old standard llc sheaidan wtp sheridan, west virginia

Old Standard LLC Sheaidan W T P

Sheridan, West Virginia

Proposal#: 031 904=02-JAmR3

Contact Information

Phone: 512-834-6019

www.enviroquip.com Fax: 5:2-83&jfi39

http://www.enviroquip.com

Enviroquip, Inc. Old Standard LLC Sheridan, 'WV 'WWTF Proposal No. 03 i 904-02-jA-Ii3

Standard LLC P

Sheridan, West Virginia

ENVIROQUIP, INC. PROPOSAL NO. 031904-02-JA-R3

Old Standard LLC Client

Baker-Pitcairm & Associates Representative

PREPARED BY:

ENVIROQUP, HNC. 2404 Rutland Drive

Suite 200 Austin, Texas 78758

TABLE OF CONTENTS

Scope of Supply .......................................................................................

MBR Equipment Description. ..................................................................

1

2

O&M ........................................................................................................ . 3

Extended Equipment Warranty.. .............................................................. 4

Equipment Specifications. ........................................................................

Equipment Data Sheets ............................................................................ Recycle Pump (P-05, P-06) ........................................................... Permeate Pump (P-03, P-04) ......................................................... Anoxic Mixer (MXR-01) ...............................................................

ES- 100 Membrane Unit ................................................................ Aeration Blowers (B-01, B-02, B-03) ...........................................

Aquionics W Disinfection System ..............................................

........................................................................................................

........................................................................................................ Trans Max Medium Bubble Diffuser (SP1) .................................. Control Valves ...............................................................................

Air Scour Diffuser Cleaning Valve (ACV- 140 1) ............... Permeate Flow Control Valve (FCV-1806). ..................

Manual Valves.. ......................................................... Pemezk Recycle Pump Isolation Valves (RAS-5/6) Recycle Pump Discharge Throttle Valve (ACV- 1204) ...... MBR Diffuser Air Isolation Valves (FA- 1/2) ..................... Waste Activated Sludge Isolation Valve (ACV- 1204) .......

Permeate/Recycle Flow Meters (FE-1805/1203) .......................... Permeate Pressure Transmitter (PT-1802) ..................................... Process Pressure Gauges (?;G-i402ii502/i 603ii607ii608ii 8Oi j

-1 T T I - - [ n n n a 3 I A \ h l a t l U l l V alVeS ( T l S l V 1 - 3 / 4 ) ......................

5

A B C D E F 1

G H 1 2 I 1

L

2 3 4 J K L

Dissolved Oxygen Probe (AE-1301) .............................................

Chemical Dosing System ............................................................... Process Tank Level Switches (LSH/L- 1 1 0 1 LIT 1206/1403). . D . .

Chemical Cleaning Tank CheTiGZl C!eaing Tmk I S G M G E 'tT2kY.e \ b Y O lPI3Cl-A w 1 'a

Process Flow Diagram ........................................................

MBR Control Panel, Electrical Layout Drawings .........................

P&IDs .......................................................................................................

Plant Layout Drawings .............................................................................

Design Calculations, Spare Parts, Standard Piping Scope of Supply, Membrane Integrity Test, Manufacturer Services, Engineering Services

M N 0

P

Q

R

s

T

Enviroquip, h c . Oid Standard LLC Sheridan, -VVV -w-WTP Proposal KO. 03 i 904-02-JA-R3

[Anoxic Tank # I I I IEauimnent

Recycle Pumps

Recycle Magnetic Flowmeters '------- Level Transmitter

Manufacturer

Enviroquip, hc . Proposal KO. 03 i 964-02-Jri-X.3

Electrical

MBR Process Air Blowers Kaeser 700 SCFM 25 PLC B-01 & B-02 2 MBR Blower Discharge Check Valves Haleson NIA N/A NIA NIA 2 MBR Blower Discharge Isolation Valve Keystone NIA NIA NIA NIA 2

Manufacturer

Enviroquip, hc . Old Ctand2rd LLC SlilP,r;,d2Eg w WWTP Proposal No. 03 1904-02-JA-R3

MBR ~~~~~~~~ Description €4 Meadworh * Fine SGWX

One (1) Enviroquip FS-800s 2mm fine screen will be placed downstream of the owner - wnn1iP.A rr-----*- mV ShaAless Screw Classifier. Screen has czpacity tc! flow 198 gpx. Gne (1) Enviroquip 304 SS Wall iklount Screen Box fbr the F5-800% One (1) Enviroquip Screenings Washer Compactor and Conveyor.

The Anoxic Basin Mixer

One (1) ABS model RW300 submersible mixer will be supplied, capable ofmixing 7,350 gallons inside the Anoxic Basin.

Two (2) Conery Model 2900 narrow angle float switches will be supplied to monitor anoxic tank high and low level, and provide for permeate pump control (influent pump, if required).

Level Switches

m The Pre-Aeration Basin J

! m Medium Bubble Diffuser The diffuser system shall include all necessary fittings, piping, mounting hardware, and supports for installation. The diffuser provides supplemental oxygen as required and mixing of tank contents. Enviroquip, Inc. shall manufacture and supply the diffuser system.

Medium Bubble Difzser Air Isolation Valve a One (1) manual Keystone Figure 221 butterfly valve will be provided for isolation and

One (1) Erdco Air Flowmeter will be provided for indication of airflow to the medium

One (1) Danfoss Evita Oxy DO monitoring system shall be provided for field

throttling of the air to the medium bubble diffuser. 8 Medium Bubble Di/'J"user Air How Indicator

b?2?b!e diE2ser. Dissolved Oxygen/Temperctture Probe

m

measurement of the DO concentration and water temFei-ature in the MBR tank. Each monitoring system shall consist of a Model Oxy 1100 sensor, Model Oxy 4100 floating ~ a l l lwiwiiitcr, Model USZ 5000 universai signai converter, and SS mounting hardware. t 11 Lp- -------

.-___ The unit housings shall b MBR Level Sw2ches ~

nstructed of 304 SS. I.. --

Two (2) Conery Model 2900 nmow angle float switches will be sripplied for each MBR Tank to monitor MBR tank low and high level.

Five (5) 2”George Fischer Type 343 vertical PVC 3-way ball valves will be supplied for each MBR Tank for isolation of the membrane unit during cleaning.

Five (5) 2” manual Keystone Figure 22 1 butterfly valves will be provided for each MBR Tank for isolation and throttling of the air to the MBR coarse bubble diffusers.

Coarse Bubble Difuser Air Flow Indicators One (1) Erdco Air Flowmeter will be provided for each MBR Tank for indication of airflow to the coarse bubble diffusers.

One (1) 4” electrically actuated George Fischer Type 106 ball valve will be provided for each MBR Tank to automate the diffuser cleaning process. The valve will operate in an ON/OFF mode.

Two (2) self-priming Goman-Rupp Model T6A3-B pumps will be supplied to provide internal feed from the MBR Tank to the Anoxic Tank.

Two (2) pressure gauges wiii be provided to iocaily monitor the recycle pump discharge pressure. One (1) Ashcroft Type 1009 pressure gauge will be provided for each recycle Pump.

Six (6) manual George Fischer Type 346 ball valves will be provided for isolation ofthe recycle pumps.

Two (2) mmud George Fischer Type 3 14 diaphragm valves will be provided for controlling of the recycle pump flow rate.

One Endress-Hauser 50H compact magnetic flow meter shall be provided for monitoring recycle flow rate.

One (1) 6” George Fischer Type 343 horizontal 3-way ball valve will be provided to allow for automatic periodic wasting fiom the MBR Basins via the recycle line.

Permeate Isolation Valves

Difluser Air Isolation Valves

i Automatic Diffuser Cleaning Valves

Recycle Pumps

Recycle Pressure Gauges

Recycle Pump Isolation Valves

Recycle Pump Discharge Throttle Valve

Recycle Magnetic Flow Meter

WAS Valve

Pre-Aeration Bc~sin Recycle Bypass Valves Four (4) 6" George Fischer Type 346 Ball Valves will be provided in order to allow the ?re-Aeration to be bypassed €or !ow flow and maintenance operation scenarios.

Permeate C~Plect i~n System Permeate Pumps

TWE! (2) se!f-'=r?r;,mir,Ec G C E E 32pp ,n,/lsde! !3,*J=E 3UXT-S wi!! J;e s 'qd icd tz. e:.:tra2rct 1 . 2 r--

effluent fi-om-the G R tanks.

One Endress-Hauser 50I-I compact magnetic flow meter shall be provided for monitoring and controlling the permeate flow.

A pressure transmitter will be provided to monitor trans-membrane pressure. One (1) Endress-Hauser cerabar T PMC 13 1 pressure transmitter will be provided.

Pressure gauges will be provided to monitor locally the permeate pump suction and discharge pressure. Two (2) Ashcroft Type 1009 pressure gauges will be provided.

Six (6) 4" manual George Fischer Type 346 ball valves will be provided for isolation of the permeate pumps fi-om permeate headers.

Two (2) 4" George Fischer Type 304 Y-check valve will be provided.

One (1) 4" George Fishcer Type 1 10 control valve with integral positioner will be provided to maintain permeate flow at the setpoint.

Permeate Flow Meter

Perm eate Pressure Transmitter

Permeate Pressure Gauges

Permeate Pump Isolation Valves

i' Permeate Pump Check Valve

Permeate Flow Control Valve

The Aeration System Blower Packnge

Two (2) positive displacement Kaeser model EB29OC-30 blower packages will be provided to supply air to the MBR units and One (1) positive displacement Kaeser model DB130C-15 Blower package will be provided to supply air to the Pre- Aeration and WAS Basins. The blowers are rated to provide 700 SCFM at 6.0- psig and 300 SCFM at 6.0 psig, respectively. The blower packages will include the following:

Inlet Silencer with Integral Filter Discharge Silencer Pressure Relief Valve Discharge Check Valve Discharge Pressure Gauge Discharge Temperature Gauge Inlet Filter Differential Pressure Gauge Shut Down Switch TEFC, EPAct Compliant Motor

Enviroquip, Inc. Old Standard LLC Sheridan, -VV-V’ -w-WTP Proposai No. 03 i904-02-3A-fC3

Enclosure

Blower Discharge Check Yulve Two (2) 6” and One (1) 3” Haleson Model HS-WACV-TD check valves will be provided.

Four (4) 6” and One (1) 3” Keystone Butterfly valve will be provided to allow blower isolation for operation and maintenance scenarios.

‘ _R!c)WP.?- Disc?m?-ge ronl’in?z V/I!?P

Chemical Dosing System Chemical Cleaning Tank

One (1) Ryan Herco 71 10-100 500-gallon HDPE make-up tank shall be provided for mixing sodium hypochlorite to periodically Clem- the m e d m n e m i t s .

Three (3) Pacer 32 gpm capable model 6521-300 dnun mount pumps with seal less pump tubes will be provided, (1) for sodium hypochlorite chmical cleanings and, (2) for ferric chloride dosing.

One (1) 62”L x 62”W x 8.75”H four drum spill pallet will be provided for chemical spill containment. The spill pallet weighs 1251bs dry has a load bearing capacity of 90001bs

Chemical Dosing Drum Pump

Spill Pallet

i \ and has a liquid capacity of 75 gallons.

MBR Plant Controls Main Control Panel

A Stainless Steel NEMA 4X control panel will be provided to house MBR electrical controls. The panel will include an Allen-Bradley SLC-505 programmable logic controller, and Variable Frequency Drives. The panel will be approximately 60”(H) x36”(W) xl0” (DP). In addition, the control panel will be furnished with a disconnect handle, system ON/OFF switch, and alarm beacon with horn.

Miscellaneous Piping

All air supply piping and fittings shall be fabricated fiom Type 304 Sch. 10s stainless steel and will conform to ASTM A3 12 and AISI304L standards. A11 remai~ing pi~ing sha!l he fahric~tec! h m Sch. 80 PTJC miterid a d z o i i i ~ m io ASTlvi 91784 stanaara. . *

Services and Documentation Loop Checking, Function Testing, and Operator Training

Enviroquip will perfonn all function testing and operator training as required for commissioning and operation of the plant, which includes five (5 ) days of plant start- uphraining and two (2) days of construction supervision and training.

Five (5) ccpies ef Q p m t t ~ n a d hfizi;z;zte;z;ia;we Miniiiils

The Kubota Corporation manufactures f l a t sheet thin-film composite membranes exclusively for use in wastewater treatment applications. Each sheet of membrane material is made by dippkg a zon-xoven mat of polyethylene tei-api'nalaie (PET) into a solution of chiokn2~ied polyethylene and subsequently allowing the wetted mat dry. During the drylng process a thin membrane skin [about 1 micron thick) fonns over the mat with a nominal pore size of 0.4 microns.

Finished sheets of membrane material are cut to size and ultrasonically welded to acrylonitrile butadiene styrene ( A B S ) panels for mechanical support. Inserted between the membrane and the panel is a polyester spacer material that serves as a plenum to evenly distribute permeate flow to channels cut into the panel. Each of the channels, or grooves, terminates at a nozzle on top of the panel. The finished product is referred to as a membrane cartridge.

F i m e 1 : A Kubota membrane cartridge.

Multiple cartridges (between 25-200) are inserted into cassettes and the cassettes in turn stacked on top of integral air diffusers. Clear plastic tubes connect the nozzle of each cartridge to a gem-eate ~ani 'n lc! &it is camected tz heder Ioc~ted uiitsids; ofilie ?VIER.

ne or two cassettes and an air diffuser is referred to as a

Fig.iii-e 2: A single-deck Kubota SII/I?T.

The engineered configuration of a Kubota SMU and specifically the fixed vertical orientation of the cairtridges allow the dif'fused air to uniformly scour each membrane sheet. In normal operation an equilibrium is established within seconds between the material being brought to the membrane surface through filtration and the material that is scoured away by the

to as a biofilm. f crossflow of mixed liquor (see Figure 3). The result of this equilibrium is commonly referred

Figure 3: Biofilm formation on the membrane surface.

2

If you were to take a cartridge out of service for examination, a typical b iof ih worilci appear

of a few microns. Unlike other membrane applications (e.g. tertiary filtration) any membrane in a mixed liquor environment will be covered with this type biofilm or cake layer. Moreover, it is the biofilm itself that does most of the filtering making the membrane a secondary boundary between the mixed liquor and filtered effluent (permeate).

as a &!a thin slime layer r.nve,ri_ng the memhram. sllrf2c.p: a d having a thickness Q,nl the nrirer

Capitalizing on the enhanced filtration provided by biofilm formation, the Kubota membrane cartridge is able to produce reuse quality water while sustaining high permeabilityy. A direct

half of the 1300 Kubota installations worldwide operate in what is called a gravity mode. In gravity mode, roughly two feet of water head above a SMU can drive design flow (Q) and less than fQx- fset can drive peak flow (2Q) tlmugh a plant.

re!?& nf high peF-eahiIity is the ability nf the K?lbnta SWJ tn be gL?vi!y Gpc?"&?d. PITe2r,r!y

Also a direct result of high permeability is the ability of a Kubota SMU to maintain peak fluxes for hours and sometimes days. For example, pumped (light suction) systems are often designed to handle about 15 gfd on an average daily flow (ADF) basis and up to 42 gfd for several hours per day. The ability of the Kubota SMU to handle these types of peaking events usually reduces equalization and or membrane capacity requirements but does require that the ancillary equipment be designed to temporarily operate under higher loading conditions. Pe-meability plays a large part in dete-m-ining how mmy S-ms are required but the type of SMU is often a function of a plants rated ADF capacity.

In general, smaller MBR plants (c0.5 MGD) are designed using the easily accessible single- deck SMU and larger plants using the more efficient double-deck SMU (Figure 4). The double-deck SMU is more energy efficient because it requires less cleaning air and has a higher packing intensity. In practical terms, by stacking membranes on top of each other power costs can be decreased by 25-50% and the footprint of an MBR can be cut in half or morel. At present, all of installations with an ADF >0.5 MGD utilize the double-deck SMU.

(

3

F i , w e 4: k double-deck Kubota $MU.

s For municipal applications, 2-4 clean-in-place (CIP) procedures per year are typically

membranes easy to operate. Although most plants in the United States utilize semi- automated CIP systems the process can be easily automated for larger facilities. The key to keeping Kubota membranes clean is adequate and evenly distributed diffused aeration.

/ -. sufficient to maintain adequate permeability making MBR plants utilizing Kubota

Each Kubota SMU is supplied with an integral diffuser called The Centipede TM. Opening a valve on the downstream side of The Centipede TM and temporarily suspending filtration is suffisie2t to dear, this type of difhser. As shown in Figure 5, d x k g mmnal Gperatim pressurized air bubbles rise out of the holes in each lateral (leg) of the assembly. However, the opened valve allows air to take the path of least resistance bypassing the orifices and venting to atmosphere. The vented air creates a venturi or lift pwnp effect drawing in mixed liquor that scours away collected debris and other obstructions. In practice, an automatic valve is located one end of a header connecting the downstream side of several diffusers. During a cleaning a combination of mixed liquor and air can be seen spitting out of downtumed elbow jmt after the contm! vahe md back icte the MBR (or mother pr~cess &&-\ &&)* rpt- I--- -J-. - - *

IIIG pur;t;uurt: is normaiiy conducted for one minute a night.

4

Figure 5: How a difhser cleaning works.

1

5

I ?

. . .

Operation and Maintenance Manual for the KUWQTA Submerged Membrane Unit

Prepared By: Envhoquip, Inc. Document Number: 121902-1-DL-R2 Revision Date: April 24,2003

Reference Documents: Kubota Technical Manual GJW-01-002-0 Instruction Manual for Submerged Membrane Unit GJW-00-00 1-0 Instruction Manual for Submerged Membrane Unit GEW-02-004-0

TABLE OF CONTENTS

Section . Page

1.0

2.0

Introduction ............................................................................. A .............................. 1

The Submerged Membrane Unit (SMU) .............................. ................................. 2 1.1 Handling and Safety Information 1

2.1 Technology Overview 2 2.1.1 2.1.2 2.1.3 TheMBR .................................................................................................... 3

2.2.1 The F Model ................................................................................................ 5 2.2.2 The E Model (Single Deck) ........................................................................ 5 2.2.3 The A Model .(Single Deck) ........................................................................ 5 2.2.4 The K Model (Double Deck) ...................................................................... 5

The Membrane Cartridge ............................................................................ 2 The Membrane Unit .................................................................................... 2

2.2 Available Models 5

2.3 Model Identification 7 2.4 Specifications 8

3.0 Handling the SMU ................................................................................................ 10 3.1 Receiving and Offloading 10 3.2 Storage 12 3.3 How to Install a SMU 12

3.3.1 3.3.2 3.33 3.3.4 3.3.5 3.3.6

3.4.1

Difiser Case Installation ......................................................................... 13 Guide Pipe Installation .............................................................................. 14 Lower Membrane Case Installation .......................................................... 15 Upper Membrane Case Installation (Double-Deck Only) ........................ 4.5 Stabilizer Pipe Installation ........................................................................ 16 Lifting Chain Set Instzllation (Optional) .................................................. 17

General Permeate Piping Guidelines ........................................................ 18 3.4 The Permeate System 18

19 20

3.5 The Air Supply System 3.6 The Diffuser Cleaning System

4.1 Guide Rail Sets 21 4.2 r LlLLu15 :.a:-m Chi; Sets (Optima!) 21 4*2 Llfihg Tool e* .I I

5 . I Crem Water Test Protocol 22

4.0 SMU Accessories .................................................................................................. 24.

-- 5.0 System Commissioning and Operating Guidelines .............................................. 22

MBR System Preparatisn ......................................................................... LL

Cieza w Z~XT i est F ~ ~ Z K Z ~ ~ G I I ................................................................... 22 Clean W&!ter Test Pbotoeol ........................................................................ 23

eFi 5 . 1 . 1 -c i?- . rn 5 . 1.2

J,1,3 e - i

- 1 . L G-J Si-ildge Seeding 24

5-4 The Pzper Filtration Test Method 28 ?<

e g z a . .e :-jfieys*;= "I '^-----a 9 r;+d&pes --------A. -

L CSLLILU b v L W J > L t y

Lad

.,fi - v

5-5 'T.._~:-- ~ r : - - - - :

5.6 IVBR P h t Testiilg Reqzhez-lents 3i 6. 0 Mairatenance sand Troubleshooting Procedures ..................................................... 32

Chernicd Handling Inslx-ictions ............................................................... 32 6.1.1,l Sodium HY_pochloriee/NaClO ................................................................... 32 6.1,1,2 Oxalic'Acid Cgowclered)/CzHzO, .......................................................... 33

6.1 Maintaining the §MU 32 6.1.1

6.1.2 '61.3

Membrane Recovery Cleaning Pfotocol ................................................... 33 Difhser CleaJaing Protocol ....................................................................... 36

6.1.4 M a n b m e Flux Recoverjr 37 6.2 Part Replacement Schedule and Procedures 38 6.2.1 &171QVblg W-d SC-TYiChlg 51 SMU .............................................................. 38

6.2.1. I 6.2.1.2 6.2. I . 3

Removing/Repiacing a S W in a Gravity System ............................... 39 RemoVing/Replacing a SMU in a Pumped System .............................. 39 How to Replace a Membrane CartridgeRetaining Rubber/Tube ......... 40

6.3 Trouble Shooting 42

1.0 Introduction

1.1 Handling and Safety Information Thank you for selecting the Enviroquip, Inc. membrane bioreactor (MBR) process incorporating the KUBOTA Submerged Membrane Unit (SMCT). The following sections of this manual describe in detail how to handle, install and operate a KUBOTA SMU properly. Please note that it is important to read this manual carefully in order to handle the product safely and effectively. Retain a copy of this manual for fiture reference.

Regarding the format of this manual, information of particular importance is highlighted by the use of the words ccNOTE”, “CAUTION” and “WARNING.” In the context of this document, these words have the following meanings:

NOTE: FAILURE TO COMFLY xi7rITH THIS IWOIUk?.ATION CAP4 IMPACT SYSTEM PERFORMANCE AND OR THE PRODUCT WARRANTY.

CAUTION: FAILURE TO COMPLY WITH THIS INFORMATION CAN RESULT IN EQUIPMENT MALFUNCTION OR DAMAGE.

WARNING: FAILURE TO COMPLY WITH THIS INFORMATION CAN RESULT IN INJURY OR DEATH.

EnvrroquipKuboea Submerged Membrane Umt O&M Manual i

2,o

2.1 Technology Overview P, K~UBCITA SPdU is a so!id-!iquid separatior, tecbmlogy th& c m be used tc! filter hi&- quality water from activated sludge. Incorporated into each SMU are flat-plate membranes that serve as a physical banier to wastewater contaminants. With a nominal pore diameter of 0.4. microns, the membranes prevent the passage of suspended soiids while allowing the free passage of filtered water. The configuration of the SMU when installed inside an activated sludge tank is commonly refexred to as a membrane bioTeaCt0r QT D R ,

2.1.1 The Membrane Cartridge A KUBOTA membrane cartridge, s h o w in Fi,we 1, is constructed

as by

ultrasonically welding sheets of polymer to the back and fiont of a support panel. Between the panel and the membranes, a porous spacer material serves to distribute filtered water into a series of grooves that lead to a nozzle on top of the cartridge. Membrane cartridges are housed in membrane units.

2.1.2 The Membrane Unit Each membrane unit (see Figure 2) is comprised of a lower diffiser case and at least one membrane cassette (or case). The difhser case is fitted with an air

Figure 1: The iMembrane Cartridge

. .-___ -. -.- %-&. -____ .I____

diffuser manifold that is designed to properly distribute air for membrane cleaning. The membrane cassette contains slots that support the individual cartridges. The permeate nozzle at the top of each cartridge is connected to a manifold via a transparent tube. Multiple membrane unit manifolds are then connected to a common header in a MJ3R.

EnviroquipKubota Submerged Membrane Unit O&M Manual 2

Ficure 2: The Sinde Deck SMU

2.1.3 TheMBR The MBR is essentially a highly concentrated activated sludge process with an integral solid-liquid separation mechanism, the membrane unit. As shown in Figure 3, air bubbIes are emitted at the difhser and chameled between each of the membrane cartridges as they rise to the surface. The channeled bubbles accomplish three important objectives: (1) provide adequate oxygen cell respiration, (2) scow the membranes to prevent fouling, and pressure gradient between the top and bottom cf the membrane unit. Fierare 3: Diffuser Air Flow

maintain create a

Fipure 4: Cross-Flow Filtration The przssure gradient created by the rising bubbles induces an upward cross-flow of mixed liquor over the menibraiies. The liquor is filtered as it flows across the membrane (see Figure 4) due to the trans-membrane pressure (TMP) created by the water head

filter fiowrate per area, is directly proportional to the TMF and thus can be controlled by modulating the side water depth in the MBR,

zbove the s-wu or pazp sllr.tinn_. The flux, nr

I 1

using a control valve, or changing pump i speed. I

In general, the number and type of SMUs installed tor a gven project is based on what is referred to as the designJlux. The design flux is almost aiways calculated based on the i z zm water temperature and is given in units of gallons treated per square foot of membrane area per day (gfd). For control purposes, the design flux must be converted to an instantaneous flow (gpm) and adjusted to account for relaxation of the membranes.

A MBR is said to be in relax mode when filtration is suspended (no permeate flow) and the cleaning air is left on. Typically, the MBR is relaxed for 1 out of 10 minutes. The purpose of the relax mode is to keep the biofilm at an optimum thickness and to minimize the TMP required to generate a given flow. In order to maintain the design flux, a grossflux must be calculated and converted to a flow. For example, to relax membranes for one minute out of every ten and maintain design flow, the gross flux must be 10% higher than the design flux. So if the design permeate flowrate is 10 gpm, in practice it will be 11 gpm. At some point, relaxing the MBR will not recover the design flow zit a reasonable Thap md a recovery cleaning must be performed.

On average, it is necessary to chemically clean a S M U every six months. The membrane units are cleaned in $ace quickly and efficiently by simply injecting, or pouring, a dilute chemical solution into an accessible tee on the permeate header(s). The solution remains in the membranes for about an hour, and then - nnrmnl - - ---- npetattinn is resnmed.

Recovery cleanings are generally scheduled events, however, an operator can quickly assess the status of the membranes by observing the change in TMP over time. During a cleaning of one MBR, the other MJ3Rs are left online and operated at slightly higher flux rate as required to meet plant demand.

EsviroquipKubota Submerged Membrane Unit O&M Manual 4

2.2 Available Models Although all KTJBOTA SMUs offered by Enviroquip utilize the same membrane cartridge (Type 510), different models are available that have been designed to meet the specific needs of some typical applications. In short, only the height of the diffuser case and or the number of membrane cases changes for each model type.

2.2.1 The F Model Designed for small point-of-use applications (<3,160 gpd), the F Model has the shortest standard diffuser housing available and can hold 25 membrane cartridges only.

. .

The short difiser housing supplied with the F Model can accommodate very shallow tanks but the reduced headspace between diffuser and the membranes can decrease the scouring efficiency of the cleaning air. To compensate for the reduced cleaning efficiency, the minimum cleaning air requirement is 25% higher than for other model types available.

2.2.2 The E Model (Single Deck) Designed mainly for retrofit applications, the E model is equipped with a short diffuser housing and can hold between 50 and 200 membrane cartridges in a single deck configuration (one membrane case).

Unlike for the F model, additional cleaning air is not required for the E model. However, on average, an E model is cleaned 10% more fkequently than an A Model given similar operating conditions.

.I'

2.2.3 The A Model (Single Deck) Designed for most municipal and industrial applications, the A Model has the tallest and therefore most efficient difiser assembly and can hold between 50 and 200 membrane cartridges in one membrane case. For plant capacities between 0.1 and 0.5 MGD, this is the model aaimdly recommended.

2.2.4 The K Model (Double Deck) Specifically designed to reduce footprint and aeration requirements, the K Model uses the E Model diffuser assembljy but includes an additional membrmes case. Using two membrane cases stacked on top of each other, the doubZe deck K model (see Figure 5 ) holds between 300 and 400 membrane cartridges.

Figure 5: The Double Deck SMU


2.3 ModeI'Identification Various SMLT models are available for a wide range of applications and installation conditions. The different models are assigned unique codes using the following system:

Generic Code = & 2 d

Where,

- a specifying the height of the diffuser case, is replaced with one of three letters according to the following:

F = 19 11/16" f 1/16" (500 E = 39 1/3" f 1/16'' (1OOOmm) A = 59" f 1/16" (1500 mm)

- b specifyrng the type of application, is replaced with one of three letters according to the following:

F = Low Flow Applications S = Single Deck Applications K = Double Deck Applications

I c is replaced with a number corresponding to the quantity of membrane cartridges contained in the SM[J and can range firom 25 to 400.

- d is left blank for Type 304 stainless steel or replaced with letter N for Type 316L.

For example, a double-deck SMU constructed of Type 304 stainless steel and containing 400 cartridges would be assigned the following code:

EK400

6

/'

'The lower case is connected to an interposing section that adds dry weight for Lifting purposes. Nominal value assuming an operating temperature of 15 "C and TMP of 0.7 psig. Material selected at ordering.


Caution: The water temperature and pH ranges mentioned above pertain to the membrane cartridge only and are not intended to describe the design operating ranges for an activated sludge system.

Note: Please contact Enviroquip, Inc. of Austin, Texas before subjecting a KUBOTA SMU to conditions other than those described above.

3.1 Receiving and Offloading

1. Stage the equipment (crane, hoist, or forklift) that will be used to offload the SMU shipment.

Warning: Refer to Table 1 for equipment weight information. Always operate lifting equipment per manufacturers recommendations.

2. Secure a temporary storage place for the SMU (refer to Section 3.2). 3. For most orders, the diffusers, membrane cases, and lifting tools will be

palletized and shrink-wrapped individually. To unload received equipment, insert the forks of a forkIift into a single pallet and remove it &om the shipping container. If a crane or hoist is used, first locate the lifting tool(s) provided with your order. To lift a membrane case, attach the hooks on the lifting tool to the lifting tabs cr, LIe case as shown in Figure 6. To lift a diffuser, use nylon slings to cradle the diffuser case, talung care not to damage the plastic parts when lifting.

Fieure 6: Lifting a Membrane Case

Caution: Lifting equipment should not contact plastic parts such as the diffuser assembly or membrane cartridges during offloading.

EnviroquipKubota Submerged Membrane Unit O&M LManual 10

4. Either during or following equipment delivery, inventory the shipment using the bill of lading and visually inspect the order for any signs of damage. Items that are missing or in poor condition, should be brought to the attention of Enviroquip, Inc. immediately and in writing.

Note>: Enviroquip, Inc. shall not be held responsible for missing QP damaged items unless written notification of such items is received within fourteen business days of delivery. Without notification and confirmation, replacement of equipment and materials after this time shall be a t the owner’s expense.

In the event of an improper shipment, please contact:

Enviroquip, Inc. 2404 Rutland Drive, Suite 200 Austin, Texas 78758 (512) 834-6000

3.2 Storage Each SMU shall be stored:

F

1. 0~1 a level surface. 2. Indoors at ambient temperatures ranging between 40 O F to 104 OF. 3. Covered tu protect components from direct sunlight of any kind.

Caution: Do not wet the membrane cartridges before use.

Caution: Take care to prevent damage to the membrane surfaces. Damaged membrane cartridges must be REPLACED only.

3.3 How to Install a SMU Install a SMU in steps as listed below:

Step 1 : Mount the diffuser case. Step 2: Mount the guide pipe. Step 3: Install the lower membrane case. Step 4: Install the upper membrane case (for double-deck units only). Step 5: Mount the stabilizer pipe.

Caution: Do not remove the protective plastic sheet from the upper cassette until clean water test is set to begin.

Warning: Never expose the membranes to welder or grinder sparks.

The fdlowing subsections describe ir: detail h w tc perfcm the phases listed zbove.


3.3.1 Diffuser Case Installation

1.

2. 3.

4.

5.

Mark floor penetration locations using engineering drawings and or shop drawings provided by Enviroquip. Drill floor penetrations for anchor bolts. Install anchor bolts per manufacturers instructions and applicable engineering specifications. Install the difiser case so that any point on top of the diffUser is less than 3/16” out of level. When installing multiple difhser cases, install them such that the difference in level between any and all cases is within k 3/8”. Grout in pedestal after all diffuser cases are level. Unless otherwise noted in contract documents or other, the pedestal should be 2” tall (see Figure 7).

Figure 7: Grouting the Diffuser Suppoic LeF

DIFFUSER CASE f SUPPORT LEG.

-GROUT TO BE INSTALLED AFTER

LEVELING OF DIFFUSER CASE

TANK EOTTIOM

3/4” ANCHOR BOLT SET IN TANK BOTTOM

w/CHEMlCAL ADHESIVE

1. Inuentory md stage the guide pipes and hardware shipped with the order. A typkztl list for one (1) SMlT includes the following:

-01% Rails. (2) 304 SS Guide Pipes (2) 304 SS Stabilizer Pipes (8) SS Lifting Chains (4) 5/8” &meter SS cherica! anchor bolts (8) 5/8” diameter SS washers (8) 5/8” diameter SS nuts (4) 3/8” diameter SS bolts (8) 3/8” diameter SS washers (4) 3/8” diameter SS nuts

2. Drill wall penetrations for the

MEMBRANE CASE

4. anchor bolts. Set the chemicai anchor bolts per applicable engineering drawings and or details provided by Enviroquip, Inc. The length and insertion depth of each stainless steel the manufactures recommendation.

./

CHAIN HOOK \_

STABILZER / ‘ ANCHOR PIPE: / \ BOLT

GUIDE J’

PIPE GUIDE PIPE SUPPORT BRACKET

chemical anchor bolt must conform to

4. Mount the guide pipe support brackets per Figures 8 & 9. 5. Install the two guide pipes (see Figure 9) and verify that each pipe is plumb

within k 1/8”. 6. Tighten all set screws at the diffuser case until the pipe is secure (see Figure

9). Fbure 9: Guide Pipe Instailation


3.3.3 Lower Membrane Case Installation 4

1. For double deck units only, remove the plastic wrapping. 2. Connect the lifting tool to the tab at each comer of the case and lift into

position above the diffuser. 3. Use the guide pipe to align the case before lowering into place. 4. Slide the case onto the diffuser using the guide pipe.

3.3.4 Upper Membrane Case Installation (Double-Deck Only)

1. Connect the lifting tool to the tab at each comer of the case and lift into position above the difhser (see Figure 10).

2. Using the guide pipes, lower the upper membrane case into place.

Figure 10: Upper Membrane Case,Installation

3.33 Stabilizer Fipe iisstaiiatioa

1. Slide the stabilizer pipe over the pins located on top of the upper membrane case (see Figure 1 I).

2. Bolt the stabilizer pipe to the guide pipe using hardware supplied.

Figure 11: Stabi!izer Pipe Installation

STABILIZER PIN


3.3.6 Lifting Chain Set Installation (Optional) Lifting chains are optional and are normally recommended for pumped systems. Chains are not recommended for gravity systems because the MBR water depth must be dropped to break all piping connections prior to lifting a membrane case. However, in a pumped system, a membrane case can usually be extracted for maintenance or inspection purposes by breaking above water piping connections and using the lifting chains as described in this section.

To install a lifting chain set, perform the following:

1. Connect all four chains to a membrane case at the lifting tabs using shackles as shown in Figure 10.

2. Hang the lifting chains from the hooks (see Figure 8) at the pipe bracket above the water surface until a membrane is to be lifted.

3.4 The Fermeate system There are numerous methods that can be employed to operate a KUBQTA SMU each requiring a slightly different operating strategy. In short, the different modes of operation are listed below:

o The Bumped Mode By connecting the permeate header to the suction side of a low-head p u p ,

val.i_&!p tfie rate af filtmtio:: (or flux) can he controlled mihg 8 valve fPequemy drive.

o The Constant Level Gravity Mode By maintaining sufficient water depth in the MBR, a control valve on the permeate header can be used to vary membrane flux.

o The Varying Level Gravity Mode By maintaining a minimum water depth in the MBR, the flux is self- modulated based on the hydraulic loading. For example, if flow into the MBR exceeds the cclnc-iiKeni flux (effluent flow), the level in the i m R increases thereby increasing the effluent flow to match whatever is coming into the plant.

3.4.1 General Permeate Piping Guidelines

1. Size the main permeate header piping so that the fluid velocity at average daily flow is as follows:

Pumped Mode o < 5 ft/sec, for higher fluid velocities consider water hammer impacts on

piping and excessive fiiction losses during pump design.

Gravity Mode (Constant or Varying Level) o < 1 Wsec, the objective of the low velocity is to minimize piping fiction

losses.

2. Install the permeate header piping according to the engineered design and or Enviroquip instructions.

3. Verify that the header pipes are level. 4. Install laterals off the main header to each SMCT location and temporarily cap.

Each lateral must be of a diameter equal to or larger than the permeate rnWi€Q!d 2t the! S3FJ.

Note: Each SMU connection to main permeate headers should be equipped with isolation valves.

5 . Hydrostatically test the installed permeate piping. If available, perform all quality assurance testing per applicable engineering specifications.

Enviroquip/Kubota Submerged Membrane Unit O&M Manual 1s

6. Install chemical solution injection ports on each SMU lateral or on the main permeate header. For tap points, see the engineered design and or Enviroquip instructions.

3.5 The Air Supply System At every diffiser there are supply and cleaning air connection points. The supply connection is labeled as IN and the cleaning connection as OUT. These designations are important, as the diffiser is sloped slightly from the IN to the OUT side of the housing to ensure equal air distribution.

During installation of the air supply system and before connecting to SMUs, be sure to:

1. Verify thzt the blower(s) and air supply piping are designed properly using Table 3 below:

2. Pressure test all air piping. If available, perform all quality assurance testing per applicable engineering specifications.

3. Connect a lateral lbe off the main air supply header to the “IN” side as indicated on the diffuser. The connection should be done by gluing a 2” IPS pipe nipple into the 50mm JIS slip adapter followed by a union or flange fitting.

Warning: All piping should be installed and supported per Iocal code requirements.

b

Enviroqui$Knbota Submerged Membrane U d O&M Manuai 19

3.6 -.. 1 me Diffuses Cleaning System

1. Install a diffuser cleaning header just above the highest water depth in the tank with sufficient tap point pciints to pick up a r iser from exch S W in the m R . The header should be sized according to Table 4 and installed per goveming piping codes. The diffuser should be sloped at a 1/16’’ per foot in order for the pipe to drain after each cleaning.

Note: The height of the header above the maximum side-water depth should be approximately 2’ to maximize cIeaning efficiency. If the pipe is too high, little or no air will be available to induce the pumping effect necessary to clean the diffusers.

2. Terminate the d i fhe r cleaning header at a down turned elbow inside the MBR. 3. Install an actuated ball or plug valve upstream of the terminating elbow on the

diffiser cleaning header. The valve should be equipped with limit switches and the valve position monitored.

4. Connect the OUT side of each SMU diffuser to the cleaning header. The connection should be made by gluing a 2” IPS pipe nipple into the 50mm JIS slip adapter followed by a union or flange fitting.

EnviroquipiKubota Submerged Membrane Unit 0&M Manual 20

4.0 SMU Accessories

4.1 Guide Rail Sets Guide rail sets consist of two (2) guide pipes, two (29 stabilizer pipes, and one (1) lot of all mounting hardware and appurtenances necessary for installation.

4.2 Lifting Chain Sets (Optional) Lifting chain sets are comprised of four (4) equal length chains that can require field modification (see Contract Documents).

4.3 Lifting Tool Because the dimensions and weights of different model SMUs can vary, different capacity lifting tools are available according to Table 5 below:

EnviroquipR.ubota Submerged Membrane Unit O&M Manilai 21

5.1 Clean Water Test Protocol Before the MBR is seeded, the system shouid be function tested using clean water to verify piping integrity, equipment operation, and membrane performance. However, before performing a Clean Water Test, all system components and tankage must be thmagEly cleaned mi! inspected.

5.1.1 MBR System Preparation Tke €ollowinng protocol assumes that tke S W s have been properly installed but NOT connected to header piping:

1. Connect each SMU permeate manifold to the dedicated lateral and cap the c!pposh eEd. See Sections 3.4.1 f ~ r p$ng fitup h-n-s?mctinns.

Note: A J-IS 50 mm socket coupling will be provided for all permeate connections up to and including the ES250 units, with a XIS 50 rnm end cap supplied for the opposite ends. A special JIS 65 mrn coupling will be provided for all permeate connections on the ES200 and EK400 units, with a JIS 65 mm end cap supplied for the opposite ends.

2. Rinse all tank walls with tap water to collect dust and debris. 3. Remove the rinse water through tank drains and vacuum any residual material.

5.1.2 Clean Water Test Preparation

1. Fill the system with clean tap water up to the normal operating level.

Note: High concentrations of manganese, calcium, or silicon can foul the membranes prematurely and irreversibly. Please contact Enviroquip, Inc. prior to filling the system if hard water is an issue.

2. Open the chemical injection ports for five (5) minutes to release trapped air to the atmosphere.

-. 3 Timm nn the aer~ttion h!owsrr(s) md vis~dly h q e c t the bcbble pgtittzr~ of ezsh SMU. If‘the air distribution system has been designed and installed properly, the diffuser for each SMU should generate a uniform rolling air pattern at the surface. If “dead” spots are observed or the degree of agitation varies significantly fiom unit to unit, check that all isolation valves are in the full open position. If the condition persists, refer to the Trouble Shooting Guide in Section 6.3.

Note: Temporary foaming in the MBR can occur due to the presence of a hydrophilic wetting agent used to coat the membrane cartridges.


>

4. Function test all system input/output points to confirm logic. Remediate problems as required. Refer to the system process and instrumentation diagrams (P&IDs) and control narrative to direct logic testing.

5. Calibrate all instrumentation including dissolved oxygen sensors, turbidimeters, pressure and flow transmitters, and NADH probes as applicable.

5.1.3 Clean Water Test Protocol After the system is cleaned, function tested, and filled with tap water:

1. 2. 3.

4.

5.

Make a clean copy of the Clean Water Test Results form provided in Appendix 2. Record the ambient and water temperatures. Turn on the blowers and adjust the aeration rate to the minimurn value listed in Table #3 given the number and type of SMU installed. Verify that all diffuser cleaning valves are closed and that the aeration pattern is even. Calculate the gross design and peak flowrates (QGD, QGP) given the relax period according to the example given below:

Example: The design flowrate for a plant using ES200s (single deck) is 100 gpm. The membranes are relaxed for 1 minute out of every 10 or 10% of the time. What are the gross design and peak flowrates?

Step 1: Use Equation 1 to calculate the gross design flowrate.

Equation #1:

'" = (1- %Relax) QD

1 OOgpm 0.9

= lllgprn QGD =

Step 2: Double the gross design flowrate value to determine the conesponding peak flowrate (see Table 7 for peaking factors).

Equation #2: QGP = 2'_o,, = 222gpm

6. Start filtration at 50% of calculated gross design flowate and record the transmembrane pressure ("A@). Depending on the system type$ this task can be accemplished in several ways:

kput fhe target flowrate at the System interface and aiiow fhe control valve to incrementally ramp up to the permeate setpint.

o Gravity System Using Varying Level From the closed position, manually open sul isolation valve on the main permeate header if available or on the individual drop leg from each unit.

6. Increase the permeate setpoint in 10% increments until peak flow is attained. At

depending on the system design. 7. Tun? offthe blower(s) at the completion of the clean water test. 8. Submit a copy of the completed Clean Water Test Results form to Enviroquip,

InC.

eg& flcy-~ate, c ~ t e *be cgxeSnnni?ina T W in_ t-mis of ~ i & o r -*----a - AT- r a y+rzter I e ~ ~ e l

Caution:

Caution :

Caution :

5.2

1.

2.

3. 4. 5. 6. 7.

Never aerate an SRlLJ for longer than five (5) minutes if filtration has stopped, Le., the permeate flow has stopped. Prolonged aeration without fiitration can reduce membrane iife.

Clean water testing should be limited to roughly three (3) hours in duration. Extended filtration periods without the biofilm created in a mixed liquor environment can allow scaling and or fouling to occur.

After the clean water test, do not dry the membranes. Dried membranes can become hydrophobic, resulting in low permeability.

Sludge Seeding

Calculate the amount of seed sludge required so that the initial MBR mixed liquor suspended solids (MLSS) concentration will be greater than 3,000 mg/L (5,000 mg/L is preferable). Pre-anmge deliuery of fksh activated seed sludge from a suspended growtb-type activated sludge treatment plant (preferably one employing a nitrification- denitrification processes). Drain the tap water from ancillaIy tankage @re-Air, Anoxic, etc.). Screen the-seed sludge at the MBR plant headworks (U8” or finer). Remove grit fkom seed sludge %required. Seed the reactor(s) with activated sludge prior to initial operation of the system. At startup f o m h g cslii GCCW.

antifoaming agent. To isdEce fmmiig, i i ~ e a petmlem-basetl

‘Caution: Silicone-based antifoaming agent may cause membrane clogging. (Kubota recommends the use Nissan Disfoam CC-118 as manufactured by the NOF Corporation).


5.3 Operating Guidelines All SMU maintenance, operational, and warranty claims (unless otherwise noted in Contract Documents) are contingent upon the operating parameters listed in Table 6-8. For the most part, all of these parameters are easily maintained and are defined as a range of values.

Note: Please refer to the procurement contract documents to verify applicable warranty conditions.

At all times, the MBR plant should be operated according to the guidelines set forth in Table 8. However, situations or applications may call for operating outside one or more of the parameters. Lf so, please contact Enviroquip to discuss optimization methods for your MBR.

In simple terms, to operate a SMU properly:

1. 2. 3.

4.

5.

6. 7.

0 0 s

9.

Re-Treat wastewater according to Table 6 and feed to the M E R . Always maintain at least 1 ’ of water above the SMU during operation. Always supply the minimum amount of cleaning air required per Tables 3. If necessary, extra air can be added for process purposes or in some cases to increase the critical flux.

Caution: Never exceed the Maximum Air value Iisted in Table 3. ,

Always filter wastewater at or below the design flowrate (see Contract Docm-mts) except during peak flow conditions. To do this, calculate the gross flux for each condition and convert to flow in gpm (see Table 7). Periodically relax the membranes by suspending filtration but continuing to aexde. See Tabls 7 fix Relzx times aid constraints. Periodically clean the diffusers per Table 7. See Section 6.1.3. Intermittently aerate the MBR according to Table 7 during periods of low or no flow. Always maintain &e MEID, zwordirig to the parazzetes listed in Table 8, Clean the membranes, per Section 6.1.2, every six (6) months or when:

o The Pumped Mode The pressure measured upstream of the permeate pumps changes 3y 1.5 psig at design flow. The Caanstaat Level Gravity MGde The pressure measured upstream of the pemcate control valve changes by 0.7 psig at design flow. The %w-ying Lewd Gravity Mode i iie side-wzter-deph In the kGx3 iEacrzases by 2’ to mzt desigi f i D W <

r2

e 7

i m I Not Applicable i 7 i .

0 - 5 min continuous aeration w/o filtration.

Flux'

FOG shall be less than 20% of BOD by weight.

j

i( I

Notes

1 Operating below the recommended minimum value can result in the immediate fouling ~ ..... of membranes. ~

Filtration must be suspended during diffuser cleaning or immediate fouling can occur. The maximum continuous relax time is 5 minutes. Filtration must resume for at least 5 minutes after each relax cycle. 5 mid60 min can be adequate depending

The average daily flux should remain at 50% of the design value until the MLSS concentration is 1 8,000 mgA

The ADF is usually defined in terms of daily averages (gfd) however the value also represents instantaneous flow (gprn).

Unless otherwise noted, gravity double- deck systems are not designed to fiIter

I .__-- . - - ~ - - . ~ -

1

-.--

i I-._ on plant conditions.

i

;

i /

It

! _--_.____ more than 2*ADF. ---L.-i-----' ! For gravity systems, the maximum TMP is /

: generally less than for pumped systems TMP

See Contract Documents for the warranted flux information.

EnvimquipKubota Submeged Membrane Unit O&M Manual 26

Table 8: MBR Operating Conditions ; / P a r a m e t e r j j R e f o m m e n d e d r 1 Notes i r___^_I__._.--___ -.------ -I-___..--.__ ....I..._....-..- ~ ~ _-.___-~_______I._______.___.

: i ~ -.-_-.+ Startup Value __.._..I_.___-____l_l_! ----- ~ - * -__. -- i

of 3,000 mp/L or higher. 1 i I ! Listed values assume a surface

I t measurement. In normal operation a

j

i

~~ ~~~ ~

i)

!I -.-.--.-- "iscosity_ .--I! -2.4 -..-..-I-- _." _... ; " .--. s 1oocp ..._,_.-__-____. ...._ _* _..- 1 ._-.-.--.-.-_ .l.L-.__- ...-.r---.--.l -.i j See Section _--I----- 5.4 for test protocol. -~

,I : Filterability I 2 1 0 m l / 5 min I 2 10ml15 min i--- . ----I- -----

Caution: Never put chemicals that are harmful to activated siudge, toxins, or large amounts of fats/oils/gi-ease (FOG) into the tank(s).

EnviroquipKubora Submerged Meinbrane Unit O&M Manual 27

5.4 Unlike a cor~ven%ional secondw or tertiary WW'TP, Lhe quality of MBR effluent is completely independent from the quality of the activated sludge. In practical terns, this means that filaimtom organisms c m o t impact effluent quality and, in fact, are often present in high concentrations. However, sludge quality cm affect hydraulic capaciw and must therefore be monitored.

The Paper Fiitration Test Method

The p-iL~1~3r ka&x iaed t~ sludge q&Q 2 &mpL playt is refe~c-j filterability and is measured using the Paper Fiitration Test (?FT). Extensive PFT data has been collected and correlated to filterability so that new PFT results can be used to troubleshoot membrane performance.

A PFT should be performed at least two times each week and, if possible, every day. For trouble shooting purposes, the results of each test should be recorded and trended.

To conduct a FFT:

1.

2. 3. 4.

5. 6 . 7.

8.

0 A.

Gather the following items:

o One piece of 5C filter paper as manufactured by the Toyo Roshi Company and distributed by Advantec MFS, hc .

o Two 100 ml sample bottles o Two 50 rnl graduated cylinders o One funnel ( 75 mm diameter) o One stop watch or clock

Collect a 100 ml sample of activated sludge fiom the MBR, Fill the other sample bottle with tap or distilled water. Fold the filter paper into a cone shape as shown in Figure 12. The folded filter paper should have 16 equal partitioEs if folded correctly. Set the folded filter paper into the funnel. Set the h e 1 into a graduated cylinder. Moisten the filter paper with a small amount of tap or distilled water, and wait until the water no longer drips from the filter paper. Drain the water used to moisten the filter paper and replace the funnel on top of the graduated cylinder. Fill the second gadczted cyhder -with 50 in1 of zcti-vzitteb skidge 50rn the sample bottie.

10. Pour the sludge from graduated cylinder onto the filter paper in the funnel and

11. After 5 minutes of filtration, remove the filter paper and h m e l from the

12. Measure the amount of collected filtrate and record the value.

start measuring the filtration t h e .

graduated cylinder.


13. The criterion by which the filterability of sludge is measured are as follows:

o s5 ml, the sludge filterability is poor and must be improved (see Section 6.3)

o >5 ml but 4 0 ml, the test is inconclusive o 210 ml, the sludge. filterability is considered good and should not impact

hydraulic capacity (flux)

Figure 12: The Filter Paper Test

. . . . 1 . . . ‘ . . 4 . . . . . .

h 'i

5.5 T-.-*:-- x7:--.-.-:4.

Another useful parmeter used to ckaracteffze sludge quality is viscosity. Viscosity as a measure of fl&ity (or how easily something pours) can be measured using many dif-erent techniques. The rnethod described here is oftm employed by Kubotz and is relatively simple to perfom.

P tzauug v m L w s I a j

Before measuring mixed liquor viscosity, carefully read the instructions included with the Viscotester. The instructions below are general and meant to give an overview oE the procedue. To conduct a viscosity test:

1.

2. 3.

5 . A 7.

6.

7. 8. 9.

Gather the following items:

o One Viscotester as manufactured by the Rion Co. Ltd. Model VT-03. o One 500 ml sample bottle o One thermometer

Collect a sample of mixed liquor from the MBR (500 ml sample bottle). Place the Viscotester on a level surface and attach it to the stand. Ti-... ,,;3 that the Viscotester is horizontal using the meter level. Fill the Viscotester sample container with the mixed liquor sample to just below the lip of the cup. Place the rotor in the sample container and submerge it to nearly the center of the level mark on the rotor. Disengage the needle clamp by pulling it toward you. Turn the Viscotester on. After the needle stops moving record the scale reading.

10. Measure and record the sample temperature.


5.6 MBR Plant Testing Requirements To ensure proper operation of each SMU in accordance with the parameter ranges listed above, develop a testing regimen based on Table 9. For alternative test methods please contact Enviroquip.

The sampling schedule as shown in Table 9 applies only to SMU operation and may not meet process warranty or permit requirements.

MEFFMBR refer respectively to; influent wastewater downstream of pre-treatment, permeate downstream of SMUs only (not post disinfection), and mixed liquor inside the MBR.

bCollect 24-hour composite samples for influent and efluent testing. For mixed liquor lab samples, simply submerge a container directly into the MBR. Follow sampling protocol as required for lab analysis of DO.

'Listed methods are per Standard Metliods for the Eramination of Water and Wastwater (Latest Edition). Other testing methods are acceptable per written authorization by Enviroquip.

dParameter type and testing frequency assume typical municipal waste. For industrial applications or other requirements can change.

Note: Monitoring the water phase parameters included in Table 9 facilitates troubleshooting if necessary and the data san be wed %Q optimize S M J WR-1 performsn r.e=

6.

6.1 Maintaining the SMU It is important to perform a periodic in-place chemical cleaning of the membrane cartridges at least once every six months. Generally, organic fouling of the membrane micro-pmes can be cleamd using a dilute s~lutiion of bleach. However, h the presezce of minerals (hard water, iron, aluminum, other)g oxalic or citric acid can be necessary to fblly recover membrane capacity.

Overtime, the pore structure of the membranes will expand and or the flux will irrevocably decline. Lp1 this section, the procedure to replace damaged or deteriorated membranes is discussed in detail as well as how to re-activate previously wetted and dried rncsbranes.

A uniform distribution of cleaning air is required to prevent membrane fouling and maintain a given flu. Therefore, routine maintenance of S W diffusers is necessary and is also covered in this section.

Lastly, a troubleshooting guide is provided to quickly assess some common problems. I

t 6.1.1 Chemical Handling Instructions Before handling any chemicals, please read the applicable Material Safety Data Sheet (MSDS). Always wear the appropriate personal protective equipment (PPE) recommended by the MSDS and or the manufacturer.

The MSDS for bleach (sodium hypochlorite), oxalic acid, citric acid and DK-Ester are provided in Appendix 1.

6.1.1.1 Sodium HypochlorWNaClO

1. Storage Precautions:

a. Store in a cool, dark place. Avoid exposure to direct sunlight, b. Never mix the solution with heavy metals. C. stmzige t ~ - k must be either p!as.t;,~ or ~~at,ted, coiiasioii iesistat stee:.

2. Handling Precautions

a. Carefully read and follow all of the manufacturers precautions for handling of the chemical.

b. Never mix bleach with heavy metals or acids. Mixing with acid will generate toxic chlorine gas. If the solution is accidentally mixed with acid, quickly neutralize it with a basic solution such as sodium hydroxide.

c. Always wear a mask, safety goggles, and rubber gloves when handling.


d. If accidental contact with skin or clothes occus, immediately rinse with tap water.

e. If accidental contact with the eye occurs, immediately rinse the eye with large amounts of tap water and seek medical attention.

6.1.1.2 Oxalic Acid (Powdered)/CzHz04

1. Storage Precautions

. . . - . . . . -

a. Carefully read and follow all of the manufacturers precautions for handling of the chemical.

b. Store in a cool, dark place. Avoid exposure to direct sunlight. e. The storage tank must be either plastic or coated, corrosion resistant steel.

2. Handling Precautions

a. Never mix with sodium hypochlorite because it may generate toxic chlorine gas. I€ the chemical is accidentally mixed with sodium hypochlorite, quickly neutralize it with a basis solution such as sodium hydroxide.

b. Always wear a mask, safety goggles, and rubber gloves when handling. e. If accidental contact with skin or clothes occurs, immediately rinse with

tap water. d. If accidental contact with the eye occurs, immediately rinse the eye with

large amounts of tap water and seek medical attention.

6.i.2 Membrane Recovery Cleaning Protocol ID general, a Recovery Cleaning should be conducted every six (6) months, or when the 91Mp changes by a prescribed amount (see Section 5.3). There are several factors that can cause the TMP to increase at a given flux therefore the Trouble Shooting Guide in Section 6.3 should be consulted before a cleaning is performed.

Specifically, a Recovery Clean is used to dislodge particles from the microstructure of the membranes that have accumulated over t h e . The QTe ofparticle to be removed dictates the chemical that should be used during a Recovery Clean. Unless a history of inorganic scaling has been documented, always perfom a bleach cleaning first to iemove organic

reductive acid solution to remove scaling. fehe* TCel., -,-,,L,:lSc.. A,,... -.-.+ C.ll., ---a .--- - .&.-

eL UlG yGlLIlGClUlllLy UUCD l lUL L U L l J L G b U Y G L , ~ ~ l l l v l l l l 2 DGLUllU b l G U l S Uall ls a “-11.. A ,1-..-:-- ..-:e-

To perfom a Recovery Cleaning:

i i

1 Determine the type of' chemical cleaning required using Table 10 below:

i/ ! I il----, I_

11 Oxide' 1 1 ] I Ferric 1 1 Oxalic Acid' 0.5% to 1.0% 0.5 - 1.0 hrs I

'Oxides may form in the presence of common coagulants such as alum and femc choride. bScaling may occur in the presence of hard wastewater. T o avoid the formation of the mineral scale calcium oxalate, do not use oxalic acid in the

%a, concentration of bleach can impact system biology. Therefore, be sure to adjust the cleaning solution concentration at MLSS concentrations 40,000 rng/l.

2. Calculate the amount of cleaning solution and stock chemical required to perform the Recovery Cleaning using the example below and Equations 3 through 6:

resence of hard water.

Example: Calculate how much cleaning solution and stock chemical are required to clean four ES200 SMUs assuming that the fouling is organic in nature and that the MBR is operating at an MLSS concentration of 15,000 rng/l.


Step 1: Calculate the amount of cleaning solution (V,) required using Equation #3:

Equation #3 #Cartridges 0.8gal v,, =#SMU.

SMU Cartridge (200)Cartridges 0.8gal = 640gal

SMU Cartridge vcs = (4) *

Therefore, 640 gal of solution are required to perform the Recovery Cleaning.

Step 2: Calculate the approximate concentration of the cleaning solution (C,) that should be used at the

. given MLSS concentration using Equation #4.

Equation #4

ccs = MLSS .% C, = 15,OOOmg / I. = 5,OOOmg / I = 0.5%

Therefore, assuming that the density of the cleaning solution is close to water, the weight percent of sodium hypoclorite should be 0.5%.

Step 3: Calculate the dilution factor (fD) given the concentration of the stock chemical and the cleaning solution weight percent calculated in Step 2.

Equation #5

f D = wt%CleaningSolution wt %StockChemicd

Therefore, the stock chemical must be diluted 25 times to make up the proper concentration of cleaning solution.

Step 4: Calculate the amount of stock chemical (V,,) required to perform the Recovery Cleaning using Equ2?tlon 7%.

Equation #6

3,

4,

5.

6.

7.

8.

Prcppase the necessary amount of cleanislg solution to perfom a cleaning using the chemical selected above and tap (or permeate‘; water for dilution purposes. Suspend the aeration and filtration (permeate operation) of all SMUs to be cleaned. Depending on the type of system, this may require turning off pumps a d or closing permeate valves. Veri@ that the water level 51 the MF3R is at least one (1) foot or more above the (upper) membrane case. Lfnot, use tap water to increase the water depth as iieeded. Pour the dilute cleaning solution into each membrane case individually or at a tap on the main permeate header (chemical addition should take between 5 to 10 minutes and no longer than 20 minutes).

Caution: The cieaning solution injection process must be gravity driven. Therefore, the point of injection should be open to atmosphere.

Caution: The hydrostatic head driving the injection process should range bemeen 2’ and 4’ must not exceed 7’ (instantaneous maximum).

Allow the membrane cartridges to soak in the injected cleaning solution for 0.5 to 2.0 hours (see Table 10 for approximate cleaning times). Rinse the spent cleaning solution in the permeate lines back to the anoxic tank (or head of the plant) for approximately 10 to 15 minutes.

6.1.3 Diffuser Cleaning Protocol The diffbsers are maintained using the same principle as an air-lift pump. In other words, when the diffiser cleaning valve is opened, air takes the path of least resistance bypassing the diffusers and venting to atmosphere through the open valve. The vented air draws in mixed liquor ‘;lrough the diffuser openings creating a pumping effect. The pcmped liquor the;; scours the inside =f the diffiiser ranwing any biologid gro.;vrtli a d or deposits. After a minute or so, the cleaning valve is closed and the air is forced back through the diffiser and up through the membrane cartridges €or an additional minute before putting the system back online.

To clean a SMU diffuser:

1. Observe the air pcttem zbove each SPflJ. Tqi io identify “dead” zones or signs of unequal air distribution.

2. Stop filtration of mixed liquor by turning off the permeate pump(s) and or closing the permeate control valve(s).

3. Open the diffuser-cleaning valve located above the water surface of the MBR and on the header connecting the downstream side of the SMU diffhers.

4. Close the diffuser cleaning valve after one (1) minute.


Note: Cleaning the diffuser(s) for a longer period of time will not damage equipment and can be necessary to improve diffuser performance. The procedure should be field optimized.

5. Wait for one (1) minute after the diffuser cleaning valve is closed and inspect SMIJ air patterns for uniformity. If all SMU air patterns appear even and equal, move to the next step, if not, repeat steps 3 through 5.

6.1.4 Membrane Flux Recovery If a membrane is wetted and allowed to dry, the surface can become hydrophobic and reject the passage of water. Under these conditions, the TMP can become prohibitively high and reduce treatment capacity.

To recover the permeability lost during the drying process, a hydrophilic agent called DK Ester is used. The treatment procedure is as follows:

1. Calculate the amount of dry compound necessary to prepare 100 mVcartridge of a 1 % by weight DR Ester solution.

2. Prepare the necessary amount of cleaning solution to perfom a recovery using the dry DK Ester and tap (or permeate) water for dilution purposes.

3. Soak a membrane cartridge in the solution for at least five seconds and remove &om the solution.

4. Verify clean water design flux has been recovered.

Note: The wet membrane material should appear translucent after treatment

6.2 There are only three designated we= parts that should be inspected and 3r replaced on a routine basis. Theses items and their expected service life are listed in Table 11 below:

Part Replacement Schedule and Procedures

Note: The listed service life for parts can vary for each project and are contingent on operation in accordance with Tables 6-8.

6.2.1 The procedure to remove and or replace a SMU can vary depending on whether the MBR is gravity operated or pumped. The main difference being that pumped permeate manifold connections are often above water allowing for individual units to be serviced without taking an entire MBR offline.

Removing and Servicing a SMU

.

For clarity, several of the first and final tasks of the part replacement procedure are delineated by system type in the subsections below. Once the SMU is removed fiom the basin, the procedure to replace a part is the same for either system.

Before per proceeding, read and follow these warning and cautionary notes:

r

Warning:

Warning:

Caution:

Verify that the lifting tool, chains, and equipment are rated to handle the wet weight of the membrane case o r cases to be lifted.

Refer to Tabie i for dry weight information. To caicuiate the weight wet of a SMU case, add 8.8 Ibkartridge to the dry weight. For example, the top case of an EK400 unit could weigh up to 3,696 Ib.

Anticipate that the membrane case will swing or shift once the stabilizer bars are removed and the case is lifted.

Ensure that the permeate manifold and membrane cartridge nozzles are not damaged during the lifting process by lifting the case slowly and carefully positioning the Iifting tool and chains.


6.2.1.1 RemovingDXepIacing a SMU in a Gravity System

. 1. Connect a lifting tool to the lifting device (crane, boom truck, hoist, etc.) 2. Position the lifting tool over the SMU. 3. Take the MBR offline that contains the unit to be serviced. This includes

suspending aeration, filtration and recycling in that order. 4. Drop the water level in the MBR below the permeate manifold of the

membrane case to be serviced. 5. Disconnect the permeate manifold connection. 6 . Attach the lifting chains to the hooks on the lifting tool.

Note: If lifting chains are not available, attach the hooks directly to the lifting tabs, or plates, on the membrane case.

7. Detach and remove both stabilizer bars. 8. Lift the unit out of the basin.

6.2.1.2 RemovingDXepIacing a SMU in a Pumped System

1. Connect a lifting tool to the lifting device (crane, boom truck, hoist, etc.) 2. Position the lifting tool over the SMU. 3. Suspend aeration and filtration at the SMbT using isolation valves on the

permeate manifold and air supply lateral. 4. Disconnect the permeate manifold connection above the water surface.

Caution: If the SMU is hard piped to the permeate header, that section of pipe .Will be lifted with the unit and aanst be supported during the lifting process.

5 . Attach the lift;ing tool hooks to the liftkg tabs OF, the membrane case. 6. Detach and remove both stabilizer bars. 7. Lift the unit out of the basin.

6.2.1.3 How to Replace a Membrane CartridgelRetaining RubberRube The hllowing prmedure assumes that the SMU has been removed €ram $he ?&3R basin and is located in a safe working environment.

1. For double deck units only, remove the intermediate (middle) case as show- inFigure 13.

2. Set the middle case aside.

permeate tubes with clean water and iook for the one tube that is discolored. 4. Disconnect the permeate tube on the membrane cartridge to be replaced at the

cartridge nozzle only. Ifpermeate tubes are to be replaced, do so now.

3. IdeIItiiy the cal-kidg. to be re;l!aced. If 2 Eembrze has f&& hose off &e

Caution: Pull permeate tubes straight upward in order to remove them. Never pull the tubes at an angle.

Caution: Replacement tubing must meet BXJBEbBTA specifications.

Caution: Never bend the tubing while handling.

5. Apply a molybdenum based lubricant to the bolts on the retaining plate (see Figure 14).

6. Loosen the bolts on the retaining plate. It is not necessary to remove the bolts, 7. Slide the retaining plate off the retaining rubber. 8. Remove the retaining rubber that is left on the membrane cartridges. 9. Set the hand hook into the hole on the upper part of the membrane cartridge

10. Slowly slide the new membrane cartridge into place. and lift straight up.

Caution: Never drop the membrane cartridges into place, and never force them h t ~ the cme.

Caution: Never handle a cartridge with a sharp object that can damage the membrane material.

Caution: Slowly submerge a membrane cartridge into wastewater slowly to allow trapped air to escape.

1. Xe-attadi the permeate tube to the nozzie on the new cartridge. 2. Check that all of the membrane cartridges are set securely in the membrane

3. Replace the retaining rubber over the membrane cartridges. C Z X .


Figure 13: The Intermediate Case

Figure 14: Replacing the Membrane Cartridge

ease

Retaining plate Nut

4. Slide the retaining piate back into its original position over ffie retaining mbber,

5. Tighten the retaining plate bolts. 6. For double deck unit orJy, replace the middle case.

-_.._-__---_-_-_-.----.~_-_-~-.----I-__- -_ .I___._

Possible Cause i ( Remedies Damaged blower(s).

___- -_ ..______.l__l --_._-.----__-I _.: I blower(s). "_.-..-I,.--._.... "~ ~ 2

Malfunctioning dfiser(s2,-, i -- Repair ---*- the -...-- diffuser(s). _. _._,. _._._.lll.ll i

Diffuser clogging. 1 Wash or clean the diffber(s). ;

Membrane unit diffusers are not i Level the diffusers . level. !

Operational flux is higher than i Adjust operational flux to design flux. Membrane surface is fouled. i Aerate for 10 minutes without 1

.------I_-_-- I--.----.---^-- _. - ' 1 Repair or replace the

-___---I_-_ .- __.._ --__

-.--._---.---.-------I_- ----

-_____l.___l_-_-l-..-__---__

____ --.- i -I-_--_ match the design ._--____I flux. ~

6.3 Trouble Shooting

i i / ; j j :

filtration. If the flux rate does not recover, then carry out an in-place chemical cleaning (provided there is no sludge cake on the surface of membrane) or wash membranes by water jet (if

: on the membrane f 1 b r o v e the characteristics of

_________l-_l__ _'I ---I_-- ~ I-.-_

Characteristics of the activated sludge are bad. (e.g. [ 1 the* sludge. I

filterability is low.) i The membrane surface becomes Treat the membrane with a j hydrophobic. i hydrophilic aoent. The permeate tube has Repair and replace the tube. i.

-___-------.. - ---- ~

-..-- ....--.----.4---2 -.--_.. ---.-. -*..?s ,__.. ---..-----.- L

The membrane cartridges are i damaged. Damage on the manifold. i Permeate piping connection is loose. i

-. ----- ---._._._."..-----I

._--~-.-.- ,... .--....... _-I.-,

Repair or replace the !

membrane cartridges. Repair or replace the manifold. '

Repair the permeate piping i connection.

I ~ ..--. ~ .__.-

__..__I-.-_-_____.___

-I_- _._.I_.",.. _" ,.- - _,_. ._:


. . . .

APPENDIX 1

f

M T E W SAFETY DATA SHEET May be used to comply with QSHA’S Hazard Communication Standard 29 CFR i910.1200 Standard must be consulted for specific requirements

DK ESTER F- 160

IDENTITY (As Used on Label and List): DK-ESTER F-I 60

SECTION I: Manufacturer’s Name: DAI-ICHI KOGYO SEIYAKU Co., Ltd. Address (Number, Street, City, and ZIP Code): 614, Shioksji dori, Skimokys ku, Kyoto, Japan Emergency Telephone Number: Telephone Number for information: 075-322-2541 Date Prepared: December 4,1998 Signature of Preparer (optional):

SECTION 11: HAZARDOUS INGREDIENTS/ IDENTITY INFORMATION Hazardous Components (Specific Chemical identity; Common Name(s)):

Non-Hazardous Components: Sucrose Fatty Ester Not Applicable

OSHA PEL ACGiH TLV Other Limits %(optional) NONE Recommended

100

WARNING! May form flammable dust-air mixtures Static charges generated by emptying package in or near flammable vapors may flash fire.

SECTION 111: PHYSICAL/CHEMICAL CHARACTERISTICS Boiling Point: None Specific Gravity (H20=1): Not Applicable Vapor Pressure (mmHg): None Melting Point: Not Determined Vapor Density (Air=-l): None Evaporation Rate (Butyl Acetate=l ): None Solubility in Water: Almost soluble Appearance and Odor: White to pale yellowish brown powder and almost Odorless


DK ESTER F-I60

SECTION IV: FIRE AND EXPLOSION HAZARD DATA Flash Point (Method Used): Not Determined

Flammable Limits: LEL 60 g/m3 (Air) LEL 10.3 VOI. % ( 0 2 )

Extinguishing Media: Water fog, Foam, Powder, CO2 Special Fire Fighting Procedures: Not Known Unusual Fire and Explosion Hazards: May form flammable dust-air mixtures

SECTION V: REACTIVITY DATA Stability: Unstable

Conditions to Avoid: Direct Sunlight and high temperature Incompatibility (Materials to Avoid): Not especially Hazardous Decomposition or Byproducts: Thermal degradation produces oxides of carbon Hazardous Polymerization: May Occur

Conditions to Avoid: Not Applicable

Stable X

Will Not Occur X

SECTION VI: HEALTH HAZARD DATA Route(s) of Entry: Inhalation No

Skin Yes Ingestion Yes

Health Hazards (Acute and Chronic):

Acute Toxicity Oral-Rat bD5Q = 8450 rng/kg Chronic Toxicity

IARC Monographs Not Listed

Signs and Symptoms of Exposure: No signs and symptoms of exposure (This Material is a food additive) Medical conditions generally aggravated by Exposure: No information is avail ab I e Emergency and First Aid Procedures:

irritation May net Cause irritation

Not unusual (Oral-Rat, 0.5 g/kg dosage, 2 years) Carc.c!mgenIcity: NTP Not Listed

OSHA Regulated N O

Skin Contact Eye cantact

F!ush with soap and water after handling Rinse with !ew pr~ssure water fa- more

than 15 minutes and call a physicr‘m DE; ESTEE p”-i6Q (Page 3)