MECHANICAL SURFACE AERATORS

JUNE 1989 PAGE 1 OF 5 EGE 26-B-3 1989

TABLE OF CONTENTS
1. Scope
2. References
3. General
4. Performance
5. Design
5.1 Process
5.2 Equipment
5.3 Mechanical Design and Materials
6. Data sheets
1. SCOPE
This Guide covers basic requirements for the design, materials, and fabrication of mechanical surface
aerators used in wastewater treating applications. The information contained in this Guide is applicable to
fixed or floating low-speed mechanical surface aerators and floating high-speed mechanical surface
aerators.
2. REFERENCES
The following publications form a part of this Guide. Unless specified otherwise herein, use the latest
edition.
Mobil Engineering Guides
EGE 00-C-4 Equipment Purchases General Engineering Requirements
EGE 26-D-3 Mechanical Surface Aerator Data Sheet
EGE 31-B-1 Steel Structures Design and Fabrication
EGE 33-D-9 Electrical Induction Motors
EGE 33-D-9 Induction Motor Data Sheet
35-B-10 Painting Manufacturing Facilities
EGE 41-B-20 Water Treating Equipment Design and Fabrication General
API (American Petroleum Institute) Publication
Manual on Disposal of Refinery Wastes, Volume on Liquid Wastes, Chapter 13: Biological Treatment*
_______
*The API DRW Manual (1969) is currently out of print and available only in libraries.
3. GENERAL
3.1 The general equipment requirements of EGE 41-B-20 shall apply to this Guide.
3.2 The mechanical surface aerator shall be furnished as a complete unit, ready for installation in an
aeration basin of an industrial wastewater treating plant. Components of the aerator shall be designed for
this service.
3.3 Equipment shall be purchased in conformance with EGE 00-C-4, except as modified for specific
equipment by the project instructions, specifications, and terms and conditions stated in Mobils request for
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quotation.
3.4 The mechanical surface aerator shall maintain the contents of the aeration basin in a uniformly mixed
state while transferring the specified amount of oxygen to the system.
4. PERFORMANCE
4.1 The equipment vendor shall furnish the oxygenation capacity rating of the aerator in terms of mass
transfer coefficient, KLa, at standard conditions for the given geometric basin design. Standard conditions
shall be taken to be clean tap water with a temperature of 20C (68F), a dissolved oxygen solubility relative
to tap water of 100 percent, and a pressure of 101.3 kPa abs (14.7 psia).
4.2 The maximum line power drawn per unit shall not exceed 100 percent of motor nameplate horsepower
rating when the unit is operating in the range of the impeller submergence specified in EGE 26-D-3.
4.3 Oxygen transfer tests shall be required at a mutually acceptable site. The test site shall conform to
the aerator surface area and depth configuration specified in EGE 26-D-3. The test procedure shall follow
the "Unsteady State Clean Water Test" recommended in the Development of Standard Procedures for
Evaluating Oxygen Transfer Devices, published by the USEPA. [EPA-600/2-83-102, Development of
Standard Procedures for Evaluating Oxygen Transfer Devices, Office of Research and Development, United
States Environmental Protection Agency, Cincinnati, OH, 45268 (1983).] The test site and test procedure
shall be submitted to Mobil for approval prior to field testing.
4.4 The mechanical aerator shall provide complete mixing so that the mixed liquor suspended solids
(MLSS) concentration in the aeration basin shall not deviate from an arithmetic average MLSS value by
more than 10 percent. [MLSS = the concentration of activated sludge in the aeration basin derived
through standard method 209C, Standard Methods for the Examination of Water and Wastewater
(APHA-AWWA-WPCF), 16th edn., American Public Health Assn., Washington, DC 20036 (1985).]

On the basis of a minimum of 12 MLSS samples taken from selected locations within a given time interval,
a coefficient of variation of less than 0.28 shall substantiate acceptable solids uniformity throughout the
aeration basin. This includes a 10 percent error due to sampling and analyzing procedures. Location of
sample points from a representative horizontal and vertical profile shall be approved by Mobil prior to field
testing.
4.5 The field testing, including sampling, shall be witnessed by a Mobil representative to ensure that the
equipment will meet the specified performance. All test results shall be submitted to Mobil for approval. All
costs for the field tests (chemicals, power, water, instruments), laboratory analysis, and test reports shall
be defrayed by the manufacturer and shall be quoted separately from the equipment costs.
5. DESIGN
5.1 Process
5.1.1 The biological oxygen requirement and oxygen transfer capacity of the mechanical aerator shall
be designed in accordance with the API Manual on Disposal of Refinery Wastes, Volume on Liquid Wastes,
Chapter 13.
5.1.2 Design of the mechanical aerator mixing requirement shall be a sufficient power/liquid volume ratio
to maintain in suspension the given MLSS concentration for the basin geometry specified in EGE 26-D-3.
5.2 Equipment
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5.2.1 The low-speed (100 rpm or less) mechanical surface aerator shall be the vertical updraft type
suitable for either platform or flotation mounting and shall include the following equipment components:
(a) Electric motor.
(b) Coupling and guard (if required).
(c) Gear reducer.
(d) Drive hub.
(e) Impeller shaft and assembly.
(f) Flotation assembly (if specified).
(g) Anchoring accessories.
5.2.2 The high-speed (900 to 1200 rpm) mechanical surface aerator shall be the vertical updraft type
with the impeller shaft directly driven by the motor shaft and shall include the following equipment
components:
(a) Electric motor.
(b) Coupling and guard (if required).
(c) Impeller shaft and assembly.
(d) Flotation assembly (if specified).
(e) Anchoring accessories.
5.2.3 The equipment vendor shall furnish all appurtenances, including splash plates, anti-vortex baffles,
anti-erosion plates, draft tubes, and other items necessary for the proper operation of the aerator in the given
basin geometry. These items shall be included separately in the vendors quote.
5.2.4 All structural steel used in the fabrication of the aerator shall conform to EGE 31-B-1.
5.2.5 In the case of a flotating aerator, the vendor shall supply the floating structure for the aerator and
a complete description of the mooring facilities necessary to secure the aerator. The vendor shall also
provide the design basis for the mooring facilities. This design shall be approved by Mobil.
5.2.6 Where a fixed platform will be utilized, the vendor shall provide a description of the support platform
and foundations required. This design shall be approved by Mobil.
5.2.7 The vendor shall supply a list of minimum requirements for electrical wiring cable and motor
starters.
5.3 Mechanical Design and Materials
5.3.1 Electric Motor The motor shall be specifically designed for aerator duty in a severe exposure
atmosphere and high shock loads and shall comply with EGE 33-B-9. The motor shall be totally enclosed,
fan cooled, and rated for 40 C (104F) ambient, with a 1.15 service factor and Class F insulation or as
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specified in EGE 33-D-9. The motor shall be furnished with drip cover, cast junction box with gaskets, lifting
lugs, and condensate drain plug.
Surface preparation and painting shall be in accordance with EGE 35-B-10 and as defined in Table 3 of that
Guide for rotating equipment in the temperature range of ambient to 82C (180F).
5.3.2 Coupling and Guard
Where power transmission is required, a coupling shall be supplied between the rotating shafts of two pieces
of equipment. Couplings shall have a minimum service factor of 2.0. The coupling guard shall conform to
local safety requirements as applicable. Nonlubricated couplings with stainless steel flex discs and steel
hubs are preferred. Alternative couplings require Mobil approval.
5.3.3 Gear Reducer
Gearing shall be of the helical type, with an integral motor [equal to or less than 19 kW (25 hp)] or a coupled
motor [greater than 19 kW (25 hp)] connected to the gear reducer. Alternative gearing types require Mobil
approval. Gearing shall be designed for continuous duty and high shock loads in a corrosive atmosphere
and shall be constructed in accordance with applicable AGMA (American Gear Manufacturers Association)
criteria. The gear reducer shall be designed for vertical downshaft aerator operation and shall have a
minimum service factor of 2.0.
Bearings shall be the ball or roller type and shall have a minimum AFBMA L-10 bearing file of 100,000 hours.
The design life for the primary and intermediate gear train shall be a minimum train shall be a minimum of
100,000 hours at full-load conditions.
All gear meshes and bearings in the gear reducer shall be splash lubricated. Positive lubrication
accomplished by an oil circulating pump shall be acceptable only if the pump is externally accessible and
driven directly by one of the gear trains. Oil level sight windows and drain fittings shall be provided. An oil
pressure switch shall automatically shut off the aerator in the event of low oil pressure. Proper cooling shall
be provided if the thermal rating of the gear reducer does not exceed the design load.
The base of the gear reducer shall serve as a rigid baseplate for the entire aerator assembly The baseplate
shall be furnished with vertically adjustable support legs and shall be sufficiently rigid to transfer all torque,
shock, and other loads to the platform.
The drive housing shall be of cast iron construction and covered with a protective (epoxy) coating designed
for severe exposure conditions. All surface preparation and painting shall be in accordance with EGE
35-B-10 and as defined in Table 3 of that Guide for rotating equipment ranging in operating temperature from
ambient to 82C (180F). Suitable lifting lugs shall be provided on the gear case.
5.3.4 Drive Hub
The impeller shaft shall be positively connected to the gear reducer shaft by means of a bolted keeper plate.
Torque shall be transmitted to the impeller shaft through a bolt, key, and drive hub arrangement that permits
removal without disturbing the gear reducer.
5.3.5 Impeller Shaft Assembly
In the case of a low-speed aerator, the shaft shall be sized to withstand operating and static stresses.
These data shall be subject to Mobil approval. Each end of the impeller shaft shall have a bolting flange
welded to it. The impeller assembly shall be positively fastened to the shaft and designed so it can be easily
removed. Detachable blades shall be bolted to the impeller assembly. Shaft and impeller material shall be
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manufacturers standard, subject to Mobil approval.
In the case of a high-speed aerator, the impeller shaft shall be either directly coupled to the motor shaft or
one continuous piece and shall be constructed of a higher-strength, corrosion-resistant stainless steel (Type
17-4 precipitation-hardened stainless steel, for example). The impeller shall be the nonclog type,
dynamically balanced, and a precision casting of corrosion-resistant stainless steel. A two-piece shaft joined
by a rigid coupling shall be supported by a water-lubricated cutless rubber bearing or an alternative
acceptable means to limit radial deflection of the impeller shaft. The impeller shall be housed in a
corrosion-resistant stainless steel core.
5.3.6 Flotation Assembly
In the case of a floating low-speed mechanical aerator, a support structure including pontoons, framework,
and access platform shall be provided. The structure shall be designed to safely withstand all normal
operating loads. This design, including the dynamic force analysis, shall be reviewed by Mobil. The support
structure shall include three pontoons connected by a framework or fabricated steel members joined
together at the central access platform. Each pontoon shall be constructed of fiberglass-reinforced polyester
resin or corrosion-resistant alloy metal filled with high-density polyurethane, foamed in place, and completely
sealed from the environment.
The pontoons shall be designed to support the aerator during dry dock. An integral access platform,
consisting of the necessary floor plates, beams, and stiffeners, shall be furnished to provide a working area
for maintenance of the drive assembly. Design and fabrication of steel structures shall comply with EGE
31-B-1. The support structure shall be manufacturers standard, subject to Mobil approval.
In the case of a floating high-speed mechanical aerator, the flotation unit shall be constructed of
fiberglass-reinforced polyester or corrosion-resistant alloy metal filled with high-density polyurethane, foamed
in place, and completely sealed from the environment. The minimum flotation capacity shall be twice the
aerator weight. The float shall be designed to carry operating loads from the mooring cable to the motor and
shall be equipped with no less than three mooring eyes. The diffuser head shall be designed to distribute
the impeller discharge uniformly in a 360 degree low-spray horizontal plane. The deflector shall be a
monolithic casting of corrosion-resistant stainless steel. The flotation assembly shall be manufacturers
standard, subject to Mobil approval.
Surface preparation and painting of all carbon steel components on the flotation assembly shall be in
accordance with EGE 35-B-10 and as defined in Table 3 of that Guide for structural steel. For highly
corrosive environments, carbon steel components on the flotation assemblies may require additional
corrosion protection, such as glass-reinforced polyester coatings.
5.3.7 Anchoring Accessories The vendor shall furnish all anchoring accessories and mooring fasteners
in corrosion-resistant stainless steel or other approved material, inclusive of cables, clamps, column collars,
bolts, etc.
6. DATA SHEETS
The vendor shall complete as part of the proposal EGE 26-D-3 and, if applicable, EGE 33-D-9.