DIVISION 11 - EQUIPMENT SECTION SOLIDS CONTACT CLARIFIER EQUIPMENT

Transcription

1 DIVISION 11 - EQUIPMENT SECTION SOLIDS CONTACT CLARIFIER EQUIPMENT PART 1 GENERAL 1.01 SUMMARY A. Section Includes: 1. Equipment alterations required to replace deteriorated components on the 66-ft solids contact clarifier pretreatment equipment, remove and replace select components, and improve the existing system. a. Scraper bearings. b. Drive bearing. c. Tube settlers and supports. d. Launder support connections. e. Drive sprocket replacement. f. All other appurtenances required or shown on the Contract Drawings. 2. Equipment alterations required to replace deteriorated components on the 38-ft solids contact basin in Plant No. 2, remove and replace select components, and improve the existing system. a. Drive sprocket replacement. b. All other appurtenances required or shown on the Contract Drawings. B. Related Sections include, but are not limited to: 1. Section Submittals. 2. Section Quality Control. 3. Section Material and Equipment. 4. Section Starting of System. 5. Section Contract Closeout. 6. Section Operation and Maintenance Data. 7. Section Concrete. 8. Section Fabrications Metal. 9. Section Painting. 10. Section Process Pipe and Fittings. 11. Section Process Valves REFERENCES A. Reference Standards include, but are not limited to: 1. HI - Hydraulic Institute Standards 2. ASTM - American Society for Testing and Materials 3. AISI - American Iron and Steel Institute 4. ANSI - American National Standards Institute. 5. NEC - National Electric Code. 6. NEMA - Standards of National Electrical Manufacturers Association. 7. OSHA - Occupational Safety and Health Act. 8. AGMA - American Gear Manufacturer s Association. 9. IEEE - Institute of Electrical and Electronic Engineers. 10. AISC - American Institute of Steel Construction

2 11. ASCE - American Society of Civil Engineers. 12. AWS - American Welding Society. 13. SSPC - Steel Structures Painting Council. 14. UBC - Uniform Building Code. 15. AFBMA - Anti Friction Bearing Manufacturers Association 1.03 SYSTEM DESCRIPTION A. General: 1. The project includes rehabilitation and replacement of select components of the 66-ft Pretreatment Basin and as alternate P1 the replacement of the existing tube settlers and associated support system. Rehabilitation will include scraper and drive bearings, new tube settlers and supports, repairs to stationary cone, replacement of launder support connections, and drive sprocket replacement. 2. The project also includes rehabilitation and replacement of select components of the 38-ft Solids Contact Basin in Plant No. 2. Rehabilitation will include drive sprocket replacement. B. Criteria Existing 66-ft Square Pretreatment Unit (General Filter Type C ContraFlo ) 1. Equipment shall meet the following design criteria (per O&M manual): a. Basin Size (ft.): 66-0 x 66-2 x 16-8 b. Side water depth (ft.): 16-0 c. Area at Separation Zone 1) Gross (sq. ft.) 4,367 2) Net (sq. ft.) 3,808 d. Flow Rate (gpm) 1) Design 8,400 2) Maximum 12,600 e. Basin Capacity (gal) 522,000 (ignoring fillets) f. Detention Time (min.) 62 g. Center Column Size Diameter (in.) 86 h. Maximum Recirculation Rate (gpm) 25,200 i. Propeller 1) Diameter (in.) 80 2) Material Steel 3) Max. rpm 37.5 j. Mixer Drive 1) Motor Eurodrive 7 ½ hp 2) Reducer Helical gearing k. Sludge Collector 1) Design Torque (ft-lbs) 31,730 2) Tip Speed (fpm) ) Motor ½ hp Eurodrive 4) Overload Indicating type 5) Reducer Helical gearing l. Launder Type Radial with V-notches

3 m. Sludge Blowdown Assembly 1) Timer Pulse frequency counter and duration time 2) Blowdown Valve Grinnell 6 Diaphragm n. Tube Settlers 1) Manufacturer Enviropax 2) Height (in) 30 (field verify) 3) Design Application Rate (gpm/ft2) 2.5 C. Criteria Existing 38-ft Square Solids Contact Unit (General Filter Type C ContraFlo ) 1. Equipment shall meet the following design criteria (per O&M manual): a. Basin Size (ft.): 38-0 ft square x 15-6 b. Side water depth (ft.): 15-0 c. Area at Separation Zone 1) Gross (sq. ft.) 1,444 2) Net (sq. ft.) 1,145 d. Flow Rate (gpm) 1) Design 4,200 2) Maximum 6,300 e. Basin Capacity (gal) 162,000 (ignoring fillets) f. Detention Time (min.) 38 g. Center Column Size Diameter (in.) 86 h. Maximum Recirculation Rate (gpm) 25,200 i. Propeller 1) Diameter (in.) 80 2) Material Steel 3) Max. rpm 37.5 j. Mixer Drive 1) Motor Eurodrive 7 ½ hp 2) Reducer Helical gearing k. Sludge Collector 1) Design Torque (ft-lbs) 10,520 2) Tip Speed (fpm) ) Motor 1/3 hp Eurodrive 4) Overload Indicating type 5) Reducer Helical gearing l. Launder Type Radial with V-notches m. Sludge Blowdown Assembly 1) Timer Pulse frequency counter and duration time 2) Blowdown Valve Two Grinnell 4 valves 1.04 SUBMITTALS A. Shop Drawings and Product Data: Submit, in accordance with Section 01300, detailed specifications, drawings, and data covering all materials, parts, devices, equipment, and other accessories forming part of equipment for the complete operational system. B. Manufacturer s Instructions: Furnish under provisions of Section 01300, manufacturer s printed instruction for delivery, handling, storage, assembly, installation, startup, adjusting, operation, and finishing as appropriate

4 C. Manufacturer s Field Service Reports: Furnish, under provisions of Section 01400, reports covering start up, demonstration, and instructions. D. Operation and Maintenance Data: Submit in accordance with Section on all parts, devices, equipment, and other accessories forming the complete operational system. E. Certificates: Certification of proper installation and satisfactory performance. F. Calculations documenting the AGMA rating of the drive unit and life of the main bearing, prepared and signed by a registered professional engineer QUALITY ASSURANCE A. Manufacturer shall provide a certification that particular Work has been reviewed and meets all physical requirements. B. Manufacturer shall provide a copy of all hydraulic calculations for items such as launders and piping. C. All materials specifically called out, such as hardened steel, stainless steel bolts, fiberglass, as well as shop welding, shall be provided with tags or labels indicating that the particular materials and/or equipment meets the specifications. D. The equipment supplier shall have at least 15 years experience in the design, application, and supply of circular clarifiers and thickeners in water or wastewater treatment plants, and shall submit a list of not less than 25 operating installations DELIVERY, STORAGE, AND HANDLING A. Deliver, store and handle all equipment and materials in accordance with the manufacturer s instructions, leaving all seals and labels intact and legible. B. All materials and equipment shall be delivered, stored and handled in a manner to prevent damage. Any damage noted at the Site shall be immediately reported to the Engineer for instruction regarding the acceptability of damaged equipment. C. Store loose materials on solid flat surfaces in well drained areas, providing cover and ventilation to avoid condensation and potential degradation of the materials. D. Protect electrical equipment, controls, and insulation against moisture or water damage. E. Utilize the proper equipment to deliver, store and handle all equipment and materials

5 1.07 PAINTING AND IDENTIFICATION SYSTEMS A. Primer and finish painting of all materials and equipment in this Section shall be in accordance with Section 09900, unless specifically indicated otherwise REGULATORY REQUIREMENTS A. All Products that may come into contact with water intended for use in a public water system shall meet American National Standards Institute (ANSI)/National Sanitation Foundation (NSF) International Standards 60 and 61, as appropriate. A Product will be considered as meeting these standards if so certified by NSF, the Underwriters Laboratories, or other organization accredited by ANSI to test and certify each Product. PART 2 PRODUCTS 2.01 MANUFACTURERS A. Supplier shall be responsible for coordinating clarifier equipment and tube settlers and shall furnish them as a complete system. B. Clarifier Equipment 1. WesTech Inc. Salt Lake City, Utah 2. Envirodyne Systems Inc., Camp Hill, Pennsylvania 3. Approved equivalent. C. Tube Settlers 1. Brentwood Industries, Inc. Reading, Pennsylvania. 2. Approved equivalent MATERIALS A. Steel plate for the fabrication of replaced items shall not be less than 1/4 in thickness. B. All equipment and modifications including but not limited to; piping, valves, concentrator equipment and operators, backwash water system, scraper blades, scraper shaft, sump scraper, impeller blades and tie rods, impeller gear drive, and hood penetrations; shall conform to approved supplier s standard design. C. Steel equipment alterations shall match existing materials and workmanship. D. Scraper and impeller shaft shall be dynamically balanced to prevent eccentricity at all operating speeds

6 E. Structural Design: 1. The ratio of un-braced length to least radius of gyration (slenderness ratio) shall not exceed the values listed in the AISC manual. For angles, the radius of gyration shall be taken about the Z-Z axis. In addition, all structural members and connections shall be designed so that the unit stresses will not exceed AISC allowable stresses by more than one-third when subject to loading of the previously listed peak torque. 2. All steel design shall be in accordance with the AISC Manual of Steel Construction, latest edition, and the Uniform Building Code (UBC), latest edition. F. Anchorage and Fasteners: 1. Anchor Bolts: a. All anchor bolts shall be a minimum of ½ diameter and made of type 304 stainless steel. b. The manufacturer shall furnish all anchor bolts, nuts, and washers required for the equipment. 2. Fasteners: a. All structural fasteners shall be a minimum of ½ diameter and made of type 304 stainless steel. b. All stainless nuts and bolts shall be installed with anti-seize compound on the threads. c. The manufacturer shall furnish all fasteners required for the assembly of the equipment. G. Fabrication: 1. Shop fabrication of structural members shall be in accordance with the latest edition of the Structural Welding Code, AWS D1.1, of the American Welding Society. All welded connections shall develop the full strength of the connected elements and all joined or lapped surfaces shall be completely seal welded with a minimum 3/16" fillet weld. Intermittent welding shall not be allowed. All welding shall be done in accordance with the latest edition of the AWS code. H. Tube Settlers 1. PVC tube settlers specifically designed for water clarification and NSF approved. 2. Provide with uni-directional flow. 3. Loading rate as noted in Paragraph Tube Settler Support System a. Designed and furnished in accordance with tube settler manufacturer s requirements. b. Material shall be carbon steel coated per Specification Section Tube settler manufacturer is responsible for providing a complete system (tube settlers and support system). I. Spare Parts: 1. Provide all lubricant and related items necessary for startup. In addition, provide quantity of lubricant sufficient for one year of operation

7 PART 3 EXECUTION 3.01 EXAMINATION A. Verify that all demolition is completed as required to properly install new equipment. B. Verify field dimensions with erection Drawings. C. Verify field conditions are acceptable and ready to receive Work FABRICATION A. All necessary bolts for the alterations shall be included. B. Existing launders shall be inspected to locate problem areas, free of winds, warps, local deformations and bends. All burrs, irregularities, corners and edges shall be removed and dulled. C. All provisions for field connections shall be accurate and shop checked for proper fit during assembly or erection. D. All welded joints shall be continuous and watertight INSTALLATION A. All Work shall be installed according to manufacturer s directions and Drawings. B. All sharp corners of cut or sheared edges shall be dulled by a power grinder and covered with an approved coating. C. All new, altered, or existing metal surfaces, except motors and gear drives, shall be prepared and coated in accordance to Section D. In areas where existing equipment is to be maintained and new equipment is to be installed, care shall be taken to protect, support and minimize the overall impact on the existing equipment TOLERANCES A. Launders shall be inspected and adjusted so that the bottom of the orifices shall not vary more than one-eighth inch (1/8 ) at any point within the entire basin FIELD QUALITY CONTROL A. It is the responsibility of the General Contractor to schedule and coordinate onsite field services. The trips and durations of the field service personnel are required as on-site. Travel is not included in the quantity and duration of field services. If additional trip(s) are required due to improper scheduling, installations, or equipment failures, the field services shall be provided at no additional cost to the Owner

8 B. Field Verification Assistance 1. The services of a qualified field representative shall be provided to assist in field measurements and verifications prior to shop drawings. These services shall be provided in one (1) trip of one (1) day duration on-site. C. Installation Assistance 1. The services of a qualified field representative shall be provided to assist in the installation of the equipment. These services shall be provided in one (1) trip of four (4) days duration on-site. D. Start-up Service 1. The services of a qualified field representative shall be provided to perform the mechanical and electrical check-out of the equipment. This representative shall inspect the equipment for proper installation and proper mechanical and electrical operation. The start-up procedure shall be in accordance with the manufacturer s standard format. These services shall be provided in one (1) trip of two (2) days duration on-site, separate from the installation trip. E. Manufacturer s Field Service Report: Perform field inspection of all components during start-up service trip prior to placing in operation and submit Manufacturer s Installation Inspection Report addressing the following: 1. List of deficiencies found. 2. Recommended corrective action for all deficiencies. 3. Certification by manufacturer s representative that items are property installed and adjusted. F. Operator Training 1. The services of a qualified field representative shall be provided to train the Owner s personnel in the proper operation of the equipment. These services shall consist of classroom and/or hands-on training. These services shall also include but not limited to maintenance, lubrication, and trouble-shooting. The guideline for training shall be the O & M manual. It is a requirement of the Owner to provide qualified people in all areas of technical discipline required for the operation of the equipment. These services shall be incorporated into the start-up service trip and shall be provided in one (1) day commencing at the end of the equipment start-up. G. Warranty Inspection 1. The services of a qualified field representative shall be provided to perform a mechanical and electrical inspection of the equipment for proper operation. These services shall be provided in one (1) trip of one (1) day duration on-site within one month of the end of the warranty period. H. All launders shall be checked with a surveyor s level in the presence of the Engineer DISSIMILAR MATERIALS A. Where dissimilar metals are in contact the metals shall be kept from direct contact by use of isolation material

9 3.07 CLEANUP AND PROJECT CLOSEOUT A. Prior to returning a contact basin to service and before final payment is made, Contractor shall, in the presence of the Engineer, conduct a thorough inspection of all equipment and Work completed on the contact basin equipment. B. Any and all coating defects, loose bolts, or other deficiencies, shall be immediately corrected PROJECT RECORD DOCUMENTS A. Prior to final payment, the Contractor shall furnish a complete set of as constructed Drawings indication all changes made during construction. These documents shall be bound in a three-ring binder and presented to the Engineer. B. Any correspondence from the manufacturer which the Contractor received during design and concerning authorized changes, shall be included within the record document binder. END OF SECTION