TRUCK LOADOUT DISCHARGER
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Truck loadout discharge assembly.
B. Scope
1. The discharge assembly, consisting of a lower hopper section, screw conveyors,, and gates, will be installed on the existing loadout hopper following demolition of the existing system.
2. The system work must be performed in the proper sequence as detailed in Section 01140, Work Restrictions. Temporary loadout facility will be in operation while this system is installed.
C. Related Sections include but are not necessarily limited to:
1. Division 01, Additional General Requirements
2. Section 01140, Work Restrictions
3. Section 05505, Metal Fabrications
4. Section 09800, Protective Coating
5. Section 11005, Equipment: Basic Requirements
6. Section 11121, Screw Conveyors
7. Section 16220, Electric Motors
8. Section 16418, Variable Frequency Drives Below 100 HP
9. Section 17300, Control Strategies
10. Section 17405, Process Instrumentation and Control
D. Coordination:
1. Coordinate delivery, installation, and startup of hopper extension screw
1.2 discharge system, and gates.
QUALITY ASSURANCE
A. Referenced Standards:
1. American Iron and Steel Institute (AISI):
a. Steel Products Manual
2. ASTM International (ASTM):
a. A36, Standard Specification for Carbon Structural Steel
3. American Welding Society (AWS):
a. A5.1 Standard Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
b. D1.1 Structural Welding Code Steel
B. Qualifications:
1. Supplied by a single manufacturer or supplier.
2. Manufacturer shall have a minimum of three similar size and configuration units in operation.
C. Warranty
1. The truck loadout discharger and all components specified in this Section shall be warranted by the manufacturer for a minimum three (3) year period after Beneficial Occupancy of the Work pursuant to “Use Prior to Final Completion” of the General Conditions, against defects in workmanship and materials.
1.3 SUBMITTALS
A. Shop Drawings:
1. See requirements in Section 11005, Equipment: Basic Requirements.
2. Manufacturer's literature, illustrations, specifications, detailed drawings, data and descriptive literature on all valves and appurtenances.
3. Complete motor data, as required in Section 16220, Electric Motors.
4. A letter from the discharger manufacturer confirming compatibility between the drive motor and VFD being provided.
5. Control panel layout and construction Drawings showing the location of operator interface devices and other auxiliary components, as required in Sections 16442, Control Panels, and 17405, Process Instrumentation Control.
6. Panel elementary control diagrams and interconnect wiring diagrams including power wiring.
7. Functional description of internal and external instrumentation and control.
8. Deviations from Drawings and Specifications.
9. Engineering data including dimensions, materials, size and weight.
10. Structural design calculations sealed by Professional Civil or Structure Engineer registered in the State of California.
11. Fabrication, assembly, installation and wiring diagrams.
1.4 PROJECT CONDITIONS
A. Location:
1. Dewatered municipal biosolids storage and loadout facility.
2. Interior location.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable:
1. Spirac.
2. Schwing Bioset.
3. Biosec Enviro.
4. RDP Technologies.
5. Or Equal.
2.2 MATERIALS
A. Steel Plate: Stainless steel, ASTM A276, Type 304
B. Steel Shapes: Stainless steel, ASTM A276, Type 304
C. Structural Members: Stainless steel, ASTM A276, Type 304
D. Screw Flights: Stainless steel, ASTM A276, Type 304
E. Screw Torque Tubes: Stainless steel, ASTM A276, Type 304
F. Hardware: Stainless steel, ASTM A320, Type 316
G. Gates, Slide Gate Blade: Stainless steel, ASTM A276, Type 304
H. Slide Gate Frame: Stainless steel, ASTM A276, Type 304
2.3 EQUIPMENT
A. Performance and Configuration Requirements:
1. Material Description:
a. Maximum Sludge Density: 65 lb/cu. ft. (1040 kg/m3).
b. Minimum Sludge Density: 60 lb/cu. ft. (960 kg/m3.).
c. Maximum Sludge Moisture: 75 percent.
d. Minimum Sludge Moisture: 65 percent.
e. Abrasive.
f. Corrosive.
g. Contains oil, grease, and polymer.
h. Maximum Lump Size 1 inch.
B. Truck Loadout screw conveyors:
1. Quantity: Four.
2. Size: 24-inch diameter.
3. Type: Shafted with ribbon flights.
C. Conveyor Gates (15JGAT885; 15JGAT886; 15JGAT887; 15JGAT888):
1. Size 48 inches x 48 inches nominal.
2. Pneumatic actuators.
D. Capacity:
1. Discharge Rate: Load out 20 cubic yards in 15 minutes maximum with all gates open and all conveyors in operation, regardless of level in hopper.
2.4 COMPONENTS
A. General:
1. Design for both continuous and for intermittent operation at a capacity not less than that specified.
2. Static and dynamic loading of the mechanical and structural components shall be calculated using the maximum density of the dewatered sludge. Structural calculations shall assume bins are 100 percent full of maximum density sludge. All bin structural design calculations shall be sealed by a registered Professional Civil or Structure Engineer in the state of California.
3. The compatibility of the equipment with the feed equipment and all other related equipment shall be the responsibility of the CONTRACTOR.
4. The entire system (bins, dischargers, conveyors, gates, etc.) will be supported from the existing silo to which it is attached. No supports or bracing will be permitted from the floor or from the adjacent platform.
B. Loadout Hopper:
1. The bin will be constructed of A36 and A572 carbon steel plate of minimum 1/4 inch thickness and will be reinforced as required.
2. Maximum deflection to the hopper shall be limited to less than 1/200 of the span. Reinforcing members such as angles, beams, stiffeners, and gussets shall be externally mounted to provide a smooth interior surface.
3. Each bin shall be provided with appropriate structural supports to adequately support the bin and any other loads imposed upon it from other equipment.
C. Extraction Screw Conveyors:
1. General:
a. Extraction screw conveyor(s) will in general consist of conveyor with continuous flighting, shafts and couplings, high strength shaft bolting, trough ends, seals, bearings, electric motors, speed reducers, supports and grease fittings.
b. Provide means to remove and replace the extraction conveyor within the location and structure it is housed.
2. Screws:
a. The extraction screw conveyor(s) shall be furnished complete with supports suitable for mounting in the bottom of the bin.
b. The extraction screw conveyor assembly shall be an integral unit with the bin with discharge locations through the gates as shown on the Plans.
3. Drive:
a. The extraction screw conveyor assembly will incorporate a drive assembly to power the screws separately.
b. The drive assemblies will consist of a 10 HP (minimum), 480 Volt, 3 phase, TEFC motor with an AGMA Class I helical gear screw conveyor drive with adapter flange mounting and end thrust capacity to achieve specified speed.
c. The motor shall be inverter duty rated for 6 to 90 Hz with sufficient power to start and continuously operate when under full bin load.
4. Flighting:
a. Designed to achieve uniform discharge through the gates.
b. Minimum of 1/4 inch thick.
c. Torque tube shall be of sufficient size to limit deflection to 0.2 inch maximum. Pipe ends shall have a sleeve coupling with shear bolt to stub shaft to mount the drive.
5. Shafting: End shafts will be fabricated from C 1045 steel, minimum.
6. Trough End Bearings: Each screw will include regreasable roller bearing at non- drive end. The bearing will be capable of handling all impending radial loading.
7. Stuffing Box:
a. Shaft seals will be provided at the trough ends and shall be of the packing gland type with a minimum 4 rows packing.
b. A lantern ring with grease purge connection shall be provided for additional sealing.
8. Troughs:
a. Troughs shall be integral to the silo and shall transport sludge to outlets.
b. Minimum thickness of 1/4 inch complete with external stiffeners as required.
9. Discharge Gates:
a. Discharge gates (two for each conveyor section) under the bin shall be provided to seal the bin when not in use.
b. Gate Blade Maximum Deflection: 1/8 inch over actual width.
c. Fabricated from single piece of 304 stainless steel.
d. Support blade on heavy duty rollers with minimum diameter of 2-1/4 inches;
maximum 6-inch centers.
e. Gate opening shall be 48 inches x 48 inches nominal.
f. Designed to operate as an integral part of the system and shall be supplied by the manufacturer.
g. In closed position, the gate blade shall seal against an elastomer seal. Seal leakage shall not exceed 0.05 GPM per linear foot of perimeter.
10. Pneumatic cylinder gate actuator:
a. Provide two 6-inch diameter (minimum) heavy duty cylinders per gate.
b. Side mounted.
c. Double acting.
d. Hard chrome-plated rod with double seal configuration.
e. Sized for actuation at 80 psig.
f. Provide solenoid type directional control valve, four-way, double coil, three- position with cylinder ports blocked in center position. NEMA 4 rated and mounted to gate frame.
g. A gate control panel shall be provided with an Open-Close-Remote selector switches and other devices as shown on the Drawings.
11. Guarding: OSHA style guarding will be provided by the manufacturer at all rotating components.
2.5 SPARE PARTS
A. Extra Materials:
1. Furnish OCSD the following extra parts:
a. Two extraction screw conveyors
b. One extraction screw drive
c. One set of rope packings for each Conveyor seal.
2. Initial supply of necessary lubricants as recommended by the manufacturer.
PART 3 - EXECUTION
3.1 PREPARATION
A. Field verify dimensions of existing hopper prior to fabrication.
B. For protective coating of all components and required surface preparation refer to section 09800, Protective Coating.
3.2 INSTALLATION
A. See Section 11005, Equipment: Basic Requirements.
B. See sequencing requirements in Section 01140, Work Restrictions.
C. Vertically and horizontally align, level and plumb units into position.
3.3 MAINTENANCE OF INSTALLED EQUIPMENT, GATES AND VALVES
A. Maintain the operability and functionality of all installed equipment, gates and valves between the time of installation and the commissioning period. See Specification section 01660 for requirements.
3.4 MANUFACTURER’S FIELD SERVICES
A. Furnish the services of authorized technical representatives of the Manufacturer to assist/inspect the installed equipment and to certify that the equipment has been properly installed and is ready to operate, train OCSD personnel, conduct pre-operational mechanical checkout of the equipment, place equipment into operation, optimize the performances of the equipment and perform the field performance testing.
B. At a minimum, conduct three separate site visits as follows:
1. Inspection of equipment installation (8 hours minimum)
2. Training of OCSD Personnel: See Specification section 01820, Training of OCSD Personnel, for requirements.
3. Commissioning: See Specification section 01810, Commissioning, for requirements. Number of hours shall be as required to meet all testing and commissioning requirements, but shall not be less than 16 hours.
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