Prepared By: Han Kang, P.E. Reviewed By: Walid Karam, P.E. CITY OF SUNNYVALE PRIMARY TREATMENT DESIGN DESIGN INFORMATION MEMORANDUM NO. 6 GRIT REMOVAL AND GRIT HANDLING FINAL July 2014 2700 YGNACIO VALLEY ROAD SUITE 300 WALNUT CREEK, CALIFORNIA 94598 (925) 932-1710 FAX (925) 930-0208 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
CITY OF SUNNYVALE PRIMARY TREATMENT DESIGN DESIGN INFORMATION MEMORANDUM NO. 6 GRIT REMOVAL AND GRIT HANDLING TABLE OF CONTENTS Page No. 1.0 PURPOSE... 6-1 2.0 BACKGROUND... 6-1 3.0 BASIS OF DESIGN... 6-2 4.0 ELECTRICAL REQUIREMENTS... 6-4 5.0 CONTROL PHILOSOPHY OVERVIEW... 6-8 5.1 Grit Removal System Overview... 6-8 5.2 Grit Handling System Overview... 6-9 6.0 EQUIPMENT PROCUREMENT... 6-11 7.0 PRELIMINARY SYSTEM LAYOUT... 6-11 8.0 ANCILLARY FACILITIES... 6-15 8.1 Potable Water... 6-15 8.2 Utility Water... 6-15 8.3 Plant Air... 6-15 8.4 HVAC... 6-15 8.5 Fire Protection... 6-16 8.6 Drainage... 6-16 9.0 SUMMARY... 6-17 LIST OF APPENDICES A Equipment Data Sheets And Cut Sheets for Key Process Equipment B DIM Meeting 1 Minutes (March 20, 2014) C Grit Washing Equipment Selection July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx i
LIST OF TABLES Table 6.1 Design Criteria Grit Removal and Grit Handling System... 6-3 Table 6.2 Electrical Classification by Sub-Area... 6-8 LIST OF FIGURES Figure 6.1 Grit Basins Process Flow Diagram... 6-5 Figure 6.2 Grit Handling Process Flow Diagram... 6-6 Figure 6.3 Grit Pump Detailed Seal Water Supply Diagram... 6-7 Figure 6.4 Grit Basins Plan... 6-12 Figure 6.5 Grit Basin Sections... 6-13 Figure 6.6 Grit Handling Facility Plans and Sections... 6-14 July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx ii
Design Information Memorandum No. 6 GRIT REMOVAL AND GRIT HANDLING 1.0 PURPOSE The purpose of this Design Information Memorandum (DIM) is to provide the basis of design for the new grit removal and grit handling system at the City of Sunnyvale s (City s) Water Pollution Control Plant (WPCP). The grit basins remove grit material from the influent flow stream downstream of the influent pump station. The grit handling system washes the captured grit material to return organics to the flow stream and dewaters the washed grit prior to disposal. The grit removal and handling system consists of grit basins and associated channels, a grit pump station, grit washing and dewatering equipment, and a dedicated grit storage bin. 2.0 BACKGROUND As part of the Master Plan, Carollo/HDR developed a technical memorandum (TM) that presented an analysis and selection of process alternatives for preliminary treatment at the City s WPCP. Preliminary treatment processes were selected based on providing the needed improvements through buildout (2035). Key findings and recommendations from the Master Plan Preliminary Treatment TM dated March 2014 that pertain to grit removal and grit handling are as described below. Grit Removal: Implement a Eutek HeadCell system for grit removal. Design the system for target removal of grit particles with a settling velocity greater than 0.85 cm/s (12.5 gpm/sf). Provide three HeadCell grit basins. The grit removal system would have a hydraulic capacity of 58.5 million gallons per day (mgd) with one unit out of service and a design grit removal capacity of 40 mgd with all three units in service. The hydraulic capacity corresponds to the projected 2035 peak hourly flow. The grit removal capacity corresponds to the projected 2035 peak day flow and is approximately twice the ultimate average design flow rate. Grit Handling: Use flooded-suction, recessed impeller grit pumps to pump grit from the grit basins to the grit handling facility. As part of the preliminary design of the primary treatment facility, determine the level of grit particle removal that can be effectively achieved with COANDA grit washers. July 2014 - FINAL 6-1 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Implement COANDA grit washers for grit washing/dewatering if they can provide adequate removal of the grit anticipated from the HeadCell unit. If not, a cyclone/grit classifier would be implemented for grit washing/dewatering. The recommendations made as part of the Master Plan Preliminary Treatment TM were incorporated into the conceptual design of the grit removal and grit handling facilities. This DIM does not contain any deviations from the decisions and recommendations of the TM. 3.0 BASIS OF DESIGN Design criteria for the proposed grit removal and grit handling system are summarized in Table 6.1. The process flow diagrams for the proposed grit removal and grit handling systems are shown on Figure 6.1, Figure 6.2, and Figure 6.3. The grit removal system would be designed to pass a peak wet weather flow of 58.5 mgd with one basin out of service, giving each basin a hydraulic capacity of 29.3 mgd. In addition, the system would be designed to provide an overall treatment capacity of 40 mgd with all three basins in service, each with a treatment capacity of 13.3 mgd. As the flow rises above 40 mgd, the additional flow will still pass through the grit basins without adverse hydraulic impacts. However, the grit removal efficiency during that time may be reduced. All grit basins would be constructed during the initial construction phase to provide adequate capacity to accommodate increases in flow following startup. The proposed grit basin facility would consist of a common grit basin influent channel, grit basin inlet and outlet channels, grit basins, a passive bypass overflow weir, a bypass channel, a common grit basin effluent channel, and a grit pump station. Each basin would be equipped with inlet and outlet motor operated slide gates for isolation, located in the associated inlet and outlet channels. The bypass channel would include a motor operated slide gate for isolation. Stop plate guides would be provided in the inlet, outlet, and bypass channels to allow isolation of the channels for gate maintenance. The grit pump station would be a recessed area that houses six grit pumps (two per grit basin). The grit handling system would include three COANDA fine grit washers that discharge to a roll-off bin for disposal. All three grit washers are intended to be in service during normal operation at the build-out design flow. When a grit washer is out of service, the operator can take one of the following actions based on the outage duration: Keep the associated grit basin in service while draining the grit slurry continuously back to the headworks. This would be appropriate for short outages. Take the associated grit basin out of service. This would be appropriate for longer outages. July 2014 - FINAL 6-2 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Table 6.1 Flow (Buildout) Design Criteria Grit Removal and Grit Handling System Primary Treatment Design City of Sunnyvale Parameter Units Value Peak Hour mgd 58.5 Average Annual mgd 20.4 Minimum mgd 7.1 Flow (Start-up) Peak Hour mgd 39.6 Average Annual mgd 13.8 Minimum mgd 4.8 Grit Basins Type - Multi-Tray Vortex Technology - Eutek HeadCell Number - 3 duty (1) Treatment Capacity (each basin) mgd 13.3 Hydraulic Capacity (each basin) mgd 29.3 (1) Trays per Basin - 8 Tray Diameter feet 12 Target Particle Size (SES) (2) micron 103.5 Grit Pumps Type - Recessed Cup Type Impeller Number (per basin) - 2 (1+1 standby) Capacity (each) gpm 250 or 300 Power (each) HP 25 Grit Washing and Dewatering Units Type - Inverted Cone-Shaped Vortex Chamber with Stirrer and Screw Conveyor Technology - Huber COANDA, Fine Grit Washer Number - 3 duty Solids Loading Capacity (each) ton/hr 1.5 Hydraulic Capacity (each) gpm 300 July 2014 - FINAL 6-3 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Table 6.1 Grit Storage Bin Design Criteria Grit Removal and Grit Handling System Primary Treatment Design City of Sunnyvale Parameter Units Value Type - 15 Cubic Yard Roll-off Bin Number - 1 Storage Capacity, Average Flow days 4.5 (3)(4) Storage Capacity, Peak Day Flow days 1.1 (3)(4) Notes: (1) All three grit basins are intended to be in service during normal operation at the build-out design flow. However, from a hydraulic standpoint, two basins have sufficient capacity to pass the design peak hour flow at build-out (58.5 mgd). (2) Sand equivalent size. (3) All calculated values are based on buildout flow rates, unless noted otherwise. (4) Based on influent grit loading rate of 6 cf/mg for peak day, and 3 cf/mg for average day. The grit handling system would be enclosed in a building to facilitate odor control and to improve equipment longevity. The reasoning for selection of the COANDA fine grit washer, which is a modified version of the standard COANDA grit washer, is discussed in Appendix C - Grit Washing Equipment Selection. 4.0 ELECTRICAL REQUIREMENTS In general, the electrical design for the new headworks and primary treatment facilities will comply with local, state, and federal requirements. Electrical equipment and wiring methods will be in accordance with NFPA 70, National Electric Code. Areas in and around the proposed grit removal and grit handling facilities would be classified in accordance with the guidelines published in the 2012 edition of National Fire Protection Association (NFPA) 820 Standard for Fire Protection in Wastewater Treatment and Collection Facilities. The electrical area classification for each facility is summarized in Table 6.2. The motor actuators for the grit basin inlet and outlet gates would be rated for Class 1, Division 2, Group D hazardous location. The grit pump motors would be rated for Class 1, Division 2, Group D hazardous location. The grit pumps would be powered from motor control centers (MCCs) located in the headworks electrical building. The grit washer motors and other associated electrical devices would be suitable for use in unclassified areas. Each grit washer would be provided with a vendor control panel (VCP) that contains power and control devices including a motor starter, programmable logic controller (PLC), Human-Machine Interface (HMI), and other local control devices. This panel would be a NEMA 4X enclosure located in the grit handling facility. July 2014 - FINAL 6-4 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Table 6.2 Grit Basins Electrical Classification by Sub-Area Primary Treatment Design City of Sunnyvale NEC Area Description Classification (1) Grit Basins and Channels - Enclosed Space Division 1 Basin Deck Within 3 Foot, 18-inch high Envelope Around Hatches and Openings to Basin and Channels Basin Deck Beyond 3 Foot, 18-inch high Envelope Around Hatches and Openings to Basin and Channels Division 2 Unclassified Pump Station (Recessed Area) Division 2 Grit Handling Facility All Interior Spaces that House Grit Handling Equipment and Grit Storage Bin Unclassified Notes: (1) National Electric Code (NEC) Area Classification Class 1, Group D. (2) Areas not listed in the table above may be considered unclassified. 5.0 CONTROL PHILOSOPHY OVERVIEW Comments Ventilated to maintain negative pressure for odor control purposes Open to atmosphere. Equipment includes gate operators Open to atmosphere Open to atmosphere. Equipment includes pumps and motorized valves. Ventilated to maintain negative pressure for odor control purposes This section provides general control concepts for the proposed grit removal and handling systems. Specific controls for each piece of equipment and process will be determined during development of detailed control descriptions and process and instrumentation diagrams (P&IDs) during final design. Local and remote control capabilities would be provided for major process equipment. Manual controls would be provided both locally, at the equipment, and remotely. Most of the major process equipment would also be provided with automatic controls. 5.1 Grit Removal System Overview The grit removal system includes the following equipment: grit basin inlet and outlet gates, grit basin bypass gate, grit basin drain valves, grit basin fluidizing systems, and a channel level monitoring system. Local and remote controls are provided unless noted otherwise. Normal operation is in remote automatic mode where provided. Grit basins would be placed in and out of service manually (i.e., locally or remotely initiated by an operator). When a grit basin is in service, the associated fluidizing water system and duty grit pump would operate continuously. July 2014 - FINAL 6-8 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
5.1.1 Grit Basin Inlet and Outlet Gates Each grit basin would be provided with an inlet gate and an outlet gate for isolation. Each gate would be equipped with a motorized operator with provisions for local and remote manual control. The inlet and outlet gates would be open when the associated basin is in service and would be closed when it is out of service. 5.1.2 Grit Basin Bypass Gate The grit basin bypass channel would be provided with a normally closed gate. The gate would be equipped with a motorized operator with provisions for local and remote control. In remote automatic control, the gate would open automatically in the event of a high level in the grit basins influent channel to initiate bypassing the grit basins. The bypass gate would open in increments until the high liquid level alarm is cleared (i.e., liquid level drops) or until the gate reaches a full open position. The gate would remain open until manually (i.e., locally or remotely initiated by an operator) closed. 5.1.3 Basin Drain Valves Each grit basin would be provided with a drain valve off the pump suction line. Each valve would be equipped with a motorized operator with provisions for local and remote control. Normally, the drain valve would be closed. The valve would open automatically if both the associated duty and standby grit pumps fail. In addition, as part of the procedure to take a basin out of service, the valve would be opened and closed automatically to start and stop draining the associated basin, respectively. 5.1.4 Fluidizing System Each grit basin hopper would have a dedicated fluidizing system that injects water into the bottom of the grit hopper to keep collected grit in suspension. Each fluidizing water system would have a solenoid valve that would open automatically when the associated grit basin inlet gate is not fully closed. In addition, the fluidizing water system would be used to refill the basin with utility water as part of the procedure to take a basin out of service. 5.1.5 Channel Level Monitoring System The channel level monitoring system would measure liquid levels in the grit basin influent channel and transmit level data to the supervisory control and data acquisition (SCADA) system for remote monitoring. 5.2 Grit Handling System Overview The grit handling system includes the following equipment: grit pump suction valves, grit pumps, pump seal water system, grit slurry flowmeters, and grit washers. Local and remote controls would be provided unless noted otherwise. Normal operation would be in remote automatic mode. July 2014 - FINAL 6-9 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
A duty and standby pump would be provided for each grit basin. Under normal operation, the duty grit pumps would operate continuously to remove settled grit material from the grit basin hoppers. Motorized valves provided on the individual pump suction lines would operate to route flow to the duty pump. Grit slurry would be pumped to grit washers for washing, dewatering, and discharge to a common bin for disposal. The bin would be a roll-off type and receive dewatered grit from the three grit washers. Processed screenings would be collected in a separate bin. The duty and standby pumps that are associated with a grit basin would discharge into a common pipe, which would be routed to a dedicated grit washer. 5.2.1 Grit Pump Suction Valves Each grit basin would have dedicated duty and standby grit pumps. A motorized valve would be located on the individual suction line to each pump. When a grit pump is selected to be the duty pump, the associated suction valve would open and the suction valve for the selected standby pump would close. In the event of a duty pump failure, the suction valve to the standby pump would automatically open and the valve to the failed pump would close. 5.2.2 Grit Pumps Each grit basin would have dedicated duty and standby grit pumps. When a grit basin s inlet gate is not fully closed, the associated duty grit pump would run. In the event of a duty pump failure, the suction valve to the standby pump would open and the valve to the failed pump would close. After the associated suction valve is open, the standby pump would start automatically. A low-pressure switch provided in the suction piping for each pump would indicate a pipe plugging condition that would activate and alarm and stop the associated pump. An ultrasonic flow meter in the discharge header from each pair of grit pumps (acting as a flow switch) provides early detection of pipe plugging which would activate an alarm. 5.2.3 Pump Seal Water System Each pump would have an individual seal water system for its mechanical seal water supply. Each seal water system would include a solenoid isolation valve, a pressure switch, a variable area flow meter, and a manual globe valve. The solenoid valve would open when the grit pump starts and close when the pump stops through a hardwired interlock. A low-pressure condition on the seal water system would activate an alarm and stop the associated pump. 5.2.4 Grit Slurry Flowmeters The discharge header for each pair of grit pumps would include a flow meter and transmit flow data to the SCADA system for remote monitoring. July 2014 - FINAL 6-10 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
5.2.5 Grit Washers When a grit basin is in service, its duty grit pump would run continuously and would discharge to a dedicated grit washer. During this continuous feed mode, the washwater feed and the stirrer at the grit washer would cycle on and off based on timers. In addition, the grit screw at the grit washer would operate based on the grit level measured by a pressure switch; when the grit level rises and remains above the grit level start setpoint, the screw would start and when the grit level falls and remains below the grit level stop setpoint, the screw would stop. The organic valve at the grit washer would cycle between the open and closed positions based on a timer. When the feed pumping halts, the grit washer system would undergo an automatic shutdown cycle. 6.0 EQUIPMENT PROCUREMENT The technologies selected for the grit removal and grit washing/dewatering are Eutek s HeadCell and Huber s COANDA fine grit washer, respectively. Both are unique technologies that would need to be sole-sourced. Carollo recommends that their procurements be pre-negotiated with the suppliers during detailed design and their prenegotiated prices and scope of work be included in the Contract Documents. Carollo also recommends that City project staff confirm with the City s Procurement Department that the equipment can be sole sourced prior to commencing final design. The other major equipment proposed for this design including the grit pumps, slide gates, and motorized actuators may be competitively bid. 7.0 PRELIMINARY SYSTEM LAYOUT A proposed layout and its corresponding section for the grit basins are presented in Figure 6.4 and Figure 6.5, respectively. Similarly, Figure 6.6 provides the proposed layout and section for the grit handling facility. Located immediately downstream of the influent pump station and upstream of the primary sedimentation basins, the grit basins would be an elevated structure with its top deck (i.e., operating level) approximately 18 feet above grade. The grit basins and associated channels and slide gates (that rise above the deck) will be fully enclosed for odor control. Captured grit would be removed from the flow stream and grit slurry would be pumped to the grit washers that are located in the grit handling facility. July 2014 - FINAL 6-11 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
The grit handling facility could house both the grit handling equipment and the grit storage bin as well as the screenings storage bin. As a result, the building would have two-levels. The grit washers would be located at the upper level and discharge washed and dewatered grit into a roll-off bin at the lower level. The screenings washer/compactors would be located outside the building and discharge washed and dewatered screenings into a separate roll-off bin that is located at the lower level of the grit handling facility. The structure would consist of concrete walls and steel beams covered by a membrane roofing system. 8.0 ANCILLARY FACILITIES 8.1 Potable Water Potable water would not be required for the new grit basins or grit handling facility. 8.2 Utility Water Utility water (disinfected tertiary effluent) would be required for washdown purposes at both the grit basins and the grit handling facility. It would also be used for process purposes at the grit basins, including continuously fluidizing the grit basin hopper while the basin is in service to prevent grit blockages, refilling the grit basin with utility water after it is taken out of service, flushing the grit piping, and scouring the grit basin hopper as needed in case of blockages. At the grit handling facility, utility water would be supplied to the grit washers to fluidize grit slurry and wash grit particles. 8.3 Plant Air Plant air connections would be provided at each utility water station at the grit basins facility and grit handling facility. In addition, at the March 20, 2014 DIM Workshop No. 1, the City expressed a desire to have air scouring provisions (in addition to water scouring) to break up potential grit blockages in the grit basin hopper. The manufacturer of the selected grit removal technology assessed the impact of adding such air scour provisions on their equipment and recommended that compressed air be not used for this purpose due to concerns with potential re-suspension of settled grit. 8.4 HVAC The grit basins and associated channels would be ventilated to maintain negative pressure for odor control. The lower level in the grit handling facility (where the bins are located) would be ventilated for odor control and to provide a suitable work atmosphere for plant operations and maintenance (O&M) staff. The grit washing and dewatering units located at the upper level, which are considered enclosed point sources, would be ventilated for odor control. However, the general air space at the upper level of the grit handling building would July 2014 - FINAL 6-15 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
be ventilated to atmosphere. The grit pump station would be an open recessed area with no forced ventilation. Foul air withdrawn from spaces ventilated for odor control would be routed to the odor control facility for treatment. Reference DIM No. 10, Ventilation and Odor Control, for ventilation requirements, air flow diagrams, and other HVAC criteria. 8.5 Fire Protection The new headworks and primary treatment facilities will be designed to be code compliant in regard to fire protection and will undergo a detailed review by the City s Building Division during final design. Based on initial review, it is anticipated that the following fire protection measures will be required. If further fire protection measures are required by the City Building Division, they will be incorporated during final design, Fire protection requirements for occupied spaces are determined through the use the 2013 California Building Code (CBC) by determining the use and occupancy classification. However, many structures that are part of the treatment process are not occupied spaces and therefore using an occupancy classification to determine fire protection requirements is not possible. NFPA 820 also provides recommendations for fire protection for typical wastewater treatment plant locations, including facilities that are not occupied, and will be used in conjunction with the CBC to determine fire protection requirements. The grit basins are not considered an occupied space. Per NFPA 820, the materials of construction should be non-combustible and portable fire extinguishers, water hydrant protection, and combustible gas detectors in enclosed areas should be provided. To address these requirements and recommendations, portable fire extinguishers will be provided, water hydrants will be included as part of the site improvements, and combustible gas detectors will be provided in the channels. The grit handling facility is considered an occupied space with an F-2 classification. Per the CBC an automatic fire sprinkler system or fire alarm system are not required for this structure but portable fire extinguishers must be provided. Per NFPA 820, the materials of construction should be non-combustible and portable fire extinguishers, water hydrant protection, and a fire alarm system should be provided. To address these requirements and recommendations, portable fire extinguishers will be provided inside the structure, water hydrants will be included as part of the site improvements, and a fire alarm system will be provided. 8.6 Drainage Each grit basin would have drainage provisions by means of a drain line and a motorized valve. Trench drain and a sump would be provided at the grit pump station of the Grit Basins to collect wash-down water and rainwater, and flow would be routed back to the screening facility by gravity. July 2014 - FINAL 6-16 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Trench drains and floor drains would be provided throughout the grit handling facility for wash-down purposes. Process drain lines from the grit washers would also be required. Floor drains would be routed to discharge into the bar screens inlet channel. Process flow drains from the COANDA grit washers will be routed to the grit basins effluent channel. 9.0 SUMMARY The following summarizes information presented in this DIM: All the key recommendations pertaining to grit removal and grit handling included in the master plan preliminary treatment technical memorandum will be implemented. Eutek HeadCell multi-tray vortex grit basing will be used for grit removal. Huber COANDA fine grit washers would be used for grit washing and handling. Both of these technologies are unique and require sole-source procurement. The design criteria for the grit removal and grit handling systems will be in accordance with Table 6.1. Electrical equipment at the grit basins and grit handling facility will be rated in accordance with Table 6.2. Automatic control will be provided for the grit removal and grit handling systems. The frames of the slide gates that extend above the grit basin channels will be enclosed to facilitate odor control. The grit handling system and the storage bin for washed and dewatered grit will be housed in a 2-story building. It is currently envisioned that this building would also house the screenings storage bin. this will be confirmed when the site layout is further developed (DIM No. 1) The grit basins would be ventilated to maintain negative pressure for odor control. The lower level in the grit handling facility (where the bins are located) would be ventilated for odor control and to provide a suitable work atmosphere for plant O&M staff. The grit washing and dewatering units located at the upper level, which are considered enclosed point sources, would be ventilated for odor control. The general air space at the upper level of the grit handling building would be ventilated to the atmosphere. Foul air withdrawn from spaces ventilated for odor control would be routed to the odor control facility for treatment. It is anticipated that that automatic fire sprinkler systems would not be required at either the grit basins or the grit handling facility, subject to review by the City s Building Division. Water hydrant protection, portable fire extinguishers, and combustible gas detectors would be provided at the grit basins. Water hydrant protection, portable fire extinguishers, and a fire alarm system would be provided at the grit handling facility. July 2014 - FINAL 6-17 pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Design Information Memorandum No. 6 APPENDIX A EQUIPMENT DATA SHEETS AND CUT SHEETS FOR KEY PROCESS EQUIPMENT July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Design Information Memorandum No. 6 GRIT BASINS July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Carollo Engineers/HDR Equipment Selection and Data Sheet PROJECT : Sunnyvale Primary Treatment Facility Design JOB # : 9265A.10 DATE : 4/15/2014 REV: 1.0 Equip. Name : Grit Basins Location (Area): Area 05 - Grit Basins MECHANICAL Equip. Type: Multi-Tray Vortex Basins Size: 16' x 16' x 19' Connection Sizes: NA Weight: TBD lbs Capacity Max: 29.3 MGD Avg: 13.3 MGD Min: TBD Speed: NA Class - Rating: NA Service: Raw Sewage Status: New Special Requirements (if any): 1: 2: 3: ELECTRICAL/ MOTOR Horsepower : NA Motor Enclosure: NA Standby Power: NA RPM Const: 2-Speed: Reversible VFD: NA Voltage:NA NA NA NA NA Phase: NA NEC Rating Class: 1 Div: 1 Group: D Remarks: INSTRUMENTATION Normal Control Mode: Remote Auto Remarks: Refer to Operating Philosophy. NORMAL ENVIRONMENTAL CONDITIONS Site Elevation: 110 ft Inside Building: No Direct Sun: No Corrosive Area: Yes Damp Area: Yes Subject to Flooding: Yes Explosive Area: Yes Dusty: No Other: EQUIPMENT SELECTION Equipment Alternate No. 1 Equipment Alternate No. 2 Equipment Alternate No. 3 Manufacturer Hydro International Model Eutek Headcell Attention: Please reference attached catalog cut sheets. USE ADDITIONAL SHEETS FOR COMMENTS IF NECESSARY Equipment Datasheets-Sunnyvale.xls
Eutek HeadCell Advanced Stacked Tray Grit Separation Water & Wastewater Solutions Grit Removal at its Finest...
Eutek HeadCell - Stacked Tray Grit Separation The Eutek HeadCell is the ideal grit separator for both new and retrofi t applications. The Eutek HeadCell is a multiple tray separator that can be sized to remove fi ne grit over a wide range of fl ows with less than a foot of headloss. The Eutek HeadCell provides high performance with a small footprint. Applications New wastewater treatment plants Treatment plant retrofi ts Sediment removal pretreatment for potable water Grit removal for industrial effl uent Pre-treatment for MBR and many other process upgrades Advantages Large surface area in a small footprint No moving parts or external power source Less than a foot of headloss to operate Double treatment capacity in the same footprint as existing equipment Economical to own and operate How it Works Accommodates high turndown ratios The stack of hydraulically independent polyethylene trays are submerged in a concrete chamber. Screened sewage enters the influent duct and passes into the grit chamber. The influent duct directs the flow into the high efficiency distribution header to evenly distribute the influent tangentially into the modular multiple-tray system. Tangential feed establishes a vortex flow pattern causing solids to fall into a boundary layer on each tray. Grit settles out by gravity along the sloped surface of each tray and then solids are swept to the center opening which allows them to fall to a common collection sump. Degritted effluent flows out of the trays, over a weir and into an effluent trough. The HeadCell typically requires less than 12 inches of headloss. Often, the settled solids are continuously pumped from the grit sump to a Eutek SlurryCup or Eutek TeaCup grit washing system and then dewatered by a Eutek Grit Snail dewatering escalator, depending on grit load. Settling Trays Distribution Header Effluent Influent Effluent Water & Volatile Solids Influent Grit, Volatile Solids, & Water Volatile solids Grit Water Concentrated Grit & Volatile Solids Underflow (to washing) Underflow Collection Sump www.hydro-int.com Tel: (866) 615 8130
+ SlurryCup, TeaCup or GritCup washing Grit Snail or SpiraSnail dewatering HeadCell (in concrete tank) grit removal Confi gurations The Eutek HeadCell fits into existing structures and uses existing channels, which significantly reduces concrete costs during installation. A retrofitted Eutek HeadCell system can increase flow capacity and still capture finer grit in the same footprint. Inlet and outlet orientation and location can be configured to meet many design requirements. Eutek HeadCell Performance Removes 95% of particles equal to or greater than 75 microns at the design fl ow rate when used with Hydro washing and dewatering equipment Typically less than 12 inches headloss at peak fl ow Less than 15% volatile solids and greater than 60% total solids 3.14159265 - Design Notes Short settling distances eliminate ineffi ciency and increase grit capture Large surface area effectively uses plant space Evenly split fl ows eliminate short circuiting Continuous boundary layer fl ows over hydrophobic surfaces, minimizes grease buildup and keeps trays clean All-hydraulic design with no moving parts ensures a long product life Capacity Two Eutek HeadCell Units Retrofitted Into An Existing Grit Basin Sized for peak fl ow at peak grit loads Virtually no turndown ratio limits Modular and expandable combinations to fi t any size plant www.hydro-int.com Tel: (866) 615 8130
What is HX? HX is Hydro Experience, the essence of Hydro. It s interwoven into every strand of Hydro s story, from our products to our people, our engineering pedigree to our approach to business and problem-solving. HX is a stamp of quality and a mark of our commitment to optimum process performance. A Hydro solution is tried, tested and proven. There is no equivalent to Hydro HX. Water & Wastewater Solutions 2925 NW Aloclek Drive Suite 140 Hillsboro, OR 97124 Tel: (503) 615 8130 Fax: (503) 615 2906 www.hydro-int.com Grit Removal at its Finest... 2013 Hydro International. All rights reserved. V13.1
DO NOT CHANGE DUCT LAYOUT OR PIPE ORIENTATION WITHOUT CONSULTING HYDRO INTERNATIONAL PROJECTION 1. ALLOW GRIT PUMP TO FULLY DRAIN HEADCELL TANK. 2. PLANT FLOW BYPASS RECOMMENDED TO ALLOW THE HEADCELL TO BE TAKEN OUT OF SERVICE IF MAINTENANCE IS REQUIRED. 3. CLOCKWISE & COUNTERCLOCKWISE UNITS ARE AVAILABLE. 1' [0.30 m] HEADLOSS 10'-8 1/2" [3.26 m] EFFLUENT WEIR 4. ALTERNATE EFFLUENT CONFIGURATIONS ARE AVAILABLE. 5. THE GRIT PUMP SUCTION LINE SHOULD BE DESIGNED FOR A 4-7 ft/s [1.2-2.2 m/s] LINE VELOCITY. 6. FLUIDIZING WATER REQUIREMENTS 11 gpm [0.7 l/s] FOR 4', 6', AND 9' HEADCELL 20 gpm [1.3 l/s] FOR 12' HEADCELL 5'-10" [1.78 m] 12'-6" [3.80 m] 119 0-45 UNDERFLOW PIPE SUPPLIED BY OTHERS BY CONTRACTOR FLANGED CONNECTION (SEE NOTE 7) 16'-4 1/2" [4.99 m] GROUT FILL UNDERFLOW INSERT GROUTED IN PLACE DEGRITTED EFFLUENT A 6" [150mm] DIA. UNDERFLOW TO GRIT PUMP (SEE NOTE 5) 1" [25mm] DIA. FLUIDIZING SUPPLY WATER LINE (SEE NOTE 6) 4'-4" [1.32 m] INFLUENT SCREENED SEWAGE BLOCK OR STEP 16' [4.88 m] TANK ID 1'- 1/2" [0.32 m] BY CONTRACTOR BY CONTRACTOR 1'-3 1/2" [0.39 m] 18'-8 1/2" [5.70 m] EFFLUENT WEIR 16' [4.88 m] A 7. UNDERFLOW PIPE CONNCETION CAN BE SUPPLIED AT 0, 22.5, OR 45 ANGLE. Date Drawn By Title - SR 9/3/2010 FIRST RELEASE REV BY DATE DESCRIPTION REVISION HISTORY SR Checked By Scale 9/3/2010 3/16" = 1'0" Approved By EUTEK HEADCELL PROPOSAL DRAWING 12' DIAMETER 8 TRAY 212 MICRON - - w a s t e w a t e r SECTION A-A ANY WARRANTY GIVEN BY HYDRO INTERNATIONAL WILL APPLY ONLY TO THOSE ITEMS SUPPLIED BY IT. ACCORDINGLY HYDRO INTERNATIONAL CANNOT ACCEPT ANY RESPONSIBILITY FOR ANY STRUCTURE, PLANT, OR EQUIPMENT, (OR THE PERFORMANCE THERE OF) DESIGNED, BUILT, MANUFACTURED, OR SUPPLIED BY ANY THIRD PARTY. HYDRO INTERNATIONAL HAVE A POLICY OF CONTINUOUS DEVELOPMENT AND RESERVE THE RIGHT TO AMEND THE SPECIFICATION. HYDRO INTERNATIONAL CANNOT ACCEPT LIABILITY FOR PERFORMANCE OF ITS EQUIPMENT, (OR ANY PART THEREOF), IF THE EQUIPMENT IS SUBJECT TO CONDITIONS OUTSIDE ANY DESIGN SPECIFICATION. HYDRO INTERNATIONAL OWNS THE COPYRIGHT OF THIS DRAWING, WHICH IS SUPPLIED IN CONFIDENCE. IT MUST NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SUPPLIED AND MUST NOT BE REPRODUCED, IN WHOLE OR IN PART, WITHOUT PRIOR PERMISSION IN WRITING FROM HYDRO INTERNATIONAL. 2010 HYDRO INTERNATIONAL DO NOT SCALE DRAWING UNLESS OTHERWISE SPECIFIED, DIMENSIONS ARE IN INCHES. TOLERENCES ARE: FRACTIONS `1/4 DECIMALS `0.25 ANGLES `1~ Approximate Weight: 5000 LBS Finish: - Treatment: - Sheet Size: B Sheet: 1 OF1 Next Assembly: Ref. No. PROPOSAL 12' 8 Tray 212m HC - Drawing No. 2925 NW Aloclek Drive Suite 140 Hillsboro, OR 97124 Tel: (503) 615-8130 Fax: (503) 615-2906 email: sales@eutek.com - Rev
Design Information Memorandum No. 6 GRIT PUMPS July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Carollo Engineers/HDR Equipment Selection and Data Sheet PROJECT : Sunnyvale Primary Treatment Facility Design JOB # : 9265A.10 DATE : 4/15/2014 REV: 1.0 Equip. Name : Grit Pumps Location (Area): Area 05 - Grit Basins MECHANICAL Equip. Type: Recessed Impeller, Centrifugal Pump Size: 4" Discharge Connection Sizes: 4" Dis x 6" Suc Weight: TBD lbs Capacity Max: 300 gpm Avg: TBD Min: TBD Speed: 1800 rpm Class - Rating: Service: Grit Slurry Status: New Special Requirements (if any): 1: Equipped with stationary variable speed (SVS) sheaves 2: 3: ELECTRICAL/ MOTOR Horsepower : 10 Motor Enclosure: Standby Power: Yes RPM Const: 2-Speed: Reversible VFD: No Voltage: 480 1800 Yes No No Phase: 3 NEC Rating Class: 1 Div: 2 Group: D Remarks: INSTRUMENTATION Normal Control Mode: Remote Auto Remarks: Refer to Operating Philosophy. NORMAL ENVIRONMENTAL CONDITIONS Site Elevation: 110 ft Inside Building: No Direct Sun: Yes Corrosive Area: No Damp Area: No Subject to Flooding: No Explosive Area: Yes Dusty: Yes Other: EQUIPMENT SELECTION Equipment Alternate No. 1 Equipment Alternate No. 2 Equipment Alternate No. 3 Manufacturer Wemco Fairbanks Morse Morris Model Model C 4500C 5100CT Attention: Please reference attached catalog cut sheets. USE ADDITIONAL SHEETS FOR COMMENTS IF NECESSARY Equipment Datasheets-Sunnyvale.xls
WEMCO Model C Torque-Flow Pump Durability and performance unmatched by any other grit-handling vortex slurry pump Two of the most pump-punishing industries, mining and dredging, had a serious problem: In addition to wear from severe abrasives, large solids were continually clogging conventional slurry pumps. They demanded constant service to unclog them as well as frequent maintenance and parts replacement. Downtime and costs were excessive. WEMCO Pump engineers, experienced in designing pumps and mineralshandling equipment, tackled the problem. They began with the design criteria for a slurry pump, then added two unique features: (1) To totally eliminate clogging, they designed a fully recessed, cup-type impeller which would efficiently handle pipe-size solids. (2) For durability and economy they designed the impeller extra thick. The case was made in two pieces with a sacrificial suction piece which could be replaced quickly, easily, and economically. For endurance, all wet-end parts were constructed of Hi-Chrome - an alloy of greater hardness than destructive silica sand and other materials. The model C pump quickly proved its superior toughness, durability, and clog-free performance. Proven in sewage treatment plants Sewage treatment plants were having even more serious pump-clogging problems than mining and dredging. Raw sludge and sewage - contained large solids, long, fibrous materials wire, rags, cans, etc. - were strangling their pumps. Most important, highly abrasive silica sand was grinding them to pieces. When they heard about the Model C pump s reputation, they put it to the test. It proved to be the solution to their problems, as well as the toughest, most durable pump they had ever used. It still is. To this day, the Model C pump offers three benefits not available in any other single vortex pump: (1) More than 10 times longer wear life that any other vortex pump; (2) pumps pipesize solids and long, fibrous materials without clogging; and (3) operates continuously for years with only occasional oil check and inspections. Records show that Model C pumps installed back in 1955 have given continuous, trouble-free performance ever since. Today, this pump is standard equipment in virtually every sewage treatment plant. 100,000 hour minimum bearing life Replaceable high-chrome wear plate Extra thick two-piece case Up to 1 1/2 thick at wear points Fully recessed, cup-type impeller Heavy high-chrome wet-end parts, 650+ Brinell hardness Meets slurry pump design criteria From the beginning, WEMCO Model C pumps have met the exacting design criteria for a superior slurry pump. These criteria are: 1. Construct the pump with good abrasionresistant materials. 2. Provide generous wear allowances on all parts subject to abrasion. 3. Adopt hydraulic designs which minimize wear. 4. Adopt mechanical designs which are suitable for the materials of construction, and allow ready access to the wearing parts for renewal. If your application demands the type of pump prescribed above, write these design criteria into your specifications!
Abrasion-resistant Alloy Extends Pump Wear Life Original MOHS Scale Silica sand is the most common grit particle any pump must handle. It is also one of the hardest (570 Bhn), most abrasive minerals on earth. To resist this abradant, pump wear parts must be of greater hardness than silica sand. (see charts) With this in mind, Weir Specialty Pumps constructs the WEMCO Model C wet-end parts from Ni-Hard or Hi-Chrome - two of the industry s toughest, most abrasion-resistant alloys. Standard hardness ranges from 650+ Bhn. 9 8 7 6 5 4 3 2 1 Corundum Topaz Quartz Feldspar Apatite Florite Calcite Gypsum Talc Bentonite Graphite Halite Antracite Kaolin Argenite Sulfur Asphalt Potash Siderite Barite Dolemite Bauxite General Plastics 1 5 10 50 100 570 1000 2000 Brinell Scale Silica Sand Taconite Pyrite Hematite Magnetite Glass Asbestos Gray Cast Iron 316 S.S. Aluminum Bronze Brinell Hardness Austenetic Manganese Steel New Condition Work Hardens Under Impact CA 40 S.S. 28% CR Iron Martensitic White Iron Ni-Hard 15/3 Alloy 1800 1340 820 560 430 163 135 32 Knoop Scale 500 400 300 200 190 140 115 100 75 50 40 30 20 10 7.5 5 4 3 2 1 Bronze Less Hard Than Silica Sand 0-570 BNH Cast Iron Steels Model C Standard Hardness 650+ BNH Model C Extra-Tough Hardness 600-700 BNH 100 200 300 400 500 600 700 800 900 1000 Brinell Hardness Generous Wear Allowances After extensive testing and analysis of wear, each wear part s thickness has been designed specifically to the amount of abrasion it would be exposed to in actual pumping use. Wear components are up to 1 1 / 2 thick. Impeller vanes and cups are up to 600% thicker, and the case and replaceable suction piece are 100% thicker, than those of any other vortex pump. Cross-section impeller blade 1 / 2 Pump case up to 7 / 8 thick Replaceable suction piece with extra thick Ni-Hard/Hi- Chrome wear area up to 1 1 / 2 inches thick Cross-Section Model C Case and Impeller Flow Pattern Minimizes Wear Minimum 1 1/4 Tapered rim area increased to minimum 1 thickness at wear areas Replaceable Ni-hard/Hi-Chrome wear plate up to 1 inch thick
Advantages of Model C Mechanical Design The power end of the pump has a heavy duty shaft designed to pump slurries with high specific gravities. Bearings have a minimum B-10 life of 100,000 hours (equal to 11 1/2 years of continuous 24-hour service) at any point on the performance curve. In most applications bearing life is more that 200,000 hours Fully recessed cup-type impeller Replaceable high-chrome wearplate Extra thick Hi-Chrome wet-end parts Easily replaceable suction piece Oversized shaft Because the suction end of a pump is exposed to the greatest abrasive wear, we designed the case in two pieces. The replaceable suction piece is sacrificial - even though it has many times more wear-life than other vortex pumps. To replace it, you merely disconnect the suction flange from the piping, remove the slotted bolts, install the new suction piece, and you re back on stream. All within 4 hours. The cost? 65% less than a whole new case. Standard packing or optional mechanical slurry seal (no external flush) Lugged bolting for fast, easy servicing Two-piece pump case with replaceable suction piece Total Head In Feet of Water Model C Pumps Performance M 3 /HR 0 50 100 200 300 400 500 600 675 140 40 120 100 80 60 2 3 4 6 8 35 30 25 20 15 40 10 5 HP 10 HP 2 HP 1700 RPM 2000 RPM 20 HP 30 HP 1500 RPM 10 HP 20 HP 40 HP 1200 RPM 30 HP 20 HP 1200 RPM 20 0 200 400 600 800 1000 1400 1800 2200 2600 3000 U.S. GPM Total Head In Meters of Water
FAIRBANKS NIJHUIS 4500C, 4600CE AND 4700E SERIES VORTEX PUMPS www.fairbanksnijhuis.com
VORTEX PUMPS FAIRBANKS NIJHUIS 4500C 1 Case 2 Impeller 3 Suction Flange 4 Bearing Housing 5 Wear Plate 6 Gland Housing 7 Bearing Cap 9 Shaft 10 Hex Head Bolt 11 Shaft Sleeve 12 Split Gland 13 Lantern Ring* 15 Inboard Bearing 16 Outboard Bearing 17 Oil Seal 20 Retaining Ring* 21 Slinger 22 Shaft Sleeve O-Ring 24 Case Gasket 25 Bearing Cap Shim 26 Bearing Cap Shim 27 Gland Housing Gasket * 28 Packing Ring* 29 Serial Plate * 30 Drive Screw* 31 Square Shaft Key 33 Shaft Sleeve Set Screw 34 Shaft Sleeve Set Screw 36 Rubber Washer 37 Cupped Washer 40 Hex Head Bolt 41 Flat Washer 42 Square Head Nut 45 Tap End Stud 46 Hex Nut 47 Flat Washer 48 Hex Head Bolt 50 Hex Head Bolt 51 Lock Washer 54 Pipe Plug, NPTM 55 Pipe Plug, NPTM* 56 Caplug Plug, NPTM* 57 Bushing, NPTM* 58 Air Vent* 59 Tap End Stud 60 Hex Nut 61 Street Elbow, 90 NPT* 63 Cupped Washer 64 Rubber Washer 83 Street Elbow, NPT F x M* 84 Sight Window, NPT* 85 Oil Level Nameplate* 86 Plug, PP NPT* 87 Thrust Washer 90 Plug, PP NPT 98 Locking Collar 99 Socket Head Cap Screw * Not shown 4600CE 1 Case 2 Impeller 4 Bearing Housing 5 Wear Plate 6 Backplate 7 Bearing Cap 9 Shaft 10 Lockscrew, Impeller 11 Shaft Sleeve 12 Split Gland 13 Lantern Ring* 15 Thrust Bearing 16 Radial Bearing 17 Oil Seal 20 Snap Ring 21 Slinger 22 Sleeve Gasket (O-Ring) 23 Bearing Cap Gasket 24 Case Gasket (O-Ring) 28 Packing Ring* 31 Shaft Key 32 Collet 78 Sleeve Drive Key * Not shown 4700E 2 Case 3 Impeller 4 Backplate and Packing Housing 5 Bearing Housing 6 Bearing Cap 7 Shaft 8 Lockscrew, Impeller 10 Impeller Key 11 Case Gasket 12 Lantern Ring* 13 Packing Ring* 14 Split Gland 17 Shaft Sleeve 18 Sleeve Gasket Slinger (S&M) 20 Bearing Cap Gasket ** 21 Oil Seal 22 Thrust Bearing 23 Radial Bearing 26 Shaft Key 40 Snap Ring P Plug * Not shown ** Outboard gaskets not shown 2
3 www.fairbanksnijhuis.com VORTEX PUMPS Pump Features and Selection 4500C 51 50 7 17 26 37 31 9 16 15 1 3 24 99 98 Test Coupon Air Vent and Oil Fill Oil Drain Oil Level 59 55 86 51 50 7 30 84 85 56 83 25 36 47 46 45 48 60 63 64 42 58 57 61 33 22 34 11 2 10 87 5 27 13 28 6 54 90 12 21 17 24 4 41 40 4600CE 1 7 4 17 23 Oil Drain Oil Level Air Vent and Oil Fill 31 9 78 16 15 7 11 12 20 17 23 22 21 12 28 13 6 24 5 32 2 10 4700E 7 20 6 21 5 26 23 22 40 6 P 4 3 2 8 17 14 21 20 18 14 13 11 12 10
History and Development Fairbanks Nijhuis Pump leads the industry in innovative pump engineering and manufacturing with a complete line of solids handling pumps including the 5400, 5700, 2400 and VTSH Series for raw sewage, return activated, waste activated, mixed liquor and other process liquids with solids concentration up to 3%. The 4500C and 4600 CE Series hard metal vortex pump handles flows from 50 3,000 GPM and heads to 200 feet using a fully recessed impeller ideally suited for grit applications with higher concentrations of solids and sludge. Fairbanks Nijhuis Vortex Pumps Model 4500C heavy duty, slow speed high chrome iron (nominal 650 Brinell) pump with fully recessed cupped type vortex impeller with two-piece case and removable wear plate. Sizes 2", 3", 4", 6", 8" discharge with various optional suction sizes Flow rates to 3,000 gallons per minute Head to 140 feet Model 4600CE standard duty pump with high chrome iron liquid end, with fully recessed vortex impeller pump and replaceable high chrome iron wear plate. Sizes 2", 3", 4", 6" discharge Flow rates to 1,400 gallons per minute Head to 160 feet Model 4700E cast iron fully recessed vortex pump with one-piece casing (other alloys are available). Sizes 2", 3", 4", 6" discharge Flow rates to 1,800 gallons per minute Head to 200 feet NoseCone Our NoseCone kit protects your impeller hardware against erosion, corrosion and abrasion. This makes removal of the impeller far easier, reduces downtime and minimizes the need to replace these components when the pump impeller is removed for service. NoseCone also enhances hydraulic efficiency by providing a smoother passage of pumped fluid at the impeller hub. Package Options Fairbanks Nijhuis can supply many different drive configurations with your vortex pump, including motors, V-belt drive or direct coupling drive. Mounting arrangements include overhead, in-line or side-by-side configuration. Fairbanks Nijhuis Pump In addition to our vortex pumps, Fairbanks Nijhuis manufactures a broad range of pumps for public works and industrial installations, including dry pit and submersible solids handling, chopper, vertical lineshaft and submersible turbine, mixed-flow and axial-flow propeller pumps, horizontal and vertical splitcase, a complete line of FM-approved and UL Listed fire pumps (both electric motor and diesel engine driven) and domestic jet and submersible well pumps. 3601 FAIRBANKS AVENUE, KANSAS CITY, KANSAS 66106 www.fairbanksnijhuis.com Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice. FM-02-1514 02/12/13 2013 Pentair Ltd. All Rights Reserved.
SERIES 6100 TYPE CT SEVERE DUTY CUP TYPE RECESSED IMPELLER PUMPS Morris 6100_3108.indd 1 14-09-2009 14:43:44
CUP TYPE IMPELLER FOR SUPERIOR EFFICIENCY UNIQUE CUP DESIGN The Morris cup type impeller is fully recessed and located completely out of the flow path. The impeller is more efficient than comparable recessed impellers. The larger diameter and the unique cup design of the MORRIS 6100 CT impeller enable the unit to run at lower operating speeds compared to other recessed impeller pumps. The lower energy consumption translates into significant dollar savings year after year. The lower operating speed also equates to less wear and longer life than other pumps. The cup design maximizes vortex action while redirecting abrasives back into the flow path. UNIQUELY FLEXIBLE The Morris 6100 CT offers an impeller capable of operating in either direction of rotation at maximum hydraulic performance, simply by reversing the casing. This symmetrical impeller and reversible casing design offer the most flexibility for installation and reduced parts inventory. 4000 HIGHER EFFICIENCY EQUALS LOWER OPERATING COST Morris 6100 CT pumps are more efficient than comparable recessed impeller pump designs. Energy costs are significantly reduced because a given flow can be achieved at a lower motor speed. It is the properties of the impeller that make this possible. Comparative trials have shown a 4 HP difference in motor power at a duty point of 600 GPM @ 60 feet. At 5 /kwh this translates into a saving of $2000 per year over the lifetime of the pump. $ SAVINGS PER YEAR 3000 2000 1000 10 /kw Hour 5 /kw Hour 2 /kw Hour 0 0 200 400 600 800 1000 GALLONS PER MINUTE SUPERIOR WEAR RESISTANCE Morris 6100_3108.indd 3 14-09-2009 14:43:49
6100 SERIES / CUP TYPE ENSURING A LONGER LIFE IN ABRASIVE SERVICE CAST-INTEGRATED SUPPORT LEGS To minimize vibration and offer simple mounting HEAVY-DUTY SHAFT Made of high carbon steel HOOK-TYPE SHAFT SLEEVE 420 stainless steel hardened to 450 to BHN to protect the pump shaft POSITIVE LIQUID SEALING AT IMPELLER Fully confined O-ring between impeller and sleeve protects the shaft from pumpage. REPLACEABLE REAR LINER Extra thick wear surface of highchrome iron for extended wear life TAPERED ROLLER BEARINGS Minimum B-10 life of 100,000 hours STUFFING BOX Suitable for either packing or a variety of mechanical seals. Machined register fits assure concentricity with shaft. INSPECTION SIGHT GLASS & VENT For oil lubricated units STANDARD FLANGE CONNECTIONS Machined flat-faced & drilled flange connections for reliability OPTIONAL CASING VENT AND DRAIN TAPS To enhance serviceability OPTIONAL GAUGE TAPS Morris 6100_3108.indd 4 14-09-2009 14:43:50
MORRIS PUMPS BUILT FOR SUPERIOR PERFORMANCE EXTRA-HEAVY REVERSIBLE CASING Casing can be reversed for rotation in either direction. High-chrome iron construction and ample wall thickness for longer life. SUCTION COVER Extra heavy, high-chrome iron construction, removable suction cover allows easy maintenance access to pump internals. FULLY RECESSED CUP TYPE IMPELLER High-chrome iron construction for superior wear resistance and maximum solids handling. Stateof-the-art design provides higher efficiencies than other recessed impeller pumps. POSITIVE DRIVE Machined fit, straight bore, key drive provides positive torque transmission that is unavailable with other hard metal pump designs. MACHINED FITS Fully machined wet-end registered fits with confined O-rings provide positive alignment and ease of maintenance. Close tolerance minimizes wear. Morris 6100_3108.indd 5 14-09-2009 14:43:52
CUP TYPE IMPELLER FOR SUPERIOR EFFICIENCY MORRIS PUMPS BUILT FOR SUPERIOR PERFORMANCE SPECIFICATIONS 3 /h) 20 CUBIC METERS PER HOUR 40 60 80 100 200 300 400 500 700 1000 TOTAL HEAD IN FEET 180 160 140 120 100 80 60 40 20 50 45 40 35 30 25 20 15 10 5 TOTAL HEAD IN METERS 50 60 70 80 100 200 300 500 700 1000 2000 3000 5000 U.S. GALLONS PER MINUTE Morris 6100_3108.indd 7 14-09-2009 14:43:56
Design Information Memorandum No. 6 GRIT WASHERS July 2014 - FINAL pw://carollo/documents/client/ca/sunnyvale/9265a10/dims/dim 6-Grit Removal and Grit Handling.docx
Carollo Engineers/HDR Equipment Selection and Data Sheet PROJECT : Sunnyvale Primary Treatment Facility Design JOB # : 9265A.10 DATE : 4/15/2014 REV: 1.0 Equip. Name : Grit Washers Location (Area): Area 06 - Grit Handling Facility MECHANICAL Equip. Type: Vortex Chamber with Stirrer Size: 8'-3" diameter Connection Sizes: TBD Weight: TBD lbs Capacity Max: 1.5 ton/hr Avg: TBD Min: TBD Speed: NA Class - Rating: NA Service: Grit Slurry Status: New Special Requirements (if any): 1: 2: 3: ELECTRICAL/ MOTOR Horsepower : FLA = 5 Motor Enclosure: NA Standby Power: NA RPM Const: 2-Speed: Reversible VFD: NA Voltage: 480 NA NA NA NA Phase: 3 NEC Rating Class: Unclassified Div: Group: Remarks: INSTRUMENTATION Normal Control Mode: Remote Auto Remarks: Refer to Operating Philosophy. NORMAL ENVIRONMENTAL CONDITIONS Site Elevation: 110 ft Inside Building: Yes Direct Sun: No Corrosive Area: Yes Damp Area: Yes Subject to Flooding: No Explosive Area: No Dusty: No Other: EQUIPMENT SELECTION Equipment Alternate No. 1 Equipment Alternate No. 2 Equipment Alternate No. 3 Manufacturer Huber Inc Model COANDA Fine Grit Washer Attention: Please reference attached catalog cut sheets. USE ADDITIONAL SHEETS FOR COMMENTS IF NECESSARY Equipment Datasheets-Sunnyvale.xls
WASTE WATER Solutions COANDA Grit Washer RoSF 4 Grit separation, washing, dewatering in one system Reduced disposal costs Utilisation of the Coanda effect ensures high grit removal efficiency. Less than 3 % organic content High solids throughput More than 1300 installations worldwide
The situation Grit from grit traps of wastewater treatment plants The grit contained in the wastewater is usually removed in grit traps by gravity or centrifugal force to protect downstream equipment. Various different grit trap systems are available for this purpose which however separate not only the grit but frequently also many of the organic particles, dependent upon the hydraulic load (inflow). The separated particles are then pumped from the grit trap to a grit classifying unit (screw or pilgrim step classifier) which remove the solids from the flow without any differentiation. As a result, the loss on ignition of the classified grit trap material varies from 10 % to 80 % depending on the screen bar spacing and inflow. The water content of the grit trap material is accordingly high (50-80 %). The result are inevitably high costs for removal, transport and disposal, and in addition very bad hygienic conditions. Grit from sewer systems, gully waste, road refuse These raw materials are more or less contaminated with organics (sludge, leaves, etc.), but they contain also foreign matter that is similar to domestic waste (such as cans, screenings, stones, etc.), and a considerable amount of water. Additionally, the individual raw materials (grit, organics, foreign matter) vary seasonally so that their loss on ignition will range from 5 % to 80 % and their water content from 40 % to 90 %. This results in inevitably high costs for dewatering, removal, transport and disposal. Description: a inlet mixture: grit organics water b vortex chamber c COANDA Tulip d motor for rabbling device e outlet f organics removal by an electric ball valve g service water h i j k l m stirrer grit fluidized bed organics grit conveying screw washed and dewatered grit < 3% loss on ignition drain outlet Ua Ul Uk Ue Uf Ui Ug Flow diagram of a COANDA Grit Washer RoSF 4
WASTE WATER Solutions Design and function Classifying and washing in one system The COANDA Grit Washer combines grit classifying and grit washing in a single and compact unit. By using the COANDA effect the process of classifying can be combined with the process of sorting to ensure a continuously high separation efficiency and outstanding washing performance. After removal of the organic material the clean grit is removed through a classifying screw, statically dewatered and discharged into a container. The organic material left in the COANDA Grit Washer is removed from the plant also automatically but discontinuously, depending on the entire process, so that a defined separation capacity is constantly available. COANDA effect for excellent grit classifying A mixture of grit, organics and water is fed through a vortex chamber where a fast spinning rotational movement is generated. The mixture then flows down through a trumpet-shaped COANDA Tulip. The flow is diverted along the curved inner surface of the COANDA Tulip by the COANDA effect that a liquid flow is adhering to the contour of a curved surface. The flow is thus smoothly, without generation of eddies, diverted from a fast rotating vertical direction to a gradually slower rotating horizontal direction. The diagram shows the high flow velocity (red vectors) along the inner surface of the COANDA Tulip, the moderate radial velocity (green vectors) underneath the water surface and the again high velocity at the weir. The solids contained in the flow (grit particles, organic material) are then separated due to the flow diversion combined with flow velocity reduction, dependent upon the particle settling velocity, and sink down to the bottom portion of the tank. The excellent flow pattern in the COANDA Grit Washer leads to a > 95 % separation of 0.20 0.25 mm diameter grit particles. The separation degree depends on the settling velocity of the solids to be separated (due to the influence of particle density and size) so that also organic material will be separated. Fluidised bed for outstanding grit washing The separated grit is then washed, i.e. attached organic matter is separated from the mineral grit particles. This takes place in the bottom portion of the COANDA Grit Washer where a fluidised grit bed is generated. Wash water is fed into a bottom chamber that is separated from the grit washer tank by a perforated plate and a perforated rubber diaphragm. The wash water flows upwards through the diaphragm and is evenly distributed over the bottom of the tank thus generating a fluidised grit bed. Within the fluidised bed the grit particles rub against each other thus removing organics from their surfaces. This process is supported by the central stirrer keeping the particles in motion. Velocity 1.254 m/s 0.125 m/s 0.012 m/s Flow velocities in the COANDA Grit Washer RoSF 4 (measured by TU Munich) Washed grit removed at a wastewater treatment plant
WASTE WATER Solutions Options for grit washing processes Reduced disposal costs washed grit, loss on ignition < 3% 95% capture rate of 0.20 0.25 mm diameter grit particles due to the COANDA Effect and low surface overflow rate grit trap outlet to S.T.W. service water Organic content reduction to < 3% loss on ignition Dewatering of washed grit to approx. 90% dry residue grit from sewer system, road refuse transporting water The user s benefits No additional preceding screening required (e.g. < 4 mm) High grit and gravel yield Suitable for treatment of grit from sewers, gully waste, road sweepings No crushing of stones and gravel inside the plant The screw is supported on both ends for minimised wear. Separate organics discharge allows for separate further treatment of organics Large diameter screws for a high solids throughput Stainless steel stirrer and screw More than 1300 installations worldwide give proof of customer satisfaction Easy to integrate into complete treatment processes Optional grit removal even during grit feeding due to on-line grit level measurement Encapsulated, odour-free plant Installation examples Innovative technology: COANDA Grit Washer RoSF 4 size III with frost protection for outdoor installation Reduced disposal costs and improved hygienic conditions with the COANDA Grit Washer HUBER SE Industriepark Erasbach A1 D-92334 Berching Phone: + 49-84 62-201 - 0 Fax: + 49-84 62-201 - 810 info@huber.de Internet: www.huber.de Subject to technical modification 0,15 / 4 8.2010 4.2004 COANDA Grit Washer RoSF 4