ECOLOGIX

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OPERATION AND MAINTENANCE MANUAL For EcoPack DAF (Dissolved Air Flotation)
For information only

Version 2010

Ecologix Technologies Asia Pacific, Inc.

33-3 Ecologix Place, Lane 203

div.of Ecologix Technologies, Inc. USA

Chunghwa North Road Section-1, Tainan,, Taiwan www.ecologix.com.tw service@ecologix.com

EcoPack-OM-2010.b

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Operation and Maintenance Manual-EcoPack

Index 1. Introduction 1.1 Information about this manual 1.2 Information about the unit 1.3 Qualified personnel Description of the unit 2.1 General description of the unit 2.2. 3. Performance(*,**)

2.

Transport, storage, installation and dismantling 3.1 Transport 3.2 Storage 3.3 Installation Use 4.1 4.2

4.

Intended use Start procedure

5.

Control and Maintenance 5.1 Daily check 5.2 Periodical check 5.3 Servicing the flotation unit 5.4 Servicing the recirculation pump 5.5 Control and adjustment of the chain extension

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Operation and Maintenance Manual-EcoPack

1.

Introduction

1.1

Information about this manual This Operation &Maintenance Manual contains information on how to maintain the EcoPack. 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 agreed between 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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Operation and Maintenance Manual-EcoPack

2.

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

The wastewater containing oil, grease, solids and/or flock (if flocculated) is mixed with an air-water mixture(Milky water) with very fine air bubbles in the range of 40 micron. These air bubbles adhere to the particles through gentle mixing in the pipe run to the EcoPack. The liquid enters the EcoPack in the inlet compartment, where heavy solids can settle. Periodic drainage is required to keep this compartment 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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Operation and Maintenance Manual-EcoPack

The clarified water leaves the plate assembly at the bottom side and is discharged via effluent channels and an adjustable overflow weir. This weir is adjusted to the actual conditions of flow and 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 the following 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 make up station, pH measuring and control, sludge pump and the electrical control panel are designed according Ecologix standard. Ecologix special designed piping flocculator(a)

Material: PVC Support stand: SUS 304 PAC, pH & Polymer dosing nozzles and sample drain valve included

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Operation and Maintenance Manual-EcoPack

3.

Transport, storage, installation and dismantling 3.1 Transport The EcoPack flotation unit has to be transported in an upright position. The skimmer system can be removed, if road regulations state that the maximum height of the flotation unit is too high to be transported. Loading and unloading has to be done using a crane. Spreader bars are required for lifting the unit. 3.2 Storage The unit has to be stored clean and dry, protected from frost. If the unit has been used clean it thoroughly. Drain the recirculation pump(s). Keep the drain valves open during storage. 3.3 Installation Check the condition of the unit before installation; check for damage caused by transport. 3.3.1 Placing the flotation unit y 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 as agreed between the owner and Ecologix Asia. if the quality or quantity of the influent changes, 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 treatment system and starts automatically as part of the total sequence.

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Operation and Maintenance Manual-EcoPack

5.

Control and maintenance 5.1 Daily check Once 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 panel y 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 aeration y Check the condition of the aeration hoses for blockages y Check for flow through the bleed off valve y 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 tanks y 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 later after 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 packets y 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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Operation and Maintenance Manual-EcoPack

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 valves after cleaning. Fill the installation with clean water after cleaning. Important: When there is danger of freezing the whole installation must be drained. The recirculation 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 mixing pipe 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 if necessary. 5.5 Control and servicing of the scraper system 5.5.1 Daily check y 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 is measured just in front of the turning sprocket. Hold the chain tight in the guide rail (pull the scraper blade), let the blade loose and measure the clearance. If the scraper blade tips over when between the sprocket and guide rail or the tension 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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Operation and Maintenance Manual-EcoPack

y chain tension is accomplished. Make sure that the chain tension is exactly the 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 to remove 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