Bioclere Operation and Maintenance Manual.pdf

BIOLOGICAL WASTEWATER TREATMENT SYSTEM

OPERATION & MAINTENANCE

MANUAL

SITE:

COAST GUARD STATION

TYBEE ISLAND, GA

BIOLOGICAL TREATMENT SYSTEM

Congratulations on your purchase of a Bioclere biological treatment system. The Bioclere is a modification of the classic trickling filter. Trickling filters have been used for over one hundred years for the treatment of wastewater due to their reliability and simplicity of operation.

Naturally occurring microorganisms break down waste (organic matter) in the Bioclere and create harmless byproducts, mainly: water, carbon dioxide and additional microorganisms (sludge). The sludge created in the Bioclere is automatically returned and stored in your primary settling or sludge holding tank. Therefore, the Bioclere unit(s) do NOT require pumping.

However, regular pumping of your grease trap(s) (if applicable) and primary tank(s) is required. Failure to maintain a regular pumping schedule will have an adverse impact on the biology in the Bioclere system. If pumping is ignored for an extended period it may become costly to get the system back to efficient operation.

Aquapoint recommends that the grease trap(s) and primary tank(s) are checked every 3 and 6 months respectively by a certified operator or septic hauler and pumped as needed.

For seasonal applications, pumping of the tanks should occur during mid-season to protect the microbiology in the filter. Failure to adhere to this pumping schedule will result in compromised treatment and will void the Bioclere warranty.

The Bioclere units are designed to reduce the effects of toxic substances that may enter the system from your facility. However, it is in your best interest to evaluate what is discharged to the system. Be aware of daily/weekly/monthly/annual activities and the quantities of chemicals that are being discharged. While the bacteria are resistant to many forms of toxic chemicals discharged in small quantities, large volumes or certain combinations of chemicals may have detrimental effects. Some items to be aware of include: cleaning agents, floor strippers, harsh chemicals, paints and solvents, as well as abnormal quantities of soaps and milk. If at any time you are unsure about using a particular chemical please call Aquapoint. If necessary, we will arrange a site meeting to evaluate your products.

Aquapoint wants you to have a good experience with your new Bioclere treatment system. If you treat the bugs with respect, they will treat you to decades of clean water and help to preserve the environment.

Please call our office if you have ANY questions concerning your new system.

Sincerely, AQUAPOINT

(508) 985-9050

INTRODUCTION

Refer to Section 2 of this manual to review the treatment equipment supplied by Aquapoint.

This document specifies the equipment included with each assembly, as well as the installation and operation procedures where applicable. Applicable OSHA guidelines for construction must be followed and wiring must be done in conformance with the National and Local Electrical Codes.

The following presents the requirements to allow commissioning of the Aquapoint supplied equipment.

Aquapoint BioclereTM WWTP Commissioning Requirements

Aquapoint will certify that the Aquapoint supplied equipment is operational upon successful completion of the following:

Aquapoint field commissioning reports are satisfactorily completed by Aquapoint personnel. Each checklist confirms that the equipment has been installed properly and according to Aquapoint’s procedures.

Successful operational test of each process using clean potable water.

In order for Aquapoint to deploy personnel for a plant commissioning the following conditions must be met:

1) Mechanical:

All treatment reactors and components must be installed as depicted on the site plan and according to Aquapoint’s installation instructions. This includes but is not limited to:

All treatment reactors, tank assemblies and valves, including pumps, slide rail systems, float switches, chemical feed tanks, chemical feed assemblies and chemical feed conduits with tubing (if applicable).

All inter-connective piping and pressure testing as specified in this manual.

Complete or “nearly” complete final grading around treatment tanks.

All tanks filled with potable water.

2) Electrical:

Control panel(s) installed in specified location(s).

Main breakers installed and power fed to individual control panel(s).

Field wiring between control panels and treatment reactors. This includes the installation of disconnect switches where required and wiring to junction boxes if provided.

All equipment must be ready for full operational testing before Aquapoint personnel arrive onsite.

3) People required onsite during commissioning:

Mechanical contractor to repair, modify or replace equipment as necessary.

Electrical contractor to repair, modify, replace or troubleshoot field wiring.

Site design engineer to confirm equipment is operational and meets the client’s requirements.

Individual component manufacturer’s representatives as determined necessary by

Aquapoint. Note that this will require a minimum of 2-3 weeks’ notice to schedule.

All punch list items identified at or prior to the commissioning must be addressed before Aquapoint will certify and commission the Aquapoint supplied treatment equipment.

Upon successful commissioning of the system and operator training, Aquapoint will provide the contractor the commissioning reports certifying the system has been installed and is ready to accept wastewater.

TABLE OF CONTENTS

SECTION 1.0 TREATMENT PLANT DESCRIPTION AND FUNCTION

SECTION 2.0 BIOCLERE SYSTEM SPECIFICATIONS & SCOPE OF SUPPLY

SECTION 3.0 EQUIPMENT INSTALLATION PROCEDURES AND SCHEMATICS

3.1 XERXES TANK INSTALLATION GUIDELINES

3.2 PRIMARY SETTLING & FLOW EQUALIZATION TANK DRAWINGS

3.3 BIOCLERE INSTALLATION PROCEDURE

3.4 BIOCLERE SYSTEM DESIGN CHECKLIST

3.5 BIOCLERE BASE PAD DETAIL

3.6 BIOCLERE RECYCLE LINE DETAIL

3.7 BIOCLERE 24/24-1600 UNIT DRAWING

3.8 EFFLUENT LIFT STATION INSTALLATION PROCEDURE

3.9 EFFLUENT LIFT STATION DRAWING

3.10 THREE WAY VALVE PIT DRAWING

3.11 GENERAL ARRANGEMENT DRAWING

SECTION 4.0 PLANT START UP

4.1 FLOW EQUALIZATION

4.2 PRE-AERATION

4.3 BIOCLERE

4.4 EFFLUENT LIFT STATION

SECTION 5.0 PLANT SHUT DOWN

5.1 FLOW EQUALIZATION

5.2 PRE-AERATION

5.3 BIOCLERE

5.4 EFFLUENT LIFT STATION

SECTION 6.0 MAINTENANCE & PROCESS CONTROL PROCEDURES

6.1 PRIMARY SETTLING TANK

6.2 FLOW EQUALIZATION

6.3 PRE-AERATION

6.4 BIOCLERE

6.5 EFFLUENT LIFT STATION

6.6 PROCESS CONTROL FOR BOD REMOVAL

6.7 PROCESS CONTROL FOR NITROGEN REMOVAL

6.8 RECOMMENDED FIELD TESTING

6.9 FIELD REPORTS

SECTION 7.0 TROUBLESHOOTING

SECTION 8.0 FINAL EFFLUENT QUALITY PROBLEMS

8.1 HIGH SUSPENDED SOLIDS

8.2 HIGH BOD

8.3 HIGH NH3N

8.4 HIGH NO3-N

8.5 WASTEWATER TREATMENT TOXICITY WARNING

APPENDICES

APPENDIX A: BIOCLERE ISOMETRIC DRAWINGS

APPENDIX B: CONTROL PANEL SCHEMATICS AND PLR OPERATING

INSTRUCTIONS

APPENDIX C: PURCHASERS WARRANTY

APPENDIX D: RECOMMENDED SPARE PARTS

APPENDIX E: PUMP CURVES & SLIDE RAIL ASSEMBLIES

APPENDIX F: BIOCLERE VENTILATION FAN SPECIFICATIONS

APPENDIX G: FLOAT SWITCH SPECIFICATIONS

APPENDIX H: SUBMERSIBLE AERATOR SPECIFICATIONS

APPENDIX I: THREE WAY VALVE SPECIFICATIONS

NOTE: This Technical Manual is for the use of the owner/operator and is applicable only to the specific Bioclere installation for which it is provided. The specifications in this manual are subject to change by the manufacturer any time.

1.0

DESCRIPTION & FUNCTION OF TREATMENT PLANT

3/19/2022 Proprietary & Confidential

WASTEWATER TREATMENT SYSTEM

DESIGN SPECIFICATIONS

SITE: COAST GUARD STATION – TYBEE ISLAND, GA

A Bioclere treatment plant is proposed to treat the wastewater from the Coast Guard Station in Tybee Island, GA. The system shall consist of the following components in series: (1) baffled primary settling tank, (1) aerated flow equalization tank (FET) and (1) model 24/24-1600 Bioclere unit. The system shall be capable of treating the daily design wastewater flow with the following maximum influent characteristics.

Raw Influent Settled Influent Effluent Daily Flow (gpd) 6,600 6,600 6,600 Min/Max WW Temp (C) 10-25 - -pH 6.5-8.5 6.5-8.5 6.5-8.5 BOD5 (mg/L) 300 200 < 30 TSS (mg/L) 560 280 < 30 TKN (mg/L) 65 65 - Ammonia-N (mg/L) 40 40 - Total Phosphorus (mg/L) 8-12 8-12 -

PRIMARY TREATMENT

Primary Settling & Aerated Flow Equalization Tank:

One 15,000 gallon nominal capacity primary settling and aerated flow equalization tank shall be provided to accomplish primary treatment, sludge storage, pre-denitrification and flow equalization. The tank shall contain a 10,000 gallon primary settling stage followed by a 5,000 gallon aerated flow equalization stage. A hydrostatic wall shall be installed to separate the chambers. Within the primary stage, a full wall baffle shall be installed to retain primary solids.

The tank shall be of fiberglass reinforced plastic (FRP) construction.

Flow Equalization Tank (FET) Equipment:

Primary settled wastewater shall flow by gravity to the flow equalization tank (FET) before processing in the Bioclere unit. The FET system shall consist of a 4,000 gallon minimum recommended capacity tank with the following equipment: (2) 0.4 HP submersible sewage pumps, (1) 2 HP submersible aerator, associated piping, valves, controls and appurtenances.

Five control float switches shall be located in the tank and govern the following functions:

1) Low level Alarm float: The low level alarm float will act as a redundant pump shut off and will activate an audio/visual alarm signal when the float switch is in the extended position (open circuit).

2) Lead level float: In the extended position the lead float switch shall create an open circuit and prevent operation of the pumps. When the circuit is closed the float switch shall allow activation of a fully adjustable timer and the pumps shall alternate between cycles, transferring wastewater to the downstream treatment reactor(s).

3) Lag level float: Upon closure the lag level float switch shall activate the second pump and the two pumps shall draw down the liquid in the equalization tank until the lag level float drops out again. Upon this occurrence, a counter shall be triggered to alert the operator that a high level condition has occurred and that the timer “ON” setting may need adjusting.

4) High level float: The high level float switch shall activate the audio/visual alarm when the circuit is closed.

5) Aerator timer enable float: The aerator float switch shall prevent aerator operation when in the extended position (open circuit). When tipped up (closed circuit) the float shall permit the aerator to operate on a fully adjustable cycle timer.

Timer Settings:

The FET pumps may be set between 0 and 10 minutes ON per 12 to 15 minute cycle using a fully adjustable timer in the FET control panel. This will allow the pumps to operate for a preset time (t) over 4 or 5 cycles per hour. The function is to prevent short-circuiting of wastewater through the Bioclere unit.

Additionally, the controls shall be designed to alternate pump cycles and in the event of a pump failure, the operational pump will take over all cycles until the failed pump is replaced.

A lag float counter shall total the number of lag float activations. Regular lag float activations suggest the FET timer settings are insufficient and ON time cycles should be increased. The absence of any lag float activations over several weeks shall suggest that ON time cycles can be reduced to optimize FET performance.

With the known FET pump and Bioclere recycle flow rates the operator can determine an ideal flow equalization timer setting.

Proprietary & Confidential

For Example:

1) 6,600 gpd avg. daily flow + Bioclere recycle = 6,600 + 3,000 = 9,600 gpd for processing through EQ tank.

2) 9,600 gpd / 24 hours = 400 gal/hr.

3) Assume 5 - 12 min cycles per hour.

4) 400 gal / 5 cycles per hour = 80 gal per 12 min cycle.

5) Assume 20 gpm pump rate (confirm with pump curve or draw down test)

6) 80 gal / 20 gpm = 4 min ON per 12 min cycle.

7) Ideal pump setting would be 4 min ON, 8 min OFF.

8) 20 gpm * (4 min/12 min cycle) * 1440 min/day = 9,600 gpd.

9) (9,600 gpd / 9,600 gpd) * 24 hrs = 24 hrs of flow equalization.

10) It is generally acceptable to equalize flow over 18 to 24 hrs each day.

Note that the above scenario is only an example of how to set the timers for the daily design flow rate. Lower average daily flow rates can result in shorter timer cycles and/or reduced FET forward flow rate.

Pre-Aeration & Agitation:

One (1) Subair Roto model AR 32-40 (2 HP) submersible aspirator shall be installed in the FET and shall be used to mix the basin, induce dissolved oxygen and help facilitate BOD5 reduction prior to treatment in the Bioclere unit. An aerated FET provides the following advantages.

1) Organic and nutrient load equalization. A large tank without mixing will exhibit plug flow and plug loading to the plant.

2) Facilitates BOD5 oxidation.

3) Elevates dissolved oxygen (DO) concentration.

4) Prevents the deposition of solids and the need to regularly pump the tank.

5) Prevents the occurrence of septic conditions which will promote odors and may cause treatability issues.

6) Strips off carbon dioxide which will shift the pH into a neutral range (6.5 to 8.5) and any volatile organic compounds with a weak Henry’s coefficient.

7) Provides an efficient means of agitation for chemical addition of pH control, odor control, nutrients, etc... (if required)

The submersible aerator shall be capable of delivering a minimum of approximately 4.4 lbs of oxygen/hour (0.073 lbs/min) into the wastewater. This equates to approximately 17.67 SCFM or about 33.34 SCFM/1000ft3. Using actual and standard oxidation air requirement (AOR & SOR) calculations the aerated FET shall conservatively maintain a DO of > 2 mg/l.

Proprietary & Confidential

BIOCLERE UNIT

One (1) model 24/24-1600 Bioclere unit will be required to produce an effluent with quality of <30 mg/l BOD5 and < 30 mg/l TSS.

The Bioclere consists of a trickling filter that is situated over a hopper bottom clarifier (settling tank). The trickling filter shell is manufactured with fiberglass inner and outer skins with the cavity between filled with polyurethane foam insulation for temperature stabilization and maximum treatment efficiency. The clarifier portion of the unit where the wastewater is stored is fabricated of ¼” thick fiberglass reinforced by stiffening ribs.

As wastewater is generated it will flow by gravity through the primary settling tank(s) to the FET tank where it will be time dosed to the Bioclere. Wastewater enters a center baffled chamber in the Bioclere clarifier and is then distributed to the Bioclere trickling filter by means of two alternating stainless steel submersible pumps that are situated in the center baffle. In the event of a pump failure, the operational pump automatically takes over both dosing cycles. Dosing is controlled using fully adjustable timer and the wastewater is uniformly distributed over the entire surface area of the filter by means of fixed nozzles that are constructed of nylon. Each Bioclere contains a PVC dosing array and nozzles centered above the filter media to ensure uniform dosing (Fig # 1 & 2).

Typical dosing rates are 8 min ON and 2 min OFF resulting in an approximate run time of 80% of the day. The dosing rate shall be approximately 50 gpm which amounts to 400 gal/cycle, 2,400 gal/hr and 57,600 gal/day processed through the Bioclere trickling filter.

Figure # 1: Bioclere Schematic

Proprietary & Confidential

Recirculation of sludge and wastewater is accomplished using a submersible stainless steel pump controlled by fully adjustable timer. The pump is located on the bottom of the cone shaped clarifier. The diameter of the clarifier is 8.5 feet with 60-degree sloping sides. Internal baffling is provided in the secondary settling tank to prevent short-circuiting of wastewater and biological solids. The biological solids generated in the filter are returned to the primary tank at regular intervals, typically every hour. The Bioclere recycle pump will be set to run 2 minutes ON and 45 minutes OFF (approx. 100 gallons per cycle). This equates to approximately 3,000 gpd recycled. Therefore, the sludge will not accumulate in the secondary clarifier and a sludge blanket will not form. The efficiency of the Bioclere secondary clarifier has been proven by the numerous installations and successful operating experience.

The benefits of recirculation are numerous and include: 1) removing biological sludge from the Bioclere so that only the primary tank(s) need periodic pumping, 2) diluting the influent pollutant concentrations which results in a thinner and more effective biofilm on the media bed,

3) odors are reduced in the primary tanks and the treatment components, 4) diluting biological inhibitors (cleaning agent, sanitizers, etc.) that may exist in the wastewater, 5) achieving nitrogen removal through denitrification due to the recirculation of nitrate to the recirculation tank.

The filter media consists of manufactured PVC randomly packed media. The media has a void ratio of >95%, is UV resistant and resistant to a wide range of aqueous solutions, acids, alkalis, oxidizing agents, oils, fats and alcohols (Fig # 3).

Fig # 2: Bioclere Dosing Array Fig # 3: Randomly Packed PVC Media

Forced air ventilation is provided in the Bioclere since it is a covered trickling filter. Each Bioclere contains an axial fan with an airflow capacity of 106 cfm. The fan is exposed to the atmosphere due to its enclosure location on top of the Bioclere. Air flows subsequently through the filter, underdrain and is discharged through the effluent pipe. A PVC vent is installed after each Bioclere unit.

Proprietary & Confidential

FILTER AND CLARIFIER SIZING CALCULATIONS

The media loading rates are based on over 15,000 municipal, commercial and industrial installations throughout the world and approximately 1,750 in the United States. The loading rates conform with those that are accepted by the United States Environmental Protection Agency (Nitrogen Control 1993 and Assessment of Single Stage Trickling Filter Nitrification 1991), Water Environment Federation (Biofilm Reactors, 2011) and Metcalf & Eddy, (Wastewater Engineering, 2013).

The filter media organic loading rates are based on the design criteria outlined on page 1 of this document. The media in the Bioclere unit will have a specific surface area of 160 m2/m3.

Organic Loading:

The organic loading on the Bioclere unit takes into account an approximate BOD5 reduction to 200 mg/l (33%) through the primary tank(s) (Crites & Tchobanoglous, Small & Decentralized Wastewater Management Systems, 1998). Assuming a recirculation rate of approximately 50%, the Bioclere will receive 11.76 lbs. BOD5/day based on the design flow of 6,600 gpd.

BOD5 Loading (lbs/day) = Influent from Primary Tank + Recycle

(6,600 gpd)*(8.34 lbs/gal)*(200 mg/l) + (3,000 gpd)*(8.34 lbs/gal)*(30 mg/l)

1x106 1x106

= (11.01 lbs BOD5/day) + (0.75 lbs BOD5/day) = 11.76 lbs BOD5 /day

= 5.35 kg BOD5/day

The proposed Bioclere unit (Model 24/24-1600) contains 9 m3 of PVC media (318 ft3). The specific surface area is 160 m2/m3 and the void ratio is >95%. Therefore, the media organic loading rate will be:

= 11.76 lbs. BOD5/day / (318 ft3 media) = 0.037 lbs. BOD5/ft3-day = 1.31 lbs. BOD5/m3-day = 0.59 Kg BOD5/m3-day

This loading rate will reduce the BOD5 by approximately 85% or to < 30 mg/l (Metcalf & Eddy, Wastewater Engineering 2013).

Proprietary & Confidential

Bioclere Clarifier Hydraulic & Solids Loading:

The model 24/24-1600 Bioclere secondary clarifier shall have the following characteristics:

Tank Diameter 8.5 ft Surface Area 56.7 ft2

Outlet Weir 1.6 feet (circumference of 6” Tee) Tank Volume 1600 gallons

Clarifier Design Calculations: Bioclere

Influent Flow Rate 9,600 gpd

Recycled Flow 3,000 gpd

Effluent Flow Rate 6,600 gpd

Design Surface Overflow Rate (SOR) (Influent Flow Rate / Surface Area)

169 (gpd/ft2)

Design Weir Overflow Rate (WOR) (Effluent Flow Rate / Weir Length)

4,125 (gpd/ft)

Design Hydraulic Retention Time (HRT) ((Tank Volume / Effluent Flow) * 24 hrs)

5.82 hrs

Influent Solids Load (Concentration) 280 mg/l

Anticipated TSS Removal Percentage (WEF MOP 35 Biofilm Reactors, 2011)

90%

Effluent Solids Load (Concentration) (Influent TSS * (1-Removal Percentage))

28 mg/l

Design Solids Loading Rate*

(lbs TSS / Surface Area)

0.4 (lbs/ft2/day)

The recommended SOR for secondary clarifiers based on average and peak flow is between 400- 800 gal/day/ft2 and 1000-1200 gal/day/ft2 respectively (Metcalf & Eddy, Fifth Edition 2013).

The recommended peak daily WOR’s are listed to be between 10,000 – 40,000 (gal/ft-day) with a typical value of 20,000 gal/day/ft (Metcalf & Eddy, Fifth Edition 2013, Unit Operation and Processes in Environmental Engineering 1982). The recommended solids loading for secondary clarifiers is <35 lbs/ft2/day (WEF MOP-35 Biofilm Reactors, 2011 and Metcalf & Eddy, Fifth Edition 2013). Therefore, the SOR, WOR and solids loading rates for the clarifiers are conservatively below the recommended ranges for design average and peak flow rates.

ELECTRICAL COMPONENTS & CONTROLS

AquaPoint supplied control panel(s) shall be furnished with an audio and visual alarm, exterior alarm silence button, and on/off/test switches. The alarm will sound during low and high amperage events (mechanical failure). Within the NEMA 4X enclosed panel, a programmable logic relay (PLR), Human machine interface (HMI) screen, run lights, current sensors, relays, circuit breakers and terminal strip shall be provided. An internal high temperature shut off switch shall protect each pump.

The flow equalization system shall have two alternating 0.4 HP submersible pumps, one 2 HP submersible aerator and five float switches. The flow equalization control panel shall require a 208v/3ph/60Hz supply rated at 40 amps.

The Bioclere unit shall have a ventilation fan, two alternating 0.75 HP SS submersible dosing pumps, a 0.5 HP SS submersible sludge return pump, and a low level shut off float switch. The Bioclere control panel shall require a 115v/60Hz/1ph supply rated at 30 amps.

OPERATION AND MAINTENANCE

The Bioclere units are shipped with three Technical Manuals that cover in detail all installation, and operation and maintenance procedures for the Bioclere unit. A service report detailing the regular maintenance procedures is also included in the Manual. Onsite operator training with an Aquapoint field technician is generally provided the day of installation and/or commissioning.

Proprietary & Confidential

REFERENCES

Conference on Biofilm Systems. Program and Proceedings. New York, New York. October 17-19 1999.

Crites & Tchobanoglous, Small & Decentralized Wastewater Management Systems – 1998 McGraw Hill Companies

Environmental Protection Agency, 1993. Nitrogen Control. EPA Process Design Manual, Washington, D.C.

Iwai, Shigehisa and Kitao, T., 1994. Wastewater Treatment with Microbial Films. Technomic Publishing Company.

Metcalf & Eddy, Inc., 2013. Wastewater Engineering, Treatment and Resource Recovery. New York: McGraw-Hill.

Water Environment Federation (WEF), 2011. Manual of Practice # 35 “Biofilm Reactors”. New York: McGraw-Hill.

2.0

BIOCLERE TREATMENT SYSTEM SPECIFICATIONS

& SCOPE OF SUPPLY

2.0 BIOCLERE TREATMENT SYSTEM SPECIFICATIONS & SCOPE OF SUPPLY:

2.1 BIOCLERE MODEL MEDIA QTY.

Unit 1 24/24-1600 BioFill160 9 m3

2.2 BIOCLERE EQUIPMENT SUPPLIED

ITEM QTY / UNIT

Filter Media (See Section 2.1 above) Dosing Assembly One (1) Dosing Pumps (Goulds LSP0711F) Two (2) Recycle Pump (Goulds 1DW51C0EA) One (1) Float Switch One (1) Fan Module Assembly One (1) Control Panel (NEMA 4X SS) One (1)

Installation Chain & Turnbuckle Assemblies One (1) Technical Manuals Three (3)

2.3 BIOCLERE PUMP TIMER SETTINGS:

Upon commissioning of the Bioclere system the following pump timer settings are to be utilized.

Unit 1 Dosing Pump ON 8 min Dosing Pump OFF 2 min Recycle Pump ON 2 min Recycle Pump OFF 60 min

Pre-Equalization 4 min. ON / 8 min. OFF @ + 20 gpm = 9,600 gpd

Submersible Aerator 10 min. ON / 10 min. OFF

NOTE: The above specified Pre-EQ timer settings are designed to accommodate 100% of the daily design flow (6,600 gpd) plus 50% recirculation (3,000 gpd) from the Biocleres (total of roughly 9,600 gpd processed through EQ). Subsequent to the start-up period, the EQ and recycle pump timer settings will need to be adjusted by the operator to provide proper 18 to 24 hr flow distribution for the actual average daily flow and influent characteristics. Refer to Section 6 of this manual for guidelines for determining appropriate EQ timer settings. Please contact Aquapoint as necessary before modifying the pump timers.

2.4 OTHER ITEMS SUPPLIED BY AQUAPOINT:

Item Quantity

A. Xerxes FRP Tanks:

8’ Diameter x 15,000 Gallon FRP Primary/EQ Tank One (1) 24” Diameter x 24” Tall FRP Risers One (1) 30” Diameter x 24” Tall FRP Riser Two (2) 36” Diameter x 24” Tall FRP Risers Two (2) Laminate & Adhesive Kits for Risers Five (5) Concrete Deadmen Straps and Turnbuckles Package One (1)

B. Flow Equalization Assembly:

Barnes SE421 Pumps (208-230v/1ph, 0.4 HP) w/ 4.25” Impellers Two (2) 1” x 10’ S.S. Slide Rails Four (4) BERS 0200 Slide Rail Assemblies Two (2) SubAir Roto AR 32-40 Submersible Aerator (230v/3ph, 2 HP) One (1)

FRP Top Rail Bracket One (1) SJE Rhombus Float Switches & Weights Five (5) 304 S.S. Float Bracket One (1) 304 S.S. Installation Hardware Included

3/16” S.S. Lifting Chains Three (3) 2” Schd 40 PVC True Union Check Valves Two (2) 2” Schd 80 PVC Gate Valves Two (2)

1.5” Pipe Grommets Three (3) 2” Pipe Grommet One (1)

4” Pipe Grommet One (1) 208v/3ph/60Hz PLR EQ Control Panel (NEMA 4X SS) One (1)

C. Effluent Lift Station Assembly:

5’ Dia x 12’ 3” OAH FRP Lift Station One (1) Barnes SE421 Pumps (208-230v/1ph, 0.4 HP) w/ 4.50” Impellers Two (2)

1” x 10’ S.S. Slide Rails (Pre-Installed) Four (4) BERS 0200 Slide Rail Assemblies (Pre-Installed) Two (2) SJE Rhombus Float Switches & Weights Four (4) 304 S.S. Float Bracket (Pre-Installed) One (1)

3/16” S.S. Lifting Chains Two (2) 5’ Dia x 3’ 0” OAH FRP Valve Vault One (1) 2” Schd 40 PVC True Union Check Valves (Pre-Installed) Two (2) 2” Schd 80 PVC Gate Valves (Pre-Installed) Two (2)

2” Valworx 565716C Three Way Valve (Pre-Installed) One (1) 1.5” Pipe Grommets Three (3) 208v/1ph/60Hz PLR EQ Control Panel (NEMA 4X SS) One (1)

2.5 PRIMARY TANK:

The system was designed with a 15,000 gallon primary settling / flow equalization tank with the primary tank being approximately 10,000 gallons and the EQ tank approximately 5,000 gallons. Aquapoint recommends that the primary tank be inspected quarterly or semi-annually by a certified operator or septic hauler for sludge and scum and pumped as needed.

2.6 GREASE TRAPS (IF APPLICABLE):

Aquapoint recommends, if applicable, that the grease trap be inspected and pumped every 3 months.

NOTE: Inadequate pumping of grease traps and primary tanks will have a detrimental effect on biological treatment. Therefore, it is imperative that pumping schedules are followed.

3.0

EQUIPMENT INSTALLATION PROCEDURES AND SCHEMATICS

3.1

XERXES TANK INSTALLATION GUIDELINES

Installation Manual and Operating Guidelines www.xerxes.com

INSTALLATION MANUAL AND OPERATING GUIDELINES

TABLE OF CONTENTS

SECTIONS

1. Introduction

2. Handling and Storing Tanks

3. Preinstallation Inspection and Testing

4. Preinstallation Testing for Specific Types of Air-Testable Tanks

5. Installing Tanks

6. Backfill Material

7. Excavation Requirements

8. Anchoring

9. Geotextile Fabric

9.1 General

10. Bottom Sumps and Fittings

10.1 General

11. Taking Diameter Measurements

12. Ballasting Tanks (adding Liquid)

12.1 General

13. Postinstallation Testing

14. Piping and Venting

15. Monitoring Tanks

16. Installing Containment Sumps

17. Adding Tanks at Existing Locations

18. Operating Guidelines

19. Limited Warranties

19.1 General

20. Supplemental Materials

20.1 General

21. Retention of Installation Manual

21.1 General

22. Use of Tank Data Charts (Appendix A & B)

APPENDICES

Installation Checklist

XERXES INSTALLATION MANUAL AND OPERATING GUIDELINES

Read all instructions, supplemental materials and operating guidelines before installation.

Compliance with the installation instructions and operating guidelines contained in this Installation Manual and Operating Guidelines are necessary for the proper installation, maintenance and use of our tanks and accessories.

Supplemental materials referenced in SECTION 20 may also be necessary to consult for proper installation of some tanks. Failure to comply will void our obligations under the applicable limited warranty for the tank(s) and could result in death, serious injury, property damage or tank failure.

To Installer: Before installation, read and understand the Installation Manual and Operating Guidelines (subsequently referred to as Installation Manual) and any applicable supplemental materials. After installation, deliver the Installation Manual with the completed Tank Installation Checklist (back of manual) to the tank owner.

To Owner: After installation, retain the limited warranty, Installation Manual and checklist for future reference and follow all operating guidelines in the Installation Manual.

1. INTRODUCTION

1.1. SAFETY

1.1.1. Before beginning the tank installation, read through

the entire Installation Manual and Operating Guidelines (subsequently referred to as Installation Manual) and any applicable supplemental materials. It is the responsibility of the owner, installer and operator to understand and follow all requirements contained in this Installation Manual.

1.1.2. Work must be performed according to standard

industry practices applicable to tank installations and operations.

1.1.3. Work must comply with all codes, regulations and

standards of appropriate governmental agencies, such as:

• construction, health, safety and environmental codes

• National Fire Protection Association standards (for example, NFPA 30, 30A and 31)

• industry standard practices (for example, PEI RP100, API RP1615).

1.1.4. For additional information, contact appropriate govern-mental agency storage tank authorities, including health, fire or building departments, and environmental agencies.

1.1.5. The following definitions will apply when reading

the Installation Manual:

Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury.

Notice indicates information considered important but not hazard related. Failure to heed this notice could result in property damage.

1.1.6. Keep this Installation Manual available at the installation site to refer to safety procedures as needed.

Follow OSHA regulations for tank excavations. Collapse of excavation walls could result in death or serious injury.

1.1.7. Working in and around excavations is dangerous.

Prior to beginning work at the site, the installer must follow any governmental or other codes and/or regulations applicable to excavation.

1.1.8. Careless activity or reckless operation of equipment

can cause death, serious injury or property damage.

1.1.9. Governmental agency codes, regulations and standards

always take precedence over our requirement.

1.1.10. No instructions or procedures presented in this

Installation Manual should be interpreted so as to put at risk any person’s health or safety, or to harm any property or the environment.

1.2. GENERAL

1.2.1. It is important to follow the procedures and instruc-

tions in this manual in order to safely and properly install our underground storage tank and accessories. Failure to follow these instructions will void our obligations under the limited warranty, could result in death, serious personal injury, property damage or tank failure.

1.2.1.1. The presence of our representative does not

relieve the installer of having sole responsibility for proper tank installation.

1.2.2. Our limited warranty applies only to a tank installed

according to these instructions. Since we do not control the parameters of any installation, our sole responsibility in any installation is that presented in the limited warranty.

1.2.3. It is the responsibility of the owner and operator

to always follow the operating guidelines set forth in our applicable limited warranty.

NOTICE

1.2.4. It is the responsibility of the owner and operator to

always follow the operating guidelines set forth in SECTION 18 of this Installation Manual.

1.2.5. It is the responsibility of the owner to retain the

limited warranty and Installation Manual provided with the tank for future reference.

1.2.5.1. A copy of the current limited warranty is available

on our website. The address can be found on the back cover of this manual.

1.2.6. Use the Tank Installation Checklist (back of Installation Manual) for all underground storage tanks throughout installation process.

1.2.7. Record the relevant information for each tank installed on the Tank Installation Checklist found at the back of the Installation Manual. Additional copies are available on our website.

1.2.8. Tank installer must retain a copy of the completed

Tank Installation Checklist and provide tank owner with a copy in order to facilitate any warranty claim.

1.2.9. Any variation to, or deviation from, the instructions

in the Installation Manual must be approved in writing from us prior to the tank installation.

1.2.9.1. All correspondence regarding any variances must

be retained in the event of a future warranty claim.

1.2.10. For any questions regarding the interpretation

of these instructions or for any other technical inquiries, contact technical support.

1.2.11. All contact information applicable to installation is found on the back cover of this Installation Manual.

1.3. EQUIPMENT

1.3.1. The following list is to be used as a guide for the

equipment recommended for installing tanks:

1.3.1.1. excavation equipment capable of producing a level-bottom hole and placing backfill material at any point in the excavation

1.3.1.2. suitable lifting equipment capable of lifting and placing the tanks and associated tank anchors

1.3.1.3. spirit level or transit

1.3.1.4. 50-foot [15-metre] tape measure

1.3.1.5. tamping rod(s)

1.3.1.6. pipe wrenches and appropriate pipe joint compound

1.3.1.7. a test manifold for each air-testable tank or compartment—see FIGURE 3-2

1.3.1.8. source of pressurized air capable of 6 psig [40 kPa]

1.3.1.9. soap and water solution (during freezing conditions, a suitable solution such as windshield wiper fluid may be added to the soap and water mixture)

1.3.1.10. soft cloth, brush or hand-held pneumatic sprayer

1.3.1.11. hand shovel

1.3.1.12. lifting sling(s)

1.3.1.13. soil compacting equipment (if necessary).

2. HANDLING AND STORING TANKS

2.1. GENERAL

2.1.1. Although our tanks are rugged, the tank owner and/

or tank owner’s representative must take care of the tank so that it is not dropped or damaged during loading, unloading, handling and storage at the jobsite.

2.1.2. Move tanks by lifting and setting only. Do not move

tanks by rolling or dragging.

2.1.3. Always lift tanks by using the lifting lugs provided

with the tank. Distribute the lifting load evenly between the lifting lugs. Use spreader bars and equal length slings as required.

NOTE: Larger tanks may be provided with guide lugs for attachment of guide ropes during lifting and positioning operations. Do not use guide lugs for lifting.

Never roll, drag or drop the tank. This could result in damage to the tank.

2.2. UNLOADING,HOISTING AND GUIDING TANKS

2.2.1. Before the tank is unloaded or relocated on the job-

site (and before preinstallation testing at the jobsite), tank owner and/or tank owner’s representative must complete the following steps:

2.2.1.1. Visually inspect the entire exterior surface of the

tank to make sure that no shipping or handling damage has occurred. Look particularly for visible damage, cracks or deep scrapes.

2.2.1.2. Sign the shipping papers accepting the tank as

delivered. Any damage observed must be noted in these papers.

2.2.1.3. Be sure that all equipment used to lift the tank is

rated to handle the load. Refer to Appendix A and/or B for weights.

2.2.1.4. Select a smooth, solid, level area on which to

place the tank, and clear that area of all large rocks, trash and debris.

2.2.1.5. Make sure that all tools and other items that may

damage the tank during unloading are removed from the trailer bed.

2.2.2. When unloading the tank from the truck, tank

owner and/or tank owner’s representative must make sure that the tank is secured in such a way that it does not roll off the truck.

Do not release straps securing the tank to the truck until lifting equipment (such as a crane) is secured to the tank’s lifting lug(s) and until anyone in a position to be injured by the tank’s movement is in a safe location.

Failure to do so could result in death, serious injury or property damage.

2.2.3. When hoisting and guiding the tank, follow these

instructions—see FIGURE 2-1, FIGURE 2-2 and FIGURE 2-3:

2.2.3.1. Choose suitable lifting sling(s) for the tank being

installed.

2.2.3.2. When using multiple lifting lugs, the angle of the

lifting sling should never exceed 30 degrees—see FIGURE 2-1.

FIGURE 2-1

2.2.3.3. When the tank is not rotated (the tank is upright), use all lifting lugs to unload and install the tank. See FIGURE 2-2.

2.2.3.4. Some tanks are rotated on the truck for shipping

purposes. These tanks have extra lifting lug(s) to aid in the loading/unloading process. See FIGURE 2-2.

2.2.3.4.1. Use the lifting lugs that are situated on top of

the tank in its rotated position to offload the tank from the truck and place it on the ground.

2.2.3.4.2. To install the tank, carefully rotate the tank to

its upright position and then use all lifting lugs situated on top of the tank in its upright position. See FIGURE 2-2.

FIGURE 2-2

2.2.4. Do not wrap chain or cable around the tank at any

time, including when securing the tank on the ground.

2.2.5. Use guide ropes to guide the tank when needed.

Do not use guide lugs for lifting. Failure to follow this warning could result in death, serious injury or property damage.

2.2.6. When handling a tank with a bottom sump or

fitting, always take extra care so that the bottom sump or fitting is not damaged by contact with any other object, such as the truck bed or the ground.

2.3. STORING TANKS

2.3.1. Whenever a tank is temporarily placed above the

ground at the site, place it on a smooth, solid, level area that is clear of large rocks, trash and debris, and then chock it in place to prevent rolling. See FIGURE 2-3.

Always chock the tank. The tank is heavy and has a large surface area. The tank will roll on sloped surfaces and could be blown about by the wind. Movement of the tank could result in death or serious injury.

2.3.2. Tie the tank down if high winds are expected. Do

not use wire rope or chains. Doing so could damage the tank. See FIGURE 2-3.

2.3.2.1. Never place tie-down straps over collars or reservoirs.

FIGURE 2-3

2.3.3. Whenever a tank is temporarily placed above the

ground at the site, always take extra care so water does not enter the collar. It is recommended that the tank be rotated and/or the collar covered.

If water enters the collar, it could freeze and could result in damage to the tank and/or collar.

30-degree maximum

Top of tank in rotated position Lifting lugs to be used when tank is in upright position

Lifting lugs to be used when tank is in rotated position

Top of tank in rotated position

Lifting lugs to be used when tank is in upright position

Tank

Sandbags Tires

Tie Downs

3. PREINSTALLATION INSPECTION AND TESTING

3.1. GENERAL

Do not conduct preinstallation testing while the tank is on a trailer. Failure to follow this warning could result in death or serious injury.

Do not put product in the tank until all necessary preinstallation inspection and testing is completed.

Failure to follow this notice could result in property damage.

3.1.1. The applicable inspection and testing procedures set

forth in SECTIONS 3 and 4 must be performed to validate the applicable limited warranty.

3.1.2. All tanks are tested and inspected at the factory prior to shipment. However, in order to verify the absence of any damage resulting from shipping or handling, prior to installation all tanks must also be inspected at the site. Some tanks must also be tested at the site prior to installation according to the applicable procedures.

Always secure the tank before moving, rotating or lifting it. This is commonly done by connecting a crane or backhoe to the lifting lugs. Failure to follow this warning could result in death or serious injury.

While moving or lifting the tank, do not position any part of your body underneath the tank. Failure to follow this warning could result in death or serious injury.

Do not lift or hoist a tank under pressure. Failure to follow this warning could result in death or serious injury.

3.1.3. Not all tanks are air-testable in the field. If a tank needs to be hydrostatically tested, see SECTION 13.3.

3.1.4. If the tank is a water/wastewater tank equipped for

optional preinstallation testing, after inspecting the tank (see SECTION 3.2.), follow procedures in the Preinstallation Testing Instructions for Water/Wastewater Tanks Factory- Equipped for Pressure Testing supplement. See SECTION 20 for information on how to obtain this supplement.

3.1.5. If damage of any kind is detected, contact customer

service before installing the tank.

NOTE: Do not attempt unauthorized repairs.

3.2. INSPECTING THE TANK

3.2.1. Thoroughly inspect the entire outside surface of the

tank for signs of shipping or handling damage. Rotate or lift the tank to inspect the bottom of the tank.

3.2.2. If damage of any kind is detected, contact customer

service before installing the tank.

NOTE: Do not attempt unauthorized repairs.

3.3. PRETESTING PROCEDURES

Do not install any piping or fittings other than test fittings until all preinstallation testing has been completed. Fail-ure to follow this notice could result in property damage.

Never pressurize a wet interstitial space. Doing so could result in damage to the primary tank and/or tank failure.

3.3.1. All UL-labeled, ULC-labeled and potable water tanks

must be air tested after backfill is brought close to the top of the tank.

3.3.2. If the tank being installed is not an air-testable tank, proceed to SECTION 5.

3.3.3. See SECTIONS 3.4. through 3.9. for specific instructions for preinstallation testing procedures.

3.3.4. See SECTION 4 for preinstallation testing instructions for specific types of air-testable tanks.

3.3.5. Someone must be with the tank at all times during

air testing.

3.3.6. Prior to the pressure test, remove all plugs, apply

sealant, and replace and tighten plugs.

Before beginning the air test, notify all people on the test site to remain in a safe location. NEVER LEAVE A TANK UNDER PRESSURE UNATTENDED. Stand clear of manways, fittings and tank ends during the test. When the tank is under pressure, the manways, access open-ings and/or fittings may dislodge, or the tank could rupture, and this could result in death or serious injury.

3.4. PREPARING THE TANK FOR AIR TESTING

3.4.1. The air-test pressure is 5 psig [35 kPa] (3 psig [21 kPa] for 12-foot-diameter tanks). See FIGURE 3-1.

Do not overpressurize the tank. Position the pressure gauges so that the pressure readings can be clearly read at all times. The pressure gauge must have a pressure-relief valve that is used and set at 6 psig [40 kPa] (4 psig [28 kPa] for 12-foot-diameter tanks).

Failure to follow this warning could result in death or serious injury.

NOTICE

FIGURE 3-1

3.4.2. The tester is responsible for verifying that all of the test equipment is in…