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  • 2

    009

    Nor

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    Project number: A12345

    Installation ManualConcrete filter(s)

    Stage I

    May

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  • 2009 Nordic Water Products AB. All rights reserved.

    About this manualThe purpose of this manual is to give you the most value out of your DynaSand Filter plant. This manual provides information about the DynaSand Filters.The manual supplied by Nordic Water Products AB is generic for different sizes of concrete Dynasand Filters and pictures show typical Dynasand Filter details.All specifications and measurements are individual for each size and version of the DynaSand Filter. There might be sections that are not applicable to your plant. These instructions refer to drawings and technical specifications provided by Nordic Water Products AB. A copy of them can be found in chapter 2.

    How to identify your DynaSand Filter modelTo identify your DynaSand Filter please see the filter plant specific information in chapter 2. Listed here are also possible deviations from the standard version for your plant.If the plant specific information is not available, please contact Nordic Water Products AB for model information.

    Using the manualThe manual is divided into numbered chapters. Each chapter is divided into sections.A text describing a procedure is not generally repeated. When it is necessary to refer to another chapter the reference is given as chapter and section number i.e. 2.5.If a reference is given as without chapter as: see section 5 it means another section in the same chapter.

    Specifications are subject to change without notice. Reservation for misprint.

    Thank you for the confidence you have shown in our company and product. We are sure that your DynaSand Filter(s) will serve you well.Please, study this manual thoroughly before installing your DynaSand Filter plant.

    Head OfficeSisj Kullegata 6 421 32 Vstra Frlunda SWEDEN

    Phone: +46 31 748 54 00 Fax: +46 31 748 54 10

    E-mail: [email protected]

    DynaSand & Service DepartmentBox 1004 149 25 Nynshamn SWEDEN

    Phone: +46 8 524 409 00 Fax: +46 8 520 173 25

    E-mail: [email protected] address:

    Industrivgen 6 149 41 Nynshamn SWEDEN

    Nordic Water Products AB

  • CON

    TEN

    TSSafety Information 1 6

    1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

    Extent of Delivery 2 82.1 Delivery specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Technical specification for DynaSand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3 Technical specification for control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

    Marking up the Basin 13 43.1 Control of elevation, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2 Marking up the lines on the ground plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.3 Installation of anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

    Preparation of Bottom Cone(s) in Steel 24 04.1 Fixture for assembling the bottom cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.2 Assembling the bottom cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3 Prepare the bottom cone for installation in the basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

    Preparations of Bottom Cone(s) in FRP 35 45.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.2 Assembling the bottom cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.3 Preparing the bottom cone for installation in the basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

    Installation of Bottom Cone 46 26.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.2 Mounting the bottom cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.3 Concrete casting of the bottom cones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

    Mounting the In-Basin Concrete Partitioners 57 47.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547.2 Casting concrete partitioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547.3 Pyramids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557.4 Pylons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587.5 Installing the concrete partitioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

    Installation of Embedded Pipes 78 08.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708.2 Installing the Embedded pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708.3 Method 1 for installing embedded pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718.4 Method 2 for installing embedded pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

    Troubleshooting 79 49.1 Problems during installation stage I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749.2 Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

    Appendix 710 810.1 Check list for installation of concrete DynaSand filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7810.2 Quick check of elevation levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7810.3 Control of marking up the basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

  • 1

    Chapter 1Safety Information

  • 6 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    1

    General1.1 These instructions must be kept by/near the machine/filter. The information has been provided in the interest of safety. The user (owner) of the machine/filter is responsible for training and safety of the operating personnel. These instructions must be handed over to concerned personnel. The user and concerned personnel are required to be familiar with the directions in these instructions.Personnel whose duties entail transport, assembly, operation or maintenance of the machine must have read and understood these instructions.The machine/filter may only be taken into service by competent personnel who have been briefed on the machine/filter and informed of the dangerous operations.These instructions contain safety provisions. These must always be observed. Account of local safety and accident regulations has to be taken.With regard to disassembly and disposal instructions, please contact the supplier.

    Special safety instructions1.2 The machine/filter may only be transported by competent personnel. General safety rules for lifting must be observed.The machine/filter may only be assembled by competent personnel, in accordance with applicable assembly and installation regulations. Local safety rules must be followed.All inspection, monitoring and repair work on the machine/filter is to be performed by competent personnel (i.e. qualified electricians). General and local safety regulations are to be observed.

    The user is responsible for the issue of permits for gaining admittance to any tanks, chemicals tanks, etc.Decrees by the Work Safety Board with regulations on work in closed areas must be followed.Personal protective equipment must be used in all cases of work with chemicals, in accordance with relevant product information sheets.Commissioning, test running and adjustment/maintenance work must be performed by competent and, if necessary, proper/authorized personnel.The machine/filter must never be taken into service without protection and safety devices in working order.EC conformity in relation to installation must be ensured prior to commissioning of the machine/filter.

    In case of work within the danger area of the machine/filter, water and compressed air supply must be disconnected. Work must not be carried out on ones own. In the case of all other work, all supplies of energy must be switched off by a lockable disconnect switch. The person in charge of the work must always bring the key. Protective equipment must be used.

    Danger Area

    Safety Information1.

    1 Safety

    DANGER! This sign appears at a number of places in the instructions. Follow the directions.

  • 2

    Chapter 2Extent of Delivery

  • 8 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    2

    Delivery specification2.1 The information stated here is unique for every filter plant. This page is normally generated from an external file and added to this manual. If this text is seen here, this manual is not specific for a certain filter plant.

    Extent of Delivery2.

    2 Extent of Delivery

  • DS 9.14 9 2009 Nordic Water Products AB. All rights reserved.

    2Technical specification for DynaSand Filter2.2

    The information stated here is unique for every filter plant. This page is normally generated from an external file and added to this manual. If this text is seen here, this manual is not specific for a certain filter plant.

    2 Extent of Delivery

  • 10 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    2Technical specification for DynaSand Filter page 2

    The information stated here is unique for every filter plant. This page is normally generated from an external file and added to this manual. If this text is seen here, this manual is not specific for a certain filter plant.

    2 Extent of Delivery

  • DS 9.14 11 2009 Nordic Water Products AB. All rights reserved.

    2Technical specification for control system2.3

    The information stated here is unique for every filter plant. This page is normally generated from an external file and added to this manual. If this text is seen here, this manual is not specific for a certain filter plant.

    2 Extent of Delivery

  • 12 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    2Technical specification for control system page 2

    The information stated here is unique for every filter plant. This page is normally generated from an external file and added to this manual. If this text is seen here, this manual is not specific for a certain filter plant.

    2 Extenct of Delivery

  • Chapter 3Marking up the Basin

    3

  • Marking up the Basin3. The following instructions describes the installation of bottom cones and embedment parts of the DynaSand filter with 2-12 modules in one concrete basin. There are two following manuals after this one, the Installation Manual Concrete filter(s) Stage II, contains information on how to install the internals, the air-lift pumps and the control systems and others. Installation Manual Concrete filter(s) stage III, contains information about how to install the pipes.

    Control of elevation, 3.1 dimensions

    Check your drawing and do the following: Check the dimensions of the basin, 1. see chapter 10.3 for the measurements of a basin with the correct number of modules. Check that the diagonals of the basin are equal, 2. see figure 3.2.

    Check the ground plates elevation. 3. The elevation of the ground plates needs to be checked over the whole plant and it is important to keep the same elevation all-over.

    Check the over all length and width of the basin. 4. The dimension in length and width shall be checked at a height of 1700 - 2100 mm over the bottom plate. If this dimension is smaller than the indicated dimension in the drawing, see appendix, a recess in the concrete has to be done.

    1905 mm 5 mm

    Figure 3.1 Control line for elevation of bottom cones.

    Note! This is a help line to see that the bottom cones are in right level. The upper edge of the bottom cone should fit to this line.

    Note! If some area of the ground plate is outside the tolerance of 5 mm, then you have to go for this elevation in the basin. This needs to be discussed with the Nordic Water Products supervisor.

    Note! If a recess has to be done in the concrete, please contact the Nordic Water Products supervisor.

    Mark up a line on the wall, the elevation shall be 5. at +1905 mm (the floor in the manual is always considered as +0 mm, see 10.2 for calculation example) added with the tolerance you have chosen in point 3 above. This line indicates where the upper edge of the bottom cone shall be located before drilling the hole in the walls, see figure 3.1.

    In figure 6.5, there is an elevation, which is the 6. most important elevation for the proceeding of the installation. This elevation can only be checked when the whole group of the bottom cones are attached to each other. More instructions about this elevation in chapter 6.2.

    3 Marking up the Basin

    14 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    3

  • Marking up the lines on the 3.2 ground plate

    Basin with two modulesMeasure the diagonal over the basin and mark 1. out the centre point where the diagonal lines are crossing each other. Check that the centre point has the same distance to all walls. Mark out two lines in the middle of the basin. 2. The lines should be parallel with the walls of the basin and form a cross, figure 3.2.

    Mark out two new lines in each direction from 3. each centre line, parallel with the walls, figure 3.3.

    In each of this new points where the lines are 4. crossing each other, a hole for the anchor bolts shall be drilled, see figure 3.3. The supplied anchor bolt size is M16. The chemical compound is supplied by Nordic Water Products AB. The drill diameter for the M16 anchor bolt has to be carried out according to the data sheet from the supplier of the chemical compound. The depth of the hole shall be 175 mm. 5.

    Before the installation can start, a control of all basins has to be carried out. The ground plates elevation in all basins shall be in the elevation 5mm. Follow the step by step instruction in this chapter to mark out all necessary lines and check them carefully so no mistakes are made. It is very important that the elevation and dimensions are followed.

    Note! The inner dimension on each basin has to be checked out from the project layout drawing in chapter 2.

    Figure 3.2 Marking up lines on the bottom plate step 2.

    Figure 3.3 Marking up lines on the bottom plate step 3.

    =

    =

    Drill hole for anchor bolts

    Note! For exact measurements see 10.3.

    3 Marking up the Basin

    DS 9.14 15 2009 Nordic Water Products AB. All rights reserved.

    3

  • Note! A fixture where all these points are marked out can be useful to use just to mark out the drilling points from the centre point.

    Basin with four modules or moreMeasure the diagonal over the basin and mark 1. out the centre point where the diagonal lines are crossing each other. Check that the centre point has the same distance to all walls, figure 3.2.

    Mark out a line (2. A) from the crossing point in the middle of the basin. The line should be parallel with the long walls of the basin figure 3.4.

    Mark out a new line (3. B) from the crossing point, parallel to the short wall. Offset the line (4. A) that is parallel with the long wall with a new line (C) on each side. Offset the line 5. (B) with a new line (D) on each side.

    Figure 3.4 Offsetting lines on the bottom plate.

    If your basin contains more than four modules, 6. repeat point 4-5 in all directions. See 10.3 for more details.In each of this, new points where the lines are 7. crossing each other a hole for the anchor bolts shall be drilled. The anchor bolt size is M16, the size of the hole, see instruction for installation of chemical anchor for this size of bolt.

    The depth of the hole shall be 175 mm. 8.

    A

    B

    C

    D

    Note! For exact measurements for the number of modules in the current basin see 10.3.

    Drill holes for anchor bolts.

    3 Marking up the Basin

    16 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    3

  • Installation of anchor bolts3.3 It is very important that all ground plates in all basins are in the same elevation. Mount the threaded rods in the ground plate; the holes are described in section 2 and the screw set in table 3.1.

    The anchor bolt shall reach at least 60-70 mm above the ground plate, depending on the elevation of the ground plate.

    Figure 3.5 Elevation of anchor bolts.

    Note! The chemical compounds are provided by Nordic Water Products AB, follow the procedure for the chemical compound and see the data sheet from the supplier of the chemical compound.

    Note! Adjust all washers to the exact same level when all anchor bolts are installed. Use a laser tool if possible.

    3 Marking up the Basin

    Screw Set for one anchor bolt

    Qty Article Description1 M16240 A2 Threaded rod2 M6M 16 A2 Nut2 50909 8080 Washer

    Table 3.1 Screw sets for mounting the anchor bolts

    Anchor bolt M16

    + 27 mm 35 5mm

    60-70 mm

    DS 9.14 17 2009 Nordic Water Products AB. All rights reserved.

    3

  • 3 Marking up the Basin

    When the chemical compound is cured, mount a square washer 8080 and nut M16 on each treaded rod. The elevation on the upper side of the washer shall be + 27 mm. The elevation has to be adjusted from the highest elevation of the ground plate in the basin, see figure 3.5 and section 3.1.

    The free end of the anchor bolt shall be 35 mm 5 mm over the square washer. If it sticks up higher it has to be cut off after the anchor bolt is tightened inside the bottom cone, see Installation Manual Concrete filter(s) stage II for more information.Repeat the steps above for the rest of the anchor bolts.

    18 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    3

  • Chapter 4Preparation of

    the Bottom Cone(s) in Steel

    4

  • 4 wooden pieces as legs

    1 piece of cone support 1 piece of leg for cone support

    2 pieces of pegs

    A fixture is supplied to facilitate the assembling of the bottom cone. The fixture is supplied as a kit, see the items for the fixture bellow. All associated parts are packed together. To assemble the bottom cone see section 2. For instructions on how to install the bottom cone see chapter 6.

    Preparation of Bottom Cone(s) in Steel4.

    Fixture for assembling the bottom cone4.1

    8 pieces of side parts to be the worktable

    4 Preparation of Bottom Cone(s) in Steel

    Figure 4.1 Items for fixture.

    20 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Assemble the four wooden pieces for the table 2. frame and lift up the cone support. The fixture for the bottom cone is ready to assemble the bottom cone (figure 4.4)

    Screw the 8 side parts together as seen in figure 1. 4.2. Put the cone support and leg for cone support together as showed in figure 4.3.

    4 Preparation of Bottom Cone(s) in Steel

    Figure 4.2 Side parts of fixture screwed together.

    Figure 4.4 Fixture for the bottom cone put together with the cone support.

    Figure 4.3 Mounted cone support.

    2436 2319

    1869

    2352

    DS 9.14 21 2009 Nordic Water Products AB. All rights reserved.

    4

  • Attach the self adhesive 12 3 mm gasket on cone section.

    Assembling the bottom 4.2 cone

    Before the installation of the bottom cones in the basin the bottom cones have to be mounted together. The bottom cone is divided in four parts with a plate in the bottom. A gasket has to be mounted on the side of the cone section. The gasket shall be mounted on the inner side of the cone section. The cone sections are delivered on a pallet and the inner side is faced up on the pallet. Attach the self adhesive gasket on the cone section before you lift it of the pallet, see figure 4.5.

    The gasket is self-adhesive and supplied on rolls. Cut it in the right length after it is attached to the cone section.

    Figure 4.5 Botton cone section.

    4 Preparation of Bottom Cone(s) in Steel

    Qty Dimension [mm] Length [mm]4 123 220

    2 128 700Table 4.1 Dimensions and length for the gasket for bottom cones in steel.

    22 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Lift the cone section up on the fixture. Check 1. so it is placed in the right position on the table (figure 4.6).

    Figure 4.6 First section in place for mounting.

    4 Preparation of Bottom Cone(s) in Steel

    Gasket on the back side here Bottom cone section

    DS 9.14 23 2009 Nordic Water Products AB. All rights reserved.

    4

  • Mount the bracket on the inside and the lifting lug on the outside of the cone section, see figure 4.7. Only one lifting lug shall be mounted on each cone section. All necessary information concerning screws, nut, washers, brackets etc. is shown table 4.1.

    Lifting lug

    Bracket

    The lifting lug on the outside.

    The bracket on the inside.

    Mount the bracket

    Figure 4.7 Mounting the bracket and lifting lug on cone sections.

    4 Preparation of Bottom Cone(s) in Steel

    Note! No washer shall be mounted on the outside of the lifting lug.

    24 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • When two cone sections are mounted take away the supporting leg. The centre of gravity is low enough for the two cone sections to stand up by themselves.

    Figure 4.8 The first cone section assembled.

    Qty Article Description1 M6S 1040 A2 Screw (figure 4.19)

    10 RB 10,5222 A2 Washer4 M6S 1090A2 Screw (figure 4.7)

    9 M6M 10 A2 Nut

    Screw sets for one bracket

    Table 4.2 Screw sets for one bracket.

    4 Preparation of Bottom Cone(s) in Steel

    DS 9.14 25 2009 Nordic Water Products AB. All rights reserved.

    4

  • Mount the second cone section equal to the first 2. one.

    Figure 4.9 Two cone sections mounted together.

    4 Preparation of Bottom Cone(s) in Steel

    Screw sets for one cone section

    Qty Article Description44 K6S M1020 H Screw44 M6M 90 Nut44 RB 10,5222 Washer

    Table 4.3 Screw sets for one cone section.

    26 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Then mount the third cone section equal to the 3. other two.

    Figure 4.10 Round head screw on the inside of the cone section.

    Figure 4.11 Three cone sections mounted together.

    Observe that the round head screw shall be mounted from the inside.

    4 Preparation of Bottom Cone(s) in Steel

    DS 9.14 27 2009 Nordic Water Products AB. All rights reserved.

    4

  • Mount the fourth cone section equal to the 4. other three.

    Note! Before you attach the fourth cone to the first cone, make sure that the fourth cone is beneath the first cone.

    Figure 4.12 All four cone sections mounted together.

    4 Preparation of Bottom Cone(s) in Steel

    28 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Prepare the bottom plate with the sealing as 5. shown below. When the bottom plate is prepared, turn over the bottom cone to one side. Drill holes for the bottom plate in the cone parts. Assemble the bottom plate with screw joints, use the same cup headed M1035 screws and M10 nuts and washers.

    8 mm

    Figure 4.13 Attach the self adhesive 128mm gasket on the bottom plate.

    Figure 4.14 Bottom plate seen from the side with 8 mm of gasket.

    Figure 4.15 Bottom plate attached to the bottom cone.

    4 Preparation of Bottom Cone(s) in Steel

    DS 9.14 29 2009 Nordic Water Products AB. All rights reserved.

    4

  • Figure 4.16 Assembled bottom cone.

    From the inside of the bottom cone, cut off the 6. extra sealing as shown in picture 4.17 - 4.18. Note the cup head on the inside of the cone.

    4 Preparation of Bottom Cone(s) in Steel

    Figure 4.18 Inside of bottom cone after the extra sealing has been cut off.

    Figure 4.17 Inside the bottom cone, before the extra sealing has been cut off.

    30 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Prepare the bottom cone for 4.3 installation in the basin

    The bottom cone has to be secured to keep the shape during casting. The cone is not constructed to take up the force from the casting, therefore the sand distributor is used as a fixture during the casting of the concrete. The casting has to be done in at least three steps, preferable in four steps, see chapter 6.3.

    Mount the sand distributor, see figure 4.18, between the four brackets. There are four holes, one on each bracket, where the M1040 bolts will fit. Secure with a nut and washer from the outside. The construction can be lifted using the sand distributor. Otherwise there are three holes on four sides to arrange a lifting device.

    Figure 4.19 Mounting the sand distributor.

    Hole in each bracket to lift the bottom cone

    Mount the sand distributor to the bracket with the supplied M1040 bolts

    Note! The bottom cone can be lifted as shown in chapter 6.

    4 Preparation of Bottom Cone(s) in Steel

    DS 9.14 31 2009 Nordic Water Products AB. All rights reserved.

    4

  • 4 Preparation of Bottom Cone(s) in Steel

    32 DS 9.14 2009 Nordic Water Products AB. All rights reserved.

    4

  • Chapter 5Preparation of

    Bottom Cone(s) in FRP

    5

  • The FRP bottom cone is assembled on a flat, hard surface. There is no need for a fixture to facilitate the assembling of the bottom cone as for the steel bottom cone.

    Preparations of Bottom Cone(s) in FRP5.

    General5.1

    5 Preparations of Bottom Cone(s) in FRP

    Assembling the bottom cone5.2 Before the bottom cones are installed in the basin, the bottom cone have to be mounted together. The bottom cone is divided in four parts with a plate in the bottom. Start by preparing the cone sections with self adhesive gasket, 203 mm (see figure 5.1). The gasket is delivered in rolls and cut in the right lengths.

    Figure 5.1 One of four cone parts prepared with self adhesive 203 mm gasket.

    Self adhesive gasket attached to the cone section.

    Note! The self adhesive gasket shall only be placed on one side of the bottom cone part.

    Gasket information

    Qty Dimension [mm] Length [mm]4 203 220

    2 203 1200Table 5.1 Dimensions and length for the gaskets.

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  • Figure 5.3 Bottom plate seen from the side with 2 layers of gasket.

    Figure 5.2 Attach the self adhesive 203mm gasket in 2 layers on the bottom plate.

    2 layers of gasket

    3 mm

    Prepare the bottom plate with 2 layers of gasket (20 3 mm). It is important that the gasket fits in the eight corners. Cut the gasket carefully and mount it as shown in figure 5.2 - 5.3.

    5 Preparations of Bottom Cone(s) in FRP

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  • Mount two of the cone parts together on a flat, 1. hard surface. Handle the FRP parts with care on the surface. Use the cup headed M1030 screws and M10 nuts and washers, see table 4.1. The washer shall only be used on the nut side.

    Figure 5.4 Two parts of the bottom cone mounted together.

    Figure 5.5 Cone parts connected with screw joints.

    5 Preparations of Bottom Cone(s) in FRP

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  • Mount cone parts three and four together with 2. cone parts one and two, in the same way. When the bottom cone is mounted together, 3. turn it over and prepare the bottom plate. Assemble the bottom plate with screw joints, use cup headed M10 30 screws and M10 nuts and washers.

    Figure 5.6 Assembled bottom cone.

    Screw set for one cone section

    Qty Article Description48 M6S 1030 A2 Screw96 RB 10,5222 A2 Washer48 M6M 10 A2 Nut

    Tabell 5.1 Screw sets for one bracket.

    5 Preparations of Bottom Cone(s) in FRP

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  • Cut off the extra sealing from the inside of the 4. bottom cone, figure 5.8 - 5.9.

    Figure 5.7 Assembled bottom cone turned over.

    Figure 5.9 Inside of bottom cone after extra sealing has been cut off.

    Figure 5.8 Inside the bottom cone, before the extra sealing has been cut off.

    5 Preparations of Bottom Cone(s) in FRP

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  • Preparing the bottom cone 5.3 for installation in the basin

    The bottom cone has to be secured to keep the shape during casting. The cone is not constructed to take up the force from the casting, therefore the sand distributor is used as a fixture during the casting of the concrete underneath. The casting has to be done in at least three steps, preferable in four steps, chapter 6.3.

    Mount the sand distributor, (see figure 5.10 for sand distributor in FRP amd figure 5.11 for sand distributor in stainless steel) between the four brackets. There are four holes, one on each bracket, where the hook bolts will fit. Secure with M10 nut and washer from the outside. The construction can be lifted using the sand distributor, see figure 5.12.

    Bottom coneSand distributor

    Bracket

    Nut M10 Washer M10

    Hook bolt fixed to sand distributor at the workshop

    Figure 5.10 Mounting the sand distributor (FRP) in the bottom cone.

    5 Preparations of Bottom Cone(s) in FRP

    Note! The sand distributor material can vary, see figure 5.10 and 5.11.

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  • Figure 5.12 Example of how to lift the bottom cone.

    Bottom cone

    Sand distributorBracket

    Nut M10 Washer M10

    Figure 5.11 Mounting the sand distributor (stainless steel) in the bottom cone.

    5 Preparations of Bottom Cone(s) in FRP

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  • Chapter 6Installation of Bottom Cone

    6

  • Installation of Bottom Cone6.

    General6.1

    6 Installation of Bottom Cone

    To lift the bottom cone into the basin, lifting equipment must be attached to the bottom cone. The lifting equipment can be strapped around the sand distributor, see figure 6.1.

    Figure 6.1 Lifting the bottom cone into the basin.

    For steel bottom cones a shackle can be attached to the brackets attached to the sand distributor, see figure 4.18.

    No personnel shall be in the basin during the lift of the bottom cone. General and local safety regulations shall be observed when work is performed in the basin.

    Example of temporary support

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  • Mounting the bottom cone6.2

    InstallationLift one bottom cone into the basin and place it over the anchor bolt. Start in one of the corners since a single cone is unsteady and needs temporarily support to prevent it from falling (figure 6.1). Check so that the upper edge of the bottom cone is approximately at the same level as the elevation line on the wall, figure 3.1.

    To avoid water from the concrete to leak into the bottom cone use some silicone compound on the washer before you lift in the cone.

    Figure 6.3 Elevation control when the first bottom cone is mounted.

    6 Installation of Bottom Cone

    Figure 6.2 Bottom cone mounted on the anchor bolt.

    +0

    +27

    Washer 8080

    Washer 8080

    +1905 5

    +2100 5

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  • Mount a 8080 washer and a nut M16 on the anchor bolt inside in the bottom cone and tighten slightly.

    Figure 6.4 Two cones screwed together.

    When the first cone is in place, proceed in the same way with the second cone and so on. Put the cones together with the screw joints in the middle, see figure 6.4.

    Screw set for assembling two bottom cones

    Qty Article Description4 M6S 1030 A2 Screw8 RB 10,5222 A2 Washer4 M6M 10 A2 Nut

    Table 6.1 Screw set for assembling two cones.

    6 Installation of Bottom Cone

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  • Figure 6.5 Elevation control for top surface of all sand distributors.

    Note! Check the elevation for the top surface of all sand distributors. The elevation must be with in 5 mm. See figure 6.5.

    Expansion bolt M1090, washer M10 Nut M10

    Screw M1030, washer M10, nut M10

    + 0

    + 1905 5

    When the two cones have been screwed together with the M1030, a check must be done; the top of the sand distributor must be exactly horisontal (see figure 6.5). This elevation is the most important elevation. The closer the installation is carried out to the elevation of +0 mm, the more equal the flow will be through the filter groups. So when the elevation for the sand cones in one filter group is ensured, the purpose of the rest of the installation is to reach the same elevation.

    6 Installation of Bottom Cone

    Horizontal surface +2100 5

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  • Lift in the other cones and mount them in the same way as bottom cone number one. When all cones are mounted check all elevations and gaps carefully before tightening all screw joints.

    Figure 6.6 Two bottom cones are installed in the basin.

    6 Installation of Bottom Cone

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  • If everything has been carried out in accordance to this instruction, tolerances and elevations, indicated in the drawings, then there should be a gap between the outer side of the bottom cones and the wall. Depending on the tolerance the gap can vary in size. Use a wooden shim or equal to keep this gap. Drill the holes into the wall, through the holes in the bottom cones.

    Figure 6.7 Drill holes in the concrete wall through the existing hole in the bottom cone and mount the expansion bolts.

    Figure 6.8 Wooden shims between bottom cone and basin wall.

    Wooden shim

    6 Installation of Bottom Cone

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  • Figure 6.9 Wooden shims between bottom cone and basin wall.

    Aggressive waterAggressive water is for example salt water with high contents of chloride or some kinds of fabrication water. Please contact the process department at Nordic Water Products AB for more information about aggressive water. The threaded rod size is M10. See installation instructions for chemical anchor for this size of threaded rods.The chemical compounds are provided by Nordic Water Products AB. Follow the procedure for the chemical compound and see the data sheet from the supplier.Use the threaded rod M10, length ~100mm, washer M10, nut M10, see packing list from Nordic Water Products AB.When the chemical compound is cured mount a washer M10, nut M10 on each threaded rod and check the wooden shims so it fits the gap between the bottom cone and the wall.Tighten the nuts and check that all nuts and screws are tightened.

    StandardThe expansion bolt size is M10, the size of the drilled hole is 10 mm.

    The depth of the hole shall be 70-100 mm, depending of the basin tolerance. Drill all holes into the wall and mount the expansion bolts. Check that all anchor bolts and screws are tightened. This distance has to stay until the casting underneath is done. In figure 6.9 an example of the design for the wooden shim between the wall and the bottom cone is shown.

    6 Installation of Bottom Cone

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  • Concrete casting of the 6.3 bottom cones

    Before starting with the four steps of concrete casting a small undercasting has to be done under each cone. Cast by hand as illustrated in figure 6.10.

    Do not vibrate the concrete! This might damage or buckle the bottom cones.

    Figure 6.10 Undercasting of cones.

    Note! The concrete shall cure between each step of concrete casting.

    6 Installation of Bottom Cone

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  • First stepCast around 430 mm concrete in each step. Let the concrete cure before the next step is casted.

    Figure 6.11 First step in concrete casting.

    Second step After the concrete has cured, continue with the second step of concrete casting.

    Figure 6.12 Second step in concrete casting.

    Note! Fill up the cone with water at least to the same level as an imaginary line of the next step of casting. This will hold back the force from the concrete during the casting.

    6 Installation of Bottom Cone

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  • 30

    Third stepContinue the concrete casting when the concrete from the second step has cured.

    Fourth stepThe last step of concrete casting shall not be filled up to the upper edge of the bottom cone. Cast the concrete no higher than 30 mm from the top, figure 6.15.

    Figure 6.13 Third step in concrete casting. Figure 6.14 Fourth step of concrete casting.

    Figure 6.15 Maximum concrete casting in step four.

    6 Installation of Bottom Cone

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  • 6 Installation of Bottom Cone

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  • Chapter 7Mounting the In-basin

    Concrete Partitioners

    7

  • General7.1 The function of all concrete partitioners is to guarantee movement in the filter media. The in basin concrete partitioners are different for DS 5000 concrete and DS 6000 concrete versions. The difference depends on the total volume of the filter media, where DS 5000 needs a higher in basin paratitioner than DS 6000.

    The in basin partitioner for DS 5000 is called pylons while the in basin partitioner for DS 6000 is called pyramids. Chapter 2.1 contains information about your system.

    Note! The in basin concrete partinioners can be prefabricated and lifted into place or casted directly in the basin.

    Mounting the In-Basin Concrete Partitioners7.

    7 Mounting the In-basin Concrete Partitioner

    Figure 7.1 Pylons in basin.

    Casting concrete 7.2 partitioners

    The concrete partioners can be prefabricated or casted directly in the basin. If the prefabricated method is chosen, the concrete partioners are casted in a mould, built according to Nordic Water Products dimensions (see section 3-4). After the concrete has cured the partitioners are lifted into place and fastened with wet concrete and/or bolts. More instructions on installation of concrete partitioners in section 5.

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  • Figure 7.2 Example of full pyramid.

    Pyramids7.3 Pyramids are casted in different shapes in concrete. The full pyramids are used in the basin between the bottom cones, the half pyramids are used along the sides of the basin and the quarters are used in the corners of the basin.

    DimensionsThe dimensions and form of the different prefabricated pyramids are shown in figures 7.2-7.7.

    The full pyramidThe prefabricated full pyramid (figure 7.2) is used in the basin, between the bottom cones. The dimensions to build the mould is shown in figure 7.3.

    7 Mounting the In-basin Concrete Partitioner

    Figure 7.3 Dimensions of the prefabricated full pyramid.

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  • The half pyramidThe prefabricated half pyramid (figure 7.4) is used along the sides of the basin and the dimensions to build the mould is shown in figure 7.5.

    Figure 7.4 Example of half pyramid .

    Figure 7.5 Dimensions for half pyramid.

    7 Mounting the In-basin Concrete Partitioner

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  • The quarter pyramidThe quarter pyramid (figure 7.6) is used in the corners of the basin and the dimensions to build the mould is shown in figure 7.7.

    Figure 7.6 Example of quarter pyramid.

    Figure 7.7 Dimensions for quarter pyramid.

    7 Mounting the In-basin Concrete Partitioner

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  • Pylons7.4

    Pylons are prefabricated in different sizes. The full pylons are used in the basin between the bottom cones, the half pylons are used along the sides of the basin and the quarter pylons are used in the corners of the basin.The pylons differ from the pyramids since they are higher than the pyramids.

    Dimensions of the pylonsThe dimension and form of the different prefabricated pylons are shown in figure 7.10-7.15. The height of the pylons depends on the filter model. Heights are shown in table 7.1.

    Figure 7.9 Prefabricated full pylon.

    Figure 7.8 Prefabricated pylons installed in basin.

    7 Mounting the In-basin Concrete Partitioner

    Bodyheight [H] for pylons

    Model Height [mm]N 320E 820D 1320

    DD 1820Table 7.1 Heights for pylons. H in dimension drawings.

    Note! The pylon is fastened in 20-30 mm of concrete, see section 5.

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  • HThe full pylonThe prefabricated full pylon (figure 7.10) is used in the basin, between the bottom cones. The dimensions to build the mould is shown in figure 7.11.

    Figure 7.10 Full pylon.

    Figure 7.11 Dimensions for full pylons.

    7 Mounting the In-basin Concrete Partitioner

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  • HThe half pylon

    The prefabricated half pylon (figure 7.12) is used along the sides of the basin and the dimensions to build the mould is shown in figure 7.13.

    Figure 7.12 Half pylon.

    Figure 7.13 Dimensions of half pylons.

    7 Mounting the In-basin Concrete Partitioner

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  • HThe quarter pylon (figure 7.14) is used in the corners of the basin and the dimensions to build the mould is shown in figure 7.15.

    The quarter pylon

    Figure 7.14 Quarter pylon.

    Figure 7.15 dimensions for quarter pylons.

    7 Mounting the In-basin Concrete Partitioner

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  • Installing the concrete partitioners7.5

    Figure 7.16 Square gap to be filled with wet concrete.

    Fill this square area with wet concrete

    Prefabricated full concrete partitionerFill up the square gap shown in figure 7.16 with 20 mm of wet concrete. Use this concrete as glue when fastening the prefabricated concrete partitioner.

    7 Mounting the In-basin Concrete Partitioner

    Note! Pyramids and pylons might need to be secured with bolts or similar, consult the concrete designer.

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  • Put the prefabricated quarter partitioner in the wet concrete between the walls and the edges of the bottom cone. There will be some spaces between the bottom cone, walls and the partitioner. Fill these spaces with fine concrete (light area in figure 7.17).

    Figure 7.17 Prefabricated quarter pyramid lifted in place. The spaces (light area) is filled with fine concrete.

    Fill the light spaces with wet fine concrete

    7 Mounting the In-basin Concrete Partitioner

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  • Prefabricated half partitioners Fill up the triangular gap in figure 7.18 with 20mm with wet concrete. Use this concrete as glue when fastening the prefabricated partitioner. See figure 7.19-7.20.

    Figure 7.18 Triangular gap to be filled with concrete for installation of half pyramids.

    Fill this triangular area with wet concrete

    7 Mounting the In-basin Concrete Partitioner

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  • Put the prefabricated half partitioner in the wet concrete between the wall and the edges of the bottom cone. There will be some spaces between the bottom cone, wall and the partitioner. Fill these spaces with fine concrete (light area in figure 7.19)

    Figure 7.20 Prefabricated half pyramid lifted into place. The light area shows where fine concrete has been used as glue.

    Fill the light area with wet concrete (~30 mm)

    Figure 7.19 The spaces between the wall, the bottom cone and the half partitioner is filled with fine concrete.

    The light spaces has been filled with fine concrete.

    7 Mounting the In-basin Concrete Partitioner

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  • Prefabricated quarter partitionersFill up the triangular gap in figure 7.21 with 20mm of wet concrete. Use this concrete as glue when fastening the prefabricated quarter partitioner.

    Fill this triangular area with wet concrete

    Figure 7.21 Triangular gap to be filled with wet concrete to use as glue.

    7 Mounting the In-basin Concrete Partitioner

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  • Put the prefabricated quarter partitioner in the wet concrete between the edges of the bottom cone and the wall. There will be some spaces between the bottom cone and the quarter partitioner. Fill these spaces (light area) with fine concrete, figure 7.22 - 7.23.

    Figure 7.22 The spaces between wall and bottom cone (light area) is filled with fine concrete.

    Fill the light area with wet fine concrete (~30 mm) after the quarter pyramid is lifted in place

    Fill the light area with wet concrete

    Figure 7.23 Prefabricated quarter pyramid lifted in place. The light area shows fine concrete.

    7 Mounting the In-basin Concrete Partitioner

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  • All partitioners in placeAn example of a basin with four modules is shown in figure 7.24 after installation of the in basin partitionerns.

    Figure 7.24 Example of basin with four modules and installed pyramids.

    7 Mounting the In-basin Concrete Partitioner

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  • Chapter 8Installation of

    Embedded Pipes

    8

  • Installing the Embedded 8.2 pipes

    There are two different methods when installing embedded pipes. Method 1 should only be used if an exact location can be guaranteed. Nordic Water Products AB recommend that method 2 is used.

    General8.1 The embedded pipes shall be installed according to drawings see chapter 2, see also Installation Manual concrete filter(s) stage II, for internals, and Installation Manual Concrete filter(s) stage III, for pipes.Chapter 2.1 contains information about your system.

    Installation of Embedded Pipes8.

    8 Installation of Embedded Pipes

    Figure 8.1 Before casting.

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  • 8 Installation of Embedded Pipes

    Note! This method can only be used if an exact location of the pipes can be guaranteed.

    Method 1 for installing 8.3 embedded pipes

    Mount the embedded parts to the right location 1. before the cast of the walls, see drawings. Cast the wall. 2.

    Method 2 for installing 8.4 embedded pipes

    Use block outs (see figure 8.2)

    Lift the embedment pipe and stick it into the 1. block out in the wall.Secure it temporarily.2. Install all pipes.3. Cast the block out.4.

    Figure 8.2 Example of casted block outs

    Casted block out

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  • 8 Installation of Embedded Pipes

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  • Chapter 9Troubleshooting

    9

  • Troubleshooting9.

    9 Troubleshooting

    Problems during installation stage I9.1

    Error Steps to be taken

    Is the bottom cones askew? - Check that the anchor bolts have been drilled in the exact position according to appendix figure in chapter 8.

    - If the anchor bolts is misplaced, they have to be drilled in the right place.

    Is the elevation between the sand distributors more than + 5mm in the basin?

    - Check the level of the washer on the anchor bolt. All washers shall have an elevation of + 27 mm over the bottom plate.

    Is the bottom cone cracking during concrete casting?

    - Check that the bottom cone is filled with water up to the level of the concrete casting. - Have the concrete been vibrated? This can damage the bottom cone. - The concrete casting must be done with an undercasting and in at least 4 steps.

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  • 9 Troubleshooting

    Service Offices9.2 Sweden

    Nordic Water Products ABDynaSand- and Service department Box 1004 149 25 Nynshamn

    Tel: +46 8 524 409 00 Fax: +46 8 520 173 25

    E-mail: [email protected]

    Germany

    Nordic Water GmbHHansemannstrasse 41 414 68 Neuss

    Tel: +49 2131 30 06 00 Fax: +49 2131 3106 10

    E-mail: [email protected]

    The Netherlands

    Nordic Water Benelux BVVan Heuven Goedhartlaan 121 1181 KK Amstelveen

    Tel: +31 20 503 26 91 Fax: +31 20 640 04 69

    E-mail: [email protected]

    For information about your local service office, please contact the Service department in Sweden.

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  • 9 Troubleshooting

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  • Chapter 10Appendix

    10

  • 10 Appendix

    Appendix10.

    Check list for installation of 10.1 concrete DynaSand filter

    Check dimensions, diagonals and elevation of 1. the basin (See 3.1-3.2 and 10.3).

    Check that the holes for the anchor bolts are 2. drilled in the exact right place. After the bottom cones are mounted, check the 3. elevation of the sand distributors, max elevation is 5 mm, see 6.2.Check that concrete casting is done in 4 steps 4. without vibrating the concrete.

    +0

    +27

    Washer 80x80

    +1905 5

    Quick check of 10.2 elevation levels

    In figure 10.1 are the most important elevation measures shown. If the installation manual has been followed correctly, the measures of the current project corresponds with the measures in figure 9.1. The measures in the manual is given with the basin floor as +0. mm For exact measurements for installation see example calculation on the next page.

    Figure 10.1 Elevation levels for installation.

    +0 -20

    +2100 5

    +1550 5

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  • 10 Appendix

    Figure 10.2 Example of layout drawing with actual measures for plant.

    Example:Figure 10.2 is an example of the layout drawing for the project. The measure +0 (in figure 10.1) corresponds to the measure +5000 in figure 10.2. This measure is the floor of the basin. Check the layout drawing for the right measure of the basin floor in the current project. To calculate the important measurements, use the value for the basin floor of the provided layout drawing instead of the +0 in the manual. Add the measures given in the manual to the value of the layout drawing to calculate the measurements for the current project.

    1

    Calculations(+5000) + (+27) = +5027 mm 1.

    (+5000) + (+1550) = +6550 mm2. (+5000) + (+1905) = +6905 mm3.

    (+5000) + (+2100) = +7100 mm 4.

    Note! This is an example, use the actual measures from the layout drawing to calculate the right measures for the current project. Check the elevations compliance to calculations during the project according to the manual.

    23

    4

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  • Control of marking up 10.3 the basin

    Basin with two modulesCheck that the offset lines are according to 1. figure 10.3

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Parallel linesParallel lines

    Drilling points (2 pcs)

    Centre point

    Figure 10.3 Basin with 2 modules.

    10 Appendix

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  • Basin with four modulesCheck that the offset lines are according to 1. figure 10.4

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Figure 10.4 Offset for basin with 4 modules.

    Parallel linesParallel lines

    Drilling points (4 pcs)

    Centre point

    10 Appendix

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  • Basin with 6 modulesCheck that the offset lines are according to 1. figure 10.5

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Figure 10.5 Offset lines for basin with 6 modules.

    Parallel lines

    Parallel lines

    Drilling points (6 pcs)

    Centre point

    10 Appendix

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  • Basin with 8 modulesCheck that the offset lines are according to 1. figure 10.6

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Figure 10.6 Offset lines for basin with 8 modules.

    Parallel lines

    Parallel lines

    Drilling points (8 pcs)

    Centre point

    10 Appendix

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  • Basin with 10 modulesCheck that the offset lines are according to 1. figure 10.7

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Figure 10.7 Offset lines for basin with 10 modules.

    Parallel lines

    Parallel lines

    Drilling points (10 pcs)

    Centre point

    Parallel lines

    10 Appendix

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  • Basin with 12 modulesCheck that the offset lines are according to 1. figure 10.8

    Check that the holes for the anchor bolts are 2. drilled at the exact right place.

    Figure 10.8 Offset lines for basin with 12 modules.

    Parallel lines

    Parallel lines

    Drilling points (12 pcs)

    Centre point

    Parallel lines

    10 Appendix

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  • 1. 1.1 1.2

    2. 2.1 2.2 DynaSand2.3

    3. 3.1 , 3.2 3.3

    4. 4.1 4.2 4.3

    7. 5.1 5.2 5.3

    9. 6.1 6.2 6.3

    7. 7.1 7.2 7.37.47.5

    8. 8.1 8.2 8.3 1 8.4 2

    9. 9.1, 9.2

    10.10.1 DynaSand 10.2 10.3