wwmt-d1s2.3 -malaysia’s experience in upgrading existing wastewater treatment plants by ir....

8/3/2019 WWMT-D1S2.3 -Malaysia’s Experience in Upgrading Existing Wastewater Treatment Plants by Ir. Mahesan Kandiah

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“Malaysia’s Experience inMalaysia’s Experience inUpgrading Existing Wastewaterpgrading Existing Wastewaterpgrading Existing Wastewaterpgrading Existing Wastewater

Treatment Plants”reatment Plants”

Presented By:

h d hr. Mahesan KandiahSenior General Manager

Indah Water Konsortium Sdn. Bhd.



Governance Structure of Sewerageovernance Structure of Sewerage

Serviceservices

Ministry of Finance

Ministry of Natural

Resources &Environment

Ministry of Energy,

Green Technology &Water

• 100% Equity

Regulator of Regulator of

• Govt. SupportLoan & Subsidy

SewerageServices

gEffluent

Standards

1. Sewerage Services2 Operator in 88olicy & Control 2. Operator in 88

Local AuthorityAreas.

3. Sewerage ServicesBilling & Collection.

4. Undertakes

Policy & Controlof NationalSewerageAgenda

Refurbishment/Upgrading Projects

Funded by Govt. 2



IWK at a GlanceWK at a Glance

9,347 Public Sewage Treatment

Plants

IWK covers most parts of Malaysia for operation andmaintenance whilst providingtechnical expertise to the

826 Network Pump Stations

remaining un-service area.

14,825 km Pipelines

As at September 2011, IWK served a population equivalent of about 23 million users & responsible for operating & maintaining 9,347 STP, 826NPS & 14,825 km sewer networks. Provide responsive desludging services to 1.8 million IST / Pour Flush.

•IWK TOTAL OPERATIONAL AREA AND POPULATION SERVED

•AREA•(Sq. Km)

•% •POPULATIONEQUIVALENT

(PE)

•%

3

•IWK •68,505.88 •51.79 •19,333,568* •72.42

•NON-IWK •63,769.54 •48.21 •7,361,729 •27.58

•TOTAL •132,275.42 •100.0 •26,695,297 •100.0



Indah Water Services

O i & M i P bli S Speration & Maintenance Public Sewerage SystemsProvide regular and scheduled operation and maintenance of 14,342 km of public sewers,778 pumping stations and 5,605 public sewage treatment plants within service areas.Provide corrective and preventive maintenance of public sewers, network pump stations,

sewage and sludge treatment facilities to meet the regulatory requirements.

S i T k D l d i S ieptic Tanks Desludging Services

Scheduled desludging services for government offices’ communal septic tanks andresponsive desludging of communal and individual septic tanks.

Sewerage Capital Works and Refurbishment Management

Research and Development (R&D) Works in Sewerage SectorIn-house R&D works and Continuous Improvement Projects, External Vendor Led R&D,

’

Sewerage project management, monitoring on compliance of capital works andrefurbishment of national and regional sewerage projects.

, .

Sewerage Technical and Operational Skills TrainingProfessional technical and non-technical training on sewerage planning strategy,engineering, environmental monitoring and analysis, operational, preventive maintenance,health and safety in sewerage systems, etc. Local and international training on sewerage

management an operat on ma ntenance.

Sewerage Technical and Environmental Services / Consultancy Works

•International consultancy on sewerage management, policy, public awareness, etc.

•Conduct audit of sewerage systems/company’s (international projects, Indonesia, MiddleEast, etc)

4

•Hazard and Operability Study (HAZOP studies) for water and wastewater industries



Evolution of WW Treatment Technologies involution of WW Treatment Technologies inMalaysiaalaysia

Technologyrior to1950-s

Year950-s 1970-s 1980-s 1990-s 2000960-s

Pour Flush

Septic Tank

Imhoff Tank

OP/AL Activated Sludge/Biological Filters

Fully MechanisedPlant

Year950 s 1970 s 1980 s 1990 s 2000

Primitive/PrimaryTreatment

Partial/ Full Secondarytreatment

1960 s

Address PublicHealth

Address RiverPollution

AddressEnvironment

FutureTertiary

Treatment

Health Pollution Environment



Sewage Discharge Qualityewage Discharge QualityUpstream Of Water Intake

(Standard A)Downstream Of Water Intake

(Standard B)

Water SupplyDistribution

Reservoir

Water TreatmentPlant

CollectionOf Sewage

Category 1 (Rivers)ategory 1 (Rivers) Temp PH BOD COD SS NH3N NO3N P O&G

Standard A 40 6-9 20 120 50 10 20 n/a 5

Standard B 40 5.5-9 50 200 100 20 50 n/a 10

Category 1 (Lakes)ategory 1 (Lakes)

Standard A 40 6-9 20 120 50 5 10 5 5

Standard B 40 5.5-9 50 200 100 5 10 10 10

Category 2ategory 2 Temp PH BOD COD SS NH3N NO3N P O&G

Standard A n/a n/a 20 120 50 n/a n/a n/a 20

Standard B n/a n/a 50 200 100 n/a n/a n/a 20

Category 3ategory 3 Temp PH BOD COD SS NH3N NO3N P O&G

CST n/a n/a 200 n/a 180 n/a n/a n/a n/a

IT n/a n/a 175 n/a 150 n/a n/a n/a n/a

OP n/a n/a 120 360 150 n/a n/a n/a n/aP n/a n/a 120 360 150 n/a n/a n/a n/a

AL n/a n/a 100 300 120 n/a n/a n/a n/a

MP (STD A) n/a n/a 60 180 100 n/a n/a n/a 20

MP (STD B) n/a n/a 80 240 120 n/a n/a n/a 20



WWTP By Group

3,632

4,345

4,000

4,500

5,000

2,000

2,500

3,000

3,500

735

422

2130

500

1,000

1,500

54% of STPs are capable of providing primary and

CST IT OP MP WITH MEDIA MP WITHOUT

MEDIA

Nos.

54% of STPs are capable of providing primary andpartial treatment.

Hence, upgrading is necessary to achieve requiredeffluent standardsffluent standards.



Objective of Upgradingbjective of Upgrading

Main objectives of WWTP Upgrading :

To improve treatment performance ofexisting system in order to comply withstandard requirement (Non compliance totandard requirement. (Non compliance toStandard)

To amplify treatment capacity of system too amplify treatment capacity of system tocater for additional load.

To identify plants which can bep

decommissioned and transfer flows to theupgraded plant. (Rationalization –Economic efficiency)conomic efficiency)



Potential Treatment Systemotential Treatment Systemto be Upgradedo be Upgraded

Bio – Soil (23 Nos.)

Imhoff Tank/Comm. Septic Tank (4,367 Nos.)

Oxidation Pond (432 Nos.)xidation Pond (432 Nos.)

Rotating Biological Contactor (32 Nos.)

Bio Drum (26 Nos ) Bio – Drum (26 Nos.)

Bio Filter (113 Nos.)



Consideration for Upgrading Worksonsideration for Upgrading Works

•to consider orientation of new structure to fit in reserve area

•can only be done if land is surrendered to Government

Land Area Availability/ Land

Status

•parallel with long term Catchment Strategy

•design PE to future growthatchment Strategy

•upgrade to same system (EA, AL, SBR)Existing Process

•upgrade to mechanized system (BS, BF, IT)xisting Process

•<10% PE* increase, no structure change

•Sufficient free board requiredxisting Structure

•calculate existing capacity to determine actual capacityxisting Capacity

•upgrade to fully mechanized plantlant located Above Water

•higher treatment imposedIntake

•joint scheme to have own funding

•SCC discounted based on offset from construction costinancial



Types of Upgrading Worksypes of Upgrading Works

• Major upgrading includes changingsystem type to capture the extra

• Minor upgrading, e.g. smallchange of pumps or retention

• Involves whole STP, e.g. changing of pumps, blowers, new additionalstructure, scrapers, etc.

, ,setting of blower/blowercapacity or extra area of sludgedrying beds and no structural

–usually >10% of existing capacity• The capacity of upgrading

works – usually <10% of

existing capacity

Minor

Upgrading

MajorUpgrading



Upgrading Works Procedures

Procedure currently available

Method Statement LTC if neededInventory List

Method Statement

(QP)

LTC if needed

(UO, DEV)verification (after)

(QP, CA, UO)

Kick Off meeting

(CA, UO, QP)

Periodical Inspections

(QP, CA, UO)

Monthly Progressive

report and effluent

sampling

(QP)

Letter of Undertaking &

Indemnity

(DEV)

Bank Guarantee

(DEV)

Hand over system to SL

(QP, DEV, UO)

Inventory List

verification (before)

Notice of

Commencement of

Works(QP, CA, UO)

(QP)



Bio Soilio Soil

Strategy Proposed:

Due to large area available on existing, most suitableretrofit system is Extended Aeration.

PE < 5,000 economical to convert to Package Plant.



Bio Soil to Packaged STPio Soil to Packaged STP

300

100

150

200

250BOD COD AMM

050

a r -

2 0 0 0

e p

- 2 0 0 0

a r -

2 0 0 1

e p

- 2 0 0 1

a r -

2 0 0 2

e p

- 2 0 0 2

a r -

2 0 0 3

e p

- 2 0 0 3

a r -

2 0 0 4

e p

- 2 0 0 4

a r -

2 0 0 5

e p

- 2 0 0 5

a r -

2 0 0 6

e p

- 2 0 0 6

a r -

2 0 0 7

e p

- 2 0 0 7

a r -

2 0 0 8

e p

- 2 0 0 8

a r -

2 0 0 9

e p

- 2 0 0 9

a r -

2 0 1 0

e p

- 2 0 1 0

a r -

2 0 1 1

Taman Bukit Belimbing STP – Bio Soil to Packaged STP

4,600PE (1,035m3/day)

M S M S M S M S M S M S M S M S M S M S M S M



Bio Soil to IDEA System

300

350

400

BIOSOIL to IDEA Performance for SEN052

50

100

150

200

250

1 7 / 0 4 / 1 9 9 5

0 2 / 1 0 / 1 9 9 5

0 9 / 1 0 / 1 9 9 5

1 4 / 0 3 / 1 9 9 6

2 9 / 0 3 / 1 9 9 6

1 1 / 0 9 / 1 9 9 6

1 2 / 0 3 / 1 9 9 7

2 9 / 0 5 / 1 9 9 7

1 2 / 0 6 / 1 9 9 7

1 3 / 0 8 / 1 9 9 7

0 3 / 1 0 / 1 9 9 7

1 1 / 1 1 / 1 9 9 7

1 1 / 0 2 / 1 9 9 8

1 4 / 0 5 / 1 9 9 8

1 4 / 0 1 / 2 0 1 0

2 8 / 0 1 / 2 0 1 0

0 4 / 0 8 / 2 0 1 0

0 8 / 0 9 / 2 0 1 0

3 0 / 1 1 / 2 0 1 0

1 4 / 1 2 / 2 0 1 0

2 0 / 0 4 / 2 0 1 1

1 4 / 0 6 / 2 0 1 1

2 7 / 0 6 / 2 0 1 1

2 7 / 0 7 / 2 0 1 1

0 9 / 0 8 / 2 0 1 1

2 9 / 0 9 / 2 0 1 1

BS BS BS BS BS BS BS BS BS BS BS BS BS BS IDEA IDEA IDEA IDEA IDEA IDEA IDEA IDEA IDEA IDEA IDEA IDEA

BOD COD NH3N SS

Taman Senawang Indah – Bio Soil to IDEA System1,860PE (418m3/day)



Bio Soil to Extended Aeration System

450

500

BOD COD AMM OG SS

150

200

250

300

350

050

a n

- 2 0 0 0

u l - 2 0 0 0

a n

- 2 0 0 1

u l - 2 0 0 1

a n

- 2 0 0 2

u l - 2 0 0 2

a n

- 2 0 0 3

u l - 2 0 0 3

a n

- 2 0 0 4

u l - 2 0 0 4

a n

- 2 0 0 5

u l - 2 0 0 5

a n

- 2 0 0 6

u l - 2 0 0 6

a n

- 2 0 0 7

u l - 2 0 0 7

a n

- 2 0 0 8

u l - 2 0 0 8

a n

- 2 0 0 9

u l - 2 0 0 9

a n

- 2 0 1 0

u l - 2 0 1 0

a n

- 2 0 1 1

u l - 2 0 1 1

Taman Shamelin STP – Bio Soil to Extended Aeration System

28,000PE 8(6,300m3/day)

J J J J J J J J J J J J



Imhoffmhoff Tank/Communal Septic Tankank/Communal Septic Tank

Strategy Proposed :

Due to integrity of tank structure, space limitation for upgrading.

Approach for effluent to comply Std B., refurbish like-to-like.

With additional loading and/or effluent to comply Std A Upgrading is requiredith additional loading and/or effluent to comply Std. A, Upgrading is requiredwith total demolish of existing system.

Needs to upgrade IT/CST:

Majority partially functioning or disrepair Effluent does not comply to requirement.



Imhoff Tank to Packaged STP

Taman Badlishah STP – Imhoff Tank to Packaged STP

2,500PE (562m3

/day)



Oxidation Pondxidation Pond

Strategy Proposed :

Upgrade to Aerated Lagoon by installing mechanical aeration.

Provision for desludging and baffles to partition the aerobic zoneand settling zone is necessarynd settling zone is necessary.

Confirm depth of existing pond for mechanical aeration device.

Needs to upgrade OP due to :g

Problem encountered such as overloading, algae mats, duckweedcover & bad odor

Increase of loading.



Oxidation Pond to SBR System

250

300

100

150

200

BOD COD NAMM

0

50

- 2 0 0 0

- 2 0 0 0

- 2 0 0 0

- 2 0 0 1

- 2 0 0 1

- 2 0 0 2

- 2 0 0 2

- 2 0 0 3

l - 2 0 0 3

- 2 0 0 3

- 2 0 0 4

r - 2 0 0 5

- 2 0 0 5

- 2 0 0 5

r - 2 0 0 6

- 2 0 0 6

- 2 0 0 6

- 2 0 0 7

- 2 0 0 7

- 2 0 0 7

- 2 0 0 7

r - 2 0 0 8

- 2 0 0 8

- 2 0 0 8

- 2 0 0 8

r - 2 0 0 9

- 2 0 0 9

- 2 0 0 9

- 2 0 0 9

r - 2 0 1 0

- 2 0 1 0

- 2 0 1 0

- 2 0 1 0

r - 2 0 1 1

- 2 0 1 1

- 2 0 1 1

Bandar Tun Razak - Aerated Lagoon to SBR System100,000 PE (22,500m3/day)

F e J u

S e

M a

N o J u

N o

M a J u

N o

N o

A p

S e

D e

A p

A u

N o

F e

M a

S e

D e

M a

J u S e

D e

M a

J u S e

D e

M a

J u S e

D e

M a

J u S e



Aerated Lagoons to Conventional ActivatedSludge System

240270

300BOD COD AMM

90

120

150

180

210

0

30

60

- 2 0 0 0

l - 2 0 0 0

- 2 0 0 1

l - 2 0 0 1

- 2 0 0 2

l - 2 0 0 2

- 2 0 0 3

l - 2 0 0 3

- 2 0 0 4

l - 2 0 0 4

- 2 0 0 5

l - 2 0 0 5

- 2 0 0 6

l - 2 0 0 6

- 2 0 0 7

l - 2 0 0 7

- 2 0 0 8

l - 2 0 0 8

- 2 0 0 9

l - 2 0 0 9

- 2 0 1 0

l - 2 0 1 0

- 2 0 1 1

l - 2 0 1 1

Pantai STP - Aerated Lagoon to CAS System377,000 PE (84,825m3/day)

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l

J a n

J u l



Oxidation Pond to Modifiedxidation Pond to Modified Oxidation Ditchxidation Ditch

600

700

200

300

400

500BOD COD AMM

0

100

a n

- 2 0 0 0

u l - 2 0 0 0

a n

- 2 0 0 1

u l - 2 0 0 1

a n

- 2 0 0 2

u l - 2 0 0 2

a n

- 2 0 0 3

u l - 2 0 0 3

a n

- 2 0 0 4

u l - 2 0 0 4

a n

- 2 0 0 5

u l - 2 0 0 5

a n

- 2 0 0 6

u l - 2 0 0 6

a n

- 2 0 0 7

u l - 2 0 0 7

a n

- 2 0 0 8

u l - 2 0 0 8

a n

- 2 0 0 9

u l - 2 0 0 9

a n

- 2 0 1 0

u l - 2 0 1 0

a n

- 2 0 1 1

u l - 2 0 1 1

J J J J J J J J J J J J

Bayan Baru STP – Oxidation Pond to MOD System

200,000 PE (45,000m3/day)



Rotating Biological Contactor (RBC) tootating Biological Contactor (RBC) toRotating Biological Disc (RBD)otating Biological Disc (RBD)

Taman Puteri Gunung STP – RBC to RBD System5,000PE (1,125m3/day)



Bio Drum to Bi Act Systemio Drum to Bi Act System

Taman Jentayu – Bio Drum to Bi Act System

1,477 PE (332m3/day)



WWTPs Upgrading Cost/PE

6000

STP Upgrading Cost

4,348 4,500

4,6004,605

5,025

4000

5000

2,6002,900

3,500,500

2000

3000

COST

593 614

473

835

1,090

1,532

251244

320440

450

450600

1,0501,100

1,250

1,675

1,7001,800

1,800

1000

2000

473 244295

440 450

0

80

30

20

10

10

60

20

10

15

18

23

19

16

12

13

14

12

12 8 8 8 6 7 6 6 6 6 5 5 5

PE



STP Undergone Upgrading Works

1840

ANNUAL CAPEX OF STPs UPGRADING WORKS

22.4

33.717

13 12

14

16

25

30

35

s ( R M )

P s

19.8

15.0

19.6

11.9

9.6

7

11

10

6

8

10

15

20

r a

d i n g C o s

M i l l i o n

N o .

o f S

3.7 3.3

1

4 4

3

0

2

4

0

5

2002 2003 2004 2005 2006 2007 2008 2009 2010

U p

70 STPs were upgraded with a total cost of RM140 million. Additionalt f RM2 Billi ll t d t d 13 j STP d th

CAPEX Upgrading Cost (RM) No.of STP

cost of RM2 Billion was allocated to upgrade 13 major STPs under theJBIC Loan.

To date about 100 Nos. of non performance STPs were upgraded to abetter system



Sludge Managementludge Management

Trenching System(25 Sites)

Drying Beds(3 Sites)

Lagoon System(1 Site)

Mobile Dewatering Unit

(21 Sites)

Integrated Sludge Reception(4 Sites)

Geotube(5 Sites)



Interim Treatment Using Microbe,nterim Treatment Using Microbe,Enzyme & Chemicalnzyme & ChemicalInterim dosage to improve STP performance pending STPupgrading

Treatment cost is in the range of RM1/PE to RM3/PE



Annual O&M Costnnual O&M Cost

2,677,5661,846,506 2,179,733 2,177,379

5,935,2740,000,000

No. of STP by Plant Type and Cost/PE

75,740114,258

417,802

123,592143,306

367,252

59,487

117,927

444,807

100,000

1,000,000

1,000

10,000

10

100

OP AL BS CST IT TF AS BF SBR BD OD RBC IDEA EA

Nos of plants 109 165 23 3632 166 41 163 113 178 27 176 32 56 3010

PE 75,740 2,677,5 114,258 417,802 123,592 143,306 1,846,5 367,252 2,179,7 59,487 2,177,3 117,927 444,807 5,935,2

O&M Cost per PE (RM) 5.50 7.18 9.47 11.80 13.07 14.75 15.24 16.48 18.21 19.57 20.50 24.84 26.22 29.89

1



Creating Value for Seweragereating Value for SewerageDevelopmentsevelopments

- R&D Findings for Operational, Environmental & Socio&D Findings for Operational, Environmental & Socio-Economic Benefitsconomic Benefits

Technology(e.g: Sewerage systemimprovement, Energy Efficiency& Savings)

Solutions(e.g: Sewage by-productsrecycling & environmentalassessment)

-Evaluation(e.g: Social study, economicevaluation of treatment

system

Technical Training Certification & R&DTechnical Training, Certification & R&D

Training(e.g. O&M of sewer network,

STP equipment Maintenance

ons ruc onContractors Training(e.g: M&E of STP construction,

Health & Safety)

(e.g: Planning & DesignSewerage System, NutrientRemoval Process, CCTV

Training, )



Summaryummary

Upgrading of WWTP focused on the non-compliance WWTP tomeet effluent quality standard and operation & maintenancerequirements.

Upgrading of WWTP has improved efficiency and productivityof WWTP.

Upgrading of WWTP was implemented largely using theexisting plant structure through detail engineering study.

e upgra e as a so a owe e ac y o an eadditional capacity without violating effluent dischargequality.

Upgrading was able to reduce the nos of WWTP throughrationalization of nearby WWTP.

.



THANK YOUHANK YOUmahesan@iwk com myahesan@iwk com [email protected]@iwk.com.my

wwmt-d1s2.3 -malaysia’s experience in upgrading existing wastewater treatment plants by ir....

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