WASTEWATER CLARIFIERS

DECEMBER 1996

PAGE 1 OF 8

EGE 26-B-4 1996

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References General Performance Design 5.1 Process 5.2 Equipment 5.3 Mechanical Design and Materials 5.4 Electrical Classification 5.5 Utility Station 6. Data Sheets EGE 26-D-4 Wastewater Clarifier Data Sheet

1. SCOPE This Guide covers the basic requirements for the design, selection of materials, and fabrication and installation of circular clarifiers and associated equipment used in wastewater treatment applications. The application of this Guide is limited to the clarification of mixed liquid suspended solids (MLSS) from activated sludge tanks. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. Mobil Technology Company (MTC) Guide Sponsor should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-C-4 EGE 01-B-7 EGE 16-B-1 EGE 31-B-1 EGE 33-B-9 EGE 33-D-9 EGE 35-B-2 (1993) (1993) (1993) (1989) (1991) (1991) (1993) Equipment and Packaged Units General Purchasing Requirements Concrete Design and Construction Piping General Design Steel Structures Design and Fabrication Electrical Induction Motors Electrical Induction Motor Data Sheet Painting Coating and Lining of Storage Tanks

API (American Petroleum Institute) Publications RP 500 Std 650 (1991) (1993) Classification of Locations for Electrical Installations at Petroleum Facilities Welded Steel Tanks for Oil Storage

ASTM (American Society for Testing and Materials) Standard A283 (1993) Low and Intermediate Tensile Strength Carbon Steel Plates

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3. GENERAL 3.1 The clarifier mechanism and associated equipment shall be furnished as a complete unit, ready for installation in a circular tank of an industrial biological wastewater treatment plant. Components of the clarifier shall be designed for this service. 3.2 Use of clarifiers shall be limited to the gravity separation of biological solids.

3.3 The preferred design shall provide for a minimum of two clarifiers and shall include the means to isolate the influent, effluent, skimming, and recycle systems of each clarifier to facilitate the cleaning and maintenance of individual clarifiers. Single clarifier designs shall be subject to Mobil approval. 3.4 The design of tanks and equipment shall conform with all applicable national and local environmental regulations. 3.5 Equipment shall be purchased in conformance with EGE 00-C-4, except as modified for specific equipment by the instructions, specifications, and terms and conditions stated in Mobils request for quotation. 4. PERFORMANCE 4.1 The clarifier shall be designed to provide a quality of effluent in accordance with EGE 26-D-4 by separating the suspended solids from the mixed liquor of the activated sludge tank. 4.2 The clarifier shall also be designed to provide an underflow sludge concentration equal to or greater than that specified in EGE 26-D-4 in order to maintain the desired MLSS concentration in the aeration tank. 4.3 The supplier shall test the field performance of the clarifier mechanism after erection to verify that the operations meet the design criteria of the unit. The supplier shall provide performance verification data on the following as a minimum: (a) Proportional settled sludge removal, to ensure hydraulic balance in the tank and uniform sludge withdrawal for the entire tank bottom. (b) Capability to achieve the given hydraulic sludge recirculation rates at the predicted head losses. (c) Compliance with the specified torque requirements.

Complete shop and field test procedures shall be submitted to Mobil for approval prior to award of contract. 4.4 The field tests shall be witnessed by a Mobil representative to ensure that the equipment meets the specified performance level. All test results and calculations shall be submitted to Mobil for approval. All costs associated with labor, materials, and test apparatus necessary for conducting the field tests shall be paid for by the manufacturer and shall be quoted separately from the equipment costs.

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EGE 26-B-4 1996

5. DESIGN 5.1 Process Design

5.1.1 The clarifier shall be designed in accordance with the process specific conditions as specified in EGE 26-D-4. 5.1.2 The normal continuous operating torque requirements of the drive mechanism shall be designed in accordance with the following formula: T = WR

Where:
T = normal continuous running torque, Nm (lbfft). W = uniform sludge loadings as specified in EGE 26-D-4, N/m (lbf/ft). R = clarifier tank inside radius, m (ft). 5.1.3 Sludge shall be withdrawn through hydrostatic pressure into a sludge well. The sludge removal device shall be designed to provide the return sludge flow in accordance with EGE 26-D-4. The sludge shall be returned to the aeration tank after a portion has been removed to the solids waste handling scheme. The supplier shall submit in the proposal the hydraulic calculations of the sludge removal device. 5.2 Equipment

5.2.1 The wastewater clarifier mechanism shall be center drive, suction type with a center feedwell and peripheral weir outlet installed in a circular tank. A typical suction type clarifier is illustrated in Figure 1. Peripheral drive circular clarifiers may be considered, but their use requires specific Mobil approval. 5.2.2. (a) (b) (c) (d) (e) (f) (g) (h) The clarifier shall be furnished as a complete unit, including the following equipment: Drive mechanism complete with reducer, motor, and overload device. Influent feedwell and supports. Center pier. Sludge removal device. Access bridge (including handrailing, toe plate, and grating). Surface skimmer with scum box. Weirs and baffles. Circular tank, if specified in EGE 26-D-4.

5.2.3 All structural steel used in the fabrication of the clarifier mechanism shall conform to EGE 31-B-1.

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FIGURE 1 WASTEWATER CLARIFIER

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EGE 26-B-4 1996

5.2.4 The tank floor shall have a constant bottom slope of not less than 2.0 cm in 1.0 m (1/4 in. in 12 in.) toward the center. 5.2.5 A hopper and associated piping shall be included in the tank floor for grit removal. The piping shall also serve as the tank drain. The tank drain shall be designed so that the sludge withdrawal pump can completely empty the clarifier. 5.2.6 The supplier shall furnish all associated piping inside the clarifier. When concrete tank construction is used, the supplier shall furnish internal piping connections that extend 150 mm (6 in.) inside the tank wall. When a steel shell is used, pipe connections shall extend 150 mm outside the tank wall. All piping shall be furnished with flanged connections. Piping design shall be in accordance with EGE 16-B-1 or applicable project specifications. 5.2.7 All surface preparation and painting of steel members shall be in accordance with EGE 35-B-2 and as defined in Table 3 of that Guide for wastewater service. 5.3 5.3.1 Mechanical Design and Materials Drive Mechanism

A drive mechanism shall be provided for the sludge removal arms and surface skimmer. The motor shall be designed for continuous duty, totally enclosed fan cooled, and shall meet the requirements of EGE 33-B-9. Motors shall be rated for 40C (104F) ambient temperature, Class F insulation, 1.0 service factor, and a power rating of at least 125 percent of the maximum required power. The minimum acceptable motor size is 0.375 kW (0.5 hp). The motor shall be integrally mounted on a gear reducer. The gear reducer shall consist of a primary worm gear, heavy-duty reduction unit and a main gear and worm assembly enclosed in a turntable base. All gearing shall be fully enclosed in cast iron housings and designed for the continuous operating torque. All bearings shall be of the oil bath lubricated, antifriction type. The performance and thermal ratings of gear reducers shall be in accordance with the latest American Gear Manufacturers Association standards. The main gear shall be driven by the primary gear motor through roller chain and sprockets enclosed in a removable guard that meets local safety requirements. The gear reducer shall be designed for the continuous operating torque and have a minimum service factor of 1.5. Consideration of an alternative drive mechanism requires prior Mobil approval. A torque overload protecting device shall be furnished as part of the drive unit. This device shall visually indicate the relative torque by means of an indicator dial. In case of an overload, it shall actuate a microswitch, or Mobil-approved alternative, at a set alarm torque value and a set motor cutoff torque value. Connections to an audible alarm shall be provided. The torques at which alarm and cutoff occur shall be independently adjustable as a percent of the design continuous running torque. 5.3.2 Influent Feedwell

The influent feedwell shall be of adequate size to diffuse the mixed liquor flow into the tank. The feedwell shall be designed so that the exit velocity does not exceed 0.03 m/s (0.1 ft/s) at maximum flow. Ports with baffles shall be provided in the feedwell to permit the escape of entrapped scum. The supplier shall specify the feedwell material, its thickness, and the method of support. These specifications shall be submitted to Mobil for approval.

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5.3.3

Center Pier

A cylindrical steel center pier shall support the drive mechanism and access bridge. The center pier shall have a drive mechanism mounting plate and shall be anchored to the tank floor. The center pier shall serve as an influent pipe and have a series of ports to diffuse the flow into the influent feedwell at a velocity not to exceed 0.3 m/s (1 ft/s) at maximum flow. 5.3.4 Center Cage

A center cage shall be of all-welded construction and made up of structural members with a minimum thickness of 6 mm (1/4 in.). The cage shall be provided with connections for the two sludge removal arms and feedwell supports and shall be bolted to the main gear. 5.3.5 Sludge Removal Device

Hydraulic suction is the preferred method of sludge removal. Two types of hydraulic designs (header and riser pipe) are acceptable. Control of sludge withdrawal shall be external of the basin and consist of a single operation for each basin. The riser pipe sludge removal device shall include two steel truss-type sludge collection arms, each including V-plow rake blades with spring brass squeegees. Flexible plastic squeegees shall be subject to Mobil approval. The sludge collection arms shall be connected to the center cage. Each collection arm shall completely rake the bottom during each revolution. A sludge drawoff pipe shall be attached to the apex of each V-plow. Each drawoff pipe shall be designed to provide the design range of sludge recycle. The drawoff pipe material shall be polyvinyl chloride (PVC), not less than NPS 4 Schedule 40 and arranged to facilitate cleaning. Alternative pipe material may be used, subject to Mobil approval. Drawoff pipe outlets shall terminate in sludge control boxes located inside the feedwell. Each sludge control box shall be provided with a manually controlled gate operated from center platform with a positioning stem and positioning indicator. The sludge being withdrawn shall be controlled by a submerged orifice. Sludge control boxes shall be visible and accessible to the operator from center platform. Alternative sludge removal designs may be submitted to Mobil for approval. The header type of design uses a rectangular-shaped, full tapered section as the collection system. The header shall vary in size from a maximum near the tank center to a minimum at the outer end to provide uniform sludge draw-off velocities throughout the header. Inlet orifices varying in size from a minimum diameter near the tank center to a maximum at the outer end shall be located in the header. The header shall be mounted at a 45 degree angle with the tank bottom to physically trap sludge for maximum solids concentration. The bottom edge of the header shall extend downward to provide a fluidizing vane as an integral part of the header and to direct the sludge into the area of influence of the orifices with minimum sludge agitation. Attached to this vane shall be a neoprene squeegee. The squeegee shall be capable of vertical adjustment. 5.3.6 Access Bridge

A walkway with handrailing, toe plate, and grating shall extend from the tank wall to a point sufficiently beyond the center of the tank to provide access to the drive mechanism. An operating and maintenance platform shall be included around the drive. All grease fittings, oil fill and drain points, and the torque overload device shall be readily accessible from the platform. The bridge and walkway shall be designed in accordance with EGE 31-B-1 and as specified for a minimum width of 1 m (3.3 ft). Nonskid, open-surface grating shall be used for walkways and access stairways. A double handrail shall be furnished for both sides of the walkway. 5.3.7 Surface Skimmer and Scum Box

A full-surface skimming device shall be furnished for surface scum removal. The skimming equipment shall consist of a scum blade with a hinged neoprene or Mobil-approved flexible plastic wiper at the

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EGE 26-B-4 1996

periphery of the tank assembly. The scum shall be collected in the scum box assembly supported from the tank wall. The assembly shall have a sloping ramp and trough. The method of supporting the skimming device, as well as the materials of construction and their thickness, shall be subject to Mobil approval. It shall be the suppliers responsibility to winterize the surface skimmer. The supplier shall also specify and submit to Mobil for approval the method of winterizing. 5.3.8 Weirs

Effluent weirs shall be furnished. They shall consist of either steel plate or ultraviolet light resistant, reinforced fiberglass sections with 63 mm (2 in.) deep, 90 V-notches at 150 mm (6 in.) intervals. The weir sections shall be curved and fastened to the tank wall with anchor bolts and be easily replaceable. The weir plate shall be level when installed and shall be capable of adjustment as necessary to compensate for differential settlement of the tank. The weir plate shall be designed to provide a minimum 75 mm (3 in.) adjustment. 5.3.9 Baffles

Scum baffles shall consist of curved sections of steel plate cantilevered off the tank wall. The minimum projection below maximum water surface shall be 0.3 m (1.1 ft). Slots shall be provided in the baffles to allow vertical and radial adjustment. 5.3.10 Circular Tank

The clarifier tank construction shall be in accordance with EGE 26-D-4. The supplier shall provide complete drawings for foundation details pertinent to the clarifier equipment installation, including anchorage location. Construction and materials for the various types of circular tanks shall be as follows: (a) Steel Shell and Concrete Bottom The tank shall be designed in accordance with API Standard 650 requirements. Tank design calculations shall include all live and dead loads. A 1.6 mm (1/16 in.) corrosion allowance shall be provided in excess of the shell plate thickness calculated in accordance with API Standard 650. A cold tar epoxy 400 m (16 mil) coating shall be applied to all internal steel surfaces. However, even if the minimum thickness specified in API Standard 650 exceeds the calculated thickness, the corrosion allowance shall be added to the minimum thickness. The suppliers design calculations shall be subject to Mobil's approval. The plate material of construction shall be Grade C mild carbon steel in accordance with ASTM A283, or equivalent. The steel tank shell shall be carbon steel of welded construction. The effluent weir wall, trough, and scum baffle shall be integral components of the steel tank. The tank shall have properly sized flanged connections at the inlet, outlet, the scum discharge, and bottom sludge draw-off. The supplier shall furnish the tank shell and a structural steel channel ring for embedding in the concrete slab. The supplier shall furnish with the proposal full details of the method by which the ring is to be embedded and installation requirements to ensure a watertight joint, taking into consideration stresses caused by uneven heating of portions of the tank from sunlight. The steel shell shall be welded to the portion of the channel ring projecting above the concrete. All welding procedures and all welders shall be qualified in accordance with API Standard 650. Shell welds shall be full-penetration buttwelds and shall be spot radiographed in accordance with API Standard 650. The tank shall be hydrotested upon completion. (b) All Concrete The clarifier tank concrete design and construction shall be in accordance with EGE 01-B-7. The equipment supplier shall not be required to furnish the tank bottom, outer

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walls of the clarifier, effluent weir wall, and trough unless otherwise specified. The equipment supplier shall furnish all dimensions of equipment governing concrete construction. 5.4 Electrical Classification

The electrical classification for clarifiers shall be in accordance with API RP 500. 5.5 Utility Station

A utility station with air, electrical, and water sources should be provided and located to give ready access for housekeeping and maintenance activities. 6. DATA SHEETS The supplier shall complete as part of the proposal EGE 26-D-4 and EGE 33-D-9.

MOBIL ENGINEERING GUIDE WASTEWATER CLARIFIER DATA SHEET

ISSUE 1 2 CLARIFIER TYPE DIAMETER FLOOR SLOPE MANUFACTURER* FREE SOURCE TANK CONSTRUCTION PERFORMANCE DATA Flowrates, liters/h: Forward Feed Rate Return Sludge Flow Mixed Liquor Flow Aeration Basin Mixed Liquor Suspended Solids (MLSS) Concentration Temperature Effluent SS Concentration Return Sludge SS Concentration Uniform Sludge Loading Surface Hydraulic Loading Rate Solids Loading Rate Hydraulic Detention Time Effluent Weir Overflow Rate NCm PROCESS DESIGN AT DESIGN FLOW 2 liters/day/m 2 g/day/m hours liters/day/m MECHANICAL COMPONENTS DRIVE*: Torque Rating, NCm Running Type of Overload Device Type of Visual Readout MOTOR: Enclosure Type* kW* Volt Manufacturer* REDUCER*: Type Gearing Output rpm Manufacturer INFLUENT FEEDWELL*: Diameter Maximum Exit Velocity Support Arrangement Material CENTER PIER*: Influent Pipe Diameter Material SLUDGE REMOVAL DEVICE*: Type No. of Orifices Min. Flow Velocity Sludge Drawoff Pipe Diameter Material *Items designated by asterisk shall be completed by vendor. Nominal pipe size, inches. m/s NPS m m/s Thickness Min./Max. Flow Velocity, m/s: Thickness No. of Arms Orifice Size Max. Head Loss NPS Thickness / Depth m rpm* Phase Mounting Service Factor Hertz Model* Material Service Factor Hardness Class Alarm Shutoff C mg/liter mg/liter Minimum Normal Maximum APPROVED 3 4 NUMBER OF UNITS SIDE WATER DEPTH FREEBOARD MODEL NO.* ISSUE SI (METRIC) UNITS APPROVED JOB NO. LOCATION UNIT

EGE 26-D-4a 1996

Page 1 of 2 ITEM NO.

mg/liter

mm m

MOBIL ENGINEERING GUIDE WASTEWATER CLARIFIER DATA SHEET

SI (METRIC) UNITS MECHANICAL COMPONENTS Contd SKIMMING MECHANISM*: Support Arrangement Scum Trough Length Scum Drawoff Pipe Diameter Material WEIRS*: Material BAFFLES*: Material SURFACE PREPARATION AND COATING: Corrosion Allowance Corrosion Allowance for Internal Parts Surface Preparation Primer Coating Final Coating Thickness Thickness m NPS Thickness

EGE 26-D-4a 1996

Page 2 of 2

Adjustment Adjustment

MOBIL ENGINEERING GUIDE WASTEWATER CLARIFIER DATA SHEET

ISSUE 1 2 CLARIFIER TYPE DIAMETER FLOOR SLOPE MANUFACTURER* FREE SOURCE TANK CONSTRUCTION PERFORMANCE DATA Flowrates, US gpm: Forward Feed Rate Return Sludge Flow Mixed Liquor Flow Aeration Basin Mixed Liquor Suspended Solids (MLSS) Concentration Temperature Effluent SS Concentration Return Sludge SS Concentration Uniform Sludge Loading Surface Hydraulic Loading Rate Solids Loading Rate Hydraulic Detention Time Effluent Weir Overflow Rate lbfCft PROCESS DESIGN AT DESIGN FLOW 2 US gal/day/ft 2 lb/day/ft hours US gal/day/ft MECHANICAL COMPONENTS DRIVE*: Torque Rating, lbfCft Running Type of Overload Device Type of Visual Readout MOTOR: Enclosure Type* hp* Volt Manufacturer* REDUCER*: Type Gearing Output rpm Manufacturer INFLUENT FEEDWELL*: Diameter Maximum Exit Velocity Support Arrangement Material CENTER PIER*: Influent Pipe Diameter Material SLUDGE REMOVAL DEVICE*: Type No. of Orifices Min. Flow Velocity Sludge Drawoff Pipe Diameter Material *Items designated by asterisk shall be completed by vendor. Nominal pipe size, inches. ft/s NPS ft ft/s Thickness Min./Max. Flow Velocity, ft/s: Thickness No. of Arms Orifice Size Max. Head Loss NPS Thickness / Depth ft rpm* Phase Mounting Service Factor Hertz Model* Material Service Factor Hardness Class Alarm Shutoff F mg/liter mg/liter Minimum Normal Maximum APPROVED 3 4 NUMBER OF UNITS SIDE WATER DEPTH FREEBOARD MODEL NO.* ISSUE CUSTOMARY UNITS APPROVED JOB NO. LOCATION

EGE 26-D-4b 1996

Page 1 of 2 ITEM NO. UNIT

mg/liter

in. ft

MOBIL ENGINEERING GUIDE WASTEWATER CLARIFIER DATA SHEET

CUSTOMARY UNITS MECHANICAL COMPONENTS Contd SKIMMING MECHANISM*: Support Arrangement Scum Trough Length Scum Drawoff Pipe Diameter Material WEIRS*: Material BAFFLES*: Material SURFACE PREPARATION AND COATING: Corrosion Allowance Corrosion Allowance for Internal Parts Surface Preparation Primer Coating Final Coating Thickness Thickness ft NPS Thickness

EGE 26-D-4b 1996

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Adjustment Adjustment