Operating Instruction
For
KW11-Series High-performance Mixing Disinfectant
Generator
Jiangsu BODA Environmental Protection Co., Ltd
2001/2/19
Content
1. Preparation for Commissioning 2. Operating Procedure 3. Maintenance 4. Points for Attention 5. Troubleshooting
Written By:
Approved By:
1. Preparation for Commissioning
(1) Check whether the equipment is well-installed, whether the wiring of power source and electrode is correct and whether the earthing is perfect.
(2) Check whether the pipelines for water supply, water drainage, alkali drainage and liquid chlorine are connected properly.
(3) Check whether the ventilating facility in chlorine adding workshop is in normal condition.
(4) Check whether the salt for electrolyzing is prepared (as per 1.6 kg of salt for 1 kg of chlorine), whether corrosion-proof device are provided for salt-storage part.
2. Operating Procedure.
(1) Open the cover of the salt solution tank and add salt to fill in one third of its volume; Open the water inlet valve of the tank to dissolve the salt. Close the valve when the level reach to the height of baffle plate. Meanwhile remove the solution surface dirt with strainer (made of 8# galvanized iron wire).
(2) After the salt is dissolved, open brine inlet valve of the electrolyzer to dose saturated brine into its inner chamber, meanwhile open the inlet valve of the outer chamber to add tap water in. Close two valves after there is liquid overflowing from both chambers.
(3) Switch on and gradually adjust the power voltage to 12 volts to initiate electrolyzing process. Observe the changes of the electric current. When the
current rise to the rated range (this rising procedure last 3 to 8 hours), it should be adjusted and stabilized to the value that meet the need of the chlorine generation.
(4)When the power is on, open the source water (tap water ) inlet valve and adjust the flow rate to form a negative pressure in the air suction pipe of water-jet device, and protect the tap water from flowing back from the suction pipe to the electrolysis bath; meanwhile ensure a proper temperature (40℃)for the water in the cooling water drain pipe of the outer chamber in the electrolysis bath.
(5) Measure the residual chlorine in the treated water after 24 hours of operation, and adjust the voltage and current as per the measured value so as to meet the residual chlorine of various water quality.
A. residual chlorine standard for drinking water: 0.05mg/l.
B. Residual chlorine standard for hospital wastewater: 3 to 5 mg/l after one hour of contact.
(6) After 2 to 3 hours of normal operation, the equipment should undergo alkali-drainage one time. It will last 0.5 to 1 minute and for the equipment with a capacity of over 400g/h, it will last 1 to 2 minutes.
(7) After 2 to 3 hours of normal operation, the cooling water inlet valve in the electrolysis bath should be opened.
(8) For temporary closedown of the equipment, the source water valve shouldn’t be closed (it should be closed 30 minutes after closing of the equipment) to ensure that the chlorine in the inner chamber can be extracted and protect the chlorine
from escaping.
(9) For short time of closedown (below 24 hours), it’s necessary to adjust the voltage, ensuring that the electric current is 1% of the rated current.
(10) For long-time closedown, switch off and extract the residual chlorine in the inner chamber, then empty the inner and outer chamber and clean them for future operation.
(11) For closing the equipment, adjust the voltage to zero and then switch off.
3. Maintenance.
(1) For every 1 to 2 months of normal operation, the equipment should undergo cleaning one time as per following procedure: switch off, empty the inner and outer chambers, then rinse with clean water.
(2) For every half to one year of normal operation, replace the diaphragm as per following procedure: take the inner chamber out and unload the diaphragm in the diaphragm frame, clean the frame, load and weld the new diaphragm, then reset the chamber.
4. Points for Attention.
(1) As chlorine is toxic and harmful, ventilating facility should be provided in the chlorine adding room, ventilation shall be carried out 8 to 12 times every hour. FRP structure of the blower is preferred for the sake of corrosion-resistance. The blower should be located near the ground (distance to the ground within 20cm). Steel net should be provided on both sides of the wall holes for the
blower to protect the working staff.
(2) Explosion-proof lamp should be used in the chlorine adding room. (3) There should be notable “ No Smoking” mark in chlorine adding room. (4) The window fan should be turned on when the equipment is started.
(5) The positive and negative poles of the DC electrode should be connected with the positive and negative poles of the electrolysis bath correctly (the bolts should be tightened) to avoid any damage to the electrode.
(6) Washing basin and water tap should be provided in chlorine adding house. In the course of clean up, the DC power box must be protected from wetting to avoid damage to equipment. In case of wetting, measures should be taken. Only after the drying of the box can the equipment be started.
5. Troubleshooting. No. Cause Trouble Removal a. Temperature in inner Enlarge the cooling water chamber is too high. valve. b. The electric current is high. Drain out the alkali. c. Temperature in chlorine adding house is low. Increase the activation time. d. The diaphragm is not sealed well. Re-install the diaphragm. a. The pipeline is blocked. Clean the pipeline. b. The tap water pressure is Enlarge the inlet water low. pressure. c. There is air in pipeline. Excel the air out of pipeline. a. Contact defect of the two Examine the poles and tighten poles. if necessary. b. Diaphragm is blocked. Clean the inner chamber. c. The brine concentration is Add salt into the electroly low. -sis bath. 1 The chlorine out-put is insufficient. 2 No negative pre-ssure in water-jet device. The voltage of electrolysis bath is high while its current is low. 3
Operating instruction
for
Control Cabinet of the Chemical Adding System
Jiangsu BODA Environmental Protection Co., Ltd
Dec, 2000
Content
1. Flow Chart for Electric Control 2. General Description
Written By:
Approved By:
1. Flow Diagram for Electric Control
all electric devices off
off Power on switch on switch on system general breaker sub-breakers “on/off” button
on control “on/off” 2 metering pumps and 1 agitator sub-buttons are controlled manually
2. General Description.
A manual control system is employed for the chemical adding system. For control, set the system “on/off” button at “ on” mode and control each “ on/off” sub-button to realize a manual control. The power source for the control system is introduced from the control cabinet of the sewage treatment equipment. For installation, operation and points for attention, please refer to the operating instruction of the sewage treatmentplant.
Operating Instruction
for
Control Cabinet of 2×10T/H Sewage Treatment Plant
Jiangsu BODA Environmental Protection Co., Ltd
Dec, 2000
Content
1. Flow Chart for Electrical Control (of sewage treatment plant) 2. Flow Chart for Electrical Control (of sewage aeration lift system) 3. Flow Chart for Electrical Control (of filter system) 4. Flow Chart for Electrical Control (of sludge lift system) 5. System Briefing
6. Operating Procedure for Electrical Control 7. Installation and Operation 8. Points for Attention
Written by:
Approved by:
1. Flow Chart for Electrical Control (of sewage treatment plant)
2. Flow Chart for Electrical Control (of sewage aeration lift system)
3. Flow Chart for Electrical Control (of filter system)
4. Flow Chart for Electrical Control (of sludge lift system)
5.System Briefing
Computerized control system is introduced for the 2×10T/H sewage treatment plant, which employs the programmable controller made by Siemens Company as the central controller. Despite its expensiveness, the controller can operate steadily for a long time (over 0.4 million hours) and control harmoniously 3 blowers, 3 sewage lift pumps, 2 sludge lift pumps, 1 auto grit and 2 motor valves. Programmable controller is prevailing in case that there is a high requirement for the control system.
6. Operating Program for Electrical Control
(1)Timed operating style is adopted for the auto-grit and it operates for 20 minutes every 2 hours. (2) In regulating tank:
Below the low level (middle-level indicator lights off, low-level indicator lights on or lights off), 3 sewage lift pumps will not operate; On or above the middle-level, 2 sewage lift pumps and 2 blowers operate, one pump and one blower remains stand-by; Above the high level, 3 sewage lift pumps and 2 blowers operate, one blower remains stand-by. (3) In No.1 ( No.2) filter:
On or above its high level, close No.1 ( No.2) outlet motor valve, then start No.1 ( No.2) backwash pump to operate for 5 minutes, then stop the pump and open No.1 ( No.2) outlet motor valve.
(4) Timed operating style is adopted for sludge lift pump and it operates for 5 minutes every 4 hours.
(5) The control program can be adjusted according to local commissioning condition.
(6) In case of an electrical overloading, the relative electric device will stop automatically and an sound-light alarm is sounded, the stand-by device will be in position automatically. What the operator shall do is to turn off the breaker of overloaded device and switch to manual mode so as to avoid accident.
7. Installation and Operation.
(1) Connect the electrical devices with control cabinet by piped cable correctly and check whether the motors are in normal position.
(2) Check whether the input voltage is as required (U line = 380±10%). (3) Check whether every electrical device is required.
After above three checks, switch on the automatic air break switch and corresponding breakers, switch the system to “auto” mode, then system will operate automatically.
For a complete plant, the auto mode and manual mode is separated completely. In manual mode, the operation of pumps are controlled by liquid level. Please notice the liquid level and stop the pump and blower in time if necessary. For a complete plant, there are quiescent breakers which can be used to switch off the corresponding electrical device without any affect to the normal operation of the programmable controller and AC contactor. They can also be used to simulantly observe the whole control process while not operating the electrical device (only the simulation action of a level ball is needed). The
quiescent breakers also has the function of over-voltage, under-voltage and over-current protection, which make it possible to turn off the power automatically and protect the electrical devices.
8. Points for Attention
(1) Control cabinet and motor shall not share the same earthing wire with other high-voltage equipment. An independent earthing wire shall be used.
(2) Control cabinet can not be installed in a place where there is serious vibration and corrosive gas.
(3) For maintenance, the automatic air break switch should be switched off to avoid an electrical shock.
(4) For formal operation, check thoroughly whether the motors are normal, whether the electrical devices are perfect and whether the fuses are connected. (5) For formal operation, it’s necessary to measure the voltage value (line voltage Ul = 380±10%).
Operating Instruction
for
Domestic Sewage Treatment Plant
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Design Reliance 2. Process Flow 3. Process Description
4. Installation, Operation and Maintenance 5. Points for Attention
Written By:
Approved By:
1. Design Reliance.
(1) inlet water: domestic sewage from Dujiangyan Lafaji Cement Mill. (2) outlet water: comply with the emission standard required by customer. (3) capacity: 20 T/H for each set (total 2 sets).
2. Process Flow.
blower house
Source grit regulating contact oxi secondary sed- filter water well tank -dization tank imentation tank return of supernatant sludge tank backwash water backwash water
emission disinfection tank (as backwash tank)
sterilization device
3. Process Description.
(1) The sewage flows into regulating tank through grit well, where floating matter with large size is removed to protect pumps, pipes and packing from being blocked and ensure normal operation of downstream facilities. The sewage is
equalized in quantity and quality in regulating tank to ensure the balance operation of the bio-chemical treatment equipment and protect it from any shock.
Three submersible sludge pumps are provided in regulating tank (2 in operation and 1 spare) to lift the sewage into the downstream facilities. (2) The sewage then undergoes bio-chemical treatment in contact oxidization tank, which is the nucleus of the process. TDK flexible packing is provided in the tank, aeration is carried out by the perforated aeration pipes in tank bottom. With sufficient oxygen, there is large quantities of bio-membrane on the surface of packing. Organic matter is transformed, stabilized by the metabolization of micro-organisms and become harmless. The great mass of organic matter is degraded after 6 hours retention of the sewage in contact oxidization tank.
(3) The sewage then flows into secondary sedimentation tank, where the aged, shedded bio-membranes and undegraded SS are removed.
(4) Direct emission of the sludge in sedimentation tank will lead to secondary pollution as there is still many undegraded organic matter in it. It should be pumped into the sludge tank and undergo anaerobic digest. Supernatant of digested sludge will overflow into the regulating tank, and the stabilized sludge will be moved by the customer with suction dredge for further disposal. (5) The outlet water of the sedimentation tank must be filtered in order to clean the water further and to meet the customer’s requirement. Ceramsite filter material is used. Then the filtered water undergoes sterilization and flow into clean
water tank. After a period of operation, there is many SS on the filter material, which will increase the resistance of the filter bed, so it’s necessary to backwash the filter bed. Backwash pump is provided in clean water tank to wash and restore the filter bed with the water in clean water tank. The wash interval depends on inlet water quality of the filter tank.
(6) As there exists many disease germs in domestic sewage, it’s necessary for the water in filter tank to undergo sterilization before emission as per the stipulation of clause 6·11·3 under GBJ14-87 in order to avoid possible disease. Chlorine tablet is used in the sterilization device. When the water flows from filter tank into sterilization device, disinfectant in the tablet is dissolved immediately and most of disease germs will be killed. The chlorine tablet features safety and convenience. After sterilization, qualified emission will be achieved.
(7) 3 Roots blower (three-lobe, SSR model, 2 in duty and 1 standby) are used to provide the regulating tank and contact oxidization tank with oxygen. In both the air inlet and outlet of blower, mufflers are used, which can reduce the noise greatly and eliminate the possibility of noise pollution.
4. Installation, Operation and Maintenance.
(1) Check the equipment foundation to ensure that it complies with the requirement of the drawing.
(2) Lift the equipment into foundation as per the plan layout drawing and installation drawing. Observe to secure that the location and direction is right
and that the inter-space is correct. Then execute pipe connection as per installation drawing.
(3) Fill the equipment with water fully after installation and check carefully to secure that there is no leakage for the pipe connection, then conduct preservative treatment on the pipeline.
(4) Connect the pumps and blowers with relative wires of the control cabinet, switch on the cabinet. After the power is on, adjust the rotation direction of blowers, motors and pumps. Only when the rotation direction is right can the equipment be started.
(5) After the equipment is started, adjust the reflux valve of sewage pumps to ensure that the flow rate complies with the designed one. Then the equipment can be put into normal operation.
(6) A regular maintenance system should be established. Blowers, pumps and valves are the quick-wearing parts. For blowers, it’s necessary to replace the lubricating oil every 1 to 2 months and to maintain after every 10,000 hours of operation; For sewage pumps, it’s necessary to check the insulation value and maintain them every 5,000 to 8,000 hours after normal operation, and record the data.
5. Points for Attention.
(1) After the equipment is installed, the tanks should be protected from water pooling in rainy days and there shouldn’t be any heavy objects on the equipment.
(2) PLC is employed in the equipment (for details please refer to operating instruction of control cabinet) to ensure that the supply voltage of the control cabinet is 380v±10v.
(3) The grit well should be cleaned everyday to remove the floating dust and protect pumps and pipes from blockage.
(4) Blowers can not remain idle for long time in order to avoid the sludge deposition in equipment and avoid the death & shedding of bio-membrane caused by insufficient oxygen.
(5) Sludge in the sludge tank should be cleaned out with suction dredge every 3 months so as to secure the outlet water quality.
(6) Check the position of level controller in regulating tank periodically so as to secure normal operation of relative electrical devices.
Operating Instruction
For
Chemical Dosing System
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Preparation for Commissioning 2. Operating Procedure 3. Dosage of Coagulant
Written By:
Approved By:
1. Preparation for Commissioning.
(1) Check whether the equipment is installed as required, whether power wiring is correct.
(2) Check whether pipe connection is correct. (3) Check whether the chemical agent is well-prepared. (4) Check to see whether water source (tap water) is provided.
2. Operating Procedure
(1) Open No.1 valve to fill water into the chemical dissolving tank. After it is filled with 300 to 400 liter of water (it will be measured and labelled on site), close the valve.
(2) Add coagulant (aluminium chlorohydroxide) into dissolving tank till that the solution concentration is between 5% and 10%. Then start the agitator (local manual control) and stir for 0.5 to 1 hour (agitation time depends on local condition). Stop the agitator manually when the solution is well-proportioned. (3) Open the No. 2 valve to introduce the solution into solution tank for use. (4) For system operation, adjust the dosage of the metering pump, then open the No.5 valve to start the pump.
(5) After the chemical dissolving tank and chemical solution tank is purged, open the No.3 and No.4 valve to drain the purge water out.
3. Dosage of Coagulant (aluminium chlorohydroxide) Sewage Turbidity (mg/l) Dosage (mg/l) 100～500 500～1000 1000～2000 2000～3000
＜10 10～15 15～25 25～40
Operating Instruction
for
Gravitative valvedless filter
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Working Principle 2. Design Parameter 3. Flow Chart
4. Installation Requirement 5. Operating Instruction
Written By:
Approved By:
1. Working Principle.
The source water flows through inlet pipe into filter, where it goes through the filter bed gravitatively and is filtered. The filtered water then flowS into the water tank for storage through connecting pipe. When the water tank is full, the filtered water will flow into the filtered water reservoir. As the filter bed removes the SS in the water continuously, its resistance increases gradually, which leads to continuous level rise in siphon raiser tube, and when the level is equal to the siphon auxiliary pipe orifice, the water will fall into the auxiliary tube and the air in siphon falling tube will be taken away through air exhaust tube, thus create a vacuum. When the vacuum reaches to a certain degree, siphoning will take place, and the water in water tank will go through the filter bed ascendantly, conducting backwash on the filter bed. When the level of water tank falls to the orifice of siphon destruction tube, air will be suctioned into the siphon tube to break down siphoning, which brings backwash to an end. Then the filter will get into its operation of next turn.
From above we can say for this filter, the whole procedure of filtration、starting and ending of backwash and operation of next turn is conducted automatically. The automation is a hydraulic one and no personnel is needed for it. Therefore no valve is needed, no control instrument for time program or procedure program is needed for control of the whole operation.
2. Design Parameter.
(1) average filter speed: 9 meters per hour.
(2) average backwash intensity: 15 l/m2·s. (3) backwash time: 5 minutes. (4) final head loss: 1.7 meters.
(5) inlet turbidity: not more than 20 mg/l. (6) outlet turbidity: not more than 3 mg/l.
3. Flow Chart. (1) for normal operation.
source water distri filter backwash outlet water -bution tank device water tank water
(2) for backwash. backwash backwash filter siphon water dis water water tank device tube -charge tank source water distri discharge water -bution tank
4. Installation Requirement.
(1) Foundation: The surface should be strictly level. The error for elevation of four sides of a foundation must be controlled within ±5mm and the error for elevation of all foundations must be controlled within ±10mm.
(2) For installation, the levelness for water collecting trough of the valvedless filter tank should be guaranteed to ensure that it can hold water evenly.
(3) For installation of siphon raiser tube, it should be guaranteed that the head loss of valvedless filter tank is 1700 mm.
(4) For installation of inlet pipe、siphon raiser tube、siphon falling tube、auxiliary siphon tube、air exhaust pipe, etc, it should be strictly ensured that there is no leakage so as to avoid the destrution of siphon backwash in the course of backwash. The welding seam of the steel pipes and other spare parts should be smooth.
(5) The filter media should be selected with sieve strictly. As there is a certain amount of small-sized media lost in the time of trial run, the media should be filled 50 mm thicker than the designed one.
5.Operating Instruction.
(1) The water should be introduced into the steel filter tank slowly in time of its first operation or after overhaul, so as to exhaust the air out of filter media clearance and eliminate the air resistance.
(2) For operation, the siphon destruction bailer should be lowered as far as possible, observe the level of the siphon raiser tube. Record the backwash time and adjust the height of the bailer accordingly until the backwash time is fixed at about 5 minutes. Record the operation parameter of the equipment.
(3) The backwash intensity should be adjusted gradually till that the proper intensity is obtained. For it, it’s necessary to adjust the distance between the damper of backwash intensity regulator and the orifice of siphon falling tube from 1/6D (for such light filter media as smokeless coal and ceramsite) or 1/5D
(for such heavy media as quartz sand, etc) to larger distance gradually, till that a proper intensity is formed (D means the inner diameter of siphon falling tube).
(4) In case that the valvedless filter can not execute backwash automatically, open the inlet valve of the pressurized water to contact backwash compulsively, meanwhile inspect the air-tightness of siphon system.
(5) It’s necessary to check periodically the levelness of filter media and whether there is sludge ball or crack.
(6) As the service life of filter media depends on inlet water quality, it should be replaced in time when the outlet turbidity can not comply with requirement; meanwhile conduct cleaning, maintenance and corrosion-protection on the equipment.
Operating Instruction
for
Integrated Water Purifier
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Design Reliance 2. Process Flow 3. Process Flow Briefing 4. Installation
5. Operation & Maintenance 6. Points for Attention
Written by:
Approved by:
1. Design Reliance.
(1) Generally the turbidity of source water is only umpty. However in rainy season, it will rise sharply to several hundred or over one thousand. The maximum in a short period is over 2,000 mg/l. (3) Outlet turbidity requirement: ≤3 mg/l.
2. Process Flow Chart.
chemical dosing
source mixing reaction sedimentation filter water device tank tank tank qualified clean water water tank
(Note: The dotted-lined parts is integrated water-purifier.)
3. Process Flow Briefing.
The source water and coagulant is mixed fully in mixed device and the mixture then enters the integrated water purifier (as show in following diagram).
Source water flows into the reaction area of water-purifier through inlet pipe and undergoes reaction、coagulation and sedimentation. The settled sediment is drained out periodically by two sediment valves and the water enters sedimentation area via guide hole. Now turbidity of the water features flocculent aggregate. The aggregate settles along the tilting pipe into sludge area, then drained out periodically by two sludge valves (every 8 hours). The volume of sludge area is 5.8 m3 and the volume of discharge each time is about 5 m3 (the volume can be adjusted on site). The water then enters clarification & stabilization area, which leads to the level rise in this area and the water flows into water distribution tank. The turbidity in this tank should be not more than 20 mg/l.
Water in distribution tank enters the filter area through U-shape pipe and filtered by the filter bed gravitatively. The filtered clean water flows into backwash water tank for storage through connection pipe. When the water in backwash tank
reaches to a certain level, there is water flowing out from water purifier. As the filter bed removes the SS in water continuously, its resistance increases gradually, which leads to continuous level rise in siphon raiser tube, and when the level is equal to the siphon auxiliary pipe orifice, the water will fall into the auxiliary tube and the air in siphon falling tube will be taken away through air exhaust tube, thus create a vacuum. When the vacuum reaches to a certain degree, siphoning will take place, and the water in water tank will go through the filter bed ascendantly, conducting backwash on filter bed. When the level of water tank falls to the orifice of siphon destruction tube, air will be suctioned into the siphon tube to break down siphoning, which brings backwash to an end. Then the filter will get into its operation of next turn.
Backwash intensity and backwash time is controlled by the backwash intensity regulator and siphon destruction bailer respectively. The concrete intensity and time can be adjusted on site.
4. Installation
(1) Foundation: The surface should be strictly level. The error for elevation of four sides of a foundation must be controlled within ±5mm and the error for elevation of all foundations must be controlled within ±10mm.
(2) For installation, the levelness for water collecting trough of the valveless filter tank should be guaranteed to ensure that it can hold water evenly.
(3) Filter media should be laid in ascending order. It should be guaranteed that the surface of the filter bed is level. Mis-laying is forbidden to ensure reasonable
gradation of filter media.
(4) For installation of siphon raiser tube, it should be guaranteed that head loss of filter tank is 1.8 meters, that is, distance between the tank level and the maximum level in backwash front pipe is 1.8 meters.
(5) For installation of pipes, it should be guaranteed that there is no air leakage to avoid siphon destruction.
(6) After installation, inspect equipment interior to remove wastes and check carefully whether there is blockage for the perforation hole of perforated pipe.
5. Operation & Maintenance
(1) For operation, open inlet valve and the rest valves remain closed. Adjust the inlet valve, adopt a small water flow (1/2 to 1/3 of designed flow) and increase chemical dosage (1.5 to 2 times of normal dosage). Take samples from water distribution tank for analyzing. When the turbidity declines to about 20 mg/l and there is a clear mud line (observe through the viewing port), enlarge inlet valve gradually and the dosage of coagulants should be decreased to the normal one correspondingly.
(2) During the course of operation the inlet water flow shouldn’t vary greatly. The maximum flow should be controlled within 1.2 times of the designed flow. (3) Adjust the height of siphon destruction bailer to control the backwash time within 4 to 6 minutes.
(4) The backwash intensity should be adjusted gradually until a proper one is obtained.
(5) In case that equipment can not execute backwash automatically, open the inlet valve of pressurized water to contact backwash compulsively, meanwhile inspect the air-tightness of siphon system.
(6) As the service life of filter media depends on inlet water quality, it should be replaced in time when the outlet turbidity can not comply with requirement; meanwhile conduct cleaning, maintenance and corrosion-protection on the equipment.
(7) It’s suggested that equipment undergo maintenance every year. Check whether there is sediment or damage for the devices of sedimentation and reaction area, whether there is sediment and losing of filter media in filter area in order to clean and add filter media when necessary.
6. Points for Attention
(1) The period for sediment removal of water purifier should be controlled strictly. Observe to prevent the suspended mud layer from flowing into tilting-pipe area, affecting the water quality.
(2) Backwash intensity should be controlled carefully to prevent filter media from escaping. For adjusting of backwash intensity, it’s necessary to adjust the distance between the damper of backwash intensity regulator and the orifice of siphon falling tube from 1/6D to larger distance gradually, till that a proper intensity is formed (D means the inner diameter of siphon falling tube). (3) If the equipment must be kept idle for a long time, backwash should be conducted before its closedown to prevent it from blocking during next operation.
Instruction Book
for
YG-I Integrated Water Purifier
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Briefing
2. Working Principle 3. Features
4. Main Performance Figures 5. Process Flow 6. Data Sheet
7. Installation, Operation & Management 8. Drawings Attached
Written By:
Approved By:
1. Briefing
YG-I integrated automatic water purifier is a new-fashioned one developed by our company. Integrating the advanced technologies for water treatment into one and absorbing the advantage of fellow products, it makes a perfect design and combination of the purification process of reaction、sedimentation & filtration, and backwash of the filter media. This equipment is suitable for treatment of middle- and low-turbidity water from all kinds of rivers and lakes.
It possesses the advantage of compact structure, low investment and full automation, etc. For source water with a turbidity of less than 500 mg/l (shock load of 3000 mg/l in a short time), the turbidity of outlet water can be reduced to below 3 mg/l. Therefore the equipment is widely used in rural area、towns、enterprises、construction worksites and military campus, etc.
2. Working Principle.
Source water is added with coagulant and mixed in a mixing device before it flows into the purifier. In the reaction area of purifier, coagulation reaction is carried out and flocculus appears. Then after buffering, the water enters the tilting-pipe sedimentation area. By the inlet pressure the clarified water is forced into water tank and flows into filtration area gravitatively. The filtered water then enters the clean water tank for storage. Once the clean water tank is full, qualified outlet water flows out for use.
When the resistance loss in filtration area reaches to designed head loss, the water in clean water tank will flow back to the filtration area to backwash the filter bed.
The backwash water then flows into drainage well and drains out.
3. Features
(1) Well-distributed twisted PP packing in sedimentation area ensures that there is no dead spot.
(2) Automation is achieved for operation and backwash.
(3)The designed head loss can be adjusted according to source water quality, so as to guaranteed outlet water quality.
(4)Well-designed and compact structure leads to small occupying area.
4. Main Performance Figures
(1) inlet turbidity: below 500 mg/l (shock load can reach to 3000 mg/l in a short time).
(2) outlet turbidity: not more than 3 mg/l. (3) inlet pressure: over 0.08 Mpa. (4) final head loss: 1.9 meters.
5. Process Flow. (1) for normal operation.
source mixing reaction sedimenta highly-located water device (pump) area -tion area water tank
outlet clean filtration water water tank area
(Note: the dotted-lined area is integrated water purifier.) (2) for backwash.
clean filter siphon drainage discharge water tank area pipe well 6. Equipment Data Sheet. Size model YZJ-5 YZJ-10 YZJ-15 YZJ-20 YZJ-30 YZJ-40 YZJ-50 YZJ-75 YZJ-100 YZJ-120 D H D1 D2 65 D3 50 D4 D5 80 80 80 H1 H2 H3 H4 H5 H6 1800 5800 65 25 4000 1800 310 120 180 200 25 4000 1800 340 150 180 200 25 4000 1800 340 150 180 200 2200 5800 100 100 50 2400 5800 100 100 50 2800 5800 100 100 80 3200 6000 125 125 80 3700 6100 150 150 80 4000 6100 150 150 80 100 25 4000 1800 340 150 200 200 100 25 4200 1800 400 180 200 200 100 25 4300 1800 420 200 200 200 100 25 4300 1800 420 200 200 200 5200 6200 150 150 100 150 25 4400 1800 420 200 300 200 6000 6300 200 200 100 150 25 4500 1800 500 220 300 200 6500 6300 200 200 100 150 25 4500 1800 500 220 300 200
7. Installation, Operation and Management. (1) Installation.
a. In most of southern area, the equipment can be installed outdoors while in cold area, it’s preferred to be installed indoors.
b. Equipment foundation should be kept level to ensure normal operation; after pipe connection, check whether there is air leakage or water leakage.
c. After installation, inspect equipment interior to remove wasteS, check carefully whether there is blockage for the perforation hole of perforated pipe.
d. Filter media should be laid in ascending order. It should be guaranteed that the surface of the filter bed is level. Mis-laying is forbidden to secure a reasonable gradation of filter media. (2) Operation.
a. For operation, open inlet valve and the rest valves remain closed. Adjust the inlet valve, adopt a small water flow (1/2 to 1/3 of designed flow) and increase chemical dosage (1.5 to 2 times of normal dosage). Take samples in water distribution tank for analyzing. When the turbidity declines to about 20 and there is a clear mud line (observe in the viewing port), enlarge inlet valve gradually and the dosage of coagulants should be decreased to the normal one correspondingly.
b. During the course of operation, the inlet water flow shouldn’t vary greatly. The maximum flow should be controlled within 1.2 times of the designed flow. (3) management.
a. The coagulant of aluminium chlorohydroxide is preferred as it features high
efficiency and low corrosion. Because metering pump is used for dosing, the dosing pipe should be well-sealed. The amount of coagulant should be fixed as per daily demand or per-shift demand. Coagulant should be diluted before dosing.
b. For discontinuous operation of the equipment, the off-hours should not be too long (generally not over one day). When the equipment resumes operation, parts of the aged sludge should be removed in time, and enlarge the inlet flow and dosage to activate the bottom sludge, then adjust the flow to 2/3 of the designed one. When the outlet water quality is stable, gradually enlarge the inlet flow and reduce the dosage to normal value.
c. In case that the sludge pipe and sediment pipe can not operate normally, open the pressure water pipe to rinse.
d. During the course of normal operation, it’s necessary to check every half to one year whether the filter media is level, whether there is sludge balls on it, whether the perforated inlet pipe and sludge pipe is blocked.
e.The equipment should undergo corrosion-proof treatment every 3 years.
8. Drawings Attached.
Instruction Book
for
KW11 ClO2 Generator
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Briefing 2. Application
3. Main devices & Working Principle 4. Equipment Features
5. Reference Dosage for Various Conditions 6. Installation Requirement 7. Model & Specification
Written By:
Approved By:
1. Briefing
KW11 ClO2 Generator is developed by our company on the base of various disinfectant generators. It absorbs the advanced technology from USA and combines it with China’s practice. For development of it, researches and tests are conducted repeatedly on the electrode material, interspace between cathode and anode, electrolyzing area and diaphragm materials, etc. ClO2 is the chief gas generated, mixing with such strong oxidants as Cl2, O3 and H2O2, etc. These disinfectants have wide-spectrum oxidation and sterilizing ability and can kill various gemmae virus. Comparison tests certify that ClO2 has the best result as it can kill 100% of various gemmae virus in five minutes, meanwhile it can oxidize organic matters、Fe2+、Mn2+ and CN-, etc while producing no trichloro methane and chlorophenol,etc. Scientific test has demonstrated that sterilization ability of ClO2 is better than other disinfectants. Especially for sterilization of drinking water, it’s safe and reliable and widely used.
2. Application.
(1) sterilization in water works.
(2) secondary water supply of higher-rise building and sterilization of drinking water.
(3) drinking water sterilization in rural area、towns、military campus、mineral mines and railway water stations, etc.
(4) sterilization of swimming pool water and bath water.
(5) algae-removal & sterilization of cooling cycle water in such industries as
power plant and boiler, etc.
(6) sterilization and odor-removal of the reusing water. (7) wastewater sterilization.
(8) sterilization in hotels, restaurants and dinnerware. (9) apparatus sterilization in food & drink industry. (10) (11) (12) (13) (14)
pipeline sterilization in dairy and slaughter-house. hospital sewage and apparatus sterilization.
cyanogen-breakdown treatment of metal plating cyanophoric wastewater. Decolouring treatment of dying wastewater.
Dephenolization treatment of phenol-containing wastewater.
After sterilization with ClO2, all relative parameters comply with sanitary and emission standard.
3. Main Devices & Working Principle. (1) main devices.
The generator is composed of electrolysis bath, DC power source, salt dissolving bath, matching pipes, valves and instruments, etc. (2) working principle (refer to drawing attached).
Add saturated salt solution (or salt solution of given concentration) into anode chamber of electrolysis bath and switch on 12V-DC-power to initiate electrolysing. Then mixed disinfectants of ClO2, Cl2, O3 and H2O2, etc. will be generated. The negative pressure pipe of water-jet device suctions the mixed disinfectants into the water to start sterilization.
4. Equipment Features.
(1) Totality, compaction, light-weight and good-looking. (2) 5 to 7 years of service life for the anode.
(3) Controllable silicon DC power is employed, which features reliability. (4) Excellent corrosion-protection performance, the electrolysis bath is of stainless steel or PVC material.
(5) The diaphragm is well-conductive and easy of replacing.
(6) All connecti The cooling of electrolysis bath is controlled automatically by temperature. Stable and continuous operation is achieved. (7) on pipes and valves are made of ABS engineering plastics.
5. Reference Dosage for Various Conditions. condition dosage a b c d e f g gram of gas / m2 of water 0.1～1.2 0.1～0.5 2～5 0.5～2.0 10～30 20～40 30～45 (Note:
ⅠDosage for other sewage is to be tested and fixed, depending on the sewage data. Ⅱ Table symbol: a—drinking water; b—secondary water supply of higher-rise building; c—swimming pool water; d—shower water; e—bath water; f—hospital sewage; g—cyanophoric sewage.)
6. Installation Requirement.
(1) For model selection, it should be stated whether the disinfectant is for direct use or for indirect use. Connect DN2 and DN3 for indirect use and connect DN1, DN2 and DN3 for direct use.
(2) The equipment should be placed on concrete foundation with a size of (A+200)×(B+200)×100mm. Control cabinet can share the same foundation with equipment body. An inter-space of 300 mm is preferred for them.
(3) In the course of site construction for blower house, it’s necessary to take the waste crating and air vent into consideration. Besides, for a selected model, air suction shield, as well as the specification and vent position of the blower can be provided by our company.
model Speci- A B C D E A × B × H
7. Model & Specification. KW 11-1 5 1.6 0.05 220 ≤5 350×300×350 10 10 10 KW 11-2 10 1.6 0.12 220 ≤10 500×300×500 15 15 15 KW 11-3 20 1.6 0.25 220 ≤20 800×500×1200 15 15 15 KW 11-4 50 1.6 0.6 220 KW 11-5 100 1.6 1.2 220 ≤100 800 × 650 × 1200 20 20 15 KW 11-6 200 1.6 2.5 380 ≤200 1000 × 800 × 1200 20 20 15 KW 11-7 400 1.6 4.5 380 ≤400 1000 × 800 × 1250 25 25 20 KW 11-8 600 1.6 6.8 380 ≤600 1200 × 800 × 1450 25 25 20 KW 11-9 800 1.6 9.5 380 KW 11-10 1000 1.6 12.0 380 KW 11-11 2000 1.6 24.0 380 ≤2000 2400 × 1200 × 1450 40 40 20 ≤50 800 × 500 × 1200 15 15 15 ≤800 ≤1000 1600 × 800 × 1450 32 32 20 1600 × 1000 × 1450 32 32 20 F DG1 g DG2 DG3 (Note:
(1) table symbol: A—capacity (g/h); B—salt consumption (g/g of gas); C—power (YD); D—voltage (V); E—electrolysis current (A); F—measurement (mm); G—joint pipe caliber (mm).
(2) For models of over KW11-5, the interspace between equipment body and control cabinet is 300 mm preferablly.
(3) If the model with a capacity of over 2000 g/h is needed, it can be manufactured as well.
(4) The measurement of control cabinet is as follows: 100A～200A 600×450×1200 400A～800A 750×550×1400 1000A 750×550×1600 2000A 850×650×1600
Operating Instruction
for
Installation, Maintenance and Operation
of
FRP Cooling Tower
Jiangsu BODA Environmental Protection Co., Ltd
Feb 19th, 2001
Content
1. Basic Parameter 2. Circulating pump 3. Motor and Speed Reducer 4. Location 5. Installation 6. Operation and Maintenance
Written By:
Approved By:
1. Basic Parameter. (cooling) capacity
150 m3/h 43 ℃ 33 ℃ 31.5 ℃ 28 ℃ 753 MMHg
inlet water temperature
outlet water temperature
atmospheric dry bulb temperature atmospheric wet bulb temperature atmospheric pressure
2. Circulating Pump.
The flow rate and head should be guaranteed. Flowmeter should be installed in its outlet for inspection and check.
3. Motor and Speed Reducer.
(1) ambient temperature: not more than 45 ℃. (2) rated frequency: 50HZ.
(3) working mode: continuous operation. (4) rated voltage: as per label description.
(5) For installation, the motor should be fixed on the support, with the axial line remaining level. For every 2000 hours of operation, the bearing should be cleaned with gasoline and the lubricant should be replaced. In case that the bearing wears out, a new one of the same model should be replaced. If the motor must remain idle for a long time, it’s necessary to check its insulating resistance before installation to secure that the resistance is not less than one megahm. Meanwhile check periodically the compaction of motor to protect it from any loosing.
(6) For operation, the speed reducer should be lubricated. Check periodically the level of lubricating oil.
4. Location.
(1) The cooling tower should not be installed in workshop, boiler house, substation roof, roadside and the place where there is serious dust and heat emission. (2) It should be guaranteed that the suctioned air is fresh, dry with low temperature.
(3) In order to avoid that the expelled air is suctioned repeatedly, for circular counter-flow tower, the inter-space of two towers should be not less than one half of the tower diameter and kept not less than 1.5 meters.
5. Installation.
(1) Before installation, check as per the delivery list whether all spare parts are available, whether there is any damage. In case of spare parts absence and damage, contact our company for a good solution.
(2) Before installation, check strictly whether the foundation of cooling tower is constructed as per the drawing from our company, whether all the bracing surfaces are of the same level and whether embedded steel plates are level. In case of any discordance, correct in time. Only after above preparation can the installation be carried out.
(3) Installation of circular counter-flow cooling tower. a. Installation order.
Assemble the tower lower part as per numbering order: lower bracket、water inlet & outlet device, positioning water inlet & outlet as per pipe-jointing requirement、middle support、middle water inlet pipe、upper water inlet pipe、
support of packing bed、(air guide plate)、tower upper part、ladder、packing、water distribution device (including bracket, copper rod, nylon liner and water distribution head)、bracket of water-drop collector、water-drop collector、packing、blower bracket、speed reducer of motor、lug、blower lobe、shutter and water outlet pipe.
b. The lower pillar and water inlet & outlet devices should be well-welded with the embedded steel plates. The axial line of pillar should be vertical to foundation surface.
c. Place the water inlet & outlet device on foundation “B”, and place the lower pillar on foundation “A” as per its numbering order. Adjust and fix the inlet water direction by regulating the direction of flange screw hole. Correct the axial line one by one. Weld the inlet & outlet device and lower pillar firmly with foundations.
d. Assemble the lower tower part as per numbering order. Rubber gaskets should be used in joint place to prevent water leakage. The middle and upper water inlet pipe should be vertical to the upper pillar and remains equidistant with all sides of tower body.
e. The packing support should be kept level.
f. When assembling the upper part of tower, the central axial line of fan drum should be in the same line as that of central water inlet pipe. Ensure that the size of fan drum is as designed.
g. The PVC packing should be coiled around central water pipe. Avoid overdrawing and loosing. The packing of each neighbouring layer should be placed crosswise. Check the levelness of each layer. The outer-sides of each layer should contact the inner wall of tower very well.
h. For installation of water distribution pipe, check the levelness. The pipe should
be 30 to 45 degree angled with the level surface. Pores of distribution pipes should be of the same direction. Inter-space between the pipes and packing surface should be kept within 50 to 80 cm and that between the pipes and tower wall should be kept at about 40 mm. It’s OK if the packing bed can be rotated freely.
i. Install the support of water-drop collector. Fill in the water-drop collector packing only after check of levelness.
j. Check the levelness of air outlet, then fix it with the flange by bolts.
k. The blower bracket should be installed in air outlet and check the levelness. The central axial line of blower and the central axial line of fan drum should be at the same line.
l. The distance between blower lobes and tower wall of the air outlet should be even, the error should be as required, mounting angle of lobes should be uniform. It should be guaranteed that the rotating surface of lobes be vertical to the central axial line.
m. When installing the motor, the connection box should locate at the side of power source line. The cable in fan drum should be coated with plastic pipe. The connection box should be sealed with epoxy glue to conduct water protection. Only after the earthing line is provided can the power be switched on to secure safety.
n. Fix the location of feed water pipe and outlet water pipe as per concrete design drawing.
o. Rubber gaskets should be provided for all flange jointing.
p. After installation, the flange jointing of lower tower part should undergo water-proof treatment.
6. Operation and Maintenance.
(1) The cooling tower should be operated and maintained by technical personnel. (2) After installation, conduct thorough inspection of the tower to remove the wastes in pipelines、packing and surface of water-collecting device to prevent it from blockage and guarantee the normal operation.
(3) For normal operation, the equipment should undergo trial run to ensure its stability, the uniformity of water distribution and moisture-protection of motor, etc. only after its qualified trial run can the equipment be put into normal operation.
(4) The rotating speed of the water distribution device should be controlled within 8 to 10 rpm. The maximum speed should not exceed 20 rpm. The allowable error for water amount should be controlled within ±10%.
(5) During the course of operation, observe regularly whether the blower, motor, water distribution pipe and spray nozzle operates normally, whether the power, voltage, noise and oil level of gear box is normal and whether there is oil leakage and belt loosing. Adjust and correct in time if necessary.
(6) HJ-40 (GB413-64) machine oil or HL-20 gear oil should be used for gear box. Generally the box should be filled to the required level. For every one year of operation, the box should be cleaned thoroughly and filled with new oil. In special case please refer to the label marks of speed-reducer.
(7) In case that there is algae hindering the normal operation, add chlorine (4～6 mg for every liter of water) to kill them. The inlet turbidity should not more than 50 mg/l, carry out waste discharge periodically according to water condition, or conduct water quality stabilization treatment to meet special requirement.
(8) For large and medium-scale cooling tower, filtering device should be provided. The capacity of the device is about 5% of circulating water amount.
(9) For every one year of normal operation, conduct a thorough inspection to drain away the waste, to tighten the bolts and jointing parts and to re-paint the corrosion-proof layer of the metal parts.
Frequent Failure and Removal
The blower and water-distribution section of a cooling tower is liable to fail. The cause and removing method is as follows.
Troubleshooting Table
No. Trouble Cause 1. The support is not mounted as 1. Check the levelness required. (refer to 5·(3)·k & j). 2. The blower is not mounted as 2. Refer to 5·(3) and required. 5·(1). 3. The mobile & static balance of Vibration 1 body. 4. The motor shaft bends. blower. 5. The motor rotates too fast, 4. Replace the blower. which cann’t coincide with the 5. Replace the blower. speed of lobes. 6. Tighten the bolts. 6. Bolts is loose. 1. Insufficient water flow and 1. Find out the cause, insufficient water pressure. The water-distribution 2 device doesn’t rotate. 3. The upper water inlet pipe is 3. Check the obliquity not vertical, leading to leaning strictly when mounting. of the device. Rubber gasket can be used required. 2. Refer to 5·(3) ·h. remove the waste or of tower blower is not good. static balance or replace 3. Correct the mobile & Solution 2. The device is not mounted as replace the pump. 4. The device is jammed by spare to correct in case of a part or by foreign matter. small obliquity. 5. Remove the foreign matter or re-mount it in case of jamming by other spare parts. The Water-distribution 3 device leakage. distribu-tion pipe is loose. 1. Re-install and check the levelness. 1. The pipe is not mounted levelly. 2. Replace or correct the 2. The pipe is too long. pipe. The water-distribution 3. The tower loses its roundness. 4 pipe collides the tower. 4. The resin piles up in tower. 4.Remove the piled parts 5. The water inlet pipe is not in the of resin with emery wheel. tower center. 5. Correct the location of water inlet pipe. 1. The distribution device doesn’t 1. Check the distribution rotate. 2. The The 5 distributed evenly. 3. Rubber gasket is not provided 3. Use rubber gasket. for distribution head flange and 4. Refer to the solution for distribution pore flange, leading distribution to serious water escape. leak-age. device water is not distribution pore device. is 2. Remove foreign matters from distribution pipe. 3. Correct the tower body. water-distribution device and Tighten the bolts. bolts for connecting blocked. 4. Distribution device leaks. 5. Packing is blocked. 5. Remove the wastes on packing surface. 1. Adjust to rated amount. Replace the pump in case of insufficient pump head. 2. Improve tower 1. Circulating water is insufficient. sur-rounding condition, or 2. Influence of humid air reflux. 3. Influence of other heat source. The temperature of 6 outlet water rises. 5. Distribution pore is blocked. 6. Distribution rotate. device -ing condition. doesn't 5. Clean the distribution pores. 6. Check whether parts device of is 4. The suctioned air not uniform. 4. Improve tower surround change tower location. 3. Change tower location. rotat-ing distribution jammed or wears out. 1. Pre-strainer of water suction 1. Unload the strainer to pipe is blocked, The circulating water 7 declines. water-collecting insufficient. The 8 rotate. 9 rotate or under-rotates. 2. The voltage declines. 2. Adjust the voltage. 2. Motor fails. 2. Inspect the motor. 1. Replace the bearing. The blower doesn’t 1. The bearing is not good. motor doesn't 1. Electric circuit fails. 1. Inspect the circuit. tank is increase the feed water. 2. Pump fails or water in 2. Inspect the pump or clean it up. 1. Inspect or replace the 1. The motor fails. motor. 2. The blower bearing fails. 10 Over-current of motor. 3. Mono-phase operation of motor. 3. Inspect and repair. 4. The voltage declines. 4. Inspect and repair. 1. Replace the bearing. 1. The bearing fails. 2.Check the cause, then 2. The motor fails. repair or replace. 11 Abnormal noise. 3. The blower lobes are not 3.Check the cause, then balanced. adjust or replace lobes. 4. The fastening bolts are loose. 4. Check and tighten them. 1. Too much circulating water. 2. Too much.suctioned air. 3. Blockage Over-loss of water due 12 to blowing. 4. Distribution device is not replace packing. good. 5. Distribution over-rotates. 1. Too much circulating water. Water overflows from 13 lower part of tower. 3. Blockage of water outlet pipe. water outlet.
2. Too much feed water. 3.Remove the wastes in 2. Reduce the feed water. 4. Improve the distribution device device. 5. Adjust rotation speed. 1. Reduce the inlet water. or damage 1. Reduce the inlet water. 2.Adjust the mounting of angle of blower lobes. 3. Remove the blockage or 2. Replace the bearing. packing pores.
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