Legacy Environmental Process, LLC 1445 Ashville Road, Suite 103 Leeds, Alabama 35094 In USA 1-205-640-1035 Fax: 1-205-640-1039 www.legacyenvpro.com Pre-Plant Delivery And Installation Manual For Project Name City, State LEGACY: Project Number
Introduction: The wastewater treatment system is a complete; factory built prefabricated system, shipped to you, ready to be placed into the owner's excavation site. As you know, several of the subassemblies have been shipped loose for field re-assembly where shipping height limitations will not permit them to be attached. Instruction for re-assembly is provided. There are certain important details that must be checked by the owner's contractor prior to the system arriving at the job site. Please review the following instructions carefully and study the drawings of your system to obtain a working knowledge of the equipment you will receive. If you have any questions or require further information to proceed, please contact the office of Legacy Environmental @ (205) 640-1035. Please have the project name and number available for reference. Should you note an error, please contact Legacy Environmental immediately. With proper care and by following the suggested, simple instructions, money & time can be saved. These suggestions are for your guidance; by carefully reading those before you begin your work you may avoid costly mistakes. Scheduled Delivery Date: After production schedules have been reviewed, you will be advised of a shipping and delivery date. If this schedule does not meet with your project site plans, please contact Legacy Environmental immediately so we can reschedule shipment. If we are not notified before highway permits are purchased, the customer will be responsible for any additional cost for new shipping permits if rescheduling is required. The highway permits vary from state to state and are usually valid for only three (3) to five (5) working days. Excavation (If Required) For below grade system installation: A study of the shop drawings on your wastewater treatment system will permit you to determine the size and depth of the excavation needed for installation (if required). The size of the excavation should be at least two (2) feet wider and longer than the tank dimensions, allowing room for anchoring and paint touch-up prior to backfilling (if required). Pile excavating materials far enough away from the excavation site will allow the trucks and crane to operate safely from either side. Note: Shipping drain plugs with your system. These tank drains are for draining excessive water while your shipment is being moved over the road in case of heavy rain showers. Note that these shipping drains are shipped loose, and must be installed prior to any backfilling. Pre-Plant Delivery Instructions-2 Page 2 of 15
Warning Working in trenches-guard against cave-in. It is best to back-fill to a point above the water level in the treatment system, and on all four (4) sides to prevent freezing in cold climates. Foundation Slab Data: Due to the construction of the wastewater treatment system, a concrete foundation slab is necessary. The slab is used as a tank base, for anchoring the vessel to prevent flotation. Note: The design and construction of the slab is the responsibility of the customer's Project Engineer. For typical designs and construction methods, refer to the systems foundation pad detail drawings supplied within your submittal package. WARNING Working in Trenches-guard against cave-in To determine the exact slab design needed, assume that the total weight of the wastewater treatment system is uniformly distributed along the entire length of the foundation slab. It is extremely important that the foundation slab is level; if it is not level, the system will not function properly. The slab must be level within tolerances of ½" per each ten (10'-0") of width and within ¼" per each ten (10'-0") of length. In instances where crowns in the slab or any other non-standard workmanship exist, corrections must be made by resurfacing the slab or by placing a sand cushion on top of the slab to achieve full uniform bearing. Pre-Plant Delivery Instructions-2 Page 3 of 15
The Project Engineer should check the foundation slab before the wastewater treatment system arrives at the job site. Where flotation conditions exist, as in fluid soil, a foundation slab of adequate size & weight should be supplied to equal the bearing soil pressures. WELD BAR TO SIDE OF TANK WELD BAR TO SIDE OF TANK #6 REINFORCING BAR #6 REINFORCING BAR 4" 4" 2'-0" 2'-0" 3'-4" 3'-4" Suggested Anchor Methods Note: Legacy Environmental assumes no responsibility in the design and/or construction of the concrete foundation pad, including the anchoring of the wastewater treatment system to the concrete foundation pad. Drawings supplied are typical layouts only not to be used for construction purposes. Following are a few final details, which should be checked by the owner's contractor before the system arrives: 1.) Site check-the excavation and foundation pad to see that it is clear and free of mud, water or debris. The excavation site should be clear of dirt piles around the adjacent system area for truck access and safe crane clearance. 2.) Unloading facilities-arrangements should be made for obtaining a crane with sufficient capacity to lift and boom the system over and onto the base foundation pad. The wastewater treatment system will have lifting lugs properly located for balance for use with a four (4) leg cable sling with the use of a 20'-0" spreader bar to prevent undue stress on the lifting lugs. Pre-Plant Delivery Instructions-2 Page 4 of 15
Shipping: In almost every case, shipment of your wastewater treatment system is by special lowboy trucks. When Legacy Environmental ships your system; delivery will be made directly to the project site. Adequate road access must be available as tanks are shipped on lowboy trucks; trailer clearance is at a minimum, and the trucks can exceed 80 feet in length. When the truck(s) arrive, direct the driver to position the trailer so the outlet end of the system will be placed at the discharge end of the pad, whenever possible. Pre-Plant Delivery Instructions-2 Page 5 of 15
Other means of shipment: Common carrier service can be used for shipping those systems small enough in both size & weight. In these cases, the system will be delivered to the nearest truck dock. It will then be the customer's responsibility to arrange for moving the system from the dock to the project site. Systems may also be shipped by rail. In this case, the car will be directed to the nearest rail site. It will then be the customer's responsibility to arrange for removing the system from the rail car, and providing a flat bed truck to move the system to the project site. This responsibility includes making all necessary arrangements with local authorities for special permits, when required. Unloading: When the system arrives at the project site, the contractor should have the necessary equipment available to unload and set the system on the concrete foundation pad. A crane of adequate size is usually the simplest method for unloading the tank(s). Lifting lugs are supplied on the tank(s) to ease handling. A spreader bar is required to eliminate undue stress on the lifting lugs. Legacy Environmental wastewater treatment system will be completely assembled and shipped as a unit where shipping dimensional regulations permit this procedure. A portion of the equipment is packaged separately at the factory for field installation. The equipment will be installed by the contractor at the project site. Re-assembly instructions will be supplied. Pre-Plant Delivery Instructions-2 Page 6 of 15
The blower/motor units, control panels, grating, handrails, UV disinfection unit (if supplied), and flowmeter is a list of typical items shipped to the project site via common carrier Note: Check inside the tank(s) for pallets of equipment, which may have been placed there for shipping. Remove these pallets and or equipment with the crane before it leaves the project site. Handrail, shipping plugs, accessory hardware, and grating are type of items shipped inside the tank(s). Unloading Miscellaneous Items: Other loose items or accessory cartons should be removed from the tank and placed in a safe place until installation on the system. The truck driver has a packing list of equipment shipped with the tank(s); this should be checked to see if all equipment is received prior to signing the shipping manifest. Please note that any shortage and/or damage must be listed on the shipping manifest, also any claims must be made within ten (10) days from delivery, and damaged goods must be reported to the trucking firm by the customer. Legacy Environmental shall not be held responsible for any damage not annotated on the shipping manifest. Contractor Responsibilities: A. Field unloading and setting of the wastewater treatment system on its concrete foundation pad as defined by the contract specifications. B. Assemble into position, at the location shown on the plans, and the component equipment that have been disconnected at the factory for shipping purposes. C. Field welding of tank(s) (if required). D. Grouting base slope of mechanical clarifier (if required) including supply of grout. E. Interconnecting of piping and wiring which may have been disconnected at the factory for shipping purposes. F. Tie in all piping, wiring, and power connections to the site utilities. G. Furnish the concrete foundation pad to set the wastewater treatment system on. H. Attach wastewater treatment system to concrete foundation pad by customer's Engineer anchor methods. I. Install drain plugs and fill the system with water to prevent flotation. J. Install the magnesium anode packages as shown on the magnesium anode layout supplied in the submittal package. K. Complete 24-hour leak test prior to backfilling. (If possible use water (not sewage) for leak test. CAUTION Once the wastewater treatment system has been set and anchored into position, the drain plugs must be installed and the tank(s) filled with water prior to leaving the project site. This system is very buoyant and will float easily. Legacy Environmental assumes no responsibility for systems that float out of position of off the concrete foundation pad due to high water tables at the project site. Pre-Plant Delivery Instructions-2 Page 7 of 15
Electrical Characteristics: Special precautions should be taken to make sure the correct electrical requirements are supplied at the project site. Check your data sheets and wiring diagrams, and then advise your electrical contractor as well as the Local Power Company of the necessary power requirements. A disconnect switch should be mounted within sight (if required), preferably adjacent to the system site, and wiring from the switch to the electrical control panel on the wastewater treatment system must be furnished and installed in accordance with your local electric codes. Pre-Plant Delivery Instructions-2 Page 8 of 15
Electrical Hook Up: The contractor must connect the wire leads provided within the wastewater treatment system to their proper terminals within the control panel. A general wiring diagram showing the locations of these items will be found within the submittal package. Note: Panel boxes shipped without knock-outs in bottom of panel for conduit connections, installing contractor will punch out panel boxes as required, and also will need to supply cord grips as required. Pre-Plant Delivery Instructions-2 Page 9 of 15
Note: In order to prevent damage to the blower/motor units from backflow of water, it is important to maintain the proper rotation of the blower motors. Rotation should be in the direction of the arrows located on the motors. Similarly, proper pump rotation must be maintained in order to avoid damage to the pump(s) (if required). Failure to insure proper rotation of these items will negate any manufacturers' warranties. BLOWER MOTOR UNIT MOUNTING HARDWARE FLEXIBLE HOSE CONNECTION AIR SUPPLY LINE RUBBER VIBRATION MOUNTS STEEL SUPPORT PLATE Blower Motor Unit(s): The blower motor units should be lifted onto the system with the crane before it leaves the project site. The housing sits on steel support plates, located on top of the system drilled to receive the flexible hose connection, and the four (4) rubber vibration mounts through the bottom of the blower housing with the system air supply line, which is stubbed for connection during assembly. Note: The four (4) rubber vibration mounts w/ mounting hardware, and flexible hose connector are located inside the blower housing for shipping purposes. The blower motor units are assembled and lubricated at the factory prior to shipment to the project site. Refer to O & M manuals for lubrication schedule. Pre-Plant Delivery Instructions-2 Page 10 of 15
DISINFECTION CHAMBER GFCI RECEPTACLE UV CHANNEL UV MODULE DISCHARGE WEIR WASTEWATER TREATMENT PLANT OUTLET FIGURE A UV Disinfection Unit: (if supplied) The UV Disinfection unit is bolted into position with the hardware supplied. The discharge weir located at the outlet end of the UV system is to be facing the outlet end of the wastewater treatment system (see figure A). Note: Prior to installation of the UV channel into the wastewater treatment system, remove the UV modules from the channel and store in a safe place, as the bulbs located within the modules are very fragile. Replace UV modules into the channel and plug the modules into the GFCI receptacles supplied within the disinfection chamber. Note: If intensity monitor is supplied, refer to figure B next page for electrical, transducer & temperature sensor connections. Pre-Plant Delivery Instructions-2 Page 11 of 15
FIGURE B Pre-Plant Delivery Instructions-2 Page 12 of 15
Flowmeter Mounting: (if supplied) Flowmeter comes supplied within a pre-wired enclosure that will mount within the UV disinfection chamber (see equipment layout drawings). Bolt the flowmeter cabinet to the location as shown on the drawings, install the transducer & temperature sensor into the mounting bracket located within the effluent chamber and install wiring as shown in the illustration listed below: Note: Installing contractor must insert knockouts within the panel, as Legacy Environmental does not have conduit knockouts installed within the enclosure. MODEL OCM III FLOWMETER BLACK WHITE BLACK WHITE SHEILD 1 2 3 4 5 14 15 16 34 35 36 TRANSDUCER BLACK WHITE POWER CONNECTIONS GREEN BLACK WHITE TEMPERATURE SENSOR MODEL ARC 5000 RECORDER GROUND 1 2 3 TB1 GREEN BLACK WHITE 115V SUPPLY 1 2 3 TB2/TB3 BLACK WHITE JU2 MILLI-AMP JUMPER Pre-Plant Delivery Instructions-2 Page 13 of 15
Field Services: At the time the wastewater treatment system is filled with water or sewage, all power connections have been completed, and all equipment is approved for service, the buyer shall, at his option, request the services of an Legacy Environmental service technician who shall instruct the owner's representative in the proper operation and maintenance of the wastewater treatment system, including instructions in conducting all required operational tests. Note: If start-up services are required, and were included within the scope of work, Legacy Environmental requires two (2) weeks notification for scheduling purposes; please contact the Customer Service department @ (205) 640-1035 for scheduling. Storage Procedures General: RECOMMENDATIONS FOR INSTALLED EQUIPMENT (NOT BEING UTLIZED) 1. All equipment that will remain idle after installation must be properly maintained. Following these instructions will help you insure that the equipment will not be damaged by lack of attention during periods when it is not being used. This is not to be construed as providing or extending any Warranty by Legacy Environmental Process, LLC or any manufacturer of components supplied with the equipment. Installed Equipment Standing Idle: 1. Equipment should be operated for at least one (1) hour weekly to keep all enclosed gear surfaces wetted or otherwise with lubricant to prevent water etching or false brineling of the bearings and seizure of the seal lips on the shaft. This includes pumps and blower/motor units. 2. Space heaters, if furnished with electric motors or control panels, must be connected and operating during all idle periods. 3. If unit is being operated under power, then periodically check the level and condition of oil in each piece of equipment (if applicable). Add or replace if necessary. LONG TERM STORAGE OF EQUIPMENT NOT INSTALLED ON SYSTEM All equipment which will not be installed within one (1) month after receipt of equipment on the project site will fall under these guidelines for long term storage. 1. Specified long term storage guidelines for motors, reducers, pumps, blowers may have been covered under their respective section in the O & M manual. Pre-Plant Delivery Instructions-2 Page 14 of 15
2. Primer paints are not intended to be left unprotected indefinitely waiting for the finish coat to be applied. Any touch-up or re-priming will become the contractor s responsibility if equipment falls into long term storage. 3. All electrical related items, whether they are control panels, solenoid valves, torque overload devices, magnesium anodes, and chlorination tablets should be stored in a heated enclosed clean dry area to protect it against excess moisture, physical damage, and construction dust and kept away from high humidity. Leave the equipment on the skid until ready for installation. Note: Do not open chlorination tablets until ready for use, as moisture will dissolve tablets and render them useless. Pre-Plant Delivery Instructions-2 Page 15 of 15