BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT

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1 SECTION PART 1 - GENERAL 1.1 SUMMARY A. Description of Work: 1. Furnish, install, and test a complete biofiltration odor control system contained in a concrete reactor. Odor control system shall be ready to operate and complete with all engineered media, fiberglass reinforced plastic blower(s), FRP ductwork, irrigation system, recirculation system, fluid controls, instrumentation, control panel accessories, and appurtenances including spare parts, to form a complete operating system in compliance with these specifications and as shown on the Drawings. 2. All components of the biofilter odor control system, including all accessories, shall be provided by a single manufacturer. The manufacturer shall have unitary responsibility for the performance and compatibility of the entire system in conformance with the Contract Documents. System components not provided by equipment manufacturer shall be rejected. Unitary responsibility includes all equipment listed herein, even if described in more detail in another specification section or on the Contract Drawings. 3. To assure proper interfacing and reliable operation of all system components, the manufacturer shall assume sole responsibility for the quantity and proper functioning of all components, including those not of his manufacture. 4. Contractor shall review all aspects of the equipment installation with the manufacturer to ensure systems that are capable of functioning as described and that are fully compliant with the manufacturer s recommendations. 5. During bidding, the manufacturer shall provide general arrangement drawings, process and instrumentation diagrams (P&IDs), and any other information necessary for Contractor to adequately price materials and labor required for a fully functional system including system startup and testing requirements. Electrical and instrumentation wiring, cabling and conduit requirements, as well as plumbing and process piping, ancillary equipment, and temporary equipment required for startup and testing shall be determined by Contractor in coordination with the manufacturer and be provided by Contractor if not provided by the manufacturer. B. Section Includes: 1. Biofilter reactor. 2. Media. 3. FRP Covers 4. Media support system. 5. Humidification systems. 6. Irrigation system. 7. Blower. 8. Accessories. 9. Motors and drives. 10. Controls. PLANT EXPANSION PROJECT

2 C. Related Documents: 1. Section Contractor Submittals. 2. Section Quality Requirements. 3. Section Product Requirements. 4. Section Equipment Testing and Plant Startup. 5. Section Operation and Maintenance Data. 6. Section Protective Coatings. 7. Section Fiberglass Reinforced Duct. 8. Section General Electrical Requirements. 9. All electrical equipment, control panels, and wiring shall be in full compliance with Division 26 Specifications. 1.2 REFERENCES ACMA AMCA 210 ANSI ASTM C582 ASTM D790 ASTM D883 Reference ASTM D2563 ASTM D2583 ASTM D3299 ASTM D4097 IEEE NEC NEMA ICS 2-88 NEMA ICS 6-88 NEMA MG 1-87 NFPA 820 Title American Composites Manufacturers Association Air Movement and Control Association Test Code and Certified Ratings Program American National Standards Institute Standard Specification for Contact-Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion-Resistant Equipment Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulation Materials Definition of Terms Relating to Plastics Recommended Practice for Classifying Visual Defects in Glass Reinforced Plastic Laminate Parts Test for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor Standard Specification for Filament-Wound Glass Fiber Reinforced Thermoset Resin Corrosion-Resistant Tanks Standard Specifications for Contact Molded Glass Fiber Reinforced Thermoset Resin Chemical Resistant Tanks Institute of Electrical and Electronic Engineers National Electrical Code Industrial Control Devices, Controllers and Assemblies Enclosures for Industrial Controls and Systems Motors and Generators Standard for Fire Protection in Wastewater Treatment and Collection Facilities UL Motors and Generators, Electric, for Use in Hazardous Locations, Class I, Groups C and D, Class II, Groups E, F and G PLANT EXPANSION PROJECT

3 1.3 DEFINITIONS A. The terms manufacturer and equipment manufacturer listed herein are used to describe the manufacturer and supplier of the biofiltration odor control system. B. The term equipment listed herein is used to describe the biofiltration odor control system and all accessories. C. D/T: Detection to threshold. The odor concentration or dilution ratio which has a probability of 0.5 of being detected under the conditions of the specified test. D. OU: Odor Unit. The quantity of any odor or mixture of odors that, when dispersed in one cubic foot of odor-free air, produces a median threshold odor detection response. 1.4 PERFORMANCE AND DESIGN CRITERIA A. One (1) biofiltration odor control system shall be provided to treat foul air collected from the Primary Clarifiers and Equalization Basin. B. System shall be suitable for outdoor installation in a Class I, Div 2, Group D area in accordance with NFPA 820. C. Any electrical component located within 3 feet of a potential leak source shall be labeled for use in a Class I, Dive 1, Group D environment. D. All components of the biofilter shall be compatible with the conditions and chemicals to which they will be subjected during normal operation. Compounds with which the materials must be compatible include, but are not limited to: 1. Hydrogen sulfide. 2. Sulfuric acid. 3. Other reduced-sulfur compounds. 4. Ammonia. E. Biofiltration odor control system shall meet the following criteria: 1. Design criteria: Airflow Capacity, total H 2 S Loading, peak H 2 S Loading, average Total Reduced Sulfur Compounds Loading, average Ambient Air Temperature Make-up Water Supply Biofiltration System 10,000 cfm 100 ppmv 30 ppmv 2 ppmv degrees F Plant effluent Reactor Pressure Drop, maximum 2.0 inches w.c. (1) PLANT EXPANSION PROJECT

4 Empty Bed Residence Time, minimum Blower Motor Horsepower Pump Motor Horsepower Notes: Biofiltration System 30 seconds 25 HP 3 HP (1) Maximum reactor pressure drop is taken from blower inlet to discharge at media surface. This pressure rating does not include collection system ductwork upstream of odor control blower. (2) Maximum ductwork pressure drop is taken from the odor source to the blower inlet. This pressure rating does not include blower or media losses. 2. Performance criteria: Inlet H 2 S (1-10 ppmv) H 2 S (>10 ppmv) Outlet 0.1 ppmv >99 percent removal of inlet Total Odor Reduction >90 percent removal of inlet (1) Notes: (1) Removal percentage for average inlet conditions shall be >90% d/t or below 600 d/t, whichever is greater. 1.5 SUBMITTALS A. Submittals shall be in accordance with the Contract Documents including Section B. At a minimum, the submittals shall contain, but not be limited to, the following information to establish compliance with these specifications: 1. Shop Drawings in accordance with Section a. Additional shop drawing requirements: 1) Drawings showing plan, elevation, and appropriate cross sections of the equipment being provided. Detailed drawings showing irrigation piping, nozzles, electrical, instrumentation and structural connections. 2) Complete engineering data including, but not limited to, all pertinent engineering calculations including odor removal performance and pressure drop, descriptive data, material specifications, equipment weights, piping diagrams, instrumentation diagrams, and wiring diagrams, as appropriate, to support the design of the equipment being provided. 2. A test procedure for the performance testing specified in Part 3. Test procedure shall be in accordance with Section and as specified in Part 3. Procedure shall include: a. Test equipment and apparatus. b. Calibration and setup procedures. c. Specific testing methodology to be used. PLANT EXPANSION PROJECT

5 d. Sampling and analysis procedures. e. Final report providing a narrative of the sampling activities, a copy of the original sampling log, photographs showing locations of velocity and pressure measurements, tabular summary of velocity, pressure, H2S and odor removal data, calculated results, and conclusions of these results. 3. Complete operation and maintenance data on equipment in accordance with Section Manufacturer's certification that the equipment has been properly installed, aligned and tested, and meets all requirements for satisfactory performance under the conditions specified in accordance with Section and all related test results and associated forms. 5. Manufacturer's instruction certification that instructions to operators have been completed in accordance with Section Whenever the manufacturer receives notice that components that are part of his system are to be discontinued from manufacture, manufacturer shall inform Engineer within seven (7) days of receiving that notice along with his recommendations on how to resolve this issue. 1.6 SOURCE QUALITY ASSURANCE A. In order to maintain a standard of quality and compatibility, all equipment and accessories specified in this Section shall be provided by a single manufacturer who has been regularly engaged in the design and manufacture of the equipment for at least three (3) years and with no less than ten (10) similar units installed in the United States in similar applications using site constructed concrete structures. B. Factory Performance and Shop Tests: 1. Factory performance tests will not be required. However, the manufacturer must be prepared to guarantee the performance requirements specified herein. 1.7 DELIVERY, HANDLING AND STORAGE A. Packing, Shipping, Handling, and Unloading: 1. Equipment shall be shipped and handled in accordance with the requirements of Section of these specifications. 2. Avoid cross-contamination of foreign materials with media during handling and placement. All media shall be delivered in bulk bags or boxes. B. Storage and Protection: 1. Equipment shall be stored and protected in accordance with the requirements of Section of these specifications. 2. Media shall be covered if stored longer than one week. PLANT EXPANSION PROJECT

6 1.8 WARRANTIES A. The biofilter media shall be warranted not to compact, degrade or decompose for a period of 10 years from the date of Substantial Completion. B. Mechanical equipment shall be warrantied for the standard manufacturer s warranty, for no less than 1 year from the date of start-up. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Subject to compliance with the specifications given herein, the following manufacturers are acceptable: 1. BIOREM Environmental, Inc. (Basis-of-Design) 2. Or equal. B. Dimensions and locations shown on Drawings for equipment and accessories are based on equipment provided by BIOREM Environmental, Inc. Any change in the dimensions or location of equipment or accessories or type of accessories required to accommodate alternate manufacturers and models shall be at Contractor s expense. C. All costs associated with modifying the design and construction of the building, structural, piping, electrical, mechanical, plumbing and instrumentation systems required to accommodate alternate manufacturers and models shall be responsibility of Contractor. D. In the case of an or-equal, Contractor shall demonstrate in writing, to the satisfaction of the Owner and Engineer at the time of the shop drawing submittal that the manufacturer has produced the specified type and size of equipment for sanitary wastewater service that has been in successful operation in at least 20 different locations for a minimum period of 5 years prior to the bid date. 2.2 BIOFILTER REACTOR A. The biofilter reactor shall be constructed of reinforced concrete and finished as specified herein and in Section B. The reactor shall be operated in the up-flow configuration. C. Interior reactor floor shall be continuous and maintain a 1-percent slope towards the reactor plenum for leachate collection and drainage. D. Access hatches shall be provided as shown on the Drawings. PLANT EXPANSION PROJECT

7 2.3 EQUIPMENT DESIGN A. Media: Media shall be made up of a porous, acid resistant base designed to facilitate biological growth. The substrate materials shall be capable of being handled or driven over by machinery. Lava rock is not acceptable as a substrate. Base media shall be processed and enhanced by permanently affixing an engineered coating comprised of buffering agents, nutrients and other minerals to control ph and propagate biological growth. Uncoated or untreated media is not acceptable. Organic components in the media bed are not acceptable. Media that requires onsite treatment for enhancement is not acceptable. Media that requires nutrient addition or other means of on-site treatment to facilitate or accelerate acclimation are not acceptable. Additives shall be suspended in a time release engineered coating. The following, at a minimum, shall be provided as part of the submittal: 1. General non-proprietary details on the coating system including buffering and nutrient content. A random sample taken by the client of the delivered media may be sent to an independent testing lab for analysis to confirm content. 2. Location of media processing facility. Engineer shall be given full access to visit this facility and confirm the media is being coated with the submitted content. 3. ph control plan utilizing buffering agents, and anticipated bed ph graduation based on specified process treatment airstream. 4. Media life calculations based on a minimum of ten (10) previous installations. At least one installation shall have been in operation for a minimum of five (5) years. Supplier shall provide documentation and photographic evidence that media in the 5-year installation was the same product being submitted manufactured using the same material and process. Owner/Engineer may, at their discretion require additional proof if submitted information does not satisfy their requirements. 5. Know engineered media products that are acceptable to the engineer are Biosorbens by Biorem and BioPure by ECS. Alternate products must be pre-approved 20 days prior to bid tender. To achieve pre-approval a full submittal package satisfying all requirements of this specification section should be submitted. B. Media Support System. 1. The biofilter media shall be supported by a corrosion resistant FRP grating, reinforced with FRP angle beams. 2. Angle beams shall be supported on both sides of the treatment cell. 3. Grating/beam system shall support a minimum loading of 100 pounds per square foot. 4. A mesh polypropylene screen shall be placed on the FRP grating to prevent the biofilter media from falling through the grating openings. C. Humidification System. 1. The humidification recirculation system shall designed such that it meets the design requirements as listed in Section 1.4 of this specification. The system shall include a PVC spray nozzle assembly above the packing media and a centrifugal recirculation pump. 2. Water piping shall be Schedule 80 PVC. D. Water Cabinet. PLANT EXPANSION PROJECT

8 1. A water cabinet, which houses components necessary for water recirculation shall be provided. 2. Water cabinet to be a NEMA 4X enclosure of either FRP or Type 304 stainless steel with mounting feet if required. 3. Water cabinet shall be mounted a minimum of 3 feet from any potential leak point to comply with NFPA Water cabinet shall contain the following: a. Ball valves and plumbing required for media irrigation. b. Field connection (1-inch) to make-up water supply. c. Fuse block and terminals for all field connections. d. One (1) flow indicator/switch, to display re-circulated water flow rate, signal alarm and shut-off recirculation pump in case of reduced water flow. e. One (1) flow indicator to display blow down water flow rate. f. One (1) flow totalizer on make-up water supply line. g. One (1) pressure indicator for recirculated water flow. 5. One (1) solenoid valve for irrigation control. E. Irrigation system. 1. The irrigation system shall consist of a spray irrigation assembly above each biofilter media cell. 2. The biofilter media bed shall be irrigated intermittently. F. Blower. 1. Blower shall be designed for continuous service. 2. Blowers shall be FRP, backward inclined or radial-bladed centrifugal type. 3. Blower shall be statically and dynamically balanced. 4. Blower shall be equipped with a slip inlet connection, outlet flange, drain connection at bottom of blower scroll and inspection panel. 5. Blowers shall have a Type 316 stainless steel shaft. 6. Blower shall have self-aligned grease-packed bearings with minimum 100,000 hour B-10 life, neoprene shaft seals and OSHA approved weatherproof motor/drive cover. 7. The blower shall be manufactured by New York Blower, Hartzell, Universal Fan and Blower or approved equal. G. Accessories. 1. Fluid Control Systems: a. One (1) lot fluid control valves and 1.8 mm (1800 micron) strainers as required. b. One (1) lot 0.25-inch tubing for differential pressure gauges. c. One (1) lot drip legs for differential pressure gauges. 2. Field instrumentation external to Water Cabinet: a. Two (2) differential pressure gauges to measure pressure drop across media. b. One (1) inlet air temperature indicator. c. Pressure indicators at outlet of each recirculation pump. 3. Piping PLANT EXPANSION PROJECT

9 a. The supplier shall provide all piping between the fan and the humidification tower, and from the tower to the biofilter reactor. The supplier shall also provide the drain piping from the humidification tower into the reactor. b. The supplier shall provide all necessary flexible connections for the fan and the humidification tower. 2.4 MOTORS AND DRIVES A. Recirculation pump motor. 1. Conform to Section and the following: 2. Suitable for Class 1, Division 2, Group D classification. 3. Horsepower: As listed in Design Criteria. 4. Electrical: 460-V, 3-phase, 60 Hz. 5. Service Factor: Duty: Continuous. B. Blower. 1. Drive: Constant V-belt drive. 2. Motor: a. HP: As listed in Design Criteria. b. Suitable for Class 1, Division 2, Group D classification. c. Electrical: 460-V, 3-phase, 60Hz. d. Enclosure: TEFC. e. Speed: 1800 rpm. f. Service factor: g. Duty: Continuous. 2.5 CONTROLS A. All control panels shall comply fully with Division 26 and shall be located as shown on Contract Drawings. Interface with the plant-wide SCADA system shall be coordinated with the system integrator. B. General Requirements. 1. Manufacturer shall provide all necessary controls including all sub-systems as specified herein and as recommended and required for a complete and operational system. Instances of Hand-Off-Auto selector switches herein shall refer to physical switches mounted in the control panel. Contractor shall be responsible for installation of all controls supplied by manufacturer including all related wiring and conduit and connections to plant SCADA system, in coordination with manufacturer. Contractor shall also be responsible for providing any additional components required or recommended by manufacturer. 2. All control panels shall be NEMA 4X rated and fabricated of Type 304 stainless steel. C. Local Control Panel. PLANT EXPANSION PROJECT

10 1. Provide a single control panel to service the biofilter system. Provide all items which are required to implement the specified functions and the functions required for proper system operation. a. Panel shall contain the local control and monitoring for the odor control system components, including: 1) Mounting pedestal, if required. 2) Door-mounted fused disconnect. 3) Motor starter and Hand/Off/Auto switch for blower. 4) Motor starter and Hand/Off/Auto switch for recirculation pumps. 5) Status light (on when running) for blower and recirculation pumps. 6) Recirculation low flow alarm. 7) General alarm indicating light. 8) Alarm reset push button. 9) Space heater. 10) Controls transformer. 11) Timer relay for control of irrigation water. 12) Dry contacts for transmitting signals to remote location. 2. The power feed to the control panel shall be 480-volt, 60 Hz, 3-phase. 3. Panel shall be UL certified and shall be mounted a minimum of 3 feet from any potential leak point to comply with NFPA Panel shall be equipped with SCADA signals (dry contacts) for the following signals that shall be wired to terminals located inside master control panel: D. Functional Control Description. 1. The solenoid valves shall be controlled on a timer with field-adjustable set points. The open status indication for the solenoid valves shall be derived by flow switches located downstream of the valve to verify the valve is open and flow is present. 2.6 FABRICATION A. Anchorage: 1. All bolts, nuts, washers, and other fasteners shall be Type 316 stainless steel unless otherwise noted and shall be provided by Contractor unless otherwise supplied by equipment manufacturer. Inform Engineer any time Type 316 stainless steel parts will not be used prior to using alternative materials. 2. Anchor bolts shall be Type 316 SS HILTI-style epoxy anchors and shall be provided by Contractor unless otherwise required by odor control system manufacturer. Inform Engineer any time Type 316 stainless steel parts will not be used prior to using alternative materials. 3. Contractor shall provide lock nuts and/or lock washers when recommended or required by equipment manufacturer or as necessary for Work to prevent nuts from disengaging from their seated positions due to vibration or other factors associated with equipment operation. PLANT EXPANSION PROJECT

11 2.7 FINISHES A. Surface preparation, shop painting and field painting and other pertinent detailed painting specifications shall be in accordance with Section and manufacturer s standards. Manufacturer shall coordinate fully with the Contractor the system and application of paints used. Machined and polished surfaces, stainless steel, non-ferrous, and galvanized metals shall not be primed or painted. All surfaces not specified to be factory-primed shall be protected from corrosion by applying a rust inhibitor or other acceptable means of protection. Surfaces to be painted shall include metal surfaces of motors, speed reducers, bases, and accessories unless otherwise exempted. 1. Unless otherwise specified below, all system components shall be received at the project site with full factory-applied finishing in accordance with Section For those components to be painted at the project site by Contractor, manufacturer shall supply all components with factory-applied prime coat in accordance with Section Contractor shall be responsible for providing all other coats, including any necessary touchups to the prime coat, in accordance with Section Manufacturer shall provide Contractor with correct paint and/or prime coat materials in the correct color and any other special materials required by Contractor to make any necessary field repairs to the factory applied finish should said finish be marred or damaged. 4. The following system components shall be field painted by Contractor: a. All internal walls of the humidification filter stage shall be coated in accordance with Section b. All internal walls of the biofilter stage shall be coated accordance with Section PART 3 - EXECUTION 3.1 INSTALLATION A. Coordinate any required interruptions with operation of Owner s facilities with Owner and Engineer. B. Contractor shall furnish and install all equipment, accessories, and appurtenances according to the Contract Documents, including Section , and equipment manufacturer s written instructions. Conflicts of information shall be called to the attention of the Engineer before proceeding with work. C. Contractor shall field verify all dimensions and elevations and shall notify Engineer of any specific differences. D. Contractor shall provide all necessary equipment (including temporary equipment, measuring devices, etc.), materials (including temporary materials, lubricants, chemicals, etc.) and labor necessary for initial system startup, testing, and operation. Grades of oil and grease for all equipment shall be in accordance with the recommendations of the equipment manufacturer. Contractor shall account for fact that many of the other plant systems may or may not be online when the equipment is started up and tested. PLANT EXPANSION PROJECT

12 E. Contractor shall be responsible for ensuring that all equipment is rigidly and accurately anchored into position. Contractor shall be responsible for providing all necessary foundation bolts, plates, nuts, washers, and other fasteners not provided by equipment manufacturer. F. Equipment manufacturer shall provide Contractor with engineering and technical support related to the specified equipment, and participate in the commissioning, startup, testing, and training of the Owner s personnel as required by the Contract Documents and as necessary to allow Contractor to provide a complete and operable system. 3.2 FIELD QUALITY ASSURANCE AND INITIAL OPERATION A. Field Acceptance Testing: 1. Preliminary tests, field tests, start-up and initial operation shall be performed in accordance with the Contract Documents, including Sections , , and this specification section. 2. All testing shall be done in the presence of the Engineer and the equipment manufacturer or their approved representative. All testing shall be conducted by an independent testing lab at the Contractor s expense. 3. Three week acclimation period will be deemed as equivalent to the equipment start-up period. 4. Performance Testing of Odor Control System. a. Verify conformance to specified parameters using actual inlet conditions of the site. Testing to be completed no sooner than a 3-week acclimation period, but not later than 10 weeks, after system startup and shall include: 1) Verification of proper airflow. 2) Measurement of inlet and outlet H2S concentrations. 3) Test will be conducted for a period of not less than 8 continuous hours with H2S readings being logged continuously with a data logger. 4) Record pressure drop readings across media lift. 5) Bag samples will be collected at two different times, on the inlet and outlet of the biofilter, for odor panel analysis. 6) A report of the test results shall be provided. B. Final acceptance of the equipment shall be made after the equipment has been demonstrated in the field to meet the performance requirements stated in this specification under all normal operating conditions and verification that the motors are not overloaded in normal operating conditions. C. Adjust, repair, modify, or replace any components of the system, which fail to meet all specified requirements. Retest entire system after repairs, adjustments, and modifications have been made and until all issues are resolved and system operates in full compliance with the Contract Documents and manufacturer s specifications and requirements. All such work shall be at Contractor s expense. Owner and Engineer shall review and approve of any modifications proposed by Contractor necessary to correct any issues prior to work commencing. PLANT EXPANSION PROJECT

13 3.3 MANUFACTURER S SERVICE A. Provide services of the equipment manufacturer or their approved representative in accordance with Sections , , and Representative for the specified equipment shall be present at the job-site for the following services: 1. Installation assistance: 1 man-day(s). 2. Final acceptance: 2 man-day(s). 3. Job-site training: 1 man-day(s). B. Provide jointly to the Owner and the Engineer an installation certificate from the equipment manufacturer or their approved representative stating that the equipment has been properly installed, tested to their satisfaction, that all final adjustments required have been made and equipment will be warranted as required by the specifications. C. All test results, forms, and certifications shall be included in O&M manual. D. In addition to the site visits specified herein above, the equipment manufacturer shall provide one person for a 2-day site visit (time represents time at the project site and does not include travel time) 6 months after Substantial Completion to: 1. Verify conformance to specified parameters, to be conducted using actual inlet conditions of the site. Testing shall include: a. Verification of proper airflow. b. Measurement of inlet and outlet H2S concentrations. c. Test will be conducted for a period of not less than 8 continuous hours with H2S readings being collected every 30 minutes. d. Record pressure drop readings across media lift. e. Bag samples will be collected at two different times, on the inlet and outlet of the biofilter, for odor panel analysis. f. A report of the test results shall be provided. 2. Provide additional training as required. END OF SECTION PLANT EXPANSION PROJECT

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