EcoPack Operation and Maintenance Manual 2010.b.

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    OPERATION AND MAINTENANCE MANUAL

    For

    EcoPack DAF (Dissolved Air Flotation)

    For informat ion only

    Version 2010

    Ecologix Technologies Asia Pacific, Inc. div.of Ecologix Technologies, Inc. USA

    33-3 Ecologix Place, Lane 203

    Chunghwa North Road Section-1, Tainan,, Taiwanwww.ecologix.com.tw [email protected]

    EcoPack-OM-2010.b

    ECOLOGIXTECHNOLOGY

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    Index

    1. Introduction

    1.1 Information about this manual

    1.2 Information about the unit

    1.3 Qualified personnel

    2. Description of the unit

    2.1 General description of the unit

    2.2. Performance(*,**)

    3. Transport, storage, installation and dismantling

    3.1 Transport

    3.2 Storage

    3.3 Installation

    4. Use

    4.1 Intended use

    4.2 Start procedure

    5. Control and Maintenance

    5.1 Daily check

    5.2 Periodical check

    5.3 Servicing the flotation unit5.4 Servicing the recirculation pump

    5.5 Control and adjustment of the chain extension

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    1. Introduction

    1.1 Information about this manual

    This Operation &Maintenance Manual contains information on how to maintain theEcoPack.

    Read this manual carefully before putting the equipment into operation or performing

    maintenance or repair work on it.

    1.2 Information about the unit

    The flotation unit is manufactured by Ecologix Asia at the factory in Tainan, Taiwan,

    manufacturing authorization by Ecologix U.S.A.

    The unit is specially designed to treat influent with characteristics as agreedbetween the owner and Ecologix Asia, if these characteristics change, the required

    effluent conditions may not be achieved.

    Contact Ecologix Asia for support.

    1.3 Qualified personnel

    Operation, maintenance, inspection and mounting of a system may only be

    performed by qualified personnel. If the personnel do not have the required

    knowledge, they must be trained and instructed.Make sure the content of this operation and maintenance manual is fully understood

    by the responsible personnel.

    Ecologix Asia will provide training to appointed personal during installation

    supervision and commissioning.

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    2. Description of the unit

    2.1 General description of the unitThe EcoPack flotation unit is a high-build open tank separator for dissolved airassisted separation of oil, grease and floc from water.

    The wastewater containing oil, grease, solidsand/or flock (if flocculated) is mixed with anair-water mixture(Milky water) with very fine air

    bubbles in the range of 40 micron. These airbubbles adhere to the particles through gentlemixing in the pipe run to the EcoPack.

    The liquid enters the EcoPack in the inletcompartment, where heavy solids can settle.

    Periodic drainage is required to keep thiscompartment clean.

    Fast rising particles and air bubbles will immediately collect in the sludge layer floating on

    the liquid in the EcoPack.

    Slower rising particles are being separated in the corrugated plate assembly.

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    The clarified water leaves the plate assembly at the bottom side and is discharged via effluentchannels and an adjustable overflow weir. This weir is adjusted to the actual conditions of flowand sludge characteristics.

    Part of the treated water is recirculated for the aeration of the raw water.

    Air is dosed into a saturation pipe just after the recirculation pump.

    In the EcoPack flotation system air bubbles in the range of 40 micron are formed,which are ideally sized for removal of the (and coarse) oil and solids particles.

    2.2. Performance(*,**)

    Based on and for the given design parameters and composition we expect to the reach thefollowing reductions after filter/flocculation/flotation:COD : 75 - 85 %BOD : 75 - 85 %TSS : 90 - 95 %Free oil and grease : 90 - 95 %

    * Subject to confirmation by jar test.

    ** We assume that the filter, feed pumps, flocculator(a)

    , chemical dosing units, flocculant makeup station, pH measuring and control, sludge pump and the electrical control panel aredesigned according Ecologix standard.

    Ecologix special designed piping flocculator(a)

    Material: PVC

    Support stand: SUS 304

    PAC, pH & Polymer dosing nozzlesand sample drain valve included

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    3. Transport, storage, installation and dismantling

    3.1 TransportThe EcoPack flotation unit has to be transported in an upright position. Theskimmer system can be removed, if road regulations state that the maximum heightof the flotation unit is too high to be transported.

    Loading and unloading has to be done using a crane. Spreader bars are requiredfor lifting the unit.

    3.2 Storage

    The unit has to be stored clean and dry, protected from frost. If the unit has beenused clean it thoroughly. Drain the recirculation pump(s). Keep the drain valvesopen during storage.

    3.3 InstallationCheck the condition of the unit before installation; check for damage caused bytransport.

    3.3.1 Placing the flotation unity The flotation unit is designed for operating in a dry and frost free area. If

    placed outside the DAF unit has to be protected against frost.y The floor must be calculated to be able to handle the total full weight of the

    flotation unit.y for the correct scraper function the flotation unit has to be leveled out very

    precisely to both directions. tolerance +/- 2mm (0.08).y All the legs have to be supported. Put, if required, filling plates under the legs.

    4. Use

    4.1 Intended use

    The EcoPack flotation unit is designed to separate fat and solid particles from water,and may not be used for any other purpose.

    The EcoPack flotation unit is designed to treat influent with characteristics asagreed between the owner and Ecologix Asia. if the quality or quantity of the influentchanges, and the influent no longer meets the data for which this unit is designed,please contact Ecologix Asia.

    4.2 Start procedure

    Once the unit is installed correctly, it is an integrated part of the water treatmentsystem and starts automatically as part of the total sequence.

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    5. Control and maintenance

    5.1 Daily checkOnce the installation is in normal operation, its proper working should be examined,initially a few times per day.

    This examination will mainly be visual.

    Points to check are:y Sediment drainage (regular draining, cycling time)y Optical signals electrical panely Check for leakage (piping, pumps, unit)y Check the quality of the effluent (flock carry-over etc.)y Check the quality of the floating layer (thickness)y Check the pressure of the recirculation pump and the feed pump (has to be

    constant)y Check the setting of the air flow meter / quality of the aerationy Check the condition of the aeration hoses for blockagesy Check for flow through the bleed off valvey Check the proper functioning of the scraper system (refer to concerning

    paragraph)y Check the proper functioning of the chemical dosing pumps (if present) and the

    level in chemical storage tanksy Check the proper functioning of sediment drainage systems (regular draining)

    5.2 Periodical check

    The periodical check will be done first at short regular intervals (weekly) and laterafter becoming more familiar with the installation with longer intervals (monthly).

    Points to check are:y Accumulation of dirt in the flotation unit or pump pit(s), for this purpose unit and

    pump pit must be all cleaned up.y Control of adjustments.y Lubrication of different parts of the installation.y Corrugated plate packetsy Control of the scraper system.y When sludge lines are not used for more than a week, the lines have to be

    cleaned (flushed) with water to avoid damage due to clogging.

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    5.3 Servicing the flotation unit

    Clean the installation regularly, using a high pressure jet.Be careful not to damage the plate pack; spray parallel to the plates.

    Open the drain valves during the spray cleaning, do not forget to close these valvesafter cleaning.

    Fill the installation with clean water after cleaning.

    Important:When there is danger of freezing the whole installation must be drained. Therecirculation pump must be drained by removing the drain plugs.

    5.4 Servicing the recirculation pump

    Check the pressure of the discharge of the pump and the pressure of the mixingpipe regularly.A low pH value of the recirculated water may cause damage to the recirculation

    pump; check the pH value regularly.

    Make sure the pump does not contain any sand; adjust the sand drain cycle ifnecessary.

    5.5 Control and servicing of the scraper system

    5.5.1 Daily checky Check if the system runs shock-proof.y Check if there is any friction on the sprockets at the drive-side and the

    turning-side.y Listen if the scraper system is creaking. a creaking chain should be

    lubricated. A multi purpose lubricant or oil can be used.If problems occur caused by a loose chain or poor alignment of the system,checks and adjustments should be made as described in the next paragraph.

    5.5.2 Check and adjustment of the chain tension the tension

    the clearance measured should be between 8 and 12 mm. the clearance ismeasured just in front of the turning sprocket. Hold the chain tight in theguide rail (pull the scraper blade), let the blade loose and measure theclearance.

    If the scraper blade tips over when between the sprocket and guide rail or thetension of the chain is otherwise too low, chain tension should be adjusted.y Adjust the chain tensioners equally at both sides of the unit until the desired

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    y chain tension is accomplished. Make sure that the chain tension is exactlythe same for both chains.

    y Start the scraper system and check the tension.

    When the chain is too long, and the right tension can not be achieved, it is necessary toremove one of the chain links.

    Insufficient or excessive tension of the chain may cause damage to the scraper system!!

    EcoPacks ultilize parallel plate High scum floating performance

    Milky water test before shipment Control box and air regulator included

    EcoPack-OM-2010.b