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HomeMy WebLinkAbout1.0 ApplicationSCHMUESER GORDON MEYER ENGINEERS SURVEYORS January 25, 2008 Garfield County Planner 108 8th Street Suite 201 Glenwood Springs, CO 81601 I 18 W. 6TH, SUITE 200 P.O. BOX 2155 GLENWOOD SPRINGS. CO 81 601 ASPEN. CO 8 161 2 970-945-1004 970-925-6727 FX: 970-945-5948 FX: 970-925-4157 RE: Canyon Creek — WWTF Site Amendment Application P.O. BOX 3088 CRESTED BUTTE. Co 81 224 970-349-5355 FX: 970-349-5358 Dear Sir or Madam: Enclosed you will find a copy of the Site Application Amendment submitted on behalf of the Canyon Creek Homeowners Association for a proposed remodel of the current wastewater treatment facility. You have 15 days from the date of receipt of this document to comment on the proposal. Please address all comments directly to the State of Colorado Water Quality Control Division. Thank you in advance for your time and if you have any questions please call at 970-945-1004 or e-mail: alexk©sgm-inc.com. Sincerely, SCHMUESER GORDON MEYER, INC. Alexandra Kordick, E.I. Design Engineer Robert W. Pennington, P. Project Engineer Enclosures: Canyon Creek WWTF Site Application Amendment JAN '2 5 2008 Application for Amendment of An Existing Site Location For Canyon Creek Homeowners Association Wastewater Treatment Facility Improvements ENGINEERS REPORT By: Schmueser Gordon Meyer, Inc. 118 West 6th Street, Suite 200 Glenwood Springs, CO 81601 (970) 945-1004 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SITE APPLICATION COMPLETENESS CHECKLIST Application Procedures for Amendment of an Existing Site Approval Name of Project: Canyon Creek Estates HOA WWTF Applicant Name and Address: Canyon Creek Estates HOA, 45855 Hwy 6 & 24, GWS, CO 81601 Consultant Name and Address: SGM, 118 W. 6th St., Ste 200, GWS, CO 81601 Type of Project: A Change of Treatment Process dealing with the Liquid Stream Section Elements Addressed on Submittal Page (Applicant) Complete (Division) 22.7(1) The application for amendment of an approved site application, and, where necessary, the discharge permit shall be submitted on proper form with recommended action by all applicable local authorities and planning agencies 22.7(2) An amendment to the site approval and the discharge permit, where applicable, shall be required for any of the following changes from conditions reflected in an approved site application or from conditions at a domestic wastewater treatment plant constructed prior to November 1967 and not expanded since that date. Supporting documentation to the amendment request shall be in the form of an engineering letter report, which provides sufficient information for the Division and the reviewers to evaluate the validity of the proposed change: 22.7(2)(a) The addition of a treatment process dealing with the liquid stream 22.7(2)(b) A change from the type of treatment process approved to a different process for dealing with the liquid stream 22.7(2)(c) A decrease or increase in the approved, rated hydraulic and/or organic treatment capacity of the treatment plant 22.7(2)(d) A change in the type of discharge employed 22.7(2)(e) A change in the location of the discharge point, unless that change is within the same defined segment of the same receiving surface water Page 1 I:\2003\2003-24e\CDPHE\Phases 2a E. 2b -Site Amendment\Site Application Completeness Checklist - Liquid Stream.doc COLORADO DEPARTMENT OF PUBLIC HEALTH AND ENVIRONMENT Water Quality Control Division 4300 Cherry Creek Drive South Denver, Colorado 80246-1530 (303) 692-3574 APPLICATION FOR AMENDMENT OF AN EXISTING SITE LOCATION APPROVAL (Section 22.8(2)(a).(b)(i)(iii)(iv)(v)(vi).(c).(d), and (e) Regulation No. 22) Applicant: Canyon Creek Estates HOA Address: 45855 Hwy. 6 & 24 City, State, zip: Glenwood Springs, CO 81601 Email Address Primary Contact (for project inquiries): Robert Pennington P.E. Consulting Engineer: Schumueser Gordon Meyer, Inc. Address: 118 West 6th St. Suite 200 City, State, zip: Glenwood Springs, CO 81601 Email Address bobp@sgm-inc.com 1. Site Approval Number: 3638 Site Approval Date: October 19. 1983 Phone: 970-945-8583 Phone: 970-945-1004 2. Permitted treatment plant capacity: Requested treatment capacity: Hydraulic: 21.000 gal/day Hydraulic: No Change gal/day (maximum monthly average) Organic: 50.0 lbs. BOD5/day Organic: No Change lbs. BOD5/day Phone: 970-945-1004 If an increase in rated capacity of the treatment plant is being requested, include an engineering evaluation of the plant's treatment capacity as well as its ability to meet all applicable effluent limitations at the higher rated capacity. 3. Current treatment process: RBC (Rotating Biological Conductor) Proposed treatment process modifications: Two phase construction: Phase 2a - •Construction of a two compartment reinforced concrete tank ("Triton Tank") with temporary influent bypass piping; •Realignment of influent and aeration piping to the new process tank; •Installation of SBR electrical and control conduits and appurtenances; ,Return function of the effluent polishing tank. WQCD-3d (Revised 6/06) Page 1 of 3 Phase 213- -Installation of the Triton Aerator/Mixer, decanter and sludge pump; •6 -inch effluent piping from SBR to existing chlorine contact chamber; •Install associated electrical panels. conductors and controls for SBR in existing conduits; •Decommission the RBC plant.Conversion to a SBR (Sequencing Batch Reactor) 4. Current type of discharge: Surface discharge to watercourse (list receiving watercourse) Canyon Creek Subsurface disposal: ❑ Land Application: ❑ Evaporation: ❑ Evapo-transpiration: ❑ Other: (List) Proposed type of discharge: Surface discharge to watercourse (list receiving watercourse) No Change State water quality classification of proposed receiving watercourse: Recreation. Class 2 Aquatic Life, Cold, Agriculture Subsurface disposal: ❑ Land Application: ❑ Evaporation: ❑ Evapo-transpiration: ❑ Other: (List) 5. Current location of discharge (stream segment and legal description): Segment 4 Lower Colorado River Basin Proposed location of discharge (stream segment and legal description): No Change 6. Please identify any additional factors that might help the Water Quality Control Division make an informed decision on your amendment request: B. If the facility will be located on or adjacent to a site that is owned or managed by a federal or state agency, send the agency a copy of this application for the agency's review. Not Applicable WQCD-3d (Revised 6/06) Page 2 of 3 C. Request submitted to the following governmental entities: The application shall be forwarded to the planning agency of the city, town, or county in whose jurisdiction(s) the treatment works is to be located and to the water quality planning agency (agencies) for the area in which the facilities are to be constructed and for the area to be served by those facilities. Please list below those entities to whom copies of this application have been provided as well as the date on which the application was transmitted to each entity. These entities shall be allowed 15 working days from receipt of the request to comment directly to the Water Quality Control Division. If you have any further comments or questions, please call (303) 692-3574. Entity Agency Name Date Sent 1. Management Agency: (If different from entities listed below) 2. Coonty: (If site is outside located in an unincorporated area of the County) 3. City or Town: (If site is located within 3 miles of the boundaries of a City or Town) 4. Local Health Authority: 5. 208 Planning Agency: 6. Other State or Federal) Agencies: (If facility would be located adjacent any land owned or managed by state or federal agency) I certify that I am familiar with the requirements of the "Site Location and Design Approval Regulations for Domestic Wastewater Treatment Works". Date I q'Je cc 2Geg. _ ____ Steve Ehlers, President Signature of Applicant' Typed Name and Title *The applicant must sign this form. The Consulting Engineer cannot sign this form. WQCD-3d (Revised 6/06) Page 3 of 3 TABLE OF CONTENTS Table of Contents Project Description 3 Primary Effluent Levels 4 Wastewater Flow and Load Projections 4 Existing Treatment Facility 5 Headworks 5 Pre -Aeration Basin 5 Rotating Biological Contactor 6 Clarifier 6 Chlorine Contact Chamber 6 Operational Impacts of Proposed Changes 6 Phase 2a 6 Phase 2b 6 Implementation Schedule 7 Sequencing Batch Reactor Process Description Utilizing Aire -02 Triton® Aeration System 7 SBR Basin 8 Floating Aeration/Mixing Equipment 8 Decant mechanism 8 Waste sludge pumps 9 Dissolved oxygen control system 9 Process control system 9 SBR Design Calculations 9 Influent Characteristics & Assumed Design Parameters 9 SBR Operating Cycle Schedule 11 Check Reactor Dimensions from Mass Balance on Solids 11 Hydraulic Retention Time 13 Solids Retention Time 13 Mixed Liquor Volatile Suspended Solids 14 Nitrogen Oxide 15 Aeration Time for Nitrogen Oxygenation 15 Decant Pumping 17 Oxygen Transfer Calculations 17 Sludge Production 18 Aerobic Digester Design Calculations 19 Influent Characteristics & Assumed Design Parameters 19 Volatile Suspended Solids Reduction Calculations 20 Digester Biological Air Demand Calculations 21 Volume of Sludge Digested 23 Volume of Digester 23 Total Digester Air Demand for Aeration and Mixing 24 Power Requirement for Blower 25 Disinfection Design 25 Summary of Project 26 Table 1: Historic Influent Loading Data 5 Table 2: Implementation Schedule for Construction of Phase 2a 7 Table 3: SBR Influent Parameters 9 Table 4: SBR Reactor Design Parameters 10 Table 5: Kinetic Coefficients 10 Table 6: SBR Physical Design Parameters 11 Table 7: Effluent Design Criteria 11 Table 8: Digester Design Parameters 20 Table 9: Digester Design Constraints 20 Table 10: Physical Digester Design 24 Table 11: Blower Design Parameters 25 I:\\SGMSERV1\Projects12003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 2 This engineering report is in support of an Application for an Amendment of an Existing Site Location, Approval Number 3638, approved October 19, 1983 for the Canyon Creek Estates Homeowners Association. Project Description The Canyon Creek Estates Homeowners Association is proposing to make operational modifications to the existing (and aged) Rotating Biological Contact (RBC) wastewater treatment facility by ultimately converting to a Sequencing Batch Reactor (SBR) wastewater treatment facility. The proposed plan is to adapt the current treatment plant in two stages of construction due to limited funds. Throughout this report the first stage will be referred to as Phase 2a and the second stage will be referred to as Phase 2b. This site application amendment is being submitted for changes to the facility in Phase 2a and Phase 2b. The facility installed pretreatment works (screening) to remove Targe and floating debris and aeration equipment to pre -aerate the influent during Phase 1 in 2005. A major component of the Phase 1 construction plan was to convert an unused buried equalization basin to the pre -aeration basin. A pre -aeration basin was needed to prevent the influent from becoming anoxic before reaching the RBC and to keep the solids in suspension so they would enter the RBC for treatment. During the Phase 1 improvement installation it was discovered that the buried equalization basin was not structurally sound. Said discovery led to the conversion of the effluent polishing tank into to a pre -aeration basin. As the plant stands today, the screened influent flows from the bar screen to the 'polishing tank' that has been converted to a pre -aeration basin. Then, after pre -aeration, the influent flows back to the head of the RBC. This temporary configuration has eliminated the effluent polishing tank from the treatment train. The goals of Phase 2a are to build a two part "Triton" tank. The larger first compartment of the tank will be bypassed during Phase 2a. The influent will flow into the second, smaller, compartment that will serve as the pre -aeration tank until the equipment can be purchased and installed (Phase 2b) to convert the new two part "Triton" tank into a SBR. This will allow the polishing tank to be returned to its original function, and allow the entire project to move forward toward the SBR system. In the final design the first compartment of the "Triton" tank will serve as the SBR itself and the second compartment will function as an aerobic digester to stabilize and store the waste sludge. There will be no change in the type of treatment (Rotating Biological Contact) for the proposed Phase 2a improvements or a change in the approved, rated hydraulic and/or organic treatment capacity of the facility. The discharge type and location will remain as approved and permitted. The only changes will be the construction of the two compartment "Triton" tank, the reinstallation of the effluent polishing tank, and the movement of the pre -aeration basin to the second compartment of the "Triton" tank. 1:1\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 3 The Phase 2b improvements will accomplish a conversion of the existing RBC facility to a modern SBR plant in which the influent flows will be treated in a batch mode and will also provide an aerobic digester for waste solids management. It is anticipated that biosolids will be thickened/stored in the aerobic digester and periodically removed by a contract hauler. The existing clarifier will be converted to a part of the chlorine contact chamber. This creates a larger volume chlorine contactor to provide sufficient contact time for inactivation and disenfection. Below is an outline of the proposed improvements: PHASE 2a: • Construction of the two compartment Reinforced Concrete Process Tank ("Triton Tank") including temporary bypass influent piping; • Realignment of influent and aeration piping to the new process tank; • Installation of SBR electrical and control conduits and appurtenances; • Return function of the effluent polishing tank. PHASE 2b: • Installation of the Triton Aerator/Mixer, decanter and sludge pump; • Combine existing Clarifier and chlorine contact chamber into a single disinfection reactor. • 6 -inch effluent piping from SBR to existing clarifier/chlorine contact chamber; • Install associated electrical panels, conductors and controls for SBR in existing conduits; • Decommission the RBC plant. The HOA has budgeted funds to accomplish the Phase 2a proposed improvements and will receive bids to perform the work. Site drawings and related details are attached to this report for the proposed Phase 2a improvements. Appendix 1 contains the cut sheets and associated specifications of the proposed equipment and applicable calculations for Phase 2a, Appendix 2 contains information for phase 2b. The HOA plans to have funds to accomplish Phase 2b by the fall of 2009. Primary Effluent Levels PELs are not included in this document because there will be no change in the hydraulic and organic capacity of the plant, type of disinfection, or discharge point, and thus they are not required. Wastewater Flow and Load Projections The facility surface discharges to Canyon Creek within Segment 4 of the Lower Colorado River Basin. The plant serves the Canyon Creek Estates Development and is permitted for 0.021 million gallons per day (MGD) of hydraulic capacity I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 and 50 lbs. BOD5 per day organic loading. There are no plans to expand the facility. There are two vacant lots to be developed within the HOA and one existing residence that could be connected to the collection system. Of the total 68 available connections, 65 are on-line as of the date of this report. Please see the lot and utility map in Appendix 3 The proposed Phase 2a and Phase 2b designs are based on the assumption that the flows to the treatment facility will remain constant. This is a reasonable assumption due to the fact that the HOA is 95% built out. Even if the three remaining lots hook up to the system no major increase in flow is expected. Historic inflows to the facility are tabulated below. This data comes from the EPA registry for water discharge (permit number COG584003) and has been averaged from monthly values measured from February of 2000 until September of 2007. Table 1: Historic Influent Loading Data The average historical flow parameters tabulated above are lower than allowed for in the discharge permit (COG -584000). The historic recorded monthly maximum BOD5 is 34.6 Ib/d, which is -30% less than the permitted limit, of 50 Ib/d. Since no additional hydraulic or organic loading is expected all designs were based on the allowable values from the discharge permit. Because historic values have been significantly less than allowable inflows, there is additional capacity within the system to allow for any future variability in flows. Existing Treatment Facility The following information is a discussion of the existing process train as it stands today. Headworks The phase 1 expansion in 2005 installed a covered headworks building. The existing equipment within the headworks room includes an influent channel, a MEVA Rotoscreen Model RS -19-30-6 automated bar screen, and a bypass for the bar screen. The headworks building also houses the aeration compressor used for pre -aeration of the influent. Pre -Aeration Basin Upon leaving the headworks, flows travel to a tank for pre -aeration. This tank was originally designed as an effluent polishing tank. Preaeration within this tank is accomplished using a Red Valve TideFlex Model TFA-1.5 coarse bubble I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 5 Average Historic Monthly Maximum Average Historic Monthly Average Discharge Permit Influent Flow (MDG) 0.015 0.012 0.021 Influent 20 °C BOD5 day (Ib/day) 22 19 50 The average historical flow parameters tabulated above are lower than allowed for in the discharge permit (COG -584000). The historic recorded monthly maximum BOD5 is 34.6 Ib/d, which is -30% less than the permitted limit, of 50 Ib/d. Since no additional hydraulic or organic loading is expected all designs were based on the allowable values from the discharge permit. Because historic values have been significantly less than allowable inflows, there is additional capacity within the system to allow for any future variability in flows. Existing Treatment Facility The following information is a discussion of the existing process train as it stands today. Headworks The phase 1 expansion in 2005 installed a covered headworks building. The existing equipment within the headworks room includes an influent channel, a MEVA Rotoscreen Model RS -19-30-6 automated bar screen, and a bypass for the bar screen. The headworks building also houses the aeration compressor used for pre -aeration of the influent. Pre -Aeration Basin Upon leaving the headworks, flows travel to a tank for pre -aeration. This tank was originally designed as an effluent polishing tank. Preaeration within this tank is accomplished using a Red Valve TideFlex Model TFA-1.5 coarse bubble I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 5 diffuser delivering air from a 7.5 Hp Kaeser Omega-pak Rotary Blower housed in the headworks. Rotating Biological Contactor After the pre -aeration process, the screened flows enter a small 609 gallon equalization basin. Flows are metered to the 3347 gallon RBC tank utilizing a rotating bucket system that is hydraulically connected to the pre -aeration tank. A three compartment RBC treats the flow. Clarifier After treatment in the RBC, flows are separated and settled in a 3043 gallon clarifying tank. From the clarifier there is a 2" return activated sludge (RAS) line connected to a Hydromatic SK50 submersible sewage pump with level controls within a 300 gallon Norwesco vertical poly -storage tank. Return sludge is pumped back to the RBC using the sewage pump. Solids are periodically removed from the RBC tanks by a contract hauler. Chlorine Contact Chamber After leaving the clarifier the flow enters the disinfection unit. Disinfection occurs in a 1217 gallon chlorine contact chamber where sodium hypochlorite is dosed into the system. After disinfection occurs the effluent passes through a Parshall Flume for flow measurement and is then discharged to Canyon Creek. Operational Impacts of Proposed Changes Phase 2a During Phase 2a, the only change in the treatment process will be the reinstallation of the polishing tank. This will improve effluent quality because it will remove additional solids. The other changes to the facility during Phase 2a will not affect the operation or effluent from the system because they do not change the actual treatment process, just the physical location of the pre - aeration basin. These changes include the construction of the two compartment "Triton" tank, the construction of a bypass through the first compartment of the tank, the movement of the pre -aeration basin to the second compartment of the constructed tank, and the installation of electrical equipment for the final SBR design in Phase 2b. Phase 2b During Phase 2b the RBC will be taken off-line and the treatment process will be converted to a SBR process. The modification of the treatment process is necessary because the existing RBC is aged, in disrepair, and requires excessive maintenance. Upon evaluation of options for the repair/replacement of the RBC, in conjunction with an alternatives analysis of other treatment alternatives, the SBR was selected as the best treatment alternative. I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Implementation Schedule It is proposed to begin the Phase 2a improvements upon approval of the Site Application Amendment and Design Review by CDPHE. Once additional funding ($175,000) is obtained, the Phase 2b improvements will be purchased and installed (—Fall 2009). Table 2: Implementation Schedule for Construction of Phase 2a Description Estimated Date Submittal to CDPHE Jan. 14, 2008 Public Notifications Jan. 14-30, 2008 Anticipated Approval Feb. 8, 2008 Solicit Bids for Phase 2a Feb. 4-19, 2008 Approval by HOA Board (Notice of Awards) Feb. 20, 2008 Notice to Proceed (Begin Construction) Mar. 18, 2008 Substantial Completion June 10, 2008 Phase 2a Start Up July 9, 2008 Sequencing Batch Reactor Process Description Utilizing Aire -02 Triton® Aeration System This SBR process is a three stage process with all steps occurring in one single reactor unit. The functions of flow equalization, biological oxidation, nitrification, sedimentation, and aerobic sludge stabilization are all carried out in the same reactor. Flow to the vessel is not interrupted at any time. The steps involved are listed and described below: 1. React -The reactor is aerated and mixed. Aeration aids in growth of biomass, and mixing creates contact between biomass and waste, facilitating in waste reduction. 2. Settle- Mixing and aeration are stopped allowing reactor solids to settle by gravity. 3. Decant- The supernatant is withdrawn from the water surface of the reactor. The influent is continuously received in the SBR basin at all times, irrespective of the sequence of operation of the treatment system. The system is designed so that the basin configuration prevents short circuiting of the influent during the decant sequence, by introducing the influent flow stream downward and into the sludge blanket area of the SBR. Also, the rectangular configuration of the SBR tank provides a longer flow path between the influent introduction location and the effluent overflow location, providing optimized settling and treatment of incoming waste. Equipment and controls, includes the following: Floating aerator/mixer I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc Decant mechanisms Waste sludge pumps Dissolved oxygen control system PLC based process control system SBR Basin The treatment reactor consists of a poured -in-place concrete, as shown in the Appendix 2 drawings with a total volume of 3520 ft3 or 26370 gallons. The SBR basin will be equipped with a high level float switch to trigger an alarm should the basins maximum design water level be exceeded. Floating Aeration/Mixing Equipment One AIRE-02 Triton electric motor -driven direct drive propeller -type aerator/mixer, float assembly, and slide pole assembly will be used in the SBR reactor. The Triton aerator/mixer consists of a net 5 HP (3.5 HP mixer and 1.5 HP blower), TEFC, 230/460 volt, 3 phase, 60 Hz, 900 RPM motor; regenerative blower; field replaceable, water lubricated lower bearing; field replaceable wear - resistant sleeve; bronze dual -bladed primary PowerMix M propeller; stainless steel Saturn RingTM diffuser; stainless steel housing, mounting flange, and hollow shaft. The unit is able be operated in both a mixing and a mixing/aeration mode controlled completely independently of each other. The mounting system for the aerator consists of a 304 SS slide pole assembly which will be anchored to the concrete to accommodate water level fluctuations in the reactors. The float assembly moves up and down freely on the slide poles via poly rollers, to adjust the aeration and mixing for variable water levels. Decant mechanism The SBR aeration basin includes a solids limiting decanter controlled by the SBR logic system to provide sequencing decants compatible with the hydraulic requirements of the system. The logic controls may be adjusted to modify the duration and/or frequency of the decant mode. The decanter can be operated only in a vertical direction. The decanter will move up and down by a jack screw. The speed and direction of the decanter shall be controlled by a Duff -Norton translating machine screw actuator connected to a 1/2 HP, 230 volts, single phase, 60 cycle gear motor. The decanter will be parked above top water level during aeration and settling periods, thereby eliminating any possibility of solids carryover during these periods. At top park position, the decanter shall provide "fail safe" overflow protection in the event of a power failure. Settled supernatant will flow via gravity out of the decanter into the effluent collections system. The decanter solids exclusion weir shall prevent the carry over of any floatables during such emergency periods. 1:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Waste sludge pumps The SBR unit includes a waste activated sludge (WAS) submersible pump for pumping waste sludge from the reactor basin to the digester. The WAS pump is controlled by SBR logic system. The logic controls may be adjusted to modify the duration and/or frequency of the sludge wasting. The waste activated sludge pumps are submersible pumps capable of pumping up to 95 gpm against a total dynamic head of up to 34 ft. The pumps are Model SX50 as manufactured by Myers (or equal), 1/2 HP, 230 Volt, single PH, 60 Hertz. Dissolved oxygen control system A Hach SC100 dissolved oxygen (DO) control system with a compatible LDO sensor continually monitors and transmits DO data to the SBR aeration process control system. The dissolved oxygen control system is integrated with the sequencing batch reactor aeration system and process control system so aeration can occur when necessary to maintain the desired DO levels. Process control system This system utilizes a process control system with Programmable Logic Controller (PLC) and graphic operator interface. SBR Design Calculations Influent Characteristics & Assumed Design Parameters The plant was designed with the influent characteristics tabulated below: Table 3: SBR Influent Parameters Description Variable Value Unit Maximum Flow Rate Q 21,000 gpd 79.4 m /d Minimum Temperature T 10 °C Total 5 -day Biochemical Oxygen Demand BOD 50 Ib/d 286 mg/I Total Suspended Solids TSS 250 mg/I Total Kjeldahl Nitrogen TKN 30 mg/I Soluble 5 -day Biochemical Oxygen Demand sBOD 217 mg/I Total Chemical Oxygen Demand COD 646 mg/I Soluble Chemical Oxygen Demand sCOD 160 mg/I Readily Biodegradable Chemical Oxygen Demand rbCOD 80 mg/I Volatile Suspended Solids VSS 190 mg/I Ammonium NH4-N 25 mg/I Ratio of bCOD / BOD 1.65 The following influent constituent values are calculated from the influent data above in Table 3: Biodegradable chemical oxygen demand (bCOD): I:\\SGMSERV1\Projects\2003\2003-2461CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 bCOD=1.65BOD=1.65.286g / m3 = 472g / m3 Equation 1 Biodegradable particulate chemical oxygen demand (bpCOD): bpCOD = BOD (BOD — sBOD) =114g / m3 Equation 2 Particulate chemical oxygen demand (pCOD): pCOD = COD — sCOD = (646 —160)g / m3 = 468g / m3 Equation 3 Non -biodegradable volatile suspended solids (nbVSS): 3 nbVSS =[1 _(bpCOD VSS = 1 1148 / m 190g /m3 =145.5g /m3 Equation 4 pCOD 348g/m3 The following SBR reactor values are used for design: Table 4: SBR Reactor Design Parameters Description Variable Value Unit Mixed Liquor Suspended Solids MLSS 4500 g/m3 Sludge Volume Index SVI 150 ml/g Reactor Dissolved Oxygen DO 2 g/m The following kinetic coefficients and equations from Wastewater Engineering Treatment and Reuse 4th Edition 2003 Metcalf and Eddy Tables 8-10 & 8-11, are used in the design: Table 5: Kinetic Coefficients Coefficient Value Unit Equation Used To Determine Coefficient Y 0.4 g VSS/g bCOD kd 0.08 g VSS/g VSS d kd= 0.12 g/gd (1.04)7-2° fd 0.15 g / g Yn 0.12 g VSS/g NO), kd, 0.05 g VSS/ g VSS d kdn = 0.08 g/gd (1.04)7-20 Kn 0.22 g NH4-N/m3 Kn = 10"51(11-1158 Ko 0.5 g/m3 iu,mn 0.38 g VSS/g VSS d /.[,mn= 0.75g/gd (1.07)7-20 The physical system design parameters used are: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Table 6: SBR Physical Design Parameters Description Variable Value Unit Aeration/Reaction Time to 165 min Settling Time is 30 min Decant Time td 45 min Tank Volume V 99.7 m3 Fill/Decant Volume Vf 18.9 m3 Settled Volume Vs 80.8 m3 Maximum Liquid Depth H 2.4 m Decant Depth Hd 0.46 m The system is designed to meet the following effluent constraints: Table 7: Effluent Design Criteria Total 5 -day Biochemical Oxygen Demand BOD 30 g/m3 Total Suspended Solids TSS 30 g/m3 Ammonium NH4-N 1 g/m3 SBR Operating Cycle Schedule The total time to complete a cycle in the SBR is the time to fill/aerate/react, time to settle, and time to decant. CycleTime = tc = td + is + td = (165 + 30 + 45) min = 240min = 4hrs Equation 5 The number of SBR cycles per day is: 24hrs l day 24hrs l day Cycles l Day = _ = 6Cycles l Day Equation 6 CycleTime(hrs) 4hrs The SBR will be run through six 4 hour cycles each day. Check Reactor Dimensions from Mass Balance on Solids The reactor can be thought of consisting of two volume components. The first volume component is the liquid or fill component (\/f), this is the amount of material or volume that is added to the tank after each decant cycle. The second volume component is the settled volume (Vs), or the volume of material that remains in the tank through the decant process. To conduct a mass balance on the solids in the system, first the fill fraction must be calculated from the initial physical tank design. The fill fraction is the percent of the tank that can be filled by influent during each cycle, and it can be calculated by using the following physical parameters: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 11 Volume _of _Fill Vf 18.9m3 _ Total Volume V 99.7m3 — 0.19 Equation 7 The amount of solids in the system remains constant throughout a cycle. This means that the amount of solids in the tank after it is filled should be equal to the amount of solids in the tank after it is decanted, because the solids should remain in the tank and not leave with the supernatant. The mass balance of solids in the system is: Mass of Solids in Full Tank = Mass of Solids in Settled Tank Tank Volume (V)* MLSS (X) = Volume in Tank after Decant (Vs) * MLSS in settled volume (Xs) V (X) = Vs (Xs) The settled volume solids concentration is found by using the sludge volume index: XS = 1 = 1 = 6.6.10-3 g / ml = 6666.7g / m3 Equation 8 SVI 150m1 /g The settled fraction of the system can now be found: VS X 4500g/m3 = 0.675 Equation 9 V XS 6666.7g /m3 An additional twenty percent liquid volume should be provided above the sludge blanket to ensure solids are not removed by the decanting mechanism. So the settled fraction becomes: VS = VS (1.2) = 0.675(1.2) = 0.81 Equation 10 By solving for the settled fraction of the system using influent parameters rather than physical tank design parameters, the fill fraction can be recalculated and compared to the physical design value to check if the tank design parameters are valid. Calculate fill fraction from settled fraction: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 12 V V —Vs ✓ V Vr=1—Vs ✓ V Vf =1. --Ar— =1-0.81=0.19 ✓ Xs Equations 11a, 11b, 11c The fill fraction calculated from the physical tank volume is equal to the fill fraction calculated from the influent parameters plus a 20% factor of safety, so the physical tank dimensions are acceptable. Hydraulic Retention Time The overall hydraulic retention time within the SBR is: V = 99.7m3 T = =1.3days = 30.1hours Equation 12 Q 79.4m3 Id Solids Retention Time To calculate the solids retention time, a value of NO„ must be assumed. NO = 0.7 • TKN = 0.7.30g / m3 =21.0g/m3 Equation 13 It is assumed that bCOD is the growth limiting substrate and all of the bCOD is consumed in each cycle. Therefore at the end of each cycle there is no bCOD left in the supernatant to be decanted, thus: So —SSS„ Equation 14 So bCOD = 472g/m3 The mass of solids within the system is: (Px,rss )SRT = V (XMLss) = 99.7m3 4500g / m3 = 448560g Equation 15 The average solids retention time within the reactor is calculated iteratively using the following equation: Equation 16 I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering Ietter.doc 13 • (Px,rss )SRT = QY(So — S)SRT + Q(nbVSS)SRT + QY" (NOx )SRT [1+ (kd)SRT](0.85) [1+ (kd")SRT](0.85) (fd)(kd)Q(Y)(So — S)SRT2 + [1+ (kd)SRT](0.85) + Q(TSS — VSS)SRT 448560g79.4m3/d(0.4g/g)(472g/m3)SRT = [1+(0.08g/g • d)SRT](0.85) +79.4m3 /d(145.5g/m3)SRT + 79.4m3 /d(0.12g/g)(21g/m3)SRT [1+ (0.05g / g • d)SRT](0.85) + (0.15g/g)(0.08g/g • d)79.4m3 /d(0.4g/g)(472g/m3)SRT2 [1+ (0.08g / g • d)SRT](0.85) + 79.4m3 /d(250g/m3—190g/m3)SRT SRT=18days The average solids retention time within the reactor is 18 days. Mixed Liquor Volatile Suspended Solids The net volatile suspended solids produced as a function of the solids retention time are: Equation 17 (Px,vss )SRT = QY(S0 — S)SRT + Q(nbVSS)SRT + QY" (NO X )SRT [1+(kd)SRT] [1+(kd")SRT] + (.fd )(kd)Q(Y)(S0 — S)SRT2 [1+(kd)SRT] 79.4m3 /d(0.4g/g)(472g/m3)18d (Px'v)SRT = + 79.4m3 /d(145.5g/m3)18d [1+(0.08g/g•d)18d] + 79.4m3 /d(0.12g/g)(21g/m3)18d [1+(0.05g/g•d)18d] + (0.15g /g)(0.08g / g • d)79.4m3 / d (0.4g / g)(472g / m3 )18d 2 [1+(0.08g/g•d)18d} (Px,vss )SRT = 341464g = 341.5kg The concentration of mixed liquor volatile suspended solids XMLVSS within the reactor is: 1:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 14 (Px.vss )SRT 341464g 3 s XMLvss = = 3 = 3425g /m3 = 266.71b/ ft Equation 18 V 99.7m The fraction of MLVSS is: X MLVSS 3425g /m3 = 0.76 XMA 4500g/m3 Equation 19 Nitrogen Oxide The rate of biological nitrogen oxidation is: Equation 20 QY(S0 — S) QYn (NOx) (fd)(kd)Q(Y)(So — S)SRT PX ,bio = [1 + (kd )SRT] [1+ (kdn )SRT] + [1+ (kd )SRT] P = 79.4m3 /d(0.4g/g)(472g/m3) + 79.4m3 /d(0.12g/g)(21g/m3) x'b`o [1 + (0.08g / g • d)18d] [1+ (0.05g / g • d)18d] + (0.15g / g)(0.08g / g • d)79.4m3 / d(0.4g / g)(472g / m3 )18d [1+ (0.08g /g • d)18d] PX ,bio = 7549g / d = 7.5kg / d The amount of nitrogen oxide is calculated from the nitrogen balance equation. The nitrogen balance equation accounts for nitrogen in the influent, minus the nitrogen in the effluent, and the nitrogen that is incorporated into the cell tissue of biomass: NOx = TKN — Nefnenr — 0.12 PP,bio NOx = 30g/m3 —1g/m3 —0.12 7549g/d NOx=17.6g/m3 79.4m3 / d Equation 21 Aeration Time for Nitrogen Oxygenation The amount of ammonia and nitrite that can be oxidized in each cycle is the sum of the oxidizable nitrogen added during the fill process, and the remaining oxidizable nitrogen that is left in the settled volume after decant. I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 15 TotalNH4 –N=Vf(NO x)+Vs(Neffluent) TotalNH4 – N=18.9m3 (17.6g /m3) + 80.8m3(1g /m3) Equation 22 TotalNH4 – N = 413.2g /cycle The initial concentration of NH4-N in each cycle is: N _ TotalNH4 – N V 413.2g N _ ° 99.7m3 N° = 4.15g/m3 Equation 23 The nitrifier concentration is: _Q(YN)(NOx )SRT XN [l+(kd)SRT]V _ 79.4m3 / d(0.12g / g)(17.6g / m3 )18d X N [1+ (0.08g /g • d )35d $99.7m3 XN=12.3g/m3 Equation 24 The aeration cycle design is based on the assumption that the biological oxidization of nitrogen is rate limiting process during aeration. The reaction time for oxidation of nitrogen to reach the 1 mg/I effluent limit is determined using the following equation: ta ta ta — KN ln( )+(N° –N,) XN(/umnDO )( ) YN K° + DO KN 1n(-2-)+ (N –Nt) N, � nm DO XN( YN )(K° +DO) 3 4.15g/m3 s 3 0.22g/m ln( )+(1.0g/m–4.15g/m ) 1.0g/m3 12.3g/m3(0.36g/g•d)( 2.0g/m3 ) 0.5g/g 0.5g/m3 +2.0g/m3 to = 0.03d = 0.77hr = 46 min Equation 25 I:\\SGMSERV1\Projects12003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 16 The aeration cycle design provides 165 min of aeration; this is more than three times the required time necessary for biological reactions to occur. The longer design aeration time provides a factor of safety in the time allotted for reactions to take place, as well as allowing time for the tank to fill, and to mix before aeration takes place. Decant Pumping The decant pumping rate is: V f 18.9m 3 3 Decant _Pump _Rate = — = = 0.42m /min=111gal / min Equation 26 td 45 min Oxygen Transfer Calculations The total oxygen demand includes the oxygen required to remove carbonaceous material plus the oxygen required for ammonia and nitrite to oxidize into nitrate. The oxygen demand is: Ra = Q(So — S)—1.42Px.bio + 4.33Q(NOx ) Ro=79.4m3/d(472g /m3) — 1.42(7549g / d) + 4.33(79.4m3 /d)(17.6g/m3) Equation 27 Ro = 32758g02 / d = 32.8kg / d =1.4kg / hr =3.01b1 hr The total daily time that aeration needs to take place to facilitate biological reactions is: totat _daily _t a required = (# cycles / d) • (ta ) totat _daily _t a required = 6cycles / d • 93 min/ cycle Equation 28 totat _daily _ to _required = 9.3h/ d The total daily time that aeration is taking place by design is: totat _daily _ta = (#cycles/d) • (ta) totat _daily _t a = 6cycles / d • 165 min/ cycle Equation 29 totat _daily _ to = 990 min/ d = 16.5h / d The average oxygen transfer rate for the time that aeration needs to occur is calculated by dividing the oxygen demand by the required daily aeration time. AORrequired —Ra 9.3h d = 3.5kg / hr Equation 30 total daily —t a _required I:\\SGMSERV1\Projects12003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 17 The average oxygen transfer rate for the time that aeration is occurring is calculated by dividing the oxygen demand by the actual daily aeration time. AOR = Ro _ 32.8kg / d = 2 0kg / hr Equation 31 total _daily _t,, 16.5hr / d By multiplying the required average oxygen transfer rate by the number of hours required for aeration, or the actual oxygen transfer rate by the actual number of hours of aeration we see the average daily oxygen transfer rate is the same: Daily _AOR = AORrequired • total _daily _t a _required = 3.5kg / hr • 9.3hr / d Daily _AOR = 32.8kg / d Daily _AOR = AOR • total _daily _t = 2.0kg / h • 16.5hr / d Daily _AOR = 32.8kg / d Therefore, the daily oxygen transfer rates is: Daily _AOR = 32.8kg / d - 72.31b / d Equation 32 The actual oxygen demand is higher at the beginning of the aeration cycle so the design oxygen demand includes a factor of safety to account for this initial accelerated demand. The SBR is designed to deliver 184.8 Ib 02/d which is more than twice the required daily oxygen demand. This provides 2.9 Ib 02/Ib BOD5 exceeding the 1.2 Ib 02/lb BOD5 required in section 5.14.5.b of the CDPHE 96-1 regulation. Sludge Production The net sludge produced each day is: (Px,_rss )SRT 448560g Px,7ss = SRT 18d Equation 33 Px,rss = 25088g/d = 25.1kg/d =53.31b I d The biodegradable chemical oxygen demand removed each day is: bCOD = Q(bCOD) = 79.4m3 / d • 472g / m3 bCOD = 347459g / d =37 .5kg / d =82.61b / d Equation 34 The biochemical oxygen demand removed each day is: BODre,,,oved = bCODren,oved _ 37.5kg / d = 22 7kg / d =50.01b / d Equation 35 bCOD : BOD ratio 1.65 I:\\SGMSERV1\Projects\200312003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 18 The observed yields produced by the system are calculated below. Tss/BOD = PX ,TSS = 25.11b/d=1.11gTSS/gBOD BODremoved 50.01b / d _ [MLVS / }TSS/BOD = 0.76.1.11= 0.84gVSS/gBOD MLSS J• / BOD PX .TSS YTSS/bCOD = = 25.11b / d = 0.67gTSS / gbCOD bCODremoved 82.61b / d YVSS / bCOD = [ML VSS/m_ s ]TSS/bCOD = 0.76 * 0.67 = 0.51gVSS / gbCOD The F: M ratio is calculated by: QS 79.4m3/d•(472g1m3) FIM = _ = 0.011 Equation 37 XMLvssV (3425g/ m3) • (99.7m3) The organic loading on the system is calculated by: _ _ QS„ 79.4m3 / d • (472g /m3) L°rg V (99.7m3) Lorg=227.8gBOD/m3 •d =14 1bBOD/1000ft3 •d Equation 38 Aerobic Digester Design Calculations Equation 36 Influent Characteristics & Assumed Design Parameters In the design of the digester the following assumptions were made: 1. Wasting to the digester occurs only during the decant cycle after the reactor has been settled, thus the influent concentration of suspended solids to the reactor is equal to the concentration of MLSS in the settled volume of the SBR, X; = 6666.7 g/m3 from equation 8. 2. The sludge wasted to the digester includes: Heterotrophic Biomass, Cell Debris, Nitrifying Biomass, Non -biodegradable VSS in the reactor Influent, and the Inert TSS in influent. The total amount of sludge influent to the digester is PX = 25.1 kg/d, 55.3 Ib/d, from equation 33. 3. The volatile fraction of influent to the digester is equal to the volatile fraction within the reactor or 0.76 gMLVSS/gMLSS from equation 19. 4. No Primary solids are included in the digester. 5. The percent solids of the influent flow from the settled volume is: 6666.7 g/m3 = 6666.7 mg/L = 6666.7 ppm or Ps= 0.0067 % solids. I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 19 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 The following parameters where used in the digester design: Table 8: Digester Design Parameters Description Symbol Quantity Minimum Winter Water Temperature Tmin 10° C Maximum Summer Water Temperature Tmax 25 ° C Specific Gravity of Sludge SG 1.03 Air Temperature of Diffused Air Tair 20 ° C Density of Diffused Air pair 1.205 kg/m3 Percent of Diffused Air that is Oxygen Pair 23.2 Oxygen Requirement for CeII Tissue OCeli 2.3 kg 02/ kg VSS 5 % Oxygen Transfer Efficiency OTE The design constraints for the digester are tabulated below: Table 9: Digester Design Constraints Description Symbol Quantity Minimum Percent Solids Reduction PsoIids 38 Minimum Solids Retention Time SRT 60 d Ratio as a percentage of Sludge Concentration in Digester to Sludge Concentration in Reactor Xdigester/XSBR 150 % The EPA's 503 biosolids regulations dictate that the minimum solids reduction must be at least 38%, and the solids retention time within an aerobic digester must be at least 60 days for proper digestion to occur for the stabilization of the solids and to reduce pathogens. This digester exceeds the 60 day 15° C Temperature — MCRT requirement in section 6.3.2.a of the CDPHE 96-1 design criteria. Volatile Suspended Solids Reduction Calculations Because the digester will be an open tank, the liquid temperatures within the digester are dependant on the weather conditions. As with all biological systems, lower temperatures retard the process, whereas higher temperatures accelerate it. The digester is designed to meet performance criteria for cold winter temperatures. The Volatile Suspended Solids reduction necessary in winter and summer is calculated by determining the degree days: W int erdeg .days = Tmin • SRT =10°C • 60d = 600°d Equation 39 Summerdeg.days = Tmax • SRT = 25°C • 60d =1500°d I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 20 The percent reduction of Volatile Suspended Solids determined from figure 14-31 Metcalf and Eddy 2004, using the degree days is: %VSS Re duction W int er 42% Equation 40 %VSS Re duction Summer 50% Both the summer and winter percent reduction of VSS are greater than the required 38% minimum reduction for pathogen destruction. Thus the retention time is sufficient in the temperature regime the digester will operate under. The total mass of VSS reduction is calculated by: Total Mass _ VSS = X MLVSS p = 0.76 k25.1kg / d XMA x kg Equation 41 Total _Mass _VSS =18.3kg/d = 40.4/b/d The mass of VSS reduction under the extreme temperatures is: VSS %VSS Re duction _Wint er Total_Mass_VSS W inter Re duction 100% VSSWint er Reduction = 42% 18.3kg/d=7.7kgVSS_reduced /d=17.01b/d 100% Equation 42 VS S Summer Re duction %VSS Re duction Summer 100% Total_ Mass _ VSS VSS = 50% 18.3kg / d = 9.2kgVSS _reduced / d = 20.21b / d Summer Re duction 100% Digester Biological Air Demand Calculations The volume of air used by the digester for biological processes must be calculated by first determining the amount of oxygen necessary to carry out these reactions. I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 21 Voxygen _W int er = VSS WinterReduction °cell Vox,gen _W inter = 7.7kgVSS/d • 2.3kg02 /kgVSS Voxygen _Winter =17.7kg02 / d = 39.11b02 / d Equation 43 Voxygen _Summer = VSSSummerReduction °cell Voxygen _Summer = 9.2kgVSS / d • 2.3kgO2 I kgVSS Voxygen _Summer = 21.1kgO2 / d = 46.51b02 I d Since there is more biological activity in the summer, the oxygen demand is greater under higher temperatures, thus the system will be designed to meet these maximum oxygen demands. The volume of air necessary is calculated below: _ Voxygen _ W int er Vair_winter = P Pair • air 17.7kg02 /d Vair winter = 1.205kg / m3 •[23.2o/b00%] Voir winter Vair summer Vair summer Vair summer 63.4m302 /d = 2237.7ft302 /d VOxygen —Summer PaPai• r rr 100% 21.1kgO2 / d 1.205kg / m3 • [23.2%X00%1 o ] = 75.4m302 /d = 2663.9ft302 /d Equation 44 Since biological organisms do not uptake all the oxygen they receive, an oxygen transfer efficiency coefficient must be included to provide adequate air for the organisms to uptake sufficient oxygen. The total air flow rate to the digester to carry out biological reactions is: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 22 Vair winter _ 63.4m3 /d = gair winterOTE 10% 1440 min/ d 1440 min/ d 100% 100% gair wint er = 0.88m3 /min = 31.1fi3 /min __ Vair _summer _ 75.4m3 /d gair _summer OTE 10% 1440 min/ d 1440 min/ d 100% 100% gair summer=1.05m3 /min = 37.063 /min Volume of Sludge Digested The Total volume of sludge digested each day is: Qsi"age =(1000kg _ water / m3). (SG) • Ps = J 25.1kg _sludge / d Qsiudge (1000kg _ water / m3). (1.03kg _ sludge / kg _water) 0.67% _solids l 100% Qsivage = 3.65m3_ solids I d =129.0ft3 I Px Equation 45 Equation 46 Once the sludge has been digested it is ready for disposal. Thus the amount of sludge digested each day is equal to the amount that needs to be disposed of or stored within the digester until it can be disposed. Volume of Digester When sizing the digester, the winter conditions govern. The reduced temperatures in the winter reduce biological activity thus the digester needs to accommodate a larger population of biological bacteria to properly digest wastes forcing a larger digester size. The minimum volume for the digester is calculated below: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering Ietter.doc 23 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Vmin Qsludge • X i X [rdigmerlkd MLVSS Xsax i• MLSS SRT Vmm _ 3.65m3 / d • 6667g / m3 Equation 47 6667g/m3.ftp5o% 100%) 0.08g / gd • 0.76 [60dJ1 Vm;n = 34.6m3 =1222.4 ft3 The actual tank is designed to have the following dimensions and volume: Table 10: Physical Digester Design Description SI Value English Value Length 7.9 m 26 ft Width 1.8 m 6 ft Depth 2.5 m 8.25 ft Volume 36.4 m3 1287 ft3 Since the actual digester is design volume of 1287 ft3 is greater than the minimum calculated volume of 1222 ft3 necessary for biological activity, the volumetric design is sufficient to allow for adequate digestion and storage of waste sludge. The VSS loading within the digester is 18.9 kg/d from equation 41 so the total VSS loading per volume of the digester is 0.50 kg VSS/ m3 of digester volume per day, which is less than the required maximum of 1.5 kg VSS/ m3 of digester volume from CDPHE design criteria 6.3.2.b. Total Digester Air Demand for Aeration and Mixing The digester is designed to have air supplied to it by a blower. This blower must provide sufficient air for both aeration, to meet biological demand calculated in equation 45, and for mixing, to facilitate contact between bacteria and substrate. The total air demand is calculated as required by the CDPHE in 96-1 design criteria section 6.3.2 c. gair total = (0.02m3 _ air / min m3 _ digester) • V gair _total = (0.02m3 _ air / min_ m3 _ digester) • 36.4m3 _ digester Equation 48 gair total = 0.73m3 _ air /min = 25.7 ft3 _ air /min I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 The actual blower is designed to deliver 120 ft3air/min; this is more than four times the required 25.7 ft /min necessary for mixing and aeration. Power Requirement for Blower The power requirement for the blower is calculated under a winter condition because the decreased temperatures in winter cause greater air density, this in turn increases the air pressure and the power demand of the blower for the compression process. The blower design is based in the following parameters: Table 11: Blower Design Parameters Description Value SI Value English Inlet Air Temperature T 0 °C 32 °C Inlet Air Density p 1.293 kg/m3 0.081 Ib/ft3 Gas Constant R 8.314 kJ/ kmol °K 53.3 ft Ib/Ib air °R Blower Efficiency E 0.70 0.70 Absolute Inlet Pressure p1 0.70 atm 10.3 psi Absolute Outlet Pressure p2 1.12 atm 16.47 psi The power requirement for the blower is: Pw _ 0.283 wRT pz —1 550(0.283)e p, Equation 49 P _ (0.811b1 J 3) l f 3 ) l _ ° ) ( ° p 0.283 —1 t 25.74 t /min 53.31b / lb _air°R) 32 C + 490°C)16.47 psi P,, (550 ft _lb / s • hP) • (0.283) • 0.70 10.3psi Pw=1.183hP = 0.86kW (Note that this equation is valid only for English Units): The power requirement for the blower is 1.18 hP, which is less than the 7.5 hP power Kaeser Omega-pak Rotary Blower can provide. This blower meets the mixing requirement outlined in section 6.3.2.c of the CDPHE 96.1 design criteria by delivering 5.83 hP/1000 ft3of digester volume. Disinfection Design The SBR produces large batches of effluent during the decant cycle. From equation 26 the flow rate into the chlorine contact chamber is 111 gallons per minute. The addition of these large doses to the disinfection reactor will overload the existing chlorine contact chamber; thus the volume of the contactor will be increased by combining the existing clarifier and chlorine contact chamber into one unit. The CDPHE (Policy 96-1 Design Criteria 5.16.1.a) mandates a 30 minute contact time in the contact chamber during the maximum monthly average flow. The contact time in the combined disinfection reactor is: I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 25 tc% - Vcl_contact = 4260ga1 _ 38.3min Equation 50 decant 1 l lgal / min The 38 minute detention time within the chlorine contactor adds a 20% factor of safety to the required detention time. Summary of Project The current RBC system in place at the Canyon Creek Estates is in an extreme state of disrepair, and in constant need of maintenance. The community recognizes the need to update its wastewater treatment system and in 2005 began this necessary renovation. The HOA has selected a SBR process utilizing an Aire -02 Triton® Aeration System as its final treatment design because batch treatment is a cost effective method of handling peaking associated with subdivisions. The proposed plan is to adapt the current treatment plant in two stages of construction (Phase 2a and Phase 2b) due to limited funds. The proposed change to a SBR exceeds all state design criteria from the CDPHE 96- 1 regulations, and provides a high quality effluent. The goals of Phase 2a are to build a two part "Triton" tank, the reinstallation of the effluent polishing tank, and the movement of the pre -aeration basin to the second compartment of the "Triton" tank. The Phase 2b improvements will accomplish a conversion of the existing RBC facility to a new SBR plant in which the influent flows will be treated in a batch mode and will also provide an aerobic digester for waste solids storage and management. I:\\SGMSERV1\Projects\2003\2003-246\CDPHE\Phases 2a & 2b -Site Amendment\engineering letter.doc 26 APPENDICES Appendix 1 IMM N o— o M MI N-- N e— s N=— NM= 1:12003\2003-246\PHASE_2_REPLACEMENT A/RE-02.dwg Saved: Tue, 08 Jai?' 08 4:11pm Plotted: Tue, 08 Jon 2008 4:11pm bpennington m IT O O z I1\ x Zk Ire* ;�o � too • w� r l7 c. NI -- --- ES " N o k (�- ES o 1 L O • 5..3'-. Z".` a I1 na N ,Q o oit x a I w s' a 3 o o • { CT I 0\ re p 0 -. - rn 3 k .z, , .... 5. LS3 — S3 o `� 0 0 0 re $3 k Vi .A J ` y Q O1 �. cD I m �D $ cp j• j. 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I 11 �0 "S• K) k — ./� 11� n; mrti os II T IIGUI o c� �� 1 11 L�- _- --J �t (7. o_ I k ("0 0 T 0 0. \. .—a i I w \11 I V.10 o too J j rb O y JP )l-oN cA c3' • --, iii 1)o k' c O 0 po Q0. mo, Canyon Creek HOA WWTF Phase 2a Job No. Drawn by: Dote: 2003-246 RWP Appr. by: Fiiirse_2 Replacement_Aire-02 1 1 1 1 1 1 1 1 Appendix 2 — 11111 MN M 11111 111111 N1N I MN 1..•\2003\2003-246\PHASE2_ REPLACEMENT AIRF-02.dwg Soved: Tue, 08 Jon 200k 3:43pm Plotted: Tue, 08 Jon 2008 3.43pm bpennington rn I N O o qz S3 S3 x y 5- §-# 4:) .O4:) o.1 / II 11 IIS I I II 11 11 II 11 11 91uooap H N c cb •'J. j. cb CO 3t cb Phase 2b Job No. 2003-246 Drown by: Dote: RWP 1/8/08 Appr. by: 9 e_2 Replocement_Aire-o2 Appendix 3 i *— M NM I = 1 I A 111=1 M M = = = tlX051~-2.4Attle 1wi^ 1b & A1 -9k, A*`w.+N••.WrNw.••lM Siwe !It fr A. zoos 146.. Amor JYp O.r. AWN &2b wry ti COMM Ai AY •t 'as+y auoyda/ai ash ?ola,3 I I , I I 1 , I , I f , I I 1 I I y I , I a 1 1 n II II I 1 I 1 1 1 "-t n r, j, / V , 001 .=„1 •371105 Appendix 4 AIRE-02® Process Calculations Argos SBR Treatment System Canyon Creek, CO Date: 12/14/2007 06-10-05028SW Prepared By: SMS Municipal Revision: - Input Flow Parameters Effluent Limits Flow Average Design Flow Signifigant Delivery Period, SDP Percentage of flow in SDP SDP Row Average Flow Rate in SDP Peak Daily Flow Peak Hourly Flow Biochemical Oxgen Demand (BOD5) Total Suspended Solids (TSS) NH3 pH Basin Temperature (Min) Basin Temperature (Max) Elevation gpd 875.00 gph 16 h 95 % 19950 gpd 1246.88 gph 5000 gph 7500 gph 25mg/I mg/I 7 degrees C degrees C ft MSL output output output BOD5 Q 3 % mg/I BOD5 5.25 Ibs/day output TSS K mg/I TSS 5.25 Ibs/dat output NH3 mg/I NH3 0.18 Ibs/day output Reactor Tank Sludge Holding Tank BOD5 Removed 38.53 lbs/day output NH3 Removed 4.20 lbs/day output Number of reactors Decants per day 6 Decants per day in SDP 4 Gallons per decant in SDP 4987.50 gallons output Gallons per decant outside of SDP 525.00 gallons output Food to Microorganism ratio (F:M) 0.06 Biosolids in reactors, VSS inventory 642.18 lbs/day output Mixed Liquor suspended solids percentage 75 % Mixed Liquor suspended solids (MLSS) 856.24 lbs output MLSS concentration at HWL 4500 mg/I MLSS concentration at LWL 6000 mg/I Total Reactor Volume at LWL 0.02 million gallons output Individual Reactor Volume at HWL 22098.61 gallons output Size of each reactor tank 2954.36 cubic feet output Total reactor tank volume 2954.36 cubic feet output Pounds of dry solids / pound of BOD5 remv. 0.55 Pounds of dry solids per day 21.19 lbs/day output Gallons per day of wet sludge 169.40 gallons output Gallons per month of wet sludge 5082 gallons output Cubic Feet of Wet Sludge per month 679.411765 cubic feet output C SingleD Divided Tank Batch Rea Tank Design Choice L Single Continuous Flow Reactor Width 20 ft Reactor SW D 20 ft Reactor Length 7.39 ft output Sludge Tank Length 1.70 ft output Total Tank Length 9.08 ft output Reactor Width 30 ft Reactor SW D 20 ft Reactor Length 4.92 ft output Sludge Tank Length 1.13 ft output Total Tank Length at (12'W x 10'6" SWD) 6.06 ft output Multiple Tank Batch Reactor Width Reactor SW D Reactors' Length Sludge Tanks' Length Total Tanks' Length L Concrete .Ta Reactor Width Reactor SW D Calculated Reactors' Length Actual Length Total Calculated Reactor Tank Volume Actual Reactor Tank Volume 20 ft 20 ft 7.39 ft output 1.70 ft output 9.08 ft output 30.77 ft 2954.36 ft3 0.0263 MG 99.68 m3 3519.99 ft3 (30' max) output Oxygen Requirement AireO, Mixing Requirement Pounds of 02 per pounds of BOD Pounds of 02 per pounds of NH3 Process Oxygen Requirement (AOR) alpha beta tau 0.90 omega 0.80 Cs 6.54 Cw 2 mg/L C's20 9.09 mg/L Temperature 25 degrees C 1.5 4.6 77.13 lbs 02 / day output Process Oxygen Requirement (SOR) 184.87 1b02/day 84.03 k902/day Aeration Period 16.5 hrs/day 11.20 IbO2/hr 5.09 kg02/hr Type of Aerator SAE of Aerator Power Required Installed Power per Unit # of Units Total Installed Power Percentage ritor 3 Ib02/Hphr 1.82 kgO2/kWhr 3.73 Hp 2.79 kW HP 3.73 kW 5 HP 3.73 kW 133.87 Reactor Type of Aerator Design Mixing Intensity Power Required Installed Power per Unit # of Units Total Installed Power Percentage Triton 75 HP/MG 14.77 W/m3 1.97 HP 1.47 kW AHP 3.73 kW 5 HP 3.73 kW 253.18 % Decanter Sizing and Travel Alkalinity Decant Time 60 minutes Rate of Decant 83.13 gpm output Weir depth over weir edge 0.5 inches Reactor Footprint Area 439.99992 ft^2 output Decant Volume 666.78 ft^3 output Vertical Travel of Decanter in feet 1.52 ft output Vertical Travel of Decanter in inches 18.18 inches output lbs of Alkalinity per lbs of oxidizable NH3 7.1 lbs of Alkalinity required per day 29.84 lbs/day output Recommendation Summary Reactors Based upon the information given above, Aeration Industries recommends using one (1) reactor (12' wide x 36'-8" long x 8' SW D), using one (1) 5 Hp AIRE-02 Triton Aerator for supplying oxygen and mixing for this system. Worksheet Worksheet for Trapezoidal Channel Project Description Worksheet Trapezoidal Charm( Flow Element Trapezoidal Charm( Method Manning's Formula Solve For Channel Depth Input Data Mannings Coeffic 0.060 Channel Slope 090000 ft/ft Left Side Slope Right Side Slope Bottom Width 2.00 H : V 2.00 H : V 12.00 ft Discharge 432.00 cfs Results Depth 2.38 ft Flow Area 39.9 ft2 Wetted Perim( 22.64 ft Top Width 21.52 ft Critical Depth 2.90 ft Critical Slope 0.043573 ft/ft Velocity 10.83 ft/s Velocity Head 1.82 ft Specific Ener 4.20 ft Froude Numb, 1.40 Flow Type Supercritical Project Engineer: djc untitled.fm2 schmueser gordon meyer inc FlowMaster v7.0 [7.0005) 01/08/08 04:20:57 PM © Haestad Methods, Inc. 37 Brookside Road Waterbury, CT 06708 USA +1-203-755-1666 Page 1 of 1 SECTION 11375 SEQUENCING BATCH REACTOR SYSTEM PART 1 — GENERAL 1.01 SCOPE A. Single train sequencing batch reactor system for treating municipal wastewater. B. Equipment and controls, including, but not limited to, the following: 1. Electric motor -driven direct drive propeller -type floating aerator/mixer. 2. Portable davit crane. 3. Decant mechanisms. 4. Waste sludge pumps. 5. Dissolved oxygen control system. 6. Process control system with Programmable Logic Controller (PLC) and graphic operator interface. C. Installation and start-up assistance and training. D. Process guarantee. 1.02 SYSTEM DESCRIPTION A. Design Requirements 1. The system incorporates continuous activated sludge technology with continuous systems operation. The system uses a single vessel in which the activated sludge is alternately aerated and mixed over a number of pre- determined cycles. Solids liquid separation occurs during the settling phase of the cycle. After the settling phase, treated effluent is decanted or withdrawn from the liquid surface. Flow to the vessel is not interrupted at any time. The functions of flow equalization, biological oxidation, nitrification, sedimentation, and aerobic sludge stabilization can all be carried out in the same treatment system. 2. Influent Wastewater Characteristics & Site Conditions © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 a. Average Daily Flow: 0.021 MGD b. BOD5: 250 mg/1 c. Total Suspended Solids: 250 mg/1 d. Ammonia Nitrogen: 25 mg/1 e. Temperature Range (Water): 10-25 °C f. Site Elevation: 5,500 feet B. Performance Requirements 1. The following effluent limits shall be on a 30 -day arithmetic average: a. BOD5: 30 mg/1 b. Total Suspended Solids: 30 mg/1 c. Ammonia Nitrogen (NH3-N): 1 mg/1 2. It is the intent of these specifications that a single manufacturer -supplier, regularly engaged in the design, manufacture, assembly and production of sequencing batch reactor systems of the type specified, shall have complete responsibility for the final design, furnishing, coordination, and installation supervision of all components in the sequencing batch reactor system. It is also intended that said manufacturer -supplier make all adjustments, alterations, replacements and tests specified and required for a complete, satisfactory and trouble-free operating installation. 1.03 SUBMITTALS A. Shop Drawings 1. Submit under provisions of Division 1. Submittal shall contain, as a minimum: a. Product and dimensional data. b. Process calculations. c. Electrical connections and specifications. d. Installation instructions. © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 e. System accessories. f. Electric motor data. B. Operation and Maintenance Data 1. Submit under provisions of and in conformance with Division 1. 2. Submittal shall include: a. Operational, maintenance, and trouble -shooting procedures. b. Installation information. c. Replacement part numbers. d. Electrical control diagrams. C. Start -Up 1. Provide trip report, Certificate of Proper Installation, and Certificate of Contract Conformance prior to final acceptance by the OWNER. D. Pre -Qualification Requirements 1. The following manufacturer is pre -qualified: a. Aeration Industries International, Inc. — ArgosTM SBR 2. Other manufacturers must pre -qualify prior to bidding, as specified below. 3. This project was designed around the Aeration Industries Argos SBR system. If modifications to the current design are required, other manufacturers shall include the re -design cost in their bid price. 4. Any manufacturers not listed above shall furnish the ENGINEER the following information a minimum of 15 days prior to opening of bids: a. Operation data from a minimum of three SBR (3) installations using the proposed equipment. b. Photographic submittal, including: i. Overall view of the plants for which operational data is supplied. © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 ii. Details of the aeration and mixing equipment and how this equipment is installed and operates in the basin and how the equipment is accessed for maintenance. iii. Effluent decanter. c. Engineering reports conducted by an independent testing laboratory stating clean water oxygen transfer efficiency, including description of test facility, methods of sampling, calculations, and certified oxygen transfer curves. d. A listing of sewage treatment plants in which similar sequencing batch reactor (SBR) systems have been installed, including operator names and current telephone numbers. e. A statement of the equipment manufacturer listing any deviations or exceptions taken to these specifications. Include specification reference and proposed alternative with reason stated for exception. 5. Within 5 days prior to opening of bids, the ENGINEER shall issue an addendum listing manufacturers who have pre -qualified. Equipment Suppliers listing equipment manufacturers who have not pre -qualified shall be considered non-responsive and shall subject their bid to automatic rejection. 6. Incomplete pre -qualification submittals shall not be evaluated by the ENGINEER, and shall automatically represent rejection of the submittal. PART 2 — PRODUCTS 2.01 MANUFACTURERS A. Aeration Industries Argos SBR, or pre -qualified equal. B. Refer to Paragraph 1.03.D. for Pre -Qualification requirements. 2.02 DESIGN CRITERIA A. Parameters 1. Number of SBR Basins: 1 2. Inside Width/SBR Basin: 12'-0" 3. Inside Length/SBR Basin: 36'-8" © 2007 Aeration Industries International, Inc. Argos"'"' SBR Specification -121407 4. Water Depth at Top SBR Water Level: 8'-0" 5. Water Depth at Bottom SBR Water Level: 6'-6" B. The influent shall be continuously and simultaneously received by all SBR basins at all times, irrespective of the sequence of operation of the treatment system. The system shall be designed so that the basin configurations prevents short circuiting of the influent during the decant sequence. In addition, the influent feed piping to the system shall include a distribution header located on the inside bottom of each SBR basin at the opposite end of the basin from the decanter. The distribution header shall distribute the influent flow evenly into the bottom of the SBR basins to minimize disturbance of the settled sludge blanket during the settling and decant cycles. 2.03 EQUIPMENT A. Provide the following equipment: 1. Electric motor -driven direct drive propeller -type floating aerator/mixer. 2. Portable Davit Crane. 3. Decant mechanisms. 4. Waste sludge pumps. 5. Dissolved oxygen control system. 6. Process control system. 2.04 SBR BASINS A. The treatment plant basins shall be constructed of poured -in-place or precast concrete, as shown on the drawings. B. Each basin shall be equipped with a high level float switch to trigger an alarm should the basins maximum design water level be exceeded. C. The treatment plant manufacturer shall provide all internal piping for connection to the wall fittings as delineated on the drawings. 2.05 FLOATING AERATOR/MIXERS A. Each SBR aeration basin shall include a 5 H.P. Aire -02 Triton Aerator/Mixer. © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 B. Aerator/Mixer General Description 1. The unit supplied must be able to provide and be operated in both a mixing and a mixing/aeration mode controlled completely independently of each other. 2. The aerator consists of an electric motor and regenerative blower located above the water surface. The motor is connected to a hollow shaft within a protective housing positioned at desired angles for water displacement downward into the water. Aerators with submersible motors are not acceptable. Solid shafts are not acceptable. 3. The hollow shaft drives a primary propeller beneath the water surface. Attached to the primary propeller is a Saturn ring diffuser, which disperses the air into the stream of displaced water beneath the water surface. 4. The Aerator/Mixers shall be fitted with float assemblies and a stainless steel slide rail system which shall be anchored to the basin walls to allow for the Aerator/Mixer to move up and down in the basins as the water level varies. C. Manufacturer 1. The equipment shall be manufactured by Aeration Industries International, Inc., Chaska, Minnesota. D. Aerator Drive Motor 1. The motors for the SBR aeration basin Tritons shall deliver 3.5 horsepower at 900 RPM nominal and shall be rated for 230 volts, 60 cycle, 3 phase service. Motors shall be specifically designed for operating angle of 45°. 2. Motor enclosure configuration shall be totally enclosed, fan cooled. 3. The motor shall, in all cases, equal or exceed current NEMA specifications. 4. The motor windings shall be nonhygroscopic. 5. Insulation shall equal or exceed NEMA Class F with Class B temperature rise. 6. A service factor of 1.15 shall be furnished. © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 7. A condensate drain shall be located at the lowest point in the lower end - bell housing. 8. A stainless steel nameplate shall be provided with each motor and shall be securely fastened thereto. Information shall include voltage, speed, phase, insulation class, amperage, service factor, wiring diagram, and motor serial number. 9. The motor shaft shall be balanced to within 1 mil to be measured on any part of the motor frame including the C -face. 10. The motor terminal box shall be firmly bolted to the motor frame at four points. The terminal box shall be sized to meet the NEMA standards. 11. The terminal box shall be drilled and tapped to receive one compression watertight fitting to accommodate the appropriate electrical service cables. E. Blower 1. The equipment shall include a high efficiency regenerative blower sized to provide sufficient airflow to yield the rated oxygen transfer capacity. Each blower includes the following features: i. Maintenance free ii. Aluminum alloy construction iii. Inlet and outlet sound attenuating silencers to minimize noise. iv. Inlet filters with epoxy -coated wire mesh media rated for 70 microns or better. v. CE compliant — Declaration of Conformity on file vi. The blowers shall be tropicalized for corrosion resistance. vii. The blowers for the SBR aeration basin Tritons shall deliver 1.5 horsepower maximum rated for 230 volts, 60 cycle, 3 phase service. viii. Blower motors shall be wired separately. F. Mounting Flange 1. The mounting flange shall be 304 stainless steel. © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 G. Shaft/Universal Joint Coupling 1. The shaft shall be 304 stainless steel full -welded to a forged carbon steel universal joint coupling. The shaft must be hollow to promote maximum airflow and oxygen transfer. Units with solid shafts are not acceptable. The shaft shall be dynamically balanced. 2. The universal joint coupling shall include standard grease fitting for maintenance lubrication. Units that utilize flexible couplings to attach to the shaft of the motor are not acceptable. 3. The shaft shall be stabilized by replaceable water lubricated bearing located within one inch from the propeller hub. The area of the shaft supported by the bearing shall be fitted with a replaceable hardened non- metallic sleeve. 4. Units supplied with couplings that require alignment are not acceptable. 5. Any shafts requiring factory replacement to validate warranty requirements are not acceptable H. Housing 1. The housing shall be 304 stainless steel and flanged for mounting to the aerator. 2. The housing shall form a guard around the hollow shaft and support a field replaceable, water -lubricated bearing press -fitted into the housing lower end. 3. Water lubrication holes shall penetrate the housing in the area surrounding the bearing. I. Bearing 1. The aerator shall be supplied with a field replaceable water lubricated lower support bearing. The bearing shall be press -fitted into the housing to allow ease of replacement. 2. Units utilizing a cantilever design without a lower support bearing or regreaseable tapered roller bearings are not acceptable. 3. Bearings requiring factory replacement to validate warranty requirements are not acceptable. J. Propeller © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 1. The bronze mixing propeller shall be specifically designed to maximize oxygen transfer and mixing characteristics. Propeller shall be self - tightening such that the propeller threads tighten on the shaft threads during normal operation. The entire flow of air shall pass through the propeller shaft via the hollow drive shaft along the axis of the propeller hub. Aluminum propellers are not acceptable. 2. The propeller design shall be tested in clean water and shown to draw a minimum of 85% of the recommended full motor amperage load at nameplate voltage and power factor. 3. The propeller shall be designed to allow easy removal and replacement in the field. K. Saturn Ring/Diffuser 1. The Aerator shall be equipped with a 304 stainless steel secondary Saturn Ring diffuser, smaller than the mixing propeller, consisting of two concentric rings of differing diameters fixed to the diffuser body. The rings shall be specially designed to maximize oxygen transfer and to prevent self aspiration when the regenerative blower is turned off to accomplish anoxic mixing. 2. The entire flow of forced air shall exit through the Saturn Ring diffuser opening. L. Vortex Shield 1. A vortex shield shall be furnished with each mounting assembly to eliminate the formation of vortices, maximize shaft airflow and prevent cavitation damage to the propeller during operation. 2. Units without vortex shields are not acceptable. M. Floatation 1. The aerator floatation assembly shall be constructed of molded low- density polyethylene with ultraviolet inhibitor. The pontoon shape shall be designed with smooth, beveled edges to allow freezing into ice without breakage. 2. The pontoons shall be connected by (galvanized/stainless) steel structural members to prevent corrosion. To allow for servicing by not removing the © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 aerator from the floatation, the floatation assembly shall be designed so the aerator may be pivoted completely out of the water. 3. Structural aluminum is not acceptable. Welded stainless steel floats will not be acceptable. N. Electrical Service Cable 1. Cable shall be CSA/UL approved for severe environments, suitable for underwater service and one continuous length. 2. The cable shall be jacketed, flexible stranded cable with individually wrapped conductors rated SEO-WA or equivalent. O. Slide Rails 1. Slide pole assemblies constructed of 304 stainless steel pipe shall be provided for anchoring to the basin walls. 2. The slide pole assemblies shall be designed to handle the thrust and torque produced by the aerator/mixer and shall allow for free vertical movement of the aerator/mixer without binding as the water level in the basin changes. 3. The pipe shall be filled with concrete by the CONTRACTOR after installation to seal the piping and minimize vibration during operation of the equipment. P. Controls 1. Local control stations shall be provided for operation of the Triton mixer and blower motors. Q. Delivery, Storage, and Handling 1. Aerator shall arrive at the installation site fully assembled and ready for attachment to the floatation or support equipment. 2. Units with couplings that can become misaligned during shipment or installation are not acceptable. R. Warranty 1. The aerator Manufacturer shall supply a 3 - year non -prorated factory warranty. © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 2. All parts supplied by the aerator Manufacturer must be warranted by the same. 3. Field replacement of aerator components shall in no way affect the factory warranty. 4. All warranty repairs must be done in accordance with the factory 0 & M Manual. 2.06 PORTABLE DAVIT CRANE AND BASES A. A portable davit crane shall be provided for ease of removal of the aerator/mixer units for periodic maintenance. Each aerator/mixer shall have a crane base installed on the walkway near each unit to accept the davit crane and allow for the main drive unit of each aerator/mixer to be lifted off of the float assembly and onto the walkway for inspection, servicing, or transport. Openings in the handrail on the walkway or removable sections of handrail shall be provided to enable the unit to be swung onto the walkway. The portable davit crane shall be manufactured by Them, Inc. or approved equal. B. The crane shall be designed with an ultimate design factor greater than 3:1 for all components including the lifting winch and base. C. Boom shall telescope up to 4 different lengths allowing for variable hook reach. Hook height shall be adjustable by moving the boom up or down between horizontal and 45 degrees from vertical. Boom angle shall be adjustable at all times including when under full rated load with a hand operated screw jack acting to raise or lower the boom. D. Wire rope shall pass over a sheave at the end of the boom. Sheave shall have a bronze bearing. E. Mast and boom shall rotate 360 degrees in the base on pin bearing and bearing sleeve, with a rotational handle attached to mast to facilitate rotation. F. Crane components shall be fastened together using stainless steel clevis style pins, secured with lynch pins with lanyards fastening the lynch pins to primary structural components. G. Davit crane shall break down into portable components with no single component weighting more than 100 pounds (45.4 kg). Carrying handles shall be welded to mast and boom. H. Lifting winches shall be located such that the center point of the drive shaft is behind the centerline of the mast. © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 I. Wire rope construction shall be 7 x 19 type 304 stainless steel cable. Latch type hooks shall be used and shall be either non -rotating eye type or swivel type to allow 360 degree rotation under all load conditions. Hooks shall be heat treated drop forged type 304/316 stainless steel. J. Crane bases shall allow for easy removal of the mast. Bases shall have a pin bearing to support the end of the mast and a Nylatron GSM bearing sleeve to support the mast at the top of the base. K. Lifting winches shall have machine cut hears, an adjustable handle that mounts securely to the drive shaft, bronze and radial ball bearings, and a positive load holding Weston style brake able to stop and hold the load automatically if the winch handle is released. L. Lifting winch shall have a zinc and iridescent dichromate plated corrosion resistant finish. Crane boom, mast, and base shall be fabricated from steel meeting ASTM standards and have a corrosion resistant finish. 2.07 DECANTERS A. Each SBR aeration basin shall include a solids limiting decanter controlled by the SBR logic system to provide sequencing decants compatible with the hydraulic requirements of the system. B. The logic controls may be adjusted to modify the duration and/or frequency of the decant mode. C. The solids limiting decanter shall be 304 SS construction. D. The decanter shall be a four-sided flat weir decanter with an integral solids exclusion baffle. E. The decanter shall be operated in a vertical direction. Decanters with operators operating at an angle and/or floating decanters are not acceptable. F. The decanter shall be moved up and down by a jack screw. The speed and direction of the decanter shall be controlled by a Duff -Norton (or equal) translating machine screw actuator connected to a 1/2 HP, 230 volts, single phase, 60 cycle gear motor. G. The actuator shall be supplied with a steel base plate for anchoring to the basin wall to support the load of the actuator and decanter. H. The actuator and decanter shall be located near the side of the basin to allow for easy inspection and maintenance. © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 I. The decanter slip tube welded to the decanter pan shall be stainless steel and shall be sized to fit the connecting riser pipe. The slip tube shall be a minimum of 16 ga. stainless steel and incorporate a 150 lbs. stainless steel companion flange and 1/4" (7mm) thick neoprene wipe gasket. J. The decanter shall be parked above top water level during aeration and settling periods, thereby eliminating any possibility of solids carryover during these periods. K. At top park position, the decanter shall provide "fail safe" overflow protection in the event of a power failure. Settled supernatant will flow via gravity out of the decanter into the effluent collections system. The decanter solids exclusion weir shall prevent the carry over of any floatables during such emergency periods. L. The actuator drive shall incorporate limit switches at the top and bottom of travel to ensure reliable operation. The limit switches shall be fully integrated with process control time overrides and interlocks. M. Local control stations shall be provided for operation of the decanters. 2.08 WASTE ACTIVATE SLUDGE PUMPS A. Each SBR unit shall also include a waste activated sludge (WAS) submersible pump for pumping waste sludge from the reactor basin to the sludge holding basin. B. The WAS pumps shall be controlled by SBR logic system. The logic controls may be adjusted to modify the duration and/or frequency of the sludge wasting. C. The waste activated sludge pumps shall be submersible pumps capable of pumping up to 95 gpm against a total dynamic head of up to 34 ft. The pumps shall be Model SX50 as manufactured by Myers (or equal), 1/2 HP, 230 Volt, single PH, 60 Hertz. D. The pump motors shall be fully submerged in an oil filled chamber for efficient heat dissipation, permanent lubrication of bearings and seal and for protection against submerged environment. E. A heavy duty submersible power cord shall be provided. The cable shall be heavy-duty STO type, water and oil resistant. An epoxy seal at the motor end provides a secondary moisture barrier in case of damage to the jacketing. F. Pump impeller to be two -vane design keyed to shaft and with ejector vanes on the backside for further protection of the seal chamber. The pumped liquid © 2007 Aeration Industries International, Inc. Argos'T' SBR Specification -121407 shall flow through a passage providing true full -diameter solids passing capability of 2 in. G. A twin guide rail system with floor mounted break -away coupling shall be provided for each pump. No additional sealing measures are required as the pump weight provides sufficient force for a proper seal. The system shall be self-cleaning in that during pump engagement, shearing action wipes the sealing surface clean. Guide rails to be fabricated of 3/4 in. diameter schedule 40 galvanized pipe. H. A galvanized steel lifting chain of adequate strength shall be attached to each pump and hook onto the station top. The chain shall be utilized to pull the pumps from the chamber for service/inspection. 2.09 DISSOLVED OXYGEN CONTROL SYSTEM A. Provide one (1) dissolved oxygen (DO) control system for each SBR aeration basin. The dissolved oxygen control system shall be integrated with the sequencing batch reactor aeration system and process control system. B. The dissolved oxygen control system shall be a Hach SC100 Controller with a compatible LDO sensor, or approved equal. The system shall, as a minimum, consist of the transmitter, sensor, and mounting hardware for monitoring dissolved oxygen on a continuous basis. The equipment should be designed for wastewater treatment applications. C. The mounting hardware for the LDO sensor shall consist of a pole mount assembly and a ball float mount allowing the probe to move up and down in the basins to accommodate fluctuating water levels. D. The DO signal shall be displayed at the SBR control panel Operator Interface Terminal (OIT) and shall have a 4-20 mA input to the PLC. The PLC, using a PID control function will output a signal to the aerator/mixer blower motor to control the operation of the blower as needed to maintain the dissolved oxygen setpoint. 2.10 PROCESS CONTROL SYSTEM A. A complete SBR control system shall be provided. This shall include: 1. A SBR control panel with a OIT, PLC, control switches, pilot lights and motor starters. 2. Local control stations for the aerator/mixers and decanters. B. A NEMA type 4 electrical control panel, designed for a 230 volt, © 2007 Aeration Industries International, Inc. ArgosTm SBR Specification -121407 single phase, 60 hertz electrical distribution system, shall be provided for the SBR treatment plant and components. C. The control panel shall include main breaker, motor circuit breakers, magnetic starters for the pumps and decanter drives, and slow speed magnetic starters for the aerator/mixer motors as well as all selector switches, relays, timers and all additional secondary circuit controls required for manual and/or automatic control of the treatment plant. A phase converter shall also be provided for the Triton aerator/mixer to convert single phase power to three phase power. D. All internal devices shall be clearly marked and identified on the outside and inside of the panel. All terminals and wires shall be clearly tagged in accordance with the schematic and wiring diagrams. E. Secondary control circuit voltage shall be 120 volt, 60 cycle provided from a direct step down of the incoming electrical service and provided with surge suppression. F. The SBR treatment plant shall be controlled by a micro processor based automatic programmable logic controller. The PLC shall be an Allen-Bradley Micrologix series, or equal. G. The PLC processor shall be equipped with two RS232 ports for communications. A modem shall be provided with auto answer for remote technical support. The modem shall be a Motorola 3220+, or equal. H. The OIT shall have a sixteen position key pad menu controller and a LED status display. The OIT shall be an Allen-Bradley PanelView series, or equal. I. The menu screen shall provide a readout for both stage time and status of operating stage time (time elapsed or time remaining). The controller shall automatically start and stop the SBR cycles based on adjustable field settings. At the completion of the react time (aeration/mix), the SBR unit will settle for a preset adjustable length of time. It will then automatically decant through the decanter for a preset length of time. The above react, settle and decant cycles will then automatically be repeated in accordance with an operator adjustable preset sequence. J. An override selector switch shall be provided to allow the operator to manually override the aeration cycle and stop the system for manual sludge pumping. PART 3 - EXECUTION 3.01 GENERAL © 2007 Aeration Industries International, Inc. Argos SBR Specification -121407 A. All work shall be accomplished to the satisfaction and approval of the OWNER/ENGINEER and in accordance with these specifications. B. In case of conflict between any of the contract requirements, the ENGINEER shall be the sole judge of the criteria to be used to resolve the conflict. The intent, however, is that the contract documents complement each other in the following order of precedence: (1) These Specifications, (2) National Standards (AWWA, ASTM, ASSHTO, etc.), and (3) Contract Drawings. C. The CONTRACTOR shall provide temporary connections and by-passes where necessary to maintain continuous operation of any and all existing mechanical systems and equipment as necessary until new systems and equipment to be furnished under this contract are ready for operation. D. The CONTRACTOR shall verify the location and inverts of all existing utilities at the various points of connection and/or crossing prior to starting any work. Any discrepancies in locations or inverts shall be brought to the attention of the OWNER in order that the designs may be adjusted accordingly. Damages suffered or additional costs incurred by the CONTRACTOR as a result of his failure to conform to the requirements of this paragraph shall be the sole responsibility of the CONTRACTOR. Connections to existing utilities shall be made by the CONTRACTOR at such a time and in such a manner as the OWNER may direct, and the cost shall be borne by the CONTRACTOR. No valve, switch, hydrant or other control on existing utility systems shall be operated for any purpose by the CONTRACTOR without written approval of the OWNER and the ENGINEER. 3.02 INSTALLATION A. The components of the treatment plant shall be installed in strict accordance with the manufacturer's recommendations and instructions and as indicated on the drawings, installation instructions, and elsewhere in these specifications. B. Aerator/mixer units shall not be operated for any period of time out of water. C. The CONTRACTOR shall supply paint for field touch-up and field painting. The CONTRACTOR shall touch-up all shipping damage to the paint and stainless steel as soon as the equipment arrives on the job site. D. Prior to assembly, all stainless steel bolts and nut threads shall be coated with a non -seizing compound by the CONTRACTOR. E. The Manufacturer shall include in their Bid the services of a competent factory representative familiar with the installation of the equipment as required to instruct the CONTRACTOR prior to installation of the equipment © 2007 Aeration Industries International, Inc. Argos"" SBR Specification -121407 and to instruct the OWNER's personnel in the operation and maintenance of the equipment. F. CONTRACTOR shall test the operation of the system per the manufacturer's recommendations. G. CONTRACTOR shall form and pour all concrete structures and bases in accordance with the project plans and manufacturer's installation drawings, paint equipment and piping, and grout in embedded items where required. H. Electrical CONTRACTOR shall wire in all motors and controls. 3.03 PROTECTION A. The CONTRACTOR shall properly and efficiently protect, at all times, mechanical units and equipment from damage and the intrusion of foreign materials. The open ends of all piping shall be effectively closed at the end of each day's work or before backfilling. B. The CONTRACTOR shall assume responsibility for any damage done by him, his agent or employees to any work already in place, the building, grounds, trees, or appurtenances by reason of his work or any part of same. C. All paved roads, curbs and gutters, driveways and walkways surfaces damaged in the course of this work shall be replaced equivalent to existing surfaces in a manner approved by the OWNER. D. All lawn and grass areas disturbed in the course of this work shall be backfilled as described above and shall be finished with topsoil, seeding and mulch approved by the OWNER. 3.04 SERVICES A. The CONTRACTOR shall provide the services of the manufacturer to: inspect/advise during installation, supervise start-up and provide general operational adjustments as required, and thoroughly train the OWNER's operators in the operation of all process equipment. In addition, one inspection visit will be made during the warranty period to observe plant operations and report results to the OWNER/ENGINEER. A total of 5 days on site shall be allotted for the preceding services, excluding travel and set-up time. B. At start-up, the following at a minimum shall be performed: 1. Inspect all rotating equipment to see if it is properly lubricated. © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 2. Check rotation of all motors. 3. Check all instrumentation and controls to determine that they function properly at all stages of the treatment process. 4. Check and correct equipment malfunctions. 5. Report all malfunctions to the ENGINEER. C. At substantial completion of the treatment facilities, the CONTRACTOR shall direct sewage flow through the new sewage treatment plant. The CONTRACTOR shall operate the plant and demonstrate to the OWNER and ENGINEER that the facility is operational and in substantial compliance with the discharge permit limitations. If the plant is unacceptable to the OWNER and ENGINEER, or if discharges are in violation of the permit limitations, necessary modifications shall be made by the CONTRACTOR at no additional cost to the OWNER. All chemical materials utilized during the demonstration period shall be furnished by the CONTRACTOR. D. During the demonstration period, the CONTRACTOR shall provide training of the OWNER's operators for a minimum of 8 hours in the operation of all process equipment. 3.05 WARRANTIES A. The manufacturer shall guarantee that all items furnished and installed will be warranted against defects in material and workmanship for a period of 12 months after start-up. The aerator/mixer equipment shall be warranted for a period of 36 months after start-up. Exempted from this warranty are expendable items such as drive belts, light bulbs, etc. B. In addition, the manufacturer shall guarantee to the OWNER and ENGINEER that the system shall operate in such a fashion as to ensure compliance with the effluent standards imposed by the state in their operating permit for a period of 12 months after start-up. The warranty shall consider operation at flow rates and raw wastewater characteristics anywhere from 75% to the permitted levels, with occasional instantaneous peak variations of up to 125% in both flows and strengths. END OF SECTION © 2007 Aeration Industries International, Inc. ArgosTM SBR Specification -121407 AIRE-O,• April 5, 2007 Aeration Industries International, Inc. P.O. Box 59144 u Minneapolis, MN 55459 u USA To: Bob Pennington, P.E. SGM, Inc. Re: Canyon Creek WWTF SBR Design Information Dear Bob, Per your request, I have included, with this cover sheet, information on the design of the SBR for Canyon Creek. Triton Aerator/Mixer The Triton unit will be float mounted. The float assembly is designed with a Rail System Mounting Assembly on the outside of each side float consisting of UHMW Rollers. The rollers ride up and down on guide rails that are made up of 4" 304 SS pipe rails. The guide rails will be anchored into the existing tank using adhesive anchors. I have attached the following information on the Tritons: 1. Triton Blower motor data sheet —1 '/2 hp 2. Triton Mixer motor data sheet — 5 hp 3. Triton Mixer motor cut sheet — Reliance XT Motors 4. Cable sizing reference chart for Triton motors 5. Triton Tri -Float System Typical Layout Drawing — dwg. SK06-020, sht. 1 6. Triton Guide Rail System Typical Layout Drawing — dwg. SK06-020, sht. 3 7. Triton Spec Decanter The decanter is fixed mounted (vs. floating) and rides up and down on a jack screw controlled by a worm gear motor. The decanter effluent pipe is 6" diameter. Distance from the face of the concrete divider wall separating the reactor tank from the sludge holding tank and the centerline of the decanter effluent pipe will be 2'-9". The decanter gear motor is powered by a %2 hp motor. We will provide supports for the decanter and piping inside the tank which will be installed using adhesive anchors. I have attached the following information on the decanter: 1. Decanter drive unit cut sheets 2. Decanter Layout Drawing — attached separately in AutoCAD (*.dwg file) Sludge Pump Piping for the sludge pump will be routed over top of the divider wall. The slide rail system for the sludge pump will be anchored to the face of the concrete wall using adhesive anchors. I hope this information adequately covers your needs at this time. If you need additional information, or have any questions, please feel free to contact me. Most Sincerely, G. Shawn Brown Systems Product Manager Aeration Industries International, Inc. shawn.brown(r�aireo2.com 1-952-448-6789, ext. 706 fax: 952-448-7293 CC: D.Goodyear — Water Technology Group P.Ingle — AIII T.Martin — AIII B.Randall - AIII 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 FPZ, Inc 2091 N.Port Washington Rd Grafton, WI, 53024 - U.S.A. Tel. (262) 375.7380 Fax (262) 375.7381 E-mail usapfpz.com TECHNICAL CHARACTERISTICS - Aluminium alloy construction - Smooth operation - High efficiency impeller - Maintenance free - Mountable In any position • Recognized TEFC - cURus motor OPTIONS - Special voltages (IEC 38) . Surface treatments ACCESSORIES • Inlet and/or Inline filters - Additional inleIJoullet silencers - Safely valves - Flow converting device - Optional connectors Dimensions In inches Model K03 -MS a b H REGENERATIVE BLOWERS - PRESSURE SCL K03 / K04 / K05 / K06 MS SERIES SN 1874-4 1/2 •p1 i 3x120' eu A5Cessory / Possible elternelive positions, please refer to drw SI 1839 c d 9.49 110.55 6.79 1.69 e 9.06 f G 8.07 1"114 NPT e• 0 p1 b c Q 6 u z K0444. K05 -MS K06 -MS 11.22 12.40 6.77 1.93 12.87 14.37 7.87 2.13 14.8016.47 8.07 2.13 10.04 8.86 1"1 72 NFT 12.60 10.24 2" NPT 12.80 11.42 2" NPT 0.47 3.39 0.39 3.273 5.59 8.07 4.02 4.72 1 0.59 4.02 1 0.59 3.74 1 8.73" 8.74 4.63 10.43 [12.60 5.51 10.43 13.15 0.71 0.71 0.71 0.71 2.96 2.76 3.86 3.36 0.16 0.16 0.18 0.16 t46 MB M8 M8 5.61 6.89 7.87 9.46 0.47 0.71 0.75 0.76 Model Maximum flow Salm 60 Hz 3500 rpm 50 Hz 2900 rpm Installed power Hp 60 Hz 3500 rpm 50 HZ 2900 rpm Maximum differential 4p(InWG) 60 Hz 3500 rpm pressure 50 Hz 2900 rpm Noise Lp dB ( 60 Hz 3500 rpm level (A) 50 Hz 2900 rpm Overa 1 dimensions H Inches Weight Lbs 1:03-145 62 43 3M 3/4 64 60 62.0 60.0 10.43 24.30 1 80 . 62.3• 11.97 26.60 ) 04 -MS 98 81 1 Y. 1 56 80 64.8 62.8 11.66 36.40 2 2 85 100 66.0 63.0 13.78 43.00 3 120 66.2 63.2 13.78 49.60 ) 0V -MS K06•MS 166 129 2 2 62 70 70.6 66.5 13.20 51.80 3 3 90 110 70.8 68.8 13,20 58.40 4 3 4 3 128 60 120 71.1 69.1 14.40 216 179 65 73.0 71.0 13.54 67.20 60.70 4 4 76 95 73.3 71.3 14.17 71.65 6'Y. 5 2 110 140 73.6 71.6 14.17 77.60 6 v6 in - 132• 73.9 - 14.46 77.60 O o se meesured al 1 m d131snce wdh inlet end outlet porta piped, in accordance to ISO 3744_ (2) No cURus motor - For proper use, the blower should be equipped with Intel filler and safety valve; other accessories available on request. - Ambient temperature from +5' to +104'F. • Specifications subject to change without notice. F.P.Z. effeplzeta s.r.I. FPZ UK LTD • •A. F 0.M 1654 20040 00ne0laeee .1699)- ITAUA TH. 439 030 601 1620 F. •39 039 601 1296 E -m.4 Ib6.Qlp9K0K G,elrley Bualneaa Part. Chelde nun Fo.d Gr NeleyA doves HW,1PEHIHE.5P1111S1•1• 051150 KINGDOM Tal •14 1204 190001 Far •441204 569003 E-m.e ult2rye 4910 F.P.Z. France a.r.I. F.P.Z. GmbH PA E.cope- 10 cue de "0ali 6-0710 - ra,ma •FRANCE T41. +33 10)1722 50 12 13 Fu •33 (0)472 55 03 40 Ean.9 km4 ,seam 1060109.64 142 63425 H0mbe19 - DE9ISCHLAND Tel •/910)911 36 76 6600 Fe. •4610)911 3e re 64.01 E.mae deu4er.nct494 am FPZ IBERICA S.L. Pdpouo Ina E"ola 046.ibn 20770 • ANOETA GIPUZKOA - ESPANA Tel +34 943 656464 Fla +34 643 655654 E -m w 10.093041 amn 1 1 1 1 1 1 1 1 1 1 1 1 • 1 1 1 FPZ, Inc 2091 N.Port Washington Rd I I / /0 Grafton, WI, 53024 - U.S.A. ‘7, / Tel. (262) 375.7360 / Fax (262) 375.7361 E-mail usa@fpz.com . . - - ..... 2 6 1 a 1 1 1 1 REGENERATIVE BLOWERS - PRESSURE S.CL K03 / K04 / K05 / KOG MS SERIES SN 1874-4 212 140 100 110 60 40 20 0 6 2 3 4 5 1 0 26 4o 00 100 120 HP 140 T ABSORBED POWER TEMPERATURE INCRESASE 160 2 I a 5 120 3. 21 100 Bo 60 40 20 160 120 s 60 60 0 20 0 50 100 110 200 Selon ' • 1 1 , i 1 • I 1.... ' A $004551 AB III II KIWAS .... . 1 1 IA _ _ I(050,00. 14054.4 Min A 1034. 16 P izt •irnri . i NAN 6 2 3 4 5 1 0 26 4o 00 100 120 HP 140 T ABSORBED POWER TEMPERATURE INCRESASE 160 2 I a 5 120 3. 21 100 Bo 60 40 20 160 120 s 60 60 0 20 0 50 100 110 200 Selon ' • 1 1 , i 1 • I 1.... ' A $004551 AB KIWAS .... . 1 1 IA _ _ Min min 2 • HP 0 20 40 GO 00 100 120 140 100 100 200 •F Curves refer to air al 68°F temperature end 29.92 In Hg atmospheric pressure (abs) measured at inlet Pert. Values for flow, power consumption and temperature rise: +/-10% tolerance. Data subject to change without notice, 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ir • COMPRESSORI . ASPIRATORI A CANALS LATERALS LATERAL CHANNEL BLOWERS • EXHAUSTERS Dalt nominali molori eletirici Trifase 9 -phase rated data electric motors PaD.Mn SN 2103 3-PHASE MOTOR GENERAL SPECIFICATIONS: 1- Tj'pe: 3-phase AC MOTOR - IEC 60034 2- Marks: cURus, CE 3- Poles: 2 4- Frequency: 60 Hz 5- Insulation Class: F 6- Enclosure: TEFC 7- Protection: IP 56 8- Thermal Protector: KLIXON 160 °C 9- Service Factor: 1,16 10- Max. Ambient: 40°C 11- Duty: Cont. 12- Construction: Aluminium frame POWER Hp kW VOLTAGE 60 Hz V 50 Hz EPEED min 60 Hz " 50 Hz FLA A STARTING CURRENT A POWER FACTOR cos 80 Hz tp 50 Hz 1/3 0.25 208-230/460 230M00 3310 2760 15 / 0,7 5,0 / 2,3 0,79 0,73 1/2 0,37 208-230/460 230/400 3270 2720 2,3 / 1.0 8.1 1 3,5 0,75 0,70 314 0,55 208-230/460 230/400 3380 2640 2,7 / 1,2 10,6 / 4,7 0,85 0,78 1 0.75 208-230/460 230/400 3410 2840 3,3 / 1,5 13,0 / 6,3 0,84 0,78 14 208.230/00 230/400 3400" ` 2810 ; 5,0 /';2,3 21,0 1°. 9,7 0,86 0,82 2 1.5 208-230/460 230/400 3380 2830 6.L3 ,/ 2,9 24;4 / 12,2 0,00 0,82 3 2.2 208-230/460 230/400 3420 2860 9,0 / 4,1 46,8 / 21,3 0,87 0,81 4 3,0 208-230/460 230/400 3420 2860 12,9 / 6,1 74,8 / 35,4 0,85 0,05 5'4 4,0 208-230/460 230/400 3400 2835 16,21 8,1 94,0 / 47,0 0,88 0,88 7 It 5,5 208-230/460 230/400 3460 2890 19,7 / 11,4 110,3 / 63,8 0,82 0,82 10 7,5 208-230/460 230/400 3440 2880 26,5 / 15,3 164,3 / 94,9 0,87 0,87 15 11,0 208-230/460 230/400 3460 2880 37,5 / 21,7 228,7 / 132,4 0,84 0,84 20 15,0 208-230/460 230/400 3530 2940 51,6 ;/ 2928_ 319,9 / 184,8 0,85 0,85 25 18,5 208.230/460: 230/400 3540 2950 60,0 / 34,8 372,0 / 215,8 0,87 0,87 IA M N TENSIONE !MIN VOLTAGE j Y MAX TENSIONE 1 MAX VOLTAGE Uc V2 w2 U2 -VC �wt. 0 () 0 �UI 0Vl 0VI c," v 1 -�p� BUJ' �T7ryry 0 e THERMAL PROTECTION NORMALLY CLOSED THERMAL CUT•OfF ° f.,*,INt 77laQM° 'Ai: Rhe c.uu.:w 0,p. Me Gad MN. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REL. S.O. FRAME HP TYPE PHASE/ HERTZ RPM VOLTS 1MAN38024 254TCZ 5 P 3/60 870 230/460 AMPS DUTY AMB°C/ INSUL. S.F. NEMA DESIGN CODE LETTER ENCL. 15.2/7.6 CONT 40/F 1.15 B H TEFC-XT E/S ROTOR TEST S.O. TEST DATE STATOR RES.1125°C OHMS (BETWEEN LINES) 585811 411287 -70 -CE --- --- .668/2.67 PERFORMANCE LOAD HP AMPERES RPM % POWER FACTOR % EFFICIENCY No LOAD 0 4.1 900 11.2 0 1/4 1.25 4.4 893 37.8 71.0 2/4 2.50 5.1 886 57.1 80.2 3/4 3.75 6.2 877 68.6 82.3 4/4 5.00 7.6 868 74.7 82.0 5/4 6.25 9.4 857 77.7 80.5 SPEED TORQUE RPM TORQUE % FULL LOAD TORQUE LB. -FT. AMPERES LOCKED ROTOR 0 168 50.8 40.0 PULL UP 300 151 45.8 36.4 BREAKDOWN 700 238 72.0 27.4 FULL LOAD 868 100 30.3 7.6 AMPERES SHOWN FOR 460. VOLT CONNECTION. IF AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE REMARKS' TYPICAL DATA -NEMA NOM. OTHER VOLTAGE CONNECTIONS ARE AVAILABLE. THE EFF 81.5 PCT RELIANCE ELECTRIC Q CLEVELAND, OHIO 44117 U.S.AwDAT ''. A -C MOTOR E00056 -A -D003 PERFORMANCE 08/19/96 DATA ISSUE DATE CK. BY w; • 1a APP. ex AILMI : • 18 sir li=Y File #79279 RELIANCE ELECTR/C� RELIANCE ELECTRIC® XT EXTRA TOUGH AC MOTORS 1/4-300 HP (EMT) 1/4-400 HP (XEX) Extra Protection For Tough Industrial Applications fockwell Automation XTTMAC Motors: Extra Tough For Extra Protection The XT family of Duty Master AC motors offers an extra tough mechanical package especially designed to meet the challenges of severe applications. Premium features protect motor components from chemicals, corrosion, and abrasives, extending motor life and improving performance in the harshest industrial environments. Reliance Electric XT cast iron motors come in a wide range of ratings and enclosures with a variety of performance characteristics to meet standard or premium energy efficiency requirements. Every Reliance Electric XT motor is manufactured in a plant using stringent ISO 9001 certification quality control procedures. Comprehensive testing and quality control procedures ensure compliance with a broad range of industrial performance standards as well, including NEMA, IEEE, and UL®. 1. Cast iron frame provides extra strength, vibration resistance, and added protection in harsh environments. 2. Cast iron end brackets are precision fit to maintain precise rotor alignment for mechanical integrity. 3. Cast iron fan cover offers extra protection, 4. Cast iron, oversized, conduit box rotates in ninety -degree increments for easier lead connection. 5. Cast iron inner caps offer added protection for bearings. 6. Annealed stator and rotor laminations are stamped from the same electrical -grade steel for matched electrical performance. 7. Dynamically balanced rotor/shaft assembly exceeds NEMA MG1 standards for smooth operation. 8. Forged steel, removable, shouldered eyebolt provides easy handling. 9. Eyebolt hole is designed to prevent moisture and foreign material from entering the motor when the eyebolt is removed. 10. Neoprene lead separator/gasket between the conduit box and the frame prevents moisture and condensation from migrating into the motor enclosure. 11. Neoprene conduit box gasket between the conduit box and the cover provides internal protection. 12. Non-metallic slinger provides a stationary and running shaft seal. 13. Clamp -type ground lug provides U.L.-listed integrity. 14. Corrosion -resistant, non -sparking, bi-directional cooling fan is clamped, keyed, and shouldered to the motor shaft. 15. Non -wicking leads are permanently numbered for easy identification. 16. Patented PLS' Positive Lubrication System is available as an option with some XT motors for applications requiring extended motor and bearing life. Built to Withstand the Toughest. Applications FOOTNOTE Some construction features may vary. Consult your local Rockwell Automation sales representative for details. 11. The complete internal rotating assembly and stator winding are epoxy coated for maximum corrosion protection of electrical components from dust, acid, moisture, and other contaminants. 18. Condensation drains, mounted in the lower part of both end brackets, provide drainage in any position. 19. Full Class F insulation system consisting of Class F and H materials extends motor life by providing extra protection against high thermal and electrical shock. Compatible for operation with Variable Frequency Drives. 20. Mounting hardware is hex head, high strength and zinc plated for exceptional corrosion protection. Corrosion -resistant stainless steel nameplates. 21. Fits between the frame and end brackets are completely sealed with compounds to prevent contaminant intrusion. R FL7ANCE le D GE' f iJCTR ,c • Rockwell Automation 6040 Ponders Court Greenville, SC 296154617 Tel 1.664.297.4800 Far 1.864.281.2433 email adv+;ppowersystems.rod;well.com Web www.dodge-pt.can www.reliance.com www.ptplace.com Proven in Performance Duty Master XT motors are hard at work in petrochemical, paper, water and waste treatment, mining, and other tough industrial applications around the world. A Duty Master XT motor drives a barge loading conveyor at a coal handling terminal. • This paper mill waste handling conveyor relies on a Duty Master XT motor. Reach us now at www.rockwetlautomation.com Rockwell Automation, a business of Rockwell International Corporation (NYSE: ROK), brings together leading brands in industrial automation, including Dodge mechanical power transmission products, Reliance Electric motors and drives, Allen-Bradley controls and Rockwell Software. Rockwell Automation's unique Complete Automation- approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners, distributors and solution providers around the world. Headquarters for Dodge and Reliance Electric Americas Rockwell Autorr849O1 1040 Ponders Coot Greer -irk. 5C 296154617 USA Tel: 0)1364 297 4803 Far: n) 864.2652433 Europe Rockwell Automation Brlristre&e 22 D74834 EntacDallau Germany Tel: PIM 6261 9410 Far: 149) 6261941-122 Asia Pacific Rockwell Automatic's 55 Newton Rd. 111-01/02 Pererue Hose Singapore 307987 1a: (65) 351.6723 Fac 165) 355.1733 Awvnn sr ❑ Rockwell Automation Headquarters for Allen-Bradley and Rockwell Software Americas Rockwell Automation 1201 South Sword SUM Mil adee, w157334-2496 USA Tel: 0)414382.2000 Fac (1) 414.3824444 Europa Rednaea Autanetio0 5M46 Brs4rnab 8 Soviere 136 1170 acts, Belgrm 1e: (31) 2 663 0606 Far: CO 2 663 06 40 Asia Pectic Rockwell Autantim 27/1 Citiccrp Case 18 Whitfield Road favi85. Hang Kong 18S2 29914788 Fou (85 4 2887 1846 0 2000 Rockwell international Corporation DODGE and REUANCE ELECTRIC are trademarks of Rockwell Automation. Printed in USA RAPS -545 11/0O.10M-K This material is not irden ed to provide operational instructions. Appropriate Rocawetl Automation kevuction manuals and preranias stvaid be studied prior to insiallatiurt operation at nlairdoenee of e9rQnwL 10.2 CABLE SELECTION BY VOLTAGE CHARTS cml 30 cmt35cm1400 0 Rt 0 Cr) O 0 1 N ft 0) ft 0 as N ac (;t n. i 0) 0 N co h a) 0) O (n N O 0) 10 t` 0 N N (0 0 0) co to r 0 10 M 1` N 1796 2227 r co t` N r - n O N _) 0) (f) (0 N (0 If) CO N N CO n N iD () O (0 to r- r (0 0 0) 0 N 0) (0 N 0 in 0 Ca N r r (no to NrnCD0 (n t.ro co (o• 0) 0M) CO CO O V 0) N N r N N(n(D0) 0) ( ) N r r M N to 11 0) N co S 1` Ti; N r- 0 O o co 0) (kr) (0 w 0) O 0 O r 8 1t) 0 N M co N (0 O t` 6.. - co co N O N co co 11) 0 ts. (n N N (0 M r N N N 0 0) r (0 tc) r M co co M co N '(t N M M (0 N 01 (0 V) co co o 0' r r r OV N r r N h N 0 0 (t) 0 N O 0 to (0 r CO CO 4 0) CO n a t�D (6n d� M CO t` V M C) CO v t0 0) M N N N N (vr O N 11 11 11 11 11 0 co co (0 (0 (n (0 co a) cvN N N CO tf n f, N N u) to 0) o M In 0 0) 0r) r° ih N O m CO (t) D) CC?, CD r (() t` r 0 O N (n A M N 0 N v t") (f) N 0 O 0 r) If) (0 N (n 0 CO 0 (i) 0) 0 0 O N (0 O (r) t'• r v r 0 O 10 0) r N (n CV 0 CO 0 (:) 62 0 t 16 <113 `a 2 g o °fi E co a) - ,0 .co U coat U 8 .0 C N co. -C 3 w O C N N al C ¢ p 0 U O p) f. (fl N U0 0 m .c c 2 y w jw a -c °oa)Q . mg w w (o U A 0 < o 0 a r a) w o Q .o a Q a 5 O C w W O" C .a Fj y c c q 0 d c L mE u. c°)E — Zc.td0 U a) of c E�'1.m 0 c 0 o 3 0•- (o (`o o d O J a CO y 0 a o 3 LL (o (A ,..A8 E To 22. t0 (d C o o) o1:3ra2U E a.:o d (o (f) o N < y T CN a)�V w N"O' 0• [O ^ -C 0:t co a717 ) M d .0 aO0W C 0 ai Ew oc'0 RI ° c W )( ti d C c Z r u) E 0 d y.3o C d W C y d (C c E o >6 t re Z O w .t., y v 'E E as c o o w (o O a) a) w O Cf of yC C ._ a •O —_ N 7 '� .:03092 d w coi 132 (o '3 . ea 'a' '(n ad cx O .a o w a CN yOCCO Ud .tO O No0 O 0 L d IT y O U E 5 3 0 a) E 0."'ov > a 8(4 •V o w 3 w E v)aF-dc at O C O u O ° w W h :o - LL a E c J ccD .c (0 o +- 5 g w 3 r U w CL 0 o Ll1 `� w i I IL 0 Y Q 0 U c (o (V M . io Z N- V N 2 - 7.5 Hp AIRE-D ® Aerator 4.0 SCH 80 PIPE TYPE 304 SS 0 0 0 t 02.0 UHMW ROLLER C2) 0 GUIDE RAIL TRI -FLOAT SYSTEM 1 amminnismm +»M 0 'TANK BOTTOM �a GO' J v 7 N Mr L.. w CO F h fn 0 L7 Y � x3 x I- JAI IL >03N N SECTI❑N A - A INSTALLATI❑N z 1- n1 '. 0 3" w d 0 7. i N 1"x-'1(4 4^ N AIRE-02 TRITON® PROCESS AERATOR/MIXER STANDARD SPECIFICATIONS PART 1 GENERAL 1.1 SUMMARY A. SCOPE OF WORK 1) This specification defines an electric motor -driven, air assist, propeller -type floating aerator equipped with a regenerative blower. The aerator induces the flow of air below the surface of the water and provides flow -linkage mixing in multiple unit arrangements. B. SYSTEM DESCRIPTION 1) The unit supplied must be able to provide and be operated in both a mixing and aeration mode controlled completely independently of each other. 2) The aerator consists of an electric motor and regenerative blower located above the water surface. The motor is connected to a hollow shaft within a protective housing positioned at desired angles for water displacement downward into the water. Aerators with submersible motors are not acceptable. Solid shafts are not acceptable. 3) The hollow shaft drives a primary and secondary propeller beneath the water surface. Attached to the primary propeller is a secondary propeller -atomizer, which dispenses the air into the stream of displaced water beneath the water surface. 1.2 QUALITY ASSURANCE A. The equipment Manufacturer shall provide written calculations showing all assumptions made in the design of the system. 1.3 DELIVERY, STORAGE AND HANDLING A. Aerator shall arrive at the installation site fully assembled and ready for attachment to the floatation or support equipment. B. Units with couplings that can become misaligned during shipment or installation are not acceptable. © 2005 Aeration Industries International • www.aireo2.com AIRE-O2 Triton® AIRE-02 TRITON® PROCESS AERATOR/MIXER STANDARD SPECIFICATIONS 1.4 WARRANTY A. All parts supplied by the aerator Manufacturer must be warranted by the same. B. Field replacement of aerator components shall in no way affect the factory warranty. C. All warranty repairs must be done in accordance with the factory 0 & M Manual. PART 2 PRODUCTS 2.1 MANUFACTURER A. The equipment shall be manufactured by Aeration Industries International, Inc., or pre - approved equal. Aeration Industries International, Inc. P.O. Box 59144 Minneapolis, MN 55459-0144 (952) 448-6789 www.aireo2.com B. Any alternate equipment Manufacturer shall be approved at least two (2) weeks prior to the bid date. C. Alternate equipment Manufacturers shall have a minimum of five installations of the same equipment model and design in a similar application for a period of five years. A reference list shall be provided with names, telephone numbers, and addresses of the qualified installations. D. Pre -approved equipment Manufacturers not meeting the requirement in 2.1C are invited to bid, provided they furnish a Performance Bond underwritten by a bonding agent acceptable to the Owner for a period of five years. Equipment and/or components failing within this period due to deficiency in design, workmanship, or material shall be replaced at no cost to the Owner. 2.2 AIRE-02 TRITON® PROCESS AERATOR/MIXER COMPONENTS: A. AERATOR DRIVE MOTOR 1) The motors shall deliver 5 horsepower at 900 RPM nominal and shall be rated for 230/460 volts, 60 cycle, 3 phase service. 2) Motor enclosure configuration shall be totally enclosed, fan cooled. 3) The motor shall, in all cases, equal or exceed current NEMA specifications. © 2005 Aeration Industries International • www.aireo2.com AIRE-02 Triton® AIRE-02 TRITON® PROCESS AERATOR/MIXER STANDARD SPECIFICATIONS 4) The motor windings shall be nonhygroscopic. 5) Insulation shall equal or exceed NEMA Class F with Class B temperature rise. 6) A service factor of 1.15 shall be furnished. 7) A condensate drain shall be located at the lowest point in the lower end -bell housing. 8) A stainless steel nameplate shall be provided with each motor and shall be securely fastened thereto. Information shall include voltage, speed, phase, insulation class, amperage, service factor, wiring diagram, and motor serial number. 9) The motor shaft shall be balanced to within 1 mil to be measured on any part of the motor frame including the C -face. 10) The motor terminal box shall be firmly bolted to the motor frame at four points. The terminal box shall be sized to meet the NEMA standards. 11) The terminal box shall be drilled and tapped to receive one compression watertight fitting to accommodate the appropriate electrical service cables. B. BLOWER 1) The equipment shall include a high efficiency regenerative blower sized to provide sufficient airflow to yield the rated oxygen transfer capacity. Each blower includes the following features: a) Maintenance free b) Aluminum alloy construction c) Inlet and outlet sound attenuating silencers to minimize noise. d) Inlet filters with epoxy -coated wire mesh media rated for 70 microns or better. e) CE compliant — Declaration of Conformity on file f) The blowers shall be 1.5HP 230/460 volts, 3 phase, 60Hz and tropicalized for corrosion resistance. Blower motors shall be wired separately. C. MOUNTING FLANGE 1) The mounting flange shall be stainless steel. D. SHAFT/UNIVERSAL JOINT COUPLING 1) The shaft shall be 304 stainless steel full -welded to a forged carbon steel universal joint coupling. The shaft must be hollow to promote maximum airflow and oxygen transfer. Units with solid shafts are not acceptable. The shaft shall be dynamically balanced. © 2005 Aeration Industries International • www.aireo2.com AIRE-02 Triton. AIRE-02 TRITON® PROCESS AERATOR/MIXER STANDARD SPECIFICATIONS 2) The universal joint coupling shall include standard grease fitting for maintenance lubrication. Units that utilize flexible couplings to attach to the shaft of the motor are not acceptable. 3) The shaft shall be stabilized by replaceable water lubricated bearing located within one inch from the propeller hub. The area of the shaft supported by the bearing shall be fitted with a replaceable hardened non-metallic sleeve. 4) Units supplied with couplings that require alignment are not acceptable. 5) Any shafts requiring factory replacement to validate warranty requirements are not acceptable E. HOUSING 1) The housing shall be stainless steel and flanged for mounting to the aerator. The housing shall form a guard around the hollow shaft and support a field replaceable, water -lubricated bearing press -fitted into the housing lower end. Water lubrication holes shall penetrate the housing in the area surrounding the bearing. F. BEARING 1) The aerator shall be supplied with a field replaceable water lubricated lower support bearing. The bearing shall be press -fitted into the housing to allow ease of replacement. 2) Units utilizing a cantilever design without a lower support bearing or regreaseable tapered roller bearings are not acceptable. 3) Bearings requiring factory replacement to validate warranty requirements are not acceptable. G. PROPELLERS 1) The bronze mixing propeller shall be specifically designed to maximize oxygen transfer and mixing characteristics. Propellers shall be self -tightening such that the propeller threads tighten on the shaft threads during normal operation. The entire flow of air shall pass through the propeller shaft via the hollow drive shaft along the axis of the propeller hub. Aluminum propellers are not acceptable. 2) The propeller design shall be tested in clean water and shown to draw a minimum of 85% of the recommended full motor amperage load at nameplate voltage and power factor. 3) The propeller shall be designed to allow easy removal and replacement in the field. © 2005 Aeration Industries International • www.aireo2.com AIRE-02 Triton* AIRE-02 TRITON® PROCESS AERATOR/MIXER STANDARD SPECIFICATIONS H. SATURN RING DIFFUSER 1) The Aerator shall be equipped with a investment -cast stainless steel Saturn ring diffuser, smaller than the mixing propeller, consisting of atomizer fins extending longitudinally beyond the end of the hollow propeller shaft. The fins shall be specially designed to maximize oxygen transfer and mixing characteristics. 2) The entire flow of forced air shall exit through the propeller / diffuser opening. I. VORTEX SHIELD 1) A vortex shield shall be furnished with each mounting assembly to eliminate the formation of vortices, maximize shaft airflow and prevent cavitation damage to the propeller during operation. Units without vortex shields are not acceptable. J. FLOATATION 1) The aerator floatation assembly shall be constructed of molded low-density polyethylene with ultraviolet inhibitor. The pontoon shape shall be designed with smooth, beveled edges to allow freezing into ice without breakage. The pontoons shall be connected by galvanized steel structural members to prevent corrosion. To allow for servicing by not removing the aerator from the floatation, the floatation assembly shall be designed so the aerator may be pivoted completely out of the water. Structural aluminum is not acceptable. Welded stainless steel floats will not be acceptable. PART 3 EXECUTION 3.1 LOCATION, SUPPORT, AND MOORING A. The Manufacturer shall provide recommendations on aerator placement, installation and operation. B. Mooring cables and mooring hardware shall be stainless steel. 3.2 FIELD SERVICES A. The aerator Manufacturer, through its local representative shall provide service to verify the proper installation and supervise the start-up of the aerators. Operation and maintenance instructions shall be given to the Engineer/Owner through the use of illustrated material within the manual. END OF SECTION © 2005 Aeration Industries International • www.aireo2.com AIRE-02 Triton® Machine Screw Actuator Models Advantages: • Positive, mechanical positioning • Uniform lifting speed • Multiple arrangements ■ Anti -backlash fe.attlre (optional) Top Plate - Must be bolted to lifting member to prevent rotation except when screw is keyed. Lifting Screw - Available with threaded end or clevis end instead of top plate_ Shell Cap - Looked into place by set si,rnws. Thrust Bearing and Grease Seals - At each end of worm, 1114, 1/2, and 1 -ton models do not have seals. Load Bearings • Be artngs, trop and bottom to take Ic3;ids in either direction. Worm Gear - Aluminum bronze... Accurately notified for rater pear contact. Worm - Available with double or single shaft extension. Capacities from -1/4 'Fon to 250 Tons Worm Gear Ratios from 5:1 to 50:1 Rt.' 'rlu5.e tlal Cuff -Morton nw:Ialne ,;crov 11ae hanial actuator is produced in many standard models with a wic.Ii• range of capacities, there is a standard model for almost any requirement. Models can be furnished to' 250 tuns ca paci ty. Operated manually or by means of gear motors, machine screw actuator models can be used singly, in tandem or in multiple arrangements (see. page 24 Since most capacities have a uniform lifting speed, added economy can be realized in raising unevenly distributed loads by operating the different capacities in union. Most Duff 'Norton machine screw actuator models with higher ratios are self -locking and will hold heavy loads in position indefinitely without creep. They can be used to push, pull, apply pressure and as linear actuators. They are furnished with standard raises in increments of I inch. Depending upon size and type of load, models are avail- able with raise up to 20 feet. Opwrwortan www.dufnorton core Housing - Aluminum on 1/4 to 1 -ton models. ductile iron on 2 - ton through 15 -ton models, cast steel on 20 -ton through 250 -ton models. Dust Guard - Protects lifting screw threads. 800-477-5002 29 More Than 200 Standard Combinations ■ Precise Positioning -Can be controlled accurately for positioning within thousandths 01 an inch. ■ Self Locking -Will normally hold toads in position avithout creeping when using the higher ratio touts, as long .as the actuator unit is not subject to vibration. ■ Uniform Lifting; Speed -Since many models have the same gear ratios, various capacities can be used in the Upright Screw sante application to lift unevenly distributed loads with uniform speed. ■ Quick, Sure Operation -Designed and built to be positive acting.. for accurate response to motive power. • Anti -Backlash OPtion -Reduces vertical backlash between the screw and the worm gear nut to a practical minimum for smooth, precise operation and minimum wear. Rotating Screw (Upright) Available in both upright and inverted types With such a wide range of standard machine screw actuator configurations, Duff -Norton gives your design flexibility and economy. -Examples of these standard options include upright or inverted screws with threaded or top plate screw end, as well as upright and inverted screws with top plate, keyed lifting screw; limit switches, (Awe cruor flanges and position indicators, Duff -Norton machine screw actuators are available in standard inodels to meet almost any requirement. Capaci- ties cover a wide range, from 1;4 to 250 tons. Operated manually or with air, hydraulic or electric motors, machine screw actuators can be used individually, in tandem or in multiple arra.ng;ements. Since most citpaci- ties have similar gear ratios, you can realize added ec i no ny by using different capacities in unison to raise unevenly distributed loads. ( Inverted Screw Clovis Threaded Most higher ratio Duff -Norton machine screw actuators •ire self-locking and will hold heavy loads indefinitely without creeping. However, it self-locking is absolutely necessary, a motor brake or other restraining device should be considered. They can be used to push, pull and apply pressure and position precisely. Raises, measured in increments of I inch, are available up to 20 feet. ATTACHMENTS NEMA C -face flanges, motors, gear bores, reducers and couplings are available for single actuator drive or multiple actuator arrangements. Position control components include limit switches, potentiometers, digital encoders ( and meters with LED display. 30 800-477.5002 wwrfdcrffnoIlon.com DI tFf-Ntatrton 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Machine Screw Actuator Units Modal No. Upright .. 255e 15 2031 19132, 7032 913C5 9)10 4C15 = - no 25 355075 1&50 & 9-J5C 9004 = .45 91:16 le' tat -1 T2S3 In rted 2554 2024 Ka (...._„.. . ' 1,11. 9 d 4101 , 9339 9014 0016 9224 9334 1949 A 9049 6074 .. .9069 19143 2249 ,„.Ce pd city, Tons p4 '. • I - t, 100 1 5 4, -,, 5 '..) Po N2(1 2C Lining Straw Olamoter (Inches) 12 1.'4 Path S18 125 Pittk Aura 34 re Nth Acme 26,1 F' 11 Ammo 1 112 375 Pc Aema 2 f01.1Ptt 4.-0) :: 14 fO3 Pk1 Act's) 2 1/2 5O3 i1t1 Acne 3 itE6 FIS,S le -me 3 314 I� ihk.t A.:Nire 4 112 Kb PIb Squat) f (186 Pia Stztoe e Tca ?ocr, Sqwer 2 i oft) Pith $AvAr9 5 iala Pirl iAtimate 'A 1 worm soar Ratios ,... Std. Ratio 't 1 *, I •I J" .,(27 it 4 1 ,e•"r, 11 ...":1 ' 10 '6 I 1 '1., I* 1.1' L' 1 Optional IStd,Rallal - N 40 $.I 25 11 /6 241 16 • 16 A` 10 32 I 16 I, 1 19 „1,,1 16 19 ,N, 10 -A• 12 53 Turns of Worm tor 1" /taloa Optional - -- 1C1) f4 114 48 48 48 48 49 4e 40 49 3, - HeLad torque (In-L Std. Rollo '• '4 'i,. ..,„ f, . 1' l A • 1 ..., 11..onal ., ' 't .9 I ;!. 1.. ,i lo'll 153 3, *I, Optional . - maximum up par Actuator ltd. Rollo 13 1,3 ire 2 -111011F '.:J 4 6 5 5 e 5 15 1.5 26 2. optional Std. Ratio _ It _ 21 14 r.... N4 :l'i 1 la :•• i 1 112 • i A. 1 112 7.i31 2 1/2 2'4' 1 IQ 49 ,.. b -.)1 b ' '...••1 11 '6 (.1 11 0,' 0 ,'.h' Torquo At Full Load' (In..1.bsi optional „ ,.. :k tl. "": 1.3 IA 1 114 1 9 =, 10: efficiency Rating (%) Std. Ratio 3.5.E 216 7.4 5 23.2' ,,-..)7 25.2 111 a 182 158 135 114 12I 141 90 Optional » ff,r, 1k . 121 -1 1:10 120 10' 13 21 Jt 0' - Weight With Rasa Raise oI 6" (Lbs) , ,, . h 0 , I . ... . ...,1 j., ' * .1.0 • . ' Walsh* tor Each Additional 1" Rai** Lb . 01 i11 /7 .0 1 4 1 ., 2 11 .i c 3: ... '.. Sil, 'ID t: •C . '.P.) .1'1•"•,11•11" .101 1., 1 ` 1.1i. ih•7 t. 41 t 11;0. 1-4-•,11., I 11.1 1.11111 1\0.1 VI' 1., Ir.. he, lir -.1 i tr. t .01.61k. 1/4111'1,1nd Hitt h .1 .I11...1PC It' \t 'VI 101 :II,' '111,11.. • .1 hi.i111 W., '11.)'.: 111Il• 1,1. 111 ^ `.1.i1;•.111•.1 i1.1 1.1. '14 1. Nfinwric Controls: to 25 TOrtActuators with Decimal Ratio at No Extra Cost .., '--.,Numeric Control Ratios - 100 Turns = 1' of Travel Mode) No..- -fi Upright 2501 18027002 , 9005 ... 0019 -." - 9015 9020 9025 , .. OVerited 1 1801, 700 1 • & 9001 s, 2 9004 = .45 ,--- ..--- 9009 - - 10 9014 15 9019 20 9024 '25 Capacity, Tons LtHing Screw Dlimatir . . (Inchtte) , 3/4 <.200 Pitch Arne 1 ' .259. h ,-A me ,..- 1 1,2 .250 Pitch Acme 2 .25OPilch Acme 2 1/4 .250 Pitch Acme 2 1t2 250 Pilch Acme 3 .320 Pitch Ac.rne Worm Gear Ratios 20 '.. 25:1 '.1 25:1 25 1 25 1 32:1 Turns of Worin for 1" Raise 'to 100 101 100 ' 100 100 100 No Load Torque (In. - Lbs.) , -- 5 '..) in N2(1 2C 30 .111 Tcrque at Fuli.taccl(tn.,...--tile.) -Rating (%) 24 11 :3 48 13,2 175 ' 9,1 37Q 8.6 N, 640 7%5 925 6.9 15(10 53 Actuator Efficient Maxi's -aim HP r Acttsati=_.12±y2__.._yi.....:_IEF2 22il21L2 r . vet) it) , 101 D Duff -Norton www denor(on com 600-417-5002 .31 Machine Screw Actuators, 2 Ton, 1800 Series 3442 r 1..H. EST, 4 HOLES ,,432 7417 J CLOCKWISE ROTATION PAISES LOAD A.14. EXT. •• DIA TYP. .4110 342 f '\.1 14,4 \KErwA 4144 4 HOLES 1132 04A. EQUALLY SPACED IP 90. ON 3 01A 1" Diameter x .250 Lead Lifting Screws Inverted IA42,00. ACAOSSPl_ATS L S-114 CLOSED 4. ftE113141 .344 1441 1142 _ CLOSED. Avow Cievie End r•-• 3M Double Clevis: CCM -1802 Maximum Allowable RaLs4 in Compression 14- --Raiing 3000 Lbs, Maximum Rasi I Flatod Load In ComptesSoon 12' s: 444 f 1.14 - 114 (tom Upright: M-1002 r Is 14.142.1314L ECVAL ----414.-34.4 4147 10 fosse Inverted: M-1801 • Upright Rotating: UM -1803 0 Inverted Rotating: DM -1803 t :king tw.t 7Neyed. 4.04r.r.i to .1 111,, prey E -n: rotation. %Viva ani.t med. s,ve I:2: Whom I i innum-vons are •itibject :0 change witim111 1Vben roe11 IflJ, , hvyv.I. leolet .n at.: t.p plito stII a.4 VIVS.:12!, 4.110 Li. a a :It., po:Att.in LJ uff-Nortpn wveve.dutinorkiacom 800-477-5002 Appendix 5 I Jl'L716-04 FRI 02:56 PM WATER TECHNOLOGY Water Technobgy Gip 275.5 3. Locust St Suite 221 Denver, CO tto222 ASN: Drew Goodyear PROPOSAL NUMBER: OEM042204-1088 / �� �,(iiFOR C>_ CAITFrtrn inlet Volume: 1n1•t Pressure. Inlet TempertrtUre: Discharge Pressure: Differential Pressure: Ambient Pressure: Relief Valve getting: sae: FAX NO, 3035849920 kaeser Omega-pa/CM Rotary Two Lobo Blower Packager Phone: (303}x+0000 Fax: (303)-484-egz0 no -• m•tw, DATE: 1/22/04 ER layitEmiz 188 is fm Mower Model: 11.8 pia Oraega-F#K" Model: 100 •F Speed: / Percent of Max. SpOed: 16.5 he'a Design Brake Horsepower: 4.9 ps19 Relief Valve Brake Horsepovwj 11.6 pala Discharge Temperature: 8.8 psro Recommended Motor: Air Estimated Noise Lever P.02/03 P. e2 era. Omega 41 OB130 1965 rpm / 45 % 4.9 bhp 7.5 bhp 187 °F 7.5 hp <67 d8(A) t3P ' Pt.Y ANDISjtll (1) -pee Model D13130 - 7.8 hp rotary two robe blower package designed for the herein. The Omega -pee blower package includes the followingstandard performance Specified features and accessories: • • Model 41 Omega, rotary fwo-tiobe, positive disp+ecemern blower, horizontally mounted Elevated, table -top style, heavy duh, compact base frame • • Motor, TEFC enclosure, 7.5 hp, 1 Ph, 230 V, 80 Hz with 1.15 SF V-bett drive And guard • Auto V belt tenssoner • • Inlet silencer- absorptive type with Integral wire mesh filter and indicator • Discharge silencer - absorptive type with stub Connection Spring loaded rarer valve (shipped loose) • Flexible Connector on discharge connection • Blower pre -enact with lubricant and oil drains pre -piped to edge of base • Vibration isolator* • Sap test, mechanical run test • Twenty-four (24) month warrent, • Twenty-four (24) hour emergency replacement • Estimated weight 774 lbs. guarantee Total Price for (1) Omega-peK7i DR1= -TS hip ...� ..$ 7 312 • 0 0 Estimated Delivery; 3-4 weeks after receipt of order. P ° Net 30 days, subject to prior crsdf approval All other terms in accordance with Keeser Terms and Conditions of Sale. EX Works Shipping Point Freight Cdtect or Prepaid and Acid ( not subject to discount). Thirty (30) days from date o1 this proposal, 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 JL"L-16-04 FRI 02:57 PM WATER TECHNOLOGY PROPOSAL NUMBER: DEN062204-105e QTY SLOWER A OPTIONS: 1 Ornage-paKrx° DB/30 1 standard enclosure wtth gauges........................................................ .......... 1 SinglePhase adder for _.... 1 Spool Va 7.g -• ................ 1 the for retlef vat and unload ... valve ............. start valve AFE15:, •........... . e4 start .......... .......... FAX NO. 3035899920 DATE: PRICE EACH $7,312:00 53,085.08 053.80 $203.33 $888.00 TOTAL P. 03/03 8122/04 EXT PRICE $7,312.00 33,083.08 • $853.00 *203,3.3 - seee.00 moo $12,139.99 PRESSURE APPLICATION VACUUM APPLICATION -r ON _ , 1 r wuUiIIQNAt��7'S: . 8730 is rahgeadesigned around frame available.customer supplied engeering dant. Due to the use of st DI9130ti at no extraachargenor pt apaseplication motors athre Compressors recommends a 1 ONP motor for this app8taat}� and is 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 mil Ns de to 5 is "kr dip w IMP do dig 10"141g diging 0 1 sal dgo 01) z Air Diffuser 2003.xls 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 LL 0 0 c o 0 > d C - la 0 Input Data & Design Parameters for Biological 1 Chemical Process Systems >' co E O) 1 n d 0) 0) 0) a) 0) 0) o E E E E E E 0 •O O C 23.57 N c O) 0 C) 0 O O O O O O O O Q O Q O O O N > CO 0 Q) 0 f0 r -0E O O 0 0 m m 0) m CV CV Y �C 0) O) Y Y O N CO 0 0 m m d N N co Oco co c ° N CD O CD (0 E E a `a O co N O 0 O O N 0) 0) \ 2 S o) a) v) Axa .E.E E E ELL Lr)CO N •O O C 23.57 N c O) 0 C) 0 O 0 co O O O tt Cr T O N Coarse Bubble a CO C LL 73) EE 0 N N CO n EE N O 0) O N O CD O O N O O N rn O 0) O O a) 0 0 0 0 0 0 'p a c 2 Y ^a a) v) LL a @ _o .o .o .o .o o m m a) >• 0) �i ❑ a coU ~ o o ° y 3 c ° E CO CO CO CO CO m a s o o c E U D 0 (5 coo m o V U % o n d ° c c c c c c O. E E 0 o 0 c E a 0 a a) ° LL LL LL co co L N -o c c ►- LLCo)vvvvv na `c�m� omc�uni>No�y@ it rE. aoia"@iLL�arnEv�O a 0 0 0 o o 0 O O Q Z .O `m° y n`. C w a, E .7C m~ 45°❑❑ N~ �J `.° 0000000 m O o c E v a) .4 c.2 °� o iA Q Cn `o .S -I) o m 0) >> j> a) CO 0 c m iO o a) '� x a a) �_ O U W 0 .S ate) c a) .c a) cf Y Cu - c >. a) ❑ c o v '5 -o io U O 3 m Q 112 ❑ 000 d v 0 CO 0 n° V c 0 CO Ca 2u) t0 >� a) a `° H y m o CO o� 0000I/ 0 0 � � • � c � LL v v) ° 0 com a) � uN) �' 0 'O c o` °' Q o ° co c c c c c aci rn .� '� J ._ ° > > m _` m g 2 o) aci Q) °) .Q) 75 .� . rT ' Q Wo (n 7 x >, 0 co w - ` C ' w ❑000 CO0 a)60 2X o w �O°0 > o�03 u) Cn 37 �❑ Q) a) a) N ❑ 0 '� V) N N co O a 'co t co co o c o. w❑ c CI) c d m T, as v o d 0 a E c4.; x x ~ m p 2 75 E -o a) a o o c E o f c) a) o) o U o co ac) 0 >s m a x m 0 o N J J 0 a) d 3 0 0 m Input Parameters for Post Aeration Systems CO 95 N a) Q) co d d rn > coEEa a E 0 U CD a) 0 > O CO a) O 0 O 0 0 o 0 U I.= m F.o LL T C C" C OO 0 a 0 0 o W w > x c O O ~ > C j N o p 0 0 to c c- a) a) ) E LL ai Ei a) N H Z u) RECTANGULAR TANK DIMENSIONS 0 d C▪ D 0 0 N a) N 0 0 O 0 0 0 0 O 0 i6 N O 0 0 o O V • 0 Cr c0 1— "5 N E Z E C CO d w _ d B C _7 E ) a) O 0 < E>a G c E O E C w O 4+ o • m> E E ci- N 0 4 a 0 11 3 E E t r0+ E t w 4- 0) O) 4+ C J E 0 0 o 0 O 1- T Red Valve Company, Inc. M O 0 N Oxygen Required for Volatile Solids Reduction Sludge Wasting Flowrate Determination M ti v M E C O d d t to m -o a) co a) ° > E S co U .c an. 0) c • a) O Q) _ • o u) 3 -`00 0) o -V) U v t L()wo N to rn CO Q) 'O C 'c 'O 0) 0 0) E E ° O N O O N N O O O CO O 'a co O 0 CJUUu_LL x ES' 7) 0 o C'J 3 co L.T. a) o m 0 mC c0)a) o -O C a) (0 U co Q d w C LL O a J •c 2 c 0) (DEc J w j 2 0 O Waste Sludge Stream Temperature tly CO CO O 0 0 O 0 .0+^M o 0 � U E • M 474 m • C7 0) U � • M CO 0 t B U 0 Waste Sludge Volume Determination m N C 0 f0 0) co o 0 eay 0 0) 17) i+ (0 10 a) 0) O O O 0) E lbs./ cu.ft. - day Volatile Solids Loading (0.005 - 0.3) 5�2 lbs/day Sludge Total Mass of Sludge in Influent( lbs./day Sludge Total Mass of Sludge in Influent( 0 0- C N 0 -0 7 O L C 15 C_ • ed • N- 13 13.0 O • t O E O • E 1— co m To Volatiles in Total Mass O CO Total Mass of Volatile Solids (30-40 % Standard) 0 O O % Reduction of Volatiles through Digestion N 0 N (0 Total Volatiles Reduced Ibs.O2/ lbs. Volatile solids 0 N T a) N 0 N .0 M W C d V E g fX 0 d 0) Q: 0) 0) 0 x 0 O (0 .2 co) c0 w A Aeration Design Value L h t) Actual Oxygen Transfer Rate (AOR) Red Valve Company, Inc. mc rn E O a) a) w C N 0) T X 0 O C CO 0 (fi L O 0) O 0 vi L 0 O E co otSz 0 0 m 0 co 0) O a to .0 O O C CO 0 to O 0 0 c o v u) O p Q rn X O Q IY (730 CLQ O Q Q CO M C CO .0 M CO CO M CO r M co M 0 4- O E E O O O O O E a < < < < Red Valve Company, Inc. 0 0 y O L IJ f° c° c .O c c 1 L c O � o c T. cv X O c c6 7 � Q • O 11 1 CC CC 0 0 (1) o ce re 1- o r Oi U N N C 7 c' E M w r V r to T.- L co t M M E L )M t 71) a) M � Y I, t .0 s M E • t0 O U to M W O 0 L 'Cr) N a0 • 0 C) O c zr, .O 0_ 0 L U_ cq N a N 2 U Q W O O c curio z W LL LL LL W W _1 Z Q CO CO 0 Ce U O Q U � z AOR /SOTR Ra Red Valve Company, Inc. 0 0 E O > 5 Wco ▪ V >- y 7 � U C N O M LL LL ❑ 2 W O) J CO CO m w Lu < o O U C 13 a- ce scfm/diffuser m3/hr/diffuser 0 0) (3) Diffuser Airflow Rate • U U O O 0 0 o T � E "i - co tn E 0 O O O 0 0 ao Applied Design Unit Airflow Rate Mai to '"Cf) a) C o m >3 = m 1—> c o U) c "d N /) .N 0 c O t0 N Y 0 7 Y U EW E 0 H T2 •—° co m ) in -0a) E ° o 0 O LO to O N M O O O LO 0 0 E E • • O • u E• o N CO CO Cr) 0 N 0 0 0 N T 0 0 0 T C 7 0 a) • c t) • '3 E a9 rn a c 3'� o `E O v d r a rn a '0 ca CI) cy w 0 N a) • -5 5 N r t • cn • or U) L r i0cu ✓ • a) O wo • w C (9 ✓ 6. ._x co tm K 0 o w E N F- w — o 4..L 0. hi O O Z Red Valve Company, Inc. LL 1) a) o U 0 c Q o 0 a) C • Q 0 E a7 N r co E O E a= n Q) 0 O To' 0 4) a7 O O 2 LL 0 0 m c ❑. 0 E 0 G0 CO To 0 H 0 O Era rn 1 c 0 0. 0 0 .0 E Z L L CO CO E E 0 0 O E E 0 w LL O O N 0 N O) O O ((5 m a0 m O 11 11 11 0 H a O 0 m 0 E 0 a) (0 a o, 0 0 CD• HU 3 E o O m � m C N O n Blower Efficiency Estimate = E E E N n (f) 0 O c c c (D Total Headloss = (0 m co M O 0) (a N 0 0. a 0 rn d' n tt O O a) r M E N N E U T it 2 LL 0 0 0 U) 0 m a) U W LL N r) M a 2 N a 2 N ('4) a 2 a 0 0 c E O 0 To 1- co w 0 co a) 0) CO CL. 0 c (o a 0. :L E — 0 0 (f) `0' > Na) I.L Total Combined Brake HP = 0 C 4:0 O 0 470 V �� Q tv V 0 tU :.� Q a) 4- .173 4F) o co a. tis 0 (0 L() ct M N `uoRpnpaN spHos ani;eioA O 0 0 0 0 0 O O c0 O O d 0 0 c0 0 O O 0 N 11377 Coarse Bubble Elastomer Diffusers 1.0 General The following specification defines the requirements for construction and operating performance for a coarse bubble, elastomer tapered nozzle style diffuser. The approved manufacturer for this system to be included within the Base Bid shall be manufactured by Red Valve Company, Inc. Refer to section 10.0 for alternate equipment specifications and requirements. 2.0 Diffuser Construction 2.1. The coarse bubble diffuser body shall be constructed of thick elastomer and provide free flow operation of air discharge when submerged. The elastomer shall be heat vulcanized and compression molded into one homogeneous unit. 2.2. The elastomer diffuser must be clamped to a bushing or pipe nipple using a heavy duty clamp to ensure the diffuser will not separate from the connection during operation. Unrestrained elastomer components using compression fit, snap -on, and friction fit connections will not be accepted. 2.3. The diffuser shall seal tightly closed in submerged applications when the airflow is discontinued. Diffusers must provide constant closure at zero airflow and prevent contact of the process fluid onto any internal portions of the diffuser airflow path as well as the distribution piping. Diffusers with open and fixed port discharge orifices are required to provide a separate ball type check valve at the connection point between the diffuser and the manifold for each diffuser. The check valve shall be 3/" npt constructed of 316L stainless steel. 2.4. The diffuser shall be capable of operating in an orientation of 360 degrees in the X, Y and Z plane without clogging or effects on the airflow discharge pattern. 2.5. The diffuser shall be capable of withstanding an impact load of 10 pounds against the discharge tapered end of the diffuser, deflect to a minimum allowance of 45 degrees and recover to the normal operating position. If stainless steel (horizontal mount) tube type diffusers are supplied then the associated piping material required shall be schedule 10 — 304L stainless steel, to ensure pipe integrity from loads to the cantilevered connection, in lieu of any plastic piping specified or shown on the drawings. Stainless steel diffusers shall be constructed of 316L stainless steel with a minimum gauge thickness of 0.125" throughout the entire housing. Units less than this minimum gauge thickness shall be equipped with a1/2" diameter 316L SS rod continuously welded along the top edge of the diffuser unit, across the entire length of the diffuser, to resist bending of the unit from loading on the cantilevered free end. Print Date: 01/08/08 11377 - 1 11377 Coarse Bubble Elastomer Diffusers 2.6. The elastomer material shall be constructed of EPDM unless otherwise specified on the drawings. Stainless steel type diffusers shall be constructed of 316L stainless steel. 3.0 Guidelines for Sizing 3.1. Submergence — The diffuser shall be capable of orienting the discharge point downward at a distance within 4" above the finish floor elevation of the tank. The emittence point of air from the diffuser shall not be greater than 4" above the tank floor for the diffusers closest to the top of slope of the floor elevation. 3.2. Lateral Distribution Pipe Clearance — The diffuser shall be capable of connection to the distribution pipe which shall be located with a minimum of 4" of clearance from the bottom of the pipe to the finish floor elevation. 3.3. Diffuser Spacing — the maximum center to center diffuser spacing shall be 24" unless shown to be less on the contract drawings. The exact quantity of diffusers shown on the drawings shall be provided, reducing the quantity of diffusers by utilizing oversized units will not be approved, adhering to the spacing requirements to maintain the required mix pattern is required for approval. 4.0 Process Performance Criteria 4.1. The diffuser shall be capable of complete submersion in sludge and biomass when airflow is discontinued and return to normal operation when airflow is re-initiated. The diffuser shall prevent the entrance of sludge and biomass during these submersion periods. Diffusers not equipped with backflow prevention shall be equipped with a separate ball type check valve installed between the diffuser connection and the manifold. The valve shall be %" npt and constructed of 316L stainless steel. 5.0 Submittals 5.1. The aeration equipment manufacturer shall supply to the Engineer the Certified Oxygen Transfer Curve for the applied coarse bubble diffuser. 5.2. The aeration equipment manufacturer shall supply to the Engineer the Certified Diffuser Headloss Curve for the applied coarse bubble diffuser. 6.0 Installation 6.1. Diffusers shall be installed in accordance with the installation guidelines supplied by the aeration system manufacturer. Print Date: 01/08/08 11377 - 2 11377 Coarse Bubble Elastomer Diffusers 6.2. Clamp type connections on fixed mounted discharge ports shall be made with heavy duty hose clamps or band -it clamps constructed of 304 stainless steel. 6.3. Threaded type connections shall be 3/" NPT stainless steel or 3/" NPT schedule 80 PVC (to match manifold pipe material) with the nipple threaded into a reducer bushing clamped to the elastomer portion of the diffuser. 6.4. Discharge orientation of the diffuser shall be shown on the installation drawings. 6.5. Installation of the diffuser shall be free of any obstructions within the tank that would cause the flexible end to be bent from it's standard molded form. 7.0 Start-up Procedures 7.1. Start-up procedures shall be outlined in the Installation, Operation and Maintenance Manual provided by the aeration equipment manufacturer. 8.0 Spare Parts 8.1. The aeration manufacturer shall supply [ ] spare diffuser assemblies, equipped with elastomer nozzle, PVC reducer bushing, and 3/" stainless steel NPT nipple pre -assembled and ready for installation. 8.2. The aeration manufacturer shall supply [ ] diffuser replacement kits which consist of one elastomer, diffuser and one stainless steel clamp. 9.0 Warranty 9.1. The coarse bubble diffusers assemblies shall be warranted by the aeration manufacturer against failure under design conditions for a period on one (1) year from the date of final installation approval by the Engineer. 9.2. Elastomer Diffuser nozzles shall be warranted by the aeration manufacturer against failure under design operating conditions for a period of one (1) year from the date of final installation approval by the Engineer. Elastomer components damaged as a result of maintenance activities, foreign debris in the process solution, or excessive exposure to direct ultraviolet and thermal radiation shall be excluded warranted coverage. 10.0 Alternate Equipment 10.1. Equipment other than the specified Base Bid Equipment shall be considered an alternate and must comply with the following specifications and requirements. Alternate equipment shall be listed separately on the Bid Form Print Date: 01/08/08 11377 - 3 11377 Coarse Bubble Elastomer Diffusers as an alternate add or alternate deduct in the areas provided or written in and designated accordingly. The manufacturer of the alternate equipment must be indicated and accompanied with a detailed equipment itemization. Alternate equipment must comply with all material and equipment specifications as defined within the base bid specifications as well as the specifications listed within this section. 10.2. Stainless steel tube diffusers with open orifices shall provide the following ancillary equipment. In order to provide the equivalent backflow prevention capability as the base bid equipment the alternate equipment manufacturer shall provide ancillary backflow prevention with a supplemental check valve. A ball check valve shall be supplied for each diffuser between the diffuser and the tee assembly. The ball valves provided shall be in accordance with the following specification. 10.3. Ball check valve specification; all components of the valve shall be constructed of 316L stainless steel. End ports shall be 3/" FIPT. Valve shall have a maximum operating pressure capacity of 50 psi. 10.4. Elastomeric membrane diffusers are not considered as an equivalent and shall not be submitted as an alternate. End of Section Print Date: 01/08/08 11377 - 4 11379 Diffused Aeration Piping Equipment 1.0 General The specifications in this section include all components of the Diffused Aeration System with the exception of the individual diffuser units. Refer to sections 11376 and 11377 for diffuser unit specification. 1.2. The complete aeration system shall be supplied by the Aeration Diffuser Manufacturer to maintain single source responsibility for the system. The complete system shall be defined as beginning at the top flange of the air supply drop pipes through all submerged piping, wall brackets, lateral supports, expansion joints, diffusers and any other equipment specified within this section of the specifications. Approved manufacturer is Red Valve Company, Inc. 2.0 Referenced Standards ASTM A240 — Chromium -Nickel Stainless Steel Plate ASTM A380 — Corrosion Protection, Acid Pickling ASTM A480 — Stainless Steel Finish ASTM A530 — Specialized Carbon and Alloy Steel Pipe ASTM A554 — Welded Stainless Steel Mechanical Tubing ASTM A774 — Stainless Steel Welded Fittings ASTM A778 — Stainless Steel Welded, Unannealed Austenitic Pipe ASTM D1171 — Elastomer Deterioration ASTM D1784 — PVC/CPVC Pipe Compounds ASTM D1785 — PVC Pipe, Schedules 40, 80 & 120 ASTM D2466 — PVC Solvent Cement ASTM D2855 — PVC Solvent Joints ASTM D3915 — PVC Pipe Fitting Compounds AISI 304 — 304 Stainless Steel Plate AISI 304L — 304L Stainless Steel Plate AISI 316 — 316 Stainless Steel Plate AISI 316L — 316L Stainless Steel Plate ANSI B-16.1 — Pipe Flanges ANSI B-16.5 — Pipe Flanges 3.0 Stainless Steel Pipe Materials 3.1. All stainless steel pipe supplied shall conform with the associated referenced standards as listed in the section Referenced Standards. 3.2. All stainless steel pipe components shall be passivated by complete immersion in nitric-hydrofluric acid as specified in the associated referenced standard as listed in the section Referenced Standards. Print Date: 01/08/08 11379 - 1 11379 Diffused Aeration Piping Equipment 3.3. If the stainless steel stock pipe has been previously passivated prior to welding, as defined in the previous section, an acceptable alternative to re - immersion of the complete welded assembly shall consist of the following procedures: 3.3.1. Wire brush all welded joints to remove burrs and excess residual debris. 3.3.2. Liberally apply a coat of 'OAKITE 33' (phosphoric acid based passivating solution) at 50% concentration or immerse in the same at a concentration of 25% volume to all welds for a minimum period of 30 minutes. 3.3.3. Rinse the OAKITE 33 solution completely from the manifold or fabricated part with warm water after the curing period. Immediately towel dry the surface and inspect. 3.3.4. Repeat the procedure until all free residuals and discoloration is eliminated. 3.3.5. OAKITE 33 conforms to the following Federal Government Specifications: TT -C-490, Method VI, and MIL -C10578, Type 1. Mfg. By Oakite Products, Inc. P.O Box 602, 50 Valley Rd., Berkley Heights, NJ 07922 800-526- 4473 4.0 Vertical Piping Support Brackets 4.1. All components of the bracket assembly shall be 304 stainless steel. 4.2. The components of the bracket assembly shall be 304 stainless steel. 4.3. The bracket assembly shall provide a minimum of 2" of lateral adjustment for alignment of the vertical pipe section with the connection to the lateral piping. 4.4. The assembly support bracing shall be anchored to the concrete wall with drill and tap expansion anchors, the pull-out rating of the combined anchors shall be a minimum of 10 times greater than the static weight of the vertical pipe section. 4.5. All welded structural components of the assembly shall be passivated in accordance with the section Stainless Steel Pipe Materials. 5.0 Lateral Piping Support Brackets 5.1. All components of the bracket assembly shall be 304 stainless steel. 5.2. Support brackets shall allow for a minimum of 2" adjustment in elevation of the lateral pipe. 5.3. Assembly components shall consist of two riser type clamps minimum width of 1.75" and minimum thickness of 0.190", two all -thread rods minimum diameter of 0.5", one neoprene strip minimum 0.125" thick with a length equivalent to the lateral pipe circumference, and stainless steel lock nuts with integral nylon ring. Riser clamps shall provide a minimum of 0.0625" of compression of the neoprene strip when assembled around the lateral piping. Print Date: 01/08/08 11379 - 2 11379 Diffused Aeration Piping Equipment 5.4. Threaded rods shall be anchored to the concrete floor using drill and tap stainless steel expansion anchors. Epoxy type anchors will not be accepted. 6.0 Stainless Steel Welding 6.1. All welding of pipe and structural support members shall be conducted at the factory using TIG, MIG, inert gas or plasma -arc welding methods. 6.2. Field welding will not be permitted without the approval of the Engineer. 6.3. All welded components shall be passivated in accordance with section 3.2. 6.4. Weld cross-sections shall have a thickness equal to or greater than the welded material. 6.5. All butt welds shall be fully penetrated with gas shielding to the interior and exterior of the joint. 6.6. All face rings and flanges shall be continuously welded on both sides unless lap joint flanges are specified. 6.7. All welding practices shall be in accordance with the referenced standards listed in the section Referenced Standards. 7.0 Polyvinyl Chloride (PVC) Pipe 7.1. All PVC pipe and PVC pipe fittings shall be a minimum schedule 40. SDR 33.5, sewer drainage pipe or plastic pipe with a sidewall thickness Tess than schedule 40 will not be accepted for any portions of the piping material. 7.2. PVC pipe compounds shall be in accordance with the standards listed in the section Referenced Standards. 7.3. PVC solvent and solvent joints shall be in accordance with the standards listed in section Referenced Standards. Field solvent welding will not be allowed unless approved by the Engineer or if field pressure testing is required within these specifications. 8.0 Vertical, Air Supply Piping 8.1. Vertical air supply piping shall be a minimum of schedule 10 304 stainless steel. 8.2. The vertical pipe section must be capable of reducing the internal air temperature to 120 °F or less prior to connection to any PVC pipe or fittings. Manufacturer shall provide heat transfer calculations showing specified pipe length is adequate to reduce the temperature as specified. Print Date: 01/08/08 11379 - 3 11379 Diffused Aeration Piping Equipment 8.3. Lap Joint type plate flanges shall be provided at each end of the pipe section, flanges shall be in accordance with ANSI bolt hole diameters and spacing. 8.4. Each drop pipe shall be equipped with a stainless steel lifting lug capable of sustaining twice the static weight of the drop pipe assembly. 8.5. Stainless steel bolts, nuts and neoprene gasket shall be provided for field connection of each vertical pipe to the non -wetted field routed air supply piping at the top of the tank. 9.0 Lateral, Air Distribution Piping 9.1. Lateral air distribution piping shall be a minimum of schedule 40 PVC in accordance with the specifications for PVC pipe as listed in the section Polyvinyl Chloride (PVC) Pipe. 9.2. All PVC lateral pipe components shall be completely submerged during normal system operation. Any portions that would be exposed to atmosphere during normal operation must be a minimum of schedule 5 304 stainless steel. 10.0 Pipe Joints 10.1. All pipe joints that are to be field connected shall be either flanged or threaded union type. No ball and socket, slip-on or compression fit joints will be accepted when joining PVC to PVC. 10.2. Flanged connections shall be in accordance with ANSI bolt diameter and hole spacing standards. Flange material shall be either stainless steel or PVC to match the associated pipe material. Bolts and nuts shall be a minimum of 304 stainless steel. Gasket material shall be neoprene or EPDM elastomer. 10.3. Threaded union connections shall be a minimum schedule 40 PVC with EPDM internal o -ring. Threaded connections will only be allowed for pipe diameters of 4" and less. 6" pipe diameter and greater shall be a flanged connection. 11.0 Pipe Clean -Outs 11.1. Pipe clean -outs shall be provided at the end of each lateral distribution pipe. 11.2. For PVC pipes a transition coupling, socket x FIPT, with a threaded plug with square nut shall be provided. The diameter of the transition piece and plug shall be equal to the lateral pipe diameter. All fittings shall be a minimum schedule 40 PVC. Print Date: 01/08/08 11379 - 4 11379 Diffused Aeration Piping Equipment 11.3. For stainless steel lateral piping, a flange and blind flange plate shall be provided at the end of each lateral pipe. Stainless steel bolts, nuts and neoprene gasket shall be provided. 12.0 Expansion Joints 12.1. Expansion joints shall be provided at the end of each vertical air supply piping at the transition point to the lateral distribution piping. If an extended section of the vertical pipe is required to reduce internal air temperature to the required level the expansion joint shall be connected to the end of the air supply pipe run. 12.2. The joint shall either be flanged with a minimum face to face dimension of 6". Flange bolt hole diameters and locations shall be in accordance with ANSI flange standards, or stainless steel compression type with a minimum length of 6" and fully gasketed at 6" long by'/2" thick neoprene or PGR and have a pressure capacity of 50 psi. 12.3. Flanged expansion joints must be constructed of either EPDM elastomer or 304 stainless steel. Elastomer expansion joints will require 304 stainless steel backing rings. 12.4. The expansion joint shall be capable rated for a minimum operating pressure of 50 psi and a maximum temperature of 250 F. 13.0 Diffuser Connection Assemblies 13.1. Diffusers shall be connected to the lateral distribution piping or saddle assembly by a 3/" NPT threaded connection. 13.2. PVC distribution piping shall have either a factory solvent welded saddle with an FIPT thread or a removable compression type saddle fitted with an FIPT thread. Saddle assemblies not providing a threaded connection for the diffusers will not be accepted. 13.3. Stainless steel distribution piping shall have single welded thred-o-lets or a welded duplex tee with FIPT threads oriented as shown on the contract drawings 14.0 Airflow Monitoring Equipment 14.1. Stainless steel Pitot Tubes shall be installed through threaded ports in all vertical air supply pipes. Ports shall be located adjacent the top of the pipe within the non -wetted operating range. The Pitot diameter and length shall be in accordance with the diameter of the vertical pipe. The Pitot tube shall be oriented in the direction of airflow through the vertical pipe. Print Date: 01/08/08 11379 - 5 11379 Diffused Aeration Piping Equipment 14.2. Each Pitot tube shall be equipped with duplex hose connection ports on the external side of the vertical pipe, 1/8" to 3/8" diameter, with individual shut-off valves. 14.3. One portable magnehelic gauge and carrying case shall be provided. The scale shall be at least 120% of pipe capacity but no greater than 200% of pipe airflow capacity. 50 linear feet of flexible rubber air hose, at the same diameter as the connection ports, shall be provided. 14.4. A laminated conversion chart showing equivalent airflow rate to differential pressure reading shall be provided for each size vertical pipe diameter supplied. 15.0 Manual Air Flow Control Valves 15.1. Valves are to be of the full cast metal body, mechanical pinch type with flange joint ends on both the body and the sleeve trim. The valve shall have face-to- face dimensions of standard gate valves, in accordance with ANSI B16.10 up to 12" size. Sizes 14" and larger shall have a face to face dimension no longer than twice the nominal valve port diameter. The flanges shall be drilled to mate with ANSI B16.1, Class 125/ANSI B16.5, Class 150 flanges. 15.2. The sleeve trim shall be one piece construction with integral flanges drilled to be retained by the flange bolts. The sleeve trim shall be reinforced with calendared nylon or calendared polyester fabric to match service conditions. The sleeve trim shall be connected to the pinch bar by tabs imbedded in the sleeve trim reinforcing ply. All internal valve metal parts are to be completely isolated from the process fluid by the sleeve trim. 15.3. For full port and reduced port sleeves, the port areas shall be 100% of the full pipe area at the valve ends. For Cone and Variable Orifice sleeves the inlet port area shall be 100% of the full pipe area, reducing to a smaller port at the outlet. 15.4. The steel mechanism shall be double acting with pinching of the sleeve trim occurring equally from two sides. ACME threads shall be used on all valve mechanisms. There shall be no cast parts in the operating mechanism. The stem shall be non -rising and have a non -rising handwheel. Valve position indication shall be in the center of the stem. Mechanism lubrication fittings shall be provided. Bevel gear operators shall be provided on all valves over 8" size. 15.5. Function: Rotating the handle clockwise lowers a pinch bar above the sleeve, while raising a pinch bar below the sleeve simultaneously, pinching the sleeve closed at the center of the valve. Turning the handle counter -clockwise separated the two pinch bars to open the valve. Print Date: 01/08/08 11379 - 6 11379 Diffused Aeration Piping Equipment 16.0 Delivery, Storage, and Material Handling 16.1. Individual diffuser units shall be packaged separately and wrapped in protective plastic or packaging paper separate from the piping equipment. 16.2. All flanges shall be protected by using plastic inserts or plank wood, pipe sections are to be fully supported to prevent pipe deflection or damage to fittings or connections. 16.3. All equipment shall be shipped on pallets capable of fully supporting the pipe sections across their entire length. Pallets should be accessible for fork lift transport or strap and hoist means without causing any Toad to the pipe equipment. 16.4. All stainless steel components shall be stored separately away from any carbon steel components or other materials which could stain or deface the stainless steel finish from run-off of oxidized ferrous materials. 16.5. AH pipe equipment should be covered and stored in areas free from contact with construction site sediment erosion to prevent accumulation of materials within pipe threaded connections. 16.6. Diffuser membranes should be protected from contact with rigid objects during handling and storage. The contractor shall be responsible for replacing any diffuser membranes or elastomer components which are damaged after arrival on the site through installation and start-up of the system. 17.0 Submittals 17.1. System Installation Drawings 17.1.1. The aeration equipment manufacturer shall be responsible for providing engineering installation drawings of the complete aeration system supplied by the manufacturer. These drawings shall include plan view piping arrangement, sections and elevations as required, support bracket installation details, diffuser orientation details, and all dimensions required for locating the system within the specified dimensions of the tank. 17.1.2. Drawings shall be a minimum of 11 x 17 inches. 17.1.3. Six (6) sets of plans shall be provided to the Engineer for review and approval. 17.1.4. Two (2) sets of final fabrication and installation drawings shall be included with the shipment of aeration equipment. Print Date: 01/08/08 11379 - 7 11379 Diffused Aeration Piping Equipment 17.2. Installation, Operation and Maintenance Manuals 17.2.1. Within 30 days of final approval of the installation drawings, by the Engineer, the aeration manufacturer shall provide four (4) sets of the installation portion of the Installation, Operation and Maintenance (IOM) Manuals for the applicable aeration system. Within 30 days of final approval, by the Engineer, of the installed aeration system the aeration manufacturer shall provide six (6) copies of the complete Installation, Operation and Maintenance (IOM) Manual for final review and approval. 17.2.2. The manuals shall be in the following format and include the listed required information as a minimum: • Enclosed in a 3 -ring binder with project title and system designation shown on the front cover and side binder. • Table of contents with separation tabs. • Copy of Process calculations for aeration system (as developed by aeration manufacturer). • Copy of complete set of installation plans. • Parts and equipment list with specification numbers for ordering of replacement parts. • Product specification sheets for diffusers, expansion joints, expansion anchors, flow metering equipment and any other specialized items supplied with the system. • Installation guidelines for the aeration system and individual diffuser units. • Operational procedures for the aeration system. • Guidelines for repair of system components. • Schedule for suggested periodic maintenance of the aeration system. 18.0 Installation 18.1. Installation of the aeration system shall be in accordance with the guidelines provided by the aeration manufacturer as specified in the installation section of the IOM manual. Refer to section on Submittals for quantities and delivery schedules of the documents. 19.0 Start -Up and Testing Procedures 19.1. Leveling of Lateral Piping Print Date: 01/08/08 11379 - 8 11379 Diffused Aeration Piping Equipment 19.1.1. The centerline elevation of all lateral distribution piping shall be installed at the same elevation across the entire system unless eccentric reducers are utilized then the governing elevation point shall be the bottom invert of the pipes. 19.1.2. The Contractor shall be responsible for providing a leveling instrument during installation of the piping for maintaining distribution pipe constant elevation as specified on the installation drawings. The Contractor shall survey points along each distribution pipe at lengths no greater than 10 linear feet. The Contractor shall note the survey locations on a copy of the plan view for the piping system and maintain a field ledger with the surveyed elevations. 19.1.3. The Contractor shall provide to the Engineer and the aeration equipment manufacturer a copy of the field ledger and noted piping plan with installed survey elevations. 19.1.4. The elevation variance shall not exceed +/- 1/" difference of the specified elevation on the installation drawings. 19.2. Distribution Test 19.2.1. The Contractor shall fill the tank with clean water (or re -use water if approved by the Engineer) to an elevation of 12" above the diffuser discharge elevation. 19.2.2. Air shall be supplied to the Aeration System at a rate of 25% of the design airflow capacity. The bubble pattern at the water surface shall be observed for having a even distribution of airflow across all manifolds. Diffusers not showing visually equivalent airflow shall be inspected for proper elevation and adjusted as required. 19.2.3. Air shall be supplied to the Aeration System at a rate of 100% of the design capacity (or current capacity of the blower system if 100% is not available) and observed for even air distribution. 19.2.4. If even airflow distribution is not achieved through elevation adjustment and corrections then the Aeration System Manufacturer shall provide additional flow control adapters until even distribution is achieved. 20.0 Spare Parts 20.1. Diffuser Assemblies, Per Sections 11376 and 11377 20.2. Diffuser Replacement Kits, Per Sections 11376 and 11377 21.0 Warranty Print Date: 01/08/08 11379-9 11379 Diffused Aeration Piping Equipment 21.1. The complete aeration system shall be supplied by the Aeration Diffuser Manufacturer to maintain single source responsibility for the system. The complete system shall be defined as beginning at the top flange of the air supply drop pipes through all submerged piping, wall brackets, lateral supports, expansion joints, diffusers and any other equipment specified within this section of the specifications. 21.2. All piping, support brackets, saddle assemblies, joint connections, expansion joints, and anchors shall be warranted by the aeration manufacturer against failure under design conditions for a period on one (1) year from the date of final installation approval by the Engineer. 21.3. Elastomer Diffuser membranes, elastomer check valves, and diffuser housings shall be warranted by the aeration manufacturer against failure under design operating conditions for a period of one (1) year from the date of final installation approval by the Engineer. Elastomer components damaged as a result of maintenance activities, foreign debris in the process solution, or excessive exposure to direct ultraviolet and thermal radiation shall be excluded warranted coverage. End of Section Print Date: 01/08/08 11379 - 10