100% water. Taking care of the world s water. CIRCULAR CLARIFICATION EQUIPMENT & PROCESSES
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1 100% water Taking care of the world s water. CIRCULAR CLARIFICATION EQUIPMENT & PROCESSES
2 THE RIGHT CHOICE FOR RELIABILITY AND VALUE For more than half a century, U.S. Filter/Envirex has provided custom designed, circular sludge collector mechanisms for municipal and industrial water and wastewater treatment applications. The quality of the engineered designs, the superior fabrication of the finished products and the consistency of experienced, after-installation services have contributed to U.S. Filter/Envirex s reputation as a leading supplier of proven clarifier equipment. DESIGN CONCEPTS Two basic design concepts are available. Each has a wide range of sizes and options to select from, allowing every circular clarifier to be tailored to meet specific application requirements. The bridge supported design (full bridge) consists of a bridge spanning the tank s diameter, with the sludge collector mechanism supported from the bridge. The center pier supported design (half bridge) consists of a mechanism support- ed on a center pier, with an access bridge leading to it from the tank s wall. Both designs incorporate a minimum of two sludge scraper arms per mechanism. Sludge removal mechanisms are designed for continuous operation over the life of the clarifier, and are based on the concept that solids within the water or wastewater will settle out in a quiescent tank. DESIGN PARAMETERS The basic operating parameter of a clarifier is to remove settled solids from the bottom of the clarifier tank as quickly as possible. This improves the efficiency of other treatment processes. Inlet design, flocculation, scum removal and operator needs should be considered to match the needs of the installation. The objective is to provide a hydraulically quiescent tank with the greatest detention time practical to improve the ability of solids to settle to the bottom of the tank. Considerations involving inlet energy dissipation, solids settling characteristics, liquid flow patterns and effluent collection are part of this design parameter. 2.
3 THE RIGHT CHOICE FOR RELIABILITY AND VALUE Circular Collector Components- General Benefits Cast iron drive housings Shop fabricated for bolted field assembly Full surface adjustable skimmers Reinforced influent well Ample walkway and drive platform widths Deep scraper blades and adjustable squeeges No underwater bearings Designed to exacting specifications Half Bridge Clarifier COMMON FEATURES OF U.S. FILTER CLARIFIERS Beginning with tanks ten feet in diameter and larger, U.S. Filter circular sludge collectors are available in either full or half bridge designs. Every clarifier is equipped with a U.S. Filter built drive designed to AGMA standards, assuring proper torque ratings and longevity under continuous operation. U.S. Filter drives perform...providing years of reliable service. Surface skimmers, sludge scraper arms and other components are welded in the shop to reduce field installation time. Only bridge splices are field welded assuring quality fabrication. All components are preassembled at the factory, an operation that reduces field fitup time and erection costs. OPTIONS Each custom designed U.S. Filter circular sludge collector can be provided with features such as center drive platform, choice of walkway and handrail material and styles special service protective coatings, special material assembly bolts, etc. For details, contact your local U.S. Filter representative. 3.
4 FULL BRIDGE CIRCULAR CLARIFIERS U.S. Filter full bridge (F Type) sludge collector mechanisms are available in sizes beginning at ten feet in diameter. Generally, the economics of the design limit the F Type to 50 feet in diameter, although larger sizes can be built for special requirements. In the F Type design, a structural steel bridge spanning the tank s diameter supports the drive mechanism. A center torque tube bolted to the drive, supports and rotates the sludge collector mechanism. INFLUENT FEEDWELL Influent enters the tank from the side of the basin and is fed into the center influent feedwell. The feedwell reduces the influent s energy while eliminating or reducing density currents. The feedwell permits only a low velocity flow to enter the tank, assuring maintenance of quiescent conditions and the most efficient removal of solids. For wastewater applications, the feedwell is equipped with baffled scum ports that permit floating material to escape from the feedwell while preventing short circuiting. The feedwell is supported from either the bridge or beams spanning the tank as dictated by the design. SCRAPER ARMS Scraper arms are bolted to the torque tube and rotate with it. The scraper arms are engineered to complement the drive and anticipated sludge loads. Scraper arms extend from the torque tube to the periphery of the basin. A minimum of two scraper arms are provided, allowing the basin floor to be scraped at least twice in each removal. Each scraper arm is furnished with a number of scraper blades that are arranged to collect and direct the sludge to the center of the tank for hydraulic removal. SUPPORT BRIDGE The support bridge provides access to the drive mechanism. For operator convenience and safety, the bridge is provided with a minimum three foot wide walkway. All walkways have handrails and a four inch high kickplate along both sides and around the drive. 4.
5 FULL BRIDGE CIRCULAR CLARIFIERS Full Bridge Clarifer 35' diameter industrial Full Bridge Clarifier Installation SKIMMING/EFFLUENT WEIRS Various skimming and effluent arrangements are available for water and wastewater treatment circular clarifiers. Generally, a full radius, surface scum blade directs floating material to the peripheral scum skimmer. The skimmer concentrates the floating material and deposits it in the scum trough. Adjustable weirs are generally located on the periphery of the basin, although radial and other arrangements are employed. 5.
6 FULL BRIDGE DRIVE TYPE F BUILT TOUGH CUSTOM DESIGNED STABLE, VIBRATION FREE LOW FRICTION PLATFORM Specifically designed for the particular demands and operating conditions of water and wastewater treatment plants, the U.S. Filter Type F drive is built for years of continuous service with a minimum of maintenance. Each custom designed Type F drive is completely manufactured by U.S. Filter, providing owners with one source of responsibility for service assistance and replacement parts. In addition to new installations, U.S. Filter Type F drives are available for retrofit and upgrade applications. A large diameter ball bearing supports the worm gear. This bearing provides the worn gear with a stable, vibration free, low friction platform that translates into extended, durable drive performance. An outboard bronze steady bearing supports and stabilizes the torque tube. In doing so, it reduces and/or eliminates tipping loads on the main gear and bearing. Without this unique feature, unequal and unbalanced loads could cause premature failure of the main gear or bearing. The U.S. Filter Type F drive is designed for the loads applied by a circular clarifier mechanism. This is an important consideration, since it is in direct contrast to off-the-shelf drive units that are not designed for the loads or conditions encountered by circular clarifiers. The primary reduction unit is a heavy duty helical gear designed for efficient speed reduction. It is coupled to the secondary reduction unit by a chain and sprocket that can be equipped with shear pin overload protection. The secondary reduction unit consists of a cut tooth steel worm and cast worm gear. The worm gear is supported by a precision bearing. This bearing operates within an oil bath. Overload protection, including alarm and shutdown micro-switches, operates from the thrust of the worm shaft. All U.S. Filter Type F drive components are designed to AGMA standards for worm gears. The use of the external steady bearing eliminates the need for an underwater bearing. 6.
7 FULL BRIDGE DRIVE TYPE F FOR YEARS OF EFFICIENT SERVICE Full Bridge Drive- General Benefits Cast iron construction Designed per AGMA 20-year continuous duty requirements Factory assembled Extended torque tube steady bearing Large diameter worn gearing Helical gear primary reduction Electro-Mechanical overload protection Oil bath lubricated Condensate taps Full Bridge Drive 7.
8 HALF BRIDGE CIRCULAR CLARIFIERS The U.S. Filter/ Envirex half bridge, pier supported circular sludge collector is available as small as 30 feet in diameter, although the economics of construction generally favor half bridge designs no less than 40 feet diameter. There is no upper limit on the diameter of the collector other than process considerations. For clarifiers between 40 and 50 feet in diameter, operator preference will usually decide between the full bridge and half bridge designs. MAIN COMPONENTS The pier supported design consists of a support pier, influent feedwell, rotating cage and scraper arms, and access bridge spanning from the tank wall to the center column and H Type drive unit. A wide range of scraping, skimming and process options are available with this design. Half Bridge Drive INFLUENT FEEDWELL AND PIER Flow enters the influent dispersion well through the center support pier or a side feed pipe. If a side feed is used, the pipe is supported from the bridge structure. When used as an influent pipe, the support pier is provided with a large inlet area designed to reduce inlet turbulence. Depending on the process, the well can be a simple influent well with baffle arrangement or a flocculation well. In all instances, the well is designed to diffuse and disperse inlet water energy, based on process requirements. The well can be supported from the sludge scraper arms, from the cage or from the access bridge, depending on design conditions. For wastewater applications, the influent well is equipped with baffled scum ports that permit floating material to escape from the feedwell while preventing short circuiting. Storm water clarifier installation with walk through truss bridge 8.
9 HALF BRIDGE CIRCULAR CLARIFIERS Half Bridge Clarifier SCRAPER ARMS A minimum of two scraper arms, each with individual scraper blades, move settled sludge toward the center sludge hopper for removal. Scraper blades are arranged to scrape the floor twice in each revolution. Some applications require four scraper arms to achieve the required sludge removals. In all designs, sludge scrapers arms are supported and rotated by a center cage supported from the Type H drive unit. Scraper arms and the rotating cage are constructed of structural steel. All welding is done in the factory to assure quality fabrication and to minimize field erection requirements. All submerged structural material is a 1/4 inch minimum thickness. SKIMMING/EFFLUENT WEIRS Various skimming effluent arrangements are available for water and wastewater treatment circular clarifiers. Generally, a full radius, surface scum blade directs floating material to the peripheral scum skimmer. The skimmer concentrates the floating material and deposits it in the scum trough. Adjustable weirs are generally located on the periphery of the basin, although radial and other arrangements may be employed. ACCESS BRIDGE Depending on the size of tank, the access bridge to the drive mechanism will be of beam or truss design. Handrail and four inch kickplate are provided for operator safety with the beam design. In the truss design, the truss acts as the handrail and kickplate. A platform is normally provided at the drive mechanism for safety and efficient maintenance. 9.
10 HALF BRIDGE DRIVE TYPE H THOUSANDS ARE INSTALLED Designed to AGMA standards and manufactured by U.S. Filter for circular sludge collector operations, the Type H drive will provide the full rated torque over its 20 year service life. That is one assurance of dependable sludge collector performance. Another is in the field, where thousands of H Type drives are installed in municipal and industrial water and wastewater treatment facilities worldwide. In addition, each Type H drive is backed by U.S. Filter, so owners have single source responsibility for service and replacement parts, if required. The Type H drive consists of primary, intermediate and final reduction units, designed as a workhorse system with a low power draw. A helical gear unit serves as the primary reducer. Power is transmitted from it to the intermediate worm gear reduction unit via a chain and sprocket coupling arrangement. This can be provided with a shear pin overload device, if desired. The driven worm shaft in turn drives the main worm gear. Overload protection, including alarm and shutdown micro-switches, operates from the thrust of the worm shaft. Stability of the large diameter worm gear is assured by a hardened, precision ball bearing. The final reduction pinion gear, driven by the worm gear, engages the spur gear to complete the transmission of power. The spur gear is supported by a large diameter ball bearing, contained in a raceway with removable liners. All gears and bearings run in an oil bath for extended and trouble free operation. Oil levels are easy to monitor and maintain. An easy to reach drain makes changing oil simple. MAIN COMPONENTS The spur gear is split for easy access to the ball bearing and raceway liners. The gear, bearings and liners can be replaced without moving the access bridge. With this feature, not commonly available in the water and wastewater marketplace, maintenance costs can be significantly reduced. In most instances, a worn spur gear, bearings and raceway can be replaced for far less than the cost of a new drive. 10.
11 HALF BRIDGE DRIVE TYPE H 20 YEAR SERVICE LIFE Half-Bridge Drive- General Benefits Cast iron construction All gear sets designed to meet AGMA 20-year life requirements Replaceable hardened alloy steel bearing races independent of gear Factory assembled Oil bath lubricated Intermediate worm gear reduction Large diameter split internal main gear Electro-Mechanical overload protection Condensate taps H-90 Floc-clarifier H-90 Half Bridge Drive Platform 11.
12 U.S. FILTER FLOC- CLARIFIERS FOR SIMULTANEOUS FLOCCULATION AND CLARIFICATION A U.S. Filter floc-clarifier reduces overall operating costs and initial capital outlay, when compared to separate flocculation and clarification units. It combines the basic components of the circular clarifier with flocculation. The U.S. Filter floc-clarifier can be applied to process requirements such as water treatment (removal of color, particulates, chemicals) or wastewater treatment (phosphorous removal, trickling filter solids contact systems). Changes to the design include a larger influent well, sized to provide the required flocculation time. In some instances, modifications to the bridge and supporting structure may be required. Mixing is also added to achieve economical flocculation. Proven designs include mechanical mixing, air supply, or hydraulic baffles. Mechanical flocculation is provided by either concentric stacked drives or independent mixes. CONCENTRIC FLOC- CLARIFIER REACTOR CLARIFIER A special adaptation to the U.S. Filter floc-clarifier is the reactor clarifier. It employs sludge recirculation with in the clarifier to increase floc formation and particle interaction and uses the sludge recirculation within the clarifier to increase floc formation and particle interaction and uses the sludge bed to filter the effluent flow. While it is an excellent performer, it is more restrictive regarding application than a floc-clarifier. 12.
13 U.S. FILTER FLOC- CLARIFIERS CONCENTRIC-FLOC DRIVES TYPE CF This special drive concept provides the most positive method of achieving complete flocculation and generally reduces capital and operating costs. It employs a Type H or Type F drive for flocculation, stacked on top of the respective Type H or Type F drive used for the circular clarifier mechanism. The Type CF drive allows the use of a full concentric flocculation device within the flocculation well. As contrasted to independent mixers, all incoming flow must pass through the flocculating device ensuring complete flocculation of all flow entering the clarifier. Variable speed units match mixing speed to the required flocculation intensity. All concentric drives are designed to the same high standards as used for U.S. Filter s clarifier drives. The result is a low maintenance unit with extended longevity. GRAVITY THICKENERS U.S. Filter s gravity thickeners are heavy duty circular collectors, custom designed for handling concentrated industrial and municipal sludges. To meet the increased sludge loads, gravity thickeners are designed with higher service factors. Additionally, U.S. Filter gravity thickeners can be provided with pickets for dewatering, lifting devices for heavy solids applications, etc. Since gravity thickeners are designed for sludge handling rather than liquid handling, they are furnished with steeper floor slopes than conventional clarifiers. 13.
14 SKIMMING EQUIPMENT SYSTEMS FOR EVERY NEED Removal of floating debris from the surface of a circular clarifier is often one of the most difficult tasks to accomplish in a treatment facility. U.S. Filter/Envirex, with more than 50 years experience in designing skimmers and cixcular collectors, has the knowledge and type of skimmers to provide positive removal. Extended beach trough with flushing device FULL RADIUS SKIMMERS A full radius scum blade, skimmer and stationary scum trough comprise the standard circular collector skimming device. The system moves floating materials to the periphery of the tank where it is collected for further treatment. To increase scum removal efficiencies, an anti-rotation scum baffle, submerged shelf scum trough or dual skimmers can be furnished. Full radius skimmer in Half Bridge tank REVOLVING TROUGH SKIMMER The revolving trough skimmer is an economical alternative to the ducking skimmer. It is an easy to operate, high volume scum removal skimmer. It incorporates a number of full radius, revolving scum troughs with fixed skimmers transporting scum into the troughs. Scum flows to a center collection well where it is removed by pumping. Revolving trough skimmer with Tow-Bro Header 14.
15 SKIMMING EQUIPMENT SYSTEMS FOR EVERY NEED DUCKING SKIMMER For heavier scum removal needs, the ducking skimmer is an efficient, high volume scum removal device. It incorporates a rotating scum trough and multiple, full radius skimmers. It allows flexible control of scum removal via electrical control, but is more complex and involves more operator attention than other systems. Additionally, it increases the amount of liquid to be handled by the scum system. Ducking Skimmer Installation Above: Revolving Trough Scum Well Revolving Scum Trough 15.
16 SETTING THE STANDARDS IN CIRCULAR COLLECTION U.S. Filter engineers have furnished proven designs for virtually every type of application requiring clarification, floc-clarification, gravity thickening and skimming. With more than half a century experience, U.S. Filter can point to its equipment operating in industries and municipalities worldwide. From drive design to factory fabrication, U.S. Filter sets the standards for how a circular collector should be built. With reliability. With longevity. And with integrity. OTHER CLARIFICATION PROCESSES The Rex Rim-Flo clarifier provides economical, highly efficient secondary and tertiary clarification using a peripheral influent/peripheral effluent design. It is designed for greater capacity and a higher overflow rate than a conventional center feed unit because of its inherent hydraulic efficiency. Increased efficiency means either a smaller tank or a tank with a conservative loading rate can be designed. The Rex Tow-Bro sludge removal device is recommended to remove activated sludges. It offers rapid sludge pickup, minimum sludge agitation and maximum solids concentration. The Tow-Bro can be easily retrofitted to an existing circular scraper sludge collector providing increased sludge removal concentrations and reduced floating sludge problems. Rim-Flo Clarifier Half Bridge Tow-Bro with pony truss bridge For more information, contact your local U.S. Filter sales representative, or U.S. Filter/Envirex. Taking care of the world s water. Products manufactured and marketed by U.S. Filter/Envirex are protected by patents issued or pending in the United States and other countries. P.O. Box 1604 Waukesha, WI phone fax Bulletin No. U.S.F R2 7.5M-9/97 Printed In U.S.A UNITED STATES FILTER CORPORATION
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