EDI Aeration/Mixing Equipment Submittal

27 Pages·2010·1.45 MB·English

EDI Aeration/Mixing Equipment
Typical Installation, Operation, &
Maintenance Manual

For:

Mapocho, Chile

FlexAir® 9-inch Disc Diffusers with
Integral Saddle Mount (ISM)

Date: May 28, 2010
EDI Aeration/Mixing Systems Project Special Notes

Notice
This document and all information contained within is the
property of Environmental Dynamics Inc. This document is
submitted under a confidential relationship specifically for
the recipient's use on a designated project. Reproduction of
this document or use of its contents in whole or in part
without the written permission of EDI is prohibited.

Information included in this manual is typical and for
informational purposes only. Actual content shall be
confirmed during the submittal process.
Table of Contents
Storage Instructions ....................................................................................................................... 1
Receiving Inspection ............................................................................................................................................. 1
Pre-Installation Storage Requirements for Plastic Piping .................................................................................... 1
Pre-Installation Storage Requirements for a Flexible Membrane System ............................................................ 1
Post-Installation Storage Requirements for a Flexible Membrane System .......................................................... 1
Installation Instructions ................................................................................................................ 3
Air Piping Installation ........................................................................................................................................... 3
Slotted Flange Installation..................................................................................................................................... 3
Super-Strut™ GFPP Pipe Support Installation Instructions ..................................................................................4
Rigid/Simple Pipe Support Installation Instructions ............................................................................................. 4
Leveling of Air Piping .......................................................................................................................................... 9
Installation of the Manual Purge Assembly .......................................................................................................... 9
Optional Water Flush and Air Purge Cleaning of Piping .................................................................................... 10
Installation Instructions for 9 Inch Disc Diffuser Units with ISM ..................................................................... 11
Start-Up Instructions ................................................................................................................... 14
General Aeration/Mixing Systems Start-Up Instructions .................................................................................... 14
Blower Components ............................................................................................................................................ 14
General Air Piping .............................................................................................................................................. 14
Initial System Start-Up ........................................................................................................................................ 14
Safety Considerations .................................................................................................................. 16
Personal Protection Measures ............................................................................................................................. 16
Personal Protective Equipment ........................................................................................................................... 17
Confined Space Hazard ....................................................................................................................................... 17
Operation Instructions ................................................................................................................. 18
Description of the Aeration-Mixing System ....................................................................................................... 18
Normal Operation of the Aeration System .......................................................................................................... 18
Normal Operation of the Blower System ............................................................................................................ 18
Shutdown Conditions .......................................................................................................................................... 18
Operation of the Diffuser Unit ............................................................................................................................ 19
Normal Operation of the Manual Purge Assembly ............................................................................................. 19
Corrective Maintenance ............................................................................................................... 20
Troubleshooting .................................................................................................................................................. 20
Replacing FlexAir Disc Diffuser Membrane ...................................................................................................... 20
Replacing Saddle Mounted Diffuser Assembly .................................................................................................. 21
Manufacturer Services ................................................................................................................. 23
Warranty Statement ............................................................................................................................................. 23
Diffuser Express® ............................................................................................................................................... 24
EDI Aeration/Mixing Systems Storage

Storage Instructions
Receiving Inspection
If the pipe components are to be stored for more
than 6 months, pipe sections are to be shaded
(FOB EDI only) Shipments shall be inspected
from sunlight.
for damage upon receipt. The recipient/receiver
is responsible for all damages. EDI offers to act Accessories such as pipe supports, fasteners,
on behalf of the recipient / receiver in filing a etc., packaged in original boxes are to be
claim for damage incurred during shipment. To protected from excessive moisture and rain.
file a claim against the freight company, a Outdoor storage is acceptable provided the
damage report must be submitted to EDI within ambient air temperature is below 140°F (60°C).
24 hours of delivery.
Small items should be stored in a secure location
(FOB Jobsite only) Shipments shall be inspected to avoid misplacement and theft.
for damage upon receipt. Any damages
Pre-Installation Storage
observed upon receipt must be reported to EDI
within 24 hours of delivery. EDI will repair or Requirements for a Flexible
replace damaged goods when notified within
Membrane System
this notification period.
Diffuser components packaged in original crates
(Ex-Works only) Shipments shall be inspected
and/or cardboard boxes may be stored outdoors
for damage upon receipt. The recipient/receiver
provided the ambient air temperature is below
is responsible for all damages. To file a claim
100°F (40°C). In the case of components that
against the freight company, file a damage
are received in cardboard packaging, these
report directly with the shipping company.
packages must be protected against excessive
A full inventory of shipped components shall be moisture and rain to maintain package integrity.
completed within 14 days of the receipt of
If the ambient air temperature exceeds 100°F
shipment. Any deficiencies in the shipment that
(40°C), then containers shall be shaded or stored
are clearly deemed to be the result of EDI will
indoors in which the ambient air temperature
be reconciled by EDI when notified within this
does not exceed 125°F (52°C).
time period.
Storage of diffuser membrane components shall
Pre-Installation Storage
be limited to one year.
Requirements for Plastic Piping
Post-Installation Storage
PVC, CPVC and ABS piping components may
Requirements for a Flexible
be stored outdoors provided the ambient air
Membrane System
temperature is below 140°F (60°C).
Pipe sections are furnished with end caps to When the reactor is drained and the aeration
minimize the entry of foreign materials (dirt, system is exposed for a short period of time (less
debris, etc.) into the pipe. Any foreign materials than 4 to 6 weeks), the system shall be protected
that are allowed to contaminate the pipe will from foreign objects including but not limited to
need to be removed from the system prior to paint or weld splatter, falling objects, etc.
installation and start-up.
If the ambient air temperature is above
Piping shall be stored on a flat surface to avoid 100°F (40°C), the system should be shaded
damaging the pipe sections. to protect the system from UV light and
excessive heat. A gray fabric tarp is
recommended to shade the aeration
components. The gray fabric tarp is to be
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EDI Aeration/Mixing Systems Storage

suspended above the aeration system by airflow condition until the ice is no longer
approximately 6” (150 mm) to prevent present.
damage to the system.
The water level should never be lowered if
Note: Do not use any form of plastic to ice is present. The weight of the ice may
cover the aeration components. Plastic damage the system.
can create a hotter environment and/or
When the aeration system is to be idle for an
fuse to the surface of the diffusers.
extended period time (greater than 4 to 6 weeks)
When the aeration system is to be idle for an and the units are going to be removed and
extended period time (greater than 4 to 6 weeks), stored, then the following storage conditions
the system should be submerged in would apply.
approximately 4 feet of clean water provided the
If the ambient air temperature is going to be
ambient air temperature is greater than 32°F
less than 100°F (40°C), then a fabric tarp is
(0°C).
recommended to cover the equipment.
If the ambient air temperature is below 32°F
If the ambient air temperature exceeds
(0°C), the water level may need to be
100°F (40°C), then the equipment shall be
increased so that the ice layer does not
shaded or stored indoors in which the
contact the aeration system.
ambient air temperature does not exceed
When reactivating a system where ice exists, 125°F (52°C).
operate the system at a minimum airflow to
avoid movement of ice and maintain this

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EDI Aeration/Mixing Systems Installation

Installation Instructions
Air Piping Installation segment. All arrows should point away from the
header toward the lateral end at final installation.
The Contractor is to confirm that the air piping
is clean during fabrication of laterals and should Slotted Flange Installation
swab out any debris found in the pipe before
1) Lateral piping is connected with slotted
installing the diffuser units. Dirt and debris may
flanges and supported by partially
clog the diffuser unit requiring an extended start-
assembled pipe supports.
up procedure and MAY require the Contractor
to remove and replace diffuser unit at 2) Gaskets and stainless steel fasteners are
Contractor's expense. If piping requires further provided by EDI for flanged connections.
cleaning before diffuser installation, Contractor Recommended bolt-tightening torque values
may elect to perform water flush or air purge are indicated in torque table on Flange
procedures described at the conclusion of this Installation Detail Drawing.
section. NOTE: If this procedure is performed,
3) An industrial grade anti-seize lubricant
do so before installing the diffusers.
MUST be used on stainless steel bolt threads
Transition from the drop pipe to the air lateral to prevent galling. Contractor will be
piping is made by a stainless steel coupling responsible for replacement of all damaged
clamp provided by EDI. The aeration system items resulting from not using anti-seize
typically features a drop stub designed to be lubricant.
field cut to length and solvent welded to the air
4) Lay out sections of pipe to be joined in
laterals by Contractor. The pipes must be
order, making sure orifices are correctly
aligned vertically prior to installing the coupling
oriented (at top centerline for top-mounted
clamp or the clamp may leak. The clamp has
diffusers, at bottom centerline for bottom-
limited ability to seal misaligned piping. Also,
mounted diffusers). Flow arrows and labels
the gap between the drop pipe and drop stub
on pipe correspond to labels on layout
shall be less than 0.25”(6.5 mm) to ensure
drawing. Use the centerline marked on pipe
proper sealing of the coupling clamp.
and flanges to assist in orientation.
Assemble the aeration piping per the EDI layout
5) Align flange with gasket and flange to be
drawing. Start with the drop pipe section to
connected. Elongated bolt slots through
ensure proper drop pipe alignment. Pipe
flange allow for slight adjustments.
supports should be partially assembled with the
bottom pipe strap, then placed under the drop 6) Place one 5/16” flat washer on each 5/16”
pipe section for support. Pipe support assembly 304 S.S. bolt, then place bolts through bolt
instructions are in the following section. See the slots in first flange. Place gasket over ends
EDI layout drawing for pipe support locations. of bolts.
Do not install the anchor bolts until the final
alignment is established for the complete
aeration grid. The remaining air lateral piping
shall be installed using this same method. All
piping segments will be labeled with a sequence
number that indicates that segment’s position in
the lateral run. Additionally, EDI will provide
an arrow on the lateral piping. This arrow
indicates the direction of airflow in the lateral
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EDI Aeration/Mixing Systems Installation

7) Carefully join flanges, until all bolts project
9) When all bolt assemblies have been
through corresponding bolt slots in the
correctly positioned, torque nuts to 5 ft-lbs.
second flange.
Bolt assemblies must be tightened in the
sequence shown on Flange Installation
Detail Drawing.
10) As lateral sections are assembled, maintain
correct alignment of the orifices on the
lateral so that diffusers will be level when
installed.
11) If the specifications require the system to be
pressure or leak tested, all openings are to be
plugged before the system is tested. EDI
recommends not exceeding 10 psi during
pressure or leak testing.
Super-Strut™ GFPP Pipe Support

Installation Instructions
8) Place a second 5/16” flat washer onto each
bolt, then a 5/16” lock washer, then place
The lateral piping is supported by Glass Filled
the S.S. nut LOOSELY on bolt to complete
Polypropylene support assemblies (provided by
bolt assembly (do not tighten at this time).
EDI).
Repeat for remaining bolt assemblies around
flange.
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EDI Aeration/Mixing Systems Installation

2 in. of exposure. Anchors should be placed
as shown on layout drawing.

2) Temporarily assemble support to measure
the height to center line of the lateral piping.
EDI’s Super Strut™ supports are packaged If the lateral pipe is more than 7 ½” C/L the
assembled with the standard height base. extended base is required. When using the
extended base, the standard base is
unthreaded from the support assembly and
discarded.

To maintain proper clearance for the diffuser
mount, EDI recommends a minimum distance of

four inches between any outlet hole and pipe
support. When a support must be relocated due 3) The extension base can be field cut to match
to the support clearance indicated, shorten rather site conditions with a hack saw (or similar).
than lengthen the support spacing. See EDI The extended base has molded in marks
layout drawing for proper pipe support spacing every two inches for ease of field measuring.
and locations. Be sure to leave enough tolerance for an
inch of vertical adjustment. Minimum
1) Drill hole for the anchor as vertical as
engagement of base into saddle cradle is two
possible and insert anchor. To assure full
threads. Clean burrs from around cut for
holding power, do not ream the hole or
ease of threading into saddle.
allow the drill to wobble. Then clean the
hole to ensure proper performance. Make
sure to get at least 3 in. of embedment, with
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EDI Aeration/Mixing Systems Installation

the slope. The pipe will fit within the lip
under support base.

4) Place extension base over 3/8 anchor stud.
Next slide the 3/8”x1” S.S. flat washer over
the anchor stud until it rests on the support
8) Place the lateral on the supports and make
base. Place the 3/8” lock washer on the flat
connections to header or subheader as
washer then thread the 3/8” nut onto anchor
required. Level pipe by lifting and rotating
stud and torque to 20 ft-lbs.
support cradle or by loosening the anchor
nut and spinning the base. Be sure to
Recommended Bolt/Nut Torque Values
retighten the anchor if this method is chosen.
Bolt Sizes Torque
3/8 inch (10 mm) 20 ft-lb (27 N-m)

9) Once leveled, slide the upper locking clamp
on the support. This is accomplished by
squeezing the KLIKLOK™ connection tabs
on the lower cradle and sliding the clamp
5) Thread lower support cradle portion onto
over the tabs by hand. Slide clamp unit it
support base to match previously determined
can no longer be moved and releases the
C/L of lateral piping. Note: this must be
tabs. Do not use any hammer or mallet to
threaded 2 full turns onto support base to
install the upper clamp.
maintain support integrity.
6) Use a laser in the basin to adjust the
threaded cradle of the SuperStrut to the field
elevation.
7) Note: For sloped floors, 2” (50mm) PVC
pipe shall be cut and used to accommodate
Page 6
EDI Aeration/Mixing Systems Installation

Rigid/Simple Pipe Support
Installation Instructions

Air laterals are anchored to the basin floor by
stainless steel pipe support assemblies (provided
by EDI).
To maintain proper clearance for the diffuser
mount, EDI recommends a minimum distance of
four inches between any outlet hole and a pipe
strap. When a support must be relocated due to
the support clearance indicated, shorten rather
than lengthen the support spacing. See EDI
layout drawing for proper pipe support spacing
and locations.

1) Connect floor mount to support bracket with
When properly installed the tabs will extend
one 3/8” x 1 1/4” (~9.5mm x ~32mm)
beyond the upper clamp.
stainless steel bolt and double 3/8”
(~9.5mm) stainless steel nuts (See
Installation Detail B). the slotted side of the
floor mount is to the floor when properly
assembled. Rest the double nuts against the
support bracket and lock against each other.
Page 7