An In House Phased

Approach for Final Clarifier

Rehabilitation
Providing a high level of sanitary benefits to the communities we serve.

Angel Rivera
Superintendent of Mechanical
Maintenance
Providing a high level of sanitary benefits to the communities we serve.

History of the Buffalo Sewer Authority

When Buffalo was established as a village, all
waste was disposed in adjacent bodies of water.
In the 1890s, health officials agreed that the
pollution to the adjacent bodies of water was
responsible for many diseases, most notably,
typhoid.

Slide 3

Because of persistent pollution on the Niagara

River, Canada and the US entered into a treaty
in 1909 to protect boundary waters.

History of the Buffalo Sewer Authority

Slide 4

Bird Island prior to the construction of the WWTP

History of the Buffalo Sewer Authority

In 1935, the New York State Department of Health
mandated the City of Buffalo to stop polluting the Niagara
River with waste. Because the city was in financial turmoil
at the time, a new authority was created the Buffalo
Sewer Authority.
By 1938, the Authority completed its system of
intercepting sewers, and built its primary treatment plant
on Bird Island where all city sewage was treated.
This start of the art Primary Sewage Treatment Plant:

Removed and incinerated all solid matter.

Chlorinated all liquid matter prior to discharging into the

Niagara River
Slide 5

History of the Buffalo Sewer Authority

Slide 6

Bird Island Primary Treatment Plant in 1938

History of the Buffalo Sewer Authority

With the increasing national awareness of the need to
more fully protect our water resources, the State in 1966
directed further improvement of our facilities by providing
secondary treatment.
With the help of federal and state grants, secondary
treatment facilities were constructed and placed in service
by 1981.
Continual process improvements and upgrades
Examples of Major Capital Improvements since 1981
Fine Bubble Diffuser and Blower Re-rating Project

WWTP SCADA System

New Grit Removal & Disposal System

Sludge Dewatering Centrifuge

Slide 7

History of the Buffalo Sewer Authority

Slide 8

Bird Island Primary Treatment Plant 1980s & 90s

Angel Rivera

Superintendent of Mechanical Maintenance

Supervise and coordinate all activities of the Maintenance Department at the
Buffalo Sewer Authoritys Bird Island Wastewater Treatment Plant (WWTP).
Responsible for the upkeep and repair of all equipment, utilities, buildings and
grounds at the WWTP and eleven (11) Remote Pumping & Metering Stations.
Implemented capital projects totaling over $8 million in a 6 year period, including:
Installation of sludge withdrawal equipment on 16 clarifiers, $2.2 million project.

Cleaning of two large (1 million gallon) anaerobic digesters, $1.7 million project.

Rehabilitation of South Buffalo Pumping Station, $1.5 million project.

Annual Rehabilitation of 3 WWTP Incinerators, $1.2 million in total projects.

Rehabilitation of motors and impellers on three 3000/5000 HP blowers,

$900,000 project.

Rehabilitation of 2-550 HP RWWP and 2-1850 HP SWWP Pumps $300,000

Re-tubing of Natural and Digester Gas Fired Boilers, $150,000 project.

Rehabilitation of Substation and Switchgear, $150,000 in total projects.

Slide 9

Final Clarifiers
Whats Their Purpose

Improve Effluent Quality

Provide a means for solids and floatables to separate

from the forward flow and be collected

Main Components
Method of Settled Solids Removal

Inlet Arrangements

Method of Scum Removal

Drive Units

Slide 10

Final Clarifiers at the Bird Island WWTP- 2001

Quantity: 16
Diameter: 130 feet
Depth: 12 @ Side-Wall, 12.5 @ Tank Center
Total Average Design Flow: 180 mgd
Total Peak Design Flow: 360 mgd
Type Design: Riser Pipe
OEM: FMC (US Filter / Siemens Water Technology)
Slide 11

Approximate Age: 25 Years (Installed in 1975).

Final Clarifiers at the Bird Island WWTP

Slide 12

Final Clarifiers at the Bird Island WWTP

Slide 13

Rise Pipe Pier Supported Type Clarifier

Diameters larger than 30 feet

Slide 14

Riser Pipe Clarifier Sludge Withdrawal Flow

Slide 15

Riser Pipe Clarifier Sludge Control Box

Riser Pipe
Control

Slide 16

Final Clarifiers at the Bird Island WWTP

Slide 17

Existing Peripheral Feed & Overflow

Influent
Flow
Sludge Box

Slide 18

Sludge to Center Drain

Effluent
Wastewater
Flow

Existing Peripheral Feed & Overflow

Influent
Flow

Effluent
Flow

Slide 19

Final Clarifiers at the Bird Island WWTP

1998 Field Evaluation of Secondary Clarifiers By John Esler, P.E.
Conclusion:

Moderate short circuiting up to a flow of 11 mgd

High sludge blankets and direct short circuiting at higher flows

At all flow rates, high degree of rotational stirring, creating instability at

the tank periphery and retarding the inward current

Recommendations:
Reduce rotational rate.

Reconfigure sludge pipes to lay horizontal on collector frame.

Replace variable sized return sludge tubes.

Control individual sludge tube flow in center RAS box with new control
valves (twist turn orifice terminals).

Slide 20

Final Clarifiers at the Bird Island WWTP

Drive Unit
24 minutes
per revolution

Pipes Create
Wall Effect
Mass Rotation

Sludge
Box Flow
Control
One of five
pipes
plugged
At least
20% floor
not picked
up

Slide 21

Final Clarifier Rehabilitation December 2001

December 2001

Final Clarifiers 7B & 8B Out of Service Due to Drive

Failures and Structural Misalignment.

The Structural Integrity of Truss Arms, Center Cage and

Center Pier on both units are in question.

Treatment Plant Maintenance unable to repair units

utilizing available parts, supplies and equipment.

US Filter (FMC) brought on site to inspect the condition of

the remaining 14 tanks.

Drives on 7 of the remaining 14 tanks in determined to be

marginal condition (Replacement gap setting >0.375).
Slide 22

Final Clarifier Rehabilitation December 2001

Slide 23

Final Clarifier Rehabilitation December 2001

Slide 24

Final Clarifier Rehabilitation December 2001

Slide 25

Final Clarifier Rehabilitation

Repair of Final Clarifiers 7B & 8B Choices?
Replace existing drive unit.

Inspect and repair all failed structural components.

High Cost repair with no improvement in performance.

No guarantee that remaining components will not fail in the near

future.

Reliability of remaining Final Clarifiers unknown.

Continual high maintenance cost for existing Final Clarifiers

Constant withdrawal tube plugging
Repairing damaged to collector piping, boots, wipers and
supports.
Long draining and cleaning time.

Slide 26

Proposed Repairs to Final Clarifiers 7B & 8B

Use crane to remove
bridge & Railing

Separate arms from center cage.

Inspect and repair structural damage.

Use crane to remove

and replace Center
Drive Unit
Inspect and
repair:
Center Pier,
Sludge Box
and Center
Cage.

Repair or replace all damaged piping,

boots, wiper blades, piping support.
Slide 27

Proposed Repairs to Final Clarifiers 7B & 8B

Re-attach and rebalance arms.

Adjust and level rotating plane.

Slide 28

Final Clarifier Rehabilitation

December 2001 - Meet with US Filter rep to discuss
purchase of new Sludge Withdrawal Equipment.
Presented with a proposal for two new Tow-Bro Header
Sludge Withdrawal mechanisms, including:
Unitube sludge removal headers and supports

H40Ht Drive Unit w/ Reducer, Motor and Overload

Drive Platform

Center Pier

Skimmer Assembly

Associated Bolts and Anchors

Structural Steel Hot Dip Galvanized

Slide 29

Tow-bro Clarifier Design

Slide 30

Tow-bro History and Development

Tow-bro developed in 1920s by Darwin Townsend and
James Brower.
Envirex, as Rex Chain Belt, installed the first Tow-Bro in
1929.
Refinements to design resulted in Unitube header
developed in 1955 by Envirex
To date over 2500 Tow-Bro clarifiers installed.

Slide 31

Tow-Bro Header
Peripheral Feed & Overflow

Slide 32

Tow-Bro Header
Drive Unit
33.3 minutes
per revolution
Unitube Header with
23 Withdrawal Points

21 x 21 Manifold Inlet

Approximate 2 Horizontal Profile

Slide 33

Exiting Riser Pipe Final Clarifiers

Drive Unit
24 minutes
per revolution

Sludge Box
Largest Inlet
Pipe 8

Only 5 Withdrawal Pipes,

Horizontal Pipe Arrangement

Approximate 5
Horizontal Profile

Slide 34

Sludge to Center Drain

Existing Peripheral Feed & Overflow

Influent
Flow

Effluent
Flow

Slide 35

Existing Peripheral Feed & Overflow

Influent

Effluent

Flow

Flow

Sludge
Box

Slide 36

Sludge to Center Drain

Tow Bro H-drive

Slide 37

Tow-Bro Strip Liner Drive Unit

Slide 38

Riser-pipe Ball Race Bearing

Felt Bearing
Race Cover

4 pt. Ball
Bearing

Slide 39

Oil Bath

Circular Clarifier Drive Units

Bearing Arrangements

Strip Liner

Riser-Pipe Ball Race

Bearing (4-Point)

Slide 40

Tow-Bro H-Drive
Bearing

4 Pt. Contact

Tow-Bro H-Drive
Bearing Arrangements
Strip Liner
Split Gear
Field Inspection of bearing
38 to 42 Rc
Can be rebuilt, in-place, in the
field
Low Cost, quick delivery
Keeps working after failure
Slide 41

Tow-Bro H-Drive Replaceable Strip Liner

Replaceable
Strip Liner

Main
Gear

Slide 42

Tow-Bro H-Drive Replaceable Strip Liner

Main Gear Split for On Site Disassembly

Slide 43

Riser-Pipe Ball Race Bearing

4 Point Contact
Higher Hardness
Higher Loads
Factory Repair Only
Requires Crane and Lifting of
Bridge
Locks up with Failure

Slide 44

Circular Clarifier Drive Units Main Bearing Failures

Condensate, water, produces oxidation, rust

High carbon content of the balls, races oxidize very

quickly

Oxidation leads to surface pits

Surface pits lead to stress risers

Stress risers lead to critical shearing stress

Broken balls

Slide 45

Circular Clarifier Drive Units

Main Bearing Arrangements

Oil Lubricated

Water Lubricated
Slide 46

Passive Automatic Condensate Drain System

The Drive is Equipped with piping that allows any
Condensate that would otherwise accumulate in the
main Drive Housing to drain out.
The difference in Specify Gravity between water and
lubricating oil used in drive is the principle upon the
system functions.
Note: Successful operation of the system depends
upon the sequence of filling the drive housing
initially and every time periodic maintenance is
performed.

Slide 47

Note: Heat Trace required for operation during

periods of below freezing temperature.

Passive Automatic Condensate Drain System

Slide 48

Main Tank Skimmer Assembly

Scum Blade Length
From Center to Side of Tank

Slide 49

Main Tank Skimmer Assembly

Slide 50

Tow-Bro Benefits for Final Clarifiers 7B & 8 B

New drive, collector, and structural components.

Reduced rotational rate, less stirring of the FC tank.

Lower header profile.

Increased number of withdrawal points, reducing

the effect of plugging.

Removal of Sludge Box

Passive Automatic Condensate Drain System

Downside - Real World Performance at BSA

Unknown?

Slide 51

Final Clarifier Rehabilitation December 2001

Final Clarifiers 7B and 8B Out of Service and Cleaned by
Maintenance for Repairs by 12/4/01.
Maintenance begins initial repairs to both tanks. Discovers
structural damage to drive unit, truss arms, center cage and
sludge box.
Contact US Filter for preliminary budgeting information regarding
the replacement Drive Units. Request on-site inspection and
evaluation of remaining 14 FC tanks.
US Filter on site on 12/10/01 for tank inspection.
US Filter submits proposal for Tow-Bro equipment
Slide 52

Final Clarifier Rehabilitation Dec 2001 to Jan 2001

Maintenance Department reviews and evaluates proposed
equipment. Contacts references and validates past
performance claims.
Maintenance Department works with Process Department to
determine design flows.
Maintenance Department presents findings to BSA management
(General Manager, Financial Officer, Plant Manager).
BSA management agrees with finding and BSA Board is polled
for approval.
January 9, 2002 - BSA Board Approvals purchase of Tow-Bro
Headers for a not to exceed price of $195,000.00
Slide 53

Final Clarifier Rehabilitation Jan 2001 to Feb 2001

Maintenance Department develops final purchase specifications.
January 4, 2002 Maintenance submits purchase specs for
design of new Tow-Bro system.
January 25, 2002 Maintenance Department reviews and
approves arrangement plan and elevations for 2 new Tow-Bro
Sludge Collectors
January 29, 2002 US Filter releases the design for fabrication.
February 5, 2002 Meet with Mechanical Maintenance
Contractor Quackenbush (Q Co.) to review installation
requirements for 2 new Tow-Bro Sludge Collectors
Slide 54

Final Clarifier Rehabilitation Feb 2001 to March 2001

February 18 2002 Q. Co. submits proposal for Tow-Bro
installation under the terms of the existing Maintenance Contract.
Proposal reviewed by maintenance and submitted to BSA
Management for approval.
Approximate cost for installation of Tow-Bro equipment on both
tanks $70,000.
February 27, 2002 BSA Board approves Q. Co, proposal for a
not to exceed cost of $70,000.
March 4, 2002 US Filter begins shipping Tow-Bro components
Slide 55

March 18, 2002 Q. Co mobilizes on-site and begin receiving

major Tow-Bro components (Trusses, Headers, Drive Unit)

Final Clarifier Rehabilitation March 2001 to July 2001

March 22, 2002 Last major Tow-Bro components ships from US
Filter fabrication shop.
March 22, 2002 to May 24, 2002 Q. Co proceeds with
installation of Tow-Bro equipment in Tanks 7B & 8B. Maintenance
Department supervises and inspects all work by contractor.
May 27, 2002 US Filter and Maintenance Department complete
the start-up and testing of completed units. Both units on-line by
first week in June.
June 2002 to July 2002 Both units in service with Plant
Operations.
July 24, 2002 Performance Testing by CPE Services begins.
Slide 56

Final Clarifier Rehabilitation Construction Photos

Slide 57

Final Clarifier Rehabilitation Construction Photos

Slide 58

Final Clarifier Rehabilitation Construction Photos

Slide 59

Final Clarifier Rehabilitation Construction Photos

Slide 60

Final Clarifier Rehabilitation Construction Photos

Slide 61

Final Clarifier Rehabilitation Construction Photos

Slide 62

Field Verification Study - Goals

July 2002, CPE Service Inc. (John Elser, P.E.) hired to Study
performance of new Tow-Bro verse existing Riser-Pipe
Field investigation designed to a accomplish the following:

Develop flow curves and determine detention times

Determine location and intensity of major currents using velocity

profile test and full-depth solids profiles.

Determine Theoretical solids loading capacity of each clarifier

using solids flux / state point analysis

Characterize the relative performance of the two clarifiers.

Slide 63

Field Verification Study Conclusions

Tow-Bro clarifier develop the inward flow pattern that is
desirable for peripheral feed / peripheral overflow clarifier.
Tow-Bro clarifier maintained a lower blanket further assisting
the inward flow pattern.
Tow Bro better controlled sludge blanket as flow rates
varied.
Tow-Bro was able to operate at significantly higher flow rate
that the existing Rise-Pipe.
Two-Bro able to maintain a more concentrated return
activated sludge flow that existing Rise-Pipe.
Slide 64

Phased Approach for Final Clarifier Rehabilitation

Based on documented performance of the new Tow-Bro system the BSAs
management developed a phased approach to rehabilitating the remaining
14 final clarifiers.
A preliminary plan calling for the rehabilitation of the remaining clarifiers at
a rate of four clarifiers per year was submitted as part of the BSAs Annual
Capital Improvement Plan.
Equipment purchase and installation funded annually based on savings
and rollover of operating funds from previous budget years.
Tow-Bro equipment purchased by Maintenance directly from the
manufacture US Filter as funding became available.
All purchase specification developed by Maintenance Department without
the use of outside consultants
Slide 65

Phased Approach for Final Clarifier Rehabilitation

Installation contract developed by and bid annually by the BSA
Maintenance and Engineering Departments.
Contract installation requirements developed by Maintenance
Department without use of outside consultants.
All contract equipment, supplies and labor inspected directly
by Maintenance Department.
Rehabilitation of tanks based on severity of existing tank
conditions (i.e. Worst Tanks First).
Installation contract revised annually, prior to bidding, to
address problems encountered in previous years contract (i.e.
Change Orders, Contract Clarifications, Etc)
Slide 66

Phased Approach for Final Clarifier Rehabilitation

Start
Year

Final
Clarifiers

Purchase
Cost

2002 7B, 8B

Installation
Cost

Total Project
Cost

Per Unit
Cost

$195,000

$74,463

$269,463

$134,731

$142,320

$477,008

$119,252

2003 3A,4A,4B,6B

$334,688

2004 2A,7A,8A,1B

$334,688

$151,200

$485,888

$121,472

2005 1A,5A,2B,5B

$387,834

$151,800

$539,634

$134,909

2006 6A,1B

$194,000

$261,790

$455,790

$227,895

$781,572

$2,227,782

$139,236

Cost to Date

$1,446,210

Slide 67

Footnotes:
1. Equipment price held for 2 years at $83,667 per FC.
2. Price increase to $97,000 per FC due to escalating Steel Price.
3. Installation Completed without Change Orders.
4. First project to include Weir Wall Rehabilitation

Phased Approach for Final Clarifier Rehabilitation

Installation Contract revision include the following activities:

Material Disposal

Electrical Connections

Floor leveling and concrete breakouts

Scum trough piping.

Weir Plate Adjustment

Weir Plate Pipe Support Replacement

Sandblasting and Painting of all Metal Surfaces in Final Effluent Tank.

Slide 68

Phased Approach for Final Clarifier

Rehabilitation Photos

Slide 69

Upper Weir Wall Supports

Phased Approach for Final Clarifier

Rehabilitation Photos

Slide 70

Lower Weir Wall Supports (under skirt)

Phased Approach for Final Clarifier

Rehabilitation Photos

Slide 71

Rehabilitated Upper Weir Wall Supports

Phased Approach for Final Clarifier

Rehabilitation Photos

Slide 72

Rehabilitated Weir Wall

Phased Approach for Final Clarifier

Rehabilitation Photos

Slide 73

Rehabilitated Lower Weir Wall Supports (under skirt)

Phased Approach for Final Clarifier

Rehabilitation
Next Phase Weir and Tank Rehabilitation. Activities that may be
included are the following:

Weir Plate Adjustment

Weir Plate Pipe Supports both above and bellow Weir Skirt

Sandblasting and painting of all metal surfaces.

Final Clarifier Floor Coating (re-lining).

Repositioning of Inlet Channel flow holes

Raising of inlet channel wall to increase peak influent flow

Continue rehabilitation rate of 4 tanks per year.

Completion of all final tanks project to be completed by 2010
Slide 74

Special Thanks to the following:

James Skrabacz Maintenance Department
Roberta Gaiek P.E., Jane Ork Process Department
Sal LoTempio (Ret.), James Keller WWTP Superintendent
Frank DiMascio P.E., Joe Baudo (Ret.), Jim Eagan BSA Engineering
David Comerford BSA General Manager
Herbert Bellamy - Buffalo Sewer Authority Board Chairman
US Filter / Siemens Water Technology

Providing a high level of sanitary benefits to the communities we serve.

Angel Rivera

Superintendent of Mechanical Maintenance

Thank you very much for your attention.

Buffalo Sewer Authority

90 West Ferry St.
Buffalo, NY 14213-1799
Office:
(716) 883-1820 ext 217
Fax:
(716) 883-4922
E-Mail:
arivera@sa.ci.buffalo.ny.us

Providing a high level of sanitary benefits to the communities we serve.