SECTION 11222 SLUDGE REMOVAL SYSTEM

SECTION 11222
SLUDGE REMOVAL SYSTEM

PART 1 - GENERAL

1.1.        WORK OF THIS SECTION

A.   SCOPE: This section covers furnishing of a complete sludge removal system as specified herein. The sludge removal equipment shall be designed for installation in basins having the dimensions indicated herein and on the drawings. Sludge removal equipment that will be installed within the basins above the sludge removal system is covered in other sections.

B.   CONTRACTOR: Shall furnish all labor, materials, equipment, and incidentals as shown, specified and required to provide a complete sludge removal system as specified herein..

C.   GENERAL: Equipment finished under this section shall be fabricated and assembled in full conformity with drawings, specifications, engineering data, instructions, and recommendations by the named equipment manufacturer.

D.   MANUFACTURER of the sludge removal equipment shall be vested with unit responsibility for the proper function of the complete sludge removal system as specified. The equipment covered by this specification is intended to be standard equipment of proven ability as manufactured by reputable concerns having extensive experience in the production of such equipment.

1.2.        REFERENCES

A.   The following is a list of standards which may be referenced in this section:
1.    American Society for Testing and Materials (ASTM)
2.    ASTM A167 – Type 304L & 316L Stainless Steel
3.    American National Standards Institute (ANSI)
4.    American Welding Society (AWS)

1.3.        SUBMITTALS

A.   Submit for approval the following
1.    Provide (4) complete approval submittal manuals. Manuals shall be in a white 3-ring binder, and include tabbed sections defining scope, process calculations, mechanical and structural calculations, catalog cuts, and drawings.
2.    All structural design calculations shall be prepared by the manufacturer and sealed by a registered professional engineer.
3.    Manufacturer’s literature, illustrations, specifications, and engineering data including total weight of each unit, structural loads at supports, connection details, and performance data.
4.    Drawings shall show dimensions, overall arrangement of equipment and materials of construction.
5.    Literature and certified shop drawings describing the equipment and showing all important details of construction and dimensions. Dimensions shall show overall size and space requirements including that for installation, leveling, dismantling and maintenance.
6.    Cross sections and details, as to show that all components are in conformance with the intent of the specification and are satisfactory from the standpoint of design and physical arrangement.
7.    All information required for the detailed design and location of all connecting or adjacent structural, mechanical, items, such as foundations, anchor bolts, steel supports, piping, conduit,
etc. Any recommended or required deviations from the dimensions and locations of connecting or adjacent items as shown in the Drawings shall be described completely in the submittal.
8.    Weight of the equipment and its distribution on the supports.

B.   Operations and Maintenance Manuals
1.    Submit (4) complete operation and maintenance manuals. Manuals shall be in a white 3-ring binder with tabbed sections to include reinforced 8.5” x 11” paper, 11” x 17” B-size drawings when practical, and individually sleeved D-size drawings.
2.    The manual shall include: Equipment Introduction and Operation, Warranty, Troubleshooting, Maintenance, and Drawings.
3.    Field start-up reports as described in paragraph 3.3 (Manufacture’s Services) shall be submitted after start-up for owner’s insertion into approved O&M manual.

1.4.        QUALITY ASSURANCE

A.   Basis of Design: The structural, mechanical and process design for the sludge removal system are based on information provided by the first-listed Manufacturer. The cost of any changes and modifications resulting from the use of other approved sludge removal equipment shall be borne solely by the CONTRACTOR. Fundamental changes in the configuration of the sludge removal system will not be allowed. The CONTRACTOR shall submit drawings and supporting documents, identifying all proposed changes, to the ENGINEER for approval. Supporting documents shall delineate all proposed changes including complete structural calculations stamped and signed by a Registered Professional Engineer.

B.   Structural Design

1.    The structural design of the sludge removal system shall be in accordance with the requirements of the International Building Code 2006 (IBC).
2.    The sludge removal arrangement shown on the Contract Drawings is based on design information provided by the first listed Manufacturer. The actual installation requirements including the location of outlet piping shall be based upon shop drawings submitted by the CONTRACTOR and approved by the ENGINEER based upon the requirements specified herein.

C.   Responsibilities

1.    The S Manufacturer is responsible for delivery of equipment and supplies required under these specifications. The CONTRACTOR is responsible for proper coordination and integration of all equipment required for installation in the basins and all other associated work shown on the drawings and specified in the Contract Documents. The CONTRACTOR is responsible for ensuring that the sludge removal system shall be properly coordinated and will function as a unit
in accordance with these specifications. The CONTRACTOR shall bear ultimate responsibility for equipment coordination, installation, operation, and guarantees.

D.   Workmanship

1.    Workmanship in the fabrication of the sludge removal system shall be first-class, including the following requirements. The sludge removal system shall have members that are straight and true. Structural distortions, warps, and other defects shall not be present in the sludge removal before or after installation in the sedimentation basins. All exterior surfaces and edges of the sludge removal system shall be smooth. Sharp corners shall be ground round and smooth.

1.5.        PRODUCT DELIVERY, STORAGE, AND HANDLING

A.   All equipment shall be shipped with suitable in transit protection. Special handling instructions shall be included.

B.   Equipment shall be stored and protected in accordance with the manufacturer's recommendations.

1.6.        SYSTEM DESCRIPTION

A.   The sludge removal system shall be designed for operation in the sedimentation basin as indicated on the Contract Drawings. The equipment shall be designed for the following conditions as listed in the Process Table B below.
B.   PROCESS TABLE


Service New Intermediate Existing Intermediate  
Number of Basins 2 2  
Inside Basin Width (ft) 24 24  
Inside Basin Length (ft) 40 40  
Side Water Depth (ft) 12’- 5” 12’- 5”  
Basin Bottom Flat Flat  
Raw Water Characteristics Prior To Flocculation  
Temperature, Fahrenheit 33-90 33-90  
Turbidity, NTU 10-500 10-500  
pH 5.5-8.0 5.5-8.0

PART 2 - PRODUCTS

2.1.  ACCEPTABLE MANUFACTURERS

A.   The equipment shall be manufactured by:
1.    Jim Myers & Sons, Inc. (JMS), of Charlotte, NC
2.    Siemens
3.    Or approved Equal.

B.   The equipment described by this specification defines minimum equipment requirements as supplied by the first listed manufacturer. All unforeseen costs associated with any deviation from this specification shall be the sole responsibility of the Contractor.

C.   The equipment shall be the product of a manufacturer engaged in the design and manufacture of water treatment equipment in successful operation in similar applications. The manufacturer shall have a minimum of 30 years of United States municipal water experience.

D.   Pre-qualification requires manufacturers to submit the following 60 days prior to bid:

1.    A list of at least 10 previous installations, including contact information, of similar size, design, and complying with the requirements as set forth within this specification.
2.    Preliminary drawings and process calculations specific to this project.
3.    A letter stating that their proposed design complies with all requirements as specified herein. If there are deviations from the specification a letter must address each deviation in detail.
4.    Equipment shall be manufactured in the United States by US citizens fully certified by the American Welding Society for the tungsten inert gas (TIG) welding process to standard AWS D1.6. Letters of current certification shall be provided prior to bid and within the submittals.

2.2.        MATERIALS OF CONSTRUCTION

A.   The components of the sludge removal system shall be made from the following material:
1.    Type 304L SS unless otherwise specified.
2.    All field mounting and assembly hardware shall be Type 316 stainless steel.

2.3.        DRIVE ASSEMBLY

A.   Drive assembly designed to move the header assembly back & forth across the length of the basin. The drive unit shall be mounted on the concrete wall at one end of the basin and consist of:

1.    SEW Eurodrive ½-HP parallel shaft helical gearmotor.
2.    Take-up & payout cable drums.
3.    3/16-inch Type 304 stainless steel stranded cable.
4.    Overload mechanism.
5.    Rotation proximity switches
6.    End of travel proximity switches.
7.    Upper and lower cable sheaves.
8.    Type 304 stainless steel cover with hold down clips.

B.   Each assembly shall be towed along the length of the basin by a stainless steel stranded wire cable. C.   The drive cable shall be affixed to the header guide assembly.
D.   All rotating parts shall be provided with guards conforming to OSHA standards.

2.4.        IDLER ASSEMBLY

A.   Complete with Type 304 stainless steel base. B.   UHMW polyethylene sheaves.

C.   The idler assembly, complete with base and UHMWPE sheave, with a Type 304 stainless steel shaft, shall be provided for installation as shown on the plans, and as needed for a complete installation.

2.5.        DUAL COLLECTION HEADER ASSEMBLY

A.   Type 304 stainless steel dual collection header assembly consists of:
1.    Suction header pipes with sludge removal orifices, constructed of 4-inch schedule 10S Type 304 stainless steel.
2.    Collection pipe constructed of 4-inch schedule 10S Type 304 stainless steel.
3.    Removable end caps.
4.    Flanged suction hose connection.
5.    Cable connection rings.

B.   All fittings used in the header pipe shall be continuously welded. C.   Pipe and fittings shall be Type 304 stainless steel.
D.   A header pipe shall be furnished with removable stainless steel clamps. The end caps shall be easily removable for inspection of the interior of the header pipe.

E.   Orifices shall be located along the leading edge of the header pipes, with size and location as determined by the manufacturer to optimize sludge removal and head loss characteristics.

F.   The header pipe shall be a minimum of 4" diameter.

G.   The guide assembly shall be fitted with UHMWPE lineal capturing guides conforming to the monorail shape. This is to prevent the mechanism from coming off the monorail inadvertently.

2.6.        MONORAIL AND GUIDE TRUCK ASSEMBLY

A.   Type 304 stainless steel guide assembly consists of:
1.    Linear bearing guide trucks constructed of Type 304 stainless steel.
2.    UHMW polyethylene guide rail capture slide blocks/wheels. B.   The monorail shall be constructed of Type 304 stainless steel.
C.   The ends of each section of monorail shall be rounded and carefully ground smooth to allow the drive guide truck assembly to move unimpeded across the joints between the guide rail sections.
2.7.        FLEXIBLE SLUDGE HOSE

A.   Flexible sludge extraction hose of high density polyethylene, consisting of:
1.    4-inch flexible high density polyethylene hose.
2.    Stainless steel fittings.
3.    Hose connectors.

B.   A flexible sludge extraction hose shall be provided by the manufacturer of the sludge removal equipment. The hose shall be sized to effectively remove sludge and operate within appropriate headloss constraints.

C.   The flexible hose shall be manufactured of polyethylene hose reinforced with an integral polyethylene helix.

D.   Hose shall be a minimum of 4" diameter.

2.8.        CONTROL PANELS

A.   control panel completely factory prewired and assembled for manual and automatic operation of the sludge collection units for field mounting by others, including:
1.    NEMA 4X stainless steel wall mount enclosure
2.    programmable controller
3.    solid state speed DC motor control system with speed control
4.    status indication lights
5.    overload protection system
6.    reversing control system
7.    emergency stop push button
8.    relays, terminals, surge arrestor, and receptacle, factory internally mounted
9.    open-auto-close selector switches with contacts for operation of the sludge valves

B.   The control panel shall be completely prewired and tested by the sludge collector manufacturer for manual and automatic control of the units.

C.   A key operated door interlock system and selector switches shall be installed on the control panel door. D.   A PLC controller shall be provided to vary the speed of the drive assembly.
E.   A reversing function shall be provided with time delay to change the header pipe direction of travel.

F.   All electrical components shall be labeled to agree with the electrical schematic. All wiring shall be in accordance with the National Electric Code.

G.   The enclosure for the control panel shall be 304 stainless steel, NEMA 4X, mounted on supports provided by others. Power requirements shall be 120 volt, 60 Hz, single phase.

H.   A rotation switch is to be affixed to the driven pulley shaft to provide a signal source indicating drive overload condition.

I.    The control panel shall include relay contacts for external overload condition alarm.

J.    The control panel shall provide an output signal to open and close sludge control plug valves as shown on the drawings

2.9.        HARDWARE

A.   All field assembly bolts and anchor bolts, nuts, and washers shall be Type 316 stainless steel. B.   All submerged connections shall utilize Type 316 stainless steel nylon insert locknuts.
C.   Anti-seize compound shall be applied to the threads of all stainless steel bolts before assembly.

PART 3 - EXECUTION

3.1.  INSTALLATION

A.   The Contractor shall install the sludge removal equipment in strict accordance with the manufacturer's recommendations.

B.   Anti-seize thread lubricant, which is NSF-61 approved, shall be applied to the male threads of all stainless steel bolts at the time of the assembly.

3.2.  WARRANTY

A.   The supplier shall guarantee in writing that the equipment furnished is appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of 1 year after the equipment is satisfactorily placed in service. If the equipment is not placed in service within 6 months of delivery, the 1 year guarantee period shall commence 6 months after delivery.

3.3.  MANUFACTURER'S SERVICES

A.   Manufacturer’s Field Services: The CONTRACTOR shall provide the following services in addition to any other services specified herein, and required by these Specifications.

1.         A factory trained manufacturer’s representative shall be provided for a minimum of two (2) trips and a minimum of three (3) eight hour days to provide installation supervision, start-up and field testing services, and O&M training services. The installation services shall be coordinated between the CONTRACTOR and the manufacturer. The start-up and field testing services, and the O&M services shall be coordinated with the ENGINEER.
2.         After installation supervision and field testing services by the manufacturer, the CONTRACTOR shall submit to the ENGINEER, a certification letter on the manufacturer’s letterhead and signed by the manufacturer certifying that the equipment was installed per the manufacturer’s recommendations.
3.         The manufacturer shall provide start-up reports covering installation inspection and start up activities.
4.         The manufacturer shall provide operator training to all required plant personnel.

B.   All costs, including travel, lodging, meals and incidentals for manufacturer service shall be included in the CONTRACTOR’S bid