Yanbu WwTW (Saudi Arabia)

Imran Baloch
28 June 2016
Contents
Project scope

Design criteria

Process units description

Plant performance

Conclusions
Project
PROJECT TITLE:
Yanbu WwTW Rehabilitation and Expansion (Kingdom of Saudi Arabia)

CLIENT:
Marafiq - Power and Water Utility Company in Yanbu and Jubail (Kingdom
of Saudi Arabia)

JACOBS ROLE:
Project Management Consultant
(including scope of works, bid management,
contract documents, engineering support,
construction supervision)

CONTRACT:
Type: Engineering, Procurement & Construction
(Client Bespoke Contract)
Engineering Main Responsibilities
Review of Client Basis of Design
Design parameters and conditions

Front End Engineering Design and Scope of Works

Basis of design, technology selection, optioneering, engineering design and
preparation of bid documents

Bids Evaluation and Clarification Meetings

RFIs, meetings and site visits in KSA

Engineering Review in Saudi Arabia, Korea, UK

Contractor design, HAZOP, EIA, fire protection etc.

Support to Jacobs Site Team

Commissioning & Performance Testing

Project Scope
Yanbu WwTW (domestic or sanitary) to provide design capacity for an
average flows of 47,000m3/d with treated effluent complying with Royal
Commission Environmental Regulations (RCER) Irrigation discharge
and Red Sea standards

Irrigation Discharge Quality NH4-N NO3-N

(selected parameters) BOD COD TSS Turbidit TKN TP
(mg/l) (mg/l) (mg/l) y (NTU) (mg/l) (mg/l)
(mg/l) (mg/l)
Average
RCER Irrigation N/A N/A N/A 2 N/A 35 N/A 20
Limit
Discharge Quality
Maximum
Irrigation Discharge Quality also requires minimum FRC of 0.5 mg/l
Consent 10 50 10 5 5 60 10 30
Limit

Red Sea Discharge Quality BOD COD TSS Turbidit

NH4-N
TKN
NO3-N
TP
(selected parameters) (mg/l) (mg/l) (mg/l) y (NTU) (mg/l) (mg/l)
(mg/l) (mg/l)
Average
RCER Red Sea 15 75 25 8 1 5 1 1
Limit
Discharge Quality
Maximum
Project Scope (cont.)
Process sampling survey to define design process parameters for
crude sewage (i.e. BOD, COD, TSS, ammonia, TKN etc.)

Design flows
Criteria Unit Flow rate Comments
Design average flow. The design include a
factor of 1.15 x average daily flows, referred as
maximum daily flows (54,050 m3/d). The
Daily average /d 47,000 process units downstream of Equalisation
Tanks are designed to treat average and
maximum daily flows.

2.4 x of average daily flows.

Peak hourly /hr 4,700 Process units are designed to handle this flow
up to Equalisation Tanks

Out of service conditions (equipment, tanks)

Yanbu WwTW (Original Plant)
Built in 1982 with a design capacity of 27,000m3/d

Effluent quality compliance based on old environmental quality standards

of RCER for Irrigation discharge standards only

Original Plant

Location of newly built Yanbu WwTW

Simplified Process Flow Diagram (Proposed Plant)
New Refurbished Refurbished
units units and Expansion

Wastewater Stream
Inlet Screens Primary Biological Treatment Secondary
Equalisation
pumping Grit Settling (4 stage Bardenpho Settling
Tanks
Station removal Tanks process ) Tanks

Chlorine
Dosing
Chlorine Plant Irrigation via Existing Emergency
Sand
Contact Irrigation Storage Tanks Storage
Filters
Tanks Do Tank
Conditioning Red Sea
Tanks

Sludge Stream (NOT DISCUSSED IN THIS PRESENTATION)

Belt Aerobic Gravity Belt
Presses Sludge cake for disposal
Thickeners Digesters Thickeners
 Yanbu WwTW (Jan 2016)
DO Conditioning
Aerobic Tanks
Chlorine Contact
Digesters Pressure
Tanks Chlorination Building
(new and Filters (refurbished)
refurbished)

Sludge
Thickening &
Dewatering Irrigation
Storage
Tanks
Primary (existing)
Settlement
Tanks
(refurbished)

Inlet
Pumping
Station
(refurbished)
Secondary
Equalisation Biological Process Settlement
Inlet Screens Tanks Tanks Emergency Storage
Also there are number of pumping stations, tanks, blowers
Grit Chamber and other miscellaneous items not highlighted above
Tank
 Flows (Measured at Equalisation Tanks Outlet, m3/d)
EQT Outflow
35,000

30,000

25,000
m3

20,000 EQT Outflow

15,000

10,000

5,000

-
42436 42438 42440 42442 42444 42446 42448 42450
42435 42437 42439 42441 42443 42445 42447 42449 42451

Average flows ~ 25,000 m3/d (during commissioning and

performance testing)
There is a proposal to discharge additional flows of 15,000
m3/d
Inlet Pumping Station 2 duty / 1 standby
Each pump rated at 668 l/s

Inlet Pump Station B (pumps B and C)

Inlet Pump Station B (overflow to
emergency storage tank)
All site returns (liquors from sludge processing units, tanks drainage,
emergency storage tank return are discharged into inlet pump station except
dirty backwash water from pressure filters
Inlet Pumping Station (cont.)

Bypass pump station (inlet pump A)

Inlet Pump Station C (pump D)
Inlet flows 24 hr profile 2016 (prior to
Equalisation Tanks)
m3
Inlet Screens

4 No. 6 mm HUBER fine screens with two bypass channels

Inlet screens are designed to handle peak hourly flows
Inlet Screens (cont.)

Parameter Measured Criteria

Average TS% of compacted
screenings 51% > 45% TS
Aerated Grit Chambers

2 No. units
Aerated grit chambers are designed to handle peak hourly flows
Site can operate with only one grit chamber in operation
Aerated Grit Chambers (cont.)

3 No. roots blowers (2 duty/1

Scum removal standby when two grit
chambers are operating)
Grit Classifier

Parameter Measured Criteria

Average TS% of grit 93% > 80% TS
Average VS% of grit 1% < 10% VS
Equalisation Tanks

2 No. tanks with jet mixing and pass forward pumps

The Equalisation Volume is derived based on providing 2hr
storage at peak hourly flows of 4,700m3/hr
All process units downstream of equalisation tanks are designed
to handle average and maximum daily flows
Equalisation Tanks (cont.)

4 pass forward pumps in each tank 4 jet aerators in each tank

(3 duty/1 standby)
Equalisation Tanks Outlet 24 hr flow
profile 2016
m3
Primary Settlement Tanks

4 existing horizontal flow rectangular PSTs

Refurbished units
Primary Settlement Tanks (cont.)

Primary settlement tanks efficiency measured during performance

acceptance testing:

TSS removal of 45%

BOD removal of 30%
Biological Treatment (Four Stage Bardenpho
Process)

Biological tanks consists of:

3 No. anoxic tanks
10 No. aerobic tanks
3 No. post-anoxic (inc. swing lane) tanks
1 No. post aerobic polishing tank
Anoxic Tanks

3 No. tanks or lanes

Designed to achieve 6-7 mg/l nitrate nitrogen on irrigation mode with 3 hrs
retention time
Each anoxic tank is equipped with two mixers to avoid settlement of solids
Anoxic Tanks (cont.)
Diffuser Density in 10 No. Aeration
Tanks

First zone Second zone Third zone

Diffuser density in first zone of aeration tank is 50%, 30% in second zone
and 20% in third zone

Diffusers were tested for their SOTE(%) at test facility clean water oxygen
transfer test
 Aeration Tanks

Aeration tank Post anoxic tank

(swing lane, i.e.
can be operated
as aeration tank)
10 No aeration tanks
Biological process (with secondary settlement
tanks) designed to achieve BOD, COD, TSS,
ammonia and TKN removal of >90%
Design operating MLSS 3,500 mg/l
Turbo Blowers for biological tanks

4 Siemens turbo blowers (3 duty/1

standby)
Turbo Blowers for biological tanks (cont.)
RAS and Internal Recirculation Pumps

RAS - 7 pumps (5 duty / 1 standby)

Internal Recirculation - 4 pumps (3

duty/1 standby)
Secondary Settlement Tanks

4 No. radial flow tanks

Each tank - 30m diameter, 3.7m side wall depth
Design solids loading 5 kg/m2/hr
Design surface loading rate of 18 m3/m2/d
Secondary Settlement Tanks (cont.)
Pressure Filters

11 No. pressure filters, each 2.4m diameter and 9.4m long

Single sand media
Design based on nine in operation with one backwashing and one out of service
Design maximum filtration rate of 12.25 m/hr with 9 units in operation
Pressure filters (cont.)

Pipework arrangement
Pressure filters (cont.)

Pressure filters pressure differential and turbidity meter

Backwash pumps and blowers

3 No. backwash blowers (2duty / 1 2 No. backwash water pumps (duty /

standby) standby)
Performance of pressure filters (measured
during performance testing period)

Performance measured during 6 March 2016 12 April 2016

Secondary Settlement Pressure Filters Pressure Filters

Tanks Effluent Effluent Performance
TSS Turbidity % TSS % Turbidity
Turbidity (NTU) TSS (mg/l)
(mg/l) (NTU) removal removal
Averag
12.9 7.5 1.6 1.1
e 88 85
Maximu
36 24.8 2.8 1.7
m
Backwash Water & Chlorine Contact
Tanks

2 No. backwash tanks to hold filtered effluent from pressure filters. This is to
provide filtered effluent for a minimum of two backwashes
2 No. chlorine contact tanks to provide minimum of 30 mins chlorine contact time
Chlorine Contact Tanks
DO Conditioning Tanks (required for Red Sea
discharge)

2 No. tanks to achieve minimum DO levels of 5 mg/l for Red Sea discharge
standards
Tanks provide retention time of ~ 30 mins
DO Conditioning Tanks (cont.)
Emergency Pumping Station

Collects emergency overflows from inlet pumping

station and other tanks
Consists of high level emergency overflow to
mitigate for pumps failure which pump into
emergency storage tank
Emergency Storage Tank

To provide 4 hr storage at design average flow conditions

Tank equipped with 4 No. surface aerators
Contents are discharged back to inlet pumping station
Chemical Dosing for Red Sea Discharge

Alum dosing for phosphorus removal Methanol dosing for nitrate nitrogen removal

Dosed at the outlet of biological Dosed on the feed to post anoxic tanks
tanks (i.e. feed to secondary
settlement tanks)
Irrigation to Red Sea control mode
Sludge Cake

Sludge cake dry solids is >20% after belt presses

About 12 m3 of sludge cake is produced on current operating conditions
Odour Treatment

Odour treatment for sludge building, pre-thickening sludge

storage tank and thickened sludge storage tanks
Sampling Performance Acceptance
Testing
Performance Testing March / April 2016
(No. of units in operation)

The testing was done with following number of

main units in operation to mimic design conditions:

2 No. Primary Settlement Tanks

Biological Tanks:
2 No. anoxic tanks
4 No. aerobic tanks
2 No. post anoxic tanks
2 No. Secondary Settlement Tanks
6 No. Pressure Filters
Performance Acceptance Test (Final
Effluent)
Red Sea Discharge Quality (6 March 2016 24 March 2016)
NH4-N NO3-N
BOD COD TSS Turbidit TKN TP
(mg/l) (mg/l) (mg/l) y (NTU) (mg/l) (mg/l)
(mg/l) (mg/l)
Meausred Final Average 1.9 16.6 1.6 1.0 0.6 1.7 0.9 0.6
Effluent Quality Maximum 3.3 41.4 2.6 1.5 0.9 2.4 2.6 1.1
Average
RCER Red Sea 15 75 25 8 1 5 1 1
Limit
Discharge Quality
Maximum
Consent 25 150 40 15 3 10 10 2
Limit
Irrigation Discharge Quality (25 March 2016 12 April 2016)
NH4-N NO3-N
BOD COD TSS Turbidit TKN TP
(mg/l) (mg/l) (mg/l) y (NTU) (mg/l) (mg/l)
(mg/l) (mg/l)
Meausred Final Average 1.0 14.6 2.1 1.40.5 0.7 4.7 1.7
Effluent Quality Maximum 2.8 29.6 3.5 1.91.0 1.5 7.6 2.0
Average
RCER Irrigation N/A N/A N/A 2 N/A 35 N/A 20
Limit
Discharge Quality
Maximum
Consent 10 50 10 5 5 60 10 30
UK Standards ComparisonLimit
/ Trend
UWWTD: BOD = 25mg/l, COD = 125 mg/l, although BOD consents are moving below 10mg/l
TP of 1 or 2mg/l is common but its moving to 0.1 to 0.6mg/l
Ammonia is moving towards 1mg/l
Generally no consent on NO3-N but few sites have TN consent of 10mg/l
Conclusions

Yanbu WwTW was fully commissioned in April 2016

The plant is successfully complying with environmental quality standards

for Red Sea and Irrigation discharge standards

Jacobs input from scope of works to final commissioning provided a

significant contribution to the success of the project

Any Questions?