VERIFICATION TEST PLAN FOR
INDUCTION MIXERS MANUFACTURED BY THE U.S. FILTER/STRANCO
FOR HIGH RATE DISINFECTION OF WET WEATHER FLOWS
Submitted to
NSF INTERNATIONAL
789 Dixboro Road
Ann Arbor, MI 48105
United States Environmental Protection Agency
Environmental Technology Verification Program
Wet Weather Flow Technologies Pilot
October 2000
ALDEN RESEARCH LABORATORY, INC.
30 Shrewsbury Street
Holden, MA 01520
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TABLE OF CONTENTS
PAGE
INTRODUCTION 1
ROLES AND RESPONSIBILITIES OF INVOLVED ORGANIZATIONS 2
General 2
U.S. Environmental Protection Agency (EPA) 2
NSF International (NSF) 3
Alden Research Laboratory, Inc. (Alden) 3
Vendor (Mixer Manufacturer) 5
The S.O. Conte Anadromous Fish Research Center (CAFRC) 6
Technology Panel on High Rate Disinfection 7
CAPABILITIES AND DESCRIPTION OF EQUIPMENT TO BE TESTED 7
General Description 7
Series SWCF Specifications 8
Operating Requirements 8
Mixer Flow 9
DESCRIPTION AND REQUIREMENTS FOR HYDRAULIC TEST FACILITY 10
General Site Arrangement 10
Test Flume 10
Flume Flow Control 12
Instrumentation for Dye Dilution 13
TEST PROCEDURES 17
Test Objectives 17
Test Conditions 17
Method and Materials 18
Test Procedures for Dye Concentration Evaluation 19
Data Analysis 25
Reporting 26
Verification Statement 28
QUALITY ASSURANCE PROJECT PLAN (QAPP) 29
Alden QA Plan 29
Test Variables for QA Plan 29
Uncertainty of Measurements (Bias and Precision) 32
Transmission of Data 32
SAFETY MEASURES 33
REFERENCES 33
APPENDIX A - DRAWINGS, SPECIFICATIONS AND PHOTOGRAPHS OF MIXERS
APPENDIX B - METHODS AND PROCEDURES
APPENDIX C - MEASUREMENT UNCERTAINTY OF TRACER CONCENTRATION
AND FLUME UNCERTAINTY
APPENDIX D - ALDEN GENERAL Q A PLAN
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VERIFICATION TEST PLAN FOR
INDUCTION MIXERS MANUFACTURED BY U.S. FILTER/STRANCO
FOR HIGH RATE DISINFECTION OF WET WEATHER FLOWS
1. INTRODUCTION
The Environmental Technology Verification (ETV) program of the United States Environmental
Protection Agency (EPA) was established to promote the marketplace acceptance of commercial-
ready environmental technologies. The purpose is to provide credible third-party performance
assessments of environmental technologies so that users, developers, regulators, and consultants can
make informed decisions about such technologies. The ETV is not an approval process, but rather
provides a quantitative assessment of technology performance as determined in accordance with this
verification test plan.
The Wet Weather Technologies Pilot was established to verify commercially available technologies
used in the control and abatement of urban storm water runoff, combined sewer overflows (CSO) and
sanitary sewer overflows (SSO). Experience has shown that the long disinfection contact time
required for conventional wastewater treatment is not appropriate for the disinfection of CSO due
to the infrequent peak flow rates that would require large tankage. However, disinfection of CSO
can be achieved with less contact time be providing an increased disinfection dosage and intense
mixing.
This Verification Test Plan (VTP) applies to the U.S. Filter/Stranco Series SWCF chemical induction
mixer, manufactured by U.S. Filter/Stranco, which are suitable for submerged service in wet weather
flows such as CSOs and SSOs. This VTP was developed in accordance with Draft 3.4 of the
"Generic Verification Protocol for Induction Mixers Used for High Rate Disinfection of Wet
Weather Flows," as prepared by the Wet Weather Flow Technologies Pilot of the U.S. EPA's ETV
Program. This VTP describes, in detail, the procedures to be followed by the Field Testing
Organization, Alden Research Laboratory, Inc. (Alden), in conducting the verification testing at the
S.O. Conte Anadromous Fish Research Center.
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2. ROLES AND RESPONSIBILITIES OF INVOLVED ORGANIZATIONS
2.1 General
The Wet Weather Flow Technologies ETV Pilot is administered through a cooperative agreement
between EPA, the National Risk Management Research Lab, and NSF International (NSF).
A Stakeholder Advisory Group (SAG) was formed to assist NSF and EPA in establishing priorities
for the verification of wet weather technologies. The SAG consists of technology vendors, state and
federal regulatory and permitting officials, technology users (POTWs and other municipal government
staff), and technology enablers (e.g., consulting firms and universities) with an interest in the
assessment and abatement of the impacts of wet weather flows.
A Technology Panel on High Rate Disinfection was established to guide the development of
protocols for the verification of high rate disinfection technologies, including induction mixers. The
ETV Technology Panel will serve as a technical and professional resource during all phases of the
verification of a mixer, including the review of Test Plans and Verification Reports, as requested by
NSF and EPA.
Upon completion of Draft 3.4 of the Generic Verification Protocol for Induction Mixers used for
High Rate Disinfection of Wet Weather Flows, NSF selected Alden as the Field Testing Organization
to conduct the testing of induction mixers. U.S. Filter/Stranco is one of two mixer manufacturers to
apply for verification.
2.2 U.S. Environmental Protection Agency (EPA)
The U.S. EPA's National Risk Management Research Laboratory provides administrative, technical
and quality assurance guidance and oversight on all WWF pilot activities. EPA personnel are
responsible for the following:
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review and approval of this Verification Test Plan
review and approval of the Verification Report
review and approval of the Verification Statement, and
posting of the Verification Report and Statement on the EPA website.
2.3 NSF International (NSF)
NSF is the U.S. EPA's verification partner on the Wet Weather Flow Technologies Pilot. In the
context of this Verification Test Plan, NSF has selected a qualified Testing Organization, the Alden
Research Laboratory, Inc. (Alden) to develop and implement the Verification Test Plan. In addition,
NSF has the following responsibilities:
review and approval of the Verification Test Plan
oversight of Quality Assurance, including the performance of technical system and data
quality audits, as described in the Quality Management Plan for the Wet Weather Flow
Technologies ETV Pilot
coordination of Verification Report peer reviews, including review by the Stakeholder
Advisory Group and Technology Panel, as deemed necessary
approval of Verification Report, and
preparation and dissemination of Verification Statement
2.4 Alden Research Laboratory, Inc. (Alden)
The Field Testing Organization (FTO) is the Alden Research Laboratory, Inc. (Alden). Alden has
prior experience in testing high-rate induction mixers and also has extensive experience with pilot
testing and experimental design. Alden was founded in 1894 as part of Worcester Polytechnic
Institute (WPI) and became a separate organization in 1986. Alden is nationally known for solving
flow related engineering and environmental problems through a combination of laboratory testing
(including flow meter calibrations and verification of equipment performance), computational fluid
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dynamics (CFD) and field testing. In addition to private corporations, Alden's clients have included
major governmental agencies such as the U.S. Nuclear Regulatory Agency, the U.S. Department of
Energy and the U.S. Fish and Wildlife Service.
Alden is located in Holden, Massachusetts on about 25 acres of land used for experimental research
and testing, and has a staff of about 40 people. The full address is:
Alden Research Laboratory, Inc.
30 Shrewsbury Street
Holden, MA 01520
Phone: (508) 829-6000
Facsimile: (508) 829-5939
e-mail: arlmail@aldenlab.com
The Project Investigator in charge of conducting the tests will be Philip S. Stacy, Hydraulic Engineer.
The overall guidance for the test program will be provided by Dr. Mahadevan Padmanabhan
("Padu"), Vice-President. Both Padu and Phil will act as contact persons at Alden.
Philip S. Stacy
Phone Extension: 425; e-mail: pstacy@aldenlab.com
Dr. M. Padmanabhan ("Padu")
Phone Extension: 442; e-mail: padu@aldenlab.com
Primary responsibilities of Alden will include:
preparation of this site-specific Verification Test Plan, including revisions in response to
comments made during the review period
coordination with the manufacturer (vendor) of the mixer to be tested
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contracting with the hydraulic laboratory for implementation of the approved Verification
Test Plan
providing logistical support for the hydraulic laboratory, establishing a communication
network, and scheduling and coordinating the activities for the verification testing
overseeing and conducting the verification testing with the help of the hydraulic laboratory,
in accordance with this Verification Test Plan
managing, evaluating, interpreting and reporting on data generated during the verification
testing, and
preparation and review of a draft Verification Report
2.5 Vendor (mixer manufacturer)
The mixers to be tested are manufactured by:
The U.S. Filter/Stranco Company
595 Industrial Drive
Bradley, IL 60915
Phone: (800) 882-6466 or (815) 932-8154
Facsimile: (815)939-9845
e-mail: marcukaitis@usfilter.com
All communication should be addressed to:
Mr. James Marcukaitis, Director of Engineering
The U. S. Filter/Stranco will supply three submersible chemical mixers to be tested that are of differing
horse power and typical of their product line. All associated mounting hardware, chemical feed lines
and other ancillary equipment needed for operation will be supplied. A list of any special
requirements, limitations and instructions shall also be provided, as should descriptive details about
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the capabilities and intended function of the mixers. Close communication with Alden is to be
maintained to insure on time delivery of all equipment, consistent with the schedule in the Verification
Test Plan. That document will be reviewed and approved by the U.S. Filter/Stranco (after any
necessary changes have been made) prior to the start of testing.
One person will be supplied by the U.S. Filter/Stranco Company to provide technical support and to
oversee mounting and operation of their mixers during testing. That person will certify that the
mixers have been mounted and operated properly.
The U.S. Filter/Stranco will also review and comment on the Draft Verification Report and
Verification Statement.
2.6 The S.O. Conte Anadromous Fish Research Center (CAFRC)
Verification will take place at the S.O. Conte Anadromous Fish Research Center (CAFRC). CAFRC
is a United States Geological Survey (USGS) Facility where research and equipment testing is
conducted on a regular basis. CAFRC has previously participated in the testing of high rate induction
mixers and has large indoor flumes and flow capacity which are uniquely suited for this purpose.
Actual facilities to be used are described in Section 4 below.
The contact person at CAFRC will be:
Mr. John Noreika
S.O. Conte Anadromous Fish Research Center
One Migratory Way
Post Office Box 796
Turners Falls, MA 01376
Phone: (413) 863-3839
Facsimile: (413) 863-9810
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e-mail: john_noreika@usgs.gov
Under the direction of Mr. John Noreika, CAFRC personnel will have the following responsibilities.
modify the test flume to provide the required dimensions and features
provide steady flow to achieve the required velocities
measure, evaluate and report on velocities and flows established during testing
provide the needed electrical power for the mixers and sampling equipment
• assist with installation and repositioning of the sampling rig
provide any needed QA/QC documentation for the flow and velocities
2.7 Technology Panel on High Rate Disinfection
The ETV Technology Panel on High Rate Disinfection will serve as a technical and professional
resource during all phases of the verification of a mixer, including the review of Test Plans and
Verification Reports, as requested by NSF and EPA.
3. CAPABILITIES AND DESCRIPTION OF EQUIPMENT TO BE TESTED
3.1 General Description
U.S. Filter Stranco will provide three Submersible Water Champ F Series (SWCF) induction mixers
nominally rated at 5, 10 and 20 horsepower. The mixers will be typical of the product line, and no
special provisions or changes will be made to the mixers. All mixers will be powered electrically at
460 VAC, 3 phase using the standard power cable. The manufacturer will provide a line for the
induction flow, and an orifice plate flow meter assembly will be added by Alden as part of the test
equipment. Drawings, photographs, and specifications provided by U.S. Filter are included as
Appendix A.
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The principle of operation is that rotation of the uniquely shaped propeller causes a reduction in
pressure in the chamber surrounding the impeller shaft. Connecting a flow line to the port in the
chamber causes flow to be induced. This flow is propelled outward by the rotating propeller and
mixed vigorously with the surrounding water (flow).
3.2 Series SWCF Specifications
Each mixer to be tested will have a unique identification number, such as a serial number, which will
be part of the test log record. That unique number is to be inscribed or attached onto the mixer in
a manner that does not allow for removal or alteration. The 20 hp mixer has the Model designation
of SWC20F and has a maximum liquid induction flow of 60 gpm, the 10 hp is designated as SWC1 OF
and has a maximum liquid induction flow of 40 gpm, and the 5 hp is designated as SWC5F and has
a maximum liquid induction flow of 25 gpm. The rpm of all units is 3,450.
The "F" Series submersible offers high quality design and construction, the motor being hermetically
sealed 316 stainless steel and most wetted materials being constructed from Grade 2 Titanium
(unalloyed). An innovative mounting is configured for open channel applications and can be easily
retrofitted to basins and tanks. Both a horizontal and vertical orientation of the mixer is possible.
For this test, a horizontal orientation will be used, with the propeller pointed upstream into the
flowing water.
3.3 Operating Requirements
The mixer must stay submerged by at least 18 inches at all times. The mixer should not run out of
water. All power supplies should be locked out when performing any maintenance to the system.
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3 .4 Mixer Flow
The mixer flow specifications for each mixer size (hp) vary between manufacturers. For this
comparative investigation of mixer performance, the test flows for each size mixer have been
established by Moffa & Associates per their facsimile dated October 13, 2000, and the details are
given below.
The disinfectant feed rate to an induction mixer is a function of the:
wastewater flow (Qf),
the disinfectant concentration (Cc), and
required disinfectant dose (Cf).
Additionally, the mixer horsepower is related to the wastewater flow; a typical mixer sizing criteria
for CSO applications is 0.14 hp/MGD (Moffa & Associates, 1999). Therefore, the proposed mixer
sizes for the verification testing and their associated wastewater design flows are:
5 hp for 35 MGD
10 hp for 70 MGD
20 hp for 140 MGD
A mass balance equation is used to estimate the disinfectant feed rates based on the mixer hp and
design wastewater flows listed above:
Qf*Cf = Qc*Cc (1)
Assuming a 7.5% sodium hypochlorite injected concentration and a final mixed dose of 20 mg/1 in
the wastewater flow, solving for Qc (the required disinfectant flow) yields the following mixer flows:
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Mixer Size (hp)
Mixer Flow (gpm)
5
7
10
13
20
26
4. DESCRIPTION AND REQUIREMENTS FOR HYDRAULIC TEST FACILITY
4.1 General Site Arrangement
The S.O. Conte Anadromous Fish Research Center (CAFRC) is situated in the town of Turners Falls,
MA, on the right (looking downstream) bank of the canal to the Cabot Hydroelectric Power Station.
Water enters the building with the test flume from an inlet structure on the bank of the power canal.
The inlet to a below ground conduit will be used for intake flow. Flow from the buried conduit is
controlled by a sluice gate in the building. This flow is distributed to a forebay upstream of the test
flume by an inlet chamber and floor diffuser.
Only one of the three flumes in the building will be used. That flume is longer, wider and deeper than
needed, and therefore, false walls will be constructed to generated the desired test flume dimensions.
4.2 Test Flume
A rectangular channel section 7 ft wide with a water depth of 7 ft will be established for testing. To
provide for a relatively uniform velocity distribution at the mixer, the length of the flume upstream
of the mixer will be 20 ft, and the test channel entrance will be rounded to avoid flow separation, as
shown in Figure 1. Upstream of the test channel entrance, the flow will be guided by a straight flume
10 ft wide and 32 ft long, with an upstream flow distributor, see Figure 1. The test channel has a
once-through flow system drawing water from the power plant canal and discharging the outflow to
the canal with no possibility of discharged water re-entering the channel.
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PLAN
*
flow
; DISTRIBUTOR
' . 1 in
—— 4 1 „
TRAVERSE LOCATION
(TO BE CONFIRMED IN TEST PROTOCOL)
, p f \°' r
L=^|J
\ n^ow j' J
- MIXER
1 FLOW
7 FLOW CONTROL
1 I GATE
-32'- _
20'
— 28-
—i
-24'
ELEVATION
SCALE 1" —15'
FIGURE 1 PLAN AND ELEVATION OF PROPOSED TEST SETUP
ALDEN
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The 7 ft wide test flume will extend 28 ft downstream of the mixer before expanding to the wider
10 ft flume width. Provisions will be made to accommodate installation of the mixer at the designated
location in the test flume, in accordance with instructions and mounting hardware from the vendor
with the assistance of a representative from the vendor.
A 25 point water (dye) sampling rig will be located along sections 5, 10, and 15 ft downstream from
the mixer. Only one location will be sampled at one time, and provisions will be made for locating
and moving the sampling rig.
Adequate electrical power will be supplied to operated mixers of up to 20 hp and to supply power
to the instrumentation used in the tests. Power is supplied by the Cabot Power Station. No backup
power is available for the flume.
4.3 Flume Flow Control
Flow and water level in the flume will be controlled by a hinged steel weir. The weir will be
calibrated prior to initiation of tests to obtain the head-flow relationship of the weir at three positions
and the desired water level of 7 ft. The weir will be located 24 ft downstream of the end of the test
flume so that there will be no effects on the flow distribution in the test flume caused by the weir.
To obtain the required maximum velocity of 3 ft/sec, the test flume will be supplied with a maximum
flow of 150 cfs. Lower velocities will be set by reducing the inflow with the upstream sluice gate and
raising the weir to maintain the water level. The flow required for a given test will be set by
presetting the weir and adjusting the flume inflow until the required 7 ft depth is achieved. As a part
of the weir calibration, the velocity distribution at a 7 ft x 7 ft cross-section just upstream of the mixer
location will be measured for each flow using a Sontek ADV velocimeter available at CAFRC. All
instrumentation are listed in Table 1 in Section 6.0 and a description of the weir calibration is
provided in Appendix B.
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4.4 Instrumentation For Dye Dilution
4.4.1 Dye Injection
Rhodamine WT will be used as the tracer dye. Rhodamine WT has low adsorption characteristics
and is supplied at nominal 20% concentration by weight. Stock injection solutions will be prepared
at Alden to a concentration of 2 x 107 ppb by serial dilution of the supplied solution with distilled
water. The rate of injected dye will be set according to the plume velocity to produce a theoretical
(perfect mixing) concentration at the sampling locations of approximately 12 ppb, using the following
mass balance equation.
Ci Q, - c, Q, (2)
where
Q = injected tracer concentration
Qi = injected tracer flow
Ct = mixed concentration
Qt = mixed flow
Based on experience with mixers of this type, it is expected that the actual flume concentrations may
be up to five times greater than the theoretical average. It is, therefore, necessaiy to choose an
injection rate so that the potential highest sample concentration is below a value that would be in the
non-linear response range of the fluorometer; above approximately 80 ppb. As a result, the
anticipated tracer injection rates will be 0.4 ml/s, 1.0 ml/s, and 2.5 ml/s, for the three flume velocities
of 0.5 ft/s, 1.25 ft/s, and 3.0 ft/sec.
Fluorescence is a function of water temperature and temperature variations from the water
temperature during calibration are accounted by
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C = Crek(Tr-Tc)
(3)
where
C
Cr
T,
concentration (ppb)
apparent concentration at Temperature Tr (ppb)
calibration temperature (°F)
temperature connection coefficient (1/°F)
k
The temperature coefficient, k, used is 0.01444/°F, which is a standard value [Reference 2] for
Rhodamine WT and has been verified at Alden,
4.4.2 Dye Sampling Rig
A sampling rig with five vertical arrays of sampling ports will be fabricated. The sample ports will
be located at 10%, 30%, 50%, 70%, and 90% of the total depth (center of five equal distances) at
a longitudinal spacing selected to generate equal areas of sampling for each port, as shown in
Figure 2. Thus, the sampling rig will have 25 suction tubes across the 7 ft x 7 ft cross-section. The
number of sampling ports deviates from the minimum specified in the Draft 3.2 Protocol. The 7 ft
x 7 ft flume cross-section, which exceeds the 6 ft x 6 ft minimum in the Draft 3.2 Protocol, was
chosen to improve the experimental design by moving the walls and their potential effects on mixing
away from the mixer. As a result of the increased section area of 7 ft x 7 ft, it becomes impractical
to adhere to the one port per spare foot requirement of the Draft 3.2 Protocol, which would require
49 sample bottles; doubling the proposed sampling and analysis effort. The number of sample ports
was chosen based on Alden's experience with similar testing of induction mixers, where 25 ports with
similar spacing (in terms of percent depth and width) were used and found to adequately map the
tracer plume within a flume with larger cross-section (8 ft x 8 ft and 8 ft x 10 ft). A continuous flow
withdrawal from the ports will be accomplished by individual pumps and a part of the flow will be
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FIGURE 2 LOCATION OF SAMPLING TUBES
ALDEN
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directed by valving arrangement to sample collection bottles, while the remainder will be returned to
the flume. The 25 sample flows will be established by adjusting each flow through its own rotameter.
4.4.3 Fluorometer
A Turner Designs Model 10 fluorometer will be used to measure tracer concentration. The
fluorometer is capable of detecting concentrations as low as 0.01 ppb. Rhodamine tracer used in
concentrations below 20 ppb provides sufficient measurement accuracy while being low enough to
be undetectable by eye. Concentration of tracer in the samples is determined by fluorescence intensity
which is proportioned to the voltage output of the fluorometer.
The Turner Designs Model 10 fluorometer has multiple settings to increase the range of measurable
concentrations. Two settings are available, XI and X100, having a 100 to 1 effect on output. Within
each range, the sensitivity may be changed from XI to X31.6 in four equal steps, having about a 30-
fold effect on output. The instrument span and zero offset are also adjustable to match the output
to the measured concentration. The fluorometer will be set up to read in the upper one third output
of the XL sensitivity scale to ensure good resolution for a wide concentration range.
Fluorometer voltage output and two RTD thermometers, measuring water and instrument
temperatures, will be recorded by a portable computer with a 12 bit analog to digital converter. Full
scale on the computer is two volts with a resolution of 0.0005 volt. Transmission characteristics of
the primary light filter in the fluorometer change slightly with temperature, affecting instrument
sensitivity. Therefore, a platinum resistance temperature sensor is mounted on the filter to monitor
the temperature and assure instrument drift is within acceptable limits. A similar temperature sensor,
mounted in a 1/8" diameter rod, measures the water sample temperature, which is used to correct
measured fluorometer voltage output to calibration water temperature with Equation (3). The
thermometer used to determine the water temperatures at the fluorometer and the dye injection
temperature have been calibrated versus an NIST traceable thermometer standard, and were found
to be accurate within 2°F. Resolution of the digital temperature readout is 0.1 °F.
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5. TEST PROCEDURES
5.1 Test Objectives
Manufacturers of an induction type mixer make claims about the mixing capabilities of their product
and provide values for parameters indicative of mixing intensity. However, there is not a standard
way for calculating such parameters since the volume of water involved in the mixing is unknown.
This Verification Test Plan establishes a method for determining the volume of process water affected
by the induction mixer.
The objective of this testing is to characterize the performance of high rate induction mixers with
respect to their ability to rapidly transfer a non-reactive tracer (instead of a chemical disinfectant) into
a flowing body of clean water. Mixer performance will be characterized by the degree of tracer
uniformity achieved over measured portions of the flow cross-section (the mixing zone) at various
distances downstream from the mixer. This characterization will be for a range of flow velocities
representative of those in wet weather flow collection and treatment facilities.
5.2 Test Conditions
Each verification test series will evaluate a single induction mixer under three velocities, namely 0.5,
1.25, and 3.0 ft/sec. The prescribed velocity of 2 ft/sec in the Draft 3.4 of the protocol is replaced
with 1.25 ft/sec to allow a better distribution of data in the 0.5 to 3 ft/sec range. Each test series will
consist of one test run at each of the velocities, as shown in the test matrix in Section 6.0, Table 2.
No repeat testing is included in the present test matrix. If the results of these tests show
inconsistencies that warrant further investigation, additional repeat tests may be conducted at a later
date. For each test run, the flow velocity is to be held steady, the water depth will be maintained at
7 ft, and the cross-sectional mixing will be evaluated by concentration measurements. The sampling
rig used to measure the extent of cross-sectional mixing will be located at 5, 10, and 15 ft
downstream of the mixer, but only one sampling rig will be installed in the channel during each test.
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Each verification test series will be for an induction mixer of a given power. Verification tests will
be conducted for three mixers of the Series SWCF mixers (horsepowers of 5, 10 and 20).
5.3 Method and Materials
After a mixer has been installed and the desired flow conditions have been set and stabilized, the
mixer will be operated with measured induction flow and measured injection of concentrated
Rhodamine WT dye stock solution. Details of the test procedure and measurements are included in
Appendix B. An orifice meter, calibrated at Alden's gravimetric facility, will be used to measure the
induction flow and a periodic volumetric check will be made of the dye metering pump flow. The
metering pump will draw from the stock solution of dye and discharge into the hose that conveys
water to the mixer. Amperage and voltage readings of the electrical power to the mixer will be
recorded using a Fluke power meter. Sample data sheets are included in Appendix B. Sufficient dye
will be injected to insure that the mixed dye concentration is considerably above the 0.01 ppb
detection limit of the fluorometer. The entire system will be operated for a minimum of 5 minutes
to insure steady state conditions before sampling will begin. Mixer power will be calculated by using:
Power = Amps x Volts
A single sampling rig (as described in Section 4.4.2) will be used. This rig and the associated
sampling tubes and instrumentation will be moved to the next sampling location by rolling the entire
system along rails installed on top of the test flume walls. The desired position of the sampling rig
at distances of 5,10 and 15 ft downstream of the mixer impeller will be pre-marked on the flume wall.
A commercial Turner Model 10 fluorometer will be used to determine the concentration of dye in
each water sample collected. Samples will be analyzed while at CAFRC to insure that any
inconsistencies can be detected and rectified earlier.
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Prior to mixer testing, a velocity meter (Sontek ADV) will be used to measure the flow distribution
just upstream of the mixer location to verify that the velocity is relatively uniformly distributed over
the 7 ft x 7 ft section and that the desired velocity has been obtained. These measurements will be
made once for each of the three flume velocities to be tested, while documenting the position of the
downstream weir/gate. Thereafter, each test flow condition will be reestablished by setting the weir
to a noted position. Water level will be set to a 7 ft depth by adjusting inflow gates upstream of the
flume flow straightener.
5.4 Test Procedures for Dye Concentration Evaluation
5.4.1 Dye Inj ection
Stock dye solution will be injected into the mixer flow by a constant displacement pump, whose
variable stroke controls the dye injection rate. Figure 3 schematically shows the injection system.
The injection pump and a 100 ml pipette with reduced area measuring stations will be supplied from
a 20 liter Mariotte vessel (a vessel which maintains a constant inlet pressure on the injection pump
regardless of liquid level in the vessel). Dye injection flow will be constant for each test and will be
measured by the volumetric method; the supply line from the Mariotte vessel is shut off via a valve,
dye is supplied to the pump solely from the pipette, which is to be a Class A vessel having a volume
uncertainty of 0.1%. A digital timer with 0.001 second resolution will be started and stopped, as the
meniscus of the dye passes the measuring locations on the pipette. The dye injection rate will be
recorded one to two times per test (sample data sheets are included in Appendix B). The dye
injection flow will be low, from 0.4 ml/sec to 2.5 ml/sec, so that a secondary transport flow will be
needed.
The transport flow will be flume water, withdrawn upstream of the mixer using a sump pump, will
be used as transport flow. The transport flow can be any flow between 2 gpm to 10 gpm and is
introduced via a tee in the inlet pipe of the pump providing flow to the mixer.
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PUMP INTAKE
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5"
ISOLATION
VALVE
VARIABLE SPEED CONSTANT
DISPLACEMENT PUMP
FLOW CONTROL
VALVE
ROTAMETER
TRANSPORT"
FLOW
FLUME WATER FROM
UPSTREAM OF MIXER
FIGURE 3 SCHEMATIC OF DYE INJECTION SYSTEM
ALDEN
-------
The mixer flow will be provided by a pump of approximately 2 hp, that will withdraw flow from the
flume approximately 4 ft to 6 ft upstream of the mixer. The tracer dye will be injected into the intake
pipe of the pump, ensuring that it will be fully mixed with the flow delivered to the mixers. The mixer
flow will be adjusted using a valve downstream of the orifice meter.
The flow to the mixers will be pumped and measured using an ASME design orifice plate meter
section calibrated at Alden's gravimetric calibration facility, which will produce a flow measurement
accuracy within ±2%. Without pumping, use of the orifice meter could artificially reduce the induced
flow. The orifice meter produces a pressure differential proportional to the square of the flow passing
through it. This differential will be measured manually on a manometer board, and recorded before
and after each test (see Appendix B for a sample test data sheet).
5.4.2 Dye Sampling
A continuous flow will be withdrawn from each sample port using individual pumps having control
valves and the majority of the flow will be discharged back to the test channel (downstream of the
sampling ports). The balance of the sample flow will be piped through a rotameter and control valve
to exit as a free jet. Twenty-five 1 liter bottles will be installed on a tray, which will be slid under the
discharge jets of the sample lines to obtain simultaneous samples of all 25 points. The sample flows
will be approximately equalized using the rotameters, and a sample of 10 to 12 minutes will be
obtained at each location, adequate to produce a time average, or typical, concentration reading. The
1 liter bottle size, though smaller than prescribed in the Draft 3.4 Protocol, was chosen because the
one liter bottle provides ample liquid volume for fluorometer analysis, and the 10 minute sample
period is adequate, given that the flow will be well conditioned by the upstream flow straightener and
long approach section. The sample bottles will be amber glass to protect light sensitive contents, with
threaded green melamine caps with a chemical resistant Teflon seal. Information identifying each
sample, with respect to mixer make and size, sample location, and test, will be written on the bottle
caps at the time of sampling (see Appendix B for a test procedure check list and test data sheet).
-21-
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5.4.3 Fluorometer Calibration
A 2,500 ppb preliminary calibration solution will be prepared from the stock injection solution at
Alden with distilled water to expedite fluorometer calibration during testing. This will be
accomplished by serial dilution of the commercial 20% concentrated Rodamine WT using the
following dilution ratios.
From Initial Stock 20%
Concentration, Serial Dilution Ratio
Tracer: Distilled Water
Resulting
Concentration (ppb)
1:19
1E7
1:19
5E5
1:19
2.5E4
1:19
2.5E3
At CAFRC, the 2,500 ppb concentration will be further diluted using flume water to prepare the
calibration samples. By this method, flume water becomes the primary constituent of the calibration
samples, and therefore, any effects related to the water quality are common to the calibration and test
samples. Calibration samples will be prepared by sequential dilution using the following dilution
ratios.
-22-
-------
From Initial 2,500 ppb Solution
Serial Dilution Ratio
Tracer: Flume Water
Resulting Calibration
Concentrations (ppb)
1:9
250
(not used to calibrate, only
for dilution)
1:4
50
1:1
25
1:1
12.5
0:1
0
The first 1:10 dilution with flume water will not be used for calibration. It is mixed in the field so that
the major constituent in each subsequent calibration sample is the flume (> 98%) water. This ensures
that both the calibration samples and the test samples are subjected equally to any effects due to flume
water quality.
The 2,500 ppb solutions will be used to prepare four calibration solutions of 0, 12.5, 25, and 50 ppb
for fluorometer calibration (all concentrations are relative to the injected stock solution of
2x10 ppb). The fluorometer will be calibrated with the above samples and recorded on individual
calibration data sheets (provided in Appendix B). A linear equation is calculated to convert
fluorometer volts (V0) to tracer concentration:
Concentration = m ¦ V0 + b (4)
where
m = slope of the linear equation
b = intercept of the linear equation
Equation 4 will be used to evaluate the sample concentration from the fluorometer average output.
-23-
-------
Based on experience, the calibrations of the type, using field water, should produce a linear response
in fluorometer output that is within ±2% full scale, or about 2 to 3 ppb. Deviation above this limit
will be suspect, and a second set of calibration samples will be prepared using the prepared stock
(2,500 ppb) and flume water (enough flume water will be withdrawn to prepare multiple calibration
samples).
The fluorometer will be calibrated in this way for each mixer at each flume velocity, for a total of
18 calibrations. It is planned that the three sample location data (per mixer/velocity) will be collected
within two hours, thus, allowing a single calibration to be used for the entire sample set at each
velocity. If collecting samples for the three locations per velocity requires more than three to four
hours, additional calibration samples may be required.
5.4.4 Dye Concentration
Fluorometer voltage output and the output from the two RTD thermometers, measuring the sample
water and instrument (light source filter) temperatures, will be recorded by a portable computer with
a 12 bit analog to digital converter. Aplatinum resistance temperature sensor, mounted in an 1/8 inch
diameter rod, will be used to measure each water sample temperature, so as to correct measured
fluorometer voltage output to calibration water temperature (Equation 3). Fluorometer output, water
temperature, and filter temperature will be read at eight hertz and, after 80 readings (about
10 seconds), the averages and standard deviations will be calculated, stored, and printed. During data
acquisition, individual temperature and fluorometer readings will be displayed on the PC monitor for
manual recording on data sheets. Variation of the corrected output from the previous test point will
be displayed as a percent to show trends on a magnified scale. After the fluorometer output reaches
a steady value for each sample (approximately 20 seconds), three 10 second readings will be averaged
and recorded on a test data sheet (see Appendix B).
The concentration of all mixer samples will be measured once at CAFRC and approximately 10% of
the mixer samples will be chosen at random and re-analyzed either while at CAFRC, if time permits,
-24-
-------
or at Alden. The results of the repeat analyses will be plotted; concentration (original) versus
concentration (repeat), as shown below. Based on Alden's experience with repeating the fluorometer
analyses, these data should produce a straight line, as shown below.
14
S* 12
CL
CL
£ 10
D
CO
25 6
—I
i 4
<2
or ,
o 2
0
0 2 4 6 8 10 12 14
REPEAT MEASUREMENT (PPB)
The standard deviation of the data around a straight line curve fit will be used to quantify the
repeatability of the repeat analysis. The results of the repeat analyses will be included in the
verification report.
5.5 Data Analysis
The dye concentration data will be normalized to facilitate interpretation. The average dye
concentration for each sampling port, as described in Section 5.4.3, will be normalized by dividing
by the uniform concentration Cu, which is defined as,
m
¦
¦
m
—i—
—i—
—i—
1
1
1
-25-
-------
Cu - tracer stock concentration x tracer feed flow rate / flume water flow rate
A normalized concentration of 1 will represent perfect mixing. The normalized concentrations at the
25 sampling ports for each of the three cross-sections will be used to generate an isopleth diagram,
as shown in Figure 4.
In addition, the standard deviation of the normalized concentrations for each cross-section will be
computed and a plot of standard deviation with distance from the mixer will be obtained to indicate
the mixer effectiveness.
A percent mix factor will be calculated once the uniform theoretical dye concentration isopleth
diagrams are established.
Percent mix factor = c^anrte^ area with tracer concentration > uniform concentration
total channel cross-section area
The percent mix factor indicates the area of the channel that has experienced complete mixing.
5.6 Reporting
The final report will incorporate all data collected for each test, which include the flume test flow
(from head over weir), mixer flow (orifice meter), dye stock injection flow (positive displacement
pump), dye stock concentration (fluorometer measurement), and the individual concentration data
for each of the twenty five points for each of the three cross sections (fluorometer measurements on
each collected sample). The data will be presented in the Verification Report (final report) as tables
(listing the average measured concentrations at each measured location for each test run), isopleth
diagrams, percent mix factors for each mixer at each tested flow, and plots of standard deviation of
measured concentration versus distance from the mixer. Raw data in a tabular form (spread sheet
format) will be included as an appendix in the report.
-26-
-------
CHANNEL WIDTH
FEET
- DATA NORMALIZED BY DIVIDING POINT VALUES
BY THEORETICAL UNIFORM CONCENTRATION
FIGURE 4 TYPICAL TRACER CONCENTRATION
ISOPLETH DIAGRAM
ALDEN
-------
The report will identify the tested mixer and its maj or characteristics, and describe the procedures and
methods of testing, results, conclusions and recommendations, and will include photographs of the
test facility and mixer setup. The report will also include instrument calibration data as an Appendix.
The verification report will first be issued as a draft and will undergo a complete review by NSF and
the EPA, as well as a peer review, as recommended by the Technology Panel on High Rate
Disinfection. The mixer vendor will also review the report and be provided the opportunity for input
on its content. After receiving all comments, the report will be revised, as needed, and the required
number of copies will be submitted to NSF.
The report outline will be as follows.
• Introduction
Executive Summary
Description and Identification of Product Tested
Procedures and Methods Used in Testing
• Results and Discussion
• Conclusions and Recommendations
• References
Appendices to include mixer information and test data
5.7 Verification Statement
NSF and EPA will prepare a Verification Statement that briefly summarizes the Verification Report
for issuance to the mixer vendor. The Verification Statement shall provide a brief description of the
testing conducted and a synopsis of the performance results. The Statement is intended to provide
verified vendors a tool by which to promote the strengths and benefits of their product.
-28-
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6.0 QUALITY ASSURANCE PROJECT PLAN (QAPP)
6.1 Alden QA Plan
The general Alden QA plan applicable for the study, is included as Appendix D of this report.
Appendix C includes the project management and organization for QA, data and correspondence,
file system, documentation with data log book and computer disks, and review procedure including
procedure for documentation of revisions.
6.2 Test Variables for QA Plan
Test items subject to QA and uncertainty analysis are listed below:
-29-
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TABLE 1 - TEST VARIABLES AND/OR PARAMETERS SUBJECT TO QA
V ariable/Parameter
Instrument Number and Description
Flume Width
1 1
Stanley® 25 ft retracting tape measure (or equivalent) 1
Water Depth
2
UNIDATA™ model 6541/c water level instrument with internal
data logger |
Weir Position
J 3
RITTmeyer Angle Transmitter resistive/optical model MGAx |
Water Velocity
1 4
Sontek® ADV three axis velocity probe. 1
Water (Flume)
Temperature
5
Platinum RTD and Omega® digital readout 1
Alden S/N: 0500
Mixer Location
1
Stanley® 25 ft retracting tape measure (or equivalent) reference to 1
flume floor and walls |
Mixer Power
1 6
Fluke® 4IB Power Meter 1
Mixer Flow
7
Orifice Meter Section S/N: 1064 |
Orifice Meter Manometer
8
Lufkin® 066D 6ft Red End Engineer's Folding Wood Rule
Tracer Injection
Concentration
9
Serial Dilution of 20% Stock using Class A pipettes and flasks 1
Tracer Injection Rate
10
Timed 100 mL Class A pipette (Integral with tracer injection
system)
Tracer Injection Timer
11
Newport® Model 6130A Digital Timer (Integral with tracer I
injection system) |
Tracer Injection
Temperature |
12
Omega® Model 199B platinum RTD (Integral with tracer injection
system)
Sample Port Location 1
1
Stanley® 25 ft retracting tape measure or equivalent 1
Reference to mixer impeller |
Sample Concentration
13
Fluorometer 1
Turner Designs Model 10 |
Sample Water
Temperature
14
Newport® RTD (Integral with fluorometer system) 1
Fluorometer Filter (light)
Temperature J
15
Omega® Model 199 Platinum RTD (Integral with fluorometer
system) |
Fluorometer Calibration |
16
Serial Dilution of 2500ppb Stock using Class A pipettes and flasks |
-30-
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TABLE 2 - TEST MATRIX
Mixer
Size (hp)
Flume Velocity
(ft/sec)
Sampling Location
(ft from mixer impeller)
0.5
10
20
1.25
3.0
0.5
1.25
3.0
0.5
1.25
10
15
10
15
10
15
10
15
10
15
10
15
10
15
10
15
3.0
10
15
-31-
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6.3 Uncertainty of Measurements (Bias and Precision)
Measurement uncertainties result from a combination of precision and bias uncertainties. Estimates
of uncertainties of flow measurement in the flume will include uncertainties associated with the weir
calibration (weir setting versus flow involves uncertainties due to velocity traversing, i.e.,
measurement of velocities and water depth) and uncertainties associated with weir setting during
tests. These uncertainties will be evaluated with input from CAFRC. Estimates of precision
uncertainty for injection flow and concentrations will be made from the standard deviations of repeat
measurements multiplied by the Student t factor to correct the standard deviation from the limited
number of measurements to an estimate of the standard deviation with an infinite number of points.
Bias uncertainty will be determined from comparative tests and Alden experience. The overall
uncertainty will be reported as the sum of the precision and bias uncertainties at the 95% confidence
level.
Tracer injection flow measurement will have precision uncertainties from time and temperature
measurements and bias uncertainties from time measurements and temperature effects on volume and
density. The concentration measurement uncertainties need to include both fluorometer calibration
uncertainty (from preparation of solutions, temperature effects and instrument errors, for example,
due to electronic noise) and the data acquisition and reduction uncertainty.
6.4 Transmission of Data
The final report will include (as an Appendix) calibration data for the flume flow and instruments for
injection flow and concentration measurement, raw data of flows and concentrations, revisions
resulting from reviews, calculations, and a list of references. Any relevant data that are collected,
reduced and/or calculated using a computer data acquisition system will be provided in the electronic
form (spread sheets) in addition to hard copies.
-32-
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7. SAFETY MEASURES
As the test flume at CAFRC is routinely used for testing with similar flows, conformance to electrical
codes and confined space work procedures are followed. Precautions will be taken to avoid storing
dye near the flume. Only the small quantity of dye stock for testing will be kept near the flume.
Preparation of the stock will be restricted to confined areas with no consequences from inadvertent
spilling. Dye bottles carrying samples will be stored in containers and will be handled carefully to
avoid spilling.
The safety of test personnel and visitors will be given utmost importance. Harnesses and life jackets
will be available at the site. CAFRC has a safety officer on its stafl; whose services will be available,
as needed.
8. REFERENCES
[ 1 ] Generic Verification Protocol for Induction Mixers Used for High Rate Disinfection of Wet
Weather Flows," Draft 3.4, ETV for NSF International, by MofFa & Associates, June 2000.
[2] "An Evaluation of Some Fluorescent Dyes for Water Tracing," Smart, P.L. and Laidlaw,
I.M.S., Water Resources, February 1977, pp. 15-33.
-33-
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APPENDIX A
DRAWINGS, SPECIFICATIONS
AND PHOTOGRAPHS OF MIXERS
-------
WATER CHAMP®
CHEMICAL INDUCTION SYSTEM
-------
ENHANCED CHEMICAL FEED
INNOVATIVE TECHNOLOGY
The Water Champ® vacuum chemical induction system has revolutionized the
concept of chemical feed systems with its innovative design and unlimited chemical feed
applications in potable water and wastewater treatment. The Water Champs superior
mixing characteristics represent a major step forward in chemical feed and disinfection
applications. Virtually any process feed application can benefit from Water Champ's
direct vacuum chemical induction capability. Water Champ eliminates the necessity of
costly carrier/make-up water and conventional rapid mix systems. A unique feature of the
Water Champ is its ability to provide the mixing intensity required to maximize chemi-
cal reaction while using less energy. USFilter and its ChemFeed and Disinfection Group
stand committed to the design and production of quality systems that will provide
efficient and dependable service.
INNOVATIVE FEATURES AND BENEFITS
• Quality Diffusion/Mixing
• Maximum Chemical Concentration
• No Chemical Off-Gassing
• Elimination of Carrier/Make-Up Water
• Efficient Energy Transfer
• Vacuum Gas Feed to 10,000 PPD
• Vacuum Liquid Feed to 150 GPM
The introduction of the Water Champ chemical induction system represents an
important advancement over conventional vacuum chemical feed and disinfection
systems. That technology, introduced in the 1920s by Wallace &Tiernan Co., was based
upon the use of an injector system for the gas and liquid withdrawal process. The
innovative Water Champ vacuum chemical induction concept eliminates the need for an
injector. Additionally, the Water Champ induction system can be retrofitted to any exist-
ing chemical feed/disinfection system. The Water Champ system consists of a motor-
driven open propeller which creates a vacuum in the chamber directly above the propeller.
This vacuum is transmitted to the chemical metering/control system by a vacuum line
similar to current remote injector systems.
CHEMICAL FEED TRIAD
Chemical
Metering
Monitoring
and Control
f]
Diffusion/Mixing
Water Champ is the dynamic component of the triad that forms any modern chemi-
cal feed system. The other elements of the triad are chemical metering, monitoring and
control equipment, i.e. USFilters Wallace &Tiernan and Stranco Products.
-------
STREAMLINED PROCESS
WATER CHAMP VERSUS THE TYPICAL
INJECTOR SYSTEM
COST EFFECTIVE
Fig 1
With the Water Champ installation, there is no
need for a water supply, pump, strainer, injec-
tor, mixer or diffuser.
Fig 3
Water Champ can be easily retrofitted to any
current system.
How cost-effective is the Water Champ
system? With a Water Champ installation,
you eliminate the need for a water
supply, pump, strainer, injector, mixer or
diffuser. Figure 1 illustrates Water Champs
efficiency in capital equipment savings and
water savings when compared to conven-
tional injector systems. In systems where
potable water is used for make-up solu-
INSTALLATION & MAINTENANCE
The Water Champ is easy to install due
to its light weight, simplicity of construc-
tion and non-corrosive moving parts.
Maintenance is kept to a minimum due to:
Fig 2
In systems where potable water is used for
make-up solution, the Water Champ eliminates
the need for an injector, mixer or diffuser.
POTABLE WATER TREATMENT CHEMICALS
In addition to chlorine and ammonia,
many other chemicals used in potable
water treatment depend upon proper
mixing. This is particularly evident during
the coagulation process, where chemicals
(alum being the most predominant) are
added for charge neutralization and floc-
culation.
The chemical reactions that precede
charge neutralization with alum occur
within microseconds and within
one second if hydrolyzed aluminum
tion, the Water Champ eliminates 100%
of these components (Figure 2). This
translates into substantial savings. In either
system, all you need is the existing chemi-
cal metering equipment and the Water
Champ unit. The Water Champ can be
easily retrofitted to any current system
(Figure 3).
• Heavy Duty Bearing Design
• Mechanically/Hermetically Sealed
Motor
• Titanium Construction in Chemically
Wetted Areas
• 316 Stainless Steel Corrosion
Resistant Motor Housing
(III) polymers are present. Due to the
competitive nature of these reactions, it is
imperative that the coagulant be dispersed
in the raw water stream as rapidly as possi-
ble. This will allow the polymer products
that develop instantaneously to efficiendy
destabilize the colloidal suspension.
Incorporating the Water Champ into this
initial mixing phase maximizes
liquid/solid separation.
-------
AVAILABLE MODELS
SWCF SUBMERSIBLE
The Submersible Water Champ F
Series (SWCF) offers the highest quality
design and construction of any
submersible chemical induction unit.
The hermetically sealed motor is
constructed of 316 stainless steel for the
highest level of durability and perfor-
mance. All chemically wetted compo-
nents are Grade 2 Titanium (unalloyed)
and are compatible with most treatment
chemicals. The innovative mounting
O
system is configured for open-channel
applications and can be easily retrofitted
to existing basins.
ILWC IN-LINE
The In-line Water Champ Series
(ILWC) is designed to offer the same high
level of quality and performance as the
submersible unit. The ILWC Series is
installed through a packing gland/knife
gate valve arrangement.
This arrangement allows the ILWC
Series to be installed into closed
conduits to maximize the chemical
induction/mixing. This configuration
eliminates downtime during construction
and scheduled maintenance, saving time
and money.
The unit is fitted with a chemical-duty
motor for the highest level of atmospheric
resistance and maximum durability.
The ILWC features Grade 2 Titanium
(unalloyed) induction body, stainless steel
packing gland, and stainless steel mount-
ing system. The unit can also be config-
ured with an optional insertion/retraction
device that simplifies routine mainte-
nance.
CONTROL PANEL
The Water Champ Control Panel
offers the ultimate protection for your
Submersible Water Champ F Series
chemical induction system. The
Control Panel features the Subtrol-Plus
submersible motor protection system.
This microprocessor-based system
provides underload and overload motor
protection, and incorporates an auto
restart feature in addition to an alarm
contact for external fault indication.
-------
i
ZONE OF INFLUENCE
Fig 4
SS GUIDE RAIL SYSTEM
SECTION VEW
Fig 5
The area where rapid mixing occurs is
referred to as "the zone of influence." The
zone of influence can be visualized as a
three-dimensional cone or "frustum"
(Figure 4). This zone with its highly
turbulent axial flow pattern extends away
from the propeller outward into the
process flow. The chemical (gas or liquid)
is dispersed directly into the process
stream without the need for dilution
water.
The Water Champ instantly creates a
homogeneous solution. The unit's
propeller rotates at 3450 rpm. At this
speed the chemical molecules are blasted
into the process stream in excess of 60
ft./sec. Flow can be directed either verti-
cally or horizontally (Figure 5) developing
a zone of influence across or into an influ-
ent pipe. In some open-channel applica-
tions, a horizontal configuration (Figure
6) achieves the greatest diffusion zone.
The Water Champ's axial mixing
pattern is important in wastewater post-
chlorination applications because it
achieves a rapid homogenous mixture that
improves process control. Another impor-
tant feature of the Water Champ system is
its ability to locate the propeller close to
the process water surface, thus eliminating
off-gassing—regardless of the chemical
flow rates or channel depth.
A network of factory trained represen-
tatives are available to assist you with
product selection, application questions,
start-up, and on-going service and
support. Important installation considera-
tions include: motor, propeller, and
vacuum chamber sizing; unit location,
orientation, guide rail design; and chemi-
cal handling and delivery.
Fig 6
-------
RUGGED DESIGN
TITANIUM CORROSION RESISTANCE
THE POWER WITHIN
The unique airfoil design of the propeller
enables the Water Champ to achieve maxi-
mum energy transfer.
All of the Water Champ's primary
wetted parts subject to initial chemical
contact are constructed of titanium. The
exceptional corrosion resistance of titani-
um is virtually unchallenged over a broad
spectrum of corrosive agents. Titanium
demonstrates excellent resistance to gener-
al and localized corrosion under most
oxidizing, neutral and reducing condi-
tions.
Titanium derives its corrosion resistance
from the protective, stable tenacious oxide
film which forms on the metal surface and
instantly reforms when damaged. This
oxide film protects the metal from both
corrosion and mechanical damage at
temperatures up to 600° F.
Titaniums greatest benefit lies in its resis-
tance to wet/moist chlorine chemicals and
chlorides such as hypochlorite, chlorate,
perchlorate and chlorine dioxide.
Titanium also exhibits outstanding
resistance to nitric, chromic, and
hydrochloric acids.
ENERGY AND CHEMICAL SAVINGS
The Water Champ provides signifi-
cant chemical and energy savings by
reducing the horsepower requirement as
compared to conventional mixing/chem-
ical feed systems, and improving the
mixing efficiency of the chemical addi-
tion. A Midwestern wastewater treat-
ment plant realized the chemical and
energy saving benefits of the Water
Champ system by retrofitting their exist-
ing chlorination/dechlorination mixing
chambers. Installing two compact 10
horsepower Water Champ units
(a primary and a spare) enabled the facil-
ity to eliminate their 40 horsepower
mechanical agitator, 60 horsepower
water transfer pumps and the chemical
injector. The energy savings, combined
with chemical efficiency savings of 30%,
allowed the customer to recover their
capital investment in less than 18
months. The chart below illustrates a
direct comparison of the energy cost
between the 10 HP Water Champ
system and the 100 HP conventional
system.
.08/kwh
Power Savings
¦ 09/kwh 0.10/kwh
Cost per kwh
,11/kwh
-------
TITANIUM CONSTRUCTION FEATURES
• Light weight
• Chemical resistant
• Cavitation resistant
• Tenacious oxide film
• Temperatures to 600°F
Thrust Bearing
Kingsbury Type
Anti-Track Self Healing
Resin System
316 SS Hermetically
Sealed Motor
Grooved Radial
Carbon Bearings
Integral Titanium Shaft
Removable Lead Connector
Power Cable.
Titanium Vacuum
Chamber
Vacuum Port —
Rotary Face Seal
The SWCF Series, with a hermetically sealed
316 stainless steel motor, is designed for corri-
sive environments.
Vacuum Enhancer-
Titanium Propeller
-------
SUPERIOR MIXING EFFICIENCY
ZONE OF INFLUENCE
Fig 4
SS GUIDE RAIL SYSTEM
SECTION VIEW
Fig 5
The area where rapid mixing occurs is
referred to as "the zone of influence." The
zone of influence can be visualized as a
three-dimensional cone or "frustum"
(Figure 4). This zone with its highly
turbulent axial flow pattern extends away
from the propeller outward into the
process flow The chemical (gas or liquid)
is dispersed directly into the process
stream without rhe need for dilution
water.
The Water Champ instantly creates a
homogeneous solution. The unit's
propeller rotates at 3450 rpm. At this
speed the chemical molecules are blasted
into the process stream in excess of 60
ft./sec. Flow can be directed either verti-
cally or horizontally (Figure 5) developing
a zone of influence across or into an influ-
ent pipe. In some open-channel applica-
tions, a horizontal configuration (Figure
6) achieves the greatest diffusion zone.
The Water Champ's axial mixing
pattern is important in wastewater post-
chlorination applications because it
achieves a rapid homogenous mixture that
improves process control. Another impor-
tant feature of the Water Champ system is
its ability to locate the propeller close to
the process water surface, thus eliminating
off-gassing—regardless of the chemical
flow rates or channel depth.
A network of factory trained represen-
tatives are available to assist you with
product selection, application questions,
start-up, and on-going service and
support. Important installation considera-
tions include: motor, propeller, and
vacuum chamber sizing; unit location,
orientation, guide rail design; and chemi-
cal handling and delivery.
Fig 6
-------
APPLICATIONS
The Water Champ operates on the
simple principle of applying all available
energy directly to the chemical that is
being activated. Todays state-of-the-art
water and wastewater chemical feed
systems, whether municipal or industrial,
look to the Water Champ vacuum chem-
ical induction systems to solve their
complex feed requirements.
Remember, with Water Champ, the
application of chemicals is only limited by
one's own imagination.
BNR Process
Coagulation
Color Removal
CSO (Disinfection)
DAF Systems
Disinfection
Dechlorination
Leachate Treatment
Odor Control
pH Control
RAS (Filamentous)
Coagulation
Disinfection
Filtration
pH Control
Taste & Odor Control
Rapid Mix
Recarbonization
Zebra Mussel Control
Chloramination
Refining
Petrochemicals
Pulp & Paper
Steel
Textile
Mining
Food Processing
Pipeline
Plating
Cooling Towers
pH Control
Chlorine
Potassium Permanganate
Sodium Sulfite
Sulfur Dioxide
Metabisulfite
Sodium Thiosulfate
Calcium Hypochlorite
Sodium Bisulfite
Carbon Dioxide
Sodium Hypochlorite
Anhydrous Ammonia
Lime Slurry
Air
Ferric Chloride
Soda Ash
Ozone
Aluminum Sulfate
Hydrochloric Acid
Oxygen
Sodium Aluminate
Sulfuric Acid
Hydrogen Peroxide
Ferrous Sulfate
Ammonium
WARRANTY
Water Champ is warranted for a period
The warranty may be renewed annually
of one year from the date of service
to be free from defects in material and
workmanship.
by purchasing a preventive maintenance
service agreement.
Priory Works, Tonbridge
Kent, TNI 1 OQL
United Kingdom
011-441-732-771777 tel
011-441-732-771800 fax
© 1999 United States Filter Corporation
Stranco® Products
P.O. Box 389
Bradley, II 60915 U.S.A.
800/882-6466 tel
815/932-8154 tel
815/939-9845 fax
http://www.stranco.com
Lit No. 1700-9911
-------
PRODUCT DATA SHEET
WATER CHAMP
CONTROL PANEL
General Description
The Water Champ® Control Panel is specifically designed to
offer ultimate protection for your submersible Water Champ
"F" Series Chemical Induction System. The Control Panel
includes the SUBTROL-PLUS submersible motor protection
system.
Computer technology is applied to provide a unique system of
detecting overloads, underloads and rapid cycling. The
SUBTROL-PLUS will turn off the "F" Series unit should any
of these faults occur and provide a visual display of the fault
condition. It offers automatic restart when the problem is
temporary, or can signal an alarm or back-up system if it is
constant.
WORKING TO BETTER TREAT *phe Water Champ NEMA 4X control panel with the SUBTROL-PLUS protection
POTABLE WATER & WASTEWATER • i j l r 11 ¦ r
system includes the following features:
Features
• NEMA 4X corrosion resistant
enclosure. (FRP-standard; stainless
steel-optional)
• Viewing window for all operator
usable functions and diagnostics.
• Control start/stop of Water
Champ (locally and remotely).
• Overload and underload trip set-
tings (field adjustable).
• Fault display and auto-restart.
• One minute forced wait between
starts.
• Non-resetable hour meter.
• Three phase disconnect with lock-
out capability.
• Remote "alarm" contacts.
• Remote "running" and "stopped"
contacts.
• Surge arrestor which exceeds
ANSI/IEEE standard C62.11.
• Terminal strip for external connec-
tions.
-------
PRODUCT DATA SHEET
WATER CHAMP F SERIES 6" SUBMERSIBLE
CHEMICAL INDUCTION SYSTEM
(MODEL NO. SWC20F)
General Description
The Water Champ® is an innovative device designed for the
application of a variety of chemicals used for the treatment
of potable water and wastewater. The unique feature of the
Water Champ is its ability to provide instantaneous miring
and diffusion.
The "F" Series submersible offers the highest quality of
design and construction of any submersible chemical
induction unit. The motor is a hermetically sealed 316 SS
motor for the highest level of durability and performance
required for chemical feed applications. Most wetted
materials are constructed from Grade 2 Titanium
(unalloyed) and are designed for use with most treatment
chemicals. The innovative mounting is configured for
mounting in open-channel applications and can be easily
retrofitted to existing basins and tanks.
WORKING TO BETTER TREAT
POTABLE WATER & WASTEWATER
Features
• Titanium Wetted Parts*
• Rugged Construction
• Heavy Duty Bearing Design
• Motor Monitoring System
Capacities
• 20 HP
• Gas to 10,000 lbs./day**
• Liquid to 60 GPM
Benefits
• Instantaneous Diffusion/Mixing
• Energy and Chemical Savings
• No Off-Gassing
• Easily Serviced
• Maximum Chemical Concentra-
tion
• Warranty - 1 Year From Start-up
or 18 Months After Delivery
"Custom materials quoted upon request.
"Feed rates are application dependent. (Consult factory.)
PERFORMANCE SPECIFICATIONS
Model No.
HP
Maximum
Gas
Induction
CL2 (ppd)
Maximum
Liquid
Induction
GPM
Maximum
Vacuum
(in. Hg)
SWC20F
20
10,000*
60*
26
Specifications subject to change without notice.
*Feed rates are application dependent. (Consult factory.)
-------
PRODUCT DATA SHEET
WATER CHAMP F SERIES 6" SUBMERSIBLE
CHEMICAL INDUCTION SYSTEM
(MODEL NO. SWC10F)
General Description
The Water Champ® is an innovative device designed for the
application of a variety of chemicals used for the treatment
of potable water and wastewater. The unique feature of the
Water Champ is its ability to provide instantaneous mixing
and diffusion.
The "F" Series submersible offers the highest quality of
design and construction of any submersible chemical
induction unit. The motor is a hermetically sealed 316 SS
motor for the highest level of durability and performance
required for chemical feed applications. Most wetted
materials are constructed from Grade 2 Titanium
(unalloyed) and are designed for use with most treatment
chemicals. The innovative mounting is configured for
mounting in open-channel applications and can be easily
retrofitted to existing basins and tanks.
WORKING TO BETTER TREAT
POTABLE WATER & WASTEWATER
Features
• Titanium Wetted Parts*
• Rugged Construction
• Fleavy Duty Bearing Design
• Motor Monitoring System
Capacities
• 10 HP
• Gas to 6,000 lbs./day*"
• Liquid to 40 GPM
Benefits
• Instantaneous Diffusion/Mixing
• Energy and Chemical Savings
• No Off-Gassing
• Easily Serviced
• Maximum Chemical Concentra-
tion
• Warranty - 1 Year From Start-up
or 18 Months After Delivery
*Custom materials quoted upon request.
**Feed rates are application dependent. (Consult factory.)
| PERFORMANCE SPEanCATIONS
Model No.
HP
Maximum
Gas
Induction
CL2 (ppd)
Maximum
Liquid
Induction
GPM
Maximum
Vacuum
(in. Hg)
SWC10F
10
6,000*
40*
23
Specifications subject to change without notice.
"Feed rates are application dependent. (Consult factory.)
-------
PRODUCT DATA SHEET
WATER CHAMP F SERIES 6" SUBMERSIBLE
CHEMICAL INDUCTION SYSTEM
(MODEL NO. SWC5F)
General Description
The Water Champ® is an innovative device designed for the
application of a variety of chemicals used for the treatment
of potable water and wastewater. The unique feature of the
Water Champ is its ability to provide instantaneous mixing
and diffusion.
The "F" Series submersible offers the highest quality of
design and construction of any submersible chemical
induction unit. The motor is a hermetically sealed 316 SS
motor for the highest level of durability and performance
required for chemical feed applications. Most wetted
materials are constructed from Grade 2 Titanium"
(unalloyed) and are designed for use with most treatment
chemicals. The innovative mounting is configured for
mounting in open-channel applications and can be easily
retrofitted to existing basins and tanks.
WORKING TO BETTER TREAT
POTABLE WATER & WASTEWATER
Features
• Titanium Wetted Parts*
• Rugged Construction
• Heavy Duty Bearing Design
• Motor Monitoring System
Capacities
• 5 HP
• Gas to 3,000 lbs./day**
• Liquid to 25 GPM
Benefits
• Instantaneous Diffusion/Mixing
• Energy and Chemical Savings
• No Off-Gassing
• Easily Serviced
• Maximum Chemical Concentra-
tion
• Warranty — 1 Year From Start-up
or 18 Months After Delivery
"Custom materials quoted upon request.
"Feed rates are application dependent. (Consult factory.)
PERFORMANCE SPECIFICATIONS
Model No.
HP
Maximum
Gas
Induction
CL2 (ppd)
Makimum
Liquid
Induction
GPM
Maximum
Vacuum
(in. Hgj
SWC5F
5
3,000*
25*
22
Specifications subject to change widiout notice.
*Feed rates are application dependent. (Consult factory.)
-------
APPENDIX B
METHODS AND PROCEDURES
-------
GENERAL TESTING PROCEDURE
STEP
DESCRIPTION
Setuo for Testin2 and Recording
1
Mixer manufacturer's representative inspect and "sign off' on mixer installation.
2
Establish flume flow by setting weir and water level.
3
Turn on mixer.
4
Set mixer flow using manometer board deflection.
5
Establish sampling pump flows using rotameters.
6
Establish tracer injection flow using timed pipette.
7
Allow entire system to stabilize 5 minutes.
8
Collect 3 liters "background sample" transport flow (upstream of tracer injection
box). Background sample will be used to create calibration samples for each
mixer/velocity combination.
9
Fill in pretest section on "Mixer Test Data Sheet".
10
Collect 25 simultaneous flume samples (1 liter, approximately 10 minutes).
11
Fill in post test section on "Mixer Test Data Sheet".
12
Cap, label, and box the flume samples, move samples to analysis.
13
Move sampling rig to next longitudinal location.
14
Repeat steps 7 through 12 until 3 sampling locations complete.
15
Turn off tracer injection flow while setting new flume velocity.
16
Repeat steps 2 through 14 for each flume velocity/mixer combination.
Fluorometer Setup
1
Turn on fluorometer and allow to warm up for 1/2 hour.
2
Set up cuvette water bath using building tap water.
3
Prepare calibration samples using background flow collected from 8 above, using
serial dilution technique described below.
4
Cap, label, and store the calibration samples in 1 liter amber bottles.
-------
Fluorometer Calibration
5
Fill 4 cuvette to within 1 inch of top with calibration dilutions and place on
cuvette rack labeled; 1, 12.5, 25, 50.
6
If the cuvettes are not dry, fill and discard each calibration cuvette with the
corresponding calibration dilution to rinse the cuvette for the calibration sample
(the 1 liter bottle provides enough volume for several analysis).
7
Place cuvette rack in water bath and fill with calibration solution to stabilize
temperature (10 minutes).
8
The fluorometer acquisition program is started and a unique filename is recorded
for each calibration.
9
Individually, the calibration samples are removed from the temperature bath, the
outside is dried, and placed into the fluorometer chamber.
11
Three 10 second periods are recorded and averaged. The average is recorded on
the "calibration data sheet" along with the sample and fluorometer filter light
temperature. A computer file is generated for each calibration.
12
The cuvette is removed and its contents discarded. The next calibration cuvette is
placed in the fluorometer and steps 8 through 11 are repeated.
13
The 4 calibration data of concentrations and fluorometer voltages are imported
into a quattro spreadsheet and a first order curve fit equation is calculated. The
curve fit coefficients (slope and intercept) are used to convert fluorometer
readings of the test samples to units of concentration.
Sample Analysis
1
Fill 25 cuvettes with the test samples following steps 5 through 7 above. The 25
samples are to be placed in a rack labeled, as shown in the "Sample Analysis Data
Sheet".
2
Individual cuvettes are analyzed following steps 8 through 13 above with the
sample averages recorded on the "Sample Analysis Data Sheet" (Step 11).
-------
Serial Dilution
1
Rhodamine WT tracer is purchased in a 20% concentrated form (2E8 ppb). This
concentration will be diluted to 2,500 ppb using the following set of serial
dilutions with distilled water at Alden. Dilutions will be performed using
"Class A" pipettes and graduated Flasks (0.1% measurement vessels).
Dilution Ratio
2E + 08 Distilled
ppb Tracer Water
1 19
1 19
1 19
1 9
Concentration
EEh
10,000,000
500,000
25,000
2,500
2
The 2,500 ppb concentration will be brought to the test site and further diluted
(following the serial dilution given below) using flume water to produce
fluorometer calibration samples at the following concentrations. Dilutions will be
performed using "Class A" pipettes and graduated flasks (0.1% measurement
vessels).
Dilution Ratio
2.500 Flume
ppb Tracer Water
1 9
1 4
1 1
1 1
0 1
Concentration
EEh
250
(not for calibration)
50.0
25.0
12.5
0.0
-------
MIXER TESTING DATA SHEET
RECORDED BY
DATE
TEST ID
(circle)
MIXER MANUFACTURER
USF
MAS
MIXER HP
5
10
20
SAMPLING LOCATION
5
10
15
FLUME VELOCITY
0.5
1.25
3.0
RECORD
NO.
PRETEST1
1
2
3
4
5
POST TEST1
1
2
3
4
5
FLUME
MIXER
TRACER
WEIR
WATER
TEMP
FLOW
kW
AMP
VOLTS
CONC.
TIMING
TEMP.
ELEVATION
LEVEL
F
(FT METER)
ml/sec
F
(2 Readings) (1 Reading) (2 Readings) (2 Readings)
1. MANUAL RECORDING: UNLESS OTHERWISE NOTED, 5 READINGS RECORDED PER ITEM WITH 5 SECONDS BETWEEN READINGS.
-------
SAMPLE ANALYSIS DATA SHEET
RECORDED BY
DATE
(circle)
MIXER MANUFACTURER
USF
MAS
MIXER HP
5
10
20
SAMPLING LOCATION
5
10
15
FLUME VELOCITY
0.5
1.25
3.0
FLOUR. PROGRAM DATA FILENAME .DAT & .AVE
FLOUROMETER VOLTAGE (AVG. 3-10sec readings)
A1
A2
A3
Port Location Key
A4
(Viewed looking downstream)
A5
A1 B2 C3 D4 E5
A2 B2 C3 D4 D5
B1
A3 B3 C3 D3 E3
B2
A4 B4 C4 D4 E4
B3
A5 B5 C5 D5 E5
B4
B5
C1
C2
C3
C4
C5
D1
D2
D3
D4
D5
E1
E2
E3
E4
E5
TIME
-------
FLOUROMETER CALIBRATION DATA SHEET
RECORDED BY
DATE
FLOUR. PROGRAM DATA FILENAME .DAT & .AVE
(circle)
MIXER MANUFACTURER USF MAS
MIXER HP 5 10 20
SAMPLING LOCATION 5 10 15
FLUME VELOCITY 0.5 1.25 3.0
TIME
SAMPLE
CONCENTRATION
SAMPLE
TEMP (F)
FILTER
TEMP (F)
FLOUROMETER VOLTS
(Average of 3 10s readings)
-------
APPENDIX C
MEASUREMENT UNCERTAINTY
OF TRACER CONCENTRATION AND FLUME VELOCITY
-------
APPENDIX C
MEASUREMENT UNCERTAINTY
OF TRACER CONCENTRATION AND FLUME VELOCITY
1. TRACER CONCENTRATION MEASUREMENT UNCERTAINTY
Estimates of precision indices were made from measurement standard deviations, while bias
uncertainties are estimated from comparative tests and experience. Bias and precision components
are propagated separately from the individual measurements to the final result. Elementary error
source uncertainties for each component are combined by the root sum square (RSS) method.
Precision uncertainty is estimated as the precision index (estimated by the standard deviation of the
test data) multiplied by the Student t factor. The Student t factor corrects the standard deviation
calculated using the limited number of measurements in the sample to estimate the standard deviation
of a population having an infinite number of points. The overall uncertainty of the result is reported
as the sum of the bias and precision uncertainties at 95 percent confidence level.
Water Quality
A potential source of uncertainty in the sample concentration measurements is the effect of variable
water quality including suspended solids on fluorescence. The effect is minimized by preparing
calibration samples with site water at the same time as the flow measurement is conducted. This
procedure takes into account the actual water quality and possible degradation of the tracer with time.
However, the calibration samples are not integrated over the entire time period of the sample
measurement so that water quality changes may occur which are not compensated by the calibration
solutions. A bias uncertainty of 2 percent is estimated for changes in water quality during a test from
the water quality used in calibration sample construction.
-------
Injection Flow Uncertainty
Injection mass flow was determined by the volumetric method, that is, measurement of the time
required to inject a given volume times the density of the dye.
Bias elementary error sources in the injection flow measurement include temperature effects on the
volume determination, temperature effects on the density determination, and time measurement.
Precision uncertainties also occur in the time and temperature measurements. Using the average
standard deviation of the dye injection flow measurements, the time precision index was estimated
at 0.14 percent. The time measurement bias uncertainty was estimated from manufacturer's
specifications and calibrations at 0.01 percent. The maximum range of the dye temperatures, 5° F,
was used to determine a density precision index of 0.03 percent (density from Reference 1).
Experiments at Alden on the measuring flasks determined the flask volume rate of change with the
temperature to be 0.002 percent per degree. Calculations using the thermal expansion rate of the
glass used in the flasks confirmed the experimental results. The minimum ambient temperature of
about 40° F resulted in a 20° F variation from standard temperature (60° F) which causes a volume
bias uncertainty of 0.04 percent. A 2° F temperature measurement bias results in a 0.01 percent
density bias uncertainty. Table CI summarizes and combines the uncertainty estimates for the
elementary error sources.
TABLE CI
INJECTION FLOW UNCERTAINTIES (%)
Elementary Error Source
Bias
Precision
Volume; Manufacturer Specification
0.10
NA
Temperature (20° F Variation from 60° F)
0.04
NA
Density
0.01
0.03
Time
0.01
014
Root Sum Square (RSS)
0.019
0.143
-------
Concentration Measurement
The concentration measurement uncertainty is estimated by evaluation of the fluorometer calibration
uncertainty and the data acquisition and reduction uncertainty. The elementary error sources for the
calibration uncertainty include preparation of the calibration solutions, temperature effects on the
fluorescent activity, and electronic noise and environmental effects on the instrumentation. All
calibration solutions will be prepared from the stock injection solution with site water, so that results
are calculated from dilution ratios (expressed in ppb for convenience) and no uncertainty occurs due
to the stock injection solution concentration magnitude.
A 2,500 ppb initial calibration solution will be constructed by four serial dilutions with distilled water
at Alden, an overall dilution of 1 to 80,000. For the instrument calibration procedure, an additional
four dilutions are required with site water to construct calibration solutions of 50, 25, and 12.5 ppb
(including the intermediate 250 ppb dilution). Calibration volume measurements are subject to the
same bias uncertainties as the injection flow volume uncertainty, i.e., bias uncertainties of 0.1 percent
(from manufacturer's specifications of Class A flasks, see Table 1) and 0.002 percent per degree
variation from standard temperature of 60° F for temperature effects or 0.04 percent for 40° F water.
The precision index of the volume measurements is dependent on the number of dilutions constructed.
The volume precision uncertainty for a single measurement is estimated at 0.05 percent from tests
at Alden determining the sensitivity of volume to level measurement errors. A precision uncertainty
occurs during the calibration solution preparation due to changes in water quality at the time of
solution preparation. This precision uncertainty is estimated at 0.8 percent from the standard
deviation of the difference of the calibration solution data from linear regression of each test. The
bias uncertainty due to water quality is estimated at 1 percent. Precision and bias uncertainties for
the calibration solution preparation are estimated in Table C2 and the resulting bias and precision
uncertainties are included in the overall calibration and data acquisition procedure uncertainty in
Table C3.
-------
TABLE C2
CALIBRATION SOLUTION PREPARATION UNCERTAINTY (%)
Elementary Error Source
Bias
Precision
Calibration Solution
Initial Volumes (4) Measurements
0.10
0.09
Temperature (20° F Variation from 60° F)
0.04
NA
Solution Volumes (4) Measurements
0.10
0.07
Temperature (20° F Variation from 60° F)
0.04
NA
Water Quality
1.0
0.8
Root Sum Square (RSS)
1.01
0.81
The calibration and sample analysis procedure elementary error sources and their estimated certainties
are listed in Table C3. Fluorescence intensity is dependent on temperature and, a temperature
correction is used in concentration measurement has the form given by Equation (3), Section 4.4.1.
Therefore, the sensitivity of the concentration measurement to temperature measurement is
1.44 percent times the deviation in temperature in degrees F. The temperature measurement bias
uncertainty due to environmental effects on the thermometer is estimated at 0.1° F from the
manufacturer's specifications, which results in a fluorescence bias uncertainty of 0.14 percent. The
temperature measurement precision index is taken to equal the resolution of the thermometer, 0,10 F,
resulting in a fluorescence precision index of 0.14 percent for fluorescence.
The fluorometer has inherent electronic noise, which has been evaluated by determining the precision
index of the output voltage of the calibration samples and the test samples at a constant temperature.
The voltage precision index was minimized by averaging the output for about one half minute. The
average precision index used for all the samples will be 0.3 percent.
Environmental effects on the fluorometer output are caused by temperature changing the transmission
coefficient of a critical filter. The transmission coefficient has been estimated to change by
0.10 percent per degree from measurements at Alden. The filter temperature will be monitored
-------
during calibration and analysis, and assuming that the maximum difference during any test is 1.5° F,
resulting in a bias uncertainty on concentration measurement of 0.13 percent. If this is found, no
corrections will be made to calibration results for filter temperature variations.
The bias and precision uncertainties due to the measurement of temperature, for the correction of
temperature effect on fluorescence, are estimated from a temperature measurement precision index
of 0.2° F, which results in a concentration precision index of 0.14 percent and temperature
measurement bias uncertainty of 0.05° F. This results in a concentration bias uncertainty of
0.07 percent. The temperature correction coefficient, k in Equation (2), is an average value.
Experiments at Alden have shown that the value is less than 5 percent in error, so that if the maximum
temperature corrections used is about 3.5° F, the bias uncertainty in concentration due to the
coefficient is estimated at 0.25 percent (5 percent of the correction for 3.5° F, which is 5 percent).
TABLE C3
CONCENTRATION MEASUREMENT UNCERTAINTY (%)
Elementary Error Source
Bias
Precision
Calibration Solution (from Table C2)
1.01
0.81
Fluorescence Temperature (3.5° F)
0.25
0.1
Filter Temperature Effects (1.4° F)
0.13
NA
Averaging Precision
NA
0.3
Root Sum Square (RSS)
1.05
0.87
Total Concentration Uncertainty
Table C4 summarizes the RSS bias and precision uncertainties for the four components of the sample
concentration measurement, data acquisition, and reduction. Bias and precision uncertainties are
combined by assigning a Student t factor to the precision indices to attain the 95 percent confidence
level. A Student t of 2 may be assigned to achieve the 95 percent confidence level, if either the
number of measurements for the precision index was greater than 20 or half the range was used.
-------
TABLE C4
SUMMARY OF UNCERTAINTIES - CONCENTRATION MEASUREMENT (%)
Elementary Error Source
Bias
Precision
Injection Flow
0.11
0.14
Water Quality
2
NA
Data Acquisition and Reduction
1.05
0.87
Root Sum Square (RSS)
2.24
0.88
The estimated overall flow measurement uncertainty is 2.85 percent at the 95 percent confidence
level i.e., [2.242 + (2 x (0.88)2]172.
2. FLUME VELOCITY MEASUREMENT UNCERTAINTY
The flume velocity is a function of the flume flow divided by the flume cross-sectional area. The
three test flume velocities will be established by setting the weir elevation to a calibrated position, and
adjusting the inflow until the desired water level is attained. For calibration, the elevation of the weir
will be adjusted until the (measured) average velocity (0.5, 1.25, 3.0 ft/sec) and required depth (7 ft)
is attained. Thereafter, the test velocities will be set by positioning the weir and adjusting the inflow
to bring the water level to 7 ft.
The uncertainty of flume velocity, therefore, is a function of:
1. The calibration of weir position with the velocity traverses
2. Weir position measurement
3. Water level measurement
-------
Velocity Traverse Uncertainty
Velocity Instrument
The velocity traverse will be conducted using a SonTek Acoustic Doppler Velocity (ADV) meter.
From the manufacturers specifications, the instrument resolution is 0. lmm/s, which results in a
precision index of 0.07 and the meter has a velocity bias of 0.5 percent.
Point Velocities
The uncertainty in the measured velocity is the sum of several elementary sources. While the average
flow in the measured section may be assumed to be constant over the (weir calibration) test period,
the velocity at any point in the flow will have a fluctuating component. A measurement averaging
period of 120 seconds was chosen to approximate the true average velocity according to Reference 1.
The average flume velocity will be determined by averaging 49 measured point velocities taken at a
cross-section upstream of the mixer location. Two minute samples will be recorded at a sampling
frequency of 10 hz for a 1,200 data set at each point. The point velocity precision index will be
estimated using the average standard deviation of each of the 49 point velocity measurements. From
the 0.5 ft/sec flume velocity traverse (available from CAFRC), the point velocity precision index is
estimated to be 0.23 percent. Bias uncertainty for the individual points is the same as the instrument
uncertainty above.
Data Reduction
The flume velocity will be calculated by averaging the forty nine point velocities. The precision
uncertainty in this average is due to the size of the data set and the standard deviation of each point
with respect to the overall average. From the 0.5 ft/sec flume velocity traverse (available from
CAFRC), the traverse velocity precision index is estimated to be 0.36 percent.
-------
TABLE C5
VELOCITY TRAVERSE UNCERTAINTY (%)
Elementary Error Source
Bias
Precision
Instrument
0.5
0.07
Point Velocities
NA
0.23
Averaging Precision
NA
0.36
Root Sum Square (RSS)
0.5
0.43
Table C5 summarizes the RSS bias and precision uncertainties for the three components of the flume
velocity measurement.
Weir Position Uncertainty
The weir location will be measured using an angle transmitter located on the face of the weir. The
angle transmitter signal will be correlated to the weir crest elevation which will be measured using
an optical level and staff referenced to the floor of the flume. Sources of error in setting the weir
include; calibration to weir elevation, transmitter resolution and repeatability, and stability of the weir
when loaded (with water).
Using the manufacturers specifications, and the results of the calibration, the estimated precision
index of angular position is 0.29 percent and bias is negligible. The transmitter signal was acquired
using a PC. The precision index of the 8 point calibration (curve fit) of transmitter signal to weir
elevation, based on the average standard deviation of the predicted (curve fit) elevation to the
measured values is 0.20 percent. The calibration bias is negligible. The same PC and acquisition
software used to calibrate the transmitter will be used during testing. Monitoring the angle
transmitter for several hours while the velocity traverse measurements were being collected, CAFRC
personnel reported (recorded) virtually no change in indicated weir elevation, meaning that
structurally the weir was stable under load.
-------
TABLE C6
WEIR POSITION UNCERTAINTY (%)
Elementary Error Source
Bias
Precision
Angle Transmitter
NA
0.29
Calibration
NA
0.20
Weir Structural Stability
NA
NA
Root Sum Square (RSS)
NA
0.35
Water Level Uncertainty
The flume water level transmitter has been calibrated in place using an optical level and staff and
measurements to the flume floor. Using the manufacturer's specifications of 0.01 ft resolution and
the test depth over the weir or 1 to 3 ft, the estimated instrument precision index is 1.0 percent. The
same PC and acquisition system used for the calibration will be used during testing. An 8 point
calibration was conducted. The estimated precision index of the calibration (curve fit) of transmitter
signal to weir elevation, based on the average standard deviation of the predicted (curve fit)
elevation to the measured values, is 0.35 percent. Based on experience with operating the flume,
CAFRC personnel estimate that the required 7 ft water depth can be repeatedly established, within
a reasonable time, to within 0.05 ft. This produces a precision index estimate of 0.7 percent.
Negligible bias is expected in setting the water level.
-------
TABLE C7
WATER LEVEL UNCERTAINTY (%)
Elementary Error Source
Bias
Precision
Float
NA
1.00
Calibration
NA
0.35
Repeatability
NA
0.7
Root Sum Square (RSS)
NA
i in
X. JV
Total Velocity Uncertainty
Table C8 summarizes the RSS bias and precision uncertainties for the three primary components
involved in setting the flume velocity; velocity traverse used to locate the weir elevation, weir
position, and water level. Bias and precision uncertainties are combined by assigning a Student t
factor to the precision indices to attain the 95 percent confidence level. Because the number of
measurements used in the calibrations, a student t of 2.3 was assigned to achieve the 95 percent
confidence level.
TABLE C8
FLUME VELOCITY (%)
Elementary Error Source
Bias
Precision
Velocity Traverse
0.5
0.43
Weir Position
NA
0.35
Water Level
NA
1.30
Root Sum Square (RSS)
0.5
1.41
The estimated overall velocity measurement uncertainty is 3.33 percent at the 95 percent confidence
level, i.e., (0.52 + (2.3 * 1.432)1/2.
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REFERENCE
"Jet Injections of Optimum Mixing in Pipe Flow," Fitzgerald, S.D, and Holley, E.R.,
University of Illinois at Urbana-Champaign, Research Report No. 144, December, 1979.
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APPENDIX D
ALDEN GENERAL QA PLAN
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ALDEN RESEARCH LABORATORY, INC.
QUALITY ASSURANCE PROGRAM
1.0 Organization and Personnel
1.1 Aid en General Organization
The Alden President has ultimate responsibility for the technical, fiscal, and
contractual aspects of all studies conducted at Alden. Responsibility for technical
aspects of a study is delegated to a Vice President or a senior level engineer, who will
serve as the Principal Investigator of the study.
The various support services report to a combination of the President and various
Vice Presidents.
1.2 Project Organization and Personnel Responsibilities
The Principal Investigator is directly responsible to the Purchaser for conducting the
study. The Principal Investigator is responsible for activities such as planning,
designing, testing, and reporting for the project. Other engineers and technical
assistants, if assigned to the study, report directly to the Principal Investigator.
The Quality Assurance Program will be implemented by the Principal Investigator
through the supervisory chain. The Principal Investigator shall have the responsibility
of issuing a written stop work order whenever any work in progress is not in
accordance with the project specification or the Alden Quality Assurance Program.
The Principal Investigator shall have the responsibility of training all personnel
assigned to the project with respect to implementation of the Alden Quality Assurance
Program.
Services required for proper and timely execution of the study, such as
instrumentation, crafts, and graphic arts, are requested directly by the Principal
Investigator from the desired services unit. The Vice President supervising that
service becomes involved if conflicts in priorities arise.
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Records and Documents
2.1 Routing and Recording Incoming and Outgoing Correspondence
All incoming correspondence for the study will be received by or routed to the Alden
Main Office. At the Main Office, the original will be stamped "file copy," copied, and
the original filed in the Central File. The Principal Investigator and President will be
provided copies. At the discretion of the Principal Investigator, additional copies will
be provided to other key personnel. Action items will be marked as such and the
action assigned.
All outgoing correspondence will be mailed by the Alden Main Office. Copies will
be maintained in the Central File and copies provided to the originator, Principal
Investigator, and President.
Telephone conversations related to the project will be documented with notes.
2.2 File System
A Central File will be maintained in the Alden Main Office under client name and job
code. All originals of incoming correspondence and copies of all outgoing
correspondence will be kept in this file, with the possible exception of drawings, see
Section 2.3. Copies of appropriate project drawings, calculations, computer disks and
data will be entered in the Central File upon completion of the study.
The Main Office head secretary will have responsibility for maintenance of the Central
File system.
2.2.1 Distribution
Copies of the Quality Assurance Manual will be maintained at the following
locations:
1. One copy in the Central File,
2. One copy in the Principal Investigator's office,
3. One copy at the Alden job site,
4. One copy is sent to the Purchaser (additional copies may be issued to
the Purchaser upon request).
All copies will receive any revisions made to the QA Manual.
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2.3 Drawings
Drawings received by Alden from the Purchaser will be transmitted to the Principal
Investigator. If two copies of drawings are received, one copy will be maintained in
the Central File.
A copy of relevant internally generated drawings will be filed in the Project Notebook
or in the Central File, all such drawings eventually being retained in the Alden storage
area.
Project drawings will be numbered, and a log of project drawing numbers will be
maintained by the Principal Investigator or his authorized agent. Revisions will be
recorded on the log of project drawings.
2.4 Study Documents
2.4.1 Log Book
The Project Log Book will be kept at the experimental facility while
conducting experimental studies. The Project Log Book will contain a daily
record of all activities during the test program. Data recorded on data sheets,
computer printouts, etc., shall be assigned a sequential test number and a
document number, which will be referenced in the daily log. It is not
necessary that all data and pertinent drawings be bound in the Project Log
Book, but they must be referenced in the log and maintained as part of the
project documentation.
2.4.2 Computer Disks
Removable computer disks that are used to store study results will be
identified by project name, the Alden project code, the test number, and a
document number. An entry identifying the disk will be made in the test log.
Such disks will be stored as part of the project file in the Central File at the
end of the study.
2.5 File Retention
Upon completion of the project, all pertinent data and drawings generated by the
project, including hard copies of computer data and portable disks, will be placed in
a common storage box(es). The storage box will be placed in a designated Alden
storage area for retention. The Central File maintained in the Main Office will be
retained at that location for a period of one year after project completion.
Subsequently, the Central File will also be placed in the common storage box for the
study.
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2.6 Revisions
If a design calculation or drawing requires revision, a new document will be originated
under the requirements of Section 3.0. In addition, the new document shall include
the phrase "revision of document" and the superseded document number. The
original document shall have the phrase "revised" and the superseding document
number added with the initials of the Principal Investigator and the date.
Revisions of a test procedure or calibration procedures will include a revision number.
The Principal Investigator will have the responsibility to transmit the requisite
procedures to the test operator. When a procedure revision is implemented, the
revision number and implementation date will be recorded in the test log.
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3.0 Design
3.1 Applicable Standards, Criteria, Specifications
Any design memorandum issued by the Principal Investigator will list applicable
published and generally available standards, codes, criteria, and specifications. The
design memorandum will indicate where copies of such applicable criteria are filed,
which sections are to be applied to the design, and which criteria apply to specific
design phases and facility components.
If any changes or deviations from applicable standards are made during the facility
design, these shall be documented by a memo of change, to be approved by the
Principal Investigator.
3.2 Design Process
Standard Alden calculation sheets will be used to perform manual calculations.
Sources of input data, factors, equations, etc., will be identified and referenced to
provide traceability. Assumptions will be identified. The object of the calculations
will be stated, and the conclusions highlighted or set aside. All design drawings,
calculations, graphs, and other design documents will be identified by appropriate
project and subject titles, and be dated, initialed, and numbered by the originator.
3.3 Review Requirements
At the completion of the design of each component of the project, the Principal
Investigator or his authorized agent will review and initial critical drawings and
calculations for the component reviewed.
An authorized reviewer will be in the position of Engineer or higher. In no case will
review by the originator be considered acceptable. (This does not preclude review by
the originator prior to second party review.) If the reviewer notes any error, these
will be discussed with the preparer, and if changes or corrections are agreed to by
both parties, those changes or corrections will be made in another color by the
reviewer. Completion of the review will be indicated on each reviewed document by
the initials of the reviewer and the date reviewed.
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Construction
4.1 Review of Test Equipment and Components
Components will be inspected and checked for accuracy after completion. The test
facility will be inspected immediately upon completion to ensure conformance to
design. The reviewer will be the Principal Investigator or his authorized agent.
4.2 Review Requirements
The component and test facility reviews will verify conformance to design. The value
of measured dimensions will be recorded on a copy of the appropriate design drawing
by the reviewer. The drawing copy will be dated and initialed by the reviewer. In the
case of discrepancies beyond mutually agreed upon tolerances, the appropriate
changes will be made, and the drawing copy will be marked to reflect as-built
conditions.
4.3 Review Report
The reviewer will make an entry in the project log book to reflect review findings.
The work order will be initialed and dated by the reviewer to indicate that the
component or installation is complete and in accordance with the design.
The reviewed and initialed design drawing copies marked with as-built dimensions (if
different than those shown) will be retained in the Project Notebook.
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5.0 Instrumentation/Equipment
5.1 Calibration Procedure Requirements
• Each instrument in the calibration program will bear a unique number,
date of last calibration, and initials of person performing calibration.
All resulting calibration sheets and plots will be dated and numbered.
Each data calculation involving an instrument calibration shall
reference the appropriate numbered calibration form.
5.2 Equipment/Material Purchases
If Alden purchases any equipment or non-expendable materials from outside sources
(vendors) for use in the model study, the vendor QA Program will be revised to
involve appropriate QA requirements on their suppliers. No QA program will be
necessary for expendable materials.
5.3 Computer Software
If any software programs other than commercially available programs (e.g., Quattro
Pro, Lotus) are used in conjunction with the model study, Alden's QA program will
be revised to add provisions for verification and validation of the software. Use of
computer software, other than spreadsheets, is generally not anticipated.
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Operation and Testing (including computer analysis)
6.1 Test Plan Report
Prior to commencement of the test program, a Test Plan Report will be written, which
will, as a minimum, include:
• A statement of the test purpose
• A description of all variables which are to be controlled
• A description of the physical parameters to be measured
A description of the necessary instrumentation
• A description of the operational sequence of events required
• A description of the procedures for data retrieval
Model parameters relevant to a specific test, such as water level, flow rates, and
special model geometry, will be defined by the Principal Investigator or his authorized
agent and transmitted to the model operator. A unique test number will be assigned,
and the test order will become a permanent part of the test log.
The Test Plan Report will be reviewed and approved by the client. Copies of the Test
Plan Report will be available at the experimental facility.
6.2 Data Retrieval Procedures
Standard Alden sheets and log books will be used to record data. All data will be
recorded in a clear, legible manner and properly formatted, as appropriate. The data
set for each test will be identified by, as a minimum, the following general
information:
Job name and number
Sponsor
Test number
Title of test
List of instruments used (serial numbers)
Special test procedures
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Data recorder initials
Data reviewer initials
Date
6.3 Data Reduction and Analysis
Standard Alden calculation sheets will be used to perform data analysis. Sources of
input data, calibration factors, equations, etc., will be identified and referenced to
provide traceability. Assumptions will be identified. The preparer will initial, number,
and date all pages, and identify each document by appropriate project and subject
titles. If computer analysis is used, then a copy of the printout will be attached to
the calculation sheet. This copy will be clearly marked to identify the program and
filename used.
In cases where a number of minor calculations are required, several may be done on
one sheet provided they are clearly identifiable.
6.4 Reporting of Data
Normal Alden procedures will be used in preparing reports. Tables, figures, and
graphs will be checked for accuracy by the Principal Investigator or his authorized
agent.
All reports will be reviewed by the Principal Investigator in draft form prior to being
submitted to the Purchaser for review. Review completion will be noted by initials
of the reviewer and date on the draft copy filed in the Central File. Comments will be
evaluated and incorporated when appropriate. Final reviews will be conducted prior
to and after printing.
6.5 Test Review Procedures
Audits, accomplished by the Principal Investigator, will verify the test parameter
setup, and these audits will be recorded, including signature and date. Non-
conformance and required remedial action will be noted.
As soon as possible after a data sheet has been completed, it will be reviewed. The
review, conducted to check accuracy and completeness, will be indicated by the
signature of the reviewer and the review date.
Data analysis calculations will be reviewed in a similar manner. The review will take
place as soon as possible after calculation completion and before any use is made of
the calculation conclusions for further study or reporting.
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