NC0065684_Regional Office Historical File Pre 2018

1997
Package Style mv,�h� � ieY��at f
�r; :
Wastewater
Treatment Systems
Tyson Construction Company
Country Wood Facility
Union County, North Carolina
Reference Number: 96-128
April 7, 19.97
Permit No. ,NC0065684
McCall Brothers, Inc.
6700 Brookshire Blvd
Charolette, North Carolina
MC 6'12:Doc
Tipton Environmental International,
Inc.
Park 50 Technical Center - 2002-G Ford Circle
Milford, Ohio 45150

Tipton Environmental
20,02 Ford Circle _ Suite G fftrL'l'i�tfl
N,lilford, ON 45150
Voice: 513.248.4067
Fax: [phone]
I NPEX
nal, Inc.
www,ti )tunefl'v cum
- Equipment Specifications
Technical Data Sheets
- Electrical Controls
- Project Site Photos
- Corrosion Ef Painting
- Pre -Plant Delivery Instructions
- Operations 8- Maintenance

Prefabricated Steel Wa to tt+er " re .to ent Pi tnt
Lipton Environmental,rternational, n
miltord, Ohio USA

Tipton Environmental intcn atir'.rnal, Tne
an important part in the wastewater treatment
industry. 'This industry is important to sustain a
clean environment and to improve the conditions in
which we live, We have developed a high efficient
wastewater treatment system that will produce the
quality of effluent our environment requires. This
effluent can then be used for garden water,
trrigataon, grey water
applications.
many other
The TEll System is a unique interttaediate size
biological wastewater treatment It is
designed and engineered specifica.liy for people:
who are temporarily or permanent] residing
outside the reach of tatttmic pal waste disposal
ystemts. "11tis systen irrelles settling and filter
c 1urn b rs, disinfection m,ethoc➢s, and other aaneiliary
equipment such as 'blower motor units, pumps,
electrical controls. sewage grinder's, and bar
screens, These items can he added to our extended
aeration process cltattaftwr to achieve a clear and
odor -free effluent. The system is pre -built at the
factory and shipped to the proja site as a self
contained. unit that requires only minimal field
assembly.
1`ylical applications for
1`rcatnlea%t Systems w
1,000 gallons to 3004OOt7
a industrial Faci➢ities
Apartment Complexes
• Suburban Subdivisions
• Resort Areas
Recreational Facilities
• Mobile Home Parks
• highway Rest Areas
Power Stations
Motes/Hotels
• Housing Developments
• Condominiums
Features of the TFII System
"I J ill Systems are compact and self-contained, they
can be installed both below or above grade iv
tuininsunt of installation expense, The facilities are
portable and reusable and can be expanded for
additional capacity. Since they are relatively small
and odor free. they can be installed at :almost
. `Fhey can even be landscaped to match
dung area, Several other features of the
rde:
grof Treatment (85-9O%X RODS Removal)
ante Cost
Ease of
How does i
V
'I1?lt Systems are a type of biological treatment lrr
domestic waste using the extended aeration cameept
(a modification of the activated sludge process),
Under the conditions of a low flow and high 13O1),,
loadings, a high quality effluent can he achieved.
The basic design is an extended aeration period that
is approximately 24 hours, coupled with a defined
settling period that is approximately four hours, The
extended aeration process ,purities the sewage by
the destruction of the organic compounds using air
to mix and oxidize the volatile .material into gas,
water and sludge, 13y the continued. aeration of
these concentrated solids biological organisms are
produced and grow- in colonies.. These colonies will
attach themselves to the volatile materials breaking
it down into water, carbon dioxide and ash. `]he
result being a clear and odor -free effluent, The
same thing happens in streams and rivers, When
waste enters a stream, the dissolved oxygen in
water decreases and the bacterial population
s As the wastewater hooves down stream,
is will consume all organic- tnaateriaal i
Mother Nature does but, by
the aeration chaamther,
environuaent for bacterial
consume orgy tut materials,
we do it faster,
conlined space called
This provides an
'owlh to produce and
Ile difference is that

Packaged Air Systems
knits available in ttberlass< metal. and
structural steel. Our units are designed for high
ice to corrosion and sound suppression.
fiber lass unit is shownn on the left and the
structural stool base blower is pictured to the
right,
TIC
tis
5
1,0
Control Panels
Ultraviolet Disinfection
ITV Disinfection provides
the ability to destroy over
99% of the bacteria in a
flow without the use of
chemicals,
nt
15
Sanuril
The Sanuril Wastewater
tablet feed system is a
complete, one piece
s zstem designed for
positive disinfection of
treated effluent.
51
W
51
Ai
1
�e5

p,,Arvsf,s,srsplei4
'Me Tank is shipped by tractor
traitor to the jobsite„
„„.
Tank is offloaded by crane to the
foundation pad„
"The tntek is positioned or the,
pick up by a crane for the
plamment onto the foundation
pad.
The tank is positioned onto the
foundation pad and then secured
to the pad by anchoring tabs„
The tank is lifted and Men
carefully placed over thc
foundation pad„
After set into the grade,
component parts are put into
place and the necessary lines are
ritn„
Tipton Environmental Intl., Inc, offers a variety of different services such as:
Engineering Support
"r- Installation
Testing Procedures
r held Service
e Site Layout
"fr Start -Up Support
Operator Training
Technical Assistance
Tipton Environmental
2002 Ford Circle - Suite G International, Inc
Milford, Ohio 45150 USA
Phone: 513248,4067 Fax: 513,248,5922
Web Pagel bitp;//www,tiplortin int:0(0.ipion.org
Represented by Mantauctureers Agents
r : 31417,SCai,

Tipton Environmental
2002 Ford Circle - Suite G
Milford, OH 45150
Voice: 513.248.4067
Fax: 513,248,5922
International, Inc,
]1"Dio79 flW.coot.
ptonenv .corn
EQUIPMENT PROPOSAL & AGREEMENT PURCHASE ORDER
April 7,1997
To: Mr Ken Sigman
McCall Brothers, Inc.
6700 Brookshire Bvd
Charalette, N.C. 28216
Phone [phone]
Subject: Package Wastewater Treatment System
160,000 god secondary with tertiary
Quotation No: 160 MC Revised 8/29/96, October 23,1997
Revised April 7, 1997
File No: Mccall 160000S:doc
Dear Ken:
We arc pleased to propose the wastewater treatment equipment for your above subject project. The
following is a description of the equipment we are proposing to supply as defined below:
SECONDARY TREATMENT SYSTEM
We are pleased to propose one (1) Model TEII- 1600 prefabricated steel Tipton Environmental extended
aeration process wastewater treatment system complete with secondary and tertiary treatment as
manufactured by Tipton Environrental, Inc. Milford, Ohio, U,S.A .. The wastewater treatment system
will have a total design flow of 160,000 gallons per day of 210 PPM BADS domestic waste . The aeration
volume shall be 160,000 gallons, The total clarifier volume shall be gallons and shall be a 24 foot
mechanical sludge collection type ,The proposed equipment package shall include the necessary tank
vessels, , internal piping, valving, weirs, baffles and all items of equipment as listed below:
Flow Equalization System
1 Surge Tank 40,000 gallons, aerated and constructed integral to main tank
2 Surge pumps 111 gpm u, 12 `TDB3/4 hp 208 volt, 3 ph
I Bar Screen, submerged type with comminutor mounting
1 Comnunutor , 8 inch , 1/2 hp, 208 volt, 3 ph with nema 4 controls

4 Liquid level sensor control
1 Flow control box with v-notch control with flow splitted
1 Diffused areation system disc diffusers
1 Discharge Muffler on Surge blower
1 Pre -wired electrical surge control system Model CP-2 complete with enclosure Nema 4 steel
with the necessary Motor IEC starters ,circuit breakers, Liquid level sensors, selector switches
all designed to operate off of 230 volt , 3 phase , 60 Hz main power
1 Pre -wiring of electrical components installed in the tankage
2 BIower motor units each with a capacity of 150 SCFM at 5 psi, equipped with 5 hp motor
230 volt, 3 phase, 60 Hz. mounted within a TEII -2 Fiberglass Blower Housing complete with
base and weatherproof hood.
Major System Equipment
3 Blower motor units each with a capacity of 750 SCFM at 5 psi, equipped with 25 hp motor
230 volt, 3 phase, 60 Hz. mounted within a TEII -3 Fiberglass Blower Housing complete with
base and weatherproof hood.
1 Blower Discharge mufflers and inlet filter silencer
1 Flow splitter chamber 3 way
1 Pre -wired electrical control system Model CP-1 complete with enclosure Nema 4 steel with
the necessary Motor EEC starters ,circuit breakers, programmable timers, selector switches all
designed to operate off of 230 volt , 3 phase , 60 Hz main power
1 Pre -wiring of electrical components installed in the tankage
1 Sludge return pump, airlift type 6 inch size
1 Skimmer pump, airlift type 3 inch size with scum beach
1 Air manifold box beam complete with diffuser drop pipe assemblies with diffusers and pressure
relief facilities complete with pressure gauge
1 8" inlet connection and 8 inch outlet connection flanged type
1 All piping to be painted steel
1 Lot of course air bubble diffusers in aeration chamber
1 24'-0" Mechanical Clarifier with Bridge and drive unit ( Concrete grouting of floor by others)
Sludge Holding Equipment
1 Sludge holding tank, aerated and constructed as integral to plant complete with 22,500 gallon
volume , air diffuser drop assemblies with diffusers.
1 Supernate and overflow assemble 3 inch airlift
1 6 inch transfer pipe
Tertiary Filter System
1 Four filter Cells unit 27 sq feet
1 Clearwell integral, 8,333 gallons
1 Mudwell chamber, 8333 gallons
1 Filtrate Holding Chamber 300 gallons
2 Mudwell pumps 100 gallons per minute
4 Clearwell pumps 405 gpm pumps
2 Blower motor units each with a capacity of 50 SCFM at 5 psi, equipped with 3 hp motor
230 volt, 3 phase, 60 Hz. mounted within a TEII -2 Fiberglass Blower Housing complete with
base and weatherproof hood for air scour system.

1 BIower Discharge mufflers and inlet filter silencer
1 Pre -wired electrical control system Model CP-3 complete with enclosure Nema 4 steel with
the necessary Motor IEC starters ,circuit breakers, programmable timers, selector switches all
designed to operate off of 230 volt , 3 phase , 60 1lz main power
1 Pre -wiring of electrical components installed in the tankage
4 Solenoid valves
1 8" By-pass with butterfly valve
1 Lot of Filter Media both sand and anthracite
Disinfection System
1 Chlorine contact tank , 3,333 gallons on the tertiary outlet end
1 Mounting only for 3 sanurils ( Feeders by McCalls)
Dechlorination System
1 DeChlorination contact tank , 1500 gallons on the chlorine contact outlet end
1 Mounting only for 3 sanurils ( Feeders by McCalls)
1 Mounting for L & S 61-r FIowmeter with enclosure and V- Notch weir
Miscellaneous Items to be Supplied
1 Flowmeter Model L&S 61-R complete with recorder
1 Lot of grating service area only
1 Lot of handrail service area only
6 0 & M Manual on the equipment being provided
10 Approval Plans and specification with 0 & M Manual
10 As built plans and specification with 0 & M manuls
1 Interconnecting piping between the clarifier and aeration chamber
1 Interconnecting piping from flow splitter to main tankage ( max 10 feet)
1 Interconnecting piping from clarifier to tertiary system
Corrosion Protection
1 All steel vessel surfaces to be prepared before painting by general cleaning
1 All steel vessel surfaces to be painted with " Koppers" #50 Bitumastic to a total dry film
thickness of 8-12 Mils.
10 Package anode 9#
A. PRICE: Based on Payment Terms "D" S
* Items Bold, Iteizes, and underlined Changes
F.O.B. Factory, Freight Allowed To Jobsite
B. Price for the erection of the system on the owner's foundation pad
( Including crane cost)
Price: $ 28,000.00
Term "D"
1) 25 % of contract price at time of release to fabrication
2) 70 % of contract price paid at time of delivery of shipment date ( partial shipments
acceptable).
3) 5 % of contract price paid at startup not to exceed 60 day from delivery

4) Retainage - None
5) All money covered by an acceptable ILOC
OTHER ITEMS
Add to the price shown above any federal, state, local, or applicable taxes which would apply.
Estimated Delivery: 10 to 12 weeks after receipt of the complete Approved Engineering Plans and
Specifications and an Acceptable Order in our Office .
Price is valid 60 days from the date of this Proposal/Agreement Form
Only those items shown in the above proposal will be furnished. All other items will be furnished by
others ,such as but not limited to: Excavation, All Concrete Work including material,Electric power to
our control panel(s) Sewage lines , Finished grading, Mounting and installation of the equipment being
provided, External piping and valving other than shown above), Field erection other than shown above ,
backfrlling, , water to fill the tank and fencing.water to fill the tankage.
It is the opinion of Tipton Environmental International, Inc. that the equipment and or services contained
in this Proposal/Agreement generally comply with the intent of the plans and specification as regards to
the type, size, performance, quality of equipment, and or treatment process provided. However, this
proposal should be interpreted as having possible changes to conform to Tipton Environmental
International,Inc. standards to avoid a complete re -design of our equipment rather than representing an
exact duplicate of the specified equipment. Engineering and/or Purchaser's written approval to seller's
submittal drawing constitutes "Notice to Proceed" with manufacture as submitted. Any changes and/or
additions to this Proposal/Agreement will be at an added price above. Tipton Environmental International,
Inc shall incur no liability to the Purchaser as a result of nonconformity prior' to and after receipt of
approval and /or acceptable order. Price is based on the Terms attached herein, and is subject to change,
written approval of seller's submittal drawings is not received in our office within 60 days from the date
submittal drawings are mailed by the seller.
ACCEPTANCE
McCall Brothers,Inc Tipton Environmental International,Inc.
Purchaser Authorized Signature Fred D. Tipton, President

TERMS AND CONDITIONS
GOVERNING LAWN VENUE
THE PARTIES ACKNOWLEDGE THAT THE TRANSACTION
DESCRIBED HEREIN IS ENTERED INTO WITHIN THE STATE OF
OHIO, AND THE RIGHTS, OBLIGATIONS AND DUTIES OF THE
PARTIES SHALL BE CONSTRUED, ENFORCED, AND PERFORMED
IN ACCORDANCE WITH THE LAWS OF THE STATE OF OHIO..
ANY SUIT TO BE FILED BY EITHER PARTY SHALL BE
COMMENCED ONLY IN A COURT OF COMPETENT JURISDICTION
IN HAMILTON COUNTY, OHIO. Additional damages for breach: Buyer
expressly agrees that, where permitted by law, Buyer shall be liable for all
reasonable expenses and attorney's fees incurred by in enforcing its rights
and remedies against Buyer resulting from Buyer's breach of any of the
terms and conditions hereof.
ACCEPTANCE
Any Purchase Order or offer to buy based upon this
ProposallPurchase Agreement is subject to acceptance by Tipton
Environmental International, Inc. at its home office in Milford, Ohio. in
the event of any conflict between the terms of any such Purchase Order or
Offer to buy and these Terns and Conditions, those set forth herein shall
prevail. The issuance of such Purchase Order or offer to buy by Buyer shall
be deemed to be Buyer's assent to be bound by the terms and conditions set
forth herein. No addition to or modification of the Terms and Conditions
contained herein shall be binding upon Tipton Environmental International,
Inc. unless specifically agreed to by the President of Tipton Environmental
International in writing.
Aber acceptance by Tipton Environmental International, Inc. Buyer's
orders are not subject to cancellation, change, reduction in amount, or
suspension of delivery, without the advance written consent of Tipton
Environmental International, Inc. It is specifically agreed that Tipton
Environmental International, Inc. will be under no obligation to give such
consent without first having been reimbursed for all costs incurred
including, but not limited to: engineering time, administrative costs,
including overhead, cost of materials, cost of storage and profit Tipton
Environmental International, Inc. may cancel the order prior to or at the
time of receiving the fowl approved drawings if Tipton Environmental
International, Inc. deems itself to be insecure or determines that it is
commercially unreasonable to proceed. In the event of cancellation by
Tipton Environmental International, Inc. all deposits made by Buyer shall
be refunded in full.
TITLE, RISK OF LOSS AND SECURED INTEREST
Title to all goods to be sold hereunder and all risk of loss thereof
shall pass to Buyer upon Buyer's receipt of written notification from Tipton
Environmental International that such goods are ready for shipment and
delivery, and Buyer hereby grants to Tipton Environmental International a
security interest in such equipment to secure the full purchase price thereof.
Such written notification may contain the requirement that Buyer shall sign
and execute one or more financing statements, in recordable form,
evidencing Buyer's grant to Tipton Environmental International, Inc.'s of a
security interest in such equipment. Such security interest shall apply to the
equipment sold hereunder, any replacements thereto, and any and all funds
or other consideration received by Buyer in the event such equipment shall
be sold prior to final payment being made to Tipton Environmental
International, Inc.
TERMS ( As shown on Equipment Proposal)
A ( ) percent deposit with order, payment of balance due upon
shipmentasper Purchase Order, i.e. (date - month/day/year)
B. ( ) percent deposit with order. ( ) percent payment
upon receipt of shipment as per Purchase Order i.e.
(date - month/day/year) prior to offloading and
( ) percent upon start-up or within sixty (60) days of original shipment
date, whichever comes first.
C. Lease or term credit subject to approval by Tipton Environmental
International, Inc. and it's finance partner, lease or term credit arrangements
may be available to qualified applicants.
D. 20% percent deposit with the order 20% due upon release to
production 20 % prior to shipment once system has been fabricated and
ready for shipment with . Balance due not to exceed thirty (30) days, and
guananteed with an acceptable In -evocable Letter of Credit to be issued to
Tipton Environmental International, Inc. from purchaser's bank.
The quoted price is based on full payment within the above terns. If
payment is not made within the above terms, Tipton Environmental
International will add an additional eighteen (I8%) percent to the net
quoted price and invoice net sixty (60) days, If full quoted price payment
is received within a maximum of thirty (30) days, the eighteen (18%)
percent handling charge may be deducted. Any balances remaining due
sixty-one (61) days beyond the invoice date will be subject to an additional
one and one-half (1-1/2%) percent monthly service fee until paid. If
Tipton Environmental 'International, Inc. engages an attorney to collect
from Buyer the balance of the purchase price past due, including time
handling charge and service fee, Buyer agrees to reimburse Tipton
Environmental International, Inc. for all collection costs including
reasonable attorney's fees.
FORCE
Tipton Environmental International, Inc. will not be liable for any
damages for any reason sustained by Buyer or any third party resulting from
the failure of Tipton Environmental International, Inc. to perform or delay
in performing any obligation hereunder if such failures or delays are caused
directly or indirectly by circumstances beyond the reasonable control of
Tipton Environmental International, Inc.; such events include but are not
limited to: acts of God, invasion, insurrection, riot, fire, flooding, labor
disputed strikes, the failure of any supplier or trucker to meet scheduled
delivery dates or restrictions imposed by governmental authorities.
WARRANTY AND LIABILITY LIMITATION
Tipton Environmental International warrants that all goods sold
hereunder shall be free from defects in material and workmanship and shall
conform to the specifications specifically set forth herein. Buyer agrees
that Buyer's sole and exclusive remedy for breach of the forgoing warranty
shall be the replacement of such goods found by Tipton Environmental
International to be defective.
NO OBLIGATIONS, EITHER EXPRESS OR IMPLIED, EXCEPT AS
SET FORTH HEREIN, HAVE BEEN UNDERTAKEN BY TIPTON
ENVIRONMENTAL INTERNATIONAL WITH REGARD TO T}IE
SUITABILITY, CAPACITY, PERFORMANCE, OR COMPLIANCE OF
THE GOODS WITH BUYER'S SPECIFICATION OR NEEDS. THE
FOREGOING WARRANTY IS CONTINGENT UPON TIPTON
ENVIRONMENTAL INTERNATIONAL RECEIPT OF NOTICE IN
WRITING FROM BUYER OF A CLAIMED DEFECT PRIOR TO THE
EXPIRATION OF DAYS FOLLOWING THE DATE OF
DELIVERY OF THE GOODS.

TIPTON ENVIRONMENTAL INTERNATIONAL, INC. HEREBY
DISCLAIMS ALL OTHER WARRANTIES WHATSOEVER EXPRESS
OR IMPLIED, INCLUDING BUT NOT LIMLTED TO WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
TIPTON ENVIRONMENTAL INTERNATIONAL NEITHER
ASSUMES, NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT,
ANY OBLIGATION OR WARRANTY OTHER THAN THOSE STATED
HEREIN. TIPTON ENVIRONMENTAL INTERNATIONAL SHALL
HAVE NO LIABILITY UNDER THE WARRANTY GIVEN HEREIN
UNLESS AND UNTIL THE GOODS SUPPLIED HAVE BEEN PAID
FOR IN FULL; THE WARRANTY PERIOD SHALL BEGIN, AS
DESCRIBED ABOVE, WHETHER OR NOT SUCH PAYMENT HAS
BEEN MADE.
IN CONSIDERATION OF THE WARRANTY SET FORTH
ABOVE AND THE OTHER TERMS CONTAINED HEREIN, BUYER
AGREES THAT BUYER'S EXCLUSIVE REMEDY AND TIPTON
ENVIRONMENTAL INTERNATIONAL' SOLE LIABILITY ON ANY
CLAIM, WHETHER TORT, CONTRACT, OR WARRANTY, SHALL
BE MATTED TO REPLACEMENT OF DEFECTIVE PARTS AS
PROVIDED INT HE PRECEDING WARRANTY, AND IN NO EVENT
WILL TIPTON ENVIRONMENTAL INTERNATIONAL BE LIABLE
TO BUYER. FOR ANY THIRD PARTY OR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES RESULTING FROM ANY SUCH
CLALM.
Buyer specifically agrees that Tipton Environmental international,
Inc. shall not have any liability to Buyer or other third party in any way
arising out of the improper transportation, installation, storage, handling,
maintenance, or operation of said equipment occurring after the equipment
is shipped and for any damage to the equipment or other property resulting
from induction into the equipment or exposure to corrosive elements which
the equipment is not designed to handle.
CREDIT APPROVAL 1 PAYMENTS
This contract shall be subject to approval and acceptance by Tipton
Environmental International, Inc. lf, in the sold judgement and discretion
of Tipton Environmental International, Inc., the terms of payment
requested by Buyer in the following paragraph shall not be sufficient to
assure Tipton Environmental international, Inc. of timely payment of the
purchase price stated herein, Tipton Environmental International, Inc. may
require full or partial payment in advance, or other modifications to the
terms of payment requested in the following paragraph. Tipton
Environmental International reserves the right to request payment by
certified or cashier's check. If shipments are delayed by Buyer, the original
payment terms prevail and payment shall become due as per the original
payment terms of the original purchase order when Tipton Environmental
International, Inc. is prepared to make shipment as stated herein.
Equipment held for Buyer beyond the shipping date shall be held at the risk
and expense of Buyer. Unless otherwise stated, prices
are FOB factory with method and route of shipment at Buyers discretion.
Special permits and/or risk of loss or damage in transit shall be the
responsibility of Buyer. Equipment price does not include sales or other
required taxes or permits, and Buyer specifically agrees to reimburse
Tipton Environmental International, Inc. for any taxes, permit fees or other
charges which it is required to pay on behalf of Buyer. Buyer is
specifically responsible for obtaining permits in connection with the sale
and/or installation of equipment sold hereunder.
INSURANCE
On and after the time at which risk of loss shall shill from Tipton
Environmental International, Inc. to Buyer hereunder and until the full
purchase price shall be paid, Buyer will insure that goods against all
hazards in form and amounts and with an insurer satisfactory to Tipton
Environmental International. Inc. If Buyer fails to obtain insurance, Tipton
Environmental International, Inc. shall have the right, but not the
obligation, to obtain such insurance at Buyer's expense without waiver of
any other remedy, and Buyer assigns to Tipton Environmental International,
Inc. all right to receive proceeds of insurance not exceeding the unpaid
balance due hereunder including any costs of collection, attorney's fees or
other costs actually incurred in connection herewith. Buyer specifically
directs any insurer to pay all proceeds directly to Tipton Environmental
International, Inc. and authorizes it to endorse any draft for proceeds. In
the event of any incurred damage to the equipment and payment of
insurance thereof, Tipton Environmental International, Inc. shall have the
option of replacing the goods or applying the proceeds on any obligation
secured hereby.
DELIVERY
Tipton Environmental International, Inc. does not in any way insure
that delivery can be made to the installation site. Buyer acknowledges that
proper delivery may require an access road to and from the job site which is
capable of supporting trucks loaded to seventy-five thousand (75,000)
pounds and with a fourteen (14) foot height clearance, and that Buyer shall
be solely responsible for providing access to the job site. Buyer shall bear
all risk of loss arising fromihe delivery of the goods to the job site.
BACKCHARGES
Buyer specifically agrees that Tipton Environmental International,
Inc. will not be responsible for any 'backcharges" or other costs and
expenses unless and until Buyer first obtains written approval from Tipton
Environmental International, Inc. for such hackcharges, costs or expenses.
EXCLUSIVE STATEMENT
This writing contains the full, final, and exclusive statement of the
contract between Buyer and Tipton Environmental International, and no
agreement or warranty, except as contained herein, shall be binding on
Tipton Environmental International, Inc. The terms and conditions set forth
herein may not be modified, supplemented, or waived by parol evidence,
Buyers purchase order, course of dealing or in any other way, except where
made in writing and signed by Buyer and the President of Tipton
Environmental International, Inc.f

Package Style
Wastewater
Treatment Systems
Tyson Construction Company
Country Wood Facility
Union County, North Carolina
Reference Number: 96-128
Apri17, 1997
Permit No. NC0065684
McCall Brothers, Inc.
6700 Brookkshire Blvd
Charolette, North Carolina
MCA96128:Doc
Tipton Environmental International, Inc.
Park 50 Technical Center - 2002-G Ford Circle
Milford, Ohio 45150

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
TIPTON ENVIRONMENTAL INTERNATIONAL, INC.
PACKAGED BIOLOGICAL WASTEWATER TREATMENT
SYSTEM EQUIPMENT SPECIFICATIONS
Wastewater Treatment System
Prefabricated Steel Construction
/'
1.0 GENERAL
1.1 The contractor shall furnish and install one package biological wastewater treatment
system, complete and ready for operation in accordance with the plans and specifications
stated herein. The treatment system shall be a TEII Model TE11-1600-C package
prefabricated steel construction as manufactured by Tipton Environmental International,
Inc. Milford, Ohio USA. The wastewater treatment system shall be known as the activated
sludge type, specifically known as 'Extended Aeration". The _unit shall be designed for
treating a total flow of 160,000 gallons per day with the influent characteristics as
described in section 2.1 below. The system shall be complete with all necessary tank
vessels, component equipment necessary for efficient and proper plant operation.
1.2 The package system shall be factory prefabricated and assembled, so far as possible, taking
into consideration shipping and erection limitations. In addition all internal tank piping and
wiring shall be supplied and ended at the appropriate joint. All vessel surfaces shall be
factory painted as described below.
1.3 OTHER SERVICES AND EQUIPMENT
1.31 The field contractor shall perform the actual installation of the TEII wastewater
treatment system. The following is a brief description of the field contractors
responsibilities:
A. An adequate access road to the plant site shall be provided to enable the
lowboy truck into the project site and off loaded.
B. Provide facilities and equipment for off loading and setting of the
wastewater treatment system onto its foundation pad, which has been
provided by the field contractor. Anchoring facilities to be positioned in
the foundation pad as defined by the contract drawings.
C. Once the plant has been set into position, it shall be reconnect including
when required field welding and re -assembly of the piping and wiring
which may have been disconnected at the factory for shipping purposes.
D. The package system shall be delivered to the project site with a majority
of the component equipment installed in position. Do to shipping
restrictions some of the ancillary equipment such as the blower motor
units and the electrical control console, handrails and gratings. The field
contractor to be responsible for assembling these items into their position.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
E. All site utilities to the system shall be tied -in to the system. The electrical
power requirements at the main power block or main circuit breaker shall
be 230 volts, 3 phase, 60 Hz., amps. Each subpanel to be also connected
to the main power by the field contractor.
F. The foundation pad for setting the system on to be furnished by the field
contractor.
G. To prevent flotation of the system once set into position the system to be
filled with water prior to backflling and after the drain plugs have been
installed.
�3. Prior to backfilling the magnesium anode packages to be set into position
and the wire lead from the anode package to be connected to the
connection points on the tank vessel.
I. Backfll, finish grade and placement of gravel around the outside
perimeter of the system.
2.0 SYSTEM DESIGN PARAMETERS
2.1 Influent Characteristics The following are the influent characteristics of the specified
system:
A.
B.
C.
D.
E.
F.
G.
H.
Maximum daily flow
Peak hourly flow rate
5 day BOD
Suspended Solids
160,000 gallon per day
2.5 times the daily flow rate
210 PPM
210 PPM
Water Temperature Range 98 to 75 degrees F
Elevation from sea level 500 feet
Air temperature range 90 to 32 degrees F
pH Range 7 to 8
2.2 The TEII system shall be capable of treating 160,000 gallons per day of crude raw domestic
wastewater.
2.3 The organic strength shall be 210 ppm 5 day BOD and 210 ppm suspended solids. No
substances shall be placed in the system in quantities which are not biodegradable or toxic
to the biological organisms. The system shall be designed to handle the average daily flows
fluctuation over a range of 50% to 100% of the design flow with the peak flow rate not to
exceed 250% of the average design flow.
3.0 VESSEL TANK CONSTRUCTION
3.1 All tank vessels shall be fabricated of one-fourth inch structural grade steel plated,( ASTM
A-36) joined by arc welding with fillets of adequate section for the joint involved. All walls
shall be continuous and watertight and shall be supported by structural reinforcing members
where required. fabrication and erection shall conform to the appropriate requirements of
"AISC Specifications of Buildings". Connection shall conform to the requirements of the
American Welding Society's Code and shall develop the full strength of the member.
Aeration tank will have reinforcing members as required. All other areas such as the floor,
end walls and internal bulkheads to be adequately reinforced.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
3.2 All piping and valving shall be provided constructed of a minimum of schedule 40 steel
pipe. The painting of this pipe and valving to be as defined in section below:
3.3 The TEII package wastewater treatment system shall be transported to the job site on
Lowboy truck in eight major section. The contractor shall be responsible for field assembly,
including bolting or field welding where required.
4.0 PAINTING AND CORROSION CONTROL
/1
4.1 All tank vessel surfaces to be painted shall be properly prepared in a workmanlike manner
to obtain a smooth, clean, and dry surface. All rust, metal fragments, dust, weld slag, and
mill scale as well as extraneous matter, shall be removed by means of cleaning by wire
brushing or whatever means necessary.
4.2 All interior tank vessel surfaces below the main box beam shall be painted with Kopper's
Superservice coal tar paint, or equal to a minimum total dry film thickness of 8-10 mils.
4.3 All exterior tank vessel surfaces including the box beam shall be painted with Kopper's
Superservice coal tar paint, or equal to a minimum total dry film thickness of 8 -I0 mils.
4.4 All steel piping & valving shall be painted with Kopper's Superservice coal tar paint, or
equal to a minimum total dry film thickness of 8 - 10 mils.
4.5 Cathodic corrosion protection shall be provided using ten magnesium anodes, weighing_ 9
pounds each. These shall be buried by the contractor adjacent to the tank sides and
provided with good electrical, contact with the tank. The anodes shall come packed in its
own low resistant bag filled with material for moisture control. The copper lead wire
brazed to the core and insulated with coal tar at that point. The anodes shall be attached to
the tank vessel at the connection provided near the top of the tank. The connection wiII also
be coated with a coal tar insulation.. The anodes shall be located at least 5 feet from the
tank structure and be at least 5 feet deep. Each of the anodes shall be located at the
position shown on the drawing. Each anode is to be then doused with 5 gallons of water
prior to backfilling.
5.0 FOUNDATION
5.1 A poured foundation pad shall be constructed conforming to the project specifications for
level and flatness as specified by the manufacturer on the foundation pad drawing.
Anchoring tabs shall be provided attached to the tank so the field contractor can attach the
anchors mounted in the pad to these tabs.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM BODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
EQUIPMENT SECTION
EQUIPMENT SECTION
//
DIVISION 1- . FLOW EQUALIZATION SYSTEM
To control the peak hourly flow rates entering the wastewater treatment system a surge
control system shall be provided. Tlie surge control system shall consist of a prefab steel
tank constructed in accordance with the contract drawings complete with dual surge
pumps, liquid level control system, electrical controls, air blower, course air diffuser with
air manifold.
The following equipment shall be provided by Tipton Environmental for the flow
equalization basin:
(A)
(B)
(C)
(D)
(E)
(G)
(I)
One
One
Four
Two
24
One
One
Two
One
Air Blower Unit
Electrical Control Panel Model CP-4
Liquid Level Sensors
SIide rail Systems for surge pumps
Course Air Diffusers with drop assemblies complete with air diffusers
Blower Motor Unit Model B-3
Fiberglass Housing
sewage surge Pumps P-3, P-4,
40,000 gallon surge tank
D 1.1 AIR SUPPLY FOR SURGE TANK (EQUALIZATION TANK)
For supplying the air requirements of the Flow equalization System control system, one (1)
Model BF-100-R36 Blower Motor Unit shall be provided and shall be item BM-3, and sha
be furnished and installed at the location shown on the drawings.
The blower motor unit shall be a Model BF-150-R36 shall be furnished for supplying
all the air requirements needed for the flow equalization Basin. The unit shall be capable
of delivering 150 SCFM at an operating pressure of 5 psi.
The blower shall be of the positive displacement type and shall manufactured by
Roots Division of Dresser Industries, Inc., ConnorsviIle, Indiana or equal Sutorbilt
Blower Division Fullen Company, Compton, California; or approval equal. The
model number of the blower will be URAI-36 and equipped with a 2.5 " discharge..
The motor shall be 5 Hp for operation on 230 volt, 3 Phase, 60 Cycle Service,
1800 RPM. It shall be of the open drip proof type.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
1'hone: 513.248.4067 Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCaIl Brothers , Sales Agent
Apri17, 1997
Permit No. NC0065684
The blower shall be mounted on a fiberglass base. The base shall be designed to
support the blower and motor unit. Furthermore, the base shall have a ivory
finish.
i
The blower shall be connected to the motor by means of a "V" belt drive unit.
The "V" belt drive unit shall be designed for easy adjustment. The "V" belt drive
will enable speed adjustment of the blower unit in those applications where flow
varies. The motor will be furnished with an adjustable motor mounting base.
The blower shall be fitted with an air inlet filter type noise silencer. For
connecting to -the air manifold, the blower shall be fitted with a flexible rubber
hose coupling with stainless steel clamps.
The blower and motor shall be enclosed with a fiberglass weatherproof
enclosure. The weatherproof hood shall be designed for easy access to service the
blower, motor, filter, or "V" belt drive unit. It shall be equipped with a lifting
handle and locking facilities. All enclosure surfaces shall be properly prepared in
a neat manner to obtain a smooth, clean dry surface. The enclosure shall have a
ivory finish.
Each blower motor unit shall be mounted on four (4) vibration pad dampers
tagged VP-1. This will help reduce blower vibration and noise
transmission. For purposes of determining the blower performance, and/or
diffuser condition, a pressure relief valve and pressure gauge .
These items shall be shipped Ioose for field installation in mounting in the air manifold of
the surge tank .
D1.2 ELECTRICAL CONTROL CONSOLE SGCP
An electrical control center Model SGCP shall be installed within a NEMA 4 steel
Electrical weatherproof enclosure complete with wall mounting facilities .
The electrical control center shall control the operation of the following
equipment:
A)
B)
C)
D)
Blower Motor Unit B-3
Surge Pump No. 1 P-3
Surge Pump No. 2 P-4
Liquid level sensors
Surge Blower Motor Unit - The surge blower unit operation shall be controlled by th liquid
level condition of the flow equalization basin. The blower shall turn on when the on liquid
level sensor side is activated and off when the low level sensor is reached.
Surge Tank Pumps Control - The surge pumps shall operate on a duplex pwnp alternator
operation I mode where as pump one will operate alternately with pump no 1 and 2 on
cycles. The pump operation shall be controlled by four (4) encapsulated mercury float
switches each individually adjustable for the following:
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
1
A)
B)
C)
D)
All Pumps off & Blower Off
Lead Pump on Blower On
Lag Pump on
High Level Alarm
The surge pumps shall operate on a lead-Iag with the two pumps alternating. If the liquid
level reaches lag pump on level, both pumps shall operate. If the liquid level reaches the
high water level, the alarm will be activated.
Alt wiring, terminal blocks, supports and accessories required for the operations of the
control panel shall be provided in compliance with the National Electric Code.
D I.3 Flow Equalization Pumps Tagged P-3, P-4,
The surge pumps shall be of the Goulds type. Each pump shall be a Model 3887
as manufactured by The Goulds Pump Company, Seneca Falls , New York . The pump
shall have a capacity of 104 GPM @ 14 feet of TDH. The puinp shall have a 1/2
horsepower motor which will operate on 230/460 volt, 3 phase, 60 hz.
Each surge pump shall be supplied with a 2 inch discharge. In addition to the pump
each pump shall be furnished with a slide rail assembly.
6.0 INLET CONNECTION
6.1 An influent connection to the TEII wastewater system shall be provided. It shall consist of
one 8 diameter flanged pipe. The inlet shall be located at the end wall of the surge
chamber..
7.0 INLET SUBMERGED BAR SCREEN
7.1 A partially submerged inlet bar screen shall be provided at the influent port at the surge
tank, its purpose is to remove any unusually large solids from the incoming crude sewage
flow rate. The bar screen shall be fabricated from one-half inch diameter bars spaced one -
inch apart and arranged as shown on the drawings. The bars shall be sloped to permit easy
cleaning of accumulating debris. A drying deck shall be furnished for drying this debris.
8.0 Aeration Chamber
8.1 There shall be supplied, an aeration chamber to work in conjunction with the clarifier
chamber..
The aeration chamber shall conform to the following specifications:
8.2 The aeration chamber shall be of sufficient capacity to provide a minimum of 24 hours
retention of the average daily flow, with a minimum chamber volume of 160,000 gallons.
The vessel shall be so shaped on each side to prevent sludge accumulation, to enhance the
rotation of the vessel contents, and to scum and froth accumulation. To insure maximum
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM GODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
retention and eliminate short circuiting of minuscule sewage particles, the aeration chamber
shall be constructed with course air diffusers, placed longitudinally along one side of the
chamber so as to, in conjunction with flow control baffles, enhance the spiral rotation of the
chamber contents. To ensure adequate circulation velocity, the proportion of the chamber
width to depth, in the direction of rotation, shall not exceed 1.33 to 1. The velocity of
rotation shall be sufficient to scour the bottom and prevent sludge filleting as well as to
prevent the escape to the surface of minuscule air diffusion bubbles and by so causing their
entrapment to provide maximum oxygenation efficiency.
/`
8.3 An air distribution manifold shall be installed longitudinally along the centerline of the
aeration tank with diffuser drop assemblies connected thereto. This manifold shall run
along the centerline of the aeration chamber with the air manifold approximately 2 feet off
the centerline and shall be designed to create a bank of air to supply the air needs of the
system. In addition to the air diffuser drop system a air supply shall be furnished to the
other ancillary equipment such as the airlift pumps, and scum skimmer to draw from this
bank of air.
8.4 Each diffuser drop assembly shall be equipped with an air regulating and/or shutoff valve, a
disconnecting union and a diffuser bar with non -clog course air diffuser nozzles mounted
on the tee bar. The air flow per diffuser shall range from 1 to 5 CFM. This minimum air
velocity shall be maintained to insure sufficient velocity for self-cleaning. The diffusers
shall be parallel to and near the base of the vessel centerline and at an elevation which will
provide the optimum diffusion and mixing of the vessel contents. The oxygen transfer
capacity of each diffuser shall be such that an adequate supply of oxygen will be maintained
in the aeration chamber to meet treatment requirements of the design sewage load. The
course air diffuser shall be on the air check diaphragm type constructed with a diaphragm
mounted on top of the diffuser body. The course air diffuser body consists of twenty, 3/I6"
diameter air discharge holes evenly distributed around the diffuser disk. The diffuser will
be supplied with standard male pipe thread connections.
9.0 Clarifier Chamber
9.1 There shall be furnished a clarifier chamber to work in conjunction with the aeration
chamber of that system. The clarifier shall conform to the following specifications:
9.2 The clarifier chamber shall be of such size as to provide a minimum of four (4) hours
retention, based upon the same design flow rate governing the aeration chamber, and shall
have proper baffling to prevent short circuiting and to provide maximum uniform solids
settling area. The clarifier shall be of the mechanical sludge collection type with a
diameter of 24 feet. It shall be equipped with sludge collection equipment to scrape the
settled sludge from the floor of the clarifier to the center well where it is picked up by the
airlift sludge return pump. Settled sludge shall be returned from the clarifier sludge well
to the aeration chamber by the positive sludge return systems, consisting of airlift pump.
The clarifier effluent shall pass over the edge of the baffled adjustable effluent weir into the
effluent trough and then, out the chamber. The weir plate will be constructed of 1/8"
galvanized steel or PVC sheet, and will be gasketed with 114" x 1" neoprene strips.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEHH Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
9.3 The outlet of the aeration chamber and the inlet of the clarifier shall be a 10 inch flanged
fitting
10.0 Airlift Sludge Recirculation System
10.1 Installed within the clarifier chamber for returning the settled sludge consisting of a
positive sludge recirculation system. It consists of one, 6 " diameter airlift sludge return
assembly, meeting the following specifications: The airlift pump system shall have the
recirculation capacity ranging from 0% to 150% of the design flow. The air Iine supplying
air to the pump shall be equipped with a needle valve varying the capacity of the pump. The
airlift pump shall be firmly supported and shall be equipped with a brass clean -out plug to
allow for easy cleaning and maintenance.
11.0 Airlift Scum Recirculation System
12.0
Installed within the clarifier chamber for controlling, and returning to floatables and scum
is a positive scum and skimming recirculation system. It shall consist of one, 3 diameter
airlift skimming device(s) meeting the following specifications: `The skimming device shall
be of the positive airlift pump type, located in . a position to skim and return floating
material to the aeration chamber. The air line supplying air to the skimming device shall
be equipped with a needle valve to regulate the rate of return. The scum intake shall be
equipped with an adjustable assembly which will enable exact positioning of the skimmer at
water level without placing a hand under the water. The discharger port shall be sloped to
enable the operator to determine the flow rate.
Air Supply System
12.1 For supplying the air requirements of the TEII wastewater treatment system, two, model
URAI-59 shall be furnished and installed at the location shown on the drawings. Each
blower motor unit shall have the capacity of supplying 100% of the wastewater air
requirements. Each unit shall be completely factory built and tested before shipping.
12.2 The blower motor units Model B-750-R59 shall be furnished for supplying all the air
requirements needed for the Swan wastewater treatment system. The units shall be capable
of delivering 750 CFM at an operating pressure of 5 psi .
12.3 The blower shall be of the positive displacement type and shall be manufactured by Roots
Division of Dresser Industries, Inc., Connorsville, Indiana or equal Sutorbilt Blower
Division FulIen Company, Compton, California; or approved equal. The model number of
the blower will be URAI-59.
12.4 The motor shall be 30 HP for operation on 230 Volt, three Phase, 60 Cycle Service, 1800
RPM. It shall be of the open drip proof type.
12.5 The blower shall be mounted on a fiberglass base. The base shall be designed to support the
blower and motor unit. Furthermore, the base shall have a Iight beige finish.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCaII Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
12.6 The blower shall be connected to the motor by means of a "V" belt drive unit. The "V" belt
drive unit shall be designed for easy adjustment. The "V" belt drive will enable speed
adjustment of the blower unit in those applications where flow varies. The motor will be
furnished with an adjustable motor mounting base.
12.7 Each blower shall be fitted with an air inlet filter type noise silencer: For connecting to the
air manifold, the blower shall be fitted with a flexible rubber hose coupling with stainless
steel clamps.
12.8 Each blower shall and motor shall be enclosed with a fiberglass weatherproof enclosure.
The weatherproof hood shall be designed for easy access to service the blower, motor, filter,
or "V' belt drive unit. It shall be equipped with a lifting handle and locking facilities. All
enclosure surfaces shall be properly prepared in a neat manner to obtain a smooth, clean dry
surface. The enclosure shall have a light beige finish.
12.9 Each blower motor unit shall be mounted on vibration pad dampers. This will help reduce
blower vibration and noise transmission. For purposes of determining the blower
performance, and/or diffuser condition, a pressure relief valve and pressure gauge shall be
mounted in the air manifold.
13.0 Electrical Control Console
13.1 An electrical control center shall be installed within a NEMA 4 weatherproof enclosure
complete with a mounting pedestal or legs and located as shown on the plan drawings.
13.2 The electrical control center shall control the operation of all the auxiliary component
equipment requiring electrical power. The blower motor unit operation time will be
intermittent and as controlled by the blower timer. The operation time shall be controlled
by the plant operator. The necessary selector switches shall be provided to allow either
automatic or manual operation of the auxiliary equipment.
13.3 The enclosure shaII be equal to a NEMA type 4 The electrical controls shall consist of
magnetic starters, timers, and selector switches necessary. All electrical equipment and
circuitry shall be protected by properly sized circuit breakers or fuses.
13.4 MI wire and conduit required between the control panel and the electrical power service
shall be furnished by and installed by the field controller. Wiring and conduit between the
control panel and plant equipment shall be furnished by the manufacturer of the Swan
system. The electrical control system shall be detached for shipping purposes. The main
power supply shall be 230 Volt, 3 Phase, 60 Cycle, with a control circuit of 110 Volt,
single , Phase, 60 Cycle.
13.5 The control console shall be a Model CP-1 and shall be completely factory assembled and
tested prior to shipment.
13.6 Controls shall be mounted to a removable sub -panel within the enclosure and shall be wired
and spaced in accordance with the latest National Electric Code.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM BODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Saks Agent
Apri17, 1997
Permit No. NC0065684
14.0
E
13.7 The 24 hour, 7-day time clock shall be capable of being programmed to control the blower
run cycle and to adjust botli the start set point and the blower run time. The clock shall also
include a skip -a -day feature wlich will allow. a separate program for weekends (when
required). The clock shall be by Paragon, Model #1015.
1
Service Walkway
13.8 All wiring conductors within the control console shall be UL. type MTW, stranded #14
AWG minimum, rated at 600 volts. Power wiring shall be color coded per National
Electric Code. Control wiring shall be numbered on each end with a permanent heat -
shrinkable sleeving made of flexible, irradiated, flame-retardant polyolefin.
14.1 A service walkway shall be provided for the service area only to service the plant
equipment and shall be approximately 200 square feet. Grating panels shall consist of one-
piece skid resistant steel plate. All grating panels shall be constructed of 18 gauge,
galvanized sheet steel with a maximum yield strength of 37,000 psi. Each grating panel
has a standard 9-inch surface width, and a 2 I/2-inch rib depth. Furthermore, each panel
shall be so supported as to have a safe uniform load carrying capacity of 50 pounds per
square foot. Refer to the attached load bearing chart for grating capacity.
14.1 A service handrail shall be provided for the service area only to service the plant
equipment as shown on the plans and shall be approximately 250 feet.
DIVISION 4 - TERTIARY FILTER SYSTEM
15.0 General
The contractor shall furnish and install one prefabricated wastewater treatment system,
complete and ready for operation in accordance with the plans and specifications stated
herein and furnished as an integral section of the secondary treatment system. The
treatment plant shall be a TEII Model HF-160-C prefabricated steel package unit as
manufactured by Tipton Environmental. The wastewater treatment system is of the tertiary
treatment type, specifically known as rapid sand filter, designed for treating a total of
160,000 gallons per day of 42 PPM-BODS domestic sewage based on composite sewage
samples of the average daily flow. The complete system includes all necessary equipment
for efficient plant operation.
The system will be factory assembled, so far as possible, with all piping and controls. All
surfaces shall be factory painted.
16.0 PROCESS AND OPERATING INSTRUCTIONS
Influent Characteristics
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow=-160,000 GPD @ 250 PPM BODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April7, 1997
Permit No. NC0065684
The system is capable of treating 160,000 gallons per day of secondary treat domestic
sewage, having an organic strength of 42 PPM 5 day BOD, and 42 PPM suspended solids.
No substances will be introduced in quantities which are toxic to biological organisms.
The system is designed to handle average daily flow of the effluent from plant .
17.0 INLET CONNECTION
The influent connection shall be one 8"' standard diameter flanged fitting Iocated at the
inlet port connection.
/'
18.0 Filtrate Holding Chamber
Four (4) filtrate holding chambers, each located above the filter media shall be of sufficient
capacity and surface area to entrap and hold floating, suspended and settleable solids until
such time these solids are returned to the wastewater treatment system during filter media
backwash by means of the mudwell and return pumps. The volume of each chamber shall
not be less than 300 gallons. Each chamber shall have a minimum water depth of 24 inches
above filter media to prevent freezing of filter media.
Means shall be provided in each chamber for manual dumping of the suspended solids into
the mudwell. An access and inspection plate 'shall be provided in the sidewall filtrate
holding chamber to allow inspection and maintenance of the filter bed.
19.0 Filter Cells
There shall be furnished four(4) filter cells for filtering the flow of the Tertiary Filter
System. Each cell shall have not less than 26 square feet of filter surface area. The filter
ceIIs shall be located at the bottom of the filtrate holding chamber. Filtrate shall percolate
through the filter bed and filter nozzles to the false bottom. From the false bottom, filtered
water shall flow to the clear well chamber. Each filter shall be accessible for inspection and
maintenance of the filter media. The filter media shall be shown on the plans and as herein
after specified.
20.0 Filter Media
Filter media shall be furnished in sealed bags not to exceed 100 pounds each. the filter
media shall be packed in a pallet and shipped to the plant site with the filter system. The
contractor shall position the filter media in the tertiary filter as shown on the plans and in
the field. The filter media bed shall consist of eight inches (8") of sand, 0.80 to 1.20 MM
effective size with a uniform coefficient of 1.4 through 1.7 and twelve inches (12") of
anthracite I.08 MM effective size with a uniform coefficient of 1.42.
21.0 Clear Weil
The clear well shall be located as shown on the plans , and shall be so designed so that the
filtrate from each of the filter cells can discharge into the clear well from the false bottom
underdrain system which is located below the media; then flow through a riser and through
the backwash pumps. The clear well shall not have less than 8333 gallons for sufficient
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM GODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
volume for backwashing. An overflow weir shall be provided for gravity effluent discharge
to the chlorine contact tank.
22.0 Backwash Pumps
23.0
Four(4) backwash pumps Model No. 388$D4 shall be furnished and installed in the clear
well so as to automatically backwash each filter cell through the water distribution manifold
when required to maintain filtration conditions. Each pump shall be designed to provide
one 5 minute backwash at a rate of 15 gallons per minute per square feet, and shall be rated
at 420 GPM at 20 TDH. The operating horsepower shall be 5 HP, 230 Volt, 60 Hz, 3
phase. Both pumps shall be manufactured by Peabody -Barnes Pump Company,Mansfield,
OH; or by Gould's Pump Inc., Seneca Falls, New York; or approved equal. The backwash
rate shall be a minimum of 15 GPM per square foot of filter surface area.
Mud Well Chamber
A mudwell chamber of the tertiary filter system shall be of such size as to handle the total
volume of the filtrate backwash. The Volume of this chamber shall not be less than 8333
gallons. A duplex set of pumps Model No. 3887 shall be provided and installed in the mud
well chamber for returning the filtrate backwash liquid to the secondary wastewater
treatment. The capacity for each pump shall be 100 GPM at 15 TDH. The operating
horsepower shalt be 3/4 HP, 230 Volt, 60 Cycles, 3 Phase. The pumps shall be
manufactured by Peabody -Barnes Pump Company, Mansfield, Ohio; or by Tait Inc.,
Dayton, Ohio; or by Gould's Pumps, Inc., Seneca Falls, New York; or approved equal. A
throttling facility shall be provided on the pump manifold to minimize hydraulic return to
the flow equalization tank of the secondary treatment system.
24.0 AIR SUPPLY BLOWER MOTOR UNITS
Dual positive displacement blower motor units shall be provided and shall be a Model BF-
50-R24, Tagged BM-4 shall be supplied, capable of providing the required CFM for air
scouring. The blower shall be Iocated on the plant as shown on the plans.
The blower shall be capable of delivering 50 CFM when operating at 5 PSI. The blower
shall be manufactured by Roots Division of Dresser Industries, Inc., Connorsville, Indiana;
or Sutorbilt blower, Fuller Company, Compton, California; or approved equal. The model
number of the blower will be URAI 24.
The motor shall be 2 Horsepower for operation on 230 Volt 3 Phase 60 Cycle service 1750
RPM. It shall be of the ODP type.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD ® 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , SaIes Agent
April 7, 1997
Permit No. NC0065684
Each blower shall be mounted on a fiberglass. The base structure shall be adequately
reinforced to support the blower and motor unit.
For easy adjustment of the "V" belt drive connection between the blower and motor, the
motor will be furnished with an adjustable motor mounting base.
The blower shall be fitted with a dry type filter silencer at the air intake. Furthermore, the
blower discharge shall be fitted with a flexible rubber discharge coupling.
The blower shall be enclosed within a fiberglass weatherproof enclosure. The fiberglass
hood is designed for easy access to service the unit. It shall be equipped with a lifting
handle and locking facilities. All enclosure surfaces shall be properly prepared in a neat
manner to obtain a smooth, clean and dry surface. The enclosure shall be Ivory in color.
To help reduce blower vibration and noise, the blower motor enclosure shall be mounted on
vibration dampners. For purposes of determining the blower performance, and/or diffuser
condition, a pressure relief valve and pressure gauge shall be mounted in the air manifold.
Facilities for air scouring the filter media prior to backwash `shall be provided. An air
distribution system shall be provided under the filter media.
25.0 ELECTRICAL CONTROL CONSOLE TTCP
An electrical control center shall be installed within a Nema 4 electrical weatherproof
enclosure and shall be provided for mounting as indicated on the plans.
26.0
When the resistance of the flow through the filter media causes the water level in the filtrate
collection chamber to rise to a predetermined liquid level, a liquid level switch shall initiate
the automatic air scour cycle. This cycle is controlled by a timer in the control panel. The
automatic program cycle will allow air scouring until backwash is required.
The enclosure shall be NEMA type 4. The electrical controls shall consist of IEC starters,
timers, and switches necessary to automatically control all electrical devices and/or motors
on the tertiary treatment system. The blower motor shall be controlled by H-O-A selector
switches and lEC starters in conjunction with the program timer. All electrical equipment
and circuitry shall be protected by properly sized circuit breakers or fuses.
All wire and conduit required between the control panel and electrical power service shall
be furnished and installed by the purchaser. Wiring and conduit between the control panel
and plant equipment shall be furnished by the manufacturer of the treatment plant. The
panel may be detached for shipping. The main power supply shall be 230 Volt, 3 Phase, 60
Cycle, with a control circuit of 120 Volt, 1 Phase, 60 Cycle.
FILTER BY-PASS
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Olio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPMBOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCaII Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
A by-pass shall be supplied to allow manual by-pass of the filter cells. The by-pass shall
consist of the necessary flow troughs, flow vanes, etc., to direct either to the filter cells or to
the tertiary outlet port.
The flow distribution trough shall be so designed as to divert the incoming flow
proportionally to each filtrate collection chamber. This shall be done by means of diversion
vanes.
27.0 CHLORINE CONTACT CHAMBER
A baffle type chlorine contact chamber shall be provided, constructed as an integral part of
the tertiary treatment system. The contact chamber shall be installed immediately following
the cleanvell. The tank shall be sized for a capacity of 3333 gallons based on 30 minute
retention of the design flow rate. Baffles shall be provided to prevent short circuiting and
shall be designed to keep floating material from leaving the chamber.
Sufficient flow baffles will be supplied to assure proper mixing of the chlorine solution with
the system effluent. Three tablet type chlorinator shall be supplied complete with mounting
facilities. The tablet feeder shall be a Sanuril Model 1000 or approved equal
28.0 DE -CHLORINE CONTACT CHAMBER
29.0
30.0
A de -chlorine contact chamber shall be provided, constructed as an integral part of the
tertiary treatment system. The de -contact chamber shall be installed immediately following
the chlorine contact tank. The tank shall be sized for a capacity of 3333 gallons based on
30 minute retention of the design flow rate.
An effluent weir trough shall be provide for measuring the flow which shall be from
leaving the chamber. The weir shall be a 90 degree v-notch weir.
Mounting falicilies shall be provided for the effluent flow meter.
Three tablet type de -chlorinator shall be supplied complete with mounting facilities. The
tablet feeder shall be a Sanuril Model 1000 or approved equal
FLOW METER
A flow meter shall be supplied for measuring the effluent flow of the wastewater treatment
system. The flow meter shall be a Model 61-R , 230 volt, 1 phase unit complete with
recorded and totalizer.
Effluent Connection
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow =160,000 GPD @ 250 PPM RODS
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
The effluent connection of the tertiary treatment system shall be located as shown on the
plans and shall consist of one 8" diameter standard flanged pipe at the Iocation shown.
Division 8 Field Service
31.0 FIELD ASSEMBLY
The shipment of the "TEII" wastewater treatment system is done by special lowboy trucks
directly to the job site. The equipment necessary to unload the plant and set it on the
foundation pad must be furnished by the field contractor. The access road into the project
site to handle these lowboy trucks will be the responsibility of the field contractor. The
approximate weight of the system is 125,000 pounds Each secondary treatment section is
35,000 pounds, and the tertiary is 45,000 pounds plus media.
The TEII package steel treatment systems shall be completely assembled units and are
shipped as a unit where shipping height limitations permit. Portion of the equipment must
be removed to meet the shipping height limitations. This equipment will be packaged
separately at the factory for reassembly at the field. The equipment should be field
assembled and instaIIed by the field contractor.
32.0 Effluent Connection
33.0
34.0
32.1 The effluent connection of the "TEII" wastewater treatment system shall be located as
shown on the plans and shall consist of one, 6 inch diameter standard flanged pipe .
Field Assembly
33.1 The shipment of the "TEII" wastewater treatment system is done by special lowboy trucks
directly to the job site. The equipment necessary to unload the plant and set it on the
foundation pad must be furnished by the field contractor. The access road into the project
site to handle these Iowboy trucks will be the responsibility of the field contractor.
33.2 The TEII package steel treatment systems shall be completely assembled units and are
shipped as a unit where shipping height limitations permit. Portion of the equipment must
be removed to meet the shipping height limitations. This equipment will be packaged
separately at the factory for reassembly at the field. The equipment and tankage should be
field assembled and installed by the field contractor.
Filed Service
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TEII Systems Specifications Sheet
Design Flow = 160,000 GPD @ 250 PPM BOD5
Tyson Project: Country Wood Facility
Union County N.C.
Project Number 96-128
McCall Brothers , Sales Agent
April 7, 1997
Permit No. NC0065684
34.1 At the time the wastewater treatment system is filled with water or sewage, all power •
connections have been completed, and all equipment is approved for service, the contractor
shall provide the services of a representative of the manufacturer who shall instruct the
'owner's representative in the proper operation and maintenance of the wastewater treatment
system including instructions in conducting all required operational tests. The
manufacturer's representative shall furnish at this time, a service manual on the equipment
installed within the wastewater treatment system. The manufacturer's representative shall
for a period of one (1) year after delivery is made, make periodic inspections of the system,
advising the owner's representative of any operational difficulties.
35.0 Guarantee
35.1 The manufacturer of the wastewater treatment system shall guarantee for one (I) year from
the date of shipment that the vessel and all component equipment shall be free from
defective materials and workmanship. the manufacturer shall furnish replacement parts for
any component considered in the opinion of the manufacturer to be defective, whether of his
other manufacturer during this guarantee period.
Tipton Environmental International Inc. 2002 Ford Circle -Suite G Milford, Ohio 45150
Phone: [phone] Fax: [phone]

TECHNICAL DATA SHEET
Packaged Air Blower
Motor Unit
Sleek, All -Season
Weatherproof Design
Keeps Your Blower
Motor Equipment
Operating for Years!
So Tough, So Well Made, This packaged blower motor unit is protected by' •
a reinforced marine grade fiberglass constructed hood and mounting base.
With this type of construction the unit will last for years. The reinforced
hood, which covers the blower base, is attached to the base by a corrosion -
resistant hinge. Locking facilities for securing the hood from access is
also furnished with this assembly.
Remarkably Adaptable
You can mount the Universal RAI blower
upside down or right side up, with vertical
or horizontal flow, and with the drive shaft
rotating in either direction. With the
different blower frame to choose from, you
can have the perfect blower to fit you
application with little or no modification.
Low Cost
The blower, motor, filter and silencers are
designed with the Iatest engineering
technology and built using the most modern
manufacturing processes. This results in
cost savings we can pass along to you.

TEC 'ICAO DATA SHEET
ROOTS DIVISION
DRESSFR I NSiJS T E a
CONNF'RV i F L —
FRINTED IN U
vi„M1MUM FRE.,_,,._S.°M R Su - 7 PS I
MAXIMUM SrS_O _

ROOTS DIVISION
DRESSER INDUSTFIE
CONNERSV I LELE , I .
PRINTED IN U.S.A.
PERFORM .NCE BASED ON INLET
SIR, ,AT 4. i PSI (S OS F
FE.PF CF;MANCE.
G
PR,- SEv E
KAX:rMUM SPEED

TEC CA J)ATASHEET
ROOTS DIVIS:CN
DRESSER INDUSTR::
CONNERSVILLE, IN,
FRINTED IN U.S.A.
2E&FGPv;Nc2
52 UNIVR s4L RI® ELC E
,AXIMU P@Essu E Rl3E = 7 2s
MAXIMUM SPED = 2850 aFM
ON INLET

+4.

-1 ;np ,�/;
TECHNICAL DATA SHEET
AIR DIFFUSERS
DISC TEE
TEII course bubble air diffuser's mixing
function provides tremendous surface
contact of the liquid being aerated by
releasing a double shear of air. Air is
sheared as it discharges from the air
orifice of the diffuser body and again as it
crosses over the diaphragm baffle. The
TEII air diffuser has two simple parts;
the diffuser body and the flexible check
diaphragm. Both parts are molded
together to prevent separation and are
designed with special materials that
prevent plugging, resist brittleness, and
eliminate diaphragm expansion due to
chemical absorption.
1
TEII-1 3/8" 3
2 - • TEII-2
3/4" 12
DIFFUSER PRESSURE LOSS
a
GRAPH
1 I Ya..a ea_)]
? W I 1 �/4" vt
3 I I 1 1
4 <
w 1
1n V...1 a.-14
0 1
Y 2 CJ•'
——
1
I I
I I
I i
I I
1 ,
0 2 4 5 8
CF1A
10 12 14

TECHNICAL DATA SHEET
Pressure Gauge
Model Gl
Pressure Gauge
For measuring the blower motor unit pressure in the air manifold a 2" diameter pressure gauge shall be
installed at the Iocation shown on the plans.
Specifications
Dual Scale Dial: PSI and KG/cm
Black Steel Case and Rim
Plastic Crystal
Back Connection Centered: 7/8" in length
Accurate Within: 2% of full Scale
Type of Connection: 1/8"
PSI Dial Range: 0-15

TECHNICAL DATA SHEET
Water Ma7ritoriag
systems
4 DIt=isk t r f Lcapotd ; Stcvons, me
i.Q
totalizer,-
•
, • for contiuous t:aiume .•
indication -
o Choice of AC
synchronous motor
drive or Quartz
Multispeed Timer,
SOS 006A•
Page 1.4
Model 61 Total Flow Meter
,, 3✓l�, j
mew et ;l
The Stevens Model B1 Total Flow
Meter (TFM) Is designed for on -site
measuring of open channel flows.
Instruments can be furnished to
record end totalize in either English
or metric units, and can be used
with virtually any type bnJ 5128 at
weir or flume. A full-scale
measuring range may run from as
tow as 14,0O0 gallons per day
(GPDI through a 22-1i2°, V-notch
weir to as much as several hundred
million gallons per day (MGD)
through large sizes of Parshall and
other types of flumes.
The volume of liquid flowing
through a primary measuring device
is a function of the height of the
surface above a reference point.
The TFM uses a float to detect this
height and converts it into a reading
of instantaneous flow.
Stevens Reputation for
Quality
The Model BT Total Flow Meter
represents Stevens continuing
effort to provide a high -quality
product which meets customer
needs at a cost-effective price.
Model61M
Convenience
The TFM converts water level
measurement to flow data for
continuous indication {61M1 or
graphic record i6113i, and uses a
mechanical totalizer for continually
indicated volume. The unit is
housed in a compact case for
portability, and comes equipped with
a bracket for shelf or table mounting.
The seven -digit totalizer and chart
drives are powered by AC
synchronous motors or. if preferred,
by a battery -driven Quartz
Multispeed Timer.
Flexibility
A major feature of these instruments
is the ability to convert them for
other flow ranges by an easy in -field
change of flow cam and flow gears.
For infiltration studies and similar
applications the operator may use
the meter en a V-notch weir in the
morning, a Parshall flume in the
afternoon, and something else later
in the week. These portable meters
are compact, lightweight, and simple
to install, service, maintain, or
relocate.

TECHNICAL DATA SHEET
▪ .._-civr�,surlh .tiit?e. ' n
s�lr� ¢:E
d7ance•:,,�
•• ; aa,b•VAIrrtne In •,, { '
w lii•dato loggers
▪ fit a d,staie • • - i' ,1
•]ecording and •
The Model 61 M provides a visual
indication only. The indicator plate
is graduated to show instantaneous
flow rate as noted by the indicator
/pointer. A white delnn slider on the
indicator plate is positioned by the
moving pointer to. indicate peak
flow The Model 61R uses a strip
chart to provide a permanent record
of flow. Both the 61M and SIR
have a seven -digit totalizer for
indicating total volume.
Long Service life
As with all Stevens products, the
Total Flaw Meter was designed to
'assure low maintenance and long
life. All bearings are lifetime
lubricated. The instrument case is
made of high -impact ABS plastic
with stainless -steel hardware, and
has a viewing port.
Model 61 R Recorder Chart
A standard 50-foot by 4-inch strip
chart is pprinted on tracing quality
paper which has been specially
selected to minimize the effects of
humidity. Curvilinear graduations
compensate for the cartridge pen's
arc swing. There are five minor time
divisions between major divisions.
Charts are overprinted every 2, 3,
or 6 or 12 hours, depending on the
time scale. The chart has uniform
divisions for flow, and consists of
seven major and five minor
divisions.
Available times scales are 3.33 (AC
clock only), 5, 10 or 20 inches of
chart travel per day, which yields
160, 120, 60, at 30 days,
respectively, of continuous records.
Far many applications, a scale of 10
inches per day is satisfactory to
Stiltirva well Installation
SOS 006A
Page 2/4
provide a clear, easily read racier]. If
the slows fluctuate rapidly, a scale
of 20 inches per day is
recommended. Scales may be
changed easily in the field by
changing gears. If the optional
Quartz Multispecd Timer is used,
time scales are changed by switch
selection,
Strip charts can be filed in
continuous farm ar cut into a
convenient size for easy filing. Strip
charts provide an advantage over
circular charts because they can be
used to verify information provided
by the totalizer. Since "Rate x Time
Total Volume," it is easy to count
the squares in the recorded section,
or to use a planimetot to determine
total volume and cross-check the
totalizer figure.
Model 61 R Cartridge Pen
The chart pen is a disposable
cartridge type with a typical life el 3
months. Replacement frequency
depends upon the chart speed of the
recorder , and the characteristics of
the flow being recorded,
Recommended Float Size
The diameter of the recommended
float will vary between 6 inches and
14 Inches, depending on the
selected now range of the
instrument, and type of flume or
weir. laecommended sizes aro listed
in Stevens Technical Data Sheet
SOS 026-
It is important to consider the
recommended float size because its
size will determines the available
input torque to the Instrument per
unit of head change in the weir or
flume.
Scow Floar Installation

TECHNICAL DATA SHEET
Rubber Mounts for Motor Noise Reduction
KARIVUlfil
RUBBER
%f
Fasten between motor and rails or base.
Used on fans, blowers, compressors,
pumps, etc., to reduce noise. Not recon--
mended for suspended load applications.
Shpg. wt. 0.1 and 0.3 lbs.
Stock
Pad Size Screw Size No.
3/4x1" dia 1/4-20x 1/2 3CC03
3/4x2" dia • 3/8-16x11/8 3CC07
J

TECHNICAL DATA SHEET
DIMENSIONS
(All tiinx.nsinns are in inches. Du not use far corlstr,IctPar purposes.).
A. —Ali rncreGaue17Wexcept stFPsingiephase 'and 1HPs"rp phasrr-A'io".
PERFDRpr1ANGE RATINGS (gallons per mnct®)
WSO7128F WSrO12PF WSlC128HF
F W50738EiF WS10383F WS1e388HF
W50722 F WS1032r7F WS'1O32E1-1F
W50734t3P 4rd51O 18a WSuO14EEHF
SIMPLEX AND DUPLEX SYSTEMS
Simplex Ejector Systems: are used where
drain facilities are below existing sewer limes.
Also can be used for septic tank applications
where effluent must he pumped away from
tank for disposal.
WATER TEEIENDLOCtEE GRCUr%
(oOUI°S
Submersible
Sewage Pump
MODEL
3887
P E. urnp
PARTS
Ptern No. OescripPPart
MODELS
Order No,
Duplex Ejector' Systems: offer the
necessary safety required by instit
which cannot afford -an interruptio
sewage disposal systems.
SPECIFICATIONS ARE SUBJECT TO
13
OTICE. FP' N Sid IN U.S.A.

APPLICATIONS
Specifically designed for the
following uses:
• Homes
• Sewage systems
• Dewatering
• Water transfer
Anywhere waste or drainage
must be disposed of quickly,
quietly and efficiently.
SPECIFICATIONS
Pump:
• Solids handling capabilities:
2" maximum.
• Capacities: up to 180 GPM.
• Total heads: up to 49 feet
TDH.
• Discharge size: flanged —
BF or BHF units have 2' NPT
threaded companion flange
as standard. Optional 3"
NPT threaded companion
flange available and must be
ordered separately. (Order
No. Al-3),
• Mechanical seal: silicon
carbide rotary/silicon
carbide stationary, 300
series stainless steel metal
parts, BUNA-N elastomers.
• Temperature:
104°F (40°C) continuous
140°F (60°C) intermittent.
• Fasteners: 300 series
stainless steel,
• Capable of running dry
without damage to
components.
Motor:
• Single phase: 1/3-1/2 HP,
115 V or 230 V, 60 Hz,
1750 RPM; % —1 HP, 230
V, 60 Hz, 1750 RPM; 1 HP,
230 V, 60 Hz, 3500 RPM.
Built-in overload with
automatic reset.
4 Goulds Pumps, Inc.
• Three phase: —1 HP,
200/230/460 V, 60 Hz, 1750
RPM; 1 HP 200/230/460 V,
60 Hz, 3500 RPM.
Overload protection must be
provided in starter unit.
• Shaft threaded 400 series
stainless steel.
• Bearings: ball bearings —
upper and lower.
• Power cord: 20 foot
standard (optional lengths
available).
Single phase:1/ - '/ HP,
16/3 SJTO with three prong
plug„ 3/ and 1 HP, 14/3 STO
with bare leads.
Three phase: V2-1 HP 14/4
STO with bare leads.
On CSA listed models: 20
foot length SJTW or STW
are standard.
Class B insulation.
Sewage Pump
MODEL
3887
CANAWAN STANCANO ASSOCIATION
6UQ E P M
FEATURES
Impeller: Cast iron, semi -
open, non -clog with pump out
vanes for mechanical sea!
protection. Balanced for
smooth operation. Silicon
bronze impeller available as
an option.
Casing: Cast iron volute
type for maximum efficiency.
Adaptable for slide rail
systems.
Mechanical Seal: Silicon
carbide vs. silicon carbide
sealing faces, stainless steel
metal parts; BUNA-N
elastomers,
Shaft: Corrosion resistant
stainless steel. Threaded
design. Locknut on three
phase models to guard
against component damage
on accidental reverse rotation.
Motor: Fully submerged in
high grade turbine oil for
lubrication and efficient heat
transfer. Designed for
continuous`operation. All
ratings are within the working
limits of the motor.
Bearings: Upper and lower
heavy duty ball bearings
construction.
Power Cable: Severe duty
rated, oil and water resistant.
Epoxy seal on motor end
provides secondary moisture
barrier in case of outer jacket
damage and to prevent oil
wicking.
0-ring: Assures positive
sealing against contaminants
and oil leakage.
METERS FEET.
DYNAA1tC HEA➢
167
14
4
a
a
MODEL: 3887
SIZE. SOLIDS
10
17
20
CAPACITY
140
180 GPM
40 roc' 1 hr
Effective May, 1994
B3887

TECHNICAL DATA SHEET
rrhr ti .k + r^ Y � ' + Y ' i':fif �f.. �y 1:7
Goulds
Effluent and Sewage
Slide Rail Systems
3" and 4" DISCHARGE SLIDE RAIL SYSTEM
Heavy Oty cast Iron
construction.
Twin guide rails provide
positive alignment with base.
No sealing devices required
— pump weight provides
sufficient force far proper
seal.
Self cleaning design. When
pump flange engages base,
the shearing action wipes the
sealing surfaces clean.
System Components
Include:
• Base with integral cast
elbow.
• Pump adapter — guide
assembly with fasteners.
• Upper guide rail
positioning bracket.
NOTE: Guide rails and lifting
cable not furnished by Goulds.
Pump
Discharge
Size
Order Discharge Piping
Number
Pump
Model
3' A10-30
4' A10-40
4' 125lb.ANSI 388803
Flange 388804
2' Pipe Guide Rails
4' 125 PSI ANSI Flange
'i.
71 331/4' = 388804
33t' = 386803
%. ma. Hales

TECHNICAL DATA SHEET
22,
Goulds
Effluent and Sewage
Pump Disconnect
Rail System
11A,1'/a and 2" red brass
disconnect and bottom
brackets are non -sparking
and corrosion resistant. Top
bracket is vinyl -coated steel.
The 60° cut-out allows
removable half of disconnect
to be removed from the
guide rails without removing
the top bracket. System will
accept PVC, stainless
steel, or galvanized steel
guide rails.
(Not supplied by Goulds
Pumps). Pump
Discharge
Size
3" red brass disconnect is
built to satisfy the greater
demands of 3" pumps.
System accepts 1'W PVC,
stainless steel, or galvanized
steel guide rails.
(Not supplied by Goulds
Pumps).
Part
No.
i'w APD12
1'/i APD15
2' APD20
Pump
Discharge
Size
Part
No.
3' APD30

TECH=MICA
MODEL aF3887
S03 BF through U520 BFH
lubmers ble Sewage Pump
Pump Specifications
`l,to2HP
Up to 220 GPM
Maximum head to 82'
Discharge size 2"
flanged NPT
Solids: 2" maximum
motor
All motors feature ball
bearing construction,
Available in Single and
Three Phase 115, 200,
230, 460 and 575V,
All single phase models
have capacitor start motors
Materials of Construction
Cast iron
Stainless steel
a DATA SHEET
T
Features and Benefits
• All models feature silicort carbide
mechanical seal faces for superior
abrasive resistance and extra
long life.
• Cast iron, semi -open, non -clog
impeller design with pump out
vanes for mechanical seal protection.
• Rugged cast iron volute type casing
adaptable for slide rail systems.
• Corrosion -resistant stainless
steel threaded shaft,
• Designed for continuous operation.
• Optional silicon bronze impeller
available.
• Optional 3" flanged discharge
available.
• CSA listed models available,
ur Underwriters Laboratories

TECHNICAL DATA SHEET
:C=5i ' w 44
(p.ex
,• -sr
Pump Specifications
11/2 to 7'/: HP
Up to.600 GPM
Maximum head to 65'
Discharge size 3° and
4° flanged
Solids: 3" and 3'/8"
maximum
Motor
All motors feature ball
bearing construction.
Available in Single and
Three Phase 200, 230, 460,
and 575V.
Materials of Construction
Cast iron
Stainless steel
iORSN PUMP
:441
MODEL 3888E13, O4
Op
r
so
Do Ise , ]uo 25
]pp SSA '<m I 420 sac 562
dm usrn
Features and Benefits
• Cast iron, two -vane, semi -open,
non -clog impeller design with
pump out vanes for mechanical
seal protection.
• Heavy duty cast iron volute'fype
casing adaptable for slide
rail systems.
• 300 series stainless steel shaft
with keyed design.
• Dual mechanical seals.
• Optional silicon bronze impeller
available.
• CSA listed models available.
® Underwriters Laboratories

triple reduction -motorized and gearmotor
ilk CVT-
SERIES: MCVTW (WITH MOTOR)
GEAR RATIOS AVAILABLE 1000:1 THRU 180,000:1
COMPLETE TORQUE AND HP RATINGS PAGES 152-222
OVERHUNG LOAD RATINGS / PAGES 153-223
SERVICE FACTORS PAGE 230
COUPLING ADAPTERS PAGE 120
HYDRAULIC MOTOR ADAPTERS PAGE 116
TABLE OF WEIGHTS
Unit-
5
6
7
8
9
/
"10
11
12
13
14
15
Net
Weight
77
92
137
172
212
317
402
508
703
933
1300
Alloy steel slow speed shafts available. 9 Weights are without motor.
Hydraulic Motor Flanges available, see pages 116-118.
Units 5 through 15 available in "C" flange coupling type. see page 120.
CVTMW
See page 120.
Additional Series Available: Series MLT
(Triple Reduction - Drop Bearing Type)
For MLT output and intermediate stage dimensions,
see MLD page 100.
For MLT input stage dimensions, see MCVT below.
For construction purposes send for certified dimen-
sion sheets.
DIMENSIONS:
OIL LEVEL PLUGS
OIL DRAIN PLUG
FRAME, KEYWAY .
and BORE DIMENSIONS
Frame No.
56C
1457C
l4src
Al
57/a
57/e
AK
41/2
41/2
BB
3(6
316
SO
61/2
61/2
BE
K4
3<4
BF
134r2
13j3
Keyway
1/46 x 35.1
1/46 x 321
} 661
Here
.6255
.8755
Dimensions apply to speed reducer only. For motor dimension see next page.
BD
---e, L4
SPEED REDUCER DIMENSIONS (in inches)
FRAMES 56C, 143TC. 145TC.
HAVE BF HOLES OUTSIDE
Arc INDEX
--OIL LEVEL PLUG
-'OIL DRAIN PLUG
'-GREASE FITTING
H DIA.
4 HOLES
GRI ASE FITTING ---
OIL FILLER PLUG-"
INEY-
Fish
�� I` o_
Idi��l 1= r
OIL DRAIN PLUG -✓T
4 _ DIA. 7
GREASE FITTING
L3
R'3
OIL FILLER PLUG
SEE TABLE FOR INPUT SHAFT
I BORE & KEYWAY SIZE
OIL FILLER PLUG
EF DIA.
4 HOLES
Unit
C,
C2
Ca
5CVT
3
2
1.33
6CVT
314
2
1.33
7CVT
4
21/
1.33
BCVT
4.6
2 s
1.33
9CVT
5.167
24
.33
10CVT
6
3
2
11CVT
614
3
2
12CVT
7
31/4
2
13CVT
7%
334
2
14CVT
a%
4
21/4
15CVT
9
5.167
21/4
Unit
A
B
B,
b
E'
F,
F2
OHJK
L,
L2
I.
L4
0
P,
P3
R,.
Ry
Z
Slew 5pe*d Shoft
Maximum
Frame Size
W'
Si
S3
T
Keyway
SMCVT
7 a
84
34
34
3 e
4';
33‘,',
a
","a
a
6 4
431'6
8 4
67/B
813(6
64
5 a
61/4
7.08
7
9 s
14
21/4
24
21/4
% x %
56C
6MCV7
8
10
414
4
314
5 a
3 a
e
36
2fi6
71/4
41/43
9 a
67,4
946
71/4
7
' 7 e
7.58
7%
9 e
1 i
31/4
34
31/4
% x K5
56C
7MCVT
9%
10%
4 e
4%
414
5 i
4 a
a
X6
0
8°S6
5 i
10 s
813(6
10116
8 e
71/4
81/4
8.58
9
10%
14
31/4
34
33/4
34x3(6
56C
BMCVT
11%
124
54
5
5
6
5
1/4
131I'6
;/6
101/
61/4
111/4
811/46
1116
91/4,
8/
84
9.58
9.6
11 a
11/4
3%
334
31/4.
3/ x3(6
56C
9MCVT
1214
16%
7 i
51.4
534
84
64
%
13<6
34,
11 s
64
S1 4
813(6
12 a
10%
9
9%
10.08
10.167
11%
2
434
41A
4%
4 x %
56C
16MCVT
14
201/4
834
6
6
11
7 i
4
13(6
1/4
121/4
8/6
131/46
911/46
1311/46
11 a
9 4
101/4
1114
114
12 s
21/4
434
414
Ay,
i x a
145TC.1840
11MCVT
141/
22
9%
7
64
11 a
84
a
1346
3(6
1334
83(6
1376
9%
1434,
1234
10%
12
111/4
12 i
13 s
234
514
5
5
1/4 xi(6
145TC-184C
12MCVT
17 i
25
114
8
74
1234.
10
1
11,
3(6
154
934
1531.6
107/s
1531'6
141,1;
11 4
13%
13
13 4
15%
2%
5 B
5 i
5%
% x X,
i45TC - 184c
13MCVT
19
27
12
9
8
13%
104
1
146
6/6
17%
10 a
151X,
107/e
16316
16 a
13%
15
14%
13%
16 s
3
6 a
6
6
4 x %
145TC - 184C
14MCVT
22%
30
13
10
91/4
15 i
111/4
11/4
1.1/46
,
20
111/4',
1816
123/4
1713(6
18%
15
1634
154
15 s
18 i
31/4
6 q
61/4
634
%x%
145TC-184C
15MCVT
251/2
30
15
101/2
11
131/4
131/4
1/
13(6
1/4. 123
133
211/e
151/2
203(6
191/7.
161/4
;171h
18%1173/4
203(6i33/4
71/4
7 L (
7 f
% x 31.6
145TC- 184C
*Shaft diameter tolerance +.000-.001. Far construction purposes send for Certified Dimension Sheets:

triple reduction
motorized and gearmotor
MOTOR DIMENSIONS:
H.P. @
1800 RAM
1 /6
IA
V3
1/2
3/4
1
I. V2
2
Phase
Single
•
Three
Single
•
Three
Single
•
Three
Single
•
Three
Single
•
Three
i
Three
Three
Three
AG
7/
71/2
73/4
814
81/A
83
8/
834
91/4
91/4
93
103/4
103/
AP
5%
5%
52J
5%
6%
63
63 64
63%%4
6%
6%
6%
6%
63%t4
*Single phase motor is capacitor tart. Dimensions as shown are for open dripproof enclosure. Motors can be
furnished open dripproof or enclosed.
PARTS LIST:
PARTS INDEX
Part No. Description
Part. No.
Description
1 Housing
2 Slow Speed Cover —Open
3 Slow Speed Cover —Closed
5 Intermediate Cover —Closed
SA Intermediate Adapter —Not Shown —
Used with Inter. Cover —Closed --
Unit 1D thru 15 incl.
6 Slow Speed Shaft —Top Extension
7 Slow Speed Shaft —Bottom Extension
9 Slow Speed oir Seal
° 1I Roller Bearing --Intermediate Slaw Speed
12 Roller Bearing —Slow Speed
13 Slow Speed Spacer —Short
14 Slow Speed Spacer —Long
15 Slow Speed Worm Gear —Bronze
16 Intermediate Stow Speed Worm and
Shaft Integral
18 Intermediate Speed Attachment Housing
19 Intermediate Speed Attachment Housing
Cover
21 Intermediate High Speed Cap —Closed
22 Interemdiate High Speed Worm and
Shaft Integral
23 Intermediate Speed Worm Gear —Bronze
24 intermediate High Speed Oil Seal
25 Roller Bearing Intermediate High Speed
26 High Speed Locknut
32 Motor Adapter
328 Motor Adapter Spacer (Sizes 14 & 15 only)
34 Intermediate Speed Locknut—Not Shown
Used on Units 10 thru 15 Incl.
35 Intermediate Speed Lockwasher—Not
Shown —Used on Units 10 thru 15 Incl.
41 High Speed Attachment Housing
42 High Speed Attachment Housing Cover
44 High Speed Cap —Closed
45 High Speed Worm and Shaft Integral
46 High Speed Worm Gear —Bronze
47 High Speed Oil Seal
48 Roller Bearing —High Speed
'Series 5 thru 9 incr. use 2 Single Row Bearings.
Series 10 thru 15 incl. use 2 Single Row
Tapered Roller Bearings.
SHAFT ARRANGEMENTS:
PLAN VIEW
ELEVATION
(A) The reducer is viewed looking at
the intermediate attachment
housing.
(B) No extra charge for the above
assemblies provided the shaft
extensions are of standard length.
(C) The input shaft may be driven in
either direction.
(D) Many other assemblies available,
request assembly data.
(E) Units may be mounted in any
position, (ceiling. sidewall, etc.),
if specified when ordered.
WINSMITH �,

TECIJTICAL DATA SHEET
////'" igr2;:z /' f ''"NWri%act ire"„. ,/? ;7t%//////%%%% �%%% A:
s.hero l vr,.me
swim
��11NU1:151;�
Weight out side float holds
switch at any height.
Switches are calor coded to
prevent error in installation.
• MODEL 1900
BLUE Control with normally open
contacts is for sump emptying or
any pump down application. Water
proof decal on switch weight main-
tains Model Number.
MODEL #1901
RED Control with normally closed
contacts is for sump or tank filling
or any pump up application. Water
proof decal on switch weight main-
tains Model Number.
Used For
Pump Control
Low And High
Level Alarm
Control
Signal Control
Such As
Telemetering
Systems
0
Filling And
Emptying Vessels,
Trucks And
Rail Cars
•
Chlorination And
Chemical Feed
Control
Sludge Return
Control
Not Position
Sensitive, Operates
In Any Tip Up
Position
0
No Diaphragms
0
No Clamps
0
No Hollow Floats
•
No Vented Cards
•
No Mechanical
Switches
•
No Support Rods

TECIDICAL DATA SHEET
A 040, . ,.-///-/-/-/f///%i/
OPERATING POSITION
OF SWITCH IN WATER
r - �
RCUjjL� `U5 ' , BITCH
� 6/1,11PSULATED. ITHF,
AMR-XT. NOMS
L BAL `w' s 4
FEATURES
Steel tube mercury switch sealed
in vinyl ball with polyurethene
foam resin. Will take consider-
able shock without damage. No
glass to break as found in other
switches.
For use in sewage water and
many other liquids where level
control is required.
Complete switch assembly is
non -toxic. Can be used for level
control in tanks and sumps con-
taining drinking water.
HOW CONTROLS ARE USED TO OPERATE
SINGLE AND DUPLEX PUMP SYSTEMS
Two controls are used to control single pump.
For sump emptying service, upper control starts
pump and lower control stops pump. For duplex
pump systems, a..third control is used as over-
ride to start second pump if level continues to
rise in sump. A fourth control is used if alarm
level is required. All controls are BLUE MODEL
_1900. If low alarm level is required a RED
MODEL #1901 control is used.
Maximum temperature of liquids
150° F. Not recommended for
use in strong acids or crude oil.
Control cord is SiOWA or SO
for better flexibility and more
resistance to oil -
Standard cord length is 15 ft.
Longer cords on application.
Positive leak proof seal on cord
and mercury switch.
For pump up or tank fill service, all are RED,
except high water alarm control and this would
require o BLUE CONTROL.
Pump control must operate through a lock in
relay or be wired through auxiliary contact on
magnetic starter. Alarm controls do not roquire
hold in relays.
Designed for over one million operations.
SPECI F!CATIONS
MERCURY SWITCH — Steel tube houses mer-
cury and contacts. Contact is through mercury
to mercury. No mechanical contacts.
SWITCH RATING — 20 amps @ 120 volts, 16
amps @ 240 volts, 10 amps @ 480 volts AC,
10 amps @ 220 volts DC, and 8 amps @ 240
volts DC.
POWER CORD — Type SJOW-A for 300 volt
max. and SO for 600 volt max. Cord supports
control at proper height in sump to tank. Stand-
ard cord length 15 ft. Longer cord available.
1000 ft. maximum.
MOUNTING BRACKET — Special bracket to
support 1 - 2 - 3 or 4 controls can be furnished.
Made for mounting to pipe or sump wall.
BLUE CONTROLS — With normally open con-
tacts for pump down service. Model _ 1900.
RED CONTROLS — With normally closed con-
tacts for pump up service. Model # 1901 .
MERCURY TUBE SWITCH & CORD — Sealed
in vinyl ball with leak proof polyurethane resin.
Switch has been tested submerged in salt water
for thousands of hours with no sign of leakage.

TECIM
ICAL DATA SHEET
PRESSURE RELIEF VALVE
A pressure relief valve's first purpose is to act as a safety valve to protect the positive displacement air
blower, working in conjunction with the air manifold. When the air manifold pressure exceeds the pre-set
pressure of the valve, the valve will open and vent the excess air presstue.
The Tipton Environmental International, Inc. pressure relief valve is a spring loaded type that is available
in six sizes, 1" diameter pipe size to 4" diameter pipe size. These valve are pre-set for the pressure of 5.0
psi. Adjustments can be made easily to increase the pressure. The pressure range of these valves is from
0 to 10 psi.
'MODEL I
TPRV-1
TPRV-1.5
TPRV-2
TPRV-2.5 1TPRV-3
TPRV-4
Inside Diameter (A)
1-1/8"
1-1/2"
2-1/8"
2-1/2"
3-1/8"
4-1/8"
Length (B)
4"
5-1/4"
5-114"
5-1/4"
5-1/4"
5-1/4"
Thread Length (C)
3/4"
7/8"
1"
1-1/4" 11-5/5"
1-1/2"
\\\
SPRING
g q 0 O 9. O• q 0 0
0 0 0, 0 tr o o
a C 9
i j
• A O O On ,4 j ftNNM" =I
_
C A P
GASKET
-CGZ//////////////////`/////////.:\
\\\\\
ADJUSTING
NUT

TECHNICAL DATA SHEET
Fiberglass Housing for
Blower Motor Units
FIBERGLASS HOOD
FIBERGLASS BASE
ISOMETRIC

TECHNICAL DATA SHEET
a91� • i'`wd ma's fn ti.
Motor Slide Base
For easy adjustment of the tension on the V-Belts
connecting the blower with the motor a adjustable
motor base shall be supplied. The adjustable motor
base shall be constructed and made with heavy duty
steel. It shall be equipped with a single screw
adjustment for frame sizes of 143 T-215, and double
screw adjustment for 254T frame sizes or larger.

TECHNICAL DATA SHEET
e OVERLY HAUTZ MOTOR BASE COMPANY
215 SOUTH WEST STREET • LEBANON, OHIO 45036-0187
[phone]
FAX [phone]
STOCK BASES
N E MA
STEEL ADJUSTABLE
MOTOR BASES
STYLE A
FRAME &
PART NO.
AL
AM,
AX
BB
E
F
AO
AR
AU
BT
AT
XC
D BOLT
AY BOLT
APPROX.
WT. (LBS)
56
10-518
6-12
1-1/8
�QC QC,Q
46666A�
2-7/16
1-12
3-13/16
2-7/8
3/8
3
.078
7/6
5/16x1
3/8x4
3
- 66
12
8-1/2
1-1/8
3-118
2.12
4-12
3-7/8
3/8
3
.078
7/8
5/16x1
3/8x4
4
'143
10-12
7-1/2
1-118
2-3/4
2
3-3/4
3-318
3/8
3
.119
13116
5/16x1
3/8x4
5
'145
10-12
8-12
1-1/6
2-3/4
2-1/2
3.314
3-7/8
3/8
3
13/16
5/16x1
318x4
6
'182
12.3/4
9-12
1-12
3-3/4
2-1/4
4-12
4-1/4
12
3
.119
.134
1-1/4
3/641-12
12x6
9
'184
12-3/4
10.12
1-12
3-3/4
2-3/4
4-12
4-3/4
12
3
.134
1-1/4
31641-12
12x6
9-12
'213
'215
15
11
1-3/4
4-1/4
2-3/4
5-1/4
4-3/4
1/2
3-1/2
.164
1-1/4
31641.12
12x6
13-12
15
12-12
1-3/4
4-1/4
3-1/2
5-1/4
5-12
12
3-1/2
.164
1-1/4
3/13641-12
12x6 !
15-1/2
Bases Noted (') Also Available
In Standard Stack Double
Adjusting Style A2
Adjusting Bo11S an Style A2 Bases are in line with 0 Bolts art F Dlmenslon
NON STOCK BASES
FRAME &
PART NO.
AL
AM
AX
BB
E
F
AO
AR
AU
BT
AT
XC
D BOLT
AY BOLT
APPROX.
WT. (LBS)
48
10
6-1/4
1-1/8
4.1/4
2-1/8
1-318
3-12
2-3/4
3/8
3
.078
718
5/16x1
- 3/8x4
2-12
186
12-3/4
12
1-12
9
3-3/4
3-12
4-12
5-1/2
12
3
.134
1-1/4
3/43641-12
1245
11
187
12-3/4
13
1-1/2
10
3-3/4
4
4-12
6
12
3
.134
1-1/4
3/641-12
12x6
12
188
12-3/4
14
1-12
11
3-3/4
4-1/2
4-12
6-12
12
3
.134
1-1/4
3/8641.12
12x6
13
189
12-314
15
1-12
12
3-3/4
5
4-12
_ 7
12
3
,134
1-1/4
3/641.1/2
12x6
14
216
15
13.12
1-3/4
10
4-1/4
4
5-1/4
6
1/2
3-1/2
.164
1-1/4
3/8x1-12
12x6
17
217
15
14.12
1-3/4
11
4-1/4
4.12
5-1/4
5-12
1/2
3.12
.164
1-1/4
3/641-12
12x6
18
218
15
15-12
1-3/4
12
4-1/4
5
5-1/4
7
1/2
3-12
.164
1-1/4
3/641-12
12x6
19
219
15
16-12
1-3/4
13
4-1/4
5-12
5-114
7-12
1/2
3-12
.164
1-1/4
3/851-12
12x5
20
Above Bases May be Used for AC Or DC Frames
DIMENSIONS ARE 1N INCHES: Bases are furnished with one
coat of corrosion -resistant gray primer and zinc plated ruts
and bolts.
Bases listed may also be used if the motor frame is suc-
ceeded by S, T, U, US or any letter combination as long as
-the motor complies with N.E.M,A.
Cove ed by Patent No. 2765997
The liability of the Overly-Hautz Com•
pany to the purchaser is limited to re-
placement of defective materials sup-
plied. One year from the date of our ship-
ment all liability shall terminate. There
are no warranties which extend beyond
the description on the face hereof.
DIMENSION SHEET
MB-200-A
6-1 -94

TECHNICAL DATA SHEET
P.D.
TYPE A
TYPE 6
TYPE C
TYPE D
TYPE E
Dimensions for Rate . sheaves are listed in the follow-
ing tables with QD bushings in place. The type of
sheave shown below is indicated by a letter, and the
construction is indicated by a number, as shown on
facing page.
Dimensions in inches, weight in pounds
1 Groove`
2 Groove
F ='r/as
F = 1 3/32
PD
Bush
L
Wt.
Bush
L
Wt.
3V
Max.
lbw
Less
Max.
Thru
Less
Part Number
0D
Belt
Type
Bush
Bare
E
K
Bore
M
Bush
Part Number
Type
Bush
Bore
E
K
Bare
M
Bush
1 3V 220 JA
220
215
E-1
.IA
I'h
'he
'he
1'I
"f:e
.7
2 3V 220 JA
WWoo
JA
1'A
"1n
'he
1'hs
"As
9
1 3V 235..1A
235
2,20
6,1
JA
111-1
Vie
rite
1'/:e
"ha
.6
2 3v 235 JA
JA
1 'A
11faa
Ms
1 Ms
"As
1.0
1 31/ 250 JA
250
2.45
E-1
JA
I
She
'h6
1'!:e
"he
.8
2 3V 250 JA
JA
.1 'A
"la
'he
1'f:s
'Ms
1.2
1 3V 265 JA
2.65
2.60
G1
JA
1 Y.
'/e
'le
1'he
0
9
2 3V 265 JA
JA
1'A
Vs
Me
1 Ms
"!2
1.3
_1 31 260 JA
2.60
2.75
C-1
JA
1 V.
Vs
'Is
1'he
0
°
2 3V 280 JA
.1A.
1 Mt
ale
Ms
1'l:e
"in
1.4
1 3V 300 ,1A
3.00
2.95
C-1
JA
1 'A
'le
'!e
1 'be
0
1,0
2 3V 300 JA
D-1
JA
1 'A
'fa
'la
1 716
"1:.2
1-6
1 3'! 315 JA
3.15
3.10
C-1
JA
1 'A
Va
'le
1 Ws
0
1.0
2 3V 315 JA,
D-1
JA
I 'fa
'is
'1e
1 'its
"!n
1.8
1 3V 335 JA
3.35
3.36
C-1
JA
1 '1.
sfa
'la
1 'As
0
1.1
2 3V 335 SH
D-1
5H
1 "Its
a'/m
M/a
1 she
"ise
2.0
1 2! 355 SH
3.65
3.60
0-1
5H
1 "ha
She
0
1 Ms
Ms
1.3
2 3V 365 SH
0-1
511
1 "As
"!a
91w
1'he
"!ss
24
i 5V 412 SH
4.12
4.37
0.1
SH
1 "he
Ms
0
I Ms
'fs '
1.7
2 3V 412 5H
0'1
SH
1 'Me
'/s
'in
1 V/16
Ms
2.7
1 31 450 EH
450
4.45
0-2
SH
1 "its
Ms
0
1 She
'he
2.1
2 31i 450 51'1
0-1
5H
1 "he
'1.
Ms
1 Me
Vex
2.9
1 3V 475 SH
4.75
4.70
D-2
SH
I "ha
91:e
0
1 she
'he
2.5
2 3V 475 SH
0-1
Sit
1 "As
'1.
a/,a
1 Ms
'in
3.1
1 3V KO SH
5.00
4.95
0-2
5H
i "Its
'1:e
0
1 she
'he
28
2 3V 500 SH
0.1
5H
1 "Its
'6
Mts
1 Ms
'Is
3.6
1 3f 530 SH
5.30
525
0-2
5H
1 "As
Its
0
1 Ms
'be
3.2
2 3V 530 SH
0.1
a-1
1 "As
'A
'he
1 she
'1,
4.5
1 2v 560 SH
5-60
555
0-2
SH
1 "he
Ms
0
1'ha
'As
3.2
'2 3V 560 5H
D-1
SH
1 "its
V.
'He,
1 4hs
'la
50
1 3V 600 SH
6.00
5.95
0-2
Sri
1 "ha
'Its
0
Ms
'he
35
2 3V 600 SH
0-1
SH
i 'Ms
Y.
Ms
1 Ma
'!s
55
1 ,Ti 650 5H
6.50
5.45
0-3
5H
1 "7m
Me
0
1'!ss
Ms
3.9
2 3V 650 505
1)-3
SOS
2
s/:6
she
1 ale
'in
5.8
1 3V 690 SH
6°0
585
0.3
5H
1 "its
She
0
1 Ms
'As
4.5
2 3V 690 SOS
0.3
50S
2
Ms
Ms
1'!5
'l2
66
1 3 600 50S
8.00
7.05
C-3
50S
2
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2 3V 5C0 505
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TE CHI\ ICAL DATA SHEET
1.
Y/1/rf�'/1.OW,/�M5diaS 'v
Industrial Belt
®i Products/Suggested List Prices
Super HC® and Super HC® Molded Notch Belts
Gates Super HC V-Belts combine
modern high capacity materials with
the revolutionary "narrow" cross sec-
tion pioneered by Gates. They can
transmit up to three times the horse-
power of conventional V-Belts in the same drive space —or the
same horsepower in 1/2 to 2/3 the space. In many cases, Super
HC Belts can replace high maintenance chain and gear drives.
Super HC V-Belts have exclusive Gates construction features for
extra long drive life.
Important Design Economies
Super HC V-Belts can provide important savings in drive space
with narrower sheaves, shorter centers, smaller sheave diame-
ters —and additional savings in drive guards, mounts and housings.
Narrower, lighter Super HC sheaves reduce weight and overhangs
on bearings, decreasing bearing loads in many cases. Super HC
sheaves can be smaller in diameter and can operate at belt speeds
up to 6,500 fpm without dynamic balancing. Speed changes can
be handled without jackshafts or mechanical speed reducers.
Lower cost high speed motors can be used on many applications.
• Gates "Curves"
Super HC V-Belts compensate for effects that occur
when a V-belt bends in a sheave. The Concave Sides
(U.S. Pat. 1813698) fill out, making uniform contact with the
sheave groove and distributing wear uniformly. Ordinary
straight -sided V-Belts bulge out, concentrating wear at the
bulge points and shortening belt life. Radius Relief minimizes
comer wear and works with the Concave Sides to assure
proper support of the belt- The Arched Top provides superior
strength to prevent "dishing" and distortion of the tensile
section. The cords operate in the same plane to help assure
uniform loading and maximum life.
• Flex -Bonded Cords (U.S. Pat. 3090716)
Gates treats tensile cords with a material that bonds equally
well with the cords and the surrounding rubber. When the belt
is vulcanized, all elements are locked in a chemical bond that
provides long service without separation. The bond between
the tensile cord and the rubber is actually stronger than the
rubber itself.
• Oil and Heat Resistance ... Static Conductivity
Super HC V-Belts are made with special material for resis-
tance to oil, heat, sunlight, ozone, weather and aging. They
meet Rubber Manufacturers' Association (R14A) require-
ment for static conductivity, when new.
19996-00C
May 28, 1993
. Supersedes 19996-00C
October 1, 199i
Gates Super HC Molded Notch
V-Belts are designed for use where
conventional V-Belt drives are im-
practical... where space, weight or
sheave limitations are present...
increased horsepower capacity of production is required and
higher speeds are necessary. With smaller sheave diameters.
these belts offer a higherhorsepower rating than any other V-best
on the market. /
Gates Super HC Molded Notch Drive System provides the most
advanced V-belt available today. To accommodate this Molded
Notch V-Belt, Gates has stocks of smaller diametersheaves—down
to 2.2 inches --which will allow speed ratios as high as 13.65!
Energy Savings: Super HC Molded Notch V-Belts allow drives
to be designed with higher RPM motors. (In some cases, for the
same horsepower rating, motors with higher speeds have a higher
efficiency at rated load than motors with lower speeds).
Additional Features -
• Full Oil and Heat Resistance ... Static Conductivity
Special material used throughout the belt —in the undercord
and around the tensile members —provides oil and heat resis-
tance. This material also helps resist ozone, sunlight, weather
and aging. These belts meet Rubber Manufacturers' Associa-
tion (RMA) requirements for static conductivity, when new.
• Tough Tensile Members for Extra Strength
Special tensile members give Super HC Molded Notch V-
Belts superior resistance to fatigue and shock loads. A specia:
material surrounding the tensile members bonds the cords and
rubber during. vulcanization into a unit that provides long
service without separation.
• Molded Notches Reduce Bending Stresses
Special notches molded into the belt during manufacture
reduce bending stress, especially on drives where the belts run
over smaller sheaves. Notches are precision engineered for
uniform distribution of stresses. Notches also help dissipate
the heat of rapid flexing.
• Bandies, Precision Machined EdgeforEvenIVedniag.Action
The edges of Super FIC Molded Notch V-Belts are precisely
machined to exact dimensions to assure uniform fit along the
sides of the sheave grooves. This provides wedging action and
reduces the possibility -albeit slippage.
Sizes Available
Gates Super HC V-Belts are available in 3V, 5V and SV sizes.
Gates Super HC Molded Notch V-Belts are available in 3VX and
SVX sizes up through 200 inches.

TECHNICAL DATA SHEET
Industrial Belt
Ii ® Products/Suggested List Prices
19996-000
May 28, 1993
Supersedes 19996-000
October 1, 1991
Super HC® and Super HC® Molded Notch Belts :,.
(continued)
3VX Section
Product No. Series 9412
T
21/54
Part
No.
Suggested
List Price
Product
.. . No.
Belt 0.C.
.(In.)
Wt. Ea.
. (Lbs.)
Customer
Pack
3VX250
$8.34
9412-0250
25.0 .
.10
1
3VX265
- ' 8.56
9412-0265
26.5
.10 -
- - 1
3VX280
8.76
9412-0280
28.0
.10
5
3VX300
8.98
9412-0300
30.0
.10
. 5
3VX315
9.41
9412-0315
31.5
.10
10
3VX335
9.62
9412-0335
33.5
.10
5
3VX355
10.05
9412-0355
35.5
.20
,10
3VX375
10.26
9412-0375
37.5
.20
- 5
3VX400
10.90
9412-0400
40.0.
.20
- 10
3VX425
11.33
9412-0425
42.5
.20
10
3VX450
11.76
9412-0450
45.0
.20
10
3VX475
12.18
9412-0475
47.5
.20
10
3VX500
12.40
9412-0500
50.0
.20
10
' 3VX530
12.83
9412-0530
53.0
.20
10
3VX560
13.25
9412-0560
56.0
.20
10
3VX600
' 13.89
9412-0600
60.0
.30
10
Bulk Packed
f
/Part -
No. _
Suggested
List Price
Product
..jNo.
Belt 0.C.
(In.)
Wt. Ea.
(Lbs.)
Customer
. Pack
3VX630
$14.32
•' 9412-0630
63.0
.30
'
10
3VX670
. 14.96
9412-0670
67.0
--.30
10
3VX710
15.82
9412-0710
71.0
- .30
10
3VX750
16.68
9412-0750
• 75.0
.30
10
3VX800
" 17.75
9412-0800
80.0
.40
10
3VX850
19.02
9412-0850
85.0
- .40
10
3VX900
20.52
9412-0900
90.0
.40
'
10
3VX950
21.59
9412-0950
95.0
.40
10
3VX1000
22.88
9412:1000
100.0
'.40
10
3VX1060
24.15
9412-1060
106.0
.40
5
3VX1120
26.29
9412-1120
112.0
.50
5
3VX1180
28.01
9412-1180
_
118.0
.50
11
3VX1250
29.93
9412-1250
125.0
.60
5
3VX1320
31.64
9412-1320
132.0 .
.60
11
3VX1400
33.56
9412-1400
140.0
.70
"
11
3V Section
Product No. Series 9222
� sra--4
1E721 64•
Part
No.
Suggested
List Price
'Product
No.
Belt O.C.
(In.)
Wt. Ea.
(Lbs.)
Customer
Pack
3V250
$8.34
9222-4435
25.0
.10
1
3V300
8.98
9222-4399
30.0
.10
5
3V315
9.41
9222-4390
31.5
.10
10
3V335
9.62
9222-4422
33.5
.10
5
3V355
10.05
9222-4333
35.5
.20
10
3V375
10.26
9222-4334
37.5
.20
5
3 V 400
10.90
9222-4436
40.0
.20
10
3V425
11.33
9222-4351
42.5
.20
10
3V450
11.76
9222-4335
45.0
.20
10
3V475
12.18
9222-4329
47.5
.20
10
3V500
12.40
9222-4330
50.0
.20
10
3V530
12.83
9222-4284
53.0
.20
10
3V560
13.25
9222-4285
56.0
.20
10
3 V 600
13.89
9222-4331
60.0
.30
10
3VF30
14 32
9272-4332
63 0
30
10
~Bulk Packed
Part
No.
Suggested
List Price
Product
No.
Belt 0.C.
(In.)
Wt. Ea.
(Lbs.)
Customer
Pack
3V670
$14.96
9222-4336
67.0
.30
10
3V710
15.82
9222-4389
71.0
.30
10
3V750
16.68
9222-4423
75.0
.30
10
3V800
17.75
9222-4388
80.0
.40
10
3 V 850
19.02
9222-4424
85.0
.40
10
3V900
20.52
9222-4387
90.0
.40
10
3V950
21.59
9222-4286
95.0
.40
10
3V1000
22.88
9222-4386
100.0
.40
10
3V1060
24.15
9222-4385
106.0
.40
5
3V1120
_ 26.29
9222-4425
112.0 i
.50
5
3V1180
28.01
9222-4384
118.0
.50
11
3V1250
29.93
9222-4426
125.0
.50
5
3V1320
31.64
9222-4400
132.0
.60
11
3V1400
33.56
9222-4383
140.0
.70
11

I`EC
ICAL DATA SHEET
11
SS-169
21 S 20
%% ;; ,, ray%////�f ,oFfAW ii
La OD_ REMFORCE 5 PwORS RESSUR�� EKI wLB/Frr
(r
114° 1"h" 2 plies 200 • E2
11I: 1 1- 2 plies 200 .75
1V.1" 1'44 2 gllea 200 r.79l
13h' 2" 2 piles 2130 .7;
1 " 2W 2 plias 210 .37
-Ili'''. 2`!" 2 plies 246 ;54 '
V'/" 21A" 2 piles 2W 1.Cra
IV4 232' 2 plea 200 1.08
2• 2%" 2 plies 243 1.11
2W 2 ;" 2 pilot 200 1.21
21/4' 2W 2plles 2110 1.25,:
re 9" 2 piles 204 i.32'
2'h" 312 2 piles 200 1.45
2W !3'w 2 pas 2I 1.53
2'', . For 2 piles 20 1
.53
Z'h alir 2 piles 200 1.64
3" 3s4" 4 plipx 250 1.52
3h 3%. 4 piles 201 1.70
0 Ye 3 4 piles 2i 0 1.15
3'h' 4'Ii 4 plies 200 1.76
4" 4% 4 piles 200 1.97
4W 4ii" 4 plies 200 1.53
41' 4'<6' 4 plies 2110 2.l9
454' S`h' 4 plies 200 2.22
5" , Jr 6 plies 200 9.54
moo` 3%* 6 pits: 2110 4.12..
5" , 7" 6 rJb 200 4.115
Csrr 74 4044 200 5.03
T r 0 pliers 200 5.31
5- 9" 6 plies J5 5.91
8 !W $ Oita 160 6.04
it 11' 6plles 150 7.83
125'4" 11' " 5plieS 1J;O 8.411
12" 13" 5 piles 103 9.113
12%" 17146 piles 161 9.46
C3ESCRIP110N:.Ptemium grade, heaw duty rnarirre exhaust
hasa. High pressure, multi -purpose product for use as a
f xilble connection to transfer wet axhax. zt Tube resists WO
temperatures found in marine engine camparlmertis. Ourab!e
cover is heat, ozone and abrasion resistant Also a+railahle
with a flame retardant cover (SS 169).
71.18E: SS 169_ &ianflc s nitrite. SS 269: 5aerales$ nitrite
Mend.
FMNF FICEhMEi1T Multiple plies of polyester.
COVER: One piers neoprene.
TEMPERATURE RAM O: -40° to -200'. F.

TECHNICAL DATA SHEET
TECHNOCHECK
MALE THREADED ENDS
';VALVE SIZE 4_
1
1-1/4
1-1/2
2
2-1/2
3
VittWCW
MALE THREADED ENDS
DIAM.
GENERAL DIMENSIONS FOR STYLE 5002
3-1/2
3-1/2
4
4
5
5-1/2
ALL DIMENSIONS IN INCHES
1.315
1.660
1.900
2-3/8
2-7/8
3.1/2
'.4,- L
�,1n.C�.H'te
1-5/8
2
2-1/4
2-3/4
3-1/4
3-7/8
VALVE SIZE '
4
5
6
8
10
12
zit <A',
STANDARD MODELS & MATERIALS
6
7
8
10
12
14
STYLE,:"
5002'
4-1/2
5-9/16
6-5/8
8-5/8
10-3/4
12-3/4
4.7/8
6-1/8
7-1/8
9-1/2
11-1/2
13.3/4
•r wma_
: $Ty LE.4.-:,,,.{`=
BODY„ ,,, v h
t , 3,f:k ;INTERNALS _ of ::;
, PSI C.W.P .
5002-AL
Aluminum
Aluminum
50
5002-BR
Brass
Brass
150
5002-304
304 Stainless Steel
304 Stainless Steel
150
5002.316
316 Stainless Steel
316 Stainless Steel
150
5002-Class A
Steel ,
Aluminum
150
5002-Class D
Steel
Cadmium Plated Steel
150
Standard Elastomer: Buna-N
OPTIONAL MATERIAL SELECTION
..INTERNAL MATERIALS +;t'-F:Sy�
• Aluminum
• Bronze
• 304 Stainless Steel
• 316 Stainless Steel
• Cadmium Plated Steel
• Electroless Nickel Plated Steel or Aluminum
• Monel'
• Titanium'
• Hastelloy'
'Non stock item — Available upon request.
SPRING MATERIALS
• 304 Stainless Steel
• 316 Stainless Steel
Monel and Inconel springs available upon request
'!SEALING MEMBER MATERIALS ..;,E" ; wl, '
MATERIAL
'TEMPERATURE RANGE
•
Bur a-N
—60 to 225° F
•
Neoprene
—40 to 225• F
•
Butyl
--65 to 325° F
•
Hypalon
—20 to 300° F
•
EPDM
—40 to 300° F
•
Vitan
—20 to 403° F
•
Teflon
—20 to 450° F
•
Silicone
—100 to 500° F
••
FDA Approved
—40 to 225° F
White Neoprene
'This temperature range i For general guidance, The
Figures may Vary with application.
CONSULT FACTORY FOR MATERIALS, SIZES AND
PRESSURE RATINGS NOT SHOWN.
• COMBINATION END CONFIGURATIONS ALSO AVAILABLE.

TECHNICAL DATA SHEET
Magnesium Anode Packages
for Cathodic Protection
The outside of the TEII steel systems are painted with suitable
paint for the application. To minimize corrosion from acid
soil, sacrificial magnesium anodes are buried in the ground
approxirnately ten feet from the metal plant. It shall be
attached to the system with a copper wire. During the
construction, proper installation of the anodes is critical.
Allowing enough slack in the copper wire so that it will not
break during backtilling is important.
Cathodic Protection with magnesium anode packages are
supplied with all below ground installations of all prefabricated
steel systems.
�s�
r�_y"
11101.11q111.4110101110. I I*
Regular Magnesium
Anodes Specifications

TECHNICAL DATA SHEET
General Purpose Relays and Timing Relays
Type H
Bulletin 700
Type H General Purpose Relays
• Plug -In and Panel Mount
Versions
• Contact Switching up to
30 Amps
o Visual On/Off Flag Indicator
Standard
• Manual Operator or Pilot Light
Version Optional
o AC and DC Coil Versions
Available
Type H General Purpose Timing
Relays '
• Single Timing Range Versions
up to 100 Hours
• Multi -Timing Range Versions
up to 100 Hours
• Single Function or
Multi -Function Versions
• AC and DC Coil Versions
Available
TABLE OF CONTENTS
Description
Page
Description
Page
Product Selection
Type HA — Tube Base, 10 Amp 5-45
Type HB — Square Base, 10 Amp 5-45
Type HC — Miniature Square Base, 1 3, & 5 Amp 5-46
Type HF— Miniature Square Base. 10 Amp 5-46
Type HD — Flanged Cover, Square Base, 10 Amp 5-47
Type HE -IF — Flanged Cover, Square Base, 25/30 Amp 5.47
Type HG — Screw Terminals, 30 Amp 5-48
Type HJ—Square Base, Magnetic Latching, 10 Amp 5-49
Type HK — Miniature Square Base, Slim Line, 5 and 10 Amp 5-49
Type HS, (HSF) —Square Base, Single Range, {Fixed) '5-51
Type HT, (HTF) —Tube Base, Single Range, (Fixed) 5-52
Type HV, (HVF) —Tube Base, Repeat Cycle, {Fixed) 5-53
Type HR, HRM, HRC—Tube Base, Multi -Range,
MUIti-Function 5-50
Accessories 5-54
Specifications 5-58
Approximate Dimensions 5-64
Description
Bulletin 700 Type H Line of General Purpose "Plug -In" Relays and Timers
combined with sockets for DIN rail or panel mounting, provides a highly flexible line
of world acceptable devices.
Conformity to Standards:
IEC 255-1-00
VDE 0435
Approvals:
CSA Certified
UL Recognized
Relays — File E3125 Guide NLDX 2
Sockets — File E96409 Guide NIA
UL Listed — Type HG
File E3125 Guide NLDX
Your order must include:
• Cat. No. of plug-in relay plus
suffixes of selection options.
• Cat. No. of socket required.
• If required, the Cat. No. of Type
HN accessories.
i

/
1.
TECHNICAL DATA SHEET
_..-.. ` !- +q.�' , A
Product Selection
Type HA Tube Base Relay with PIN Terminals- Mechanical ON/OFF Indicator is included
Description
Contact
Rating
Wiring Diagrams/CoiI
Voltage
-`-CaLTNo *,
•.-o©.]0j:`,
Price
US/Canada
International
6VAC
700-NA32A06'.,
524.06
12VAC
700-HA32Al2,:
24.c0
24VAC
700-1:1A32A21 .
24.90
/
120V AC
700_1ig92A1„ i-
24.00
' =
C ? \Q
n
240VAC
700:HA32A2. .
25.00
277VAC
70aH1132P,27.
26.00
{a
DPOT
(Q
'-rs'
,2 Pole
2 Farm C
8300
`�
to
PP
/ 2e
6V DC
700-}�P,32Z1164_
2480
.`rW : e " -
Contacts
1
i
0�
12VDC
700„1iA32Z12
24.90
: ii
YYii,, �t
Z• tl'
+
\ .....111)
�l� �7
Input
/
-
\
+
n z�
\\
U
-
24V DC
70aFjA32724
24.90
48V DC
700;HA:32Z T
=�
2440
7 i�"
a
VI
iicy DC
700= "•
25.00
h .., ,., .4g
125V DC
4700-`F;A3'2Z01
25.00
Sockets
. 700-HN125
7oQ HN1o0
140V DC
'7 ��'..
26.00
' fig r c
` }
6VAC
.-j0o- 0.,
29.50
12V AC
;7t3011?:3�3A1-2
29.50
Lb ,,. •I :ma.
.24VAC
til0U- 3
29.50
4_ II: . '.-ill
'
��
/
AC
{1 A33�A
I '`;�;; ��.�
3PDT
I/o� �
I
T
1�L� �(zy`!�j\1
240V
240V AC
7�&
30.50
30.50
3 Pole 3 Form C
B300
Q- O
t o O
6V DC
<T049320
29.59
Contacts
© a)
Q , Q
12VDC
71>A.
Z 2at
29.50
O G /
m ®
24V DC
]Oo-}f 3322
29.50
+
Input -
+
u
-
48V DC
71?a
29.50
110V DC
tZ001-1 3ZT, .t
30.50
125V DC
700YTiA332p1e
31.00
Sockets
70011N126
700-HNIOT
140V DC
1700-RA33Z37,
31.50
Type HB Square Base Relay with Blade Style Quick Connect/Solder Terminations - Mechanical ON/OFF Indicator is
included.
'S
N ....r�=�
? f -: r
4 .,
=a 1
3
,,��gga��;: f
7 x: rL , •2 `
. r F'tta; y I5 ` i
�,(
45
E ?•1
a .;
$.74 p .:
' 1,4- t'" � a
:
3 ''' 1 •4b;+P+ tivi.
rl '
DPOT
2Po!e
2 Farm C
Contacts
/•
Sockets ,,/
10A
13300
6VAC
;760-}iB32, 06
18
12VAC
7004833T]i/2f,
18
24VAC
; 0a1'i632A2Y
18
t
:1
l i
21
Lam'
u
g
Yt
24
g112.6V
A
i20VAC
-70U$-I932 f`aT
18
240VAC
70aS32A?3 ?
t9
DC
_70f}kiB32206 ,
-
16
12VDC
-)i x1832Zi2I
18
24V DC
A832Z24=-
18
InrAn -
700-11N127
, I u I-
700•HN102
48V DC
70o-liRil7
la
110V DC
790t1632z, fi
19
3PDT
3 Farm
3 Fprm C
Contacts
Sockets
-
10A
5300
6VAC
700-F133000
20
12V AC
bDOI833,0
20
24VAC
700-1jt333A24
20
a
ii3.1m!
�t
m.
12 m
u E'er
, Al
za
=, r
120VAC
700o-HB33dT
20
240V AC
700 H833A2y
21
6V DC
70¢1-1B33Z0_6:;
20
52V DC
700_
20
.1833Z12
700-HR't't704,_,-
24V DC
20
. lam I -
700-HN127
u I_
700-HNf02
48V DC
700-H833Z48'
20
11CV DC
700-HB33Z1--'
21
O Manual Operator Option: Add suffix (-1) to the setec ed HA or HB Relay Cal. No. and add S3 to the price.
© Pilot Light Option: Add suffix (-4 to the selected HA or HB Retay Cat, No., except fa the 240V AC Units, add (-44 Pilot light replaces
me. 'an!;?! QI'WOFF indicator.) Add S5 t0 the price.

TECHNICAL DATA SHEET
v�.,J t/ . f.(T'! ",¢ ' � � ✓ f fN 'Lryil�+/llNl 7/7/ f :e
f
SMT e , excellent for a plicati®ns here
size and cost re major concerns
Economical and compact, with traditional open wound varnished coils. Ratings are
from 50 VA through 5 KVA with a time proven class 180°C insulation system, and 115°C
rise under full load. SMT transformers provide excellent size and cost benefits with regu-
lation characteristics exceeding NEMA regulation curves and electrical performance
specifications.
Features
• Ratings 50 - 5000 VA, 60 Hz unless noted 50/60 Hz
• Meets or exceeds electrical requirements of UL, CSA, NEMA, ANSI, NMTBA and JIC
• UL listed ... file #E77014
• CSA certified ... file #LR-14328-12

TECHNICAL DATA SHEET
sx"' yam. " ;d ,. �.;.� v.
¢pa..'.: .<a `%NISr .If''�. i N t
GROUP 6 -- 240 x 480 VOLT PRIMARY, 120 VOLT SECONDARY
WITH 3PB FUSE BLOCK
VA
CATALOG
NUMBER
HEIGHT
(INCH)
WIDTH
(INCH)
DEPTH
(INCH)
MTG
�/ WIDTH
MTG
DEPTH
SLOT
SIZE
APPROX WT.
LBS.
46
0-21 8 --t- ;i:
MOB
40k
3`•56
"2:50moor-Eg20.z
� 33
g^..2 5, S
95
E095-3PB
4.63
3.38
3.56
2.81
2.19
.20 x .33
3.7
Q
1;U5 P6 - F
}.+_ 63
gaftaNg`.s..
x,'-WOMBW
��
-F.33 4P-20
.sue
5 3 M
�,, ,� �. �
z,47a �t. t
,.u� �.•
180
E180-3PB
5.56
4.50
4.44 -
3.75
2.25
.20 x .33
7.0
Iletl
gable
1: _ ` rmator
so
S4 69na
3 7g`-i n
`'.' ? 50 M
!�+3 20+X 33
;yi 8 0, 47-?;
275
E275-3PB
5.56
4.50
5.06
3.75
2.88
.20 x .33
_
9.8
r32
� e,_,
x�.,. � x •.�
20� :.ar - �.
t'
�Sfr r
����'r�c�
>� N '5#25
az;h ..-a����.-
4i94. �+
�
s' �"•
�;38:,�
�3'2�
�' r.
�313X 69�.A;
n r r � 'wi
1,';, w, ji 8 �{�,^�';
380
E380.3P8
6.44
5.25
5.44
4.38
3.63 '
.31 x .69
14.2
58a 3
4- .jaw .
AlMicin
d 44,1:
Eaa7*.0
WrAgal
1i 69
,. "17 .- .,
850
E850-3P8
7.38
6.38
6.88
5.31
4.25
.31 x .69
26.5
t1.0,0r4
- 100=3R13 3 c
�:1' , ,.�., <.,r �.��-��5��
r
3P`6 38; f
c�F�k'713�.
`-�531:R ram}
=
„ 5;00;�?
1u
a?�,"31. X f9�"�
s _w f
`�'', � 33'5';;'=,`?„
k-MTG WTI
A
0
1Jm
MTG D-
Type SMT 50 thru 1900 VA design style
1-4-MTG W�
0
b
W
I MTG
Type 5MT 1500 VA and larger design style

TECHNICAL DATA SHEET
INDUSTRIAL ELECTRICAL •
•ENCLOSURES -STEEL AND ALUMINUM
• Electromate
ENCLOSURES
/
NEMA 4/4X - Electromate Enclosure Size Shipping //
Catalog MIS A x B x C Weight List/
- Single Door Enclosures Number . Number (inches) (Ibs.) Price
Enclosure less panel--- E-16H12A t* 504 0010 16 x 12 x 6 23 227.98
See page 31 for panels ' E-16H16A t* 504 0020 16 x 16 x 6 28 • 245.58
E-16H20A t* 504 0030 • . 16 x 20 x 6 32 263.07
/ E-20H16A t* 504 0040 20 x 16 x 6 • 32 263.07
li
E-20H20A t` 504 0050 20 x 20 x 6 38 283.93
E-241-I12A f' 504 0060' 24 x 12 x 6 31 256.78
E-241-I16A t* 504 0070 24 x 16 x 6 37 - 280.77
E-24H20A t' 504 0080 24 x 20 x 6 43 304.80
E-24H24A f*
E-30H20A f*
E-30H24A t'
E-36H24A t*
E-16H12B t*
E-20H16B t*
E-20H2OB t'
E-20H24B t'
E-24H2OB t*
E-24H24B t'
E-24H30B t'
E-30H2O8 t'
E-30H24B t*
E-30H30B if
E-36H24B t*
E-36H30B t*
E-42H30B t*
E-42H36B t"
E-48H36B f*
E-60H36B t'
E-20H16C t"
E-24H20C t'
E-30H24C f'
E-36H30C t*
E-48H30C t*
E-48H36C t'
E-60H36C f"
E-30H24D t*
E-36H30D t*
E-48H36D t*
E-36H30F t•
E-48H36F t'
E-60H36F f*
504 0090 , 24 x 24 x 6 49 - 328.81
504 0100 30 x 20 x 6 53 335.89
5040110 30x24x6 60 364.73
504 0115 36 x 24 x 6 63 400.75
5040130 16x12x8 25 239.28
504 0140 20 x 16 x 8 35 • 277.58
5040150 20x20x8 42 300.07
504 0160 20 x 24 x 8 47 322.37
504 0170 24 x 20 x 8 47 322.37
504 0180 24 x 24 x 8 54 347.98
504 0190 24 x 30 x 8 65 386.34
504 0200 30 x 20 x 8 57 355.85
504 0210 30 x 24 x 8 65 • 364.36
5040220 30x30x8 78 432.09
504 0230 36 x 24 x 8 75 424.82
504 0240 36 x 30 x 8 92 • 477.51
504 0250 42 x 30 x 8 106 523.11
504 0260 42 x 36 x 8 125 583.10
504 0270 48 x 36 x 8 139 635.98
504 0280 60 x 36 x 8 167 741.79
504 0290 20 x 16 x 10 39 291.97
.504 0300 24 x 20 x 10 52 340.06
504 0310 ' 30 x 24 x 10 70 407.89
504 0320 36 x 30 x 10 98 504.00
504 0330 48 x 30 x 10 125 600.12
504 0340 48 x 36 x 10 147 - , 669.50
504 0350 60 x 36 x 10 176 • 780.24
504 0360 30 x 24 x 12 75 429.57
504 0370 36 x 30 x 12 104 530.40
504 0380 48 x 36 x 12 154 703.12 -
504 0390 36 x 30 x 16 ' 117 - 584.33
504 0400 48 x 36 x 16 170 770.64
504 0410 60 x 36 x 16 202 . 895.69

TECHNICAL DATA SHEET
INDUSTRIAL ELECTRICAL
ENCLOSURES -STEEL AND ALUMINUM
Electrornate
ENCLOSURES
Panels for Extra Large
NEMA 1, NEMA 3R,
NEMA 414X, NEMA
12/13, Single Door
Disconnect, Large
"CH" Enclosures and
NEMAEMI/RFI
?./
Electromate -
Catalog MIS
Number Number Panel Size
E-12P24 :505 0010 9 x 21
E-16P12 - 505 0020 13 x 9
E-16P16' • 7-505 0030 13 x 13
E-20P12 - 505 0040 17 x 9
E-20P16 505 0050 17 x 13 ' ,
E-20P20 ' 505 0060 . - 17 x 17
E-24P16 '•• 505 0070 21-x 13
E-24P20 - '' 505 0080 21 x 17
_E-24P24 : 505 0090 21 x 21
E-30P16 505 0100 27 x 13
E-30P20 . • `: 505 0110 27 x 17
E-30P24 - - 505 0120 • 27 x 21
• E-30P30 505 0130 . • 27 x 27
E-36P24 - , 505 0140 - . 33 x 21
E-36P30 • 505 0150 ' 33 x 27 _
E-36P36 505 0160 • 33 x 33 •
E-42P24 • ,. 505 0170 39 x 21
E-42P30 505 0180 ;. 39 x 27
E-42 P36 , :- , - 505 0190 • 39 x 33
E-48P24 - 505 0200 45 x 21 •
E-48P30 505 0210. . 45 x 27
E-48P36 - • 505 0220 45 x 33
E-60P30 505 0230 57 x 27
E-60P36 505 0240 57 x 33
E-72P30 505 0250 69 x 27
E-72P36 505 0260 69 x 33
•
Use with Shipping _
This Size Weight List
Enclosure ' (Ibs.) Price
12x24 . 7 26.04
16x12 4 - 17.35
16x16_ -6 .21.35
• 20x12 '5 20.13
20x16- 7 25.41
20 x 20 9 30.70
24 x 16 9 . 30.61
24 x 20 13 '40.11
24 x 24 15 45.49
30 x 16 12 37.50
30x20 16 45.44
30 x 24 19 56.07
30 x 30 24 64.64
36 x 24 24 68.00
36 x 30 30 ' 86.36
36 x 36 37 99.31
42 x 24 28 73.81
42 x 30 35 95.50
42 x 36 43 112.80
48 x 24 32 84.24
48x30 40 113.15
48x36 49 134.14
60 x 30 51 138.31
60 x 36 61 164.98
72 x 30 62 163.53
72 x 36 77 195.78

TECHNICAL DATA SHEET
Miniature Circuit Breams
S270 •
240VAC Class
L: i977
WEO`d7 PROTECIION
K [.VOLE AND ECllRI.tcNT
RATED
CURRENT
CATALOG
RUMDER
�"•,-.-�.y'i
<-';.5�'LISf: _�,, =
, ,: _ �'-,�
DELIVERYV1cIGN(IGLY
CUSS
SUGGESTED
ORDER
O131J1+3TIES
SPIELE
:O .
•I
y,,tY
a; { - ''
�
trwEePoL�
i
- 0.5
1
1.6
2
3
4
6
8
10
•
16
20
25
32
40
50
63
5273-K0.5
S273-K1
5273-K1.6
5273-K2
5273-K3
S273-K4
S273-K6
5273-K8
5273-K10
5273-K1691:
' S273-K20
5273-K25
S273-K32��x79�
5273-K40
S273-K50 -
5273-K63.
: s 69'' •-•
69r'=
f ' 4:.K 69 *:-
'_.
= ' y<.^69'
`��69 '"�
` 69 `
--v
, fif" �+ 69
69
.� 69, = r.
69 4 f
y 18 r _
r87
-'t` i 00Y
.,114 .1
S
S
S
5
S
S
S
S
5
S
5
S -.
S
S
S
5
3
13.5
F-�; „� ;
it �41:gay _S;:r .-
,,,,c .4., -L91
5 j
~ - r
`
�i- ®
TRREE POLE with NEUTRAL
0.5
1
1.6
2
3
4
6
8
10
16
20
25
32
40
5273-K0.5NA'r�„mi00r
5273-K1NA -
5273-K1.6NA
-5273-K2NA
S273-K3NA
• 5273 K4NA;
S273-K6NA
5273-K8NA
5273-K10NA
S273-K16NA
5273-K20NA
5273-K25NA
5273-K32NA
S273-K4ONA
r
4`1~ 7Q i0tf,,�''
..ram-i 09 - -
; - '- 100 +
3*L 10 z
,-:rw
100
-tip
100 x-+
4'''100 g,-
s 100 a .
s.100
O 9100 Si,
1.
:xriO3`1 'i
'` 106' =`
'n =i12 % V
„,,.t _.:.:, ,„ -. z.,^7:
A
A
A
A
A
A
A
A
A
A
A
A
A
A
2
16.0
��j�-
AI A rr"?=
• 1.�.:%,
$.2.-, di..
�q -- :;;_ .1
...r.7.....,F � A!at..'
Ctil `"9 5� h
.1
FOUR POLE
0.5
1
1.6
2
3
4
6
8
10
16
20
25
32
40
50
63
5274-K0.5
S274-Ki
5274-K1.6
5274-K2
5274-K3
5274-K4
S274-K6
5274•KS
S274-K10
S274-K16
5274-K20
S274-K25
' 5274-K32
5274-K40
5274-K50
S274-K63
i� f 1y � a I.:j S5y � � l yl 1 F Ate r• � �.
rl _'.ice a1N Vil(I.:i�/.21'..,F. .ti�•,>tia,...�•*�yik�%
+, 01'UI•W ci - 'Q. O;O O Q.Q'O�Q'.O iO CO �:'•�
t0 O O cOyV cD-.lD l0 fO t6 SD cn to W (O tali.:
A
A
A
A
A
A
A
A
A
A
A_,�
A
A
A
A
A
2
18.0
//
/
'

TECHNICAL ATA SHEET
Bulletin 100
1EC Contactors
Product Selection
I
AC Operated Contactors
Cal. No. 100-A09.,,430
Past Shipment Program prices are printed in blue.
Cat. No. 100-A38.-..475
Cat. No. 100-B110».B500
Cat. No. 104.109...A30
Max.
le
(A}
Ratings (AC3, AC4)
Nan -Revers ng
Contactors •
Reversing
Contactors
kW (50 Hz)
HP (60 Hz)
30
10
30
220V
380V
415V
500V
660V
115V
230V
200V
230V
460V
575V
; .. W%
Cat. No; $�
Price
�Y i - w
7 Cat;No
Price
9 0
22
4
5.5
5.5
1/3
1
2
2
5
7-1/2
']O.0_AO9N®3u
S 90
:? y04lA09N®3 .:
S 254
120
3
5.5
7.5
7.5
1/2
2
3
3
7.12
10
-fatOOAi.'L_N.®_3"::
115
::'yrf04Al2NO3:T-
304
180
4
7.5
11
11
1
3
5
5
10
15
F 400-AiaN®3 =
130
;l.104.•A101®324:
334
240
5.5
11
15
15
2
3
5
7-1/2
15
20
...,.. 00-A24N 3'-
145
'.?10& 24N®3=_ti
364
30
7.5
15
18.5
18.5
2
5
7-1/2
10
20
25
lOt A30F 3 ;
178
-�-104-A30N® ,"
431
38
10
18.5
22
18.5
3
5
10
10
25
30
.; 100-828N®,3 y
210
: 04;A301V®,3,5
529
45
11
22
30
22
3
7.112
10
15
30
40
';r?i0o-A45N®3__
225
'1's104,A45H1`>3
559
60
15
30
37
37
5
10
15
20
40
50
4r100f&60N®3;-
268
-J04A8CNO:47.°
686
75
22
37
45
45
5
10
20
25
50
60
. ',100-A.75N®3. i
310
=° 104-A75N®3"
771
110
30
55
75
75
-
-
30
40
75
100
-00.611594®3;
500
" �104Bi1ON®;3'
1419
/80
45
90
110
110
-
-
60
60
150
150
=.j00-6180N0
1200
`- 04-B1B0I 3
2851
250
75
132
160
160
-
-
75
100
200
250
-P.,100-6250N853
1625
.;_ 104-B250H 3'
3919
304
90
160
200
200
-
-
100
100
250
300
700-0300N13, 3-
1781
1„1041304ON1 3
4231
414
120
220
280
280
-
-
125
150
350
400
100-044O0N®3
3875
� ;la4-Bg00N®�3;
8356
608
180
315
445
445
-
-
200
250
500
600
:4 100-6600N®3
6625
.,194-B660N®3:
15220
0 Voltage Suffix Code
The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: Cat. No.
100-A091.403 becomes Cat. No. 100-A09NJ3. For other voltages, consult your Allen-Bradley Sales Office. See page 10-1.
AC Voltage
24
42
48
100
100-110
110
120
200
208 1220
240
277
347
380
415 1440
480 1500
550 1600
50 Hz
K
W
Y
-
KF
D
KE
-
-
A
T
-
-
N
1
6
• I M
C I-
,/ 60 Hz
J
-
X
KF
-
D
-
H
L
A
F
KK
E
•G
B I-
- I C
50160 Hz
KD
•
KA
KF
-
S
-
KG
-
0 4 main poles of same ra ing. Right hand pole is normally used as auxiliary.
ALLEN-BRADLEY

TECBENICAL DATA SHEET
ya p.`
- r' m
Bulletin 193
SMP-iT"', SMP-2T4, and SMP-3TM Solid State Overload Relays
Product Selection
SMA-1 Overload Relay Manual Reset
7,15
Cat No. 133•AMA1
Cat Na 193-A71p
Cat No.193-A 1K4
Mounts to Contactor
100 and 104
M3510 A30
A1210 A30
A38 to A45
A50 to A75
8110
Adjustment
Range
.1 10.32A
.32101.0A
1.01o2.5A
1.61c 5.0A
17to 12A
12 to 32A
1210 38A
14 Io 45A
1410 45A
23 to 75A
21 to 75A
Class 10
:i93-i 1At el
;t93jAtc1�,
ytix. ay.:
793.AtD1.*
rr
y93=RtE1�
;la Nolitit
e183�1iFl2.E
�9�AfJ3:iy
ifs#ii+:ej.
193�AI K4'
Price
6 35
35
35
35
35
39
54
57
63
03
110
56 to 110A
pj93YA1L4't
110
19J=A21f4
6180
57 to 1130A
A1A.3:1
179
a93A2M5'i
CT Mounted for use with Bulletin 100 and 104 contactors 0
6250 and B300
961o300A
t'ly3t41N6-
238
B4o0
128 to 400A
��9s
193- 1PS:ti`
402
Fir
1193-A2P.6 -
6600
20013430A
J,�=-R1R69:
555
- 93•Akaao:
® Voltage Suffix Code
The Cat No. as fisted is incomplete. Select a voltage 5ulfix code from the table below to complete the Cat. No.
Example; Cat. No. 193•AtRUE/ becomes Cat No. 193'A1R6D• For other coil voltages. contact your local' Allen-Bradley Sales Odic
page 10.1,
501tz I K ID
60Nz I J I• —
-1�120_
D
0I
A
A
0 Does not include Terminal Lugs. See Accessories orl page 1.48 for listing.
N
1IB
G
B —

TECILNICAL DATA SHEET
�� ��/ I. c;7. ` � 'r � /' %',v`.' � Y :6%(fl tI a
f
Cutler -Hammer
Installation Instructions
Publication No:17978
Issue: 2re5
E22 Operators & Indicating Lights
Sealing washer
Operator
IJZTEO
sro corm Ea
A161
Contact block
Mounting adaptor ( Contact block
Anti -rotational ring'
t
Panel
Legend plate
oa
Mounting nut
lightening torque
1.7Nm (1Sin. lbs.)
recommended
Light source unit
' Supplied with selector switch. push-pull. and twist -to -release operators. Order
separately as catalog number E22LRM for use with any other operator.
Underwriter's Laboratories Listed.
For use on a flat surface of
type 1, 2, 3, 3R. 4, 4x, 12 and 13 enclosures.

it
TECIICAL DATA SHEET
Assembly and disassembly instructions
Mounting adaptor
Assembly
Embossed word 'TOP' on back of
operator
Disassembly
Gently
push
Note: Gently push locking lever and
tum as shown over locking 'nib'
Contact blocks and full voltage light units
• Assembly
'Click'
41(
Disassembly
Lamp replacement
Front of panel
Illuminated pushbuttons
Unscrew bezel. withdraw lens and
operator assembly.
Remove bayonet type lamp (push and
tum counter -clockwise).
Insert new lamp.
Re -assemble in reverse order (ensure
correct location of key in push guide
with slot in clear operator).
Tighten bezel, Recommended for
0.6Nm (5in. Ibs.).
Indicating lights and push/putt
operators
Unscrew lens and remove (remove
inner cap if fitted).
Remove bayonet type lamp (push and
tum counter -clockwise).
Insert new lamp.
Screw on lens. Recommended tarq,_..
0.6Nm (5in. Ibs.).
Illuminated selector switches
Unscrew bezel and remove lever nob
(note keyed position of leverrknob).
Remove bayonet type lamp (push and
Depress pad tum counter -clockwise).
Insert new /amp.
1 Re -assemble leverlknob in correct
Depress pad
Transformer light units
Assembly
keyed position and then screw bezel
back in place Recommended torque
0.6Nm (5in. lbs.).
Note: Use lamp extractor tool cat. no.
E2213A3 to assist in lamp removal.
Rear of panel
Disconnect power.
. Remove light unit as shown opposite.
Remove bayonet type lamp (push and
tum counter -clockwise).
Insert new lamp.
Reassemble light unit to operator as
shown opposite.
Disassembly NOTE
For ease in wiring two- circuit contact
blocks, it is recommended to wire front
terminals (terminals closest to panen
first.
Depress 2 pads
1
Depress 2 pads

-4
-

TECHNICAL DATA SHEET
K0PW Go
Protective Coatings
Product: BITUMASTIC NO. 50
TYPE OF COATING:
COAL TAR
DESCRIPTION:
Bitumastic No. 50 is a cold applied, black, thixotropic, heavy-duty protective coating. It
is based on a blend of plasticized coal tar pitch,/selected solvents and special fillers. As
received, it has the appearance of a heavy paste, however, when stirred it thins out to a
brushing, rolling, or spraying consistency without the use of thinners. On standing,
after stirring, it returns to its original thixotropic state. It is self -priming on steel.
USE: FOR INDUSTRIAL USE ONLY. NOT INTENDED FOR USE IN THE HOME.
The unique properties of this coating make it especially suitable for use under unusually
severe corrosive conditions. It can be applied easily to steel in exceptionally thick films
without sagging. It is especially adaptable to underground and/or underwater
installations. It is not recommended for use on concrete and masonry. Use Bitumastic
Super Service Black (self -priming) for concrete and masonry.
Meets the following specifications:
1. Department of Navy, Bureau of Yards and Docks - 34 Yd.
2. Military Specification - MIL-C-18480B.
3. Bureau of Reclamation - CA-50.
Do not use on surfaces in contact with potable water. Bitumastic Super Tank Solution -
High Solids for potable applications.
Volatile Organic Compound (VOC) as supplied is 354 grams/liter (3.0 lbs./gls.). When
thinned 10% using Kop-Coat Thinner 1000 or 2000, the VOC is 408 grams liter (3.4
TECHNICAL DATA:
Number of
coats:
one, minimum
Volume solids: 68%
Theoretical
coverage: 1,090 mil sq. ft./gal.
Coverage to achieve
minimum dry film
thickness: 50 to 60 sq. ft./gal. per coat on smooth metal surfaces (allows for approximate 20%
application loss.

Methods of
Applications:
TECHNICAI DATA SHEET
Film build ratio:
Minimum dry film
Minimum dry film
required per coat: 8 to I0 mils
Wet film required
per coat: 10 to 12 mils per coat
Drying time at 70°F
and 50% relative humidity:
To touch: 6 to 12 hours
Between coats: 24 to 48 hours. The first coat must be thoroughly dry before the application of the
succeeding coats.
Prior to submerging:
Normally 14 days after fmal coat is applied.
Prior to backfilling:
5 to 7 days after final coat is applied
Color: Black
Thinner: Normally do not thin.
Cleaner: Use Kop-Coat Thinner I000 or Kop-Coat Thinner 2000.
Surface Preparation:
Apply only to clean dry surfaces. Remove from metal surfaces rust, paint, dirt, of
grease and other foreign matter by sandblasting (SSPC-SP-6), pickling, wire brushing
scraping or other means.
For concrete and masonry surfaces, use Bitumastic Super Service Black (self -priming).
Primer: Do not apply over any primer.
Concrete and masonry:
Must be primed before application on Bitumastic 50. Use 1 or more coats of Bitumasti
Black Solution.
Mixing instructions:
Stir thoroughly to obtain application consistency. Power mixing is recommended. Us
of a thinner to obtain application consistency may destroy the thixotropic properties o
the coating and will cause inadequate film build.
Brush roller, conventional air spray (pressure pot, 3/16" cap, I/8" tip) or airless spra
(30;1 pump, tip ,023" to .035", line 3/8" I.D.). Use clean natural bristle brushes o
phenolic cored rollers. When application is made by brush, scoop coating fro
container with side of brush and lay the coating on the surface. Do not brush coatin
out thin. For coating large areas, spray application is recommended.
During cooler weather, the use of an in -line heater with spray equipment will facilitat
ease of heating and aid in faster drying of the coating.
Temperature
Limitations: 160°F dry: 100°F wet.
Storage life: One year minimum
Packaging: 55 gallons drums, 5 gallon pails, 1-gallon can

TECHINICAL DATA SHEET
, . ,.i3`-; pF .a �a i "r.�Is 4 1 ^7 .4`rY:'X'''',.,;•9!:,n
PRECAUTIONS:
Take these precautions during application and before the coating cures. See Material
Safety Data Sheet for this product. OBSERVE ALL APPLICABLE PRECAUTIONS.
MANUFACTURED AND LABELED FOR INDUSTRIAL USE ONLY.
CONTAINS: COAL TAR PITCH, COAL, COAL TAR SOLVENT PAPHTHA,
CREOSTOE OIL, AND TALC.
WARNING! KEEP OUT OF THE REACH OF CHILDREN. HARMFUL TO
THE SKIN AND INTERNAL ORGANS IF ABSORBED THROUGH THE SKIN,
CAUSES EYE, NOSE, THROAT AND LUNG IRRITATION. SUNLIGHT MAY
CAUSE PHOTOTOXIC REACTION. HARMFUL IF INHALED. MAY AFFECT
THE BRAIN OR NERVOUS SYSTEM, CAUSING DIZZINESS, HEADACHE OR
NAUSEA. FLAMMABLE LIQUID AND VAPOR.
CHRONIC OVEREXPOSURE' (AS DEFINED BY OSHA RECOMMENDED
STANDARDS) MAY, CAUSE CANCER OR DAMAGE TO THE LIVER, KIDNEY
OR CENTRAL NERVOUS SYSTEM
Wear eye, skin and respiratory protection. Avoid breathing of vapor or spray mist.
Avoid contact with eyes and skin. Liquid or vapor contact with and exposure to sunlight
may result in a phototoxic skin reaction. Repeated and/or prolonged contact may cause
more serious slan disorders including cancer. Application of protective sun screen
creams for coal tar products before and several times during work day may be beneficial.
Change protective equipment when contaminated. Do not take. internally. Wash
exposed areas promptly and thoroughly after contact and before eating, drinking, using
tobacco products or rest rooms. Provide enough general area and local exhaust
ventilation in both pattern and volume to keep breathing air within Threshold Limit
Values and below the Lower Explosive Limit. Failure to provide adequate forced air
ventilation in tanks and confined areas can cause death from explosion or breathing.
Follow NIOSH Pub. 80-106, "Working in a Confined Space"- Keep away from heat,
sparks, and open flame. Ground and bond container when dispensing. Use explosion -
proof equipment. Keep container closed when not in use.
Use With Adequate Ventilation
WARNING! This product contains a chemical known to the state of California to cause
cancer and/or reproductive harm.
NOTICE! REPORTS HAVE ASSOCIATED REPEATED AND PROLONGED
OCCUPATIONAL OVEREXPOSURE TO SOLVENTS WITH PERMANENT BRAIN
AND NERVOUS SYSTEM DAMAGE. INTENTIONAL MISUSE BY
DELIBERATELY CONCENTRATING AND INHALING THE CONTENTS MAY HE
HARMFUL OR FATAL.
FIRST AID: Eye Contact: Hold eye lids open and immediately flush with plenty of
lukewarm water for at least 15 minutes and call a Physician. Skin Contact: Wash
thoroughly with waterless hand cleaner and/ or soap and water. If irritation persists,
seek medial aid. Inhalation: Remove from exposure. If breathing has stopped or is
difficult, administer artificial respiration or oxygen as indicated. Seek medical aid.
Ingestion: if swallowed, call a physician, hospital emergency room or poison control
center immediately. Do not attempt to give anything by mouth to an unconscious
person.
PRODUCT EMERGENCIES: 1 800 548 0489
In Case of Spill or Leak - Eliminate all sources of ignition. _Ventilate areas. Absorb
with inert material. Fire - Use CO2, dry chemical, alcohol or universal type foams or
water spray/fog. Cool closed containers with water. Waste Disposal - Dispose of as a
hazardous waste in accordance with local, state and federal regulations.
•

TECHNICAL DATA SHEET
Empty Container: This container hazardous when empty. Residual vapors may
explode on ignition; do not cut, drill, grind, or weld on or near this container. Do no
reuse without commercial cleaning or reconditioning.
KOP-COAT, INC. Pittsburgh, PA 15219
WARRANTY
All technical advice, recommendations and services are rendered by the Seller. They are based on technical data which the seller
believes to be reliable and are intended for use by persons having skill and knowledge, at their discretion and risk. Seller assumes no
responsibility for results obtained or damage incurred from their use by Byer whether as recommended herein or otherwise. Such
recommendations, technical advice or services are not to be taken as a license to operate under or intended to suggest infringement
of -any existing patent.

TIPTON ENVIRONMENTAL INTERNATIONAL, INC.
Pre -Plant Delivery Instructions
Introduction
/I
The Tipton Environmental International, Inc. wastewater treatment system is a complete,
factory built prefabricated system shipped to you, ready to be placed into the owner's
excavation site. Several of the sub -assemblies have been shipped loose for field re-
assembly where shipping height limitations would not permit them to be attached. There
are certain important details that must be checked by the Owner's contractor prior to the
plant arriving at the job site.
Please review the following instructions carefully and study the drawings of your
wastewater treatment plant system to obtain a working knowledge of the equipment you
will receive. If you have any questions or need further information, please do not hesitate
to contact Tipton Environmental International, Inc. at 513.248.4067.
Should you notice any error, please contact us immediately. With proper care and by
following the suggested, simple instructions, much time and money can be saved.
These suggestions are for your guidance: by carefully reading them before you begin
work.
Scheduled Delivery Date
We will review our production schedule and keep you advised as to a date.
Excavation
A study of the shop drawings on your treatment system will permit you to determine the
size and depth of excavation needed for your installation.
The size of the excavation should be at Ieast two feet wider and longer than the actual
dimensions, allowing room for anchoring and paint touch-up prior to backfilling. Place
material far enough away from the excavation site to allow the trucks and crane to operate
safely from either side.

2
It is best to back -fill up to a point above where the water level in the plant will exist, and
on all four sides to prevent freezing in climates where this condition may exist.
Foundation
A concrete foundation slab is necessary due to the construction of the sewage treatment
system. This slab is to be used as a tank base and in some cases, for anchoring the vessel
to prevent any flotation. f
The customer's Project Engineer is responsible for the design and construction of this
slab. For typical designs and construction methods (based on use for alignment purposes
only), refer to the foundation slab detail drawings which are supplied. These slabs have
been designed for average soil conditions.
To determine which slab is needed, you must assume that the total weight of the plant will
act as a uniformly distributed load acting along the entire length of the foundation pad.
It is extremely important that the foundation slab be level; if not, the system wiII not
function properly. The slab must be level within tolerances of 1/2" per each 10' to 0" of
width and within 1/4" per each 10'-0" of length. In instances where crowns in the slab or
any other non-standard workmanship exist, corrections must be made by resurfacing the
slab, or by placing a sand cushion on top of the slab to achieve full uniform bearing.
The foundation slab should be checked by the Project Engineer before the treatment
system arrives at the job site. A foundation slab of adequate size and weight should be
supplied to equal the bearing soil pressures where flotation conditions exist as in fluid soil.
Sufficient anchor bolts and/or rods should be used to securely anchor the tank to the
foundation pad.

Shiyyina
In almost every situation, shipment of the prefabricated plant is by special lowboy trucks.
When your plant is shipped through our shipping company, delivery will be made directly
to the job site unless otherwise specified. When the systems are small enough, it can be
delivered to the nearest dock instead of actual site. in these cases_ it will be the
customer's responsibility to arrange for moving the system from the dock to the site.

4
7,7
Unloadi21g
•
_Sc ='r .+• �^Y"t�vw ,4..a.,y r c4.' x s�-1-. - � .
It is necessary for the contractor to have all necessary equipment available to unload and
set the vessel on the foundation pad when the plant arrives.
The equipment necessary to unload the plant and place it on the foundation pad must be
furnished by the customer. Lifting Iugs are supplied on the vessel to ease handling. A
crane of adequate size is usually the most simple method for unloading the plant.
After the plant is set, check that it is level and in the correct position.
The package steel treatment system will be completely assembled and shipped as one unit
where shipping. dimensional regulations permits. The equipment which is packaged
separately at the factory for field assembly, will be installed by the contractor in the field.
Check the inside of the aeration tank for pallets of equipment which have been placed
there for shipping. Remove these pallets with the crane. The blower motor units and
control panel are typical items which are shipped in the tank.

5
IJ
�.` n vim:
•
Unloadin.' the Blower Motor Units. The blower motor units should be lifted by the crane
onto the plant from inside the tank. The housing sits on angle supports drilled to receive
the rubber hose connection through the bottom of the base of the blower. The blower
discharge piping which extends from the bottom of the blower housing must be aligned
with the plant air supply line which is stubbed for connection during assembly.
Unloading miscellaneous Items. Other loose items or accessory cartons should be
removed from the tank and placed in a safe place until installation on the plant. The
packing list should be checked to see if all equipment is received before signing the
shipping manifest. Please note that any shortage claims must be made in writing.

r
Electrical Aspects of the Equipment
Check data sheets and wiring diagrams, then advise the electrical contractor and local
power company of the necessary requirements for power. Special precautions should be
taken to ensure correct electrical requirements are supplied at the job site.
A disconnect switch mounted preferably adjacent to the plant within sight and wiring from
this switch to the electrical control panel on the plant must be furnished and installed
abiding by the local EIectrical Codes. The wire leads provided to hook-up the blower
motor units, spray pumps, and any other accessories must be connected by the contractor
to the control panel. All electrical installations and connections must be made ready for
inspection before the factory inspector arrives.

7
Proper blower motor rotation must be maintained. Improper rotation will cause damage
to the blowers due to water being pumped back from the plant.
Electrical Hook-up: Final field hook-up must be done by the electrical contractor. A
general wiring diagram showing the details of this hook-up will be found inside the door
on the electrical control panel.
Miscellaneous Items
1) Site Check: The excavation and foundation pad should be checked to see that it is
clear and free of any debris, water, or mud. The site should be clear of piles of dirt
around the plant area for easy access for trucks and safe crane clearance.
2) Unloading Facilities: Arrangements should be made for obtaining a crane
beforehand to ensure adequate time to prepare and adequate capacity to lift tank.
Sewer connections are the owner's responsibility.
WARNING
Once the system has been set and anchored, the drain plug must be installed and the tank
must be filled with water to keep it from floating because of its buoyancy. Tipton
Environmental International, Inc. assumes no responsibility for this occurrence.

Operations And
Maintenance•
Manual
or Packaged Wastewater Treatment Systems
Tipton Environmental
IntemnatiOn4'Inc.
2002 Forb Clyde Suite G
Mi( f oral OH 45150
PH: 513.2484067 FAX: [phone]

INTRODUCTION
As our nation grew and became industrialized,
areas of growth caused concentrations of businesses and
populations. These concentrations produced quantities of
industrial and human wastes that pit privies and septic
tanks could no longer treat adequately. This led to the
development of sewers as a means to convey wastes away
from the population centers. Early systems, called
combined sewers, collected both wastes and runoff from
rainfall. Later, systems were developed to carry either
waste or surface runoff and were called sanitary sewers or
storm sewers, respectively. The type of collection system
that discharges into the wastewater treatment plant is an
important factor, as will be discussed later in this manual.
Wastewater collection.systems eliminated many
health problems associated with urban. life; nonetheless,
all the wastes were being discharged from a few pipes
into the nearest stream. As areas developed, more waste
was generated; new towns developed along rivers, thereby
reducing the distances between discharges. Eventually,
the streams could no longer handle the waste without
showing damaging effects. Rivers began to have foul
odors and were often covered with floating solids. In
some cases, the pollution caused the death of fish and
other aquatic life.
Wastewater treatment processes were developed
by observing what happened in nature. As waste entered
the stream, the dissolved oxygen in the water decreased
and bacteria populations increased. As the waste moved
downstream, the bacteria would eventually consume all
the organic material. Bacterial populations would then
decrease, the dissolved oxygen in the stream would be
replenished, and the whole process would be repeated at
the next wastewater discharge point. This natural process
worked well until the distance between discharge points
became so close that the dissolved oxygen content in the
river could not be replaced quickly enough through
natural means.
Waste material in domestic wastewater is
generally organic (biodegradable), which means that
microorganisms can use this matter as their food source.
As aerobic microorganisms consume the organic material
oxygen is also consumed. An indication of the amount of
organic material that can be consumed by the aerobic
microorganisms is called the biochemical oxygen demand
(BOD). By measuring the amount of oxygen the bacteria
consume, the amount of biodegradable material in the
waste may be determined.
From an operation and maintenance standpoint,
a plant should be installed, if possible, with the tank walls
extending approximately 150 mm (6 in) above the
ground. Such an installation allows ease of servicing,
prevents surface runoff from entering the plant, and pro-
vides some insulation in colder weather. Plants installed
completely
below grade must have extension walls or well defined
diversion ditching to prevent surface runoff from entering
the plant. Plants located totally above ground are difficult
to maintain unless walkways are provided around the
entire plant; in addition, such plants will require
insulation in cold weather areas.
A chain link fence, 1.8 m (6 ft) in height, flush
to the ground, with a locked entrance gate, and topped
with three:strands of angularly installed barbed wire, is
recommended to prevent vandalism and tampering, and to
discourage children from entering. A minimum of 1.2 m
(4 ft) of working space between the fence and plant at all
points is necessary for maintenance. A building
constructed over the plant can be used instead of a fence
if camouflage is desired or if the plant is located in a cold
climate. The building walls, like the fence, must beat least
1.2 m (4 ft) from any part of the plant to allow
maintenance; the building must be ventilated, well lit, and
have adequate headroom above the plant generally 2 m (7
ft). The building provides additional insulation in very
cold weather and prevents pine needles, leaves, and other.
foreign objects from entering the plant. Housing also
muffles noise from the blowers.
THE PLANT SHOULD NOT BE STARTED UP
UNTIL THE MANUFACTURER'S MANUAL HAS
BEEN READ AND UNDERSTOOD. If plant controls are
complicated, the manufacturer should be required to
provide training as part of the bid document; training is
recommended for all installations. Additional technical
assistance may be provided by local regulatory agencies
or an operations and maintenance services firm.
Metal and concrete are the two most common
materials used in the manufacture of package plants.
Among the advantages of concrete; it is less expensive if
a short shipping distance is involved; it will not corrode;
and it has a longer life expectancy. Some advantages of
metal;. it is Iess subject to leakage; it is easier to service
and alter; it has a high salvage value and lighter weight;
and there is less possibility of solid deposition between
clarifier hopper and outer tank than might occur in
concrete tanks because of poor field filleting.
Motors, blowers, and control panels should not
be mounted on top of the plant. This is because on -plant
locations interfere with the operator's maintenance
procedures, all control equipment is exposed to a more
corrosive atmosphere, and tools and equipment are more
likely to be dropped into the plant while making repairs or
servicing equipment.
The package wastewater treatment plant must be
installed in a level position to work properly. A steel plant
is usually placed on a level concrete pad that extends
horizontally at least one-third meter (1 foot) in all
directions •beyond the base of the plant. A concrete plant
is usually set on damp, well compacted, level sand. In all
cases, the possibility of settling trust be avoided. Because
of the segmented design of concrete plants, it is important
1

to eliminate any settling. A concrete plant will require
the same foundation considerations as a steel plant.
During start-up or during operation of the
package plant, it may be necessary to dewater the plant to
remove non -biodegradable material such as dirt, sand,
mud, or fibrous materials that may have entered the plant.
Dewatering during construction should be done only after
all sewers and lift stations have been thoroughly flushed
to remove all material from the collection system.
Dewatering should proceed from the influent end of the
plant to the effluent end until the liquid level is below the
opening between the aeration chamber and the clarifier.
The water level in both compartments will drop simulta-
neously. Cleaning is not complete until all material is
removed from all parts of the plant. Septic tank haulers
may be used to dewater the plant; however, it may be
necessary to remove mud and sand with shovels and
buckets, because even relatively small amounts of mud or
sand left in the plant can interfere with its operation.
Because a package plant may need to be
dewatered occasionally, care must be taken to prevent it
from floating out of the ground from the buoyant force of
the water in the surrounding soil. Concrete plants are not
usually anchored because of their weight; however,
concrete plants can float and could be damaged by
hydrostatic uplift pressure. During construction, it is
recommended that areas adjacent to all plants be
backfilled with free draining material (sand or gravel)
and, where the lay of the land permits, a drain should be
installed to remove surrounding groundwater. If topogra-
phy does not permit the installation of a drain, then well
points should be placed around the plant so that the
surrounding ground -water may be lowered before
dewatering.
Well points can be constructed by installing 100
or 150 min (4 or 6 in) diameter plastic pipes, placed
vertically at several locations around the plant, with a
minimum of one pipe at each corner. The bottom 1.2 m (4
ft) of the pipe must be perforated. The top of the pipe
should extend just above ground surface and be capped
loosely. The bottom of the pipe should be below the
bottom of the plant. Gravel slightly larger than the holes
in the pipe must be packed around it to allow water in and
to keep the surrounding soil out of the pipe. It is easier to
install the well points at the time the plant is being
installed.
Installation
Note: Cathodic Protection Magnesium anode packages
are Supplied with all prefabricated steel wastewater
treatment plants for cathodic protection. These packages
are to be securely connected to the aeration chamber.7bis
is done by bolting the long heavy copper wire coming
from the inside of the packaged anode to the eonheetioo
lugs on the aeration chamber. This must be a good
electrical connection. These packages are to be buried as
deep and as far from the plant as possible while leaving
plenty of slack its the wire. This is normally done when the
plant is baddiiled.
The main objective is to provide a path for the
water to travel from the area around the plant to the well
points. If possible, a package plant should not be
dewatered during wet weather. A PACKAGE PLANT
CANNOT BE DEWATERED BEFORE PERMISSION IS
OBTAINED FROM THE PROPER REGULATORY
AGENCIES. It is imperative that the drain plugs are
installed on metal tanks before being set into the ground.
Manufacturers leave the drain plugs out during fabrication
and storage so that rain water does not collect in the plant.
During final inspection, and while the plant is
empty, all parts of the plant that are normally under water
should be carefully inspected. Metal plants are usually
painted with a coal tar,epoxy' paint to prevent corrosion.
Any time an existing plant is denatured, all surfaces that
are normally submerged should be inspected for corro-
sion. If corrosion problems are corrected during the
cleaning operation, denaturing at a future date to inspect
for corrosion can be eliminated. It is also recommended
that the design engineer inspect the plant at the
fabrication site to eliminate field corrections.
The outside of all steel plants must be painted
with coal tar epoxy or other suitable paint as
recommended by the manufacturer. To minimize
corrosion from acid soil, sacrificial magnesium anodes
are buried in the ground 'approximately 3 in (10 ft) from
the metal plant and attached to the base metal of the plant
with a copper wire. During construction, proper
installation of the anodes is critical. Not allowing enough
slack in the copper wire so that it breaks when the backfill
around the plant settles is a common mistake -take. Plenty
of slack should always be left in the wire.
A frost -proof potable water hydrant with a
backflow preventer should be located near the wastewater
treatment plant for washdown and cleanup. On larger
plants clear water from the chlorine contact tank or
clarifier may be used as washdown water; however,
smaller plants do not have sufficient volume. Removal of
supernatant from the clarifier of a small package plant
will interfere with settling. Supernatant from the clarifier
is used for foam control.
At the final inspection of a new facility, the
owner should receive the manufacturer's O&M manuals
for all mechanical equipment. Information in the manuals
should include, but not be limited to, the following:
• A complete list of all replacement parts including
name of manufacturer and parts catalog number;
• Operating instructions;
• Maintenance instructions;
• Wiring diagrams;
• Troubleshooting procedures;
• As -constructed drawings; and
Drawings of plan views showing the location of:
treatment plant with respect to nearby permanent
landmarks (buildings); all underground potable water and
electric lines; underground influent and effluent lines; and
sacrificial anodes.
2

Protective Devices
Most large treatment plants are designed to
allow wastewater to flow through a primary classifier for
removal of settleable or floatable materials. This primary
settling or treatment usually removes all grit, sand, and
grease and reduces the organic loading on the aeration
chamber by approximately 30%. Small package
wastewater treatment plants do not have separate units for
primary treatment; instead, they combine primary and
biological treatment. Small plants have protective devices
similar to those of Iarger plants. Protective pretreatment
devices are designed to remove nontreatable material
from the wastewater before it reaches the aeration
chamber, or to precondition the wastewater and make it
easier to treat in the aeration chamber. Many regulatory
agencies consider the equalization tank a pretreatment
device. Equalization was discussed as .a separate topic in
Chapter 3 because of the numerous concepts its operation
involves.
SCREENS
Although most bar screens installed on small
package wastewater treatment plants are similar to those
in Figure # I its Iocation and design have caused some
problems. The bar screen is designed to remove large
untreatable material from the wastewater flow. Most
manufacturers place the comminutor before the bar
screen; this causes nontreatable material to be ground into
small pieces and passed through the bar screen.
Bar screens should be fabricated from 12 mm
by 50 mm (0.5 in. by 2 in.) bars rails and 12 mm (0.5 in.)
diameter rods. This eliminates the necessity for transverse
stiffeners, permitting easy cleaning of the screen. If the
bar screen is located in the aeration chamber, the bottom
one-third should be under water. The rolling action in the
aeration chamber will break up large organic solids,
thereby preventing buildup of treatable solids on the bat
screen. The top of the bar screen should be well below the
inlet pipe so that solids do not block the inlet pipe and
cause wastewater to back up in the line.
Protective Devices
AERATION CHAMBER
ACTIVATED SLUDGE TREATMENT SYSTEM
pH
AERATION
DIFFUSERS
BLOWER MOTOR UNIT
TEMPERATURE
RETURN SLUDGE LINE
SKIMMER LINE
FROTH SPRAY SYSTEM
BLOWERS AND MOTORS
TIME CLOCKS
Aeration Chamber
ACTIVATED SLUDGE
TREATMENT SYSTEM
1
After raw wastewater flows through the various
protective devices where pretreatment occurs, it flows to
the aeration basin. The aeration chamber is the key part of
the secondary treatment plant; bacteria and other
microorganisms thrive and multiply here as they consume
the food (organic material) in the wastewater. This
aerobic biological process biological in that bacteria and
other microorganisms are essential to the process and
aerobic, in that these microorganisms need air or
dissolved oxygen to survive is called an activated sludge
treatment system. The microorganisms or "bugs" are
typical of all Iiving things in that they need food, oxygen,
and a compatible environment in which to thrive and
multiply.
The aeration chamber and the clarifier house the
microorganisms; most of the biological action occurs in
the aeration chamber._ The clarifier allows the
microorganisms to settle, producing a clear discharge.
The food and water needed by the
microorganisms is supplied by the wastewater, the food
being the organic matter in the wastewater As the
wastewater enters the aeration chamber, it is mixed with
the microorganisms and aerated by either diffused or
mechanical aerators. The aeration provides the needed
oxygen, and the mixing brings the microorganisms in
contact with the organic material. This mixture of
wastewater and microorganisms in the aeration chamber
is called mixed liquor.
ADSORPTION AND ABSORPTION. As the food
comes in contact with the bacteria chamber, it is broken
down by two processes: adsorption and absorption.
Adsorption refers to the attachment of food to the outer
slime layer that surrounds the microorganism. Most
organic particles are adsorbed by the bacteria within 0.5
hour of entering the aeration chamber. Absorption refers
to the food being eaten or taken into the body through the
cell membrane. The microorganisms release chemicals
called enzymes that break down the adsorbed (attached)
food particles so that they can be absorbed (taken in)
through the bacteria's cell wall. These processes are illus-
trated in Figure 5.1
ACTIVATED SLUDGE. As the microorganisms
are mixed in the aeration chamber, they stick together to
form a brownish floc called activated sludge. This floc is
formed properly only when conditions in the aeration
chamber are favorable. The correct amount of food for the
3

microorganisms, the proper amount of dissolved oxygen
in the water, good mixing, proper temperature and they
are all important.
F!M RATIO. A basic bacteriological guideline
common to all activated sludge wastewater treatment
systems is the ratio of food entering the plant to the
microorganisms in the aeration chamber. This is referred
to as the Food to microorganisms (F/M) ratio. F/M is ,
based on the fact that a certain amount of microorganisms
can consume only a certain amount of food in a specific
amount of time. Too few bacteria or too many bacteria in
the system for the amount of food causes the system to
function ineffectively. For the extended aeration process,
450 g (1 lb) of microorganisms can consume
approximately 20 to 70 g (0.8 to 2.4 oz) of organic
material per day. This means that for every. 30 m3
(1000 cu ft) of liquid in the aeration chamber,
approximately 4.5 to 11 kg (10 to 25 Ib) of organic
material may be treated.
Every wastewater treatment plant is designed to
treat a certain amount of food daily. The aeration chamber
and clarifier are sized for the quantity of microorganisms
needed to treat the expected Ioad. If the actual Ioad to the
treatment plant exceeds the design load, more
microorganisms will be produced than the aeration
chamber and clarifier were designed to handle. Too many
organisms in the system could result in the following
operating problems: the aeration chamber could go septic
if the blowers are unable to supply the oxygen needed by
the additional microorganism; and solids could be lost
from the clarifier.
One reason solids are lost over the effluent wier
in the clarifier is that too much food may be entering the
plant. Two methods are often used to determine this
condition. If a laboratory is available, the kilograms
(pounds) of food entering the plant may be determined by
the influent BOD and the flow. A suspended solids test of
the mixed liquor along with the volume of aeration tank is
needed to determine the kilograms (pounds) of mixed
liquor solids. The F /M can then be determined by
dividing the kilograms (pounds) of food entering the plant
by the kilograms (pounds) of mixed liquor solids in the
aeration chamber. For the extended aeration process, this
ratio (mass of food to mass of microorganisms) should be
between 0.05 and 0.15. This method of determining if the
wastewater treatment plant is organically overloaded is
the most accurate; however, it takes a well -trained
operator to perform the tests and make the calculations.
If the plant is lightly loaded one should not add
dog food or some other source of organics to the plant.
Adding dog food usually will not improve the operation
of the plant. Dog food is high in grease content, which
will accumulate in the plant. Although a lightly loaded
plant will not operate at optimum efficiency, fewer
problems will be encountered by not feeding the plant.
For small package extended aeration treatment
plants without laboratories or without the capability of
performing the BOD or suspended solids tests, the
settleability test may be used to determine if the plant is
organically overloaded. A sample of the aeration chamber
is allowed to settle in a 1000 mL graduated cylinder or a
calibrated quart jar for 30 minutes. If the system is
intermittently aerated, the blowers must be on when the
aeration chamber is sampled. After 30 minutes, a good
settling sludge will settle to 20 to 50% of its original
volume. If the organic loading to the plant is higher than
the design loading then the reading after 30 minutes will
be greater, and may even be as high as 70 to 80%. If a
high organic loading is causing the high settled sludge
reading, then microorganisms must be removed from the
system. The aeration chamber and clarifier are only
designed for a specified amount of organisms. If the
operator does not remove the microorganisms, they will
probably be lost over the clarifier effluent weir. As will
be seen later, a high loading to the wastewater treatment
plant is only one of several reasons for a high settleability
reading.
The pH of the liquid in the aeration chamber is a
factor that affects the operation of the extended aeration
wastewater treatment plant. pH refers to the concentration
of hydrogen ions in water. Simply stated, pH is a measure
of how acid or alkaline the solution may be. The range of
the pH scale is from 0 to 14; the lower numbers signifying
acidic substances and the higher numbers, basic
substances. A pH of 7 is neutral neither acidic nor basic.
Because pH is measured on a logarithmic scale, a pH of 6
is 10 times more acidic than 7; and a pH of 5 is (10 times
10)100 times more acidic than 7. The ideal pH for
bacteria in the aeration chamber is about 7.2, although
they can thrive when the pH is within flow range of 6.5 to
8.5.
Usually domestic wastewater will have enough
chemical components to maintain the pH in the aeration
chamber between 6.5 and 8.5. However, if household
chemicals are used excessively, the pH may become too
low or too high for the microorganisms to live. Drain
cleaners usually contain sulfuric acid or caustic soda.
Excessive sulfuric acid will lower the pH well below 6.5;
excessive caustic soda will raise the pH well above 8.5. If
the pH in the aeration chamber becomes a problem, the
pH of the raw wastewater should be checked to determine
if chemicals are poisoning the microorganisms.
In addition to chemicals affecting the pH in the
aeration chamber, the activity of the microorganisms may
lower the pH. In some extended aeration plants that have
low F/M ratios or are under -loaded, nitrification may
occur. Nitrification is the conversion of ammonia to nitric
acid by the bacteria in the aeration chamber.
Variation in pH when 100 mg/L of different materials are
added to pure water. When this occurs the pH may be
lowered to below 5.0. Because nitrifying bacteria like
warm temperatures, nitrification occurs most often during
the summer months.
If the pH is below 6.0 it may be raised by
dosing the aeration chamber and the clarifier with a basic
4

material such as sodium bicarbonate or lime. Although
sodium bicarbonate is more costly, it is practical for use
in smaller plants as it does not produce the inorganic
sludge associated with lime and will not raise the pH to
above 7.5. The chemical characteristics of sodium
bicarbonate give the operator of a small extended package
aeration plant a safe guard against raising the pH too
high. If the pH is too high (above 8.5), it may be lowered
by using a weak acid, such as acetic acid (vinegar).
Problems with the pH being too low are much more
common than the pH being too high.
Chemicals should be added to the wastewater
plant in sufficient quantities to raise or lower the pH one-
half unit_ The plant should be dosed only once per day.
After the pH has been adjusted to an acceptable level, the
plant may require daily dosing to maintain the proper pH.
If the pH of a plant changes drastically from one day to
the next, the influent should be monitored.
AERATION
As mentioned earlier, aeration performs a dual
function: it provides dissolved oxygen for the
microorganisms; and it mixes the raw wastewater with the
aeration chamber mixed liquor. The oxygen supply must.
be sufficient to maintain a minimum dissolved oxygen
concentration of 2.0 mglL in the aeration chamber at all
times. If an inadequate amount of air is supplied to the
aeration chamber, the aerobic bacteria will die. Anaerobic
bacteria (those that live without free oxygen) will begin to
grow, producing a disagreeable rotten egg odor. A third
type of bacteria, called facultative, can live under either
condition.
The specific organisms involved in the process
are also important. There are -both desirable and
undesirable types of organisms. Although many
organisms may use the organics in the waste with nearly
the same efficiency, some will settle Out better than
others in the clarifiers. This is where the organics that
have been either adsorbed or synthesized into cellular
material in the aeration tanks are finally removed from
the wastewater. Desirable microorganisms are those that
clump together and form a gelatinous floc that readily
settles out. Undesirable organisms are characterized by
stringy or threadlike forms known as filaments; thus,
these organisms are called "filamentous growths."
Because of their light weight and structure, filamentous
growths do not settle rapidly and are easily washed out of
the clarifiers. Whether desirable or undesirable organisms
predominate depends on the environment and on the
sludge wasting rate, conditions which can be controlled
by the operator.
The aeration basin must be kept uniformly aerated and
mixed, thereby providing oxygen for the bacteria, keeping
the solids in suspension, and allowing a rapid mix of the
raw wastewater with the bacteria for oxidation and
synthesis of the organic matter. The aeration basin should
/
be inspected each time a site visit is made to determine
that uniform mixing is occurring. Improper mixing in the
aeration chamber could result in sludge deposits that may
become septic, thus hindering proper operation of the
aeration chamber.
On most small extended aeration treatment
plants the aeration chamber is rectangular, with the longer
side parallel to the incoming flow. Some units are square,
with an aerator located in the center. Wastewater enters
the aeration chamber at the head end of the chamber and
flows into the through a baffled crossover located at the
opposite end. The circular plant has the same units as the
rectangular plant.
DIFFUSERS
Air (oxygen) is supplied to the aeration chamber
from the blowers to vertical downfeed pipes (drop pipes),
usually located along one of the longer sides of the
chamber, then into horizontal pipes (lateral) at the bottom
of the tank, and then into the air diffusers. Each drop pipe
has a plug valve so that the flow of air can be adjusted.
Figure 5.3 shows a typical diffuser assembly. This
arrangement causes a wall of air bubbles to rise on one
side of the tank, carrying wastewater from the bottom of
the tank toward the top and across the water surface. A
rolling action, results which, when combined with incom-
ing flow, causes the wastewater in the aeration tank to
travel a corkscrew path from end to end. This action
provides excellent mixing and gives the bacteria an
opportunity to obtain both food and oxygen necessary to
thrive. Mechanical aerators may also he used to cause the
proper mixing and aeration.
The air piping should be below the plant grating
or otherwise safely located to prevent a tripping hazard.
Use of an air pipe header, as opposed to an integral air
channel inside - metal structures, is suggested for
convenience in maintenance. A check valve should be
installed on the discharge side of all blowers to reduce
solids that flow into the diffusers when the blowers are
off. This will increase the time between cleaning the
diffusers and downfeed pipes.
Eachair downfeed pipe should have a plug
valve with a disconnect on the diffuser side of the pipe
valve to allow removal and servicing of downfeed pipes
while the blowers are running. Plug valves are
recommended because they, require little maintenance, do
not vibrate open or shut, and allow visual evaluation of
their position without having to remove the grating. The
downfeed pipes should be removed carefully, because
their supports will not usually prevent them from falling
into the aeration basin when disconnected. Plug values
will generally be wide open unless a minor adjustment is
necessary to balance the roll above each downfeed pipe.
Balancing is done when all downfeed pipes and diffusers
are clean and intact. Diffusers must be cleaned
periodically. Cleaning will require the removal of the
5

diffusers and care should be taken when reinstalling them.
If a diffuser is off, most of. the air will escape through
that opening, creating an uneven rolling action. The
operator should check each downfeed pipe to ensure it is
plumb. If the downfeed pipe is not plumb, the lateral will
not be level; this will cause some of the diffusers to be
higher than others. More air will escape from the high
diffusers, creating an uneven rolling action. The length of
all downfeed pipes should be the same, if they are not,
more air will escape from the higher header, resulting in
an uneven rolling action. To ensure uniform mixing in the
aeration chamber, diffusers must he clean, laterals must
be level, downfeed pipes must be the same length, and all
the diffusers must he on. Once all of these factors have
been checked, mixing may still be deficient in the
downfeed pipes located farthest from the air source. The
air pipes and valves should then be checked for leaks with,
soapy water. If there are no air leaks, the motor, blower,
and sheave sizes should then be checked to determine
whether an adequate air volume is being supplied.
BLOWER -MOTOR UNIT. Every operator should
consult the owners manual to ensure the proper sized
motors and blowers have been installed on the plant. If an
owner's manual is unavailable, the operator should
measure the length, width, and depth of the aeration
chamber. This information allows the manufacturer to
determine the proper size blower and motor for the plant.
The measurements taken should match the specifications
listed on the nameplates of the motor and the blower at
the treatment plant.
The electric motor used to power the blower is
designed to operate at a specified number of revolutions
per minute (RPM). The speed at which the blower turns is
determined by the size of the sheave on the motor as
compared to the one on the blower. Figure 5.4 shows a
typical blower -motor arrangement. By comparing the
diameter of the two sheaves, the revolutions per minute of
the blower may be determined. By varying the size of the
sheaves, manufacturers can use the same size blower and
motor on several sizes of wastewater treatment plants.
The amount of air produced is controlled by the
revolutions per minute of the blower. The number of
revolutions per minute produced by the electric motor is
given on the motor name plate. The revolutions per
minute of the blower can be calculated by dividing the
diameter of the motor sheave by the diameter of the
blower sheave and multiplying this number by the motor's
revolutions per minute. The diameter of a sheave is the
measurement from the center of the mounting shaft to the
outer edge of the sheave multiplied by two. On most
small extended aeration plants, the sheaves are not
adjustable. Adjustable sheaves allow for small changes in
their diameter by varying the width of the sheave. A
wider sheave allows the V-belt to ride deeper in the
sheave groove, reducing the turning diameter and
increasing the revolutions per minute. When the sheave
width is reduced the groove becomes narrower, forcing
the V-belt to ride higher in the groove; this increases the
turning diameter and reduces the revolutions per minute.
A portable tachometer may also be used to check the
revolutions per minute of the motor and blower.
The importance of the proper amount of air in
the aeration chamber cannot be overemphasized. Many
factors that affect the dissolved oxygen concentration and
mixing in the aeration chamber have been noted. In later
chapters additional factors that affect the air supply' to the
aeration chamber will be discussed. With experience, the
operator will be able to determine which factors are
causing operating problems. In seeking solutions to a
problem, always try the obvious or simplest solutions
first; one should not, rebuild a plant if only a valve
adjustment is required.
TEMPERATURE
In most extended aeration plants the wastewater
temperature in the plant will he determined to a great
extent by the surrounding atmospheric temperature
(ambient temperature). The operation of the aeration
chamber isaffected in several ways by the temperature of
the mixed liquor. During winter months in cold weather
areas the activity of the microorganisms will be reduced.
If the organic loading to the plant remains constant, more
microorganisms will be needed for treatment during the
winter than in the summer. The colder Iiquid also affects
the dissolved oxygen concentration in the aeration
chamber. The colder the liquid, the more oxygen it can
hold in solution. As the liquid temperature increases, its
ability to hold gases in solution decrease. For systems that
are aerated intermittently with a time clock control, the
times and duration of the aeration cycle will be affected
accordingly. The section on Time Clocks discusses fur-
ther how temperature affects the aeration cycle.
RETURN SLUDGE LINE
After the mixed liquor has been in the aeration
chamber for 8 to 24 hours it flows to the clarifier, where
settling occurs. The settled biomass, which is now
concentrated, is returned to the aeration chamber through
the return sludge line. The return sludge is usually dis-
charged at the head end of the aeration chamber to
provide maximum contact with incoming wastewater.
Larger plants may have two or more clarifiers and,
consequently, two or more return sludge lines. Sludge
returning from the clarifier has not been aerated for
several hours, therefore, it will exert an oxygen demand
in the aeration chamber. If the second return sludge line
discharges at the mid -point of the aeration chamber, the
6

return sludge oxygen demand is distributed throughout
the aeration chamber.
SKIMMER LINE
The other (smaller) line from the clarifier to the
aeration chamber is the skimmer. The skimmer returns
floating solids from the clarifier to the aeration basin. It is
critical that only the minimum air required be supplied to
the skimmer. If more air is supplied than is needed, the
diffusers or the return sludge air lift pump will be robbed
of air. Additionally, excessive wastewater will be returned
to the aeration tank, thus decreasing the hydraulic
detention time in the clarifier And inhibiting settling.
Vibration in the air lines may vibrate the packing nuts for
the air control valves loose, making air adjustments
difficult. The operator should keep all valve packing nuts
snug so that adjustments do not change between plant
inspections.
FROTH SPRAY SYSTEM
The froth spray system consists of a
submersible pump, located in the clarifier just below the
surface, which pumps clear liquid from this chamber into
a manifold located in the aeration chamber. The manifold
is on the side opposite the air diffusers and has nozzles
attached to allow the clear liquid spray to be directed
down and to the sides. The froth spray reduces foam in
the aeration chamber. The froth spray pump should he
operated only when necessary.
Foam may appear in the aeration chamber under
certain operating conditions. The three most common
occasions during which foam is produced are:
• During initial start up;
• When excessive detergents are present in the
wastewater; and
• When the sludge remains in the treatment plant too
long.
The foam during initial start-up is very light tan in
color and fluffy it will dissipate as the solids increase in
the mixed liquor. Foam caused by detergents is extra light
and may easily overflow the aeration chamber. The froth
spray is especially effective in suppressing this foam.
Foam caused by old sludge has a heavier consistency and
will be much darker than other foams. The best way to
eliminate this foam is to waste some of the old sludge.
Reasons and methods for wasting sludge are discussed in
Sludge Wasting.
BLOWERS AND
MOTORS
Two blowers and motors, each with sufficient
aerating capacity to supply all air needs, are
recommended. This arrangement extends blower life by
allowing for alternate use, and provides 100 % standby in
the event of an emergency.
There are several types of low pressure blowers
for small package extended aeration plants. The
manufacturer's operating manual should indicate the
proper type and size of blower for the plant and give all
maintenance procedures. If a manufacturers manual is
unavailable, the blower nameplate will provide all
information required to identify .the blower. The
manufacturer shoulld then be contacted to obtain all
maintenance information. Blower maintenance such as
changing oil and grease is important to successful
operation. The operator should determine what
maintenance is required for the blower and follow the
manufacturers recommendations exactly. The blower is a
critical element in the operation of the treatment plant.
BIowers are sized according to two criteria: to
provide sufficient oxygen for the microorganisms; and to
provide for mixing in the aeration chamber and sludge
holding tank for the operation of all air lift pumps. The
second criterion requires more air and, therefore,
determines the size of the blower. Without sufficient
wastewater loading, continuous operation of the blower
will lead to overaeration, which results in poor settling in
the clarifier. Bleeding off excessive amounts of air or
drastically changing the motor sheave sizes to adjust for
the proper dissolved oxygen may result in insufficient
mixing in the aeration chamber. One way to provide
adequate mixing and aeration is to operate the blower on
a time clock. (See next section.)
An air filter should be attached to the intake of
the blower. This filter may be of the disposable type
(paper) or the permanent type (wire mesh), and must be
kept clean for maximum blower life. The advantage of
paper filters is that they are disposable. Steel mesh filters
must be washed periodically. Failure to keep the inlet air
filter clean is one of the most common maintenance
problems.
The blower has a normal discharge pressure of
20 to 40 kPa (3 to 6 psi). It is highly recommended that a
pressure relief valve be installed on the blower discharge
to protect it against excessive pressures, should an air line
becotne plugged or an air valve be accidentally closed.
This valve may be a dead-weight type or a spring -loaded
type. The deadweight type is more reliable, but must be
kept well lubricated. The gaskets on the spring -loaded
type decay with time and must he replaced.
A check valve on the blower discharge is also
highly recommended. It will help prevent water from
entering the drop pipe when the blower is off. If the
7

blowers are used with a common manifold, a check valve
must be located near the discharge of each blower to
prevent the blower that is not in operation from rotating
backwards.
If the rotation of the blower is reversed, a
vacuum will be produced. Before connecting a new
blower to the air distribution line, the blower should be
operated for a few seconds to ensure that it is producing
air at its discharge rather than drawing a vacuum. This
procedure could prevent water from being sucked into the
blower.
An electric motor is usually used to power the
blower. The most common method of transferring power
from the motor to the blower is by V-belts. The
importance of the proper size sheaves on the motor and
blower has already' been discussed. Bearings may also be
damaged by over -tightening the V-belts. The operator
should be able to depress the V-belt approximately 1 in.
at the midpoint between the blower and motor for a
properly tensioned belt. If two V-belts connect the blower
and motor and one becomes damaged, both should be
replaced. The undamaged belt has stretched and worn
with time; this condition will make proper tension
adjustment with the new belt impossible.
There is another method of connecting the
blower and motor by using a direct drive. This method
does not allow for adjustments to the blower's revolutions
per minute as the V-belt-sheave method does. For this
arrangement, care must be taken to ensure the revolutions
per minute of the motor match those required by the
blower. Likewise, any replacement motor should also
have the same revolutions per minute.
TIME CLOCKS
During normal operation, it may not be required
to run blowers continuously; time clocks that activate the
blower circuits several times each day are recommended,
if allowed by state regulations. In the case of alternate use
of two motor -blower units, two time clocks are preferred
over an alternator with one time clock. Clocks with day -
of -the -week wheels (for alternate operation) and those
with 15-minute operating intervals throughout the 24-hour
period (for on -off flexibility) are recommended.
The use of a time clock is more economical than
air bleed off and allows for adjustments to improve
effluent. If the clarifier effluent quality is poor, a change
in run time may' be recommended instead or in
conjunction with, a return sludge rate and/or wasting rate
adjustment. At least clays should be allowed for the
mixed liquor to respond before any other changes are
made, except for when the plant goes septic. The aeration
chamber of a plant receiving design flow should not be
without air for more than 60 minutes. Figure 5.8 gives a
typical aeration cycle for a plant that serves a
campground that is heavily loaded on weekends and
lightly loaded on weekdays. Aeration cycles could vary
during the day if most of the loading is received in a
couple of relatively short periods of the day.
Adjustment of the return sludge rate and of the
aeration time are only two of many variables that could
affect effluent quality. pH and temperature were
discussed previously. In addition, good mixing is needed
in the aeration chamber and the proper FIM ratio, as con-
trolled by sludge wasting, is important. With experience,
an operator should be able to evaluate how each variable
affects the plant and make the necessary corrections.
GENERAL
The theory, operation, maintenance, and
troubleshooting of clarifiers are introduced in this
chapter. Three types of clarifiers .will be described:
rectangular, circular, and hopper; the latter will be
emphasized, as the hopper type is the most commonly
used clarifier on small package treatment plants.
The mixed liquor from the aeration chamber
contains millions of microorganisms and organic solids
that would exert an oxygen demand on the receiving
stream. In a well operating aeration chamber, the mixed
liquor solids are produced by small particles which clump
together to form larger ones. This process of forming
larger, heavier particles -from smaller lighter ones is
called flocculation. Because the mixed liquor solids in a
well operated plant are slightly' heavier than water, they
can be removed by settling.
Clarifiers (setting tanks) are designed to
physically remove solids that will settle to the bottom or
float on the surface. Settled solids are either returned to
the head of the aeration chamber to be remixed with
organic matter, or wasted to a sludge holding tank.
Floating solids are either returned to the aeration chamber
or physically removed from the system. Removal of both
types of solids produces a clear liquid called supernatant;
this liquid flows from the clarifier to be eventually
discharged to the receiving stream.
The aeration chamber and the clarifier work as a
team; the clarifier cannot produce a clear discharge unless
the aeration chamber is well operated. Likewise, a poorly
operated clarifier cannot produce a good effluent even
though the aeration chamber is well operated. Thus both
must work properly to produce a good effluent.
Because the mixed liquor solids are only slightly heavier
than water, their settling rate is slow. Agitation of the
water in the clarifier will interfere with the settling
process; the clarifier must bp designed to minimize this
agitation so that a still (quiescent) environment is
provided to allow the suspended solids from the aeration
chamber to settle. As the mixed liquor enters the clarifier,
the flow is dispersed or spread out across one end (side)
of the clarifier so that the velocity slows down, allowing
the solids to settle. A discharge overflow weir controls the
exit from the clarifier and is located on the opposite end
(side) of the clarifier from the inlet. The outlet is located
8

as far as possible from the inlet to allow for maximum
settling time. As water flows over the discharge weir a
slight upward current is produced that settling solids must
overcome.
If the overflow weir is not level, water will
flow over only a portion of its length, producing a higher
discharge velocity. If this current is great enough, solids
could be lost from the clarifier. To minimize the
discharge velocity, the overflow weir must be level so
that water flows evenly over its entire length. To prevent
floating solids from leaving the clarifier, a discharge
baffle is placed in front of the overflow weir. This baffle
should only extend slightly below the water, as its sole
purpose is to keep floating solids in the clarifier. The inlet
to the clarifier should also be baffled to help disperse the
flow evenly and dissipate energy. The clarifier must
remain as quiet as possible for the solids to 'settle.
Improper.operation of skimmers return sludge pumps, and
froth spray pumps may also agitate the clarifier and
interfere with settling.
As solids enter the clarifier and begin to settle, a
distinct solids -to -liquid interface develops. The height of
this interface from the bottom of the clarifier is called the
depth of the sludge blanket. The top portion of this blan-
ket acts as a filter when it settles. It will entrap and strain
out slower settling particles that have flocculated and
otherwise might not settle, but could be carried upward by
water rising through the sludge mass to the overflow weir.
As new solids settle onto the sludge blanket, those solids
already on the bottom become more concentrated.
If solids were never removed from the clarifier,
the height of the sludge blanket would increase as new
solids entered the clarifier. Eventually the height of the
sludge blanket would reach the overflow weir, and solids
would be lost. If solids at the bottom of the sludge blanket
were never removed, they would become septic and
would float to the surface. Removal of settled solids from
the clarifier is needed, therefore, to maintain the height of
the sludge blanket at the proper level, to prevent settled
solids from becoming septic, and to maintain the
microorganism population in the aeration chamber. The
return sludge rate must satisfy all three of these
requirements.
The skimmer in the clarifier is designed to
remove floating solids, such as grease or other floating
solids; it will usually discharge to the aeration chamber.
The operator should remove any floating solids that are
not readily biodegradable, such as plastic, wood, leaves,
and grease. If left in the plant for an extended period of
time, these items will probably cause operating problems.
Good maintenance. requires that all floating material other
than sludge be removed from the plant as soon as
possible.
The treatment plant may have a rectangular
clarifier with chain driven flights, a circular clarifier, or a
hoppered clarifier; nonetheless, all will have the same
basic components. Each clarifier has an inlet structure
designed to distribute the flow evenly along one of its
sides;.it must also be well baffled so that the mixing of
the aeration chamber does not disturb the clarifier. Each
type of clarifier will have an effluent (overflow) weir to
collect the flow to minimize upflow currents, and a baffle
in front of the effluent weir to prevent floating solids
from leaving the clarifier; these floating solids will then
be removed by a skimmer. A sludge collector will he
provided to remove settled solids from the bottom of the
clarifier. While clarifiers may have different shapes and
mechanical devices, all have the same function and,
therefore, require the same devices.
RECTANGULAR
CLARIFIERS
Settled sludge in most rectangular clarifiers is
moved to a hopper at one end by wood or fiberglass
flights mounted on parallel strands of the conveyor chain.
The chains and flights are carried on submerged
sprockets, shafts, and bearings, and are driven by a motor
through a speed reducer. As the flights travel along the
bottom moving sludge to a hopper, they also travel in the
opposite direction on the surface of the tank, transporting
floating matter to the skimmer.
It is important that each of the flights in a
rectangular clarifier be the proper Length. If flights are too
short, solids will build up on the outer edges and turn
septic, rise to the surface, and be discharged in the
effluent. If a flight is too long, it may rub the tank wall
and break the flight; a broken flight could wedge in a
position that results in breaking the remaining flights.
Properly sized, each flight should have a clearance of 25
to 50 min (1 to 2 in.) between the end of the flight and the
tank wall.
Rectangular clarifiers do not experience the
operating problems of hoppered clarifiers. Their flights
are designed to continually scrape the bottom of the
clarifier. This mechanical cleaning eliminates the
ratholing problem of sucking a clear cone or channel in
the sludge frequently experienced with the' hopper
clarifier. Clear water is then returned to the aeration
chamber rather than the settled sludge. Figure 6.2
illustrates the problem of channeling sludge in a hopper
clarifier. Because the rectangular clarifier has vertical
walls, the tendency of solids to cling to them is not as
great as the sloped walls of the hopped classifier.
The rectangular classifier does have some
disadvantages, however, when compared to the hoppered
clarifier. The chains, flights, and drive motors must be
maintained properly. By contrast, the air lift pump used
commonly with the hoppered clarifier does not have any
moving parts; therefore, it requires little mechanical
9

maintenance. Rectangular clarifiers are used more often
on plants whose design capacity is greater than 5 Us (100
000 gPd)-
CIRCULAR
CLARIFIERS
Circular clarifiers use a rotating rake
mechanism to push the settled sludge to a central
collection hopper. From the collection hopper, the sludge
is then returned either to the aeration chamber or to the
sludge holding tank. Floating material is moved to the
skimmer by a surface blade attached to the sludge
collection mechanism. This type of clarifier has many of
the same advantages as the rectangular type in
comparison to the hopped classifier. It is also more
frequently used in Iarger plants.
IIOPPERED
CLARIFIERS
The hoppered clarifier is the most frequently
used clarifier on small package plants. Again, because the
return sludge pump and skimmer are air lift pumps they
have no moving parts. The only maintenance required is
to ensure that each pump is supplied the proper amount of
air and that all piping is free of any obstacles. Figure 6.4
shows a typical hopper type clarifier. Settling solids are
directed to a small bottom by sloped wall surfaces. No
sloped surface, however, should present an angle of less
than 60D to the horizontal as solids will accumulate on
the sloping surfaces and not be removed from the
clarifier. At 600 or greater, periodic scraping of the
sloped surfaces is required. Because of its design, a small
amount of gravel, sand, or mud in a hopper clarifier will
prevent proper operation of the return sludge air lift
pump. Because of this sensitivity, it is critical that plants
with hopper clarifiers receive only wastewater.
FACTORS AFFECTING
CLARIFIERS
OPERATION
Clarifiers are usually designed on four
parameters: solids loading rate; surface settling rate;
detention time; and weir overflow rate. These design
criteria are significant, as many operating problems can
be attributed to a poorly designed clarifier.
SOLIDS LOADING RATE. Solids loading rate
(SLR) is the relationship between the mass of solids
entering the clarifier and the surface area of the clarifier.
The concentration of suspended solids often determines
settling velocities; in activated sludge facilities this is an
important parameter because the suspended solids loading
to the clarifier is generally high. The settling rate, or
speed of downward movement of the solids, slows down
as the concentration of solids increases. If the
concentration of suspended solids entering the clarifier
becomes too high, the rate of downward movement of the
particles caused by sludge draw -off from the bottom
could be less than the rate at which solids enter and build
up in the clarifier. As a result solids could build up in the
clarifier and be eventually discharged with the effluent. In
a properly operating clarifier, solids will be removed from
the clarifier at approximate)'y the same rate they enter. The
height of the sludge blanket should remain approximately
the same level. SLR is calculated by the following
formula:
SLR Suspended solids entering the clarifier. kg (lb)
Surface area, m2 (ft2)
The mass of suspended solids entering the
clarifier may be calculated by determining the mixed
liquor suspended solids, the return sludge flow rate, and
the influent flow rate to the plant. The mixed liquor
suspended solids is expressed in milligrams per liter; the
return sludge and influent flow rates are expressed in
cubic meters per day (million gallons per day). Suspended
solids entering the clarifier each day are equal to:
MLSS (mglL) > (flow + return sludge rate)
The SLR should not exceed 150 kg/m2•d (30
lb/d//sq ft) on a daily average flow or 240 kg/m2•d (50
lb/d/ft2) on a peak hourly flow. Many small treatment
plant operators will need assistance to make this
evaluation. For small package extended aeration plants,
the solids loading rate will usually not be a problem;
those problems in the clarifier caused by a high sludge
blanket can generally be identified with the 30-minute
settleability test, and by observing the operation of the
clarifier.
SURFACE SETTLING RATE. A more direct way
of evaluating clarifier size is to use the surface settling
rate. Because the surface area of the settling tank is
constant, the surface settling rate varies directly with the
flow rate.
Surface settling rate, m3/m2-d (gpd/sq ft)
Flow rate, m3/d (2nd) Surface area, m2 (sq ft)
Operators of most small package extended
aeration plants can determine the surface settling rate by
dividing the average daily flow by the surface area of the
clarifier. For package extended aeration plants, the
10

surface settling rate as determined by the average daily
flow should be less than 13 m/m2•d (333 gpd/sq ft).
Solids should not leave the clarifier during high (peak)
flow periods; the operator should observe the overflow
weir during pealc flow periods to ensure that solids are not
being washed out of the clarifier. When calculating the
surface area, the area of the clarifier upstream from the
inlet baffle cannot be considered.
If the •treatment plant is equipped with a flow
measuring device, the surface settling rate for the peak
hourly flow can be determined by measuring the flow for
I hour during the peak period and -plying that quantity by
24, then dividing by the surface area of clarifier. The
surface settling rate as determined by the peak hourly
flow should be less than 40:m3/m2•d (1000 gpd/sq ft). If
j the peak surface settling rate is greater than this value,
/ solids will probably be lost from the clarifier. A common
method of /reducing peak flows is to install an
equalization chamber ahead of the treatment plant. The
equalization tank provides a uniform flow rate to the
treatment plant, eliminating peak flows and preventing
solids from being washed out of the clarifier.
DETENTION TIME. Detention time is the time
required for waste -water to flow through the clarifier. The
formula to calculate the detention time is:
Volume of clarifier (24 hr)
Detention time = Row per day
Detention time must be sufficient to allow for
almost complete removal of the settleable solids;
however, long detention times do not materially improve
removal, and may be actually harmful by allowing the
sludge to become septic. In small package extended
aeration treatment plants the clarifier will have a
detention time of 4 to 6 hours, based on the average daily
flow. When calculating detention time for hoppered
clarifiers, only the upper one-third (by height) may be
used; the Iower two-thirds is reserved for sludge storage.
WEIR OVERFLOW RATE. Wastewater leaves
the clarifier over weirs into effluent troughs. The length
of the weirs in relation to the flow is important to prevent
high velocities near the overflow weirs that may cause
solids to be lost with the clarifier effluent. The weir over-
flow rate is the number of cubic meters per day (gallons)
that flow over each meter (foot) of weir, as shown in
Equation 5:
Weir overflow rate, m3/m.d (gpd/sq)
Based on the average daily flow, the weir
overflow rate for small package extended aeration plants
should be between 12 and 25 m3/m.d (1000 to 2000
gpd(ft). During peak flows the overflow rate should not
be greater than 120 m3/m.d (10 000 gpd(ft). The operator
should determine the total Iength of all overflow weirs
and divide that Iength into the average daily flow. If the
resulting value does not fall in the previous range, the
overflow weir will have to be modified to increase its
length.
The overflow weir should also be evaluated for
peak hourly flows. Following the same procedure
described in the section on surface settling rates, the
operator may determine the peak hourly flow and
calculate a 24-hour flow by multiplying by 24. Dividing
this flow value by the total length of all overflow weirs
should yield a valve less than 120 m3/m.d (10 000
gpd(ft). If the resultant value exceeds this peak value,
solids are probably being lost from the plant during high
flows. Either the length of the overflow weir should be
increased or flow equalization may be required if other
clarifier parameters are also exceeded.
Finally, the overflow weir must be level to
operate properly; it was designed to have uniform flow
over its entire length. If the overflow weir is not level,
excessive discharge velocities, which will hinder settling,
may occur.
Another common problem with overflow weirs
is that they leak between_ the adjustable weir and the
effluent trough. All water leaving the clarifier should flow
over the discharge weir.
INLET AND OUTLET
STRUCTURES
Inlet and outlet structures, including appropriate
baffles, are important to clarifier efficiency. Inlet baffles
reduce the velocity of the rnixed liquor entering the
clarifier and distribute the flow evenly. Many inlet baffles
are designed improperly, resulting in short circuiting
through the clarifier. The clarifier should remain quiet
when the aeration chamber is being mixed; if disturbances
appear in the clarifier while the aeration chamber is being
mixed, the inlet baffle is not working properly. Either the
manufacturer, the local regulatory agency, or an
operations consultant should be consulted.
Discharge baffles are designed to prevent
floating solids from leaving the clarifier. The discharge
baffle will usually rise about 300 mm (6 in.) above the
liquid level and extend about the same distance below. A
common manufacturing error is to use the same design
for the discharge baffle as the inlet baffle. The inlet baffle
should extend at least 300 mm (6 in.) below the bottom of
the port from the aeration chamber to the clarifier to
reduce the liquid velocity. However, if the effluent
(discharge) baffle extends that deep below the liquid
11

surface, it may be in the sludge blanket, causing solids to
escape from the clarifier even though the supernatant may
be clear. Thus, the effluent baffle should extend only 300
min (6 in.) below the liquid level.
CLARIFIER
OPERATION
The temperature of the mixed liquor that enters
the clarifier influences the settling rate of the floc. As the
temperature decreases, water becomes more dense,
increasing the resistance to floc settling. At a water
temperature of 270C1(($0F), the settling rate of the floc
will be almost 50% faster than at 10°C (50F). The lower
liquid temperature during the winter months will usually
result in lower removal efficiencies and poorer effluent
quality.
Because the purpose of the clarifier is to
separate floating and settleable solids from the liquid, it
should be opened properly. The operator should inspect
the clarifier and its operation thoroughly during even
visit. Ideally, the plant should be visited daily however,
because of the unavailability of an operator lack of
money, or location, many small package extended
aeration plants are visited as infrequently as twice a week.
The quality of the effluent and regulatory requirements
will determine the frequency of plant visitation.
The return sludge rate will directly affect
clarifier operation. The operator must adjust the rate of
sludge withdrawal to maintain a minimum inventory of
solids in the clarifier. An excessively high return sludge
rate will increase velocities at the inlet to the clarifier and
in the clarifier itself. This will disrupt the sludge blanket
and cause solids to be swept over the effluent weir. An
insufficient return rate may allow solids to remain in the
clarifier too long, causing them to become septic, float to
the surface, and possibly flow out with the effluent. Gas
bubbles in the clarifier are another indication that sludge
is remaining in the clarifier too long. Floating sludge and
gas bubbles could also indicate equipment failure. If an
underwater chain or flight is broken on a mechanical
clarifier. sludge can not be removed properly from the
clarifier.
The sludge returns to the aeration chamber at
approximately the same rate it enters the clarifier. A
minimum sludge blanket is maintained in the clarifier;
however, the return rate is not excessive. If the return rate
is too high, currents could cause disruptions in the
clarifier.
A high return rate may create a rathole, cone, or
channel in the sludge blanket; a return sludge that is
relatively clear is a good indication of channeling.
Channeling may be corrected by squeegeeing the walls of
the clarifier and reducing the return sludge rate. The
operator should squeegee a hopper -type clarifier at each
visit to the treatment plant.
Many package extended aeration plants have the
problem of mud and sand entering the plant either during
construction, or as a result of a poor collection system.
Because of the hoppered clarifier design, it takes very
little mud or sand to plug the air Iift return sludge pump.
The mud and sand are too heavy for the air lift pump;
both accumulate in the hoppered bottom, preventing the
sludge from reaching the airlift pump. Because the sludge
cannot be returned, it becomes septic and floats to the top.
The operator may detect mud and sand by feeling the
bottom of the clarifier. with the squeegee. Sand will feel
gritty while mud will feel thick and heavy. Sludge is only
slightly heavier than water and will offer very little
resistance to the squeegee. A small package extended
aeration plant must be free of mud and sand.
Liquid returneci from the clarifier will contain
three to four times as many suspended solids as the liquid
in the aeration chamber if the plant is operating properly.
Therefore, a healthy return sludge should have a thicker
consistency than the mixed liquor. It should have a musty
odor; if the return sludge smells septic, it has remained in
the clarifier too long. The healthy return sludge will also
have the same or slightly darker color as the aeration
chamber. For package aeration plants with hoppered
clarifiers, the sludge return rate is usually between one-
third to one-half of the pipe diameter of sludge return
line.
Providing the lift remains the same, a return
sludge pump generally stops pumping for one of two
reasons: the air flow becomes too low for the lift or the
eductor pipe becomes clogged.
As a rule of thumb, when trying to correct a
problem the operator should always try the easiest method
first. For example, the operator could provide more air to
the airlift pump by opening the air valve fully to clear the
eductor. One might check for Ieaks (rising bubbles)
around the air supply line. It may be necessary to
determine if air is getting to the air supply line.
Loosening a union and listening for air at the closest
possible point before the air supply line goes below water
determines whether or not the problem is below the water
line. If the air lift still fails to pump, the eductor pipe is
probably clogged.
To remove an obstruction in the eductor pipe,
the operator should turn off the air and remove the plug
from the tee at the top of the return sludge pipe. A rod or
small pipe may be inserted down the eductor pipe to push
the obstruction out the bottom. The handle of the
squeegee used to scrape the clarifier will usually work.
The rod or pipe must be long enough to reach the bottom
of the clarifier. This is sometimes called rodding out, and
after performing this procedure, the air lift should resume
pumping when the air valve is re -opened. If this
procedure must be repeated several times, then the
eductor pipe should be removed and inspected.
12

Cases have been reported in which soda cans
were thrown into the plant, causing the air Iift pump to
become plugged. Each time the air was turned on, the can
would be sucked into the eductor pipe. When the air was
turned oft, the can would settle to the bottom and the pipe
would seem clear. This problem was discovered and
eliminated only after the compartment in which the air lift
was located was pumped and cleaned.
Some manufacturers install a valve on the
discharge pipe of the return sludge pump. If the clean out
plug on the tee is in place, closing this valve will force air
out the bottom of the eductor pipe and remove the
obstruction. Some plants are plumbed so that water from
the froth spray pump may be forced down the eductor
pipe to remove the obstruction. These methods of clearing
the air lift pump are called backflushing, and may be used
for an airlift pump in the equalization tank. Backflushing
is not recommended for air lifts located in the clarifier
because settled solids will be resuspended and lost over
the overflow weir. Backflushing with a garden hose from
a potable water supply is NOT recommended.
Floating solids are removed from the clarifier
by the skimmer. Maintenance of the skimmer consists of
keeping the equipment clean, adjusted, and in proper
operation. Skimmers on hoppered clarifiers are
ineffective in removing floating solids, especially solids
that collect in corners. Improperly adjusted, the air lift
skimmer can create enough turbulence to hinder settling,
and on heavily loaded plants can draw the sludge blanket.
to the surface. On hoppered clarifiers, the top of the air
Lift skimmer should be approximately 6 mm (0.25 in.)
below the liquid surface when the blowers are operating..
The air lift skimmer should use the minimum amount of
air needed to pump the liquid back to the clarifier. The
skimmer air valve should be set at the required minimum
to provide the maximum available air to the diffusers and
return sludge pump. If the air value is wide open the
skimmer will rob most of the air from the diffusers and
return sludge pump.
Some package extended aeration plants have a
submersible pump located in the clarifier to pump clear
Iiquid to the froth sprays in the aeration chamber. A hose
bib Is installed on some froth spray systems so that the
clear liquid may be used to wash down the plant or to mix
chemicals. If at all possible, have a potable line, protected
by a proper backflow preventer, installed near the plant
and used for wash down and mixing chemicals. The
submersible froth spray pump should not be operated
unless it is absolutely necessary.
The clarifier is an extremely important part of
the wastewater treatment plant. If it does not operate
properly the clarifier will cause a poor quality effluent.
The clarifier must remain quiet so that settleable and
floating solids can be removed from the mixed liquor.
The skimmer and return sludge pump must be operated
properly to remove solids from the clarifier in a timely
manner.
SLUDGE WASTING
Even when a package extended aeration plant
receives the proper amount of food, has the correct pH, is
supplied plenty of air, and has good mixing, it will not
produce a clear effluent indefinitely. The microorganisms
in the treatment plant must be wasted periodically to keep
them performing at maximum efficiency. Removal of
organic material will cause inert solids to accumulate.
Sludge may be wasted, therefore, to prevent the treatment
plant from becoming choked with solids. For the package
extended aeration process, solids should remain in the
plant for 30 to 40 days. This means that 1/30 to 1/40 of
the solids in the plant should be wasted daily. The time
the solids remain in the plant is called the solids retention
time. If sludge is n& wasted routinely, solids may
accumulate in the plant and be lost over the discharge
weir in the clarifier. Old sludge will also produce a thick,
dark, matty foam in the clarifier.
Wasting sludge is a routine process for large
treatment plants with well trained operators. The volumes
of the aeration chamber and the clarifier are known, and
the suspended solids test can be used to determine the
solids concentration in the mixed Iiquor and in the return
sludge. The quantity of solids in the plant may then be
calculated, and the solids retention time will determine
how much must be wasted daily. Because solids are
usually wasted from the return sludge, knowing the solids
concentration of the return sludge will allow the operator
to calculate the volume of return sludge that must be
wasted to an aerated sludge holding tank.
Wasting sludge from small plants is not routine.
Unfortunately, many small extended aeration plants do
not have operators who can perform the suspended solids
test or facilities that can measure the return sludge rate. In
addition, some plants do not have a sludge holding tank.
For small plants, the 30-minute settleability test is used to
determine when sludge should be wasted. Generally, not
more than 20% of the mixed liquor solids, as indicated by
the 30-minute settleability test, should be wasted in a
week. Not more than 10% of the solids should be wasted
at any one time. For example, if settleability tests
routinely indicate 50% solids, then the amount of sludge
to be wasted is 0.10 (50) equal 5%, and the settleability
test after wasting should indicate 50% minus 5% 45%.
To achieve 20% wasting for the week, another settleable
solids test is run approximately 3 days later. At that time,
10% of that reading would then be wasted. This procedure
exchanges the mixed Iiquor every 35 days.
When sludge is wasted it is usually either
pumped to a scavenger truck or a sludge holding tank.
The aerated sludge holding tank (Figure 7.1) may be an
integral part of the plant or it may be a separate unit
located near the aeration chamber. The sludge holding
tank is constructed with air diffusers that operate when
13

the plant blower is operating; this keeps the sludge
aerobic for final disposal. The over -flow from the tank is
called the supernatant return. The supernatant is routinely
returned to the aeration chamber. Wasting sludge is usu-
ally accomplished by diverting a portion of the return
sludge from the clarifier. This is done by opening the
waste sludge control valve to the sludge holding tank and
closing the return sludge control valve to the aeration
chamber. If design provisions for air-lift sludge pumping
from the plant to the sludge holding tank have not been
provided, a portable pump can be used. When sludge is
being wasted with a portable pump the air valve on the
return aeration should be closed to thicken the sludge.
The thickened sludge in the aerated sludge
holding tank may be disposed at an approved landfill, a
large municipal treatment plant, or approved land
application sites. Alternatively, the sludge may I be
pumped from the sludge holding tank to sludge drying
beds. These beds are constructed and operated similar to
surface sand filters. After drying on these beds the sludge
is hauled to an approved sanitary landfill or is used as a
soil conditioner. Some regulatory agencies may require
tests to be run on sludge transported to sites other than
that owned by the generator of the sludge.
- PROCEDURES FOR
WASTING SLUDGE
The following procedures should be followed when
wasting sludge to the sludge holding tank:
1. At least 1 hour before wasting sludge, close the air
valve to the diffusers in the sludge holding tank. This will
allow the sludge already in the tank to settle, leaving a
clear liquid (supernatant) on top. The clear liquid is
returned to the aeration chamber through the overflow
when sludge is wasted to the tank. If the diffusers are not
turned off, the same amount of sludge that entered the
tank will leave the tank. The settleable solids test in the
aeration chamber would then show no reduction in solids.
Do not begin wasting sludge until the sludge in the sludge
holding tank has settled enough to make room for the new
sludge.
2, Run a 30-minute settleable solids test on the mixed
Iiquor solids. Remember: only 10% of that reading is
to be wasted. Be sure the blower has been on long
enough to completely resuspend the aeration chamber
contents.
3. Open the valve on waste sludge line that leads to the
sludge holding tank and then close the valve on the return
sludge line leading to the aeration chamber. Valves must
be operated in this order, or the clarifier could be
backfluslled if the blower were operating.
4. Waste sludge for approximately 15 minutes. This is
an arbitrary time; with experience, the proper wasting
time for each wastewater treatment plant can be
determined.
5. Open valve on the return sludge line leading to the
aeration chamber and then close the valve on the waste
line that leads to the sludge holding tank.
6. Open air valve to the diffusers in the sludge holding
tank to obtain good mixing. Once a good rolling action
has been established, do not open the air valve any
further. It is critical ,that this valve be opened after
wasting sludge. If the valve is not opened, the sludge
holding tank will become septic and produce a foul odor.
7. Allow the wastewater treatment plant to operate
approximately 1 hour before conducting a mixed Iiquor
settleable solids test in the aeration chamber. No more
than 10% of the solids in the aeration chamber should be
wasted at a time. SIudge should not be wasted twice in 1
day.
S. Be aware that sludge will eventually become so
concentrated in the sludge holding tank that when the
diffusers are turned off, very little clear liquid will appear
over the sludge. When this occurs, the sludge holding
tank should be pumped by a septic tank pumping truck for
proper disposal, or the sludge should be pumped to drying
beds. Only during extended periods, when the wastewater
treatment plant is Lightly loaded, can the sludge be
returned to the aeration chamber (for example, at the end
of the school year or at the end of a camping season),
providing complete oxidation of all organic material.
After the sludge has been totally oxidized the plant is then
turned off until the next operating season. If for any
reason the sludge holding tank is pumped, it should be
immediately refilled with water to minimize any uplift
pressures from groundwater in the surrounding soil.
If the treatment plant does not have a sludge holding
tank, wasting sludge daily or weekly is not feasible. For
small 0.5 1Js plants (less than 10000 gpd), solids
sometimes remain in the plant until a thick, dark matty
foam is formed. The operator then calls a septic tank
pumping truck and wastes a truck load 6000 L (1500 gal)
of sludge from the plant. Although this is not the
recommended procedure, it is a common practice with
small plants as many regulatory agencies do not require
sludge holding tanks on these small plants.
The U.S. Environmental Protection Agency's
report," Package Treatment Plants," EPA-430/9-77-005,
is suggested as another source of information for wasting
sludge.
Disinfection is the process of killing disease
causing microorganisms (pathogens) that remain in the
effluent from the clarifier. Some states may require
additional treatment before the effluent is disinfected,
such as sand filtering or polishing ponds. The disinfection
unit will usually be the last treatment unit the wastewater
flows through before being discharged to the stream. In
small package extended aeration treatment plants
disinfection is usually accomplished by either
chlorination or ultraviolet radiation.
14

CHLORINATION
The most common method of disinfection used
in package extended aeration plants is chlorination. If
pathogenic bacteria are to be destroyed by chlorination,
there must be sufficient contact time between the bacteria
and chlorine. A chlorine contact tank is designed to
provide the required time (Figure 8.1). Contact time is
provided in two ways: by sizing the tank for volume; and
by putting baffles in the tank to eliminate short-circuiting.
The chlorine tank is usually attached to the
clarifier if the plants are constructed of steel; concrete
chlorine contact tanks are usually separate units. Concrete
tanks are virtually maintenance free; steel tanks must be
painted periodically with coal tar epoxy paint or other
recommended corrosion protection that is applied
according to manufacturer's instructions to prevent
deterioration caused by the highly corrosive chlorine.
Separate cathodic protection is needed if the metal tank is
separate from the treatment plant.
Eventually, solids will carry over into the
chlorine contact tank from the clarifier. These solids must
be routinely pumped back to the aeration chamber. If
these solids are allowed to accumulate, they will become
septic. Pumping a large amount of septic solids to the
aeration chamber will definitely upset the plant operation.
Regulatory agencies usually require 15 minutes chlorine
contact time during peak flow or approximately 900 L of
chlorine tank volume for each liter per second (10.4 gal
for each 1000 gpd) of design flow. In addition to contact
time, regulatory agencies also limit the amount of
chlorine that is to be added to the effluent. Because this
quantity varies from one regulatory agency to another, the
regulatory agency with jurisdiction over the wastewater
treatment plant will establish the maximum allowable
concentration of chlorine in the effluent. The discharge
criterion for most regulatory agencies is 0.2 to 1.5 mg/L.
CHLORINATORS
Three different types of chlorinators are
conunonly used in small wastewater treatment plants: gas
chlorinators; Iiquid chlorinators; and solid tablet or pellet
chlorinators. Each has its advantages and disadvantages.
Regardless of the type used, the operator should make
sure that the chlorinator is sized for the design flow of the
treatment plant. Sources of replacement parts should be
identified and pans should be readily available; if
replacement parts are difficult to find, another brand of
chlorinator should be considered. Finally, the operator
should consider the availability of chlorine supply when
evaluating chlorinators.
GAS CHLORINATORS. Gas chlorinators use
either a small portion of the effluent from the treatment
plant or potable water as the chlorine carrier. This liquid
is then pumped through an injection nozzle or diffuser,
where the chlorine gas and liquid are mixed. The liquid
containing chlorine is then returned to the treatment plant
effluent. Because this type of chlorinator uses pure
chlorine, which is toxic, the manufacturer's operating
instructions must be adhered to rigidly.
Under no circumstances should one attempt to
operate a gas chlorinator without first reading the
manufacturer's operating manual.
While a gas chlorinator may cost more initially
than other chlorinators, there can be definite savings in
the long run. The principal advantages of using the
gaseous form are: the infrequency of handling the
chlorine supply a 70 kg (150 lb) cylinder serving a 0.5 is
(10,000 gpd) plant would probably have to be replaced •
once a year; chlorine in the gaseous form is the cheapest
form available; and finally, storage does not cause a loss
of strength. If a gas chlorinator is used, the proper safety
devices (ventilation, self-contained pressurized gas
masks, and leak detectors) should be readily available. In
addition, the system should be inspected by the
appropriate regulatory agency.
LIQUID CHLORINATORS. Three common types
of liquid chlorinators used on small treatment plants are
the squeeze tube, diaphragm, and piston. These are called
positive displacement pumps because they deliver a
definite amount of solution with each stroke. The pumps
are calibrated in gallons of liquid pumped in 24 hours.
Sodium hypochlorite (liquid laundry bleach) and calcium
hypochlorite (powder H.T.H.) are used as the chlorine
sources for liquid chlorine pumps. Liquid sodium
hypochlorite (common laundry bleach) is recommended
for use because it is readily available in local grocery
stores and is easy to use. Its chief disadvantage is that it
contains only 5.25% available chlorine and is, therefore,
an expensive source of chlorine. Commercial grade
sodium hypochlorite is available at 15% strength.
Because the shelf life of liquid bleach is limited, it is
important to use a supplier with fresh stock.
Calcium hypochlorite is a white powder that
contains 65 to 70% available chlorine. When dissolved in
water for use in liquid chlorinators, a powder residue of
calcium carbonate and calcium hydroxide will remain
undissolved. The residue formed must be kept from the
chlorinator pump to avoid plugging chlorine feed lines
and fittings. This is done by dissolving as much of the
calcium hypochlorite as possible in a separate mixing
container and letting it set quietly over night. The
following day, the clear liquid is poured into the chlorine
solution tank. The residue remaining in the mixing con-
15

tainer should be discarded at a landfill; it is not to be
dumped into the wastewater treatment plant. The cost of
available chlorine in calcium hypochlorite is less than that
of sodium hypochlorite, but is more labor-intensive.
Whether the plant is equipped with a gas
chlorinator or with a liquid chlorinator, the proper amount
of chlorine must be added to the effluent. The operator
will have two control methods: the amount of time the
chlorinator operates; and the amount of chlorine injected.
Wastewater flows fluctuate during, the day; flows in the
morning and in the evening will be seyeral times greater
than the flow received during other times of the day.
More chlorine is needed during the high (peak) flows than
during low flow periods. By controlling the chlorinator
with a 24-hour, 15-minute interval clock, the operator is
able to chlorinate more often during peak flows and less
often during low flows. It is important that the time clock
have intervals of 15 minutes or less, because the contact
chamber is designed to have a 15-minute retention time at
peak flow.
For the wastewater flow pattern in the figure,
the clock would be set to operate the chlorinator
continuously from 6 a.m. to 9 a.m. and from 6 p.m. to 9
p.m. From 12 a.m. to 6 a.m. and from 9 a.m. to 6 p.m.,
the clock would be set to operate the chlorinator for 15
minutes each hour. During high flows the contact time in
the chlorinator contact tank will approach 15 minutes,
thus requiring continuous chlorine feed. During Iow
flows, the contact time is more than I hour; therefore,
feeding chlorine for 15 minutes will probably provide an
adequate chlorine residual.
Another control common to both gas and liquid
chlorinators is to vary the amount of chlorine injected
when the chlorinator is operating. For gas chlorinators,
this is done by adjusting the chlorine feed rate on the
controller; for liquid chlorine feeders, the rate can be
adjusted by the control knob on the pump. Liquid
chlorinators have one other adjustment that can be made
the strength or concentration of the chlorine solution.
For a new system or for initial start-up of a new
chlorinator the proper settings are usually found by trial
and error. Manufacturers' operating instructions will
provide an initial recommendation but the settings will
have to be fine tuned. Without any instructions, the
operator can only make an educated guess. The flow
pattern in the previous example is typical for residential
flows, but will differ from school or campground flows.
The operator must determine the flow pattern to set the
control clock. A starting point would be to set the
chlorine flow regulator at about 50% feed and then let the
system stabilize. After about 1 hour the operator should
test for the chlorine residual. If the reading is too high,
the chlorine feed or the amount of time the chlorinator
operates should be reduced. If the reading is too Iow the
opposite approach should be taken.
For liquid chlorinators, the chlorine solution
strength may also be varied. Following the manufacturer's
recommendation, enough chlorine solution should be
prepared to fill the chlorine feed tank about one -thud full.
The timer and pump setting are set as before and the
residual is checked. If the residual is too high, the
chlorine feed stock should be diluted; if the residual is too
low, more chlorine should be added to the stock. If the
manufacturer's instructions are not available, 8.4 L (a
gallon) of bleach (5.25% available chlorine) in 84 L (10
gal) of water, 1:10 by volume, or 0.5kg (I lb) of H.T.H.
dry powder (70% available chlorine) in 84 L (10 gal) of
water can be tried. REMEMBER: the dry powder must be
premixed and only the clear liquid is to be added to the
solution tank.
Liquid chlorinators must be cleaned
periodically; this can usually be done by pumping white
vinegar through the unit to dissolve any mineral deposits.
Chlorine solution tanks must also be cleaned. Even if
potable water is used to mix the chlorine a residue will
form from the minerals in the potable water. The chlorine
solution tank should be cleaned at least every 3 months.
SOLID TABLET OR PELLET CHLORINATORS.
Chlorinators using tablets or pellets of calcium
hypochlorite have become popular for use in small
wastewater systems within the last 10 years. The tablets
are placed in vertical stacks that are slotted to allow
wastewater to flow through for automatic feed as they
dissolve in the effluent 'stream from the plant. The amount
of chlorine fed is controlled by the number of stacks
containing tablets (in multiple stack chlorinators), and by
a weir that controls the water level in the chlorinator.
One major advantage of this system is its use in
remote locations where electric power is not available
and; secondly, chlorination occurs only when there is
flow. A major disadvantage is that the tablets are
relatively expensive and they can jam inside the tubes.
The same brand of tablet as the manufacturer of the
chlorinator is usually required, and the residual chlorine
concentration in the effluent is difficult to control during
periods of either high or low flows through the treatment
plant. Care must be taken when filling the stacks. If
tablets are dropped into the tube, the bottom of the tube
could be knocked off or the tablets may crack. To load the
tube, the operator must lean it on its side and slowly slide
tablets down the tube. No more than six tablets should be
placed in a stack at one time. If more are used, the lower
tablets will leave a residue that will not allow the upper
tablets to fall into the wastewater stream. Figure 8.5
shows a typical tablet chlorinate unit and servicing
schedule.
ULTRAVIOLET
DISINFECTING
There are some disinfection units used in
wastewater treatment plants that use ultraviolet radiation
16

to kill pathogenic microorganisms. The most common
source of ultraviolet radiation is the sun. Ultraviolet light
cannot be seen by the human eye and is responsible •for
sunburning and tanning; it can also destroy potential
harmful bacteria and viruses by deactivating their genetic
material. Ultraviolet mercury lamps have been used for
many years to disinfect air and water_ Increasing concerns
over the environmental effects of chlorine has led to a
renewed interest in ultraviolet light as a disinfection agent
for small wastewater treatment plants.
An ultraviolet disinfection unit consists of one
or more ultraviolet Iamps encased in a quartz or Teflon
sleeve. A thin Iayer of water passes around the sleeve to
expose it to ultraviolet light. Ultraviolet lamps are
designed to provide a maximum amount of light at the
proper wave length for the greatest bacteria killing action,
253.7 mm (2537 Angstrom units; one centimeter is
equivalent to 100 million Angstroms). Water must be
circulated to expose each droplet to_,as much light as
possible for an ultraviolet unit to be effective. The killing
action will be rapid if the light can reach the bacteria. For
this reason, the amount of suspended solids in the liquid
must be minimized. Many states require a filter after the
wastewater treatment plant, just before the ultraviolet
unit.
Maintenance of the ultraviolet unit consists of
cleaning the quartz or Teflon tubes and replacing bulbs.
Some units are equipped with either automatic or manual
wipers that allow tubes to be cleaned without removal of
the ultraviolet lamps. Small units use about the same
amount of electricity as a light bulb; replacement lamps
cost about S40.00 to S60.00 each. Care must be taken to
ensure that power is disconnected when bulbs are cleaned
or changed. Exposure to ultraviolet radiation is harmful,
and looking at the lighted bulbs for Iong periods of time
will damage the eyes.
Operating Tests
and Routine
Maintenance
Most large wastewater treatment plants are
operated by trained individuals who use sophisticated
equipment and procedures. Smaller plants are usually
operated by personnel have limited training and use
elementary testing procedures and simple equipment.
Nonetheless, smaller plants can be operated successfully.
Parameters that can be monitored easily and that give a
good picture of the treatment plant's condition are:
settleability; pH ; color; dissolved oxygen; and residual
chlorine (if chlorine is used for disinfection). If portable
test kits are used, everything will fit into a 3-gal plastic
bucket. Required test equipment includes: 3-gal plastic
sample bucket with rope, DO test kit; pH test kit; two
calibrated quart jars; a residual chlorine test kit; and
elbow -length rubber gloves. One additional piece of
equipment needed to operate the plant successfully is a
squeegee that is long enough to reach the bottom of the
plant.
SETTLLABILITY
An indicator of good settling is a test that
measures how well the biological floc will settle. There
are two such tests: settleability and settleometer.
SETTLEABILITY TEST. The settleability test, or
30-minute settling test, should be considered the major
process control test for small package plants. A 1 000-mL
graduated cylinder or a calibrated mason jar may be used
to determine the percent of settled sludge by volume.
Figure 9.1 shows a simulated settleability test using a
quart jar. The mason jar has been calibrated by markings
on a piece of adhesive tape -at 13-mm (0.5 in.) increments
from the bottom to where the jar begins to curve. The
marks are then labeled from 0 to 100% in 10% intervals.
A sample from the aeration chamber (taken
after blower has operated for 10 minutes) is allowed to
settle in the jar for 30 minutes.
After which the percent of settled solids is
determined. The samples should be taken at the same
location in the aeration chamber and at the same time of
the day to allow for comparison of tests taken on different
days. The sample should not be taken near the plant
influent or near a return sludge line. When the
settleability test is conducted, the quart jar should be
placed in the shade, on a level surface, and away from any
vibration caused by the blowers.
The operator should observe the settleability test
for the first 5 minutes. How the sludge settles is just as
important as the final amount that settles. During the 5
minutes of the settleability test, a healthy sludge should
compact slowly, forming a screening blanket, and
squeezing clear liquid from the sludge. A good settling
sludge will settle at 20 to 50% of its original volume after
30 minutes. A problem may exist if the sludge settles
quickly, leaving finer particles in the supernatant, even
though the final percent solids reading is within the
acceptable range. A rapidly settling sludge, a cloudy
supernatant, and a dark brown color usually indicates an
old sludge with a large amount of inorganic solids; in this
case, increasing sludge wasting would then be
recommended. If the settleability test results are less than
20% and the supernatant is cloudy, but the sludge settles
slowly and the color is light brown, then a young sludge
17

is probably present. In this situation, the system could be
simply lightly loaded.
At times the settleability test results will be
above the recommended range. This condition could be
caused by either too much or too little sludge in the
system. The particular problem can be determined by the
50% Dilution Test. If the wastewater treatment plant is
just experiencing start-up, the microorganisms are
growing rapidly and have not developed enough weight to
settle well. The sludge will have a light brown color and
very little settling will occur after 30 minutes. If this is
the case, then sludge wasting should be reduced or
eliminated until the microorganism population produces a
good settling floc. At that time, sludge wasting could be
initiated as described in Chapter 7
A high sludge reading could also be produced
by an old sludge/If sludge wasting is inadequate the
sludge will become old, more dense, and will compact
easily. Initially, the percent solids may seem to decrease.
If inadequate wasting is continued, the old sludge will
eventually accumulate, even though it compacts well. The
percent solids reading will continue to increase above the
recommended range.
DILUTION TEST. Because the plant effluent will
be less than optimum, it is important for the operator to
determine which condition exists so that corrective
measures may be taken. The 50% and filling the rest with
unchlorinated clarifier effluent. Clear tap water should not
be used for dilution as it tends to make the sludge rise.
The normal settleability test is then run on this sample. If
the 50% diluted sample does not settle any better than the
first test, then the sludge is young. If, however, the
diluted sample settles significantly better than the original
test, the sludge is old and sludge wasting should be
initiated. It should not be assumed that the original
sample settled poorly simply because there were too
many solids in the system.
Dilution Test will provide this information; this test is
conducted by filling one-half of the quart jar with a
sample from the aeration chamber
SETTLEOMETER TEST. Another control test
procedure similar to the settleability test is the
settleometer test. This test is conducted with a sample
from the aeration chamber. The sample is placed in a
1000-mL beaker or a quart jar and allowed to settle for 60
minutes, with readings taken every 5 minutes for the first
half hour and every 10 minutes during the second half
hour. Settling results from the settleometer will indicate
what is taking place in the clarifier.
The settleometer test readings are then plotted
on graph paper, with the time variable on the horizontal
axis and the settled sludge reading on the vertical axis.
The slope and shape of the curve indicates the sludge
quality. The ideal settling curve does not guarantee a clear
discharge. The settleometer test simply indicates how the
sludge should settle in the clarifier. If the clarifier is
designed properly and all units are operating effectively,
the effluent from the clarifier should be clearer than the
supernatant in the settleometer. If the effluent is not
clearer, there is a problem in the clarifier.
After an ideal settling curve has been
developed, the operator must try to maintain it; however,
there is no cause for alarm if the plant occasionally
deviates from the ideal curve. The operator has little
control over what enters the plant. If possible, the public
should be informed of what should and what should not
enter the system. Assuming that the plant is not receiving
a toxic material, it is important that the operator
recognize possible reasons the settling curve is above the
ideal curve and possible reasons why it is below. Figure
9.3 shows a conditionwhere the actual settling curve is
above the ideal curve. As was discussed in the
settleability test section, the high settling curve is caused
by either too little or too much sludge.
f
The 50% Dilution Test is used to determine
which condition applies the procedures described
previously should then be followed.
At times the actual settling curve may be less
than ideal, as illustrated in Figure 9.4. This condition
could result for several reasons. In the figure, the dashed
settling curve indicates an old sludge that contains a large
amount of inorganic solids, -settles very rapidly, and has a
dark brown color. This condition can usually be corrected
by increasing sludge wasting.
The other actual settling curve is also below the
recommended range. If the sludge does not settle rapidly
and has a light brown color, the plant may simply be
lightly loaded. Sludge wasting, in this case, would not be
required. How the sludge settles, and what color it is will
determine whether or nor the plant is lightly loaded. Flow
data can also help determine if the plant is lightly loaded.
The condition of the settled sludge after 60
minutes is significant. A sludge that begins to rise after
60 minutes may be over -oxidized. A properly oxidized
sludge will not rise to the surface until 2 to 4 hours after
the test begins. If the sludge begins to rise at the 60-
minute mark, sludge wasting is required.
Although many parameters can be used to
control the operation of package extended aeration plant
(for example F/M ratio, depth of sludge blanket, dissolved
oxygen, return sludge rate, sludge volume index), the
settleability and settleometer tests provide the required
information, yet do not require a laboratory or a
laboratory technician. It is important, however, that the
small plant operator understand bow to interpret test
results.
As noted before, the pH in the aeration chamber
should be between 6. be clean at all times and chemical
reagents should not become contaminated.
Once the pH valve has been determined the
operator must enter that value on the operating log. Any
time a test is conducted it should be entered on the
operating log. Poor recordkeeping is one of the biggest
deficiencies for small package extended aeration plant
18

operators. A history of the plant operation is often the key determined by a pH meter. The pH meter takes time to
to solving current operating problems. calibrate and must be maintained according to
manufacturers' recommendations, whereas the color
comparator is simple to use, but does have some
limitations.
High suspended solids or high chlorine residuals
in the testing samples will interfere with the pH test.
Samples taken from the aeration chamber must be
allowed to settle for about .10 minutes, at which time the
pH of the supernatant can be checked. Efflueni samples
with chlorine residuals greater than 1.0 mg/L must be
dechlorinated. If a color comparator is used, its range
should be at least one pH unit above 8.5 and one pH unit
below 6.5. The wide range pH test kit, with a range from
4.0 to 10.0, is popular among small plant operators.
Whether a pH meter or a color comparator kit is used; the
instructions furnished with the test equipment gist be
followed carefully. Test equipment should will'result. The
amount (concentration) of oxygen that can be dissolved in
the mixed liquor is temperature dependent -the colder the
water, the greater the amount of oxygen that can be
dissolved. The oxygen concentration is measured in
milligrams per Iiter (mg/L); the ideal oxygen
concentration in the aeration chamber is 2 mg. The DO in
a clarifier should be at least 1 mg/L to prevent septic
conditions, which would result in gas bubble formation,
rising sludge, and unpleasant odors. When wastewater
flows are erratic, aeration will be difficult to yield the
ideal oxygen concentration: It is, therefore, better to have
a DO concentration that is greater than 2 mg/L than to let
it become . completely depleted, as fewer unpleasant
consequences result.
COLOR
The color of the aeration chamber is one of the
quickest way is to check the system operation the color
should be brown, similar to coffee with cream. If the
aeration chamber is this color and has a musty odor
similar to a damp basement or mushrooms, the sludge is
probably healthy. If the color is gray, the plant is not
receiving enough air. Possible reasons for this are: the
plant is receiving too much food; the control time clocks
are not allowing the aerators to operate enough; the
diffusers may be partially plugged; or the plant may have
received some toxic material. A black color accompanied
by a rotten egg odor indicates that the plant is septic.
When this occurs, the plant should be placed on constant
aeration until the light brown coffee color returns. A
septic plant is usually the result of poor attention by the
operator. Although aerator failures, power failures,
plugged diffusers, and toxic material will cause the plant
to go septic, the most cotnmon cause is neglect.
Other colors that may be observed occasionally
are white, red, and purple. A white aeration chamber
occurs when the plant is extremely lightly loaded. The
sludge, in this case, is completely oxidized and only ash
remains. Feeding the plant is not recommended. A red
color may be encountered when the plant is overaerated,
and a filamentous bacteria called leptothrix is present.
The sludge will settle poorly and a thick matty foam will
form. A purple color is not natural, but has been
encountered when iron removal water systems, which use
potassium permanganate to regenerate the media, use the
wastewater system to dispose of backwash and flushing
water. Therefore, the operator should know what is
connected to the wastewater system. REMEMBER: the
package extended aeration treatment plant is designed to
treat domestic waste only; anything else can cause an
operating problem.
DISSOLVED OXYGEN
Dissolved oxygen (DO) is one of the most
important ingredients of the mixture in the aeration
chamber. Oxygen is necessary for aerobic bacteria to use
organic material; without it, septic conditions 5 and 8.5
for microorganisms to grow. Either a pH meter or a small
liquid color comparator test kit may be used to test the
pH. Although the color comparator is excellent in
determining pH for operational control, its results may
not be accepted by the appropriate regulatory agency. The
regulatory agency should be contacted to determine
whether color comparator results are acceptable. If the
results are unacceptable, the effluent pH must be
DO METER. The test for DO is performed on the
mixed liquor from the aeration chamber for operational
control, and may have to be conducted on the plant
effluent for regulatory control. Because oxygen is
required in the aeration chamber at all times, plants that
are aerated intermittently must be sampled near the end of
the off aeration period, to indicate the minimum oxygen
dissolved in the water. The best method for testing the
DO in the aeration chamber is to use a DO meter. If the
probe is placed at mid -depth in the aeration chamber, the
DO concentration can be read directly. The meter
eliminates the need to obtain a sample from the aeration
chamber, a common source of error. Sampling is
ineffective when: samples are inadvertently agitated,
which induces oxygen; the sample is taken near the
surface, which does not give a true indication of the
oxygen content in the aeration chamber; or the sample is
not tested immediately. If a DO meter is unavailable, the
proper sampling equipment to obtain a sample at mid -
depth of the operation chamber should be used. The
American Society for Testing and Materials (ASTM)
Special Technical Publication No. 148-1 and the U.S.
Geological Survey (USGS) Water Supply Paper No. 1454
are good references for determining proper equipment.
19

DROP TITRATION COLORIMETRIC TEST.
Satisfactory DO data may also be obtained from a drop
titration colorimetric test kit. If discharge DO data must
be sent to a regulatory agency, the testing procedure
should be approved by that agency. The operator should
follow the test kit directions; test equipment must be kept
clean, and all test data recorded on an operating log.
DO AMPULES. Although not approved for
regulatory test data, DO ampules containing premeasured
reagents may be used to test DO in the aeration chamber.
These ampoules are quick, inexpensive, and easy to use.
Although this method is not suited to give research type
results, it has proven successful for operational purposes.
Color and odor may also be used to determine that DO is
sufficient. If the color of the mixed liquor is coffee with
cream and there are no disagreeable odors, the DO is
. probe ly satisfactory.
• Because operation of the aerators costs money,
the operator should aerate no more than required.
However, small systems do not have the personnel or the
operating controls that large plants have; therefore, the
operator should be cautious when fine tuning the system
to the ideal DO concentration. DO concentrations of 5
mg/L in the aeration chambers of small plants are
common. Unlike large plants, where each milligram per
liter of DO may cost hundreds of dollars in electrical cost,
the operating cost for each milligram per liter of DO in
small package extended aeration plants is relatively small.
FLOW
Flow in small 11 plants is normally expressed
in liters per second (gallons per day). Because flow
information is important for plant operation, a flow
measuring device is required. For raw wastewater, an
open -channel type flowmeter, such as a parshall flume, is
desirable so that wastewater solids will be passed without
clogging. At the plant effluent, a V-notch weir is
satisfactory. It is also highly desirable to have a flow
recorder that displays instantaneous flow rates and
cumulative flow. The chart will show peak and low flow
periods that may radically affect not only the clarifier, but
overall plant operation. Flows that exceed the hydraulic
capacity of the clarifier or other process units can be
detected. A single peak flow period occurring daily can
cause solids washout in the clarifier, and prevent the
activated sludge process from becoming established. If
this condition exists, peak flows must be reduced by
increasing plant size, adding flow equalization, or
diverting flow elsewhere. Daily flow records should be
maintained with readings taken at the same time each day.
Although peak flows will not be reflected, water meter
readings will give a good indication of the average flow
to the plant.
RESIDUAL CHLORINE
If possible, the residual chlorine test should be
run daily to determine whether sufficient chlorine is being
fed to consistently disinfect the plant effluent. The
required chlorine residual range is usually between 0.2
and 1.5 mg/L; other values may be required if bacterio-
logical tests show disinfection to be adequate or
inadequate. The effectiveness of disinfection at a given
residual level will vary, depending on the concentration of
solids or nitrogen. Changes in the concentrations can
cause the chlorine residual to change with a given feed
rate. It is important, therefore, to monitor residual chlo-
rine often and make feed adjustments as needed. The
regulatory agency' should be contacted to determine what
procedures may be used to detect chlorine. The most
common field test kit used is the DPD kit; this kit is sold
commercially by several companies. As always, the
instructions on the kit should be followed carefully, the
kit should be clean, and all test data should be recorded.
Samples for the chlorine residual test are to be taken at
the point nearest to the receiving stream or at the exit
point of the chlorine contact tank.
Some regulatory agencies may require that the
plant effluent contain little or no chlorine residual. In that
case, the operator must apply a dechlorinating agent to the
plant discharge. If dechlorination is required, the operator
should consider UV radiation rather than chlorine to
disinfect the discharge. The UV method causes no side
effects to the environment, as nothing is added to the
plant effluent. A variety of styles and sizes of UV units
are available. The method may require that the effluent be
filtered before disinfection.
TYPICAL OPERATOR
VISIT
Ideally, the operator should visit the plant daily. Some of
the major items which should be checked include:
COMMINUTOR. Check for sticks, rags, and rocks that
may have become caught in the comminutor.
REMEMBER: Turn OFF power before cleaning. Perform
maintenance as required by owners instructions. Do not
use hands to remove debris.
• BAR SCREEN. Remove material from bars and place
on drying rack; place dried material in plastic bag and
dispose at landfill.
• EQUALIZATION TANK. If system has an equalization
tank, remove any floating material and dispose with bar
screen debris. Check diffusers to ensure they operate
properly,'. Inspect floats and observe operation of the
unit.
20

• AERATION CHAMBER. Perform settleability and
settleometer test; note color of aeration chamber; note
rate of return sludge, color, and odor; check pH; check
DO; inspect froth spray nozzles; inspect rolling action
produced by diffusers (remove and clean every 3 months);
record all test data; and wash down as needed.
• CLARIFIER. Gently squeegee all sides; adjust return
sludge if needed; adjust skimmer if needed; remove
nonbiodegradable floating material (for example, rags,
sticks, plastic, grease balls, water -melon seeds); check
packing nuts on all air valves; inspect overflow weir
(must be level); inspect clarifier for high currents; check
depth of clarity (12 to 18 in. is common) with Secchi disk
(see Glossary); and finally, record all results.
• CHLORINE CONTACT TANK. Check chlorine residual
and make feed adjustments if needed; ,check chlorine
supply for/chlorinator; and inspect chlorine contact tank
for solids
• MECHANICAL EQUIPMENT. Check time clocks for
correct time of day and day of week. Ensure that air is
supplied to the plant daily. Establish a routine lubrication
schedule for each piece of mechanical equipment, as
recommended by the manufacturer. Record the date of
each lubrication in both a maintenance log and on a tag
placed on the piece of equipment. Finally, check air
filters, clean, or replace as needed; check air relief valves;
and inspect air piping for leaks.
CORROSION
CONTROL
Why do metals corrode? There are two basic
causes of corrosion: one is chemical attack; and the other
involves electrochemical reactions between metals and
their environment.
CHEMICAL ATTACK
Direct chemical attack is associated with attacks
on metals by acids, alkalis, and other similar corrosive
chemicals. This contributor to corrosion in wastewater
treatment plants can occur where chemicals such as
aikalines or acids are used for pH control, or where
chlorine is used for disinfection of wastewater before
discharge. This type of corrosion can be minimized
greatly if materials resistant to chemical attack are used.
Plastics and fiberglass materials are available, for piping
or tubing, chemical storage tanks, and pumping
equipment used for chemical feed systems in wastewater
treatment plants. These materials are usually incorporated
into the treatment plant design and are installed at the
time the plant is constructed. Older treatment plants,
however, may have been built with other materials that
may
have been worn or corroded over time by direct chemical
attack. When any of these items must be replaced, plastic
or fiberglass materials suited for the intended use should
be considered. The required items and components such
as tubing or pipe, chemical feed pumps, and tanks can
usually be obtained from plumbing houses or equipment
manufacturers. Care should be used in the selection of
such items to ensure they will resist corrosive attack by
the chemicals with which they may come in contact.
ELECTROCHEMICAL
CORROSION
The second, and more common, type of
corrosion is known as electrochemical (galvanic)
corrosion, and is most obvious in the case where two
dissimilar metals are electrically coupled. A battery is an
excellent example of this corrosion process. One metal,
acting as an anode, provides electrons to the second
metal; as a result of providing these electrons, the single
metal dissolves into the solution in contact with both
metals. This action causes metal loss and eventually
destroys the device supplying the electrons. Figure 11.1
illustrates this action. The solution carrying the metal ions
is known as an electrolyte. The electrons generated as a
result of this reaction travel to the cathode, where a
second reaction occurs. This electrolytic t)--e of corrosion
occurs wherever two dissimilar metals are in contact, or
when both are in contact with a electrolytic solution. This
electrolytic solution may be chemicals stored in tanks or
chemical feed tanks, wastewater in any one of several
treatment processes, or a thin liquid film coating the
various metal components.
There can be numerous opportunities for this
type of corrosion in wastewater treatment plants because
metals are used for such items as piping, tanks, grating,
pumps, and blowers. Awareness of this type of
electrochemical corrosion may alert the operator to a
potential situation where corrosion may occur. The most
effective preventive methods are to use similar metals
that will be in contact with each other, isolating the two
Metal components with a nonmetallic material such as
fiberglass or plastic, or to completely substitute the
metallic components with nonmetallic ones. Although
there may be a situation where dissimilar metals could
corrode, it is important to note that this process may
occur very slowly. Therefore, the operator should
occasionally check these locations for evidence of
corrosive attack.
Metal corrosion can also occur when only one
metal is in contact with an electrolytic solution. These
electrolytic cells are called differential aeration cells and
occur when there are different concentrations of ox)'gen.
As indicated in Figure 11.2, this corrosion can develop
when iron rusts. The concentration of oxygen under the
rust is lower than that around the outside of the iron and
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rust, thereby resulting in corrosion. The threaded surfaces
of two coupled pipes provides a suitable environment for
this type of corrosion. This corrosion can account for the
pitting damage that can occur under rust or at the water -
air interface of a tank wall.
Corrosion can also occur in metallic
components such as piping, tanks, door and window
frames, and grating, where there is no contact with a
dissimilar metal and where oxygen concentrations do not
vary from one metallic surface to another. The process by
which this type of corrosion occurs is electrochemical in
nature. However, metals are not totally pure and
homogeneous, but contain small quantities of impurities,
and these impurities can act as anodes or cathodes with
the primary metal. This is especially true of iron and
steel, where the anodes and cathodes cannot be isolated.
The metal surface must receive a protective coating to
prevent contact with an electrolytic solution or the
atmosphere. Although there are several other mechanisms
that can cause corrosion, those just described are
generally associated with corrosion in wastewater
treatment plants.
In addition to the preventive methods already
mentioned, there are other ways to minimize corrosion.
For example, the environment may contribute to the
corrosion reaction. Treatment plants enclosed within
buildings may cause damp conditions; this moisture, in
combination with particulate matter in the atmosphere,
can produce the proper electrolyte to initiate corrosion.
Proper ventilation can greatly reduce corrosion potential
by removing or reducing this electrolytic source. Other
methods to control or increase corrosion resistance of
metal include: use of protective metal coatings;
production of oxides or phosphates for coating iron and
steel; application of protective paints; and other surface
treatments.
All of these methods (with the exception of
paint application) require specialized skill, knowledge, or
equipment for their application. Corrosion protection for
cathodic or anodic protection is often used for large
structures, such as buried or submerged tanks and buried
pipelines. Individuals who have the required specialized
knowledge in corrosion protection should be contacted to
evaluate the potential for cathodic or anodic protection.
PAINT APPLICATION
Usually, the only practical method the plant
operator can use to control and minimize corrosion is to
apply protective paint. There are numerous paint types
available for use as protective coatings. The type selected
will be determined by the metallic surface to be coated,
the type of atmosphere to which it is or will be exposed,
and any desired special paint characteristics, such as
electrical insulation or heat reflection.
STEEL. Because steel (with the exception of
steel alloys, such as stainless steel) is not highly
corrosion -resistant, treatment plant manufactured from
steel will require a protective coating. When a treatment
plant is constructed, exterior and interior steel surfaces
should receive proper corrosion protection. In addition,
some steel components such as buried tanks may be
provided cathodic protection through a sacrificial
magnesium anode. Nonetheless, steel surfaces and
components may begin to experience corrosion over time.
This can occur when the effectiveness of a paint or other
coating decreases under repeated attacks by moisture,
fungus, sunlight, or age. In addition, nicks in painted steel
surfaces expose base metal, providing an opportunity for
corrosion.
Major painting of large buried tanks will be
beyond the capability of even large, fully staffed
treatment facilities. When such a situation arises, the
operator is advised to seek professional assistance, this
may involve preparing specifications and advertising for
contractors to perform the required work. Less extensive
painting requirements may permit the operator to perform
these painting tasks. Care should be taken to prevent paint
from getting into the wastewater.
Components to be painted should be evaluated
for any possible signs of corrosion. This evaluation may
enable the operator to apply other corrective measures
that may extend the Iife of the paint or reduce the severity
of potential corrosion. Steel and iron surfaces to be
painted should be thoroughly cleaned first. Solvents will
aid in removing oil and grease, while scale and rust may
be removed by scraping, power wire brushing, power
sanding, or sandblasting. A commercial phosphoric acid
wash is recommended before painting, unless the surface
has been sandblasted. The phosphoric acid wash aids in
bonding the paint and provides a thin phosphate coating
on the steel surfaces to retard corrosion. This procedure is
especially important in the case where an existing paint
film has been scratched.
Steel surfaces should receive a primer after
cleaning and acid washing before painting. The primer
may be applied in one or more coats and should contain
rust -inhibiting pigments. This will also provide a bonding
surface for the top coat of paint. Paint suppliers can
usually be helpful in selecting the proper coatings for the
proposed application. Where hydrogen sulfide exposure is
possible, lead base paints should not be used as hydrogen
sulfide will cause the lead to break down.
GALVANIZED IRON. Normally, galvanized iron
will better resist corrosion found in wastewater treatment
plants. Yet, when the coating becomes nicked or
scratched, the potential for corrosion is increased.
Galvanized iron should be treated with proprietary etch-
ing solution or phosphoric acid wash before priming and
painting. The paint used for the prime coat should contain
22

zinc chromate. Primers containing red lead should not
be used because of the possible galvanic or
electrochemical reaction between the lead in the primer
and the zinc; furthermore, lead paints are toxic.
ALUMINUM. As with the application of all other
coatings, surface preparation for aluminum is important.
This includes removal of any grease and oil. The
aluminum that is to be painted must first be treated with a
phosphoric acid wash, because paints do not normally
adhere well to aluminum. A prime coat containing zing
chromate should be applied before the top coat. This will
prevent a similar galvanic reaction mentioned previously
for galvanized iron.
MAGNESIUM ANODES. For metal plants, in addition to
painting, periodic replacement of the magnesium anodes
is required. Frequency of replacement will depend on the
painting of the exterior surface and the soil conditions:
Because placement of the magnesium anode sacks makes
them difficult to inspect, it is recommended that they be
replaced every 10 years. A location sketch should be
made when the plant is installed.
SUMMARY
Corrosion prevention and correction. is a
continuous, ongoing process in wastewater treatment
plants. The operator must be alert to conditions within the
treatment plant that enhance corrosion reactions. Equally
important is proper treatment of corrosion once it is
discovered. Preventing or minimizing some types of
corrosion will extend the life of corrosion prevention
measures when corrosion is encountered. If corrosion
recurs frequently. substitute materials should be
considered. The use of protective coatings requires proper
surface preparation and selection of the primer/paint
system to resist potential corrosive atmospheres. Where
extensive repainting is necessary preparing specifications
and advertising for experienced contractors should be
considered. Other protective measures such as anodic or
cathodic protection may, be desirable. The operator
should retain the services of a qualified engineer when
extensive repainting or other corrosion prevention
measures are to be used.
REGULATORY
k!r E Y UIREMENTS
Regulatory controls on the wastewater treatment
plant will vary depending on the size, stream location,
and geographic location of the plant. If the operator does
not know what monitoring is required, the local
regulatory agency should be contacted. Some common
tests that may be required for effluent monitoring are:
• Biochemical oxygen demand;
•Suspended solids;
' PH;
•Residua! chlorine;
°Fecal coliform;
°Dissolved oxygen;
• Nitrogen;
• Phosphorus; and Flow
If discharge monitoring is required, a discharge permit
will be issued. This permit will provide the following
/1
information:
• Reporting frequency;
• Tests required;
• Sampling techniques to be used;
• Reporting forms; and
• Compliance schedule (to be followed if system is
to be modified).
SAFETY
The wastewater industry has been identified in
annual Water Pollution Control Federation (WPCF) safety
surveys as having one of the highest accident records.
Therefore, good safety habits are essential in wastewater
treatment plants.
Because each treatment system will be
somewhat different, it is recommended that a written
safety program be developed for each plant.
WPCFs MOP No. 1," Safety and Health in
Wastewater Systems" and "Guidelines for Developing a
Wastewater Safety Program" are excellent guides to use
for developing good safety habits. Another good reference
is the Minnesota Pollution Control Agency's Activated
Sludge Package Plant Operators Manual." Safety
instructions contained in manufacturers' O&M manuals
are also helpful.
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