Installation, Operation

& Maintenance Instructions

for:

FlexAirTM Magnum SDM

Pipe Mounted Diffuser
w/Orifice Plug

Diffuser Express is a Division of Environmental Dynamics, Inc.,

5601 Paris Road, Columbia, Missouri 65202
1-800-683-6099 E-mail: [email protected]
 Notice
This document and all information contained within is the
property of Environmental Dynamics, Inc. This document is
submitted under a confidential relationship specifically for the
recipient's use on a designated project. Reproduction of this
document or use of its contents in whole or in part without the
written permission of EDI is prohibited.
 Installation & Start-Up
• Installation of the FlexAir™ Magnum diffusers
• The FlexAir diffuser units are furnished completely factory assembled. The only work
required by the Contractor is the installation and placement of the diffuser units on the
laterals in the basin.
• FlexAir diffusers utilize rubber sheath membranes as the air diffusers media. EDI
recommends care in handling and storage to prevent tearing, puncturing or fouling of the
rubber membranes. If units are to be stored before installation, EDI recommends utilizing
the original unopened shipping cartons. Stored in a clean, cool location that avoids potential
mechanical damage.
• Air distribution through the FlexAir system is a function of the individual diffuser elevation.
For proper system operation, EDI recommends a leveling tolerance of ± 1/2” for the
diffusers. If the diffusers are mounted with excessive elevation tolerances, the airflow
distribution in the system will be adversely impacted.

Shipment/Storage of Equipment

• Upon delivery, check equipment for structural damage during shipment. Damages must be
reported to EDI within 10 days of delivery.
• All aeration system piping and diffusers must be stored in such a manner as to prevent any
deformation resulting from flexing, cracking or softening. Contractor shall insure that the
stored equipment is properly stacked to avoid warpage, has adequate cover and ventilation
to avoid exposure to the heat of the day or direct sunlight. EDI recommends utilizing the
original unopened shipping cartons.
Installation Instructions for FlexAir® SDM Diffuser Units with locking rib on
wedge.
Each duplex diffuser assembly consists of:
• One "Male" diffuser that has protruding alignment pins, a red “TOP” sticker applied near the wedge
ramp, and wedge retaining ribs at small end of ramp.
• One "Female" diffuser that has alignment slots, a red “TOP” sticker applied near the wedge ramp, and
wedge retaining ribs at small end of ramp.
• Two wedges with locking rib.
• Two o-rings.
• One alignment plug

Locking Rib

Interlocking Ribs

Other standard materials/tools required for installation include:

• Non-metallic mallet (not included by EDI).
• Bubble/laser level (not included by EDI).
Preparation for installing diffusers on air lateral piping:
1) Insure that the air laterals are installed with the orifice holes horizontal.
2) Locate the 1.0 inch holes in the lateral and place the alignment plug up to and centered on the hole.
Only one plug is required per pair of diffusers.

Note: The lateral will have two different sized holes. The smaller hole is the air flow orifice for one side
of the duplex diffuser and the larger hole is for the alignment plug.
3) Tap the plug into the lateral using a soft blow hammer and a short piece of 1.0 inch diameter dowel
(provided by EDI).

4) Ensure that the plug is correctly seated and was not damaged during the installation. Replace any plug
if damage occurred.
Installing of diffusers on air lateral piping:
5) Install O-ring immediately before saddle is to be installed on lateral. The o-ring is placed in the
internal groove. DO NOT USE ANY MASTIC OR OTHER ADHESIVE.
6) There are retaining bumps to hold the o-ring in place during installation. Note: The o-ring must be
able to move to seal when pressure is applied. Note: During cold weather installation, below 40°F
(4°C), it is advisable to keep the o-rings warm. One method is to place the o-rings in a bucket of
warm water.

7) Position the diffuser unit in the proper orientation (see table below) while positioning the alignment
plug to the center hole in the saddle. The plug fits into the saddle.

RED
Ear of “TOP”
Unit Type Perforation Clamp Sticker
MiniPanel On Top On Top On Top
Magnum On Sides On Top On Top
8) Note: Ensure that the saddles’ alignment pins mate properly when installing the opposing saddle
before sliding on the wedges. The red “TOP” stickers should face up.

9) Install the top wedge ¾ inch from being flush by hand.

10) Install the bottom wedge hand tight-approximately 3/4 inch (19mm) from being flush with the saddle.
11) Ensure that the diffuser assembly is in the correct location, level, and that each diffuser arm is in line
with the rest of the diffusers on the shared lateral.

12) Tighten the top wedge and bottom wedge EQUALLY with a non-metallic mallet or rubber faced
hammer. When properly tightened, each diffuser should be level and resist rotation. Note: Metal
mallets or hammers may crack or shatter the wedge assembly or damage the unit. Do not use metal
hammers directly. Note: Extra care is needed during cold weather installation, below 40°F (4°C).
Plastic components become brittle and may fracture with excessive impact force.
13) Ensure that wedges are driven on as equally as possible while maintaining level on the diffusers. The
wedges should be flush with that saddle when complete. Over-tightening wedges can cause
irreversible damage to the diffuser saddle.

NOTE: Diffusers must be protected from the sun. Long term exposure to direct summer sunlight
can cause failure. Diffusers need to either be protected from the sun or heat by covering them with
clean water or shade over the basin.
 (OPTIONAL) Water Flush and Air Purge Cleaning of
Piping
These instructions cover the general procedure, which may be utilized to clean the piping in a
fine or medium bubble diffuser system. Special pipe cleaning requirements outlined in the
Engineer’s specifications, contract documents, or instructions offered by EDI shall be
supplementary to or take precedent over the general instructions outlined below.
Water Flush Cleaning
• Water flush cleaning is the recommended method to clean assembled piping systems where
pipe segments are too long for manual cleaning. This procedure can be used in conjunction
with air purge cleaning and is recommended when fine debris is not removed prior to
assembly of piping. When both water flush and air purge are used, the water flush
procedure should be implemented first.
• To water flush the system, connect a water supply to the air header or make individual
connections to each lateral. If flush water is piped to the header, it is imperative that the
header be throttled or stubbed such that water does not flood the blowers.
• Clean water must be used. It is not necessary to use potable water but the flush water must
be free of silt or debris.
• Flush header assembly prior to water flushing the laterals. To flush the header, fill it with
water and open the end lateral to create a flush velocity in the header of at least two feet per
second (if possible).
• Next, the laterals are to be individually flushed at a recommended velocity of five to six feet
per second. Opening one isolation valve will produce a significant flushing action in the
lateral as water is pumped through the header. The lateral end cap or one or two drilled air
outlet holes should be uncapped to allow water and debris to be flushed out of the piping.
• The cleaning procedure in the previous step should be completed for each of the laterals.
This is done by sequentially opening and closing the isolation valves on the individual
laterals.
• As an alternate to using the main header/lateral flush procedure, the individual laterals may
be cleaned independent of the main header. For this operation, the individual laterals are
disconnected from the main header and cleaned individually.

Air Purge Cleaning

• Remove weights and cap from the pressure relief valve during initial start-up of the system.
This eliminates potential damage to the blowers from blocked valves or obstructions in
piping system. Cap and weights can be added back to the pressure relief valve as
necessary to provide proper operating pressure capability.
• NOTE: When a blow-off valve is provided for the blower system, it may be operated in lieu of
using the pressure relief valve procedure listed above.
• Open all lateral valves prior to start-up of the blowers. Provide an opening at the end of the
air laterals to allow air and foreign materials to be discharged from the system. The opening
may be made at the end of the air lateral by leaving the end cap off of the lateral.
• In order to increase the velocity of air through the header and air laterals, it may be
desirable to operate at maximum blower capacity. In addition, it may be necessary to close
some of the lateral throttling valves to achieve a high velocity through the balance of the
laterals that are open to the atmosphere. A high velocity is required in order to blow out any
accumulated foreign materials.
• As laterals are consecutively cleaned, the isolation valves are operated in a manner that
allows the remaining laterals to be cleaned by an air purge.
• Upon completion of the air purge, the blowers are shut down and the laterals are capped.
FlexAir units are installed and all isolation valves are open prior to filling the basin with
water.
• If only an air purge is used to clean the piping, the basins are now ready to be filled with
water to check the operation of the FlexAir units.
 Start Up
General Aeration/Mixing Systems Start-up Instructions
These instructions cover the general start-up requirements for the FlexAir diffuser system. Special start-up
requirements outlined in the Engineer's specifications, contract documents, or instructions offered by EDI
shall be supplementary to or take precedent over these general instructions.
An overview of Start-up procedures is related below:
• Confirm that piping and diffusers are level by filling the basin with water. Adjust supports or diffusers as
required.
• Continue filling the basin with water until the diffusers are 1" to 2" under water. In the event of air leaks,
the diffusers are accessible.
• Activate the blower and introduce air to the FlexAir system. Check piping and diffusers for leaks, and
repair if required.
• While maintaining air to the system, continue filling the basin until the design depth is reached.
Blower Components
Reference the blower installation and start-up instructions to assure all blowers components are
mounted properly and ready for operation. When EDI provides the blower assemblies, detailed
installation and start-up instructions are provided in the blower submittal package.
Blower Installation and Service
• Blower components should be fully installed and fully serviced prior to making final electrical
connections and starting up the FlexAir aeration system.
• Precautions should be taken throughout system installation to minimize the discharge of airborne
particles to the aeration system. As a minimum, air inlet filter should be installed and operated during
blower servicing procedures. EDI recommends a filter efficiency of 99.5% removal of 2 micron particles
and larger. Any solvents used to clean blower should be bypassed from the aeration piping.
• The discharge of airborne particulate matter or solvent into aeration piping may result in damage to
diffuser membranes.
• Upon completion of blower manufacturer's recommended service, the subsequent start-up procedures
may be followed.

General Air Piping

Contractor is to confirm the cleanliness of the air piping. If existing header piping is used, the air purge
or water flush cleaning procedure is recommended prior to installation of FlexAir units to remove any
internal debris that may have accumulated in the header piping. Inspect air piping and diffuser
connections for loose fittings, or damaged pipe. Damaged piping sections and connections should be
repaired prior to commencing system operations.
Initial System Start-Up
• To start-up the system, completely open all valves in the air supply system, including blower shut-off
valves, header valves and lateral isolation/throttling valves. This instruction assumes that uniform
water level is present in all aerated basins served by a single blower. If varying water levels are
present, basins with lower water levels will need to be throttled back to avoid improper air distribution.
Failure to completely open all valves may result in over-pressuring blower unit, release of pressure
relief valve, motor overload, or poor air distribution in aeration system with the potential of over
pressuring diffuser units and damaging the diffuser membranes.
• Once valve positions have been confirmed, blower unit may be started up. EDI does not recommend
starting up multiple blower units at initial system start-up. Subsequent blowers should be brought on-
line after the system has equalized and uniform diffuser activity is observed throughout the system.
• Use recommended blower manufacturers start-up procedures. EDI recommends that initial pressure
surge be reduced through PRV or blow-off valve.
• Start-up procedures should follow the basic guidelines as listed below:
a. When starting up initial blower, the PRV or blow-off valve should be used to reduce the start-up
pressure surge. This is accomplished by removing weights and the cap from the PRV or by
opening the blow-off valve.
b. When the basin has been filled, note the operating pressure at the blowers. The pressure relief
valve should be adjusted to free-flow at approximately 1 psig above the normal operating
pressure of the system.
c. To confirm the PRV operates, partially close blower shut-off valve until PRV releases air.
Reopen the shut-off valve to confirm that PRV will reseat. If required, readjust the PRV to the
recommended setting per instructions in the Blower IOM manual.
d. To properly assess the airflow distribution on the aeration system, the blower system must be
operating at the design operating point. On dual blower systems, design airflow is typically
achieved by operating one blower at 100%. On three blower systems, design airflow is typically
based on operating two blowers at 100%.
e. Airflow distribution adjustment between laterals should not be conducted until the full operating
depth is obtained and the blower system has been in operation for several days. Small
adjustments may be made to the isolation/throttling valves on the laterals receiving the most air.
System balancing should be completed on an incremental basis. Changes in airflow distribution
may require 2-8 hours to fully stabilize when fine-tuning a system. In addition, in situations
where multiple basins are employed and varying water levels exist, adjustments of lateral valves
will be required to maintain air distribution in the tanks. EDI recommends that the system
Operator contact the Engineering Department of EDI at 573-474-9456 prior to making any
adjustments to the airflow distribution.
 Operation For Aerated Basins
Description of the FlexAir Aeration-Mixing System
The FlexAir aeration-mixing system employs a main air header and throttled lateral piping
system to distribute air throughout the basin. Diffusers are mounted directly the pipe to supply
diffusers with air. EDI normally designs the aeration system piping to provide uniform air
distribution without adjustment to the isolation/throttling valves on the laterals. However, these
valves are typically provided for direct control of airflow distribution on large aeration systems or
for process control. If process demands dictate a revised airflow distribution pattern, contact
EDI for guidance on modification to the system.

Normal Operation of the Aeration System

The following procedures should be followed on a regular basis to assure consistent and
satisfactory performance of the FlexAir aeration-mixing system.
• The air rate to the system may be adjusted to maintain the desired dissolved oxygen levels
in the basin. When adjusting the airflow rate, the diffusers should be operated within the
normal operating range of the diffuser. Excessive airflow rates will result in high-pressure
drops across the diffuser and reduced oxygen transfer performance. Low airflow rates may
result in incomplete utilization of the diffuser membrane and reduced air distribution.
• The FlexAir aeration-mixing system is designed to provide uniform aeration. Positive
dissolved oxygen concentrations should be present throughout the entire system during
normal operation. A dissolved oxygen profile analysis may be used to confirm the
performance of the aeration system. Typically, the dissolved oxygen levels are measured at
the inlet, the outlet, and the midpoint locations of each basin to determine the aeration
system performance. In regulating the system airflow to control dissolved oxygen levels, the
diffuser units should be operated within their minimum and maximum airflow limits.

Varying Water Level Operations

In applications where water level variations may exist between aeration basins supplied by a
single blower, the isolation valves may need to be adjusted to maintain adequate airflow
distribution. This normally requires throttling back the air to the basin with the reduced water
level. NOTE: It is important to confirm the operating airflow range of the diffuser units before
throttling back any isolation valve. Damage could result to the aeration diffuser if airflow is
above the recommendations listed in Table 1. Please consult EDI Engineering Department to
confirm operating procedure before adjusting any aeration isolation/throttling valve.

Trouble Shooting
The FlexAir aeration system requires very little maintenance for long term operation. Periodic
visual inspection of the system should allow the Operator to determine if the system is
performing at optimum levels. For example, diffuser unit elevation variations greater than the
design tolerance, typically ± 1", will reduce the uniformity of air distribution in the system. In
addition, operating airflows below the design condition will also reduce the uniformity of air
distribution. If operating conditions warrant airflow rates below the design condition, contact EDI
for additional operational guidelines.
Below are symptoms and procedures to follow if inspection of the aeration system reveals
abnormal operating characteristics:
1. Large volume of air in localized area
Possible Cause: a. Air leak in aeration piping.
b. Diffuser sleeve damaged or missing.

Procedure: a. Drain basin to access area in question. Maintain airflow

to units. Inspect joints for evidence of breakage.
b. Inspect diffuser units for membrane damage. Repair as
required.

2. Decreased diffuser activity and increased back pressure noted at blower.

Possible Cause: a. Diffusers becoming fouled.
b. Reduced blower discharge air volume.
c. Restriction in air header.

Procedure: a. Access diffusers and inspect for external fouling.

b. Confirm blower operating point and rpm reading.
c. Confirm isolation valve position on header and drops.

3. Dissolved oxygen profile not satisfactory throughout basin.

Possible Cause: a. Increased loading to system.
b. Reduced blower discharge air volume.
c. Improper distribution of air in system.
d. Air leak in system.

Procedure: a. Confirm loading to system.

b. Confirm blower operations.
c. & d. Reference items 1 and 2 above.

Normal Operation of the Blower System

The FlexAir Aeration-Mixing System normally utilizes a centrifugal or positive displacement (PD)
blower system consisting of one or more blower units for normal operation plus one on-line
spare unit. All blower units including the spare unit must be operated on a regular basis to
maintain their proper working condition. EDI recommends that blower units be operated
sequentially with idle blower units brought on-line weekly. EDI does not recommend the
simultaneous operation of on-line and spare blowers for an extended period. This operating
condition may deliver airflows exceeding the air capacity of the diffuser units.

Shutdown Conditions
If an interruption in air service is experienced at any time, restoration of air service should be
instituted as soon as possible. When restarting positive displacement blower units, the start-up
pressure surge should be reduced by down-weighting the pressure relief valve (PRV) or
operating the blow-off valve. Once the blower is operational, reset the PRV or slowly close the
blow-off valve over a five to ten minute period. The PRV must be set properly to prevent
overloading of the blower system. Operate water purge devices if provided. If the PRV
releases air for an extended period of time, the relief setting should be checked.
• If the basin is to be idle for a prolonged time period, the basin should be drained and
cleaned. NOTE: Maintain the minimum airflow to the system during the drain down
procedure. For maximum protection of the aeration system, refill the basin to completely
submerge the aeration system. This provides thermal protection in the event of severe cold
or hot weather conditions.
• Contact EDI for additional operation and maintenance information if it is necessary to
decrease the system airflow during cold weather.
Operation of the FlexAir Diffuser
The FlexAir unit has no moving parts and requires very little maintenance for long term
operation. EDI recommends that the air supply to the diffusers be maintained at all times for
optimum performance. The airflow to the FlexAir units must be kept within the ranges
summarized in Table 2 to maintain the structural and operating characteristics of the diffuser
membrane. Continuous application of high airflows, greater than denoted for normal operation
may result in physical damage to the diffuser membrane. Under no circumstances should the
airflows indicated as maximum be exceeded. NOTE: Use caution when adjusting several
lateral throttling valves in the same piping system. This procedure can result in elevated
airflows in sections of the basin, exceeding the maximum allowable airflow to each FlexAir unit.

Table 2: Recommended Airflows for FlexAir Units

Normal Operating Maximum Operating
Condition (SCFM) Condition (SCFM)
FlexAir 84P Magnum Unit 0 to 20 32

Maintenance For Aerated Basins

Maintenance of the FlexAir Diffuser
The following guidelines should be referenced in maintaining the FlexAir diffuser system and
diffuser membrane:
• The diffuser membranes should be protected from petroleum products, i.e., mineral oils and
aromatic hydrocarbons.
• Good air filtration is required with all FlexAir units. The blower system should be equipped
with inlet filters having a performance efficiency of 99.5% removal of 2 micron particles to
prevent clogging of the diffuser membrane.
• The inlet filters of the blower system should be changed before the inlet filter headloss
reaches 20 inches water column. This headloss is normally measured with a spring-type
gauge mounted on the filter housing or with a water manometer. Improper maintenance of
the air filtering system may overload the blower system due to a high inlet loss or may result
in reduced filtration efficiency which could lead to diffuser clogging.
• As a result of biological and/or inorganic materials building up on the membrane surface,
pressure build-up and/or increased headloss may be experienced over a long period of
 operation. To restore membrane performance and decrease the operating headloss, refer to
the following sections.

Accessing the FlexAir Diffuser Assembly

EDI recommends accessing the FlexAir units on a regular basis (annually) to visually inspect
the units. The FlexAir aeration system is designed to allow the diffuser units to be accessed by
dropping the water level in the basin being serviced. The air to the basin being serviced should
be turned off to prevent the possibility of excessive airflows to the units or damage to the blower
unit. The following items may be helpful in servicing the FlexAir diffuser assemblies during
periodic inspections or maintenance procedures:
• Ladder to access the de-watered basin
• Protective gloves and clothing
• Crimping or nipper pliers
• Long-handled bristle brush for cleaning assembly for observation
• Spare FlexAir membranes and crimping clamps

Insitu Cleaning of Membrane

Typically diffuser units will require cleaning because of two common types of surface build-up:
biological and inorganic scaling. The recommended cleaning procedure for both types of build-
up are detailed below:
• A moss like growth characterizes biological build-up. The recommended cleaning
procedure is to physically dislodge the growth either by gently brushing the substance off or
by using low pressure hosing. Care should be taken not to abrade the diffuser surface
during the cleaning procedure.
• A granular mineral like precipitate that can form on the membrane surface characterizes
inorganic scaling. If brushing and hosing the diffuser membrane does not remove the
scaling, contact EDI for further instructions.

Replacing FlexAir Diffuser Membranes

If it becomes necessary to replace rubber membranes, the guidelines below should be followed:
• Remove the stainless steel (SS) crimping clamps. This is easily accomplished by bending
back the small tab on the clamp with a crimping tool or screwdriver. The operator should not
attempt to snip or cut the ear of the clamp because SS material is very strong and excessive
force is required to shear the material.
• Gently pull the membrane off the support to avoid breaking or damaging the support.
• Gently install new membrane ensuring the non-perforated area is installed centered over the
air discharge holes.
• SS crimping clamps should be fully compressed with outside edge of the clamp located 1/4"
from the edge of the membrane and ear of clamp offset approximately 45º from top of unit.
Replacing FlexAir Diffuser Assembly
If it becomes necessary to remove an entire FlexAir assembly, the general procedures outlined
below should be followed:
• Use a rubber or plastic mallet to remove sliding wedges from the saddle body.
• Unhinge the left portion of the saddle body from the right. Be careful not to damage the
lateral near the predrilled holes. The Spectrum diffuser mount forms a tight seal to the
lateral with compressed O-rings. Heavy scratches in the lateral near these O-rings could
break the pressure seal and require special EDI sealant to prevent leaks.
• Reinstall the diffuser assembly by following the general procedures below: See the
Installations Instructions of this manual for reference.
Properly operated and maintained, the FlexAir aeration diffusers will provide years of high
efficiency treatment with minimum operator attention. Questions regarding FlexAir system
operation, maintenance, etc. should be forwarded to:
Environmental Dynamics International
5601 Paris Road
Columbia, Missouri 65202
(573) 474-9456