Technical Memorandum
To: Chris Ehlers – City of Brentwood Casey Wichert – City of Brentwood From: Michael Ducker, P.E. Chad Coleman, P.E. Reviewed By: Greg Chung, P.E. – West Yost Associates David Anderson, P.E. – West Yost Associates Date: March 25, 2015 Revised April 15, 2015 Project: Brentwood Wastewater Treatment Plant Subject: Tertiary Filters
PROBLEM STATEMENT The City of Brentwood currently experiences high electricity costs due to peak loads from the air scour blowers for the deep bed sand filters. The City is interested in exploring the use of cloth media filters instead of deep bed sand filters since cloth media filters require no air scour blowers. This replacement could be a means of reducing the peak electrical load and associated costs of tertiary filtration. The purpose of this report is to summarize the issues and quantify the payback time required to recover the capital investment assuming the filters are changed.
If the use of a cloth filter is determined to be feasible, then cloth filters may be installed for the Phase 2 expansion in conjunction with the existing Phase 1 deep bed sand filters. If a Phase 2 expansion of cloth filters proves to reduce the power consumption and load requirements, then the existing Phase 1 sand filters may eventually be replaced. This memo will include a comparison of the qualitative and quantitative costs and benefits associated with the installation of a cloth media filter.
DISCUSSION OF EXISTING TREATMENT PROCESS The City of Brentwood WWTP is a suspended growth activated sludge process. The plant operations and processes included the following: • fine screens • grit classifiers • denitrification basins
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• oxidation ditches • secondary clarifiers • return activated sludge • tertiary deep bed sand filters • chlorine contact basin • belt filter press for biosolids dewatering
Un-disinfected tertiary effluent can be diverted to onsite disposal ponds, and chlorine disinfected tertiary effluent can be reused as plant water or in the community as non-potable water. The remaining tertiary disinfected effluent flows over a cascade aerator prior to discharge into Marsh Creek. Sludge is dewatered and trucked to a local landfill as daily cover material.
EXISTING TERTIARY SAND FILTERS The existing tertiary filters are constructed around the Tetra Technology Underdrain Block system. There are three duty and one standby deep bed sand filters each installed in 54’-0” long, 9’-6” wide, 18’-1” deep above ground concrete tanks. The Phase 1 design flows are 5 MGD Average Dry Weather Flow (ADWF), 7.5 Average Dry Max Month (ADMM) flow, and 10.0 MGD Peak Wet Weather Flow (PWWF). The Phase 2 design flows are double that of Phase 1 or 10.0 MGD ADWF, 15 MGD ADMM, and 20.0 MGD PWWF. The Phase 1 facility has been constructed with provisions for the Phase 2 expansion including pumps, piping, valves, pipe penetrations, concrete tie-rods and break away sections for future tanks, electrical supply, controls, and instrumentation. The Phase 2 expansion will include the addition of four additional concrete tanks and deep bed sand filters.
Secondary effluent (SE) from the conventional circular secondary clarifiers flows by gravity to the secondary effluent wet well and pump station. Alum and polymer can be mixed and injected into the secondary effluent stream to aid with coagulation and settling within the tertiary sand filters. No alum or polymer is being added at this time. Secondary effluent is gravity drained through a 6-foot deep bed of sand filter media, 1’-6” deep bed of layered gravel, and then through the Tetra Technologies underdrain blocks. The plastic underdrain blocks are hollow with screened tops to retain gravel and sand above and open on the bottom to let filtered effluent drain below.
Filtered effluent (FEF) from the filter underdrain flows by gravity through the effluent box to the chlorine contact basins then out to onsite effluent disposal ponds, surface water discharge, or reuse. A portion of the filtered effluent overflows the effluent box to fill the clear well. Submersible backwash pumps located in the clear well are used to intermittently reverse flow
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upward through the gravel and sand media filter bed to remove and waste particulates trapped in the sand media. Air from the backwash blowers is piped into the hollow underdrain blocks in conjunction with the up flow from the backwash water to scour and lift particles from the gravel and sand media. The air helps to roll the sand media and lift the waste particles to the water surface where they will overflow the filter weirs and gravity flow to the mud well.
Motorized valves on the secondary effluent, backwash, and air lines are used to switch between filter and backwash cycles. The added air increases the effectiveness of the backwash cycle and reduces the volume of backwash water. Submersible pumps in the mud well send the dirty backwash waste (WW) back to the plant inlet screen.
Each of the four sand filters are backwashed every other day. Two backwash cycles are run each day. A typical backwash cycle is started with the air blowers lifting the media and suspending the solids for a set time (currently 10 minutes) prior to the backwash pumps running. One backwash pump (rated at 2,900 gpm) pumps at 2,600 gpm for 25 minutes for a total daily backwash flow of 127,600 gallons. The backwash is wasted to the mud well and returned to the WWTP headworks for retreatment.
Equipment supporting the Phase 1 tertiary filter process includes the following: • 2 each – 200 hp, 2,540 scfm positive displacement backwash air blowers • 2 each – 40 hp 2,900 gpm backwash (clear well) pumps • 2 each – 20 hp, 1,000 gpm waste (mud well) pumps
No additional blowers or backwash pumps are required for the ultimate Phase 2 design flows so it is assumed that there is one duty and one standby pump for each application. The air blower has the largest electrical load in the plant.
The filter backwash cycles are set to run on a timed schedule rather than on increasing headloss and water surface elevation through the filters to ensure that the air blowers are operated only during the off-peak electrical demand times of the day.
The blowers are the single largest electrical load in the plant and at 200 hp each they increase reserve demand charge and billing tier rate fee for the plant. The City Operations Group estimates that the fees paid to reserve power for possible peak electrical demands of the plant and the cost associated with the increased electrical usage rates caused by moving to the next higher billing tier have an approximate annual cost of $75,000 per year.
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The backwash waste pumps are sized to empty the mud well quickly in case there is a plant upset and the filters need more frequent or extended backwash cycles. For normal flow conditions the waste pumps are throttled down using the discharge valve to meter flow back to the headworks and a slower rate over a longer period of time. The backwash waste pumps are constant full speed pumps.
A reduction in the volume of backwash water generated and air blower size by switching to another type of tertiary filter should reduce the plants monthly electrical use.
One of the sand filters was taken off line for inspection and repair approximately 12 years after start up. It was deemed easier to dispose of the old sand media and replace with new rather than return the used sand media back into the filter basin. The cost to replace the sand was $80,000. There has been no need to replenish sand in the filter basins due to wash-out nor replace sand due to fouling or lack of performance. There is currently no need or schedule to replace the existing sand media.
CLOTH TERTIARY FILTERS Operations staff at the City of Brentwood WWTP are considering the design parameters and costs of installing cloth media filters. The use of cloth media filters may decrease the backwash demand and wastewater sent back to the headworks for retreatment, and may reduce or eliminate the energy used to operate the backwash air blower. Cloth media filters may be installed instead of sand filters in the Phase 2 expansion and may be used to replace of the existing Phase 1 sand filters.
TYPICAL OPERATION OF CLOTH FILTERS In a cloth media filter the secondary effluent is gravity fed or drawn by a suction through the media. Cloth media filters come in both inside-out flow and outside-in flow variations. The effective pore size of the cloth media reduces as the filter is used due the buildup of particles on the filters surface builds. When the water starts to move slowly through the media the water surface will rise.
In a gravity fed filter, particulates continuously collect on the cloth filter surface which slows the flow through velocity and filtering rate, increases headloss, and raises the water level in the basin. The water level will rise to a control set point that will start a cleaning or backwash cycle. Typical cleaning systems either vacuum the filter surface, or use pressurized backwash spray. The backwash water is wasted to the treatment plant headworks.
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Some models of cloth filters are made specifically to be retrofitted into concrete sand filter basins. There are some cloth filters that fit nicely into sand filters equipped with a traveling bridge where the traveling bridge is reused to clean the media. Some modifications to the existing concrete tanks may be required to install a packaged cloth media filters. Some cloth media filters come in prepackaged plug and play units within a custom fabricated steel tanks that can be set on a concrete pad.
For this facility there is no immediate need to repair or replace the existing filters. The filters are still within their expected useful lifespan, are working well, and still meet the discharge requirements. If a new filter were needed then it would be desirable to continue operations of the existing filters while the new filters are being installed. Currently the plant has not undergone the Phase 2 expansion and there is still space and provisions for a mirrored set of 4 concrete sand filter basins to be constructed adjacent to the existing sand filters.
CLOTH MEDIA FILTERS VS. DISCHARGE REQUIREMENTS FOR SURFACE WATER DISCHARGE AND RECYCLED WATER The three cloth media filters shown in Table 1 below claim to meet CCR Title 22 discharge requirements. Two of the three have been tested and are Title 22 approved in the State of California. The local Regional Water Quality Control Board district office should be consulted prior to equipment selection to verify the testing and approval required to produce water for reuse and surface water discharge.
This technical memo compares three cloth media filters, Aqua-Aerobic Systems, Fluidyne and Kruger. A comparison of the design capacity, required utilities, scope of supply, and unit costs are provided in Table 1.
Table 1– Budgetary Cloth Filter Equipment Cost Item Description AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS Design Capacity Model Aquadisk Filter Model F150048C HSF2216/15-1F ADFSC-54x14E-PC Qty. of Filter Units 3 each units 2 each units 3 each units Recommended 2 duty, 1 standby 1 duty, 1 standby 2 duty, 1 standby No. of Disks per Unit 14 disks/unit 16 modules/unit 15 discs/unit Total No. Disks 42 32 45 Total Filter Area 2,259.6-ft2 1,536-ft2 1,764-ft2 (48 ft2/element) (submerged filter area)
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Item Description AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS Filter Media Cloth OptiFiber PA2-13 100% Acrylic pile cloth GRP Type media Maximum Flux Rate 6 gpd/ft2 5.0 gpm/ft2 Filter Direction Outside-in Inside-out Inside-out Average Hydraulic 2.15 gpm/ft2 3.16 gpm/ft2 4.13 gpm/ft2 Loading @ 7.0 MGD Maximum Hydraulic 3.07 gpm/ft2 5.0 gpm/ft2 5.91 gpm/ft2 Loading @ 10.0 MGD w/ 2 duty +1 standby w/ 1 duty + 1 standby w/ 2 duty + 1 standby 4.6 gpm/ft2 out of service w/ 2 duty + 1 standby out of service Solids Loading Rate 0.55 lbs. TSS/day/ft2 Total Solids Removal 1,251 lbs/day Daily Backwash Flow 56,160 gpd, 2.4% influent flow, <=3% influent flow, =(2 pumps/unit)*(3 118,988 gpd 68,900 gpd units)*(130 gpm/pump)*(3 min/hr)*(24 hr/d) Required Utilities Overhead Winch and Not Required Required, Not Required Rail Not Included Air Compressor Not Required 25-30 scfm @ 90-100 Not Required psi, 10 hp For air scour and pneumatic valves, Included Main electrical supply 460 VAC, 3ph, 4 wire, 120 V, 1 ph, 60 Hz 460 VAC, 3ph, 4 wire, 60 Hz 20 Amp circuit breaker 60 Hz 25 Amp breaker Backwash/Waste Qty. (6) 2.0 hp pumps Gravity backwash, Qty (3) 15 hp pumps Pumps (130 gpm @ 23 ft), Pumps Not Required (99 gpm), Included Included Drive Motor Qty. (1) ¾ hp drive Not Required Qty. (1) 1.5 hp drive motor, motor, Included Included Valves Motor Operated Valves Pneumatic Valves Included Qty. (7) 115VAC Qty. (30) influent backwash Qty. (30) backwash Qty. (7) 115VAC waste Included Included
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Item Description AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS Scope of Supply Steel Tanks Qty. (3) Std. Epoxy Qty. (5) 304 SST Tanks, Qty. (3) 304 SST Tanks, Coated Steel Tanks or Optional - Not Included Optional - Not Included SST, (18’-7 ¾”L x 8’-5 ¾”W, 11’-11”H each), Optional - Not Included Concrete Basin Qty. (3) Concrete Qty. (2) Concrete Qty. (3) Concrete Basins, Basins, Basins, Retrofit Existing Filter (34’L x 34’W x 12’H), Retrofit Existing Filter Basins, Construct New Filter Basins, Not Included Basins, Not Included Not Included Drive, Filter, Included Included Included Backwash, and Waste Assemblies, piping, hoses, tubes, valves, supports, brackets, and etc., Included Backwash/Solids Included No pumps required, Included Waste Pump(s) Gravity backwash, Included Controls Qty. (1) NEMA 4X Qty. (1) NEMA 4X MCP Qty. (1) NEMA 4X local fiberglass enclosure panel/each unit, Allen- control panel/each and Allen-Bradley Bradley Pico Controller unit, Included Micrologics 1400/each Included unit, Included Instrumentation level float switch, Included Included vacuum transmitter, pressure transmitter, pressure gauges Included Alarms, SCADA Ready 115 V dry contact 115 V dry contact 115 V dry contact General alarm, General alarm, General alarm, SCADA ready Optional SCADA ready Optional SCADA ready Title 22 Approved Yes Meets Requirements, Yes Not Tested
CDPH CCR Title 22 Section 60301.320.a.1
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Item Description AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS Budgetary Cloth Filter $840,000 $1,100,000 $708,000 Equipment Cost Options Cost of Optional SST $380,000 Cost of Optional SST tank not provided 304 SST Tanks tank not provided
MONTHLY ENERGY COST The estimated monthly electrical cost is approximately $300/month. The following assumptions were made for the use of electricity and the results are shown in Table 2 below.
• The annual energy cost for the Kruger filter is 44,500 kW/hr/yr. • Using a cost of electricity at $0.08 per kW/hr • Monthly electrical cost for the filter is $296.67/mo. • (44,500 kW/hr/yr) / (12 mo/yr) * ($0.08 /kW/hr) = $296.67/mo
The monthly electrical cost for the Fluidyne unit including the intermittent use of the air compressor, but excluding the control panel and valves is $31.20/mo.
• (13kW/hr/day) * (30 day/mo) * ($0.08/kW/hr) = $31.20/mo
Table 2 – Monthly Energy Cost Item AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS
Electricity Usage 15,378 kW/hr/yr 13 kW/hr/day 44,500 kW/hr/yr Monthly Energy Cost $102.52/mo $31.20/mo $296.67/mo Cost of Electricity $0.08/kW/hr
These utility costs are based on preliminary sizing of a filter unit. For calculations purposes in this analysis, and to be conservative, the maximum energy cost will be used and is estimated at $300 per month.
These electrical energy costs include the onboard cloth media backwash/waste pumps for the cloth filters. The cloth filters will not share the energy costs of the existing backwash clear well pumps or air blowers but will share the cost of the mud well waste pumps which are required for both the existing sand filters and cloth media filters.
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For the existing and proposed equipment that did not have and energy usage provided the following calculation was made to estimate a monthly electrical usage fee to that piece of equipment.
Clear Well Backwash Pump • Per NEC table a 40 hp pump at 480 Volts draws 52 Amps. • kVA = 52 Amps * 480 Volts / 1000 = 25 kVA • The pump runs for 22 minutes per day • kW-h/mo = 0.9 * kVA * hrs/mo • kW-h/mo = 0.9 * 25 kVA * (22 min/d)*(30 d/mo)/(60 min/hr) = 247 kW-hr/mo • Monthly Cost of Electricity = $0.08/kW-hr * 247 kW-hr/mo * 2 pumps = $39.60/mo
OPERATIONS AND MAINTENANCE Daily operation of the cloth media filters and effluent testing is expected to require the same or fewer labor hours than effort spent on the existing deep bed sand filters and the associated ancillary equipment. If cloth media filters were installed, it is assumed that much of the existing equipment would still be utilized such as the clear well, mud well, motor operated valves, and etc. For the purpose of this memo it will be assumed that the level of effort is the same for the existing sand filters and the prospective cloth media filters. The number of labor hours and labor rate for the following tasks are estimated.
Testing, Monitoring and Reporting • (8 hr/d)*(1 d/wk)*(4 wk/mo)*($100/hr) = $3,200/mo
Daily Operational Labor • (30 d/mo)*(2 hr/d)*($100/hr) = $6,000/mo
The Kruger filter unit requires partial filter replacements after the first 5 years of continuous operation. The cost for replacing 4% to 6% of the media from years 6 through 8 is $5,250 per year and the cost of replacing 6% to 8% of the media from years 9 through 20 is $7,350 per year. The manufacture estimates that Operations staff can replace the fabric in a filter unit in an 8 hour shift. Including labor the average annual repair and replacement cost is estimated at $9,750 per year.
Maintenance, Repair and Replacement • ($7,350/yr) + (8 hr labor)*(3 person crew)*($100/hr) = $9,750/yr or $812.50/mo
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The tertiary filtration of the secondary effluent must operate continuously without interruption. Redundant filter units are to be installed and ready for operation. In reality, normal operation will include both duty and standby units operating at lower than designed filtration rates. If a unit were to fail or be taken out of service for maintenance or repair the other unit(s) will run at the average and peak design filtration rates.
Filter replacement costs were not provided for the other filter manufactures. For this conceptual level report it is assumed the monthly O&M, testing, and replacement costs are similar for all three units. The additional operations and maintenance costs associated with running cloth filters is estimated and shown in Table 3 below.
Table 3– Monthly Operations and Maintenance Item AQUA-AEROBIC FLUIDYNE KRUGER SYSTEMS Monthly O&M Labor - - $6,000/mo Monthly Testing, - - $3,200/mo Monitoring and Reporting Monthly - - $812.50/mo Maintenance, Repair and Parts Replacement (estimated) Monthly O&M Cost - - $10,100/mo Monthly O&M costs are estimated.
For this memo it will be assumed that the Operations and Maintenance cost for the existing sand filter is approximately equal to that of a cloth filter design. The installation of cloth filters as a Phase 2 expansion would conceivably create a new list of O&M standard operating procedures and maintenance schedule. This would be in addition to the O&M for the existing sand filters, resulting in a total filtration O&M cost of $20,200/mo; Phase 1 sand filters ($10,100/mo) plus Phase 2 cloth filters ($10,100/mo). Some of the O&M would overlap as the secondary effluent pumps, valves, and mud well waste pumps would be used for both operations.
COMPARISON OF SAND FILTER TO CLOTH FILTER To make a comparison of the two filter systems (sand or cloth media), this memo will report on a review of three project alternatives.
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1. The first alternative is the Phase 2 expansion as per the original plant design intent to install four additional deep bed sand filters. 2. The second alternative is to install cloth media filters as the Phase 2 expansion in conjunction with the existing Phase 1 sand filters. 3. The third alternative is to replace the Phase 1 sand filters with cloth media filters and to install cloth media filters as the Phase 2 expansion.
Table 4 subjectively compares relative costs of the existing sand media filter versus the cloth media filter.
TABLE 4 – FILTER COMPARISON Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Description Phase 1 sand filters Phase 2 build-out, Phase 1 remove sand are already installed, install cloth filters at filters basins from perform well, and additional cost. service and retrofit to require no additional Construct concrete accommodate cloth repair or elevated deck. Use filter units, one basin replacement. provisions for at a time. mechanical and Phase 2 build-out, structural expansion Phase 2 build-out, install sand filters at included in Phase 1 install cloth filters at additional cost for design plus additional cost. concrete basins, additional yard Construct additional Tetra underdrain piping, electrical and concrete basins, if block units, sand control system. required. Use media, and controls. provisions for Provisions for mechanical and mechanical, structural expansion structural, and included in Phase 1 electrical, expansion design plus have been included additional piping, in Phase 1 design. pumps, and electrical and control systems.
EQUIPMENT Filter Package Tetra block units Treatment Units Treatment Units Assume $40,000 $839,889 2x $839,889 = /basin x 4 = $160,000 $1,679,778
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Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Prefabricated Tanks None Use custom None fabricated SST tanks supplied by manufacture $380,000 Sand Media Four (4)*($80,000) = Not required Not required $320,000 Process Piping, Mechanical Tie-in to Phase 1 Tie-in to Phase 1 Tie-in to Phase 1 and points of connection points of connection Phase 2 points of for Phase 2 for Phase 2 connection. expansion. expansion. Limited new process No new penetrations Requires pipe piping required required, most piping penetrations through $75,000 and valves were existing filter installed in Phase 1. building, yard piping $50,000 and valves. $100,000 Automated Valves Motor Operated, (4) Solenoid or Motor Operated, (4) 18”FEF, (4) 20”SE, (4) Pneumatic Operated 18”FEF, (4) 20”SE, (4) 14”BW, (4) 10”A $300,000 14”BW, (4) 10”A $400,000 $400,000 Electrical Supply, Controls, Assume that existing Assume that existing Assume that existing Instrumentation, SCADA electrical service and electrical service and electrical service and main switch board main switch board main switch board has capacity for has capacity for has capacity for cloth Phase 2 expansion. Phase 2 expansion. media filters. $ No Cost $ No Cost $ No Cost
Requires new motor Additional electrical Additional electrical operated valve supply, and SCADA supply, and SCADA controls, and programing required. programing required. additional SCADA $100,000 $100,000 programing. $50,000 Subtotal Equipment Cost $980,000 $1,720,000 $2,254,778 STRUCTURES Building Phase 1 building is Phase 1 building is Phase 1 building is constructed and constructed and constructed and would be used for would be used for would be used for Phase 2 build-out. Phase 2 build-out. Phase 2 build-out. $No Cost $No Cost $No Cost
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Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Concrete Tanks/Structures Construct four (4) Construct new Retrofit four (4) new concrete tanks elevated deck existing Phase 1 adjacent to Phase 1 adjacent to Phase 1 concrete tanks filters, use existing filters. $50,000 design, concrete $400,000 elevated breakouts, rebar tie- deck Construct two (2) ins, and pipe new concrete tanks penetrations. adjacent to Phase 1 $600,000 filters, use existing design, concrete breakouts, rebar tie- ins, and pipe penetrations. $300,000 Subtotal Structure Cost $600,000 $400,000 $350,000 OPERATIONS AND MANTENANCE Daily Operations and Additional SOP and $6,000/mo Maintenance $6,000/mo O&M Schedule Repair Replacement $6,000/mo Sampling, Monitoring and Same routine. Same routine. Same routine. Reporting $3,200/mo $3,200/mo $3,200/mo Filter Media Replacement Sand media removal Cloth filter removal Cloth filter removal and replacement cost and replacement cost and replacement cost $80k every 20 years, after first five years. after first five years. if required. $9,750/yr $19,500/yr $80,000/filter * 4 Or Or filters / 20 $812.50/mo $1,625/mo years/filter = $16,000/year Or $1,333/mo Subtotal Monthly $10,533/mo $10,013/mo $10,825/mo Operations and Maintenance Cost ENERGY Air Blower Existing (2) 200 hp, Not Required Not required Backwash Air Scour 2,540 scfm $No Capital Cost Electricity $91/mo
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Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Air Compressor Not Required (1) 10 hp, 25-30 scfm (2) 10 hp, 25-30 scfm Air scour and pneumatic @ 90-100 psi @ 90-100 psi valves Equip. Cost Included, Equip. Cost Included, Electricity $240/mo Electricity $480/mo Clear Well/Backwash Pumps Existing two (2) 40 Backwash pumps (3) Backwash pumps (6) hp, 15 hp, 15 hp, 2,900 gpm, Equip. Cost Included, Equip. Cost Included, $No Capital Cost $ Electricity $80/mo $ Electricity $160/mo Electricity $ 40/mo Mud Well/Waste Pumps Existing one (1) duty Existing one (1) duty Existing two (2) duty at 20 hp, at 20 hp, at 20 hp, 1,000 gpm 1,000 gpm 1,000 gpm $No Cost $No Cost $No Cost Electricity $10/mo Electricity $10/mo Electricity $20/mo Onboard Backwash/Waste Not Required Same as backwash Same as backwash Pumps pumps listed above, pumps listed above, (3) 15 hp, (6) 15 hp, Chemical Feed Pumps Existing Alum and Existing Alum and Existing Alum and polymer Addition polymer Addition polymer Addition System, installed but System, installed but System, installed but not used not required not required $No Cost $No Cost $No Cost Chemical Cost Not Used Not Required Not Required $No Cost $No Cost $No Cost Cost to Retreat Backwash to (127,600 gpd)*($2.00 (68,900 gpd)*($2.00 (137,800 gpd)*($2.00 Waste /1,000 gal)*(30 days) /1,000 gal) *(30 days) /1,000 gal) *(30 days) = = = $7,656 /mo $4,134 / mo $8,268 / mo Subtotal Monthly Energy $7,797/mo $4,464/mo $8,927/mo Cost
CONSTRUCTION The following facilities, equipment and tasks would be required. The cloth tertiary filters have been added to the existing liquid treatment flow diagram in Figure 1. Figure 2 shows the conceptual mechanical improvements for Alternative 2. The equipment shown in these figures shows only a conceptual layout of how the cloth filter units may be implemented into the existing sand filter system. The facilities shown have not been sized, and are not shown to scale.
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Retrofit Existing Tanks Versus New Concrete Deck – The existing Phase 1 sand filters are still operating well and will probably function properly with minimal maintenance and repair and replacement cost well past the typical 20 year lifespan for equipment. The existing filtration system must remain in full operation through any filter expansion or replacement project. Many of the current models of cloth filtration units can be installed in existing concrete tanks with some modifications to the existing tank.
Alternative 2 considers a cloth filter system in a prepackaged stainless steel tank that would be ready to place on an elevated concrete deck where the future Phase 2 sand filters tanks 5 through 8 were to be constructed. The tanks would need to be elevated to provide gravity flow through the chlorine contact basin and plant outfall. Stairs and hand railings will be required for equipment access and health and safety.
Alternative 3 considers the existing sand filters replaced with cloth filters and the retrofit of the existing concrete tanks and construction of new concrete tanks.
New Concrete Tanks – New concrete tanks would be required for a Phase 2 expansion using sand filters and possibly cloth filters. The most economical and user friendly design would be expand the facility as planed in the Phase 1 design. Four additional tanks would be constructed adjacent to and with shared walls to the existing sand filter tanks 1 through 4. The user friendly design would be the installation of cloth filters as a Phase 1 replacement and Phase 2 expansion project. Either of these Alternatives 1 and 3 will provide the Operations staff with a single type of process equipment to operate and maintain.
Piping – The use of either filter systems will require tying into the existing secondary effluent (SE), finished effluent (FEF), backwash waste (WW), backwash (BW), and possibly the air (A) piping systems. Alternative 2 using prefabricated stainless steel tanks on an elevated deck will require modifications to the planned Phase 2 tie-in pipe routing and will require extensive concrete wall penetrations and yard piping.
Building – No building is required. The existing filtration building already houses all the pumping, piping, mechanical, and electrical components necessary for an expansion of the sand filters. The electrical control panels for a cloth filter may be located remotely in the building or locally on the equipment skid or outside in a NEMA 3R or 4 enclosure that could be air conditioned or located under a simple shade structure. All pumps required for and supplied with cloth filter equipment will be mounted on the prepackaged filter skid.
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Instrumentation, Control, and SCADA – To make the simpler for the operations and maintenance group all electrical, instrumentation, and control equipment should be compatible or match the current standard equipment at the WWTP, including PLCs, VFDs, protocol language, SCADA hardware and software, electrical switch gear, flow meters, gauges, flow control valves, and etc. All new control panels should be tied into the existing plant wide SCADA monitoring and control system including new supplemental programing and screens for the plant control center. The SCADA hardware, software, protocol, point address, should match or be compatible with the existing SCADA system and historian.
Permitting – It is anticipated that a new tertiary filter facility will require a building permit through the local City or County building department. Revised the existing National Pollutant Discharge Elimination System (NPDES) permit.
DESIGN The following tasks would be required to produce a full set of design and construction documents.
Preliminary Design Report – A preliminary design report would be generated as a result of this technical memo to further investigate the feasibility of tertiary filter units, select a preferred unit, and produce design parameters and preliminary design layout and budgetary cost estimate for the project.
Geotechnical – A geotechnical investigation may be required for the purpose of designing additional tanks or slab on grade foundation plan, or elevated concrete deck. If the previous geotechnical report is still valid then it may be reused.
Survey – A topographic and utility survey in the area of the proposed improvements is essential for the design development and construction of this project.
Environmental – It is assumed that the City of Brentwood WWTP has an existing CEQA document and SWPPP. This project would not be outside of the existing footprint or predefined use and therefore it is not anticipated that any new environmental studies would be required. It is possible that Addendums or supplements to the existing documents may be required.
Design – A full set of plans and technical specifications will need to be produced for the construction of a new tertiary filter process. A cloth filter project would include civil, structural, mechanical, electrical and possibly architectural disciplines. If the Phase 2 improvements were
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similar to the existing system and tank then the existing design should be revisited and brought up to current codes and standards.
SUMMARY OF COSTS Construction Cost - For a budgetary cost estimate the construction cost is assumed to be 100% of the filter equipment cost. This would include all the ancillary equipment not provided in the equipment scope of supply, any utility service connections, site improvements, building, wet and dry utilities, controls and instrumentation, programing, construction inspection, construction staking, construction permits, compaction testing, and construction management. The structures were estimated using a cost per cubic yard of concrete installed including materials and labor for reinforcing steel, forming, and pouring.
Design Fees - The design fees are assumed to be 10% of total construction and equipment cost. Design fees would include the topographic survey, geotechnical investigation, laboratory testing, environmental report, preliminary design report, construction plans and technical specifications, and regulatory permitting.
The summary of the budgetary capital improvement costs and the monthly operation and maintenance costs are shown in Table 5 below. Note that a construction contingency cost is not included in Table 5. A typical conceptual level contingency is 30% of the total construction, equipment, and design costs.
The capital improvement cost for the sand filters is higher than the cloth filters because there is the addition of a new and parallel process and control systems. During the preliminary design phase more work would be done to quantify this analysis and more accurately determine the most feasible filtration system.
Table 5 – Budgetary Costs Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Tertiary Filter $480,000 $1,220,000 $1,680,000 Equipment Mechanical & Electrical $500,000 $500,000 $575,000 Structures 4 $600,000 $400,000 $350,000 Construction 1 $480,000 $561,000 $584,000 Design 2 $206,000 $268,000 $319,000
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Item Alternative 1 Alternative 2 Alternative 3 Phase 2 Sand Filter Phase 2 Cloth Filter Phase 1 & 2 Cloth Filter Capital Improvement $2,266,000 $2,949,000 $3,508,000 Cost 3 Monthly Energy $7,797/mo $4,464/mo $8,927/mo Monthly O&M $10,533/mo $10,013/mo $10,825/mo Monthly Operational $18,330/mo $14,476/mo $19,752/mo Cost Notes: 1 Estimated total construction cost including all the ancillary equipment, utility service connections, site improvements, building, controls and instrumentation, programing, construction inspection, construction staking, compaction testing, construction permits, and construction management equal up to 100% of the filter equipment cost, up to $500,000. For equipment costs over $500,000, the construction cost is estimated at $500,000 plus an additional 5% of the equipment cost.
2 Design would include initial topographic survey, geotechnical investigation, laboratory testing, environmental report, preliminary design report, construction plans and technical specifications, and permitting. Assume 10% of total construction and equipment cost.
3 Capital Improvement Cost does not include a contingency. A typical conceptual contingency is 30% of improvement cost.
4 Labor and materials are included in cost estimate.
CONCLUSIONS The only issue with the existing sand filtration system reported by the City WWTP Operations group is that horsepower rating of the backwash air blowers raises the peak electrical demand and billing tier of the entire wastewater treatment plant. This raised electrical billing rate increases the annual electrical cost by an estimated $75,000 per year ($6,250/mo). The following are some of the possible ways to reduce the electrical demand from the filtration system.
1. Contact customer energy efficiency department from the electrical surface provider and consult with them about how to rerate the peak demand and possibly reduce the billing tier. It is possible that the reallocation of equipment that is considered duty, standby, essential, and emergency may help to reduce the peak load and reserve power requirements.
Page 18 of 22
2. Replace the two (2) existing 200 hp air blowers with more efficient newer model blowers. Preliminary investigation has shown that two (2) new 125 hp positive displacement air blowers can produce the required 2,540 scfm at 8.4 psi (19 ft) and can be purchased at a budgetary price of $100,000 ($50,000 ea). That would reduce the duty kW requirement from 104 kW to 67 kW and the duty + standby requirement from 208kW to 134kW. Assuming a budgetary equipment and construction cost of replacing the blowers of $200,000 and assuming that the reduction in peak electrical demand were enough to reduce the electrical billing tier sufficient to avoid the $75,000/year surcharge, then the payback period would be 2.6 years ($200,000 / $75,000 year).
3. The peak electrical demand and peak billing rate may be reduced for the entire WWTP if the existing air blower were removed from service by using cloth filters to replace the existing sand filters and for the Phase 2 expansion. Alternative 3 in Table 5 shows the budgetary cost of installing both Phase 1 and Phase 2 sand filters in concrete tanks at $3.5M. The cost for installing just the Phase 1 cloth filter into the existing concrete tanks is estimated to be $2.1M. The payback period to replace the Phase 1 sand filters with the savings in electrical fees is approximately 30 years, $2,100,000/$75,000/year). The projected payback period would be reduced as the cost of electricity increases.
4. The City expressed interest in exploring the possibility of installing variable frequency drives (VFD) on the mud well backwash waste pumps. This would enable the operators to vary the return pumping rate of the waste pumps back into the plant headworks for retreatment. Metering the flow reduces the effects of sending a slug flow through the plant each time the filters go through a backwash cycle. This would not reduce the billing tier as the full load motor horsepower rating will not be reduced. However, the actual power draw by the motor will be reduced when the pump is running a low speed thereby reducing the energy use and cost. This energy savings is calculated to be on the order of $5 per month which will not produce a timely payback period for the improvement cost of installing a VFD. Installing a VFD on the existing pumps can be done easily if the existing motors are inverter duty rated. If not it would be best to replace the existing pumps with those that can be fit with VFD.
5. Continue to run the filters on a timed schedule during the off-peak electrical demand time of the day rather than on a headloss or backwater elevation. It is recommended, if not already implemented, that an alarm be sent to the plant PLC if the water surface in a filter rises to high level set point indicating excessive head loss through filters and the need for a manual start of the a backwash cycle.
Page 19 of 22
The cloth filters examined for this technical memo produce 57% to 100% of the existing backwash flow. This may provide up to an estimated $3,300/mo cost savings in the cost of retreating wastewater each month depending on the selected equipment and final standard operation.
The need to replace cloth media starting at year 6 is probably not over exaggerated and the cost will be approximately $9,750 per year. The sand in only one of the existing four filters has been replaced in the 12 years of operation. The replacement of the sand media was to simplify a system inspection and repair. The cost of replacing the sand for the entire filter was $80,000. The filters have been in operation now for 15 years and the operations group does not see an immediate or foreseeable need to replace the sand in any of the four filters. In a 20 year projection, the cloth media will cost approximately $123,000 to replace, versus a preventative sand media replacement cost of $0.
The existing sand filters are in good condition, are not difficult to operate and maintain, have a robust design, are sized with ample redundancy, and perform very well. Although there is an existing alum and polymer storage, handling, and injection system available for the sand filters no chemical addition is necessary or utilized. The Phase 1 sand filter facility is constructed to easily go through a Phase 2 expansion. If the peak electrical load requirements and billing tier can be reduced by replacing the existing 200 hp blower with a smaller 125 hp then it is recommended that the Phase 2 expansion of the tertiary filters include sand filter basins 6 through 8 as shown in the plant master plan. If the peak electrical load requirements cannot be reduced by replacing the blower and a +/-30 year payback period is acceptable then it is recommended that more detailed study or pre-design report be prepared for replacement of the existing sand filters with cloth media filters.
REVISIONS This tertiary filter technical memo was reviewed and commented on by the design team and the following revisions were made to the original memo dated March 25, 2015. The following parameters were changed. These changes were then incorporated into the calculations resulting in a revised set of tabulated values. Revised Tables 3 through 5 are attached to this memo.
1. In each backwash cycle, one (1) blower operates for 10 minutes while one (1) backwash pump runs for 25 minutes at 2,600 gpm for a total of 127,000 gallons.
Page 20 of 22
2. There is no PG&E electrical cost tier for the plant. The potential cost savings of $75,000 per year for eliminating the 200 HP blowers was not correct. The cost savings is calculated by the Operations group to be 200 HP * (0.746 kW/HP) * ($19.71/kW) = $2,941/mon * 12 = $35,300/year
3. It is assumed that there will be no increase in operations staffing hours, and that all work including daily operations, cleaning, and maintenance of the filter units will be absorbed into the work details of the existing filtration crew.
4. It is assumed that there will be no increase in operations or laboratory staffing hours, and that all work including regular testing, monitoring, and reporting of water and bio- solids quality will be absorbed into the already regular water quality testing, monitoring, and reporting procedures.
5. The following twenty (20) year average of the cloth filter media replacement cost were used: Phase 1 $433/month and Phase 2 $867/month.
6. Electrical Costs changed from $0.08/kWh to $0.14/kWh.
7. Design fees shall be a percentage of the construction cost and not the major equipment cost.
REVISED CONCLUSIONS The operations cost for maintaining either the sand filters or the cloth filters is believed to be the same as the existing operations cost. A blended system such as in Alternative 2, using both the Phase 1 sand filter and Phase 2 cloth filters, will likely result in an increase in operational costs due to operating two different systems.
The maintenance cost of the existing sand filters has been minimal over the past 12 years and is not expected to change. The need for replacement of the sand media is not yet anticipated and may not be required until sometime near the 20 year lifecycle. However, it is anticipated that the cloth media filters will start to need replacement during year 5 of operation. Although, it is generally accepted that cloth filters required little O&M it is reasonable to believe that they will require significantly more O&M than the existing sand filters due to the shorter life span of the filter media.
It is recommended that the existing Phase 1 sand media filters remain in full operation and that the Phase 2 improvements include the expansion of the future sand filter tanks 5 through 8.
Page 21 of 22
It is recommended that the existing 200 HP blowers be replaced with newer more efficient blowers that have been preliminarily sized at 125 HP. This reduced load will decrease the peak electrical demand on the plant. It is also recommended that a more detailed analysis of the electrical billing and rate structure of the treatment plant be completed including discussions with PG&E regarding billing tiers, rate structures, peak demands, duty versus standby equipment, times of operation, and conservation. Any electrical savings would go toward the payback of the new blowers.
FIGURES • Figure 1 – Flow Schematic, Liquid Treatment • Figure 2 – Mechanical, Tertiary Filter Plan
APPENDICES • Appendix A – Aqua Aerobics • Appendix B – Fluidyne • Appendix C – Kruger • Appendix D – Revised Tables 3 through 5
Page 22 of 22
Figures
• Figure 1 – Flow Schematic, Liquid Treatment • Figure 2 – Mechanical, Tertiary Filter Plan
Appendix A
Aqua Aerobics
From: Tim Brekke To: Michael Ducker Cc: John Compoginis Subject: FW: Brentwood WWTP CA 103320A -- Responses, O&M, and Drawings Date: Thursday, March 05, 2015 8:13:06 AM Attachments: [email protected] image001.png 2015-03-04 AquaDisk 14-Disk Concrete 139652.pdf 2015-03-05 O&M 139652.pdf
Michael,
Below is the information that you were looking for.
Regards,
Tim Brekke Sales Engineer
New Logo - Outlook
Your Wastewater Specialists
Gierlich-Mitchell, Inc. 10533 Progress Way Suite A Cypress, California 90630 P: (714) 236-6070 D: (714) 503-0533 C: (310) 344-8487 F: (714) 236-6080 E: [email protected]
From: Joann Riedl [mailto:[email protected]] On Behalf Of Dawn Brady Sent: Thursday, March 05, 2015 8:05 AM To: Tim Brekke Cc: Angelica Sunday; Dawn Brady; Joann Riedl; William Moore; File Archive Subject: Brentwood WWTP CA 103320A -- Responses, O&M, and Drawings
Tim,
Please review the attached standard drawings, O&M estimates, and responses to the engineer's questions regarding preliminary Design #139652 for the Brentwood WWTP project in CA. This design consists of three (3) 14-disk AquaDisk® Cloth Media Filters to be installed in concrete basins. The engineer's questions can be addressed as follows:
1. The backwash flow rate is 130 gpm per pump at 12 ft discharge head.
2. Backwash volume varies with solids loading. At the design loading rates, we would anticipate about 2-3% of the forward flow would be sent through the backwash line.
3. Yes, the filter is Title 22 approved. The filter recommendation has been designed in accordance with the State of California Title 22 Code of Regulations related to recycled water.
4. Yes, the PLC can indeed be connected to the plant wide SCADA system. Ethernet is required for this connection. Yes, the SCADA system can be remotely monitored. Settings can be remotely controlled. Equipment such as pumps cannot be remotely controlled.
5. The 14-disk AquaDisk filters can be placed in new or existing concrete basins. Preliminary review of existing drawings indicates that two (2) filters could probably fit into one (1) existing concrete basin.
6. Please find attached standard drawings for a 14-disk AquaDisk filter installed in a concrete basin. Please note that the plan view shows two (2) filters installed in separate concrete basins. This drawing differs from that of the AquaDisk in a steel tank. The package and concrete filters are otherwise functionally equivalent with respect to hydraulic and solids loading capacities.
7. The preliminary budget price for providing the recommended filters in painted steel tanks is $1,241,196. This price includes freight to the job site and our standard start-up supervision services.
Please let us know if you have any questions or need additional information.
Kind regards,
Dawn Brady Applications Engineer
AQUA-AEROBIC SYSTEMS, INC. 6306 N. Alpine Rd. Loves Park, IL 61111-7655 Ph: 815/639-4462 (Direct) Fax: 815/654-8258 E-mail: [email protected] www.aqua-aerobic.com
http://www.aqua-aerobic.com
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© copyright by Aqua-Aerobic Systems, Inc. All rights reserved. PROCESS DESIGN REPORT
BRENTWOOD WWTP CA
Design#: 139652
Option: Preliminary Design
Designed By: Angelica Sunday on Tuesday, February 10, 2015
The enclosed information is based on preliminary data which we have received from you. There may be factors unknown to us which would alter the enclosed recommendation. These recommendations are based on models and assumptions widely used in the industry. While we attempt to keep these current, Aqua-Aerobic Systems, Inc. assumes no responsibility for their validity or any risks associated with their use. Also, because of the various factors stated above, Aqua-Aerobic Systems, Inc. assumes no responsibility for any liability resulting from any use made by you of the enclosed recommendations.
Copyright 2015, Aqua-Aerobic Systems, Inc Design Notes
Filtration
- The cloth media filter recommendation is based upon the following conditions (as shown on the design sheet): 10 mg/l average daily influent TSS, 15 mg/l peak influent TSS, and an acceptable upstream process such as an activated sludge plant with a minimum SRT of 5 days.
- The anticipated filtered effluent quality is based on the filter influent conditions as shown under "Design Parameters" of this Process Design Report. In addition, the filter influent should be free of algae and other solids that are not filterable through a nominal 10 micron pore size media. Provisions to treat algae and condition the solids to be filterable are the responsibility of others.
- For this application, pile filter cloth is recommended.
- The following filter recommendation has been designed in accordance with the State of California Title 22 Code of Regulations related to recycled water.
A. The cloth media filters shall: 1. Provide a 24-hour average filtered effluent of 2 NTU or less. 2. Provide a filtered effluent not to exceed 5 NTU for more than 5% of the time within a 24-hour period. 3. Provide a filtered effluent not to exceed 10 NTU at any time.
B. Filter influent turbidity is continuously measured, and shall not exceed 5 NTU for more than 15 minutes and never shall exceed 10 NTU, and that there is the capability to automatically activate chemical addition or divert the wastewater from the filter should the filter influent turbidity exceed 5 NTU for more than 15 minutes.
Equipment
- Equipment selection is based upon Aqua Aerobic Systems' standard materials of construction and electrical components.
- Aqua-Aerobic Systems, Inc. (AASI) is familiar with the Buy American provision of the American Recovery and Reinvestment Act of 2009 as well as other Buy American provisions (i.e. FAR 52.225, EXIM Bank, USAid, etc.). AASI can provide a system that is in full compliance with Buy American provisions. As the project develops AASI can work with you to ensure full compliance with a Buy American provision, if required. Please contact the factory should compliance with a Buy American provision be required.
02/10/2015 10:15:13AM Aqua-Aerobic Systems, Inc CONFIDENTIAL Page 2 of 5 BRENTWOOD WWTP CA / Design#: 139652 AquaDISK Tertiary Filtration - Design Summary
DESIGN INFLUENT CONDITIONS
Pre-Filter Treatment: Oxidation Ditch Avg. Design Flow = 7 MGD = 4861.11 gpm = 26498 m³/day Max Design Flow = 10 MGD = 6944.4 gpm = 37854 m³/day Effluent
DESIGN PARAMETERS Influent mg/l Required <= mg/l Anticipated <= mg/l Avg. Total Suspended Solids: TSSa 10 ------
Max. Total Suspended Solids: TSSm 15 ------
*Turbidity: NTU 5 NTU 2 NTU 2 *Note: Tubidity represented in Nephelometric Turbidity Units (NTU's) in lieu of mg/l.
AquaDISK FILTER RECOMMENDATION Qty Of Filter Units Recommended = 3 Number Of Disks Per Unit = 14 Total Number Of Disks Recommended = 42 Total Filter Area Provided = 2259.6 ft² = (209.92 m²) Filter Model Recommended = AquaDisk Concrete: Model ADFSC-54 x 14E-PC
Filter Media Cloth Type = OptiFiber PA2-13
AquaDISK FILTER CALCULATIONS
Filter Type:
Vertically Mounted Cloth Media Disks featuring automatically operated vacuum backwash.
Average Flow Conditions:
Average Hydraulic Loading = Avg. Design Flow (gpm) / Recommended Filter Area (ft²) = 4861.1 / 2259.6 ft² = 2.15 gpm/ft² (1.46 l/s/m²) at Avg. Flow
Maximum Flow Conditions:
Maximum Hydraulic Loading = Max. Design Flow (gpm) / Recommended Filter Area (ft²) = 6944.4 / 2259.6 ft² = 3.07 gpm/ft² (2.09 l/s/m²) at Max. Flow
Solids Loading:
Solids Loading Rate = (lbs TSS/day at max flow and max TSS loading) / Recommended Filter Area (ft²) = 1251 lbs/day / 2259.6 ft² = 0.55 lbs. TSS /day/ft² (2.70 kg. TSS/day/m²)
The above recommendation is based upon the provision to maintain a satisfactory hydraulic surface loading with (1) unit out of service. The resultant hydraulic loading rate at the Maximum Design Flow is: 4.6 gpm / ft² = (3.1 L/s / m² )
02/10/2015 10:15:13AM Aqua-Aerobic Systems, Inc CONFIDENTIAL Page 3 of 5 BRENTWOOD WWTP CA / Design#: 139652 Equipment Summary
Cloth Media Filters
AquaDisk Tanks/Basins
3 AquaDisk Model # ADFSC-54x14E-PC Concrete Filter Basin Accessories consisting of:
- Concrete basin(s) (by others). - 304 stainless steel support brackets. - Effluent seal plate weldment. - 316 stainless steel anchors. - 3" manual butterfly valve(s).
AquaDisk Centertube Assemblies
3 Centertube(s) consisting of:
- 304 stainless steel centertube weldment(s). - Centertube driven sprocket(s). - Dual wheel assembly(ies). - Rider wheel bracket assembly(ies). - 304 stainless steel centertube support beam(s). - Centertube bearing kit(s). - Effluent centertube lip seal(s). - Pile cloth media and non-corrosive support frame assemblies. - Disk segment 304 stainless steel support rods. - Neoprene media sealing gaskets.
AquaDisk Drive Assemblies
3 Drive System(s) consisting of:
- Gearbox with motor. - Drive spocket(s). - Drive chain(s) with pins. - Stationary drive bracket weldment(s). - Adjustable drive bracket weldment(s). - 316 stainless steel anchors. - Chain guard weldment(s). - Warning label(s).
AquaDisk Backwash/Sludge Assemblies
3 Backwash System(s) consisting of:
- Backwash shoe assemblies. - Backwash shoe support weldment(s). - 1 1/2" flexible hose. - Stainless steel backwash shoe springs. - Hose clamps. - 304 stainless steel backwash collection manifold(s). - 304 stainless steel union(s). - PVC solids manifold installation(s). - 304 stainless steel backwash floor plate(s). 3 Backwash/Solids Waste Pump(s) consisting of:
- Backwash/waste pump(s). - Painted steel backwash pump stand(s). - 316 stainless steel anchors. - 0 to 15 psi pressure gauge(s). - 0 to 30 inches mercury vacuum gauge(s).
02/10/2015 10:15:13AM Aqua-Aerobic Systems, Inc CONFIDENTIAL Page 4 of 5 BRENTWOOD WWTP CA / Design#: 139652 - Throttling gate valve(s). - 3" ball valve(s).
AquaDisk Instrumentation
3 Pressure Transducer Assembly(ies) each consisting of:
- Mounting bracket weldment(s). - Transducer pipe weldment(s). - Pressure transducer(s). - Aneroid bellows. - Stainless steel anchor kit(s). - Nylon electrical cable tie wrap(s). 3 Vacuum Gauge with Transmitter(s) consisting of:
- 0 to 30 inches mercury vacuum gauge(s). - Vacuum transmitter(s). - 1/4" Threaded bronze ball valve. 3 Float Switch(es) consisting of:
- Float switch mounting bracket(s). - Float switch(es). - Stainless steel anchor kit(s).
AquaDisk Valves
3 Set(s) of Backwash Valves consisting of:
- 2" full port, two piece, stainless steel body ball valve(s), flanged end connections with single phase electric actuator(s). Valve / actuator combination shall be TCI / RCI (RCI, a division of Rotork), Nibco, or equal. 3 Solids Waste Valve(s) consisting of:
- 2" full port, two piece, stainless steel body ball valve(s), flanged end connections with single phase electric actuator(s). Valve / actuator combination shall be TCI / RCI (RCI, a division of Rotork), Nibco, or equal.
AquaDisk Controls w/Starters
3 Control Panel(s) consisting of:
- NEMA 4X fiberglass enclosure(s). - Circuit breaker with handle. - Transformer(s). - Fuses and fuse blocks. - Line filter(s). - GFI convenience outlet(s). - Control relay(s). - Selector switch(es). - Indicating pilot light(s). - MicroLogix 1400 PLC(s). - Ethernet switch(es). - Power supply(ies). - Operator interface(s). - Motor starter(s). - Terminal blocks. - UL label(s).
02/10/2015 10:15:13AM Aqua-Aerobic Systems, Inc CONFIDENTIAL Page 5 of 5 BRENTWOOD WWTP CA / Design#: 139652 AquaDISK: Operation & Maintenance Requirements Design# 139652 Project: BRENTWOOD WWTP CA
Qty / Model#: 3 / ADFSC54x14E-PC
Description: AquaDisk Concrete: Model ADFSC-54 x 14E-PC
Avg Flow (Gal): 7,000,000
Influent TSS (mg/l): 10
Qty Of Disks Per Unit: 14
Area Provided/Disk: 53.8
I. LUBRICATION REQUIREMENTS # of Units Minutes/Unit Times/Year Hours/Year
1) Backwash / Solids Waste Pump - Routine Lubrication: 6 x 5 x 12 / 60 = 6.00
2) Backwash / Solids Waste Pump - Drain and Refill: 6 x 30 x 1 / 60 = 3.00
3) Drive Gear Box: 3 x 30 x 0.25 / 60 = 0.38
4) Drive Motor: 3 x 5 x 0.25 / 60 = 0.06
TOTAL LUBRICATION REQUIREMENTS: 9.44
II. PARTS REPLACEMENT
Replace Interval Hours Per Material Cost Total Material (Years) # of Units Minutes/Unit Replacement Per Unit Cost
1) Main "V-Ring" Seal: 10 3 x 240 = 12.0 $1,003 $3,009
2) Filter Media Cloths (6/Disk): 7 252 x 15 = 63.0 $239 $60,228
III. POWER CONSUMPTION
1) Backwash / Solids Waste Pump (kW Hours/Year): 9,613.0
2) Disk Drive Motor (kW Hours/Year): 1,564.9
3) Power Control Panel (kW Hours/Year): 4,200.0
Total Annual Power Usage (kW Hours/Year): 15,377.9
Printed on: 3/5/2015 8:47:07AM Aqua-Aerobic Systems, Inc. CONFIDENTIAL Page 1 of 1 876 5 4 3 2 1
223 3/4" 1 IF FREEZING IS A CONCERN AQUA-AEROBIC SYSTEMS RECOMMENDS THE FILTERS BE PLACED IN A HEATED BUILDING. 203 7/8" IF A BUILDING IS NOT PROVIDED, ANY NECESSARY PROTECTION, 40" INCLUDING BUT NOT LIMITED TO, HEAT TRACING AND INSULATION EFFLUENT 155" INSIDE FILTER CHAMBER OF PUMPS AND PIPING, AS WELL AS PROTECTION AGAINST CHAMBER INTERNAL TANK FREEZING, SHALL BE PROVIDED BY THE INSTALLING CONTRACTOR. D D 2 THE FILTER CONTROL PANEL IS SHOWN IN THE STANDARD LOCATION. IF THE FILTER IS LOCATED OUTSIDE, THE CONTROL PANEL MAY BE RELOCATED TO THE SIDE OF THE FILTER FACING NORTH, TO LIMIT EXPOSING THE H.M.I. TO DIRECT SUNLIGHT.
3 THE GRAPHIC ELEMENTS OF THIS COMPUTER GENERATED 93" DRAWING ARE DRAWN FULL SIZE. THE DIMENSIONS ARE INSIDE FILTER ASSOCIATIVE. IF THE SIZE OF THE GRAPHIC ELEMENTS IS CHAMBER CHANGED THE DIMENSIONS WILL NOT BE CORRECT.
4 AN INFLUENT VALVE IS REQUIRED FOR ISOLATION / MAINTENCE OF THE FILTER UNIT. THE INFLUENT VALVE SHALL BE PROVIDED BY OTHERS AND INSTALLED BY OTHERS.
213 9/16" FLANGE TO FLANGE
C C
48" MINIMUM CEILING CLEARANCE REQUIRED 101 3/4" 56 1/16" 9"
143" B ON
O
F F B 138" MAX.
CAUTION BEFORE PROCEEDING WITH REPAIR WORK, ALL SOURCE S OF POWER TO THE MACHINE MUS T BE TAGGED-OUT AND/OR SECURED WITH A LOCK ING DEVICE
DRIVE BACKWASH BACKWASH ! DANGER MOTOR PUMP 1 PUMP 2 Arc Flas h and Shock Hazard Appropriate PPE Required Do not operate controls o r open covers ON ON ON without appropriate personal protection equipme nt. Fai l ure to c omply may result in injury or death! Refer to NFPA 70E for minimu m P PE r eq uirements
O O O H A HAA H
91 5/8"
26 0748 8
® Aqua-Aerobic AquaDisk® CL OTH MEDIA FILTER SYSTEM
MODEL # SER # AQUA -AER OBIC SYSTEMS, INC . 6306 N ALPI NE R D ROCKFO RD IL 6 1 1 1 1 PH# 815-6 54-2501 FAX # 815-654 -2508
ONE OR MORE OF THE FOLLOWING U. S. PATENTS APPLY: 409 0965 , 463 9315 , 536 2401, 5876 612, 6090 298,6 1031 32,6 1103 74,6 29409 8, 644 76176 79718 6,67 9382 3 68"
42 3/16" 29"
14 1/4" 4 1/2" 14 9/16" 50 3/4" 72" 41 3/4"
JOB NAME: XXX A A JOB LOCATION: XX AQUA-AEROBIC SYSTEMS, INC. ®
DO NOT UNLESS OTHERWISE SPECIFIED FRACTIONAL DIMENSIONS +/- 1/16 SCALE ALL TWO PLACE DECIMALS +/- 0.010 ALL THREE PLACE DECIMALS +/- 0.005 ANSI DRAWING ALL ANGLES +/- 1/2° MATERIAL: SIMILAR TO: TYPE: DRY WT (LBS) OPER. WT. (LBS) DRAWN BY: XXX DATE: XXX CHECKED BY: DATE: APPROX. 15,200 lb. APPROX. 70,600 lb. REV ERN / ECO DATE BY REVISION DESCRIPTION WEIGHT: SHEET:1 OF DRAWING NAME: DRAWING NUMBER: SCALE: SIZE: AQUADISK FILTER MODEL ADFSP-54 X 14E-PC - LH 2802033 D
876 5 4 3 Copyright 2012 Aqua-Aerobic2 Systems, Inc. All Rights Reserved. This Drawing May Not Be Copied All Or In Part Without The Expres1s Written Permission Of Aqua-Aerobic Systems, Inc. 876 5 4 3 2 1 3/4 HP GEARBOX, CHAIN, DRIVE A B DIRECTION OF ROTATION SPROCKET, AND CENTERTUBE SPROCKET C C FLOAT SWITCH BACKWASH SUPPORT WELDMENT THE BACKWASH SUCTION MANIFOLD IS FABRICATED FROM STAINLESS STEEL, FILTER DISK THE SHOE FACE AREA IS 4.5" WIDE UHMW POLYETHYLENE PLASTIC WITH SMOOTH ROUNDED EDGES. CENTERTUBE WELDMENT STAINLESS STEEL STAINLESS STEEL TORSION SPRINGS D D D
118" REF.
STAINLESS STEEL BACKWASH D SUCTION MANIFOLD
UHMW SHOE FACE SECTION D-D NOT TO SCALE
HOSE TO BACKWASH COLLECTION MANIFOLD SECTION C-C A B BACKWASH DISCHARGE AND RECIRCULATION NOT TO SCALE C PIPING BY OTHERS C PUMP PORTS ARE FILTER TERMINATIONS SECTION A-A SOLIDS MANIFOLD
THE FILTER DISK IS COMPOSED OF (6) IDENTICAL REMOVABLE SECTIONS, EACH ONE HELD TO THE CENTERTUBE BY (2) 5/8" DIAMETER STAINLESS STEEL RODS. EACH DISK SECTION HAS A RIGID PLASTIC FRAME TO SUPPORT THE CLOTH FILTER MEDIA. THREE PLASTIC "TACK" STRIPS ARE USED TO STRETCH AND HOLD THE CLOTH FILTER MEDIA TO THE FRAME.
3" THREADED MANUAL BALL VALVES SUPPLIED LOOSE INSTALLED IN BACKWASH / WASTE LINE BY OTHERS NORMALLY CLOSED
3" THREADED MANUAL BALL VALVES SUPPLIED LOOSE BACKWASH SUPPORT WELDMENT IS B INSTALLED IN BACKWASH / WASTE LINE BY OTHERS NORMALLY OPEN B MANUFACTURED OF STAINLESS STEEL WITH ALL BRACKETS AND CLAMPS MADE OF STAINLESS STEEL
RECIRCULATION 3" 150# FLANGES FILTER TERMINATION N.C. 3" THREADED MANUAL GATE VALVES SUPPLIED LOOSE INSTALLED IN BACKWASH / WASTE PUMP DISCHARGE LINE BY OTHERS BACKWASH DISCHARGE 3" TO 2" CONCENTRIC REDUCER AND UNIONS OR FLANGES BY THE INSTALLING CONTRACTOR TYPICAL EACH PUMP BACKWASH SUCTION MANIFOLD PRESSURE GAUGES SUPPLIED LOOSE INSTALLED BY OTHERS BACKWASH HOSE
BACKWASH / WASTE PUMPS FIELD INSTALLED BY OTHERS
BACKWASH COLLECTION MANIFOLD 2" BACKWASH / SOLIDS WASTE ELECTRIC BALL VALVE ASSEMBLIES 1 ALL EXTERNAL PIPING AND FITTINGS SHALL BE PROVIDED BY OTHERS 3 THE STANDARD BACKWASH / WASTE PUMP PROVIDES 23.2 FEET OF TOTAL HEAD SECTION B-B ACTUAL PIPING LAYOUT AND PUMP LOCATION TO BE DETERMINED BY OTHERS AT A FLOW RATE OF 130 GPM. THE SUCTION SIDE PIPING REQUIRES JOB NAME: XXX A A WHEN THREADED OR WELDED PIPE IS USED IN LIEU OF FLANGED APPROXIMATELY 11 FEET OF THIS HEAD. THIS LEAVES APPROXIMATELY JOB LOCATION: XX AQUA-AEROBIC SYSTEMS, INC. PIPE, UNIONS SHALL BE USED AT EACH PUMP AND VALVE 12 FEET (5 PSIG) FOR THE DISCHARGE SIDE. THE DISCHARGE DIAMETER, ® CONNECTION TO FACILITATE SERVICE. EQUIVALENT LENGTH, AND VERTICAL LIFT MUST RESULT IN A HEAD LOSS LESS DO NOT UNLESS OTHERWISE SPECIFIED FRACTIONAL DIMENSIONS +/- 1/16 THAN 12 FEET. INSTALLATIONS WITH MORE THAN ONE BACKWASH / WASTE PUMP MUST SCALE ALL TWO PLACE DECIMALS +/- 0.010 ALL THREE PLACE DECIMALS +/- 0.005 ANSI ACCOMODATE ALL BACKWASH / WASTE PUMPS RUNNING SIMULTANEOUSLY WITHOUT DRAWING ALL ANGLES +/- 1/2° 2 2 H.P. BACKWASH / WASTE PUMP CONNECTIONS ARE 2" N.P.T. BACKWASH / WASTE EXCEEDING 12 FEET OF DISCHARGE HEAD. MATERIAL: PIPING IS 3" DIAMETER. 3" TO 2" CONCENTRIC REDUCER FITTINGS SHALL BE SIMILAR TO: PROVIDED AND INSTALLED BY OTHERS AT EACH PUMP PORT. FOR INSTALLATIONS THAT REQUIRE MORE DISCHARGE HEAD, ALTERNATIVE TYPE: DATE: PUMPS ARE AVAILABLE. PLEASE CONSULT AASI ENGINEERING TO VERIFY THE DRAWN BY: XXX XXX CHECKED BY: DATE: SUITABILITY OF THE DISCHARGE PIPING OR FOR SPECIAL PUMP REQUIREMENTS. REV ERN / ECO DATE BY REVISION DESCRIPTION WEIGHT: SHEET:2 OF DRAWING NAME: DRAWING NUMBER: SCALE: SIZE: AQUADISK FILTER MODEL ADFSP-54 X 14E-PC - LH 2802033 D
876 5 4 3 Copyright 2012 Aqua-Aerobic2 Systems, Inc. All Rights Reserved. This Drawing May Not Be Copied All Or In Part Without The Expres1s Written Permission Of Aqua-Aerobic Systems, Inc. 876 5 4 3 2 1
D D
ELEVATION
11.50'
A 9.24' INFLUENT WEIR ELEVATION F E B B 9.53' NAPPE OVER INFLUENT WEIR AVERAGE A FLOW G 9.65' NAPPE OVER INFLUENT WEIR MAXIMUM FLOW D C 7.32' C 18" INFLUENT LINE EFFLUENT WEIR ELEVATION C H C
D 7.68' NAPPE OVER EFFLUENT WEIR AVERAGE FLOW
7.83' NAPPE OVER EFFLUENT WEIR MAXIMUM FLOW
E 9.67' OVERFLOW WEIR ELEVATION
F 10.12' NAPPE OVER OVERFLOW WEIR AVERAGE FLOW 18" EFFLUENT LINE
10.32' NAPPE OVER OVERFLOW WEIR MAXIMUM FLOW G 9.20' BACKWASH INITIATE LEVEL
B H B 6.82' MAXIMUM AVAILABLE LIQUID LEVEL FOR EFFLUENT CONVEYANCE 0.00'
HYDRAULIC PROFILE BASED UPON AVERAGE FLOW RATE OF 3.25 GPM PER SQUARE FOOT (3.53 MGD) WEIR LENGTHS BASED UPON MAXIMUM FLOW RATE OF 5.53 GPM PER SQUARE FOOT (6.0 MGD) INFLUENT = 10.42' EFFLUENT = 7.75' OVERFLOW = 5.33'
JOB NAME: XXX A A JOB LOCATION: XX AQUA-AEROBIC SYSTEMS, INC. ®
DO NOT UNLESS OTHERWISE SPECIFIED FRACTIONAL DIMENSIONS +/- 1/16 SCALE ALL TWO PLACE DECIMALS +/- 0.010 ALL THREE PLACE DECIMALS +/- 0.005 ANSI DRAWING ALL ANGLES +/- 1/2° MATERIAL: SIMILAR TO: TYPE: DRAWN BY: XXX DATE: XXX CHECKED BY: DATE: REV ERN / ECO DATE BY REVISION DESCRIPTION WEIGHT: SHEET:3 OF DRAWING NAME: DRAWING NUMBER: SCALE: SIZE: AQUADISK FILTER MODEL ADFSP-54 X 14E-PC - LH 2802033 D
876 5 4 3 Copyright 2012 Aqua-Aerobic2 Systems, Inc. All Rights Reserved. This Drawing May Not Be Copied All Or In Part Without The Expres1s Written Permission Of Aqua-Aerobic Systems, Inc. B A D C D SIZE: ANSI SCALE: 4 +/- 1/16 +/- 0.010 +/- 0.005 +/- 1/2° XXX DATE: DATE: SHEET: OF s Written Permission Systems, Of Aqua-Aerobic Inc. 1 1 FRACTIONAL DIMENSIONS DECIMALS TWO ALL PLACE ALL THREE PLACE DECIMALS ANGLES ALL UNLESS OTHERWISE SPECIFIED OTHERWISE UNLESS AQUA-AEROBIC SYSTEMS, INC. SYSTEMS, AQUA-AEROBIC XXX ® SCALE DO NOT 2802033 DRAWING MATERIAL: SIMILAR TO: TYPE: DRAWN BY: CHECKED BY: WEIGHT: DRAWING NUMBER:
OFF ON DANGER WITHDEVICE A LOCKING ! Refer to NFPA 70E for minimum PPE requirements BEFORE PROCEEDING WITH CAUTION Appropriate PPE Required PPE Appropriate TAGGED-OUT AND/OR SECURED REPAIR WORK,REPAIR SOURCES ALL OF Arc Flash and Shock Hazard Shock and Flash Arc POWERBE THE MACHINE TO MUST Do not operate controls or open covers without appropriate personal protection equipment. or injury in result may to comply Failure death! STARTER CONTACTOR STARTER FLOAT SWITCH A 2 2 O ON H BACKWASH ® ® Aqua-Aerobic SER # SER MODEL # MODEL PUMP 2 PUMP Copyright 2012 Aqua-Aerobic Systems, Inc. All Rights Reserved. This Drawing May Not Be Copied All Or In Part Without The Expres The Without Part In Or All Copied Be Not May Drawing This Rights Reserved. All Inc. Systems, 2012 Aqua-Aerobic Copyright O CLOTH MEDIA FILTER SYSTEM ON REVISION DESCRIPTION H 32 1/2" BACKWASH AquaDisk AQUA-AEROBIC SYSTEMS,INC. 6306 N ALPINE RD ROCKFORD IL 61111 IL ROCKFORD RD ALPINE N 6306 PH # 815-654-2501 FAXPH # 815-654-2501 # 815-654-2508 ONE OR MORE OF THE FOLLOWING U. S. PATENTS APPLY: U. PATENTS S. FOLLOWING OF THE MORE OR ONE 6294098, 6110374, 6103132, 6090298, 5876612, 5362401, 4639315, 4090965, 6793823 6797186, 6447617 BY 2607488 A PUMP 1 PUMP O ON HA DRIVE MOTOR DATE XX XXX TRANSDUCER FUSE AQUADISK FILTER MODEL ADFSP-54 X 14E-PC - LH - X 14E-PC ADFSP-54 MODEL FILTER AQUADISK REV ERN / ECO JOB NAME: JOB LOCATION: DRAWING NAME: 3 3 40 3/8" 4 4 VARIABLE FREQUENCY DRIVE FREQUENCY VARIABLE PNEUMATIC OPERATED VALVE OPERATED PNEUMATIC VFD P 40" HEIGHT X 32" WIDE X 12" DEEP 32" WIDE X 40" HEIGHT X CONTROL PANEL CONTROL STANDARD CONTROL PANEL SIZE (1) CONTROL PANEL PER FILTER ENCLOSURE NEMA 4X WALL MOUNTED TYPE FIBERGLASS REASSEMBLED ON-SITE BY CONTRACTOR. MAY BE RELOCATED TO THE SIDE OF THE FILTER FACTORY ASSEMBLED ON THE FILTER, DISASSEMBLED AND SHIPPED LOOSE. SHIPPED AND DISASSEMBLED FILTER, THE ON ASSEMBLED FACTORY FACING NORTH TO LIMIT THE EXPOSURE H.M.I. TO DIRECT SUNLIGHT. IF THE FILTER IS LOCATED OUTSIDE, THE CONTROL PANEL THE LOCATED OUTSIDE, IS FILTER IF THE SYMBOL KEY 1 2 3 5 5 ELECTRICAL DISCONNECT ELECTRICAL OVERLOAD MOTOR (2) 115 V (2) GRD. (1) ALARM COMMON CONTACT SHIELDED TWISTED PAIR AQUADISK PRESSURE TRANSMITTER SHIELDED TWISTED PAIR
S (3) POWER (3) GRD. (1)
L VACUUM
O AQUADISK TRANSMITTER
R
T
N 2.0 HP 1750 RPM 2.0 HP 1750
O (2) 115 V (2) GRD. (1) (3) POWER (3) (1) GRD. (1)
C AQUADISK 2) (TYP BACKWASH / WASTE PUMP WASTE / BACKWASH
CIRCUIT BREAKER CIRCUIT
/ TRANSFORMER
AQUADISK
C HIGH LEVEL HIGH FLOAT SWITCH FLOAT
L
P DRIVE MOTOR DRIVE (7) 115 V (7) GRD. (1) M AQUADISK 3/4 HP VALVE WASTE SOLIDS AQUADISK (7) 115 V (7) GRD. (1) M AQUADISK BACKWASH VALVE 7) (TYP BY AQUA-AEROBIC SYSTEMS AQUA-AEROBIC BY FILTER CONTROL SYSTEM C. B. 460 VOLTS 115 VOLTS MOTOR OPERATED VALVE OPERATED MOTOR MOTOR 25 AMP 876 876 M NOTE: SOME SYMBOLS MAY NOT BE APPLICABLE BE NOT MAY SYMBOLS SOME NOTE: 460 VOLT Hz 3 PH , 60 WIRE (4) B A D C
Appendix B
Fluidyne
FluidyneFluidyne FFPFFP™™
FF ii xx ee dd PP ll aa tt ee CC ll oo tt hh MM ee dd ii aa FF ii ll tt rr aa tt ii oo nn
FluidyneFluidyne FFPFFPTM FixedFixed PlatePlate ClothCloth MediaMedia FilterFilter withwith GravityGravity BackwashBackwash
INNOVATIVE DESIGN SIMPLE OPERATION Fluidyne FFP™ Cloth Fluidyne FFP™ Cloth Media Filters feature an The Fluidyne FFP™ Cloth Media Media Plate Filters innovative fixed panel design that uses simple Plate Filter’s unique design generates backwash offer high performance, low gravity to produce filtration and backwash flow. flow WITHOUT the use of backwash pumps, mani- maintenance solutions This high performance, low-operating folds, spray headers, or other moving parts. ideally suited for: cost, tertiary cloth Backwash is produced using already Municipalities media filter is available differential head, sim- Smaller Communities suitable for both ple open close valves, Residential & Mobile large and small and gravity along Home Developments wastewater treat- with a small Industrial Applications ment applica- amount of pressur- Food Processing tions. Packaged ized air to enhance Please contact Fluidyne or systems are cleaning. your local rep for specific available in com- recommendations. pletely assem- NO MOVING PARTS bled, 100% SS All filter components free- remain stationary standing during filtration and units backwash, reducing from maintenance and power 10gpm to usage. Filter tankage 1.2 MGD. and internal components Modular are 100% stainless steel or systems are available for non-corrosive for long life and eased larger flows or for new or existing maintenance. Acrylic cloth media removes solids concrete tanks. particles down to 10um, is chemically resistant and can be changed easily without disrupting incoming flow.
Fluidyne Corporation 5436 Nordic Drive Cedar Falls, Iowa
P: (319) 266-9967 F: (319) 277-6034 www.fluidynecorp.com FLUIDYNE FFP™ CLOTH MEDIA Each independent media plate is made PLATE FILTERS: up of two rectangular cloth panels PROVEN PERFORMANCE IN which face each other within a EFFICENT PACKAGES. stationary framework. Influent enters
EASY MAINTENANCE the filter, then is directed to the All mechanical bottomside of each plate. Suspended equipment, including filter panels, can be solids fall to the bottom of the channel removed from the tank or collect on the interior surfaces of the without dewatering or diverting Incoming cloth plates, with clean, treated water flow. All connections required for removal of collecting in the filter’s main area. the cloth elements are located at the top of the tank, within easy reach, eliminating the As solids accumulate on the cloth need for the operator surfaces, water level in the influent to enter the tank for normal maintenance. channel begins to rise, eventually initiating a backwash operation. Each PROVEN DESIGN Fluidyne FFP™ cloth independent cloth plate is cleaned in media filters use sequence by allowing gravity to force proven fixed plate cloth media flow in reverse. Backwash flow is technology. Testing produced entirely by gravity, by simply has shown exceptional solids and turbidity opening each plates associated removal capabilities even at high or backwash valve. Air is injected within fluctuating solids the interior of the plate during backwash loadings, producing reuse quality effluent to enhance cleaning. with TSS less than 4 mg/l and NTU below 1 NTU for most wastewater types.
PILOTING Mobile test and demo units are available from 0.5 gpm up to 600 gpm full size units. FluidyneFluidyne FFPFFP™
T h e E x p e r i e n c e d L e a d e r i n W a s t e w a t e r T r e a t m e n t T e c h n o l o g y
Please contact our authorized Rep in your area:
All materials, representations, data, and/or information contained in this brochure are for information and estimation only. Specific information regarding equipment sizing, delivery, prices, and capabilities should be obtained directly from Fluidyne Corporation or one of its authorized agents.
Patents pending. Fluidyne & Fluidyne FFP™ are registered trademarks of Fluidyne Corporation. All rights reserved. From: MFC - klindsley To: Michael Ducker; [email protected] Cc: [email protected]; [email protected] Subject: City of Brentwood, CA FFP Filter Follow-up (email 2 of 2) Date: Wednesday, March 04, 2015 2:26:27 PM Attachments: FFP110048C-Brentwood Calcs.pdf F110000-Multi-Interconnection.pdf F110048.pdf
Attached calc sheet & example package drawings......
Kurt L.
-----Original Message----- From: MFC - klindsley [mailto:[email protected]] Sent: Wednesday, March 04, 2015 4:20 PM To: 'Michael Ducker'; '[email protected]' Cc: '[email protected]'; '[email protected]' Subject: City of Brentwood, CA FFP Filter Follow-up (email 1 of 2)
Mike,
Please find FFP calculation sheet attached to email 2 of 2. It contains the info you've requested...... please call my cell 608-240-8987 if you have questions.
Note: calcs show a SCFM of ~25-30scfm resulting in a 10HP compressor that runs intermittently resulting in a power usage of 13kwh/day. This would be able to supply the packaged filters below as well.
Optional alternative for packaged filters: We'd recommend Five (5) FFP110648 units, each of which contains 6 x F110048 cloth media elements of 48sf each...... Budgetary price for Five (5) FFP110648 packaged FFP(tm) filters in 100% 304SS delivered to CA would be ~1.48M. I've attached a GA drawing of this size filter to email 2 of 2.
Note: We do offer tank configurations with more elements per package (up to 12), which would simplify piping (but not significantly affect pricing). Please let me know if you want me to expand on this option.
Please let me know if you need a specific proposal or layout showing 5 total filters or if you need formal proposal language or specification. I'll be back in the office on Friday.
Kurt L.
-----Original Message----- From: Michael Ducker [mailto:[email protected]] Sent: Wednesday, March 04, 2015 12:08 PM To: [email protected]; [email protected] Cc: [email protected]; [email protected] Subject: RE: City of Brentwood, CA FFP Filter Budget Pricing
Jim and Kurt,
I have not received a call yet, but this is the information I am looking for.
What is the daily backwash flow (gallon per day)? What is the flow requirements for the air compressor? (### scfm @ 90-100 psi, ## hp) What is the power usage? (kW/hr/day or month or year) What is the total wet filter area? (ft2) What is the cost for the Optional steel tanks and a pre-packaged pad mounted system?
I need to wrap this up very soon. When can you have answers for me?
Thanks,
Michael Ducker, P.E. Coleman Engineering [email protected] 916-791-1188
-----Original Message----- From: [email protected] [mailto:[email protected]] Sent: Wednesday, March 04, 2015 4:57 AM To: Michael Ducker Subject: Fw: City of Brentwood, CA FFP Filter Budget Pricing
Kurt is calling this AM
Thanks,
Jim Zaiser
916-607-5500 www.jbiwater.com
-----Original Message----- From: [email protected] Date: Tue, 03 Mar 2015 15:54:31 To:
Jim,
I've been traveling in NC but will try and call mike yet today.....
KL
------Original Message ------Subject: Re: City of Brentwood, CA FFP Filter Budget Pricing From: [email protected] Date: Mar 3, 2015 1:44 PM To: "Kurt Lindsley"
Kurt?
Thanks,
Jim Zaiser 916-607-5500 www.jbiwater.com
-----Original Message----- From: [email protected] Date: Tue, 3 Mar 2015 14:29:33 To: Kurt Lindsley
Let me know when you can do this
Thanks,
Jim Zaiser
916-607-5500 www.jbiwater.com
-----Original Message----- From: Jim Zaiser
Kurt, can you call mike tomorrow?
I am in training mtg and he has questions
Jim Zaiser
916-933-5500 www.jbiwater.com
> On Feb 19, 2015, at 5:01 PM, Kurt Lindsley
RECOMMENDED EQUIPMENT Filter Recommendation : 2 filters x 16 Elements per filter Filter Area (Each filter) : 768 ft2 Total Filter Area (All filters) : 1,536 ft2 Loading Rates: Average Peak Daily Peak Hourly All filters & elements in service: 2.26 gpm/ft2 4.52 gpm/ft2 - gpm/ft2 1 element out of service: 2.33 gpm/ft2 4.67 gpm/ft2 - gpm/ft2 1 filter out of service: 4.52 gpm/ft2 9.04 gpm/ft2 - gpm/ft2
OPERATIONAL PARARMETERS Solids Removal Rate: 0.27 Lbs of TSS Removed / Sqft / Day 208.43 Lbs of TSS Removed / Filter / Day Backwash Interval: 2.7 Hrs at ADF, 1.6 Hrs at PDF, - Hrs at PHF Backwash Volume: 840 gpm / element for 30 sec / element = 420 gal / element or 6720 gal / backwash
Total BW: 59,494 Gal / Filter / Day or 2.4% of forward flow
ESTIMATED POWER USAGE Compressor Air Flow Required: 27.68 ACFM intermittently Compressor Size Recommended: 10.0 HP running intermittently Compressor Power Usage: 12.68 KWH/Day. Typical Utility Power Cost: 0.08 $/KW-Hr
F110000 Total Power: 1.01 $ / day to run all filters.
Page 1 REV 1 of al layout and SHEET F110048.vsd Algae Cover Algae (Optional) Scour Supply Hose, Air 1" ID w/ coupler (Typ 6 Places) Hoist Socket (Optional) Channel Effluent Tank Connection Effluent Flange 12" Scour Valve, 1” Air (Typ 6 places) Air Scour Manifold Common Air ½” NPT-FConnection, Underdrain Filter (Typ 6 Places) F110648-GA CAD FILE Drawing for gener sizing purposes only, NOT FOR FABRICATION DRAWING Cloth Media Filter – Filter General Arrangement – Filter Cloth Media General Filter ™ FFP Job # Job SCALE Date DATE Rev Engr Filter Element (Typ 6 Places) FFP™ 110048 110048 FFP™ Air Scour Vent Hose ID 2" w/ Coupler, (Typ 6 Places) This Drawingappurtenant and all matter contains information proprietary to Fluidyne Corporation and is loaned subject to return be reproduced, not and must upon demand for any used nor copied, loaned, revealed, other than purpose that for which it was specifically furnished without expressed written consent from Fluidyne Corporation. DRAWN REVISED DATE ~108 ½” +/- ½” Lay Length ½” +/- Lay ~108 6.75" BW Header Influent Air Vent Peak Channel L ). 8" Flange C Backwash 12" Flange 12" Connection Manifold, 8" Coupling, 6" Coupling, Flexible Pipe Tank Influent and and (Typ 6 places) (Typ 6 Places) mounted mounted Tank Overflow, Overflow, Tank Stainless L L
C C 7" weir. Influent Valve, 6" Influent 8" (Typ 6 places) Backwash Valve, all elevations and and all elevations 118" ave a commonMCP 6" 108" 106"
100" Backwash Rate Control Valve, 8" 73" applications (capacity 300lbs (capacity applications Concrete, pad, anchors, design, anchors, pad, Concrete, BW s. Multiple filter systems will h will s. Multiple filter systems ing flow up over up to and the ing flow overflow at a loading of ______gpm/sf of media & of media gpm/sf of at ______a loading Infl Over side. Wiring and conduit between remote between conduit and Wiring side. the overflow weir. Engineer shall design shall Engineer weir. overflow the BW 60Hz, 20Amp) by others. by 60Hz, 20Amp) BW nd overhead winch & rail nd overhead for indoor other non-corrosive materials. All piping to be Schedule 10 materials. 10 other non-corrosive All to be Schedule piping with stainless steel anchorage. with stainless steel anchorage. ~101.5" BW influent side for single filter system filter power (120VAC, 1Ph, filter (120VAC, power Nominal Element Element Nominal Centers BW pected in the filter influent channel, includ channel, pected in the filter influent to operate valves & air scour system. 16" ctory mounted to each filter at the influent at the to each filter ctory mounted float level) is set approximately 2" below below 2" approximately set is level) float BW to and to and from filter by others. ______gpd (_____ gpm) at Average Daily Flow Daily Average at gpm) (_____ gpd ______ory mounted to tank at ANSI standard 125 lb Flanges. lb 125 ANSI standard L C Only for clarity for clarity Control Weir Tank Effluent Effluent Tank Filter Element (Typ 6 places) (Typ 6 Places) (Typ 6 Places) Influent Valve, 6" Influent Filter HWL / BW Init Filter HWL Backwash Valve, 8" Filter Control Panel, Filter Control Backwash Manifold, 8" Level (See Critical Note) Level w/ Blind Flange One End w/ One Blind Flange Steel. All connections to be be to All connections Steel. Lbs. ______wet weight: / operating Nominal Lbs. ______weight: / dry assembly Nominal - capacity of - Filter shown has as gpm/sf. gpm) at ______(_____ gpd ______capacity of daily basis mg/l instantaneous. or mg/l on an 50 average not to 25 exceed - TSS loading connections piping - All and piping anchored pad and floor or to concrete - Filter mounted shall be Critical Notes: initiation HWL (backwash Filter Influent - hydraulics all water levels ex to accommodate Notes: - All materials 304 Stainless Tank & to be Type Steel fasteners or installation by others. not shown. Recomme removal Hoist for element Manual - Optional - Compressed air source required @90psi - Filter control panel (MCP) fact box fa loose with a junction shipped panel for conduit and Wiring others. J-Box by MCP and ValveActuators not shown Valve Actuators not shown Conduit not shown for clarity shown not Conduit Notes: - Handrail & Walkway shown for reference only. Material, width, and details shall be determined by local engineer familiar with local codes. Handrail, decking, 11 2 11 2 stairs, installation and assembly by others unless otherwise noted. 9 - All piping and piping connections to and from filter by 10 3 11 others. - Filter shall be mounted to concrete floor or pad and anchored with stainless steel anchorage. Concrete, pad, anchors and installation by others. - Overflow piping shown to backwash channel. May optionally be directed to effluent or elsewhere as determined by engineer or local engineering standards. - Some filter components not shown for clarity. - Filter Main Control Panel (MCP) not shown for clarity. MCP mounted to tank at influent side or shipped loose for field mounting to railing or remote location by electrical contractor. - Refer to drawing F110048-Elev for item nos and notes. - Refer to drawing F110648-GA for Tank dimensions. 5 13
3 13
11
2 2 13 1 2 2 1 13
6 3 3 6 7 5 1 1 1 1 5 7 Drawing for general layout and sizing purposes only, NOT FOR FABRICATION
This Drawing and all appurtenant matter 4 2 9 2 7 10 2 14 2 7 contains information proprietary to Fluidyne Corporation and is loaned subject to return upon demand and must not be reproduced, copied, loaned, revealed, nor used for any other purpose than that for which it was specifically furnished without expressed written consent from Fluidyne Corporation. FFP™ Cloth Media Filter – Filter General Arrangement DRAWN DATE Job # CAD FILE REV Engr Date F110048.vsd REVISED DATE SCALE DRAWING SHEET F110648-PlanIn2 1 of 1 Item Quantity Description 1 1 FFP™ 110048 Tankage, 304 SS 2 2,4, or 6 FFP™ Element, typical, 48 sf ea 3 Optional Element Overhead Winch, Indoor locations 3 6 4 Optional Removable Hoist Assembly, Indoor or Outdoor locations Top of Influent 1 1 5 7 9.5 Ft 5 Element Removal Position Overflow Level 6 1 Air Scour Manifold, 304SS, Factory Mounted to Tank 9.0 Ft 7 Others Influent piping, CS or equivalent, 10" or 12" Dia Influent HWL 8.83 Ft 8 Others Effluent piping, CS or equivalent, 10" or 12" Dia 9 Others Backwash Discharge piping, CS or equivalent, 8" Dia 14 10 10 Others Overflow piping, CS or equivalent, 8" Dia Top of Tank 7.33 Ft 11 Others Concrete Pad or Floor - Design Details by Others Influent Normal Operating Level Tank Operating Level 6.75 Ft 6.6 Ft Notes: Influent Pipe Effluent Pipe x 1) All tank materials to be Type 304 Stainless Steel, PVC, Acrylic or other non- (To Here By Others) Top of Element (To here by others) corrosive materials. All fasteners to be Type 304 Stainless Steel. 5.5 Ft 2) All piping to be Schedule 10 Stainless Steel. All connections to be ANSI standard 125 lb Flanges. All piping and piping connections to and from filter by others. 3) Nominal Assembly Weight (Dry): ______Lbs. Nominal Filter Operating Weight when full (Wet): ______Lbs INFL 4) Backwash manifold optional, may be replaced with individually attached downward facing elbows directed to a backwash channel. 4 5) For single tank systems, filter control panel (MCP) shall be factory mounted to tank 6 8 at influent side and wired to all valves, floats, and controls. 2 6) For Multiple filter system, filters will have a common MCP panel shipped loose and EFFL 9 tank mounted junction box factory mounted to each filter at the influent side. Wiring 2 7 and conduit between remote mounted MCP and J-Box by others. 8 2 7) Contractor shall provide wiring and conduit for filter power (120VAC, 1Ph, 60Hz, 20Amp). See electrical interconnection diagram for wiring connection details. 8) Pneumatic airlines for all valves shall be provided at the factory to a common connection point near the air scour manifold inlet. Pressurized air from a local Concrete Elev. compressor or plant air source of 90 psi minimum shall be connected at the common BW 0.0 Ft connection point. Air line, plumbing, and conduit from compressor to the filter by others. 9) Concrete design, details, thickness, rebar, strength requirements, and substrate to be determined by engineer familiar with site and appropriate for local conditions. Installing contractor to provide appropriate anchorage for tank and pneumatic skid. 11 10) All dimensions, loads, elevations, and other information provide for illustrative purposes only and are not specific to any particular project or location. Not for 3 9 fabrication or field erection. 10 11) Any stairs, walkways, railings, and details shown are for illustrative purposes only & shall be designed and provided by others. All walkways should support minimum loads as dictated by local construction codes. 12) Tankage dimensions and details can be found on drawing F110048-GA. 13) Hoist or overhead winch for element removal only, Not for moving people, or loads over people. Weight not to exceed 300 lbs. 14) Tank overflow piping not shown for clarity. Overflow can be optionally directed to effluent channel, backwash channel, or to another location as determined by others.
This Drawing and all appurtenant matter contains information proprietary to Fluidyne Corporation and is loaned subject to return upon demand and must not be reproduced, copied, loaned, revealed, nor used for any other purpose than that for which it was specifically furnished without expressed Drawing for general layout written consent from Fluidyne Corporation. FFP™ Cloth Media Filter – Filter General Arrangement DRAWN DATE Job # CAD FILE REV and sizing purposes only, Engr Date F110048.vsd NOT FOR FABRICATION REVISED DATE SCALE DRAWING SHEET F110048-Elev 1 of 1 REV 1 of SHEET F110048.vsd ngineer familiar with ngineer familiar to and to and from filter by others. ) not shown for clarity. MCP ) not ere as determined by engineer by engineer determined as ere F110048-Rail CAD FILE . Concrete, pad, anchors and and anchors pad, . Concrete, Drawing for general layout and sizing purposes only, NOT FOR FABRICATION decking, stairs, installation and assembly assembly and installation stairs, decking, determined by local e determined DRAWING Cloth Media Filter – Filter General Arrangement – Filter Cloth Media General Filter ™ FFP Job # Job SCALE Date Notes: only. & shown for reference Material, width, - Handrail Walkway and details shall be local codes. Handrail, noted. otherwise by others unless connections piping - All and piping anchored pad and floor or to concrete - Filter mounted shall be anchorage steel with stainless installation by others. channel. shown to backwash May optionally piping - Overflow or to effluent elsewh be directed standards. engineering or local clarity. not shown for - Some filter components Control Panel (MCP Filter Main - loose for field shipped influent side or to tank at mounted contractor. electrical by or location remote to railing mounting notes. for item nos and - Refer to drawing F110048-Elev for Tank dimensions. - Refer to drawing F110448-GA DATE Engr This Drawingappurtenant and all matter contains information proprietary to Fluidyne Corporation and is loaned subject to return be reproduced, not and must upon demand for any used nor copied, loaned, revealed, other than purpose that for which it was specifically furnished without expressed written consent from Fluidyne Corporation. DRAWN REVISED DATE
15' 6" Minimum Interior Ceiling Height 8 2 8 6
EFFL 13 13 3 3 10 9 3 11 for removal) (Up Position (Up Position Media Panel Panel Media 1 BW 1 4 2 9 3 5 6
7 INFL 10 7 2 14 Filter Main MCP Filter #1 J-Box Filter #2 J-Box Conduit & Wiring by Fluidyne Shipped Loose for field Factory Mounted to Filter #1 Factory Mounted to Filter #2 mounting by contractor. Conduit & Wiring by Others Air Line by Fluidyne 20 Terminals @ 20 Terminals @ 12ga max each. 12ga max each. Air Line by others
Filter #1 Level Sensors Filter #2 Level Sensors Mounted to Tank at influent Mounted to Tank at influent channel and effluent weir Customer Power channel and effluent weir 120 VAC, 1 phase, HWL HWL 60 Hz, 20A LWL LWL Filter #1 Filter #2 ¾” Conduit w/ (20) 18ga wires Valves ¾” Conduit w/ (20) 18ga wires Valves SV SV
Filter #1 Filter #2 Air Scour Valves Air Scour Valves SV SV
Filter #1 Air Filter #2 Air Scour Manifold Scour Manifold Mounted to Tank at Mounted to Tank at effluent side effluent side PSI PSI
Common Common Connection Point Connection Point ½” NPT(F) ½” NPT(F) Customer Compressed Air
90 PSIG Minimum This Drawing and all appurtenant matter contains information proprietary to Fluidyne Corporation and is loaned subject to return upon demand and must not be reproduced, copied, loaned, revealed, nor used for any other purpose than that for which it was specifically furnished without expressed written consent from Fluidyne Corporation. FFP™ Cloth Media Filter – Electrical DRAWN DATE Job # CAD FILE REV Engr Date F110000-Multi-Interconnection.vsd CHECKED DATE SCALE DRAWING SHEET F110000-Multi-Interconnection 1 of 1 FFP™ FIXED PLATE CLOTH FILTER INSIDE – OUT OPERATION
THE ONLY CLOTH FILTER WITH NO MOVING PARTS! General Fluidyne Corporation (FC) offers the FFP™ fixed plate cloth media filter system for tertiary treatment of industrial and municipal wastewater. The FFP™ system utilizes fixed cloth media elements and pump free backwash capability, which are quite different than currently marketed technologies, yet offer substantial benefits in operation, maintenance, and installed equipment costs.
Inside-Out Operation FFP™ fixed plate cloth media filters incorporate an ‘inside-out’ flow pattern which is operationally advantageous compare to those designs that utilize ‘outside-in’ flow (where solids collect on the external areas of the media elements). FFP™ systems trap solids and biological material on the inside of the media elements, with cleaned effluent occupying the majority of the main tankage volume. Avoiding solids floating in the filter basin and solids sinking and collecting in the bottom of the tank.
Inside-out Operation Benefits: Allows the operator to readily see the quality of the effluent. Offers a more aesthetic and clean operation and avoids frequent cleaning of floatable solids Reduces operator contact with collected biological solids. Heavier solids settle to the bottom of the filter, for removal without additional pumps during normal gravity backwash step. Heavy solids never contact the cloth media or need to be ‘handled’. No need for hopper bottoms or sludge collection manifolds at the bottom of the main tank.
Also, some ‘outside-in’ systems utilize mechanical spray bars for cleaning, which spray high pressure water from the outside into the filter media, forcing some solids through the cloth to the clean water or interior side of the cloth, contaminating the effluent. In these systems, a separate 'rinse' cycle is then required where filtered water is diverted for several minutes after a spray cycle. High pressure spray also damages the cloth media over time, enlarging the filter media openings and causing premature failure and replacement.
Fluidyne FFP™ filters utilize an acrylic pile cloth media, and its No Moving Parts design eliminates the need for high pressure spray bars or mechanical suction headers and allows for reduced overall maintenance and improved performance.
Overall Operation Fluidyne FFP™ cloth filters reduce mechanical complexity by eliminating pumps, drive motors, gears, rotating drums, spray bars, and other mechanical items which significantly increase mechanical wear, potential problems and associated maintenance. Fluidyne FFP™ systems are simple to operate, easy to maintain.
FFP™ FIXED PLATE CLOTH FILTER INSIDE – OUT OPERATION
Rotating Disc Filter
Heavy solids accumulation (After 1 year in Operation)
Fixed Disc Filter
Grease and floatable solids (Week 1 of Operation)
Fluidyne FFP™ Fixed Plate Filter
Clean Inside – Out Operation (After 1 year in Operation)
FIXED PLATE CLOTH MEDIA FILTER FEATURES AND BENEFITS (REDUCED REDUNDANCY)
General Fluidyne Corporation (FC) offers the FFP™ fixed plate cloth media filter system that utilizes multiple isolated fixed cloth media panels and pump-free backwash capability. The methods for solids removal and backwash in FFP™ filters are quite different than currently marketed technologies, yet offer substantial benefits in operation, maintenance, and installed equipment costs.
One significant benefit is the ability to completely remove one or multiple media elements without disrupting flow to other on-line filter elements, offering significant operational advantages described below.
Installed Redundancy FFP™ Fixed Plate cloth media filters utilize multiple isolated media panels within each tank or concrete basin to provide filtration & backwash of wastewater. This plurality of filter elements allows incoming water to continue to enter the filter system while individual filter elements are being backwashed or are removed from the system.
Incoming water is filtered through remaining on-line filter elements. Treated water continually replenishes Fluidyne FFP™ the clean water reservoir or main System with tank area. This liquid level is 6 filter elements maintained while individual elements operating in parallel. are gravity backwashed. Each element is backwashed in sequence, allowing complete system backwash without discontinuing or diverting flow during the process.
During the backwash, flow to only one element has to be discontinued. The filter shown contains six media elements, only 1/6th of which would have to be off-line at any particular time, with the remaining 5/6th or 83% of the media area remaining online. By sizing the unit to handle design flows with 5 of 6 elements installed, one element can be removed from the flow stream without disruption to capacity, upstream processes, or influent treatment.
Fluidyne FFP™ Pg 1 of 2 Features & Benefits Fixed Plate Cloth Filter Reduced Redundancy F11000 Element Removal & Maintenance without Stand-by Fluidyne FFP™ Filter Element If periodic inspection of FFP™ media is required, individual out for maintenance (5 of 6 elements remain online) media elements can be isolated from the remaining elements and removed from the filter system for periodic inspection and media replacement. ALL internal components of FFP™ cloth media elements are modularized and integral to the media element (and NOT attached to the tank). Therefore, ALL internal components for each element are removed from the tank while flow continues to the other online filter elements.
This feature, in combination with an appropriate tank or basin design, allows elements to be removed, inspected and returned to service without decreasing system capacity or interrupting flow. ALL media within the system can be changed sequentially, while the remaining installed online elements treat the full design flow.
Comparison to ‘Disk’ type filters In contrast, many marketed cloth filter systems (Aqua-Aerobics, Entex, others) use multiple cloth disks or panels made up of multiple pie-shaped or semi-circular panels bolted to a common header. During media replacement, systems have to be dewatered to access the media and provide replacement.
Alternately, some systems (Kruger, Siemens, etc) have gotten around this deficiency by providing partial submergence of installed media. This allows non-submerged media to be replaced while submerged media provides treatment. Aqua-Aerobic Aqua-Disk® with disk segment This, however, requires out for maintenance, remaining filters Off- Line excess media (sometimes in excess of 2X) and mechanical equipment, as only a portion of the cloth is ever submerged and used for treatment at any time. This increases equipment cost and overall installed lifetime expense.
Overall The FFP’s use of elements that are fully submerged during operation, but removable from the flow stream without disruption to influent flow, allow FFP™ filter systems to operate without stand-by units, diversions tanks, or bypass lines which greatly reduce installed equipment costs, lifetime Siemens, Kruger, Etc. – Easy Media operational expenses, and operator maintenance replacement, partial submergence. requirements.
Fluidyne FFP™ Pg 2 of 2 Features & Benefits Fixed Plate Cloth Filter Reduced Redundancy F11000
FIXED PLATE CLOTH MEDIA FILTER OPERATIONAL DESCRIPTION
General Operation Fluidyne Corporation (FC) offers the FFP™ fixed plate cloth media filter system for tertiary treatment of wastewater from municipal & industrial secondary treatment processes (activated sludge, extended air, oxidation ditches, SBRs, etc).
FFP™ fixed plate cloth media filters offer several key advantages as a result of combining 2 important concepts; 1) utilizing cloth media that does not require excessive pressurized spray or backwash volume to clean and 2) using already available differential head to produce backwash flow.
FFP™ cloth filters use simple open-close pneumatic valves – operated by a small air compressor and simple controls - to control the filtering and backwash operations. The position of 2 valves associated with each isolated filtering element determines the direction of flow. No pumps are needed to create backwash flow, which allows media panels to be fixed in place (instead of rotated past a stationary spray or suction manifold), which also allows elements to be square or rectangular (vs. circular) easing manufacture, installation, removal, and maintenance. FFP™ filters utilize 100% acrylic filtering media fixed within 100% stainless steel element framework & tankage, all of which remain static during all operations, limiting mechanical wear and maintenance.
The static plate design is also very compact compared to many types of tertiary filters, particularly granular media filters. Much of this is due to the ability of the cloth media to be placed vertically, as opposed to requiring large flat sand beds or horizontal surfaces. Cloth media also has a significantly higher throughput capacity than granular media, and therefore helps to reduce overall size and footprint.
The filter operates through the use of gravity, requiring only small water level differential or head to push water through the filter cloth, making it ideally suited for treatment facilities located in low lying areas or where available gravity head is limited. FFP™ filters are ideally suited for smaller communities, industrial applications, mobile home parks, or residential developments which require tertiary filtration for water reuse, discharge to sensitive waterways, irrigation, or many other applications.
Filtering Operation FFP™ filters use a series of cloth media ‘membranes’ of long acrylic fibers attached to a woven, porous acrylic backing layer. This proprietary cloth technology is very effective at removing suspended solids (TSS) carry-over from secondary treatment processes.
During normal filtration, flow enters the influent channel that runs the entire length of the filter basin and is evenly distributed to multiple influent drop pipes which are attached to individually isolated filter underdrains (1 per element). Flow enters the vertically placed media elements
Fluidyne FFP™ Pg 1 of 3 Operational Description Fixed Plate Cloth Filter F11000
from the bottom, which allows larger, heavier solids to drop to the bottom of the underdrain - not on the media – while light-weight particles travel upward and are collected on the inside of the cloth media. This is referred to as ‘inside-out’ filtration, the advantages of which are described in FC’s “Features & Benefits – Inside-Out Operation” document.
Each Element is rectangular in design, has its own internal support framework, and is made up of 2 rectangular cloth media panels, one on each side of the frame. Typical packaged tanks have from 2 to 6 elements per tank and come in a variety of sizes to accommodate flows from 10,000 gpd to 1.2 MGD @ ADF. Multiple packaged filters can be placed in parallel to treat significant wastewater flow. Concrete tanks can also be utilized and can often accommodate many more elements than packaged units.
Backwash Operation As the filter continues to operate and remove solids, the water level or head in the influent channel rises. At a predetermined level (or based on time or operator initiation) the filter goes into a backwash stage to remove the collected solids and clean the media.
FFP™ cloth media filters feature a unique ‘fixed’ design, which limits mechanical wear and maintenance. Other cloth media filters use pumps or vacuums to force collected materials off the cloth. To do so, the cloth must move
Fluidyne FFP™ Pg 2 of 3 Operational Description Fixed Plate Cloth Filter F11000
past a stationary manifold, requiring the media panels to be circular or made of multiple pie- shaped sections. FFP™ cloth media panels are rectangular and remain stationary during all operations.
Once a backwash stage is initiated, the influent valve to the first element is closed and its associated backwash valve is opened. Water continues to enter the remaining online filter elements, producing clean water, which is collected in the main tank. Backwash flows in reverse due to the water level differential between the main tank level and backwash pipe. This reverse flow elongates the fibers of the pile media and carries away collected solids through the isolated underdrain, backwash valve & collection manifold. A small amount of compressed air is added during each element’s backwash to further agitate the media and enhance cleaning. Problematic backwash suction manifolds that have to ride on top or very near the media are eliminated. Also, suction or spray pumps are eliminated since the FFP™ system utilizes the already available differential head generated by incoming flow to the other filter “cells”.
Each filter element is backwashed in sequence, all while influent continues to enter the filter. This limits upstream disturbances since water does not have to be diverted or stored during the backwash cycle.
Maintenance Although resistant to chlorine and other chemicals, over time the cloth media panels can become clogged with algae or other foreign particles. Media may periodically be removed from its framework for cleaning or replacement. In this event, the individual media elements, each with its own supporting framework, are designed to be easily lifted from the tank and removed, even while flow continues to enter the filter through other online elements. The influent/backwash channel for the removed element can be isolated from incoming flow by closing both the influent and backwash valves for that element.
Each element has 2 lock-down mechanisms that, when released, allow the entire element to be lifted out of the filter bay, all while other elements continue to filter incoming flow. Once out of the filter, the media retention cover plate is easily removed and the media is cleaned or replaced. Within a short period, new cloth can be installed and reinserted back into the flow. This process has been found to be as short as 1 man-hour per media element for Larger FFP™ elements, and shorter for smaller filters.
All other components are 100% stainless steel, plastic, or acrylic and do not require regular maintenance. During normal operation, there are NO moving parts other than simple open-close pneumatically operated valves, further limiting mechanical complexity and associated maintenance. There are NO drive gears or chains, rotating disks, spray manifolds, pumps, or sludge collection manifolds to maintain making the FFP™ systems uniquely simple to install, operate, and maintain.
Please contact your local FC representative for project specific information.
Fluidyne FFP™ Pg 3 of 3 Operational Description Fixed Plate Cloth Filter F11000
Appendix C
Kruger
185 MGD Gothenburg, Sweden
Hydrotech Discfilter Pure Performance Hydrotech Discfilter
The Discfilter Process
The Hydrotech Discfilter provides proven experience for today’s demanding wastewater treatment applications through an efficient, yet easy-to-operate design. Influent flows by gravity into the center drum and then passes through the filter media mounted on both sides of the discs. The solids are retained on the media within the discs. Only purified water flows to the collection tank. The inside-out flow path prevents solids accumulation in the tank.
HYDROTECH ADVANTAGES
As solids collect on the inside of the media ● Unmatched experience and performance the influent water level rises. Maximum ● Innovation: patented designs offer real savings head loss through the media is <12 inches. ● The inlet water level is measured and the Robust construction with 304 or 316 SSTL control system automatically initiates ● Proven media: durable and chemically resistant backwashing. The filtered effluent is ● Meets or exceeds Title 22 requirements at pumped to the backwash spray nozzles, hydraulic loading rates up to Tankand aboveInstallation 6 gpm/ft² washing solids into the sludge trough as the ● Consistently produces high quality effluent discs rotate. The backwash water is typically despite high-solids loadings and upset conditions 1% to 2% of the total flow to the filter, while ● the sludge return is typically <1%. Filtration is Ideal for “retro-fit” projects in existing basins continuously maintained, even during ● Compact design requires far less space backwash. ● Simplified control system and lower installation costs than other filtration technologies ● Improved backwash efficiency reduces operating costs and carbon footprint Progressive Innovation
The Hydrotech Discfilter utilizes many patented designs including the oscillating backwash spray header, which provides efficient media cleaning while reducing water consumption by 20 percent. Ongoing research ensures the most cost effective filtration methods available.
The Hydrotech Discfilter is available in a variety of models:
1700 series Up to 8 discs Up to 1 MGD per unit in effluent polishing Ideal for small scale projects
1700 Series 2200 series Up to 24 discs Up to 9 MGD per unit in effluent polishing Excellent for a wide range of project sizes
2200 Series
2600 series Up to 30 discs for 15 MGD per unit in effluent polishing Provides highest filtration area and most compact footprint High flow rates maximize treatment in a given footprint 2600 Series Energy reduced 15% and footprint by 25% User-friendly design for minimal maintenance
DiscĮlter Study Data Total P Removal vs. Coagulant Dose 2 100% Advanced Treatment 1.8 90% 1.6 80% The Hydrotech Discfilter enables facilities to 1.4 70% meet stringent performance requirements. 1.2 60% Kruger has pioneered use of the discfilter in 1 50%
0.8 40% % Removal combination with coagulation/ flocculation as a Tot al P ( mg /L) cost effective means to reduce effluent 0.6 30% phosphorus to < 0.1 mg/L. 0.4 20% 0.2 10%
0 0% Coagulant Dose InŇuent Total P Eŋuent Total P % Removal Proven Performance
The compact Hydrotech Discfilter is used in a wide range of applications:
Effluent polishing of wastewater Activated Sludge Phosphorus removal Water reuse (Title 22 approved) InspectionRetrofit/replacement and maintenance of existing is simple systems because the filter discs operate partially submerged, allowing access without de-watering the tank. ACTIFLO® CSO, SSO, and primary treatment Process water filtration Membrane pre-treatment
MBBR The Hydrotech Discfilter is ideal for treating effluent from a variety of processes (e.g., activated sludge, fixed film, etc.). Kruger offers full-scale pilots to demonstrate And Others performance. Designed To Save
Hydrotech systems enable customers to achieve performance with lower cost and straight-forward maintenance. Hydrotech Discfilters provide a large filter area in a small footprint; up to 75% smaller than sand filters and up to 20% smaller than other cloth filters.
The discfilter is delivered as an assembled unit. Other cloth filters require substantial labor for site assembly and a larger footprint for backwash pumps and valves. The discfilter eliminates these concerns and costs. Installation is as simple as off-loading from a trailer, anchoring the unit, and completing mechanical and electrical connections.
O&M is simple and reduces operating costs. Fabrication is in 304 or 316 SSTL for trouble-free operation in the toughest conditions. Durable filter media provides long life without frequent and costly replacement. The efficient backwash process reduces energy costs.
Hydrotech Discfilters are easy to inspect and maintain, saving time and money. Experience You Can Trust
Today’s demanding applications require proven experience. Hydrotech Discfilters lead the market with over 350 installed units in the United States and over 1,800 worldwide.
Oconomowoc, WI Fox Lake, IL
Retrofit of tertiary sand filters Retrofit of tertiary sand filters 12 MGD 30 MGD
Mesquite, TX Holly Springs, NC
Effluent polishing Water reclaim and phosphorus removal 48 MGD 15 MGD Kruger Inc. Phone 919.677.8310 Fax 919.677.0082 www.krugerusa.com [email protected] 13-1 Marketing Kruger From: Jim Zaiser To: Michael Ducker Subject: Fwd: Brentwood, CA Phase 1 Info (Proposal, O&M Estimates) Date: Saturday, February 21, 2015 8:58:21 AM Attachments: Brentwood, CA Discfilter Proposal 2015-02-20.zip ATT00001.htm
Michael, please review this and advise thoughts.
Thanks
Jim
Jim,
I have included proposal, unit drawings, brochure, O&M estimates for the Brentwood project. See attached zip file as well as below for information regarding 20 year media life cycle costs and estimated energy consumption and backwash consumption for both options. I'll follow up in a separate email with the sketch for Phase 2.
Operation & Maintenance Estimates
Option 1 (Three HSF2216/15-1F units)
Filter Fabric Filter Fabric Year Replacement1 Year Replacement1 1 $0 11 $7,350 2 $0 12 $7,350 3 $0 13 $7,350 4 $0 14 $7,350 5 $0 15 $7,350 6 $5,250 16 $7,350 7 $5,250 17 $7,350 8 $5,250 18 $7,350 9 $7,350 19 $7,350 10 $7,350 20 $7,350
1 Filter replacement costs based on replacing 4-6% of media years six through eight, 6-8% annually thereafter
· Estimated Annual Energy Consumption: 44,500 kWhr/year
· Backwash Consumption Sludge Return: 68,900 gallons/day Option Two (Two HSF2622-1F Units)
Filter Fabric Filter Fabric Year Replacement1 Year Replacement1 1 $0 11 $7,546 2 $0 12 $7,546 3 $0 13 $7,546 4 $0 14 $7,546 5 $0 15 $7,546 6 $5,390 16 $7,546 7 $5,390 17 $7,546 8 $5,390 18 $7,546 9 $7,546 19 $7,546 10 $7,546 20 $7,546
1 Filter replacement costs based on replacing 4-6% of media years six through eight, 6-8% annually thereafter
· Estimated Annual Energy Consumption: 35,800 kWhr/year
· Backwash Consumption Sludge Return:40,500 gallons/day
On Thu, Feb 12, 2015 at 8:17 PM, Georger, Jim
Why did you pick 1F for filter rehab?
What I need for Phase 1 is:
2+1, 5 mgd each. TSS in is 10-15
1+1, 10 mgd each TSS in is 10-15.
Proposal, O&M, media replacement estimate, backwash waste estimate.
Phase 2
Can I get a simple sketch, plan and section showings a DF in existing filter cell. Assume 3+1 for existing.
Questions? Coleman Engineering Mike Ducker, P.E. 1358 Blue Oak Blvd 200 Roseville, CA 95678 [email protected]
On Thu, Feb 12, 2015 at 10:23 AM, Ray, Brandon
For Peak of 10 MGD - we'd look at (2+1) HSF2216/15-1F units.
If they want 3+1 treating 10 MGD, tell them that this is not a cost efficient option compared to the (2+1) option. However for that scenario we're looking at (3+1) HSF2210-1F units.
On Thu, Feb 12, 2015 at 11:17 AM, Georger, Jim
What if they want one unit per basin. 3+1 at peak flow? What size. (design Table notes Peak as 10 mgd)
Jim
James T. Georger, P.E. Regional Sales Manager, US Municipal Solutions WATER TECHNOLOGIES
On Thu, Feb 12, 2015 at 10:06 AM, Ray, Brandon
Based on the information I have gathered from the drawings and Michael's email below, we would size the system as:
2 (1 Duty, 1 Redundant) HSF2216/15-1F Units Design would treat the peak flow of 5.0 MGD that is referenced in Michael's email Peak Inf TSS: I'm assuming around 20-30 mg/L peak TSS based on treating oxidation ditch effluent\ There are 4 basins 9.5' W x 54' L. Our filters would easily fit length- wise. Width-wise is tighter, but we have made similar retrofit installations work in the past.
Drawing is attached. -Brandon
On Thu, Feb 12, 2015 at 10:43 AM, Georger, Jim
Can i get you to look at this. See sheet 6 and 7 (1 and 2) and also the tertiary Filter Mechanical drawings.
Based on the design criteria given in the table (sheet 6) for current design, what size DF will we need and will it fit. That is all I need at this time.
Jim
Jim,
I am interested in a cloth media filter that will fit into the existing concrete filtration tanks. The current equipment and operation of the plant produces effluent which is consistently less than 2 NTU. The purpose in replacing the filters is to reduce O&M (energy) costs.
Please refer to the design parameters on sheet G6 for information. The design BOD was 220 mg/L but current levels are more like 250 mg/L which can sometimes reach 300 mg/L. The plant has been built to Phase 1 capacity (5.0MGD) but runs now at 3.5 to 4.0 MGD.
Please contact me if you require further information.
Thanks, Hydrotech Discfilter Preliminary Proposal Brentwood, CA Kruger Project: 5700105503
CONFIDENTIAL: The information or data contained in this proposal is proprietary to Kruger and should not be copied, reproduced, duplicated, or disclosed to any third party, in whole or part, without the prior written consent of Kruger. This restriction will not apply to any information or data that is available to the public generally.
1. Design Summary and Scope of Supply
Kruger is pleased to propose the Hydrotech Discfilter system for this project. The system design is based on the information listed in the following tables and will be supplied according to Kruger design standards: Design Criteria
Table 1: Influent & Effluent Design Criteria Wastewater Characteristics Influent Source Secondary Clarification following Oxidation Ditch Peak Hour Flow, MGD (gpm) 10.0 (6,944) Average Day Flow, MGD (gpm) 5.0 (3,472) Peak Influent TSS, mg/L 20 Average Influent TSS, mg/L 10 Average Influent Turbidity, NTU 10 Monthly Average Effluent TSS, mg/L 5 Monthly Average Effluent Turbidity, NTU 2
Equipment Supply Table 2A: Discfilter Design Information (Option 1) Proposed Discfilter System Discfilter Model Number HSF2216/15-1F Total units (duty/standby) 3 (2/1) Total filter area per unit, ft2 904 Submerged filter area per unit, ft2 588 Peak hydraulic loading rate, gpm/ft2 5.91* Number of Discs per unit 15 Media Pore Size, µm 10 Chassis Material 304 SS Cover Material GRP Self Enclosed Tank Material 304 SS SEW drive motor, hp 1.5 Backwash water pump, hp 15 Backwash pump rated flow, gpm 99 Influent and Effluent Flange ANSI 20” Backwash Reject as % Influent Flow ≤ 3% * Hydraulic loading rate does not include standby unit.
Kruger Proposal Date: February 20, 2015 4001 Weston Parkway Page 1 Cary, NC 27513
Hydrotech Discfilter Preliminary Proposal Brentwood, CA Kruger Project: 5700105503
Table 2B: Discfilter Design Information (Option 2) Proposed Discfilter System Discfilter Model Number HSF2622-1F Total units (duty/standby) 2 (1/1) Total filter area per unit, ft2 1,800 Submerged filter area per unit, ft2 1,170 Peak hydraulic loading rate, gpm/ft2 5.94* Number of Discs per unit 22 Media Pore Size, µm 10 Chassis Material 304 SS Cover Material GRP Self Enclosed Tank Material 304 SS SEW drive motor, hp 1.5 Backwash water pump, hp 25 Backwash pump rated flow, gpm 211 Influent and Effluent Flange ANSI 36" Backwash Reject as % Influent Flow ≤ 3% * Hydraulic loading rate does not include standby unit.
An instrumentation and control system will be included with the Kruger equipment. The control system will be designed and supplied according to Kruger standards. It will include the following: NEMA12 main control panel with PLC (Option 2 Only) NEMA4X local control panel for each Discfilter unit (Option 1 and Option 2)
Process and Design Engineering Kruger provides process engineering and design support for the system as follows:
Equipment specifications for equipment supplied by Kruger Technical instructions for operation and start-up of the system Equipment location drawings and installation plans Project specific O&M manuals
Field Services Kruger will furnish a Service Engineer as specified at the time of start-up to inspect the installation of the completed system, place the system in initial operation, and to instruct operating personnel on the proper use of the equipment. Specifically, Kruger will provide:
Field Service Engineer/Technician – Four (4) days on site in not more than two (2) site visits to assist with inspection check-out, start-up, and operator training. I&C Field Service Engineer/Technician – Four (4) days on site in not more than one (1) site visit to assist with inspection and I/O check-out, start-up, and operator training.
Kruger Proposal Date: February 20, 2015 4001 Weston Parkway Page 2 Cary, NC 27513
Hydrotech Discfilter Preliminary Proposal Brentwood, CA Kruger Project: 5700105503
Installation Requirements The following items will be installed by the Contractor/Others: Control panel(s) Interconnecting wiring and/or conduit between the supplied control panel(s) and Discfilter equipment Any junction or pull boxes or any other like device needed to supply the interconnecting wiring All field connections/terminations to the supplied control panels, the Discfilter equipment and between the Discfilter and supplied control panels All supports and anchoring required to install the Discfilter unit Plumbing/interconnecting piping, electrical connections, access platforms, grating & handrails
2. Pricing
The pricing for the Discfilter system, as defined herein, including process and design engineering, field services, and equipment supply is as follows:
Option 1: $707,500.00 Option 2: $880,300.00
Please note that the above pricing is expressly contingent upon the items in this proposal and are subject to I. Kruger Inc. Standard Terms of Sale detailed herein.
This pricing is FOB shipping point, with freight allowed to the job site. This pricing does not include any sales or use taxes. In addition, pricing is valid for ninety (90) days from the date of issue and is subject to negotiation of a mutually acceptable contract.
3. Company Information
I. Kruger Inc. (Kruger) is a water and wastewater solutions provider specializing in advanced and differentiating technologies. Kruger provides complete processes and systems ranging from biological nutrient removal to mobile surface water treatment. The ACTIFLO® Microsand Ballasted Clarifier, AnoxKaldnes MBBR, BIOCON® Dryer, BIOSTYR® Biological Aerated Filter (BAF), NEOSEP™ MBR and HYDROTECH Discfilters are just a few of the innovative technologies offered by Kruger. Kruger is a subsidiary of Veolia Water Solutions and Technologies (VWS), a world leader in engineering and technological solutions in water treatment for industrial companies and municipal authorities.
4. Energy Focus Kruger is dedicated to delivering sustainable and innovative technologies and solutions. Veolia’s investments in R&D outpace that of our competition. Our focus is on delivering neutral or positive energy solutions migration towards green chemicals or zero chemical consumption water-footprint-efficient technologies with high recovery rates Our carbon footprint reduction program drives innovation, accelerates adoption and development of clean technologies, and offers our customers sustainable solutions. By committing to the innovative development of clean and sustainable technologies and solutions worldwide, Kruger and VWS will continue to maximize the financial benefits for every customer.
Kruger Proposal Date: February 20, 2015 4001 Weston Parkway Page 3 Cary, NC 27513
Hydrotech Discfilter Preliminary Proposal Brentwood, CA Kruger Project: 5700105503
5. Schedule and Payment Terms
Schedule Shop drawings: submitted within 6-8 weeks of receipt of an executed contract by all parties. Equipment: delivered within 18-20 weeks of receipt of written approval of the shop drawings. Operation & Maintenance Manuals: submitted within 90 days of receipt of approved shop drawings.
Terms of Payment The terms of payment are as follows: 10% on receipt of fully executed contract, 15% on submittal of shop drawings, and 75% on the delivery of equipment to the site. Payment shall not be contingent upon receipt of funds by the Contractor from the Owner, and there shall be no retention in payments due to I. Kruger Inc. All payment terms are net 30 days from the date of invoice. Final payment shall not exceed 120 days from delivery of equipment. All other terms are per the Kruger Standard Terms of Sale.
Revision Date Process Eng. Comments 0 02/20/2015 BMW Initial, budgetary proposal.
Kruger Proposal Date: February 20, 2015 4001 Weston Parkway Page 4 Cary, NC 27513
Hydrotech Discfilter Preliminary Proposal Brentwood, CA Kruger Project: 5700105503
6. I. Kruger Inc. Standard Terms of Sale
1. Applicable Terms. These terms govern the purchase and sale of the equipment and related services, if any (collectively, "Equipment"), referred to in Seller’s purchase order, quotation, proposal or acknowledgment, as the case may be ("Seller’s Documentation"). Whether these terms are included in an offer or an acceptance by Seller, such offer or acceptance is conditioned on Buyer’s assent to these terms. Seller rejects all additional or different terms in any of Buyer’s forms or documents.
2. Payment. Buyer shall pay Seller the full purchase price as set forth in Seller’s Documentation. Unless Seller’s Documentation provides otherwise, freight, storage, insurance and all taxes, duties or other governmental charges relating to the Equipment shall be paid by Buyer. If Seller is required to pay any such charges, Buyer shall immediately reimburse Seller. All payments are due within 30 days after receipt of invoice. Buyer shall be charged the lower of 1 ½% interest per month or the maximum legal rate on all amounts not received by the due date and shall pay all of Seller’s reasonable costs (including attorneys’ fees) of collecting amounts due but unpaid. All orders are subject to credit approval.
3. Delivery. Delivery of the Equipment shall be in material compliance with the schedule in Seller’s Documentation. Unless Seller’s Documentation provides otherwise, Delivery terms are F.O.B. Seller’s facility.
4. Ownership of Materials. All devices, designs (including drawings, plans and specifications), estimates, prices, notes, electronic data and other documents or information prepared or disclosed by Seller, and all related intellectual property rights, shall remain Seller’s property. Seller grants Buyer a non-exclusive, non-transferable license to use any such material solely for Buyer’s use of the Equipment. Buyer shall not disclose any such material to third parties without Seller’s prior written consent.
5. Changes. Seller shall not implement any changes in the scope of work described in Seller’s Documentation unless Buyer and Seller agree in writing to the details of the change and any resulting price, schedule or other contractual modifications. This includes any changes necessitated by a change in applicable law occurring after the effective date of any contract including these terms.
6. Warranty. Subject to the following sentence, Seller warrants to Buyer that the Equipment shall materially conform to the description in Seller’s Documentation and shall be free from defects in material and workmanship. The foregoing warranty shall not apply to any Equipment that is specified or otherwise demanded by Buyer and is not manufactured or selected by Seller, as to which (i) Seller hereby assigns to Buyer, to the extent assignable, any warranties made to Seller and (ii) Seller shall have no other liability to Buyer under warranty, tort or any other legal theory. If Buyer gives Seller prompt written notice of breach of this warranty within 18 months from delivery or 1 year from beneficial use, whichever occurs first (the "Warranty Period"), Seller shall, at its sole option and as Buyer’s sole remedy, repair or replace the subject parts or refund the purchase price therefore. If Seller determines that any claimed breach is not, in fact, covered by this warranty, Buyer shall pay Seller its then customary charges for any repair or replacement made by Seller. Seller’s warranty is conditioned on Buyer’s (a) operating and maintaining the Equipment in accordance with Seller’s instructions, (b) not making any unauthorized repairs or alterations, and (c) not being in default of any payment obligation to Seller. Seller’s warranty does not cover damage caused by chemical action or abrasive material, misuse or improper installation (unless installed by Seller). THE WARRANTIES SET FORTH IN THIS SECTION ARE SELLER’S SOLE AND EXCLUSIVE WARRANTIES AND ARE SUBJECT TO SECTION 10 BELOW. SELLER MAKES NO OTHER WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE.
7. Indemnity. Seller shall indemnify, defend and hold Buyer harmless from any claim, cause of action or liability incurred by Buyer as a result of third party claims for personal injury, death or damage to tangible property, to the extent caused by Seller's negligence. Seller shall have the sole authority to direct the defense of and settle any indemnified claim. Seller’s indemnification is conditioned on Buyer (a) promptly, within the Warranty Period, notifying Seller of any claim, and (b) providing reasonable cooperation in the defense of any claim.
8. Force Majeure. Neither Seller nor Buyer shall have any liability for any breach (except for breach of payment obligations) caused by extreme weather or other act of God, strike or other labor shortage or disturbance, fire, accident, war or civil disturbance, delay of carriers, failure of normal sources of supply, act of government or any other cause beyond such party's reasonable control.
9. Cancellation. If Buyer cancels or suspends its order for any reason other than Seller’s breach, Buyer shall promptly pay Seller for work performed prior to cancellation or suspension and any other direct costs incurred by Seller as a result of such cancellation or suspension.
10. LIMITATION OF LIABILITY. NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY, SELLER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES, AND SELLER’S TOTAL LIABILITY ARISING AT ANY TIME FROM THE SALE OR USE OF THE EQUIPMENT SHALL NOT EXCEED THE PURCHASE PRICE PAID FOR THE EQUIPMENT. THESE LIMITATIONS APPLY WHETHER THE LIABILITY IS BASED ON CONTRACT, TORT, STRICT LIABILITY OR ANY OTHER THEORY.
11. Miscellaneous. If these terms are issued in connection with a government contract, they shall be deemed to include those federal acquisition regulations that are required by law to be included. These terms, together with any quotation, purchase order or acknowledgement issued or signed by the Seller, comprise the complete and exclusive statement of the agreement between the parties (the “Agreement”) and supersede any terms contained in Buyer’s documents, unless separately signed by Seller. No part of the Agreement may be changed or cancelled except by a written document signed by Seller and Buyer. No course of dealing or performance, usage of trade or failure to enforce any term shall be used to modify the Agreement. If any of these terms is unenforceable, such term shall be limited only to the extent necessary to make it enforceable, and all other terms shall remain in full force and effect. Buyer may not assign or permit any other transfer of the Agreement without Seller’s prior written consent. The Agreement shall be governed by the laws of the State of North Carolina without regard to its conflict of laws provisions.
Kruger Proposal Date: February 20, 2015 4001 Weston Parkway Page 5 Cary, NC 27513
Appendix D
Revised Tables 3 through 5 Table 3 Calculations Aqua‐Aerobic Tertiary Filters Systems Fluidyne Kruger
O&M run hours per day 24 hrs/day 24 hrs/day 24 hrs/day run days per week 7.00 days/wk 7.00 days/wk 7.00 days/wk
labor hours per day 0 hrs/day 0 hrs/day 0 hrs/day cost of labor$ 100.00 $/day$ 100.00 $/day$ 100.00 $/day weekly O&M $ ‐ $/wk $ ‐ $/wk $ ‐ $/wk Monthly O&M $ ‐ $/mo $ ‐ $/mo $ ‐ $/mo
Monitoring
hours per day 0 hrs/wk 0 hrs/wk 0 hrs/wk days per week 1 days 1 days 1 days labor hours per week 0 hrs/day 0 hrs/day 0 hrs/day cost of labor$ 100.00 $/day$ 100.00 $/day$ 100.00 $/day weekly cost $ ‐ $/wk $ ‐ $/wk $ ‐ $/wk Monthly Testing, Monitoring and Reporting $ ‐ $/mo $ ‐ $/mo $ ‐ $/mo
Maintenance monthly maintenance$ 83.33 $/mo$ 83.33 $/mo$ 83.33 $/mo
annual maintenance$ 1,000.00 $/yr$ 1,000.00 $/yr$ 1,000.00 $/yr Monthly Maintenance, Repair and Parts Replacement$ 83.33 $/mo$ 83.33 $/mo$ 83.33 $/mo
O&M Filter Replacement Estimates Filter Replacement Years Cost 5 $ ‐ $/year 3$ 5,250 $/year 12$ 7,350 $/year 20$ 103,950 Totals
$ 5,197.50 Yearly Average $ 433.13 Monthly Average Table 3‐ Monthly Operations and Maintenance Aqua‐Aerobic Item Systems Fluidyne Kruger Montly O&M $ ‐ $ ‐ $ ‐
Monthly Testing, Monitoring and Reporting $ ‐ $ ‐ $ ‐
Monthly Maintenance, Repair and Parts Replacement (estimated) $ 83.33 $ 83.33 $ 83.33
Monthly Filter Replacement (estimated)$ 433.13 $ 433.13 $ 433.13
Monthly O&M Cost.$ 433.13 $ 433.13 $ 433.13 Table 4 ‐ Filter Comparison Alternative 1 Alternative 2 Alternative 3 Alternative 4 Phase 2 Sand Filter Phase 2 Cloth Filter on new conc elevated deck Phase 1 and 2 Cloth Filters in existing conc tanks and new conc tanks Phase 1 Replace existing Phase 1 sand filters with Phase 1 Cloth Filters only in existing conc tanks 1‐4. Capital Cost Monthly Comments Capital Cost Monthly Comments Capital Cost Monthly Qty Comments Capital Cost Monthly Qty Comments Description $ ‐ $ ‐ $ ‐ $ ‐ Equipment Filter Package$ 160,000 $ 839,889 $ 1,679,778 2 Phases of filter units$ 839,889 1 Phases of filter units Prefabricated Tanks $ 380,000 $ ‐ $ ‐ Sand Media$ 320,000 $ ‐ $ ‐ $ ‐ Subtotal $ 480,000 $ 1,219,889 $ 1,679,778 $ 839,889
Mechanical/Electrical Process Piping$ 50,000 $ 100,000 piping on deck$ 75,000 piping to existing conc t $ 37,500 Only Phase 1 of Alt 3, 50% cost Automated Valves$ 400,000 $ 300,000 $ 400,000 $ 400,000 Same as Alt 1 and Alt 3 valves for existing conc tank. Electrical$ 50,000 $ 100,000 reroute power to deck and S$ 100,000 reroute power to existi $ 75,000 reroute 50% power to existing tanks and 100% SCADA programin Subtotal $ 500,000 $ 500,000 $ 575,000 $ 512,500
Structures Building $ ‐ $ ‐ $ ‐ $ ‐ Concrete Tanks/Deck$ 600,000 new tanks 5‐8, total of 8 requ $ 400,000 new deck $ 350,000 new tanks 5‐6, total of $ 50,000 Existing conc tank mods to fit in cloth filters Subtotal $ 600,000 $ 400,000 $ 350,000 $ 50,000
Operations and Maintenance Daily O&M $ ‐ $ ‐ $ ‐ $ ‐ Sampling Monitoring $ ‐ $ ‐ $ ‐ $ 3,200 Repairs$ 83 $ 83 $ 83 Phases of filter units Filter Media Replacement$ 433 $ 5,198 per year$ 433 $ 5,198 per year$ 433 $ 5,198 per year 2$ 433 $ 5,198 per year 1 Subtotal $ 516 per month $ 516 per month $ 516 per month $ 3,633 per month
Energy Air Blower$ 160 $ ‐ $ ‐ $ ‐ Air Compressor $ ‐ $ 140 $ 279 2 Qty Phases of filter units$ 139.71 1 Qty Phases of filter units Clear Well Pumps$ 69 $ 419 $ 838 2 Qty Phases of filter units$ 419.13 1 Qty Phases of filter units Mud Well Pumps$ 18 $ 18 $ 36 2 Qty Phases of filter units$ 17.86 1 Qty Phases of filter units Onboard Waste Pumps $ ‐ $ ‐ $ ‐ $ ‐ Chemical Feed Pumps $ ‐ $ ‐ $ ‐ $ ‐ Chemical $ ‐ $ ‐ $ ‐ $ ‐ Retreat Backwash$ 7,656 $ 4,134 $ 8,268 2 Qty Phases of filter units$ 4,134 1 Qty Phases of filter units Subtotal $ 7,903 per month $ 4,711 per month $ 9,421 per month $ 4,711 per month
Tertiary Filter Equipment$ 480,000 $ 1,219,889 $ 1,679,778 $ 839,889
Construction Cost$ 1,100,000 $ 900,000 $ 925,000 $ 562,500
Design (15% of Construction)$ 165,000 $ 135,000 $ 138,750 $ 84,375
Capital Improvement Cost$ 1,745,000 $ 2,254,889 $ 2,743,528 $ 1,486,764
Contengency (30% of Const. & Design) $ 379,500 $ 310,500 $ 319,125 $ 194,063
Budgetary Improvement Cost $ 2,124,500 $ 2,565,389 $ 3,062,653 $ 1,680,827
Monthly Energy$ 7,903 $ 4,711 $ 9,421 $ 4,711
Monthly O&M$ 516 $ 516 $ 516 $ 3,633
Monthly Operational Cost$ 8,419 $ 5,227 $ 9,938 $ 8,344
Design 15% of Equipment and Construction Cost 15% 15% 15% Contengency 30% of Construction and Design 30% 30% 30% Table 5 Budgetary Costs Alternative 1 Alternative 2 Alternative 3 Alternative 4
Tertiary Filter Equipment $480,000 $1,219,889 $1,679,778 $839,889
Construction Cost $1,100,000 $900,000 $925,000 $563,000
Design $165,000 $135,000 $139,000 $84,000 (15% of Construction) Capital Improvement Cost $1,745,000 $2,255,000 $2,744,000 $1,487,000
Contengency $380,000 $311,000 $319,000 $194,000 (30% of Const. & Design) Budgetary Improvement Cost $2,125,000 $2,565,000 $3,063,000 $1,681,000
Monthly Energy $7,903 $5,000 $9,000 $5,000
Monthly O&M $516 $1,000 $1,000 $4,000
Monthly Operational Cost $8,419 $5,000 $10,000 $8,000
Design (% of Equipment and Construction Cost) 15% 15% 15% 15% Contengency (% of Construction and Design) 30% 30% 30% 30%