemicals dosing, Flash Mixer , coagulation, Flocculation, Pr imary Settler , sludge dewatering)

3. Secondary/ Biological t reatment (Extended ASP with clar ifier) 4. Tert iary treatment (disinfect ion using chlor inat ion and fi lt ration consist ing of

Pressure sand Filters & Act ivated Carbon Filters).

The oil / grease, grit & other similar solids shall be removed in pre-settling/ grit removal chambers. The suspended solids & colour , if any, shall be removed by physico-chemical

t reatment whereas the removal of bio-degradable soluble organic matter shall be achieved

in the biological t reatment. Chlor inat ion will be provided to kill the bacter ia in the treated



effluent.



Although norms for treated effluent discharge into the inland surface water stipulated

by Bihar State Pollution Control Board shall be achieved after Secondary treatment but

tertiary treatment shall also be provided in our scheme to remove residual/ escaped

organic matter and TSS.

Flow meters shall be installed in the pump pipe line of equalized wastewater and final outlet after filt rat ion. A calibrated 90o V-notch shall be installed for flow measurement, in

open channel before equalizat ion tank.

The common effluent treatment plant would have following treatment units:

1) Raw effluent intake and bar screen chamber 2) Raw effluent pump house 3) Effluent receiving/ sti lling chamber 4) Flow measurement channel 5) Medium screen 6) Oil/ grease Skimmer and Gr it Removal Tank 7) Equalizat ion tank 8) Chemical House – Solut ion Preparat ion and dosing system. 9) Flash mixer and coagulat ion tanks 10) Flocculation chamber 11) Pr imary Clar ifier 12) Aeration Tanks (Extended ASP) including DO sensors, air -blowers, diffusers and PLC 13) Secondary Clar ifier 14) Return Sludge collect ion Tanks (with/ w ithout Pump house) 15) Wet sludge collect ion Tanks and Pump house 16) Sludge dewater ing system – Filter press and Volute press/ Centr ifuge 17) Dewatered/ dry Sludge storage area 18) Chlor ine dosing system 19) Chlor ine Contact & Pre-fi lt ration Storage Tank 20) Pressure Sand Filters and Activated Carbon Filters 21) Treated effluent/ disposal pipe/ channel

The above units shall be provided with necessary mechanical equipment, electr ical ar rangements, instrumentat ion & automation with SCADA for Aeration operat ion. In

addition to above, CETP campus shall have an office and a laboratory with essential facili t ies for analysis of common parameters.



7.2 DETAILED TREATMENT SCHEME

The effluent from industr ial units in Muzaffarpur shall be collected through RCC drain/ sewer line approaching to CETP area.

1. Raw Effluent Tank with Screening: Effluent would pass through a pair of bar screens to be installed in intake chamber, then into raw effluent storage tank and pump house. The intake shall have stairs to reach up to screens platform. The screen in the intake shall be mechanical type for collection of screenings on the screen platform. The spacing between bars of screen will capture large mater ials (30mm or more size) from the effluent and hence these would not get entangled with pump impellers and other machinery of the plant.

2. Effluent Receiving Chamber: The raw wastewater collected in the wet well, would be pumped into effluent receiving chamber . The pumps ( through MC panel) are linked to level controllers for automatic ON/ OFF operat ion. Effluent from receiving chamber flows (under gravity) into flow measurement channel, provided with Gauge chamber to measure the flow of incoming effluent and a medium spacing (manual cleaned) bar screen to capture finer screenings.

3. Oil/ Grease Skimmer & Grit Chamber: The raw effluent shall pass through Oil/ grease Skimmer and Gr it Removal Tank. The floating oi l and grease present in the effluent is retained in oil and grease traps. The recovered oil/ scum formed on the top sur face of effluent shall be removed through Oil skimmer and stored in the drums for disposal. The gr it shall be removed from tank floor , though a mechanical scraper . Gr it shall be kept on dewater ing platform for draining out and shall be stored with dewatered sludge.

4. Equalization Tank: The equalization tank of sufficient holding capacity is provided to

dampen the flow var iations and shock loads in terms of volume and strength and to achieve a consistent quality in downstream processes.

5. Physico-chemical Treatment: The use of fer rous sulphate dur ing physico-chemical t reatment removes TSS in form of sludge. The soluble sulfur in presence of fer rous sulfate forms insoluble precipitate of fer rous sulfide. This removes sulfides from the effluent. Similar ly, chromium present in the effluent would also be removed as chromium hydroxide at alkaline pH maintained by addition of lime. The concentrat ion of phenolic compounds in raw effluent shall be negligible, hence does not require specific treatment for removal.

The expected character ist ics of effluent after pr imary sett ler are shown in Table 7.1.

Table 7.1: Expected Characteristics of Effluent after Physico-chemical treatment



S. No. Parameters Units Approx. Values

1 pH - 8.0 - 8.5

2 Total Suspended Solids (TSS) mg/ l 150

3 Chemical Oxygen Demand (COD) mg/ l 600

4 Biochemical Oxygen Demand (BOD, 3-days, 270C) mg/ l 350

5 Oil and Grease mg/ l Less than 15

6 Total residual Chlor ine mg/ l Less than 1

7 Total Chromium as Cr mg/ l Less than 2

8 Phenolic compound as C6H5OH mg/ l Less than 5

6. Flash Mixer 1&2 (Coagulation & Flocculation Tank): The equalized effluent from equalizat ion tank shall be pumped at constant rate into two stage flash mixer followed by flocculation tank. Chemical solut ions namely fer rous sulphate and lime solution will be added in flash mixers and poly electrolyte solution into the flocculat ion tank with the help of dosing pumps attached to chemical dosing tanks. The chemicals w ith effluent get completely mixed by rapid mixing in flash mixers whereas slow mixing in flocculat ion tank allows formation of bigger size fast settling flocs. The pH of the mixture of fer rous sulphate and effluent in flash mixer is maintained around 8.5 by dosing of lime.

7. Primary Clarifier: After floc formation, this mixture enters into pr imary settler /

Clar ifier where sludge settles at bottom and the clear supernatant effluent flows into Aeration tanks. The sludge is w ithdrawn into wet sludge pit w ith the help of valve provided in the valve chamber . The fi lt rate shall be discharged into inlet of Aeration tanks. The physico-chemical t reatment shall remove about 30% of BOD and 40% COD load of the effluent, in addition to complete removal of colour .

8. Biological Reactor (Extended Activated Sludge Process): Major par t of soluble BOD

& COD load (organic mater ial present in the effluent) would be removed by biological t reatment in Aeration tank. Extended aerat ion - Activated sludge process (ASP) allows for the oxidat ion of bio-degradable matter and conversion into bio-cell mass, carbon-dioxide and water .

Extended ASP also generates less sludge compared to the convent ional ASP. The desired cell mass concentration in the aerat ion chamber is maintained by required

degree of bio- sludge recycling from the Return sludge sump (connected to secondary clar ifier ). Proper mixing of bio-cells mass with influent and necessary oxygen supply for

oxidation of bio-degradable matter is done by means of air diffusers.

The DO level in aeration tanks shall be maintained by controlling the operat ion of Turbo

Blowers connected through DO sensor and PLC. Aerat ion tank including air -blowers with net work of air pipelines, diffusers and PLC shall be provided. Aeration tank shall have two chambers. The oxygen required shall be supplied through fine bubble Diffused

Aeration System with auto control of oxygen (DO) level in the Tanks. The biological



activity of microbes requires nutr ients i .e. Nitrogen and Phosphorous, which are vital elements for the growth of biomass in the effluent. The industr ial effluent would

contain wastewater also from canteens, toi lets/ septic tanks; therefore, required “N” and “P” are available in the influent. Return sludge would be recycled with the help of pumps so as to maintain the required degree of MLVSS and excess par t (waste sludge)

would be sent into wet sludge collect ion pit.

The expected character istics of treated effluent after biological t reatment are shown in Table 7.2:

Table 7.2: Expected Characteristics of treated Effluent after Biological Treatment

S.

No.

Parameters Units Values

1 pH - 7.5 - 8.0

2 Total Suspended Solids (TSS) mg/ l Less than 100

3 Chemical Oxygen Demand (COD) mg/ l Less than 200

4 Biochemical Oxygen Demand (BOD, 3-days, 270C) mg/ l Less than 25





9. Chlorine Contact Tank: After Secondary clar ifier , about 2.0 PPM of chlor ine gas

through chlor inators shall be mixed in to settled effluent which shall be collected in Chlor ine Contact & Pre-fi lt ration Storage Tank for tert iary treatment. This w ill provide contact time while storage into effluent tank of Pump House before fi ltr ation.

10. Media Filters: Pressure Sand fi lters and Act ivated Carbon Filters shall be used in ser ies for filtr at ion. The operation of these filters shall be continuous. The back-wash of fi lters shall be car r ied out when residual pressure about 1.0kg/ sq. cm. indicated on the pressure gauge. The back-wash effluent shall be discharged into inlet of Aerat ion tanks/ Equalizat ion tank.

A par t of fi ltered effluent shall be pumped for preparat ion of chemicals solution, required for chemical house of this CETP and water ing the plantation/ hor t iculture in CETP premises. A par t of t reated effluent may be used for construct ion act ivit ies, after

mixing with fresh water . The remaining final t reated ( fi ltered) effluent shall be discharged into existing drain which ultimately meets with r iver .



The expected character istics of final treated effluent after ter tiary treatment ( final outlet of act ivated carbon fi lters) are shown in Table 7.3:

Table 7.3: Expected Characteristics of final treated effluent after Tertiary treatment


1 pH - 7.0 - 8.0

2 Total Suspended Solids (TSS) mg/ l Less than 50

3 Chemical Oxygen Demand (COD) mg/ l Less than 150

4 Biochemical Oxygen Demand (BOD, 3-days, 270C) mg/ l Less than 20





The treated effluent would meet the effluent discharge standards as specified by Bihar

State Pollution Control Board/ in latest amended Environment (Protect ion) Act 1986,

subject to fulfi llment all of the following:

i . Implementat ion of Treatment scheme in totality (CETP units of matching capacity, shape/ configurat ion as per the approved drawings/ Detail Project Repor t.

i i. Total Daily Discharge of Untreated effluent (combined influent to CETP) should not

exceed 5.0 MLD (5000 m3/ day). i ii . Continuous Operation of CETP as per guidance of consultant/ technology provider .



Fig 7.1 Flow chart of Proposed Treatment Scheme



7.3SLUDGE HANDLING SYSTEM

The chemical sludge generated from the physico-chemical t reatment would be collected into Wet Sludge Pit at tached to Sludge Pump house. The wet sludge (TSS range 8.0 to 10.0 g/ L) shall be pumped at constant rate for dewater ing through fi lter press and centr ifuge/

Volute Press. Filter press and centr ifuge are installed at elevated platform. The dewatered sludge cake from the fi lter press would drop into the trolley and shall be stored into dry

sludge storage collect ion shed for a per iod of about one month. Later , the dry sludge shall be transpor ted to sludge disposal site as per directions of Bihar State Pollut ion Control

Board.

Waste bio-sludge from biological treatment, though negligible quant ity is biodegradable

and r ich in nutr ients. Bio-sludge shall not be mixed with chemical sludge so that it can be used as manure and water for plantat ion within CETP and industr ial area. Proposed Plant

layout enclosed as Annexure-V.

*****



CHAPTER-8

DESIGN SPECIFICATION OF TREATMENT UNIT

8.1. SPECIFICATIONS FOR CIVIL UNITS

1) Requirement for all Concr ete Structures a) All bedding & leveling concrete shall be minimum 100 mm thick in concrete grade

M-10 (1:3:6) unless other wise specified. b) Liquid retaining structures: The wall & bottom slab thickness shall not be less than

150 mm in any water retaining str ucture except in launders & channels. The same shall be designed using M-30 concrete design mix with OPC-43 gr ade and maximum 20 mm aggregate size for all str ucture member s.

c) Other structures: concrete shall be M-25. d) Medium reinforcement & cover of concrete shall be as per 7.1 & 7.2 of IS: 3370 par t

II. e) Water retaining str uctures such as tanks and sumps and concr ete roofs shall be

designed on a no crack basis & against upli ft pressure assuming sub soil water at Ground Level.

2) The size and number s of CETP units and Minimum recommended Sizes are given in the following Table.

3) Any item not covered in this Table, the specifications shall be as that of similar other i tem. The unit’s sizes had been worked out consider ing var ious design par ameter s as applicable to

the r elevant tr eatment units w ith appropr iate arrangement and housing of equipment to handle the design flow.

Basic Assumptions for working out cost of civil works

1) Item rates for civi l works had been taken as per Bihar Govt. Schedule of Rates (7th Edition, Oct 2014) for working out the cost of civi l works.

2) Plinth Area Rates (Aug 2014) had been taken for working out the cost Buildings. 3) Thickness of RCC structure members had been assumed on basis of similar previous works 4) Assumed avg. quantity of reinforcement steel per cu.M. of RCC

a) 60 kg for walls & slabs and b) 80 kg for columns , beams & footings

5) All bui lding had been considered RCC framed structur e with RCC footings, beams, columns, RCC roof slab. However dry sludge store shall have prefabr icated/ AC sheet roofing.

6) All pump houses as required leak-proof, has been considered RCC walls up to plinth level. Liquid retaining structure shall M-30 concr ete design mix w ith cement OPC-43 grade for all

structur e members. Reinfor cement steel shall be TMT high str ength bar s Fe-500.



Table 8.1: CETP UNITS AND MINIMUM RECOMMENDED SIZES

Part-1: CETP Units - Calculation of Civil Quantities

S.

No. Unit Name Internal Size RCC- WALLS RCC- BASE /SLAB Earthwork / Excavation PCC Vol. Other Items-RCC Total

RCC

(cu.M)

Finishing Works

L-B-D Av. Thk. Volume L W Av.Th

k. Volm. L W D Volum

e Area Vol. Are

a Av.Th

k Volum

e Inter.

Area Exter.

Area 1 Raw Effluent Intake & Screen

Chamber , incl. staircase 6.0x3.0x4.0 0.35 31.23 8.3

5 5.35 0.3 13.40 9.3

5 6.35 4.4 261.24 44.67

3 4.47 6 0.25 1.5 46.14 110.51 19.40

2 Raw Effluent Tank- Pump House-1

9.0x6.0x5.6 0.4 70.34 11.4

8.35 0.3 28.43 12.4

9.35 5.4 623.55 94.773

9.48 0 98.77 235.21 31.40

3 Pump Room - Pump House-1 8.0 x 6.0 x 10.0 0.5 95.55 10.4

8.35 0.45 38.89 11.4

9.35 5.5 583.67 86.423

8.64 85 0.3 25.5 159.94 244.12 141.12

4 Pump Room - Pump House-2 8.0 x 6.0 x6.5 0.3 26.46 5.8 5.8 0.45 15.14 6 6 1.5 54.00 33.64 3.36 80 0.3 24.00 65.60 141.22 141.12

5 Elevated Receiving Chamber 2.0x 2.0 x2.0 0.25 4.50 2 2 0.3 1.20 4 2 1.5 12.00 9 0.90 10.00 15.70 23.06 23.06

6 Open Channel 7.0x0.80x0.80 0.25 1.66 7.5 1.7 0.3 3.83 7.5 1.5 1.5 16.88 12.75 1.28 6(1.5x1.5,0.3) 14.00 19.49 13.28 13.28

7 Platform for Gr it dewater ing 2.5x2.5x1.0 0 0 3 3 0.9 8.10 9 0.90 11.0 0.25 2.75 0.00 10.48 10.48

8 Equalizat ion Tank 20.6 x 20.6 x4.9 0.35 143.72 23 22.95

0.35 184.35 24 23.95

4.5 2581.2 526.7 52.67 7.0 0.25 1.75 329.81 849.52 167.60

9 Flash Mixing Tank -1 4.20x2.20x 2.40 0.25 8.28 5.45

3.45 0.3 5.64 6.45

4.45 0.75

21.53 18.80 1.88 6.0 0.25 1.50 15.42 44.02 33.12

10 Flash Mixing Tank -2 4.20x2.20x2.40 0.25 8.28 5.45

3.45 0.3 5.64 6.45

4.45 0.75

21.53 18.80 1.88 6.0 0.25 1.50 15.42 44.02 33.12

11 Flocculat ion Tank 3.80x 3.80x2.40 0.35 13.94 6.2 6.2 0.3 11.35 7.2 7.2 0.75

38.34 37.8 3.78 3.0 0.25 0.75 26.04 57.06 39.84

12 Lime Solut ion Tanks (2nos.) 1.40x1.40x2.0 0.25 6.60 2.15

1.9 0.25 2.04 0 0 9 0.25 2.25 10.89 37.29 13.20

13 Ferrous Sul. Solut ion Tanks(2nos.)

1.40x1.40x2.0 0.25 6.60 2.15

1.9 0.25 2.04 0 0 8.64 37.29 13.20

14 Polyelectrolyte Solut ion Tank 1.30x1.30x2.0 0.25 3.10 2.05

2.05 0.25 1.05 0 0 1.00 5.15 14.80 12.40

15 Inlet, channel, Launder of Aer .Tank

1.0x 1.0x10.0 0.2 12.08 29.0

1.4 0.25 10.15 0 0.00 50 0.2 10.00 32.23 92.80 92.80

16 Aerat ion Tank, Platforms,Tie Beams, Columns (15nos), w ith inter . Wall

29.0x29.0x6.1 0.45 404.20 31.5

31.45

0.4 395.64 33.5

33.45

3.5 3916.2 989.1 98.91 55 0.3 16.50 816.34 1585.88 400.52

16 1.0(W), 0.5x0.3 0.3 9.90 10.00 19.9 132.00

17 Return Sludge (RAS) Holding Tank

8.0x7.30 x3.0 0.35 39.20 10.4

9.65 0.3 29.96 11.4

10.65

2.5 302.19 99.88 9.99 0 69.16 175.88 32.00

18 Pump Room - RAS Pump House

6.0 x 5.0 x 4.5 0.35 36.86 8.35

7.35 0.45 27.62 9.35

8.35 5.5 429.40 61.373

6.14 55 0.3 16.5 80.97 139.27 23.40

19 Chlor ine Contact & Filter Feed Water StorageTank

10.0 x6.4 x3.0 0.35 35.91 12.4

8.75 0.3 32.42 13.4

9.75 2.9 377.471

108.06

10.81 6.4 0.15 0.96 69.28875

172.46 34.20

20 Filtrat ion Pump House Not Provided 0.00 0.00

21 Wet Sludge holding Tank (in two par ts)

7.20x7.0 x3.1 0.3 34.32 9.5 9.3 0.3 26.51 10.5

10.3 3 324.45 88.35 8.84 6 0.25 1.50 62.322 91.76 142.08

22 Pump Room-Wet Sludge Pump House

7.80x5.0x7.50 0.3 60.30 10.1

7.3 0.3 22.12 11.1

8.3 4 368.52 73.73 7.37 8 0.25 2.00 84.419 42.93 26.80

23 RCC Platform / Foundns. for PSF

11.2 x 4.0x 1.0 11.2

4 1 44.80 12.2

5 1 61 44.8 22.40 44.8 44.80 30.40



Table 8.1: CETP UNITS AND MINIMUM RECOMMENDED SIZES

Part-1: CETP Units - Calculation of Civil Quantities

S.

No. Unit Name Internal Size RCC- WALLS RCC- BASE /SLAB Earthwork / Excavation PCC Vol. Other Items-RCC Total

RCC

(cu.M)

Finishing Works

L-B-D Av. Thk. Volume L W Av.Th

k. Volm. L W D Volum

e Area Vol. Are

a Av.Th

k Volum

e Inter.

Area Exter.

Area 24 RCC Platform / Foundns. for

ACF 12.1 x 4.0x 1.0 12.

1 4 1 48.40 13.

1 5 1 65.5 48.4 24.20 48.4 48.40 32.20

25 RCC Platform / Foundns. for Volute / Filter Press & centr ifuge

7.5 x5.0x 3.0 6 4 0.6 14.40 7 5 1.2 42 24 2.40 7 1 7.00 21.4 37.50 10.00

26 Platform, Foundns. For Subm. Pumps

6.40 x 2.0x 0.40 6.4 2 0.3 3.84 6.4 2 0.9 11.52 12.8 1.28 1.28 1 1.28 5.12 12.80 6.72

27 Storm water drains w ithin CETP area

0.60x0.80 (av.D) 0.15 135.20 500 0.95 0.15 71.25 500 1 0.9 450 475 47.50 206.4525

1275.00

28 Grit removal Tank-Oil

skimmer 6.80 Int. Dia 0.3 20.06 8 8 0.3 15.07 9 9 1.5 95.38 50.24 5.02 10.6

7 0.18 1.9202

7 37.06 117.29 55.74

Central Shaft 0.7 0.25 1.88 1.5 1.5 0.3 0.53 2.5 2.5 1.5 7.36 1.7663

0.18 0 2.41 7.54

Valve Chamber 1.2x1.2x2 0.2 2.912 2.4 2.4 0.25 1.44 3.4 3.4 2.3 26.59 5.76 0.576 0 4.352 16.52

Grit Pump sump 2.75x 2.75x2 0.25 7.8 4 4 0.25 4 5 5 2.3 57.50 16 1.6 0 11.8 40.20 3.00

29 Primary Clarifier 17.0M ( ID)x3.0M

0.3 48.89 18.2

18.2 0.3 78.01 19.2

19.2 2.0 578.76 260.02

26.00 25.08

0.18 4.51453

131.41 462.26 108.64

Central Shaft 1.2 0.25 6.26 2.35

2.35 0.3 1.30 3.35

3.35 1.5 13.21 4.3352

0.43 0 7.56 25.04

Valve Chamber 1.4x1.4x2 0.2 3.328 2.6 2.6 0.25 1.69 3.6 3.6 2.3 29.81 6.76 0.676 5.018 19.20 1.28

30 Secondary Clarifier 24.0M ID 0.3 68.67 25.2

25.2 0.3 149.55 26.2

26.2 1.5 808.28 498.51

49.85 34.97

0.18 6.29491

224.52 819.40 137.34

Central Shaft 1.3 0.25 7.30 2.45

2.45 0.3 1.41 3.45

3.45 2.5 23.36 4.712 0.47 0 8.71 29.20

Valve Chamber 1.4x1.4x2 0.2 3.328 2.6 2.6 0.25 1.69 3.6 3.6 2.3 29.81 6.76 0.676 5.018 19.20 1.28

Total of Quantities 1358.67 1294.80

12240.3

414.55

164.97 2815.68 7269.23 1830.75

Rate as Per BSR-2014 13200 13200 150 2350 11000 240 200

Amount (Rs. Lac) 179.344 170.9

13 18.360 9.742 18.147 17.446 3.661

Total Amount (Rs. Lac) 417.614



Part-2: BUILDINGS- on Plinth Area Rate (basis BSR-2014)

S.N. Name / Description Internal Size Rate

(Rs./Sq.M)

Amount (Rs.

Lac)

1 Chemical House- CC & IPS Floor

14.0x8.50 x 5.0 13120 15.613

2 Pump Room - Pump House-1 8.0 x 6.0 x 8.0 13400 6.432

3 Pump Room - Pump House-2 8.0 x 6.0 x4.5 13400 6.432

4 Housing for Turbo Blowers 10.0x6.0x4.0 13120 7.872

5 PLC Room (Control Center ) 6.0 x 6.0 x 3.30 13120 4.723

6 Housing for Chlor inators 5.0 x 5.0 x 4.0 12800 3.200

7 Shed for Chlor ine Tonners 5.0 x 5.0 x 4.0 9000 2.250

8 Workshop –cum- store 6.0 x6.0 x 4.0 13120 4.723

9 Panel Room-1 7.00x 6.0 x 4.0 13120 5.510

10 Panel Room-2 7.0x 6.0 x 4.0 13120 5.510

11 Air Compressors Housing 4.0 x 4.0 x 4.0 12800 2.048

12 Dry Sludge Storage shed 12.0 x6.0 x 3.30 9000 6.480

13 Room for Watchmen 4.0x3.50x3.50 12800 1.792

14 Toilets in Plant area 3.50x3.5x3.50 14000 1.715

15 Office building 15.0x10.0 15000 22.500

Total Cost of Part-2

96.801

Part-3: Based on Rate Analysis

S.N. Name / Description Brief Spec. Rate Amount

(Rs. Lac)

Remark

1 Boundary Wall surrounding CETP area

0.25Thk. X 2.0Ht.

8000 32.00 Length as per site,

2 Per ipheral RCC Road-complete including approach roads to var ious Buildings and Tanks

3.0M wide, w ith WBM

base, nominal reinft .

1600 24.00 Length as per Layout Plan.

Total Cost of Part-3

56.00



Part-4: Based on Lump Sum Cost

S.N. Name / Description Size or Area Amount

(Rs. Lac)

Remark

1 Finishing works, plinth

protect ion of all pump houses and buildings.

Lump sum 10.00 As per site,

2 Misc. CC base, cover ing of pipe

with PCC, man holes, Valve

chambers, Foundations for 2nos. DG sets.


3 Connection chamber, inlet pipe

lines to Pump house and out let

disposal channel w ithin CETP

boundary


4 Filling of Low lying Area- using

Mur ram, si lt and stone chippings - in areas around

buildings, Tanks and for under

roads base up to required depth.

Lump sum 15.00 As per site. Nett

quantity of

Ear thwork shall be

bsed on actual site

levels.

5 Fresh water Over Head Tank &Tube well w ith Submersible

pump set

7.0KL, 10.0M

staging

1.00

6 Staging/ Platform at top of PSF

& ACF

9.0x4.0 at

4.0M ht.

1.00

Total Cost of Part-4 36.00



8.2. SPECIFICATION FOR MECHANICAL EQUIPMENTS AND WORKS

The pipes used shall be as follows:

Table–8.2 Pipe Details

S. No. Type of pipe Class

1. Duct i le Iron S&S K9

2. Cast Iron S&S AB ( for grouted/ bur ied under Concrete)

3. Cast Iron Flanged B

4. Rigid PVC 10 Kg f/ sq.cm

5. GI Heavy duty-class B

6. Stainless Steel Medium class

7. RCC Pipe S&S NP3

8.3. PIPE FITTINGS

Fitt ings above 80 NB shall be DI as per relevant specificat ions in IS/ BS conforming. The puddle collars embedded in the wall shall be of DI.

If flanged cast ir on pipes and specials shall be used in the pump houses and to the limit of both suct ion and delivery pipelines they shall be manufactured and tested according to IS

1536 and 1537 respect ively & Flanges shall conform to IS 1538.

Notes on Equipment Materials

1) Mater ials thickness, where ever not mentioned, shall be sufficient to w ithstand against the loads including allowance for corrosion, wear & tear .

2) Makes of all fabr icated and bought out equipments including major components, shall be as per List of suggested Vendors / makes.

3) Specificat ions given below are indicative to specify the equipment requirement and their quant it ies. Accessor ies for completeness and required operational per formance are understood to be included.



Table-8.3 Mechanical Items Details

S.

No.

Equipment Name Specifications Quantity

1

Coarse Screen For

inlet / intake chamber of Pump

House-1

Mechanically cleaned.

Screenings to be brought up to tank top level using mechanical conveyor .

MC: SS flats 40 x 4 mm

Clear Spacing 30mm. Angle 600 with hor izontal

2 nos.

(one)

2 Medium Screens Manual cleaned.

MC: SS flats 30 x 3mm.Clear Spacing =20mm. Angle 600 with hor izontal.

1no.

(one)

3a) Pumps for

untreated effluent Transfer from Pump House-1 and

Pump House-2.

Type: Centr ifugal, Hor izontal, Flooded Suction.

Mater ial of Construct ion: C.I. Casing, SS impeller , SS Shaft, MS Base plate/ Frame. Capacity: 220 m3/ hour . Head: 15m of Water .

Motor HP – to be confirmed by manufacturer

2nos.

(two)

3a)

Pumps for

untreated effluent

Transfer from

Pump House-1 and Pump House-2

Type: Centr ifugal, Hor izontal, Flooded Suction.

Mater ial of Construct ion: C.I. Casing, SS impeller ,

SS Shaft, MS Base plate/ Frame.

Capacity: 110 m3/ hour . Head: 15m of Water . Motor HP – to be confirmed by manufacturer .

4nos.

(Four)

4 Pumps for RAS (Return Act ivated

Sludge) Transfer

( for extended ASP)

Type: Centr ifugal, Ver t ical, Submerged. Mater ial of Construct ion: C.I. Casing, SS Impeller ,

SS Shaft, MS Base plate/ Frame.

Capacity: 165 m3/ hour . Head: 14m of Water . Motor HP –to be confirmed by manufacturer .

2nos. (two)

5.1 Centr ifugal Pumps for chemical sludge

slur ry Transfer

from Pump House

Type: Centr ifugal, Hor izontal, Flooded Suct ion, SP ser ies pumps. Mater ial of Construction: C.I.

Casing, SS impeller , SS Shaft , MS Base plate/

Frame. Capacity: 6.0 m3/ hour and Head: 30 to 32m of

Water . Sp. Gravity of liquid= 1.08. Motor HP –to be confirmed by manufacturer .

2nos. (two)

5.2

Screw Pumps for chemical sludge slur ry from Pump

House

Type: Screw/ Progressive cavity, Hor izontal, Flooded Suction, fi lter press pump. Mater ial of Construction: C.I. Casing, SS screw, MS Base plate/

Frame. Capacity: 3 to 5m3/ hour . Head: 45M of Water . Sp. Gravity of liquid=1.08.

Motor HP –to be confirmed by manufacturer .

2nos. (two)



S.

No.


6 Pumps for Filt rat ion Pump

House to PSF and ACF

Type: Centr ifugal, Hor izontal, Suct ion 3.50 meter . Mater ial of Construction: C.I. Casing, SS impeller

and Shaft, MS Base Frame. Capacity: 1no. @220m3/ Hour . & 2nos. @110

m3/ Hour . Total Head= 30.0 m.

Motor HP –to be confirmed by manufacturer .

Total

3nos. (three)

7

Oil/ grease

skimmer-cum-Gr it Removal scraper

Type: Mechanical Scraper as clar ifier .

Tank Size- As per table unit sizes Mater ial of Constr .: SS blades and rake arms.

Under water par ts SS. Br idge- MS, sand blasted Epoxy painted. Sp. Gravity of mater ial (gr it) = 2.60.

Complete with dr ive, Oil skimmer and trough.

1no.

(one)

8

AGITATORS /

MIXERS for Flash Mixer Tanks

MC: SS-316 Impeller & shaft . Tank Size: As per

Table -Unit Sizes. Turbine type, 4 blades, detachable Impeller .

Impeller dia.=0.5M approx. Final RPM= 100approx. HP=2 or as recommended by manufacturer . Complete including coupling, MS

base Frame.

4nos. (two)

9

PADDLE TYPE

FLOCULATORS For Flocculation

Tanks.

MC: SS-316 impeller & shaft .

Tank Size: As per Table -Unit Sizes. V-shaped Paddle type, Detachable Impeller .

Impeller dia..= 2.80M approx. Shaft bottom suppor ted on bush. Final RPM = 15 approx.

HP = 2 or as recom By Mfr .

Complete-Coupling, MS Base Frame.

1no.

(one)

10

AGITATORS /

MIXERS for Lime Solut ion Tanks and

F. Sul. / Ferr ic Alum

Solut ion Tank

MC: SS-316 Impeller &shaft.

Tank Size: As per Table -Unit Sizes. Propeller type, Detachable Impeller .

Final RPM= 100 approx.

HP = as recom. By Manufacturer . Complete-Coupling, MS Base Frame.

4 no’s

(four)

11

AGITATOR / MIXER For Polyelectrolyte

Solut ion.

MC: SS-316 Impeller & shaft . Tank Size: As per Table -Unit Sizes.

Propeller type, Detachable Impeller . Final RPM= 100 approx.

1no. (one)



S.

No.


HP = as recom. By Manufacturer . Complete-Coupling, MS Base Frame.

12 a)

Dosing Pumps for F S / Fer r ic Alum and

Lime Solution

Discharge range = 500 to 1500LPH each Head = 30 Meters of Water

Type: meter ing. MoC: SS-316 Motor HP as recommended by manufacturer . Complete with Base Frame.

4 (four)

12 b)

Dosing Pumps for PE (Polyelectrolyte)

Solut ion

Discharge range = 500 to 1500LPH each Head = 30 Meters of Water

Type: meter ing. MoC: SS-316 Motor HP as recommended by manufacturer . Complete with Base Frame.

2 (two)

13 Mechanical Scraper for Pr imary

Clar ifier

Clar ifier , size- As per Table -Unit Sizes. MOC – Water immersed parts and scraper shall be

of SS-304.

Br idge MS, sand blasted, Epoxy painted. All par ts should be Epoxy Painted after sand blast ing and pr imer applicat ion. Per ipheral/ Central Dr ive system.

Inner baffle chamber - 2.30M (D) x 1.20M (H). Motor HP as per manufacturer . Motor w ith speed

reduction gear box to get final RPH~ 3. Scraper base Slope = 1:10 towards centre.

MS br idge 1000mm wide, rai ling 1000mm (H),

40mm dia. class B, GI/ MS pipe. Br idge should have MS gratings of 12x12mm.

Moving scraper arms fi tted with blades, neoprene rubber Squeegee pads.

With over load alarm device and on / off remote

push button switch.

1 Set

14 Mechanical Scraper for Secondary Clar ifier

Clar ifier , size- As per Table -Unit Sizes. Inner baffle chamber - 3.0M (D) x 1.20M (H).

Water immersed parts and scraper shall be of

SS-304.

All other same as above.

15 Turbo Air Blowers for Air supply

High Speed Centr ifugal Turbo Blowers capacity: 4500 m3/ hour at delivery air pressure head

6.25M of water column.

2 nos. (1W +1



S.

No.


TEFC Motor- HP (75 approx.) and RPM (25000 approx) as per manufacturer .

Complete with accessor ies- noise si lencer and Acoust ics (noise control) enclosure.

SB)

16 Air Diffusers and Air supply grid

Tubular , dia.= 90mm (minimum). Length=1.0M (minimum). PU/ Silicon membrane, w ith SS feed pipe and SS clamps.

Air supply grid- of suitable dia., maximum velocity of air 18m/ sec.

Pipe Mater ials shall be- i) From top of tanks / freeboard to inlet for

diffusers- SS304. i i) Grid for air diffusers – CPVC / SS-304.

Qty. to match air

supply

=3500 cum/ hr .

17

a)

Filter Press For Chemical

sludge dewater ing

Filter Press: Size: 36” x 36” w ith 35 plates including end plates. Center feed. Operat ion-

Hydraulic for 2nos and Manual for 1no.

MOC: PP plates, End plates- CI, MS Beam and

suppor t frame, CI gears, MS shaft. Polyester filter cloth with spare 2 sets. Out lets: 25mm Dia. and filt rate channel.

Dewatered cake thick 50mm.

2 nos.

17

b)

Centr ifuge /

VOLUTE press for sludge dewater ing

Capacity =10 KL/ hr . Feed sludge concentrat ion

=8.0 g/ L. Complete with motor , piping, flocculator and feed tank.

1no.

18 Air Compressors for Equalization

Tank.

Reservoir volume = 300 Liters approx. PVC Per forated pipe line at base / floor in

Equalization tank.

Operat ing Pr . Range= 7 to 9 kg/ cm2. TEFC motor w ith IP 55 Protection, 3-Phase, 415V,

Motor HP= 15. Complete with Main GI pipeline, Ball valves,

Pressure Gauge, Noise si lencer , Belt guard, FRP/ GI cover over motor .

1 (one)

19 Air Blowers for

Chemical Mixing Tanks (in Chemical

house)

Twin Lobe Rotary Type.

Blower Capacity: 100M3/ Hr . Air Pressure = 4.0M of water column.

Blower RPM = 1200 approx. TEFC Motor = 5HP, RPM 1450.

1 (one)



S.

No.


Complete with accessor ies- noise si lencer , Belt Dr ive with Guard.

20 Chlor inators with Tonners

On-line dosing (1.0-2.0 kg/ hr .) w ith instrumentation for dosing display and control.

2 ( two) sets

21

a)

EOT , Chain Pulley 1.0 MT. Manual operated for pumps, motors and

sluice gate li ft ing.

6 no’s

(six)

21 b)

EOT , Chain Pulley 3.0 MT Electr ically operated for centr ifuge/ volute press li ft ing.

1 (one)

22 Piping, valves,

fi tt ings

As per approved drawings.

MOC- C.I., MS, G.I. and similar –class B.

DI pipes- K9.

HDPE, CPVC, PVC and similar - Heavy duty/ Pr . Class 10kg/ cm2

Lot

23 Centr ifugal pumps for dewater ing pits

Centr ifugal, ver t ical, motor coupled, flooded suction.

MOC: C.I. Casing and impeller , CS Shaft ,

Capacity: 5.0 M3/ Hr . Head: 15.0M. TEFC Motor , 3-Phase, IP-55, 415V.

HP= 3.0 or as recom. By manufacturer . Complete with cable.

6 nos. (5W+1S)

24 V-notch MOC- 3mm thick SS-304 sheet fi tted in SS frame. Opening (V) Size=700x350mm.Central angle=90o. Calibrated and embossed flow depth (cm) and

flow rate (cu.m / hr .)

1 no.

25 PSF (Pressure Sand

Filters)

Size: Dia. 2.70M x 2.50M (H, excl. dishes) .

Other Specifications same as GACF, except

Act ivated Carbon layer .

2 nos.

(two)



S.

No.


26.

GACF (Granular Act ivated

Carbon Filters)

Type of Filters – Ver t ical w ith Cylindr ical Cell and Ellipt ical dish ends.

Size: Dia 3.0 x 2.50(H, excl. dishes). Operat ion = continuous (24 hours/ day).

Working Pressure= 3.0 to 1.25 kg/ cm2.

Residual Head before Regen=1.0kg/ cm2 Air Scour ing inlet =100mm NB

Mater ials of Construction – Casing /shell – 8mm thick MS sheet, inside rubber

lined, outside epoxy paint over pr imer. Top & bottom Dishes – 10 mm thick MS sheet, inside rubber lined, outside epoxy paint over

pr imer . Strainers- PVC. Filter Media Details-

Si lica sand, pebbles, gravels as per approved drawing. Mater ial depth =0.90 M approx. Granular Act. Carbon (GAC)- Coconut shell, depth

600-650 mm.

2 nos.

(two)

The Turbo blowers are energy efficient, have negligible noise compared to other blowers. Hence, for ASP, only Turbo Blowers shall be provided.



8.4. SPECIFICATION FOR ELECTRICAL & INSTRUMENTATION WORKS

8.4.1. Automatic Power Factor Control Panel

The Automatic Power Factor Control of Suitable KVAR capacity suitable for automatic operation and control of Power Factor within the set limits, free standing floor mounting

type made out of 2mm CRCA Sheet steel powder coated with channel ir on base frame

suitable for operation on 3-phase, 4 wire, 50 Hz equipped with the following: -

Incoming

Suitable sets equipped with 250 A MCCB, PF meter , APFC Relay suitable for sequent ial operation of all capacitor banks.

Outgoing

- Suitable sets of 32A 415V power contactors with fuses.

- Suitable sets of 63A 415 V power contactor w ith fuses.

- Capacitors Banks as per design & requirement of power Supply Company. -LT Panel capacitor Banks shall be mounted in the separate LT Panel Board.

Diesel Generating Set

D.G set of capacity to meet 100% (full load) requirement including all ancillary equipment

such as base frame, coupling, coupling guard, control panel and exhaust piping system etc. including electr ic w ir ing between control panel and start ing batter ies.

8.4.2. Electrical Panel

A separate panel (bay) should be provided for individual pump house. The control panel shall be made up of 2mm sheet steel w ith 7/ 9 tank process powder coating for long life.

The control panel should contain ACB/ MCCB (as per design requirement) of suitable rat ing contacts relays of reputed make.

GENERAL SPECIFICATIONS FOR ELECTRICAL PANELS

There shall be separate Power panels for each pump house, chemical house and blowers etc.

Power panels shall contain Incomer , MCCB, Bus bars, SFU, Relays, Online Indicators, ON/ OFF Rotary switches, Star ters (DOL star ter up to 10 HP and Star -Delta Star ters above 10 HP load) and Spares of suitable capacities and adequate in numbers.

Proper ear thling systems/ ear th pits shall be provided wherever required. Each equipment shall be provided with push button station for local ON/ OFF. Panels shall be indoor type, metal clad, floor mounted, free standing, totally

enclosed, extensible type, air insulated, cubicle type for use on 415 Volts, 3 phase, 50



cycles system with a fault level w ithstand of 31 MVA / 35 MVA RMS. Panels shall be designed to conform to the requirements of conform to the relevant

IS specificat ions and shall be provided with required hardware such as control cabling, contactors, and spares.

The structure shall be mounted on a MS Channel of required size. The design shall ensure that the weight of the components is adequately suppor ted without deformation or loss of alignment dur ing transit or dur ing operat ions.

Panel’s doors and covers shall be of minimum 2 mm thick sheet steel. Sheet steel shrouds and par ti tions shall be of minimum 2mm thickness. All sheet panels shall be smoothly finished, leveled and free from flaws. The corners should be rounded.

The apparatus and circuits in the power control centers shall be so arranged as to faci litate their operation and maintenance and at the same t ime to ensure the necessary degree of safety.

All doors / covers providing access to live power equipment / circuits shall be provided with toll operated fasteners to prevent unauthor ized access.

Provision shall also be made for permanent ly ear thing the frames and other metal par ts of the switchgear .

Specificat ions as per relevant BIS codes shall apply. There shall be separate Power panels for each pump house, chemical house and

blowers etc. Power panels shall contain Incomer , MCCB, Bus bars, SFU, Relays, Online Indicators,

ON/ OFF Rotary switches, Star ters (DOL star ter up to 10 HP and Star -Delta Star ters above 10 HP load) and Spares of suitable capacit ies and adequate in numbers.

Proper ear thing systems/ ear th pits shall be provided wherever required. Each equipment shall be provided with push button station for local ON/ OFF

operation.

The following protect ions should be provided in the panel board:-

Over load protection Short circuit protect ion Earth fault protect ion Shunt tr ip & under voltage protection.

OPERATIONAL REQUIREMENT/INTERLINKING OF ELECTRICAL PANEL AND

INSTRUMENTATION

The biological t reatment process (extended ASP) shall be PLC controlled through SCADA.

All MC panels shall have provision of Change –over Switches for operat ion of 100%

equipment through CAPTIVE (DG) Power . All MCC panels shall have provision of Change –over Switches for operat ion of 100%

equipment through CAPTIVE Power (DG set ) for each module. 1. Effluent Transfer Pumps in Pump House-1 (PH-1) :



a) Each Pump for independent operation manual/ automatic modes. b) Level sensor in Wet Well w ith Alarm system, when TWL (or Water Depth) reaches 2500 mm above the Base floor .

2. Pumps in Pump House -2 (PH-2): Each Pump for independent operat ion manual/ automatic modes.

3. RAS Transfer Pumps: Each pump for automatic operation/ manual modes. 4. Pumps in Wet Sludge Pump House -3 (PH-3) : Each Pump for independent operat ion

MANUAL modes.

5. Flash mixer Agitators and Flocculat ion Paddle Mixers: - to be inter locked with Chemical dosing pumps for synchronous operation.

6. Chemical Solution Tanks Agitators and Air Blowers: Independent and Separate control.

7. Air blowers and all other Equipments: For independent and Separate control for each SBR basin.

8. Pumps in Filtration Pump House-4 (PH-4): Each Pump for independent operat ion

manual modes.

The level controllers of Pump Houses shall be connected to MC panel in such a manner that pump (which was running) star ts operat ing when water level reaches at the upper ON

level and stops when water level reaches at the Lower OFF level in Effluent tank. The level controllers of Raw Effluent Pump House-1 shall be connected to panel in such a manner that third pump ( first standby) star ts operat ing when water level reaches above

the normal TWL level in the wet well.



8.5. INSTRUMENTATION

8.5.1. The Aeration System Shall be PLC Controlled Automatic Operation Through

SCADA

a) ULTRASONIC FLOW METER &TOTALIZER

Compact on-line ultrasonic flow conver ter directly mounted on the ultrasonic flow sensor .

Input: Effluent of pressure sand fi lters and Activated carbon fi lters having solid par ticle content < 2%, gas content < 1% (by volume) and TSS less than

100mg/ L. Pipe dia. 300mm to 500mm.

Output required:

Measurement funct ionality: Digital display of Flow rate and Total volume. Measur ing range: Flow= 0 to 700 cu.m. / hour .

Measur ing error (under site conditions): Not to exceed ± 1.0% of value.

b) ON-LINE pH METER

Compact weather proof and temper - proof on-line probe with Digital display.

Input: Effluent of pressure sand fi lters and Activated carbon fi lters having

Solid par ticle content < 2%, gas content < 1% (by volume) and TSS less than 100mg/ L.

pH range 5.0 to 11.0

Output required:

Measurement funct ionality: on-line pH value.

Measur ing range = 5.0 to 11.0. Perm. Error (under site condit ions) : Not to exceed ± 2.0% of measured value.

c) On Line Water Quality Monitoring at Common Effluent Treatment Plant

(CETP)

List of Effluent Water Parameter Monitor ing at each process stages at CETP

A) At inlet pH, Flow, BOD, COD, Total Suspended Solids (TSS)

Universal Mult i Controller w ith Display Unit



Wireless Remote Data Logger for Transmit ting Data Using GSM/ GPRS

B) Aeration Basins Dissolved Oxygen measurement and Luminescent display for each Tank.

Nitrate Sensor w ith spectro-photometry pr inciple.

Universal Mult i Controller .

Wireless Remote Data Logger for Transmit ting Data Using GSM/ GPRS.

C) Third Point at filters / final out let – BOD,COD, Nitrate, Total Suspended Solids (TSS), TDS with self-cleaning Universal Multi Controller

Wireless Remote Data logger for Transmitt ing Data Using GSM/ GPRS

8.5.2. Online Real Time CETP Water Quality Monitoring

As per CPCB guidelines Real Time CETP Water Quality Monitor ing & Central Network shall be installed for parameters viz. pH, TSS, temperature, Biochemical Oxygen demand (BOD), Chemical Oxygen Demand, Nitrate, and DO. Chlor ine and

Flow with remote as well as local display in control room. The wireless connect ion shall be prefer red for control room display.

The Water Monitor ing Stations shall provide real time data through GSM/ GPRS

network at scheduled intervals automatically or as and when requested by the users.



8.6. ELECTRICAL LOAD

Estimated Electrical Load of CETP Equipment for Estimate purposes

Table-8.4 Electrical Load Sheet

S.

No. Equipment / Drive Name

Nos

.

KW of

each

Total

KW

Running

KW

1 Centr ifugal Pumps (220 m3/ Hr), in Pump Houses PH-1 & PH-2

2 18.75 37.5 37.5

2 Centr ifugal Pumps (110 m3/ Hr), in Pump Houses PH-1 & PH-2

4 7.5 30 0

3 Centr ifugal Pumps (170 m3/ Hr) , in RAS Pump House

2 15 30 15

4 Pit Dewater ing Pumps, centr i., 5m3/ Hr 7 1.5 10.5 3

5 Centr ifugal Pumps (220 m3/ Hr), in Pump House PH-4.

1 30 30 30

6 Centr ifugal Pumps (110 m3/ Hr m3/ Hr), in Pump House PH-4.

2 15 30 0

7 Gr it removal devices, oi l skimmers (2.2+0.75) 1 3 3 3

8 Air Compressors 1 7.5 7.5 7.5

9 EOT hoists 6 1.1 6.6 1.1

10 EOT hoists 1 2.2 2.2 2.2

11 Agitator - Lime Dosing Tank 2 1.1 2.2 2.2

12 Agitator - F. S. / F.A. Dosing Tank 2 1.1 2.2 2.2

13 Agitator - Poly Electrolyte Dosing Tank 1 0.75 0.75 0.75

14 Mixer - Flash Mixer Tank-1&2 4 1.5 6 6

15 Rotary Air Blowers for Chem. house 1 3.7 3.7 0

16 Mixer for Flocculat ion Chamber 1 2.2 2.2 2.2

17 Dosing Pumps for Lime Solut ion 2 1.1 2.2 1.1

18 Dosing Pumps For Fer . Sul. / F.A. Solu. 2 1.1 2.2 1.1

19 Dosing Pump For P E Solution 2 0.75 1.5 0.75

20 Pr imary Clar ifier Mechanism 1 1.5 1.50 1.5

21 Secondary Clar ifier Mechanism 1 2.2 2.20 2.2

22 Turbo Air Blowers for Aeration Tanks 2 175 350 175

23 Sludge Feed Centr i. Pumps for PH-3 2 3.75 7.5 3.75

24 Sludge Feed Screw Pump to Filter Press for PH-3 2 7.5 15 7.5

25 Service Water Pump, 6m3/ hr 2 3.75 7.5 3.75

26 Centr ifugal Pumps for reuse of Treated effluent in 2 2.2 4.4 2.2



S.

No. Equipment / Drive Name

Nos

.

KW of

each

Total

KW

Running

KW

Chem. house

27 Instrumentat ion 1 5 5 5

28 Centr . Pumps for biological sludge from wet Sludge Pump House. 2

3.75 7.50 3.75

29 Centr . Pumps for chemical sludge from Sludge Pump House. 2

3.75 7.50 3.75

30 Screw Pumps 2 3.37 6.74 3.37

31 Filter Press with Hydraulic system 1 1.5 1.50 1.5

32 Centr ifuge for bio-sludge dewater ing 1 15.0 15.00 15.00

33 Twin Lobe Rotary Blowers for Chem. Mixing Tanks and bio-sludge sump 2

3.75 7.50 3.75

34 Miscellaneous- office, lab, workshop, street Lighting etc.

1 20 20.00 15

Total 669.1 362.62

Approximate proposed Installed load = 670 KW

Approximate proposed Running load = 365 KW

*********



CHAPTER - 12

ENVIRONMENTAL MANAGEMENT PLAN

12.1. ENVIRONMENTAL MANAGEMENT PLAN (EMP)

Preparat ion of environmental management plan is required for formulation, implementat ion and monitor ing of environmental protection measures dur ing and after commissioning of projects. The plans should indicate the detai ls as to how var ious measures have been or are proposed to be taken including cost components as may be required. Cost of measures for environmental safeguards should be treated as an integral component of the project cost and environmental aspects should be taken into account at var ious stages of the projects:

Conceptualizat ion: preliminary environmental assessment Planning: detailed studies of environmental impacts and design of safeguards

Execution: implementation of environmental safety measures

Operation: monitor ing of effectiveness of built -in safeguards

The management plans should be necessar i ly based on considerations of resource conservation and pollut ion abatement. Some of which are:

1. Liquid Effluents

Effluents from the industr ial area should be treated well to the standards as

prescr ibed by the Central/ State Water Pollut ion Control Boards.

Deep well bur ial of toxic effluents should not be resor ted to as it can result in re-sur facing and ground water contaminat ion. Re-sur facing has been known to cause

extensive damage to crop and livestock. In all cases, effor ts should be made for re-use of water and its conservation.

2. Air Pollution

The emission levels of pollutants from different stack should conform to the

pollut ion control standards prescr ibed by Central or State Boards. Adequate control equipment should be installed for minimizing the emission of

pollutants from the var ious stacks.

In-plant control measures should be taken to contain the fugit ive emissions.

Infrastructural facilit ies should be provided for monitor ing the stack emissions and

measur ing the ambient air quality including micro-meteorological data (wherever required) in the area.



Proper stack height as prescr ibed by the Central/ State Pollution Control Boards should be provided for better dispersion of pollutants over a wider area to minimise

the effect of pollut ion. Community buildings and townships should be built up-wind of plant w ith one-half

to one ki lometer greenbelt in addition to physiographical barr ier .

3. Solid Wastes

The site for waste disposal should be checked to ver ify permeabili ty so that no

contaminants percolate into the ground water or r iver/ lake. Waste disposal areas should be planned down-wind of vi llages and townships.

React ive mater ials should be disposed of by immobilizing the react ive materials

w ith suitable additives. The pattern of fi lling disposal site should be planned to create better landscape and

be approved by appropr iate agency and the appropr iately pretreated solid wastes should be disposed according to the approved plan.

Intensive programs of tree plantat ion on disposal areas should be under taken.

4. Noise and Vibration

Adequate measures should be taken for control of noise and vibrat ions in the industry.

5. Occupational Safety and Health

Proper precaut ionary measures for adopt ing occupat ional safety and health standards should be taken.

6. Prevention, maintenance and operation of Environment Control Systems

Adequate safety precaut ions should be taken dur ing preventive maintenance and shut down of the control systems.

A system of inter -locking with the product ion equipment should be implemented

where highly toxic compounds are involved.

7. House – Keeping

Proper house-keeping and cleanliness should be maintained both inside and outside of the industry.



8. Human Settlements

Resident ial colonies should be located away from the solid and liquid waste

dumping areas. Meteorological and environmental condit ions should be studied

proper ly before selecting the site for residential areas in order to avoid air pollut ion problems.

9. Transport Systems

Proper parking places should be provided for the trucks and other vehicles by the

industr ies to avoid any congestion or blocking of roads.

Sit ting of industr ies on the highways should be avoided as it may add to more road accidents because of substant ial increase in the movements of heavy vehicles and

unauthor ized shops and sett lements coming up around the industr ial complex.

Spillage of chemicals/ substances on roads inside the plant may lead to accidents. Proper road safety signs both inside and outside the plant should be displayed for

avoiding road accidents.

10. Recovery - reuse of waste products

Effor ts should be made to recycle or recover the waste mater ials to the extent possible. The treated liquid effluents can be convenient ly and safely used for

ir r igation of lands, plants and fields for growing non-edible crops.

11. Vegetal Cover

Industr ies should plant trees and ensure vegetal cover in their premises. This is

par t icular ly advisable for those industr ies having more than 10 acres of land.

12. Disaster Planning

Proper disaster planning should be done to meet any emergency situation ar ising

due to fire, explosion, sudden leakage of gas etc. Firefighting equipment and other

safety appliances should be kept ready for use dur ing disaster/ emergency situat ion

including natural calamities like ear thquake/ flood.

13. Environment Management Cell

Each industry should ident ify within i ts setup a Depar tment/ Sect ion/ Cell w ith

trained personnel to take up the model responsibi li ty of environmental

management as required for planning and implementation of the projects.



12.2. ENVIRONMENTAL MANAGEMENT DURING OPERATION OF CETP

The common effluent treatment faci li ty w ill compr ise of following stages

Pr imary Treatment

Physico-Chemical Treatment

Biological Treatment Ter t iary Treatment (Disinfection using Chlor ination and Filt ration) .

On line monitor ing system for var ious parameters such as pH, TOC and DO is provided.

However , for smooth operat ion and to achieve the treated effluent quality, regular

monitor ing of the plant is very much required. The samples from different stages of t reatment should be collected and analyzed as per details given in the table. Samples will

be analyzed in the CETP laboratory & record will be maintained in the Log-book.



LIST OF PARAMETERS & SAMPLING POINTS LOCATION.

D=Daily. M= Monthly. All parameters in mg/ l except pH, temperature & SVI

Sampling Point Equalization

Tank

Primary

Clarifier

Outlet

Aeration /

SBR Tank

Secondary

Clarifier

Outlet

Pre-filtration

Water

Storage Tank

Final

Treated

Effluent for

Disposal

Tube well-

Fresh Water

samples for

HHSEHS

Parameter

Oil & Grease Thrice/ week Thr ice/ week Thr ice/ w eek Once/ week

pH D D D D D D Once/ week

Temperature D D D D D D Once/ week

COD D D D D M

BOD Twice/ week Twice/ week Twice/ week Twice/ week Twice/ week Once/ week M

TSS D D D Twice/ week D M

NH3-N Once/ week Once/ Month Once/ Month Once/ week M

Total-P Once/ week Once/ Month Once/ Month Once/ week M

SVI Thr ice/ week



In addition to environmental monitoring plan for the CETP, for successful operation and maintenance of CETP it is very essent ial that CETP receives waste water which is w ithin the

parameters selected for design of CETP. In order to control the inlet parameters of CETP it is very essent ial for the regular monitor ing of industr ies discharging into CETP. It is also

essential to carry out regular sampling, surpr ise sampling of discharge waste water from each member industr ies on 24 hours basis.

If industr ies are found discharging more than the specified inlet parameters of CETP, it

must be brought to notice of industry and they should be given notice for controlling their outlet parameters. On repeated occurrence of such incidence they should be disconnected

t ill compliance is achieved. This clause must be added in the membership agreement w ith

the CETP.

*****



CHAPTER-13

CONCLUSION

13.1. CONCLUSION

It is evident from the Feasibi li ty study finding that the effluent generated from the industr ial estate/ area is highly polluted and it is not fit for direct discharge on land or sur face water . There is no wastewater treatment plant at the individual industry level.

Since the industr ies are small and medium scale, they cannot afford to have cost effective Effluent Treatment Plant (ETP) to meet the discharge standard st ipulated by the Bihar

State Pollution Control Board. Therefore, i t is very much essential to set up a Common Effluent Treatment Plant (CETP) to treat the wastewater generated from all the industr ies

in the industr ial area in a cost effect ive way. There is no dedicated sewerage line for the

conveyance of domestic wastewater which would be treated along with the city domest ic wastewater in the terminal Sewage Treatment Plant (STP). Therefore, i t is proposed to

treat domest ic as well as Trade Effluent in the proposed CETP.

The storm water dur ing the rainy season creates water logging in the industr ial area due to absence of storm water drainage system. The storm water gets mixed with the hazardous

and solid waste generated from the industr ies which are being disposed nearby the

boundary of the industr ies. There is no proper collect ion of Solid and Hazardous waste generated from the industr ies. Due to poor Hazardous and Solid Waste Management an

addit ional highly polluted wastewater stream generated dur ing the rainy season which are harmful to the soil as well as ground water and sur face water . Therefore, there is a need of

proper collect ion and treatment of Solid and Hazardous waste from the industr ial area. Since there is no Common Hazardous Waste Treatment Storage Disposal Facili ty (TSDF)

exists in Bihar , it is suggested to have TSDF facili ty for proper Handling of Hazardous Waste as per Hazardous Waste Management & Handling Rules of CPCB. Also it is very impor tant to have separate proper storm water drainage system in the industr ial area. As

per discussion with BIADA, they are already in process to construct Drainage Facili ty in the Industr ial Area.

The treated effluent from the recommended Common Effluent Treatment Plant (CETP)

shall be par t ially used for hor t iculture, chemical solution preparation in the CETP itself, for construct ion of the Civil works in the nearby locality ( those who opt to collect from the CETP), par tially for Automobile service station and water ing on the road side to reduce the

fresh water consumption and sustainabili ty of the environment. The residual part shall be disposed in the nearby drain which will ult imately meet to the r iver .



Bela, Muzaffarpur Industr ial Area has been dominated by Tannery Cluster and contr ibute about 40% of the estimated wastewater discharge. The tannery effluent is having very high

value of Total Suspended Solids and their wastewater is having highly acidic and highly alkaline streams. In order to avoid damage of the conveyance system and clogging, i t is

recommended to have Pre-treatment unit at the individual industry level. The scheme for the Pre-treatment has already been discussed in Chapter 10.

The projected wastewater generat ion from the industry to be allowed in future in the

vacant or cancelled plot would also be worked out in the Draft Project Repor t so that the quant ity of the wastewater would not be exceeded than the recommended capacity of the

CETP. The change in the production or expansion in the existing product ion capacity by the

individual industry would be only allowed after due consent from the BIADA.

The Capital Expenditure for sett ing up of the CETP would be shared by Central Government, State Government and Entrepreneur of the industr ial area. The operat ing

expenses would be borne by the Entrepreneur based on shar ing of quantum of flow and pollut ion load generated from the individual industry.

As per the EIA not ificat ion 2006 issued from Ministry of Environment & Forests, sett ing up

of CETP in the designated Industr ial Area requires Environmental Clearance under Category “B”. Therefore there is a need to obtain Environmental Clearance from State Level Environment Impact Assessment Author ity (SEIAA)/ Bihar State Pollut ion Control Board.

For this, the detai led study is required for Environment Impact Assessment (EIA).

Therefore, it is recommended to star t the EIA study after finalizat ion of Draft Repor t.

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