life12 env/es/000265 deliverable db1.3: user manual of

LIFE12 ENV/ES/000265 Deliverable D.B.1.3

LIFE Project Number

LIFE12 ENV/ES/000265

DELIVERABLE D.B.1.3: USER MANUAL OF BOTH PROTOTYPES.

ADNATUR: Demonstration of natural coagulant use advantages in physical & chemical treatments in industry and urban waste water.


CONTENTS

1. INTRODUCTION ............................................................................................................ 3

2. INDUSTRIAL WASTEWATER PROTOTYPE. ................................................................... 4

2.1. MAIN COMPONENTS OF THE PROTOTYPE. .............................................................. 4

2.2. START / STOP PROCEDURES. .................................................................................. 12

2.3. MAINTENANCE INSTRUCTIONS. ............................................................................. 13

2.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS. ................... 24

3. URBAN WASTEWATER PROTOTYPE. ......................................................................... 26

3.1. MAIN COMPONENTS OF THE PROTOTYPE. ............................................................ 26

3.2. START / STOP PROCEDURES. .................................................................................. 35

3.3. MAINTENANCE INSTRUCTIONS. ............................................................................. 36

3.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS. ................... 53

4. CONCLUSIONS ............................................................................................................ 60

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1. INTRODUCTION

The present report summarizes the most important properties of all the components of both prototypes. Every item has been fully detailed including brief description, user instructions and important warnings. Thus, start up and stoppage procedures have been completely explained.

The maintenance process is crucial in order to maximize the efficiency of the plants. For that reason, an exhaustive point regarding maintenance issue has been also included. Finally, a complete explanation of points to check in case of malfunction and what measures have to be taken in order to solve the problems has been reported in current ADNATUR deliverable.

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2. INDUSTRIAL WASTEWATER PROTOTYPE.

2.1. MAIN COMPONENTS OF THE PROTOTYPE.

2.1.1. Control box.

The aim of the control box is to monitor and control each constituent of the prototype and to access in every moment to the current situation of the facility as well as the alarm and data log.

The setting of the pump frequency is important because it depends on it the water pressure through the system and, accordingly, the inlet flow.

These kinds of controllers are modular systems that can be adapted optimally to the required automation task. Thus, it is possible to be customized, using different modules. In case that later the requirements of the system would change the controller is easily expandable by adding further modules.

With the tactile screen the different states of the displays can be seen, as well as all variables of the plant.

 Engines Stop / Start.

 Pumps Stop / Start.

 Flow reading.

 pH reading in the decantation tank.

 Hours of equipment operation, etc...

Graphical programming is structured into different screens with different security levels.

Different color graphics give a clear look of the current state of the plant stop and start of the engines, and making graphic levels for those variables that require it.

2.1.2. Inlet wastewater pump.

The injection of inlet wastewater to the pilot plant is carried out with a pump with the following technical specifications:

Height

Width

Depth

Est. Ship Weight

PVDF 5 kg (10 lbs) Air Inlet

Inlet

Outlet

Suction Lift

Displacement per Stroke

Max. Flow Rate

Max. Size Solids

277 mm (10.9")

234 mm (9.2")

201 mm (7.9")

Polypropylene 4 kg (8 lbs)

6 mm (1/4")

13 mm (1/2")

13 mm (1/2")

4.5 m Dry (14.7') 9.3 m Wet (30.6')

0.10 l (0.027 gal.)*

57.0 lpm (15.0 gpm)

1.6 mm (1/16")

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*Displacement per stroke was calculated at 4.8 bar (70 psig) air inlet pressure against a 2 bar (30 psig) head pressure.

Figure 1. Inlet wastewater pump for industrial prototype.

The air distribution system incorporates three moving parts: the air valve spool, the pilot spool, and the main shaft/diaphragm assembly. The heart of the system is the air valve spool and air valve. This valve design incorporates an unbalanced spool. The smaller end of the spool is pressurized continuously, while the large end is alternately pressurized then exhausted to move the spool. The spool directs pressurized air to one air chamber while exhausting the other. The air causes the main shaft/diaphragm assembly to shift to one side — discharging liquid on that side and pulling liquid in on the other side. When the shaft reaches the end of its stroke, the inner piston actuates the pilot spool, which pressurizes and exhausts the large end of the air valve spool. The repositioning of the air valve spool routes the air to the other air chamber.

2.1.3. Inlet water tank.

Water tank is cylindrical shaped, white coloured and made of polyethylene. At the top, have a screw cap, also made of polyethylene but black coloured. Its capacity is 500 litres.

The water flows into the tank through a tube connected at the top, and then flows out of the tank through a tube which is set at the bottom side. Inlet water tank includes a stirrer at low speed with reducer crown. The axis of Stainless Steel Aisi-316, is coupled with key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization and flocculation processes with flange for application to open or semi-open containers. The stirrer has the follow specifications:

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Type:

Speed:

Relation:

Propeller:

Material:

RV-12 S-35-05

49 rpm

1:30

600 mm

Aisi-316

Engine:

Weight:

1/3 HP

14,00 Kg

Figure 2. Stirrer for inlet water tank, including specifications.

2.1.4 Multi-parametric Sensor.

The current detector is a multiple digital controller system. It reads and controls up to 5 channels that can be programmed to control pH, ORP (oxidation reduction potential), turbidity, temperature, conductivity. It features 6 set point outputs, 6 proportional pump outputs, 6 mA outputs, 1 cleaning probe output and 5 level tank inputs. I contains three way set point outputs program mode: on/off - PID - PWM. The detector can be connected to a PC for remote controlling

/ programming using a standard USB port, RS485 connection, GSM or GPRS modem, ETHERNET.

The working ranges of the device are:

 pH: from 0 to 14 pH.



ORP: from 0 to 1000 mv.



Turbidity: from 0 to 30 NTU.



Temperature: from 0 to 200 °C.



Conductivity: from 0 to 300.0 mS.

All the information is provided through a widescreen LCD display (240x64) provided with a control wheel, in order to program the instrument. The detector is housed into a plastic box, and its measures are: L325 x H235 x D125 (including wheel and connectors).

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Figure 3. Multi-parametric Sensor.

2.1.5. Coagulation Tank.

The coagulation tank is rectangular shaped, made of stainless steel. Its capacity is 150 litres. A stirrer at low speed with reducer crown is included. The axis of Stainless Steel Aisi-316, is coupled with key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization and flocculation processes with flange for application to open or semi-open containers. In order to have a proper mixer between the ADNATUR technology and inlet water, a mixer is used with the following specifications.

Type: RV-12 S-35-05

Speed:

Relation:

Propeller:

Material:

Engine:

Weight:

49 rpm

1:30

600 mm

Aisi-316

1/3 HP

14,00 Kg

Figure 4. Stirrer for coagulation tank, including specifications.

2.1.6. ADNATUR dosing system.

ADNATUR dosing system is probably the most important component of the prototype. It is necessary in order to maximize the coagulant efficiency of the ADNATUR natural based products.

It contains a dosing pump and a static mixer system. This way, the product is reaching the coagulation tank previously dissolved in water. However, dissolution procedure is made in situ so the reaction time is low and then the stability of the product is unaltered. Proposed dosing pump includes the following specifications:

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Power supply:

Number of pump injections:

Maximum flow (7 Bar):

Injections/Minute aspiration Height:

Room temperature:

230 VAC (180-270 VAC)

115 VAC (90-135 VAC)

24 VAC (20-32 VAC)

12 VDC (10-16 VDC)

0 ÷ 180

6 litres/hour

1,5 metros

0 ÷ 45°C (32 ÷ 113°F)

Additive temperature:

Contamination level:

0 ÷ 50°C (32 ÷ 122°F)

2

Sound level: 74 dbA

Delivery and storage temperature: -10 ÷ +50°C (14 ÷ 122°F)

Protection grade: IP65

Figure 5. ADNATUR dosing system, including the dosing pump (left) and the static mixer (right).

2.1.7. Flocculant mixer.

The flocculant mixer is cylindrical shaped, white coloured and made of polyethylene. At the top, have a screw cap, also made of polyethylene but black coloured. Its capacity is 200 litres. In order to have a proper mixer between the wastewater, previously mixed with the coagulant, and the flocculant, solid flocculant needs to be pre-dissolved in water. Accordingly, the product is manually added in a deposit with water and exhaustively stirred. Finally, the solid content of the flocculant, polyacrylamide based, needs to be between 0,1 and 0,2 per cent in water. Flocculant tank includes a deposit and a stirrer in polypropylene and PVDF for acids without support with flange for application on the tank. Sealing at the top is achieved against a fixed ceramic blind Vring and propeller through an O-ring. The stirrer has the following specifications:

Type:

Speed:

Voltage:

Engine:

Axis:

Coated axis:

E-600-4

940 rpm

230 single-phase; 230/400

1/6 HP

600 mm

P.P. or PVDF

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Propeller:

Weight:

P.P. or PVDF

5 Kg

Figure 6. Flocculant mixer, including the stirrer (left) and the mixer deposit (right).

2.1.8. Flocculation tank.

The flocculation tank is rectangular shaped, made of stainless steel. Its capacity is 300 litres. In order to have a proper mixer between the wastewater, previously mixed with the coagulant, and the flocculant, previously dissolved in water, a specific deposit with a stirrer is required.

The stirrer is at low speed with reducer crown. The axis of Stainless Steel Aisi-316, is coupled with key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization and flocculation processes with flange for application to open or semi-open containers. The stirrer has the following specifications:

Type:

Speed:

Relation:

Propeller:

RV-12 S-35-05

49 rpm

1:30

600 mm

Material:

Engine:

Weight:

Aisi-316

1/3 HP

14,00 Kg

Figure 7. Stirrer for flocculation tank, including specifications.

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2.1.9. Decantation tank.

Once the chemicals are dosed and conveniently blended with the wastewater, the floc is formed but still need some time to decant. For that reason a specific system called decantation tank is still required. Its main specifications are described bellow.

Lamellar settler made of stainless steel AISI-304:



Length: 1.600 mm.



Width:



Height:

800 mm.

1.100 mm.

Finishes:



Stainless steel AISI-304.

Thickness:



Body thickness: 2,5 mm.



Cone thickness: 2,5 mm.



Chamber separation: 2,5 mm

Accessories:



1 Flange DN 50 (AISI-304).



1 Flange DN 50 sludge outlet (AISI-304).



2 Flange DN 50 reactors cleaning (AISI-304)

Structure:



4 Pillar HEB-100.



6 Beam HEB-80.

Stirrers:



PVC Lamellas.



Manual throttle valve DN 50.



Automatic throttle valve DN 50.

Figure 8. Lamellar decanter of industrial wastewater prototype.

2.1.10. Sludge extraction.

When the floc is correctly decanted, the sludge needs to be extracted and sent to the dewatering system. In this case, a sludge extraction pump with the following properties is required:

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Height

Width

Depth

Est. Ship Weight

PVDF 5 kg (10 lbs) Air Inlet

Inlet

Outlet

Suction Lift

277 mm (10.9")

234 mm (9.2")

201 mm (7.9")

Polypropylene 4 kg (8 lbs)

6 mm (1/4")

13 mm (1/2")

13 mm (1/2")

4.5 m Dry (14.7') 9.3 m Wet (30.6')

Displacement per Stroke

Max. Flow Rate

0.10 l (0.027 gal.)*

57.0 lpm (15.0 gpm)

Max. Size Solids 1.6 mm (1/16")

*Displacement per stroke was calculated at 4.8 bar (70 psig) air inlet pressure against a 2 bar (30 psig) head pressure.

Figure 9. Sludge extraction pump for industrial wastewater prototype.

The air distribution system incorporates three moving parts: the air valve spool, the pilot spool, and the main shaft/diaphragm assembly. The heart of the system is the air valve spool and air valve. This valve design incorporates an unbalanced spool. The smaller end of the spool is pressurized continuously, while the large end is alternately pressurized then exhausted to move the spool. The spool directs pressurized air to one air chamber while exhausting the other. The air causes the main shaft/diaphragm assembly to shift to one side — discharging liquid on that side and pulling liquid in on the other side. When the shaft reaches the end of its stroke, the inner piston actuates the pilot spool, which pressurizes and exhausts the large end of the air valve spool. The repositioning of the air valve spool routes the air to the other air chamber.

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2.2. START / STOP PROCEDURES.

After filling the chemical tanks, the start-up of the plant can be carried out. The start-up of the plant, in automatic mode, will be carried out placing all contactors containing three positions

(MAN-0-AUTO) to AUTO. In the first start-up, or when a stop light is made, it will also have to use the reset button.

The pilot plant can be manually stopped, by pressing start-up switch to 0. In order to make an immediate stop, just press the emergency stop button (red), so that the plant will stop and be ready for its next start.

2.2.1. Electrical pumping panel description.



Inlet water tank pumps. Contactor which commands the start-up of submersible pump that feeds the inlet water tank. The pump has three positions (MAN-0-AUTO). For operation in automatic the position has to be AUTO.

2.2.2. Pilot plant electrical panel.



Alarm. The contactor which commands the reaction of the thermal of the plant has two positions (0-1). In position 1, if a thermal cut-off occurs, the plat will stop, in position 0, the thermal cut-off will only affect to the stopping of the corresponding motor.



General stoppage. Blue light signal indicating a stop of the plant.



Plant. The contactor which commands the start-up of the plant has three positions (MAN-0-

AUTO). In position 0, the plant is completely stopped; in manual position, the start up of the plant will be carried out. In AUTO position, the automatic start up will be carried out.



ADNATUR dosing pump. The contactor which commands the start-up of the pump of

ADNATUR technology dosing has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Flocculant dosing pump. The contactor which commands the start-up of the dosing flocculant pump has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Flocculant stirrer. The contractor which commands the start-up of the flocculant preparer mixer has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Sludge discharge. The contactor which commands the start of the discharge of sludge by a solenoid valve has three positions (MAN-0-AUTO). For automatic operation must be in the

AUTO position.

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

Reset plant. This device has the function of start-up the plant, it is used only when a stoppage in the power supply occurs and in the initial operation of the plant.



Emergency stop button. It consists of an emergency stop device of the plant, according to regulations.



Safety symbol according to ISO 3864-1984. Symbol of warning-risk, power danger not handle any electrical power without prior authorization of the manufacturer.

2.3. MAINTENANCE INSTRUCTIONS.

2.3.1. General cleaning.

The plant cleaning depends on the estimated time of stoppage. In general terms, these two kinds of cleaning can be carried out, but they always have to be done during the stoppage of the plant.



Deep cleaning of the decantation tank. It is recommended every three months. In order to clean the plant, three quarters of capacity must be empty, enough to access the lamellar filters and to clean the fouling.



Revision of piping and pumps of the pilot plant.



Cleaning of all the components of pilot plant, inlet water tank, coagulation tank and flocculation tank.

2.3.2. Proper operation controls.

The proposed controls aim to optimize the operation of the pilot plant, prevent possible breakdown and reduce the accidental risks. The next type of control must be done, in all cases with the plant stopped. The main diary controls are described bellow:



Inlet water control: colour, smell, solids, pH.



Treated water control: colour, smell, pH.



Treatment: Coagulation and flocculation. In case that the treatment is not carried out properly, the dose of chemicals will be change after test a sample.



Replacement of products: Product replacement should guarantee the correct dosage at any time, thus, there will be no problems in the treatment during operation of the plant. In addition, day of no attendance at the facility should be taken into account.



Flocculant preparation.



Checking:

- Proper operation of inlet water pump.

- Flow control valve.

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-

Proper operation of coagulant and flocculant pumps.

- Regulate coagulant and flocculant pumps depending on the inlet water.

- Sludge discharge control.

2.3.3. Pumps maintenance operations.

The aim of this section is, in the first place, to describe the pump in order to get to know its operation mode. Then, details about its storage, manipulation, start up and stoppage procedures are given.

The current pumps are horizontal end suction centrifugal with single impeller. Feet are casted together with the pump casing which is open at the back to allow the rotating parts been dismantled without disturbing the suction and delivery pipes of the system. The impeller is closed type. The rotation direction is clockwise (to the right) viewed from coupling side. The sealing box built into the casing cover is prepared to accept packing, with different types depending on the liquid being pumped. The drive shaft is held by two rigid ball bearings, lubricated either by grease or oil. Pump can be driven by a diesel engine or electric motor, set on a common bedplate and joined by a semielastic coupling.

Storage.

The pumps should be stored in well-ventilated zones free of damp. For short storage periods the machined parts should be protected with an oil or anti-corrosion product.

If the pump is to be left for longer periods in the store, precautions should be taken to prevent the pump from corroding by using an anti-corrosion product, also proceeding to cover up the suction and delivery flanges.

Turn the shaft by hand every 15 days to prevent any possible seizing up. Make sure that the diesel engine or electric motor is not exposed to atmospheric agents which might not be compatible with its degree of protection and might cause damage to it. Before storing a pump, which has recently been installed, proceed to clean and then air-dry it (do not used hydrocarbidebased products).

Manipulation.

Pumps in bare shaft disposal must be handled using the delivery flange as lifting point, and to position them use the suction flange and the bearing support if required. The electric motor should be handled using the securing point(s) provided for this purpose consisting on a ring located at the top of the casing.

To handle the motor pump set use a sling going under the bed so as to ensure stability during lifting and displacement. Under no circumstances use the ring located over the motor or pump.

Start up and stoppage procedure indications.

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For the first start up, after making all the checks, this should be done with the drive valve closed, to reduce the consumption of the pump as far as possible. When the running speed has been reached, the valve should slowly be opened, observing at the same time the variation in consumption, until this opens completely. In normal operation the consumption, measured in amperes, should not be over what is stated on the motor plate.

To stop the pump, the delivery valve should be returned to the original position as before the start up. When installation has an anti-water hammer device there is no need to close the delivery valve for stopping the pump. Check that motor deceleration is normal and after it has completely stopped close the auxiliary circuits.

When the equipment is to be idle for long periods, the pump and piping should be completely drained, to prevent the risks of frost during the winter and any possible rusting of the mechanical items that might be caused through trapped liquid.

2.3.4. Stirrers maintenance operations.

Precautions before commissioning.

Before starting the stirrer is essential to carry out the following checks. The motor voltage stated on the nameplate must match the voltage available online. Check that the mechanical and thermal motor protections are adequate for proper operation. The motor housing must always be grounded. Remove the motor fan cover and turn the same hand to confirm that no blocking points and the fan impeller rotates freely. During this check it must be made sure that the motor or the machine is not connected to the network, to avoid any possible mishap.

After the test, proceed with the following checklist:



Replace the lid Fan verifying that the grid is unobstructed.



Confirm that the speed reducer (if any) have the appropriate level of lubricant.



Check the tightening of the screws holding the flange or plate agitator to structure is correct and are not loose.



Check that the coupling screws connecting the head agitator shaft are properly tightened.



In the case of the agitator shaft was attached to plates, prior to assembly, rigid coupling must be removed any dirt from the faces that will be in contact.



Check the correct tightening of the screws that hold the propeller shaft.

Safety Recommendations. Protection against mechanical hazards.

The control system must be designed and installed to prevent the operation of the stirrer while not in place and position, including:

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

The control unit shall include a manually operated device that allows the unemployment insurance.



The stirrer should be fixed stably working and so that parts phones are protected by the container in which the work will develop.

Therefore, the control unit must include a protective device that prevents achieving moving part of the agitator during their work. The agitator should not be possible to start while it may come into contact with moving parts.

Protection against electrical hazards.

The user must connect the different electrical circuits and drives for completing the electrical installation in accordance with EN60204-1, to operate the stirrer safe conditions.

Protection against chemicals.

Before installing the agitator, check that the selected model is appropriate to the possible presence of chemicals in the work area of the agitator.

Moreover, if necessary, shall be provided in an exhaust system of toxic gases or dusts suspension that may arise during agitation and related processes work.

Protection against risk of explosion.

Before installing the agitator, check that the selected model is appropriate to the classification of the area where it will be installed stirrer. It is the user's responsibility adequacy of electrical equipment to the characteristics of the area classified according to laws and regulations.

Transport and location.

For the maintenance of the agitator without packing a suitable suspension should be used to weight model, taking into account its centre of gravity. Never submit to extreme efforts the proximal shaft stirring element. The necessary space must be provided to make the installation work and maintenance.

Connections.

When connecting the motor, you should check that the direction of rotation of the agitator matches the indicated by arrow incorporating the agitator. Otherwise, you must change the sequence of the phases.

2.3.5. Detector maintenance and calibration procedures.

In the following lines, how to control the detector is explained, including its menu points. Then, the most important maintenance operation, which is calibration, is detailed for every measurement.

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Located in the upper right side of the detector there is a wheel that must be used to control the instrument. This wheel can be rotated in both directions to scroll over the menus and / or pressed to confirm highlighted selection / value.

Note: Once changes are made press “OK” to save and exit from submenu. Press “ESC” to exit without saving.

Figure 10. Detector set point screen.

Into main menu rotate the wheel to cycle-loop through all options.

Clockwise: Set point --> Calibration --> Option --> Manual -->Exit or Counter clockwise.

Figure 11. Detector set point channels screen.

Press the wheel to move on submenu for selected option. From main screen all instrument functions can be reached by rotating the wheel and highlighting the selected option. Options available are located in the low right corner of the screen.

Figure 12. Detector screen.

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The most important maintenance operation of the detector device is the calibration of its measurements: pH, mV, NTU, temperature and conductivity.

Regarding the calibration process, from set up menu rotate wheel to highlight “Calibration” then press wheel. Again rotate wheel until to reach desired calibration measure, as shown in the figure:

Figure 13. Detector calibration screen.

a) pH calibration.

pH calibration procedure involves two calibration points and it requires two buffer solutions.

Default buffer solutions are pH=4.00 and pH=7.00. pH reading value can be also automatically temperature compensated.

Figure 14. pH calibration screen.

In the following example, instrument will calibrate pH using default buffer solutions value. This procedure assumes that the instrument is correctly configured and a working pH probe connected. Otherwise unattended results may occur.

1st Point Calibration: Once into “Calibration pH” menu move wheel on “Calib 1st Pt” then press wheel to enter into first point calibration submenu. Prepare 7.00 pH buffer solution and dip probe’s sensor on it. Wait until reading value is stable and according to buffer solution value move wheel until it is the same on display (“pH default” field). Default value is 7.00 pH. To end procedure move cursor on “OK” and press wheel to proceed to next step.

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Note: Buffer solution value may change if environment temperature it’s different than 20°C. Read solution’s label for more information. According to this occurrence “pH Default” must be changed.

2nd Point Calibration: Move wheel on “Calib 2nd Pt” then press it to enter into second point calibration submenu. Prepare 4.00 pH buffer solution and dip probe’s sensor on it. Wait until reading value is stable and according to buffer solution value move wheel until it is the same on display (“pH default” field). Default value is 4.00 pH. To end procedure move cursor on “OK and press wheel to proceed to next step.

Note: Buffer solution value may change if environment temperature it’s different than 20°C. Read solution’s label for more information. According to this occurrence “pH Default” must be changed.

Comp Auto / Select Temp. Once into submenu, to enable automatic temperature compensation, move wheel on “DISABLE”, press it and change option to “ENABLE”. This procedure will automatically set temperature compensation. Otherwise, exit from this menu, move wheel on

“Select Temp” and according to the following table enter required temperature. This procedure will manually set temperature compensation.

Figure 15. Typical electrode response as a function of temperature.

End procedure by moving cursor on “Exit” from “Calibration pH” main menu and press it. If an error occurred during calibration procedure then the instrument will show an error message and will ask to proceed to a new calibration, cancel current operation or restore default settings.

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b) mV calibration.

ORP calibration procedure involves one calibration point and it requires one buffer solution.

Default buffer solution is 650mV.

Figure 16. mV calibration screen.

This procedure assumes that instrument is correctly configured and a working ORP probe connected. Otherwise unattended results may occur. Once into “Calibration mV” menu move wheel on “Calibration” then press wheel to enter into calibration submenu.

Prepare 650 mV buffer solution and dip probe’s sensor on it. Wait until reading value is stable and according to buffer solution value move wheel until it is the same on display (“mV default” field). Default value is 650 mV. To end procedure move cursor on “OK” and press wheel to proceed to next step.

Note: buffer solution value may change if environment temperature it’s different than 20°C. Read solution’s label for more information. According to this occurrence “mV Default” must be changed.

End procedure by moving cursor on “Exit” from “Calibration mV” main menu and press it. If an error occurred during calibration procedure then the instrument will show an error message and will ask to proceed to a new calibration, cancel current operation or restore default settings.

c) NTU calibration.

NTU calibration (turbidity) procedure involves probe “zero” calibration and 2nd point calibration.

It requires distilled water and a 30NTU buffer solution to inject into ETORB.

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Figure 17. NTU calibration screen.

This procedure assumes that instrument is correctly configured and a working NTU probe mod.

“ETORB” is connected. Otherwise unattended results may occur.

Once into “Calibration NTU” menu move wheel on “Range” to see probe’s scale. Then choose

“calib 1st Pt”. From ETORB inlet inject distilled water until it leaks from outlet. Move cursor on

“OK” and press wheel. Before to calibrate 2nd point be sure that all distilled water has been purged from ETORB. Then repeat procedure for 2nd point calibration using a 30NTU buffer solution instead of distilled water.

End procedure by moving cursor on “Exit” from “Calibration NTU” main menu and press it. If an error occurred during calibration procedure then the instrument will show an error message and will ask to proceed to a new calibration, cancel current operation or restore default settings.

d) Temperature calibration.

Temperature calibration needs an external thermometer to match probe’s reading value.

Figure 18. Temperature calibration screen.

This procedure assumes that instrument is correctly configured and a working temperature probe connected. Otherwise unattended results may occur.

Once into “Calibration Temp” menu move wheel on “Calibration” then press wheel to enter system temperature obtained from a thermometer. Press wheel to confirm then move cursor on

“OK” and press wheel to proceed “Calibration Temp” main menu. End procedure by moving cursor on “Exit” from “Calibration Temp” main menu and press it.

If an error occurred during calibration procedure then the instrument will show an error message and will ask to proceed to a new calibration, cancel current operation or restore default settings.

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e) Conductivity (μS) calibration.

Conductivity calibration involves several points. The procedure must be followed carefully in order to get correct conductivity values. After a defective calibration, the efficiency of the detection could be greatly decreased. The current steps are briefly described in the following lines:

1) Working scale setup

Figure 19. Conductivity calibration screen 1.

Move cursor on “Range” then press wheel. According to prove reading capacity select proper scale by rotating wheel. Once satisfied press wheel, move cursor on

“OK” and press wheel again.

2) Turn off the detector. Remove cover and locate CD module jumper settings. Set jumpers as required. Put cover back to the detector.

3) Turn on the detector. Once into conductivity menu choose Calib 1st Pt. Calibration.

Conductivity calibration procedure involves a zero calibration (1st point calib) and a 2nd calibration point that requires a buffer solution with value near working range. During this procedure probe must be dry and clean and not installed in plant. Once into

“Calibration uS” menu move wheel on “Calib 1st Pt” then press wheel, move cursor on

“OK” and press wheel again.


Page 22 of 60


Move wheel on “Calib 2nd Pt” then press wheel to enter into second point calibration submenu. Prepare buffer solution and dip probe’s sensor on it. Wait until reading value is stable and according to buffer solution value move wheel until it is the same on display (“uS default” field). End procedure moving cursor on “OK”.


This procedure assumes that instrument is correctly configured. Otherwise unattended results may occur.

4) Move cursor on “Comp Auto” then press wheel. Rotate wheel to Enable or disable automatic temperature compensation. Enabling this option will override “Select Temp” setup then move cursor on “ESC” or “OK” and press wheel to confirm.


5) Move cursor on “Temp Coeff” then press wheel. This option set conductivity % variation based on temperature. To disable it enter 0.0 % as value. Move cursor on “ESC” or “OK” and press wheel to confirm.


Page 23 of 60


6) Move cursor on “Select Temp” then press wheel. If a temperature probe is not connected, pool temperature must be set manually. Rotate wheel to set it and confirm by pressing wheel. Move cursor on “ESC” or “OK” and press wheel to confirm.


Measurement temperature has a significant influence on conductivity readings; but appropriate temperature compensation is a powerful tool to allow meaningful comparison of readings taken at different temperatures. The analyst must ensure that the type of temperature compensation utilized is appropriate for both the type of sample being analysed and the required test accuracy.

This is an essential factor for determining the suitability of a conductivity instrument for measurement applications. A conductivity measurement taken with the sample at the reference temperature will always be more accurate than a temperature compensated reading taken away from the reference temperature. This point is essential for critical applications requiring high accuracy of measurements.

2.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS.

Breakdown

No wastewater arrives to the plant

The wastewater flow is insufficient

The plant does not start up

Possible Cause

Verify the proper performance of feeding pump.

If in the control box the pilot is in red, reset thermal protection.

Verify valve opening.

Check that the tank has enough water for proper pumping.

Check position of the feed valve.

Systematically check the following points:

If there is level inlet water above the level sensor.

If it is not pressed any safety shutdown.

Page 24 of 60


Breakdown

No coagulation and flocculation occurs

Flocculation occurs irregularly and the resulting liquid is very turbid and flocs escape through the top of the decanting tank

Flocculation occurs irregularly and the resulting liquid is slippery

Possible Cause

Verify that the water and coagulant and flocculant mixing occur and are dosed correctly.

Verify that there are reagents in coagulant and flocculant preparation tanks.

Verify that reagent dosing is correct and, in that case increase them.

Verify that reagent dosing is correct, and in that case reduce it.

NOTE: Checking of circuits to prevent leakage of chemicals should be done every 24 hours with the plant stoppage, using the appropriate personal protective devices. For any sign of leakage, the replacement of the damaged material before the start of the plant should be carried out.

Page 25 of 60


3. URBAN WASTEWATER PROTOTYPE.

3.1. MAIN COMPONENTS OF THE PROTOTYPE.

3.1.1. Control box.

The aim of the control box is to monitor and control each constituent of the prototype and to access in every moment to the current situation of the facility as well as the alarm and data log.

The setting of the pump frequency is important because it depends on it the water pressure through the system and, accordingly, the inlet flow.

These kinds of controllers are modular systems that can be adapted optimally to the required automation task. Thus, it is possible to be customized, using different modules. In case that later the requirements of the system would change the controller is easily expandable by adding further modules.

With the tactile screen the different states of the displays can be seen, as well as all variables of the plant.

 Engines Stop / Start.

 Pumps Stop / Start.

 Flow reading.

 Ammonium-nitrate reading in the anoxic tank.

 Dissolved oxygen reading in the biological reactor.

 Hours of equipment operation, etc...

Graphical programming is structured into different screens with different security levels.

Different color graphics give a clear look of the current state of the plant stop and start of the engines, and making graphic levels for those variables that require it.

3.1.2. Inlet wastewater pump

The injection of inlet wastewater to the pilot plant is carried out with a pump with the following technical specifications:

Flow

Temperature

Model

Number of vanes

Solids pitch

Pressure port

Nominal tension

Power output

Power factor

2,5 m

3

/h

20 °C

MF 334 D

6

30 mm

1½"

400 V

0,556 kW

0,86

Trademark

Impeller

Impeller diameter

Frequency

Rated speed

Yield

Nominal current

Nominal torque

Protection grade

ABS

Vortex

98 mm

50,0 Hz

2560 l/min

66,8 %

1,4 A

2,07 Nm

<IP 68>

Page 26 of 60


3.1.3. Anoxic tank.

Anoxic treatment is the first step of the process. In this case, oxygen content is absent and, this way, nitrogen and ammonium content is conveniently reduced. The structure of the tank is similar than the biological reactor, rectangular shaped, made of fibreglass. Its capacity is 900 litres. The tank contains a specific stirrer in order to keep the water/sludge conveniently homogenized. It is a stirrer at low speed with reducer crown. The axis of Stainless Steel Aisi-316, is coupled with key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization and flocculation processes with flange for application to open or semi-open containers. Technical specifications of the anoxic tank stirrer are described bellow:

Type:

Speed:

Relation:

Propeller:

Material:

Engine:

Weight:

RV-12 S-35-05

49 rpm

1:30

600 mm

Aisi-316

1/3 HP

14,00 Kg

Figure 25. Stirrer for anoxic tank, including specifications.

The water flows into the tank through a tube connected at the top, and then flows out of the tank to the biological reactor though a tube at the top that connects both tanks. At the bottom there is another tube for the active sludge recirculation. In order to ensure the correct recirculation ratio a specific pump is defined. This way, activated sludge is returning from the biological reactor in order to fit defined requirements. Selected pump presents the following technical specifications:

Flow

Temperature

Model

Number of vanes

Solids pitch

Pressure port

Nominal tension

Power output

Power factor

2,5 m

3

/h

20 °C

MF 334 D

6

30 mm

1½"

400 V

0,556 kW

0,86

Trademark

Impeller

Impeller diameter

Frequency

Rated speed

Yield

Nominal current

Nominal torque

Protection grade

ABS

Vortex

98 mm

50,0 Hz

2560 l/min

66,8 %

1,4 A

2,07 Nm

<IP 68>

Page 27 of 60


3.1.4. Ammonium-Nitrate probe.

Ammonium-Nitrate levels help us to determine the efficiency of the anaerobic process, for this reason ammonium-nitrate probe is installed in anoxic tank with specifications explained in the table below. The probes have been developed for use in municipal waste water applications.

The ISE feature ion-selective electrodes for continuous measurement of ammonium and/or nitrate in the tank itself. They operate without reagents and require no further processing of the sample. The ammonium/nitrate ions are measured using an ion-selective electrode. The only wearing part is the sensor cartridge. The sensor cartridge consists of the ion-selective electrodes for ammonium and potassium (compensation electrode for ammonium) or nitrate and chloride

(compensation electrode for nitrate), a pHD reference system and a temperature sensor for comparing temperatures.

The functioning of the ion-selective electrodes is because they have a special membrane to which only a specific type of ion can adhere. As a result, an ion-specific potential forms on the membrane surface. To measure a potential difference, a reference system is required that will not be affected by the sample to be measured.

The CARTRICALTM technology reduces cross-sensitivity by calibrating not only the individual electrodes but also the measuring electrode against the compensation electrode and the reference; this is carried out at the factory. The reference system is designed using pH-differential technology and is therefore particularly stable in terms of drift and contamination.

The AN-ISE sc probe uses the ion-selective electrode technology to measure ammonium ions

(NH

4+

) and nitrate ions (NO

3

–

) in a waste water sample.

Known interfering factors due to potassium (when measuring ammonium), chloride (when measuring nitrate) and temperature are compensated by suitable built-in electrodes.

Page 28 of 60


Figure 26. ISE probe and sensor cartridge.

General information

Measurement method

Measurement range

Precision

Reproducibility

Response time (90 %)

Measurement interval pH range

Calibration methods

Power consumption

Power supply

AN-ISE sc

Potentiometric measurement using ion-selective electrodes (ISE)

Ammonium and potassium, nitrate and chloride, reference system

0 to 1000mg/L [NH

4

0 to 1000mg/L [K

+

]

–N]

0 to 1000mg/L [NO

3

–N]

0 to 1000mg/L [Cl

–

]

5 % of the measured value + 0.2 mg/L

1

5 % of the measured value + 0.2 mg/L

1

< 3 minutes (5 to 50 mg/L)

Continuous pH 5 to pH 9

Sensor code for sensor cartridge, 1 and 2-point value correction or matrix correction

1 W

Via sc controller

Page 29 of 60


Data transfer

Ambient data

Typical environment

Via sc controller

Storage temperature

Operating temperature

Sample temperature

Maximum flow velocity

Maximum sensor immersion depth/pressure

Maximum Compressed air output during cleaning unit operation

Used in the biological phase of municipal waste water treatment

Sensor: –20 to 60 °C (–4 to 140°F)

Sensor cartridge: 5 to 40 °C (41 to 104°F)

Air: –20 to 45 °C (–4 to 1 13 °F)

+ 2 to 40 °C (35 to 104°F)

< 4 m/s

Can be immersed to a depth of 0.3 to 3.0 m (1 to 10 ft);

Maximum pressure: 0.3 bar (4.4 psi)

3.1 bar (45 psi)

General information about the probe

Probe dimensions

Length of probe cable

Probe weight

+ 2 to 40 °C (35 to 104°F)

Standard: 10m (33.8ft)

Extension cables are available as an option in the following lengths:

5, 10, 15, 20, 30, 50 m (16.4, 33.8, 49.2, 65.6, 98.4, 164ft).

Maximum overall length: 100 m [328 ft]

Approximately 2380g (83.95oz)

Wetted materials

Installation angle

Only for immersed installations:

Probe: stainless steel (1.4571), ASA + PC, silicon, PVC and PU

Sensor cartridge: PVC, POM, ABS, stainless steel (1.4571), NBR

Optional cleaning unit: TPE, PUR, stainless steel (1.4571)

45° +/– 15° vertically in flow direction

1

With standard solutions and ISE electrodes under laboratory conditions

3.1.5. Biological reactor.

Biological reactor is the second step of the process. In this case, oxygen content is present and, this way, organic matter and phosphorus content are conveniently reduced. Biological reactor is located in the same structure that anoxic tank. Thus, it is rectangular shaped, made of fibreglass, and its capacity is 4000 litres.

The water flows into the reactor though a tube at the top which connect anoxic tank and biological reactor, and then flows out of the reactor to the conical decanter through a tube connected to the ADNATUR dosing system.

In order to have the proper amount of dissolved oxygen the biological reactor has an aeration system. This system consists in a blower group time-controlled, which introduces air uniformly though fine bubbles diffusers and low maintenance, in order to guarantee proper oxygen supply.

In this way it is possible to reduce energy costs by introducing only the necessary oxygen. An irregular oxygen application can produce biological problems and, as a result, in the effluent. Fine bubbles diffusers have the next advantages:

Page 30 of 60




More efficiency in the transfer of oxygen.



Uniform distribution of dissolved oxygen in every cross-section of the tank, avoiding deposition of solids can cause odors.



Less volume of air to be supplied with the consequent energy savings.

3.1.6. Dissolved oxygen electrode.

In order to control bacteria requests and correctly grown, dissolved oxygen should be controlled, for this reason dissolved oxygen detector with the following specifications is included in the biological reactor.

Specification

Wetted materials

IP classification

Wetted materials (sensor cap)

Measurement range (dissolved oxygen)

Measurement accuracy (dissolved oxygen)

Repeatability (dissolved oxygen)

Response time (dissolved oxygen)

Resolution, sensor (dissolved oxygen)

Measurement range (temperature)

Measurement accuracy (temperature)

Interferences

Figure 27. LDO sensor.

Details

Standard Probe, Standard Class 1-Div 2 Probe

 CPVC, sensor end and cable end

 Polyurethane, over-molding on cable end and cable jacket

 316 stainless steel body and screws

 Viton, O-ring

 Noryl, nut on the cable end

IP68

Acrylic

0 to 20 ppm (0 to 20 mg/L)

0 to 200% saturation

Below 5 ppm: ± 0.1 ppm

Above 5 ppm: ± 0.2 ppm

0.1 ppm (mg/L)

T

90

<40 seconds

T

90

<60 seconds

0.01 ppm (mg/L): 0.1% saturation.

0 to 50 °C (32 to 122 °F)

± 0.2 °C (± 0.36 °F)

No interferences from the following: H

Mg

Fe

2+

, Ca

3+

, Mn

2+

2+

, NH

, Cu

2+

4

+

, Al

, Ni

2+

3+

, Pb

, Co

2+

2+

, Cd

, CN

-

2+

, Zn

NO

3-

2+

, SO

2

S, pH, K

, Cr (total), Fe

4

2-

, S

2-

, PO

+

, Na

4

3-

+

,

2+

,

, Cl

-

,

Anion Active Tensides, Crude Oils, Cl

2

< 4 ppm

Page 31 of 60


Storage temperature

Maximum temperature

Hazardous location classification (9020000-

C1D2 sensor only)

-20 to 70 °C (-4 to 158 °F)

0 to 50 °C (32 to 122 °F)

Class I, Division 2, Groups A-D, T4 / Class I, Zone 2

Group 2C, T4

Note: This product dos not fulfil the requirements of the

94/9/EC Directive (ATEX Directive).

Certification (9020000-C1D2 sensor only)

Minimum flow rate

Calibration/verification

ETL listed to ANSI/ISA, CSA and FM standards for use in hazardous location.

Note: This product dos not fulfil the requirements of the

94/9/EC Directive (ATEX Directive).

Not required

Air calibration: One point, 100% water-saturated air

Sample calibration: Comparison with standard instrument

Probe immersion depth and pressure limits Pressure Limits at 34 m (112 ft.), 345 kPa (50 psi) maximum; accuracy may not be maintained at this depth

Sensor cable 10 m (30 ft) integral cable with quick disconnect plug

Probe weight

Probe dimensions

Power requirements

Warranty

(all sensor types)

Up to 100 m possible with extension cables (non-Class

I, Division 2 sensor types only)

Up to 1000 m with junction box (non-Class I, Division 2 sensor types only)

2.0 kg (2 lb, 3 oz)

Standard probe (diameter x length): 49.56 x 255.27 mm

(1.95 x 10.05 in.)

12 VDC, 0.25 A, 3W

Probe: 3 years against manufacturing defects

Sensor cap: 2 years against manufacturing defects

3.1.7. ADNATUR dosing system.

ADNATUR dosing system is probably the most important component of the prototype. It is necessary in order to maximize the coagulant efficiency of the ADNATUR natural based products.

It contains a dosing pump and a static mixer system. This way, the product is reaching the coagulation tank previously dissolved in water. However, dissolution procedure is made in situ so the reaction time is low and then the stability of the product is unaltered. Proposed dosing pump includes the following specifications:

Power supply:

Number of pump injections:

Maximum flow (7 Bar):

Injections/Minute aspiration Height:

Room temperature:

Additive temperature:

Contamination level:

Sound level:

230 VAC (180-270 VAC)

115 VAC (90-135 VAC)

24 VAC (20-32 VAC)

12 VDC (10-16 VDC)

0 ÷ 180

6 litres/hour

1,5 metros

0 ÷ 45°C (32 ÷ 113°F)

0 ÷ 50°C (32 ÷ 122°F)

2

74 dbA

Page 32 of 60


Delivery and storage temperature: -10 ÷ +50°C (14 ÷ 122°F)

Protection grade: IP65

Figure 28. ADNATUR dosing system, including the dosing pump (left) and the static mixer (right).

3.1.8. Conical decanter.

Once the chemicals are dosed and conveniently blended with the water coming from the biological reactor, the floc is completely formed but still need some time to decant. For that reason a specific system called conical decanter is still required. Its main specifications are described bellow.

Conical settler made of fibreglass:



Length: 1.400 mm.



Width: 1.400 mm.



Height: 1.900 mm.

Finishes:



Fibreglass.

Accessories:



Flocculation cylinder.



Pipes, valves and electrovalves.

Structure:



4 Pillar HEB-100.

Figure 29. Conical decanter of urban wastewater prototype, including main specifications.

Page 33 of 60


3.1.9. Sludge extraction.

When the floc is correctly decanted, the sludge needs to be extracted and partially sent to the dewatering system and back, to the biological reactor. In this case, a sludge extraction pump with the following properties is required:

Type

Efficiency level (Reg. 640/2009)

No. of Poles

Rotation speed [min-1]

Insulation Class

Protection degree(CEI EN 60034-5)

Power rating

[kW]

[HP]

Frequency [Hz]

Voltage [V]

Casing material

Base material/motor support

Dimensions of cable entry

Electric - TEFC

Three Phase

IE2 from 1.1 kW up to 3.0 kW

2

» 2800

F

IP 55

1.1 ÷ 3

1.5 ÷ 4

50

230/400 ±10%

Aluminium

Aluminium

PG11 - PG13.5

Maximum working pressure [MPa]

Impeller

Open centrifugal type

0,8

Construction

Pipe Connection

Material

Shaft seal type

Mechanical seal

Bearing

Sealed ball bearing

Suction

Discharge

Casing

Impeller

Casing cover

Shaft seal

Casing cover

Shaft

Bracket

Applicable standard of test

G 2

G 2

AISI 304

AISI 304

AISI 304

Ceramic/Carbon/NBR Ceramic/

Tungsten Carbide/Tungsten Carbide/FPM (for DWOHW)

SiC/Tungsten Carbide/FPM (for DWOHSW)

Carbon/FPM (for DWOH) SiC/SiC/FPM (for DWOHS)

SiC/SiC/FPM (for DWOHS)

AISI 304

AISI 304 (Wet extension)

Aluminium

ISO 9906 – Annex A

Page 34 of 60


Figure 30. Sludge extraction pump for urban wastewater prototype.

3.2. START / STOP PROCEDURES.

After filling the chemical tanks, the start-up of the plant can be carried out. The start-up of the plant, in automatic mode, will be carried out placing all contactors containing three positions

(MAN-0-AUTO) to AUTO. In the first start-up, or when a stop light is made, it will also have to use the reset button.

The pilot plant can be manually stopped, by pressing start-up switch to 0. In order to make an immediate stop, just press the emergency stop button (red), so that the plant will stop and be ready for its next start.

3.2.1. Electrical pumping panel description.



Inlet water tank pumps. Contactor which commands the start-up of submersible pump that feeds the inlet water tank. The pump has three positions (MAN-0-AUTO). For operation in automatic the position has to be AUTO.

3.2.2. Pilot plant electrical panel.



Alarm. The contactor which commands the reaction of the thermal of the plant has two positions (0-1). In position 1, if a thermal cut-off occurs, the plat will stop, in position 0, the thermal cut-off will only affect to the stopping of the corresponding motor.



General stoppage. Blue light signal indicating a stop of the plant.

Page 35 of 60




Plant. The contactor which commands the start-up of the plant has three positions (MAN-0-

AUTO). In position 0, the plant is completely stopped; in manual position, the start up of the plant will be carried out. In AUTO position, the automatic start up will be carried out.



ADNATUR dosing pump. The contactor which commands the start-up of the pump of

ADNATUR technology dosing has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Flocculant dosing pump. The contactor which commands the start-up of the dosing flocculant pump has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Flocculant stirrer. The contractor which commands the start-up of the flocculant preparer mixer has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO position.



Sludge discharge. The contactor which commands the start of the discharge of sludge by a solenoid valve has three positions (MAN-0-AUTO). For automatic operation must be in the

AUTO position.



Reset plant. This device has the function of start-up the plant, it is used only when a stoppage in the power supply occurs and in the initial operation of the plant.



Emergency stop button. It consists of an emergency stop device of the plant, according to regulations.



Safety symbol according to ISO 3864-1984. Symbol of warning-risk, power danger not handle any electrical power without prior authorization of the manufacturer.

3.3. MAINTENANCE INSTRUCTIONS.

3.3.1. General cleaning.

The plant cleaning depends on the estimated time of stoppage. In general terms, these two kinds of cleaning can be carried out, but they always have to be done during the stoppage of the plant.



Deep cleaning of the decantation tank. It is recommended every three months. In order to clean the plant, three quarters of capacity must be empty, enough to access the lamellar filters and to clean the fouling.



Revision of piping and pumps of the pilot plant.



Cleaning of all the components of pilot plant, inlet water tank, coagulation tank and flocculation tank.

Page 36 of 60


3.3.2. Proper operation controls.

The proposed controls aim to optimize the operation of the pilot plant, prevent possible breakdown and reduce the accidental risks. The next type of control must be done, in all cases with the plant stopped. The main diary controls are described bellow:



Inlet water control: colour, smell, solids, pH.



Treated water control: colour, smell, pH.



Treatment: Coagulation and flocculation. In case that the treatment is not carried out properly, the dose of chemicals will be change after test a sample.



Replacement of products: Product replacement should guarantee the correct dosage at any time, thus, there will be no problems in the treatment during operation of the plant. In addition, day of no attendance at the facility should be taken into account.



Flocculant preparation.



Checking:

-

Proper operation of inlet water pump.

- Flow control valve.

- Proper operation of coagulant and flocculant pumps.

-

Regulate coagulant and flocculant pumps depending on the inlet water.

-

Sludge discharge control.

3.3.3. Pumps maintenance operations.

The aim of this section is, in the first place, to describe the pump in order to get to know its operation mode. Then, details about its storage, manipulation, start up and stoppage procedures are given.

The current pumps are horizontal end suction centrifugal with single impeller. Feet are casted together with the pump casing which is open at the back to allow the rotating parts been dismantled without disturbing the suction and delivery pipes of the system. The impeller is closed type. The rotation direction is clockwise (to the right) viewed from coupling side. The sealing box built into the casing cover is prepared to accept packing, with different types depending on the liquid being pumped. The drive shaft is held by two rigid ball bearings, lubricated either by grease or oil. Pump can be driven by a diesel engine or electric motor, set on a common bedplate and joined by a semielastic coupling.

Storage.

The pumps should be stored in well-ventilated zones free of damp. For short storage periods the machined parts should be protected with an oil or anti-corrosion product.

Page 37 of 60


If the pump is to be left for longer periods in the store, precautions should be taken to prevent the pump from corroding by using an anti-corrosion product, also proceeding to cover up the suction and delivery flanges.

Turn the shaft by hand every 15 days to prevent any possible seizing up. Make sure that the diesel engine or electric motor is not exposed to atmospheric agents which might not be compatible with its degree of protection and might cause damage to it. Before storing a pump, which has recently been installed, proceed to clean and then air-dry it (do not used hydrocarbidebased products).

Manipulation.

Pumps in bare shaft disposal must be handled using the delivery flange as lifting point, and to position them use the suction flange and the bearing support if required. The electric motor should be handled using the securing point(s) provided for this purpose consisting on a ring located at the top of the casing.

To handle the motor pump set use a sling going under the bed so as to ensure stability during lifting and displacement. Under no circumstances use the ring located over the motor or pump.

Start up and stoppage procedure indications.

For the first start up, after making all the checks, this should be done with the drive valve closed, to reduce the consumption of the pump as far as possible. When the running speed has been reached, the valve should slowly be opened, observing at the same time the variation in consumption, until this opens completely. In normal operation the consumption, measured in amperes, should not be over what is stated on the motor plate.

To stop the pump, the delivery valve should be returned to the original position as before the start up. When installation has an anti-water hammer device there is no need to close the delivery valve for stopping the pump. Check that motor deceleration is normal and after it has completely stopped close the auxiliary circuits.

When the equipment is to be idle for long periods, the pump and piping should be completely drained, to prevent the risks of frost during the winter and any possible rusting of the mechanical items that might be caused through trapped liquid.

3.3.4. Stirrers maintenance operations.

Precautions before commissioning.

Before starting the stirrer is essential to carry out the following checks. The motor voltage stated on the nameplate must match the voltage available online. Check that the mechanical and thermal motor protections are adequate for proper operation. The motor housing must always

Page 38 of 60


be grounded. Remove the motor fan cover and turn the same hand to confirm that no blocking points and the fan impeller rotates freely. During this check it must be made sure that the motor or the machine is not connected to the network, to avoid any possible mishap.

After the test, proceed with the following checklist:



Replace the lid Fan verifying that the grid is unobstructed.



Confirm that the speed reducer (if any) have the appropriate level of lubricant.



Check the tightening of the screws holding the flange or plate agitator to structure is correct and are not loose.



Check that the coupling screws connecting the head agitator shaft are properly tightened.



In the case of the agitator shaft was attached to plates, prior to assembly, rigid coupling must be removed any dirt from the faces that will be in contact.



Check the correct tightening of the screws that hold the propeller shaft.

Safety Recommendations. Protection against mechanical hazards.

The control system must be designed and installed to prevent the operation of the stirrer while not in place and position, including:



The control unit shall include a manually operated device that allows the unemployment insurance.



The stirrer should be fixed stably working and so that parts phones are protected by the container in which the work will develop.

Therefore, the control unit must include a protective device that prevents achieving moving part of the agitator during their work. The agitator should not be possible to start while it may come into contact with moving parts.

Protection against electrical hazards.

The user must connect the different electrical circuits and drives for completing the electrical installation in accordance with EN60204-1, to operate the stirrer safe conditions.

Protection against chemicals.

Before installing the agitator, check that the selected model is appropriate to the possible presence of chemicals in the work area of the agitator.

Moreover, if necessary, shall be provided in an exhaust system of toxic gases or dusts suspension that may arise during agitation and related processes work.

Protection against risk of explosion.

Page 39 of 60


Before installing the agitator, check that the selected model is appropriate to the classification of the area where it will be installed stirrer. It is the user's responsibility adequacy of electrical equipment to the characteristics of the area classified according to laws and regulations.

Transport and location.

For the maintenance of the agitator without packing a suitable suspension should be used to weight model, taking into account its centre of gravity. Never submit to extreme efforts the proximal shaft stirring element. The necessary space must be provided to make the installation work and maintenance.

Connections.

When connecting the motor, you should check that the direction of rotation of the agitator matches the indicated by arrow incorporating the agitator. Otherwise, you must change the sequence of the phases.

3.3.5. Detector maintenance and calibration procedures.

3.3.5.1. Calibration and maintenance of Dissolved oxygen electrode for measurements.

CALIBRATION

The sensor is calibrated to specification at the factory. The manufacturer does not recommend calibration unless periodically required by regulatory agencies. If calibration is required, let the sensor come to equilibrium with the process before calibration. Do not calibrate the sensor at setup. The next table shows options for calibration.

Option

AIR CAL

SAMPLE CAL

RESET DFLT CAL

Description

Recommended calibration method. This calibration modifies the slope.

Calibration by comparison with a hand-held DO meter . This calibration modifies the offset.

Resets the calibration gain (slope) and offset to the factory default: default gain=1.0; default offset=0.0

Calibration with air.

User notes:

• Make sure that calibration bag has water inside.

• Make sure that the seal between the calibration bag and the sensor body is tight.

• Make sure that the sensor is dry when it is calibrated.

• Make sure the air pressure/elevation setting is accurate for the calibration location.

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• Allow enough time for the sensor temperature to stabilize to the temperature of the calibration bag location. A large difference in temperature between the process and the calibration location can take up to 15 minutes to stabilize.

1. Remove the sensor from the process. Use a wet cloth to clean the sensor.

2. Put the entire sensor in a calibration bag with 25-50 mL of water. Make sure that the sensor cap is not in contact with the water inside the calibration bag and that no water drops are on the sensor cap (Figure 37).

3. Use a rubber band, tie or hand to create a tight seal around the sensor body.

4. Let the instrument stabilize for 15 minutes before calibration. Keep the calibration bag out of direct sunlight during stabilization.

5. Make sure that the current absolute air pressure or elevation is configured correctly.

Note: The manufacturer recommends the use of absolute or actual air pressure as a best practice.

6. Go to MENU>SENSOR SETUP>[Select Sensor]>CALIBRATE>AIR CAL.

7. Select the option for the output signal during calibration:

Option Description

Active

Hold

The instrument sends the current measured output value during the calibration procedure.

The sensor output value is held at the current measured value during the calibration procedure.

Transfer

8. The controller will show "Move the probe to bag". Allow the value to stabilize. Push ENTER to accept the stable value. Alternately, let the calibration continue until the display shows

"Complete".

A preset value is sent during calibration. Refer to the controller user manual to change the preset value.

9. When the sensor is calibrated, put the sensor into the process. Push ENTER.

Figura 31. Air calibration procedure.

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If the value does not stabilize, the display will show "Unable to Calibrate" followed by an error message. The next table shows the error message and resolution for calibration problems.

Message Description

Cal fail, gain high

Cal fail, gain low

Cal fail, unstable

The calculated gain value is too high.

The calculated gain value is too low.

The value did not stabilize in the maximum allowed calibration time.

Sample CAL - calibration by comparison.

Resolution

Repeat the calibration.



This calibration method uses an alternate sensor attached to a hand-held meter.

1. Put the alternate sensor into the process. Put the second sensor as close as possible to the first sensor.

2. Wait for the DO value to stabilize.

3. On the controller for the first sensor, go to MENU>SENSOR SETUP>[Select

Sensor]>CALIBRATE>SAMPLE CAL.

4. Select the option for the output signal during calibration:

Option

Active

Option

Hold

Description

The instrument sends the current measured output value during the calibration procedure.

Description

The sensor output value is held at the current measured value during the

Transfer

calibration procedure.

A preset value is sent during calibration. Refer to the controller user manual to change the preset value.

5. The controller will show:

• "Press ENTER when stabilized"

• The current dissolved oxygen measurement

• The current temperature measurement

6. When the measurement is stable, push ENTER. The display will show an entry screen.

Note: The measurement will usually stabilize in 2 to 3 minutes.

If the value does not stabilize, the display will show "Unable to Calibrate" followed by an error message. The next table shows the error message and resolution for calibration problems.

Message Description Resolution

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Cal fail, offset high

Cal fail, offset low

The calculated offset value is too high.

The calculated offset value is too low.

Cal fail, unstable

The value did not stabilize in the maximum allowed calibration time.

Exit the calibration procedure.

1. During calibration, push the BACK key. Three options are shown:

Option Description




ABORT

Stop the calibration. A new calibration must start from the beginning.

BACK TO CAL Return to the current calibration.

LEAVE

Exit the calibration temporarily. Access to other menus is allowed while the calibration continues in the background. A calibration for a second sensor (if present) can be started. To return to the calibration, push the

MENU key and select Sensor Setup, [Select Sensor].

2. Select one of the options. Confirm.

Reset calibration defaults.

Calibration settings can be reset to the factory defaults. Gain and offset values are set to 1.0 and

0.0, respectively.

1. Go to MENU>SENSOR SETUP>[Select Sensor]>CALIBRATE>RESET CAL DEFLT.

2. The display will show a confirmation message. Confirm to reset the sensor to the factory default calibration curve.

MAINTENANCE

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Maintenance schedule.

The maintenance schedule shows minimum intervals for regular maintenance tasks. Perform maintenance tasks more frequently for applications that cause electrode fouling.

Note: Do not disassemble the probe for maintenance or cleaning.

Maintenance task

Clean the sensor

Inspect the sensor for damage

Calibrate the sensor

Recommended minimum frequency

90 days

90 days

As recommended by regulatory agencies

Clean the sensor.

Clean the exterior of the sensor with a soft, wet cloth.

Note: If the sensor cap must be removed for cleaning, do not expose the interior of the cap to direct sunlight for extended periods of time.

Set or change the clean interval.

Application conditions may need shorter or longer durations between manual sensor cleanings. The default clean interval is 0 days. To change the interval, refer to the steps in this procedure.

1. Go to MENU>SENSOR SETUP >[Select Sensor]>CONFIGURE>CLEAN INTRVL.

2. Change the shown value as needed. Confirm the change.

• To turn off the clean interval, set the value to '0'.

Change the sensor cap.

Replacement sensor caps and setup caps are shipped with installation instructions. Refer to the included instructions to change the cap.

For best performance and accuracy, replace the sensor cap:

• Every two years

• When routine inspection shows significant erosion of the sensor cap

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3.3.5.2. Calibration and maintenance methods of the Ammonium-Nitrate ISE.

CALIBRATION

Matrix correction.

The four electrodes with the reference system of the compact sensor cartridge were calibrated with one another at the factory using special standard solutions (CARTICALTM). However, the membranes on the ion-selective electrodes are not 100% selective due to other substances that may affect the measurement. Perform a matrix correction to compensate for other ions present on the ISE electrodes.

Potassium has the largest interference effect on the ammonium membrane, while chloride has the largest effect on the nitrate membrane. The AN-ISE sc probe compensates for this problem with the aid of a built-in potassium/chloride electrode.

Sensor code calibration.

The sensor code is a calibration code and is delivered with the sensor cartridge certificate.

Instruments with automatic sensor code recognition (LXG440.99.x000x) read this automatically and assume the Cartrical calibration.

Instruments without automatic sensor code recognition (LXG440.99.x001x) require the sensor code to be entered during the initial setup and whenever a new sensor cartridge is activated. If the sensor code certificate has been lost, carry out factory calibration (under the sensor code menu) as a temporary solution.

After activating the code, the sensor is fully calibrated but not yet adapted to the specific matrix of the relevant application on a waste water treatment plant. At least 12 hours must elapse before a matrix correction is performed to allow the cartridge to adapt to the specific matrix.

Proceed as follows to change the sensor code: 1. Select S ENSOR MENU > AN-ISESC or AISESC or

NISE SC > CALIBRATE > FURTHER CORR. > SENSOR CODE > ENTER 2. Enter the sensor code. 3.

Press ENTER to confirm and activate the sensor code. The day meter for the cartridge is set to zero.

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All old calibration data are now overwritten with the new calibration data from the sensor code.

The sensor code data is checked by the system. If an error is indicated, check the sensor code and, if necessary, enter the sensor code again.

Matrix correction via LINK2SC.

The LINK2SC procedure offers a secure method of data exchange between process probes and

LINK2SC-compatible photometers using an SD memory card or via a local area network (LAN).

Two different options are available:

a. The pure laboratory control measurement

b. A matrix correction that involves the measurement data generated in the laboratory being used to correct the probe

During a pure control measurement, the measurement data is transferred from the probe to the photometer where it is then archived together with the photometric reference data that has been recorded.

During a matrix correction, the reference data generated in the laboratory is transferred to the probe to be used for the correction.

The matrix correction process requires operating steps to be completed on the sc controller and on a LINK2SC-compatible photometer.

Refer to the LINK2SC user manual for a detailed description of the LINK2SC procedure.

Matrix correction – manual.

ISE probes offer different options for correcting the sensor value with laboratory values (as a reference value).The laboratory value of the water sample is entered as nitrate nitrogen (NO

3

–N) and/or as ammoniacal nitrogen (NH

4

–N). This laboratory value replaces the prior value measured by the sensor.

Correction option Application

MATRIX 1 A MATRIX 1 is the most commonly used correction option and performs a

1 point matrix correction for ammonium and/or nitrate. It is advisable to perform a MATRIX1 as the first correction. The Matrix1 correction can be performed both with and without correction of the compensation electrodes (potassium or chloride); in most cases, it is sufficient to perform it without correction. A correction featuring potassium and/or chloride is only necessary if a high level of accuracy is required. With a MATRIX1, a sample must be taken when the correction is triggered and analyzed in the laboratory. The MATRIX1 is activated when the laboratory value is entered.

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VALUE CORR. 1

VALUE CORR. 2

Value correction 1 (correction at one concentration point) corresponds to a

MATRIX1 correction with an alternative entry format. Comparison values between the ISE probe and the laboratory can be collected over a period of around a week with this correction. The correction can be performed at a later stage.

Value correction 2 (correction at 2 different concentration points) should be performed if dynamic concentration fluctuations are present over at

least half a decade

1

and a MATRIX1 or VALUE CORR. 1 does not achieve a

sufficiently accurate result. Comparison values between the ISE probe and the laboratory can be collected over a period of around a week with this correction. The correction can be performed at a later stage.

MATRIX 2 The MATRIX 2 correction corresponds to a VALUE CORR. 2, but uses an

alternative entry format and is recommended if there is a dynamic process with a large nitrate/ammonium fluctuation greater than at least half a decade

1

. With a MATRIX2, a sample must be taken for both points when the correction is triggered and analyzed in the laboratory. The MATRIX2 is activated when the laboratory value is entered.

HIST. CORR. Return to one of the last matrix and value corrections performed if a

correction has not produced a successful result.

1

Examples of half a decade: The concentration of nitrogen nitrate shifts between 1 and 5 mg

NO

3

–N or between 5 and 25 mg/L NO

3

–N. (conc2 = (conc1 x 10)/2)

Performing the matrix correction.

Note: Take laboratory value measurements or reference values promptly or, alternatively, take these from the stabilized sample. This will prevent changes in sample concentration, as time is a factor in comparative tests.

MATRIX 1 correction (1 point matrix correction)

Proceed as follows to perform MATRIX 1:

1. Select SENSOR MENU > AN-ISE SC > CALIBRATE > MATRIX CORR.

2. Select MATRIX 1 from the selection window and press ENTER.

3. Select the parameters you wish to correct and confirm by pressing ENTER.

Selection options for AN-ISE sc:

NH

4

+ NO

3

; NH

4

; NO

3

; NH

4

+ K; NO

3

+ Cl; NH

4

+ K NO

3

+ Cl

The sensor saves the current values of the selected parameters at this point.

4. Take a water sample immediately from the closest point possible to the sensor. Filter the sample as quickly as possible and carry out a prompt laboratory analysis of the selected parameters, as the measurement value can change quickly.

When the laboratory value has been determined, proceed as follows:

5. Select SENSOR MENU > AN-ISE SC or AISE SC or NISE SC > CALIBRATE >

ENTER LABVALUE. 6. The laboratory values for the parameters can only be entered if the MATRIX1 correction has been selected beforehand. Once the laboratory values have been entered, select ENTRY COMPLETE to confirm.

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When the entered laboratory value is confirmed, the matrix correction is activated.

7. Once the correction is activated, the result CORR-RESULT is shown.

Note: This process must always be carried out in full to make sure the matrix correction is completed successfully. If a correction does not produce a successful result, calculations are made

with the previous correction.

Value correction 1

The one-point value correction VALUE CORR. 1 offers the option of retrospectively performing a matrix correction at one point (MATRIX1).

1. Take several samples with different concentrations on various days, preferably within one week. Analyze the samples in the laboratory. During the time the samples are being taken, the sample temperature should be around a maximum of 5 °C, as temperature changes are not taken into account in the value correction.

2. Make a note of the two values measured in the samples and displayed for the parameters to be corrected (ammonium and potassium values, or nitrate and chloride values)

3. Also note the laboratory values measured for ammonium or nitrate.

These three values form the correction point.

4. From the values taken, select a correction point that lies in the middle of the expected concentration range.

5. Go to the sensor menu and select CALIBRATE > MATRIXCORR > VALUE

CORR. 1 and confirm by pressing ENTER.

6. Select the parameter1 (NH

4

–N or NO

3

–N) that requires correction. Note: The

example opposite shows the NH

4

-N and K correction of the AN-ISE sc probe.

7. Enter the three values for the sought correction point and confirm with

ENTRY COMPLETE to activate the correction.

Correction result CORR-RESULT is shown.

Note: If a correction does not produce a successful result, calculations are made with the previous correction. After successful completion of value correction, the corrected value is shown as the

display value for ammonium or nitrate the next time the menu is opened.

Value correction 2

The two-point value correction VALUE CORR. 2 makes it possible to perform a subsequent 2-point correction (MATRIX2) to achieve higher accuracy for a larger concentration range.

Note: Value correction 2 and MATRIX 2 are comparable from a calculation perspective.

1. Take several samples on various days with different concentrations, preferably within a week, and perform an analysis of the samples in the laboratory. During the time the samples are being taken, the sample temperature should be around a maximum of 5 °C, as temperature changes are not taken into account in the value correction.

Note: The MATRIX CORR. 2 concentrations should be within a range greater than half a

decade. The following formula can assist in the calculation of the half decade:

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Con

2



Conc

1

2



10

2. Make a note of the two values measured with the sensor in the samples and displayed for the parameters to be corrected (ammonium and potassium values, or nitrate and chloride values).

3. Also note the laboratory value measured for ammonium or nitrate.

All three values form one of the two correction points.

4. Look for two correction points where the laboratory values are at least half a decade apart and display typical operating conditions for the installation.

5. Go to the sensor menu and select CALIBRATE > MATRIX CORR > VALUE

CORR. 2 then confirm with ENTER.

6. Select the parameter1 (NH

4

–N or NO

3

–N) that requires correction.

7. Enter the three values for the first correction point and confirm with ENTRY

COMPLETE.

Note: The example opposite shows the NH4-N and K correction of the AN-ISE sc probe.

8. To activate the correction, enter the three values for the second correction point and confirm with ENTRY COMPLETE.

Correction result CORR-RESULT is shown.

Note: If a correction does not produce a successful result, calculations are made with the previous correction. After successful completion of value correction, the corrected value is shown as the

display value for ammonium or nitrate the next time the menu is opened.

MATRIX 2 correction (2 point matrix correction)

Proceed as follows to perform MATRIX 2:

1. Select SENSOR MENU > AN-ISE SC > CALIBRATE > FURTHER CORR..

2. Select MATRIX 2 from the selection window and press ENTER.

3. Select the parameters

1

requiring a two-point matrix correction.

4. Select the point to be corrected.

5. SELECT MEAS CONC 1 or MEAS CONC 2

6. Take a water sample from the closest point possible to the sensor. Filter this sample promptly and perform an immediate laboratory analysis of the selected parameters. The measurement value can change very quickly:

When the laboratory value has been determined, proceed as follows:

7. Select SENSOR MENU > AN-ISE > CALIBRATE > FURTHER CORR. > MATRIX2

8. Select the parameters to be corrected with the laboratory value entry.

9. Enter the laboratory reference value and confirm.

The MATRIX2 CORR. is activated when the entry is confirmed for both points.

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LIFE12 ENV/ES/000265

MAINTENANCE

Deliverable D.B.1.3

Schedule.

Maintenance task

Clean the probe

2

Replace the sensor cartridge

3, 4

30 days

1

x

12 months

x

Check probe for damage x

Compare the measured value with a reference laboratory analysis and correct the values as required via a matrix correction

3 x

1

Recommended: Weekly during the first month of operation

2

The frequency of cleaning depends on the application. Some applications may require cleaning to take place more or less frequently.

3

In typical operating conditions, a different interval may be required depending on the specific application and local conditions.

4

Sensor cartridges are wearing parts and are not covered by the instrument warranty.

Note: Do not test the sensor with the usual NH

4

-N and/or NO

3

-N standard solutions, as the ion strength of normal solutions is not high enough.

Clean the sensor.

1. Clean the sensor cartridge using the soft brush supplied.

2. Clean the probe body (not the sensor cartridge) with a sponge or brush.

3. Rinse the sensor with clean, lukewarm water.

Polish the chloride electrode.

Polish the chloride electrode if it looks heavily coated/contaminated. After polishing, a new nitrate + chloride MATRIX1 correction should be performed after 12 hours.

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Figure 32. Chloride electrode.

Replace the sensor cartridge.

The sensor cartridge is replaced as described below.

1. Replace the cartridge using menu item

AN-ISE SC > DIAG/TEST > SERVICE > CHANGE CARTR.

2. Clean the probe and thoroughly dry the sensor cartridge and probe adapter.

3. Loosen the 4 socket head screws.

4. Pull the sensor cartridge out of the probe adapter and discard the old sensor cartridge as per the applicable regulations.

5. Make sure that a new black gasket is installed every time the sensor cartridge is replaced.

Before the gasket is installed, clean the surface that faces the cartridge and the groove for the gasket.

6. Insert the new sensor cartridge into the probe adapter. Observe the marker hole on the sensor cartridge flange and the probe adapter.

7. Secure the sensor cartridge with the 4 socket head screws.

8. The sensor code (calibration data) is automatically read for instruments with automatic recognition (LXG440.99.x000x). For instruments with non-automatic recognition

(LXG440.99.x001x), enter the new sensor code manually (refer to certificate).

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Figure 33. Replace the sensor cartridge.

Storage.

Take the probe out of the sample flow and clean thoroughly. Short term storage

Keep the membranes and reference system moist (do not use distilled or demineralized water).

This will help avoid long response times when the probe is placed back in the sample flow.

Otherwise, the correct operation of the probe is no longer guaranteed.

Long term storage.

Check the membranes and ensure they are still moist every 2-4 weeks, depending on environmental conditions.

Note: A storage container is supplied to keep the sensor cartridge moist. Keep the sensor cartridge sealed in the storage container during short and long term storage.

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LIFE12 ENV/ES/000265

Probe and sensor cartridge.

Deliverable D.B.1.3

3.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS.

3.4.1. Pilot plant.

Breakdown

No wastewater arrives to the plant.

The wastewater flow is insufficient.

The plant does not start up.

No flocculation occurs.

Flocculation occurs irregularly and the resulting liquid is very turbid and flocs escape through the top of the decanting tank.

Flocculation occurs irregularly and the resulting liquid is slippery.

Possible Cause

Verify the proper performance of feeding pump.

If in the control box the pilot is in red, reset thermal protection.

Verify valve opening.

Check that the tank has enough water for proper pumping.

Check position of the feed valve.

Systematically check the following points:

If there is level inlet water above the level sensor.

If it is not pressed any safety shutdown.

Verify that the water and coagulant mixing occurs and are dosed correctly.

Verify that there are reagents in tank.

Verify that reagents dosing is active and correct.

In that case, increase them.

Verify that reagent dosing is correct, and in that case reduce it.

NOTE: Checking of circuits to prevent leakage of chemicals should be done every 24 hours with the plant stoppage, using the appropriate personal protective devices. For any sign of leakage, the replacement of the damaged material before the start of the plant should be carried out.

3.4.2. Troubleshooting of Ammonium-Nitrate ISE.

Error messages.

If the sensor is in an error state, the measurement value for this sensor will flash on the display and the relay contacts and current outputs associated with this sensor will be stopped. The errors are described in table below.

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Displayed errors Cause

NH4 mV RANGE! Ammonium mV exceeds the measurement range

K

+

mV RANGE!

Potassium mV exceeds the measurement range

NO3 mV RANGE!

Nitrate mV value exceeds the measurement range

Cl

-

mV RANGE!

Chloride mV value exceed the measurement range

REF1 mV

RANGE!

REF1 reference value is out of measuring range

REF2 mV

RANGE!

ORP electrode mV value is out of measuring range

TEMP RANGE! Temperature value exceeds measurement range

Resolution

Refer to

Troubleshooting during operation

NO CARTRIDGE No sensor cartridge connected

SENSOR CODE Sensor code calibration failed

HUMIDITY Humidity in the probe

Connect the sensor cartridge

Refer to

Troubleshooting during calibration

Inform service engineer

NH4-N CONC

HIGH

NH4-N CONC

LOW

NO3-N CONC

HIGH

NO3-N CONC

LOW

K

+

KONZ HOCH

K

+

CONC LOW

CL CONC HIGH

CL CONC LOW

NH4 mV RANGE!

K+ mV RANGE!

Ammonium concentration value exceeds measuring range

Ammonium concentration value is below measuring range

Nitrate concentration value exceeds measurement range

Nitrate concentration value is below measurement range

Potassium concentration value exceeds measuring range

Potassium concentration value is below measuring range

Chloride concentration value exceeds measuring range

Chloride concentration value below measurement range

Ammonium mV value is closet o measuring range limit

Potassium mV value is closet o measuring range limit

NO3 mV RANGE!

Nitrate mV value is closet o measurement range limit

Cl- mV RANGE!

Chloride mV value is closet o measurement range limit

REF1 mV RANGE!

1st reference value is close to limit

REF2 mV RANGE!

2nd reference value is close to limit

TEMPERATURE Temperature is close to limit

Refer to


Warnings.

In the event of a sensor warning, all menus, relays and outputs continue to function as normal but a warning symbol lights up.

Warnings may be used to activate a relay; users can set warning levels to define the severity.

Warnings are defined in next table.

Displayed warning

RFID DATA

Cause

Cartridge faulty, read process failed

Resolution

Replace cartridge, check probe with test cartridge

Refer to


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CARTRIDGE OLD Sensor cartridge more than 1 year old

NH4-N CONC HIGH Ammonium concentration value exceeds measuring range

NH4-N CONC LOW Ammonium concentration value is below measuring range

NO3-N CONC

HIGH

K+ CONC LOW

CL CONC HIGH

Nitrate concentration value exceeds measuring range

NO3-N CONC LOW Nitrate concentration value is below measurement range

K+ KONZ HOCH Potassium concentration value exceeds measuring range

Potassium concentration value is below measuring range

CL CONC LOW

Chloride concentration value is below measurement range

Chloride concentration value is below measurement range

AMMONIUM

OFFSET

SLOPE

POTASSIUM

Ammonium offset exceeds measurement range

Ammonium slope exceeds measurement range

OFFSET

SLOPE

NITRATE

Potassium offset exceeds measurement range

Potassium slope exceeds measurement range

OFFSET

SLOPE

CHLORIDE

OFFSET

SLOPE

Nitrate offset exceeds measurement range

Nitrate slope exceeds measurement range

Chloride offset exceeds measurement range

Chloride slope exceeds measurement range

Troubleshooting during operation.

Symptom

Incorrect measurement values


See


Refer to

Troubleshooting during calibration

Possible cause

Calibration too old; calibration was not suitable for the particular application; large change in the waste water matrix

Corrective measures

Perform a suitable calibration.

Severely contaminated membranes and/or reference electrode

Sensor membrane damaged

Reference element damaged

Clean the sensor cartridge using a brush and/or rinse the sensor cartridge with clean water

(without cleaning agents), and wipe the sensor cartridge carefully with a soft, clean cloth.

Clean all components

(membranes/reference electrode/temperature sensor)

Install the cleaning unit

Increase the cleaning interval

Check the sensor installation/replace the sensor

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Incorrect measurement values

Unstable measurement values

cartridge

NO3 mV RANGE! (Nitrate mV value is out of measurement range)

CL mV RANGE! (Chloride value is out of measurement range)

REF1 RANGE! (measuring range exceeded on 1 st

reference value)

REF2 RANGE! (measuring arrange exceed on 2 nd

reference value)

TEMPERATURE (Temperature value is out of measurement range)

Moisture at the contacts of the sensor cartridge

Replace the sensor cartridge/check the waste water temperature

CARTRIDGE OLD (sensor cartridge mote than 1 year old)


Dry the contact with a cloth or paper. Check the black gasket for damage and make sure it is in the correct position. Screw the 4 socket head screws tight

Moisture inside the measurement probe/faulty sensor electronics Check the sensor electronics by using the test cartridge.

1 Select SENSOR MENU > DIAG/TEST >

SERVICE > TEST CARTRIDGE > Test cartridge ready? Press ENTER

2 If all channels are confirmed with

OK, the sensor electronics are operational: Test cartridge

OK

ENTER

Potassium concentrations too high

(e.g.: > 700mg/L in the case of small ammonium concentrations) or chloride concentrations too high (e.g.:

>1000mg/L in the case of small nitrate concentrations)


If the test cartridge data is not within this range and/or if the test cartridge check is not successful, contact the service department

Switch off potassium/chloride compensation (in the configuration menu - then potentially enter a fixed value for potassium/chloride)

Air bubbles, depth of immersion

Moisture at the contacts of the sensor cartridge

Sensor membrane damaged

Reference element damaged

Check the sensor installation.

Check the cleaning unit configuration.

Dry the contacts with a cloth or paper. Check the black gasket for damage and make sure it is in the correct position.

Screw the 4 socket head screws tight

Check the sensor installation/replace the sensor cartridge

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Troubleshooting during calibration.

Symptom

SENSOR CODE

Possible cause

Sensor code entered incorrectly

Corrective measures

Using the certificate, check whether the sensor code was entered correctly.

AMMONIUM

OFFSET

SLOPE

Error during the last ammonium correction, sensor cartridge too old, contaminated, faulty

Repeat the correction.

Use the previous correction.

Clean or replace the sensor cartridge.

POTASSIUM

OFFSET

SLOPE

Error during the last potassium correction, sensor cartridge too old, contaminated, faulty




NITRATE

OFFSET

SLOPE

Error during the last nitrate correction, sensor cartridge too old, contaminated, faulty




CHLORIDE

OFFSET

SLOPE

Error during the last chloride correction, sensor cartridge too old, contaminated, faulty




3.4.3. Troubleshooting of Dissolved oxygen electrode.

Diagnostic and test menu.

The diagnostic and test menu shows current and historical information about the LDO sensor.

To access the diagnostic and test menu, go to MENU>SENSOR SETUP>[Select Sensor]>DIAG/TEST.

Option

SENSOR INFO

Description

SOFTWARE VERS—Shows the installed software version

BOOT VERSION—Shows the installed boot version

DRIVER VERS—Shows the installed software driver version

LOT CODE Shows the sensor cap manufacturing lot

SERIAL NUMBER Sensor serial number

GAIN CORR

OFFSET CORR

PHASE DIAG

Adjust the calibration gain value.

Range: 0.50 to 2.00

Adjust the calibration offset value (mg/L or ppm).

Range: –3.00 to +3.00

Shows the phase for total, red and blue wavelengths. Updates once per second.

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AMPL DIAG

DAYS TO CLEAN

SENSOR LIFE

Shows the amplitude for red and blue wavelengths. Updates once per second.

Shows the number of days until the next scheduled manual cleaning.

Shows the number of days until the next scheduled sensor cap replacement

Error list.

If an error occurs, the reading on the measurement screen flashes. Output behavior is determined by controller settings. Refer to the controller manual for details.

To show the current sensor errors, go to MENU>DIAGNOSTICS>[Select Sensor]>ERROR LIST.

Error Possible cause

RED AMPL LOW (Value is below 0.01) OR

The sensor cap is not installed, or is not installed correctly.

BLUE AMPL LOW (Value is below 0.01)

The light path is blocked in the sensor cap.

The sensor is not operating correctly.

Resolution

Remove the sensor cap and install it again.

Inspect the inside of the sensor cap and lens.

Make sure that the LED is flashing. Contact the manufacturer.

Warning list.

When the warning icon flashes (sc100 and sc200) or when the screen turns yellow (sc1000), a message is shown on the bottom of the measurement screen. On the sc1000, the screen turns yellow to show a warning. To show the current sensor warnings, go to

MENU>DIAGNOSTICS>[Select Sensor]>WARNING LIST.

Warning

EE SETUP ERR

EE RSRVD ERR

TEMP < 0 C

TEMP > 50 C

RED AMPL LOW

RED AMPL HIGH

BLUE AMPL LOW

BLUE AMPL HIGH

CAP CODE FAULT

Definition

Storage is corrupt. The values have been set to the factory default.

Resolution

Contact technical support.

The process temperature is below 0 °C (32 °F)

The process temperature is above 50 °C (120 °F)

Value falls below 0.03

Value is greater than 0.35

Value is below 0.03

Value is greaten than 0.35

The sensor cap code has become corrupt. The code has

Increase the process temperature or stop use until the process temperature is in the sensor specification range.

Decrease the process temperature or stop use until the process temperature is in the sensor specification range.

Refer to error list Table.

Call technical support.

Refer to error list Table.

Call technical support

Complete the sensor setup cap procedure. If no setup cap

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been reset automatically to the default cap and lot codes. is available for the sensor cap, call technical support.

Event list.

The Event list keeps a log of changes to how data is recorded by the sensor. To show sensor events, go to MENU>DIAGNOSTICS>[Select Sensor]>EVENT LIST.

Event

ALT/PRESSURE UNIT CHANGE

ALT/PRESSURE CHANGE

TEMP UNIT CHANGE

MEAS UNIT CHANGE

SALINITY CHANGE

SET DEFAULT

SENSOR SETUP CHANGE

CLEAN INTERVAL TIMER

CHANGE

SENSOR CAP LIFE TIMER

CHANGE

Description

Atmospheric pressure or altitude units have changed.

The value for altitude or atmospheric pressure has changed.

The units for temperature have changed.

A new unit of measurement has changed.

The value for salinity has changed.

Sensor settings have been reset to the default values.

The sensor setup has changed.

The time between sensor cleaning has changed.

The time between sensor cap replacements has changed.

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4. CONCLUSIONS

The present report summarizes the technical characterization of the components developed prototypes, including the industrial wastewater plant and the urban wastewater plant. User instructions are conveniently defined for both plants and, thus, every item has been briefly described, including important warnings.

On the other hand, start up and stoppage procedures have been completely explained. The maintenance process is also detailed because it is crucial to maximize the efficiency of the plants.

Finally, a complete explanation of points to check in case of malfunction and what measures have to be taken in order to solve the problems has been reported in current ADNATUR deliverable.

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life12 env/es/000265 deliverable db1.3: user manual of

LIFE Project Number

LIFE12 ENV/ES/000265

DELIVERABLE D.B.1.3: USER MANUAL OF BOTH PROTOTYPES.

ADNATUR: Demonstration of natural coagulant use advantages in physical & chemical treatments in industry and urban waste water.

CONTENTS

Move cursor on “Range” then press wheel. According to prove reading capacity select proper scale by rotating wheel. Once satisfied press wheel, move cursor on

“OK” and press wheel again.

Clean the sensor.

Clean the exterior of the sensor with a soft, wet cloth.

Set or change the clean interval.

Application conditions may need shorter or longer durations between manual sensor cleanings. The default clean interval is 0 days. To change the interval, refer to the steps in this procedure.

• To turn off the clean interval, set the value to '0'.

Change the sensor cap.

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