Western Water Products
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Western Water Products
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1.0 Water Recovery
System General Specifications: Heavy Duty SC-C-RPS Series with Hopper Bottom Pit, Sludge
Removal System and extra Holding Tank with Repressurization Pumping System for use with a
combination of a pressure washer and hose wash or other wash.
1.01 Performance: The wash water recycling equipment shall be a Heavy Duty system, of the type manufactured by WaterCycle, Irvine, CA, Model SC-015CC (0-15 GPM) or SC-025CC (0-25 GPM). The water recovery system shall be rated and sized for continuous operation and shall be capable of producing wash quality water for use hand held, hot water, high pressure washers demanding oil free 10 micron or better wash quality water and/or for a hose bib or other type wash equipment. The system shall be capable of producing "positive" 10 micron or better water which shall be virtually free of all free floating and emulsified oils to avoid damaging the high pressure washer piston or plunger pump. 1.02 Water Collection: Water
shall be collected in a below ground sump. Three common types of sumps may be used. 1) A small sump (commonly called a sand
trap): A sump measuring 24" square x 24" deep is the smallest sump that can be
used. When using a small sump all the water, dirt and other contaminants will be pump out
of the sump and therefore a cone or hopper bottom pretreatment tank at least 100 gallons
in size must be used.. This will also require the use of a second transfer pump. 2) Multi-compartment clarifiers: 2 or 3
stage clarifiers will provide adequate underground storage and also assist in removing
free floating oils. The water transfer pump should be located in the final stage of the
clarifier. Clarifiers tend to build up with dirt and must be pumped out regularly. 3) The preferred method is to utilize a "Hopper Bottom Pit" described below. The pit can be either located in the center of the wash pad as the primary sump or off to the side after the water has gone through a small sump first. If the hopper bottom pit is selected it shall consist of at least a single pit which shall be a minimum size of 36" square x 54" deep and shall be constructed with a "Hopper Bottom" which shall allow for the placement of an OPTIONAL independent sludge removal pump (described in section 1.02.01 below) to facilitate the removal of sludge from the pit to an above ground mud hopper (described in section 1.02.03 below) for easy disposal. The sump shall either be cast out of concrete or, as an option, a WaterCycle #HBP, preformed polyethylene pit, may be used. For heavy dirt loads a drainage ramp may also be used in conjunction with the hopper Bottom Pit(s). 1.02.01 Independent Sludge Pump: The "Hopper Bottom" pit shall allow for the placement of an independent sludge removal pump to facilitate the removal of sludge from the pit to an above ground mud hopper for easy disposal. The pump shall be at least 1/3 HP in size and shall be an effluent pump capable of pumping objects up to 1-1/4" in size. 1.02.02 Sludge Pump Control: The independent sludge removal pump shall be controlled by a separate timing control which is timed to come on periodically to remove sludge from the pit and place it into an above ground mud/oil hopper for easy disposal. 1.02.03 Mud/Oil Hopper: The mud/oil hopper shall come equipped with a device for slowly decanting off the water and returning it to the pit while allowing the sludge to settle out in the hopper. 1.02.04 Pit to Console Water Transfer Pump: A separate water transfer pump shall be located in the pit to provide water on demand to the water recovery-filtering console. The transfer pump shall be a minimum of 1/3 HP in size and shall be housed within a 650-micron filtering barrel, which is designed to filter out debris and thereby avoid plugging the pump. 1.02.05 Transfer Pump Control: The water transfer pump shall be operated by a separate control and shall receive its signal from the water recovery system to provide water as required. The purpose of this pump is to positively feed water to the water recovery system to avoid loosing prime in the line commonly associated with foot valves. Therefore, a foot valve shall not be allowed. 1.03 Fresh Water Make-Up: When the water recovery system requires water because of a low water level signal in one of its holding tanks and in the pit, the transfer pump shall energize and supply water to the water recovery console provided there is sufficient water in the pit. If there is insufficient water in the pit, a fresh water make-up valve shall be automatically opened to provide water to the system until the low water level condition has been satisfied. 1.04 Cyclone Separator (Solids Removal): A Cyclonic Separator shall be used as the primary filtering device due to its "self cleaning" nature and due to a lack of need for continual maintenance. Water shall be filtered at this stage to a nominal 10-micron and fed into a process tank for oil coalescing and removal through skimming. 1.05 Oil Coalescing/Stilling/Skimming Process Tank: Oil shall float to the top of the process tank where it will be removed through a passive skimming technique of "periodic forced overflow" thereby eliminating the need for electro-mechanical oil skimming wheels or drums. Oil shall be diverted into the Mud/Oil hopper where it will be absorbed into disposable oil pillows for easy disposal. Alternately, a separate oil barrel may be used whereby the water will be drained back to the pit leaving behind the oil which may then be bled off for easy disposal. 1.05.01 Process Tank Stilling: The oil coalescers shall be designed in such a manner as to "still" the movement of water when water is not being pumped through the tank thereby reducing turbulence in the water which will allow the settling of solids which are heavier than water but smaller than 10 micron in size. The tank shall be manufactured with a sloped hopper bottom and be equipped with an automatic purge valve which will be timed to open periodically to remove sedimentation which falls to the bottom of the tank and return it to the pit. 1.06 Oil and Particle Polishing Filters: Water shall be pumped from the process tank through an additional oil filter and a particle polishing filter to a cleaned water storage tank for re-supply to the pressure washer on demand. 1.6.01 Oil Polishing Filter: The oil-polishing filter shall contain an oil adsorbing filter foam to remove any remaining emulsified oil from the water. The filtering foam shall be manufactured of a material, which can withstand constant re-cleaning and reuse. The filter shall be approximately 3 cubic feet in volume. 1.06.02 Dual Particle Polishing Filter(s): The system shall be equipped with a set of two final polishing filter consisting of 10 Micron Cartridge Filters of at least 75 Square Feet of filtering surface area each. The system shall be designed so that water passes through one of the filters and, when it becomes plugged, the system will automatically switch to the cleaned filter and notify the machine operator with an indicator light that the dirty filter requires cleaning. Once cleaned, the system shall be able to be reset with a single button so that the filtering process can continue automatically. 1.06.02 Carbon Filter: As an option where required by design or specification a Carbon filter may be supplied as a final filter. Due to the nature of carbon filters, it will be the customers responsibility to monitor water quality and to replace or regenerate the carbon filter as required in the instruction manual as there is no cost effective monitoring device available to detect when carbon becomes spent. 1.07 Tank Design: All tanks shall be vertical as opposed to horizontal tanks standing in an upright position to minimize their footprint and shall have conical or hopper bottoms to facilitate the easy removal of sludge using an automatic "fast flush" purge control system which will operate periodically controlled by a timer. This will eliminate the need to take the system apart regularly to clean out the build-up of unwanted sludge. 1.08 Diagnostic/Indication Lights: The system shall come equipped with diagnostic lights mounted on the systems electrical panel indicating "System On". All electrical back panels and pit panels shall be UL listed. 1.09 Continuous Water Recirculation: The system shall employ a method of continuous water recirculation for the constant aeration of water throughout the system which will aid in the prevention of a build-up of bacteria, virus, algae, etc. and also to prevent the build-up of foul odors. 1.10 Disinfectant System: The primary disinfectant control system employed shall be an ozone injection control system which shall also act as a DAF (Diffused Air Floatation) system and cause oil to float to the top of the process tank for the purpose of skimming. 1.11 Expansion Tank and Repressurization System: The system shall also be capable of storing additional water for supply to a hose bib and shall come equipped with an external tank with a minimum of 500 gallon capacity. A separate repressurization pump stand shall be supplied to provide water to the hose bib equal to city water pressure. The pump stand shall be mounted on a pump stand made of steel tubing and shall include all necessary electrical controls to interface with the pumping console as necessary. A bladder tank shall be used to signal the pump to start and stop. The tank shall be supplied with an automatic purge drain valve, which shall be programmed to drain water from the tank every few hours to avoid stagnation. 1.12 Instruction Manuals: The system shall come with an instruction manual complete with a description of operation of the system as well as all major components, with a complete parts list showing manufacturer's names and part numbers of all major buyout components, with a complete trouble shooting guide and with a complete diagnostic guide keyed to the trouble shooting lights located in the electrical panel. 2.00 Construction Materials and Specific Specifications for Major Components: 2.01 Console Frame and Housing: The console frame and housing shall be made of steel and shall be completely painted with a polyester powder coat paint to provide maximum resistance to corrosion in an outdoor environment. It shall be constructed with a steel framework for supporting all tanks and components. All connections for water and power shall be available from either the right or left-hand side for easy installation. The plumbing connections for incoming and outgoing water shall be located at the bottom of the console and brought out to each side. All plumbing connections shall be supplied with female NPT fittings. All plumbing within the console shall be schedule 40 PVC or flexible spa hose. All electrical connections will consist of UL approved plugs and cords or be routed through conduit where necessary. The corner posts of the frame shall extend down at least 4 inches providing mounting feet and shall be supplied with adjustment devices at the bottom of the feet to accommodate irregular surfaces and for leveling purposes. 2.02 Above Ground Tanks: All tanks shall be made of a chemical inert, corrosion resistant, material such as cross-link polyethylene. This material shall pass an impact test of 120 foot pounds at minus forty degrees Fahrenheit per Phillips test SSL-193. Every vessel shall be capable of containing 12 pounds per gallon liquids without rupturing. This material must resist stress cracking and provide a minimum of ten years life and be warranted for a minimum of five years. It shall be a completely enclosed vessel and shall incorporate a cover made out of similar material to allow access for service or inspection. Each vessel or combination of vessels must be specifically sized to retain enough water to handle the rate of flow for the wash. Each process water tank shall have a conical or hopper type bottom to assure that all dirt and debris that settle converge to a single point. At this point a drain connection shall be made to enable purging the tank either by automatic periodic purging. The periodic purging of the above ground tanks shall purge sludge and aerate the water and thereby minimize odor from bacteria growth that occurs from sludge build up normally found in flat bottom tanks. 2.03 Cyclone Separator: The cyclone separator shall be made of fiberglass reinforced nylon capable of withstanding 110 psi. It shall clean particles that have a specific gravity of 2.7 or more to within a nominal 10 micron range. The quantity and size of the separator(s) must be adequate to handle the flow rate of the wash system. Its dirty water discharge flow must not be obstructed so as to reduce its efficiency in cleaning. The pump feeding the cyclone must be capable of developing at least 50 psi (115 feet of head), in order to assure the 40-psi pressure differential across the cyclone necessary to obtain the nominal 10-micron water for reuse. The cyclone is to be 98% efficient with proper viscosities and have a lower cone section of polyurethane or equivalent, and the lower case must be easily removable for service or replacements due to wear. When in operation, the centrifugal G-force for particle removal shall approach 7500 G's, and the suspended solids shall be ejected out the bottom of the cyclone and be directed to a mud/oil hopper or other appropriate receptacle. 2.04 Pumps and Motors: Each pump motor must be designed to the latest in NEMA standards. It is to be properly housed and protected within the system to ensure that no contaminants enter the motor to shorten its life. It shall utilize the latest in Class B insulating technologies and be built for severe environmental duty applications. It shall utilize non-regreasable ball bearings to minimize maintenance and ensure contamination-free bearing life. It must be built to NEMA standards MGl-12.53.A and be UL recognized with approval per E-46145. All steel components are to be coated with rust inhibiting undercoat and an overcoat of durable enamel. All rotors are to be coated with a rust inhibitor and the motor must use non-hygroscopic Class B or better varnish impregnated windings. The motor is to be oversized so that it will not be taxed, to allow it to run cooler, draw less than nameplate amps and extend its life expectancy. The motor shall be rated to run continuously 24 hours a day, have CSA approval and be batch tested for efficiency performance per I.E.E.E. 12A Method B. 2.04.01 Pumps must be designed and built to handle the water quality being handled at each point in the system. They must also be sized to provide the proper flow and pressure demanded by each process in the system. Pumps must have proper seals and bearings and an efficient reliable proven impeller construction. All pumps shall have a ruggedly constructed high tensile strength housing suitable for the application. Pumps shall have a sealed lubrication system for the pumps chamber with easy access to provide lubrication to the pumps seal when necessary. 2.04.02 The cyclone and repressurization pumps shall be centrifugal pumps and shall incorporate enclosed corrosion resistant bronze impellers, dynamically and hydraulically balanced to reduce axial thrust supported by two single row, single shielded, grease packed, radial ball bearings. The pump is to have a stainless steel input shaft with a molded rubber slinger to help protect against contaminants entering the bearing chamber. The pump must be capable of producing in excess of a minimum of 10 psi over the required wash or supply pressure to compensate for assumed pressure losses in the piping to the wash. Its GPM rating should also match the wash supply requirements to assure an adequate supply. 2.04.03 Transfer pump is made with corrosion resistant coated steel housings with Class B non-hygroscopic varnish impregnated windings and supplied with a rust inhibitor coated rotor. The activation switch should be proven, easily adjustable, float type, mechanically compatible with the motor. Each pump motor shall be rated 1725 RPM and be equipped with its own 20' heavy-duty power cord with a 3 prong plug. The pump vortex impeller is to be made of a minimum of non-clogging fiberglass reinforced noryl. The pump end shield and base is to be made of corrosion protected cast iron. The bearings are lifetime lubricated double ball. Each pump shall provide the required flow against an existing designed head. Each motor must have inherent protection by means of an automatic thermal overload device designed as an integral part of the motor. All hardware shall be made of stainless steel to facilitate easy removal for repair. It shall be capable of handling 3/4" spherical solids and be classified as an industrial duty effluent pump. 2.05 Bladder Tank: The bladder tank shall operate as the presoak arch supply pump "ON" switch and as a water hammer arrester when properly applied. The bladder material shall be made of a synthetic compound capable of withstanding the types of wash water that it will be subjected to. The housing shall be made of corrosion resistant stainless steel or equal and the system shall have an internal pressure switch that is to signal the supply pump to go on. It is also to have a check valve so that when the operation is complete, the bladder retains a positive head of pressure on the downstream supply valve in the same fashion as would normal city water pressure. The bladder tank must be sized such that it prevents water hammer and nuisance cycling of the supply pump. The bladder tank shall be conveniently located in the console housing for easy access, if necessary. All components of the bladder tank shall be built for high cycle industrial use. 2.06 Valves: All valves are to be made of high quality materials suitable for the environment. Each valve is to be properly sized to meet its application requirement and ensure the minimum amount of pressure loss in the system where pressure is a vital consideration. All valve installations must be located and plumbed such that they can be easily replaced, if necessary. 2.06.01 Automatic Valves: All automatic valves must be built such that their electrical connections are suitable for the environment and meet NEC and I.E.E.E. codes. The operation of each valve shall be sequenced by the system PC controller and be easily re-programmable if functional changes are required. All automatic valves are to be rated for high cycling industrial applications. 2.07 Electrical Panels: The main control panel is to be mounted on the water recovery console and shall be housed in an adequately sized corrosion resistant housing with a hinged cover. The housing shall be adequately sealed to prevent the entrance of moisture and a direct spray of water. It shall contain the proper NEMA sized starters for the horsepower rating of each pump, properly sized heater thermal protection and fusing as required. The housing shall also contain a properly sized circuit breaker handle mounted on the panel door, which will prevent access inside the panel without the power being shut off. The cover of the main electrical panel is to include various indicator lights, which will indicate: power on, low level, low pressure, etc. All electrical panels shall be UL recognized. 2.07.01 System Programmable Logic Control: If required because of design, a simple industrial quality programmable controller (PC) may be supplied with the panel to minimize the number of discreet relays and timers in the panel and also to provide simplified logic control of the entire system. The PC shall have a minimum of eight inputs and seven outputs and be easily programmable if any sequence needs to be changed. Diagnostic lights on the PC shall be capable of being used to advise if there is any problem with any of the pumps, valves, floats or pressure switches. 2.07.02 The pit and timing panels shall be housed separately in a NEMA IV enclosure and shall contain any timers, starters, etc. necessary for proper operation of the transfer and sludge pumps. 2.08 Testing: Each major component shall be tested prior to shipment from the factory. The complete console shall be pressure and electrically tested. The factory-assembled portion of the system shall be thoroughly checked for leakage. Each unit shall be accompanied by an inspection "check list" showing what inspections have been performed and shall be "signed off" by the inspector. This test shall include the operation of all floats, valves, signal and diagnostic indicators. Pressure and flow rates shall be checked to assure that all plumbing connections, hoses are properly applied and all valves function as they should.
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Western Water Products
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