DISSOLVED GAS FLOTATION SEPARATORS

MARCH 1995 PAGE 1 OF 19 EGE 26-B-2 1995

TABLE OF CONTENTS
1. Scope 5.3 Mechanical Design and Materials
2. Reference 5.4 Fire Protection Equipment
3. General 5.5 Electrical Classification
4. Performance 5.6 Utility Station
5. Design 6. Data Sheets
5.1 Process Design History of Change
5.2 Equipment EGE 26-D-2 Dissolved Gas Flotation
Separators Data Sheet
1. SCOPE
This Guide covers the basic requirements for the design, selection of materials, and fabrication and
installation of dissolved gas flotation (DGF) separators and associated equipment used in wastewater
treatment applications. While primarily directed toward refining operations, this Guide is applicable to Mobil
facilities such as petrochemical and chemical plants, marketing terminals and bulk plants, pipelines, and
onshore oil and gas production operations.
2. REFERENCES
The following publications form a part of this Guide. The references cited with dates in this Guide were used
in its development. For all references which have been superseded, revised, and/or corrected, the user of
this Guide is obligated to determine if the latest versions of the cited references have any impact on the
content of this Guide or its use. Mobil Technology Company (MTC) Guide Sponsor should be consulted if
there are any concerns or questions.
Mobil Engineering Guides
EGE 00-C-4 (1993) Equipment and Packaged Units General Purchasing Requirements
EGE 01-B-7 (1993) Concrete Design and Construction
EGE 14-S-8 (1993) Storage Tanks Foam Connections
EGE 15-B-3 (1991) Centrifugal Pumps for Nonhydrocarbon General Plant Services
EGE 16-B-1 (1993) Piping General Design
EGE 31-B-1 (1989) Steel Structures Design and Fabrication
EGE 33-B-9 (1991) Electrical Induction Motors
EGE 33-D-9 (1991) Induction Motor Data Sheet
EGE 35-B-2 (1993) Painting Coating and Lining of Storage Tanks
EGE 41-B-28 (1991) Water Treating Equipment Design and Fabrication Chemical Feed Equipment
EGE 45-B-61 (1993) Fixed and Portable Fire Fighting Monitors
EGE 45-B-62 (1992) Live Hose Reels for Fire Protection
EGE 45-B-63 (1991) Portable Fire Extinguishers and Fire Blankets
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EGE 26-B-2 1995 PAGE 2 OF 19 MARCH 1995
EGS 626 (1986) Fire Protection Storage Tanks
EGS 629 (1991) Fire Protection and Loss Prevention Refineries and Petrochemical Plants
API (American Petroleum Institute) Recommended Practice
RP 500 (1991) Classification of Locations for Electrical Installations at Petroleum Facilities
Std 650 (1993) Welded Steel Tanks for Oil Storage
ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code
(1992) Section VIII, Pressure Vessels, Division 1
ASTM (American Society for Testing and Materials) Standards
A283 (1993) Low and Intermediate Tensile Strength Carbon Steel Plates
D2240 (1991) Test Method for Rubber Property Durometer Hardness
3. GENERAL
3.1 The DGF separator equipment shall be furnished as a complete unit with integral flocculation chamber
ready for installation in the tank of an industrial wastewater treatment plant. Components of the DGF
separator shall be designed for this service.
3.2 Use of DGF separators shall be limited to removal of free and emulsified oil and suspended solids.
3.3 The preferred design shall provide for a minimum of two channels and shall include the means to
isolate the influent, effluent, skimming, and recycle systems of each channel to facilitate the cleaning and
maintenance of individual channels. Single channel DGF separator designs shall be subject to Mobil
approval.
3.4 The design of tanks and equipment shall conform with all applicable national and local environmental
regulations.
3.5 Equipment shall be purchased in conformance with EGE 00-C-4, except as modified for specific
equipment by the project instructions, specifications, and terms and conditions stated in Mobils request for
quotation.
4. PERFORMANCE
4.1 The DGF separator shall be capable of removing all oil globules having a rise rate in accordance with
EGE 26-D-2.
4.2 The DGF separator shall be designed to provide a quality of effluent with both free oil and suspended
solids concentrations in accordance with EGE 26-D-2.
5. DESIGN
5.1 Process Design
5.1.1 The DGF separator shall be designed in accordance with the process specific conditions as noted
in EGE 26-D-2.
5.1.2 The ratio of recycle flowrate to design normal flowrate shall be 25 percent for dissolved air
pressurization systems using effluent water at temperatures less than 40C (100F). Higher ratios and/or
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MARCH 1995 PAGE 3 OF 19 EGE 26-B-2 1995
increased operating pressure should be considered for other gases and higher water temperatures because
of their possible lower solubility rates. Alternative ratios and/or operating pressures shall be subject to Mobil
approval.
5.2 Equipment
5.2.1 The DGF separator shall be the two-shaft chain and flight type installed in a rectangular tank. See
Figures 1 and 2 for a schematic view of a typical DGF separator. Unless otherwise agreed to by Mobil, only
the pressurized recycle DGF separator design is acceptable. Proprietary designs may be considered, but
their use requires specific Mobil approval.
5.2.2 The DGF separator shall be furnished as a complete unit, including the following equipment:
(a) Rectangular tank, if specified in EGE 26-D-2.
(b) Horizontal flocculator.
(c) Rotatable slotted pipe skimmer.
(d) Recycle flow distribution header.
(e) Perforated baffle.
(f) Two shaft chain type mechanical skimmer.
(g) Scum trough.
(h) Retention baffle.
(I) Effluent weir and compartment.
(j) Scum sump and pump.
(k) Pressurized recycle system.
(l) Covers, if specified in EGE 26-D-2.
(m) Walkways.
(n) Chemical feed equipment.
5.2.3 All surface preparation and painting of steel members shall be in accordance with EGE 35-B-2 and
as defined in Table 3 of that Guide for wastewater service.
5.3 Mechanical Design and Materials
Mechanical design considerations and materials are summarized in Table 1.
5.3.1 Rectangular Tank
The DGF separator tank construction shall be in accordance with EGE 26-D-2. The supplier shall provide
complete drawings for foundation details pertinent to the DGF separator equipment installation, including
anchorage location.
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EGE 26-B-2 1995 PAGE 4 OF 19 MARCH 1995
FIGURE 1
TYPICAL DISSOLVED GAS FLOTATION SEPARATOR TWO CONCRETE CHANNELS
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MARCH 1995 PAGE 5 OF 19 EGE 26-B-2 1995
FIGURE 2
TYPICAL DISSOLVED GAS FLOTATION SEPARATOR SIDE VIEW
(CONCEPTUAL)
Construction and materials for the various types of DGF separator tanks shall be as follows:
(a) Steel Shell and Bottom The tank shall be designed in accordance with API Standard 650
requirements. Tank design calculations shall include all live and dead loads. A 2 mm (0.08 in.)
corrosion allowance shall be provided in excess of the shell plate thickness calculated in accordance
with API Standard 650. A cold tar epoxy 400 m (16 mil) coating shall be applied to all internal steel
surfaces. However, even if the minimum thickness specified in API Standard 650 exceeds the
calculated thickness, the corrosion allowance shall be added to the minimum thickness. The supplier's
design calculations shall be subject to Mobil approval. The plate material of construction shall be
Grade C mild carbon steel in accordance with ASTM A283, or equivalent.
The steel tank shall be of welded construction with a flat steel bottom for the full length of flotation
compartment. The baffling between compartments, effluent weir wall, flow distribution baffle,
skimming and return run angle tracks, scum sump, and drive supports shall be integral components
of the steel tank. The tank shall have properly sized flanged connections at the inlet, outlet, the scum
sump, and recycle draw-off. A drain connection at the effluent end of the tank shall be provided to
allow drainage of the tank.
All welding procedures and all welders shall be qualified in accordance with API Standard 650. Shell
welds shall be full-penetration buttwelds and shall be spot radiographed in accordance with API
Standard 650. The tank shall be hydrotested upon completion.
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EGE 26-B-2 1995 PAGE 6 OF 19 MARCH 1995
TABLE 1
MECHANICAL COMPONENTS
General:
Number of channels required. Two minimum, unless approved by Mobil.
Area classification. Class I, Group D, Division 1.
Flocculator:
Type Horizontal with two paddle wheel assemblies.
Peripheral speed. Variable, 0.15 to 0.45 m/s (0.5 to 1.5 fps).
Paddle wheel assembly. Four 76 mm x 203 mm (3 in. X 8 in.) fiberglass-
reinforced plastic blades supported by Type 316L
stainless steel angle arms and hubs.
Shaft for paddle wheel assembly. Solid, cold finished Type 316L stainless steel.
Shaft bearings. Cast iron, babbitted, water lubricated, and self-aligning.
Motor Explosionproof, Class F Insulation, 1.0 service factor.
Motor mounting. Integrally mounted.
Gear reducer. Variable speed (3:1) helical gear type, cast iron
housing, designed for continuous service and a 1.5
minimum service factor.
Overload protection device. Torque limiting shear pin device with overload switch
trip lug.
Drive chain. ANSI heavy-duty heat treated steel roller type.
Drive chain guard. Split, oil-tight design.
Oil Skimming Device:
Type Rotatable slotted pipe skimmer.
Operation Manually operated by means of rack and pinion
assembly.
Size of pipe. A minimum of NPS 6 (NPS = nominal pipe size, inches)
outside diameter. A minimum of 6.3 mm (0.25 in.) wall
thickness.
Slot dimensions. 60 degree slot with openings a maximum of 760 mm
(30 in.) with 50 mm (2 in.) wide bands for stiffening.
Material of pipe. Carbon steel.
Support of pipe. Carbon steel collar welded to adjustable carbon steel
plate.
Seal gasket for open end support. Viton.
Stem assembly. Threaded brass, nonrising stem, and cast iron
handwheel.
Adjustable rotation angle. 75 degrees (total 150 degrees).
Recycle Flow Distribution Header:
Pipe size. Sized for proper flow distribution.
Pipe and bracket material. Type 316L stainless steel.
Number and size of orifices. Sized for proper flow distribution.
Pipe length. Width of flotation chamber.
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TABLE 1 Contd
Perforated Baffle:
Inclination angle. 6 to 15 degrees from the vertical and toward the
influent side.
Number and size of orifices. Sized for proper flow distribution.
Baffle and bracket material. Type 316L stainless steel.
Mechanical Skimmer:
Type Two-shaft, chain-type flight skimmers.
Travel speed. Variable speed, 0.9 to 3.6 m/min (3 to 12 ft/min).
Number of sprockets. Two (2) sets.
Space between flights. 1.5 m (5 ft) apart on skimmer chain.
Skimming travel supports. Type 316L stainless steel angle supported by brackets
from the tank wall.
Flight size. 203 mm (8 in.) in depth, rectangular in cross-section.
Material of flight. Fiberglass-reinforced vinyl ester composite.
Flight wipers. Full length Viton wiper with Type 316L stainless steel
backing plate and hardware.
Material of skimmer chain. High strength polymeric type having 152 mm (6 in.)
pitch links.
Allowable minimum working load of collector Minimum 2,041 kg (4,500 lb).
chain.
Sprockets for skimmer chain. Molded polyurethane, split construction, and Type
316L stainless steel mounting hardware. Head shaft
sprockets keyed to shaft. Corner shaft sprockets
revolve on bearing sleeves clamped to static shafts.
Shafts for skimmer chain. Solid, cold-finished Type 316L stainless steel with
deflection a maximum of 3.9 mm/m (0.05 in./ft) of shaft
length.
Shaft bearings. Cast iron, babbitted, lubrication fittings, and self-
aligning.
Drive Mechanism:
Motor Class I, Group D, Division 1, explosionproof, Class F
insulation, 1.0 service factor.
Motor mounting. Integrally mounted.
Gear reducer. Variable speed (4:1) helical gear type, cast iron
housing, designed for continuous service and a 1.5
minimum service factor.
Overload protection device. Torque limiting shear pin device with overload switch
trip lug.
Drive chain. ANSI heavy-duty, heat-treated steel roller type.
Sprockets for drive chains. Heavy-duty machined steel and hardened.
Drive chain guard. Split design, oiltight design.
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TABLE 1 Contd
Scum Trough:
Type Combined beach and scum trough.
Material Type 316L stainless steel.
Oil Retention Baffle:
Location A minimum of 0.3 m (1 ft) downstream of mechanical
skimmer.
Submergence From top of channel to a minimum of 55 percent water
depth.
Material Type 316L stainless steel or concrete.
Effluent Weir:
Location A minimum of 0.6 m (2 ft) downstream of retention
baffle.
Weir Plate. Type 316L stainless steel sharp-crested weir with
75 mm (3 in.) adjustment.
Pressurized Recycle System:
Retention tank operating pressure. Allowable minimum working pressure of 517 kPa gage
(75 psig).
Liquid level control. Water level float switch.
Gas supply system. Solenoid valve bleed in activated from float switch.
Gas control nest. Designed to control gas source.
Recycle pumps. Single-stage, horizontal centrifugal-type pumps.
Flow control valve. Cast-steel, weir-type valve with Viton diaphragm.
Flowmeter. Differential pressure flowmeter with orifice plate.
Back pressure control valve. Ductile iron, weir type valve, Teflon lining, and Viton
diaphragm.
Separator Tank:
Construction Carbon steel or concrete.
Skimmed Float Sump:
Construction Carbon steel or concrete.
Cover:
Type Fixed cover.
Material of construction. Fiberglass fixed covers.
Gas blanketing for fixed covers. Nitrogen gas.
Off-gas control. To atmosphere or vapor recovery/treatment system.
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(b) All Concrete The separator tank concrete design and construction shall be in accordance with
EGE 01-B-7. The DGF separator equipment supplier shall not be required to furnish the tank bottom,
outer walls of the DGF separator, effluent weir wall, and flocculation underflow baffle unless otherwise
specified. The equipment supplier shall furnish all dimensions of equipment governing concrete
construction.
5.3.2 Horizontal Flocculator
The preferred flocculator configuration is horizontal. Alternative configurations, such as vertical, shall be
subject to Mobil approval. The horizontal flocculator shall consist of one shaft, with two paddle wheel
assemblies attached to the shaft. Each paddle wheel assembly shall rotate at peripheral speeds, fully
variable, from 0.15 to 0.45 m/s (0.5 to 1.5 ft/s), and shall be driven from the reducer low-speed shaft by a
system of chain and sprockets. The motor and reducer shall be located atop the tank walls of the
flocculation chamber for ease of servicing and lubrication. The axis of rotation of the paddle wheel assembly
shall be parallel to the direction of the flow. Alternative flocculator designs shall be subject to Mobil
approval.
(a) Drive Chain and Sprockets The horizontal flocculator drive chain shall be of the steel roller
type.
The maximum chain load shall not exceed one-eighth of the ultimate tensile strength of the chain. The
drive sprocket shall be fitted with a bronze bushing and shall be complete with a torque-limiting device
to provide full protection for the equipment in case of excessive loading. The driven sprocket shall be
of split construction to facilitate handling in the field. All teeth of the sprockets shall be accurately
ground to fit the chain, and the sprockets shall be keyed to the shafts. The sprockets shall be
hardened to a depth of not less than 5 mm (0.20 in.), with a Brinell hardness of not less than 360 HB
at the tooth bearing surface.
(b) Chain Guard An oil-tight chain guard shall be furnished. The chain guard shall be of a split
design or equipped with fill and drain plugs and oil level indicator or sight glass.
(c) Paddle Wheel Assembly Each paddle wheel assembly shall consist of four 76 mm x 203 mm
(3 in. x 8 in.) nominal-size fiberglass-reinforced plastic blades and shall be supported by Type 316L
stainless steel angle arms. These angle arms shall be bolted to fabricated Type 316L stainless steel
hubs, which in turn shall be keyed firmly to the shaft.
(d) Bearings The horizontal flocculator shaft shall be supported at each end by a wall-mounted,
self-aligning bearing. The bearings shall be babbitted and shall be water lubricated for service below
water.
(e) Shafting The shaft shall be constructed of Type 316L stainless steel, extend across the full
width of the flocculation tank, and be held in alignment with set collars secured by set screws. The
shaft shall contain keyways with fitted keys, where necessary, and shall be of sufficient size to transmit
the power required.
(f) Motor The motor shall be designed for continuous duty, Class I, Group D, Division 1,
explosionproof, and shall meet the requirements of EGE 33-B-9. Motors shall be rated for 40C
(104F) ambient temperature, Class F insulation, 1.0 service factor, and a power rating of at least
125 percent of the maximum required power. The minimum acceptable motor size is 0.375 kW
(0.5 hp).
(g) Reducer The motor shall be integrally mounted on a variable-speed, helical gear reducer, fully
enclosed in a cast iron housing with antifriction bearings throughout. The reducer shall provide a 3:1
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EGE 26-B-2 1995 PAGE 10 OF 19 MARCH 1995
speed variation. The performance and thermal ratings of gear reducers shall be in accordance with
the latest American Gear Manufacturer Association standards. The gear reducers shall be designed
for continuous service and have a minimum service factor of 1.5.
5.3.3 Rotatable Slotted Pipe Skimmer
A rotatable slotted pipe skimmer shall be provided in the flocculation chamber for the manual removal of
floating material (see Figure 3). Alternative designs shall be subject to Mobil approval. The rotatable slotted
pipe skimmer shall be mounted so that the slots can be rotated 75 degrees in either direction. Standard
carbon steel pipe, a minimum of NPS 6 in outside diameter and a minimum of 6.3 mm (0.25 in.) in wall
thickness, shall be used. A 60 degree slot shall be cut symmetrically about the vertical axis of the pipe with
the edges of the slot serving as a weir which the oil flows over when the pipe is rotated. The edges of the
slot shall be parallel to the longitudinal axis of the pipe. At regular intervals a maximum of 760 mm (30 in.),
50 mm (2 in.) wide bands of the full pipe periphery shall be left in the pipe to act as stiffeners.
The rotatable slotted pipe skimmer shall be supported at each end to allow it to be adjusted to the water
level. The pipe shall be supported by and revolve in a rolled steel collar which shall be welded to an
adjustable steel plate. A Viton seal shall be furnished on the open end pipe support to provide a watertight
connection to the channel wall without grouting. This seal shall be constructed so that it remains tight even
with a slight misalignment of the pipe and collar. The seal shall be readily renewable without removing the
pipe from the supporting brackets and shall not bind or impede the smooth action of the revolving pipe.
FIGURE 3
TYPICAL ARRANGEMENT OF ROTATABLE SLOTTED PIPE SKIMMER
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MARCH 1995 PAGE 11 OF 19 EGE 26-B-2 1995
The rotatable pipe shall be manually operated by means of a cast iron handwheel with handle and rack and
pinion assembly. The handwheel shall be fitted to a structural steel floor stand of welded construction
having a nonrising stem. The stem shall be threaded brass and shall turn inside a standard pipe lifting stem
which raises and lowers the sliding rack assembly. The rack assembly shall consist of two angles fastened
together by two connecting pins and welded to a plate which is welded to the lifting stem. The rack
assembly shall move in a cast iron guide bracket to assure positive contact of the connecting pins with a
steel pinion segment welded to the pipe. The pinion segment shall rotate on the rack connecting pins so
as to permit an easy and accurate means of adjusting the pipe through a 75 degree angle in either direction,
for a total of 150 degrees. The operating mechanisms on a double-channel assembly shall be designed for
location at the outer ends.
5.3.4 Recycle Flow Distribution Header
A perforated Type 316L stainless steel distribution header for distributing the recirculated flow across the
flotation chamber shall be provided. The orifices shall be spaced and designed for proper flow distribution
across the full width of the tank to ensure adequate blending of the pressurized recycle stream with the
incoming wastewater stream.
5.3.5 Perforated Baffle
A perforated baffle shall be provided to ensure that the combined influent and recycle flow is distributed
across the full width of the flotation chamber. The baffle shall be constructed of Type 316L stainless steel
plate of 6.35 mm (0.25 in.) minimum thickness.
5.3.6 Two Shaft Chain Type Mechanical Skimmer
The mechanical skimmer shall consist of two strands of chain with pivoted flights running above the liquid
surface over two sets of sprockets driven by a variable speed drive. The mechanical skimmer shall enter
the liquid at the effluent end of the flotation chamber, convey the floated material toward the influent end,
and scrape the material up an inclined dewatering beach into a scum trough. A Viton wiper shall be
furnished to clean the flights at the point of discharge into the trough. The flights shall be spaced a
maximum of 1.5 m (5 ft) apart and shall travel at a speed of 0.9 to 3.6 m/min (3 to 12 ft/min).
(a) Skimmer Chain Nonmetallic chain is the preferred material for the mechanical skimmer.
Alternative materials, such as metallic chain, shall be subject to Mobil approval. The skimmer chain
(see Figure 4) shall be a high-strength polymeric type having 152 mm (6 in.) pitch links with an average
weight of 2.4 kg/m (1.6 lb/ft). The chain shall have a minimum working load of 2041 kg (4,500 lbs)
based upon strength, fatigue and wear considerations. Chain side bars shall be of fiberglass
composite construction. The side bars shall be of a loop configuration to minimize stress
concentrations within the member and shall include provisions to maintain pin orientation. The chain
pin shall not be less than 25.4 mm (1 in.) diameter pultruded fiberglass rod. The pin shall include an
aramid reinforced acetile resin sleeve to isolate the rotating members from the fiberglass containing
components. Chain pins shall be held in place by Type 316L stainless steel cotter pins. UHMW
polyethylene chain rollers shall be attached between the chain links and supported by the chain pin.
The chain rollers shall support the chain above the skimmer tracks.
The high strength links shall be continuous for the full length of the chain strand with no interspersed
attachment links allowed. Flights shall be mounted to UHMW polyethylene bearing blocks which are
supported on extended chain pins secured with Type 316L stainless steel cotter pins.
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(b) Flights The flights shall be pivoted providing a full 360 degree movement and shall be
designed to provide effective removal of the floated material up the beach. The flights shall be
fiberglass-reinforced vinyl ester composite with a minimum of 203 mm (8 in.) in depth and have a
full-length Viton wiper with Type 316L stainless steel backing plate and hardware. Alternate materials
shall be subject to Mobil approval.
(c) Sprockets and Shafts Sprockets for the nonmetallic skimmer chain shall be molded totally of
polyurethane having a minimum hardness of 80 Shore "D" in accordance with ASTM D2240.
Alternative materials such as machined steel and hardened, shall be subject to Mobil approval. The
sprockets shall be of split construction and shall have a tooth profile compatible with nonmetallic chain.
The headshaft sprocket halves shall be assembled on the shafting with two Type 316L stainless steel
full-width clamping bands which exert compressive force around the full periphery of the hub, thereby
clamping the sprocket to the shaft where required. The headshaft sprockets shall have the keyway
molded into the hub in such a way as to restrict lateral movement of the key and to ensure chain
alignment. The cornershaft sprockets shall revolve on bearing sleeves clamped to static shafts. The
bearing sleeves shall be molded of polyurethane having a minimum hardness of 80 Shore D in
accordance with ASTM D2240. The sleeves shall be of split construction and shall include a shoulder
at each end to restrict lateral movement of the sprocket. The two sleeve halves shall be secured to
the shaft by two Type 316L stainless steel clamping bands.
All shafting shall be constructed of Type 316L stainless steel, straight and true, and shall extend
across the full width of the tank. The headshaft shall be held in alignment with set collars secured by
set screws. The headshaft shall turn in bearings mounted to the tank walls. The headshaft shall
contain keyways with fitted keys, where necessary, and shall be of sufficient size to transmit the power
required. The static shaft shall be supported by fabricated Type 316L stainless steel brackets mounted
to the tank wall. Shaft no-load deflection shall not exceed 3.9 mm/m (0.05 in./ft) of shaft length.
Bearings for skimmer shafts shall be self-aligning, be babbitted, and have lubrication fittings for service
above water. Take-up bearings shall be furnished for the tail shaft, if required.
(d) Track Angle Track and supporting structure shall be furnished for the carrying and return runs
of the skimmer chain. The track and supporting structure shall be constructed of 6.35 mm (0.25 in.)
minimum thickness Type 316L stainless steel. The carrying and return track shall be mounted on top
of the tank or on the tank wall. Consideration should be given to bolted or screwed fixings rather than
welded design to facilitate replacement.
(e) Drive Mechanism Each mechanical skimmer shall be driven from a gear reducer through a
chain and sprocket drive. The drive chain for mechanical skimmers installed in concrete tanks shall
be Type 316L stainless steel having 66 mm (2.6 in.) pitch links with an average weight of 5.8 kg/m
(3.9 lbs/ft). The chain shall be 22 mm (0.87 in.) diameter rollers and the links shall be assembled with
11 mm (0.43 in.) diameter pins. All chain components shall be manufactured of Type 400 series
martensitic stainless steel and shall be through-hardened. The drive chain shall have a rated working
load a minimum of 1,497 kg (3,300 lbs) and an ultimate strength of 10,886 kg (24,000 lbs). The drive
chain driven and driver sprockets shall consist of a polymeric toothed rim bolted to a split polymeric
body. The rim and body shall be molded of high performance polyurethane having a minimum
hardness of 80 Shore "D" in accordance with ASTM D2240. The sprocket shall have a molded keyway
designed to restrict the lateral movement of the key. All sprocket hardware shall be Type 316L
stainless steel. A chain tightener shall be provided to allow proper adjustment of the drive chain. A
chain guard of fiberglass or other approved material shall be provided.
The drive chain for mechanical skimmers installed in steel tanks shall be an ANSI heavy-duty steel
roller type. This chain shall be fabricated from heat-treated steel for wear service, designed for quiet
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operation, and shall match the sprockets with which it operates. The maximum chain load shall not
exceed one-eighth of the ultimate tensile strength of the chain. Drive chain sprockets shall be heavy-
duty type designed for operation with ANSI roller chain. The sprocket can be constructed of machined
steel and hardened after machining. A drive unit slide base shall be provided to allow proper
adjustment of the drive chain. An oiltight chain guard shall be furnished. The chain guard shall be of
a split design or equipped with fill and drain plugs and an oil level indicator or sight glass.
Drive units of skimmer assemblies shall meet the following requirements:
(1) All motors shall be designed for continuous duty, Class 1, Group D, Division 1,
explosionproof, and shall meet the requirements of EGE 33-B-9. Motors shall be rated for 40C
(104F) ambient temperature, Class F insulation, 1.0 service factor, and a power rating a minimum
of 125 percent of the maximum required power. The minimum acceptable motor size is 0.375 kW
(0.5 hp). The motor control shall include a timer to permit intermittent operation.
(2) The motor shall be integrally mounted on a variable-speed, helical gear speed reducer fully
enclosed in a cast iron housing with antifriction bearings throughout. The reducer shall provide
a 4:1 speed variation. The performance and thermal ratings of gear reducers shall be in
accordance with the latest American Gear Manufacturer Association standards. The gear
reducers shall be designed for continuous service and have a minimum service factor of 1.5.
(3) The driven or drive chain sprocket shall be provided with a torque limiting shear pin device
with overload switch trip lug. In case of an overload, it shall actuate a microswitch or
Mobil-approved alternative at a set alarm torque value equal to the design running torque.
5.3.7 Scum Trough
(a) Beach and Scum Trough A combination Type 316L stainless steel beach and scum trough
shall be provided in each flotation chamber. The beach and trough shall extend across the full width
of the tank, with watertight seals on all sides. The trough shall be sloped to drain to a sump adjacent
to the tank. The beach shall be installed level ensuring the wiper blades full contact over the entire
width of the tank.
(b) Scum Trough Screw Conveyor (if required) The scum trough shall be equipped with a
full-pitch nominal 229 mm (9 in.) diameter screw conveyor of sufficient length to move the floated
material to a discharge point beyond the tank wall for subsequent handling. Solid steel shafting shall
be furnished for all intermediate bearings and at all tail drive ends. Where winter weather conditions
warrant, provision shall be made to prevent freezing and accumulation of frozen float in the trough.
The end shafts of the screw conveyor shall revolve in babbitted end bearings. The conveyor shall be
provided with a bronze thrust washer to take the end thrust of the screw. All bearings located outside
the tank shall be babbitted, equipped with lubrication fittings for service above water, and shall be
furnished with structural steel supports.
The conveyor motor shall be designed for continuous duty, Class I, Group D, Division 1,
explosionproof, and shall meet the requirements of EGE 33-B-9. Motors shall be rated for 40C
(104F) ambient temperature, Class F insulation, 1.0 service factor, and a power rating a minimum of
125 percent of the maximum required power. The minimum acceptable motor size is 0.375 kW
(0.5 hp).
MOBIL ENGINEERING GUIDE
MARCH 1995 PAGE 15 OF 19 EGE 26-B-2 1995
The conveyor motor shall be integrally mounted on a helical gear reducer fully enclosed in a cast iron
housing with antifriction bearings throughout. The performance and thermal ratings of gear reducers
shall be in accordance with the latest American Gear Manufacturer Association standards. The gear
reducers shall be designed for continuous service and have a minimum service factor of 1.5.
5.3.8 Retention Baffle
A retention baffle shall be located downstream of the mechanical skimmer in the flotation chamber. The
baffle shall be installed a minimum of 0.3 m (12 in.) downstream of the mechanical skimmer with a minimum
submergence of 55 percent of water depth.
Baffles shall be constructed of Type 316L stainless steel or concrete and positioned to provide positive oil
control for the design life of the DGF separator. Baffles may be vertical or inclined up to 15 degrees in the
downstream direction, and they should extend to the top of the channel.
5.3.9 Effluent Weir and Compartment
The effluent weir wall and weir plate shall be located a maximum of 0.6 m (2 ft) downstream of the retention
baffle and shall extend from the floor of the channel to a height equal to the water depth minus the depth
of normal flow over the weir plate. An adjustable, straight-edge Type 316L stainless steel weir plate of
6.35 mm (0.25 in.) minimum thickness shall be attached to the upstream face of the weir wall along the top.
The weir plate shall be level when installed and shall be capable of adjustment as necessary to compensate
for differential settlement of the tank. The weir plate shall be designed to provide a minimum 76 mm (3 in.)
adjustment.
The effluent compartment should be sized to provide a minimum retention time of two minutes of the design
plus recycle flowrate or in accordance with EGE 26-D-2.
5.3.10 Scum Sump and Pump
Skimmed oil and scum shall be discharged to a common wall sump. The scum pumps shall be installed in
pairs, one acting as a spare. Scum pumps shall be sized to handle design flows without excessive cycling
of the motors. Pump type and materials of construction require specific approval by Mobil.
5.3.11 Pressurized Recycle System
Treated effluent shall be pumped from the effluent compartment to the pressurized recycle system to
dissolve the gas prior to its release in the recycle flow distribution header. Each flotation chamber shall be
furnished with a dedicated pressurized recycle system. A typical pressurized recycle system is shown in
Figure 5.
(a) Pressure Retention Tank The pressure retention tank shall be constructed in accordance with
Section VIII, Division 1 of the ASME Boiler and Pressure Vessel Code and shall be inspected and
certified to have a maximum allowable working pressure of at least 517 kPa gage (75 psig). The tank
shall be complete with angle legs, code stamping, and the necessary flanged connections. It shall be
designed for floor mounting. In addition, the pressure retention tank shall include an internal gas
distributor to enhance gas saturation.
The pressure retention tank shall also be fitted with gas supply piping and a solenoid valve for
controlling the gas volume in the tank. The solenoid valve shall be actuated by an electrical impulse
from a water-level float switch. The float switch and solenoid valve combination is required to maintain
the proper gas-liquid ratio within the pressure tank. The water-level float switch shall include a device
to sound an alarm at high/low water level should the system fail to maintain the proper gas-liquid ratio.
The tank shall also be fitted with a 0 to 690 kPa gage (0 to 100 psig) pressure gage, sight glass, and
pressure relief safety valve.
MOBIL ENGINEERING GUIDE
EGE 26-B-2 1995 PAGE 16 OF 19 MARCH 1995
FIGURE 5
PRESSURIZED FLOW SYSTEM
(b) Gas Control Nest A gas control nest shall be supplied on which the filter gages, gas
flowmeter, throttling valve, and regulators shall be completely assembled. The gas control nest shall
include the required valves and piping for mounting to the pressure retention tank. A continuous
supply of gas shall be provided to the gas control nest a minimum of 552 kPa gage (80 psig) or more
than 690 kPa gage (100 psig). Compressed gas source and flowrate shall be furnished in accordance
with EGE 26-D-2.
(c) Recycle Pumps and Piping The recycle pumps shall be single-stage, horizontal, centrifugal-
type with flanged connections, suitable for delivering the specified flow at the required head. Pumps
shall meet the requirements of EGE 15-B-3. The motor shall be a squirrel cage induction motor
suitable for use in a Class I, Group D, Division 2 area. The motor shall conform to NEMA standards
and shall be selected in accordance with the requirements of EGE 33-B-9, including winter conditions.
Each DGF separator shall be designed with a dedicated pressurized recycle system. A common spare
pump should be provided for multiple DGF separators.
The recycle pump flow control valve shall be a weir type diaphragm valve of cast steel construction
with a Viton diaphragm. A differential pressure flowmeter with orifice plate shall be provided with local
indicator.
MOBIL ENGINEERING GUIDE
MARCH 1995 PAGE 17 OF 19 EGE 26-B-2 1995
All recycle system piping and valving shall conform to the requirements of EGE 16-B-1. In applications
where internal corrosion or erosion is anticipated because of wastewater characteristics, the use of
lined or reinforced plastic piping components should be considered. The use of reinforced plastic
piping components requires specific review and approval by Mobil.
(d) Back-pressure Control Valve The back-pressure control valve shall be located as close to the
recycle distribution header as possible to minimize agglomeration of air bubbles in the recycle flow
distribution header. The back-pressure shall be a weir type diaphragm valve of ductile iron
construction with a Teflon lining and Viton diaphragm. The valve shall be equipped with a handwheel
and position indicator.
5.3.12 Covers
In accordance with environmental regulations, fixed covers may be required on DGF separators and scum
sumps. Fixed covers shall be of lightweight construction and made of vinyl estor resin fiberglass reinforced
plastic or other suitable corrosion-resistant material. To avoid formation of iron sulfide inside the DGF
separator, carbon steel shall not be used. Access panels for servicing of grease fittings and similar items
shall be included on the covers. Fixed covers shall be provided with chain- or cable-restrained explosion
vents. The design and installation of the cover and cover seals shall be given careful consideration to
ensure that the cover will be pressure-tight at the maximum design internal pressure. The use of a cover
mandates utilization of a flotation gas other than air if formation of explosive mixtures is to be avoided. Gas
purging shall be provided between fixed covers and the liquid surface to avoid formation of an explosive
mixture. Vapors shall be controlled in accordance with national or local environmental regulations. The
design of fixed covers shall be subject to Mobil approval.
5.3.13 Walkways
Walkways shall be furnished to allow access to areas where routine servicing must be performed. All grease
fittings, oil fill and drain points, gear mechanisms, and valve operators shall be readily accessible from the
top of the walkway without heavy covers or floor plates being raised. In addition, stairways shall be provided
for aboveground separators. Ladders are not acceptable. Walkways shall meet the requirements of
EGE 31-B-1.
5.3.14 Chemical Feed Equipment
Emulsion-breaking or flocculation chemicals may be added prior to the flocculation chamber. The piping
upstream of the DGF separator should be sufficiently long to provide a minimum of 30 seconds of residence
time in the pipe at maximum flow.
Chemical Feed equipment shall be designed and fabricated in accordance with EGE 41-B-28.
5.4 Fire Protection Equipment
DGF separators shall comply with the fire protection requirements of EGS 629. One 14 kg (30 lbs) dry
chemical extinguisher meeting the requirements of EGE 45-B-63 shall be located within 15 m (50 ft) of the
DGF separator in a fire-safe and easily accessible location. Fixed firewater monitor coverage in accordance
with EGE 45-B-61, or a live hose reel meeting the requirements of EGE 45-B-62 shall be available for fire
protection of the DGF separator. One hydrant shall also be located in the vicinity of the DGF separator.
For fixed covered DGF separators, a semifixed foam protection system shall be installed in accordance with
EGS 626 and EGE 14-S-8 to extinguish fires inside the DGF separator.
MOBIL ENGINEERING GUIDE
EGE 26-B-2 1995 PAGE 18 OF 19 MARCH 1995
5.5 Electrical Classification
The electrical classification for DGF separators shall be in accordance with the latest edition of API RP 500.
5.6 Utility Station
A utility station with air and water sources should be provided and located to give ready access for
housekeeping and maintenance activities.
6. DATA SHEETS
The supplier shall complete as part of the proposal EGE 26-D-2 and EGE 33-D-9.
MOBIL ENGINEERING GUIDE
MARCH 1995 PAGE 19 OF 19 EGE 26-B-2 1995
HISTORY OF CHANGE
The history of change contained herein does not constitute a complete listing of revisions and changes
made to this document. Only revisions and changes of significant technical content (per sponsor and
Steering Committee) are listed.
EGE 26-B-2 1995
EGE 26-B-2 1995 supersedes the 1988 version with the following significant technical changes:
1. Nonmetallic chain and flights are the preferred materials.
2. A new data sheet has been added.
3. A tabulated listing of the mechanical components and materials for quick reference has been added.
MOBIL ENGINEERING GUIDE
DISSOLVED GAS FLOTATION SEPARATORS DATA SHEET EGE 26-D-2 1995
Page 1 of 2
ISSUE APPROVED ISSUE APPROVED JOB NAME JOB NO.
1 4 ITEM NAME ITEM NO.
2 5 LOCATION
Number of Channels:
DGF Separator Tank Dimensions m (ft): Length Width Wall Height Freeboard
Flocculation Tank m (ft): Length Width Wall Height Freeboard
Effluent Chamber Dimensions m (ft): Length Width Height
Tank Wall Construction:
Tank Floor Construction:
PERFORMANCE DATA
Minimum Normal Maximum
Design Flowrate liters/h (US gpm)
Influent Wastewater Temperature C (F)
Influent SS Concentration (mg/l)
Influent pH
Influent Oil Concentration (mg/l)
Effluent SS Concentration (mg/l)
Effluent Oil Concentration (mg/l)
PROCESS DESIGN AT MAXIMUM FLOW
Rate of Rise of Oil Globule m/min (ft/min)
Horizontal Velocity m/min (ft/min)
Flotation Tank Retention Time (min)
Effective DGF Separator Dimension m (ft): Length Width Depth
Flocculation Tank Retention Time (min)
Effluent Chamber Retention Time (min)
Pressurized Recycle Flowrate liters/h (US gpm)
Compressed Gas Source
Compressed Gas Flowrate m /min (SCFM)
3
Compressed Gas Pressure kPa gage (psig)
MECHANICAL COMPONENTS
General:
Corrosion Allowance
Corrosion Allowance for Internal Parts
Coatings:
External Required
Internal Required
Flocculator:
Type
Peripheral Speed
Paddle Wheel Assembly
Shaft for Paddle Wheel Assembly
Shaft Bearings
Motor
Motor Mounting
Gear Reducer
Overload Protection Device
Drive Chain
Drive Chain Guard
Oil Skimming Device:
Type
Operation
Size of Pipe
Slot Dimensions
Material of Pipe
Support of Pipe
Seal Gasket for Open End Support
Stem Assembly
Adjustable Rotation Angle
MOBIL ENGINEERING GUIDE
DISSOLVED GAS FLOTATION SEPARATORS DATA SHEET EGE 26-D-2 1995
Page 2 of 2
MECHANICAL COMPONENTS Contd
Recycle Flow Distribution Header:
Pipe Size
Pipe and Bracket Material
Orifices Number and Size
Pipe Length
Perforated Baffle:
Inclination Angle
Number and Size of Orifices
Baffle and Bracket Material
Mechanical Skimmer:
Type
Travel Speed
Number of Sprockets
Space Between Flights
Skimming Travel Supports
Flight Size
Material of Flight
Flight Wipers
Material of Skimmer Chain
Allowable Minimum Working Load of Collector Chain
Sprockets for Skimmer Chain
Shafts for Collector Chain
Shaft Bearings
Drive Mechanism:
Motor
Motor Mounting
Gear Reducer
Overload Protection Device
Drive Chain
Sprockets for Drive Chains
Drive Chain Guard
Scum Trough:
Type
Material
Oil Retention Baffle:
Location
Submergence
Material
Effluent Weir:
Location
Weir Plate
Pressurized Recycle System:
Retention Tank Operating Pressure
Liquid Level Control
Gas Relief System
Gas Control Nest
Recycle Pumps
Flow Control Valve
Flow Meter
Back Pressure Control Valve
Separator Tank:
Construction
Skimmed Float Sump:
Construction
Cover:
Type
Material of Construction
Gas Blanketing for Fixed Covers
Off-gas Control