FE D\o x 7: OPERATION MANUAL Flocculator and chemical dosing Type : RPF 100 cf Serial Nr. : 1188411 NY ear. : 01-2008 Client : ARIZTIA Arica REDOX WATER TECHNOLOGY B.V. Stevinstraat 11, 7102 DZ Winterswijk P.O. Box 218, 7100 AE Winterswijk Phone: 0031 (0)543-531030 Fax: — 0034 (0)543-519089 x) E-mail: info@redox.n! ) Edition: 15-01-2008DOX TABLE OF CONTENTS: 45 Zi Introduction. Technical information. 2.1. Technical data 2.2. Auxiliary equipment. 2.3. Necessary tools and makeshifts. 2.4, Flowsheet. 2.5. Additional information from sub-suppliers. Safety aspects. 3.1. Incorporated safety measures. 3.2. Operators and working environment. 3.3. Personal protection. Installation, 4.1, Transport instructions. 4.2. Mounting instructions. 4.3. Connections. Directions for use. 5.1. Process description. 5.2. Item description ‘A: Sample points. B: Flow-switch. C: Coagulant dosing section. D: Neutraliser dosing section. E: pH-measurement. locculant dosing section. G: Aeration points. 5.3. Start up. 5.4. Operators and working environment. Inspection / maintenance. 6.1. Qualification of maintenance personnel. 6.2. Safety measures and risks during maintenance. 6.3. Maintenance, 6.4. Cleaning, 6.5. Due date guarantee / product liability, Malfunctioning and repair. Discard and environment. 8.1. Re-use. 8.2. Dis-mantling, Customer service. 9.1. Ordering parts. 9.2. Helpdesk for process and product information. ‘Type: RPF 100 Project ARIZTIA Arica OnW: 1188411 Cade: 5.3-5.4 54 55 55-56 5.6 61 61 62 62 7a 2@ eo( EDOX Project ARLEIA Aa oi ae 1, INTRODUCTION - The scope of this manual is to provide a reference document for operating the installation. = In this manual is described how to start up the installation till how to put the installation out of order. - After start up special attention is given to: + Maintenance of the installation, * Operation of the installation. «Safety aspects. - The anticipated operating conditions and procedures defined in this manual are to be used as guides and are not to be accepted as rigid standards. = Some maintenance and periodic control is necessary to ensure an optimal and trouble free operation - This manual or a complete copy of this manual should be kept, up to time (without exception), near the installation - Read this manual every month. - Every month the maintenance personnel and the operators have to be instructed with the maintenance and the safety aspects in this manual. This manual is written compact and as complete as possible. Should there be any questions left about the installation, please contact your supplier. tf 4 i ¢0 i z = i te + # ie Fiqure 1.1 Flocculator (RPF) 142. TECHNICAL INFORMATION. 2.4, TECHNICAL DATA. ‘Type: RPF 100 Project: ARIZTIA Arica ‘OHW: 1188411 Code Make: Redox [Type: Flocculator RPF 100 Serial number. 1188411 Nominal capacity ‘90 m*/hr. Noise level: The noise level is minimal and considerable lower than 70¢B(A). Heat development: Heat development is not present. Radiation: Radiation is not present. Vibrations: Vibrations are very low. ‘Temperature range surrounding: 5 °C till 35 °C. ‘Temperature range product (wastewater): |10 °C till 30 °C (assumed) pH-range at the outlet of the flocculator. [6 till 9 This to prevent serious damage to the installation and pumps! The solid parts in the incoming wastewater may not be larger than 1 mm. Tn case larger paris are present, these parts screening system before entering the flotation unit! have to be removed by a Dimensions: Length x width x height ‘Approx: 4680 x 830 x 1200mm. Weight: ‘Weight empty: ‘Approx. 304 Kg. ‘Weight full: Approx. 1110 Kg. ‘Connections: influent: DN 150, PN10 flange Effluent: DN 150, PN10 fiange Materials: a Frame flocculator: AISI 304 Piping: HDPE Dosing sections: PVC ‘Sample: a Material: PVC e Flow-switch: By measuring pin(s) in the effluent compartment of the GPL 80-S Coagulant (for example FeCl): Material: PVC piping EF Ball valve (PVC) Art.no.: PKE.000.025 Safety valve, type MV 310 Non return valve (PVC) 24REDOX Pigject ARIZTA ea or ier Neutraliser (for example NaOH): e Material: PVC piping Ball valve (PVC) Non return valve (PVC) pH: 3%" connection For more details, see datasheet pH electrode. Flocculant (for example Poly): 1 Material: PVC piping Ball valve (PVC) ‘Arino.: PKK.000,025 Non return valve (PVG) ‘Art.no.: PTK.904.025 Aeration: e Material: HDPE elbow 2.2. AUXILIARY EQUIPMENT. Not applicable. 2.3. NECESSARY TOOLS AND MAKESHIFTS. + Forstart-up, maintenance and control no special tools are required. 22Type: RPF 100 Project ARIZTIA Arica = FLOWSHEET. Aeration (option) 4 Effluent Flocculant injectionm 5 Influent “e (S| Coagulant injection a» Sp py Neutraliser injection {kj} —— [Sk] = Pneumatic valve TX = Non return valve Da = Valve Figure 2.1 2.5. ADDITIONAL. INFORMATION FROM SUB-SUPPLIERS. Information about the chemicals you can find on the datasheet of the dosing pumps (in index) and the datasheets from the sub-supplier. 23REDOX Pipe ARITA Aca ont esas 3. SAFETY ASPECTS. 3.1, INCORPORATED SAFETY MEASURES. Keep all warnings readable, if necessary clean or replace it! Biting (corrosive) substance. pj mest This warning is placed at the front side of the flocculator. Warnings: * Coagulants are corrosive (acid) liquids, which causes irritation, if in contact with eyes, skin and respiratory organs. + Neutralisers are corrosive (basic) liquids, which causes irritation, if in contact with eyes, skin and respiratory organs. ‘+ When contact with one of these liquids takes place, immediately wash it with lots of water and call (if necessary) a doctor. + THINK OF THE SAFETY CLOTHING AND DO NOT FORGET TO TAKE SAFETY MEASURES. Warning for consequence: Operating not in accordance with the safety prescriptions. '* Operating by inexperience and / or insufficient instructed personnel. * Adjustments, modifications or alterations without the knowledge of Redox. The consequences can be very extensive and in these cases the vendor (supplier) will be safeguarded against any warranty, guarantee and / or liabilities. 3.2. OPERATORS AND WORKING ENVIRONMENT. In the first place the operator should always be informed about the kind of processing substances. The operator also should know the danger of the chemicals which, are used in the flocculator. On this base the operator has to protect himself. The allowed temperature for the system is mentioned at chapter 2.1 of this manual. If temperatures outside this range can be expected, the system needs to be protected, for ‘example by installing the system inside a heated or cooled building. The installation has to be placed in a frost-free environment. If not take the measurements mentioned at chapter 4.1 & 4.2. 3.1x ‘Type: REF 100 Project ARIZTIA Arica OHW: 1188411 Code: 3.3. PERSONAL PROTECTION. (On the basis of the upper mentioned operators and working environment the operator has to protect himself with safety-clothes. For the flocculator the operator needs the following safety clothes: Safety clothes (chemical resistant). Safety shoes (chemical resistant). Safety glasses. Working gloves (chemical resistant). 3.2‘Type: RPF 100 Project: ARIZTIA Arica HW: 1188411 Code: 4. INSTALLATION. 4.1 TRANSPORT INSTRUCTIONS. ‘Transport For dimensions and weight see chapter 2.1 in this manual. Transport by truck has to be in accordance with the following conditions: * The truck needs to have sufficient stability to transport the installation. * The installation has to be tied with bands or any applicable transport appliances to guarantee correct and safe transport. * During transport and hoisting the flocculator needs to be empty. ‘+ The flocoulator must be transported in a straight position. Storag The flocculator has to be placed in a frost-free environment. When frost can influence the process, all valves must be opened and the entire unit including pumps must be drained ‘empty. It's also recommended placing a calamity tank under the flocculator. At the same time the flocculator has to be protected against any corrosive influences like seawater etc. All electrical components must be protected against all weather influences. Load and unload, For (un}loading of the flocculator a forklift ruck can be used very well. The flocculator has to be lifted and approached from the backside of the frame. On this way the injectors on the front can not be damaged. The flocculator can also be lifted with a crane. For this you'll need duly hoisting material, what can be tied welll on the flocculator (take care that the appendages on the flocculator do not damage by hoisting ropes etc.). Hoisting accessories have to be of proven quality. At no situation anybody may come in the hoisting area because falling products can cause injuries. At no situation the frame of the flocculator, (which is constructed of stainless steel), may come in contact with carbon steel since carbon steel scratches will cause corrosion of the stainless steel. ‘4.2 MOUNTING INSTRUCTIONS. Check the installation for damages, and check whether the functioning of all moving parts is ‘correct (direction of rotation?). Also check if all (design) conditions are fulfilled to ensure a ‘correct functioning of the installation. The Transport Company only can leave after inspection and signing of the transport documents. Redox is not responsible for transport, load, or unload damages. The Transport Company is responsible for these damages. Foundation. The system has to placed in a dry, frost-free environment and has to be levelled on a horizontal / fiat foundation. Install and cramp, the installation with the supplied wall-ties. (See the enclosed reference general drawing / layout drawing in this manual) If the installation has to be placed outside then the following measures has to be taken: ‘+ Insulation of the installation, pipes and pumps 44REDOX ject ARITA Aca OnW:t188411 Code: C Protection against rain(water) Put on heat-tracing on pumps and pipes Protect the system against freezing. The installation is filled with water and is not frost-free, it can be placed outside when the installation is empty. Accessibility. (The below mentioned is only valid for standard systems, There needs to be one (1) meter free space on all sides of the system to allow an unhindered operation and maintenance. Make allowance for enough space for exchanging parts. This has to be determined based on the plant and system location. The supply pipes of the dosing pump(s) are tubes, chosen very carefully by Redox. These tubes have to be fastened very well on the injectors. 4.3. CONNECTIONS. ‘+ The components, which belong to the flocculator, have to be connected in accordance with national and local regulations, concerning water, electricity and sewerage etc. 42RE o x “Type: RPF 100 Project ARIZTIA Arca ‘nw 1168411 Cote 5. DIRECTIONS FOR USE. 5.1, PROCESS DESCRIPTION. The main function of the flocculator (RPF) is to achieve optimal mixing of chemical additives in a water stream. The feed pump pumps the wastewater (after coarse filtration) to the inlet of the flocculator. The flocculator is characterised by the plug flow principle. Chemicals are therefore dosed only if there is flow. Near the inlet side, coagulant (pos. C) will be dosed. Directly behind the dosing point, a mixing-unit is installed to mix the coagulant very intensively with the wastewater. Coagulation is the destabilisation of the polluting matter in the wastewater. Fine particles are formed, which are not ideal for separation. Before the second mixing unit, flocculant will be dosed to let these particles grow to flocs. Liquid flocculant is made in a separate poly-electrolyte make-up unit from poly-electrolyte granulate powder and water, and is then dosed to the flocculator. The floc will be made in the flocculator-part behind the ‘second mixing-unit. Mixing energy and reaction energy in the mixing unit and in the pipe are result of turbulence. The flocculator can be provided with optional fittings for dosing of chemicals for neutralisation and for pH measurement. <= effluent a <= influent Figure 5.1. 5.1> “Type: RPF 100 Project. ARIZTIA Arica ‘OHW: 1188411 Coe: 5.2, ITEM DESCRIPTION. ‘A: Sample points. Before taking a sample read chapter 3 of this manual! By taking a sample, think of the safety clothes. Figure 5.2 Pos. A1: Sample point untreated influent. At sample point A1, a sample of the influent can be taken as it flows into the flocculator, before any chemical additives are dosed Pos. A2: Sample point after coagulant dosing. ‘At sample point A2, a sample after coagulant dosing can be taken, to check whether ‘coagulant is dosed optimally. Pos. A3: Sample point after neutralising agent dosing. At sample point A3, a sample after neutralising agent dosing can be taken, to check whether neutraliser is dosed optimally. Pos. A4: Sample point after lant dosing. At sample point A4, a sample after flocculant dosing can be taken, to check whether flocculant is dosed optimally. Pos. AS: Sample point pre-aeration. At sample point A5, a sample after pre-aeration can be taken, to check whether the pre- aeration is optimally. 5.2Cy R x Prec ARICA Aca OW: 1188411 Code: low-switch. The flow of the incoming water is controlled by a measuring-pin in the GPL 80-S. See manual GPL in manual index chapter F. C: Coagulant dosing section. ia Pipe flocculator # s Safety valve _, Figure 5.4 Generally, as a first treatment step coagulant (for example FeCl.) is dosed, to obtain coagulation. Directly behind the coagulant dosing point, a mixing-unit is installed to mix the coagulant very intensively with the wastewater. Coagulation is the destabilisation of the polluting matter in the influent. Fine particles (so called pin flocs) are formed, which are not ideal for separation. To avoid coagulant to be pumped into the flocculator while the pump is not pumping or pumping an insufficient amount of wastewater, a safety valve is installed in the injection part. The valve is controlled by the flow pressure detection unit (see pos B). The valve is controlled by the pneumatic valve in the pneumatic control panel. Redox must be informed when an other coagulant than FeCl, 42 wt% is dosed. D: Neutraliser dosing sectior Pipe flocculator Figure 5.5 5.3REDOX Pict AREA Arca revise ote Generally neutralising agent (for example NaOH) is dosed to neutralise the wastewater after coagulant dosing. Neutralisation is often required to obtain the correct pH value to allow discharge of the treated effluent, to obtain an acceptable pH value for the flotation unit and / or to obtain a suitable pH value for optimal functioning of the poly-electrolyte for flocculati Redox must be informed when an other neutraliser than 30 wt% is dosed. E: pH measurement. ‘Armature with +“— pH-electrode inside Pipe flocculator_,. Figure 5.6 The system is delivered including pH control, at this point the pH value is measured. The pH measurement and control system can be used for controlling the neutralising or coagulant agent dosing. For further information see manual pH measurement in manual index chapter E. 5.4BD io x “Type: RPE 100 Project: ARIZTIA Arica ‘OHW: 1188411 Code F: Flocculant dosing section. ‘ Pipe flocculator Figure 5.7 At this point flocculant (generally poly-electrolyte) will be dosed to let grow the pin point flocs (formed after coagulation) to flocs. Liquid flocculant is made in a separate poly-electrolyte make-up unit from granulate poly-electrolyte powder (or concentrated liquid) and water and is then dosed to the flocculator. The fioc will further develop in the flocculator part behind the second mixing-unit after the flocculant dosing point. The optimal type of flocculant (poly-electrolyte) can differ per application. It is advised to contact suppliers of flocculant (poly-electrolyte) to perform tests to determine the optimal type of flocculant. Aeration points. See figure 5.1. At these points, air saturated water from the recirculation system of the flotation unit can be added to the pre-treated wastewater. The addition of air saturated water to the flocs in the flocculator can give a better result in the flotation system. 5.3. START UP. ‘© Start up the flocculator: 1) Be sure that the flocculator is clean (no dirt in the flocculator). This to prevent damages on pumps etc. 2) Be sure that everything is connected according to the drawings. 3) Be sure that the entire installation is checked (working, rotating directions and damages)! 4) Be sure that all samples are closed 5) Check if the ball valve from the coagulant dosing section is open. 6) Check if the non-retum valve from the coagulant dosing section works properly. 7) Check if the ball valve from the neutraliser dosing section is open. 5.5“Type: RPF 100 Project: ARIZTIA Arica OHW: 1188411 Code: 8) Check if the non-retum valve from the neutraliser dosing section works properly. 9) For adjusting the pH measurement see the manual of it in the manual index. 10) Check if the ball valve from the flocculant dosing section is open. 11) Check if the non-retum valve from the flocculant dosing section works properly. 12) Decide or pre-aeration is necessary. Too much pre-aeration results in big air bubbles at the influent of the installation. 13) Fill the flocculator with clean water. For start up procedure see electrical diagram in the manual index chapter PQ. For further information about the dosing pumps / poly-electrolyte make-up unit see the manual of it in the manual index chapter B till D 5.4. OPERATORS AND WORKING ENVIRONMENT. There is no fixed working area required for an operator. For accessibility see paragraph 4.2. Only regular maintenance and a periodic check to control the correct functioning of the ‘system operation are required. The operator therefore can also take care of the maintenance of the system; the requirements for this function are described in chapter 6. 1. Very important for a good and hygienic operation of the flocculator system is to take care that the equipment and working area are clean. 5.6ox “Type: RPF 100 Project: ARIZTIA Arica ‘OHW: 1188411 Code: 6. INSPECTION / MAINTENANCE. 6.1. QUALIFICATION OF MAINTENANCE PERSONNEL. Only personnel, who are instructed by Redox, are allowed to carry out operation and maintenance activities. They are informed with the associated manual. The operator and/or maintenance engineer must have an average technical level: This person must have sufficient knowledge of: Chemicals working and dangers / process technology when applicable. * Mechanical engineering, pumps and valves. * Pneumatical knowledge, follow the working of the installation on the basis of the pneumatic diagrams and analyse malfunctioning. ‘* Electrical knowledge, follow the working of the installation on the basis of the electrical diagrams and analyse malfunctioning. He / she must associate with measuring devices like ohmmeter, voltmeter and amperemeter for measuring starting- and nominal currents. Ifa technical service / maintenance department is available, than it is strongly recommended to have the maintenance carried out by this department. 6.2. SAFETY MEASURES AND RISKS DURING MAINTENANCE. ‘See manual dosing pumps / poly-electrolyte make-up unit etc. in the manual index chapter B till D. «Maintenance, repair, inspection, checking for malfunctioning or removal of parts (pumps, poly units, etc.) is only allowed when the electric supply has been switched off and when all drives, pumps etc. are stopped. * Tum the main switch (figure 6.1, pos 4) in the “off position” on the electric control panel. Turn the maintenance switch in place in the "off position" (when applicable), + Secure the main switch (figure 6.1, pos 4) against incompetent switch on! Figure 6.4 All persons who are working on the machine must have their own padlock with matching key to lock the main switch (figure 6.1, pos 4) in a “safe position’. Only when all padlocks are removed from the main switch, the machine can be switched on again. Padlock is no Redox delivery, © Before doing maintenance, repair or removal of parts the flocculator has to be empty also. 61EDOX Piject ARIZA Aa ont as 6.3. MAINTENANCE. Daily maintenance: Daily maintenance consists of the below item © Check if the pH value is according to the mentioned range * Check the installation for freezing * Check the emergency stop Weekly maintenance: Checking / maintenance depends on the amount of working hours and the used substance. The following points needs to be checked / maintained for at least once a week: ‘* Check tubes, pipes, valves, non-retum valves ete. for fouling, if necessary clean it. © Check the samples for fouling, if necessary clean it © Check if the dosing is all right, if necessary change the dosing. © Check the working of the coagulant safety valve. Maintenance for supplied p: Ifa pH measurement and control system is installed on the flocculator, the pH for optimal pre-treatment will be adjusted automatically. If no pH-measurement and control system is installed, a frequent check is necessary. Take samples of each sample point from the flocculator and check these samples. Based on these samples the operator can determine the functioning of the chemical dosing system © For maintenance of the pH measurement and control system see manual in the manual index chapter E. * For maintenance on the aeration points see manual of the GPL80-S in the manual index chapter F. 6.4. CLEANING. Before cleaning the system read chapter 6.2 of this manual. For cleaning the pH electrode see the manual in the manual index. 6.2Type: RPE 100 Project ARIZTIA Avica OnW: 1188411 Code: 6.5. DUE GUARANTEE / PRODUCT LIABILITY. ‘* The guarantee clause is described in the purchase documents. The standard guarantee covers a half (¥4) year with a maximum of 1500 operation hours after delivery at site. * Product breakdown of the Redox products which is caused by defects of the Redox products within the guarantee period and by Redox remarked as a Redox failure will be replaced by Redox. Only the material will be compensated by Redox. The defect part can be send to Redox for judgement and eventually repair. THE FOLLOWING ITEMS ARE EXCLUDED FROM THE GUARANTEE and LIABILITIES: All mistakes caused by not checking the warnings in this manual. Damage, caused by poor foundation of the installation. Defects caused by normal wear and tear, injudicious handling / operation, incorrect maintenance or defects which are the result of alterations / modifications by order of the client or third parties. See ,Orgalime". Damages and / or defects caused by incorrect operation of the installation. Damages and / or defects caused by extreme temperatures like freezing. Damages and / or defects caused by dismounting pumps, drives and other parts of the installation. * After a defect to pumps and / or drives, dismounting them by anybody other than the manufacturer automatically makes the guarantee invalid. * Damages, which are caused by using not original parts, are not included in this guarantee. + When components are built in the electrical control panel afterwards by anybody other than the manufacturer (Redox). Wear ang tear parts are not included in this guarantee. Exchange of materials. 6.3x Type: RPF 100 Project: ARIZTIA Avica OW: 1186411 Code: 7. MALFUNCTIONING AND REPAIR. Before doing maintenance or repair, read chapter 6.2 of this manual very carefully. For maifunctioning on dosing pumps / pH measurement see the manual of it in the manual index. 7Ax “Type: RPE 100 Project ARIZTIA Arica ‘OHW: 1188411 Code 8. DISCARD AND ENVIRONMENT. The steels / synthetics / chemicals / medium / substances etc. must be dismantled according to the national and / or local regulations of that moment. 8.1, RE-USE. The flocculator is constructed from durable materials and components. For re-use there must be known which materials are used in the installation, so that can be considerate for what can be re-used, when and how can be recycled, The stainless steel frame is made of AIS! 304 (werkstoff. Nr:1.4301) and can be re-used for other purposes. The piping is made of chemical resistant synthetic (HDPE). The dosing sections are made of PVC. 8.2. Dis-MANTLING. Drives, pumps, electrical switch and control panel, etc., can be dismantled. The stainless steel frame is welded in full and cannot be dismantled in parts. Dismantling of the flocculator has to be executed by professional personnel. 8.1ox “Type: RPF 100 Project: ARIZTIA Arica ‘OHW: 1188411 Code 9. CUSTOMER SERVICE. 9.4. ORDERING PARTS. ‘The Redox repeat order procedure is described in the enclosed recommended spare parts / wear and tear parts order list. See manual index chapter M. This list has been composed carefully. Redox doesn't have all the parts in stock. Therefore it is important that you have these parts in stock, to prevent possible failures that can cause a long standstill of the system. By giving the item number and the description, the correct part with according connection will be supplied. In case of special / exceptional location etc., parts can be modified. 9.2. HELPDESK FOR PROCESS AND PRODUCT INFORMATIO! The address for all your questions is: REDOX WATER TECHNOLOGY B.V. Service department Stevinstraat 11, 7102 DZ Winterswijk P.O. Box 218, 7100 AE Winterswijk Phone: 0031 (0)543-531030 Fax: 0031 (0)543-519089 E-mail: info@redox.n! E-mail Service department: info@redoxservice.nl Internet: http:/www.redox.nl 9.1