MRI Inclined Plate Settlers The High-Capacity Inclined Plate Settler System

— Driven by Continuous Innovation

— Best-in-class performance

— Lowest cost of ownership

— Industry leader you can trust

— Proven reliability for decades of operation

Proudly made in the USA

The Leader in Clarifi cation MRI’s Inclined Plate Settler System maximizes surface area within a basin by incorporating rows of inclined plates, often at 55°, which effectively condense the capacity of a large conventional clarifier into a significantly smaller footprint. Equipped with MRI’s advanced inlet flow diffusers, these systems ensure optimal flow distribution, improving performance and efficiency. MRI systems are more economical compared to traditional clarifiers, delivering increased capacity, substantial savings in footprint and construction costs, and consistent quality effluent.

All-stainless steel, self-cleaning system provides long lasting durability. No plastics -no UV degradation.

Best-in-Class Performance We Stand Behind

— Effluent <1 NTU possible from influent >100 NTU

— Superior turbidity spike leveling to reduce downstream impacts during upset conditions, water source changes, and seasonal events

— Optimized basin hydraulics to ensure steady, high-quality effluent under varying conditions

— Full scale, in-basin or side stream pilots available for on-site testing supported by our in-house engineers

— In-house lab testing for performance confidence, including chemical dosing and loading rate optimization Performance guarantees backed by a performance bond for the ultimate confidence

MRI’s flat plate top deck provides the safest surface for operator access, with the ability to hold 500 lbs+ over one s.f. surface area.

A maximum 2” water level above the plate top deck allows cleaning during operation.

Plate and trough covers reduce operating expenses and eliminate algae growth, ice, and contaminants.

NSF-61 approved for superior product health and safety confidence.

MRI’s helical inlet flow diffusors designed to reduce inlet velocity up to 75%

MRI Inclined

Plate Settler

Conventional Clarifier

Driven by Continuous Innovation

— Over 50 patents - MRI leads the market in innovation and performance

— Graduated Inlet EcoFlow Slots: enhanced design for improved flow control and solids settling

— Increased capture velocity by reducing particle travel distance creating more efficient settling

— Reduces particle travel distance for more efficient separation

— Provides precise inlet flow for consistent performance

— Precise metering Top Tube Orifices to extract flow evenly across the width, providing better flow control and uniform distribution

— Stronger flat plate top deck for safe operator access, hold up to 300 lbs overone ft2 surface area

Lowest Cost of Ownership

MRI’s superior effluent performance

— Extended filter runs

— Reduced total organic carbon (TOC)

— Lower disinfection by-products (DBP)

Turbidity reduction

— Leveled turbidity spikes

— Up to 1” of headloss

— Uniform system flow distribution

Lower capital and operating costs

— Shared trough design

— Concealed beam design

— Chemical dosing and loading rate optimization

A Flow Control Deck Proven for

Performance MRI provides up to

1 inch of headloss to ensure uniform flow distribution across submerged orifice deck.

MRI produces stable effluent quality even during significant influent spikes, while others do not.

MRI NTU

Competitor NTU

Industry Leader You Can Trust

Combined with Parkson and the original Lamella, MRI leads the inclined plate settler market with over 50 years of experience and thousands of installations worldwide.

— In-house process, design, and service teams offer trusted support throughout an entire project lifecycle

— Custom equipment and design support for new and retrofit projects to solve unique plant challenges

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MRI vs. Competitor Effluent Turbidity Comparison

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(303) 279-8373 mrisales@parkson.com www.meurerresearch.com

Aerial view of circular clarifier installation with

22 shared effluent troughs (unique to MRI) which can treat up to 8 MGD and are proven to produce better quality water.

Flow Control System

Composed of top support/ outlet tubes, MRI’s unique

Flow Control System extracts clarified water evenly across the plates and distributes it evenly into the effluent troughs.

Self-Sealing Side Baffles

Plates are installed so that they stack and interlock to form a solid wall, which causes influent to enter the side ports.

Effluent Troughs

Side-mounted troughs work with the Flow Control System to provide even flow distribution off the tops of the plates.

Flow Control Orifices

Only MRI plates provide metered flow distribution across the entire plate width for even flow as water rises up through the plates and into the effluent tubes.

MRI Hoseless Cable-Vac™ Sludge Collector

The low-profile sludge collector removes settled solids efficiently and effectively.

Inclined Plates

MRI can customize the 100% stainless steel plate length and width to fit any application.

Side Inlet Ports

Introducing the influent flow across the plate from the side allows the down-flowing sludge to escape into the quiet zone beneath the plates.

Leveling Flow Weir

Combined with MRI’s patented Flow Control

System, the adjustable weir easily manages irregular flow velocities.

How It Works Influent flows into the basin, enters the plates through side inlet ports, and rises between stainless steel inclined plate settlers. As flow travels up the plates, solids settle out onto the plate surface. The clarified water is evenly extracted across the Flow Control System through orifices into the top tubes and is then distributed over a weir into troughs where it flows out of the basin. The Flow Control System creates a slight, but precise, pressure drop to ensure uniform flow across the entire system and to maximize plate settling performance across the entire settling area.

Sludge slides into the quiet zone beneath the plate settlers and is removed from the basin via MRI’s Hoseless Cable-

Vac™ Sludge Collector through differential head or via

MRI’s Ultra-Scraper™ Sludge Collector into a sludge removal channel.

MRI Hoseless Cable-Vac™ Sludge Collector The Original Hoseless Sludge Removal System

— Highest sludge concentration and least water waste in the industry

— Forward-facing, tangential inlet orifice maximizes sludge removal efficiency

— Non-clog orifice* eliminates orifice blinding

— Flow Balancing Ring* ensures even sludge removal

— Performance guarantees for ultimate confidence in our quality product

* Patented

The Integrated Local Control Module (ILCM) is built into the collector drive.

This option offers many of the same capabilities as a PLC/HMI and is a cost-effective alternative.

The MRI Hoseless Cable-Vac eliminates the hose.

The MRI Hoseless Cable-Vac™ Sludge Collector delivers all the benefits of suction sludge removal without the need for hoses.

Perfect for use in new or existing basins and with complete design flexibility, the patented system has four key components:

– Tandem header pipes with forward-facing tangential flow orifices optimize sludge removal and concentration

– Telescoping sludge conduit is self-priming and eliminates the need for hoses

– Shared-Reel Drive ensures reliable power without tensioning or extreme fleet angles, extending lifespan of the cable, pulley and bearing

– MRI’s signature control system designed and manufactured in-house to project requirements

Sludge collection products built on experience.

Meurer Research began developing high-quality equipment in

1978 to provide water and wastewater treatment facilities with effective, reliable and economical methods of removing sludge from sedimentation basins. Over the years, MRI has built upon these standards by incorporating new ideas and technology into the design and manufacture of its products. The MRI Hoseless

Cable-Vac™ Sludge Collector now has over 1,500 units of its current design (finalized in 2002) installed worldwide.

MRI’s patented Shared-Reel Drive assembly offers above-water position limit sensors and a powerful, low RPM gear reducer. A lightweight aluminum drive cover comes standard and an elevated drive stand can be offered for ease of maintenance.

PLC/HMI panels designed and built in-house to meet any specification need.

Flow Balancing Ring Designed around CFD analysis to ensure even flow distribution across all orifices from a collapsed to fully extended position.

Innovative tandem collectors maximize efficiency.

Unlike conventional equipment, MRI’s system has two collectors instead of one, with sludge collection orifices located on the side and facing forward, rather than pointing downward. This allows for enhanced, one-way directional sludge extraction as the assembly moves into the sludge. On the reverse stroke, suction ceases and water is pushed backward through the orifices ensuring they are free of debris for the next cycle. The orifices direct sludge into the collection pipe tangentially to prevent clogging, reduce system headloss, and remove more solids with less wasted water.

Side view of MRI Hoseless Cable-Vac shows the low profile design. This enables use under plate settlers or tube settlers where clearance can be limited or in open basins.

MRI offers flexibility for custom designs to fit all new and retrofit applications. Drive and sludge exit can be located at either end of a basin.

BACKWARD FORWARD

High water level

Shared-Reel Drive

Double cable pulleys

Urethane castors

Single-end cable pulley

Sludge exit pipe

Conventional Sludge Collectors In conventional sludge collectors, the incoming flow enters at the bottom and continues upward, perpendicular to the internal flow, which is moving laterally toward the center outlet. This causes the two flows to collide at the orifices, disrupting the flow pattern and decreasing sludge removal.

MRI’s Exclusive Tandem Collectors With MRI’s tandem collection design, the incoming flow enters tangentially to the bottom of each collector, causing the internal flow to travel in a spiral toward the center outlet. As the spiraling flow passes each orifice it is re-energized by the incoming flow.

This creates a uniform, organized flow pattern that increases sludge removal and prevents clogging.

M R

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(303) 279-8373

(303) 279-8429 FAX

mrisales@parkson.com www.meurerresearch.com

Unsurpassed MRI Hoseless Cable-Vac.

Shared-Reel Drive

The efficient cable drive design provides strength and durability. By combining the take-up and pay-out cables on one reel, the cable is kept in a single layer without tensioning.

Telescoping sludge pipe

Floor-hugging, the sludge pipe extends the full length of the basin, eliminating the need for hoses. It is completely self-priming and easy to install.

Non-clog orifices*

Virtually eliminates orifice blinding due to leaves and other large debris common in open basins.

Flow balancing ring

Designed for precision, the flow balancing ring* assures even flow control, front to back.

Tandem header pipes

Unequaled in performance, the tandem header pipes have two collectors instead of one, significantly increasing solids removal and sludge solids concentration.

Front scraper

Angled to grade sludge for even removal and cleaning of the final end of basin.

*Patented

MRI Hoseless Cable-Vac:

low profi le, fl oor-hugging and powerful.

MRI’s Hoseless Cable-Vac features a floor-hugging, telescoping sludge removal pipe and a simple, powerful cable-winch movement. Durable enough for continuous operation, treatment plants generally run the Hoseless Cable-Vac from one to several times a day. Offering a highly scaleable design, the Cable-Vac is available in widths up to 30 feet and length up to 300 feet per unit. It can be used with flat sloping or slanted floors and has variable travel speed and orifice sizes to accommodate all applications.

SECTION 11XXX

INCLINED PLATE SETTLERS

PART 1 - GENERAL

A. Provide a complete Inclined Plate Settler System as described herein and shown on the contract drawings consisting of inlet diffusers, inclined plate settlers, baffles, flow control deck, effluent troughs, and support beams, for a complete working system.

1.1 SCOPE OF WORK

A. Plate Settlers

1. The Contractor shall provide and install plate settlers including but not limited to inlet diffusers, inclined plate settlers, flow control deck, collection troughs, support beams, support structures, isolation baffles, mounting brackets, anchor bolts and fasteners, and related appurtenances. This equipment shall be provided as an integral package by a single system supplier regularly engaged in the production of this equipment who shall take responsibility for coordination of all components to assure proper functioning of the sedimentation equipment as a system.

1.2 RELATED WORK

A. Sludge Collection- Section11xxx

1.3 REFERENCE STANDARDS

A. NSF Standard 61 – Drinking Water Systems Components - Health Effects

B. American Iron and Steel Institute (AISI) - Material Specifications

C. American Institute of Steel Construction (AISC) - Guidelines for the Design of Steel Structures

D. American Society for Testing and Materials (ASTM) - Stainless Steel Material Specifications

E. American Welding Society (AWS)

1.4 SUBMITTALS

A. The System Supplier shall provide product data, drawings and calculations as follows:

1. Basin design and layout of equipment indicating all dimensions.

2. Head loss calculation through the plate settlers at maximum and design flow.

3. Complete submittal drawings of all equipment furnished.

4. Connection locations and support attachment details.

5. Supplier’s literature and cut sheets for all equipment.

6. Weights for major components and materials of construction

7. Provide equipment certification by NSF to ANSI Standard 61. To ensure public safety, only certificates issued by NSF are acceptable.

Seals or certifications by any agency other than NSF are not acceptable.

8. Statement indicating terms of the warranties.

9. Operation & Maintenance Manuals

1.5 DELIVERY, STORAGE AND HANDLING

A. Plate settlers shall be shipped on flatbed truck to allow access by crane provided by the Contractor.

B. If access by crane to the basins is not possible, then the plate settlers shall be shipped as a cartridge which can be disassembled for individual component installation.

C. Equipment shall be stored and protected in accordance with the system supplier’s recommendations.

1.6 SKILLED SUPERVISION

A. System supplier shall have a skilled representative available for installation inspection and start-up services as specified.

1.7 QUALITY ASSURANCE

A. Award for this project shall be based on the Plate Settler system as shown on the contract drawings and listed in these specifications. Any costs resulting from changes to the structural, piping, mechanical, electrical, instrumentation, or any other changes of whatsoever nature, required for alternate equipment shall be borne by the Contractor.

B. Manufacture all components in a fabrication facility producing only stainless-steel equipment. Due to potential for cross contamination, facilities that produce or handle both stainless and carbon steel materials will not be accepted.

C. The Inclined Plate Settlers shall be manufactured and provided by Meurer Research, a Parkson Brand, of Golden, Colorado. No substitutions will be allowed without pre-bid approval. Any costs resulting from changes made necessary by the approval of other plate settler equipment shall be borne by the Contractor and at no additional cost to the Owner. This shall include all design work and drawings, and specification revisions by the Engineer. Also, the Contractor shall submit drawings to the Engineer for approval showing all changes made necessary by the other equipment.

1. Meurer Research (Basis of design)

2. Parkson Corporation

3. Monroe Environmental

4. No Equal

D. To assure system integrity and responsibility, all items of equipment described in this section shall be manufactured by a single system supplier regularly engaged in the production of the specified equipment.

E. Contractors wishing to pre-qualify manufacturers as alternate suppliers shall submit the following information, in triplicate, to the Engineer a minimum of thirty (30) days prior to bid opening to be considered.

1. A list of ten (10) reference systems of identical type and similar size which have been installed and in successful operation for at least five (5) years, using the processes, material thicknesses and methods specified herein.

2. Detailed equipment drawings, to scale, and complete detailed information covering equipment, processes and methods specified.

3. A minimum of six month's operation data from three of the above reference installations.

4. Proof that the supplier has been active in manufacturing of inclined plate settlers for at least ten (10) years.

5. An unpriced proposal indicating the total scope of the work being proposed and containing an itemized list of all equipment, materials, and appurtenances, including structural configuration drawings and details.

6. Process performance guarantee. System supplier shall guarantee in writing that their system will meet the process performance guarantee listed in this specification (section 3.4.C).

7. Installation, operation, and maintenance manuals from the ten references in paragraph (D.1) above.

8. Provide equipment certification by NSF to ANSI Standard 61. To ensure public safety, only certificates issued by NSF are acceptable. Seals or certifications by any agency other than NSF are not acceptable.

9. Include a written indemnification against patent infringement to the Owner.

10. Warranties and Bonds. Proof of ability to furnish warranties and bonds as described elsewhere in this specification.

11. Failure to submit the pre-qualification documents as described above shall cause rejection of the contractor's bid if such bid indicates a manufacturer other than Meurer Research, a Parkson Brand.

F. The Contractor must list the price for the Base Bid System Supplier.

G. The “Alternate” Supplier will be considered by the Engineer and Owner only after award of the Contract. Contract award will be made based on the equipment and price of the “Base Bid System Supplier”

H. If the Alternate Supplier is awarded to manufacture the equipment, this is not an indication that the Alternate Supplier’s standard equipment is acceptable in lieu of the specified component features.

I. Any alternate system supplier who does not have written acceptance by the Engineer prior to bid will not be considered after the bid.

PART 2 - PLATE SETTLERS

2.1 DESIGN AND SCOPE OF WORK

A. The work shall include supply, delivery, installation inspection and training in the use of plate settlers.

B. The basins shall be in number and dimension as shown in the contract drawings and as specified herein.

C. The inclined plate settler system shall be comprised of the following elements without exception:

1. Stainless steel helical inlet diffusers.

2. Stainless steel plates and frames with isolation baffles.

3. Stainless steel distribution “top tubes” with orifices to ensure proper distribution across the plate width. Continuous slots with less than 0.50” of headloss will not be allowed.

4. Stainless steel effluent collection troughs with adjustable weirs.

Distributive elements shall conform to ten-state standards.

5. Stainless steel support I-beams which span the basin width to support ends of the plate packs. Beams and mounting brackets shall be designed and provided by the basis of design plate settler manufacturer. Support columns will be provided as needed.

6. Systems with more than 2.0 inches of water over the plates during operation at design flow are not allowed as they will prohibit routine cleaning, promote algae growth and solids settling atop the plates.

7. Plate covers shall be provided over the flow control deck to minimize biological growth due to light.

8. All wall mounted brackets, anchors and hardware as required.

2.2 DESIGN CONDITIONS

A. Number of Basins X (X)

B. Dimensions of each Basin X’ L x X’ W

C. Design flow, each basin (process) X MGD

D. Peak flow per basin (hydraulic) X MGD

E. Effective Loading Rate at design flow 0.30 gpm/sq ft

F. Alternate manufacture plate efficiency 80%

G. Angle of plate inclination 550

H. Maximum plate dimensions 9.50’L x 4.50’W

I. Number of plate rows per basin X (X)

J. Number of plate cartridges per basin X (X)

K. Maximum cartridge weight allowed 6000 lbs

L. Minimum clearance from plate bottom to floor 6.8 (ft)

M. Minimum clearance beneath support beam X (X)

N. Number of effluent troughs per basin X (X)

O. Design velocity in feed channels <0.5 fps

P. Effluent Requirement X NTU

RAW WATER CHARACTERISTICS PRIOR TO FLOCCULATION

Q. Temperature, Fahrenheit 33-80

R. Turbidity, NTU 2-100

S. pH 6.0 to 9.0

2.3 MATERIALS OF CONSTRUCTION

A. All components of the plate settler system shall be fabricated of stainless-steel materials with the only exception of gasketing materials.

Support Frame - ASTM A554, AISI Type 304L Plates - ASTM A240, AISI Type 304 Troughs - ASTM A240, AISI Type 304 Weirs - ASTM A240, AISI Type 304 Support Beams - ASTM A240, AISI Type 304L Bolts, Nuts, Fasteners – IFI-104 GRADE 304

Gasketing – ASTM D1056 Closed Cell Polyurethane

B. All fabricated stainless-steel components shall be properly treated to prevent future corrosion. All welds shall be bead blasted or mechanically cleaned per ASTM A-380. Nitric acid or other hazardous chemicals shall not be allowed for cleaning. Non welded parts shall be supplied with standard mill finish.

C. If chlorine is present in enough concentration to allow corrosion of 304SS, all components shall be constructed of 316SS. This includes plates, troughs, weirs, end and side baffles.

2.4 INLET FLOW CONTROL

A. The plate system supplier shall provide helical flow inlet diffusers to reduce the velocity to less than 0.25 fps in a spiraling motion when entering the plate settler basin to prevent floc damage and to minimize velocity currents. The inlet diffusers shall direct the flow to properly line up with the plate settlers. The Contractor shall mount inlet diffusers as shown in the Contract drawings.

B. Flow shall pass through the concrete inlet port and be separated into two flow streams as it exits the diffuser. The diffuser shall create a helical flow pattern perpendicular to flow entering the inlet port opening.

Deflector plates or diffusers that do not provide a helical flow pattern are not acceptable.

2.5 PLATES

A. To ensure public safety, plate settlers shall be certified by NSF to ANSI Standard 61. Only certificates issued by NSF are acceptable. Seals or certifications by any agency other than NSF are not acceptable.

B. The plate settling units shall operate in counter-current mode with clarified water flowing upward while settled solids move down. The incoming water shall be fed near the lower end of the plate from the side to allow the settled solids to fall to the floor of the clarifier without being re-entrained by the incoming flow.

C. The plates shall be of the size and quantity specified in the calculations to meet the settling area requirements. Plates will be arranged in factory assembled packs and shipped to the jobsite as one assembly.

D. The plates shall be inclined at an angle of 55° from the horizontal. The plate settlers shall have no moving parts.

E. Plates shall delivered to job site pre-assembled inside each cartridge frame with a factory inspection certificate of proper fit and assembly.

For quality assurance purposes, onsite assembly of plate packs is not allowed.

F. Provide gasketing at any barrier to clarified and unclarified water to prevent short circuiting of unclarified water. This includes between the top of the cartridge frame and each plate, end baffling, trough connections with the cartridge frame and between flanged trough sections. Liquid sealants like Sikaflex shall not be the primary gasketing material for any parts of the Inclined Plate Settler Clarification System.

G. Effluent flow at the top of the plate shall be removed in at least four (4) points to ensure even distribution across the full width of the plate. Plate settlers with less than four (4) take off points per plate or continuous full width slots are not acceptable. A plate settler using a flow control device with less than 0.5” of headloss shall use a plate efficiency factor 20% below the specified efficiency. Open top plates with no integral flow control device that utilize only weirs for flow control will not be allowed

H. Any plate settler not utilizing at least four (4) points of effluent removal at the top of each individual plate shall include troughs on both sides of the plate such that clarified water flow travels no more than half the plate width to a trough.

I. In order to prevent short circuiting occurring above the plates and to allow cleaning of the plate tops without disrupting flow, a water depth of less than 2.0” above the plate settlers shall be maintained during operation at design flow. A depth of more than 2.0” of water over the plate settlers at design flow will prohibit cleaning and is not allowed.

J. The plates shall be visible for inspection during operation. No troughs shall be required to be removed in order to view the plates.

K. Minimum clearance from bottom of plate to basin floor shall be no more than 6.8 feet. This should be considered a minimum sludge zone depth for cold and/or colored water residuals settling and compaction to keep solids below and out of the clarification zone.

L. The inclined settling plates shall be a full size, 24-gauge minimum, single piece of Type 304 stainless steel material. Each plate shall have a tubular top support structure, integral bent sides and bottom stiffening element manufactured of 24-gauge (0.0239” minimum) stainless steel.

Plates designed without an integral top tube shall be 22-gauge (0.0292” minimum). 26-gauge plates, FRP (fiberglass), textured, ribbed or corrugated sheets will not be accepted. Intermediate (center) stiffners or corner stiffeners that may interfere with sludge migration and will increase upflow velocity thus removing laminar conditions with a high Reynolds number indicating turbulent flow are not allowed.

M. The top plate deck shall provide a flat walking surface for access during operation and maintenance activities. Top decks with an uneven or pointed surface are a safety hazard and will not be allowed.

N. The plate pack frames shall be manufactured of rectangular or square tubing of adequate size and minimum thickness of 16-gauge stainless steel to meet the structural design criteria. Packs shall be self-supporting and shall not exceed the maximum allowable deflection limits under load conditions stipulated below.

O. The top of each plate shall be visible for inspection and cleaning. Flow control angles welded to the frame are not acceptable.

P. Include end and side baffles of minimum 16-gauge material bolted watertight to the cartridge frame with gaskets. Field applied liquid sealants are not acceptable as the primary method of sealing bolted connections anywhere within the plate settler system. Provide sufficient baffle freeboard at peak flow.

Q. Plate Settler covers:

1. Covers shall be provided over the top of the plate packs.

2. Plate covers shall be in contact with and shall completely cover the water surface to mitigate algae growth.

3. Plate covers shall be in contact with and shall insulate the water surface to prevent freezing.

4. The plate settler covers shall be manufactured of 20-gauge T-304 stainless steel with closed cell foam contained beneath the cover without the need for glue or adhesive.

5. Each cover shall span the entire width of the plate settler top deck. Covers shall be 54.5” wide by 48” long with shorter pieces making up the total length of each module. The edges shall be bent down 1” on each side. A ridged closed cell foam shall fill the underside of the covers.

6. The covers shall be placed on the top deck end to end and shall float at the water surface allowing flow into the top tubes.

7. The covers shall be provided with a hold down mechanism.

8. The plate covers shall not interfere with the flow through or above the plate settlers at any flow rate.

9. The covers shall be meet NSF Standard 61 requirements and shall be provided with an up-to-date NSF-61 certificate in the interest of public safety.

R. The plates shall be designed structurally for the following conditions:

1. 0.67 pounds per square foot of plate area live load (sludge load)

2. Maximum live load deflection of L/360 for all structures, etc.

3. A concentrated live load of 250 lbs. anywhere on the plate top flow deck designed per ASCE 7-10, Minimum Design Loads referenced for Catwalks and Maintenance Access.

2.6 EFFLUENT COLLECTION TROUGHS

A. The effluent troughs shall be u-shaped and located to the side of the plate rows. Include flanged and bolted connections with gasketing at all trough connections. Troughs located over the plate settlers obstructing access to the tops of the plates will not be accepted.

B. Weirs shall meet the Ten States Standard for Water Works regulatory requirement of <20,000 gpd / linear foot of weir length or orifice circumference under peak flow conditions.

C. Effluent troughs and weirs shall be manufactured from minimum 16-gauge stainless steel. Fasten troughs on plate pack frames every 24-inches minimum with minimum 3/8” hardware and adequate bracing to support a water-filled trough while the basin is empty or an empty trough while the basin is full. Include gasketing to prevent short circuiting between clarified and unclarified water at the frame-to-trough connection.

D. Design troughs to support a water-filled trough while the basin is empty and associated uplift forces for basin full and trough empty conditions.

Include all brackets, trough supports, reinforcing sections, stiffeners, flanges and hardware.

E. The effluent weirs shall be of the flat crested rectangular design. Weirs shall be adjustable without loosening bolts or nuts. V-notch weirs and bolt-on weirs are not acceptable. Weirs that establish a water level greater than 2 inches above the plates at design flow are not allowed.

F. The specified number of effluent troughs shall be provided. Basins with an even number of plate settler cartridge rows shall have one trough per two rows to minimize installation cost and effluent wall penetrations. To ensure even distribution between inclined plates at all flow rates, multiple orifices across the width of each plate shall be used. Full width flow control angles are not a substitute for multiple orifices. V-notch weirs are not allowed without troughs on both sides of the plate cartridge such that flow travels no more than half the plate width to an effluent trough.

2.7 STRUCTURAL SUPPORT SYSTEM REQUIREMENTS

A. To ensure compatibility, the system supplier of the plate settlers shall provide stainless steel I-beams or wall brackets of 1/4” minimum material to support the plate settler packs.

B. Support frames and beams shall be adequately sized to carry the load of the plate settling system under both wet and dry conditions without exceeding a maximum deflection of L/360 of the span.

C. The packs shall be supported from below on stainless I-beams. C-channel or tube-shaped supports are not allowed.

D. The system supplier shall be required to coordinate structural details of the design with the Engineer. This will be required to determine the final location of beams, through wall inlet and effluent openings, sludge collection mechanism and other design details which may affect the supply of structural support components.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Equipment shall be stored in a secure area in strict accordance with the manufacturer's drawings and recommendations prior to installation.

B. Install plate settler equipment as indicated on the contract drawings and in accordance with the system suppliers’ recommendations.

C. Inclined Plate Settlers:

1. Install wall brackets and support beams level as shown on drawings.

2. Plate packs shall be shimmed and leveled, aligned, and anchored in place onto support beams as needed.

3. Install troughs between plate packs and grout effluent openings.

4. Install side and end zone baffling and level weirs.

3.2 WARRANTY

A. The system supplier shall guarantee that the equipment including buy-out items are appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of 12 months commencing from the date equipment is satisfactorily placed in service or 18 months from equipment delivery, whichever comes first.

3.3 PATENTS

A. The Contractor shall certify to the Owner that all equipment installed and any process resulting from use of the equipment provided is not subject to patent infringement or litigation which may result in a patent controversy in which the Owner or Engineer may be named as a defendant.

3.4 PERFORMANCE REQUIREMENTS

A. Plate settler troughs shall be tested at peak flow to prove capacity.

B. Plate settlers not using a distribution orifice type top tube across the width of each plate, or systems using v-notch weirs, must pilot test for a minimum 3-week duration prior to bid to prove plate settler performance based on the given loading rate and efficiency.

C. Minimum Headloss Induced by the Plate Settlers = 0.65 inches @ 32 mgd (Measured from the weir elevation to the basin water surface upstream of and outside of the first plate pack).

D. Maximum Headloss Induced by the Plate Settlers = 2 inches @ 32 mgd (Measured from the weir elevation to the basin water surface upstream of and outside of the first plate pack).

E. Maximum Flow Maldistribution along a Plate Pack Row = less than 10% (Measured between the first and last plate pack in a given row of plate packs at peak flow per basin).

F. Maximum Turbidity Maldistribution along a Plate Pack Row = less than 1 NTU difference (Measured between the first and last plate pack in a given row of plate packs at peak flow per basin).

G. Maximum acceptable daily average turbidity in the plate settler effluent trough shall be no greater than 1.0 NTU 95% of the time with influent turbidity at 1-50 NTU and 98% reduction over 50 NTU incoming at peak flow as measured over a 2-week test period.

3.5 INSPECTION AND START-UP

A. Provide a factory certified service technician to inspect the installation and observe start-up and initial operation of the plate settler system.

B. The system supplier shall provide a factory trained representative to perform the following:

1. Inspect installation of the plate settlers and provide a field report certifying that the equipment is properly installed, fully operational and ready for use.

2. Support start-up and train the Owner’s personnel on operation and maintenance of the equipment.

3. Include a minimum of one trip of at least one eight-hour day for inspection, startup, adjustment, and training.

END OF SECTION

SECTION 11XXX

SLUDGE COLLECTION SYSTEM

PART 1 - GENERAL

A. The Hoseless Sludge Removal System shall be installed in the sedimentation basin(s). Include all equipment, controls and appurtenances for a complete working system.

B. Specifications are based on system supplier’s standard equipment. This specification section supersedes all other specification sections including PLC’s, panel design and electrical requirements. Components will not be varied per system supplier’s standard design.

1.1 SCOPE OF WORK

A. Hoseless Sludge Removal System

1. The Contractor shall provide and install sludge collector system(s) which include collector assembly, sludge exit pipe, electric drive assembly, drive cables, cable pulleys, control system for fully automatic operation, and all other miscellaneous accessories and hardware as required for a complete installation.

2. The sludge collector(s) shall remove settled solids from the basin floor by means of differential head. The solids shall be discharged through the sludge exit pipe (by MRI) which are connected to the fixed piping (not by MRI) to exit the basin. Flexible hoses or articulating pipes shall not be used for sludge removal.

1.2 RELATED WORK

A. Inclined Plate Settlers- Section 11xxx

1.3 REFERENCE STANDARDS

A. NSF Standard 61 – Drinking Water Systems Components - Health Effects

B. American Iron and Steel Institute (AISI) - Material Specifications

C. American Institute of Steel Construction (AISC) - Guidelines for the Design of Steel Structures

D. American Society for Testing and Materials (ASTM) - Stainless Steel Material Specifications

E. American Welding Society (AWS)

F. Underwriters laboratories Inc. – Industrial Control Panels (UL) and Industrial Control Panels Certified for Canada (cUL)

1.4 SUBMITTALS

A. The Manufacturer shall provide product data, drawings and calculations as follows:

1. Basin design and layout of equipment indicating all dimensions.

2. Head loss calculation through the sludge collector at design flow.

3. List of spare parts which could be purchased and kept on hand.

4. Complete submittal drawings of all equipment furnished.

5. Connection locations and support attachment details.

6. Manufacturer’s literature and cut sheets for all equipment.

7. Weights for major components and materials of construction

8. Provide equipment certification by NSF to ANSI Standard 61. To ensure public safety, only certificates issued by NSF are acceptable.

Seals or certifications by any agency other than NSF are not acceptable.

9. Statement indicating terms of the warranty.

10. Operation & Maintenance Manuals

1.5 DELIVERY, STORAGE AND HANDLING

A. Hoseless sludge collectors shall be shipped on flatbed truck to allow access by crane provided by the Contractor.

B. Equipment shall be stored and protected in accordance with the manufacturer’s recommendations.

1.6 SKILLED SUPERVISION

A. Manufacturer shall have a skilled representative available for installation inspection and start-up services as specified.

1.7 QUALITY ASSURANCE

A. Award for this project shall be based on the Hoseless sludge removal system as shown on the contract drawings and listed in these specifications. Any costs resulting from changes to the structural, piping, mechanical, electrical, instrumentation, or any other changes of whatsoever nature, required for alternate equipment shall be borne by the Contractor.

B. Provide equipment manufactured in a UL/cUL certified facility as defined by the Underwriters Laboratories Inc. and provide documentation of registration in shop drawings.

C. Manufacture all components in a fabrication facility producing only stainless-steel equipment. Due to potential for cross contamination, facilities that produce or handle both stainless and carbon steel materials will not be accepted.

D. Hoseless Sludge Collectors shall be manufactured and provided by Meurer Research, a Parkson Brand, of Golden, Colorado. No substitutions will be allowed without pre-bid approval. Any costs resulting from changes made necessary by the approval of other sludge collector equipment shall be borne by the Contractor and at no additional cost to the Owner. This shall include all design work and drawings, and specification revisions by the Engineer. Also, the Contractor shall submit drawings to the Engineer for approval showing all changes made necessary by the other equipment.

1. Meurer Research (Basis of design)

2. Monroe Environmental

3. No Equal

E. To assure system integrity and responsibility, all items of equipment described in this section shall be manufactured by a single manufacturer regularly engaged in the production of the specified equipment.

F. All Hoseless sludge collector manufacturers must have at least fifty (50) Hoseless sludge collector installations. Installations shall have been in operation for at least five (5) years, be of a similar design complying with these specifications for use in municipal applications as described above.

G. Contractors wishing to pre-qualify manufacturers as alternate suppliers shall submit the following information, in triplicate, to the Engineer a minimum of fifteen (15) days prior to bid opening to be considered.

4. A list of ten (10) reference systems of identical type and similar size which have been installed and in successful operation for at least five

(5) years, using the processes and methods specified herein.

5. Detailed equipment drawings, to scale, and complete detailed information covering equipment, processes and methods specified.

6. A minimum of six month's operation data from three of the above reference installations.

7. Proof that the manufacturer has been active in manufacturing of their current design hoseless sludge collector for at least ten (10) years.

8. An unpriced proposal indicating the total scope of the work being proposed and containing an itemized list of all equipment, materials and appurtenances, including structural configuration drawings and details.

9. Installation, operation and maintenance manuals from the ten references in paragraph (D.1) above.

10. Provide equipment certification by NSF to ANSI Standard 61. To ensure public safety, only certificates issued by NSF are acceptable.

Seals or certifications by any agency other than NSF are not acceptable.

11. Include a written indemnification against patent infringement to the Owner.

12. Evidence of manufacturer's engineering staff experience necessary to complete this project. Included shall be the resume of the supervisory P.E. who will affix his stamp on the submittal drawings. Such engineer shall be a direct employee of the manufacturer.

13. Warranties and Bonds. Proof of ability to furnish warranties and bonds as described elsewhere in this specification.

14. Failure to submit the pre-qualification documents as described above shall cause rejection of the contractor's bid if such bid indicates a manufacturer other than Meurer Research, a Parkson Brand.

H. The Contractor must list the price for the Base Bid Manufacturer.

I. The “Alternate” Manufacturer will be considered by the Engineer and Owner only after award of the Contract. Contract award will be made based on the equipment and price of the “Base Bid Manufacturer”

J. If the Alternate Manufacturer is awarded to manufacture the equipment, this does not an indication that the Alternate Manufacturer’s standard equipment is acceptable in lieu of the specified component features.

K. Any alternate manufacturer who does not have written acceptance by the Engineer prior to bid will not be considered after the bid.

PART 2 - HOSELESS SLUDGE COLLECTORS

2.1 PROCESS DESIGN AND CONDITIONS

A. Number of Basins X (X)

B. Dimensions of each Basin X’ L x X’ W

C. Number of units per Basin X (X)

D. Sludge Flow per unit 150 - 250 gpm

E. Solids removal concentration: 0.5 - 2.0%

2.2 MATERIALS OF CONSTRUCTION

A. All major components of the sludge collector shall be fabricated of stainless steel materials accept as noted.

Cross bracing - ASTM A240, AISI Type 304

Header Assembly and Pipe - AISI Type 304

Bushings, Flow Balancing Ring and Tangential Orifices – UHMW-PE

Cable Pulleys, collector pipe supports and wall casters - Polyurethane

Bolts, Nuts, Fasteners – IFI-104 GRADE 304

B. All fabricated stainless steel components shall be properly cleaned to prevent future corrosion. All welds shall be passivated by mechanical cleaning per ASTM A-380. Nitric acid or other hazardous chemicals shall not be allowed for cleaning. Non welded parts shall be supplied with standard mill finish.

2.3 SHARED REEL DRIVE ASSEMBLY

A. Each drive assembly shall consist of an SEW Eurodrive 3 Phase 230 VAC ¼ HP inverter duty motor and SEW Eurodrive gearbox which shall be coupled to a single rotating drum for manipulation of the cable that is attached to the tandem suction header assembly. Food grade lubricant shall be included. DC drives are not acceptable.

B. Only single drum drives are acceptable. Two or more cable drums are not allowed due to the high fleet angle created between drum and floor pulley.

C. The cable shall be firmly attached to the rotating drum to prevent slippage. Tensioning the cable between multiple pulleys or use a cable tensioning device to prevent slippage will not be allowed.

D. The cable shall store on the reel in a single layer, the placement of which shall be organized by the drive mechanism. To minimize cable travel and the fleet angle, the cables shall share the same space on a single drum.

E. The complete drive mechanism shall be packaged on a single powder coated stainless base

F. A two-piece powder coated aluminum safety cover with handles for ease of handling shall be supplied, requiring complete coverage of both the reel and drive assembly. Covers made of steel or stainless steel will not be allowed due to excessive weight during maintenance.

G. The drive cable shall be Type 304 Stainless Steel with a minimum diameter of 1/4". Cable lengths over 150-feet shall use pre-stretched cable. Pneumatic or steel tape drive systems are not acceptable.

H. The drive assembly shall be capable of ceasing operation on an excessive load without physical damage to the drive unit. During an overload, protection built into the VFD will cease operation and activate an alarm. Operation will continue after alarm is reset. Back up protection in the form of a shear pin is required.

I. The drive assembly shall have integral position sensors which determine when the collector is at the end of the basin or the beginning of the basin.

No under-water position sensors shall be required or allowed.

J. The drive shall have an emergency disconnect button pre-wired to a junction box assembly which shall be a large, red, palm operated single button.

2.4 HOSELESS COLLECTOR ASSEMBLY

A. To ensure public safety, sludge collectors shall be certified by NSF to ANSI Standard 61. Systems that do not have stamped NSF-61 certification for the collectors as specified in the manufacturers name will not be accepted. Other agencies or certificates will not be allowed.

B. The sludge collector assembly shall be manufactured entirely of Type 304 Stainless Steel, except for non-metallic parts such as casters, bushings, orifices, etc. which will be manufactured of non-metallic materials.

C. Each collector assembly shall consist of four sludge collection header pipes each equal to half the basin width. Each header pipe shall have helical flow orifice blocks of UHMW-PE material spaced by the manufacturer to insure proper distribution across the length of the header. Header pipes shall have removable end caps for easy clean out.

D. Header pipes shall be 3-inch diameter attached to the collection chamber by means of a flanged connection. Use of clamps or other pipe connection methods will not be allowed.

E. The helical flow orifice blocks shall be designed to cause flow to enter tangentially into the header pipe for more efficient sludge removal and reduced head loss. Orifices shall be ¾-inch in diameter shaped to cause a spiral flow inside the header pipe to prevent solids from settling and shall point forward to remove the settled solids ahead of the pipe as it travels down the basin. Holes drilled in the bottom of the header pipe shall not be allowed. Systems without forward facing tangential flow orifice blocks of UHMW-PE will not be allowed.

F. The 6-inch collection chamber shall “telescope” over the smaller 4-inch fixed sludge exit conduit. Articulating pipes, flexible sludge hoses, flexible hose joints, or swivel joints are not allowed.

G. The collection chamber shall be isolated against the horizontal sludge exit conduit by means of a UHMW-PE bushing. The bushing shall be designed to pass small amounts of water to act as a lubricant during operation. A fully sealed connection between the two pipes is prone to binding and not acceptable.

H. The sludge exit conduit shall include a UHMW-PE flow balancing ring designed by CFD analysis to assure equal flow from the front and back sludge collection headers. Systems without a flow balancing ring will not be allowed. Lateral piping or flow diagonals from sludge headers to the collection chamber shall not be an acceptable alternative to the flow balancing ring.

I. Each header pipe shall be equipped with a blade which is triangular and is roughly equal in length to the header pipe. These blades will move the settled solids away from the end walls.

J. The Hoseless collector assembly shall be guided along basin length by means of horizontal casters on the ends of the header pipes.

K. Flow through the Hoseless sludge collector shall be controlled by a sludge valve as directed by the collector control panel. Submerged pump systems shall not be acceptable. Pumps (if used), valves, local disconnects, power and actuator with position limit switches shall be provided by others under separate specification section(s).

L. Each Hoseless collector shall be complete with polyurethane rolling casters to support the collector assembly and horizontal side wall casters located near the end of each of the four sludge collector headers. Use of anti-rocking skids in lieu of casters are not acceptable. Include all necessary mounting hardware.

M. Concrete curbs with a minimum 6-inch vertical profile shall be provided by the Contractor as required between multiple units. Material vendor can also provide stainless steel curbing that allows for manual hose cleaning under and between installed curbing if concrete curbing is not appropriate.

N. Include stainless steel end stops to be anchored to the basin floor at the header assembly’s end of travel.

O. All shop and field welds shall be performed by qualified welders in accordance with AWS D1.6. All seal welds shall be continuous, and all welds shall be mechanically cleaned per ASTM A-380. Any field welding of pipe to complete the assembly shall include use of a pickling paste.

P. All underwater bearings shall be specifically designed for underwater use.

2.5 CONTROL SYSTEM

A. There shall be XX collector control panel(s) to operate up to XX Hoseless sludge collectors. The control panel(s) shall communicate to the Master Control Center (SCADA) via Ethernet communication or dry contacts.

B. The sludge valve(s) or…