Tube Diffuser

Assembly, Operating and Maintenance Instructions

Jaeger Group of Companies

Jäger Umwelt-Technik GmbH & Co. KG GummiJaeger LLC. Jaeger Rubber and Plastics (Shenzhen) Ltd.
Kreisstrasse 24 c 14300 I-25 Frontage Rd. 1/F, No. A13 Factory Building
30629 Hannover, Germany Longmont, CO 80504, USA Silicon Valley – Automobile Industry Park
Phone: (+49)511 898668-0 Phone: +1 970 535-0554 Guanlan, Baoan, Shenzhen,
Fax: (+49)511 898668-99 Fax: +1 970 535-0945 China 518110
www.jaeger-envirotech.com www.gummijaeger.com Phone: +86 755 29832412
[email protected] [email protected] Fax: +86 755 29832413
www.jaeger-shenzhen.cn
[email protected]
 Specifications

1 AERATION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 INCOMING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 STORAGE OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.1 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.2 DIFFUSER ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.3 INSTALLATION (type 63/0 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.1 START-UP INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.2 REGULAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.3 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7.4 MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7.4.1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7.4.2 MECHANICAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7.4.3 CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8 REPLACEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8.1 REPLACING MEMBRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8.2 REPLACING TUBE DIFFUSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9 RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 DISCLAIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

11 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
 Specifications

1. Aeration Systems
This manual describes in detail the installation and operating of tube diffuser JetFlex TD 63/0 with
perforation lenghts of 500, 750 and 1000 mm, respectively.

2. General
Jäger Umwelt-Technik GmbH & Co. KG (JUT) supplies diffuser for diffused air aeration in residential and
industrial waste water treatment plants.

The diffusers deliver fine bubble aeration suitable for the efficient treatment of wastewater treat-
ment plants using the activated sludge process. Specially formulated EPDM compounds with high and
durable elasticity allow a long-term intermittent operation needed to apply the de-nitrification
process.
The treatment of industrial wastewater (typically a share of more than 10% in residential wastewater
is considered to be industrial wastewater) may require the use of different materials like Silicone,
Nitrile, Viton® or PUR. Contact JUT for details.

JUT controls every step from compounding to final assembly and documents the conformance of the
diffusers to your requirements. All diffusers are factory-assembled and ready to install. Please treat
diffusers carefully during transport, storage and assembly.

Our General Conditions of Sale apply to all shipments; the actual issue can be downloaded from our
website at any time. www.jaeger-envirotech.com

3. Shipment
We ship diffusers in cardboard boxes. See individual data sheets for packaging details.

4. Incoming Inspection
Upon arrival check packages, equipment and products for structural damage during shipments, par-
ticularly the rubber membranes and stainless steel clamps. Any damage must be reported to JUT and/
or shipping agent within 5 working days from delivery. JUT reserves the right to inspect damaged
shipments. Warranty applies to products in their original and intact packing only!

5. Storage of Equipment
• Store equipment and diffusers as well as all accessories in their original packaging in a dry
and aerated room according to DIN 7716 or ISO 2230.
• Prevent products from frost, excessive heat, direct sunlight, UV emitting lamps, dust, mineral oil
and hydrocarbons.
• Do not store near electrical motors, especially blowers.
• Avoid work that may damage the diffusers or their packaging.
• Do not store outdoors! Storage time until installation/start up operation should not exceed one
year. Consult JUT for precautions otherwise.
• On the construction site all parts must remain in their original packaging and protected from
rain, moisture etc. Open crates exposed to direct sunlight must be covered with tarpaulin to
protect against UV-radiation.
• Do not use packaging material containing plasticizers.
 Specifications

6. Assembly
6.1 Preparations

• Prior to assembly of the aeration system remove all debris (stones, metal scrap, wooden pieces
etc.) from the aeration tank.
• Stainless steel square tubes (80 x 80 mm or 100 x 100 mm) are recommended as laterals for
JetFlex TD 63/0 diffusers with SS-connectors.
• Standard round lateral tubing require the use of a special clamp. See TD 65/2 data sheet.
• All laterals must be levelled within ± 6.35 mm (± 1/4”) for proper function of diffusers.
• Air outlet holes in lateral for each diffuser must be predrilled and adjusted in accordance to the
individual data sheets. Hole diameter ± 0.1 mm, horizontal alignment of holes within ± 0.5 mm.
• Do not drill holes within welded area of tubing.
• Deburr all holes.
• Remove all corroded spots etc.
• Remove all internal debris from within the laterals with a water flush through the laterals.

6.2 Diffuser Alignment

• Align diffusers longitudinal to the water flow.

• Keep enough distance to water accelerators (propellers etc.). Water velocity at diffusers must not
exceed 0.5 m/s.
• If water speed is perpendicular to the diffusers use additional fixtures or reduce diffusers length
to avoid breaking of the plastic tubes. Contact JUT for details.

6.3 Installation (type 63/0 only)

This type of diffuser is installed in pairs. To ease tightening the gaskets may be wetted with a
lubricant. Recommended lubricants are commercial-grade water-based soap (5 - 10%) or regu-
lar household detergents (0.01 - 0.1%). Do not use lubricants containing mineral oils or other
hydrocarbons.

• Screw the connector into one diffuser and slip one gasket over the connector.
• Slide the free end of the connector through both holes of the lateral an put on the second
gasket.
• Thread the second diffuser onto the connector and tighten both diffusers just lightly by hand.
• Tighten both units an additional 1/2 to 3/4 turn with two fork wrenches. Across-flats measure is
55 mm.
• Do not twist the rubber membrane of the diffuser.
• Both gaskets should be equally deformed.
• The non-perforated strips of the diffusers are now on top and bottom.
 Specifications

7 Operating Instructions

7.1 Start-Up Instructions

Prior to start-up clean the aeration tank from debris like stones, wooden pieces, metal parts etc.
Keep the time between assembly and filling of the basin as short as possible. Ohterwise take the
following steps:

• Do not perform any work near the diffuser or above the aeration tank, which may damage
diffusers; e.g. painting, welding, concrete sealing etc.
• Safeguard diffusers from falling parts.
• Fill tank with clean water approximately 20 cm above diffusers. Start blowers for 5 - 10
minutes and check for obvious leaks. Have blowers stopped and immediately check again for smaller and
hidden leaks when airflow seizes. Tiny leaks may be detected now with lower turbulences.
• Start wastewater treatment now or raise water level to 1 m with clean water.
• Operate blowers for 10 minutes at medium speed at least once a day.
• Raise water level even more if temperatures drop below freezing. (~20 cm additional water for
each degree Celsius below zero.)
• Prior to SOTE testing allow diffusers to run at maximum design airflow for one week (minimum 3
days).

7.2 Regular Operation

During regular operation adjust airflow of diffusers to maintain the required oxygen level in the
aeration tank. Keep airflow within recommended range of diffusers (see data sheets).

Too high an airflow reduces efficiency and may eventually damage the diffuser membrane
irreversibly. Very low airflow rates may cause uneven oxygen supply and excessive fouling of the
membrane surface. Water temperature should range from 5 °C to 35 °C; air temperature at the diffuser
should not exceed 60 °C. Consult JUT in case either temperature is higher.

Air from blowers must not contain oil, dust, or solvents. Use dust filters according to DIN EN 779 (>80%,
better >90% dust removal, class G3 or G4, respectively.) Air going into the blowers must correspond
to local regulations (see e.g. TA-Luft for Germany).

Diffuser headloss should be monitored continuously. An increase of more than 20 mbar/year may indi-
cate a clogging problem caused by deposits of carbonates, iron-salts, or biological growth. See section
7.4 for details of cleaning. Inspect diffusers visually on a regular basis at least once a year.
 Specifications

7.3 Trouble Shooting

JetFlex Diffusers need very little maintenance even for long-term operation due to their
high-performance materials. JUT recommends regular inspection intervals every 12 to 18 months in
order to monitor fouling processes. Check pressure loss permanently with accurate pressure gauges,
an increase of more than 20 mbar per year may indicate fouling or other problems.

The most common problems and their recommended corrections are:

1. Indication: Large volume of air in localized area

Possible cause: Leakage in lateral piping
Procedure: Drain basin to access area in question, maintain medium air flow, check
connectors and pipes for evidence of breakage, repair or exchange
Possible cause: Diffuser membrane is damaged or missing
Procedure: Drain basin to access area in question, maintain medium air flow, inspect
visually diffuser, exchange membrane or complete diffuser

2. Indication: Non uniform bubble pattern

Possible cause: Insufficient blower capacity
Procedure: Confirm blower operations, switch on additional blowers
Possible cause: Check valve of drop lines closed or not open enough
Procedure: Inspect position of check valve
Possible cause: Incomplete air distribution to diffusers
Procedure: Drain basin to access area in question, check diffuser horizontal levelling,
level within tolerance of ± 0,6 cm / ± 1/4”, inspect piping and joints for inter-
nal clogging from debris, air purge or water flush cleaning
Possible cause: Deposits on diffuser membrane
Procedure: Inspect diffuser membranes for deposits and encrustation, clean or exchange
membrane or exchange diffuser

3. Indication: Decreasing of dissolved oxygen level, increase of system pressure drop

Possible cause: Deposits on diffuser membrane
Procedure: Inspect diffuser membranes for deposits and encrustation, clean or exchange
membrane or exchange diffuser

4. Indication: Non uniform dissolved oxygen profile throughout basin

Possible cause: Insufficient air volume
Procedure: Confirm blower operations, switch on additional blowers, check equipment
and operation conditions, see 1-3

Depending on type of waste, individual constructions and operation conditions other causes can lead
to disturbances. If necessary contact the contractor or engineering office.
 Specifications

7.4 Maintenance and Cleaning

7.4.1 Maintenance

Check aeration continuously during regular operation for non-uniform bubble pattern and higher than
expected headloss. Depending on the type of wastewater, treatment process, and operating conditions
fouling of membranes may occur, thus reducing oxygen transfer. Remove deposits from membrane
regularly, at least once a year. Sludge must not dry on the surface of the membrane, once hardened
the sludge sticks to the membrane and will clog diffusers permanently.

7.4.2 Mechanical Cleaning

Deposits on membranes can be removed just with the use of a good household scrubber, brush
gently and flush generously with a water hose. If necessary use a pressure-washer1 instead, but keep
a minimum distance of about 50 cm to the membrane and set the nozzle to a broad spray and not to
a sharp jet.
Pressure washer are recommended to remove fouling from aluminium- and/or iron-salts used for
precipitation of phosphor from the wastewater. The chemicals themselves do not attack the surface of
the membrane but may sometimes cause additional fouling.

7.4.3 Chemical Cleaning2

Certain deposits (CaCO3) can be removed during regular operation – without stopping the treatment
process – by adding formic acid (HCOOH) into the air-stream. Depending on the degree of fouling spray
10 cm³ of HCOOH (50% to 85% concentration) into each m³N of air (at normal conditions) for about 30
to 60 minutes. Set airflow to maximum design airflow for diffusers used; see individual data sheets
for details. Keep airflow high for another two hours in order to remove any condensed3 HCOOH from
the laterals and diffusers.
The exact amount of acid and details of the cleaning process must be determined beforehand by
appropriate tests.

8 Replacements

8.1 Replacing Membrane

Either the membrane only or the entire diffusers should be replaced whenever necessary. Exchange of
membrane typically takes more time, so usually installing new diffuses makes economic sense.

• Remove sludge from diffusers with pressure-washer1.

• Grab ear of clamps with a pair of nippers and twist, turn, and bend back ear until clamp opens.
• Remove both clamps and pull off sleeve. If sleeve sticks to the plastic tube, cut-off sleeve with a
sharp knife4. Do not over-bend the tube, maximum bend 6° - 8°, i.e. about 10 cm at the end of
a 1 m diffuser tube.
• Clean support tube with pressure washer.

1)
Follow safety guidelines of manufacturer of pressure-washer.
2)
Formic acid is dangerous and can cause severe injuries and death. Professional equipment and specially trained
personel required. Follow all safety instructions and MSDS recommondations with the use of formic acid.
3)
HCOOH has a vapour point of 106°C, so even a fine mist will not vaporize entirely. It is therefore advised to remove
most of the condensed water in laterals before starting the acid-cleaning process.
4)
Wear protective gloves with appropriate protective layers.
 Specifications

• Check if air outlets of diffuser tube are pointing up/downwards. Adjust position if necessary, see
chapter 6.3 for details. Use new gaskets!
• Push membrane over tube. Compare both non-perforated ends, and slide the longer zone first
onto the plastic tube, it should cover the coloured zone of the tube. Both non-perforated strips
along the membrane must face exactly up/downwards.
• Pull new clamps over the sleeve and adjust them at the proper position on both ends of the
diffuser. Use spare diffusers from JUT to locate the optimum position of clamps.
• Use special pair of nippers (JUT # 12001) to close the clamp. The gap of the ear should not
exceed 2 mm after closure (recommended are 1.0 to 1.5 mm).
• Fold ends of sleeves over clamp.
• Run leak-test as described in chapter 7.1.

8.2. Replacing Tube Diffuser

• Remove sludge from diffusers with pressure-washer.

• Unscrew diffuser with two fork-wrenches of 55 mm width.
• Clean sealing area and connector, use new gaskets.
• Mount new diffusers as described in chapter 6.3.
• Run leak-test as described in chapter 7.1.

9. Recycling
Observe all local and federal regulations for waste deposit at time of disposal. Clamps may be dis-
posed of as scrap metal. In case of contamination check with authorities and/or a certified waste
management consultant.

10. Disclaimer
This information is based on our present state of knowledge and is intended to provide general
notes on our products and their uses. It should not therefore be construed as guaranteeing specific
properties of the products described or their suitability for a particular application. US units are for
convenience only. Any existing industrial property rights must be observed. The quality of our prod-
ucts is guaranteed under our General Conditions of Sale.

11. Reference
• DIN 7716, Erzeugnisse aus Kautschuk und Gummi, Anforderungen an die Lagerung, Reinigung
und Wartung, Beuth Verlag, Berlin 1982.
• TA Luft, Technische Anleitung zur Reinhaltung der Luft, 1986.
• DWA-M 115, Indirekteinleitung nicht häuslichen Abwassers, DWA, Hennef, 2004
• ATV M-209, Messung der Sauerstoffzufuhr von Belüftungsein­richtungen in Belebungsanlagen,
in Reinwasser und in belebten Schlamm, Gesellschaft zur Förderung der Abwassertechnik e.V.
(GFA), Hennef 1996.
• PrEN 12255-15, Wastewater treatment plants - Part 15: Measurement of the oxygen transfer in
clean water in activated sludge aeration tanks, European Committee For Standardization, Brussels,
1999. ANSI/ASCE 2-91, Measurement of Oxygen Transfer in Clean Water, American Society of Civil
Engineers, New York, 1992.
JUT_2007_04