JUPITER. Installation Manual. Revision

Transcription

1 JUPITER Installation Manual Revision

2 List of Contents Description of Manual Page 3 General Conditions page 4 Instruction 1 Control of Packing List page 5 Instruction 1.1 Jupiter Overview page 6 Instruction 2 Unloading and Handling the Jupiter Tanks page 7 Instruction 3.1 Installation of Jupiter on-ground page 8 Instruction 3.2 Installation of Jupiter in-ground page 9 Instruction 5 The Jupiter Inlet and Outlet page 10 Instruction 6 The Jupiter Sludge Return page 11 Instruction 7 Installation of Inlet Pumps page 12 Instruction 8 Installation of Blower page 14 Instruction 9 Installation of Float Switch System page 15 Instruction 10 Power to Control Box page 16 Instruction 11 Commissioning of the System page 17 Appendix 1 Installation Control Plan page 18 BIOKUBE INSTALLATION MANUAL JUPITER 2

3 Description of Manual The current manual is the first manual in a series of totally four manuals related to the Standard BioKube Jupiter system with pump well, settling tank and treatment plant. This manual concerns procedures and guidelines for installation of the treatment plant. Pump well and settling tank are assumed to be constructed locally. The total set of manuals consists of the following: 1: Installation Manual 2: Commissioning Manual 3: Service and Maintenance Manual 4: Trouble shooting Manual 3

4 General Conditions Introduction The Jupiter system which is designed to treat ordinary household sewage ranging from 100 to 600 PE. You may not lead any other water than grey- and black household sewage to the treatment plant unless specifically approved by BioKube Ltd. Maximum Load The BioKube Jupiter systems are designed to treat ordinary household sewage up to 600 PE. The Jupiter 75 unit can handle a maximum flow up to 125 m3/day. The Jupiter 25 unit system can handle a maximum flow of up to 60 m3/day. The plant allows for fluctuations in both concentrations and volume of the incoming water. However if the average daily load exceeds the designed performance, a larger system must be installed. Performance Level The performance of the BioKube Jupiter system in its different configurations are: BOD < 10 mg/l NH4< 5 mg/l (3 units) BOD < 10 mg/l (2 units) BOD < 25 mg/l (1 unit) Energy consumption during normal operation. Jupiter PE 300 PE 200 PE 90 kwh/year/pe Jupiter PE 450 PE 300 PE 90 kwh/year/pe Jupiter PE 600 PE 400 PE 90 kwh/year/pe Each person equivalent (PE) consumes approximately 150 to 250 ltrs per day and loads the system with 60 g BOD per day and 13 g nitrates Chemical consumption (optional) Where required automatic dosage of Poly Aluminium Chloride (PAC) ensures chemical precipitation of phosphorous. The yearly consumption of PAC is approximately 10 ltr per PE. The chemical tank is external and is placed next to the plant. 4

5 Instruction 1 Control of Packing List Always control that the components and parts received are in accordance with your order and packing list. Also control that the goods are without visible damages or faults. All pipe dimensions in this manual are external diameter. Treatment Plant The Jupiter system consist of one to three tanks. Control tanks and filters are intact and undamaged. Pump Well Prior to the Jupiter system client/owner installs a pump well with a volume that equals or exceeds twice the hourly peak volume. Pump System The system is delivered with a pump system for installation in the pump well. The system consists of submerged sewage pump on pedestal for easy service and maintenance. Control components for pump system are in accordance with check list on Instruction 6.1 of this manual. Float Switch System The float switch system contains of a bar where three independent float switches are placed. Control components for float switch system are in accordance with check list on instruction 8 of this manual. Air System Rooth Blower for generation of air supply to the biological treatment is delivered on a separate pallet. Control Rooth Blower and air-pipes are intact and undamaged and in accordance with specs. Electrical Cabinet Control Electrical cabinet and control unit are undamaged. Inlet pipe from pump well 50 mm PEL pipes and quick compress fittings supplied. Inlet/Outlet pipe to treatment plant 15 meters of PVC pipe according to scheme below. Pipe must be undamaged and should not be discolored. The pipes are kept on top of the plant during transportation. Sludge return pipe 20 meters of 110 mm PVC pipe together with 5 fittings. Pipe must be undamaged and should not be discoloured. The pipes are on top of the plant during transportation. Parts All other connection pipes, fittings, bolts, brackets and spare parts are located in the front of the top of the Jupiter tank. Jupiter Element Air supply connection [mm] Pump connections [mm] 5 Inlet/outlet [mm] Jupiter /110 Jupiter /110 Jupiter /160

6 Instruction 1.1 Jupiter Overview Different standard models of Biokube Jupiter: Jupiter 75 Jupiter 50 Jupiter 25 One step Biokube Jupiter for treatment level BOD 25 mg/l: Outlet Two steps Biokube Jupiter for treatment level BOD 10 mg/l: Two submerged sewage pumps in local constructed pump well Three steps Biokube Jupiter for treatment level BOD 10 mg/l and NH 4 -N+NH 3 -N 5 mg/l: Inlet Electrical cabinet Rooth blower for aeration Contact filter in settling zones Settling tank supplied by the client/ Sludge return pipe Aerated submerged filter zones 6

7 INSTRUCTION 2 Unloading the Jupiters The system will normally be forwarded in a standard 20 og 40 container to the site of installation. The tanks fit narrowly through the door opening of the container. It is important that precaution is taken during unloading to avoid impact and damage on the tanks and equipment. Jupiter Element Height [mm] Width [mm] Length [mm] Weight [kg] Jupiter Jupiter Jupiter To facilitate the unloading, the tank may be equipped with ropes on the side of the tank. These ropes are not to be used for lift of the tank, but only to help dragging the tanks out of the container. Recommended handling tools (not included) The safest way of transporting the system is by means of a fork lift. Either by use of a fork lift truck or by use of fork lifts installed on an excavator or on a front loader. Use long forks. The forks shall be at least 2 meters long. For any lifts we recommend to use heavy straps around the tank as illustrated to the right. Do not attach straps to any part of the tank, and do not use yellow ropes for lifts. To avoid damaging the plastic weldings during lifts make sure that the straps used are minimum 12 mtrs long and evenly distributed over the length of the tank. We recommend to attach the straps to a yoke (steel frame as illustrated) to avoid any deformation of the tank. (Yoke and straps are not included in the delivery) Notice: Never lift the BioKube Mars 2000 with water inside. 7

8 INSTRUCTION 3.1 Installation of Jupiter on-ground If specifically ordered, the Jupiter system can be installed on-ground. In this case, the tanks are equipped with reinforcing steel bars around the perimeter of the tank as illustrated to the right. Reinforcement is necessary to avoid any deformation of the tank subjected to water pressure. If you need to install the system on the ground, please note that it most likely will be necessary to place the pump well after the settling tank. Foundation for the Jupiter on Ground During operation the tanks are filled with water, and must be placed on load bearing horizontal, leveled surface with a maximum variation of +- 1 cm per 4 mtrs.. Surface must consist of either stable compressed gravel or 200 mm cast concrete slab built on stable soil. 8

9 INSTRUCTION 3.2 Step 1 Level the bottom of the excavation, make sure that the soil is stable and can handle the load. Depth of excavation: mm. Cast a concrete floor: Width: mm Length: (length of system mm) Thickness: 200 mm Concrete quality: 20 MPa Reinforcement: Ø10 mm bars per 200 mm 25 mm from bottom and 25 mm from top. Attach 600 mm Ø10 mm bars for each 200 mm at the tank perimeter to connect to reinforcement of walls. (Remember to vibrate concrete) Curing: Allow for min 8 days of curing during which the concrete must be kept wet. Place the Jupiter element on the Concrete floor after minimum 8 days of curing. Observe Instruction 2 for any lifts of tanks. Step 2 To keep the tank in position, fill water in the tank to a level of app 750 mm from the bottom. Construct the formwork for 200 to 250 mm concrete wall around the Jupiter tank. Use the Jupiter tank as the inner formwork. Respect in and outlet pipes. Concrete around the sides protects the Jupiter from buoyancy, gives strength and prevents deformation of the Jupiter tank subjected by high soil pressure. Concrete quality: 20 MPa Reinforcement: Ø10 mm bars per 200 mm 25 mm from external surface and 25 mm from tank. Attach the grid to the connecting bars from the floor. (Remember to vibrate concrete) Curing: Allow for min 8 days of curing during which the concrete must be kept wet prior to removing the formwork. Step 3 Follow the scheme below to determine the minimum height of the formwork and consequently the concrete walls. Mind the in and outlet pipes if you choose to cast concrete to the top of the Jupiter. For two or three tank systems, remember to cast concrete walls between the tanks using the tanks as formwork. Installation of Jupiter in ground Model Height of wall, no ground water pressure Height of wall, ground water pressure Jupiter mm mm Jupiter mm mm Jupiter mm mm 9

10 INSTRUCTION 5 The Jupiter Inlet and Outlet Inlet of Sewage Sewage enters the standard system at the pump well. Prior to the pump well, sewage must pass a coarse grid with a mesh size of approximately 25*25 mm to prevent damaging the pumps. Both coarse sieve and pump well are constructed locally. The pump well is meant to equalize any peak flows and should be sized no less than 25 % of the daily sewage load. If the max hourly peak load exceed 20 % of daily sewage, contact BioKube for advice on the required size of the pump well. The pump solution consists of a two pump system placed on pedestals and guider pipes for easy maintenance and service. The pump solution is normally supplied by Biokube. It is important to use vortex pumps designed for raw sewage. (For installation of pump system see instruction 6) The pump system secures that sewage is pumped through 50 mm pipes to the settling tank. The 50 mm pipes must be securely fastened to the pump well and the settling tank to maintain pipes in position when subjected to pressure during pumping. Settling Tank to Treatment Plant Sewage gravitates from the settling tank to the treatment plant through a 110 or 160 mm pipe according to scheme Instruction 1. The pipe must gravitate minimum 10 0/00 to keep the pipe free of any sludge particles. For systems with more than one tank the same guidelines apply for interconnection pipes. Outlet to recipient The dimension of the outlet pipe follows the scheme in Instruction 1. The outlet pipe must gravitate minimum 10 0/00 to recipient, pump well (if topography requires that treated water is pumped to recipient) or holding tank. 10

11 INSTRUCTION 6 The Jupiter Sludge Return Recirculation and sludge return As an important part of the treatment process treated water and biological sludge is recycled back to the settling tank. The recirculation leaves the side of the treatment plant through a 110 mm PVC pipe. Install the recirculation pipe so that the water gravitates back to the settling tank. Fix the pipe to the side of the Jupiter. And protect the pipes against impact and sun radiation to avoid damages and corrosion of pipes. Sludge return pipe 11

12 INSTRUCTION 7 Installation of Inlet Pumps In order to pump sewage from the locally built pump well, the two adjoining pumps are installed on a pedestal system for easy service and maintenance. Pumps, pedestals, guider pipes, brackets, expansion bolts for fastening, PEL-pipes and fittings are located inside the STP are located inside the STC during transportation. The main pump P1 is activated according to settings of the control unit. The emergency pump P2 is activated if water level of pump well increases above the max level (of the upper floater). Step 1 The two basic brackets must be installed in the bottom of the pump well. Step 2 Install the 50 mm PEL pipes to the basic brackets and connect to the inlet pipe for the Settling Tank. Step 3 Install the top brackets and the guider pipes. To fit the guider pipes to the top of the pump well, simply cut the pipes to the right length. Step 4 Install the pumps by sliding them down the guider pipes. Remember to attach wires to the pumps for pulling them up for maintenance. Pumps must be electrically connected to the electrical cabinet. If necessary pump cables can be extended. Brackets and expansion bolts for fastening are located inside the STP together with Pumps, guider pipes and brackets for pedestals. PEL pipes and fittings are located on top of STP during transportation. 12

13 INSTRUCTION 7 Installation of Inlet Pumps Parts needed for INS. 7 In the list to the right is the list for one pump installation. Normally a two pump system is installed. Item No. Qty Description 1 1 Upper guide bracket 2 1 Bottom Pedistal 3 2 Guide pipe 3000 mm 4 1 Submersive pump electrical wire 20 meters. 5 4 Elbow 50 mm Compress fitting (extra 3 pcs.) 6 1 PEL Pipe 50 mm 25 meters 7 1 No return valve 8 1 compress fitting 50 mm (extra one pcs.) 9 1 Plastic Bracket 10 4 Ekspansion bolt 10 mm (ekstra 2 pcs.) Pipecarrier 50 mm 12 6 Ekspansion bolt for pipe bracket (extra 3 pcs.) 13 5 Self cutting screw for container wall (extra 3 pcs.) 14 1 Screw for plastic bracket (extra 3 pcs.) 13

14 INSTRUCTION 8 Installation of the Blower Rooth Blower Installation Biokube supply all pipes needed for the blower installation. Follow the illustration to the right to connect the air system of the treatment plant to the Rooth Blower. Steel pipe must be used to avoid deformations caused by heat. It is equally important, that the reduction from 75 to 50 mm is installed in the proximity of the treatment plant to reduce pressure loss as much as possible. Use the 16 mm hose to connect magnet valve to air lift system at the settling chamber of the Jupiter tanks Protection of blower and electrical installations We recommend that Rooth Blower, electrical cabinet and frequency transformer are placed in a locally constructed shed to protect the installations against wind, rain, dust and direct sunlight. In hot areas shading and ventilation is important to avoid over heating of the blower. 16 mm hose for air lift system connected to magnet valve Typical Shed for installations 14

15 INSTRUCTION 9 Installation of Float Switch System The Float Switch system serves the purpose of controlling the inlet to the treatment system. The Float Switch bar must be installed in the pump well next to the pedestal systems. The bar with the floaters are placed in the pump well. The bar is fixed with normal pipe brackets. The floaters are placed on the bar. It is okay to adjust the height of the floaters. the order of the three float switches must not be altered. Step 1: Fix the float switch bar to the pump well using brackets and expansion bolts. Step 2: Adjust the level of the three switches to fit the size of the pump well as follows: Floater no Floater no: 3 Floater no: 2 Name of floater Placement of floater Upper float switch Middle float switch located at the chosen maximum water level of the pump well. located at 75 % of the chosen maximum water level of the pump well. Floater no: 1 Lower float switch located 40 cm above the bottom of the pump well. The float switch system, the brackets and expansion bolts are located inside the STP during transportation to site. Parts needed for INS. 9 Component PCS/m Model Remarks Bar for Floater 1 For control of the pump function, float switch in total. Electrical wire 20 meters. Pipe brackets 3 PVC To fix 50 mm pipes. Expansion bolts for brackets 3 AISI 306 For fixing the brackets in the concrete wall of the pump well. 15

16 INSTRUCTION 10 Power to the Control Box The control unit is located in the electrical cabinet. All electrical components of the system are powered through this unit to which the supply cable must be connected. Upon request the system is delivered for 3 phase 400 volt, Zero and Ground. If only one phase is available a frequency transformer need to be installed in front of the control box. The frequency transformer can generate 3 phase supply. See more: The Biokube E-III Controller.pdf Upon opening the door of the electrical cabinet all connections are visible. Power supply cable and extension cables for pumps and float switch system are not included. Dimension of the 5 core supply cable to be determined on site based on distance to power source. Note: Maximum voltage loss in cable may not exceed 10 V. Component Runtime Installed Power Power supply Blower continuously 1-5 kw 3 phase, 380 Submerged pump 5 hours a day 0,750 kw 3 phase,

17 INSTRUCTION 12 Commissioning of the Jupiter System For commissioning of the system, please see the commisioning manual. 17

18 Appendix 1 Installation Control Plan Project: Contractor: Place Area: Installation Date: Reference Delivery Control Subject What to control Where to control Control method How to control Accept criterium Documentation Remarks Responsi ble Init accept Ins 1 BioKube and spare parts: Treatment Plant Sewage Pumps Float Switch System Air System Electrical Cabinet Visual control Make and quantity in accordance with packing list Treatment plant and parts are undamaged without miscolours Photo, control scheme, packing list Frequency Transformer Pipes Fittings, brackets, etc. accesories Unloading and lift of treatment plant Ins 2 Unloading container, Use of adequate lifting tools and heavy straps. Lift and craning of plant by means of yoke or heavy straps min 12 m long Installation of plant Visual control No deformation or damage of treatment plant or weldings Photo Ins 5 Ins 3 Ins 3.1 Coarse Grid installed in front of inlet to pump well Pump well constructed with sufficient volume Settling Tank constructed to separate particles Levelled Surface for Jupiter Foundation: 200 mm Compressed Gravel or Concrete Ins 3.2 Excavation depth mm to leveled surface Dimensions of Concrete floor Overlap of reinforcement in joint between floor and wall Dimensions of Concrete walls Visual control No deviance accepted Measurement Minimum 25 % of daily flow volume Visual, measurement Measurement Three Chambers, T-pipe at outlet Max +- 1 cm per 4 mtrs Measurement Min 98% Standard Procter for Gravel, Concrete 20 MPa Measurement No deviance accepted Measurement Width: 2850 mm Thickness: 200 mm Length: Jupiter length mm Photo Control Scheme, photo Control Scheme, leveling report Control Scheme, casting report Measurement 600 mm Measurement According to scheme instruction 3.2. Concrete Quality Casting report 20 MPa Reinforcement Delivery Note 10 mm, 160 MPa 18

19 Appendix 1 Installation Control Plan Reference Subject What to control Where to control Control method How to control Ins 3.2 Curing time Floor: min 8 days prior to placement of walls Accept criterium No deviance accepted Documentation Remarks Responsib le Init accept Pipe Connections Walls: min 8 days prior to removal of formwork No deviance accepted Ins 5 Ins 5 & 6 Installation of 50 mm pipes from pumps to settling tank Gravitation of sewage pipes: Settling tank to treatment plant Treatment plant to outlet Recirculation from treatment plant to pump well Installation of Mechanical Components Visual, physical levelling Pipes must be securely fastened to pump well and settling tank All sewage pipes must gravitate min 10 0/00 Ins 7 Installation of pumps, pedistals and guider pipes Visual, physical Pedistals and guider pipes must be securely fastened, length of guider pipes fit the height of the well Pumps glide smoothly on guider pipes, wires are attached to pumps Pumps are electrically connected to electrical cabinet Ins 8 Ins 9 Installation of Rooth Blower Installation of Float Switch System Visual, physical Visual, physical Measurement Install Rooth Blower in shed or similar on concrete floor. Connect airpipes from blower to diffuser system. Conect 16 mm hose from magnet valve to air lift system Float Switch Bar installed with brackets and expansion bolts securely fastened Floater 1 located 40 cm above floor of pump well 19

20 Appendix 1 Installation Control Plan Reference Ins 9 Subject What to control Where to control Installation of Float Switch System Control method How to control Measurement Accept criterium Floater 2 located at 75% of max level Documentation Remarks Responsib le Init accept Measurement Floater 3 located at max level Ins 10 Installation of Electrical Cabinet Visual Visual Visual Measurement Floaters connected to the electrical cabinet Electrical cabinet installed on wall in Shed or similar Power cables to all components securely fastened Maximum Voltage loss in supply cable 10 V Ins 11 Installation of SIM-Card Visual Connection to control unit via GSM-net Only for systems with remote control (GSM) 20