SECTION 46 43 11.50

CHAIN-AND-FLIGHT ALIGNMENT MONITORING SYSTEM

_{PART 1 – GENERAL}

_{1.1 DESCRIPTION}

A. Scope:

1. CONTRACTOR shall provide all labor, materials, equipment and appurtenances required to provide a complete chain and flight collector alignment monitoring system for Primary Settling Tank (PST) Nos. 1 TO 6. The system shall detect chain failure, attachment link failure, and excessive chain misalignment from a chain jumping a sprocket tooth. The monitoring system shall monitor three (3) Longitudinal mechanisms and one (1) Cross Collector mechanism for each PST. See Specification 46 43 11 for a full description of the collector mechanisms

2. Manufacturer shall design and fabricate extension mechanisms for sensing flight movements as required to assure a proper functioning system.

3. Manufacturer of this Section must also be the provider of Section 46 43 11, Rectangular Chain and Flight Sludge Collection Equipment.

4. Upon ENGINEER’s approval, proprietary monitoring systems designed by the chain and flight manufacturer may vary from the specification requirements in Part 2.3 of this Section given the proprietary design meets the system’s overall performance requirements and intent. The remaining requirements of this Section and Section 40 61 96, Process Control Descriptions, shall be met.

5. CONTRACTOR shall provide wiring and conduit of the sensors from the deck level to the flight monitoring system control panel.

6. Monitoring system shall meet the environmental and NEC classified areas described in specifications and/or shown on drawings.

7. The CONTRACTOR shall remove existing PAC E29_PT_DN and turn over the panel and all contents to the OWNER. The CONTRACTOR shall be responsible for replacing all the components and functionality of PAC E29_PT_DN with the new Rockwell ControlLogix PAC 25-PA-PLC-PST. CONTRACTOR shall also add two new ControlLogix RIO PAC panels as specified and as shown on the drawings.

B. System Description:

1. Provide electrical and control equipment to monitor the chain and flight collector alignment / run status by forwarding an alarm (via Ethernet/IP) to new ControlLogix PAC 25-PA-PLC-PST located in the Central Gallery. Alarm shall be provided to 25-PA-PLC-PST in the event of chain failure, attachment link failure, or excessive misalignment. The flight misalignment alarm setpoint shall be adjustable through the PAC programming.

2. The new flight alignment monitoring Rockwell ControlLogix PAC 25-PA- PLC-PST located within the new control panel shall communicate directly with ControlLogix RIO panels 25-PA-RIO-PST-SE and 25-PA-RIO-PST- SW via Ethernet/IP. See drawings for Ethernet setup. RIO panel 25-PA- RIO-PST-SE shall be connected to the CONTRACTOR-supplied I/O for PST tanks 2, 4, and 6. RIO panel 25-PA-RIO-PST-SW shall be connected to CONTRACTOR-supplied I/O for PST tanks 1, 3, and 5. New PAC panel shall also contain an Allen-Bradley PanelView Plus 6 operator interface, “Type “B”. Details for the new PACs and PanelView are found in Specification Section 40 64 00 and on the drawings.

3. All hardware, including extension mechanisms required to provide contact with submerged flights and sensor mounting brackets, shall be designed and fabricated by the monitoring system or sensor manufacturer. Hardware shall be 316 or 304 stainless steel.

C. Coordination:

1. Review installation procedures under this and other Sections and coordinate installation of items to be installed with or before the Chain and Flight Monitoring System Work.

D. Related Sections:

1. Division 26, Electrical.

2. Division 40, Instrumentation.

3. Section 46 43 11, Rectangular Chain and Flight Sludge Collection

Equipment.

_{1.2 REFERENCES (NOT USED)}

_{1.3 QUALITY ASSURANCE}

A. Qualifications:

1. Manufacturer: Shall have a minimum of five years experience of producing equipment substantially similar to that required and shall be able to submit documentation of at least five installations in satisfactory operation for at least five years each.

B. Component Supply and Compatibility:

1. Obtain materials and equipment included in this Section, regardless of component manufacturer, from the chain and flight collector equipment manufacturer.

2. Chain and flight collector equipment manufacturer shall review and approve, or shall prepare, all Shop Drawings and other submittals for components furnished under this Section.

3. Equipment shall be specifically constructed for specified service conditions.

Equipment and components shall be integrated into overall chain-and-flight clarifier equipment system by chain-and-flight clarifier equipment manufacturer.

_{1.4 SUBMITTALS}

A. Action Submittals: Submit the following:

1. Shop Drawings

a. Complete description in sufficient detail to permit an item comparison with the specification.

b. Dimensions and installation requirements.

c. Descriptive information including catalog cuts and manufacturers specifications for all components.

d. Electrical schematics and layouts.

e. Programmable logic computer ladder logic.

f. A statement by the equipment manufacturer listing any deviations or exceptions taken to these specifications, including specification reference and proposed alternative with the reason for the exception. The acceptability of the deviation or exception will be at the sole discretion of the ENGINEER.

g. Control Panel Shop Drawings shall be in accordance with Section

40 67 17, Process Control Panels and Enclosures.

2. Product Data:

a. Manufacturer’s literature, illustrations, specifications and engineering data.

B. Informational Submittals: Submit the following:

1. Manufacturer’s Instructions:

a. Special shipping, storage and protection, and handling instructions.

b. Installation data for the equipment, including setting drawings, templates, and directions for installing anchorage devices and paddle extension arms.

c. Routine maintenance requirements prior to start-up. d. Instructions for start-up and troubleshooting.

2. Source Quality Control Submittals:

a. Report of results of testing and inspections performed at manufacturer’s shop.

3. Site Quality Control Submittals:

a. Report of results of operating test.

4. Supplier Reports:

a. Submit written report of results of each visit to Site by Supplier’s service technician, including purpose and time of visit, tasks performed, and results obtained. Submit within two days of completion of visit to the Site.

5. Qualifications Statements:

a. Manufacturer, when submittal of qualifications is required by

ENGINEER.

C. Closeout Submittals: Submit the following:

1. Operations and Maintenance Data:

a. Submit in accordance with Section 01 17 30, Operations and

Maintenance Data.

b. Include acceptable test reports, maintenance data and schedules, description of operation, wiring diagrams, and list of spare parts recommended for one year of operation with current price list.

_{1.5 DELIVERY, STORAGE, AND HANDLING}

A. Packing, Shipping, Handling, and Unloading:

1. Deliver materials and equipment to Site to ensure uninterrupted progress of the Work. Deliver anchorage materials to be embedded in concrete in ample time to prevent delaying the Work.

2. Comply with Section 01 16 00, Products, Materials and Equipment.

B. Storage and Protection:

1. Comply with Section 01 16 00, Products, Materials and Equipment.

_{1.6 WARRANTY}

A. General Warranty: Refer to Article 8.5 of General Conditions.

_{PART 2 – PRODUCTS}

_{2.1 EQUIPMENT PERFORMANCE}

A. All equipment and electrical devices in this specification shall be suitable for use in Primary Settling Tanks which includes primary sludge and scum handling and comply with NFPA 820 which requires that all devices be rated and UL, FM or CSA listed and labeled for Class I, Division 1, Group D for enclosed spaces and Class I, Division 2, Group D for areas open to atmosphere and within the classified area envelope.

B. Description: Provide a "chain and flight collector monitoring system" for each Longitudinal Collector mechanism and each Cross Collector mechanism, complete with flight sensing paddles, Hall Effect or inductive type non-contacting immersible sensors, mounting brackets, control panel and control panel-mounting stand.

_{2.2 MANUFACTURERS}

A. Manufacturers: Provide equipment of one of the following:

1. Siemens.

2. PolyChem.

3. Or equal.

_{2.3 MATERIALS AND ASSEMBLY}

A. Sensing paddles: For 4-shaft collectors: The sensing paddles shall be manufactured from type 316 stainless steel and will be mounted on a single axle point. The paddle shall be arranged to contact the flight at the wear shoe or flight as the flight passes the sensing point.

B. Mounting Brackets: The mounting brackets shall be manufactured from cast C6 nylon, fiberglass or Type 316 stainless steel and will be mounted to the tank walls with Type 316 stainless steel epoxy anchors. All attachments to the brackets shall be with Type 316 stainless steel bolts, nuts and washers.

C. Sensors: The sensors shall sense the movement of the paddles. The sensor shall be an inductive type to create a non-contacting sensing of the position of the flight. For above water installation within the NFPA 820 classified area envelope, the sensors shall be rated and UL, FM, or CSA listed and labeled for Class I, Division

1, Group D for enclosed spaces and Class I, Division 2, Group D for spaces open to atmosphere and within the classified area envelope. Intrinsic safe barriers in conjunction with the sensors to meet the hazardous area installation requirements shall be acceptable. On submersible installations, the sensor shall be at a minimum NEMA 6P rated for prolonged or continuous submersion within the installation depth. The sensor cable shall be potted directly to the switch cavity. The cable shall be of sufficient length to be able to directly connect a NEMA 7 conduit box located at the top of the tank wall. Cables shall run in conduit or and be in compliance with Section 26 05 33.13, Rigid Conduits.

D. Flight monitoring system for 3-Shaft sludge collectors shall monitor the flights to ensure they are not skewed or stalled. The system shall consist of intrinsically safe proximity sensors field installed on each side of each collector mechanism near the lower cornershaft. If required, targets mounted to flights shall be constructed of stainless steel. The sensors shall be suitably potted with integrally connected cable that will eliminate electrical connections under water. Manufacturer shall provide cable from the sensor to the tank operating floor, of sufficient length for connecting to CONTRACTOR’s supplied conduit box. CONTRACTOR shall provide conduit and wiring from CONTRACTOR’s supplied junction box to equipment manufacturer’s control panel. The sensors shall have a minimum sensing distance of 1 inch and shall be able to sense stainless steel.

_{2.4 CONTROLS}

A. Local PAC Control Panels:

1. The locally mounted PAC control panels shall comply with Section 40 64

00, Programmable Automation Controllers and Section 40 67 17, Process Controls Panels and Enclosures, and shall be of NEMA 4X stainless steel construction and shall be mounted indoors in the Central Gallery according to the drawings. Conduit entry shall be through the bottom of the PAC

panels.

2. The control panels shall be mounted at a height that places the center line of the PanelView operator interface, operators, and displays at approximately five feet above the finished floor elevation.

3. The main PAC control panel shall be outfitted with a PanelView Plus 6 “Type B” keypad and touch screen PAC interface mounted on the front face of the main PAC control panel. The PanelView shall be sealed with a gasket to maintain the NEMA 4X rating of the enclosure. See Specification Section 40 64 00 and on the drawings for the new PACs and PanelView details.

4. The touch screen interface shall monitor and display collector alarms for each monitored collector, system off-on selection for each collector, a horn silence, and a common alarm reset. The panel shall be outfitted with a beacon and horn which is annunciated as a result of collector misalignment.

5. Heaters, fans, or air conditioning shall be included as necessary.

CONTRACTOR shall provide heat rise calculations for all panels for approval.

B. PAC: The panels [main PAC panel (25-PA-PLC-PST) and two RIO panels (25- PA-RIO-PST-SE and 25-PA-RIO-PST-SW)] shall include a Rockwell ControlLogix programmable automation controller to monitor the sensors, activate collector malfunction alarms and provide human interface via keypad and touch screen PanelView mounted on the main PAC panel. The panels shall provide remote alarm contact defining flight misalignment (alarm and shutdown). Outputs shall be provided to shutdown each collector drive upon loss of motion or flight misalignment. Main PAC panel shall communicate to the RIO panels using Ethernet/IP protocol in a ring configuration. All collector flight monitoring equipment for PST Nos. 1 through 6 shall be included within the control panels. All PACs shall be Rockwell ControlLogix “Type A”, no substitutions.

C. Operation: With the individual tank monitoring system off-on selector switch in the "on" position flight position monitoring will begin when the chain drive is started. Zero speed will shut down the chain drive motor, and a loss of motion alarm indication will be turned on and displayed on the PanelView. If one chain jumps one link based on flight detection by the sensors, the misalignment alarm indication will be turned on and displayed on the PanelView. If one chain jumps two links or more based flight detection by the sensors, the misalignment shut down alarm indication will be turned on and displayed on the PanelView and the chain drive will be shut down.

D. Local Control Mounting: The local control panels shall be fastened to the wall using stainless steel strut to maintain minimum ½ inch clearance from the wall. Use Type 316 stainless steel epoxy anchors.

_{2.5 TOOLS AND SPARE PARTS}

A. Two (2) proximity sensors of each type with cable and watertight flexible conduit.

_{2.6 SOURCE QUALITY CONTROL}

A. Shop Tests:

1. Upon completion of manufacture of equipment and appurtenances, conduct manufacturer’s standard shop tests on the control panel prior to shipment. Shop tests shall be conducted using the control panel and sensors to be furnished for the Project.

_{PART 3 – EXECUTION}

_{3.1 INSPECTION}

A. Examine conditions under which materials and equipment will be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions are corrected.

_{3.2 INSTALLATION}

A. Install products in conformance with Laws and Regulations, applicable standards, manufacturer’s instructions and recommendations, and the Contract Documents.

B. All electrical power shall be furnished under Division 26.

C. Process monitoring and remote control shall be furnished under Division 40. D. Anchorages and Base Plates:

1. Provide anchorages in new or existing concrete, as applicable, in accordance with equipment manufacturer’s recommendations and the Contract Documents.

E. General:

1. For contact surfaces between aluminum and dissimilar surfaces, use a coat of bituminous paint or other approved insulating material.

2. Prior to energizing electric motor-driven equipment, rotate drive motor by an external source to demonstrate free operation of mechanical parts. Do not energize equipment until safety devices are installed, connected, and functional.

_{3.3 FIELD QUALITY CONTROL}

A. Site Tests:

1. After installation, CONTRACTOR and qualified field service representative of manufacturer shall conduct at the Site operating tests of equipment, including all functions, and controls, in presence of ENGINEER.

2. Field Operating Test:

a. Field test equipment and associated controls, followed by demonstrating proper operation and controls in operation with the PST Nos. 1 through 6 chain and flight collectors. Demonstrate that each part individually and all parts together function properly in manner intended. Equipment shall operate free of vibration, jamming, jerking, and overheating to satisfaction of ENGINEER. Running tests shall be performed to demonstrate proper operation of warning signals, chain break, and flight misalignment. Total duration of testing shall be 24 hours minimum, continuous and uninterrupted with the chain and flight collector equipment running. All testing equipment and labor shall be provided by CONTRACTOR.

b. Should tests indicate defective Work, including malfunctions, make necessary repairs, revisions, and adjustments and restart test from the beginning. Repeat tests and repairs, revisions, and adjustments until, in ENGINEER’s opinion, installation is complete and equipment is functioning properly and accurately, and is ready for permanent operation.

B. Manufacturer’s Services: Provide a qualified, factory trained serviceman to perform the following:

1. Instruct CONTRACTOR in installing equipment.

2. Inspect and adjust equipment after installation and ensure proper operation.

3. Instruct operations and maintenance personnel in operation and maintenance of the equipment.

4. Manufacturer’s technician shall make visits to the Site as follows:

a. Installation: Included in time and duration specified in Section

46 43 11, Rectangular Chain and Flight Sludge Collection Equipment. b. Start-up of system; Included in time and duration specified in Section

46 43 11, Rectangular Chain and Flight Sludge Collection Equipment c. Operational Training: Instruct operations and maintenance personnel.

1) Furnish services of manufacturer’s qualified, factory-trained specialists to instruct OWNER’s operations and maintenance personnel in recommended operation and maintenance of equipment.

2) Training requirements, duration of instruction and qualifications shall be in accordance with Section 01 79 23, Instruction of Operations and Maintenance Personnel.

3) Number of hours on-Site shall be in accordance with Section

01 79 23, Instruction of Operations and Maintenance Personnel.

d. Technician shall revisit the Site as often as necessary until installation is acceptable.

5. All costs, including expenses for travel, lodging, meals and incidentals, and cost of travel time, for visits to the Site shall be included in the Work.