THE ART & SCIENCE OF WASTEWATER TREATMENT ClariMax Inclined Plate Clarifier Installation, Operation & Maintenance Manual
TABLE OF CONTENTS 1.1. WARRANTY 3 1.2. INSPECTION 3 1.3. STORAGE 3 1.4. ADDITIONAL INFORMATION 3 2. INSTALLATION 4 2.1. TOOLS REQUIRED FOR INSTALLATION 4 2.2. LIFTING THE UNIT 4 2.3. ANCHORING AND LEVELING OF EQUIPMENT 4 2.4. PLUMBING CONNECTIONS 5 3. SLUDGE AUGER 6 3.1. Sludge Auger INSTALLATION 6 4. Plate Pack INSTALLATION 10 5. Partition Wall INSTALLATION 10 6. Effluent Trough INSTALLATION 12 6.1. Effluent Trough ADJUSTMENT 13 7. ELECTRICAL CONNECTIONS 14 8. MECHANICAL 14 9. PRINCIPAL OF OPERATION 14 9.1. SLUDGE REMOVAL 14 9.2. EFFLUENT QUALITY 15 10. MAINTENANCE 15 10.1. COATING MAINTENANCE 15 10.2. RECOMMENDED PERIODIC MAINTENANCE TABLE 16 2
PREFACE The information found in this manual is based on years of experience with the installation, operation and maintenance of this type of equipment, however it is intended only as a guide. The methods that are available to you may require other, more appropriate procedures for the proper installation of this equipment. Proper care and safety should always be paramount. Use only qualified technicians and procedures in compliance with local building codes. 1.1. WARRANTY warrants its equipment to be free from defects in materials and workmanship for a period of one year from startup or 16 months from shipment, whichever occurs first. All component manufacturer s warranty will supersede this warranty and shall take precedence. HYDRO-FLO TECHNOLOGIES, INC. will not accept any back charges for warranty work, changing, adjusting, servicing or any other work that has not received advanced written authorization. HYDRO-FLO TECHNOLOGIES, INC. will grant authorization for the changing, adjusting or servicing of this equipment only in the interest of warranty repair, or to correct any deficiency discovered. Such work will only be considered upon written agreement from to do so. 1.2. INSPECTION Thoroughly inspect all equipment upon arrival. If any items are missing or damaged, note this on the shipping papers and contact your transportation company representative and HYDRO-FLO TECHNOLOGIES, Inc. immediately. Touch up all coatings damaged during shipment immediately. See the specification information for this particular piece of equipment for proper procedures for coatings touchups. 1.3. STORAGE If you are not ready to install the equipment upon arrival, store it in an area away from traffic. The ground should be level and free of any sharp objects that might damage the structure or coatings. Store the equipment with all factory packing intact as much as possible until ready for installation. Store the equipment out of the elements, preferably indoors. If this is not possible, make sure the equipment does not fill with water and debris. Verify that ancillary components (accessories, pumps, instruments) were not shipped inside the unit prior to outdoor storage. If components were shipped inside of the unit, insure that they are stored in a manner that is appropriate with their respective I, O & M manuals. For outdoor storage, we recommend you cover the equipment with a tarp! Store any pumps and other accessory items in a similar fashion. 1.4. ADDITIONAL INFORMATION For additional information that may be required for this installation or for answers to any questions you might have, contact: 3
Hydro-Flo Technologies. 3985 Commerce DR. St Charles, IL 60174 Tel: (630) 762-0380 Fax: (630) 762-0390 2. INSTALLATION CAUTION! Prior to off-loading and installation of equipment, study the general arrangement drawing(s) and make yourself familiar with all aspects of the installation, operation and maintenance of this equipment. 2.1. TOOLS REQUIRED FOR INSTALLATION Crane for offloading and placing Masonry drill with masonry bit set for the installation of the equipment anchors (if applicable). Standard socket set, wrench set and miscellaneous drift pins for the installation and adjustment of the effluent weir. Carpenter's level for leveling width of unit. Machinery shims and grout for leveling the unit 2.2. LIFTING THE UNIT Warning: Unit must be empty (no water) when lifted! All units are designed to be lifted vertically and moved into place. Always lift the unit with a spreader bar to prevent damage to the float skimmer system. Attach lifting cables directly to all lifting eyes on the unit. Check load balance and readjust if required. 2.3. ANCHORING AND LEVELING OF EQUIPMENT For the Clarifier to operate correctly the unit must be level. Steps for anchoring and leveling of the equipment are as follows: Make sure that the ground is free of any sharp objects that might damage the coating. Set the tank in position on a level floor or pad. If the floor or pad is not level, use a good quality machinery grout to level the unit after drilling and installing the anchor bolts. Follow the grout manufacturer s instructions for shimming and grouting when leveling the unit. Mark the anchor bolt locations. 4
Move the equipment aside and drill holes for the anchors of your choice. Install the anchor bolts per the manufacturer's recommendations. We recommend using, as a minimum, 3/4" diameter x 4" - 6" long embedment type anchor bolts. Check local codes for seismic or other anchoring requirements. *HYDRO-FLO TECHNOLOGIES does not supply the anchor bolts. Note: If grouting is required, the height the anchor bolts extends above the surface must be increased to compensate for the thickness of the grout layer. Set the unit back in place. Level the unit from side to side by placing a good quality level on top of the fixed effluent weir wall. Level the unit from influent end to effluent end by using the clear tubing filled with water. Level the unit so that the water in the clear tubing on both ends is at the top of the flange radius. Check level at several points on each end. Securely tighten anchor bolt nuts. 2.4. PLUMBING CONNECTIONS The plumbing connections typically required for the installation of a Clarifier unit include but are not limited to: influent, effluent, sludge draw off and effluent chamber drain. Please refer to the instructions below and your project specific drawings for details. When making plumbing connections to the unit, the plumbing must be properly supported to carry the weight of the plumbing when full of water. Damage caused to this equipment by improperly supported plumbing will void the warranty. Connections do not have to be made in the order listed below. Review your situation and make the plumbing connections in the most logical order for your installation. The fittings on the unit are not designed to support a load due to connecting piping. When making connections to the unit, do not use the unit as a pipe support. All plumbing connections should be properly supported so as not to add stress to the unit s fittings. HYDRO-FLO TECHNOLOGIES, INC. cannot honor a warranty for tank failure due to improperly supported piping or incorrect installation. 2.4.1. CONNECT THE EFFLUENT PLUMBING The effluent plumbing must be the same size or larger than the nozzle size on the equipment. Do not reduce the size of the effluent piping as this might cause hydraulic overloading of the equipment. Also, try to run the discharge piping as short a distance as possible, through as few changes of direction as possible and at a pitch of not less than 1/16" per foot. 2.4.2. CONNECT THE INFLUENT PLUMBING The influent plumbing must be the same size as the nozzle size on the equipment for a minimum of 20 pipe diameters. Do not reduce the size of the influent piping as this might cause inappropriate velocities before it enters the unit. Also, try to run the inlet piping as 5
short a distance as possible, through as few changes of direction as possible and at a pitch of not less that 1/16" per foot. 2.4.3. CONNECT THE SLUDGE DRAW-OFF PLUMBING Connect a valve to the sludge draw-off flange and run a short length of pipe to a place where the sludge can be periodically decanted. When selecting a valve make sure that it is suitable for use with the type of sludge collected in your unit. Plumb up all sludge draw off nozzles for best evacuation of accumulated sludge. This includes the fittings on both sides of the sludge hopper. 3. SLUDGE AUGER If the unit comes equipped with a sludge auger/thickener device it will be powered by an electric motor connected to a gearbox for speed reduction to the auger shaft. The gearbox is maintenance free and may be mounted in any position. The auger shaft enters the tank directly adjacent the auger drive motor. The shaft incorporates a stuffing box type seal with a compression gasket and two mounting studs with gland seal nuts. The stuffing box seal will wear over time and begin to drip excessive water. The stuffing box seal will require tightening of the gland seal nuts to reduce leaking. When you tighten the gland seal nuts you must tighten them no more than ½ turn each and check for leaking while the shaft is turning. Never tighten more than ½ turn without checking for leaking. 3.1. Sludge Auger INSTALLATION The sludge auger /thickener rotates on 3 types of shafts, bearing assemblies. First is the end shaft assembly. It consists of the following components... Next is the intermediate shaft assembly. It consists of the following components... 6
Last is the driven shaft assembly. It consists of the following components... When assembling the auger, follow these basic guidelines... Always use anti-seize on all hardware. Assemble the auger starting with the end shaft followed by the intermediate shafts and finishing with the driven shaft. DO NOT assemble the thickener paddles until all the shafts and auger tubes are in place. DO NOT install the auger drive until the entire auger is assembled and checked for clearance. 7
Adjust the center bearing hanging rods so that all the shafts evenly spaced from the clarifier floor and the assembly runs in as straight a line as possible (from the end shaft to the driven shaft) When installing the paddles, adjust them so that there is 1/4" minimum clearance from the end of the paddle to the closest tank wall. 8
After the paddles are installed, they can be set in place with 1/8" diameter set pins or they can tacked in place with small spot welds. While not necessary, pinning the flights in place will prevent them from shifting. Pilot holes have been located in each flight for the location of dowel pins. Also, tacking the flights in place with small tack welds will also prevent them from shifting, but tacking the flights in place will make auger maintenance / flight replacement a bit more difficult. Below is an exploded view of a typical auger assembly. 9
4. PLATE PACK INSTALLATION Installing the plate packs is the most critical and time consuming aspect of the clarifier assembly. Care must be taken that each plate or plate pack is installed properly and that no gaps are allowed to develop during the installation. When assembling the clarifier plate pack, follow these basic guidelines... Start media installation at the influent end of the clarifier. Install the two EXTERIOR rows first. Install the two INTERIOR rows last. Check the angle of EACH plate as they are installed to make sure that they match the angle of the influent and effluent clarifier support walls. Any accumulated misalignment will have a negative effect on the overall installation. Take your time. Install one plate at a time. Check the angle. Contact Hydro-Flo immediately if you have any questions or concerns during the media installation. 5. PARTITION WALL INSTALLATION There are two partition walls that need to be installed after the media pack installation is completed. All of the panels are identical except for the 4 located on each end of the clarifier. 10
When assembling the partition walls, follow these basic guidelines... All of the central partition plates are identical and can be installed on either side of the clarifier. Install all the identical central partition plates first. Each plate will hang from a single hole located in each truss section. LOOSLY hang all sections in place. DO NOT tighten ANY of the bolts of the assembly until all sections of the partition walls are located in position. The bent flanges and threaded studs will always face toward the INSIDE of the clarifier. Install the 4 end sections. Install the central pack "T" baffles (these will be the items facing the center of the clarifier). All of these items will be identical except for the ones located at the far ends of the partition walls. Position them over the studs and loosely thread the nuts and washers over the studs. Install the exterior pack "T" baffles (these will be the items facing the exterior of the clarifier). All of these items will be identical except for the ones located at the far ends of the partition walls. Set them in position and loosely install the nuts, bolts and washers. 11
6. EFFLUENT TROUGH INSTALLATION There are two major components in the trough assembly. First are the individual trough sections and second are the trough mating channel. All of the mating channels are identical. The troughs themselves come in three different configurations. The influent end trough has one end sealed off and will be located at the clarifiers influent end. the discharge troughs are identical to the intermediate troughs except in overall length and are located at the effluent end of the clarifier. The intermediate troughs are all identical and are located in between the influent end trough and the discharge troughs. When assembling the effluent weir troughs, follow these basic guidelines... Pre-Assemble all of the trough adjustment studs to the clarifier mating channels Start at the EFFLUENT end of the clarifier. Set each trough section in position and loosely bolt a trough mating channel to each end. Install the trough leveling studs (4 at each mating trough). Install the intermediate troughs one at a time. Bolt them to the mating channels. Bolt the adjustment studs to the clarifier truss. Install the end troughs. Snug all the mating channel bolts (tight enough to pull the troughs together but not so tight that they restrict movement). DO NOT tighten them down until the troughs are basically leveled. 12
6.1. Effluent Trough ADJUSTMENT Each unit is supplied with multiple, adjustable, effluent collection troughs. The troughs and media packs may or may not be shipped installed depending on clarifier size etc. Generally speaking, if the clarifier must be shipped laying down due to size, then the plate packs are likely not installed and will be required to be installed in the field. Also, the clarifier internals may not be installed if there is a chance of damaging the internals during shipment. In addition, other items that may have to be removed for shipping will be required to be re-installed in the field.. Field adjustment of the effluent troughs after clarifier installation will be required in order to level troughs to ensure the water spilling in the troughs is even and consistent to ensure proper flow across all the plate packs. NOTE: Please read and understand the entire instruction before performing this task. This is an important requirement for proper clarifier operation. SAFETY FIRST! Never perform any work or make any adjustments to ANY mechanical or electrical system without first disconnecting and locking out power to the unit or serious injury can result. Tools needed: A 4 foot bubble level and a set of wrenches and a set of socket wrenches Step 1. Remove clarifier lid(s) if supplied. Step 2. The leveling of the effluent troughs is ESSENTIAL to good clarifier performance and should not be overlooked nor taken lightly. Leveling of the effluent troughs achieves totally even distribution of water and floc thru the clarifier which is needed to take advantage of the entire plate settling system and ensure proper clarifier performance. Step 3. Set the four foot level on the width of the clarifier near the troughs to determine the high side (if any). We ll select the high side as the starting point and adjust the other troughs up to it. Typically there is one trough per side, separated in the middle of the clarifier by the influent trough. All of the troughs will need to be perfectly level to one another as explained further on. Step 4. Use the four foot level on the selected highest trough to level the length of the trough. The trough is leveled by adjusting the threaded rod bolts to achieve long elevation and side to side elevation. Use the two foot level to level the troughs side to side. There are threaded rods at the end of each individual trough section. These rods are used to adjust level along the length and from side to side. Step 5. Use the two foot level to level from the first leveled trough to the adjacent trough. Step 6. Now level the length and side to side of this trough. Step 7. Double check that these first two troughs (or single trough in small clarifiers) are perfectly level to one another before proceeding to the other troughs. Step 8. All the troughs pierce the effluent chamber wall and stick out into the effluent chamber approximately 6. This is where we get to match level between the two plate chambers that are separated by the center influent trough. Use the four foot level to match the elevation of the effluent end of a previously leveled trough to it s adjacent trough in the adjacent plate chamber. 13
Step 9. Now carefully and precisely level the length of this trough using the effluent end of the trough as the start point. Be sure to level side to side as well. Step 10. Repeat steps 5, 6, and 7 until all troughs are perfectly level to one another. Double check the level between all trough ends in the effluent chamber to be sure they are all perfectly matched level to one another. Step 11. As you fill the clarifier for the first time you can watch the water spill into the troughs thru their entry weir holes. All of the "V" notch weirs should spill water into the troughs at very nearly the same moment, within 1-2 seconds from one another. Additionally, the cascade of water spilling into the troughs over the "V" notch weirs should appear about the same size (approximately 10-15% variance) with no one being much larger or smaller than the other. If the cascade size varies beyond 10-15% from one another it indicates a different flow rate thru that weir hole and therefore potentially uneven flow distribution. 7. ELECTRICAL CONNECTIONS SAFETY FIRST! Never perform any work or make any adjustments to ANY mechanical or electrical system without first disconnecting and locking out power to the unit or serious injury can result. Refer to project specific electrical drawing for all required field connections. 8. MECHANICAL SAFETY FIRST! Never perform any work or make any adjustments to ANY mechanical or electrical system without first disconnecting and locking out power to the unit or serious injury can result. Prior to sustained operation, bump all motors to ensure proper rotation. The unit may be equipped with a mechanical sludge auger/thickener. These units will be equipped with a gearbox for speed reduction. The standard gear reducers are maintenance free and may be installed in any position. 9. PRINCIPAL OF OPERATION Clarifier systems remove settlable solids and floc. They utilize inclined plate media packs in order to greatly increase the amount of projected surface settling area available in a smaller than normal footprint. The solids removal efficiency of the clarifier is directly related to the amount of projected surface area offered for a given flow rate and translates to an Hydraulic Loading Ratio (HLR) ratio of GPM/ft 2. A typical overflow ratio range is 0.25 gpm/ft 2.to 0.50 gpm/ft2. 9.1. SLUDGE REMOVAL Please consult your local city and state regulatory agency regarding specific requirements on the proper disposal of the sludge generated in your process. If you need help with the disposal or treatment of the collected sludge, please contact your local HYDRO-FLO TECHNOLOGIES representative. 14
Sludge removal is very important to the proper operation of your Clarifier. Draw off the settled sludge regularly. Do not allow it to accumulate excessively or operational malfunctions can result. If sludge accumulates to an excessive level, the sludge level will rise to a point where it will contact and interfere with the operation of the media packs and floc or solids may be washed out of the clarifier. Any settled sludge should be drawn off periodically according to the accumulation rate. We recommend sludge be drawn off using a timer controlled sludge pump operating at 1-3% of the clarifier flow rate for 30 seconds every 15 minutes and adjust from there to match the accumulation rate. This will prevent any major sludge and effluent performance related problems. If your system was supplied with a bottom sludge auger/thickener it should be allowed to operate continuously as it will assist in preventing the sludge from naturally compacting in the sludge chamber. 9.2. EFFLUENT QUALITY Regularly check the effluent quality of your unit. If you notice any loss in effluent quality, take steps to correct the situation immediately. Some areas to check if your effluent quality has deteriorated are: Have you exceeded the unit s maximum rated flow? Have the influent characteristics changed due to some process change upstream? Are you chemically treating before the unit and if so have these chemicals changed? Are the chemicals being used for treatment completely mixed and are they fresh? Has the sludge collected to the point where it has begun to interfere with the media packs? Have you introduced anything new or foreign into the waste stream? 10. MAINTENANCE 10.1. COATING MAINTENANCE Touch up all damaged coatings immediately prior to putting the clarifier into service. Regularly inspect the coatings ANNUALLY for damage or degradation and repair immediately to prevent severe damage. Drain the clarifier completely, wash out any accumulated sludge and inspect the coatings from the top to the bottom sludge chamber. CAUTION: Observe proper confined space entry procedures for internal inspections. Pay particular attention to coating condition at the weld seams, and any corners. See the specification information for this particular piece of equipment for proper procedures for coatings touchups for the coatings applied to this equipment. Pay particular attention to coatings condition and perform touchups after installation of any accessory equipment such as mixers, electrical, and media plate packs. Coatings used can vary depending on project requirements. 15
See Project Specific Drawings and Data for coatings used for your project 10.2. RECOMMENDED PERIODIC MAINTENANCE TABLE MAINTENANCE TASK Check chemical supplies (if used) and replenish as needed. Remove accumulated sludge from the sludge collection chamber. Check for proper operation of the sludge auger/thickener (if supplied). Check auger drive shaft seal. Tighten enough to eliminate excessive leaking. Drain unit and inspect interior coatings. Touch up as necessary. RECOMMENDED MAINTENANCE SCHEDULE AS REQUIRED Daily if possible. AS REQUIRED Daily if possible. AS REQUIRED Daily if possible. AS REQUIRED Weekly if possible. Annually 16