DOMAAI202482 - IOM Manual ACP2 MK2 - Rev B Ok PDF

ACTIFLO TURBO ACP2 MK2
INSTALLATION, OPERATION AND

MAINTENANCE MANUAL
Rev.: B
Veolia Water Technologies

L'Aquarène - 1, Place Montgolfier - 94417 Saint-Maurice cedex France
Tel : +33(0)1 45 11 55 55 - Fax : +33(0)1 45 11 55 00
www.veoliawatertechnologies.com
DOMAAI202482
ACTIFLO TURBO ACP2 MK2 Issue A
IOM MANUAL 8 November 2018
Page 2 of 118
REVISION STATUS
Description of
Issue Date Created Reviewed Approved
Changes
Morten
A 08/11/2018 David Walsh Lindegaard Pierre Girodet First version
Santiago Parent
Update to add
additional safety
recommendations
B 14/06/2019 David Walsh Pierre Girodet Pierre Girodet
+ update of
weight for
transportation
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ACTIFLO TURBO ACP2 MK2 Issue B
IOM MANUAL 14 June 2019
Page 3 of 118
T AB L E O F C O N T E N T S
1. Introduction ........................................................................................................... 11
1.1. Intent of this Manual....................................................................................................11
1.2. Disclaimer Statement ..................................................................................................11
1.3. Proprietary Rights Statement ......................................................................................12
2. Health & Safety ..................................................................................................... 13
2.1. Safety Instructions ......................................................................................................13
2.2. Operator Care .............................................................................................................14
2.3. Personal Protective Equipment ...................................................................................15
2.4. Safety Notes - Following Installation ...........................................................................16
2.4.1. Electrical ..............................................................................................................16
2.4.2. Water ...................................................................................................................16
2.4.3. Chemicals ............................................................................................................17
2.4.4. Fire ......................................................................................................................17
2.4.5. Natural disasters ..................................................................................................17
2.5. Safety Notes - Daily Operation ....................................................................................17
2.5.1. Electrical ..............................................................................................................17
2.5.2. Water ...................................................................................................................18
2.5.3. Performance ........................................................................................................18
3. Actiflo Turbo ACP2 MK2 Process and Components Description..................... 19
3.1. Actiflo Turbo Process general description ...................................................................19
3.2. ACP2 MK2 Range: Description and Specificities ........................................................20
3.3. Parts description .........................................................................................................21
3.3.1. Tank ....................................................................................................................21
3.3.2. Mixers ..................................................................................................................22
3.3.3. Scraper ................................................................................................................22
3.3.4. Lamellas ..............................................................................................................24
3.3.5. Recirculation pumps ............................................................................................25
3.3.6. Hydrocyclones .....................................................................................................26
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3.3.7. Recirculation pipework and sand pot ...................................................................26

3.3.8. Instruments ..........................................................................................................26
3.3.9. Valves ..................................................................................................................27
3.3.10. Control panel and junction boxes .....................................................................28
4. Shipping and Handling Requirements ................................................................ 29
4.1. Transport ....................................................................................................................29
4.1.1. Packing description ..............................................................................................29
4.1.2. Transport and Reception .....................................................................................31
4.2. Lifting procedure .........................................................................................................31
4.3. Storage .......................................................................................................................34
4.3.1. Outdoor storage ...................................................................................................35
4.3.2. Indoor storage......................................................................................................35
4.3.3. Maintenance required during storage ...................................................................35
5. Mechanical Installation & Piping Connection .................................................... 37
5.1. Concrete slab & anchoring requirements ....................................................................37
5.2. Equipment reassembly after tank anchoring ...............................................................38
5.2.1. Handrails and ladder ............................................................................................38
5.2.2. Mixers ..................................................................................................................38
5.2.3. Scraper ................................................................................................................38
5.2.4. Outlet troughs and lamellas .................................................................................40
5.2.5. Gratings ...............................................................................................................40
5.2.6. Hydrocyclones skid ..............................................................................................40
5.2.7. Microsand recirculation pump(s) ..........................................................................40
5.2.8. Recirculation pipework .........................................................................................40
5.2.9. Drain valves .........................................................................................................41
5.3. Instrument assembly after tank anchoring ...................................................................41
5.3.1. Clarified water pH-meter ......................................................................................41
5.3.1. Clarified water turbidity meter ..............................................................................41
5.3.2. High level switch ..................................................................................................41
5.3.3. Torque switch ......................................................................................................41
5.3.4. Raw water flow meter (optional) ...........................................................................42
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5.3.5. Raw water turbidity meter (optional) .....................................................................42

5.3.6. Raw water pH meter (optional) ............................................................................42
5.4. Hydraulic connections .................................................................................................42
5.4.1. Raw water ............................................................................................................42
5.4.2. Clarified water ......................................................................................................42
5.4.3. Drains ..................................................................................................................42
5.4.4. Service water .......................................................................................................43
5.4.5. Sludge outlet ........................................................................................................43
5.4.6. Chemicals ............................................................................................................43
6. Electrical Installation ............................................................................................ 46
6.1. Grounding ...................................................................................................................46
6.2. Field wiring .................................................................................................................46
6.3. Control panel main power ...........................................................................................46
6.4. Pre-commissioning checks .........................................................................................47
7. Commissioning and Start-up ............................................................................... 49
7.1. Utilities commissioning ................................................................................................49
7.2. Tank Filling and Wet tests ...........................................................................................50
7.3. Process start-up and follow-up ....................................................................................52
8. Operation and Monitoring .................................................................................... 55
8.1. Shutdown and draining ...............................................................................................55
8.1.1. Shutdown standard procedure .............................................................................55
8.1.2. Coagulation tanks draining...................................................................................55
8.1.3. Flocculation tank draining ....................................................................................55
8.1.4. Partial draining of settler ......................................................................................55
8.1.5. Full draining of settler...........................................................................................55
8.2. Starting up the unit after a normal shutdown ...............................................................56
8.3. Starting up the unit after an emergency shutdown or a power failure ..........................56
8.4. Chemical dosing .........................................................................................................56
8.5. Micro-sand management ............................................................................................62
8.5.1. Micro-sand specifications .....................................................................................62
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8.5.2. Recommended concentrations of microsand .......................................................62

8.5.3. Microsand concentration measurement ...............................................................63
8.5.4. Make-up microsand .............................................................................................64
8.6. Jar tests ......................................................................................................................65
8.6.1. Principle ...............................................................................................................65
8.6.2. Material required ..................................................................................................66
8.6.3. Laboratory procedures .........................................................................................67
8.6.4. Analysis ...............................................................................................................68
8.7. Normal operations and parameters to monitor ............................................................68
9. Control of the unit using the HMI ........................................................................ 70
9.1. Start-up Delay Screen.................................................................................................70
9.2. Home Screen ..............................................................................................................72
9.3. Login Screen...............................................................................................................74
9.4. Alarm Screen ..............................................................................................................76
9.5. Alarm History Screen ..................................................................................................77
9.6. Schematic Overview Screen .......................................................................................77
9.7. Instrument / Mixers / Pump / Valve Pop-up Screens ...................................................80
9.8. Dosing Screen ............................................................................................................82
9.9. Starting Conditions Screen ......................................................................................82
9.10. Production Data.......................................................................................................83
9.10.1. Volumes ...........................................................................................................83
9.10.2. Trends Screen..................................................................................................85
9.11. Contact Screen........................................................................................................85
9.12. IO Screens ..............................................................................................................86
9.12.1. Digital Input / Output Screens ...........................................................................86
9.12.2. Analogue Input / Output Screens......................................................................89
9.13. Options Screen........................................................................................................91
9.14. System Information Screen .....................................................................................95
9.15. Process Screens .....................................................................................................96
9.15.1. Steps Screens ..................................................................................................96
9.15.2. Settings Screen ................................................................................................97
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9.15.3. Dosing Screen..................................................................................................98

9.15.4. Instruments Screen ..........................................................................................99
9.15.5. Equipment Screen ............................................................................................99
10. Maintenance and Troubleshooting ................................................................ 102
10.1. Daily inspection .....................................................................................................102
10.2. Components maintenance .....................................................................................102
10.3. Troubleshooting.....................................................................................................107
10.3.1. Clarified water turbidity increase.....................................................................107
10.3.2. Clarified water true color or UV 254 increase (Dissolved Organic Carbon) .....108
10.3.3. Clarified water pH change ..............................................................................109
11. System Specification ...................................................................................... 110
11.1. Environmental conditions, feed water requirements, and performance Levels .......110
11.2. Key process sizing parameters ..............................................................................111
11.3. Materials for construction and coatings .................................................................112
11.4. Standard and norms ..............................................................................................113
12. ANNEXES ......................................................................................................... 114
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LIST OF FIGURES
Figure 1: ACTIFLO Process description ....................................................................................19
Figure 2: ACP2-60 scraper .......................................................................................................23
Figure 3: Motorisation of the ACP2-40 scraper..........................................................................24
Figure 4: Lamellas and outlet troughs during assembly in a workshop ......................................25
Figure 5: MA hydrocyclones from MA80 to MA1 .......................................................................26
Figure 6: Lifting lugs of the Actiflo .............................................................................................33
Figure 7: Installation of the scraper shaft...................................................................................39
Figure 8: Connection of the scraper shaft for large Actiflos .......................................................39
Figure 9: Coagulant injection recommended .............................................................................44
Figure 10: Sand pot Calculate the sludge concentration with the formula:.................................64
Figure 11: Start-up Screen ........................................................................................................71
Figure 12: Home Screen ...........................................................................................................72
Figure 13: Home Screen with Available Sub-Screens ...............................................................73
Figure 14: Login Screen - Empty ...............................................................................................74
Figure 15: Login Screen - Engineer Login Active ......................................................................75
Figure 16: Alarm Screen ...........................................................................................................76
Figure 17: Alarm History Screen ...............................................................................................77
Figure 18: Overview Schematic Screen ....................................................................................78
Figure 19: Overview Schematic Screen - with Engineer Override .............................................79
Figure 20: Mixer Pop-up Screen ...............................................................................................80
Figure 21 Dosing Screen ..........................................................................................................82
Figure 22: Starting Conditions Screen .......................................................................................83
Figure 23: Counters Screen ......................................................................................................84
Figure 24: Contact Screen ........................................................................................................86
Figure 25: Digital Inputs Screens ..............................................................................................87
Figure 26: Digital Outputs Screens............................................................................................89
Figure 27: Analogue Inputs Screen with Override .....................................................................90
Figure 28: Analogue Output Screen ..........................................................................................91
Figure 29: Options Screen ........................................................................................................92
Figure 30: System Information Screen ......................................................................................95
Figure 31: Timers Screen - Production ......................................................................................96
Figure 32: Settings Screen ........................................................................................................97
Figure 33: Dosing screen 1 .......................................................................................................98
Figure 34: Dosing screen 2 .......................................................................................................98
Figure 35: Instrument Limits Screen..........................................................................................99
Figure 36 Equipment Timer Limits Screen 1 ...........................................................................100
Figure 37 Equipment Timer Limits Screen 2 ...........................................................................100
Figure 38: Components maintenance guidelines.....................................................................103
Figure 39: Suggested material for lamella cleaning .................................................................105
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L I S T O F T AB L E S
Table 1: Actiflo Tank dimensions, prepared for transport, with control panel .............................30
Table 2: Actiflo Tank dimensions, prepared for transport, with junction boxes ...........................30
Table 3: Disassembled components prepared for transport, with Control panel ........................30
Table 4: Disassembled components prepared for transport, without control panel ....................31
Table 5: Tightening torque for lifting lug bolts ............................................................................33
Table 6: Factor for initial micro-sand load calculation ................................................................50
Table 7: Coagulant type and dosing rates for Waste water applications ....................................58
Table 8: Coagulant type and dosing rates for drinking or process water applications ................59
Table 9: Flocculant type and dosing rates for Waste water applications ....................................60
Table 10: Flocculant type and dosing rates for drinking or process water applications ..............61
Table 11: Micro-sand specifications ..........................................................................................62
Table 12: Micro-sand concentration recommended ranges for Actiflo Turbo used in waste water
applications ...............................................................................................................................63
Table 13: Micro-sand concentration recommended ranges for Actiflo Turbo used in drinking
water or Process water applications ..........................................................................................63
Table 14: User Access Overview ..............................................................................................75
Table 15: System Options .........................................................................................................92
Table 16: Daily inspection tasks ..............................................................................................102
Table 17: Environmental conditions ........................................................................................110
Table 18: Feed water requirements.........................................................................................110
Table 19: Actiflo typical performance levels for treatment of ground or surface water (Drinking or
Process water applications) ....................................................................................................111
Table 20: Actiflo typical performance levels for treatment of Waste water (Municipal or Industrial
applications) ............................................................................................................................111
Table 21: Actiflo ACP2 MK2 process data...............................................................................111
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1. INTRODUCTION
1.1. INTENT OF THIS MANUAL

This document describes the functions of the various components of the Actiflo® Package
Plant, and the procedures for the installation, start-up and standard operation of the system. It
also plans preventive maintenance measures and describes procedures for the regular
maintenance of the equipment as well as troubleshooting.
The Actiflo® Package Plant is manufactured and supplied by Veolia Water Technologies. This
equipment of proven design will ensure decades of trouble-free operation. However, in order to
reach and maintain peak efficiency and performance of the system, it is imperative to take into
consideration all guidelines described in this manual and also in the components manuals.
To obtain any additional information regarding characteristics, operation or maintenance of this

equipment, or if a problem persists, please do not hesitate to contact us:
Veolia Water Technologies

L'Aquarène - 1, Place Montgolfier - 94417 Saint-Maurice cedex France
Tel : +33(0)1 45 11 55 55 - Fax : +33(0)1 45 11 55 00
www.veoliawatertechnologies.com
1.2. DISCLAIMER STATEMENT
This manual may include original manufacturer’s literature. These manuals should provide
complete and accurate information to meet your operating and/or service requirements based
on the information available at the time of publication. However, Veolia Water Technologies
assumes no responsibility for the technical content of original manufacturer’s component
literature.
The information in these manuals may not cover all operating details or variations or provide for
all conditions in connection with installation, operation, and maintenance. Should questions
arise which are not answered specifically in this manual, contact the Veolia Water Technologies’
Service Department.
Veolia Water Technologies reserves the right to make engineering refinements that may not be
reflected in these manuals. The material in these manuals is for informational purposes and is
subject to change without notice.
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1.3. PROPRIETARY RIGHTS STATEMENT

This manual discloses information in which Veolia Water Technologies has proprietary rights.
Neither receipt nor possession of this manual confers or transfers any right to the client, and by
its retention hereof, the client acknowledges that it will not reproduce or cause to be reproduced,
in whole or in part, any such information except by written permission from Veolia Water
Technologies. The client shall have the right to use and disclose to its employees the
information contained herein for the purpose of operating and maintaining the Veolia Water
Technologies equipment, and for no other purpose.
In the event the content of this manual is altered or section/items are omitted during a
reproduction, in whole or in part, and instructions or definitions within the reproduction result in
personal injury to those who follow the altered instructions, the burden of responsibility for
personal injury falls solely on the party who affects the reproduction.
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2. HEALTH & SAFETY
2.1. SAFETY INSTRUCTIONS
The safety instructions listed in this document must be read carefully and strictly adhered to in
order to reduce possible health hazards and to avoid dangerous situations.
In this chapter you will find general safety instructions that draw attention to hazards in the
handling of the system as well as unavoidable residual risks.
Action-related safety instructions are shown ahead of the corresponding instructions.
The “Safety” chapter is fundamentally important and must be read carefully and adhered to. It is
the only way to ensure that all operations and work on the system can be carried out safely and
correctly.
Not adhering to the safety instructions can result in danger to persons and material damages to
the system.
Please keep this Operator Manual & these safety instructions close to the unit so that they are
available for reference by the operators at all times.
To the Operator:
It is your responsibility to read & become familiar with the instructions in this manual.
If in doubt, seek guidance before carrying out an operation / procedure with this equipment.
The following indications:
Danger Warning Attention
are shown at various points in this manual for your protection - please take note of them.
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2.2. OPERATOR CARE
The plant / unit has been designed and manufactured to applicable harmonized standards and
technical specifications and with the greatest possible safety in all operating modes.
The safety of the plant / unit operation can only be achieved if all of the following points are
adhered too.
The operator must pay particular attention to the following:
 The plant / unit is used as only as specified
 The plant / unit are operated only when in good functional condition. All safety devices
should be checked regularly to ensure proper functioning.
 Personnel Protection Equipment (PPE) is available in good condition and used when
required.
 The operating instructions are complete, readable and available on site for use on the plant /
unit.
 Only trained, qualified and authorised personnel are permitted to operate, maintain and
repair the plant / unit.
 Those personnel are instructed with regard to safe working practices and environmental
protection, and know the contents of the operating instructions and any safety notes.
 All safety and warning labels on the plant / unit are visible, readable and are not removed.
 Modifications are only to be carried out by authorised specialised personnel.
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2.3. PERSONAL PROTECTIVE EQUIPMENT
To minimise safety hazards, personal protective equipment has to be worn correctly during
operation of the plant.
Please respect any additional signs regarding personal protective equipment which are installed
in the plant area.
Protective clothing
Protective clothing is tightly fitted and resistant to tearing, with tight sleeves
and no external parts. It is mainly used to protect against being grasped by
moving machinery.
Do not wear rings, necklaces or other jewellery.
Pair of goggles with side protection

Used to protect the eyes from splashes and from contact with hazardous
substances.
Safety gloves
Used to protect the hands from hot or cold surfaces and from contact with
hazardous substances.
Safety boots
Used to protect the feet from falling parts and slipping on slick surfaces.
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2.4. SAFETY NOTES - FOLLOWING INSTALLATION
2.4.1. Electrical
Fire Risk!
The unit should not be installed near flammable liquids or gases.
Danger
Maintenance
Isolate / switch off the mains power supply before carrying out electrical work
on the control enclosure.
Only qualified personnel should carry out electrical work.
Warning On completing maintenance work close & lock the control enclosure.
Confirm the equipment is properly earthed - failure to do so may result in

electric shock!
Ensure that the control enclosure & other electrical components are protected
from water ingress / water spray.
Attention
2.4.2. Water
Where water ingress is possible / expected, ensure that measures are taken
to allow water to exit the electrical enclosure and / or provide a water leakage
sensor and alarm system.
Attention Ensure that there is sufficient drain capacity.
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2.4.3. Chemicals
Refer to Chemical Safety Data Sheets before handling any chemicals.

Where chemicals are added to the system there is a risk of splashing.
Wear suitable personal protective equipment (PPE) - safety glasses, rubber
gloves etc, when handling chemicals. Detailed information for the HYDREX
products described in this leaflet can be found in our relevant health and
safety information (Safety Data Sheet) available on following link:
Attention http://frclg11msdgenp1.vws.vh20.net/MSDSViewer/Default.aspx .
This tool is only accessible to VWT employees. Please contact your Hydrex
water treatment additives expert for further information.
2.4.4. Fire
Fire Risk!
The unit should not be installed near flammable liquids or gases.
Lamellas are made in Polystyrene that is highly flammable. Submerge with
water as soon as possible after installation. Don’t perform any welding or
action that could ignite a flame next to the lamellas.
Hydrocyclones are made in Polyurethane that is flammable. It must not be put
Danger
in contact with direct flame.
2.4.5. Natural disasters
Possible impacts of natural disasters (earthquake, cyclones, floods or others)

have not been considered in the system standard conception. Risks criticality
must be evaluated on a case by case basis by the company in charge of
installation, in order to put in place suitable protective measures for the
designated installation site (extra-reinforcements, clearance area,...)
Attention
2.5. SAFETY NOTES - DAILY OPERATION
2.5.1. Electrical
Make sure your hands and the place where you are standing is dry before
touching any live electrical components.
When working on electrical equipment make sure that the mains power has
been isolated / switched off.
Danger
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Keep flammable liquids and gases away from electrical components.

While cleaning with water the unit or the area around the unit, make sure that the mains power
has been isolated / switched off.
When conducting maintenance work on electrical components make sure that

the mains power supply has been isolated / switched off.
Only qualified personnel should carry out electrical work.
On completing maintenance work close & lock the control enclosure.
Warning
Avoid touching electrical components / terminals with wet hands.

Switch off / electrically isolate the equipment during electric (thunder) storms.
Attention
2.5.2. Water
Ensure that all electrical enclosures are sealed & / or locked during operation
of the equipment.
Attention
2.5.3. Performance
Do not supply out-of-specification feed water to the equipment under any

circumstances.
A regular weekly, monthly and annual schedule of maintenance should be
instigated to ensure continued good & cost-effective performance.
Attention
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3. ACTIFLO TURBO ACP2 MK2 PROCESS AND COMPONENTS

DESCRIPTION
3.1. ACTIFLO TURBO PROCESS GENERAL DESCRIPTION

The ACTIFLO® Turbo process is a high performance and compact clarification system using
micro-sand ballasted flocculation and settling. A coagulant is added to the raw water prior to the
coagulation tank, where it is mixed for a period of time that depends on the flow rate. The water
then flows into the flocculation tank where micro-sand and polymer are added. The micro-sand
provides a large contact area and acts as ballast, therefore accelerating the settling of the
precipitate. The destabilized suspended solids will bind to the micro-sand particles via polymer
bridges. Increased mixing energy from the addition of a draft tube surrounding the flocculation
mixer continues to enhance coagulation of the newly formed flocculated particles (floc.)
Particles agglomerate and grow into high-density floc known as micro-sand ballasted floc. The
flocculated particles then flow with the water out of the flocculation tank and into the last tank,
known as the settling tank. In the settling tank the floc settles rapidly to the bottom. The
efficiency of settling is further increased by the use of inclined lamella. The sludge/micro-sand
mixture collected at the bottom of the settling tank is pumped to hydrocyclones where the
sludge is separated from the micro-sand by the centrifugal force of the vortex action. The
recovered clean micro-sand is then recycled to the flocculation tank and the separated sludge is
continuously discharged.
Figure 1: ACTIFLO Process description
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In wastewater treatment, the ACTIFLO® process is appropriate for use in any application that
would benefit from physical-chemical treatment including coagulation, flocculation and settling. It
can be applied to primary and tertiary wastewater treatment where either better performance or
cost reduction is desired. It is ideally suited for storm water treatment including CSO, SSO or
other overflows due to its high performance, small footprint, and extremely short start-up time. It
is also suited for clarification after fixed-film processes. It can also be used for the treatment of
Biofilter and Sand filter backwash water treatment. The process consistently displays efficient
removals of TSS, BOD, Total P, COD, metals, fecal coliform, and other typical wastewater
contaminants, which can be removed by physical-chemical processes.
In drinking water treatment and process water treatment, the ACTIFLO® process is appropriate
for use in any application that would benefit from physical-chemical treatment including
coagulation, flocculation and settling. It can be applied to both ground water and surface waters
where either better performance or cost reduction is desired. It is ideally suited for difficult to
treat waters such as rapidly fluctuating sources or extreme raw water conditions. The process
consistently displays efficient removals from raw waters containing Turbidity (high and low),
Color, TOC, algae, particle counts, Cryptosporidium, iron, manganese, arsenic and other typical
undesirable water contaminants.
3.2. ACP2 MK2 RANGE: DESCRIPTION AND SPECIFICITIES

The ACP2 mk2 is a standardized range of package plants based on the ACTIFLO® Turbo
process. There are 8 models listed in the section 11.2. Each is suitable for different flowrates
and/or treatment objectives. They are assemblies of components assembled around a steel
tank.
Specificities of the ACP2 mk2 compared to the Actiflo Turbo general operation are:
- There are 2 coagulation tanks. The second one is always equipped with a mixer but the
first one is equipped with an optional mixer only when required to have a longer
coagulation time (for example in case of cold water or when flowrate treated by the unit
is in the upper part of the treatment flow range of the model)
- Recirculation pump(s) is(are) equipped with VFD to be able to cover different possible
recirculation flowrates. It allows operators to adjust it according to specific requirements
in terms of sand concentration, raw water flowrate or quality fluctuations, treatment
requirements, seasonal variations, etc.
- The flocculation tank is equipped with a special turbomix design based on the latest
VEOLIA patent using a pyramid below the draft tube. This technology is intended to
improve flocculation efficiency and potentially reduce polymer consumption
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3.3. PARTS DESCRIPTION

3.3.1. Tank
The standard tank of the ACP2 mk2 is in coated carbon steel. For non-standard contracts, this
tank can be in stainless steel or in FRP.
The tank is divided into 5 compartments:
- Extended coagulation compartment: Raw water flows in this tank. As an option, this
compartment can be equipped with a mixer. When it is equipped with a mixer, a high
percentage of colloidals and particles are coagulated together in the first part of the
coagulation process which occurs in this compartment.
- Coagulation compartment: When leaving the extended coagulation compartment, water
flows inside the coagulation compartment. This compartment is always equipped with a
mixer. It has exactly the same dimensions as the extended coagulation compartment
and also serves the same purpose. It has a flanged connection at the bottom to drain
this compartment as well as the extended coagulation compartment.
- Flocculation compartment: Coagulated water flows inside the flocculation tank where
micro-sand and polymer are injected. In this compartment, particles are grouped in
settleable flocs seeded with micro-sand. It has a flanged connection at the bottom to
drain this compartment. This tank is equipped with a mixer that is inside a stainless steel
draft tube. The draft tube is a cylinder bolted on the side to the coated carbon steel tank
wall and on four feet that are bolted to the tank bottom. Below the draft tube, a pyramid
in stainless steel is bolted to the coated carbon steel bottom. A baffle plate in stainless
steel is bolted at the outlet of the flocculation compartment. In certain specific cases,
Actiflo performance levels may be enhanced without using this baffle plate (especially at
very low flow rate)
- The settling compartment: Flocculated water is sent to the settler where seeded flocs
(sludge) are sent to the bottom hopper that has a collector to extract the sludge. The
clarified water goes up through lamellas and is then sent out of the settler through outlet
troughs that have spiked weirs. This tank also has an outlet flange for partial draining
that only empties the upper part allowing for access and inspection of the lamellas.
- Treated water tank: Clarified water then falls into a small tank that is above the lamella
outlet. Water can then go out through outlet flanges (one flange for ACP2-15 to ACP2-
60, 2 flanges for ACP2-70 and ACP2-75).
The complete tank with the 5 compartments has a cuboid shape. The models ACP2-15 to
ACP2-40 are slightly different from the 5 other models as the 3 reaction compartments are
elevated with an empty space below for the installation of recirculation pumps
Operators can access the top of the tank using a dedicated ladder. The Actiflo Turbo Pack
standard design includes ladder access although it can sometimes be modified to allow for the
installation of stairs. The top of the tank is covered with composite gratings and surrounded by
handrails in coated steel.
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All models, except ACP2-15, have the treated water section, including a part above the lamellas
that is not covered with gratings.
3.3.2. Mixers
Each ACP2 mk2 unit comes with 2 mixers in the standard model (coagulation mixer and
flocculation mixer) and one optional mixer (extended coagulation). They are hanging mixers,
supported by a plate in coated carbon steel, which is bolted to support beams that are bolted to
the tank walls.
They are composed of a motor reducer flanged to a shaft with a3 blade impeller bolted to the
shaft. Standard wetted materials are in SS304L but can be changed to alternative materials in a
non-standard design.
The extended coagulation mixer (when included) pumps upward and rotates clockwise.
The coagulation mixer pumps downward and rotates counter-clockwise.
The flocculation mixer pumps downward and rotates clockwise.
The flocculation mixer is VFD driven and is normally designed to work optimally at 45 Hz. At
start-up, the flocculation mixer rotates at 50 Hz for a short period to ensure that all of the micro-
sand that may have settled in the flocculation compartment is put back in suspension for
creating new ballasted flocs. In certain specific cases, flocculation performance can be
improved by adjusting the frequency between 40Hz and 50 Hz.
For more information on mixers, please refer to the specific supplier manual.
3.3.3. Scraper
The ACP2 mk2 scraper rotates in the settling compartment, with arms that scrap the circular
bottom of the compartment. The scraper moves the micro-sand that has settled at the bottom of
the hopper to its centre where a collector captures the accumulated sludge.
The hydraulic part consists of a vertical shaft bolted to 2 arms. Each arm is retained to the shaft
with radial support plates (ACP2-15 to ACP2-55) or with radial tenders (ACP2-60 to ACP2-75).
All these hydraulic parts are in SS304L in the standard version. In order to cover any issue with
dimensional tolerances that could have occurred during fabrication, the vertical shaft is design in
2 sections that are bolted, with the possibility to insert adjustment disks between the flanges to
increase the length of the shaft. There can be up to 3 disks inserted between the 2 parts of the
vertical shaft of the scraper.
2 sets of rubber pads (EPDM) are installed on each arm. These pads are adjusted to scrape the
bottom of the settling hopper.
There are 2 different reducer designs:
- ACP2-15 and ACP2-30 scrapers are designed with a solid shaft that is connected to a
hollow shaft reducer with helical gears.
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- ACP2-40 to ACP2-75 scrapers are designed with a hollow shaft separated into 2 flanged
parts. They are flanged on top to a planetary reducer. The planetary reducer (called
MECTAN) is then connected to a reducer (helical gear type) using a keyed connection
(on reducer side) inside an hollow sprocket (on Mectan side)
In both cases, the gear reducer is connected to a motor–reducer. Also, to ensure the scraper is
not rotating while there is an abnormal torque, there is a speed controller between the gear
reducer and the motor-reducer. In case of scraper blockage (for example if a tool falls down in
the settler and prevents the scraper from rotating normally), the speed controller sends a signal
above a certain torque. With the standard control panel, this signal initiates an emergency stop.
Figure 2: ACP2-60 scraper
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Figure 3: Motorisation of the ACP2-40 scraper
For more information on the motor-reducer, the speed monitor or the gear reducer, please refer
to the specific supplier manuals.
3.3.4. Lamellas
The ACP2 mk2 proposes two types of lamellas: for drinking/process water and for wastewater.
They are both made of plastic plates welded together to create tubes that have a honeycomb
shape. The main difference between them is the size of the tube (hydraulic diameter) that is
bigger for the waste water version.
In certain specific waste water treatment applications (for example for phosphorous removal in
tertiary treatment), the drinking/process water lamella can be used to enhance treatment
efficiency.
Lamellas are assembled in blocks of several lamellas and several blocks are installed on top of
the settler to cover the entire surface. The lamellas are supported by stainless steel shaped
bars on the bottom and are installed below adjustable anti-floating bars that are connected to
the outlet troughs.
WARNING: Lamellas are made of HIPS (High Impact Polystyrene) that is highly
flammable. Submerge in water as soon as possible after installation. Don’t
perform any welding or action that could ignite a flame next to the
lamellas.
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Figure 4: Lamellas and outlet troughs during assembly in a workshop
3.3.5. Recirculation pumps

Each Actiflo is equipped with one or two recirculation pumps. These are centrifugal pumps with
a body in coated cast iron and an internal rubber lining to avoid abrasion issues. They are used
to extract the mixture of sand and sludge (made of ballasted flocs and water) from the bottom
central collector of the settler. They then send this mixture of sand and sludge to the
hydrocyclone(s).
The motor of the pump is connected to the shaft using a belt and pulley transmission system
that is inside a metallic protective casing. The shaft is connected to the impeller using a dry
gland system that doesn’t require water lubrication as long as the shaft is perfectly adjusted.
The impeller is also lined with rubber.
WARNING: Don’t operate the pump when the metallic protective casing is not
installed. There is a serious risk of injury if you do so.
For more information on the recirculation pumps, please refer to the specific supplier manuals.
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3.3.6. Hydrocyclones
Hydrocyclones are polyurethane devices used to separate sludge from sand. The sand is sent
to the bottom of the hydrocyclone in order to re-inject it inside the flocculation compartment. The
sludge is sent to the top of the hydrocyclone in order to extract it for possible further treatment
outside of the Actiflo.
There can be one or 2 hydrocyclones per Actiflo according to configuration selected.
The specificity of the Hydrocyclone used by Veolia is the possibility to use service water to wash
the micro-sand before it is re-injected into the system. In certain cases, it can improve the global
efficiency of the Actiflo. In the standard model, there is no pipework installed for service water
but this can be added as a modification or directly on site. This is particularly useful for high
concentrations of sludge or to control possible bacterial growth.
Figure 5: MA hydrocyclones from MA80 to MA1
For more information on the hydrocyclones, please refer to the specific manual from Veolia.
3.3.7. Recirculation pipework and sand pot

In the standard design, there is a recirculation pipework in PEHD from the bottom of the settler
to the inlet of each hydrocyclone. There is also a small piece of PEHD pipework for sending the
hydrocyclone sludge out of the Actiflo.
In order to monitor the sludge, a transparent pot is connected to the recirculation line(s), in order
to get samples and make measurements of sand concentration. Please refer to the end of
chapter 8.5 for getting guidance for the use of this sand pot. It can be used to:
- monitor sand concentration inside the recirculation line,
- check if there is an abnormal quantity of micro-sand in the sludge outlet and
- sample outlet sludge to measure concentration
3.3.8. Instruments
In the base scope of supply, the Actiflo is equipped with a:
- Treated water pH meter
- Treated water turbidity meter
- High level switch
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- Torque switch for the scraper

- Pressure gauge and pressure transmitter on each recirculation line
The pH meter and the turbidity meter share a common transmitter. They are installed just above
the lamellas in the settling compartment.
The high level switch is a simple float level switch, installed between the flocculation
compartment and the settling compartment, after the outlet baffle plate.
The torque switch is the transmitter of the scraper speed controller. It is installed inside the
control panel (if supplied) or supplied separately for installation on site in the central control
panel.
As options, several additional instruments can be supplied:

- Raw water pH meter
- Raw water Turbidity meter
- Raw water Flow meter
- Flow meter on each recirculation line
The raw water pH meter and turbidity meter are supplied separately along with an insertion ball
valve and must be installed on site before the Actiflo, directly on raw water inlet pipework.
The flow meters used are electromagnetic. The inlet flow meter is supplied separately and must
also be installed on site before the Actiflo, with the metering part flanged on the raw water
pipework and the transmitter installed nearby (distance limited by cable length as defined in
instrument schedules).
The transmitters in the recirculation flowmeters are integrated in the metering part.
For more information on the instruments, please refer to the specific supplier manuals.
3.3.9. Valves
In the standard model, the Actiflo is comprised of:

- 2 resilient seated gate valves to fully drain the reaction compartments. They have a body
in coated cast iron. One is for both the extended coagulation and coagulation
compartments, another one is for the flocculation compartment
- 1 butterfly valve to partially drain the settling tank. It has a body in coated cast iron and
closing device in SS316.
- 1 ball valve in stainless steel that can be used for maintenance of the recirculation pipe
- 1 resilient seated gate valve for isolating each recirculation pump (in case of
maintenance for example). It has a body in coated cast iron.
- Several small PVC ball valves on the pressure gauges, pressure transmitter, polymer
dosing circuit or on the sand pot (for sampling).
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As an option, a control valve can be supplied for inlet flow control. It is a motorized butterfly
valve with a body in coated cast iron and closing device in SS316. It is supplied separately and
must be installed on site upstream from the Actiflo, directly on the raw water inlet pipework
For more information on valves, please refer to the specific supplier manuals.
3.3.10. Control panel and junction boxes

There are 3 possible alternatives in the standard design for the electrical part of the ACP2 mk2:
- A complete embedded control panel, attached to the Actiflo wall. It contains the MCC,
the PLCs, the VFDs and the HMI
- 2 junction boxes, attached to the Actiflo wall: one for power, one for signals. In this case,
there is a central control panel which is supplied separately by Veolia or an external
company.
- Both the junction boxes attached to the Actiflo wall and a control panel supplied
separately for installation at a distance from the Actiflo (in a separate control room for
example). This alternative is useful in case of aggressive environments or specific safety
requirements. In this case, the control panel has been tested during FAT but must be
installed and wired to the junction boxes on site.
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4. SHIPPING AND HANDLING REQUIREMENTS

4.1. TRANSPORT
Transport must be done by qualified staff, following local applicable legislations.
4.1.1. Packing description
After testing in the workshop and before transportation, most components are disassembled
from the Actiflo tank. The tank itself is covered by a tarpaulin on top. The scraper hydraulic part,
the lamellas and the gratings are kept in/on the tank during transport. For the ACP2-15, ACP2-
30 and ACP2-40, the recirculation pump(s) and some pieces of pipework are kept assembled
for transport.
Disassembled components are packed into wooden crates that are suitable for transport inside
general purpose containers which are transported inside covered trucks.
The control panel or the junction boxes (depending on option selected) that is/are attached to
the Actiflo wall is/are kept installed on the Actiflo wall except if requested otherwise by the client.
They are covered by waterproof plastic, which protects them from moderate rainfall for a short
period of time. The panel/junction boxes packings are not suitable for storage outdoor.
It is the responsibility of the company contracting the transport/carrier company to plan for any
extra packing required. Depending on contracts, it may be another company than Veolia that is
managing transport. The extra packing can usually be done in the Veolia workshop at an extra-
cost.
When there is the possibility of roads being salted, it is advised to completely cover the tank
walls with plastic to avoid premature corrosion. Additionally, if the wooden crates are
transported uncovered or stored outside, it is advised to provide extra-protection against
rain/water on top of the wooden crates.
Dimensional information hereafter is preliminary and provided for informational purposes only.
For each order, the real order-specific packing list would be provided by Veolia Water
Technologies.
Each Actiflo tank, prepared for transport, has different dimensions as listed in the tables
hereafter. The ACP2-15 can be transported inside an open top container but for all other
models, transport shall be done with flat rack container or a low bed truck.
For the ACP2-75, if you need to transport by sea, it is better to consider dismantling the control
panel for transport. By doing this, you would have a total length of 11.8m that fits in most 40ft
FR containers (depending on container manufacturing site). Please refer to the outline and
connection drawings for precise dimensions of the ACP2-75 tank.
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Table 1: Actiflo Tank dimensions, prepared for transport, with control panel
Model Length (m) Width (m) Height (m) Weight (tons)

ACP2-15 4.8 2.2 3 5
ACP2-30 5.6 2.4 3.3 8
ACP2-40 6.7 2.6 3.4 9
ACP2-45 6.8 2.8 3.3 10
ACP2-55 9 3.5 3.3 12
ACP2-60 10.1 4.2 3.3 17
ACP2-70 11.2 4.6 3.7 20
ACP2-75 12.5 4.8 3.7 23
Table 2: Actiflo Tank dimensions, prepared for transport, with junction boxes
Model Length (m) Width (m) Height (m) Weight (tons)

ACP2-15 4.4 2.2 3 4.5
ACP2-30 6 2.4 3.3 7.5
ACP2-40 7.1 2.6 3.4 8.5
ACP2-45 7.2 2.8 3.3 9.5
ACP2-55 8.6 3.5 3.3 11.5
ACP2-60 9.7 4.2 3.3 16.5
ACP2-70 11.6 4.6 3.7 19.5
ACP2-75 12.1 4.8 3.7 22.5
It is recommended to transport disassembled components inside a GP container. For the

smaller models, it is possible to transport the wooden crates on the same flat rack containers or
low bed trucks as the tank but additional rain protection must be provided by the company in
charge of transport contracting.
Table 3: Disassembled components prepared for transport, with Control panel
Total Gross Advised

Model
Weight (tons) container size
ACP2-15 1.4 20 ft GP
ACP2-30 1.9 20 ft GP
ACP2-40 2.1 20 ft GP
ACP2-45 2.3 20 ft GP
ACP2-55 2.9 20 ft GP
ACP2-60 3.6 40 ft GP
ACP2-70 4.2 40 ft GP
ACP2-75 4.9 40 ft GP
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Table 4: Disassembled components prepared for transport, without control panel
Total Gross Advised

Model
Weight (tons) container size
ACP2-15 0.9 20 ft GP
ACP2-30 1.4 20 ft GP
ACP2-40 1.6 20 ft GP
ACP2-45 1.8 20 ft GP
ACP2-55 2.4 20 ft GP
ACP2-60 3.1 40 ft GP
ACP2-70 3.7 40 ft GP
ACP2-75 4.4 40 ft GP
4.1.2. Transport and Reception

The freight company and its driver are responsible for ensuring that all components transported
are secured according to all applicable transport regulations at pick-up, during transport and
upon arrival.
Loading and unloading must be done as described in the following chapter.
Suitable access control and limitation as well as signalisation must be ensured at the delivery
place before the arrival of the trucks, according to local regulations.
The condition of all delivered components must be verified by the responsible party upon
delivery (usually EXW or DAP depending on contracts). Verification that all equipment has been
delivered as per contract must also be done upon arrival at the site. Notification of missing or
damaged items must be sent to VWT within 2 weeks after reception of the equipment.
If items are damaged during transport the impact must be discussed with VWT to ensure that
installation is possible without incurring significant risks.
VWT is not responsible for the replacement of any items found to be missing or damaged at the
time of installation and start-up of the supplied equipment. It is the responsibility of the party
receiving the equipment to ensure that all packaging is opened at the time of receipt and to
identify and document any and all damage which must be reported to the freight company and
VWT. Photographs and written documentation should be provided concerning all damaged
equipment.
4.2. LIFTING PROCEDURE

Lifting must be done using suitable equipment, by trained and authorized staff, following local
regulations. Before lifting, delimit the no access safety perimeter to be maintained throughout
the lifting operation. It shall also be ensured that no item is loose or damaged before lifting the
tank or the dismantled components.
For lifting, it is usually recommended to have, at minimum:

- One crane operator in charge of driving the crane
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- Two operators in charge of assisting lifting which includes positioning hooks, avoiding rotation
of the tank, helping the crane operator to position the tank, etc.
- One supervisor in charge of checking that materials are suitable before starting the lifting
operation, of checking that the operation is doable (space, loads,…) and safe, and that all
persons involved are trained and protected with suitable equipment,…
They should be able to communicate using a walky-talky (or equivalent).
Before starting the lifting, make sure there is no water in the tank. Verify that there are no loads
other than the tank, the scraper and, if applicable, the control panel (+ the pump(s) for the
ACP2-15, ACP2-30 and ACP2-40) are applied while lifting the Actiflo tank. Other elements such
as handrails, ladder, motors, etc. must not be installed while lifting the tank. Before lifting,
inspect carefully to ensure that there are no damaged or loose items that could cause injury or
damage the equipment.
WARNING : The Actiflo tank must be lifted using the 4 removable lifting lugs. Don’t
use the welded lugs that are on the corners of the tank (that are only used
during tank fabrication). Lifting related tasks such as unloading should
only be performed by qualified staff
In the figure hereafter, 2 of the 4 lifting lugs that must be used are circled in green. The 4 lugs
crossed in red must not be used for lifting the Actilo tank (on both sides of the Actiflo tank).
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Figure 6: Lifting lugs of the Actiflo
The 4 removable lifting lugs must be bolted with the protective rubber pad placed between the
tank and the lugs. (to avoid scratching the coating of the tank). The lugs must be oriented
toward the tank as per Figure 6. The torque of the lifting lug bolts must be tightened as per the
following table. It is mandatory to use carbon steel 10.9 class bolts or above, never below. If
these guidelines are not respected, significant damage can occur on the tank and could lead to
hazardous situation for the operators.
Table 5: Tightening torque for lifting lug bolts
Model Bolt diameter Bolt Material Torque (Nm)

ACP2-15 M16 Carbon steel 10.9 class 260
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Slings or chains, designed to withstand the weight of the tank, must be used. A minimum length
of slings/chains must be used to ensure there will always be an angle of at least 60° between
the surface of the tank and each sling/chain, as indicated on Figure 6. In case of height
limitations restricting the possibility of having an angle of at least 60°, one or two suitable
spreaders should be used. If these guidelines are not respected, significant damage can occur
on the tank and could lead to hazardous situation for the operators.
The length of each sling/chain must be adjusted to ensure that the tank will remain stable and
upright during the lifting operation. If required, an additional suitable device must be used to
avoid rotation of the tank.
If it is not possible to directly unload the tank to its final location, suitable equipment shall be
used for transportation of the tank between the unloading area and the final installation position.
Ensure that the means used to transport the tank will not jeopardize the mechanical integrity of
the tank, damage the coating or damage the control panel.
4.3. STORAGE
The following instructions outline the duties and responsibilities of the responsible party for
equipment storage. The responsible party shall assume responsibility for the equipment upon
arrival at the project site. These instructions shall define the minimum expectations for storage
of all equipment.
While this storage specification takes into account common environmental issues that may
affect the system during storage, common sense should be the overriding factor in determining
the best method to ensure the integrity and proper storage of the VWT equipment. In any case,
all drain valves should be kept open during storage to avoid any issue in case of flooding.
Should it be necessary to delay installation and subsequent operation of a unit for more than
one month from date of shipment, special precautions must be taken. If possible, all equipment
should be stored indoors in a dry and sheltered environment having a relatively constant
temperature (especially for gear reducers, motors, bearings, etc.).
Air may contain excessive moisture, pollutants, microorganisms, and other particulates that
accelerate the deterioration of some materials. Humidity and pollutants can produce an
aggressive atmosphere.
The storage environment into which a system is placed can have a dramatic effect on the long-
term usefulness of some spare parts. Key environmental factors are:
1) Temperature
2) Relative Humidity
3) Pollutants
The environmental indoor conditions should not exceed the following ranges:
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Min/Max Temperature Range between: 8°- 28°C

Relative Humidity Range between: 40% +/- 5% (RH)
4.3.1. Outdoor storage

Pre mounted settling tanks can be stored outside with the following storage specifications:
1) Drain water completely with special attention for sections without drain on lower point.
2) Remove all motored, electronic equipment and instruments and store them indoors
(heated and ventilated area).
3) Tanks must be stored with adequate support underneath to prevent distortion and to
raise equipment above any undesirable ground or floor conditions. It will also prevent flood
damage.
4) Completely cover the equipment with a tarp or similar protective shield to prevent direct
exposure to the elements (dust, rain, snow, etc.). The tarp should fit tightly around the
equipment to prevent accumulation beneath tarp.
5) Make sure that the plastic tarp is in perfect condition. Repair plastic tarp if needed.
6) Remove all snow, dust or water accumulation from the top of the units.
4.3.2. Indoor storage

It is necessary that all other equipment (including but not limited to electrical enclosures, spare
parts, etc.) be stored indoors in a clean, climate controlled dust free, non-aggressive and dry
environment.
1) The equipment should be stored in a manner that prevents insects, rodents, etc. from
entering the equipment.
2) Cover the equipment with a tarp or similar protective shield to prevent direct exposure to
dust or any other contamination. However, never enclose the unit or components totally in
plastic covers; always leave adequate ventilation of air to prevent condensation.
3) Storage volume depends on the size of the project.
4) Equipment must be checked on a weekly basis for tarp/wrap integrity and accumulation.
5) To avoid damage, do NOT stack crates.
6) To avoid damage, do NOT stack enclosures.
7) Do not store spare parts in a barn, equipment shed or any other building without the
capacity for heating and cooling as needed.
4.3.3. Maintenance required during storage
For mixers, scrapers and recirculation pumps, long term storage methods (including complete
lubricant filling) must be applied to the equipment. Protect machined surfaces and rotate shafts
periodically (every month). Five complete rotations of the output shafts are recommended each
time.
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Periodic checks should be made to ensure that no rusting or other damage has occurred.
Should such be noted, corrective action should be quickly initiated. Prior to putting unit into
service, drain lubricant and refill to proper level as determined by the mounting position. Refer to
manufacturer documentation.
All motors must be removed and stored indoors (in a heated and ventilated area). All motors
must be run every 3 months to prevent corrosion.
All instruments must be stored inside. Refer to manufacturer documentation.

It is necessary that all electrical equipment (including but not limited to electrical enclosures,
spare parts etc.)be stored indoors in a clean, climate controlled, dust free, non-aggressive and
dry environment.
1) The electrical equipment should be stored in a manner that prevents insects/rodents
from entering the equipment.
2) Completely cover the equipment with a tarp or similar protective shield to prevent direct
exposure to dust or any other contamination.
3) Storage volume depends on the size of the project.
4) Equipment should be checked on a weekly basis for tarp/wrap integrity and
accumulation.
5) To avoid damage, do not stack crates.
6) To avoid damage, do not stack enclosures.
7) Do not store spare parts in a barn, equipment shed or any other building without the
capacity for heating and cooling as needed.
It is recommended that tanks and pumps be stored indoors and on a raised surface to avoid
flood damage, however if this cannot be done, they must be placed on secure, high ground and
meet all other specifications provided in this document. The responsible party must be sure to
elevate the equipment off of the ground.
If the equipment is stored outdoors it must be kept on high ground not susceptible to flooding
and elevated at least 250 mm off the ground. If there is reason known to the responsible party
that more than 250 mm of elevation is required, appropriate measures should be taken.
Completely cover the equipment with a tarp or similar protective shield to prevent direct
exposure to the elements (dust, rain, snow, etc.). The tarp should fit tightly around the
equipment to prevent any type of accumulation beneath tarp. Equipment must be checked on a
weekly basis to ensure tarp integrity and absence of any accumulation.
To avoid possible module damage, do not stack module crates.
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5. MECHANICAL INSTALLATION & PIPING CONNECTION
5.1. CONCRETE SLAB & ANCHORING REQUIREMENTS

The impact from potential natural disasters (earthquake, cyclones, floods or others) has not
been taken into account in the standard system design. Risk assessment must be evaluated on
a case by case basis by the company in charge of installation, in order to put in place suitable
protective measures for the designated installation site (extra-reinforcement, specific anchoring
equipment, clearance area,...). Always evaluate if the standard design is suitable regarding local
regulations before installation. When required, special tank models can be designed and
manufactured by Veolia.
Load and foundation drawings can be provided by Veolia for the tank, the control panel (if
applicable) and the recirculation pump (if applicable). Ensure that the concrete slab that will
support the Actiflo is designed to withstand the load, especially the ring that is below the settler.
It is advised to install the tank directly on concrete.
Make sure the concrete is dry and clean before placing the Actiflo tank. The concrete slab below
the tank must be sufficiently level. It shall be levelled within +/- 3mm every 3m in any direction
and within +/- 10mm on all the surfaces that will be covered by the tank baseplate. These
guidelines are mandatory to avoid any mechanical damage to the tank during operation, due to
stress on steel plates and tubes caused by an unlevelled surface.
When the Actiflo tank is positioned properly, seal the gap between the tank baseplate perimeter
and the concrete. The use of a dedicated product, such as polyurethane sealant (example
Sikaflex 11FC) is mandatory. This seal is required to avoid possible water infiltration that could
lead to corrosion of the tank. No anchor bolts are required with the standard design. In specific
cases with special design requirements which are adapted for local seismic or cyclonic
constraints, a different design with anchor bolts might be considered. Please refer to order-
specific drawings in this case.
Inspect all coating to ensure there is no damage. If scratches are identified, touch up must be
performed by qualified personnel wearing suitable personal protective equipment, as indicated
on the coating supplier documentation.
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5.2. EQUIPMENT REASSEMBLY AFTER TANK ANCHORING
WARNING : Some of the re-assembly steps require working at heights before

handrails and ladder are installed or before gratings are securely
fastened. There are also heavy loads that require suitable lifting devices.
All work must be done with the suitable personal protective equipment at
every step. This could include, amongst others wearing/using: a helmet,
safety shoes, gloves, safety glasses, a harness, ladder, stop-fall device
and mobile platform with handrails.
Check that the 4 top lifting lugs have been unbolted and removed before starting assembly.
Then, follow the steps listed below.
5.2.1. Handrails and ladder

Install the handrails and the ladder as per assembly drawings.
The ladder is delivered separately. The contractor must assemble and install the ladder at the
job site. Grout may be used underneath the ladder to ensure that the ladder is levelled with the
top of the grating on the tank.
5.2.2. Mixers
The mixers are delivered separately. On site, the contractor must attach the impellers to the
shaft hub and the shaft to the gear box flange.
Install the motor on the appropriate tank mixer following the instructions given in the supplier’s
equipment manual. You might need to temporarily remove some of the grating plates while
doing so.
Verify the mixer blade installation and orientation (as described in chapter 3.3.2)
Verify that the set screws which secure the hub onto the shaft are well tightened.
Follow manufacturer recommendations for oil check and fill up procedure (supplier manual).
5.2.3. Scraper
In order to install the scraper motor reducer, you will need to consider the following sub-steps:
1. Connect the shaft top eyebolt to a suitable lifting device
2. Remove the transportation plate from the rake assembly.
3. Lower the shaft of the rake using the eyebolt. Be careful to do it slowly to avoid any
damage to the coating at the bottom of the tank.
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Figure 7: Installation of the scraper shaft
4. Connect the rake drive to the shaft.

a. For the ACP2-15 and ACP2-30, remove the eyebolt from the rake shaft. It must
then be inserted inside the reducer as per the reducer supplier manual.
b. For the other models ACP2-40 to ACP2-75, the shaft’s top flange must be bolted
to the Mectan crown reducer that is supplied dismantled. First remove the
eyebolt. Then bolt the Mectan reducer to the pre-drilled beams. After that,
connect the eyebolt again through the reducer to lift it during bolting. Finally
remove the eyebolt and connect the motor-reducer to the Mectan reducer, using
the pinion/Sprocket. The keyed shaft of the motor-reducer should be inserted
inside the sprocket and tightened using the dedicated bolt. You should then add
the lubricant in the primary gear box. Use Chevron lubricating oils FM Grade ISO
460 or equivalent. Please be careful about the amount of oil that is put in the
scraper drive assembly as too much oil may overflow into the tank. The oil level
should correspond to about half of the height of the gear which is around 35mm.
Figure 8: Connection of the scraper shaft for large Actiflos
5. Ensure that there is no contact between the rake arm and the bottom of the hopper. The
height of the rubber pads can be adjusted. Also, if the arm is too short, extra-disks can
be inserted in the central connection of the shaft. The inside of the settler can be
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accessed using the internal manhole located between the flocculation tank and the
settler.
5.2.4. Outlet troughs and lamellas

Adjust the level of the outlet troughs, using the threaded bars between the beams and the
troughs, as well as the oblong holes on the outlet side of the trough. The top of the notches
must be perfectly straight: there shouldn’t be a height difference of more than 2mm in any
direction.
The lamellas are delivered assembled and installed. They must be retained with anti-floating
bars that are installed on the outlet troughs. Use the threaded bars to adjust the height of the
anti-floating bars.
Further adjustments of the troughs can be made during commissioning, when the unit will be
running at full flow.
5.2.5. Gratings
Reinstall all gratings as they were at delivery and ensure that the plates are bolted tightly
together so as to avoid any movement. Install gratings properly to avoid any risk of falling. There
must be at least 4 clips per grating.
5.2.6. Hydrocyclones skid

Install the hydrocyclone(s) support skid on the top of maturation tank, following assembly
drawings. Ensure bolting is done properly with suitable tightening as indicated in the
hydrocyclone manual. On the skid, reinstall the components that might have been disassembled
for transport: sand pot, hydrocyclones, and sand receiver(s).
5.2.7. Microsand recirculation pump(s)

For proper microsand recirculation pump system location and installation, refer to field
installation drawings and follow instructions given in the supplier equipment manual.
Usually, the concrete slab under the pumps is slightly higher than the one under the Actiflo tank.
This is defined in the foundation and load drawings.
The pump base frame must be levelled within proper tolerance. Drill appropriate holes in the
concrete floor and fasten the pump with anchors.
5.2.8. Recirculation pipework

Pipework is made of different parts. It is supplied in prefabricated spools to be assembled on
site. There can be one or two complete recirculation lines, depending on projects. It is
recommended to review the assembly drawings and the P&ID to ensure proper installation.
Each step below must be done:
- First bolt the Y connection in steel at the bottom of the settler
- Bolt the gate valve(s) that should be located between the Y connection and the small
piece(s) of HDPE pipe between the valve(s) and the pump(s). if there is only one
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complete recirculation line, install the blind flange on the second branch of the Y
connection
- Connect the outlet of the pump(s) to the hydrocyclone(s) using the different HDPE pipe
spools, attaching them to the tank wall using dedicated pipe supports.
- If applicable, install the recirculation line flow meter(s) (optional item).
- Install the pressure gauge(s) and the pressure transmitter(s) with their dedicated
isolation valves.
- Install the last piece of HDPE pipe at the outlet of the hydrocyclone (top part).
- Install the sand pot and connect it to the recirculation pipe(s), using the small diameter
pipe spools available and associated valves. Thread the bottom valve of the sand pot.
At every step, it must be ensured that all required supports are properly bolted and installed.
5.2.9. Drain valves

Usually, drain valves are kept bolted after workshop assembly but can be removed in certain
cases, especially in case of dimensions limitations during transport. Check they are installed
and properly bolted, with suitable torques.
5.3. INSTRUMENT ASSEMBLY AFTER TANK ANCHORING

5.3.1. Clarified water pH-meter
Refer to field installation drawings for proper pH meter installation.
Install the pH meter with the probe mounted to handrail on the settling tank side using the
supplied bolts, nuts and washers. Refer to field installation drawings for proper location and
installation.
5.3.1. Clarified water turbidity meter

Refer to field installation drawings for proper pH meter installation.
Install the pH meter with the probe mounted to the handrail on the settling tank side using
supplied bolts, nuts and washers. Refer to field installation drawings for proper location and
installation.
5.3.2. High level switch

Refer to assembly drawings for proper level switch installation.
Install the level switch using supplied bolts, nuts and washers. Refer to field installation
drawings for proper location and installation.
5.3.3. Torque switch

The torque switch should be installed inside the control panel.
Ensure that the friction disk, which is part of the scraper’s motor-reducer, is properly connected
to the torque switch. Refer to supplier’s manuals to ensure that the torque switch is connected
correctly.
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5.3.4. Raw water flow meter (optional)

This instrument is shipped separately. The flowmeter is should be flanged near the Actiflo inlet,
inside the raw water pipework. The transmitter is supplied separately and must be installed near
the probe, at a suitable height.
For wiring, connection and installation in the inlet piping, follow the instructions given in the
supplier equipment manual.
5.3.5. Raw water turbidity meter (optional)

This instrument is shipped separately. The probe is supplied with an insertion valve that must be
installed in the raw water pipework. The transmitter is supplied separately and must be installed
near the probe, at a suitable height.
For wiring, connection and installation in the inlet piping, follow instructions given in the supplier
equipment manual.
5.3.6. Raw water pH meter (optional)

This instrument is shipped separately. The probe is supplied with an insertion valve that must be
installed in the raw water pipework. The transmitter is supplied separately and must be installed
near the probe, at a suitable height.
For wiring, connection and installation in the inlet piping, follow the instructions given in the
supplier equipment manual.
5.4. HYDRAULIC CONNECTIONS

5.4.1. Raw water
The raw water inlet flange (TP01) must be connected to the raw water pipework. The inlet
pipework (and optional inlet flow meter if applicable) must be self-supported and should not
apply significant stress on the Actiflo inlet flange. A suitable seal (not in Actiflo scope of supply)
must be used to avoid any leaks. Ensure that bolts are installed in the proper order (following
the shape of a star) with suitable torque. A device to control inlet flow rate (VFD on raw water
pump, control valve or upstream level control), must be installed upstream from the Actiflo.
5.4.2. Clarified water

The clarified water outlet flange (TP02) must be connected to the treated water pipework. The
outlet pipework must be self-supported and should not apply significant stress on the Actiflo inlet
flange. A suitable seal (not included in the Actiflo scope of supply) must be used to avoid any
leaks. Ensure that bolts are installed in the proper order (following the shape of a star) with
suitable torque. Ensure that downstream pressure is controlled so that the treated water level
will remain below the bottom of the outlet troughs.
5.4.3. Drains
All drain valves (TP05, TP06 and TP07) shall be connected to a common drain collector. The
drain collector must be self-supported and should not apply significant stress on the drain
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valves. It is usually recommended to have the drain collector connected to a trench drain.
Ensure that there is no counter pressure on this drain so as to be able to empty the Actiflo tank
when required. Suitable seals (not in Actiflo scope of supply) must be used to avoid any leaks.
Ensure bolts are installed in the proper order (following the shape of a star) with suitable torque.
5.4.4. Service water

There is a ball valve near the pump(s) (TP08) that must be connected to the service water
network. The valve is threaded., Install a flexible pipe connection to the threaded valve in order
to facilitate operation and maintenance. In the event of a long term power failure, the pressure
of the service water is sometimes not sufficient to unclog the sludge suction line. In this
situation, use a metallic bar to unclog the pipe, instead of service water.
In certain exceptional cases, service water can be also used on the hydrocyclones (for specific
applications such as Actiflo Carb or when there is the need to have a very low return of sludge
from the hydrocyclone). In such cases, when required, connect the dedicated hydrocyclone
nipple to the service water with the required flow and pressure control devices. For more
information, refer to the hydrocyclone manual.
5.4.5. Sludge outlet

On top of the hydrocyclone(s), the sludge outlet flange(s) (TP03A/TP03B) must be connected to
the sludge extraction collector. This collector shall not have any section more elevated than the
outlet flange and shall be designed to have no counter-pressure that could cause water to rise
back into cyclone. It is also recommended to install a vent at the end of the sludge collector line
to avoid issues during start-up.
There is always a very small leakage of microsand in the sludge line during normal operation
and, during commissioning or start-there could be a significant amount of microsand going to
the sludge line. It is recommended to take into account this leakage of micro-sand when
designing the sludge downstream equipment. On some sites, a sand trap is installed to prevent
any abrasion issues that could be caused by the microsand.
5.4.6. Chemicals
A proper use of chemicals is mandatory to ensure the performance levels of the Actiflo.
Coagulant must always be injected into the raw water inlet pipework, upstream from the Actiflo.
A suitable connection from the coagulant dosing pump(s) to this pipe should be installed. It is
recommended to use specific devices such as injection quills or static mixers to ensure that the
chemical is evenly dispersed in the raw water before entering the Actiflo tank. This last
recommendation is advised for all applications except waste water primary treatment where
there could be clogging of the static mixer.
In any case, it is recommended to inject the coagulant near the center of the raw water pipe as
per the Figure 9. If a simple T branch on top is used, the liquid will spread mainly at the surface
of the water in the main pipe, leading to poor dispersion and possibly corrosion.
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Raw Water pipe

(section)
Coagulant injection pipe
Figure 9: Coagulant injection recommended
Certain types of coagulant require dilution before injection (concentrated PolyDADMAC and
polyamine e.g. above 20-30% of active product). In this case, ensure that the dilution point is
placed so that there is less than 5s contact time to the injection point.
In some cases, it is also necessary to adjust the pH of the raw water in order to improve
coagulation and/or flocculation. Inject the suitable pH adjustment chemicals downstream from
the raw water pH meter and upstream from the coagulant dosing point. Usual pH adjustment
chemicals such as Acid or Soda have a contact time in raw water of 10 seconds before the
coagulation dosing point. Some others, such as lime, used in specific applications need a longer
contact time in raw water (around 2 minutes) and in some cases, mixing is required before the
coagulation dosing point. It is recommended to have a pressure loss of at least 0.3 m between
the pH injection point and the coagulant injection point to ensure good preliminary dispersion. It
is also recommended to install the pH adjustment chemicals in the same way as the coagulant
injection chemicals in order to prevent corrosion issues.
The use of polymer is always required in the Actiflo process. It is always necessary to dilute
polymer 3 to 10 times the capacity of the metering pump. The diluted polymer inlet pipe must be
connected to the dedicated connection TP04. A significant head loss between this connection
point and the dilution water injection point must be taken into account. Therefore, in some
cases, it is required to install a static mixer. Ensure that the pipework used to transport the
polymer before and after dilution has a large enough diameter to avoid clogging. Verify that the
metering pump selected is suitable for the pressure losses expected in the pipework and that
dilution water with enough pressure is available.
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It is highly recommended to use only powdered polymer. More detailed information is available
in chapter 8.4.
The only exception is for storm water applications. During storms, it is usually necessary to dose
much more polymer than during standard operation, but enough time is needed to dissolve and
maturate the polymer (1 to 2 hours). Therefore, emulsion type polymer can be used for the first
2 hours, until enough flow from HYDREX powdered polymer is available.
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6. ELECTRICAL INSTALLATION
Electrical installation must be done by qualified electricians who are employed by a qualified
sub-contractor, in accordance with local laws and regulations. Only authorized personnel, using
suitable Personnel Protection Equipment, shall be able to access the Actiflo Area during
electrical installation, until the person in charge of safety determines that access is safe.
6.1. GROUNDING
Grounding must be done on relevant components in accordance with local regulations.
6.2. FIELD WIRING

Depending on the options retained for your project, the unit can be supplied with:
- A complete control panel installed on the tank wall
- Junction boxes installed on the tank wall and a control panel supplied separately
- Only junction boxes installed on the tank wall (without control panel)
In case of junction boxes alone, the interconnection cables and related cable trays between the
junction boxes and the control panel are not supplied. They must be supplied and installed,
ensuring that the wiring is correct, according to wiring diagrams.
Wiring for all components that are installed on the tank or recirculation lines is done in the
Veolia workshop before FAT. As most components are disassembled before shipping,
connections to motors, instruments and emergency stop shall be made again on site. All the
cables related to these components installed on the tank are pre-installed in cable trays. Refer
to wiring diagrams to ensure that all connections have been made correctly.
If optional instruments or an inlet control valve are installed on the raw water inlet pipework,
cable trays and wiring must be installed made between these components and the junction box
or control panel.
During this step, Ensure that all electrical connections are properly tightened.
6.3. CONTROL PANEL MAIN POWER

When all of the components are wired to the control panel and all of the necessary tests to
ensure a good electrical installation have been made, the main power cable to the control panel
can be installed and power can be supplied. Before doing so, verify that all steps were
completed using a wiring and electrical installation check-list, and more specifically that a proper
manual tightening has been performed for all electrical connections. All related activities must
be performed only by qualified and authorized personnel. In the standard model, a 3 phase, 50
HZ, 380-415V power should be supplied to the main control panel. In any case, refer to the
electrical specifications to check the requirements particular to your site.
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6.4. PRE-COMMISSIONING CHECKS
WARNING : At this stage, verify that all handrails, gratings and related safety
equipment is now properly installed and tightened.
A complete check list for pre-commissioning (dry tests), commissioning (wet tests) and start-up
(process performance tests) is in ANNEX A. It is recommended to take pictures of all of the
components at these 3 steps (maintaining the same level of light as much as possible). This
check list must be filled in and a record kept throughout the warranty period (at minimum), as it
will be required in case of malfunction.
The minimum number of points, to verify before commissioning, are listed below. Use your good
judgement to determine if there are any other points to verify. Any additional verification
required according to project, site or local regulations must be also made.
1. Check that the emergency stops are working properly.

2. Check that suitable grounding is installed and has been tested.
3. Check also that all components, especially the ones related to safety (ladder,
handrails,…), are properly bolted/installed and that there is no unusual movement. If
there is any risk of injury, the problem must be solved before proceeding with further
tests.
4. Check that all chemical pipework and connections are properly installed and secured.
Personal Protective Equipment must be worn according to the protection guidelines
established in the dosing sets design.
5. Check that the tank is clean and completely empty of foreign objects
6. Verify the oil level in all reducers.
7. Adjust the motor overload protection to the right value as indicated on each motor
nameplate
8. Check that all mixers are installed as per supplier guidelines with special attention given
to keeping the shaft vertical. Ensure that the flocculation mixer shaft is aligned with the
centre of the pyramid.
9. Check the direction of rotation for all motors, for few seconds maximum. The pump must
be energized less than 1 second to avoid damaging the seal. , It is highly recommended
to run this test on the pump without the belt to prevent damaging the pump.
10. Check the direction of rotation for all mixers. It should be as described in the chapter
3.3.2. For the flocculation mixer, check that the blades are not touching the draft tube.
11. Run the scraper for a complete rotation to ensure that there is nothing which prevents it
from rotating freely.
12. Verify the alignment of all treated water outlet troughs, in all 3 axes
13. Check that all instruments are properly wired and energized and perform I/O tests.
Double-check suppliers’ manuals. If you have selected the Actiflo with junction boxes
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only, ensure that the scraper torque switch is properly installed and set-up as per the
supplier manual. Take special care to verify that the high level switch is working
properly. The pH and turbidity meters are normally calibrated in the factory but for
certain orders or for instruments that are not in the Actiflo scope of supply, calibration
must be done on site before commissioning. Check the FAT report of the Actiflo to
ensure that instrument calibration has been done and that the parameters used are
appropriate for your site.
14. Check that the graduations have been put on the sand pot and verify that they are
accurate.
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7. COMMISSIONING AND START-UP

To minimise the risk of injury, adequate lighting is required for proper commissioning, to reduce
the risk of biological hazards, use personal protection equipment and ensure that all personnel
working around the Actiflo have received the proper vaccines.
If you need to spend prolonged period of time near the Actiflo, consider also ear protections
against motor noise.
Commissioning must not be started until all pre-commissioning checks have been done and all
critical issues have been solved.
A complete check list for pre-commissioning (dry tests), commissioning (wet tests) and start-up
(process performance tests) is in ANNEX A.
It is recommended to take pictures of all of the components at these 3 steps. This check list
must be filled in and a record kept, throughout the entire warranty period (at minimum) as it will
be required in case of malfunction.
7.1. UTILITIES COMMISSIONING

Before filling the Actiflo tank with water, ensure that all utilities are available, suiteable for their
intended use and ready to be used. The minimum number of points to verify concerning utilities
is listed below. Use your good judgement to determine if there are any other points to verify.
Any additional verification required (according to the project, site or local regulations) must be
also done. During this review, ensure that during each action, all personnel are using the
suitable Personnel Protection Equipment.
1. Ensure electrical power available is compliant with the Actiflo control panel
requirements.
2. Review the chemical storage and dosing systems compliance with dedicated checklists
3. Ensure that all of the required chemical safety datasheets are available and have been
read by the personnel who will be handling chemicals or might be exposed to these
chemicals.
4. Ensure that JAR tests have been done and theoretical optimum chemical and micro-
sand dosing rates have been defined. The JAR tests procedure is available in chapter
8.6.
5. Check that the service water for polymer dilution is compliant in terms of temperature,
TSS, hardness, free chlorine, etc.
6. Check the polymer preparation unit configuration, especially polymer flow, residence
time and dilution water flow,
7. Review the setting of each dosing pump and that appropriate manual valves are open
8. Check that you have the appropriate quantity of micro-sand available for first loading
(see below Table 6) and that material Safety Datasheet is available and has been read
by personnel who will manipulate micro-sand or might be exposed to micro-sand. If a
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continuous micro-sand dosing system is installed on your site, review the storage and
dosing systems compliance with dedicated checklists. This task must be performed by
qualified personnel, using the suitable Personnel Protection Equipment such as
protection against heavy loads (helmet, safety shoes, etc) and protection against sand
and dust (Dust masks, respirators, etc).
9. For special applications such as Actiflo Soft and Actiflo Carb, check the related
equipment utilities (dosing screw, dilution water, etc.)
At start-up or after full drainage, load the appropriate amount of micro-sand taking into account:
 The targeted concentration in the flocculation tank (usually between 3 g/l and 15 g/l,
depending on the application
 Sand losses that always occur during start-up
 Flocculation adjustments.
This value must be calculated multiplying the factor below by the targeted sand concentration,
as per the Table 6 hereafter.
For example, the initial loading of sand should be 1 355 kg for an ACP2-45 with a targeted
microsand concentration of 5g/l in the flocculation tank. In certain cases, when particular issues
are encountered during start-up, it might be necessary to use more than this calculated weight.
It is usually recommended to have at least twice the recommended weight stored on site, in
case of such an occurrence.
Table 6: Factor for initial micro-sand load calculation
Factor (kg of micro-sand at first loading

Model
per g/l targeted in flocculation tank
ACP2-15 70
ACP2-30 188
ACP2-40 249
ACP2-45 271
ACP2-55 424
ACP2-60 611
ACP2-70 777
ACP2-75 843
This task must be performed by qualified personnel, using the suitable Personnel Protection
Equipment such as protection against heavy loads (helmet, safety shoes, etc) and protection
against sand and dust (Dust masks, respirators, etc).
7.2. TANK FILLING AND WET TESTS

When all utilities are ready to be used, check that the tank is clean and empty, close all drain
valves, open the gate valve at pump(s) inlet and check that the raw water that will be used is
properly screened upstream with mesh of maximum 4 mm.
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Check that the treated water pipe is not routing the outlet water to production during start-up (it
should go back to the inlet of the treatment plant, back to the inlet of the Actiflo or go directly to
the drain).
Verify that the sludge outlet collector lets the sludge drain freely. If required to avoid damage to
sludge treatment, route the outlet to the drain.
You can then let the raw water flow into the Actiflo. Stop the raw water immediately if you detect
any possible leakage and determine how to solve the leakage issue. Stop the unit, empty it as
required, clean it as required, inspect it and repair or reinstall any item responsible for the leaks.
These tasks must be performed by personnel using suitable Personnel Protection Equipment at
every step.
When the tank is completely filled and not leaking, follow these steps:
1. Check that all the VFDs have been configured with a suitable and safe ramp up
2. Start the mixers one after the other to ensure there is no abnormal vibration. It is normal
to have significant vibration at start-up of the coagulation mixer(s) but this should be less
than few mm after 2 minutes.
3. Run the scraper for a complete rotation at minimum to ensure there is nothing
preventing it from rotating freely.
4. Run the recirculation pump(s) and check that there is no leakage from the gland. At
start-up, there may be a few drops from the dry gland but after few minutes, there
shouldn’t be any more. If there are any leaks or any other problems such significant
noise or abnormal vibrations, stop the pump(s), close the pump’s inlet gate valve(s) and
follow the instructions in the pump supplier manual.
5. When the recirculation pump is running properly, record the pressure indicated in each
recirculation pipework pressure gauge. Then compare them with the value indicated by
the pressure transmitters. If they differ significantly, recalibrate the pressure transmitter
following the supplier manual. Compare these values with the guidelines available in the
hydrocyclone manual to ensure that the pressure measured is in the normal working
range of the cyclone
6. Review the water level at the outlet troughs. The water should flow inside the outlet
troughs equally in each V-notch all along the outlet trough but should also be divided
equally between each different trough. To ensure this is the case, measure the level of
water in each trough and adjust the position of each trough until you have the same
height of water in each trough (+/-2mm), and good flow distribution along the V-notches
of each trough.
7. When all this is done, start the polymer maturation in the preparation unit during a
minimum of 1h, preferably 1h30.
8. When the polymer is ready to be used, open the valve VM80-02 (if you have 2
recirculation lines, also open the valve VM82-02) and ensure you have a flexible pipe
going to the hydrocyclone underflow. Start the metering pump and check that polymer is
flowing into the Actiflo.
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9. You can then also start the coagulation dosing pump (and pH adjustment pump if
applicable). Ensure that the chemicals are flowing to the raw water inlet pipes.
10. Review the values of each instrument to be sure there are no calibration issues.
7.3. PROCESS START-UP AND FOLLOW-UP

When all wet tests are done, stop all motors and dosing sets. Ensure that the gate valve at each
pump inlet is open and then try all automatism sequences, including emergency stops. You can
compare the sequence steps to the process control description available in ANNEX B.
When you are sure that automation is working as planned, you can proceed with process start-
up. Start-up should only be done by trained staff who must have a good knowledge of the Actiflo
Process.
Firstly, setup the chemical dosing rates as per JAR tests results. Then start the Actiflo, the
chemical dosing sets, ensure that polymer maturation has been done for at least one hour and
begin to load the microsand. To reduce sand loss, you can usually double the polymer dosing
rate for the first few hours.
Before starting to load the microsand, Make sure you have the required personal protection
equipment:
 mask and goggles to prevent microsand inhalation or contact with the eyes.
 safety shoes and a helmet to avoid injuries if sand bags fall
 hearing protection as you will be exposed to motor noise for a long period of time.
Additionally, protect the mixer motors to avoid damaging the coating.

Ensure that the recirculation pump(s) is (are) running at 50 Hz and you can then start filling the
Actiflo with micro-sand.
If you fill the Actiflo with 25 kg bags, you can directly empty the bags inside the draft tube,
preferably underneath the hydrocyclones. This can be done through the gratings.
If you fill the Actiflo using a big bag (800kg usually), it is better to empty it in the flocculation tank
entry, outside of the draft tube, to avoid damaging the mixer if the microsand falls too fast.
In order to avoid any clogging of the recirculation pipework, you must ensure that you are not
putting microsand inside the flocculation tank too fast. To define the maximum quantity of sand
to put per minute, use the following formula:
Maximum quantity of sand loaded per minute (kg/min) = Design recirculation flow rate (m3/h) x
1.25
After 30 minutes, you should measure the sand concentration in the maturation tank. Take a
sample of water in the section that is between the flocculation tank and the settler. Be careful to
wear proper personal protection equipment if you need to remove some gratings to access this
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part of the water. If the microsand concentration is below the value defined during the JAR tests,
you should check that there is not significant leakage of micro-sand in the sludge outlet.
If you find out that there is significant leakage in the sludge outlet, it might mean that the
hydrocyclone is clogged or blocked with a foreign object. In this case, you should stop the
Actiflo, dismantle the hydrocyclone and open it for inspection. Follow the hydrocyclone manual
to perform this task, while wearing personal protection equipment (especially safety shoes and
helmets for all personnel working around the Actiflo).
If there was no significant leakage, then you can add up to 10% more micro-sand compared to
initial loading that you calculated, using the same filling method as previously. After 30 minutes,
measure the microsand concentration again in the maturation tank. If you don’t detect a micro-
sand concentration increase in the flocculation tank, there might be an issue with chemical
dosing (not enough polymer), maturation mixer speed (must be between 45Hz and 50 Hz) or
the hydrocyclone duty point (a too high recirculation flow that induces microsand loss). If you
notice an increase in microsand but concentration remains below the value defined during JAR
tests, you can repeat this refilling with up to 10% additional sand until you reach the targeted
microsand concentration.
When the optimized microsand concentration is reached, the recirculation flow rate must be
adjusted.
The optimum recirculation flow rate is normally defined by Veolia experts during the design
phase.
It is usually defined to maximize the sludge outlet concentration, taking into account the treated
water quality expected.
The flow rate of each recirculation line can be measured or estimated.

If you have the optional recirculation flow meter, you can simply read the value.
If you don’t have a recirculation flowmeter, the flow rate must be estimated based on pressure
at hydrocyclone inlet. The curves that define flow rate according to inlet pressure are found in
the hydrocyclone manual. These values are approximate as they depend on many parameters
such as type of sludge, temperature, concentration of polymer, etc. Nevertheless, these curves
give a fairly good idea of the actual recirculation flow rate.
Firstly, adjust the frequency of each recirculation pump until the calculated optimum
recirculation flow rate is reached. If there are 2 recirculation lines in duty, ensure they are set-up
at the same frequency.
Secondly, it is recommended (but not mandatory) to adjust the recirculation flowrate to reach a
concentration of sand + sludge of 150 g/l at the inlet of the hydrocyclone. In certain cases with
highly loaded waste water, it is not possible to reach 150 g/l because of limitations in sludge
outlet concentration. When setting up the recirculation flow, always ensure that the sludge
concentration at the hydrocyclone outlet stays below 10-15 g/l. It is not recommended to exceed
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these values to avoid clogging of the recirculation line and/or losses of microsand in the sludge
outlet. Always take into account the most limiting factor when defining the optimum recirculation
flowrate.
To do so, with the pump(s) adjusted at the calculated optimum flow rate, measure the sand +
sludge concentration at the hydrocyclone inlet and sludge concentration. This can be done
using the sand pot as defined at the end of chapter 8.5.
Determine which factor is the limiting one and then adjust the frequency of the pump(s) to be at
the value defined in the paragraph above.
For example, if you measure a sand+sludge concentration of 130 g/l and a sludge concentration
of 8g/l, the most limiting factor is the sand + sludge concentration (130/150=87%) compared to
the sludge concentration (8/15=53%). In this case, it is recommended to decrease the flow rate
by a factor of 1.15 (100/87), but only if the targeted flow remains in the hydrocyclone normal
operating range.
When you have reached this optimum recirculation flow rate, wait 30 minutes and then use the
sand pot to check that there is no significant quantity of microsand in the sludge.
If there is a significant amount of microsand in the hydrocyclone sludge outlet (more than
1/1000 of recirculation sand mass load), then the recirculation flow rate might need to be
reduced or increased.
After that, check outlet turbidity.

If it is below the targeted value, you can start reducing the polymer dosing rate back to the value
calculated with the JAR tests (that should be half of what you used during this start-up).
After 2 hours, measure the turbidity again at the treated water outlet. If you are still below the
targeted turbidity values, you can consider that start-up is done.
On the other hand, if you are above the targeted treated water turbidity, you might need to
increase coagulant and/or polymer and/ microsand concentration. As JAR tests are done under
optimal conditions it might be necessary to increase these lab-scale values.
In this case:
1. Increase the initial concentration of micro-sand by adding a quantity equal to 5% of the
initial loading and increase the recirculation flow rate to reach a concentration of sludge
+ sand of 150g/l
2. If after 30 minutes, the turbidity of the outlet water is still above the targeted value,
increase the polymer dosing rate by 5%
3. If after 30 minutes, the turbidity of the outlet water is still above the targeted value,
increase the coagulant dosing rate by 5%.
You can repeat this process 3 times until you reach the targeted turbidity in the treated water. If
you still have a treated water turbidity above the targeted value after doing that contact a Veolia
expert.
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8. OPERATION AND MONITORING

To minimise the risk of injury, adequate lighting is required for proper operation and monitoring.
Only authorized personnel, using suitable Personnel Protection Equipment, shall be able to
access the Actiflo Area while the unit is operating.
To reduce the risk of biological hazards, use personal protection equipment and ensure that all
personnel working around the Actiflo have received the proper vaccines.
If you need to spend prolonged period of time near the Actiflo, consider also ear protections
against motor noise.
8.1. SHUTDOWN AND DRAINING
8.1.1. Shutdown standard procedure
The standard shutdown procedure is described in process control in Annex B.
If the Actiflo has been delivered with the standard control panel, shutdown can be initiated on
the HMI or remotely through the PLC Ethernet connection.
The key element of shutdown is that the recirculation pump will run for a certain time that must
be adjusted to ensure it will remove all of the sand that is in the settler.
8.1.2. Coagulation tanks draining

To drain the coagulation tanks, it is necessary to open the gate valve on TP06 and let the water
flow out. Perform this task only when the Actiflo is completely stopped and the mixers are no
longer rotating.
8.1.3. Flocculation tank draining

Before draining the flocculation tank, first ensure that enough time has passed since the
flocculation mixer has stopped to have all microsand settled in the bottom of the tank.
Additionally, it is advised to have first fully drained the settler to avoid having water leaking in
from the settler through the internal manhole.
When it is safe to do so, full drainage of the flocculation tank can be done by opening the gate
valve on TP07 and letting the flow out. This type of action could be required, for example, for
exceptional maintenance tasks on the flocculation mixer.
During such an event, there is a small amount of microsand that will be lost in the drainage
process.
8.1.4. Partial draining of settler

To inspect and potentially clean the lamella, it is necessary to partially empty the settler. To do
so, open the butterfly valve on TP05 and let the water flow out.
8.1.5. Full draining of settler
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For exceptional maintenance activities on the scraper, it is necessary to fully drain the settler.
To do so, first perform a normal shutdown procedure. Then, run the recirculation pump(s) until
the settler is nearly empty. It is normal to have a small part of the water recirculated that will
come back to the settler (around 10-20%). To avoid losing time, you can run the pump(s) with
the VFD set at 50 Hz. Be careful to stop the recirculation pump(s) before the settler is
completely empty or there could be significant damage done to the recirculation pump(s) glands
in only few minutes of dry-running. Ensure that 2 to 5 cm of water remains inside the settler.
8.2. STARTING UP THE UNIT AFTER A NORMAL SHUTDOWN

It is recommended to follow the guidelines in chapter 7 (Commissioning and Start-up), to get the
Actiflo running properly. Some steps (like sand filling) and checks (like rotation tests) are not
required every time.
One of the key elements, when starting the unit after a normal shutdown, is that all of the
microsand has settled at the bottom of the flocculation tank. Therefore, to ensure proper
suspension of microsand, run the maturation mixer at 50 Hz for several minutes. The amount of
time depends on raw water quality but normally 30 minutes or less should be sufficient.
Also during this transitory start-up phase, the quality of treated water and the concentration of
sludge will be not compliant with the values that can be reached in stable operation. Depending
on constraints downstream, it might be necessary to send the treated water back to inlet until
required performance levels are reached. Finally, there would be a significant loss of microsand
during the start-up process and so it is usually necessary to add sand during and after this
transitory start-up phase.
8.3. STARTING UP THE UNIT AFTER AN EMERGENCY SHUTDOWN OR A POWER

FAILURE
After an emergency shutdown or a power failure, a significant amount of micro-sand is in the
settler. If the unit is stopped form more than 10 minutes, it is usually necessary to inject
pressurized service water into the sludge chimney, through TP08. To do so, ensure you have at
least 2 bars available in the service water and open the ball valve for 5 minutes. Ensure that
water does not over-flow during this process.
After waiting 5 minutes, you can perform start up as described in the chapter 8.2.
8.4. CHEMICAL DOSING

In this section, indicative ranges for coagulants and flocculants are listed per application. To
define the most efficient products and the optimum doses, JAR tests must always be performed.
A suggested procedure for performing JAR tests is described in the chapter 8.6.
If raw water quality is fluctuating significantly (for example river water in Spring with high
turbidity), JAR tests must be performed again to adjust the dosing rates according to raw water
quality.
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Some basic dosing point guidelines are detailed in section 5.4.6.
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Table 7: Coagulant type and dosing rates for Waste water applications
Coagulant (mg/L) - HYDREX Reference availability/dosage as active

TSSin TSSout
Expressed as active
(mg/L) (mg/L)
product Iron based coagulant Aluminum based cogulant Tannin based coagulant(1)
HYDREX 6250/ HYDREX 6240/ HYDREX 6861, 6862, 6863/

15-35 ppm 10-20 ppm 10-25 ppm
Storm water < 1500 < 50
(expressed as Fe°) (expressed as Al°) (expressed as active
depending on inlet TSS depending on inlet TSS tannin)depending on inlet TSS
HYDREX 6240/ HYDREX 6861, H6862, H6863/
HYDREX 6250/
5-15 ppm 6-15 ppm
Primary < 1000 < 50 8-20 ppm (expressed as Fe°)
(expressed as Al°) (expressed as active tannin)
depending on inlet TSS
depending on inlet TSS depending on inlet TSS
HYDREX 6240/ HYDREX 6861, H6862, H6863/
HYDREX 6250/
MBBR (Ssout < 20 8-15 ppm 7-15 ppm
< 1000 < 20 10-20 ppm (expressed as Fe°)
mg/L) (expressed as Al°) (expressed as active tannin)
HYDREX 6240/ HYDREX 6861, H6862, H6863/
HYDREX 6250/
MBBR (Ssout > 20 10-20 ppm 10-20 ppm
< 1000 > 20 12-25 ppm (expressed as Fe°)
mg/L) (expressed as Al°) (expressed as active tannin)
HYDREX 6240/
HYDREX 6250/
Tertiary (TP outlet < 8-15 ppm
< 50 < 10 10-20 ppm (expressed as Fe°) NA
0,3 mg/L) (expressed as Al°)
HYDREX 6240/
HYDREX 6250/
Tertiary (TP outlet = 4-10 ppm
0,3-1 mg/L) (expressed as Al°)
HYDREX 6240/
HYDREX 6250/
Tertiary (TP outlet > 3-8 ppm
1 mg/L) (expressed as Al°)
HYDREX 6240/ HYDREX 6861, H6862, H6863/
HYDREX 6250/
Backwash 10-25 ppm 10-25 ppm
< 1500 < 50 15-35 ppm (expressed as Fe°)
thickening (expressed as Al°) (expressed as active tannin)
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Table 8: Coagulant type and dosing rates for drinking or process water applications
HYDREX Reference availability/dosage as active
Coagulant (mg/L) - Iron based coagulant Aluminum based cogulant

TSSin TSSout DOC* in
Expressed as active
(mg/L) (mg/L) (mgC/L) Europe Europe
product Rest of the World Rest of the World
Compliance with Compliant with European
NSF/ANSI Standard 60 NSF/ANSI Standard 60
European standard standard EN 883:2005
Certified. ** Certified. **
EN 888 :2005 (type 1) (type 1)
Turbidity and colour Hydrex 3250/ Hydrex 3255/ HYDREX 3240/ HYDREX 3240/
(T<6°C) prefer Al 3ppm/mg DOC* + 1ppm 3ppm/mg DOC + 1ppm 1.5ppm/mg DOC + 1ppm 1.5ppm/mg DOC +
< 1000 <5 < 20
coagulant when Fe/50NTU Fe/50NTU Al/50 NTU 1ppm Al/50 NTU
water is cold (expressed as Fe°) (expressed as Fe°) (expressed as Al°) (expressed as Al°)
Hydrex 3250/ Hydrex 3255/ HYDREX 3240/ HYDREX 3240/

Turbidity and colour 3ppm/mg DOC* + 1ppm 3ppm/mg DOC + 1ppm 1.5ppm/mg DOC + 1ppm 1.5ppm/mg DOC +
< 1000 <5 < 20
(T>6°C) Fe/50NTU Fe/50NTU Al/50 NTU 1ppm Al/50 NTU
(expressed as Fe°) (expressed as Fe°) (expressed as Al°) (expressed as Al°)
HYDREX 3250/ HYDREX 3255/ HYDREX 3240/ HYDREX 3240/

Backwash 2-5 ppm depending on 2-5 ppm depending on inlet 2-4 ppm depending on 2-4 ppm depending on
< 1500 <5 NA
thickening inlet TSS TSS inlet TSS inlet TSS
(expressed as Fe°) (expressed as Fe°) (expressed as Al°) (expressed as Al°)
*DOC = Dissolved Organic Carbon
** NSF/ANSI Standard 060 certification is production facility specific.
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Table 9: Flocculant type and dosing rates for Waste water applications
TSSin TSSout HYDREX Reference availability/ dosage as commercial product

Flocculant(mg/L)
(mg/L) (mg/L) (powder)
Powder form: Hydrex 6111, 6131, 6142, 6161, 6112, 6132

Storm water < 1500 < 50
0.8 - 1.2 ppm
Primary < 1000 < 50
0.8 - 1.2 ppm
MBBR (SSout < 20 mg/L) < 1000 < 20
0.8 - 1.2 ppm
MBBR (SSout > 20 mg/L < 1000 > 20
0.8 - 1.2 ppm
Tertiary (TP outlet < 0,3 mg/L) < 50 < 10
0.6- 1.0 ppm
Tertiary (TP outlet = 0,3-1 mg/L) < 50 < 10
0.6- 1.0 ppm
Tertiary (TP outlet > 1 mg/L) < 50 < 10
0.6- 1.0 ppm

Backwash thickening < 1500 < 50
1 - 2 ppm
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Table 10: Flocculant type and dosing rates for drinking or process water applications
HYDREX Reference availability/ dosage as active

PAM based STARCH based
Europe
TSSin TSSout Anionic and non-ionic
Flocculant (mg/L) powders: Compliant with
(mg/L) (mg/L) Rest of the World
European standard
NSF/ANSI Standard 60 Europe and rest of the world
EN1407:2008.
Certified. **
Cationic powders: Compliant
with European standard
EN1410:2008
Turbidity and colour - Powder: Hydrex 3511 DR, 3621 Powder: Hydrex 3511 DI, 3621
HYDREX 3841 ,3842/
Total hardness < 50ppm < 1000 <5 DR, 3631 DR, 3552 (DR) DI, 3631 DI, 3552 (DI)
0,5-1 ppm
CaCO3 0,1-0,2 ppm 0,1-0,2 ppm
Turbidity and colour - Powder form : Hydrex 3521 DR, Powder form : Hydrex 3521 DI,
HYDREX 3841 ,3842/
Total hardness > 50 and < < 1000 <5 3523 DR 3523 DI
0,5-1 ppm
80ppm CaCO3 0,1-0,2 ppm 0,1-0,2 ppm
Turbidity and colour - Powder form: Hydrex 3531 DR, Powder form: Hydrex 3531 DI,
HYDREX 3841 ,3842/
Total hardness > 80 and < < 1000 <5 3554 DR 3554 DI
0,5-1 ppm
200 ppm CaCO3 0,1-0,2 ppm 0,1-0,2 ppm
Powder form: Hydrex 6131,

Powder form: Hydrex 6131, 6142,
6142, 3511 DR, 3502 (DR),
3511 DI, 3502 (DI), 3512 (DI),
Backwash thickening < 1500 <5 3512 (DR), 3552 (DR), 6105, NA
3552 (DI), 6105, 6107
6107
0,8-1 ppm
0,8-1 ppm
** NSF/ANSI Standard 060 certification is production facilty specific.
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8.5. MICRO-SAND MANAGEMENT

8.5.1. Micro-sand specifications
The Actiflo process uses microsand to produce seeded flocs and it is this specificity that sets it
apart from other conventional lamellar settlers. Use the appropriate quantity of microsand, as
specified in the Table 11. The non-respect of these specifications can lead to poor Actiflo
performance levels and/or premature abrasion of recirculation line components and/or
premature corrosion of internal coating. For any questions, please contact the technical
department of your local Veolia Water Technologies subsidiary.
Table 11: Micro-sand specifications
Drinking water /
Waste water (Type II)
Process water (Type I)
Type (Rolled or Crushed) Crushed Crushed
Silica concentration (SiO2) >95% >95%
Effective size (d10) 85-100 µm 130-150 µm
Uniformity coefficient (d60/d10) <1.7 <1.7
Minimum size (2/3*d10) 60 µm 80 µm
Maximum size (2*d10) 200 µm 300 µm
Real density 2650 kg/m3 2650 kg/m3
Loss on combustion Less than 0.1% Less than 0.1%
8.5.2. Recommended concentrations of microsand

The concentration in the flocculation tank should usually be between 3 g/l and 10 g/l depending
on the application.
Typical applications and usual micro-sand concentration ranges to target in the flocculation tank
are listed in Table 12 and Table 13 below
To determine the most efficient products and the optimum doses, JAR tests must be performed.
A suggested procedure for performing JAR tests is described in chapter 8.6.
If raw water quality is fluctuating significantly (for example, river water with high turbidity in
Spring), JAR tests must be performed again to adjust the optimal sand concentration according
to raw water quality.
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Table 12: Micro-sand concentration recommended ranges for Actiflo Turbo used in waste water applications
Type of treatment TSS in TSS out Micro-sand concentration

(waste water) (mg/l) (mg/l) recommended range (g/l)
Storm water < 1500 < 50 5-10

Primary < 1000 < 50 5-10
MBBR (SSout < 20 mg/l) < 1000 < 20 5-7
MBBR (SSout > 20 mg/l) < 1000 > 20 5-7
Tertiary (TPout < 0.3 mg/l) < 50 < 10 5-7
Tertiary (TPout=0.3-1 mg/l) < 50 < 10 5-7
Tertiary (TPout > 1 mg/l) < 50 < 10 5-7
Backwash thickening < 500 < 50 5-10
Table 13: Micro-sand concentration recommended ranges for Actiflo Turbo used in drinking water or Process
water applications
Type of treatment TSS in TSS out Micro-sand concentration

(drinking/process water) (mg/l) (mg/l) recommended range (g/l)
Turbidity and colour

< 1000 <5 3-5
removal (T<6°C)
Turbidity and colour
< 1000 <5 3-5
removal (T>6°C)
Backwash thickening < 500 <5 5-10
8.5.3. Microsand concentration measurement
You must ensure that the sand concentration remains stable by regularly measuring the sand
concentration at different points (as indicated in chapter 8.7). A small quantity is continuously
lost in the treated water and in the sludge outlet.
The easiest way is to use the sand pot to measure the sand concentration in the recirculation
lines and then to calculate the sand concentration in the flocculation tank.
To measure the sand concentration in the recirculation lines, you should:

- Open the valve that is underneath the sand pot (used to drain it)
- Open the isolation valve connecting the sand pot to the inlet of the hydrocyclone for 30
seconds
- Close the valve underneath the sand pot and when the sand pot is filled up, close the
isolation valve
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- Wait 1 minute to allow the solids to fully settle

- Use a stick to stir the upper part of the sand and wait for 2 minutes. This will provide a
clearer separation between the solids and the water.
- Measure the volumes V1 and V2 as indicated below
V1
V2
Figure 10: Sand pot Calculate the sludge concentration with the formula:
Micro-sand Concentration in recirculation line [g/l] = V2 [L] x 1600 [g/L]

V1 [L]
This process must be repeated 3 times total with consistent results to ensure that the measure
is precise enough.
It is usually recommended to target 150g/l of sludge + sand in the recirculation lines. In some
cases with very high concentrations of sludge, it is sometimes necessary to reduce this value of
150 g/l of sludge + sand in the recirculation lines to ensure that the sludge at outlet remain
below 30 g/l.
Then, to calculate the sand concentration, record the raw water inlet flow rate Q1 and total
recirculation flow rate Q2 (to be estimated with hydrocyclone pressure curve if you don’t have a
flowmeter). If you have 2 recirculation lines working in duty 2x50%, you should double the
measured/calculated unit recirculation flow rate. You can finally apply the formula
Micro-sand Concentration in flocculation tank [g/L] = V2 [L] x 1600 [g/L] x Q2 [m3/h]

V1 [L] x Q1 [m3/h]
8.5.4. Make-up microsand

When there is a significant decrease of sand concentration, add 25kg sand bags as required,
directly in the draft tube of the flocculation tank. This task must be performed by personnel using
suitable Personnel Protection Equipment (protection against heavy loads and dust). To avoid
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clogging, only add one 25kg sand bag per minute. Always verify that there is no more than 10%
of sand lost between 2 top ups.
8.6. JAR TESTS

8.6.1. Principle
In order to simulate the Actiflo process, a modified jar test procedure was developed. The
procedure is mandatory for optimizing process chemistry (pH, chemical dosages, etc.), which
will produce settled water low in turbidity and other pollutants.
The simulation method reproduces results that are very close to full-scale unit results. Such
reproduction is achieved by simulating the same contact times in each basin and adding the
chemicals and micro-sand along the same sequence used in the full-scale unit.
Furthermore, the modified jar test procedure has the capability to evaluate or predict process
performances of an existing Actiflo unit and make accurate diagnoses for operation
troubleshooting.
The key principle of jar tests is to simulate the variation of a single parameter at a time, while all
others remain constant.
1. Definition of optimum coagulant doses

- Pour the exact same volume of raw water into several beakers. Ensure that the raw water
is properly mixed before pouring so that the water quality will be the same in each beaker.
- If necessary, adjust the pH so that it is the same in each beaker. The pH must be in the
recommended range of use for the tested coagulant.
- Dose the same volume of polymer into each beaker (concentration must be in the
recommended range defined in Table 9 or in Table 10).
- Put the same quantity of microsand into each beaker (it must be in the recommended
concentration range defined in Table 12 or Table 13.).
- Use different coagulant doses in each beaker. The coagulant doses must be defined to
cover the complete recommended concentration range from Hydrex chemicals defined in
Table 7 or Table 8.
- Test the treated water and define the optimum coagulant doses as per the beaker that has
the best quality of treated water.
2. Definition of optimum polymer doses

- If necessary, adjust the pH so that it is the same in each beaker. The pH must be in the
recommended range of use for the tested coagulant.
- Dose the optimum volume of coagulant defined in step 1 into each beaker
- Put the same quantity of microsand into each beaker,( it must be in the recommended
concentration range).
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- Use a different dose of polymer in each beaker. The polymer doses must be defined to
cover the complete recommended concentration range from Hydrex chemicals.
- Test the treated water and define the optimum polymer doses as per the beaker that has
the best quality of treated water.
3. Definition of optimum pH
- Apply a different pH to each beaker (these different pH values must be in the
recommended range of use for the coagulant type used).
- Dose the optimum volume of coagulant as defined in step 1 into each beaker
- Put the same quantity of microsand, (that must be in the recommended concentration
range), into each beaker.
- Dose the optimum volume of polymer as defined in step 2 into each beaker
- Test the treated water and define the optimum pH as per the beaker that has the best
quality of treated water.
4. Definition of optimum microsand concentration

- Apply the optimum pH as defined in step 3.
- Dose the optimum volume of coagulant as defined in step 1 into each beaker
- Dose the optimum volume of polymer as defined in step 2 into each beaker
- Put different concentrations of microsand into each beaker, covering the range defined in
Table 12 or Table 13.
- Test the treated water and define the optimum microsand concentration as per the beaker
that has the best quality of treated water.
This test can be repeated several times using different coagulants and polymers to define the
best Hydrex Chemicals to use to reach the required performance levels in terms of target
pollutant removal.
8.6.2. Material required

There are usually jar test kits available from Veolia. If they are not available, below is a non-
exhaustive list of materials:
 Phipps & Bird jar test apparatus or equivalent lab stirrer allowing up to 300 RPM
rotational speed
 Several circular beakers (1 litre), at least 5 are recommended
 Micro-sand
 Polymer
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 Coagulant Acid or base for pH and alkalinity adjustment (NaOH, aluminates, HCl,
H2SO4, lime, carbonate, bicarbonate, CO2, or equivalent)
 Turbidimeter (Hach 2100AN or equivalent)
 pH-meter (serial Hach EC or equivalent) and calibration solutions (pH=4, pH=7 and
pH=10)
 Chronometer or stopwatch
 Micro pipettes 5 ml-1000 ml
 Disposable syringes 1 ml-5 ml
8.6.3. Laboratory procedures

Before starting the jar tests, you should:
 Ensure that operators are wearing the appropriate personal protection equipment
 Ensure that a diluted solution of coagulant is available
Ideally:
- Aluminium sulphate solution at 1 g/l Al (Fresh weekly)
- Ferric sulphate/ferric chloride solution at 1 g/l Fe (Fresh daily)
Note: If Poly Aluminium Chloride (PAC) solutions are to be tested then these should be
added neat without dilution as they hydrolyse rapidly when diluted and so effectiveness is
lost. In this case suitable micropipettes should be used for dosing.
 Ensure that a diluted pH corrective chemical is available
Ideally:
- Sulphuric acid solution at 1 g/l H2SO4
- Caustic soda solution at 1 g/l NaOH
- Sodium carbonate solution at 1g/l Na2CO3
- Lime (Calcium hydroxide) recommended saturated lime water (well mixed, settled
and filtered) at approximately 1.7 g/l Ca(OH)2. Recommended to be made up fresh
daily.
 Ensure that a diluted solution of polymer is available, usually recommended at 0.1 g/l
(0.01%)
 Ensure that sufficient quantity of the required grade of microsand is available to carry out the
number of tests envisaged. This micro-sand must be rinsed thoroughly 10 times or until the
supernatant is clear, in order to eliminate turbidity caused by micro-grains or any suspended
particles that could be introduced into the water tested in the jar test. Dry in a 104°C oven
overnight. Place the washed sand in a labelled plastic jar.
When this is done, perform the following steps:
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1. Record the settled and raw water parameter values at the plant (turbidity, colour,
dissolved aluminium, etc.)
2. Fill up the beakers with raw water.
3. Set the beakers on the bench.
4. Make sure that the raw water temperature corresponds to the desired temperature.
5. Set the paddle between 0.5 and 1.0 cm from the bottom of the beaker.
6. Start mixing and adjust the rotation speed to 150 rpm.
7. If needed, add acid, base or equivalent to all of the beakers to adjust the pH.
8. Add coagulant simultaneously to all of the beakers using micro-syringes.
9. “A” minutes after adding coagulant (“A” corresponding to full-scale plant retention time in
coagulation tank(s) at the desired flow), add all of the microsand and the quantity of polymer
rapidly, using a syringe. If you have an extended coagulation mixer installed, ensure that time A
is doubled as required reflecting the real conditions.
10. After a flocculation time of “B” minutes (“B” corresponding to full-scale plant retention
time in maturation at the desired flow), stop stirring and allow the water to settle for the next 3
minutes.
11. Sample the settled water from 5 to 10 cm below the supernatant surface using a 100 ml
syringe. Proceed slowly. Make the required analyses.
8.6.4. Analysis
Analysis of the treated water should be defined according to the treatment target of the Actiflo.
Typically, you should measure:
1. Turbidity (NTU)
2. Apparent colour (ACU) using a spectrometer (mainly for drinking/process water)
3. pH
4. Any other relevant parameters for your project such as phosphate, metallic ions, algae,
etc.
8.7. NORMAL OPERATIONS AND PARAMETERS TO MONITOR

In order to ensure optimum performance of the Actiflo, it is necessary to follow-up on several
parameters on a regular basis and to record them.
Several parameters can be monitored by using the instruments, with values recorded managed
by the automation software. On the Actiflo with the standard control panel, 3-day-trends can be
recorded on the HMI (see chapter 9.10) or on the SCADA/central system by using the ethernet
output. Some other values (like sand concentration) must be measured manually, using suitable
Personnel Protection Equipment. Finally, depending on the configuration of the plant,
supplemental instruments, (not included in the Actiflo package) can provide additional relevant
information that should be recorded.
It is recommended that the operators record the following parameters, if suitable devices are
available:
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- On an hourly basis:
o turbidity, raw water
o color and/or DOC, raw water (drinking/process water only)
o pH, raw water
o turbidity, clarified water
o color and/or DOC, clarified water (drinking/process water only)
o pH, clarified water
- Every eight hours

o flow rate, raw water
o flow rate, coagulant metering pump, and calculated concentration
o flow rate, polymer metering pump, and calculated concentration
o flow rate, alkali metering pump, and calculated concentration
o pressure at the hydrocyclones inlet
o flow rate, recirculation lines
o microsand concentration in the recirculation lines
- On a daily basis
o total quantity of clarified water
o flocculation mixers speed
o electric current drawn by the motors
o pumps VFD frequency and pressure in recirculation pipework
o other parameters of interest regarding the applications: dissolved iron and
manganese, total organic carbon...
o average raw water flow
o microsand concentration in the sludge outlet
o microsand concentration in the flocculation tank
- On a weekly basis
o flow rate, hydrocyclone underflow
o sand concentration, hydrocyclone underflow
o proper distribution of water in the outlet troughs (along all V-notches and same
level of water in each trough)
o proper distribution of water in the outlet troughs (along all V-notches and same
level of water in each trough)
WARNING : Check on a daily basis that anchoring, ladder, stairs, handrails and
gratings are stable and tightened. Also, check that there are no abnormal
vibrations that could loosen devices related to safety
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9. CONTROL OF THE UNIT USING THE HMI

This section details how to navigate through the HMI.
The HMI provides the operator with a visual indication of the operating mode and condition of
the unit. Use the various buttons on the touch screen to navigate through the HMI screens.
The HMI screens are designed to be intuitive – in most cases simply pressing the part of the
screen displaying the data, pump, valve, instrument, action or sub-screen, will take you to that
information or open a pop-up window with further instructions.
All HMI screens are available to view by the operator. However, the functions on many screens
and the re-setting of various parameters and options require password access via the Login
screen (see later in this section).
Note: Although the HMI screen is fairly robust, it is advisable to operate the screen
with clean, grease-free hands. Normal finger pressure is sufficient to make
selections on the HMI.
Important: Do not use sharp or pointed items such at pen lids or pen / pencil tips on the
HMI screen. These will cause damage and shorten screen life.
9.1. START-UP DELAY SCREEN

On start-up following a power failure / power isolation the Start-up Delay screen is displayed for
35 seconds. This allows the various components to be initiated ready for operation. Timers are
reset and any Manual Override actions are superseded by the default settings and / or actual
instrument inputs.
At start-up / power up the following screen is displayed, with the countdown timer shown in the
middle of the screen:
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Figure 11: Start-up Screen
During this process the unit remains in Shutdown mode (pump off) and will not begin a start up
until after the delay timer (35 secs) has expired.
For this reason there is no HMI function to stop the unit. In an emergency use the E-Stop.
Once the start-up delay timer has expired the Home screen is displayed - see next.
Note: There will likely be active alarms associated with the mixer (AG20-02) and the pump(s)
(PC30-01 & PC32-01) on initial start-up / start up following a power failure or E-Stop
shut down. In this case it will be necessary to clear the alarm on the pump VFD unit –
press the VFD reset button (tick button) twice, then clear the alarms on the HMI
“Alarms” screen – see later.
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9.2. HOME SCREEN
Figure 12: Home Screen
Screen details - general information / functions available on many screens:

Along the top of screen -
 Left - the current operating mode / step is displayed - this is available on all the other
screens - as the mode changes the Step detail on the screens is updated.
 Middle - seconds remaining in the current mode. Note that in the service mode time
remaining is not shown as this is dependent on water quality and the water demand
signal.
 Right - Alarms button - gives access to the live alarms screen (see later). If there are
any active alarms the button is highlighted in red.
 Far right - current date and time
Down the left hand side of the screen -

 Turbidity and pH sensor outputs / current values - alarms on these instruments are
shown, e.g. AIT 20-01 LL - flow below the LL setting. Selecting any of these instruments
activates a pop-up screen (see later) that covers the lower part of the screen, allowing
manual adjustment of instrument (Engineer access required).
 Man-icon button - gives access to the Login screen (see later)
 Stop button - manually stop the unit (Operator access) - go to Stop mode sequence.
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 Start button - manually start the unit (Operator access) - go to Standby sequence -
depending on water demand and equipment set up the process will access Internal
Recycle & then Service, or External Recycle, or Standby.
Bottom section of the screen:

 Left - left hand arrow / "back" button - return to the last screen / stay on Home screen
 House icon -> go to Home screen - this button is available on all main screen
Icons in the middle of the screen:

Clicking on the icons surrounding the Veolia symbol displays the sub-screens (where available)
as shown in the following HMI screen shot:
Figure 13: Home Screen with Available Sub-Screens
 Veolia Icon -> go to Schematic Overview screen displaying an overview of the Actiflo
system - see later.
 Production Data -> shows two further sub-menus: Volumes, Trends
 About -> shows a pop-up screen with local Veolia contact information
 IO -> shows 4 further sub-menus: DI, DO, AI, AO
 Options -> go to Options screen (see later) - this displays the software and mechanical
options available & selected on the Actiflo
 System Information -> go to System Information screen (see later) - details the last & the
next service visit due (update by Engineer) - displays system time and date (update by
Operator).
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 Process -> shows four further sub-menus: Steps, Settings, Instrum., Equip.
9.3. LOGIN SCREEN

With the exception of screen navigation, all other settings / functions require a login to make
changes.
With no access codes entered the Login screen looks like this:
Figure 14: Login Screen - Empty
Use the "Log On" / "Log Off" buttons to enter the required pass code to access the various HMI
functions.
Note: The red “Alarms” button indicates there are active alarms.
Pressing "Log On" and then entering the Engineer pass word (see next table) will change the
display to the following:
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Figure 15: Login Screen - Engineer Login Active
The word "Engineer" appears on the left hand side on the screen indicating the level of access.
The screen shows the access time (in minutes) without HMI interaction before the access is
cancelled.
With the exception of screen navigation, all other settings / functions require a login to make
changes - see table below:
Table 14: User Access Overview
Access Level Capabilities Default Passwords

Unidentified Navigate through the screens N/A
Operator Start / Stop the unit Oper
(Site Operator) Access manual functions
Reset Alarms
Reset Counters
Supervisor Operator Access + Super
(Plant Manager) Modify Alarm delays and step timers
Engineer Supervisor Access + VWTeng01!
(VWT Engineer / support) Modify set points
Access Manual & Override actions
Access Simulation actions
Note: An additional Administrator access is available only to Veolia.
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The login will remain active for as long as the HMI is being used. Any screen access / viewing
operations using the HMI will maintain the login authority.
With no HMI input the access will expire after the "Logoff time". Any subsequent HMI actions or
modifications to settings will require the relevant access code to be re-entered.
See Appendix for access details to various HMI functions.
9.4. ALARM SCREEN

This screen is accessible from any screen by pressing the "Alarms" button in the top right hand
corner of the screen. A red "Alarms" button indicates active alarms.
Active alarms are displayed on this screen as follows:
Figure 16: Alarm Screen
This screen allows the user to:

 Reset - cancels all active Alarms (Operator access) - there is no further warning
 Detail - displays any additional information on the active alarms (where this is available),
such as what to check for to correct the alarm condition
 Historical - accesses the Alarm History screen (see below)
Note: The AG20-02 fault may require a reset of the mixer VFD before the alarm can be reset
and cleared from the above screen. This may also be true for other self-contained
instruments.
Press the "back" button to return to the previous screen.
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9.5. ALARM HISTORY SCREEN

Accessed from the "Alarms" screen this provides a more permanent record of alarms. It can be
viewed, but not cleared by the operator. It is a useful tool to help in identifying persistent
operating issues - see Maintenance section.
Figure 17: Alarm History Screen
Note: The red “Alarms” button indicates that there are active alarms.
Historical alarms with additional detail are available to view. There is a scrollbar on the right
hand side of the screen to allow the user to move up / down through the alarm messages.
The "Clear All" button (Engineer access) will permanently remove all alarm history without
warning. This is useful following on-site installation / commissioning to clear faults raised during
the initial setting up process.
9.6. SCHEMATIC OVERVIEW SCREEN

Accessed from the Home screen using the Veolia symbol - this screen shows a representation
of the Actiflo process. The relevant instrument and equipment tag numbers from the P&ID are
displayed above the relevant data. Only selected equipment / instrument options are shown on
this screen.
The items are animated based on their state:
 white = on / open / good level
 grey = off / closed
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 red = alarm / fault / low level (air or water tank)
All the measured values are displayed and updated in real-time.

The peripheral screen icons are similar to the Home screen - see the Home screen description
above for details.
Figure 18: Overview Schematic Screen
Important: "AVY" indicates availability of the mixer / valve for automatic operation. If
“AVY” is missing from any components the unit will not be available for
automatic operation, i.e. can't be started. In this case operation is only by
manual override inputs from the user (with Engineer access). All items of
equipment will require manual control.
Additional peripheral functions at the bottom of the screen:
 "Water Demand" button - Engineer function forcing a Water Demand signal - this
overrides the normal water demand input. This can be used in conjunction with manual
adjustment (override) of AIT70-01 (Engineer access) to force water to service when
there is no demand and / or when water quality is poor.
Warning: Forcing a water demand can result in over-filling the DI water tank.
The manual Water Demand request overrides the digital input status. The status of the "Water
Demand" button is shown as follows:
- Grey button = inactive - no water demand
- Orange button = manual override to force Water Demand on the HMI
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- Green button = Active Water Demand input based on low DI Water Tank level
- Orange Text AND Green button = Forced Water Demand and an Active Water Demand
input
 "Starting Conditions" button - go to service / regeneration Starting Conditions screen to

see active inputs / outputs required for each operating mode - see later.
If the final water Turbidity (AIT20-01) is modified (Engineer access), this is shown on the HMI by
a yellow “O” next to instrument ID and yellow text for the new value and its units - this indicates
an Override input to the user, as is seen in the screen shot below:
Figure 19: Overview Schematic Screen - with Engineer Override
The same logic is used to override all the signals (Engineer access).
Since the pump(s) and mixers are all still available ("AVY") this unit can still be run
automatically.
In normal / automatic operation the various icons are activated:
 green = on / open
 grey = off / closed
 red = alarm / fault / low level (air or water tank)
The operating mode / step is shown in the top left hand corner of the screen.
Press the "back" button to return to the previous screen.
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9.7. INSTRUMENT / MIXERS / PUMP / VALVE POP-UP SCREENS

Accessed from the Overview Schematic or Regeneration Schematic screens (see later), these
pop-up screens allow the user with Engineer access to manually modify the instrument
readings, set points and operation of valves, mixers and the pumps.
Instrument settings can be adjusted in automatic mode. However, manual pump(s), mixers and
valve operation requires the unit to be stopped first.
The following screen is for the Flocculation mixer (AG20-02). Similar screens are available for
the flow, conductivity, temperature and pressure sensors.
Figure 20: Mixer Pop-up Screen
A yellow “O” next to instrument ID and yellow text for the new value and its units indicates an
Override input is in operation.
Pump operation can be set to:
 H = Hand or manual operation
 O = Off
 A = Automatic - normal operation
For the pump - the speed can be manually set - select "H" and the pump speed & the pump will
start.
When the operation has been completed select "O" or "A" - this will set the pump speed at zero.
Select "A" to return the pump to automatic mode for normal operation.
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The "Reset" button (Engineer access) resets the "Next Maintenance" time to the maximum
setting.
Use the "X" in the top right hand corner of the pop-up to close the screen.
Note: It is important to return the pump to its original settings once the reason for the change
has been completed. They will not reset on their own, except in the case of a power
failure / or power off operation when the default settings and standard inputs are
applied.
For the instrument pop-ups:
There is a toggle / "Override" button to set a Manual Value in place of the instrument input.
Of course with the valves these can only be either open or closed. Note that manual overrides
will affect all valves served by the same control solenoid (see Appendix for linked valves).
When the operation has been completed reset the value and toggle the "Override" back to "Off".
Valves can be set to:
 H = Hand or manual operation
 O = Off
 A = Automatic - normal operation
Note: It is important to return the instrument / valve to its original settings once the reason for
the change has been completed. They will not reset on their own, except in the case of
a power failure / or power off operation when the default settings and standard inputs are
applied.
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9.8. DOSING SCREEN

The dosing screen can be accessed from the main overview and enables the operator to
monitor and control the dosing pumps. Similarly to the mixer previously explained, the dosing
pumps can be automatically or manually controlled from that screen.
Figure 21 Dosing Screen
Indications on the chemical levels are also displayed so that when a low level is reached in one
of the chemical tanks, it can be visualised on this screen by a red circle.
9.9. Starting Conditions Screen

Accessed from the Overview Schematic screen, this screen displays the mode status signals
that initiate the Production (service).
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Figure 22: Starting Conditions Screen
Note: Green = Active, Grey = Inactive
For Production (service) the following signals are required - all must be green:
 Water Demand - if there is no demand (grey) the unit will operate in Standby / Mixing in
line with the software setup.
 No Fatal Alarm - alarms (grey) need to be reset before going into production
 Unit in Standby - must go through Standby mode to reach Production
 Inlet Water Valve Available – the valve is in automatic mode - if grey then go to
Schematic Overview screen and reset. The same logic applies for all the other
equipment.
9.10. PRODUCTION DATA

Accessed from the Home screen this section includes two sub-screens:
 Volumes screen
 Trends screen
9.10.1. Volumes
Provides access to the following data, if the inlet flow meter is fitted:
 Daily, Monthly, Yearly and Total Volume Produced
 Estimated Sand loss.
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Note: A Notification is displayed when the estimated sand loss exceeds the "Max Sand loss"
set point.
Figure 23: Counters Screen
Screen details:
 The zeros column indicates how many times the particular operation has been started.
 The "0 h" is the time in operation - this is adjustable with Engineer access.
 The "Reset" button returns the relevant volume / regen counter figures to zero -
Engineer access.
Other notable points on this screen:

Left hand side info is useful for future maintenance purposes:
 Multi-purpose Pump - This is the sum of all running times for the pump whether in
production, regeneration or recirculation.
Right hand side info (only available if an inlet flow meter is installed):
 Day Volume – is the daily volume of water that entered the Actiflo. It is reset every day
but can be reset manually at any time.
 Month Volume – is the monthly volume of water that entered the Actiflo. It is reset every
month but can be reset manually at any time.
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 Year Volume – is the yearly volume of water that entered the Actiflo. It is reset every
year but can be reset manually at any time.
 Total Volume - this is the total volume of water that entered the Actiflo. It can be reset
manually at any time.
 Estimated sand loss – is the calculation of the sand loss during operation of the Actiflo. It
can be used to keep track of the sand used in the process.
9.10.2. Trends Screen

Displays the live and historical values of the instruments:
Trends from the following instruments can be displayed on this screen (depending on options
selected).
There will always be monitoring of:
- Outlet Turbidity (AIT20-01)
- Outlet pH (20-02)
The other optional instruments that can be monitored in the trends screen are:
 Inlet Flow (FIT11-01)
 Inlet Turbidity (AIT11-01)
 Inlet pH (AIT11-02)
 Recirculation line 1 flow (FIT31-01)
 Recirculation line 2 flow (FIT33-01)
The current instrument readings are shown at the bottom of the screen. A slider bar at the far
right of the screen can be moved to reveal the other instrument data.
An SD card (memory card) can be fitted to store running data (3 days). This allows the time
span on the screen to be expanded / reduced (see icons on the screen) without loss of data.
When the card is full the oldest data is overwritten.
If no SD card is fitted then no data is stored (on power loss) & only current trend information is
available to be shown on the screen. 1 hour worth of data is available for display (PLC
temporary memory) - the user can zoom in and out without loss of data.
The trend screen is a useful tool in helping engineers to identify faults and issues with plant
operation.
9.11. CONTACT SCREEN

Accessed from the Home screen the Contact Screen provides the address, telephone number
and email of the local Veolia agent / service provider. For example:
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Figure 24: Contact Screen
Provides details of the local Veolia company or agent. This has to be updated during
commissioning.
9.12. IO SCREENS
Accessed from the Home screen these screens display:
 Display the status of the Digital Inputs / Outputs
 the Current Value and Scaling of analogue signals
And allow the user to:

 Override / re-establish the AI / AO 4-20mA signals
9.12.1. Digital Input / Output Screens

View the status of the digital inputs and outputs.
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Figure 25: Digital Inputs Screens
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Format:
 Green button = active
 Grey button = inactive
For example, in Figure 25, the coagulation mixer is failing; the emergency stop is activated, etc.
This screen is used for monitoring only - no digital inputs can be adjusted.
Notes:
 KC 20-01 is the designation for the Actiflo control panel.
 The 3 "Free" slots are for future use (& are already wired up).
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Figure 26: Digital Outputs Screens
Note: Green = Activated, Grey = Inactive

For information only – there are no active components available to the user.
9.12.2. Analogue Input / Output Screens

The "Override" button / toggle switches also allow analogue input / output values to be applied.
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Figure 27: Analogue Inputs Screen with Override
Screen detail:
 Min = value represented by 4mA signal
 Max = value represented by 20mA signal
 Raw = Analogue to Digital conversion (not adjustable)
 Real = translation of the Raw 4-20mA input to the Min - Max range given
Use the toggle sliders towards the right hand side of the screen to override the instrument input
with the Override input (Engineer access). Typically the Overview screen is used to do this, but
for set up and testing purposes this screen can also be used.
Notes:
 It is important to cancel / clear any Override settings (Engineer access) once the reason
for the change has been completed. They will not reset on their own, except in the case
of a power failure / or power off operation when the default settings and standard inputs
are applied.
 It is also possible to override the instrument inputs on the Schematic Overview and
Regeneration Overview screens. This screen is mainly designed for testing purposes.
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Figure 28: Analogue Output Screen
Refer to screen detail from the previous Analogue Input screen.
9.13. OPTIONS SCREEN

It can be accessed from the Home screen. Engineer access is required to change the settings:
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Figure 29: Options Screen
The screen is split into two parts - the left side details the purely software based options /
configurations, the right side details those that have additional mechanical components
associated with them.
Table 15: System Options
Name Type Description

Actiflo Size Enter the unit size – 15 / 30 / 45 / 55 / 80
Hydrocyclone Entering the size of the MA sets the default values for
Size some instruments
Auto Restart Enabled / Enabled: Allows the system to automatically restart

Disabled operation at the last state before shutdown
Disabled: Does not allow the system to automatically
restart - requires manual intervention & then it will restart
at the last state before shutdown
Sand Mixing Enabled / Enabled: Allows the system to start the Mixing sequence
Disabled when the Actiflo is in Standby
Disabled: Does NOT Allow the system to start the Mixing
sequence when the Actiflo is in Standby
Vision Enabled / Disabled Enabled: Enables the Modbus TCP connection
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Disabled: Disables the Modbus TCP connection

Language English Currently limited to English - other languages to follow
Chemical Fitted / Fitted: The Chemical dosing is controlled by the Actiflo
Dosing Not Fitted Not Fitted: The Chemical dosing is NOT controlled by the
Actiflo
Coagulant Enabled / Enabled: the Coagulant dosing rate varies with the
Table Disabled turbidity
Disabled: the Coagulant dosing rate is fixed
pH Table Enabled / Enabled: the pH dosing rate varies with the turbidity
Disabled Disabled: the pH dosing rate is fixed
Micro-sand PC30-01 only PC30-01 only: Only the pump 30-01 is fitted
Pump PC32-01 only PC32-01 only: Only the pump 32-01 is fitted
Duty / Standby Duty / Standby: Both pumps are fitted and they run in
In Parallel Duty/Standby with an automatic switchover if the running
pump has a failure
In Parallel: Both pumps are fitted and they run at the
same time
Inlet Flow Not Fitted / Fitted Not Fitted: this instrument is not fitted on the Actiflo
Fitted: this instrument is fitted on the Actiflo
Inlet Turbidity Not Fitted / Fitted Not Fitted: this instrument is not fitted on the Actiflo
Inlet pH Not Fitted / Fitted Not Fitted: this instrument is not fitted on the Actiflo
Inlet Valve Not Fitted / Fitted Not Fitted: this instrument is not fitted on the Actiflo
Inline Mixer Not Fitted / Fitted Not Fitted: this mixer is not fitted on the Actiflo
Fitted: this mixer is fitted on the Actiflo
Pre Not Fitted / Fitted Not Fitted: this mixer is not fitted on the Actiflo
Coagulation Fitted: this mixer is fitted on the Actiflo
Mixer
Micro-sand Not Fitted / Fitted Not Fitted: this instrument is not fitted on the Actiflo
pump Flow(s) Fitted: this instrument is fitted on the Actiflo
Polymer Not Fitted / Fitted Only visible if Chemical Dosing is “Fitted”

Dosing Pump 1: Only pump 1 is fitted
Pump 2: Only pump 2 is fitted
Duty / Standby: Both pumps are fitted and they run in
Duty/Standby with an automatic switchover if the running
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pump has a failure
Coagulant Not Fitted / Fitted Only visible if Chemical Dosing is “Fitted”

Dosing Pump 1: Only pump 1 is fitted
pump has a failure
pH Dosing Not Fitted / Fitted Only visible if Chemical Dosing is “Fitted”
pump has a failure
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9.14. SYSTEM INFORMATION SCREEN

Accessed from the Home screen -
In this screen, information related to the unit software & servicing is displayed:
 Time and Date Setting
 Unit Number
 Software Version
 Service (Last Service/ Next estimated)
Figure 30: System Information Screen
Screen details:
 The access level is shown on the left hand side; in this case Engineer access is active.
Other screen information:

 Serial Number - entered by Veolia when the unit is first set up at the Veolia production
site.
 Software Version - for information only.
 PLC and HMI IP address - can be modified by the Engineer on site
 Service visit information is updated with Engineer access.
 Service Visit Frequency - recommended service interval set by the commissioning
Engineer - in this case 12 months
 Date Last Service Visit - updated by the engineer following servicing
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 Date Next Service Visit - automatically set based on the last service visit date and the
service frequency.
 The system time and date settings can be updated with Operator access.
9.15. PROCESS SCREENS

Accessed from the Home screen -
This includes the following sub-screens:
 Steps - timer settings for Production and Recirculation
 Steps - timer settings for Regeneration sequence
 Settings - set the pump speed and other general factors
 Instrum. - set instrument alarms
 Equip - set equipment alarms
9.15.1. Steps Screens

To set step times -
Figure 31: Timers Screen - Production
The timers are set up during the factory test and may require some adjustment on site.
To re-set step timers requires Engineer access (on the above screen the access level is shown
on the far left hand side below the instrument readings.
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Select the timer to be modified and enter a new time within the range given. This overwrites the
original value.
Caution: Before modifying any of the above timers please refer to Veolia Water.
Changes may harm the equipment or disrupt the process.
9.15.2. Settings Screen

This screen is used to set product water quality time delays, Production batch size (throughput
to next regeneration), pump operation / speed & FIT10-01 flow sensor pulse per litre (K-factor).
Figure 32: Settings Screen
Screen details:
Note: All adjustments to the settings on this screen require Engineer access. Select the
setting to change - a key pad appears - enter the new setting and press enter to accept.
 Valve (VA11-01) PID and flow rate settings are factory set. They should not require
adjustment. These settings control the smooth starting / stopping of the valve & set the
flow targets for each mode of operation.
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9.15.3. Dosing Screen
Figure 33: Dosing screen 1
Figure 34: Dosing screen 2
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9.15.4. Instruments Screen

Used to set the limits for on board instrument alarms -
Figure 35: Instrument Limits Screen
This screen details the instrument set points. Set points are as shown except for:
 The toggle switches (I/O) are used to enable / disable the related alarm (Engineer
access) - not all potential alarms are active / required.
 The Low value in seconds is the time it takes to activate a low or low low alarm when the
conditions are met. The high is the equivalent for high and high high alarms.
Note: Instrument details are only shown if the related option is fitted.
9.15.5. Equipment Screen

Used to set equipment alarm limits:
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Figure 36 Equipment Timer Limits Screen 1
Figure 37 Equipment Timer Limits Screen 2
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Screen details:
 The Alarm column indicates the time delay between a fault being raised and the alarm
being activated. This helps avoid nuisance alarms. These alarm delay times should not
require modification.
 Maint. is a countdown timer representing the recommended interval until the next
scheduled maintenance, in this case 6 months. They can be updated on this screen or
via the pop-up screens on the Overview and Regeneration Schematic screens.
Note: All adjustments to the settings on this screen require Engineer access. Select the
setting to change - a key pad appears - enter the new setting and press enter to accept.
The columns 2 Starts and Start/Stop should not be used unless specified by SSP.
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10. MAINTENANCE AND TROUBLESHOOTING

For all daily inspections, maintenance and troubleshooting activities, always wear the required
personnel protection equipment (protection against heavy loads, chemicals, dust, etc). If you
need to spend a prolonged period of time near the Actiflo, wear hearing protection to reduce
motor noise. In addition, always ensure you are following the site procedures in terms of safety,
especially electrical, mechanical and hydraulic isolation/lock out-tag out.
If you need to go inside the tank, ensure you follow local requirements for work in confined
space.
If you need to use lifting devices, ensure they are suitable (max loads, etc) and that they are
operated only by qualified staff.
10.1. DAILY INSPECTION

Inspections should be carried out on a daily basis. The purpose is to confirm that the unit is safe
to operate and is fully functional.
In this section, there is a list of some major tasks to be carried out. Additional tasks may be
required depending upon site requirements. In addition to the tasks in the following table,
process parameters must also be monitored as listed in section 8.7.
Table 16: Daily inspection tasks
Task Location Action Specification

1 Unit and piping Confirm no leakage No water leakage
2 Chemical dosing tube Confirm no leakage No water leakage
3 Ladder, gratings, Confirm no abnormal No risk of falling, No
handrails and anchorings movements abnormal movement of
mechanical parts
4 Microsand recirculation Check for abnormal sounds or No abnormal sounds or
pump vibrations vibrations
5 Mixer Check for abnormal sounds or No abnormal sounds or
vibrations vibrations
6 Lamella plate Solids No accumulated solids
7 Control panel alarm Confirm no alarms No abnormal signals
In case of issues with components, refer to the supplier manuals.

In case of leakage, stop water/chemicals and check the integrity of the pipework, seals and
check that all bolts are properly tightened.
10.2. COMPONENTS MAINTENANCE

Maintenance work should be carried out on a regular basis or in response to faults found during
daily inspection. This section indicates the minimum number of maintenance tasks that are
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required. In addition, always take into account suppliers recommendations that are found in the
specific supplier’s manuals.
Equipment and spare parts should be maintained as shown below. Depending on site
conditions (SS load, temperature and humidity, flow rate, etc.), the advised frequency might
need to be increased. To optimize maintenance costs, many of these tasks can be done at the
same time during yearly maintenance visits.
Figure 38: Components maintenance guidelines
No. Location Item Action Frequency advised
Every week (Waste

1 Settler Lamella plate Clean with water Water) or every 2
weeks (DW/PW)
Micro-sand Impeller liner Replace Every year
2
recirculation pump Gland packing and V-belt Replace Every 2 years
Check every 6 months,
Bearings Grease check replace at least every 3
years
Mixers motor- Check every 6 months,
3
reducers Gear motor Oil level check replace at least every 3
years
Coating touch-up in
Coating Every month
case of damage
Check every year,
Check and replace
Rubber pad replace at least every 3
in case of abrasion
years
Bearings Grease check replace at least every 3
years
Gear motor Oil level check replace at least every 3
4 Scraper
years
Coating touch-up in
Coating Every month
case of damage
Shaft and mechanical Check torques on
Every year
part blots
Crown reducer Oil level check replace at least every 3
years
APEX Tip Replacement Every year
5 Hydrocyclone
Vortex finder Replacement Every 3 years
6 pH and turbidity Probe Check calibration - Check every 3 months,
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No. Location Item Action Frequency advised
meter replace as replace wiper on

necessary turbidity probes every 3
months
7 Flow meter - Check calibration Every year
Pressure meter
8 - Replacement Every 2 years
and transmitter
Check coating and Check every month,
External coating touch-up in case of complete refurbishment
damage at least every 10 years
9 Tank
Check coating and Check every year,
Internal coating touch-up in case of complete refurbishment
damage every 5 years
Check, clean &
10 Control panel - replace damaged at least every year
components
The frequencies shown in the table above give a rough idea of component life-spans /
replacement periods and shouldn’t be taken as a guarantee of component life-span. The table
above is completed by the spare-parts list that is in ANNEX C.
The tank coating can last up to 15 years before complete refurbishment is required (in the best
case scenario). Depending on environmental conditions, water composition and temperature,
refurbishment could be required every 5 years. In any case, yearly inspection is mandatory and
spot repairs must be performed in case of damage to ensure the maximum life span of the
coating.
Repair procedures must be done according to supplier’s requirements, and the required
personal protection equipment must be worn during this process.
For inspection and repairs inside the tank, ensure you are wearing suitable Personnel
Protection Equipment and follow local requirements for work in confined space.
To maintain Actiflo performance levels, the lamellas should be cleaned regularly. Some factors
which influence fouling are:
 the nature of the raw water,
 the quality of the clarified water produced,
 the flow rates handled
There are two types of lamella fouling:
 Visible (observable fouling from above the lamellas)
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 Invisible (fouling in the lower area of the lamellas)

Visible fouling may be an indicator of invisible fouling in the lower area. If there is significant
invisible fouling, the lamellas can be damaged. In any case, lamellas should be cleaned at least
every week although in some cases it could be only required every 2 weeks. This may be more
or less frequent according to the fouling rate observed. The cleaning frequency interval is the
operator’s responsibility, although respecting a minimum frequency is recommended.
Water used for cleaning must not be pressurized to avoid damaging the lamellas. In order to
ensure that the entire surface of the lamella can be cleaned without the risk of the personnel
falling,, use a PVC pipe fitted with a hose connector and elbow on one end and a nozzle or
sprayer on the other end to direct water or air along the inclined axis of the lamellas. The length
of PVC pipe should be sufficient for it to be handled from the top of the Actiflo unit while allowing
access to the bottom of the modules.
Figure 39: Suggested material for lamella cleaning
The cleaning procedure with water is as follows:
1. Stop the Actiflo unit according to the normal procedure;

2. Start the micro-sand recirculation system in manual mode, including the scraper if
necessary, to assist in the disposal of cleaning sludge;
3. Slowly drain the basin using the partial drain located under the lamellas so as to have a
lowering rate of 2 to 5 cm/min and start cleaning during the emptying process;
4. Ensure that you are wearing suitable Personnel Protection Equipment against water jet
and that electrical parts which could accidently be water are not representing an
electrical hazard if wet,
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5. When turning on the water, direct the jet on the wall of the decanter to avoid damaging
the lamellas;
6. Clean the lamellas with a low pressure water jet (less than 2 bars) using a cleaning tool
(refer to previous figure) while the unit is emptying. Repeat the process to clean every
lamella tube. The water jet should be directed parallel to the lamella axis to clean the
entire length;
7. Close the partial drain as soon as the level of water is below the bottom of the lamellas
8. With the aid of a high intensity beam of light, verify the quality of the cleaning. When the
lamellas are properly cleaned, it is possible to see through them;
9. Once completed, when turning off the water, direct the jet on the wall of the decanter to
prevent damaging the lamellas;
10. Finally, return the Actiflo unit to service, to the sewer or to production depending on the
quality of clarified water to be produced.
For the ACP2-15 that is fully covered with gratings, it is required to dismantle the gratings to
perform an efficient lamella cleaning. IN such case, ensure that required Personnel Protection
equipment for work at height is used.
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10.3. TROUBLESHOOTING
10.3.1. Clarified water turbidity increase
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10.3.2. Clarified water true color or UV 254 increase (Dissolved Organic Carbon)
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10.3.3. Clarified water pH change
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11. SYSTEM SPECIFICATION

11.1. ENVIRONMENTAL CONDITIONS, FEED WATER REQUIREMENTS, AND
PERFORMANCE LEVELS
Standard design of the ACP2 mk2 is suitable for the following environmental conditions:
Table 17: Environmental conditions
Parameter Unit Value

Minimum ambient temperature °C 1
Maximum ambient temperature °C 35
Max humidity % 90
It is not advised to install the Actiflo pack in locations with higher temperatures, higher humidity
or a more aggressive environmental category or you may have:
- Premature corrosion
- Unexpected failures
- Abnormal maintenance requirements
- Shorter life span of parts and spare parts
However, the ACP2 mk2 standard design can be modified according to local requirements. In
any case, it is recommended not to operate the Actiflo in a condensing humidity.
For lower temperatures, it is necessary to properly insulate after installation (especially the
recirculation pipework and pump) and the Actiflo must be fully drained when not running.
Feed water requirements for the ACP2 mk2 are:
Table 18: Feed water requirements
Parameter Unit Value

Minimum water temperature °C 2
Maximum water temperature °C 40
Max inlet TSS (3) ppm 5000
Max inlet Turbidity (3) NTU 2 000
Max inlet particle size mm 2
In addition, the risk of corrosion due to contact with water must be assessed according to water
pH and temperature and the level of chloride. Several parts inside the Actiflo are in SS304L and
the internal coating has some limitations which are dependant upon the above parameters. In
case of non-compatibility, alternative, non-standard materials/coating can be considered
(SS316L, Super-Duplex, thicker/different coating, rubber lining, FRP tank…).
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Typical ACTIFLO TURBO performance levels have been established by VEOLIA but can
fluctuate according to raw water characteristics, the model of ACP2 mk2 selected, the
concentration of micro-sand and the chemical type and dosage.
To define optimal performance levels, it is mandatory to perform JAR tests (see section 8.6).
Ensure that micro-sand concentration as well chemical dosages, (defined as optimal during JAR
tests), are adjusted for the full scale unit during commissioning and then respected.
Normally, in optimal conditions and for a unit sized properly following Veolia Technical
Department guidelines, performance levels are:
Table 19: Actiflo typical performance levels for treatment of ground or surface water (Drinking or Process
water applications)
Parameter Removal rate

Turbidity 95% to 99%
TSS – Total Solids in Suspension 95% to 99%
TOC – Total Organic Carbon 60% to 80%
Color 80% to 95%
COD – Chemical Oxygen Demand 70% to 90%
Algae 90% to 99%
Table 20: Actiflo typical performance levels for treatment of Waste water (Municipal or Industrial
applications)
Parameter Removal rate

TSS 80% to 99%
Total COD 60% to 90%
Total BOD 40% to 80%
Total Coliforms 80% to 95%
Total P 80% to 95%
Iron and Manganese 90% to 99%
Arsenic 80% to 95%
Other Heavy metals (Cu, Ni, Zn, …) 40% to 90%
Oil & Grease 50% to 95%
These values above are only indicative and may not be applicable for certain types of water
(cold temperatures or removal of special algae for example) or for very low concentrations. Also,
certain pollutants (COD, BOD, Heavy metals, oil and grease…) can have many forms that are
not always settable. Finally, the dosing of chemicals must be maintained and adjusted
according to inlet water characteristics.
In any case, if you don’t achieve these removal rates, don’t hesitate to contact your local Veolia
Water Technologies subsidiary for a process review.
11.2. KEY PROCESS SIZING PARAMETERS

Table 21: Actiflo ACP2 MK2 process data
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Model ACP2-15 ACP2-30 ACP2-40 ACP2-45 ACP2-55 ACP2-60 ACP2-70 ACP2-75
Maximum raw water flowrate(1)

3 125 250 375 500 750 1000 1563 1781
(m /h)
3
Minimum flow rate (m /h) 13 25 38 50 75 100 156 178
Hydrocyclone model small line(s) MA5 MA5 MA10 MA10 MA20 MA20 MA40 MA40
Standard Recirculation flow : one

3 (2) 4 6 8 12 16 25 35 40
small line in duty (m /h)
Standard Recirculation flow : two
3 8 12 16 24 32 50 70 80
small lines in duty (m /h)
Hydrocyclone model large line(s) MA10 MA10 MA20 MA20 MA40 MA40 MA40 MA40
Standard Recirculation flow : one

3 (3) 8 14 20 25 45 55 NA NA
large line in duty (m /h)
Standard Recirculation flow : two
3 (3) NA NA NA NA NA NA 80 100
large lines in duty (m /h)
Extended coagulation Tank
3 1,54 2,81 4,31 5,73 8,59 11,43 17,75 17,56
volume (m )
3
Coagulation Tank volume (m ) 1,54 2,81 4,31 5,73 8,59 11,43 17,75 17,56
3
Flocculation tank volume (m ) 4,58 8,34 12,79 17,28 25,82 34,24 52,18 61,35
2
Lamellas mirror surface (m ) 1,04 2,21 3,69 4,14 6,29 9,95 12,59 14,41
(1): Maximum flowrate in each specific case must be defined according to inlet water quality and
removal efficiency required. This value is the hydraulic maximum flowrate.
(2): For specific requirements, recirculation flowrate can be adjusted at a lower flowrate in a
non-standard configuration.
(3): Limitations are defined by the hydrocyclone flow ranges and the max acceptable flow
velocity in the recirculation pipework. Curves are available in the Hydrocyclone manual.
11.3. MATERIALS FOR CONSTRUCTION AND COATINGS

The materials listed below are for the standard equipment. In specific cases, alternative
materials can be proposed as part of a modified standard design. Please refer to the schedules
for more precise information.
- Tank, handrails and ladder: coated carbon steel RAL7040
- Control Panel in coated carbon steel RAL7035
- Gratings in FRP
- Motors of mixers in aluminium alloy with epoxy coating RAL5021
- Mixer, scraper, Turbomix and outlet trough: SS304L passivated
- Pump: body in coated cast iron RAL1005, motor in aluminium alloy with epoxy coating
RAL 5009, internal lining in natural rubber
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- Seals and scraper pads in EPDM.

- Recirculation pipework in HDPE
- Lamellas in high impact polystyrene
- Hydrocyclone in polyurethane
11.4. STANDARD AND NORMS

All components supplied are in conformity with CE Marking. If a standard control panel is
supplied, the complete Actiflo is also in conformity with CE Marking.
Ladder and handrails are designed as per EN ISO 14122
Tank parts in coated steel:
- Welding procedure specified (WPS) and qualified (WPQR) according to ISO 15609-1 or
ISO 15614-1.
- All surfaces in carbon steel are sand blasted to the grade SA2½ according to ISO 8501-
1.
- Tank external coating category C3 High durability according to ISO12944
- Tank internal coating category Im3 High durability according to ISO12944
Motors:
- Totally enclosed, fan cooled
- Compliant with IEC 60034, efficiency IE3 for motors bigger than 0.75 kW, efficiency IE1
for motors smaller than 0.75 kW
- Enclosure protection minimum rating IP55
- Insulation class F
Flanges: EN 1092, PN10
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12. ANNEXES
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ANNEX A: SITE INSTALLATION &

COMMISSIONING – CHECKLIST
ACTIFLO
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ANNEX B: PROCESS CONTROL

DESCRIPTION
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ANNEX C: SPARE PARTS LIST
WATER TECHNOLOGIES
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ANNEX D: COMPONENTS
SUPPLIERS MANUALS
WATER TECHNOLOGIES

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ACTIFLO TURBO ACP2 MK2

INSTALLATION, OPERATION AND

Veolia Water Technologies

3.3.7. Recirculation pipework and sand pot ...................................................................26

5.3.5. Raw water turbidity meter (optional) .....................................................................42

8.5.2. Recommended concentrations of microsand .......................................................62

9.15.3. Dosing Screen..................................................................................................98

1.1. INTENT OF THIS MANUAL

To obtain any additional information regarding characteristics, operation or maintenance of this

Veolia Water Technologies

1.2. DISCLAIMER STATEMENT

1.3. PROPRIETARY RIGHTS STATEMENT

2. HEALTH & SAFETY

2.1. SAFETY INSTRUCTIONS

Action-related safety instructions are shown ahead of the corresponding instructions.

The following indications:

Danger Warning Attention

2.2. OPERATOR CARE

The operator must pay particular attention to the following:

 The plant / unit is used as only as specified

 Modifications are only to be carried out by authorised specialised personnel.

2.3. PERSONAL PROTECTIVE EQUIPMENT

Pair of goggles with side protection

2.4. SAFETY NOTES - FOLLOWING INSTALLATION

Confirm the equipment is properly earthed - failure to do so may result in

Attention Ensure that there is sufficient drain capacity.

Refer to Chemical Safety Data Sheets before handling any chemicals.

2.4.5. Natural disasters

Possible impacts of natural disasters (earthquake, cyclones, floods or others)

2.5. SAFETY NOTES - DAILY OPERATION

Keep flammable liquids and gases away from electrical components.

When conducting maintenance work on electrical components make sure that

Avoid touching electrical components / terminals with wet hands.

Do not supply out-of-specification feed water to the equipment under any

3. ACTIFLO TURBO ACP2 MK2 PROCESS AND COMPONENTS

3.1. ACTIFLO TURBO PROCESS GENERAL DESCRIPTION

Figure 1: ACTIFLO Process description

3.2. ACP2 MK2 RANGE: DESCRIPTION AND SPECIFICITIES

3.3. PARTS DESCRIPTION

Figure 2: ACP2-60 scraper

Figure 3: Motorisation of the ACP2-40 scraper

Figure 4: Lamellas and outlet troughs during assembly in a workshop

3.3.5. Recirculation pumps

Figure 5: MA hydrocyclones from MA80 to MA1

3.3.7. Recirculation pipework and sand pot

- Torque switch for the scraper

As options, several additional instruments can be supplied:

In the standard model, the Actiflo is comprised of:

3.3.10. Control panel and junction boxes

4. SHIPPING AND HANDLING REQUIREMENTS

4.1.1. Packing description

Model Length (m) Width (m) Height (m) Weight (tons)

Model Length (m) Width (m) Height (m) Weight (tons)

It is recommended to transport disassembled components inside a GP container. For the

Table 3: Disassembled components prepared for transport, with Control panel

Total Gross Advised

Table 4: Disassembled components prepared for transport, without control panel

Total Gross Advised

4.1.2. Transport and Reception

4.2. LIFTING PROCEDURE

For lifting, it is usually recommended to have, at minimum:

Figure 6: Lifting lugs of the Actiflo

Table 5: Tightening torque for lifting lug bolts