Why stainless steel components for your Weir Cleaning system?
When we first approached Wastewater engineers with the Ford Hall Automated Weir cleaning design over 20 years, it was recommended that the Brush System for Clarifier Cleaning be made of stainless steel for durability and corrosion resistance. Stainless steel has become even more prominent in the Wastewater field, as of late, and Ford Hall Company recently upgraded all Weir-Wolf components to 316 stainless steel. This will allow us to maintain our leadership in the industry and guarantee our customers the highest quality in the highly corrosive wastewater field.
Why not aluminum components for brush system?
Aluminum is not as sturdy as Stainless steel. We also found that in colder climates the weight of the automated cleaning brush system combined with the weight of snow and ice causes an alumium system to bend; thereby, causing damage to the Automated Weir cleaning system, the skimmer arm and/ or even the clarifier drive. A stainless steel Weir Cleaning system is sturdier and more reliable, giving a customer years of trouble free service.
What is the life of the Brushes?
There are many variables that affect the life of the brushes for the Weir Cleaning systems. Frequency of use, diameter of the clarifier, linear feet the brushes travel, speed of skimmer revolutions, spring tension and roughness of the surface to be cleaned, all affect the life of the brushes. The Ford Hall Company brushes average 12 month (1 year) with continuous use 24 hours per day 7 days a week. However, the Ford Hall Weir-Wolf system has the ability to be "locked in" and "locked out"; thereby, allowing our customers intermittent cleaning and even longer brush life. In some cases, customers have seen brush life extended to as long as 4 years for one set of brushes with intermittent use. Continuous use usually requires changing out the brushes once annually.
Why have the "lock in and lock out ability" on the Automated Weir cleaning system?
Some customers are concerned with addressing safety issues or wasted man hours associated with manual cleaning of the weirs, baffle and launders but other customers are concerned with sampling, BNR readings, other equipment after the clarifiers and appearances of the tanks. With this in mind, a customer concerned about safety or man hours can lock out the brush system from time to time. While those concerned about TSS, sampling, BNR readings, UV systems, screens or filters after the clarifiers and appearances can engage their Automated Weir Cleaning systems 24 hours per day, 7 days per week.
What about torque and amp issues on the clarifier arm caused by the Clarifier Cleaning System?
Testing of the Ford Hall Weir-Wolf system on clarifiers show no noticeable increase in the torque of the clarifier drive motor. The amp reading maintained a constant measurement with and without the Brush Cleaning system.
How is the Automated Weir Cleaning Brush system powered? Will the Weir Cleaning unit add to my monthly expenditures?
The Automated Weir and Clarifier Cleaning system is attached to the skimmer arms of clarifiers, either as a retrofit or as part of a new / rehabbed clarifier project.
With no measureable amperage increase detected with the installation of the Weir-Wolf system, the Weir-Wolf system, in many parts of the US, is considered "green technology". The Weir-Wolf system takes advantage of the skimmer as it travels around the clarifiers with negligible increase in energy consumption and has no effect on the clarifiers drive motors.
What affect does winter have on the operation of the Brush system for Clarifier Cleaning?
Cold conditions do not have an adverse effect on the Automated Sweeps. This is not the case with Automated Spray Systems which use water and cannot be used in colder climates or in the winter months. However, in extreme icing, the brush system should be locked out.
If a unit jams or hangs up, what kind of safety precaution does the Weir-Wolf system have?
While hang ups are extremely rare, the Weir-Wolf has added an Shear SafetyTM component installed in each Brush holder which will allow the brush holder to break free instead of catching. This will eliminate further damage to the Weir Cleaning system, the skimmer arm or the clarifier drive.
How much does a set of replacement brushes cost?
A price for a set of brushes varies between $200 to $250.00 PER SET. (A set usually consist of 13 to 15 brushes). Brush cost is based on total linear inches of brushes.
We currently have 4 brushes that are made of 2 different materials that are UV resistant and Wastewater approved. Each is color coordinated to allow for easy distinction based on materials and bristle diameter: Ravenous Red, Attach Black, Bolder Brown and Mean Green. Brush specifications are available from the Ford Hall office.
Why not launder covers instead of Automated Brush Cleaning systems?
Many people think if they cover the effluent launders on their clarifiers they will eliminate Algae growth and accumulation on these surfaces. In reality, algae blooms start in the center of the clarifier where the "nutrient rich" water and sunlight meet. However, it is where the water exits the clarifiers (i.e. the weirs and launders) that the algae particles accumulate and build up. Launder covers usually only cover up the problem. Algae and non-algae debris will still accumulate on these surfaces; weirs, baffles and launders will still require manual cleaning; Total Suspended Solids (TSS) and Biological Nutrient (BN) sample readings will continue to be high or out of compliance. Furthermore, with the addition of launder covers, one creates access and compounds confined space issues and eliminates the ability to see the weirs, launders and your clarifier's flow which allows or may assist in diagnosing other problems at the Wastewater Plant. Lastly, Launder Covers are very expensive; usually 3 times the cost (material and labor) of a fully installed Weir-Wolf Algae Sweep systems.
Why not Spray Systems for Automated Weir Cleaning?
The Ford Hall Company completed much research on Automated Spray systems in the early 1990's but with less than pleasing results. We found that a Spray system would need multiple nozzles to be effective. With multiple spray nozzles being fed from one water line, a booster pump (and monthly energy consumption) would be required to adequately supply enough PSI to each nozzle to be effective. We also found the nozzles quickly clogged with debris and mineral build up. But most importantly, the nozzles cannot clean below the water's surface where much of the algae accumulation takes place (i.e. like between the baffle and weir and in the effluent channels or launders of the clarifiers and thickeners). Additionally, automated spray systems have to be drained off or go unused in the winter months in colder climates due to freezing, but clarifiers and thickeners still need to be cleaned during these months due to continued algae accumulations and non-algae accumulations such as grease, debris and solids which continue to build up.