PHI Design Specifications

Part 1 - General

1.01 SYSTEM DESCRIPTION

A. The PHi variable speed mixing system is a patented method of mixing liquids, including wastewater, chemicals, activated sludge and water utilizing a sequential injection of compressed air by pneumatic or electric valves through a piping system to specifically spaced forming plates anchored to the bottom of the tank. Software for the plant’s PLC (or OCS) or a programmable sequencing computer, a programmable smart relay or a non-programmable controller can operate the injection of the compressed air.

B. The compressed air is injected as a very short duration pulse or burst in order to form an air mass or bubble mass, which, as it rises, to the surface forms a powerful and thorough mixing action. Each injection valve may be connected to one or more forming plates depending on the particular application.

C. Applications include Anaerobic Zone Mixing, Aerobic Zone Mixing, Anoxic Zone Mixing, Sludge Tank Mixing, Chemical tank Mixing, Influent channels, Wet Wells, EQ tanks, Lift stations, Blending and Flocculation or Rapid Mix.

D. Mixing occurs with negligible oxygen transfer, no in-basin moving parts, is infinitely adjustable and is simple to install, operate and maintain.

E. Changing the injection time and pulse frequency can vary the mixing speed.

F. The PHi mixing system is the elegantly effective replacement to submersible mixers, vertical turbines, floating mixers, and pump based mixing systems. Features include no moving parts inside the tank, reduced maintenance and lower energy usage.


Part 2 - Products

2.01 EQUIPMENT

A. Forming Plates are 8” diameter, 3/16” thick material with one end of a 4” or longer 1” diameter pipe nipple welded over a full size hole drilled in the center of the plate. The other end of the nipple has a MPT for connecting to the distribution pipe. In custom situations materials other than those listed below may be used.

1. Double forming plates are made of two 304 stainless steel plates for installation in concrete tanks. Internal spacers provide the correct airflow spacing between the forming plates. Three 3/8” diameter, equally spaced pre-drilled holes are provided for bolting the forming plates to the tank bottom. The forming plate is bolted using a 1/4" x 2-1/4" 304SS threaded wedge expansion anchor bolt. These may also be used when the tank supplier needs to through bolt the forming plates to the tank bottom.

B. Injection Valves and Enclosure

1. Enclosure is Type 304 stainless steel with a NEMA 4X rating for outdoor use.

2. Air is sent to the forming plates by a MAC 1367G pneumatically operated injection valve which has a pneumatic/electric pilot-operator. The minimum opening/closing cycle is less than 50 milliseconds at 80 psig. Seals are nitrile/Buna-N. The valves are installed onto a special manifold to enable a quick disconnect feature for ease of servicing. Valve life is manufacturer rated at 20,000,000 cycles. Each injection valve is double-acting with two outlets per valve. Each outlet can serve up to four forming plates.

3. An IDEC Communication Module interfaces the MAC 1367G valve through a serial cable, connects and is programmable either locally or from the Owner’s computer.

4. A Watts air filter with a 40-micron element and an auto-drain feature is provided to remove particles to protect the regulator and injection valves.

5. A Watts pneumatic pilot-operated regulator with pressure gauge provides a constant pressure for proper airflow to the injection valves. Pressure to this regulator shall not exceed 120 psig. The regulator is controlled by a Watts pilot valve.

An additional feature allows the air pressure to be adjustable from the Owner’s computer. It also allows for adjustment to different air pressures to accommodate different processes. The pilot valve may be connected to an IDEC Communication Module, which becomes an addressable location through a serial cable, connects and is programmable locally or from the Owner’s computer.

6. An electric heater with integral thermostat maintains a minimum temperature during cold weather to prevent freezing temperatures within the enclosure to allow proper operation of the components.

7. Components are pre-piped with stainless steel pipe and fittings and are factory tested for leaks and function. Unions are provided for servicing of components.

8. Each enclosure requires two 15 amp, 110 volt, single phase, 60 Hz service connections. One connection serves the heater and one serves the valves and controls.

9. It is highly recommended that the Owner provide surge protection for the electrical service line to all electronics.

10. The enclosure is pressurized internally to approximately .5 psi which ensures that the caustic air found at most wastewater treatment plants does not affect the PHI system components inside the enclosure.

C. Materials

1. Piping and fittings between compressor and forming plates is recommended to be stainless steel, Type 304 (threaded)

D. Compressor

1. Compressor is a belt drive (20 HP and below) or direct drive (25 HP and above), air-cooled, oil flooded rotary screw type rated at 125 psig with intake filter, high efficiency motor and coolers and computerized control system. Food Grade coolant is factory filled. NEMA-12 enclosure.

2. Accessories include filtered moisture separator (Kaeser Compressor, Inc. KFS Series), pressure differential gauge, liquid level indicator and internal automatic drain trap or demand type 115 Volt trap.

3. Electrical service requirements are 460 Volts, 230 Volts or 208 Volts (additional cost), three Phase, 60 Hz. Amperage requirements will be determined by PHi once the compressor has been selected.

4. Included are an on-site Factory startup, two-year air-end, motor and controller and one-year package warranty.

5. A five-year extended warranty may be purchased for an additional cost. It is paid for on a yearly subscription basis and includes some replacement parts and replacement lubricant.

6. Manufacturer: Kaeser Compressors, Inc.

E. Desiccant Dryer (Outside ambient temperatures below 45ºF.)

1. Dryer is a dual tower desiccant air dryer that provides a –40F. pressure dew point with an average purge rate of airflow used to dry the desiccant with 3-way bypass, tower and purge pressure gauges, moisture indicator and electronic control panel.

2. Tanks are ASME code constructed and stamped pressure vessels with pressure relief valves.

3. Accessories include, a coalescing pre-filter (Kaeser Compressors, Inc., KOX Series) and a particulate after-filter (Kaeser Compressors, Inc., KPF Series) each with a differential pressure gauge, liquid level indicator and internal automatic drain.

4. Electrical service requirements are 115 Volts, 20 amps, single phase, 60 Hz.

5. Manufacturer: Kaeser Compressors, Inc. KAD Series.

F. Air Receiver

1. Air receiver is sized as a “control” receiver for the compressor. Vertical or horizontal. ASME rated.

2. Accessories include a safety valve, pressure gauge and a demand-type drain trap.

3. Manufacturer: Manchester Tank.

G. Condensate Filter (Oil/Water Separator)
1. Separator utilizes a three-stage, self-contained plastic filter cartridge to filter out oil and other contaminants from compressed air condensate making water safe for disposal.

2. Manufacturer: Kaeser Compressors, Inc., KCF Series


Part 3 - Execution

3.01 INSTALLATION

A. The items provided under the PHi contract are:

1. Forming Plates

2. Injection Valve Enclosure

3. Air Compressor(s)

4. Desiccant Dryer

5. Oil/Water Separator

6. Food Grade Coolant

7. Coalescing filter

8. Condensate filters (oil/water separators)

9. First year compressor warranty

B. The various components shall be installed per PHi instructions. PHi will provide plan(s) with an Installation Manual and Operation Manual, as applicable.

C. Not Included in Contract Price.

1. Piping from the air compressor to the Injection Valve Enclosure.

2. Piping from the Injection Valve Enclosure to the forming plates.

3. Electrical service wiring, components and accessories.

4. Installation of concrete pads and support framing for the Injection Valve Enclosure and Sequencing Computer/Controller Enclosure.

5. Installation and anchoring of the forming plates.

6. All labor costs.

D. A Turnkey installation can be provided upon request.

3.02 WARRANTY

A. Pulsed Hydraulics, Inc. (PHi) warrants material and workmanship in equipment, and assigns to the purchaser any express warranty granted by the suppliers of components used in the manufacture of the products. PHi's warranty shall be for a period of one (1) year after the date of shipment to the original purchaser, during which time nonconforming products shall be repaired or replaced at PHi’s option. This limited warranty is in lieu of all other warranties, expressed or implied, including design, course of dealing, merchantability and fitness for a particular purpose and PHi shall not be liable for loss of use, revenue, or profit, or injury, or for any other consequential or incidental damages.

BACK