DDS Prod Manual P

Copyright: Nopon Oy 2002. Printed in Finland.
DDS 0501 ENG 195052

NOPOL
DDS
PRODUCT MANUAL
1 NOPOL
DDS System
2 NOPOL
PIK 300
3 NOPOL
PRK 300
4 NOPOL
KKI 215
5 NOPOL
HKL 215
6 NOPOL
MKL 215
7 NOPOL
CLEAN
8 Brochures
9 Reference Lists
10 NOPOL
DDS: Installation, operation and

maintenance manual
11 NOPOL
PIKE Installation, operation and

maintenance manual for PIK 300
diffusers on PP pipes
NOPON OY Turvekuja 6 FIN-00700 Helsinki Finland Tel +358-9-351 730 Fax +358-9-351 5620
E-mail: hq@nopon.fi internet: http://www.nopon.fi/
We reserve the right to make technical changes.
1 NOPOL DDS System
NOPOL
DDS
PRODUCT MANUAL
NOPOL
DDS
Disc Diffuser Systems
41-
31001
/2
1/3
NOPON OY May 7, 2001
Written by: MR Inspected by: AL Approved by: ERN
SYSTEM DESCRIPTION
In fine bubble aeration systems compressed air is distributed through pipework to
the aeration device, called diffusers. Compressed air is dispersed into fine bubbles
and oxygen is transferred into the surrounding fluid. The grids of pipes with diffusers
installed, called an aeration group, cover the basin bottom. The pipework is fixed to
the basin bottom. Even distribution of diffusers gives equal dissolved oxygen
concentration and uniform mixing energy distribution throughout the tank.
NOPOL
DDS systems consist of one or several aeration groups. Each group is

made up of diffusers, air distribution pipes, pipe expansion joints and bottom
mounting brackets. The NOPOL
DDS system is complete including all necessary

accessories for installation. The prefabricated modular elements make installation
easy and fast. An aeration group and its main components are shown in the
drawings LD 3950 and LD 5462.
COMPONENTS OF THE SYSTEM
There are five kinds of NOPOL
DDS systems for various applications. The HKLE,

MKLE, KKIE, and PIKEV systems have different disc diffusers, but they are all made
of similar pipework and components. The PIKE system can be used with many kinds
of pipework and the components are different from the other systems.
Table 1. NOPOL
DDS systems and diffusers

System name Diffuser type Diffuser disc
HKLE HKL 215 Porous HDPE, fine bubble, 200 mm
MKLE MKL 215 Porous HDPE, medium bubble, 200 mm
KKIE KKI 215 Elastic membrane, 200 mm
PRKE PRK 300 Elastic membrane, 300 mm
PIKEV PIK 300 Elastic membrane, 300 mm
PIKE PIK 300 Elastic membrane, 300 mm
The HKL 215, MKL 215, KKI 215, and PRK 300 diffusers are designed for mounting
on a PVC or stainless steel pipe by a wedge piece attachment. The PIK 300
diffusers are designed for mounting on a PP, PVC or stainless steel pipe by a wedge
piece attachment. No solvent welding is required at site. Details of the diffusers and
its components, materials and performance are described in the respective technical
specifications.
Preassembled diffuser elements are made of O.D. 90 mm uPVC or PP pipes, cut in
length up to 5 m, to hold the diffusers and to form lateral rows spanning the whole
group. Characteristics for the pipe are given in the PVC (41-31012) and PP pipe
specifications (41-51012).
NOPOL
DDS
41-
31001
/2
2/3
Connection sleeves HSY 90 - 90 and PSY 90 are used to connect the pipe elements
and the construction allows thermal expansion of the pipe, see drawings LD 3965
and LD 4571.
The elements are fixed to the basin bottom. The whole system has to be level. This
is easily achieved by use of bottom mounting brackets, HPK 210 or PPK 90. The
adjustable bracket overcomes the unevenness of the basin bottom by adjustment to
within a range of 105-120 mm by using extension pieces. See drawings LD 3967 and
LD 4073. The PP system uses also fixed bottom mounting brackets: PKL 90 and
TKK 90. See drawings LD 5553, LD 5555 and LD 6452.
Air is conducted via distribution headers from the blower through a dropleg pipe into
the zone headers, which in turn distribute it further into the lateral rows of diffuser
elements (headers). Zone headers have a flange on a vertical pipe extension for
connection of dropleg and lateral branches to connect the diffuser elements. Zone
headers are made of uPVC, PP or stainless steel (AISI 316). The diameter of the
zone header is defined by air velocity.
The OD 90 mm PVC zone header has a loose flange, either DN80, DN100 or
DN125. The OD 160 mm PVC zone header has a loose flange, DN150. The drillings
of the flanges are according to DIN 2501, PN 10, see drawing LD 3947. Wall
thickness of the 90 pipes is 3,5 mm and 160 pipes 4,0 mm. The PVC zone
headers are anchored to the tank bottom and levelled by bottom mounting brackets,
HPK 210 or TPK 150.
The OD 90 mm PP zone header has a loose flange, DN 80. The wall thickness of the
pipe is 4,5 mm. The zone header is anchored to the tank bottom and levelled by
bottom mounting brackets PPK 90, HPK 210 or TKK 90.
The stainless steel zone headers have a fixed flange, either DN125, DN150, DN200,
DN250, DN300 or DN350. The drillings of the flanges are according to DIN 2501, PN
10. Wall thickness of the pipes is 2,0...2,5 mm. See drawings LD 3948 and LD 3998.
The stainless steel zone headers are anchored to the tank bottom and levelled by
bottom mounting brackets, TPK, see drawing LD 3966. All materials are AISI 316.
Water collection pipe, with a water drainage connection (see drawings LD 3949 and
LD 4681) connects the lateral branches of diffuser elements. In a closed loop
pipework the pressure in the aeration group is equalised and a uniform air
distribution to the diffusers is achieved. In special aeration groups in round or ring
shape basins or in smaller aeration groups, where the length of the Header pipes is
small, the water collection pipe is not needed and the water drainage connections
are mounted to the zone header. Water drainage connection is usually located in the
OD 160 PVC zone headers as well (see drawing LD 4855 B).
NOPOL
DDS
41-
31001
/2
3/3
SYSTEM FLEXIBILITY
The same main body HSA 215 is the base for HKL 215, MKL 215, KKI 215 and PRK
300 diffusers. The PRF 300 retrofit can be installed on the same main body. Thus
these diffusers are interchangeable. This enables modification of existing system.
System capacity and efficiency of HKLE, MKLE, and KKIE systems can easily be
increased by installing the PRF 300 retrofit. Continuous processes can be made
intermittent by changing to membrane diffusers.
The wedge piece attachment makes the aeration system flexible. More diffusers can
be added later as conditions change. Diffuser positions can be changed as well. To
achieve an optimal dissolved oxygen profile the disc distribution along the basin can
simply be changed.
NOPOL
DDS
41-
51001
1/1
MECHANICAL GUARANTEE FOR NOPOL
DDS AERATION SYSTEMS

The basic mechanical guarantee for NOPOL
DDS aeration systems is valid for 12

months from start of operation or maximum 24 months from the delivery, see
"General Guarantee Terms for NOPOL
Aeration Systems".
No mechanical guarantee is granted for waste waters having high concentrations of
mineral oils, vegetable oils, fats, organic solvents and chlorides. For operating and
durability requirements, see Table 1.
Table 1. Process parameter specification
Water quality normal municipal
Mineral oils max. 10 mg/l
Vegetable oils max. 40 mg/l
Fats max. 40 mg/l
Organic solvents max. 0,6 mg/l
pH 5,5 - 9,5
Cl
2
max. 0,3 mg/l
Water depth 3 - 8 m
Ambient air temperature max. 40 C
Air temperature at diffusers PIK 300 max. 100 C
others max. 80 C
Specific air flow PIK 300 max. 8 m
3
/h/diffuser
PRK 300 max. 8 m
3
/h/diffuser
KKI 215 max. 4 m
3
/h/diffuser
HKL 215 max. 5 m
3
/h/diffuser
MKL 215 max. 6 m
3
/h/diffuser
Cleaning cleaning with formic acid
OD 90 mm PVC pipe
Specification
41-
31012
1/1
Written by: MR Inspected by: AL Approved by:
ERN
PVC pipe, outside diameter 90 mm
The uPVC pipes used in the NOPOL
DDS systems are manufactured of

unplasticized polyvinylchloride (PVC-U) in accordance to the following
standards:
SFS 5108
SS 3396
EN 1329-1
In addition to the above the pipes have to fulfill the following requirements:
Table 1. Special requirements
Characteristic unit requirement
outside nominal diameter mm 90
outside average diameter
(calculated from measure around)
mm 90,2-90,3
outside maximum diameter (ellipticity) mm 91
nominal wall thickness (= permitted medium) mm 3,5
pipe length tolerance (+ 25 C) mm 5
colour: uniform gray (RAL 7037)
inner and outer surfaces have to be smooth
no grooves, no hollows
THE COMPANY RESERVES THE RIGHT TO MAKE ALTERATIONS IN THE INTERESTS OF TECHNICAL DEVELOPMENT.
+358 9 351 5620
http://www.nopon.fi
+358 9 351 730
LD 6471
Fax: Turvekuja 6
FIN-00700 Helsinki
FINLAND
HSY 90-3"
CONNECTION SLEEVE
Homepage:
E-mail: hq@nopon.fi
Nopon OY Phone:
534.054 Trade Reg. NO.
B.FIT
ARTO LEHTO 27 FEB, 2001
VAT NO. FI08925649
2
OD 90 mm PP pipe
Specification
41-
51012
1/1
90 mm POLYPROPYLENE (PP) PIPE
Material used is high molecular weight, low melt flow rate polypropylene
block copolymer (PP-B).
The polypropylene pipes used in the NOPOL
DDS systems are

manufactured in accordance to the following Scandinavian Standards:
SFS 5102
SS 3396
In addition to the above, the pipes have to fulfil the following requirements:
external nominal diameter 90 mm x wall thickness 4,5 mm
external average diameter 90,2 - 90,3 mm, around measure
max. external diameter 91 mm
min. wall thickness 4,5 mm
colour black, uniformly equal
no cold seams, no grooves, no hollows
Table 1. Properties of polypropylene
value unit test method
Density 901 kg/m
3
ISO 1183
Melt flow rate (230 C / 2,16 kg) 0,3 g/ 10 min ISO 1133
Tensile strength at yield (50 mm/min) 28 MPa ISO 527-2
Tensile strain at yield (50 mm/min) 6 % ISO 527-2
Flexural modulus (2 mm/min) 1300 MPa ISO 178
Charpy impact, notched (+23 C) 65 kJ/m
2
ISO 179/1eA
Charpy impact, notched (-20 C) 7 kJ/m
2
ISO 179/1eA
Shore D hardness 60 - ISO 868
Coefficient of linear expansion 0,15 mm/m C
Softening temperature 120 C
Bottom Mounting Brackets
Material Specification
41-
31011
/ 1
1/1
NOPON OY Inspected: April 26, 2002
AL Approved:
FOOT PTU 90
PIPE HOLDER, diam 90 mm PKI 90
EXTENSION SLEEVE PJA 3
Material is mineral filled polypropylene compound. Typical properties are:
Melt flow rate (230 C/2.16 kg) g/10 min 4 ISO 1133
Density kg/m
3
1050 ISO 1183
Stress at yield (50 mm/min) MPa 31 ISO 527-2
Strain at yield (50 mm/min) % 10 ISO 527-2
Flexural modulus (2 mm/min) MPa 2400 ISO 178
Heat deflection temp. (0.45 N/mm
2
) C 125 ISO 75-2
Charpy impact (notched, 23 C) kJ/m
2
4.5 ISO 179/1eA
Charpy impact (unnotched, 23 C) kJ/m
2
60 ISO 179/1eU
FOOT HTU 210
PIPE HOLDER, diam 90 mm HKI 210
EXTENSION SLEEVE HJA 210
Material is rigid, granulated PVC compound. Typical properties are:
Density kg/m
3
1380 ASTM D 1505
Tensile strength Mpa 40 ISO R 527
Yield point Mpa 60 ISO R 527
Elongation at break % 160 ISO R 527
Impact tensile strength kJ/m
2
500 DIN 53448
Vicat softening point C 70 ISO r 306
STRAP HPA 210
Material is polypropylene with the following specifications:
Melt flow rate (230 C/2.16 kg) g/10 min 4,20,7 DIN 53753
Ball pressure test N/mm
2
49 ISO 2039/1
Charpy impact, 0 C mJ/mm
2
6 ISO 179/1eA
STEEL COMPONENTS OF BOTTOM MOUNTING BRACKETS
Materials and standards for PKL 90, TKK 90, TKK 90-PSY, TPKs, LAH 10, LAH 12:
Material AISI 316L
316 S 11
X 2 CrNiMo 17 13 2
ASTM A 276-82
BS 970/3-91
DIN 17 440-85 W 1, 4404
Hexagonal screw M 10x20 DIN 933 A4-80
Washer KL 11/28 DIN 9021 A4 special
Hexagonal nut M 12 DIN 934 A4-80
Washer M 12 DIN 125 A4
Threaded rod M 12x400 DIN 976 A4
Threaded rod M 12x500 DIN 976 A4
Self stapping screw 3,5x32 DIN 7981 A
Drop in anchor LAH 10 M 10
Drop in anchor LAH 12 M 12
PRODUCT N0 : 161097
NOPOL
HPK210 D90
BOTTOM MOUNTI NG BRACKET
OD 90 mm PI PE
HPA210
161104
STRAP
HJA210
161102
EXTENTION SLEEVE
HKI210
161101
PIPE HOLDER
HEX SCREW M10x20
165030
LAH10
165010
DROP-IN ANCHOR
HTU210
161103
FOOT
WASHER KL 11/28
165020

NOPON OY Documentation level 4 Date: 15.06.2000
Rev. 1 : 19. 04. 2002 AL Created by: MB Approved by: MF
PRODUCT N0 : 161094
NOPOL
HPK210 D88,9 EUROPE

OD 88, 9 mm PI PE (NS 3")
PPA3
166108
STRAP
HJA210
161102
EXTENTION SLEEVE
HKI210
161101
PIPE HOLDER
HEX SCREW M10x20
165030
LAH10
165010
DROP-IN ANCHOR
HTU210
161103
FOOT
WASHER KL 11/28
165020

Rev.1: 19.04.2002 AL Created by: MB Approved by: MF
PRODUCT N0 : 161099
NOPOL
HPK4 4"
OD 114, 3 mm PI PE (NS 4")
HPA210
161104
STRAP
HJA210
161102
EXTENTION SLEEVE
HKI4
161210
PIPE HOLDER
HEX SCREW M10x20
165030
LAH10
165010
DROP-IN ANCHOR
HTU210
161103
FOOT
WASHER KL 11/28
165020

Rev.1 : 19.04.2002 AL Created by: MB Approved by: MF
PRODUCT N0 : 166097
NOPOL
PPK90 D90
OD 90 mm PI PE
HPA210
161104
STRAP
PJA3
166104
EXTENTION SLEEVE
PKI90
166101
PIPE HOLDER
HEX SCREW M10x20
165030
LAH10
165010
DROP-IN ANCHOR
PTU3
166106
FOOT
WASHER KL 11/28
165020



PRODUCT N0 : 193240
NOPOL
LT10
STRI KI NG TOLL
FOR DROP ANCHOR LAH10
(LAH10)
LT10

(LAH12)
PRODUCT N0 : 193241
NOPOL
LT12
STRI KI NG TOLL
FOR DROP ANCHOR LAH12
LT12

PRODUCT N0 : 193230
NOPOL
HPAAT
TOOL FOR STRAP
FOR ALL PLASTI C MOUNTI NG BRACKET

2 NOPOL PIK 300
NOPOL
DDS
PRODUCT MANUAL
NOPOL
PIK 300
Membrane Disc Diffuser
51-
31044
/ 3
1/3
NOPON OY 11.09.2001
Prepared by: MR Inspected by: AL Approved by: ERN
DESCRIPTION
The NOPOL
PIK 300 Membrane Disc Diffuser has an elastomeric membrane with

slits. The slits open during aeration by the pressure of compressed air and close
when not aerated. Air is then spread into small bubbles, the size is between 1 - 3
mm when released through the membrane.
The membrane is fixed by a bayonet type screw-on ring (PKR 300) to a main body
(PSA 300). Between the screw-on ring and the membrane there is the PVR 300
sliding ring which is antifriction material (POM) thus ensuring free expansion and
contraction of the membrane without any mechanical friction. The edge of the
membrane is formed like an O-ring sealing the construction when pressed by the
sliding ring against the saddle piece. The main body distributes the air evenly over
the entire surface of the membrane.
Inside the main body there is the non-return valve which is operating both as a
control orifice and automatically closing non-return valve. The orifice ensures even
pressure loss between diffusers and thus even air distribution. The non-return valve
protects the system from clogging.
Between the main body of the diffuser and the pipe there is a seal which seals the
attachment tightly. PLT 15/4 SIL flat seal is used for PP piping, PLT 15/5 flat seal for
OD 88.9 mm steel piping and PLT 15/4 flat seal for OD 90 mm PVC piping.
The diffuser is mechanically attached to pipe by a rigid PSK 90 wedge piece without
any glue or solvent welding. The requested diameter of the hole to be drilled in the
pipe is 15 mm.
The PIK 300 preassembled diffuser includes the screw-on ring, sliding ring,
membrane disc, main body, non-return valve, seal and the separate wedge piece.
All the materials of the NOPOL
PIK 300 diffuser are recyclable.

The diffuser construction is shown in the exploded views and drawings LD 5173, LD
5637 and LD 5636.
APPLICATIONS
The NOPOL
PIK 300 diffuser is suitable for normal continuous aeration systems as

well as where intermittent aeration is required, e.g. biological nutrient removal and
SBR processes.
Due to its non-clogging nature the PIK 300 rubber membrane diffuser is also
suitable for industrial effluents.
NOPOL
PIK 300
51-
31044
/ 3
2/3
NOPON OY 11.09.2001
SPECIFIC DATA OF THE PIK 300 DIFFUSER
Table 1. Diffuser specification
Design air flow range 0,5 - 8,0 m
3
/h/diffuser (+20 C; 1 013 mbar)
Membrane diameter 304 mm
Membrane surface area 0,060 m
2
Size of bubbles 1 - 3 mm
Diffuser weight 0,795 kg
Air temperature, max + 100C in operation conditions
Max/min interval, c/c 1,2 / 0,450 m
Diffuser level 250 mm above tank bottom ( standard )
Performance (SOTE) 5,5...8 %/m water depth; see graph 41-31045 / 2
Pressure loss 2,0...6,0 kPa, see graph 41-31045 / 2
COMPONENTS AND MATERIALS
Table 2. Components and materials
PKR 300 Screw-on Ring polypropylene
PVR 300 Sliding Ring POM (polyacetal)
HIK 300 Membrane Disc EPDM rubber
PTV 15 Non-return Valve polypropylene
Ball stainless steel AISI 316
O-ring VITON
PSA 300 Main Body polypropylene
PLT 15/4 SIL Flat Seal silicon
PLT 15/5 Flat Seal EPDM rubber
PLT 15/4 Flat Seal EPDM rubber
PSK 90 Wedge Piece polypropylene
NOPOL
PIK 300
51-
31044
/ 3
3/3
NOPON OY 11.09.2001
ATTACHMENT ALTERNATIVES
The PIK 300 D90 diffuser is fitted to an OD 90 mm PP pipe (outer diameter 90,25
mm 0,05 mm) with a wedge piece PSK 90 and sealed with a flat seal PLT 15/4
SIL.
The PIK 300 V D90 diffuser is fitted to an OD 90 mm PVC pipe (outer diameter
90,25 mm 0,05 mm) with a wedge piece PSK 90 and sealed with a flat seal PLT
15/4.
The PIK 300 S D88.9 diffuser is fitted to an OD 88,9 mm stainless steel pipe (outer
diameter 88,9 mm 0,75 %) or PVC pipe (NS 3: 88,9 mm 0,20 mm) with a wedge
piece PSK 90 and sealed with PLT 15/5 flat seal.
The PIK 300 4 diffuser is fitted to an OD 114,3 mm pipe (NS 4) with a wedge piece
PSK 4 and sealed with PLT 15/4 flat seal.
The PIK 300 T 3 diffuser is fitted to an OD 88,9 mm stainless steel pipe (outer
diameter 88,9 mm 0,75 %) or PVC pipe (NS 3: 88,9 mm 0,20 mm) with a wedge
piece PSK 3 and sealed with PLT 15/4 flat seal.
MAINTENANCE AND INSTALLATION TOOLS
Due to the self-cleaning properties of the diffuser membrane no extra cleaning
method is normally required. However, if needed due to process conditions, the
whole aeration system can be cleaned during operation by using the bumping
system (mechanical shock given by shortly increasing air flow rate) or using the
patented NOPOL
CLEAN method. The cleaning liquid, formic acid, is fed into the
air supply to remove materials such as lime and iron deposits from the membrane
disc.
Special tools requested for installation and maintenance are delivered with the
diffusers.
NOPOL
PIK 300
SOTE-values and Pressure loss
41-
31045
/ 2
1/1
NOPON OY Inspected: October 1, 1997
MR Approved:
STANDARD OXYGEN TRANSFER EFFICIENCY, SOTE
Clean water, standard conditions (+ 20 C, 101.3 kPa)
Submersion depth 4 m
Diffuser density, DD = total diffuser area / total bottom area
Surface area of one diffuser is 0.060 m
2

15.00
20.00
25.00
30.00
35.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00
DD
25 %
20 %
15 %
10 %
6 %
Note: The suggested design range is 1,5 - 8,0 m
3
/h/diffuser. The values are valid for full
bottom coverage with uniform diffuser distribution and can be affected by the
mixing and water flow conditions in the aeration basin. The graphs may be
changed without further notice. Always consult Nopon Oy for capacity guarantees.
WET PRESSURE LOSS
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00
Air flow, m
3
/h/diffuser ( 20 C, 101.3 kPa)
SOTE, %
kPa
Air flow, m
3
/h/diffuser ( 20 C, 101.3 kPa)
NOPOL
PIK 300
41-
51026
/2
1/1
NOPON OY 11.09.2001
Characteristics of the components
Main Body PSA 300
Wedge Piece PSK 90
Screw-on Ring PKR 300
Non-return Valve PTV 15 L
Material is mineral filled polypropylene compound. Typical properties are:
Melt flow rate (230 C/2.16 kg) g/10 min 4 ISO 1133
Density kg/m
3
1050 ISO 1183
Stress at yield (50 mm/min) MPa 31 ISO 527-2
Strain at yield (50 mm/min) % 10 ISO 527-2
Flexural modulus (2 mm/min) MPa 2400 ISO 178
Heat deflection temp. (0.45 N/mm
2
) C 125 ISO 75-2
Charpy impact (notched, 23 C) kJ/m
2
4.5 ISO 179/1eA
Charpy impact (unnotched, 23 C) kJ/m
2
60 ISO 179/1eU
Membrane Disc HIK 300
The EPDM material resists chemically all compounds of municipal sewage
and most of industrial waste waters. Temperature resistance of the
membrane disc is 100 C, for details see: spec. 41-31025/1.
Sliding Ring PVR 300
The material of the sliding ring is polyacetal POM.
Flat Seal PLT 15/4 SIL
Material is silicon.
Flat Seal PLT 15/5, PLT 15/4
Material is EPDM rubber.
Ball
Material is stainless steel AISI 316.
O - ring
Material is VITON.
NOPOL

Membrane Discs
HIK 215 and HIK 300
Specification
41-
31025
/ 1
1/1
MR Approved:
HIK 215 and HIK 300 Membrane Discs
Membranes are EPDM based with additives (stabilisators, antioxidants etc),
specially developed for the NOPOL
DDS systems.
Table 1. Mechanical characteristics and measures
Characteristic unit HIK 215 HIK 300
Diameter mm 186 304
Height at the edge mm 14 8
Thickness at the center of the disc mm 1,8 3,0
Thickness at the edge of the disc mm 1,8 2,0
Tightening mechanism U - shape
gasket
o- ring
at the edge
Perforation figure parallel lines 8 sectors
Diameter of perforated area mm 167 282
Form of slit straight straight
Length of slit mm 1,0 1,0
Slit density 1/cm
2
8,3 8,3
Distance between slits mm 3 3
Distance between slit lines mm 3 3
Number of slits 1850 5120
Table 2. Material characteristics of the NOPOL
Membrane Discs
Characteristic Unit Value Standard
Basic polymer EPDM
Hardness Shore A 605 ASTM D 2240
Tensile strength MPa min 13 ISO 37/1
Elongation at break % min 300 ISO 37/1
Heat ageing 1000 h / 100C ISO 188
- Change in hardness Shore A max +5 ASTM D 2240
- Change in tensile strength % max -10 ISO 37/1
- Change in elongation at break % max -20 ISO 37/1
Temperature resistance
- Aeration air temperature C 100 100
- Water temperature C 80 80
The membrane material is resistant to practically all components of normal
sewage and of most industrial waste waters. Aromatic and chlorinated
solvents and high concentrations of mineral oils may harm the membrane.
The membrane can be cleaned by e.g. 10 % hydrochloric acid or by formic
acid (NOPOL
CLEAN). Lifetime of the membranes in normal activated

sludge plants is typically 5 to 7 years.
PKR300
122126
SCREW-ON RING
PVR300
122127
SLIDING RING
HIK300
122320
MEMBRANE DISC
PTV15
122348
NON-RETURN VALVE
1223461
BALL
O-RING 10x2,0
122345
PSA300
122109
MAIN BODY
PSK90
122135
WEDGE PIECE
PLT15/4
122360
FLAT SEAL
PRODUCT N0 : 121704
NOPOL
PIK300V D90
MEMBRANE DI SC DI FFUSER
OD 90 mm PVC PI PE

PKR300
122126
SCREW-ON RING
PVR300
122127
SLIDING RING
HIK300
122320
MEMBRANE DISC
PTV15
122348
NON-RETURN VALVE
1223461
BALL
O-RING 10x2,0
122345
PSA300
122109
MAIN BODY
PSK90
122135
WEDGE PIECE
PLT15/4 SIL
122363
FLAT SEAL
PRODUCT N0 : 121700
NOPOL
PIK300 D90
OD 90 mm PP PI PE

PKR300
122126
SCREW-ON RING
PVR300
122127
SLIDING RING
HIK300
122320
MEMBRANE DISC
PTV15
122348
NON-RETURN VALVE
1223461
BALL
O-RING 10x2,0
122345
PSA300
122109
MAIN BODY
PSK90
122135
WEDGE PIECE
NOPOL
PIK300S D88,9
PRODUCT N0 : 121702
OD 88, 9 mm SS / PVC PI PE (NS 3)
PLT15/5
122361
FLAT SEAL

PKR300-3
122125
SCREW-ON RING
PVR300-3
122129
SLIDING RING
PTV15-3
122349
NON-RETURN VALVE
1223461
BALL
O-RING 10x2,0
122345
PSA300-3
122105
MAIN BODY
PSK3
122137
WEDGE PIECE
HIK300
122320
MEMBRANE DISC
NOPOL
PIK300T 3"
PRODUCT N0 : 121707
PLT15/4
122360
FLAT SEAL

OD 88, 9 mm SS / PVC PI PE (NS 3)

HIK300
122320
MEMBRANE DISC
1223461
BALL
O-RING 10x2,0
122345
PSA300-4
122112
MAIN BODY
PSK4
122138
WEDGE PIECE
PLT15/4
122360
FLAT SEAL
PRODUCT N0 : 121705
NOPOL
PIK300 4"
OD 114, 3 mm PI PE (NS 4")
PKR300-3
122125
SCREW-ON RING
PVR300-3
122129
SLIDING RING
PTV15-3
122349
NON-RETURN VALVE

PRODUCT N0 : 193330
NOPOL
PKLAT300 SMALL
SMALL TOOL FOR SCREW- ON RI NG PKR300
TOOL FOR PI K300 DI FFUSERS

PRODUCT N0 : 193331
NOPOL
PKLAT300 BIG
BI G TOOL FOR SCREW- ON RI NG PKR300
TOOL FOR PI K300 DI FFUSERS

PRODUCT N0 : 193326
NOPOL
TWP90
TOOL FOR OD90 WEDGE PI ECE
TOOL FOR OD90 DI FFUSERS

PRODUCT N0 : 193327
NOPOL
TWP3
TOOL FOR 3" WEDGE PI ECE
TOOL FOR 3" DI FFUSERS

PRODUCT N0 : 193328
NOPOL
TWP4
TOOL FOR 4" WEDGE PI ECE
TOOL FOR 4" DI FFUSERS

3 NOPOL PRK 300
NOPOL
DDS
PRODUCT MANUAL
NOPOL
PRK 300
61-
31004 /
1
1/3
Written by: AL Inspected by: Approved by:
DESCRIPTION
The NOPOL
PRK 300 Membrane Disc Diffuser has an elastic membrane with slits.
The slits open during aeration under the influence of compressed air and close when
not aerated. Air forms small bubbles, with a size of 1 - 3 mm when released through
the membrane.
The membrane Disc (HIK 300) is fixed by a bayonet type Screw-on Ring (PKR 300)
to an Extension Plate (PTL 300). Between the Screw-on Ring and the Membrane
there is the Sliding Ring (PVR 300) which is antifriction material (POM) thus
ensuring free expansion and contraction of the membrane without any mechanical
friction. The edge of the membrane is formed like an O-ring sealing the construction
when pressed by the Sliding Ring against the Extension Plate. The preassembled
unit including the Screw-on Ring, Sliding Ring, Membrane Disc, Extension Plate,
Circular Gasket (HUR 300) and Support Ring (HTR 300) is called PRF 300 Retrofit.
The PRF 300 Retrofit with the Circular Gasket and Support Ring is screwed onto the
Main Body (HSA 215). The Main Body is fixed to an O.D. 90 mm pipe mechanically
by a rigid wedge piece without any glue or solvent welding. The pipe drilling is 20
mm and the diffuser body is tightened by an O-ring against the pipe wall. In the Main
Body there is a combined orifice Non-return Valve. Orifice is 10 mm. The rubber
valve (HVK 215) opens when air supply is on and closes by hydraulic pressure. The
orifice creates a pressure loss which balances the air flow within all diffusers in the
system. The Non-return Valve protects the system from clogging e.g. in case of a
broken membrane or fixing ring.
The diffuser construction is shown in the exploded view and Drawing LD 6434.
APPLICATIONS
The NOPOL
PRK 300 Diffuser is especially suitable where intermittent aeration is

required, e.g. for biological nutrient removal and SBR -processes.
When converting an existing conventional activated sludge process into a nitrogen
removal process more aeration capacity is needed. The other requirement of a
nitrogen removal process is to keep dissolved oxygen concentration low in order to
avoid oxygen in the denitrification zones. For this purpose the PRF 300 Retrofit
Membrane Diffuser is an ideal solution allowing the use of existing pipework and
diffuser main bodies.
Due to its non-clogging nature, the rubber membrane diffuser is also suitable with
those industrial effluents which are known to result in clogging.
NOPOL
PRK 300
61-
31004 /
1
2/3
SPECIFIC DATA FOR THE PRK 300 DIFFUSER
Operating air flow range 0,5 8,0 m
3
/h/diffuser (+20 C; 1 013 mbar) (1
Disc diameter 304 mm
Disc surface area 0,060 m
2
Size of bubbles 1 3 mm
Air temperature, max + 80C
Diffuser density minimum 4,2 %, maximum 24 %
Diffuser level typical 250 mm above tank bottom
Performance (SOTE) 5,58 %/m; see graph 61-31023/1
Pressure loss 1,76,0 kPa, see graph 61-31023/1
Note1: Dimensioning air flow is 5,0 m
3
/h. When waste water contains
chemicals harmful to the EPDM membrane or when water temperature is
>30C or air temperature is > 80C, a lower maximum air flow should be used
in order to extend the lifetime of the membrane. A peak value of 10 m
3
/h can
be used for max. of 15 min only e.g. for cleaning the membrane.
PKR 300 Screw-on Ring polypropylene
PVR 300 Sliding Ring POM
HIK 300 Membrane Disc EPDM -rubber
PTL 300 Extension Plate glass fiber reinforced polypropylene, PP
HUR 300 Circular Gasket EPDM -rubber
HTR 300 Support Ring polypropylene
HVK 215 Non-return Valve IIR (butyl) rubber
HSA 215 Main Body unplasticized polyvinylchloride, uPVC
HOR 19,3 O-ring NBR -rubber
HSK 215 Wedge Piece unplasticized polyvinylchloride, uPVC
NOPOL
PRK 300
61-
31004 /
1
3/3
The basic system consists of a diffuser fitted to an O.D. 90 mm PVC pipe (O.D.
90,250,05) with a Wedge Piece and sealed with an O-ring (HOR 19,3x3,0).
The PRK 300 can be installed on an O.D. 88,9 mm steel pipe when using a thicker
O-ring (HOR 18x4).
In addition to the HSA 215 Main Body there are alternative diffuser main bodies,
where the PRF 300 Retrofit Membrane Disc Diffuser can be used.
The different types are:
Table 3. Alternatives of PRK 300 Membrane Diffusers
PRK 300 D90 wedge piece attachment for O.D. 90 mm pipe
PRK 300 D88.9 wedge piece attachment for nominal 3 inch
pipe (88,9 mm O.D.)
PRK 300 4 wedge piece attachment for nominal 4 inch
pipe (114,3 mm O.D.)
PRK 300 R1/2 thread attachment R
PRK 300 R1/2 K thread attachment R , taper thread
PRK 300 BSF1/2 thread attachment BSF for converting
existing ceramic dome aeration plants
Due to the self-cleaning properties of the membrane diffuser no extra cleaning is
normally required. However, if needed due to the process conditions, the whole
aeration system can be cleaned during operation by using the patented NOPOL
CLEAN method. The cleaning liquid, formic acid, is fed into the air supply to remove
materials such as lime and iron deposits from the membrane disc.
Special tools are needed for dismounting and opening the PRK 300 Diffuser, e.g.
when changing the membrane. The PRF 300 Retrofit is unfastened from the Main
Body by a tool RFIT 300P. The PRF 300 is then placed on a tool VASTE 300 and
the Screw-on Ring can be opened by a tool PKLAT 300. Same tools are used in
assembling the parts.
For diffusers with thread attachment a tool VASTE 215 is needed for fixing of the
Main Body during maintenance. Each system delivery is complete including the
necessary installation tools.

PRK 300 Membrane diffuser
SOTE-values and Pressure loss
61-
31023
/ 1
1/1
NOPON OY Inspected: July 31, 2000
AL Approved:
Clean water, standard conditions ( + 20 C, 101.3 kPa)
2
15.00
20.00
25.00
30.00
35.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00
25 %
20 %
15 %
10 %
6 %
DD
Note:The values are valid for full bottom covering with uniform diffuser
distribution and can be affected by the mixing and water flow conditions in the
aeration tank. The graphs may be changed without further notice, so always
consult Nopon Oy for capacity guarantees.
WET PRESSURE LOSS
1.00
2.00
3.00
4.00
5.00
6.00
7.00
0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00
Air flow, m
3
/h/diffuser ( 20 C, 101.3 kPa )
SOTE, %
Air flow, m
3
kPa
NOPOL
PRK 300
61-
31026
/ 1
1/1
AL Approved:
Main Body HSA 215
Wedge Piece HSK 215
Material is rigid, granulated uPVC compound. Typical properties are:
Density kg/m
3
1380 ASTM D 1505
Tensile strength MPa 40 ISO R 527
Yield point MPa 60 ISO R 527
2
500 DIN 53448
Vicat softening point C 70 ISO R 306
Extension Plate PTL 300
Material is glass fiber reinforced polypropylene (PP).
Support Ring HTR 300
Material is polypropylene (PP).
Circular Gasket HUR 300
Material is EPDM rubber.
Screw-on Ring PKR 300
The bayonet type screw-on ring is made of polypropylene (PP).
Sliding Ring PVR 300
Material is polyacetal (POM).
Membrane Disc HIK 300
The EPDM material resists chemically all compounds of municipal sewage and most of
industrial waste waters. Temperature resistance of the membrane disc is 100 C, for details
see: spec. 41-31025/1.
Non-return Valve HVK 215
The IIR (butyl rubber) material is resistant to most inorganic chemicals, mineral acids and
alkalis and to low molecular weight alcohols and ketones.
IIR has limited resistance to oxidising acids, but is non-resistant to most organic liquids and
only has a fair resistance to phenols.
O - ring 19 HOR 19
Material is NBR rubber responding ASTM D 2000 SAE Y 200.
NOPOL

Membrane Discs
HIK 215 and HIK 300
Specification
41-
31025
/ 1
1/1
MR Approved:
DDS systems.
Diameter mm 186 304
gasket
o- ring
at the edge
Slit density 1/cm
2
8,3 8,3
Membrane Discs
Basic polymer EPDM
acid (NOPOL

LD 6434
+358 9 351 730
http://www.nopon.fi
+358 9 351 5620 Turvekuja 6 Fax:
FINLAND
FIN-00700 Helsinki
MEMBRANE DIFFUSER
PRODUCT No 129220
PRK 300 D90
E-mail:
Homepage:
hq@nopon.fi
Nopon OY Phone:
Trade Reg. NO. 534.054
B.FIT
FA
VJ
MF
19-NOV.-1999
1
19-NOV.-1999
25-NOV.-1999
VAT NO. FI08925649
PRODUCT N0 : 129220
NOPOL
PRK300 D90
OD 90 mm PI PE
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

HSA215
122100
MAIN BODY

HOR19
122350
O-RING

HSK215
122130
WEDGE PIECE

PTL300

PRODUCT N0 : 129200
NOPOL
PRK300 D88,9
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

HSA215
122100
MAIN BODY

HSK215
122130
WEDGE PIECE

HOR18
122353
O-RING

PTL300

PRODUCT N0 : 129260
NOPOL
PRK300 4"
OD 114, 3 mm PI PE (NS 4")
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

PTL300
HOR19
122350
O-RING

HSA4
122104
MAIN BODY

HSK4
122132
WEDGE PIECE

PRODUCT N0 : 129240
NOPOL
PRK300R
THREAD ATTACHMENT R (I SO 228/ 1)
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

PTL300
HOR19
122350
O-RING

HSA215R
122101
MAIN BODY

PRODUCT N0 : 129250
NOPOL
PRK300R K
THREAD ATTACHMENT R (TAPER THREAD I SO 7/ 1)
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

PTL300
HOR19
122350
O-RING

HSA215RK
122102
MAIN BODY

PRODUCT N0 : 129230
NOPOL
PRK300BSF
THREAD ATTACHMENT BSF ("-16 BSF)
HVK215
122340
NON-RETURN VALVE

HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

HTR300
122332
SUPPORT RING

PTL300
HSA215BSF
122103
MAIN BODY

HOR19
122350
O-RING

PRODUCT N0 : 129270
NOPOL
PRF300
RETROFI T 300 FOR 215 mm DI FFUSER
HIK300
122320
MEMBRANE DISC

PKR300-3
122125
SCREW-ON RING

PVR300-3
122129
SLIDING RING

HUR300
122329
CIRCULAR GASKET

122170
EXTENTION PLATE

PTL300
HTR300
122332
SUPPORT RING

PRODUCT N0 : 193311
NOPOL
RFIT300P
SMALL TOOL FOR PRK300 DI FFUSERS
TOOL FOR ALL TYPE OF PRK300 DI FFUSERS

PRODUCT N0 : 193320
NOPOL
VASTE300
RETROFI T ASSEMBY TOOL
FOR PRK300 DI FFUSER

PRODUCT N0 : 193220
NOPOL
VASTE215
DI FFUSER / RETROFI T ASSEMBLY TOOL
FOR DI FFUSER WI TH THREAD ATTACHMENT

4 NOPOL KKI 215
NOPOL
DDS
PRODUCT MANUAL
NOPOL
KKI 215
41-
31002
/ 1
1/2
AL Approved:
DESCRIPTION
NOPOL
KKI 215 Membrane Disc Diffuser has an elastic Membrane (HIK 215) with
slits. The slits open during aeration under the influence of compressed air and close
when not aerated. Air forms small bubbles, the size between 1 - 3 mm when
released through the Membrane. The Membrane is supported by a rigid Support
Plate (HTL 215) which has openings close to the edge. The Membrane does not
have slits where the air is fed through the Support Plate. Back flow is thus
prevented. The Membrane and the Support Plate are fixed by a Screw-on Ring
(HKR 215) on a Main Body (HSA 215). The Main Body is fixed onto an O.D. 90 mm
pipe mechanically by a rigid Wedge Piece (HSK 215) without any glue or solvent
welding. The pipe drilling is 20 mm and the Main Body is tightened by an O-ring
against the pipe wall. In the Main Body there is a combined orifice - Non-return
Valve. Orifice is 10 mm. The rubber valve (HVK 215) opens when feeding air and
closes by hydraulic pressure. The orifice creates a pressure loss which balances
the air flow within all diffusers in the system.The Non-return Valve protects the
system from clogging e.g. in case of broken membrane or fixing ring. The diffuser
construction is shown in the exploded view and Drawing LC 3894.
APPLICATIONS
The NOPOL
KKI 215 Diffuser is suitable where intermittent aeration is required,

e.g. biological nutrient removal and SBR -processses. Due to its non-clogging
nature rubber membrane diffuser is also suitable to those industrial effluents which
are known to cause clogging.
SPECIFIC DATA FOR THE KKI 215 DIFFUSER
Operating air flow range 0,5 - 4,0 m
3
Membrane diameter 180 mm
2
Max air temperature + 80 C
Diffuser density minimum 2 %, maximum about 24 %
Diffuser level typical 250 mm above tank bottom
Performance (SOTE) 6...8 %/m; see graph 41-31007/1
Pressure loss 2,5...5,5 kPa, see graph 41-31007/1
Note: Dimensioning air flow is 2,5 m
3
/h. When waste water contains chemicals
harmful to EPDM membrane or when water temperature is >30C or air temperature
is > 80C, a lower maximum air flow should be used in order to extend the lifetime
of the membrane. The peak value of 6 m
3
/h can be used for max 15 min at a time
e.g. for cleaning the membrane.
NOPOL
KKI 215
41-
31002
/ 1
2/2
AL Approved:
HKR 215 Screw-on Ring unplasticized polyvinylchloride, uPVC
HVK 215 Non-return Valve butyl rubber
HOR 19 O-ring NBR -rubber
HTL 215 Support Plate glass fiber reinforced polypropylene
HIK 215 Membrane Disc EPDM -rubber
The basic system consists of a diffuser fitted to an O.D. 90 mm pipe (O.D.
90,250,05) with a wedge piece and sealed with an O-ring (HOR 19,2x3,0).
The KKI 215 can be installed on an O.D. 88,9 mm steel pipe when using a thicker
O-ring (HOR 18x4).
In addition to the HSA 215 Main Body there are alternative main bodies, where the
HIK 215 membrane disc can be used. The other types are:
Table 3. Alternatives of KKI Membrane Diffusers
KKI 4 wedge piece attachment for nominal 4 inch
KKI 215 R1/2 thread attachment R 1/2
KKI 215 BSF1/2 thread attachment for converting existing
ceramic dome aeration plants
Due to the self-cleaning properties of the membrane diffuser no extra cleaning
method is normally required. However, if needed due to process conditions, the
whole aeration system can be cleaned during operation by using the patented
NOPOL
CLEAN method. The cleaning liquid, formic acid, is fed into the air supply
to remove materials such as lime and iron deposits from the membrane disc.
Special tools are needed for opening and fixing the Screw-on Ring: HKLAT and a
smaller HKLIT. For diffusers with thread attachment a tool VASTE is needed for
fixing of the diffuser during maintenance. Each system delivery is complete
including the necessary installation tools.

NOPOL
KKI 215
Membrane disc diffuser
SOTE values and Pressure loss
41-
31007
/1
1/1
NOPON OY Inspected: June 26, 1997
MR Approved:
Clean water, standard conditions (+ 20 C, 101.3 kPa).
Submersion depth 4 m.
2
15.00
20.00
25.00
30.00
35.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50
15 %
10 %
7 %
5 %
3 %
DD
aeration basins. The graphs may be changed without further notice, so always
WET PRESSURE LOSS
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50
SOTE, %
Air flow, m
3
Air flow, m
3
kPa
NOPOL
KKI 215
41-
31009
/ 1
1/1
AL Approved:
Screw-on Ring HKR 215
Main Body HSA 215
Wedge Piece HSK 215
Density kg/m
3
1380 ASTM D 1505
2
500 DIN 53448
Membrane Disc 215 HIK 215
The EPDM material resists chemically all compounds of municipal sewage
and of most of industrial waste waters. Temperature resistance of the
membrane disc is 100 C, for details see specifications 41-31025/1.
The IIR (butyl rubber) material is resistant to most inorganic chemicals,
mineral acids and alkalis and to low molecular weight alcohols and ketones.
IIR has limited resistance to oxidising acids, is nonresistant for most organic
liquids and has fair resistance to phenols.
O - ring 19 HOR 19
NOPOL

Membrane Discs
HIK 215 and HIK 300
Specification
41-
31025
/ 1
1/1
MR Approved:
DDS systems.
Diameter mm 186 304
gasket
o- ring
at the edge
Slit density 1/cm
2
8,3 8,3
Membrane Discs
Basic polymer EPDM
acid (NOPOL

HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HOR19
122350
O-RING
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HTO215
122145
SUPPORT PART
PRODUCT N0 : 121115
NOPOL
KKI215D D90
OD 90 mm PI PE
FOR BASI NS DEEPER THAN 8m

HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HTL215
122140
SUPPORT PLATE
HOR18
122353
O-RING
HIK215
122310
MEMBRANE DISC
PRODUCT N0 : 121111
NOPOL
KKI215 D88,9

HVK215
122340
NON-RETURN VALVE
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HSK4
122132
WEDGE PIECE
HSA4
122104
MAIN BODY
HOR19
122350
O-RING
PRODUCT N0 : 121140
NOPOL
KKI215 4"
OD 114, 3 mm PI PE (NS 4")

HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HOR19
122350
O-RING
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HTO215
122145
SUPPORT PART
PRODUCT N0 : 121115
NOPOL
KKI215D D90
OD 90 mm PI PE
FOR BASI NS DEEPER THAN 8m

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HSA215R
122101
MAIN BODY
PRODUCT N0 : 121120
NOPOL
KKI215R

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HSA215RK
122102
MAIN BODY
PRODUCT N0 : 121125
NOPOL

KKI 215RK

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HIK215
122310
MEMBRANE DISC
HTL215
122140
SUPPORT PLATE
HSA215BSF
122103
MAIN BODY
PRODUCT N0 : 121130
NOPOL
KKI215BSF


HKLAT215
PRODUCT N0 : 193200
NOPOL
HKLAT215
BI G TOOL FOR SCREW- ON RI NG HKR215
TOOL FOR 215 DI FFUSERS

HKLIT215
PRODUCT N0 : 193210
NOPOL
HKLIT215
SMALL TOOL FOR SCREW- ON RI NG HKR215

PRODUCT N0 : 193220
NOPOL
VASTE215

5 NOPOL HKL 215
NOPOL
DDS
PRODUCT MANUAL
NOPOL
HKL 215
Porous Disc Diffuser
41-
31003
/ 1
1/2
AL Approved:
DESCRIPTION
NOPOL
HKL 215 Porous Disc Diffuser has a Porous Disc (HIL 210) as a bubble
dispersing device. Air forms small bubbles, the size between 1 - 3 mm, when
released through the disc. The HIL 210 Porous Disc is made of sintered
polyethylene. It is a dual layer disc having a thin upper surface layer of fine material
for forming small bubbles and a support layer to give mechanical strength. Around
the Porous Disc there is an U -shape rubber gasket (HUR 210). The Porous Disc
with the gasket is fixed by a Screw-on Ring (HKR 215) on the Main Body (HSA 215).
The Main Body is fixed on an O.D. 90 mm pipe mechanically by a rigid Wedge Piece
(HSK 215) without any glue or solvent welding. The pipe drilling is 20 mm and the
diffuser body is tightened by an o -ring against the pipe wall. Air is fed to the porous
disc through a hole in the pipe and through the Main Body. In the Main Body there is
a combined orifice - non-return valve. Orifice is 10 mm. The rubber valve (HVK
215) opens when feeding air and closes when air is shut off due to the influence of
hydraulic pressure. The orifice - non-return valve creates a pressure loss which
balances the air flow within all diffusers in the system.The non-return valve protects
the system from clogging when air is shut off or in case of a broken disc or fixing
ring. The diffuser construction is shown in the exploded view and in the Drawing LC
3964.
APPLICATIONS
NOPOL
HKL 215 Diffuser is suitable for the aeration of most biological processes
where the aeration is continuous. Because of its good chemical resistance, this type
of diffuser is the right solution for industrial waste waters containing solvents.
SPECIFIC DATA FOR THE HKL 215 DIFFUSER
3
Disc diameter 178 mm (effective)
2
Diffuser weight 830 10 g
Max air temperature + 80C
Diffuser level typical 250 mm above basin bottom
Performance (SOTE) 6...8 %/m; see graph 41-31021/1
3
/h. The maximum air flow is based on the
pressure loss and energy consumption. A peak value of 7 m
3
/h can only be used for
at most 15 min e.g. for cleaning the porous disc.
NOPOL
HKL 215
41-
31003
/ 1
2/2
AL Approved:
HUR 210 Circular Gasket IIR (butyl) rubber
HIL 210 Porous Disc HDPE sintered, see spec. 41-31024/1
90,250,05) with a Wedge Piece and sealed with an O-ring (HOR 19,2x3,0).
The HKL 215 can be installed on an O.D. 88,9 mm steel pipe when using a thicker
O-ring (HOR 18x4).
HIL 210 Porous Disc can be used. The other types are:
Table 3. Alternatives of HKL 215 Porous Disc Diffusers
HKL 4 wedge piece attachment for nominal 4 inch
HKL 215 R1/2 thread attachment R 1/2
HKL 215 BSF1/2 thread attachment for converting existing
In normal municipal waste water HKL 215 diffusers can be run for several years
without carrying out any maintenance. However, high calcium content (hard waters)
or e.g. simultaneous precipation of phosphorus by iron salts may cause clogging.
The whole aeration system can be cleaned during operation by using the patented
NOPOL
CLEAN method. The cleaning liquid, formic acid, is fed into the air supply
to remove materials such as lime and iron deposits from the membrane disc.
Special tools are needed for opening and fixing the screw-on ring: HKLAT and a
fixing of the diffuser during maintenance. Each system delivery is complete including
the necessary installation tools.

NOPOL
HKL 215
Fine bubble diffuser
41-
31021
/ 1
1/1
MR Approved:
2
15.00
20.00
25.00
30.00
35.00
0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50
15 %
9 %
6 %
4 %
2 %
DD
aeration basins. The graphs may be changed without further notice, so always
WET PRESSURE LOSS
1. 00
1. 50
2. 00
2. 50
3. 00
3. 50
4. 00
0. 50 1. 00 1. 50 2. 00 2. 50 3. 00 3. 50 4. 00 4. 50 5. 00 5. 50
kPa
Air flow, m
3
Air flow, m
3
SOTE, %
NOPOL
Disc Diffusers
HKL 215 and MKL 215
41-
31008
/ 1
1/1
AL Approved:
Materials and characteristics of the components of
the NOPOL
Disc Diffusers
Main Body HSA 215
Wedge Piece HSK 215
Density kg/m
3
1380 ASTM D 1505
2
500 DIN 53448
Porous Disc, fine bubble HIL 210
Porous Disc, medium bubble MIL 210
The Porous Disc is made of high density polyethylene (HDPE) by a sintering
technology specially developed for fine bubble aeration. The material
chemically resists all compounds in municipal sewage and in most industrial
waste waters. Temperature resistance of the porous disc is 80 C.
Material is IIR (butyl rubber) having a chemical resistance to:
most inorganic chemicals
mineral acids and alkalis
low molecular weight alcohols and ketones
limited resistance to oxidising acids
non-resistant for most organic liquids
fair resistance to phenols
O - ring 19 HOR 19
NOPOL
Porous Discs
HIL 210 and MIL 210
41-
31024
/ 1
1/1
MR Approved:
HIL 210 and MIL 210 Porous Discs
HIL 210 Porous Disc is a dual layer disc having a thin surface layer of fine
material for forming fine bubbles and a support layer to give mechanical
strength. As the support layer is made of a coarser material the pressure drop
remains small. Thin surface layer is easy to clean if clogged.
MIL 210 Porous Disc has one layer for forming medium size bubbles.
Characteristic unit HIL 210 MIL 210
Diameter, upper surface mm 185 2 185 2
Diameter, lower surface mm 187 2 187 2
Thickness, total mm 10,5 1 10,5 1
Thickness, surface layer mm 2,0 0,5 -
Thickness, support layer mm 8,5 0,5 -
Pore size, surface layer m 300 - 400 400 - 500
Pore size, support layer m 400 - 500 400 - 500
Particle size, surface layer m 350 - 750 750 - 2000
Temperature resistance C 80 80
Bending rigidity, 50 kPa, uniform mm 10 - 13 12 - 15
Particle size, support layer m 750 - 2000 750 - 2000
Porous discs are made of high density polyethylene (HDPE) by a sintering
process specially developed for NOPOL
Diffuser Discs. The material is pure

PE and does not contain any binding compounds that might weaken the
mechanical or chemical structure of the sintered material.
Table 2. Material characteristics of NOPOL
Porous Diffuser Discs

Density g/cm
3
0,952 - 0,956 DIN 53 479
Tensile stress, 80 C N/mm
2
10 DIN 53 445
Tensile strength, 80 C N/mm
2
13 DIN 53 455
Elongation, 80 C % > 600 DIN 53 455
Shearing strength N/mm
2
800 DIN 53 445
E - modulus N/mm
2
1300 DIN 53 457
Shore D - hardness - 63 DIN 53 505
Impact strength 23 C/ -40 C kJ/m
2
o.B./o.B. DIN 53 453
o.B. no breakage
HDPE material is resistant to practically all components of sewage and most
industrial waste waters. It can be cleaned e.g. by 10 % hydrochloric acid. The
sintered HDPE may absorb mineral and vegetable oils from concentrated
industrial waste waters. The life time of porous discs in normal activated
sludge plants is typically more than 15 years.
HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HOR19
122350
O-RING
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
HIL210
122110
FINE BUBBLE POROUS DISC
PRODUCT N0 : 121310
NOPOL
HKL215 D90
FI NE BUBBLE DI SC DI FFUSER
OD 90 mm PI PE

HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HOR18
122353
O-RING
HUR210
122330
CIRCULAR GASKET
HIL210
122110
PRODUCT N0 : 121311
NOPOL
HKL215 D88,9

Rev.1: 19.04.2002 AL Created by: MB Approved by: MF
HVK215
122340
NON-RETURN VALVE
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
HIL210
122110
HSK4
122132
WEDGE PIECE
HSA4
122104
MAIN BODY
HOR19
122350
O-RING
PRODUCT N0 : 121340
NOPOL
HKL215 4"
OD 114, 3 mm PI PE (NS 4")

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
HIL210
122110
HSA215R
122101
MAIN BODY
PRODUCT N0 : 121320
NOPOL
HKL215R

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HSA215RK
122102
MAIN BODY
HUR210
122330
CIRCULAR GASKET
HIL210
122110
PRODUCT N0 : 121325
NOPOL

HKL215RK

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
HIL210
122110
HSA215BSF
122103
MAIN BODY
PRODUCT N0 : 121330
NOPOL
HKL215BSF


HKLAT215
PRODUCT N0 : 193200
NOPOL
HKLAT215
BI G TOOL FOR SCREW- ON RI NG HKR215

HKLIT215
PRODUCT N0 : 193210
NOPOL
HKLI T215
SMALL TOOL FOR SCREW-ON RI NG HKR215

NOPON OY Documentati on l evel 4 Date: 15. 06. 2000
PRODUCT N0 : 193220
NOPOL
VASTE215

6 NOPOL MKL 215
NOPOL
DDS
PRODUCT MANUAL
NOPOL
MKL 215
41-
31033
/ 1
1/2
AL Approved:
DESCRIPTION
NOPOL
MKL 215 Porous Disc Diffuser has a Porous Disc (MIL 210) as a bubble
dispersing device. Air forms small bubbles, the size between 3 - 6 mm, when
released through the disc. The MIL 210 Porous Disc is made of sintered
polyethylene. Around the porous disc there is an U -shape rubber gasket (HUR
210). The Porous Disc with the gasket is fixed by a Screw-on Ring (HKR 215) on
the Main Body (HSA 215).
The Main Body is fixed on an O.D. 90 mm pipe mechanically by a rigid Wedge
Piece (HSK 215) without any glue or solvent welding. The pipe drilling is 20 mm
and the diffuser body is tightened by an O-ring against the pipe wall. Air is fed to the
Porous Disc through a hole in the pipe and through the Main Body. In the Main
Body there is a combined orifice - non-return valve. Orifice is 10 mm. The rubber
valve (HVK 215) opens when feeding air and closes when air is shut off due to the
influence of hydraulic pressure. The orifice - non-return valve creates a pressure
loss which balances the air flow within all diffusers in the system.The non-return
valve protects the system from clogging when air is shut off or in case of a broken
disc or fixing ring. The diffuser construction is shown in exploded view and in
Drawing LC 3964.
APPLICATIONS
NOPOL
MKL 215 Diffuser is suitable for the aeration of waste water or sludge with
a higher solids concentration, e.g. aerobic sludge stabilisation. Because of good
chemical resistance it is suitable for aeration of industrial waste waters containing
solvents.
SPECIFIC DATA FOR THE MKL 215 DIFFUSER
3
Disc diameter 178 mm (effective)
2
Diffuser weight 830 10 g
Max air temperature + 80C
Diffuser level typical 250 mm above basin bottom
Performance (SOTE) 6...3,75 %/m; see graph 41-31022/1
3
/h. The maximum air flow is based on the
pressure loss and energy consumption. A peak value of 8 m
3
/h can be used for a
max of 15 min e.g. for cleaning the porous disc.
NOPOL
MKL 215
41-
31033
/ 1
2/2
AL Approved:
HUR 210 Rubber Gasket IIR (butyl) rubber
MIL 210 Porous Disc HDPE sintered, see spec. 41-31024/1
90,250,05) with a wedge piece and sealed with an O-ring (HOR 19,2x3,0).
The MKL 215 can be installed on an O.D. 88,9 mm steel pipe when using a thicker
O-ring (HOR 18x4).
MIL 210 Porous Disc can be used. The other types are:
Table 3. Alternatives of MKL 215 Porous Disc Diffusers
MKL 4 wedge piece attachment for nominal 4 inch
MKL 215 R1/2 thread attachment R 1/2
MKL 215 BSF1/2 thread attachment for converting existing
In normal municipal waste water the MKL 215 diffusers can operate for several
years without any maintenance. However, in high calcium content effluents (hard
waters) or e.g. with simultaneous precipitation of phosphorus by iron salts clogging
may occur. The whole aeration system can be cleaned during operation by using
the patented NOPOL
CLEAN method. The cleaning liquid, formic acid, is fed into

the air supply to remove materials such as lime and iron deposits from the
membrane disc.
Special tools are needed for opening and fixing the screw-on ring: HKLAT and a
fixing of the diffuser during maintenance. Each system delivery is complete
including the necessary installation tools.

NOPOL
MKL 215
Medium bubble diffuser
41-
31022
/ 1
1/1
MR Approved:
2
10.00
15.00
20.00
25.00
30.00
1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50
9 %
6 %
4 %
2 %
15 %
DD
Note: The values are valid for full bottom covering with uniform diffuser distribution and can be
affected by the mixing and water flow conditions in aeration basins. The graphs may be
changed without further notice, so always consult Nopon Oy for capacity guarantees.
WET PRESSURE LOSS
1.00
1.50
2.00
2.50
3.00
3.50
4.00
1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50
Air flow, m
3
SOTE, %
Air flow, m
3
kPa
NOPOL
Disc Diffusers
HKL 215 and MKL 215
41-
31008
/ 1
1/1
AL Approved:
Materials and characteristics of the components of
the NOPOL
Disc Diffusers
Main Body HSA 215
Wedge Piece HSK 215
Density kg/m
3
1380 ASTM D 1505
2
500 DIN 53448
Porous Disc, fine bubble HIL 210
Porous Disc, medium bubble MIL 210
The Porous Disc is made of high density polyethylene (HDPE) by a sintering
technology specially developed for fine bubble aeration. The material
chemically resists all compounds in municipal sewage and in most industrial
waste waters. Temperature resistance of the porous disc is 80 C.
Material is IIR (butyl rubber) having a chemical resistance to:
most inorganic chemicals
mineral acids and alkalis
low molecular weight alcohols and ketones
limited resistance to oxidising acids
non-resistant for most organic liquids
fair resistance to phenols
O - ring 19 HOR 19
NOPOL
Porous Discs
HIL 210 and MIL 210
41-
31024
/ 1
1/1
MR Approved:
HIL 210 and MIL 210 Porous Discs
HIL 210 Porous Disc is a dual layer disc having a thin surface layer of fine
material for forming fine bubbles and a support layer to give mechanical
strength. As the support layer is made of a coarser material the pressure drop
remains small. Thin surface layer is easy to clean if clogged.
MIL 210 Porous Disc has one layer for forming medium size bubbles.
Characteristic unit HIL 210 MIL 210
Diameter, upper surface mm 185 2 185 2
Diameter, lower surface mm 187 2 187 2
Thickness, total mm 10,5 1 10,5 1
Thickness, surface layer mm 2,0 0,5 -
Thickness, support layer mm 8,5 0,5 -
Pore size, surface layer m 300 - 400 400 - 500
Pore size, support layer m 400 - 500 400 - 500
Particle size, surface layer m 350 - 750 750 - 2000
Temperature resistance C 80 80
Bending rigidity, 50 kPa, uniform mm 10 - 13 12 - 15
Particle size, support layer m 750 - 2000 750 - 2000
Porous discs are made of high density polyethylene (HDPE) by a sintering
process specially developed for NOPOL
Diffuser Discs. The material is pure

PE and does not contain any binding compounds that might weaken the
mechanical or chemical structure of the sintered material.
Table 2. Material characteristics of NOPOL
Porous Diffuser Discs

Density g/cm
3
0,952 - 0,956 DIN 53 479
Tensile stress, 80 C N/mm
2
10 DIN 53 445
Tensile strength, 80 C N/mm
2
13 DIN 53 455
Elongation, 80 C % > 600 DIN 53 455
Shearing strength N/mm
2
800 DIN 53 445
E - modulus N/mm
2
1300 DIN 53 457
Shore D - hardness - 63 DIN 53 505
Impact strength 23 C/ -40 C kJ/m
2
o.B./o.B. DIN 53 453
o.B. no breakage
HDPE material is resistant to practically all components of sewage and most
industrial waste waters. It can be cleaned e.g. by 10 % hydrochloric acid. The
sintered HDPE may absorb mineral and vegetable oils from concentrated
industrial waste waters. The life time of porous discs in normal activated
sludge plants is typically more than 15 years.
HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HOR19
122350
O-RING
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
MIL210
122115
MEDIUM BUBBLE POROUS DISC
PRODUCT N0 : 121510
NOPOL
MKL215 D90
MEDI UM BUBBLE DI SC DI FFUSER
OD 90 mm PI PE

HVK215
122340
NON-RETURN VALVE
HSA215
122100
MAIN BODY
HSK215
122130
WEDGE PIECE
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
MIL210
122115
HOR18
122353
O-RING
PRODUCT N0 : 121511
NOPOL
MKL215 D88, 9

HVK215
122340
NON-RETURN VALVE
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
MIL210
122115
HSK4
122132
WEDGE PIECE
HSA4
122104
MAIN BODY
HOR19
122350
O-RING
PRODUCT N0 : 121540
NOPOL
MKL215 4"
OD 114, 3 mm PI PE (NS 4")

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
MIL210
122115
HSA215R
122101
MAIN BODY
PRODUCT N0 : 121520
NOPOL
MKL215R

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HSA215RK
122102
MAIN BODY
HUR210
122330
CIRCULAR GASKET
MIL210
122115
PRODUCT N0 : 121525
NOPOL
MKL215RK

HVK215
122340
NON-RETURN VALVE
HOR19
122350
O-RING
HKR215
122120
SCREW-ON RING
HUR210
122330
CIRCULAR GASKET
MIL210
122115
HSA215BSF
122103
MAIN BODY
PRODUCT N0 : 121530
NOPOL
MKL215BSF


HKLAT215
PRODUCT N0 : 193200
NOPOL
HKLAT215
BI G TOOL FOR SCREW-ON RI NG HKR215

HKLIT215
PRODUCT N0 : 193210
NOPOL
HKLI T215
SMALL TOOL FOR SCREW-ON RI NG HKR215

PRODUCT N0 : 193220
NOPOL
VASTE215

7 NOPOL CLEAN
NOPOL
DDS
PRODUCT MANUAL
Version 2.0
Copyright: Nopon Oy 2001 product code 195062
NOPOL
CLEAN
OPERATION AND MAINTENANCE
MANUAL
NOPON OY Turvekuja 6, 00700 HELSINKI, FINLAND
Tel +358 9 351 730 internet: http://www.nopon.fi
Fax +358 9 351 5620 E-mail: hq@nopon.fi
We reserve the right to make technical changes.
NOPON Oy NOPOL
CLEAN manual Date 7.5.2001

Written by: MR Inspected by: AL Accepted by: ERN
SAFETY NOTICE FOR THE USERS OF NOPOL
CLEAN
FORMIC ACID CLEANING SYSTEM
1. Check the unit for leakage before starting up the unit by operating it with clean
water instead of formic acid.
2. Read the formic acid safety data sheet carefully and follow all the instructions
given there; always have new users to familiarise with the safety data sheet
before operating the NOPOL
CLEAN unit.
3. Check the formic acid supplier for their safety instructions and follow them.
NOPON Oy NOPOL

TABLE OF CONTENTS
PAGE
1 INTRODUCTION _____________________________________________________________1
2 CLOGGING__________________________________________________________________2
3 NOPOL
CLEAN EQUIPMENT__________________________________________________4
4 OPERATION INSTRUCTIONS __________________________________________________7
4.1 General ___________________________________________________________________7
4.2 Formic Acid Supply _________________________________________________________7
4.3 Use of NOPOL
CLEAN______________________________________________________9
4.4 Cleaning the Diffusers ______________________________________________________11
5 MAINTENANCE _____________________________________________________________12
6 CHEMICALS________________________________________________________________13
NOPON Oy NOPOL

Written by: MR Inspected by AL Accepted by: ERN Page: 1 (13)
1 INTRODUCTION
This guide deals with the clogging of fine bubble diffusers, the reasons for such clogging and how to
clean clogged diffusers. The installation and use of the NOPOL
CLEAN formic acid cleaning system

is explained in detail.
The cleaning agent used in the NOPOL
CLEAN system is formic acid, which is an ideal chemical

for this purpose. Formic acid is sufficiently strong to dissolve most deposits in porous disc pores and
membrane slits. At the same time, it is safe to use and easy to dispense and does not interfere with
the biological process. Nor does it corrode stainless steel pipework. Even zinc-coated pipes can
withstand the action of formic acid to a limited extent.
The aeration basin need not be drained nor the diffusers removed during the cleaning. As a result,
the process remains unaffected by the cleaning operation.
The NOPOL
CLEAN method offers cost savings as well. Cleaning the diffusers improves oxygen
yield and reduces back pressure. As a consequence, the required oxygen is transferred at the same
rate as with new, clean diffusers. Therefore thanks to the NOPOL
CLEAN system, it is advisable to

clean the diffusers more frequently and whenever back pressure increases to 20 mbar. The
frequency varies considerably, and must be determined from case to case - it may be once a week,
or once a year.
NOPON Oy NOPOL

Page: 2 (13) Written by: MR Inspected by: AL Accepted by: ERN
2 CLOGGING
With fine-bubble aeration, problems are caused mainly by clogged diffusers. Clogging increases
back pressure and power consumption. Clogging of the air supply side can be prevented by filtering
the inlet air carefully. However, the delivery side needs to be continuously monitored for clogging
and the diffusers cleaned at regular intervals.
Clogging on the delivery side is usually caused by calcareous or ferrous deposits such as ferro-
sulphate or particles trapped by diffuser pores or membrane slits. Clogging may be accompanied by
slime formations on the diffuser surface if the activated sludge has a high soluble BOD content
(typically industrial waste waters). Slime alone does not increase back pressure but it affects the
aeration efficiency.
Clogging is low when the aeration system operates continuously. However, if aeration is interrupted,
for example because of a power failure or process-related reasons, water pressure forces waste
particles into the porous disc pores or membrane slits. If it is known in advance that aeration will
have to be repeatedly interrupted, as in the denitrification process, it is advisable to select membrane
diffusers, which do not become clogged when idle. Any deposits are removed by membrane motion.
Clogged diffusers can be cleaned by any of the following four methods:
The basins are drained and the diffusers cleaned on site by water using a brush or high
pressure cleaning
The basin is drained and the diffusers removed and cleaned one by one
NOPOL
CLEAN cleaning during operation

The aeration group is lifted up from the basin and the diffusers cleaned one by one
The NOPOL
CLEAN method makes use of formic acid which is fed into the air supply in the
dropleg. Formic acid dissolves any deposits in the pores during operation, so that it is no longer
necessary to drain the basin and remove the diffusers.
With the NOPOL
CLEAN system, it is advisable to clean the diffusers whenever back pressure

reaches about 20 mbar because the process need not be halted. If the diffusers are to be cleaned by
draining the basin and washing the diffusers one by one, the diffusers should be cleaned when back
pressure reaches approximately 50 mbar.
NOPON Oy NOPOL

With the NOPOL
CLEAN system, the cost of chemicals is approx. EUR 0.15 to 0.5 per year per
diffuser disc (EUR 0.88 / kg HCOOH 1999). The annual consumption of formic acid is 180 to 540 g
per diffuser depending on how severely clogged they are.
Table 1: Various ways of cleaning clogged NOPOL
diffusers.
Diffuser Cause of clogging Corrective action
Membrane diffusers PIK 300, PRK 300, KKI 215, KKR 300
Chemical deposits Usually removed by membrane motion / NOPOL
CLEAN method
Power failure Membrane prevents back-flow, solid particles
removed when aeration resumed
Intermittent aeration Membrane prevents back-flow, solid particles
removed when aeration resumed
Slime formation Water-jet or high-pressure cleaning and brushing.
NOPOL
CLEAN inhibits slime formation

Porous diffusers HKL 215, MKL 215
Chemical deposits NOPOL
CLEAN washing or cleaning one by one

Power failure NOPOL
CLEAN washing or cleaning one by one

Intermittent aeration Intermittent aeration not suitable
Slime formation Water-jet or high-pressure cleaning and brushing.
NOPOL
CLEAN inhibits slime formation

NOPON Oy NOPOL

3 NOPOL
CLEAN EQUIPMENT
NOPOL
CLEAN equipment is shown in the

photos on this page.
NOPON Oy NOPOL

The cleaning system consists of a pump unit, a distribution manifold, a control box, valves and
nozzles. The pump unit draws formic acid from a container and supplies it through the distribution
manifold to the nozzles, which spray it into the droplegs (Figure 1). Pump operation times are set
with the control box. Aeration groups are cleaned one by one. The equipment is mounted on a push-
cart for easy transportation.
NOPOL
CLEAN is supplied complete with the following:

push-cart
pump and motor unit
control box
suction hose with strainer
relief valve
three-way valve
feeding hose, 5 m
return hose from relief valve
quick-disconnect fitting (female), 1 pce
quick-disconnect (male), 1 pce per aeration group
nozzles, 1 pce per aeration group
bushing for connecting the nozzles to the air supply pipes, 1 pce per aeration group
power cable
protective gear (see Chapter 6)
plugs for quick- disconnect fittings, 1 pce per fitting
bottle of oil, 0,5 l
In the push-cart there is a place for the acid container. The container is not included in the delivery,
however. The container in which the acid is delivered, usually a 35 kg plastic canister, is used as the
supply vessel.
Normally the pump case and gear box are filled with oil when the equipment is delivered. The oil
amount should anyway be checked before use, since oil might have leaked out through the breather
valve on the oil entry cover during transportation. Detailed instructions for this are in the pump
manual.
Electric current to the pump is supplied through the control box. Pump adjustments are explained in
greater detail in the pump manual.
NOPON Oy NOPOL


Control
box
HCOOH
Pump Relief valve 3-way valve
Stop valve /
quick connector
Nozzle
Air pipe
Figure 1: NOPOL
CLEAN acid cleaning system, flow chart

The bushings for nozzles are mounted to the dropleg. The acid application point cannot be placed
further upstream because formic acid may damage seals and certain valve components. The
bushings must not be fixed where a seal or joint is located. The nozzle is fixed into the bushing with
a connector. The method of installation for straight and curved pipe is slightly different. Suitable
methods are shown in section Installation into the air pipe.
quick-disconnect
fitting
NOPON Oy NOPOL

4 OPERATION INSTRUCTIONS
4.1 General
To determine when the diffusers should be cleaned, watch the back pressure. Check the back
pressure regularly and enter the values in plant records. Back pressure must always be measured at
a constant air flow rate or known air flow rate.
With the NOPOL
CLEAN system, it is advisable to clean the diffusers frequently and whenever

back pressure reaches 20 mbar. The cleaning interval is specific to each plant and may range from
one week to one year depending on local conditions.
4.2 Formic Acid Supply
Air flow rate has to be stepped up from low air flow and increased according to clogging grade.
Formic acid is dispensed in proportion to the air flow rate. During cleaning, the air flow rate should be
as close to the permissible maximum as possible to ensure that mixture of air and formic acid
effectively penetrates throughout the disc pores. Recommended air flow rates for various types of
diffusers are given in the following table.
Table 2: Maximum air flow rates for diffusers during cleaning.
Diffuser HKL 215 MKL 215 KKI 215 KKR 300 PRK 300 PIK 300
m
3
/h 5 5 4 8 8 8
Quantity of dispensed formic acid per cubic metre of air and duration of cleaning is determined by
type of blockage involved. Table 3 lists dispensing rates and cleaning times for different types of
blockage. However, these values, particularly concerning cleaning, are only indicative. The required
plant-specific cleaning time can be established by starting with shorter cycles and increasing their
duration as required. The cleaning process can be monitored by watching the change in back
pressure.
It is advisable to divide the total cleaning time into several shorter sequences. For example, first
clean one group of diffusers for 2 min, then switch to the next group. Repeat this procedure as often
as necessary. If the aeration groups are thoroughly cleaned at one go, most of the air will escape via
diffusers that have already been cleaned. As a result, cleaning of the last diffusers may fail because
the amount of supplied air is too low.
NOPON Oy NOPOL

At major waste water treatment plants, where cleaning is carried out at short intervals, it is advisable
to install an automatic system that supplies acid to each aeration group one at a time (for 1 to 5 min)
and repeats this sequence often enough (5 to 10 times).
Table 3: Formic acid dispensing rates and times for various types of blockages.
g HCOOH /
diffuser
g HCOOH /
m
3
of air
Chemical feed
time (min)
Cleaning
interval
Calcareous deposits 5 10 20 5 - 10 1 week
Ferrous deposits 50 250 50 30 - 60 1 - 2 months
Slime formation 5 10 20 10 2 - 7 d
Industrial waste water 5 250 10 50 5 - 60 1 d - 1 month
The dispenser pump delivery rate is determined by the size and air flow rate of the aeration group to
be cleaned and the quantity of acid supplied to it. Figure 2 shows the required acid pump delivery
rate (l/h) for different aeration group sizes at different air and acid flow rates.

Number of diffusers per group
0
50
100
150
200
250
300
0 200 400 600 800 1000 1200
H1
H1
H2
H2
Acid flow rate / l/h
- - - - - - - 5 m
3
/h/diffuser
----------- 3 m
3
/h/diffuser
H1 Formic acid supply rate 50 g/m
3
, ferrous deposits
H2 formic acid supply rate 20 g/m
3
, calcareous deposits
Figure 2: Acid delivery rate for different aeration group sizes at different air and acid delivery rates
NOPON Oy NOPOL

4.3 Use of NOPOL
CLEAN
The lid of the control box is shown in Figure 3. The following features can be found there:
- Starter switch S1
- Signal light, which is on whenever the switch is on
- Reset button
- Emergency switch D2 (red)
Figure 3: Control box
Starter switch S1 in the control box has three positions
K manual
0 stop
A automatic
When starter switch is turned from 0 to K, the motor runs as long as switch is kept turned to K.
When starter switch is turned from 0 to A, the motor starts immediately. The switch does not stay at
A, it jumps immediately back to 0. Running time is controlled by timer T1.
Timer T1 is located inside the control box. It has blue and grey adjuster knobs with cross heads for
screwdriver (see Figure 4). The grey knob is for coarse setting: it gives 7 different pumping time
scales: 0,1 1 s, 1 10 s, 6 60 s, 1 10 min, 6 60 min, 1 10 h and 10 100 h. The blue knob
is for fine setting: it has a scale 1 10x. If one wants, for example, the pump to run for 60 s, one has
to set the grey knob at 6 60 s and the blue knob at 10x. Timer is set to 0 when NOPOL
CLEAN
is delivered.
NOPON Oy NOPOL

Figure 4: Timer
To get the formic acid to flow, the black stroke control knob on the lower part of the pump must be
turned (Figure 5). This knob controls the stroke of pump piston. Regulating the capacity from 0 to the
maximum capacity of the pump is done by turning the adjustment knob 10 turns. The required
dosage can thus be regulated by turning the knob. When NOPOL
CLEAN is supplied, the knob is

turned to 0 to prevent accidental pumping. The knob should be turned back to 0 when pumping is
finished.
Figure 5: Stroke control knob
In control box there is a black push button with letter R (reset). In case contactors jump off, they can
be reset by this button.
Pump can be switched off by pushing the red emergency switch D2. If the emergency switch
has been used, it can be switched off by first turning the starter switch S1 to 0 and then turning the
emergency switch counter-clockwise.
NOPON Oy NOPOL

4.4 Cleaning the Diffusers
Clean the diffusers set by set by moving the equipment next to the supply point. To clean the
diffusers:
Drain any condensed water from the air supply pipes before cleaning. Remember to close the
drain valve!
Secure the acid feeding hose to the nozzle with care. Remove any impurities from the
connection
Make sure to allow replacement air into the acid container during pumping. Otherwise the acid
may vaporise
Make sure that the return hose leads back to the acid container from the three-way valve
Set the pump operation time with the control box
Regulate the acid flow by turning the stroke control knob
Start the pump
When the pump stops, remove the acid supply hose from the nozzle
Remember to replace the quick-disconnect fitting
If the pump suction and delivery piping are empty, the delivery piping must be depressurised to
make sure that the pump can draw the fluid to be distributed. This type of situation may arise when
the acid container has been unobtrusively emptied and the pump has drawn air.
The feeding hose can be drained by turning the 3-way valve into such a position that acid is carried
by compressed air from the nozzle to the acid container (Figure 6).
1 2

Nozzle
Pump
Return line

Nozzle
Pump
Return line
Figure 6: Using the 3-way valve. During normal operation, the valve is in position 1 and the acid
passes from the pump to the nozzle. To drain the feeding hoses, turn the valve to position 2 to direct
the acid from the nozzle to the acid container via the return line.
NOPON Oy NOPOL

5 MAINTENANCE
Monitor the condition of the valves, nozzles and quick-disconnect fittings. If any leaks are found in
the connections or similar locations, replace the seals and other components where necessary.
When servicing the valves, quick connectors and nozzles, remember that all materials do not
withstand formic acid.
When the quick-disconnect fittings are not in use, they must be capped. When making connections,
check that the fittings are clean and in proper condition.
Monitor the condition of the acid distribution hoses. Replace them if any sign of embrittlement is
detected. All the acid hose connections must be sealed to avoid accidents.
Maintenance instructions for the pump are given in the Dosatron manual.
NOPON Oy NOPOL

6 CHEMICALS
The chemical used for cleaning of the diffusers usually consists of 85 % technical formic acid
because it is sufficiently strong to dissolve most of the deposited matter. An acid with a higher
concentration may also be used. Formic acid is biodegradable and does not interfere with the
biological processes.
Formic acid is not aggressive to the NOPOL
CLEAN system components and NOPOL
diffusers.
Nor does the acid damage air supply tubes made of acid-proof or stainless steel. Large quantities of
acid combined with prolonged exposure may, however, attack galvanised air supply tubes. A number
of materials such as polyamide (nylon), which is commonly used in hose connections and in some
pumps, are, with time, embrittled by exposure to formic acid. PE, PVC and PP have a high
resistance to formic acid, with certain limitations.
Formic acid must be stored in a cool well-ventilated place. Formic acid may not be kept near an
open flame or other sources of heat. Ignited formic acid can be put out with a powder or carbon-
dioxide extinguisher.
Formic acid containers must not be stored at sub-zero temperatures and the vessels must not be
damaged. When making hose and other similar connections, special care must be taken to ensure
that the connections are fully sealed. Spilled formic acid can be neutralised with sodium carbonate
and flushed into the sewer using a lot of water.
85 % formic acid is a potent and easily volatile acid. It burns the skin and its vapour can irritate the
eyes and mucous membranes. Acid vapour is dangerous when inhaled. Formic acid must always be
handled in a well-ventilated space. If necessary, wear a respirator. To protect yourself from splashes,
use protective goggles, visor and gloves made of natural rubber or neoprene. Adequate instructions
for protective gear and first aid must be available at the workplace, accompanied by a formic acid
safety bulletin.
The NOPOL
CLEAN system is supplied complete with the following protective gear:

Formic acid safety bulletin
Rubber gloves
Goggles
Safety visor
NOPON Oy NOPOL CLEAN manual Date: 7.5.2001
Written by: MR Inspected by AL Accepted by: ERN
TECHNICAL SPECIFICATIONS
Dosatron membrane pump B-125N-40/B-43
- 0 - 108 l/h, 8 bar
- 220 AC, 50 Hz, 0,18 kW
- connections
The indicated capacity value is subject to changes due to norming
pressure, dosed liquid, viscosity and installation asset.
Control Box - Plastic housing, opening lid
- Comprises Contactor
Motor over heat protection
Time relay 0.1 - 1 s / 10 - 100 h
Automatic running stop switch
Start button
Reset button
Emergency switch
Suction strainer - PVC
- 19 mm hose connection
Relief valve - VSC 10/41
- 6 bar (set value)
- 1/2 " connections
3-way valve - 16 mm hose connection
Feeding hose - 16 / 22 mm tissue-reinforced PVC
Nozzle - 2,29 l/min, 8 bar (with water)
+358 9 351 5620
http://www.nopon.fi
+358 9 351 730
LD 3676 A
Fax: Turvekuja 6
FIN-00700 Helsinki
FINLAND
NOPOL CLEAN
CONTROL FOR DOSAGE PUMP
Homepage:
E-mail: hq@nopon.fi
Nopon OY Phone:
534.054 Trade Reg. NO.
ARTO LEHTO 3 MAY, 2001
VAT NO. FI08925649
1
8 Brochures
NOPOL
DDS
PRODUCT MANUAL
9 Reference Lists
NOPOL
DDS
PRODUCT MANUAL
SELECTED NOPOL
REFERENCES 13.9.2000
MUNICIPAL PLANTS
Year Country Plant Water type P.E. Diffuser Number
1998 Australia Jindabyne STW MUNICIPAL 16.000 PIK 300 980
1997 Austria Salzburg -SIggerwiesen MUNICIPAL 200.000 PIK 300 3936
1997/2000 Austria Ager - West MUNICIPAL 78.000 KRF 300/PIK 300 1620
1997 Austria Schwechat MUNICIPAL 80.000 KKR 300 2940
1997 Austria Bruck an der Leitha MUNICIPAL 116.000 KKR 300 5808
1996 Austria Wrgl - Kirchbichl MUNICIPAL 100.000 KKR 300 1440
1985 Austria Walgau MUNICIPAL 72.000 HKL 215 2208
1978 Austria Krems MUNICIPAL 150.000 MKP 600 1680
1991 Belgium Brugge MUNICIPAL 300.000 KKI 215 R1/2 4744
1986 Belgium Gent MUNICIPAL 350.000 HKL 215
HKL 215 R1/2
MKL 215 R1/2
5355
1945
1335
1983 Belgium Mechelen MUNICIPAL 60.000 HKP 600
1997 China Hangzhou MUNICIPAL 680.000 KKI 215 16504
1995 China Dalian MUNICIPAL 340.000 KKI 215 9360
1995 China Fuzhou, Xiangban STP MUNICIPAL 180.000 KKI 215 6495
1995 China Urumqi, Hedong STP MUNICIPAL 400.000 KKI 215
MKL 215
7296
2816
1995 China Xiamen MUNICIPAL 300.000 KKI 215 12800
1993 China Shenzhen MUNICIPAL KKI 215 1700
1998 Czech Republic Znojmo MUNICIPAL 64.000 KKR 300 4160
1996 Czech Republic Ostrava UCOV MUNICIPAL 580.000 HKL 215
KKI 215
19041
1800
1996 Denmark Hillerd kommune MUNICIPAL 50.000 KKR 300 2400
1992 Denmark Esbjerg kommune st MUNICIPAL 100.000 KKI 215 3120
1991 Denmark Esbjerg kommune Vest MUNICIPAL 250.000 KKI 215 9032
1989 Denmark rhus kommune, Marselisborg MUNICIPAL 220.000 KKI 215 12044
1996 Estonia Prnu MUNICIPAL 190.000 KKI 215 6224
1994 Estonia Tallinn MUNICIPAL 700.000 KKI 215 22190
1998 Finland Seinjoen JVP MUNICIPAL 55.000 PIK 300 924
1997 Finland Jyvskyl, Nenniemi MUNICIPAL 200.000 KKR 300 4016
SELECTED NOPOL
MUNICIPAL PLANTS
HKL 215 4128
1997 Finland Mikkeli, Kenkveronniemi MUNICIPAL 100.000 KKR 300 1446
1996 Finland Espoo, Suomenoja MUNICIPAL 240.000 KKR 300
KKI 215
HKL 215
13500
7000
1000
1996 Finland Lahti, Kariniemi MUNICIPAL 85.000 KKR 300 3500
1995 Finland Pori, Luotsinmki MUNICIPAL 63.000 KKI 215 3952
1994 Finland Helsinki, Viikinmki MUNICIPAL 740.000 KKI 215 12810
1993 Finland Kotka, Mussalo MUNICIPAL 100.000 KKI 215
KRF 300
2592
1152
1992 Finland Tampere, Rahola MUNICIPAL 50.500 KKI 215 3638
1991 Finland Savonlinna, Pihlajaniemi MUNICIPAL 30.000 KKI 215 1664
1990 Finland Hmeenlinna, Paroinen MUNICIPAL 47.000 KKI 215
KKI 215 BSF
KKR 300
4272
1600
806
1989 Finland Tampere, Viinikanlahti MUNICIPAL 145.000 KKI 215 6532
1998 France Ile de France MUNICIPAL PIK 300 2010
1997 France Meaux MUNICIPAL KKR 300 3150
1996 France Cise Gien MUNICIPAL KKR 300 1050
1994 France Scylas, Saint Cyprien MUNICIPAL 150.000 KKI 215 4288
1990 France Barberey, Troyes MUNICIPAL 250.000 KKI 215 4644
1988 France Cheylard MUNICIPAL 40.000 KKI 215 1116
1985 France Deauville - Trouville, Cise Touques MUNICIPAL 88.000 HKL 215 2112
1984 France Les Milles, La Pioline MUNICIPAL 77.000 HKL 215 1812
1997 Germany Frankfurt, Sindlingen MUNICIPAL 470.000 PIK 300
HKL 215
3884
7060
1994 Germany Frth MUNICIPAL 700.000 HKL 215 8208
1993 Germany Dresden Kaditz MUNICIPAL 60.000 KKI 215 4800
1988 Germany Bopfingen MUNICIPAL HKL 215 R1/2 3000
1984 Germany Frankfurt, Niederrad MUNICIPAL 1.300.000 HKL 215 39372
2000 Great Britain Aldershot MUNICIPAL 25.000 PRF 300 940
1999 Great Britain Seafield MUNICIPAL 500.000 HKL 215 23436
1999 Great Britain Littlehampton and Bognor MUNICIPAL 100.000 PIK 300 2800
1999 Great Britain Goscote MUNICIPAL 180.000 KKI 215 13968
SELECTED NOPOL
MUNICIPAL PLANTS
1998 Great Britain Belfast, Duncrue Street MUNICIPAL KKR 300 6084
1997 Great Britain Southend STW MUNICIPAL 67.000 KKR 300 1264
1997 Great Britain Thames Water, Henley STW MUNICIPAL 14.400 HKC 215 1206
1990 Great Britain Minworth, Birmingham MUNICIPAL 1200.000 KKI 215
HKL 215
3367
2960
1987 Great Britain Ham Hill, Southern Water MUNICIPAL 100.000 HKL 215 BSF1/2 4500
1986 Great Britain Rye Meads STW, Thames Water MUNICIPAL 250.000 HKL 215 BSF1/2 5400
1985 Great Britain Horley STW, Thames Water MUNICIPAL 35.000 HKL 215 4872
1995 Greece Corfu STP MUNICIPAL 100.000 KKI 215 4080
1995 Hong Kong Stanley STP, Hong Kong MUNICIPAL 27.000 KKI 215 2548
2000 Ireland Ballaghadereen MUNICIPAL 5.000 PIK 300 192
1998 Ireland Navan STW MUNICIPAL 50.000 KKR 300 1056
1999 Italy Cuasso al Monte MUNICIPAL 43.000 KKR 300 804
1998 Italy Mandello del Lario MUNICIPAL 50.000 HKL 215 1176
1998 Italy Vigonza MUNICIPAL PIK 300 2812
1997 Italy Florence MUNICIPAL 220.000 PIK 300 8778
1997 Italy Pero MUNICIPAL 400.000 PIK 300 6216
1993 Italy Roma Est MUNICIPAL 1700.000 HKL 215 26092
1992 Italy Roma Nord MUNICIPAL 800.000 KKI 215 11100
1989 Italy Roma Ostia MUNICIPAL 900.000 HKL 215 9360
1987 Italy Rimini MUNICIPAL 80.000 HKL 215 3920
1987 Italy San Miniato MUNICIPAL 120.000 HKL 215
KKI 215
4056
5392
1984 Italy Torino, Po Sangone MUNICIPAL 3600.000 HKL 215 41184
1986 Japan NKK - Yokohama City MUNICIPAL 300.000 MKL 215 10605
1997 Korea, South Goyang City WWTP MUNICIPAL KKI 215 10522
1999 Latvia Roja WWTP MUNICIPAL 13.000 KKI 215 684
1998 Latvia Riga MUNICIPAL 600.000 PIK 300 12096
1998 Lithuania Klaipeda MUNICIPAL 100.000 KKR 300 3062
1998 Lithuania Marijampole MUNICIPAL 120.000 KKR 300 1800
1998 Lithuania Ukmerge MUNICIPAL 150.000 KKR 300 1104
1998 Lithuania Vilnius WWTP MUNICIPAL 120.000 KKR 300 1800
1997 Lithuania Rokiskis MUNICIPAL KKR 300 1300
1998 Macao Coloane WWTP MUNICIPAL PIK 300 1320
SELECTED NOPOL
MUNICIPAL PLANTS
1995 Macao Etar da Taipa WWTP MUNICIPAL 300.000 KKI 215 10560
1996 Malaysia Kuala Lumpur Int. Airport WWTP MUNICIPAL 270.000 KKR 300 8192
1998 Mexico Ensenada MUNICIPAL 380.000 PIK 300 5984
1999 Norway Selmer Bekkelaget, Oslo MUNICIPAL 400.000 PIK 300 3132
1999 Netherlands Gouda MUNICIPAL 30.000 PIK 300 1000
1999 Netherlands Grote Lucht MUNICIPAL 270.000 PIK 300 6992
1998 Netherlands Sleen MUNICIPAL 10.000 PIK 300 500
1998 Netherlands Rotterdam, Kralingseveer MUNICIPAL 170.000 PIK 300 2508
1978 Netherlands Raalte MUNICIPAL 50.000 HKL 215 1434
1998 Poland Bialogard MUNICIPAL 68.000 KKR 300 1088
1998 Poland Poznan MUNICIPAL 660.000 PIK 300 24024
1997 Poland Rzeszow MUNICIPAL 190.000 KKR 300 2220
1997 Poland Sandomierz City STP MUNICIPAL 30.000 KKR 300 1080
1996 Poland Chelmno MUNICIPAL 58.000 KKI 215 1982
1995 Poland Zlotow, Warta River MUNICIPAL 27.500 KKI 215 2752
1998 Portugal Beirolas MUNICIPAL 300.000 PIK 300 5014
1997 Portugal Lisbonne, Frielas MUNICIPAL 320.000 KKR 300 3600
1995 Russia St. Petersburg, North MUNICIPAL 290.000 KKI 215 7612
1995 Russia Strugi Krasnye Military Housing MUNICIPAL 15.000 KKI 215 1440
1984 Russia Dagomys MUNICIPAL 53.000 HKL 215
1999 Saudi-Arabia Medinah MUNICIPAL PIK 300 11424
1996 Slovakia Hlohovec MUNICIPAL 56.000 KKR 300 1064
1996 Slovakia Presov COV MUNICIPAL 180.000 HKL 215 5448
1994 Slovakia Bratislava, COV Petrzalka MUNICIPAL 325.000 HKL 215 9824
1986 Slovakia Bratislava - Central UCOV MUNICIPAL 1090.000 HKP 600 7604
1986 Slovakia Zilina COV MUNICIPAL 750.000 MKP 600
HKP 600
2740
1000
1999 Spain Vendrell MUNICIPAL 145.000 PIK 300 2322
1999 Sweden Fagersta ARV MUNICIPAL 12.000 PIK 300 309
1998 Sweden Ekeby ARV, Eskilstuna MUNICIPAL 100.000 PIK 300 1944
1998 Sweden Malm, Sjlunda ARV MUNICIPAL 120.000 PIK 300
KKI 215
HKL 215
3144
3024
2192
1990 Sweden Tivoliverket, Sundsvall MUNICIPAL KKI 215 2596
SELECTED NOPOL
MUNICIPAL PLANTS
1989 Sweden Halmstad, Vstra Stranden MUNICIPAL 40.000 KKI 215 1210
1988 Sweden Malm, Klagshamn MUNICIPAL 35.000 KKI 215 3692
2000 Thailand Pattaya WWTP MUNICIPAL 170.000 PIK 300 3250
1999 Thailand Hua Hin WWTP MUNICIPAL KKI 215 1408
1998 Thailand Yannawa STP MUNICIPAL 1000.000 PIK 300 38760
1998 Tunisia Choutrana, Step Tunisia MUNICIPAL 560.000 PIK 300 6912
1999 Turkey Izmir MUNICIPAL 2.500.000 PIK 300 21600
1986 U.S.A. Manteca, California MUNICIPAL 100.000 HKL 215
1986 U.S.A. Valencia, Los Angeles MUNICIPAL 200.000 HKL 4 10000
SELECTED NOPOL
INDUSTRIAL APPLICATIONS
Year Country Plant Water type P.E. Diffuser Number
1983 Japan Mitsubishi Rayon Eng. ABS RESIN FACTORY 12.000 KKI 215 800
1994 Belgium Aqualon Hercules CHEMICAL INDUSTRY 345.000 KKI 215 11048
1992 Belgium Citrique Belge, Tienen CHEMICAL INDUSTRY KKI 215 2250
1994 Czech Republic Pardubice COV CHEMICAL INDUSTRY 700.000 HKL 215
KKI 215
13472
5000
1996 France Isle sur la Sorgue CHEMICAL INDUSTRY 130.000 KKR 300 2344
1996 Mexico Tereftalatos Mexicanos CHEMICAL INDUSTRY 315.000 PIK 300
KKR 300
3240
2160
1992 Poland Pulawy CHEMICAL INDUSTRY KKI 215 2720
1995 Spain Protein CHEMICAL INDUSTRY 2.000 KKI 215 200
1994 Spain Bioiberica CHEMICAL INDUSTRY 2.600 KKI 215 288
1996 Turkey Aksa Akrilik Kimya Sanayii A.S. CHEMICAL INDUSTRY, ACRYLIC
FACTORY
30.000 KKR 300 560
1989 Finland Rautaruukki Oy, Raahe COKERY MKL 215 437
1996 Finland AB Nyko - Frys Oy, Uusikaarlepyy FEED FOR MINKS 11.000 KKR 300 192
1992 Argentina Buenos Aires FOOD INDUSTRY 350.000 KKI 215 6831
1991 Belgium General Biscuits, Herentals FOOD INDUSTRY 23.000 KKI 215 1040
1994 Czech Republic Marysa Rohatec COV FOOD INDUSTRY 10.000 KKI 215 420
1989 Estonia Rakveren lihakombinaatti FOOD INDUSTRY 133.000 KKI 215 495
1999 Egypt Egypt Starch and Glucose, Tura Cairo FOOD INDUSTRY 140.000 PIK 300 1320
1992 Finland Lapua FOOD INDUSTRY 11.800 KKI 215 2904
1991 Finland Jrviseudun Peruna Oy, Vimpeli FOOD INDUSTRY 62.000 KKI 215 2532
1991 Finland Kaarina, Rauvola FOOD INDUSTRY 33.000 KKI 215 3060
1990 Finland Neson Oy, Jokioinen FOOD INDUSTRY 13.000 KKI 215 720
1991 Germany F.X. Wieninger, Passau FOOD INDUSTRY KKI 215 384
1986 Germany Weiterstadt FOOD INDUSTRY 27.000 HKL 215 1500
1995 Indonesia Indofood FOOD INDUSTRY KKI 215 1000
1996 Russia Coca-Cola Moscow FOOD INDUSTRY 9.000 KKR 300 110
1994 Spain Eroski FOOD INDUSTRY 4.770 KKI 215 200
1983 Sweden Mjlby FOOD INDUSTRY 36.000 HKL 215 1504
1978 Switzerland Kirchberg, Bazenheid FOOD INDUSTRY 60.000 HKL 215 2096
1997 Mexico BIMBO FOOD INDUSTRY, BAKERY 10.000 PIK 300 238
SELECTED NOPOL
1997 China Nanning Coca-Cola FOOD INDUSTRY, BEVERAGES KKI 215 700
1997 Greece Euromarket FOOD INDUSTRY, BEVERAGES 20.000 KKR 300 420
1997 Russia Coca-Cola Samara FOOD INDUSTRY, BEVERAGES 10.000 KKR 300 184
1997 Uruguay Montevideo Refrescos, Coca-Cola FOOD INDUSTRY, BEVERAGES 23.000 HKL 215 1068
1997 Indonesia Alba Sandang FOOD INDUSTRY, BEVERAGES KKR 300 400
1993 Belgium Jupille CPT FOOD INDUSTRY, BREWERY KKI 215 980
1992 Belgium Brij. Martens, Bocholt FOOD INDUSTRY, BREWERY KKI 215 2970
1994 Germany Will Brauerei, Motten FOOD INDUSTRY, BREWERY 25.000 KKI 215
HKL 215
1472
1650
1994 Portugal Marte FOOD INDUSTRY, CATTLE
BREEDING
KKI 215 108
1995 Russia Mars, Stupino WWTP FOOD INDUSTRY, CHOCOLATE 3.700 KKI 215 468
1996 Philippines San Miguel Poultry WWTP FOOD INDUSTRY KKI 215 1500
1991 Denmark MD Foods Amba, Nr. Vium RA, Videbk FOOD INDUSTRY, DAIRY 100.000 KKI 215 1810
1989 Finland Haapavesi, Partaper FOOD INDUSTRY, DAIRY 110.000 KKI 215 4643
1992 Italy Parma Est FOOD INDUSTRY, DAIRY 170.000 HKL 215 3360
1989 Spain Leche Pascoal FOOD INDUSTRY, DAIRY 15.600 KKI 215 702
1991 Germany Hobum Oele & Fette Hamburg FOOD INDUSTRY, OILS KKI 215 580
1998 Colombia Matadero Manizales FOOD INDUSTRY, SLAUGHTERY 32.000 PIK 300 516
1989 France Capdenac Gare FOOD INDUSTRY, SLAUGHTERY 25.000 KKI 215 1089
1996 Italy SIDA Pollo Aia FOOD INDUSTRY, SLAUGHTERY 26.000 KKR 300 706
1993 Mauritius Poulet Arc en Ciel, slaughterhouse FOOD INDUSTRY, SLAUGHTERY KKI 215 415
1995 Spain Unidad Alimentaria Planas S.A. FOOD INDUSTRY, SLAUGHTERY 14.000 KKI 215 480
1994 Portugal Adega Vinhos FOOD INDUSTRY, WINERY KKI 215 238
1981 Germany Leimfabrik Hcker, Vaihingen GLUE FACTORY 50.000 HKL 215 1492
1995 Mauritius J. Nehru Hospital STP HOSPITAL KKI 215 120
1996 Thailand AEK U-Dorn Hospital HOSPITAL KKI 215 105
1996 Thailand Khon Khan Hospital HOSPITAL KKI 215 360
1991 Italy Montebello LEATHER INDUSTRY 500.000 KKI 215
KRF 300
10452
4700
1998 Mexico Curtidos Temola LEATHER INDUSTRY 14.000 KKR 300 180
1996 Portugal NEIC LEATHER INDUSTRY 7.900 KKI 215 360
1998 Spain Teneria Moderna Franco Espanola LEATHER INDUSTRY 1.200 PIK 300 360
1995 Spain Soller, Mallorca OIL INDUSTRY, OLIVES 1.100 KKI 215 108
SELECTED NOPOL
1998 Argentina Shell Capsa, Buenos Aires OIL REFINERY 75.000 PIK 300 544
1983 Germany Wintershall AG Erdlraffinerie, Lingen OIL REFINERY 30.000 HKL 215
KKI 215
1488
500
1993 Norway Esso Slgen, Tnsberg OIL REFINERY 14.000 KKI 215 405
1991 Spain Petronor, Bilbao OIL REFINERY 29.000 HKL 215 R1/2 3000
1995 Thailand Rayong Refinery OIL REFINERY 76.000 KKI 215 2868
1993 Thailand Thai Oil, Sriracha District OIL REFINERY KKI 215 1290
1996 Hong Kong Hong Kong Paper Mill PAPER MILL 32.000 KKI 215 698
1994 Korea, South Dae Yang Paper MFG. PAPER MILL KKI 215 R1/2 2370
1991 Korea, South Dae Won Paper Mill PAPER MILL KKI 215 960
1989 Netherlands Wapenveld PAPER MILL 50.000 HKL 215 2352
1994 Italy Cartiera Ciacci, San Marino PAPER MILL, RECYCLED PAPER 27.000 KRF 300 812
1988 Italy Smurfit - SISA, Voghera PAPER MILL, RECYCLED PAPER 42.000 KKI 215 910
1983 Czech Republic Galena COV PHARMACEUTICAL INDUSTRY 70.000 HKL 215 4608
1991 Denmark BASF Vitaminfabrik a/s, Gren PHARMACEUTICAL INDUSTRY 100.000 HKL 215 R1/2 3340
1989 Finland Orion Yhtym Oy Fermion PHARMACEUTICAL INDUSTRY MPU 585 231
1984 Germany Hoffman - La Roche, Grenzach PHARMACEUTICAL INDUSTRY 385.000 HKL 215 2704
1998 Ireland Pharmacia Upjohn PHARMACEUTICAL INDUSTRY 38.000 KKR 300 620
1986 Italy Zambon Chimica Vicenza PHARMACEUTICAL INDUSTRY 57.000 HKL 215 779
1986 Sweden Astra, Sdertlje PHARMACEUTICAL INDUSTRY 10.000 HKL 215 R1/2 498
1995 Spain Gatnau PIG FARMING 6.700 KKI 215 450
1994 Finland Kymmene, Schauman Wood, Pellos PULP AND PAPER 15.000 KKI 215 482
1996 Great Britain Arjo Wiggings Fine Papers Ltd, Aberdeen PULP AND PAPER MILL 15.000 KKR 300 252
1990 Turkey Seka Izmit PULP AND PAPER MILL 450.000 KKI 215 12190
1989 Austria O TKV Regau RENDERING PLANT 67.000 KKI 215 2436
1995 Indonesia PT Ratna Sutera Alam, Bogor TEXTILE INDUSTRY 8.800 KKR 300 180
1996 Mauritius Novel, Union Textile TEXTILE INDUSTRY 15.000 KKI 215 728
1997 Indonesia Insan Sandang TEXTILE INDUSTRY KKI 215 320
1997 Indonesia Megatex TEXTILE INDUSTRY KKR 300 304
1995 Indonesia Triotex TEXTILE INDUSTRY KKI 215 1000
1997 Turkey Textile Dyeing TEXTILE INDUSTRY 240.000 KKR 300 2640
1997 Finland Finnforest, Punkaharjun vaneritehdas WALLBOARD FACTORY KKR 300 180
10 NOPOL DDS :
NOPOL
DDS
PRODUCT MANUAL
Installation, operation and
maintenance manual
Version 2.0 Product code 195021
Copyright: Nopon Oy 2001
The company reserves the right to make alterations in the interests of technical development.
NOPOL
DISC DIFFUSER AERATION

SYSTEM
Installation, Operation and Maintenance
Manuals
NOPON OY
Turvekuja 6, FIN-00700 HELSINKI, FINLAND
Tel +358 9-351 730 Fax +358 9-351 5620
E-mail: hq@nopon.fi
internet: http://www.nopon.fi/
NOPON OY DDS installation instruction Version 2.0 09.04.2001
Made by: MR Inspected by: AL Accepted by: ERN
NOPOL
DISC DIFFUSER AERATION SYSTEM

Installation Manual
TABLE OF CONTENTS
1. SCOPE OF APPLICATION OF INSTALLATION INSTRUCTIONS _________ 1
2. NAMES OF THE AERATION SYSTEM COMPONENTS_________________ 3
3. DELIVERY OF THE AERATION SYSTEM____________________________ 7
3.1 Contents__________________________________________________________________7
3.2 Accompanying Documents __________________________________________________7
3.3 Packaging and Transportation _______________________________________________7
3.4 Acceptance of Delivery______________________________________________________8
3.5 Handling__________________________________________________________________8
3.6 Storage___________________________________________________________________9
4. INSTALLATION OF THE AERATION SYSTEM ______________________ 10
4.1 Installation Steps _________________________________________________________10
4.2 Measures to Be Taken Before Installation_____________________________________10
4.3 Installation of Bottom Mounting Brackets_____________________________________11
4.3.1 Determining the Location of Bracket Fixing Points ____________________________11
4.3.2 Installing Bottom Mounting Brackets _______________________________________11
4.3.3 Adjusting the Height of HPK 210 Bottom Mounting Brackets ____________________12
4.4 Adjusting the Height of the TPK Bottom Mounting Bracket ______________________13
4.5 Installing Diffuser Elements ________________________________________________13
4.6 Installing Water Collection Pipe _____________________________________________15
4.7 Final Fixing of the System__________________________________________________15
4.8 Installing Dropleg and Purge Pipe / Hose _____________________________________15
4.9 Post-Installation Procedures________________________________________________17
5. INSTALLATION OF SCREW-ON DIFFUSERS _______________________ 18
5.1 Delivery__________________________________________________________________18
5.2 Installation _______________________________________________________________18
6. MODIFICATION KIT PRF 300 ____________________________________ 20
6.1 Purpose of the Modification Kit _____________________________________________20
6.2 Delivery__________________________________________________________________20
6.3 Installation of the Modification Kit ___________________________________________20
7. INSTALLATION OF ADDITIONAL DIFFUSERS ______________________ 22
7.1 Using Additional Diffusers__________________________________________________22
7.2 Before Installation_________________________________________________________23
7.3 Installing New Diffusers to Existing Piping____________________________________23
7.4 Adding New Diffuser Rows _________________________________________________24
8. INSTALLATION OF DIFFUSERS ON OD 88.9 MM PIPE _______________ 25
8.1 Delivery__________________________________________________________________25
8.2 Installation _______________________________________________________________25
9. SYSTEM LEAK TESTING _______________________________________ 27
9.1 Procedures and Permissible Air Flow Rates for Leak Tests and Trial Runs_________27
9.2 First Leak Test____________________________________________________________28
9.3 Second Leak Test _________________________________________________________32
9.4 Third Leak Test ___________________________________________________________33
9.5 Storage of System and Protection Before Start-Up _____________________________34
10. SOTR TESTING_______________________________________________ 35
APPENDIX
Installation inspection form
Made by: MR Inspected by: AL Accepted by: ERN Page: 1 (35)
1. SCOPE OF APPLICATION OF INSTALLATION INSTRUCTIONS
These instructions apply to all NOPOL

DDS aeration systems in which the diffusers
are attached to PVC or stainless steel pipes. For the purposes of this manual, the
aeration system will mean the NOPOL
DDS aeration system designed for

installation on the floor of an aeration basin (Figure 1). The system converts the
aeration air into fine bubbles.
To ensure correct operation of the system, it is extremely important that
a) The system is leak-proof. Any leaks can ultimately lead to a blockage of
the entire system.
b) Air is uniformly distributed to all diffusers.
The system is pre-assembled at the factory and supplied in the form of diffuser
elements, water collection pipes, and zone headers. Usually the delivery limit is up to
the zone header flange used for connecting the system to the air supply dropleg.
This flange is located approx. 300 mm above the centre line of the zone header.
Another delivery limit is up to the water collection pipe drainage coupling to which
the customer connects the purge pipe or hose, which is then mounted to the top of
the basin wall.
The warranty given by the manufacturer will be valid only if these installation
instructions are complied with. Included in this manual is an installation inspection
form, which must be completed, signed and returned to the manufacturer in order for
the warranty to take effect.
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1. Blower station 6. Bottom mounting bracket HPK 210 11. Water collection pipe
2. Air supply header 7. Connection sleeve HSY 90-90 12. Purge hose / pipe
3. Dropleg 8. Diffuser element 13. Pipe support
4. Zone header 9. Diffuser (here KKI 215) 14. Expansion joint
5. Bottom mounting bracket TPK 150 10. Drainage coupling VPL 90
Figure 1: Typical bottom-mounted fine-bubble aeration system
2. NAMES OF THE AERATION SYSTEM COMPONENTS
The names of the various aeration system components are given in Figure 1. The
basic unit in the system is the aeration group. There can be one or several such
groups in the basin. Air is supplied to the group via a dropleg. Zone header
distributes the air within the aeration group.
Zone headers can be made PVC or stainless steel depending on the diameter
required. Zone headers with a diameter of 90 mm are usually made of PVC. Zone
headers have right-angled branches connecting the diffuser elements to the header.
With PVC zone headers, the branches have an outside diameter of 90 mm. With
steel zone headers, the outside diameter is usually 88.9 mm. Depending on the
layout of the group, branches can be located on both sides of the header or only on
one side. Branches are connected to the zone header either on its centre line or on
its bottom.
A diffuser element is a pre-assembled cut-to-length part of 90 mm PVC pipe with
diffusers mounted onto the pipe. Depending on the type of diffuser attached to the
element, designations PIKEV, HKLE, MKLE, KKIE or PRKE are used for the
aeration systems. An example of type designation is KKIE 3000-6/500 (250, 250).
This means that the element length L is 3000 mm, it has 6 KKI 215 diffusers and the
distance E between the diffusers is 500 mm. The measurements in parenthesis
show the distance from the end of the pipe to the centre of the diffuser nearest to
the pipe end. Normally it is half of the distance between the diffusers.
Figure 2 shows the minimum distances for different diffusers.
L
E
E / 2
PIK 300 PRK 300 KKI 215
HKL 215
MKL 215
E
min
400 mm 350 mm 270 mm
E/2
min
300 mm 175 mm 175 mm
Figure 2: Minimum distances in diffuser elements.
The parts of the HKL 215, MKL 215, KKI 215 and PRK 300 diffusers complete with
type designations are shown in Figure 4 and on the PIK 300 diffuser in Figure 5.
The purpose of the water collection pipe is to collect condensed water from the
piping and to ensure a uniform air distribution (Figure 1). The water collection pipe
consists of a 90 mm PVC pipe, HTK 90/90 cross-junctions and HTP 90 end caps.
Condensed water is drained through the drainage coupling VPL 90 in the water
collection pipe. Sludge that finds its way into the pipe as a result of a leak, etc.
cannot be removed via this junction. If the system does not include a water
collection pipe, the drainage coupling is connected to the zone header or one of the
diffuser elements. When using large zone headers ( over 90 mm), water drainage
coupling is usually in the zone header and the branches connecting diffuser rows
are connected into the centre line of the zone header.
The diffuser elements are fixed to the basin floor via bottom mounting brackets HPK
210 (Figure 3). If necessary, the bracket height can be adjusted using extension
sleeves HJA 210. The elements are fastened to the bottom mounting brackets using
HPA 210 straps.
Steel and large PVC zone headers are fixed in position using stainless steel bottom
mounting brackets TPK 125 - TPK 350 (Figure 3).
1
3
2
6
4
5
7
D
1
2
3
4
5
L
H MI N. MAX. 285
Figure 3: Bottom mounting brackets HPK 210 and TPK 125 - TPK 350
HPK 210
1. Strap HPA 210
2. Pipe holder HKI 210
3. Extension sleeve HJA 210
4. Foot HTU 210
5. Hex screw M10 x 20
6. Washer KL 11/28
7. Drop-in anchor LAH 10
TPK 125350
1. Threaded rod M12
2. Hex nut M12
3. Holder 125350
4. Washer M12
5. Drop-in anchor LAH 12
Figure 4: HKL 215, MKL 215, KKI 215 and PRK 300 diffuser components for
90 mm piping
Figure 5: Parts of PIK 300 D90 diffuser
3. DELIVERY OF THE AERATION SYSTEM
3.1 Contents
The delivery includes a complete aeration system or part of one depending on the
order and related supply agreement.
A complete aeration system will include the following:
- pre-assembled diffuser elements
- zone headers (PVC or AISI 316)
- water collection pipes
- appropriate bottom mounting brackets
- pipe connection pieces
- drainage couplings
- a small number of additional parts to replace components that may be
damaged during transportation or installation
- the necessary installation tools.
3.2 Accompanying Documents
The system will be supplied complete with the following documents:
- Diffuser group layout drawings
- Bottom mounting bracket drilling layout
- Installation manual including the installation inspection form
- Operation and maintenance manual
An installation video will be supplied separately by mail.
3.3 Packaging and Transportation
Diffuser elements, zone headers and water collection pipes are usually supplied in
plywood cases (Figure 6). Other methods of packaging are also available.
To minimise transportation costs, each case is packed as full as possible. As a
result, one case contains components belonging to several groups. Before
installation, the drawings and dimensions must be checked to make sure that the
right parts will go to the right groups. Diffuser elements, zone headers and water
collection pipes are marked with stickers to help identification.
Other system components will be supplied in cardboard boxes that are packed into
a case or placed on pallets wrapped in a clear plastic film.
Usually the cases and pallets are delivered to the customer by trucks with trailers or
semi-trailers. For carriage by sea, suitable packaging is used. Delivery terms are
normally FCA Helsinki Turvekuja 6, Incoterms 2000.
Figure 6: Packaging options for aeration systems
3.4 Acceptance of Delivery
Before accepting the delivery, inspect the packages visually for damage. Any
complaints should be entered on the waybill.
To unload the goods, use a forklift truck and unload from the side of the cargo bay.
Make sure there is ample room on the unloading site for a truck carrying a case to
manoeuvre safely. In addition, a large delivery vehicle will need sufficient space for
manoeuvring if no through passage is provided.
Typical case dimensions are 540 x 112 x 112 (cm). The gross weight of a loaded
case is approx. 1 000 kg. Case height and width are usually standard, as shown in
Figure 6. However, case lengths vary according to the length of the elements.
Cases with a length of over 540 cm are only used when necessary, such as for the
transportation of long zone headers. The maximum height of a consignment on a
pallet is 200 cm.
3.5 Handling
Move the goods to the aeration basin in their original packaging using a suitable
hoist, or carry the elements there one by one. Mechanical damage to stainless steel
pipes must be avoided. If several aeration groups are to be installed in the same
basin, part of the basin area can be used for temporary storage. It is advisable not
to unpack the goods until they are to be installed. Diffuser elements must be kept
clean of dust, etc. Empty packing material need not to be returned.
At low temperatures (below +5 C), PVC and PP become brittle. Special care must
be taken when ambient temperature drops below -10 C. Recommended ambient
temperature for installation is above +15 C. Also the temperature of the
components to be installed should be above +15 C. It is not recommended to install
an aeration system when temperature is below +5 C.
3.6 Storage
The plywood cases must be stored on a level base shielded from direct sunlight. Do
not stack more than two identical cases on top of each another. The pallets must not
be stacked. Protect them from rain. Exposure to sunlight is detrimental to the rubber
parts of the diffusers and may cause plastic components and pipes to deform. When
storing packages, make sure they are not subjected to loads that may deform and
damage the parts inside.
To avoid changes in the shape of the components made of PVC, temperature during
storage must not exceed +50 C. Special notice should be paid to transportation
and storage of containers.
4. INSTALLATION OF THE AERATION SYSTEM
4.1 Installation Steps
When installing the system, make sure that,
- diffuser rows are straight
- diffusers are at the same level
- system is leak proof.
Before installation, the basin bottom must be cleaned with care. Mark and drill holes
for the bottom mounting brackets according to the drilling layout and fix the brackets
in position. Piping with a diameter of 90 mm will be fixed to the basin bottom using
the HPK 210 mounting brackets (Figure 3) whereas zone headers with a diameter of
over 90 mm will be fixed using TPK 125 - TPK 350 mounting brackets (Figure 3).
After mounting, adjust the level of the brackets.
Once the mounting brackets have been height-adjusted, install the zone header,
diffuser elements and water collection pipe. Proceed from the zone header towards
the water collection pipe.
Finally, fix the purge hose / pipe and connect the diffuser groups to the droplegs.
4.2 Measures to Be Taken Before Installation
Before fixing the bottom mounting brackets in position, remove all superfluous
materials from the basin. Clean the basin bottom to facilitate measurements and
marking of the bracket fixing points.
Bottom mounting brackets are supplied in parts, see Figure 3.
Temperature at the installation site must not exceed +50 C.
At low temperatures (below +5 C), PVC and PP become brittle. Recommended
ambient temperature for installation is above +15 C. Also the temperature of the
components to be installed should be above +15 C. Installation in temperatures
below +15 C has to be done cautiously. It is not recommended to install an aeration
system when temperature is below +5 C.
4.3 Installation of Bottom Mounting Brackets
4.3.1 Determining the Location of Bracket Fixing Points
Locations of the mounting bracket fixing points for each aeration group are indicated
on the drilling layout. To achieve the best possible aeration efficiency, the distance
between the group and basin wall should be uniform on all sides. Usually the
dimensions of the basin do not determine the exact position of the fixing points.
Often the fixing point positioning is determined by the position of droplegs. If several
groups are installed in the same basin, group layout must be planned as a whole.
Once the positions of diffuser groups have been tentatively determined, mark the
fixing points for drop-in anchors on the basin floor. It is extremely important that the
drop-in anchors are aligned as shown on the drilling layout. If not, the piping can be
subjected to lateral forces during operation.
4.3.2 Installing Bottom Mounting Brackets
Drill holes at the marked locations for drop-in anchors. Hole sizes to be used:
- bracket HPK 210 drop-in anchor LAH 10 12 mm x 40 mm
- bracket TPK drop-in anchor LAH 12 15 mm x 50 mm
Remove any debris from the hole using compressed air. Insert the anchor so that it
is flush with the basin floor. Fix the drop-in anchor in position by hitting it with the
tool as shown in Figure 7. Make sure that the shoulder of the tool strikes the top of
the drop-in anchor.
Once the drop-in anchors are fixed in position, fasten the HPK 210 mounting
bracket HTU 210 foot to the drop-in anchor using the KL 11/28 washer and M10 x
20 hex screw. Take care not to damage the plastic. Make sure that the basin floor
under the foot is clean and level.
Screw M12 threaded rods of TPK mounting brackets directly into drop-in anchors.
Figure 7: Fixing the LAH 10 and LAH 12 drop-in anchors in position
4.3.3 Adjusting the Height of HPK 210 Bottom Mounting Brackets
To achieve maximum aeration efficiency, the plane on which the diffusers lie must
be as close to the basin bottom as possible. In a finished group, the variation in
height between individual diffusers must be less than 10 mm. The diffuser heights
in various basins should be as uniform as possible. Sometimes the diffuser height
must be raised because of limited compressor capacity or other structures at the
floor of the basin. If so, the bottom mounting brackets can be installed at a greater
height using special fixings. Such fixings are not included in the delivery.
The easiest way of adjusting diffuser height is to use the height of the pipe holder
HKI 210 (Figure 8) (on which the diffuser element rests) as the reference point. Start
adjusting the height of the diffusers from the highest point of the basin floor. Screw
the mounting brackets at this point as far down as they will go. Then adjust all other
brackets to this height.
Figure 8: HPK 210 bottom mounting brackets extension sleeves are fixed to one
another and to the foot with adhesive
HPA 210 Strap
HKI 210 Pipe holder
HJA 210 Extension sleeve
M10 x 20 Hex screw
KL 11/28 Washer
HTU 210 Foot
LAH 10 Drop-in anchor
If necessary, the mounting bracket heights can be raised using the HJA 210
extension sleeve. If the height of the pipe holder from the basin floor is from 68 to
108 mm, no extension sleeve is required. Mounting bracket height can be increased
by 40 mm with the addition of one extension sleeve. The maximum number of
extension sleeves is two, which are then able to compensate for basin floor height
variations of up to 120 mm. If the height variation is greater than this, the height of
the mounting bracket must be increased by some other means in order to ensure
that the diffusers are on the same level and height.
The extension sleeves are connected to one another and to the foot with
adhesive (Figure 8) because the bottom mounting brackets will be subject to
pipework buoyancy when in water. For gluing, use standard PVC adhesives (such
as Tangit or Pevicol) and comply with the manufacturers instructions. The standard
delivery will include one extension sleeve for each bottom-mounting bracket.
Adhesive is not included in the delivery.
4.4 Adjusting the Height of the TPK Bottom Mounting Bracket
TPK bottom mounting brackets are used for steel and large PVC ( over 90 mm)
zone headers. Screw the lower nuts onto the M12 threaded rods and then place the
washer and the lower half of the holder on top of them. Lift the zone header pipe
onto the lower half of the holders. Then place the diffuser elements, closest to the
zone header, on their bottom mounting brackets. Use the nuts of the TPK bracket to
adjust the height of the zone header. Zone header branches must be horizontally
and vertically aligned with the diffuser elements.
A multi-section zone header must be adjusted to correct height section by section.
Steel multi-section zone headers have flanged joints. When fixing the flanged joint,
tighten the bolts uniformly to ensure that the flange does not bend. Plastic multi-
section zone headers have sleeve joints. With a sleeve joint, the seal and the end of
the pipe have to be lubricated with soap solution to ease the installation.
4.5 Installing Diffuser Elements
When installing diffuser elements, start from the zone header and proceed towards
the water collection pipe. The water collection pipe in each group must not be
installed until all other components have been fixed in position. Place diffuser
elements on the pipe holders as shown in the layout plan and connect them using
HSY 90-90 connection sleeves which permit thermal expansion (Figure 9). Make
sure that all the top surfaces of diffusers are exactly horizontal. Straps of the bottom
mounting brackets may not be tightened until water collection pipe has been
installed. When installing the elements, make sure that the inside of pipes is clean.
Before installing the connection sleeve, insert a lock ring in the groove at one end of
the sleeve. When the connecting sleeve has been installed, tighten the lock ring
using the correct screwdriver. When installing sleeves that connect the zone header
directly to the diffuser element, the lock ring must face the zone header. With other
connection sleeves, the lock ring must face the water collection pipe (Figure 10).
When an element is correctly installed, one of the two indication lines at the element
end remains visible. The ends of the elements are then approx. 20 mm apart.
1. Lock ring LUR 90 2. Gasket HLT 90
3. Body HSY 90R 4. Screw 3,5 x 35
Figure 9: Connection sleeve HSY 90-90
Figure 10: When installing connection sleeves that connect the zone header directly
to the diffuser element, the lock ring must face the zone header. With other
connection sleeves, the lock ring must face the water collection pipe.
Lubricate the connection sleeve gasket with a soap-based lubricant before
fixing the element. Never use lubricants that may damage the rubber.
4.6 Installing Water Collection Pipe
Install the water collection pipe after all the diffuser elements have been connected.
At this point, the elements are still resting on top of the mounting brackets so that
the connection sleeve gives some play. Long water collection pipes consist of
multiple sections, which are inter-connected using connection sleeves HSY 90-90.
4.7 Final Fixing of the System
To fix the elements to HPK 210 mounting brackets, use HPA 210 straps. Use the
special tool HPAAT (Figure 11) to install the straps. The straps can be removed with
the same tool. However, it is advisable not to reuse straps but to replace them.
The straps must be installed when warm. At low temperatures (< 5 C), the strap
becomes stiff and may break when installed. Straps can be warmed in water before
installation.
Last check the alignment of the zone header and fix the top halves of the TPK
brackets in position and tighten them in place with the top bracket nuts.
Figure 11: Fixing the pipe to the bottom mounting bracket HPK 210 using the special
tool HPAAT
4.8 Installing Dropleg and Purge Pipe / Hose
Before connecting the aeration group to the dropleg, remove any impurities from the
air supply header and droplegs using compressed air. To prevent the impurities
from getting into the piping which is laid on the basin floor, close the flanged joints
of the zone header.
After the piping has been cleaned, connect the group dropleg flange to the zone
header flange. When tightening the flange, make sure that the zone header does
not move.
HPAAT
The dropleg must be fixed to the basin wall or to the floor to ensure that the
zone header and its flange are not subjected to any load. In addition, the upper
end of the dropleg must be fitted with a connection sleeve that permits
thermal expansion and prevents movement due to expansion from being
transmitted to the diffuser group.
The material of the water drainage coupling is AISI 316. Connect the purge pipe or
hose to the drainage coupling VPL 90. Drainage couplings can also be located in
large zone headers. The other end of the pipe or hose must be fitted with a valve
and fixed above the water surface. The rising angle of the pipe or hose must be at
least 40 along its entire length, and supports must be provided on the basin wall or
other structures at least every 50 cm.
For basins where strong currents are produced, use a purge pipe and fix it with due
regard to the forces generated by the currents.
The purge pipe or hose is not included in the delivery.
Figure 12: Connecting the drainage coupling VPL 90 to the piping
4.9 Post-Installation Procedures
When the installation is completed, carry out a system leak test (see Chapter 9).
If the leak test is not carried out immediately after installation, fill the basin with
clean water. Make sure that the water level is at least one metre above the diffusers.
Water protects the diffusers from UV radiation, sub-zero temperatures and dirt. If
porous discs HIL 210 or MIL 210 are used, aeration must be switched on to prevent
the diffusers from becoming blocked. Air supply should always be started softly,
that is with small air flow which can later be increased gradually.
Keep the aeration basin clean. No heavy objects, debris or soil must be dropped in
the basin that could damage or block the diffusers. Drops of paint and welding
sparks can also damage the diffusers.
5. INSTALLATION OF SCREW-ON DIFFUSERS
5.1 Delivery
The following diffusers are of the screw-on type:
- HKL 215 R 1/2
- MKL 215 R 1/2
- KKI 215 R 1/2
- PRK 300 R 1/2
- HKL 215 BSF 1/2
- MKL 215 BSF 1/2
- KKI 215 BSF 1/2
- PRK 300 BSF 1/2
R 1/2 and BSF 1/2 are used in connection with diffuser type designation indicating
thread type and size. There are two R 1/2 versions: parallel and taper thread. Taper
thread is marked as R 1/2K. For larger thread sizes, an adapter is installed between
the diffuser and pipe. It is not advisable to mount diffusers on smaller thread sizes.
Screw-on diffusers are similar in design to diffusers mounted with the wedge piece
(HSK 215) except for the main body (Figure 4 and Figure 13).
As a rule, the diffusers are supplied fully assembled. The piping and pipe threading
are not included in the delivery. The diffusers are packed in cardboard boxes. In
handling and storage, follow the instructions given in 3.5 and 3.6.
Figure 13: Main body of screw-on diffuser
5.2 Installation
Before installation check the O-ring around the threaded nipple and the pipe
threading. Screw the diffuser onto the pipe with care. If screwed too tight, the
diffuser can be damaged as the main body threaded nipple is torn off. Make sure
that the O-ring remains exactly in position making a leakproof joint. Sealing tape or
sealing material (such as Loctite 5331) can also be used in the threading.
It is advisable to screw the diffuser onto the pipe by hand.
Drain water from the aeration system. One way of doing this is shown in Figure 12.
This method is regularly used to drain condensed water from the system.
Note the critical assembly temperatures, which are specified in Chapter 4.2.
6. MODIFICATION KIT PRF 300
6.1 Purpose of the Modification Kit
The modification kit PRF 300 can be used to increase the capacity of an existing
system without increasing the number of diffusers. No alterations to the existing
piping are required. In some cases, the zone header must be replaced because of
increased air flow rate.
6.2 Delivery
The modification kit PRF 300 is similar to PRK 300 (Figure 4) except that it is
without main body HSA 215 and wedge piece HSK 215. The delivery includes the
following:
- screw-on ring PKR 300
- sliding ring PVR 300
- membrane disc HIK 300
- extension plate PTL 300
- circular gasket HUR 300
- support ring HTR 300
The modification kit is fully assembled at the factory and packaged in cardboard
boxes. In handling and storage, follow the instructions given in Chapters 3.4, 3.5
and 3.6.
6.3 Installation of the Modification Kit
Modification kit PRF 300 can be used to replace those NOPOL
diffusers which
have HSA 215 as main body.
Before installation drain the basin and clean the outsides of diffusers and headers.
Then remove the screw-on ring of the old diffuser using the special tool HKLAT 215
or HKLIT 215 provided (Figure 18). Then remove the porous or membrane disc
including their support plates and clean the inside of the diffuser main body.
If the non-return valves in the diffusers have been used for a long time or if they are
in bad condition, replace the rubber part of the HVK 215 valve. Check the other
diffuser parts as well.
Start the installation by setting the circular gasket HUR 300 and the support ring
HTR 300 fitted into the gasket inside the saddle piece HSA 215. Verify that the
gasket is not on top of the border of the saddle. Lubricate the upper surface of the
gasket with a soapy solution. Screw the modification kit onto the main body HSA
215 by manually tightening the joint.
When installation is completed, carry out a system leak test (see Chapter 9). Use
tool RFIT300P if necessary to tighten PRF300 further.
Water protects the diffusers from UV radiation, sub-zero temperatures and dirt.
the basin that could damage or block the diffusers. Drops of paint and welding spark
can also damage the diffusers.
7. INSTALLATION OF ADDITIONAL DIFFUSERS
7.1 Using Additional Diffusers
To increase system capacity, diffusers can be added to an existing system. Extra
diffusers can either be added to the existing elements, or the number of diffuser
rows in the group can be increased. When new rows are added, the zone headers
and water collection pipes must also be replaced because of the higher number of
rows and greater air flow rate.
Extra diffusers can be added to a HKLE / MKLE / KKIE system if c/c diffuser spacing
in the existing system is at least 480 mm (Figure 14). With PRKE and PIKEV
systems, extra diffusers can be added if spacing is at least 800 mm (Figure 15).
min 240
min 240
Note the space required by a flange
and water drainage connection
Figure 14: Advisable minimum spacing of diffusers and rows for KKIE, HKLE and
MKLE aeration systems
A
B
A
min
400 mm B
min
450 mm
Figure 15: Advisable minimum spacing of diffusers and rows for PRKE and PIKEV
aeration systems
7.2 Before Installation
Before installation drain the basin and clean the diffusers and piping. This also
gives a good opportunity to check the condition of the existing system and diffusers.
Parts that are defective or bad repair must be replaced.
The diffusers will be supplied in parts or fully assembled as specified. If additional
diffusers are supplied as elements, the delivery usually includes new zone headers
and water collection pipes.
In handling and storage, follow the instructions given in Chapters 3.4, 3.5 and 3.6.
7.3 Installing New Diffusers to Existing Piping
Drill the holes for new diffusers at the top of the element pipe perpendicularly to the
existing diffuser plane (Figure 16). Required hole diameter X is
5 . 0
0
20
+
mm for PRK
300, KKI 215, HKL 215 and MKL 215 diffusers. For PIK 300 diffuser, the required
diameter of the hole X is
5 . 0
0
15
+
mm when using PVC or steel pipes. PIK 300 with flat

seal PLT 15/4 is used for 90 mm PVC pipe and with flat seal PLT 15/5 for 88.9
mm steel pipe. All new diffusers must be aligned and level. Make sure that the
drilled hole is clean to ensure a leakproof joint between the diffuser and pipe.
In steel pipes the outer edge of the hole has to be rounded (R 0.3 mm).
Figure 16: Making a hole in the diffuser element
The additional diffusers should be spaced as uniformly as possible within the group.
Uniform distribution will ensure uniform air supply in the group.
The extra diffuser is inserted in the drilled hole and the wedge is moved into
position using a rubber-headed hammer as shown in Figure 17. Installation tool
TWP is required for PIK 300 diffuser as shown in Figure 20. When installing PIK
300 diffuser, lubricate the pipe from underneath with soap solution to ensure fluent
gliding of the wedge piece. Finally make sure that the diffuser top is level. If the
element is removed from the group for installation, follow the instructions given in
Chapters 4.5- 4.8 when reassembling the group.
7.4 Adding New Diffuser Rows
To begin with, remove the existing water collection pipe and existing zone header.
Then follow the instructions given in Chapter 4. Start by fixing the bottom mounting
brackets.
8. INSTALLATION OF DIFFUSERS ON OD 88.9 mm PIPE
8.1 Delivery
Diffusers that are suitable for OD 88.9 mm pipe (PVC or stainless steel) are:
HKL 215 D88.9
MKL 215 D88.9
KKI 215 D88.9
PRK 300 D88.9
PIK 300 S D88.9
Code D88.9 means that the diffuser is meant to be installed to a pipe which outer
diameter is 88.9 mm. The diffusers are standard structured but with O-ring HOR 18.
PIK 300 S D88.9 diffuser is equipped with flat seal PLT 15/5 which fits 88.9 mm
PVC and steel pipes.
Usually the delivery contains whole, loose diffusers. Pipework is not included in the
delivery. Diffusers are packed in cardboard boxes. Instructions given in 3.4, 3.5 and
3.6 should be followed in handling and storage of packages.
8.2 Installation
existing diffuser plane (Figure 16). Required diameter of the hole is
5 . 0
0
20
+
mm for
PRK 300, KKI 215, HKL 215 and MKL 215 diffusers. For PIK 300 diffuser, the
required diameter of the hole is
5 . 0
0
15
+
mm when using PVC or steel pipes. All new

diffusers must be aligned and level. Make sure that the drilled hole is clean to
ensure a leakproof joint between the diffuser and pipe.
In steel pipes the outer edge of the hole has to be rounded (R 0.3 mm).
The requirements for PVC pipes are:
outer diameter 88.9 0.2 mm
roundness 88.9 0.76 mm
wall thickness, minimum 3.5 mm
When using stainless steel pipes ISO DN80 (outer diameter 88.9 mm), the pipe
diameter tolerance has to be 0.75 % and deviations from a perfect circle have to
be included in the diameter tolerance. Wall thickness has to be at least 1.5 mm.
The diffuser is inserted in the drilled hole in the pipe and the wedge is moved into
position as shown in Figure 17 for PRK 300, KKI 215, HKL 215 and MKL 215
diffusers. For PIK 300 diffuser, the TWP installation tool for the wedge piece is used
as in Figure 20. When installing PIK 300 diffuser, lubricate the pipe from
underneath with soap solution to ensure fluent gliding of the wedge piece.
Instructions given in Chapter 4 have to be followed when installing an aeration
system formed by loose diffusers delivered by Nopon Oy and pipework from the
customer.
When installation is completed, carry out a system leak test (see Chapter 9).
9. SYSTEM LEAK TESTING
9.1 Procedures and Permissible Air Flow Rates for Leak Tests and Trial Runs
When fully installed, the aeration system must be leak-proof. All air entering the
water must come through the diffusers. Any leaks in the aeration system will
increase energy consumption, and sludge entering the system may block the
diffusers.
The aeration system must be tested for leaks in three stages by using clean water
and feeding air into the system. Any leaks will then be detected as bubbles.
Stage 1: Raise water level until it is halfway up screw-on ring HKR 215 / PKR
300
Stage 2: Raise water level until it is approximately 5 cm above the diffusers
Stage 3: Raise water level until it is approximately 10 cm above the flanged joint
of the dropleg
The maximum air flow rates permitted in leak tests and trial operation are:
HKL 215 5.0 Nm
3
/h/diffuser (20 C, 101,325 kPa)
MKL 215 6.0 Nm
3
KKI 215 4.0 Nm
3
PRK 300 8.0 Nm
3
PIK 300 8.0 Nm
3
Trials to see that the blowers operate correctly should be carried out before the
pipes supplying process air to the diffusers are connected. However, if air is
supplied to the group during blower trials, the maximum air flow rates indicated
above must not be exceeded. Air volumes can be calculated on the basis of blower
output. Make sure that all the necessary valves are open.
If there is a long time interval between installation and leak test, the basin should be
emptied before the leak test. The aeration system is drained of possible water by
opening one HSY90-90 connection sleeve on the water collection pipe and
supplying air to the system. If the diffuser group does not have water collection pipe,
one connection sleeve on every end of the branch has to be opened.
Air supply should always be started softly, that is with small air flow which can later
be increased gradually.
Any defects found during leak tests must be entered in the installation inspection
form and then repaired immediately. A number of spare parts are supplied with the
system to replace components that may be damaged during transportation and
installation.
9.2 First Leak Test
For the first leak test, raise the water level halfway up the diffuser screw-on ring
HKR 215 / PKR 300. The diffuser tops will remain above the water surface. Switch
on the air supply and check for any leaks:
- at connection sleeves HSY 90-90
- the joint between main body HSA 215 / PSA 300 and header
- the lower section of screw-on ring HKR 215 / PKR 300
- the thread between support plate PTL 300 and main body HSA 215
- the water collection pipe and zone header
Leakage from connection sleeve HSY 90-90 is usually due to a misaligned rubber
gasket or incorrect installation of the sleeve. One of the indicating lines marked at
the element end must be visible. Repair any defects by re-installing the sleeve. Any
damaged connection sleeves must be replaced.
The PRK 300, KKI 215, HKL 215 or MKL 215 diffuser must be detached from the
element (Figure 17) if air bubbles escape from between the main body HSA 215 and
the element pipe. To remove the diffuser, force wedge HSK 215 at the locking knob
with a screwdriver while at the same time knocking the wedge with a hammer to the
direction opposite to the arrow. Once the diffuser is removed, check the main body
and O-ring and reinstall the components. Any defective parts must be replaced.
Figure 17: Removing and attaching PRK 300, KKI 215, HKL 215 and MKL 215
diffusers
If there is leak under the screw-on ring, the ring is probably not tight enough or
misaligned. The leak can also be due to a misaligned porous or membrane disc. To
repair the fault, tighten the ring or unscrew it and tighten again (Figure 18). Replace
defective parts.
Figure 18: Special tools HKLIT 215 and HKLAT 215 for the screw-on ring
If a PRK 300 diffuser leaks from the screw-on ring or between the support plate and
main body, it is advisable to remove the PRF 300 from the saddle piece with RFIT
300 P tool (Figure 19). Place the defective PRF 300 on the VASTE 300 tool and
repair it.
Figure 19: Special tools VASTE 300 and RFIT 300 P
With PIK 300 diffuser, if air bubbles escape from between the saddle piece PSA 300
and the pipe, the diffuser must be detached from the pipe (Figure 21). To remove
the diffuser, force the wedge piece PSK 90 at the locking knob with a screwdriver
while at the same time knocking the wedge piece with special tool TWP to the
direction opposite to the arrow. Once the diffuser is removed, check the hole, saddle
piece and seal and reinstall the components. Any defective parts must be replaced.
The hole must be cleaned if needed. When reinstalling the wedge piece, lubricate
the pipe from underneath with soap solution to ensure fluent gliding.
If the PIK 300 diffuser leaks from below the screw-on ring, the screw-on ring or the
diffuser is not placed correctly. To correct this, open the screw-on ring and reinstall
the components carefully. Required special tools are shown in Figure 22. Defective
parts must be replaced.
Figure 20: Attaching PIK 300 diffuser to the pipe with TWP tool
Figure 21: Removing the PIK 300 diffuser with the help of the TWP tool
Figure 22: Special tools PKLAT 300 big and small for PIK 300 diffuser
Typical leak sites in the water collection pipe and zone header are:
- the joints between cross-junction HTK 90/90 and piping
- the joint between drainage connection HTK 90/1,5 and water collection
pipe
- at drainage coupling VPL 90
- the end plug joints.
To seal any leaks in cross-junctions and end plugs, use PVC adhesive as a filler. If
a drainage coupling leaks, unscrew it and check the O-ring.
9.3 Second Leak Test
For the second leak test, raise the water level 5 cm above the diffusers. The idea is
to raise the water level high enough but not too much to make it possible for the
crew to move around in the basin. Switch on the air supplies and check the system
for leaks. Typical leak sites include:
- the support plate PTL 300 connection to main body HSA 215
- the screw-on ring HKR 215 / PKR 300
- As a result of increased back-pressure, leaks can also appear in
locations checked during the first leak test.
If there is a leak between the screw-on ring HKR 215 / PKR 300 or support plate
PTL 300 and the main body, the joint is not tight enough or the membrane or porous
disc or the circular gasket with support ring is not in correct position. To repair the
defect, tighten the ring or unscrew it and reposition the membrane or porous disc
(Figure 18). Replace defective parts. Lubricate the porous disc gasket or membrane
disc edge with soap and screw the screw-on ring in position. In the case of a PRK
300 diffuser, it is advisable to replace it and take the defective diffuser to a suitable
location for repairs.
Check that the screw-on ring and extension body are correctly tightened (max 50
Nm). When necessary tighten the diffusers when they are submerged. Diffusers
might have become loose because of the temperature changes they have
experienced since leaving the factory.
If the PIK 300 diffuser leaks from between the screw-on ring and the saddle, the
screw-on ring is not tight or the membrane is not correctly positioned. This is
corrected by opening the screw-on ring and reinstalling the components carefully.
Defective parts must be replaced.
To evaluate air distribution across the group, use an air flow rate of 3.0 to 4.0 Nm
3
/h
per diffuser for KKI 215, HKL 215 and MKL 215 and 5.0 to 6.0 Nm
3
/h per diffuser for
PIK 300 and PRK 300. The air distribution is usually not even with low air flow rates
and shallow water depths. This does not affect the fulfilment of SOTR guarantee.
If air supply through any diffuser is exceptionally low or stopped, the diffusers non-
return valve may not be functioning properly and it should be checked. With porous
discs HIL 210 or MIL 210, surface tension and the capillary action may sometimes
trap water inside the diffuser, which makes it impossible for the air to escape
through the porous disc. The non-return valve and the water blocking the pores can
be released by knocking the diffuser. If a knock is not enough, the diffuser must be
opened. A defective PRK 300 or PIK 300 diffuser should be replaced and defective
diffuser repaired in a suitable location.
If any of the diffusers passes much more air than the other diffusers, the membrane
/ porous disc and / or non-return valve must be replaced.
9.4 Third Leak Test
For the third test, raise the water level about 10 cm above the flanged joint between
the dropleg and zone header. Check the following points:
- the zone header along its entire length
- the dropleg-to-zone-header connection, joint and pipe alignment. To
seal any leak, reposition the gasket and tighten the nuts.
- the purge pipe or hose connection.
The even distribution of the aeration air is checked when air-feed is normal. The
correct operation of the water purge system is checked by opening the drainage
valve and making sure that water (mixed with air) is drained.
9.5 Storage of System and Protection Before Start-Up
If the basin is not commissioned right after the leak test, fill the basin with clean
water. Make sure that the water level is at least one metre above the diffusers.
the diffusers from becoming blocked.
If it takes several weeks before the basin is actually used, it is advisable to carry out
another system leak test before commissioning.
10. SOTR TESTING
The test protocol for SOTR testing of NOPOL
Aeration Systems should be sent to

Nopon Oy two weeks before testing. Test protocol should include all necessary
information about test methods, test conditions, description of measurement
systems, calculation method etc. Test shall be always performed in clean water and
airflow shall be measured accurately. Deviation from these and other conditions
mentioned in ASCE standard should be agreed before testing, otherwise Nopon Oy
does not take any responsibility of fulfillment of guarantee values.
The membrane surface properties have an important effect on SOTE. In order to
create realistic surface sliming, diffusers should be operated under water at least
one week before testing in normal temperatures 10 - 20 C. In case of lower
temperatures contact Nopon Oy. The aeration has to be on all the time during the
conditioning period.
INSTALLATION INSPECTION FORM
NOPON Oy DDS installation instruction Version 2.0 09.04.2001
PLEASE COMPLETE THIS FORM FOR EACH BASIN AND RETURN TO: NOPON OY
TURVEKUJA 6
00700 HELSINKI
FINLAND
FAX +358 9 3515 620
NAME OF PLANT
CONTRACTOR
BASIN NO: TOTAL NUMBER OF BASINS
DATES OF LEAK TESTS
REPLACED PARTS AND THEIR NUMBER
COMMENTS
THIS IS TO CERTIFY THAT THE INSTALLATION, LEAK TESTS AND ANY REPAIRS REQUIRED HAVE
BEEN CARRIED OUT IN ACCORDANCE WITH INSTALLATION INSTRUCTIONS AND GOOD
MANUFACTURING PRACTICE.
PLACE DATE PERSON RESPONSIBLE FOR INSTALLATION
NOPON OY DDS Operation and Maintenance Manual Version 2.0 09.04.2001
NOPOL

Operation and Maintenance Manual
TABLE OF CONTENTS Page
1. CONTENTS ____________________________________________________1
2. PERMISSIBLE AIR FLOW RATES __________________________________2
3. COMMISSIONING _______________________________________________3
3.1 Before Commissioning _____________________________________________________3
3.2 Filling the Basin ___________________________________________________________3
4. SYSTEM SHUTDOWN____________________________________________5
5. PERFORMANCE MONITORING ____________________________________6
6. CLOGGING ____________________________________________________7
7. STORAGE OF COMPONENTS_____________________________________9
8. INTERRUPTIONS IN AIR SUPPLY __________________________________9
9. DISASSEMBLY AND REASSEMBLY OF THE DIFFUSERS _____________10
9.1. Temperature Requirements_________________________________________________10
9.2. HKL 215 and MKL 215 Porous Diffusers and KKI 215 Membrane Diffuser __________10
9.3. PRK 300 Membrane Diffuser ________________________________________________11
9.4. PIK 300 Membrane Diffuser_________________________________________________12
9.5. HKL 215 R 1/2, MKL 215 R 1/2, KKI 215 R 1/2, HKL 215 BSF 1/2, MKL 215 BSF 1/2 and
KKI 215 BSF 1/2 Diffusers ______________________________________________________13
9.6. PRK 300 R 1/2 and PRK 300 BSF 1/2 Membrane Diffusers _______________________14
10. TROUBLESHOOTING___________________________________________16
10.1 Compressor Pressure Increases, Yet Insufficient Process Air Supply___________16
10.2 Air Consumption Increases while BOD Remains Constant ____________________16
10.3 Large Bubbles or Clusters of Bubbles _____________________________________17
10.4 Dead Spots in the Aeration Basin _______________________________________17
10.5 Local Oxygen Depletion in the Aeration Basin ______________________________17
Written by: MR Inspected by: AL Accepted by: ERN Page: 1 (17)
1. CONTENTS
These instructions apply to all NOPOL

DDS aeration systems in which the diffusers
are attached to PVC or stainless steel pipes. For the purposes of this manual, the
aeration system means the NOPOL

installation on the floor of an aeration basin. Aeration system converts aeration
air into fine bubbles.
For any wastewater treatment plant, aeration is an essential and the most costly
single process in terms of energy consumption. From the point of view of aeration,
the system should be monitored for the following:
- airflow rates
- blockage of diffusers
- leaks
The warranty given by the manufacturer will be valid only if the instructions
given in this manual are followed.
2. PERMISSIBLE AIR FLOW RATES
Airflow rates must be maintained within the limits shown in Table 1.
Excessively high airflow rates may damage the diffusers. In the worst case, the
porous discs may rupture and membranes may be torn. Whatever the case, the
service life of discs and membranes suffers as a result of overload.
If the airflow rate is too low, porous diffusers can become blocked because a low
airflow is not high enough to keep the diffuser clean. Normally, membrane diffusers
are not blocked even at low airflow rates, but air may be unevenly distributed within
the group. Also air distribution pattern among the various groups may change if the
supplied air volume cannot be specifically regulated to each group.
Table 1: Permissible air flow rates per diffuser (20 C, 101,325 kPa)
minimum
(Nm
3
/ h)
normal
(Nm
3
/ h)
maximum
(Nm
3
/ h)
HKL 215 1.0 3.5 5.0
MKL 215 1.5 4.0 6.0
KKI 215 0.5 2.5 4
PRK 300 0.5 5 8
PIK 300 0.5 5 8
* These rates must not be exceeded by more than 25 % even during short time (max 15 min) peak loads.
In theory due to the structure of the membrane diffuser, the lower limits for the
adjustment range is zero. However, to ensure uniform air distribution, a lower limit of
0.5 m
3
/h is recommended.
In some circumstances it is advisable to use lower maximum values for
airflows in order to extend the service lifetime of the porous disc or rubber
membrane. Use lower air flows if,
- wastewater contains chemicals which may harm the properties
of the membrane
- water temperature exceeds 30 C
- aeration air temperature exceeds 60 C
The maximum aeration air temperature for PIK 300 diffusers is 100 C. For PRK
300, KKI 215, MKL 215 and HKL 215 diffusers it is 80 C.
3. COMMISSIONING
3.1 Before Commissioning
Before commissioning, check the aeration system with care and carry out a leak test.
Also ensure that there are no corrosion products or sludge inside the piping that
may block the diffusers. Condensed water in the piping must be removed via the
drainage system.
If the system is not put into operation immediately after installation, the basin must
be filled with water so that the water level is at least one metre above the diffusers.
(Figure 1). Water protects the diffusers against UV radiation, sub-zero temperatures
and dirt. If the basin is filled with water, HKL 215 and MKL 215 diffusers must be
continuously supplied at the minimum air flow rate (Table 1).
Figure 1: When the system is not in operation, the water level must provide at least a
one-metre blanket above the diffusers
3.2 Filling the Basin
- Aeration must remain switched on throughout the filling operation
As the basin is filled up, adjust the air supply rate in response to the
backpressure caused by the rising water level. The maximum air flow rates
given in Table 1 must not be exceeded at any point during the filling process.
- Beware of ice
At low outdoor temperatures, ice may develop on the basin floor. Floating ice
may damage the aeration system or other structures in the basin.
- Fill the basin carefully
A strong current may damage the aeration system or its support structures.
- Watch the system during filling
If any leaks or other defects are detected, stop filling and repair the defect.
- When the basin is full, remove condensed water by alternately opening
and closing each water drainage valve
- Adjust aeration according to process conditions
4. SYSTEM SHUTDOWN
If the basin has not been drained before the aeration system is shut down, a
minimum air supply must be maintained to porous disc diffusers (HKL 215, MKL
215) (Table 1) to prevent potential blockages.
If aeration is discontinued for a period of over two weeks, drain and clean the basin.
Draining the aeration basin:
- Cut off waste water supply and return sludge flow to the basin
- Keep aeration on while the basin is being drained
Continued aeration prevents the silt from depositing during drainage.
- Throttle air supply as water level drops
As the basin is drained, adjust the supply air flow rate according to the back-
pressure caused by the descending water level. Never exceed the maximum
air flow rates shown in Table 1.
- Beware of ice
If the aeration has been switched off before the basin is drained, there may be
a blanket of ice in the basin. Do not drain a basin if there is any ice in it
because ice may damage the diffusers or bend the pipes.
- Clean the diffusers
Cleaning prevents dirt from drying and hardening on the diffuser surface. If
the aeration basin is out of use for more than 48 hours, it is advisable to clean
the basin and piping to avoid odour problems. The inside of the piping can
also be cleaned by removing the water collection pipes and the zone headers
of each group.
- Check the condition of the system
Pay special attention to gaskets and seals.
- If the shutdown lasts over two weeks, fill the basin with clean water. To
protect the diffusers, make sure that there is at least one metre of water
above the diffusers
The layer of water will protect the diffusers from UV radiation from the sun.
Add some suitable algaecide during warm seasons.
5. PERFORMANCE MONITORING
The indicators to be watched during aeration include:
- air compressor - energy consumption
- condition of the filter
- maintenance
- aeration basin - water temperature
- oxygen content
- water quality
- maintenance
- aeration - uniformity of bubble pattern and size
- back-pressure
- airflow rates
- condition of air supply piping joints and valves
- supply air temperature
- outdoor air temperature
- maintenance
- downtime
- quantity and quality of condensed water (check
this once a week)
- quantity of coagulants fed into the system
To ensure correct diffuser operation, the air compressors must be properly
monitored as well as maintained. Blocked or defective suction filters can lead to a
blockage of the diffuser suction side. Monitoring the compressor energy
consumption also gives an indication of the condition of the aeration system and any
blockages. When diffusers are blocked, back-pressure and energy consumption
increase.
Other factors that affect the performance of the aeration system are the temperature
and quality of the water in the basin as well as the amount of maintenance carried
out. Oxygen depletion, over-aeration or increased energy consumption can also be
due to changed loads or the composition of the waste water.
Condensed water must be drained from the piping on a regular basis. The amount
and quality of the condensed water gives an indication of the condition of the
aeration system. Usually the condensed water is clear. If the amount of condensed
water is high and the water is dirty, there is probably a leak in the aeration system.
6. CLOGGING
The diffusers may become clogged on either side (air or water) of the disc or
membrane.
Clogging on the air supply side can be due to:
- impurities in the supply air
- poor condition of the compressor air filter
- failure of the compressor silencer
- pipe corrosion
- pipe breakdowns
- welding debris in the piping
- leaks in piping through which solids can enter the system
Clogging on the fluid side can be due to:
- chemical deposits such as iron, calcium, magnesium
- oil or grease contained in waste water
- organic solids, fine silt or sand
- slime build-up on the diffuser
If the BOD of the activated sludge is high, blockage may be accompanied by slime
build-up on the diffuser surface (at the front end of a plug-flow basin, industrial
waste water). Slime build-up alone does not increase back-pressure but it reduces
aeration efficiency as the bubbles get bigger.
When diffusers become clogged:
- back-pressure in the aeration system increases
- As a result of increased back-pressure, electricity consumption per kg
of oxygen supplied into the water usually increases.
- The bubble pattern may become uneven.
- If a diffuser is nearly completely clogged, the membrane may be
damaged if air is forced through it.
When diffusers become clogged, back-pressure increases slowly. If back-pressure
changes quickly, it is usually due to a blockage in the air supply header or in some
valve etc.
To clean clogged diffusers, use one of the four following methods:
- Drain the basin and clean the diffusers in the system using a brush or
high-pressure cleaning.
- Drain the basin and remove and clean the diffusers one by one.
- Activate the NOPOL
CLEAN system during operation.

- Lift the group out of the basin and clean the diffusers one by one.
Air bumping can also be used to prevent clogging and to clean diffusers with a small
pressure increase. Bumping is carried out by increasing the air flow from the
minimum acceptable to the maximum acceptable value for the diffuser (see Table 1).
The air bumping procedure must not be carried out for badly clogged diffusers (>
300 mm pressure increase). If airflow is increased rapidly and diffusers are clogged,
they might be damaged.
The patented NOPOL
CLEAN system uses the dilute formic acid as a cleaning

agent. The acid is dispensed as a spray into the dropleg (Figure 2). The formic acid
dissolves any blockages during operation so that the basin need not to be drained
or the diffusers removed.
NOPOL
CLEAN is a procedure that results in energy savings, because the

diffusers can be cleaned when a lower increase of back pressure is reached
compared with other methods and at the same time as the normal aeration process
in ongoing. Cleaning with NOPOL
CLEAN should be carried out when back

pressure increases by about 20 mbar. If the diffusers are cleaned by other methods,
it is necessary to clean them when back pressure increases by 50 mbar above the
original value.
If a complete set of porous or membrane discs for one basin are stocked at the
plant, any soiled diffusers can be replaced immediately in connection with cleaning.
As a result, the interruption in operation will be shorter and soiled porous or
membrane discs can be cleaned as and when it is convenient.
Figure 2: NOPOL

7. STORAGE OF COMPONENTS
Porous discs HIL 210 and MIL 210 are preferably stacked on a level surface. The
disc must not be allowed to bend. Protect the diffuser discs from direct sunlight and
low (< 0 C) temperatures.
Membrane discs HIK 215 and HIK 300 should be stored at room temperature in
closed boxes protected from sunlight. Make sure that the membranes do not get
stuck to one another by inserting a piece of cardboard between each of them.
Plastic components must be stored at room temperature protected from direct
sunlight. Make sure that the parts are not deformed or subjected to any loads.
8. INTERRUPTIONS IN AIR SUPPLY
A short interruption in air supply does not cause problems. However, if air supply is
interrupted for over three hours, the pressure exerted by water can force dirt into the
porous diffusers. This is not a problem with membrane diffusers.
If the air supply has been off, the system back-pressure must be checked. If the
back-pressure remains permanently above the cleaning limit, the diffusers must be
cleaned, for example by using acid cleaning. With the NOPOL
CLEAN method, the

system should be cleaned when back-pressure increases by 20 mbar. With other
methods, the limit is 50 mbar.
During an extended stoppage, a bio-film may build up on the diffuser surface. To
remove it, it is necessary to drain the basin and clean the diffuser discs one by one.
When restarting the system, be careful. During an interruption in air supply, sludge
deposits on the diffuser surface. It is also possible that water has entered the
aeration system. If the system is restarted too quickly, the diffusers may be
damaged. Air supply should always be started softly, that is with small air flow
which can later be increased gradually.
9. DISASSEMBLY AND REASSEMBLY OF THE DIFFUSERS
9.1. Temperature Requirements
At low temperatures (below +5 C), PVC and PP become brittle. Special care must
be taken when ambient temperature drops below 10 C. Recommended ambient
temperature for disassembly and reassembly of the diffusers is above +15 C.
9.2. HKL 215 and MKL 215 Porous Diffusers and KKI 215 Membrane Diffuser
- Unscrew the diffuser screw-on ring HKR 215 using tool HKLIT 215 or HKLAT
215 (Figure 3).
- Remove porous disc HIL 210 or MIL 210 including gasket or diffuser
membrane HIK 215. The membrane is attached to the support plate.
- Clean the inside of the diffuser main body.
- Replace the diffuser non-return valve when necessary. Check the condition of
the other diffuser components and replace if defective.
- Wash the porous discs or membranes after removing them first.
- Replace the porous disc including gasket or diffuser membrane carefully
inside the main body HSA 215. When replacing the porous disc HIL 210,
make sure that the side with the finer texture faces upwards.
- Lubricate the inside of the screw-on ring with a soapy solution and screw it
into position with tool HKLIT 215 or HKLAT 215.
Figure 3: How to use tools HKLIT 215 and HKLAT 215
9.3. PRK 300 Membrane Diffuser
- Unscrew the diffuser with tool RFIT 300 P (Figure 4). The diffuser opens
between the main body and the support plate. The main body remains on the
pipe. Leave the circular gasket HUR 300 and the support ring HTR 300 inside
the saddle piece.
- Fix VASTE 300 tool in a suitable location.
- Place the diffuser on top of VASTE 300 and unscrew the screw-on ring with
tool PKLAT 300. The required turning angle is 15 counter-clockwise.
- Remove diffuser membrane HIK 300.
- Clean the inside of the diffusers.
- Replace any defective parts.
- Wash the membranes one by one.
- Place the membrane on top of the support plate and the sliding ring PVR 300
on top of the membrane on the VASTE 300 tool.
- Screw the screw-on ring in position using tool PKLAT 300.
- Check the non-return valve, the circular gasket and the support ring for any
damage. Clean the parts. If they are in bad condition, replace them.
- Lubricate the upper surface of the circular gasket HUR 300 with a soapy
solution and place it carefully with the support ring inside main body HSA
215.
- Install the top section of the diffuser on the main body. Tighten the joint
manually.
Figure 4: Tools VASTE 300 and RFIT 300 P
9.4. PIK 300 Membrane Diffuser
- Detach screw-on ring PKR 300 by turning it with tool PKLAT 300 (Figure 5).
The required turning angle is 15 counter-clockwise. The screw-on ring,
sliding ring and membrane can now be removed. The main body remains on
the pipe.
- Clean the upper part of the main body, the sliding ring and the screw-on ring.
- Replace defective parts with new ones.
- Clean and check the non-return valve and replace it if needed. The body of
the non-return valve is attached to the main body by a snap-in-place junction.
- Place the membrane centrally to the main body.
- Install the sliding ring and the screw-on ring top of the main body.
- Tighten the screw-on ring with tool PKLAT 300
PKLAT 300 Small PKLAT 300 Big
Figure 5: Special tools for the PKR 300 screw-on ring
9.5. HKL 215 R 1/2, MKL 215 R 1/2, KKI 215 R 1/2, HKL 215 BSF 1/2, MKL 215
BSF 1/2 and KKI 215 BSF 1/2 Diffusers
- Remove the screw-on diffuser from the piping with the tool HKLAT 215
(Figure 3).
- For the duration of cleaning, fix the VASTE 215 tool (Figure 6) to the basin
floor or other suitable location.
Figure 6: Special tool VASTE 215
- Place the diffuser on the VASTE 215 tool and remove the screw-on ring using
the tool HKLAT 215 or HKLIT 215.
- Remove porous disc HIL 210 or MIL 210 including gasket, or the diffuser
membrane HIK 215. The membrane disc is fitted to the support plate.
- Clean the inside of the diffuser main body.
- Replace the diffuser non-return valve when necessary. Check the other parts
as well and replace if defective.
- Clean the porous discs or membranes one by one.
- Put the porous disc HIL 210 and its gasket or diffuser membrane HIK 215 with
its support plate carefully back inside the main body HSA 215. Place the disc
the same way it used to be. A new porous disc HIL 210 is installed with the
finer texture on top.
- Lubricate the inside of the screw-on ring with a soapy solution and tighten the
ring with tool HKLIT 215 or HKLAT 215.
- Screw the diffusers carefully onto the piping while ensuring that the main
body threaded nipple is not torn off the pipe. Check also the O-ring around
the threaded nipple. Make sure that the O-ring seals the joint. A sealing tape
can also be used in the thread.
9.6. PRK 300 R 1/2 and PRK 300 BSF 1/2 Membrane Diffusers
- Remove the diffuser from piping manually or with tool RFIT 300 P (Figure 4).
- If the diffuser has been removed from the piping complete, place the diffuser
on the tool VASTE 215 and unscrew the diffuser from the main body with tool
RFIT 300 P.
- In order to disassemble the upper section of the diffuser, fix the VASTE 300
tool to the basin floor or other suitable location.
- Place the diffuser on VASTE 300 tool and unscrew the screw-on ring with tool
PKLAT 300 (Figure 5). The required turning angle is 15 counter-clockwise.
- Remove diffuser membrane HIK 300 and the sliding ring PVR 300.
- Clean the inside of the diffuser and the main body.
- Clean the other parts and replace if defective.
- Place the membrane on top of the support plate and the sliding ring on top of
the membrane on the VASTE 300 tool.
- Screw the screw-on ring into position with tool PKLAT 300.
- Lubricate the upper surface of the circular gasket HUR 300 with a soapy
solution and place it with the support ring carefully inside main body HSA
215.
- Place the diffuser top section in the main body that is on the tool VASTE 215.
Seal the joint by tightening it manually.
- Screw the diffuser carefully onto the piping while ensuring that the main body
threaded nipple is not torn off the pipe. Check also the O-ring around the
threaded nipple. Make sure that the O-ring seals the joint. A sealing tape or
sealing material can also be used in the thread.
10. TROUBLESHOOTING
A number of common malfunctions and their potential causes are listed below. Note
that malfunctions in aeration may be due to factors other than the system itself, such
as the plant load, condition of air compressors, control valve operation, oxygen
sensor performance, etc.
10.1 Compressor Pressure Increases, Yet Insufficient Process Air Supply
1. Diffusers clogged.
Check the diffuser back pressure. Clean the diffusers.
2. Malfunction of air flow control valve.
Check valve operation and repair any defects.
3. Compressor air filter clogged.
Check pressure across the filter. Replace or clean the filter according
to the manufacturers instructions.
10.2 Air Consumption Increases while BOD Remains Constant
1. Actual oxygen content of the basin is greater than the setting.
Check and calibrate the oxygen sensors.
2. Air escapes from the headers.
Check the piping for leaks and make the necessary repairs.
3. Air consumption per kg of BOD increases.
The system is running at longer sludge retention times than assumed.
Check back pressure. Clean the diffusers.
5. Intense nitrification.
Check load and sludge retention time.
6. Oxygen transfer performance impaired.
Diffusers are too old. The bubble producing parts should be replaced.
7. Reject water load not taken into account.
Check the additional load caused by reject water.
10.3 Large Bubbles or Clusters of Bubbles
1. Slime build-up on diffusers.
Slime build-up can be prevented by re-arranging water supply or
cleaning the system regularly with formic acid.
2. Pipe leakage or broken or leaking diffuser.
Drain the basin, check the system for leaks and replace any defective
parts.
10.4 Dead Spots in the Aeration Basin
1. Insufficient air flow rate.
Make sure that the air flow rate for the zone or the entire basin does
not fall below the recommended minimum air flow rate. Check and
calibrate the air flow meters.
2. Diffusers completely clogged.
Drain the basin. Clean or replace porous discs or membranes.
3. Non-uniform air distribution in the basin.
Adjust the air distribution valves to ensure uniform supply air
distribution across the basin.
10.5 Local Oxygen Depletion in the Aeration Basin
1. Organic loading is unevenly distributed or air distribution is
incorrect.
Adjust air distribution or add diffusers in the depleted area.
11 NOPOL PIKE:
NOPOL
DDS
PRODUCT MANUAL
Installation, operation and
maintenance manual for PIK 300
diffusers on PP pipes
Version 2.0 Product code 195041
Copyright: Nopon Oy 2001
NOPOL

PIK 300 DIFFUSERS
ON PP PIPING
Installation, Operation and Maintenance
Manuals
NOPON OY
Turvekuja 6, FIN-00700 HELSINKI, FINLAND
Tel +358 9-351 730 Fax +358 9-351 5620
E-mail: hq@nopon.fi
internet: http://www.nopon.fi/
NOPON OY PIK installation instruction Version 2.0 27.04.2001
NOPOL

PIK 300 DIFFUSERS
ON PP PIPING
Installation Manual
TABLE OF CONTENTS
1. SCOPE OF APPLICATION OF INSTALLATION INSTRUCTIONS _________ 1
2. NAMES OF THE AERATION SYSTEM COMPONENTS_________________ 3
3. DELIVERY OF THE AERATION SYSTEM____________________________ 8
3.1 Contents__________________________________________________________________8
3.2 Accompanying Documents __________________________________________________8
3.3 Packaging and Transportation _______________________________________________8
3.4 Acceptance of Delivery______________________________________________________9
3.5 Handling_________________________________________________________________10
3.6 Storage__________________________________________________________________10
4. INSTALLATION OF THE AERATION SYSTEM ______________________ 11
4.1 Installation Steps _________________________________________________________11
4.2 Measures to Be Taken Before Installation_____________________________________11
4.3 Installation of Bottom Mounting Brackets_____________________________________12
4.3.1 Determining the Location of Bracket Fixing Points ____________________________12
4.3.2 Installing Bottom Mounting Brackets _______________________________________13
4.3.3 Adjusting the Height of PPK90 and HPK210 Bottom Mounting Brackets ___________13
4.3.4 Installation of TKK90 Bottom Mounting Brackets _____________________________16
4.3.5 Installation of PKL90 Bottom Mounting Brackets______________________________17
4.4 Adjusting the Height of TPK Bottom Mounting Brackets and of Large Zone Header _19
4.5 Installation of Polypropylene Zone Header ( 90 mm) __________________________19
4.6 Installing Diffuser Elements ________________________________________________20
4.7 Installing Water Collection Pipe _____________________________________________21
4.8 Final Fixing of the System__________________________________________________22
4.9 Installing Dropleg and Purge Pipe / Hose _____________________________________22
4.10 Post-Installation Procedures______________________________________________23
5. INSTALLATION OF ADDITIONAL DIFFUSERS ______________________ 24
5.1 Using Additional Diffusers__________________________________________________24
5.2 Before Installation_________________________________________________________24
5.3 Installing New Diffusers to Existing Piping____________________________________24
5.4 Adding New Diffuser Rows _________________________________________________25
6. SYSTEM LEAK TESTING _______________________________________ 27
6.1 Procedures and Permissible Air Flow Rates for Leak Tests and Trial Runs_________27
6.2 First Leak Test____________________________________________________________28
6.3 Second Leak Test _________________________________________________________31
6.4 Third Leak Test ___________________________________________________________31
6.5 Storage of System and Protection Before Start-Up _____________________________32
7. SOTR TESTING_______________________________________________ 33
APPENDIX
Installation inspection form
Made by: MR Inspected by AL Accepted by: ERN Page: 1 (33)
1. SCOPE OF APPLICATION OF INSTALLATION INSTRUCTIONS
These instructions apply to NOPOL

DDS PIKE aeration systems in which PIK 300
diffusers are attached to polypropylene (PP) pipes. For the purposes of this manual,
the aeration system will mean NOPOL

installation on the floor of an aeration basin (Figure 1). The system converts
aeration air into fine bubbles.
To ensure correct operation of the system, it is extremely important that
a) The system is leak-proof. Any leaks can ultimately lead to a blockage of
the entire system.
b) Air is uniformly distributed to all diffusers.
The system is pre-assembled at the factory and supplied in the form of diffuser
elements, water collection pipes, and zone headers. Usually the delivery limit is up to
the zone header flange used for connecting the system to the air supply dropleg.
This flange is located approx. 170 - 300 mm above the centre line of the zone
header. Another delivery limit is up to the water collection pipe drainage coupling to
which the customer connects the purge pipe or hose, which is then mounted to the
top of the basin wall.
The warranty given by the manufacturer will be valid only if these installation
instructions are complied with. Included in this manual is an installation inspection
form, which must be completed, signed and returned to the manufacturer in order for
the warranty to take effect.
1
2
3 4
5
6
7
8
9 10
11
12 13
14
15
16
1. Blower station 6. Zone header 11. Diffuser element
2 Air supply header 7. Bottom mounting bracket TPK150 12. Diffuser PIK300
3. Expansion joint 8. Bottom mounting bracket HPK210/PPK90 13. Bottom mounting bracket PKL90
4. Dropleg 9. Connection sleeve PSY90 14. Drainage coupling VPL90
5. Pipe support 10. Bottom mounting bracket TKK90 15. Water collection pipe
16. Purge hose/pipe
Figure 1: Typical bottom-mounted fine-bubble aeration system
2. NAMES OF THE AERATION SYSTEM COMPONENTS
The names of various aeration system components are given in Figure 1. The basic
unit in the system is the aeration group. There can be one or several such groups in
the basin. Air is supplied to the group via a dropleg. Zone header distributes the air
within the aeration group.
Zone headers can be made PP, PVC or stainless steel depending on the diameter
required. Zone headers with a diameter of 90 mm are usually made of PP.
Zone headers have right-angled branches connecting the diffuser elements to the
header. With PP and PVC zone headers, the branches have an outside diameter of
90 mm. With steel zone headers, the outside diameter is usually 88.9 mm.
Depending on the layout of the group, branches can be located on both sides of the
header or only on one side. Branches are connected to the zone header either on
its centre line or on its bottom.
A diffuser element is a pre-assembled cut-to-length part of 90 mm PP pipe with
diffusers mounted onto the pipe. PIKE aeration system means PIK300 diffusers
installed on PP piping. Figure 2 shows a type designation for a diffuser element.
PIKE L - N / E (D,D)
PIKE 3140-6 / 500 (320, 320) L = 3140 mm
N = 6 pcs PIK300
E = 500 mm (E min = 450 mm)
D = E/2 (D min = 320 mm)
Figure 2: Type designation of a diffuser element
The parts of the PIK300 diffuser complete with type designations are shown in
Figure 3.
The purpose of the water collection pipe is to collect condensed water from the
piping and to ensure uniform air distribution (Figure 1). The water collection pipe
consists of a 90 mm PP pipe, T- or X cross-junctions (PTK90/90 or PXT90/90)
and PTP90 end caps.
Figure 3: Parts of PIK 300 diffuser
Condensed water is drained through the drainage coupling VPL90 in the water
collection pipe. Sludge that finds its way into the pipe as a result of a leak, etc.
cannot be removed via this junction. If the system does not include a water
collection pipe, the drainage coupling is connected to the zone header or one of the
diffuser elements. When using large zone headers ( over 90 mm), water drainage
coupling is usually in the zone header and the branches connecting diffuser rows
are connected into the centre line of the zone header.
Diffuser elements are fixed to the basin floor by bottom mounting brackets PPK90
(Figure 4) or HPK210 (Figure 5), TKK90 (Figure 6), PKL90 (Figure 7) and
TPK100TPK350 (Figure 8).
Plastic parts of PPK90 bottom mounting brackets are of PP. Plastic parts of HPK210
bottom mounting brackets are of PVC except of the strap HPA210 which is of PP.
PPK90 or HPK210 bottom mounting brackets are used to fix diffuser elements.
These are also used as additional fixings to 90 mm zone headers and water
collection pipes. If necessary, the bracket height can be adjusted using extension
sleeves PJA3 or HJA210, maximum 2 connection sleeves per one bracket. The
elements are fastened to the bottom mounting brackets using HPA210 straps.
1. Strap HPA210 4. Foot PTU3
2. Pipe holder PKI90 5. Hex screw M10x20
3. Extension sleeve PJA3 6. Washer KL11/28
7. Drop-in anchor LAH10
Figure 4: PPK90 bottom mounting bracket
1
3
2
6
4
5
7
Figure 5: HPK210 bottom mounting bracket
HPK210
1. Strap HPA210
2. Pipe holder HKI210
3. Extension sleeve HJA210
4. Foot HTU210
5. Hex screw M10x20
6. Washer KL11/28
Table 1: Adjustment ranges of PPK90 and HPK210 bottom mounting brackets
Number of connection sleeves L
min
, mm L
max
, mm
0 70 105
1 105 140
2 140 175
TKK90 bottom mounting bracket is used as anchor point for connection sleeve
PSY90 and for one of the two diffuser elements attached to the PSY90. TKK90 is
also used as anchor point for the connection sleeve PSY90 attached to zone header
and the first diffuser element attached to it. The height of the connection sleeve in
the bottom mounting bracket can be adjusted by shifting the PSY support,
PSY/PIPE fixed clamp and screws in the holes of the support KT90.
Figure 6: TKK90 bottom mounting bracket
PKL90 bottom mounting brackets are used as combined fixings for a 90 mm water
collection pipe and connection sleeves PSY90 connected to it. The height of the
PKL90 bottom mounting bracket can be adjusted by shifting the connection parts in
the holes of the support.
Figure 7: PKL90 bottom mounting bracket
Large zone headers ( over 90 mm) are fixed in position using bottom mounting
brackets TPK100 - TPK350 (Figure 8) depending on the pipe size. The height of the
zone header is adjusted by shifting the holders on the threaded rods.
D
1
2
3
4
5
L
H MI N. MAX. 285
Figure 8: Bottom mounting brackets TPK100 - TPK350
TPK100350
1. Threaded rod M12
2. Hex nut M12
3. Holder 100350
4. Washer M12
3. DELIVERY OF THE AERATION SYSTEM
3.1 Contents
The delivery includes a complete aeration system or part of one depending on the
order and related supply agreement.
A complete aeration system will include the following:
- pre-assembled diffuser elements
- zone headers (PP, PVC or AISI 316)
- water collection pipes
- appropriate bottom mounting brackets
- pipe connection pieces
- drainage couplings
- a small number of additional parts to replace components that may be
damaged during transportation or installation
- the necessary installation tools.
3.2 Accompanying Documents
The system will be supplied complete with the following documents:
- Diffuser group layout drawings
- Bottom mounting bracket drilling layout
- Installation manual including the installation inspection form
- Operation and maintenance manual
3.3 Packaging and Transportation
Diffuser elements, zone headers and water collection pipes are usually supplied in
plywood cases (Figure 9). Other methods of packaging are also available.
To minimise transportation costs, each case is packed as full as possible. As a
result, one case contains components belonging to several groups. Before
installation, the drawings and dimensions must be checked to make sure that the
right parts will go to the right groups. Diffuser elements, zone headers and water
collection pipes are marked with stickers to help identification.
Other system components will be supplied in cardboard boxes that are packed into
a case or placed on pallets wrapped in a clear plastic film.
Usually the cases and pallets are delivered to the customer by trucks with trailers or
semi-trailers. For carriage by sea, suitable packaging is used. Delivery terms are
normally FCA Helsinki Turvekuja 6, Incoterms 2000.
Figure 9: Packaging options for aeration systems
3.4 Acceptance of Delivery
Before accepting the delivery, inspect the packages visually for damage. Any
complaints should be entered on the waybill.
To unload the goods, use a forklift truck and unload from the side of the cargo bay.
Make sure there is ample room on the unloading site for a truck carrying a case to
manoeuvre safely. In addition, a large delivery vehicle will need sufficient space for
manoeuvring if no through passage is provided.
Typical case dimensions are 540 x 112 x 112 (cm). The gross weight of a loaded
case is approx. 1 000 kg. Case height and width are usually standard, as shown in
Figure 9. However, case lengths vary according to the length of the elements.
Cases with a length of over 540 cm are only used when necessary, such as for the
transportation of long zone headers. The maximum height of a consignment on a
pallet is 200 cm.
3.5 Handling
Move the goods to the aeration basin in their original packaging using a suitable
hoist, or carry the elements there one by one. Mechanical damage to stainless steel
pipes must be avoided. If several aeration groups are to be installed in the same
basin, part of the basin area can be used for temporary storage. It is advisable not
to unpack the goods until they are to be installed. Diffuser elements must be kept
clean of dust, etc. Empty packing material need not to be returned.
Polypropylene is shock resistant but has to be handled cautiously. At low
temperatures (below +5 C) it becomes brittle. Special care must be taken when
ambient temperature drops below -10 C. Recommended ambient temperature for
installation is above +15 C. Also the temperature of the components to be installed
should be above +15 C. It is not recommended to install an aeration system when
temperature is below 0 C.
3.6 Storage
The plywood cases must be stored on a level base shielded from direct sunlight. Do
not stack more than two identical cases on top of each another. The pallets must not
be stacked. Protect them from rain. Exposure to sunlight is detrimental to rubber
parts of the diffusers and may cause plastic components and pipes to deform. When
storing packages, make sure they are not subjected to loads that may deform and
damage the parts inside.
4. INSTALLATION OF THE AERATION SYSTEM
4.1 Installation Steps
When installing the system, make sure that,
diffuser rows are straight
diffusers are at the same level
system is leak proof
Installation steps:
1) Clean the basin bottom with care.
2) Mark and drill holes for the bottom mounting brackets according to the drilling
layout and fix the brackets in position. Piping with a diameter of 90 mm will be
fixed to the basin bottom using PPK90 or HPK210 mounting brackets (Figure
8). Zone headers with a diameter of over 90 mm will be fixed using TPK100 -
TPK350 mounting brackets (Figure 8), depending on the pipe size.
3) Adjust the level of the brackets.
4) Install the zone header, diffuser elements and water collection pipe. Proceed
from the zone header towards the water collection pipe.
5) Pipework is connected to the bottom mounting brackets PPK90 or HPK210
with straps HPA210.
6) TKK90 and PKL90 bottom mounting brackets are installed and adjusted to the
same height as the others.
7) Fix the purge hose / pipe and connect the diffuser groups to the droplegs.
4.2 Measures to Be Taken Before Installation
Before fixing the bottom mounting brackets in position, remove all superfluous
materials from the basin. Clean the basin bottom to facilitate measurements and
marking of the bracket fixing points.
The bottom mounting brackets are supplied in parts.
Polypropylene is shock resistant but has to be handled cautiously. At low
temperatures (below +5 C) it becomes brittle. Special care must be taken when
ambient temperature drops below -10 C. Recommended ambient temperature for
installation is above +15 C. Also the temperature of the components to be installed
should be above +15 C. It is not recommended to install an aeration system when
temperature is below 0 C.
4.3 Installation of Bottom Mounting Brackets
4.3.1 Determining the Location of Bracket Fixing Points
Locations of the bottom mounting brackets PPK90 or HPK210 and TPK100350 for
each aeration group are indicated accurately on the drilling scheme. Locations of
the bottom mounting brackets TKK90 and PKL90 are shown tentatively, but their
accurate positions and locations are defined during installation. The location
principle is shown in Figure 10.
To achieve the best possible aeration efficiency, the distance between the group
and basin wall should be uniform on all sides. Usually the dimensions of the basin
do not determine the exact position of the fixing points. Often the fixing point
positioning is determined by the position of droplegs. If several groups are installed
in the same basin, group layout must be planned as a whole.
Once the positions of diffuser groups have been tentatively determined, mark the
fixing points for drop-in anchors on the basin floor. It is extremely important that the
drop-in anchors are aligned as shown on the drilling layout. If not, piping can be
subjected to lateral forces during operation.
Figure 10: Location of bottom mounting brackets in an aeration system
4.3.2 Installing Bottom Mounting Brackets
Drill holes at the marked locations for drop-in anchors. Hole sizes to be used:
- bracket PPK90 and HPK210 drop-in anchor LAH10 12 mm x 40 mm
- bracket TKK90 drop-in anchor LAH10 12 mm x 40 mm
- bracket PKL90 drop-in anchor LAH10 (2 pcs) 12 mm x 40 mm
- bracket TPK100350 drop-in anchor LAH12 15 mm x 50 mm
Remove any debris from the hole using compressed air. Insert the anchor so that it
is flush with the basin floor. Fix the drop-in anchor in position by hitting it with the
tool as shown in Figure 11. Make sure that the shoulder of the tool strikes the top of
the drop-in anchor.
Once the drop-in anchors are fixed in position, fasten the PPK90 or HPK210
mounting bracket PTU3 or HTU210 foot to the drop-in anchor using the KL11/28
washer and M10x20 hex screw. Take care not to damage the plastic. Make sure that
the basin floor under the foot is clean and level.
Screw M12 threaded rods of TPK mounting brackets directly into drop-in anchors.
Figure 11: Fixing the LAH10 and LAH12 drop-in anchors in position
Bottom mounting brackets TKK90 and PKL90 require washer KL11/28 and hex
screw M10x20. The holes for the drop-in anchors of these bottom mounting brackets
are only bored after installing the aeration group.
4.3.3 Adjusting the Height of PPK90 and HPK210 Bottom Mounting Brackets
To achieve maximum aeration efficiency, the plane on which the diffusers lie must
be as close to the basin bottom as possible. In a finished group, the variation in
height between individual diffusers must be less than 10 mm. The diffuser heights
in various basins should be as uniform as possible. Sometimes the diffuser height
must be raised because of limited compressor capacity or other structures at the
floor of the basin. If so, the bottom mounting brackets can be installed at a greater
height using special fixings. Such fixings are not included in the delivery.
The easiest way of adjusting diffuser height is to use the height of the pipe holder
PKI90 or HKI210 (Figure 13) (on which the diffuser element rests) as the reference
point. Start adjusting the height of the diffusers from the highest point of the basin
floor. Screw the mounting brackets at this point as far down as they will go. Then
adjust all other brackets to this height.
Even in its highest position the pipe holder must be screwed at least five rounds to
the foot or extension sleeve.
If necessary, the mounting bracket heights can be raised using the PJA3 or HJA210
extension sleeve. If the height of the pipe holder from the basin floor is from 70 to
105 mm, no extension sleeve is required. Mounting bracket height can be increased
by 35 mm with the addition of one extension sleeve. The maximum number of
extension sleeves is two, which are then able to compensate for basin floor height
variations of up to 105 mm. The height of the upper part of the diffuser is then 295
mm from the basin bottom. If the height variation is greater than this, the height of
the mounting bracket must be increased by some other means in order to ensure
that the diffusers are on the same level and height.
Extension sleeves PJA3 are attached to the foot PTU3 and to another
extension sleeve by screwing the extension sleeve clockwise until locking
(Figure 12). The standard delivery includes one extension sleeve for each bottom
mounting bracket.
In case of HPK210 bottom mounting bracket, the extension sleeves HJA210
are connected to one another and to the foot with adhesive (Figure 13) because
the bottom mounting brackets will be subject to pipework buoyancy when in water.
For gluing, use standard PVC adhesives (such as Tangit or Pevicol) and comply
with the manufacturers instructions. The standard delivery will include one
extension sleeve for each bottom mounting bracket. Adhesive is not included in the
delivery.
Figure 12: Bottom mounting bracket PPK90
Figure 13: Mounting bracket HPK210 extension sleeves are fixed to one another
and to the foot with adhesive
HPA 210 strap
PKI90 pipe holder
PJA3 extension sleeve
M10x20 Hex screw
KL11/28 Washer
PTU90 Foot
LAH10 drop-in anchor
HPA210 Strap
HKI210 Pipe holder
HJA210 Extension sleeve
M10x20 Hex screw
KL11/28 Washer
HTU210 Foot
LAH10 Drop-in anchor
4.3.4 Installation of TKK90 Bottom Mounting Brackets
Bottom mounting bracket TKK90 (Figure 6 and Figure 14) is used as anchor point of
the connection sleeve PSY90. TKK90 fixes the connection sleeve and the diffuser
element to its position (Figure 15). TKK90 is always installed on that side of the
connection sleeve which is nearer to the water collection pipe (Figure 10). TKK90
bottom mounting brackets are also installed to the sleeve of the zone header
element part which is underneath the flange of the 90 mm zone header.
TKK90 bottom mounting brackets are installed to the locations shown in the
drawings after installation of the pipework of the diffuser group. The PSY support
and PSY/PIPE fixed clamp are placed by the muffle of the connection sleeve
PSY90. The longer edge of the clamp is attached to the pipe outside the connection
sleeve. The parts are attached to the support KT90 with two M8x80 hex screws, at
the height required by the already installed pipework. The height can be adjusted by
the holes in the support KT90. The position of the support KT90 is checked and
adjusted so that the foot is along the basin bottom, and the parts are screwed with
M8 lock nuts. Bottom mounting brackets are attached to the basin bottom with drop-
in anchors LAH10 (1 pce / support KT90).
It is to be noted that PSY/PIPE fixed clamp is different from PSY clamp. One has to
ensure that right clamps are installed to right bottom mounting brackets during
installation.
Figure 14: TKK90 bottom mounting bracket parts (numbering related to next Figure)
PSY/PIPE fixed clamp (6)
Support KT90 (1)
PSY support (5)
Hex screws M8x80 (4)
Washers 8,4/17x1,6 (3)
Lock nuts M8 (2)
Hex screw M10x20 (7)
Washer KL11/28 (8)
Drop-in anchor LAH10 (9)
Figure 15: Installation of TKK90 bottom mounting bracket
TKK90 bottom mounting brackets have at least the same adjustment range as
PPK90 bottom mounting brackets. If the height variation is greater than this, the
height of the mounting bracket must be increased by some other means in order to
ensure that the diffusers are on the same level and height.
4.3.5 Installation of PKL90 Bottom Mounting Brackets
PKL90 bottom mounting brackets (Figure 7 and Figure 16) are used for firm fixing of
90 mm water collection pipes and connection sleeves PSY90 attached to it
(Figure 17).
After installation of diffuser group pipework, the PKL90 bottom mounting brackets
are placed in the locations shown in the drawings. PSY support and PSY clamp are
placed on that muffle of the connection sleeve PSY90 which is neared to the water
collection pipe. These are attached to the support with two M8x80 hex screws, at
the height required by the already installed pipework. In addition, U-bolt is mounted
round the T-piece PTK90 of the water collection pipe. The ends of the U-bolt are
pushed through the PSY support and M6 lock nuts are screwed to them. Height can
be adjusted with the holes in the support. The position of the support is checked and
adjusted so that the foot is along the basin bottom, and the parts are screwed with
M8 and M6 lock nuts. Bottom mounting brackets are attached to the basin bottom
with two drop-in anchors LAH10. In the foot of the support there are four holes, of
which two suitable ones are used for attachment to the basin bottom.
Figure 16: PKL90 bottom mounting bracket parts (numbering related to next figure)
Figure 17: Installation of PKL90 bottom mounting brackets

PSY support (5)
Lock nuts M8 (2)
Washers 8,4/17x1,6 (3)
U-bolt M6 (10)
Washers KL11/28 (8)
Lock nuts M6 (12)
Washers 6,4/18x1,6 (11)
Drop-in anchors LAH10 (9)
PSY clamp (6)
Support (1)
It is to be noted that PSY/PIPE fixed clamp is different from PSY clamp. One has to
ensure that right clamps are installed to right bottom mounting brackets during
installation.
PKL90 bottom mounting brackets have at least the same adjustment range as
PPK90 bottom mounting brackets. If the height variation is greater than this, the
height of the mounting bracket must be increased by some other means in order to
ensure that the diffusers are on the same level and height.
4.4 Adjusting the Height of TPK Bottom Mounting Brackets and of Large Zone
Header
TPK bottom mounting brackets are used for large ( over 90 mm) zone headers.
Screw the lower nuts onto the M12 threaded rods and then place the washer and
the lower half of the holder on top of them. Lift the zone header pipe onto the lower
half of the holders. Then place the diffuser elements, closest to the zone header, on
their bottom mounting brackets. Use the nuts of the TPK bracket to adjust the height
of the zone header. Zone header branches must be horizontally and vertically
aligned with the diffuser elements.
A multi-section zone header must be adjusted to correct height section by section.
Steel multi-section zone headers have flanged joints. When fixing the flanged joint,
tighten the bolts uniformly to ensure that the flange does not bend. Plastic multi-
section zone headers have sleeve joints. With a sleeve joint, the seal and the end of
the pipe have to be lubricated with soap solution to ease the installation.
4.5 Installation of Polypropylene Zone Header ( 90 mm)
The zone header is assembled by pushing the pipe end of one element part inside
the sleeve end of another element part. The direction of the branches and the
distance between the branches have to be in accordance with the drawings.
Element parts are marked with codes and the same codes are in the drawings. The
location of every element part in the zone header is shown there as well. The
element parts of the zone header are installed on the pipe holders of the bottom
mounting brackets PPK90 or HPK210, but the straps are only installed after
installing the whole aeration group. The sleeve end, pipe end and branches of the
element part have to be cleaned of impurities before installation. The lip seal of the
sleeve end of element part is lubricated with soap based solution before connecting.
Never use lubricants that may damage the rubber.
TKK90 bottom mounting brackets are used for the zone header as well. The
installation of these is explained in Chapter 4.3.4.
4.6 Installing Diffuser Elements
When installing diffuser elements, start from the zone header and proceed towards
the water collection pipe. The water collection pipe in each group must not be
installed until all other components have been fixed in position. Place diffuser
elements on the pipe holders of PPK90 or HPK210 bottom mounting brackets as
shown in the layout drawing. Connect the elements using PSY90 connection
sleeves which permit thermal expansion (Figure 18).
1. Double lip seal HTT90 2. Single lip seal HLT90 3. Body without gaskets PSY90R
Figure 18: Connection sleeve PSY90
Connection sleeves PSY90 are installed to the zone header branches so that the
zone header is connected to that double lip seal end of the connection sleeve. This
seal is lubricated with fine layer of special lubricate (Klber Paraliq GTE702). The
single lip seal end of the connection sleeve is lubricated with soap based solution
before connecting to diffuser element. Connection sleeve is pushed to the zone
header branch until its end meets the zone header.
The ends of the diffuser elements must be cleaned before installation. The distance
between the zone header and the first diffuser of the diffuser element must be
checked from the drawings.
The rest of the connection sleeves are installed so that the double lip seal end
(lubricated with special lubricant) of the connection sleeve is on the zone header
side and the single lip seal end (lubricated with soap based solution) on the water
collection pipe. This is shown in the bottom mounting bracket location drawing.
Figure 10 shows one example.
TKK90 bottom mounting brackets are always installed on the water collection pipe
part of the connection sleeve. PKL90 bottom mounting bracket is installed to that
connection sleeve which is nearest to the water collection pipe. Check from the
drawings where the fixed bottom mounting brackets should be located. When an
element is correctly installed, one of the two indication lines at the element end
remains visible. The ends of the elements are then approx. 50 mm apart, if drawings
do not indicate something else.
A small amount (3 g/double lip seal) of special lubricant (Klber Paraliq GTE702) is
included in the delivery.
When installing the elements, make sure that the inside of the pipes is clean.
Make sure that all the top surfaces of diffusers are exactly horizontal.
Straps of the bottom mounting brackets PPK90 or HPK210 may not be tightened
until the whole aeration group has been installed.
4.7 Installing Water Collection Pipe
Install the water collection pipe after all the diffuser elements have been connected.
At this point, the elements are still resting on top of the mounting brackets so that
the connection sleeve gives some play. Water collection pipes consist of multiple
sections, which have been marked with codes. The same codes are in the drawings.
Water collection pipe is assembled by pushing the pipe end of a part element inside
the sleeve end of another. The direction and distance of the branches is checked at
the same time.
The part elements are placed on the pipe holders of the PPK90 or HPK210 bottom
mounting brackets. The straps are only installed after the whole aeration group has
been installed.
The connection sleeve which connects the last diffuser element to the water
collection pipe is pushed inside the water collection pipe branch until its end meets
the water collection pipe. The single lip seals of the part elements and of the
connection sleeves connected to the part elements are lubricated with soap based
solution before connecting. The double lip seal end of the same connection sleeve
is lubricated with a fine layer of special lubricant.
Installation of the PKL90 bottom mounting brackets used for the water collection
pipe is explained in Chapter 4.3.5.
4.8 Final Fixing of the System
Pipework is fixed to the pipe holders of PPK90 or HPK210 bottom mounting
brackets with straps HPA210. Use the special tool HPAAT (Figure 19) to install the
straps. The straps can be removed with the same tool. However, it is advisable not
to reuse straps but to replace them.
The straps must be installed when warm. At low temperatures (< 15 C), the strap
becomes stiff and may break when installed. It is recommended to warm the straps
in water before installation.
Finally the alignment of the zone header is checked. The top halves of the TPK
brackets are fitted on and tightened with top bracket nuts.
Figure 19: Fixing the pipe to the bottom mounting bracket PPK90 or HPK210 using
the special tool HPAAT
At this stage the definite location of the TKK90 (Figure 14) and PKL90 (Figure 16)
bottom mounting brackets can be determined. The drilling schemes and drawings
show where these brackets should be located. More detailed installation instructions
are given in chapters 4.3.4 and 4.3.5.
4.9 Installing Dropleg and Purge Pipe / Hose
Remove any impurities from the air supply header and droplegs using compressed
air before connecting the aeration group to the dropleg. To prevent the impurities
from getting into the piping that is on the basin floor, close the flanged joints of the
zone header.
After the piping has been cleaned, connect the group dropleg flange to the zone
header flange. When tightening the flange, make sure that the zone header does
not move.
HPAAT
The dropleg must be fixed to the basin wall or to the floor to ensure that the
zone header and its flange are not subjected to any load (Figure 1). In addition,
the upper end of the dropleg must be fitted with a connection sleeve that
permits thermal expansion and prevents movement due to expansion from
being transmitted to the diffuser group.
The material of the water drainage coupling is AISI 316. Connect the purge pipe or
hose to the drainage coupling VPL90. Drainage couplings can also be located in
large zone headers. The other end of the pipe or hose must be fitted with a valve
and fixed above the water surface. The rising angle of the pipe or hose must be at
least 40 along its entire length, and supports must be provided on the basin wall or
other structures at least every 50 cm.
For basins where strong currents are produced, use a purge pipe and fix it with due
regard to the forces generated by the currents.
The purge pipe or hose is not included in the delivery.
Figure 20: Connecting the drainage coupling VPL90 to the piping
4.10 Post-Installation Procedures
5. INSTALLATION OF ADDITIONAL DIFFUSERS
5.1 Using Additional Diffusers
To increase system capacity, diffusers can be added to an existing system. Extra
diffusers can either be added to the existing elements, or the number of diffuser
rows in the group can be increased. When new rows are added, the zone headers
and water collection pipes must also be replaced because of the higher number of
rows and greater air flow rate.
Extra diffusers can be added to a PIKE system if c/c diffuser spacing in the existing
system is at least 750 mm and there are no bottom mounting brackets or connection
sleeves PSY90 between the diffusers. Minimum spacing of diffusers and rows is
shown in Figure 21.
A
B
A
min
450 mm
B
min
450 mm
Figure 21: Minimum spacing of diffusers and rows
5.2 Before Installation
Before installation drain the basin and clean the diffusers and piping. This also
gives a good opportunity to check the condition of the existing system and diffusers.
Parts that are defective or require repair must be replaced.
The diffusers are usually supplied complete. If additional diffusers are supplied as
elements, the delivery usually includes new zone headers and water collection
pipes.
In handling and storage, follow the instructions given in Chapters 3.4, 3.5 and 3.6.
5.3 Installing New Diffusers to Existing Piping
existing diffuser plane (Figure 22). The required hole diameter X is
5 . 0
0
15
+
mm. Make
sure that the drilled hole is clean to ensure a leakproof joint between the diffuser
and pipe. Bore shavings may not enter the pipe.
Figure 22: Making a hole in the diffuser element
The additional diffusers should be spaced as uniformly as possible within the group.
Uniform distribution will ensure uniform air supply in the group.
The extra diffuser is inserted in the drilled hole and the wedge is moved into
position by pushing it uniformly on both sides with installation tool TWP90 (Figure
24) until the edges of the wedge in the same location as the edges of the saddle
piece. Lubricate the pipe from underneath with soap solution to ensure fluent gliding
of the wedge piece. Finally make sure that the diffuser top is level. If the element is
removed from the group for installation, follow the instructions given in Chapters
4.6- 4.9 when reassembling the group.
5.4 Adding New Diffuser Rows
To begin with, remove the existing water collection pipe and existing zone header.
Then follow the instructions given in Chapter 4. Start by fixing the bottom mounting
brackets.
6. SYSTEM LEAK TESTING
6.1 Procedures and Permissible Air Flow Rates for Leak Tests and Trial Runs
When fully installed, the aeration system must be leak-proof. All air entering the
water must come through the diffusers. Any leaks in the aeration system will
increase energy consumption, and sludge entering the system may block the
diffusers.
The aeration system must be tested for leaks in three stages by using clean water
and feeding air into the system. Any leaks will then be detected as bubbles.
Stage 1: Raise water level until it is halfway up screw-on ring PKR300
Stage 2: Raise water level until it is approximately 5 cm above the diffusers
Stage 3: Raise water level until it is approximately 10 cm above the flanged joint
of the dropleg
The maximum air flow rate permitted for PIK300 diffuser in leak tests and trial
operation is 8.0 Nm
3
/h/diffuser (20 C, 101,325 kPa). Air supply must always be
started softly, that is with small air flow which can later be increased gradually.
If there is a long time interval between installation and leak test, the basin should be
emptied before the leak test. The aeration system is drained of possible water by
opening one PSY90 connection sleeve on the water collection pipe and by
supplying air to the system. If the diffuser group does not have water collection pipe,
one connection sleeve on every end of the branch has to be opened.
Trials to see that the blowers operate correctly should be carried out before the
pipes supplying process air to the diffusers are connected. However, if air is
supplied to the group during blower trials, the maximum air flow rates indicated
above must not be exceeded. Air volumes can be calculated on the basis of blower
output. Make sure that all the necessary valves are open.
Any defects found during leak tests must be entered in the installation inspection
form and then repaired immediately. A number of spare parts are supplied with the
system to replace components that may be damaged during transportation and
installation.
6.2 First Leak Test
For the first leak test, raise the water level halfway up the diffuser screw-on ring
PKR300. The diffuser tops will remain above the water surface. Switch on the air
supply for two hours at maximum air flow. Check then for any leaks:
- at connection sleeves PSY90
- the joint between main body PSA300 and header
- the joint between HIK300 membrane and saddle piece PSA300
- the water collection pipe and zone header
Leakage from connection sleeve PSY90 is usually due to a lip seal that has come
off or incorrect installation of the connection sleeve. One of the indicating lines
marked at the element end must be visible. Repair any defects by re-installing the
sleeve. Any damaged parts must be replaced.
If air bubbles escape from between the saddle piece PSA300 and the pipe, the
diffuser must be detached from the pipe (Figure 23). To remove the diffuser, force
the wedge piece PSK90 at the locking knob while at the same time knocking the
wedge piece with special tool TWP to the direction opposite to the arrow. Once the
diffuser is removed, check the hole, saddle piece and seal and reinstall the
components (Figure 24). Any defective parts must be replaced. The hole must be
cleaned if needed. When reinstalling the wedge piece, lubricate the pipe from
underneath with soap solution to ensure fluent gliding.
Figure 23: Removing the PIK300 diffuser with the help of the TWP tool
Figure 24: Attaching PIK300 diffuser to the pipe with TWP tool
If the diffuser leaks from below the screw-on ring, the screw-on ring or the diffuser is
not placed correctly. This can also be due to wrongly placed membrane or sliding
ring. To correct this, open the screw-on ring and reinstall the components carefully.
Required special tools are shown in Figure 25. Defective parts must be replaced.
Figure 25: Special tools PKLAT300 big and small for PIK300 diffuser
Typical leak sites in the water collection pipe and zone header are:
- the sleeve and welded joints between cross-junction PTK90/90 and
piping
- the sleeve and welded joints between cross-junction PXK90/90 and
piping
- the sleeve and welded joints between drainage connection PTK90/1,5
and water collection pipe
- at drainage coupling VPL90
- the end plug PTP90 joints.
The leaking joints of T and X pieces are checked by opening the joint. Check the lip
seal and change it if required. If an end plug leaks, open the safety cotters, remove
the end plug and check the lip seal. If a drainage coupling leaks, unscrew it and
check the O-ring. Defective seals must be replaced.
Leaking welded joints of polypropylene pipes can be repaired by warming up the
pipe with hot air and by soldering the leaking joint with polypropylene solder. It is
also possible to use on-site resistance welding sleeves. In this case the
polypropylene pipe must be cut from the leaking point, and the pipe end must be
cleaned and fitted on a repair sleeve before connecting.
6.3 Second Leak Test
For the second leak test, raise the water level 5 cm above the diffusers. The idea is
to raise the water level high enough but not too much to make it possible for the
crew to move around in the basin. Switch on the air supplies and check the system
for leaks. Typical leak sites include:
- between the membrane HIK300 and saddle piece PSA300
- As a result of increased back-pressure, leaks can also appear in
locations checked during the first leak test.
If the diffuser leaks from between the screw-on ring PKR300 and the saddle piece
PSA300, the screw-on ring, or the membrane HIK300 or sliding ring PVR300 is not
correctly positioned. This is corrected by opening the screw-on ring and reinstalling
the components carefully. Defective parts must be replaced.
If air supply through any diffuser is exceptionally low or stopped, the diffusers non-
return valve may not be functioning properly and it should be checked. The non-
return valve can be released by knocking the diffuser. If a knock is not enough, the
diffuser must be replaced and defective diffuser repaired in a suitable location.
If any of the diffusers passes much more air than the other diffusers, the membrane
and / or non-return valve must be replaced.
6.4 Third Leak Test
For the third test, raise the water level about 10 cm above the flanged joint between
the dropleg and zone header. Check the following points:
- the zone header along its entire length
- the dropleg-to-zone-header connection, joint and pipe alignment. To
seal any leak, reposition the gasket and tighten the nuts.
- the purge pipe or hose connection.
To evaluate air distribution across the group, use an air flow rate of 5.0 to 6.0 Nm
3
/h
per diffuser. The air distribution is usually not even with low air flow rates and
shallow water depths. This does not affect the fulfilment of SOTR guarantee. The
correct operation of the water purge system is checked by opening the drainage
valve and making sure that water (mixed with air) is drained.
6.5 Storage of System and Protection Before Start-Up
If the basin is not commissioned right after the leak test, fill the basin with clean
water. Make sure that the water level is at least one metre above the diffusers.
If it takes several weeks before the basin is actually used, it is advisable to carry out
another system leak test before commissioning.
7. SOTR TESTING
The test protocol for SOTR testing of NOPOL
Aeration Systems should be sent to

Nopon Oy two weeks before testing. Test protocol should include all necessary
information about test methods, test conditions, description of measurement
systems, calculation method etc. Test shall be always performed in clean water and
airflow shall be measured accurately. Deviation from these and other conditions
mentioned in ASCE standard should be agreed before testing, otherwise Nopon Oy
does not take any responsibility of fulfillment of guarantee values.
The membrane surface properties have an important effect on SOTE. In order to
create realistic surface sliming, diffusers should be operated under water at least
one week before testing in normal temperatures 10 - 20 C. In case of lower
temperatures contact Nopon Oy. The aeration has to be on all the time during the
conditioning period.
INSTALLATION INSPECTION FORM
NOPON Oy P installation instruction Version 2.0 27.04.2001
Written by: MR Inspected by: Accepted by:
PLEASE COMPLETE THIS FORM FOR EACH BASIN AND RETURN TO: NOPON OY
TURVEKUJA 6
00700 HELSINKI
FINLAND
FAX +358 9 3515 620
NAME OF PLANT
CONTRACTOR
BASIN NO: TOTAL NUMBER OF BASINS
DATES OF LEAK TESTS
REPLACED PARTS AND THEIR NUMBER
COMMENTS
THIS IS TO CERTIFY THAT THE INSTALLATION, LEAK TESTS AND ANY REPAIRS REQUIRED HAVE
BEEN CARRIED OUT IN ACCORDANCE WITH INSTALLATION INSTRUCTIONS AND GOOD
MANUFACTURING PRACTICE.
PLACE DATE PERSON RESPONSIBLE FOR INSTALLATION
NOPON OY PIK Operation and Maintenance Manual Version 2.0 27.04.2001
NOPOL

PIK 300 DIFFUSERS
ON PP PIPING
Operation and Maintenance Manual
TABLE OF CONTENTS Page
1. CONTENTS ____________________________________________________1
2. PERMISSIBLE AIR FLOW RATES __________________________________2
3. COMMISSIONING _______________________________________________3
3.1 Before Commissioning _____________________________________________________3
3.2 Filling the Basin ___________________________________________________________3
4. SYSTEM SHUTDOWN____________________________________________4
5. PERFORMANCE MONITORING ____________________________________5
6. CLOGGING ____________________________________________________6
7. STORAGE OF COMPONENTS_____________________________________8
8. INTERRUPTIONS IN AIR SUPPLY __________________________________8
9. DISASSEMBLY AND REASSEMBLY OF THE DIFFUSERS ______________9
10. REMOVING THE DIFFUSER FROM PIPE AND REINSTALLING IT _______10
11. TROUBLESHOOTING___________________________________________11
11.1 Compressor Pressure Increases, Yet Insufficient Process Air Supply___________11
11.2 Air Consumption Increases while BOD Remains Constant ____________________11
11.3 Large Bubbles or Clusters of Bubbles _____________________________________12
11.4 Dead Spots in the Aeration Basin _______________________________________12
11.5 Local Oxygen Depletion in the Aeration Basin ______________________________12
1. CONTENTS
These instructions apply to NOPOL

DDS PIKE aeration systems where PIK 300
diffusers are installed on PP piping. For the purposes of this manual, the aeration
system means the NOPOL
DDS aeration system designed for installation on

the floor of an aeration basin. The system converts aeration air into fine bubbles.
For any wastewater treatment plant, aeration is an essential and the most costly
single process in terms of energy consumption. From the point of view of aeration,
the system should be monitored for the following:
- airflow rates
- blockage of diffusers
- leaks
The warranty given by the manufacturer will be valid only if the instructions
given below are followed.
2. PERMISSIBLE AIR FLOW RATES
Air flow rates must be maintained within the limits shown in Table 1.
Excessively high air flow rates may damage the diffusers. In the worst case,
membranes may be torn. Whatever the case, the service life of membranes suffers
as a result of overload.
Normally, membrane diffusers are not blocked even at low air flow rates, but air may
be unevenly distributed within the group. Also air distribution pattern among the
various groups may change if the supplied air volume cannot be specifically
regulated to each group.
Table 1: Permissible air flow rates per diffuser (20 C, 101,325 kPa)
minimum
(Nm
3
/ h)
normal
(Nm
3
/ h)
maximum
(Nm
3
/ h)
PIK 300 0.5 5 8
* These rates must not be exceeded by more than 25 % even during short time (max 15 min) peak loads.
In theory due to the structure of the membrane diffuser, the lower limit for the
adjustment range is zero. However, to ensure uniform air distribution, a lower limit of
0.5 m
3
/h is recommended.
In some circumstances it is advisable to use lower maximum values for air
flows in order to extend the service lifetime of the rubber membrane. Use
lower air flows if,
- wastewater contains chemicals which may harm the properties
of the membrane
- water temperature exceeds 30 C
- aeration air temperature exceeds 60 C
The maximum air temperature for PIK 300 diffusers in 100 C.
3. COMMISSIONING
3.1 Before Commissioning
Before commissioning, check the aeration system with care and carry out a leak test.
Also ensure that there are no corrosion products or sludge inside the piping that
may block the diffusers. Condensed water in the piping must be removed via the
drainage system.
If the system is not put into operation immediately after installation, the basin must
be filled with water so that the water level is at least one metre above the diffusers.
(Figure 1). Water protects the diffusers against UV radiation, sub-zero temperatures
and dirt.
Figure 1: When the system is not in operation, the water level must provide at least a
one-metre blanket above the diffusers
3.2 Filling the Basin
- Aeration must remain switched on throughout the filling operation
As the basin is filled up, adjust the air supply rate in response to the
backpressure caused by the rising water level. The maximum air flow rates
given in Table 1 must not be exceeded at any point during the filling process.
- Beware of ice
At low outdoor temperatures, ice may develop on the basin floor. Floating ice
may damage the aeration system or other structures in the basin.
- Fill the basin carefully
A strong current may damage the aeration system or its support structures.
- Watch the system during filling
If any leaks or other defects are detected, stop filling and repair the defect.
- When the basin is full, remove condensed water by alternately opening
and closing each water drainage valve
- Adjust aeration according to process conditions
4. SYSTEM SHUTDOWN
If aeration is discontinued for a period of over two weeks, drain and clean the basin.
Draining the aeration basin:
- Cut off waste water supply and return sludge flow to the basin
- Keep aeration on while the basin is being drained
Continued aeration prevents the silt from depositing during drainage.
- Throttle air supply as water level drops
As the basin is drained, adjust the supply air flow rate according to the back-
pressure caused by the descending water level. Never exceed the maximum
air flow rates shown in Table 1.
- Beware of ice
If the aeration has been switched off before the basin is drained, there may be
a blanket of ice in the basin. Do not drain a basin if there is any ice in it
because ice may damage the diffusers or bend the pipes.
- Clean the diffusers
Cleaning prevents dirt from drying and hardening on the diffuser surface. If
the aeration basin is out of use for more than 48 hours, it is advisable to clean
the basin and piping to avoid odour problems. The inside of the piping can
also be cleaned by removing the water collection pipes and the zone headers
of each group.
- Check the condition of the system
Pay special attention to gaskets and seals.
- If the shutdown lasts over two weeks, fill the basin with clean water. To
protect the diffusers, make sure that there is at least one metre of water
above the diffusers
The layer of water will protect the diffusers from UV radiation from the sun.
Add some suitable algaecide during warm seasons.
5. PERFORMANCE MONITORING
The indicators to be watched during aeration include:
- air compressor - energy consumption
- condition of the filter
- maintenance
- aeration basin - water temperature
- oxygen content
- water quality
- maintenance
- aeration - uniformity of bubble pattern and size
- back-pressure
- airflow rates
- condition of air supply piping joints and valves
- supply air temperature
- outdoor air temperature
- maintenance
- downtime
- quantity and quality of condensed water (check
this once a week)
- quantity of coagulants fed into the system
To ensure correct diffuser operation, the air compressors must be properly
monitored as well as maintained. Blocked or defective suction filters can lead to a
blockage of the diffuser suction side. Monitoring the compressor energy
consumption also gives an indication of the condition of the aeration system and any
blockages. When diffusers are blocked, back-pressure and energy consumption
increase.
Other factors that affect the performance of the aeration system are the temperature
and quality of the water in the basin as well as the amount of maintenance carried
out. Oxygen depletion, over-aeration or increased energy consumption can also be
due to changed loads or the composition of the waste water.
Condensed water must be drained from the piping on a regular basis. The amount
and quality of the condensed water gives an indication of the condition of the
aeration system. Usually the condensed water is clear. If the amount of condensed
water is high and the water is dirty, there is probably a leak in the aeration system.
6. CLOGGING
The diffusers may become clogged on either side (air or water) of the disc or
membrane.
Clogging on the air supply side can be due to:
- impurities in the supply air
- poor condition of the compressor air filter
- failure of the compressor silencer
- pipe corrosion
- pipe breakdowns
- welding debris in the piping
- leaks in piping through which solids can enter the system
Clogging on the fluid side can be due to:
- chemical deposits such as iron, calcium, magnesium
- oil or grease contained in waste water
- organic solids, fine silt or sand
- slime build-up on the diffuser
If the BOD of the activated sludge is high, blockage may be accompanied by slime
build-up on the diffuser surface (at the front end of a plug-flow basin, industrial
waste water). Slime build-up alone does not increase back-pressure but it reduces
aeration efficiency as the bubbles get bigger.
When diffusers become clogged:
- back-pressure in the aeration system increases
- As a result of increased back-pressure, electricity consumption per kg
of oxygen supplied into the water usually increases.
- The bubble pattern may become uneven.
- If a diffuser is nearly completely clogged, the membrane may be
damaged if air is forced through it.
When diffusers become clogged, back-pressure increases slowly. If back-pressure
changes quickly, it is usually due to a blockage in the air supply header or in some
valve etc.
To clean clogged diffusers, use one of the four following methods:
- Drain the basin and clean the diffusers in the system using a brush or
high-pressure cleaning.
- Drain the basin and remove and clean the diffusers one by one.
- Activate the NOPOL
CLEAN system during operation.

- Lift the group out of the basin and clean the diffusers one by one.
Air bumping can also be used to prevent clogging and to clean diffusers with a small
pressure increase. Bumping is carried out by increasing the air flow from the
minimum acceptable to the maximum acceptable value for the diffuser (see Table 1).
The air bumping procedure must not be carried out for badly clogged diffusers (>
300 mm pressure increase). If airflow is increased rapidly and diffusers are clogged,
they might be damaged.
The patented NOPOL
CLEAN system uses the dilute formic acid as a cleaning

agent. The acid is dispensed as a spray into the dropleg (Figure 2). The formic acid
dissolves any blockages during operation so that the basin need not to be drained
or the diffusers removed.
NOPOL
CLEAN is a procedure that results in energy savings, because the

diffusers can be cleaned when a lower increase of back pressure is reached
compared with other methods and at the same time as the normal aeration process
in ongoing. Cleaning with NOPOL
CLEAN should be carried out when back

pressure increases by about 20 mbar. If the diffusers are cleaned by other methods,
it is necessary to clean them when back pressure increases by 50 mbar above the
original value.
If a complete set of membrane discs for one basin are stocked at the plant, any
soiled diffusers can be replaced immediately in connection with cleaning. As a
result, the interruption in operation will be shorter and soiled membrane discs can be
cleaned as and when it is convenient.
Figure 2: NOPOL

7. STORAGE OF COMPONENTS
Membrane discs HIK 300 should be stored at room temperature in closed boxes
protected from sunlight. Make sure that the membranes do not get stuck to one
another by inserting a piece of cardboard between each of them.
Plastic components must be stored at room temperature protected from direct
sunlight. Make sure that the parts are not deformed or subjected to any loads.
8. INTERRUPTIONS IN AIR SUPPLY
A short interruption in air supply does not cause problems.
If the air supply has been off, the system back-pressure must be checked. If the
back-pressure remains permanently above the cleaning limit, the diffusers must be
cleaned, for example by using acid cleaning. With the NOPOL
CLEAN method, the

system should be cleaned when back-pressure increases by 20 mbar. With other
methods, the limit is 50 mbar.
During an extended stoppage, a bio-film may build up on the diffuser surface. To
remove it, it is necessary to drain the basin and clean the diffuser discs one by one.
When restarting the system, be careful. During an interruption in air supply, sludge
deposits on the diffuser surface. It is also possible that water has entered the
aeration system. If the system is restarted too quickly, the diffusers may be
damaged. Air supply should always be started softly, that is with small air flow
which can later be increased gradually.
9. DISASSEMBLY AND REASSEMBLY OF THE DIFFUSERS
At low temperatures (below +5 C) polypropylene becomes brittle. Special care must
be taken when ambient temperature drops below 10 C. Recommended ambient
temperature for disassembly and reassembly of the diffusers is above +15 C.
- Detach screw-on ring PKR 300 by turning it with tool PKLAT 300 (Figure 3).
The required turning angle is 15 counter-clockwise. The screw-on ring,
sliding ring and membrane can now be removed. The main body remains on
the pipe.
- Clean the upper part of the main body, the sliding ring and the screw-on ring.
- Replace defective parts with new ones.
- Clean and check the non-return valve and replace it if needed. The body of
the non-return valve is attached to the main body by a snap-in-place junction.
- Place the membrane centrally to the main body.
- Install the sliding ring and the screw-on ring top of the main body.
- Tighten the screw-on ring with tool PKLAT 300
PKLAT 300 Small PKLAT 300 Big
Figure 3: Special tools for the PKR 300 screw-on ring
10. REMOVING THE DIFFUSER FROM PIPE AND REINSTALLING IT
The diffuser can be detached from the pipe by forcing the wedge piece PSK 90 at
the locking knob while at the same time knocking the wedge piece with special tool
TWP 90 to the direction opposite to the arrow (Figure 4).
Figure 4: Removing the PIK 300 diffuser with the help of the TWP 90 tool
Once the diffuser is removed, check the hole, saddle piece and seal and reinstall the
components (Figure 5). The hole must be cleaned if needed and any defective parts
must be replaced. When reinstalling the wedge piece, lubricate the pipe from
underneath with soap solution to ensure fluent gliding.
Figure 5: Attaching PIK 300 diffuser to the pipe with TWP 90 tool
11. TROUBLESHOOTING
A number of common malfunctions and their potential causes are listed below. Note
that malfunctions in aeration may be due to factors other than the system itself, such
as the plant load, condition of air compressors, control valve operation, oxygen
sensor performance, etc.
11.1 Compressor Pressure Increases, Yet Insufficient Process Air Supply
Check the diffuser back pressure. Clean the diffusers.
2. Malfunction of air flow control valve.
Check valve operation and repair any defects.
3. Compressor air filter clogged.
Check pressure across the filter. Replace or clean the filter according
to the manufacturers instructions.
11.2 Air Consumption Increases while BOD Remains Constant
1. Actual oxygen content of the basin is greater than the setting.
Check and calibrate the oxygen sensors.
2. Air escapes from the headers.
Check the piping for leaks and make the necessary repairs.
3. Air consumption per kg of BOD increases.
The system is running at longer sludge retention times than assumed.
Check back pressure. Clean the diffusers.
5. Intense nitrification.
Check load and sludge retention time.
6. Oxygen transfer performance impaired.
Diffusers are too old. The bubble producing parts should be replaced.
7. Reject water load not taken into account.
Check the additional load caused by reject water.
11.3 Large Bubbles or Clusters of Bubbles
1. Slime build-up on diffusers.
Slime build-up can be prevented by re-arranging water supply or
cleaning the system regularly with formic acid.
2. Pipe leakage or broken or leaking diffuser.
Drain the basin, check the system for leaks and replace any defective
parts.
11.4 Dead Spots in the Aeration Basin
1. Insufficient air flow rate.
Make sure that the air flow rate for the zone or the entire basin does
not fall below the recommended minimum air flow rate. Check and
calibrate the air flow meters.
2. Diffusers completely clogged.
Drain the basin. Clean or replace porous discs or membranes.
3. Non-uniform air distribution in the basin.
Adjust the air distribution valves to ensure uniform supply air
distribution across the basin.
11.5 Local Oxygen Depletion in the Aeration Basin
1. Organic loading is unevenly distributed or air distribution is
incorrect.
Adjust air distribution or add diffusers in the depleted area.

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Copyright: Nopon Oy 2002. Printed in Finland.

DDS 0501 ENG 195052

DDS: Installation, operation and

PIKE Installation, operation and

DDS systems consist of one or several aeration groups. Each group is

DDS system is complete including all necessary

DDS systems for various applications. The HKLE,

DDS systems and diffusers

DDS AERATION SYSTEMS

DDS aeration systems is valid for 12

DDS systems are manufactured of

DDS systems are

HPK210 D88,9 EUROPE

PIK 300 Membrane Disc Diffuser has an elastomeric membrane with

PIK 300 diffuser are recyclable.

PIK 300 diffuser is suitable for normal continuous aeration systems as

CLEAN). Lifetime of the membranes in normal activated

PRK 300 Diffuser is especially suitable where intermittent aeration is

CLEAN). Lifetime of the membranes in normal activated

KKI 215 Diffuser is suitable where intermittent aeration is required,

CLEAN). Lifetime of the membranes in normal activated

Diffuser Discs. The material is pure

Porous Diffuser Discs

CLEAN method. The cleaning liquid, formic acid, is fed into

Diffuser Discs. The material is pure

Porous Diffuser Discs

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN formic acid cleaning system

CLEAN system is formic acid, which is an ideal chemical

CLEAN system, it is advisable to

CLEAN manual Date 7.5.2001

CLEAN cleaning during operation

CLEAN system, it is advisable to clean the diffusers whenever back pressure

CLEAN manual Date 7.5.2001

CLEAN inhibits slime formation

CLEAN washing or cleaning one by one

CLEAN washing or cleaning one by one

CLEAN inhibits slime formation

CLEAN manual Date 7.5.2001

CLEAN equipment is shown in the

CLEAN manual Date 7.5.2001

CLEAN is supplied complete with the following:

CLEAN manual Date 7.5.2001

CLEAN acid cleaning system, flow chart

CLEAN manual Date 7.5.2001

CLEAN system, it is advisable to clean the diffusers frequently and whenever

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN is supplied, the knob is

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN manual Date 7.5.2001

CLEAN system components and NOPOL

CLEAN system is supplied complete with the following protective gear:

DISC DIFFUSER AERATION

DISC DIFFUSER AERATION SYSTEM

DDS aeration system designed for

mm when using PVC or steel pipes. PIK 300 with flat

mm when using PVC or steel pipes. All new

Aeration Systems should be sent to