Western Water Products

SITE MAP

1.01 Performance: The wash water recycling equipment shall be of the type manufactured by WaterCycle, Irvine, CA, Model XL-Series and designed to handle the flow rate and water pressure required by the wash on a continuous basis. The wash water recovery system shall be the manufacturers "standard-duty" system for use in an exterior vehicle wash application. The system shall be suitable for use with either a drive-through or roll-over vehicle washes requiring nominal 10-micron water and be virtually free of free-floating oil. The water recovery system shall also be capable of continuously processing water through the reclaim system for constant cleaning and ozonation/aeration of the water even when there is no demand for water by the wash. Unless there is a need for a Closed-Loop water recovery system requiring further filtering of "Rinse Quality" water through a Rinse Water Filtering module, the final rinse of the automatic wash shall remain on fresh water or "Spot-Free" water.

1.02 Water Collection: Water shall travel from a sand trap located on the wash pad to a sump or pit located nears the equipment pad. Water shall enter the pit through a pre-filtering basket designed to screen out debris and prevent it from entering the pit. The basket shall be simple in design and shall be easy to remove and replace for cleaning. Straining holes in the basket shall be no larger than 1/4" in diameter and shall be sufficient in number to allow proper water flow through the basket when half full of debris.

1.02.01 OPTIONAL Independent Sludge Removal Pump: 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. The pump shall be at least 1/3 HP in size and shall be an effluent pump capable of pumping objects up to 3/4" 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. The mud/oil hopper shall be adequately size to handle the dirt and sludge load and shall be a minimum size of 40 gallons. The hopper shall be designed to allow the use of disposable oil pillows to absorb free floating oils from the water in the hopper. When full of oil, the pillows can then be disposed of in the proper manner.

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 systems pumping/filtering console. The transfer pump shall be adequately sized for the water flow required by the automatic wash 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 which shall receive its signal from the water recovery system to provide water as required to keep the above ground process and cleaned wash water storage tanks at their proper water level. 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.

1.02.06 Pit Water Level Sensors: Two floats shall be mounted in the pit. The first float (lower level) shall signal the water recovery systems pumping/filtering console that there is sufficient water in the pit for proper system operation. The second float shall tell the system that there is excess water, which will have to be discharged by first filtering the water through the water recovery system and then overflowing the excess water from the cleaned wash water holding tank to sewer.

1.03 Tank Water Level Sensors: Water level in the process and cleaned wash water holding tanks shall be controlled via a high/low level float control tube stand mounted in the console. The tube stand shall be designed in such a manner that it can monitor the water level in the external tanks. When the water recovery system requires water because of a low water level signal, the transfer pump in the sump 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. Fresh water will then continue to be added for a minimum of 5 minutes to avoid nuisance tripping by the low-level float.

1.04 Solids Removal: Water is fed from the transfer pump in the pit to the pumping/filtering console and into a cyclone pump. The cyclone pump shall then pressurize the water to at least SO psi and feed into a series of cyclone separators to remove dirt and sand from the water. Ten-micron cyclonic separators shall be used as the primary filtering devices for solids removal due to their "self cleaning" nature and due to a lack of need for continual maintenance. A sufficient number of cyclone separators shall be used to produce the water flow required to supply the Process and Cleaned Wash Water Holding Tanks.

1.05 Process Tank: Water shall be filtered at this stage to a nominal 10 micron and fed into the Process Tank (oil coalescing/stilling tank) to remove oil. The Process Tank shall be of sufficient size to accommodate the water flow rate and storage requirements of the vehicle wash system.

The coalescing tank shall be filled with a minimum of 100 pounds of a semi-hollow, free floating, reticulated space pack manufactured of an oil oleophilic material. The space pack shall perform several functions including:

1) shall cause oil to float to the top of the tank as a "slick" where it can be removed through a technique of passive oil skimming induced via a "periodic forced overflow" thereby eliminating the need for 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.

2) shall act as a "stilling well" where, when there are periods on non-flow, the space pack shall calm the water within the tank allowing any dirt, which migrated to the tanks through the cyclone separators, to settle to the bottom of the tanks. Once at the bottom of the tank, the sludge may be purged via a process of periodic "fast-flush" purging. The purge valve and control shall be located in the console.

3) shall act as an air or ozone diffuser to diffuse air and ozone injected into the water stream entering the tank. This diffused air and ozone shall act as an oxidizing agent killing bacteria, virus, algae and help oil and other contaminants to float to the surface of the tank where they may be skimmed of f.

1.06 Wash Water Holding Tank: Water shall next be processed from the Process Tank (oil coalescing and Stilling tank) into a cleaned wash water Storage Tank(s) for re-supply to the automatic wash on demand. The Storage Tank should be of sufficient size to handle the water flow rate and storage requirements of the vehicle wash system.

1.07 Filtering and Pumping Console: The console shall contain all pumps, floats, pressure switches, automatic purge valves, electrical panel, etc., so that no interconnecting wiring will be necessary between the console and the tanks. An output pump shall be supplied and mounted inside the console to provide reclaimed wash water from the cleaned wash water storage tanks to the automatic wash during the chemical application and washing cycles. This pump shall receive its signal to pump water to the chemical wash via a bladder tank also mounted within the console. The console shall be completely enclosed to provide maximum shielding of internal components from the weather and shall be provided with lift off doors all around providing easy access for servicing.

1.08 Tanks (Special features): 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 valve mounted in the console which will be opened periodically, controlled by the PC (Programmable Controller) mounted in the systems electrical panel. This will minimize the need for constant cleaning of the tanks to remove unwanted sludge and also facilitate easier manual cleaning when necessary.

1.09 Electrical Control Panel (Special Features): The system console electrical panel shall come equipped with diagnostic lights indicating conditions of "low level", "low pressure", "System On" etc., and shall also come equipped with trouble shooting diagnostic lights inside the electrical panel to indicate problems with pressure sensors, floats, pumps and valves. All electrical back panels and pit panels shall be UL listed.

1.10 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 and buildup of bacteria, virus, algae, etc. and also to inhibit the buildup of foul odors.

1.11 Disinfectant System: The primary disinfectant control system employed shall bean automatic ozone injection control system and shall be mounted within the console where ozone will be manufactured and injected into the water stream as it leaves the cyclone separator.

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 parts 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 internal components and surrounded on the top and all four sides with removable "lift off" door panels to create an enclosed console thereby offering maximum environmental protection for any motors, pumps, cyclone separators, valves and other components housed within. The console housing shall be designed to provide easy access to all internal components all around the console via the lift of f door panels. 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 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 or manual periodic purging. The periodic purging of the above ground tanks shall 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 U.L. 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. 112A 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 housings 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 and sludge pumps are 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 N.E.C. 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 to be U.L. recognized.

2.07.01 System Programmable Logic Control: A simple industrial quality programmable controller (PC) will 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 and shall carry a 5 year warranty against failure under proper usage.

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.

Western Water Products  
21756 Twinford Drive, Lake Forest, CA 92630
Tel: 949-581-8998
FAX: 949-768-4878
Internet: Webmaster@westernwater.com.