Jupiter Manual

 Design guideline
Manual
BioKube Jupiter
Manual
Jupiter manual 22-06-2017
Table of contents
1 Introduction......................................................................................................................5
1.1 Maximum load .................................................................................................................... 5
1.2 Operation cost .................................................................................................................... 5
2 Precautions when working with wastewater ..............................................................6
3 Installation ........................................................................................................................7
3.1 Concrete works ................................................................................................................... 7
3.2 Control of packing list ........................................................................................................ 7
3.3 Inspection of vital components ........................................................................................ 7
3.4 Unloading the Jupiter unit(s) ............................................................................................. 8
3.5 Installation of Jupiter......................................................................................................... 12
3.6 Installation of inlet pumps ................................................................................................ 17
3.7 Installation of pre-treatment equipment ....................................................................... 17
3.8 Installation of air blower and air piping ......................................................................... 17
3.9 Control box ........................................................................................................................ 17
3.10 Control scheme - Installation........................................................................................... 18
4 Commissioning ............................................................................................................. 19
4.1 Control of installed equipment ....................................................................................... 19
4.2 Filling the system with water ............................................................................................ 20
4.3 Control of sludge return ................................................................................................... 20
4.4 Aeration in Bio-zone.......................................................................................................... 21
4.5 Outlet treated water ........................................................................................................ 21
4.6 Control scheme – Commissioning .................................................................................. 22
5 Trouble shooting ........................................................................................................... 23
5.1 Aeration .............................................................................................................................. 23
5.2 Sludge return ..................................................................................................................... 24
5.3 Hydraulics ........................................................................................................................... 25
5.4 Quality of treated water .................................................................................................. 26
6 Operation and maintenance .................................................................................... 27
6.1 Water samples ................................................................................................................... 27
6.2 Control of connections .................................................................................................... 27
6.3 Root blower........................................................................................................................ 27
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6.4 Inlet pumps ........................................................................................................................ 27

6.5 Pre- and after treatment .................................................................................................. 27
6.6 Control box ........................................................................................................................ 28
6.7 Recommended spare parts list for Jupiter biological treatment system .................. 28
6.8 Recommended spare parts to keep in stock* ............................................................. 28
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This manual concerns procedures and guidelines for installation, commissioning,

operation, trouble shooting and maintenance of the BioKube Jupiter treatment
plant. Instructions for pre and after-treatment, inlet pump system and other
equipment included in the specific project are found in separate manuals.
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1 Introduction
The Jupiter system is designed to treat ordinary household. You may not lead any
other water than grey- and black household sewage to the treatment plant unless
specifically approved by BioKube.
1.1 Maximum load

The BioKube Jupiter systems are modular. Each module in a series increases
treatment efficiency, each parallel series of modules increases flow. The plant
allows for fluctuations in both concentrations and volume of the incoming water.
However, if the average daily load exceeds the capacity of the designed system,
a larger system or additional units must be installed.
1.2 Operation cost

System operation settings and power consumptions can be seen in the project
specific commissioning, operation and maintenance manual.
On the BioKube partner center an Excel tool for calculating the operation and
maintenance costs can be found.
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2 Precautions when working with wastewater

Protecting Workers from Infection
Along with “good” micro-organisms that break down sewage, wastewater
contains disease-causing bacteria, viruses, fungi and parasites. When workers
can’t avoid contact with sewage, management should provide the following
protective equipment and services:
 Elbow-length rubber gloves
 Rubber pants and jackets
 Goggles
 Disposable mask to be worn in dusty sludge areas or areas with heavy aerosols
 Commercial high temperature washing machines for work clothing
Workers should also take the following precautions:

 Wash gloves before removing them.
 Wash hands before smoking and eating.
 Keep protective clothing and equipment out of eating areas.
 Keep work clothes and street clothes in separate lockers.
 Shower and change into street clothes before going home.
 Consider all cuts or abrasions to be infected. Flush them with large amounts of
clean, running water and soap, and bandage them with a sterile dressing.
 Workers should have a tetanus booster every 10 years and workers, who have
never been vaccinated for polio, should consult a physician about getting a
vaccination.
 Workers should receive the hepatitis A vaccination. Workers working in sewers
that may contain fresh blood or come into regular contact with used syringes or
body parts should receive the hepatitis B vaccination.
 Trucks that carry materials contaminated with sewage should be washed
frequently.
 Records should be kept of workers’ major and minor illnesses and complaints of
irritation and discomfort.
Seek medical attention when you have diarrhea or are ill. Since doctors are often
unaware of the connections between occupation and disease, be sure to inform
your personal physician of job exposure to sewage.
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3 Installation
3.1 Concrete works

Civil works can be completed prior to arrival of the Jupiter system, which will make
the installation faster when the equipment is supplied.
The foundation must be leveled. Local norms and standards apply when
determining design loads, material strength and dimensions of concrete and
reinforcement.
The concrete foundation shall be founded on leveled load bearing soil or
alternatively gravel.
Project specific dimensioning and design are found in separate instructions
“Jupiter dimensioning and layout” and “Buffer tank/pump well”.
3.2 Control of packing list

Always control that the components and parts received are in accordance with
your order and packing list. Also control that the goods are without visible
damages or faults.
All pipe dimensions in this manual are external diameter.
The check list on the last pages of this manual can be used when controlling the
condition and quantities of the supplied equipment.
3.3 Inspection of vital components

Treatment Plant: Biokube Jupiter
Control that tanks and filters are intact and undamaged.
Concrete Tanks (locally built) or pre-manufactured tanks in plastic or fiber glass

Prior to arrival of the Jupiter system client/owner installs a pump well with a volume
according to specifications in the BioKube Buffer Tank Dimensioning Manual. If
applicable for the particular project a Septic tank should also be casted prior to
the arrival of the Jupiter treatment plant.
The buffer tank may also be supplied as pre-manufactured plastic or fiber glass
tank. Please see separate buffer tank instruction.
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Pump System
The system is delivered with a pump system for installation in the pump well. The
system consists of submersible sewage pumps on pedestals and guider pipes for
easy service and maintenance. Control components for pump system are in
accordance with check the list in this manual.
Float Switch System

The float switch system consists of a bar where three independent float switches
are placed. Control components for pump system are in accordance with the
check list in this manual.
In some cases the inlet flow is controlled by a transducer instead of the float
switches. See separate buffer tank manual.
Air System
Root Blower for air supply to the biological treatment is delivered on a separate
pallet. Control Root Blower and air-pipes are intact and undamaged and in
accordance with specs.
Electrical Cabinet
Control Electrical cabinet and control unit are undamaged.
Other parts
Control that all remaining parts are undamaged and according to parts list.
3.4 Unloading the Jupiter unit(s)

The system will normally be shipped to site in a standard 20” or 40” container. The
tanks fit narrowly through the door opening of the container. It is important that
precaution is taken during unloading to avoid impact and damage on the tanks
and equipment. Tank dimensions are found on the Jupiter fact sheet.
Recommended handling tools (not included)

The system fits narrowly in trucks and standard shipping containers. It is important
that precautions are taken during unloading to avoid impact and damage on the
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equipment.
To facilitate the unloading, the tank is equipped with ropes on the side of the tank.
These ropes are not to be used for lifting the tanks, but only to help dragging the
tanks out of the container, see Picture 1.
The ropes may never be used for lifting the units.
Picture 1
The safest way of transporting the system on site is by means of a mobile crane,
fork lift truck or by use of fork lifts installed on an excavator or on a front loader, see
Picture 2 – Lifting the Jupiter and Picture 3.
When using a fork lift, make sure to use long forks.
Lifting the Jupiter tanks shall be done heavy straps placed under the
unit to ensure full support as shown in Picture 2. Do not attach straps to
any other part of the tank, and do not use yellow ropes to lift the
Jupiter!
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Picture 2 – Lifting the Jupiter
To avoid damaging the plastic weldings while lifting the Jupiters, make sure that
the straps used are minimum 2,5 mtrs long from each corner of the tank.
The straps can be inserted by tilting the unit one side at the time using the ropes
connected on the side. The units must never be tilted more than 2cm when using
the thin ropes.
If, for practical reasons, sufficient lifting height is impossible, we recommend

attaching the straps to a yoke (steel frame) to avoid any deformation of the tank.
(Yoke and straps are not included in the delivery)
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Picture 3
Notice: Do not lift the Jupiter units with water inside.
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3.5 Installation of Jupiter

The system must be installed according to guidelines describe in the Jupiter design
and layout manual or the project specific layout drawings approved by BioKube.
Step 1 – Placing the units

The units are placed on a pre-casted levelled concrete foundation, see Picture 4.
The distance between the units should be no less than 200mm.
Picture 4
The order of the Jupiters, where more tanks are needed, is important.
The units are marked with a number corresponding to the placement.
Step 2 – Securing the units

In areas where the ground water is high, the Jupiter has to be kept in place and
prevented from buoyancy.
To keep the units in position fill the tanks with approximately 750mm of water.
Construct the formwork for 200 to 250 mm concrete wall around the Jupiter tank.
Use the Jupiter tank as the inner formwork. The concrete should cover at least the
bottom 500mm of the tank in order to secure it from buoyancy, see Picture 5. Local
guidelines and regulations concerning civil works apply.
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Picture 5
Fill the area around the tanks with gravel to support the units from the internal load,
see Picture 6. The units shall be covered to 300mm from the edge.
Compressed
gravel to
support tank.
Note! The Jupiter can’t as standard be installed above ground. Please see
separate manual for Jupiter Above Ground.
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Picture 6
Extending the concrete to go above the Jupiter treatment units will make them
drivable. Local regulations and requirements will apply when installing the unit
below ground with the purpose of making the area above is to be re-used.
Step 3 - Connecting the units

The inlet pipes are connected from the buffer tank to the first treatment unit, see
Picture 7 and Picture 8. All Ø50mm inlet pipes fittings and connections are
compression fittings.
In cases where the buffer tank is placed prior to the septic tank, the wastewater
will gravitate from the septic tank to the Jupiter treatment units in an Ø160mm
pipe.
The outlet Ø160mm pipe is connected to the recipient. The pipe leading to
recipient must decline by minimum 10‰.
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Picture 7
Picture 8
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If more Jupiter units are placed in series, these are connected with Ø160mm pipes,
see Picture 9.
Picture 9
Step 4 – Sludge re-circulation air lift pumps

To avoid accumulation of biological sludge in the system, each clarifier chamber is
equipped with top and bottom air lift pumps, see Picture 10. The air pipes/hoses
supplying air to the air lift pumps a connected directly to solenoid valves placed
on the air blower. Air supply to the two air lift pumps in a clarifier is supplied with air
from the same connection.
Picture 10
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The return sludge water is collected in a box inside the Jupiter from where the
return piping is connected, see Picture 11. Make a common return pipe for the
Jupiter units installed in series. Inclination should be min. 20 ‰. Connect the return
pipe to first step of the pre-treatment. The dimension on the sludge return pipe is
Ø110mm.
Picture 11
3.6 Installation of inlet pumps

For installation of inlet pumps in buffer tank, see separate instruction “Inlet pump
system manual”.
3.7 Installation of pre-treatment equipment

For installation of pre-treatment equipment, see separate instruction(s).
3.8 Installation of air blower and air piping

For installation of air blower, see separate instruction “Air supply system w. sludge
return - manual”.
3.9 Control box

For installation of control box, see separate instruction “Control box manual”.
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3.10 Control scheme - Installation

ID REFERENCE
(SECTION) TASK DOCUMENTS ACCEPTANCE CRITERIA
Civil works is made according to
Project specific
Follow instructions in section 3.1 project specific layout and no
3.1 layout
prior to installing the equipment cracks or similar deviations are
drawings
observed
Follow instructions in section 3.2 Project specific
Supplied equipment is according to
3.2 after equipment has arrived to parts list and
Specific parts list and packing list
customer packing list
Follow instructions in section 3.3 Project specific
No damages or errors are observed
3.3 after equipment has arrived to parts list and
on the supplied equipment
customer packing list
Project specific
Follow instructions in section 3.5 the system is installed according to
3.4 detail
when installing the system detail drawings and this manual
drawings
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4 Commissioning
4.1 Control of installed equipment

Inlet piping
Control that the connection pipe between the pre-treatment the biological
treatment plant and all other interconnections are installed, intact and fixed.
Connection between middle chambers (if included)

Control that the pipe is fixed and securely fastened to the next chamber Jupiter.
Outlet from first chamber and from final chamber to recipient

Ensure that the outlet pipe is fixed, and that the water flows freely to the recipient.
Air Lift System

Ensure air lift systems are installed in all clarifying chambers and connected to root
blower and to recirculation system, see Picture 12.
Picture 12
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4.2 Filling the system with water
Fill up the biological treatment tanks, see Picture 13 no.1, with fresh water. It’s very
important that the biological treatment tanks are only filled with fresh water during
commissioning. If there’s no access to fresh water, please contact BioKube.
Picture 13 – Example of installation
It is important, that water filling has taken place prior to switching on

the system.
4.3 Control of sludge return

As an important part of the treatment process treated water and biological sludge
are removed from the treated water. This prevents biological sludge from
accumulating in the treatment plant.
The recirculation leaves the side of the plant through an Ø110mm PVC pipe, and
water from multiple recirculation pipes can be collected in an Ø110 pipe.
The recirculation pipe is installed so that the water gravitates at an angle of
minimum 20‰
The sludge return pump is an air lift pump. The air to the airlift pump is controlled by
a solenoid valve installed directly on the air blower.
The solenoid valve controlling the air lift pump in the last clarifier chamber is
activated every 15 min. for some seconds. If the system has more than more
chamber, the air lift pumps in the chambers before the last chamber are activated
every 12hours for some minutes.
Control the functionality of the “sludge return function” by observing and timing the
airlift pump pumping into the sludge return pipe.
Timing of air lift pumps can be adjusted in the control box.
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4.4 Aeration in Bio-zone

The biological treatment of sewage is
secured by bacteria cultures that build
up on the filter media in the treatment
tank.
The build-up of bacteria is ensured by
the aeration of the bio-zones.
To ensure the overall functionality of the
system, it is important to pay special
attention to the aeration process.
When the blower is in operation, air is led
to diffusers in the bottom of the bio Picture 14
zone. The air is evenly distributed to the
system if you observe equally sized air
bubbles all over the treatment chamber,
see Picture 14.
Initially you might experience that not all
diffusers are in operation. When
sufficient pressure is build up this situation
should however change. Please control
again after 30 minutes. Picture 15
Until the bacteria culture is sufficiently
effective, the aeration of the sewage can create a certain amount of foam, see
Picture 15. This is normal and will diminish after a short while.
Depending on the temperature of the sewage, the biology is fully operational after
a period of two to six weeks.
4.5 Outlet treated water

The BioKube system will treat the sewage
biologically. The technology is based on
bacterial growth on the submerged aerated
filter-blocks, see Picture 16 & Picture 17.
The bacteria origins from the content of the
sewage, and for this reason it will need a period
of one to six weeks to fully build up in order to Picture 16
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treat the sewage to the required standard.

If local regulation allows for outlet of partly
treated sewage, the outlet pipe can be
connected directly to recipient during
installation.
In case it’s obligated to meet the treatment
demands fully at first outlet, it’s needed to
create a loop as follows: Picture 17
1. Fill up the system according to instructions described previously in this manual, but
with sewage directly in the pre-treatment equipment.
2. Disconnect sewer from inlet system.
3. Block the outlet of the treatment Plant to recipient.
4. Power the system and allow the automatic recirculation loop to run for a period
of approximately 4 weeks, upon which the bacterial growth has built up
sufficiently to treat the incoming sewage according to local regulation.
5. Connect the sewer to inlet system and unblock outlet to recipient.
To avoid a situation where you need to accumulate untreated sewage at the
facility, it’s recommended, that the sewage treatment plant is installed in the early
phases of the project. This allows for the built up of bacterial growth, prior to the
need for treating large volumes of sewage.
4.6 Control scheme – Commissioning

REFERENCE
ID TASK DOCUMENTS ACCEPTANCE CRITERIA
Follow instructions in section 4 The system is in operation and
4 NA
when commissioning the system no problems are observed
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5 Trouble shooting
5.1 Aeration
When the blower is in operation, air is led to diffusers in the bottom of the bio-zone.
Air is evenly distributed to the system. The oxygen level must be above 70 % in all
aerated chambers.
Trouble with poor or insignificant aeration in the Jupiter system can be related to
failure of the blower, controller, air pipes and diffusers or to overload of the system.
Problem Observation Cause Control Action
Oxygen Full aeration Possible Inlet values See Instruction 6, quality of

level overload of the outlet
below 70 system
%
No or little The blower Make sure the blower is in Control that the blower runs
areation operation. with normal sound and read
the pressure on the
manometer. Normal pressure is
0,25 - 0,7 bar depending on the
system. If necessary maintain
the blower following
maintenance manual.
The air Make sure the air Feel and listen for any leaks in
distribution distribution system piping is the air line piping from the
system connected correctly and blower and to the diffusers.
that no leakages occur. Repair if leaks are found.
The diffusers Some diffusers are not Double the aeration for some
working. minutes by closing the manual
valves in other parts of the
system, otherwise push
carefully on top of the diffusers
using a stick through the bio-
zone. It’s important that at no
time all valves are closed.
The bio-zone Sludge has clocked the Double the aeration for some
bio-zone. minutes by closing the manual
valves in other parts of the
system or clean the bio-zone
with high water pressure
When the problem is found and solved, remove any accumulated sludge and the
operation of the system can continue.
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5.2 Sludge return

The sludge return system pumps the biological sludge, produced by the bacteria,
out of the treatment tank. This ensures optimal performance of the plant and is an
important functionality. Ensure that maximum 20 cm of biological sludge
accumulates on the bottom of the tank. If the level increases above 20 cm, please
change the settings of the sludge return frequency.
Trouble with sludge in the biological treatment system can be related to failure of
the controller, magnetic valve, blower or air lift pipe.
Problem Observation Cause Control Action
Sludge Sludge in the Air lift pump is Settings of the airlift pump Change settings to open the
return system working valve for the air lift pump for a
longer period or more
frequently
Air lift pump is Controller is on. Check the controller in the

not working control box. Green lamps must
light, see Picture 18.
If the green light is off, turn on

the controller. If the green light
is still off replace the controller.
Solenoid valve on the Click off the 16 mm flexible

blower is working hose and wait for 15 min. until
the controller activates the
valve. Control that a large flow
of air leaves the valve when
activated.
Functionality of air lift pump. Remove the air lift pump

system from the tank and
clean the sludge return pipes.
When the problem is found and solved, remove sludge from the Jupiter and clean
the system with high pressure water before start up.
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5.3 Hydraulics
It is important that the pump well works as a buffer tank, and that inlet flow is
distributed equally. When peak flows are allowed to enter the Treatment Plant
often, the plant will not treat the sewage as expected. Water is supposed to be
pumped automatically into the plant regularly and the water level in the pump well
is expected to be low under normal operation.
Hydraulic problems can occur, when large volumes of water are pumped to the
system over a short period or if pipes are clocked.
Problem Observation Control Action
Hydraulic Pre- Level high Controller is on and pump Check the controller in the
overflow treatment continously P1 starts automatically control box. Green lights must
light. See Picture 18.
Pump P1 pumps automatically
Level is normal Make sure no pipe is Check all pipes including pipe
but raises when clocked from pre-treatment to
pumping in treatment system and outlet
pipe
Treatment Water level rises Make sure no pipe is Check all pipes including pipe
system to high when clocked from pre-treatment to
pumping in treatment system and outlet
piping
When the problem is found and solved, remove any sludge from the Jupiter system
and the operation of the system can continue.
Picture 18
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5.4 Quality of treated water

If the outlet requirement is not met, the inlet load of the plant needs to be
investigated (volume, organic content or inhibitors) and the mechanical and
electrical equipment need to be controlled.
Precaution Effect
Control the mechanical/electrical equipment No defect components are accepted,

following the maintenance manual otherwise replace the component.
Control the pre-treatment equipment following If any deviations are found, correct these.
the maintenance manual
Measure sludge in the plant Not more than 20 cm biological sludge on the
bottom of the plant is allowed, otherwise
remove sludge manually with a pump and
adjust sludge return timing in the control box.
Measure floating sludge in the following the No floating sludge is accepted in the last
maintenance manual chamber, otherwise remove sludge manually
and adjust sludge return. See maintenance
manual.
Measure the oxygen level The oxygen level must not be below 70%,
otherwise change the blower and air hoses
Measure the pH level The pH value must not be below 6,5 or above
8,5, otherwise the pH must be stabilized
Measure the inlet flow The inlet flow must be stable and not higher
than what the plant is designed for.
Sample the incoming water Analyze the inlet sample for the same
parameters as the outlet values and compare
the concentrations against the design
dimensioning.
If neither of those problems appears, but the outlet requirement is not fulfilled, it is
very likely that the biological processes in the pre-treatment or in the Biokube plant
are not working properly. This can be due to high concentrations of anti-bacterial
compounds as for example hypo chloride or detergents that are toxic. In those
cases those chemicals need to be found and alternative chemicals used. Please
contact BioKube for further help.
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6 Operation and maintenance
6.1 Water samples
To ensure that the plant performs according to specification, it is important to

measure the water quality at the outlet.
To achieve an as correct sample as possible make sure, that sample bottles are
clean, and that the sample is obtained in the last settling zone minimum 10 cm
below the surface. Bottles with water samples have to be stored cold, preferably in
a freezer alternatively in a refrigerator, until they are analyzed or frozen as quickly as
possible. Analyses are done in a laboratory. Samples must be obtained as the first
part of the maintenance procedure prior to functionality control.
The oxygen level shall be > 70 % in all chambers and is expected to increase
through the system.
The pH shall be > 6,5 and <8,5 in all chambers and is expected to fall only a little
through the plant.
6.2 Control of connections

Control that connections are assembled according to described in section 4.
6.3 Root blower

See separate instruction “Air supply system manual”.
6.4 Inlet pumps

See separate instruction “Inlet pump system manual”.
6.5 Pre- and after treatment

See specific manuals for the concerned.
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6.6 Control box

See separate instruction “Control box manual”.
6.7 Recommended spare parts list for Jupiter biological treatment system
Component Min. component replacement frequency
Diffusers 10 years
6.8 Recommended spare parts to keep in stock*

Product Description Quantity
Diffuser For aeration in biological treatment zone 2 pr. unit
*For specific brand and model; see project specific parts list
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 Design guideline

6.4 Inlet pumps ........................................................................................................................ 27

This manual concerns procedures and guidelines for installation, commissioning,

1.1 Maximum load

1.2 Operation cost

2 Precautions when working with wastewater

Workers should also take the following precautions:

3.1 Concrete works

3.2 Control of packing list

3.3 Inspection of vital components

Concrete Tanks (locally built) or pre-manufactured tanks in plastic or fiber glass

Float Switch System

3.4 Unloading the Jupiter unit(s)

Recommended handling tools (not included)

When using a fork lift, make sure to use long forks.

Picture 2 – Lifting the Jupiter

If, for practical reasons, sufficient lifting height is impossible, we recommend

Notice: Do not lift the Jupiter units with water inside.

3.5 Installation of Jupiter

Step 1 – Placing the units

Step 2 – Securing the units

Step 3 - Connecting the units

Step 4 – Sludge re-circulation air lift pumps

3.6 Installation of inlet pumps

3.7 Installation of pre-treatment equipment

3.8 Installation of air blower and air piping

3.9 Control box

3.10 Control scheme - Installation

4.1 Control of installed equipment

Connection between middle chambers (if included)

Outlet from first chamber and from final chamber to recipient

Air Lift System

4.2 Filling the system with water

Picture 13 – Example of installation

It is important, that water filling has taken place prior to switching on

4.3 Control of sludge return

4.4 Aeration in Bio-zone

4.5 Outlet treated water

treat the sewage to the required standard.

4.6 Control scheme – Commissioning

Oxygen Full aeration Possible Inlet values See Instruction 6, quality of

5.2 Sludge return

Problem Observation Cause Control Action

Air lift pump is Controller is on. Check the controller in the

If the green light is off, turn on

Solenoid valve on the Click off the 16 mm flexible

Functionality of air lift pump. Remove the air lift pump

Problem Observation Control Action

Pump P1 pumps automatically

5.4 Quality of treated water

Control the mechanical/electrical equipment No defect components are accepted,

6 Operation and maintenance

6.1 Water samples

To ensure that the plant performs according to specification, it is important to

6.2 Control of connections

6.3 Root blower

6.4 Inlet pumps

6.5 Pre- and after treatment

6.6 Control box

6.8 Recommended spare parts to keep in stock*

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