SECTION 11650 BIOSOLIDS THERMAL DRYING SYSTEM - GENERAL

This spec was part of the Des Plaines, IL River WRF project tat bid Feb 26, 2015.


SECTION 11650

BIOSOLIDS THERMAL DRYING SYSTEM - GENERAL


PART 1 GENERAL

1.1 SECTION INCLUDES:

A. Welded Steel Tanks with Sliding Frame:
1. Truck Receiving Silo: T-11-17.
2. Hydraulic Power Unit: M-11-17.
3. Feed Storage Silo: T-11-20.
4. Hydraulic Power Unit: M-11-20.

B. Progressive Cavity Pumps:
1. Cake Transfer Pump No. 1: P-11-18.
2. Cake Transfer Pump No. 2: P-11-19.
3. Dryer Feed Pump No. 1: P-11-21.
4. Dryer Feed Pump No. 2: P-11-22.

C. Biosolids Thermal Dryer:
1. Paddle Dryer: M-11-1.

D. Off-Gas System:
1. Off-Gas Duct: M-11-8.
2. Spray Tower Condenser: P-11-9.

E. Liquid Ring Compressor:
1. Dryer Off-Gas Compressor: P-11-10.

F. Dry Product Handling Equipment:
1. Dryer Discharge Conveyor: M-11-2.
2. Cooling Conveyor: M-11-3.
3. Produce Screener: M-11-4.
4. Cooling Conveyor: M-11-5.
5. Off-Spec Return Conveyor: M-11-6.
6. Rotary Valve: M-11-7
7. Rotary Valve M-11-23.

G. Tubular Drag Conveyors:
1. Product Conveyor Number 1: M-12-1.

H. Dry Bulk Storage Bolted Steel Tanks:
1. Product Silo Number 1: M-12-5
2. Product Silo Number 2: M-12-8
3. Product Silo Number 3: M-12-11.
4. Vibrating Discharge No. 1: M-12-7.
5. Vibrating Discharge No. 2: M-12-10.
6. Vibrating Discharge No. 3: M-12-13.

7. Load Out Spout No. 1: M-12-6.
8. Load Out Spout No. 2: M-12-9.
9. Load Out Spout No. 3: M-12-12.
10. Product Silo Distribution Conveyor: M-12-4. 11. FV-12-4-1.
12. FV-12-4-2.
13. FV-12-4-3.
14. Dust Collection Fan: M-12-19.
15. Fines Dust Collection Tank: T-12-19.

I. Compressed Air/Nitrogen System:
1. Air Compressor 1: M-12-14.
2. Air Compressor 2: M-12-15.
3. Desiccant Dryer System: M-12-16
4. Nitrogen Generator: M-12-18.

J. Thermal Fluid Heating System:
1. Thermal Fluid Heat Exchanger: M-11-11.
2. Thermal Fluid Pump: P-11-12.
3. Thermal Fluid Heater: M-11-13.
4. Expansion Tank: T-11-14. 5. FV-11-11-1.
6. PCV-11-14.
7. PRV-11-14-1.
8. PRV-11-14-2.

K. Local Control Panels:
1. Biosolids Dryer Control Panel: 60-LCP-11-1.
2. Heater Control Panel: 60-LCP-11-3.
3. Truck Receiving Silo Control Panel: 60-LCP-11-17.
4. Feed Storage Silo Control Panel: 60-LCP-11-20.
5. Dust Collection Control Panel: 60-LCP-12-4.
6. Silo Control Panel: 60-LCP-12-5.
7. Air Compressor Control Panel: 60-LCP-12-1.
8. Air Compressor Control Panel: 60-LCP-12-2.
9. Air Dryer Control Panel: 60-LCP-12-3.

1.2 SYSTEM DESCRIPTION

A. The biosolids drying system shall dry municipal biosolids cake to produce a Class A product in accordance with 40 CFR Part 503 requirements.

B. Product exit the biosolids drying system shall be stored in the dry product storage area. The product storage silo is complete with bin vent, vibrating bin discharger, load out spout, and dust collector.

C. The system supplier shall provide general installation details to the contractor and engineer. In addition, the system supplier shall inspect the system for proper installation and operationally test all the equipment necessary to provide a complete biosolids drying system.

D. The system supplier will provide services for supervision of commissioning, field-testing, start-up, and training of plant personnel in the operation of the system.

E. The system supplier shall furnish the complete instrumentation and control system. The system includes all materials and documentation required to install, test and place in operation a complete and operable instrumentation and control system as specified. The system shall include all measuring elements, control devices, signal converters, transmitters, local control panels, digital hardware and software, operation workstations, and communication networks to provide the functions indicated.

F. The system supplier shall guarantee performance of the complete system according to Design Requirements.

1.3 REFERENCES

A. NFPA - National Fire Protection Association

B. NEC - National Electrical Code

C. NEMA - Standards of National Electric Manufacturers Association

D. OSHA - Occupational Safety and Health Administration

E. AISC - Manual of Steel Construction

F. ASME - Standards of American Society of Mechanical Engineers

G. AGMA - American Gear Manufacturers Association

H. ANSI - American National Standards Institute

I. ASTM - American Society of Testing and Materials

J. AWS - American Welding Society

K. CEMA - Conveyor Equipment Manufacturers Association

L. IEEE - Institute of Electrical and Electronics Engineers

M. ISA – International Society of Automation

1.4 DESIGN REQUIREMENTS

A. General Requirements:
1. The drying system shall utilize indirect heating technology, where a heated metal surface comes in contact with dewatered sludge cake for drying. Direct drying systems, where the dewatered wastewater sludge is exposed directly to the heating medium (hot gases or air), are not acceptable due to the excessive amount of      air or gas required for drying and the associated magnitude of contaminated off-gas or air requiring treatment.

2. The indirectly heated thermal dryer will be of the dual counter-rotating shaft design in which thermal fluid circulates within hollow paddles to provide indirect heating of the dewatered cake.
3. The dryer design shall feature discontinuous, wedge-shaped paddles specifically designed for optimum heat transfer and proper mixing of the sludge to insure product uniformity. The heated paddles shall not be pitched. The shaft’s rotational speed shall be independent of the product throughput.
4. Because dewatered sludge cake can vary both in feed solids and in composition, it is necessary to monitor the product temperature and adjust the residence time of the sludge in the dryer. Multiple temperature sensors shall be provided to monitor the temperature of the sludge at various locations along the dryer bed. A temperature sensor shall also be required to monitor the feed inlet conditions. Residence time shall be adjustable by changing the height of the dryer discharge weir.
5. The heated paddles shall be of the non-conveyance type specifically designed to handle and mix wastewater sludge cake. The paddles shall knead the sludge and provide radial mixing to insure that the sludge dries uniformly without over heating the product. Dual shaft designs which do not incorporate wedge-shaped paddles or other designs which function as conveyors are not acceptable because they do not provide the functionality herein described.
6. The heated paddles shall be of a wedge shaped, self-cleaning design that creates variable void spaces to enhance and generate shearing action across the heated surfaces. Paddles that maintain uniform volumes between the paddles or do not create variable void spaces shall not be acceptable because they do not provide the intimate and variable energy mixing herein described.
7. Because of the intermeshing action required for self-cleaning and optimal agitation, maintaining shaft synchronization is important and is to be accomplished mechanically with the use of intermeshing timing gears. Adjustable individual shaft speeds which may result in shaft collisions, interferences, or rubbing shall not be permitted. The use of electrical sensors to maintain shaft synchronization shall not be allowed.
8. The dryer shall be designed with materials of construction appropriate for the application herein described. To withstand the corrosive characteristics of heated, dewatered, wastewater treatment plant sludge cake, stainless steel shall be used in the fabrication of the process contact surfaces, vessel trough, hood, paddles and shaft except for the shaft adjacent to the last five (5) paddles which will have hard surfacing weld applied directly onto the carbon steel shaft.
9. To withstand the abrasive nature of drying municipal biosolids the dryer paddles and trough shall have hard facing applied in selected areas.
10. For thermal fluid heated dryers, the mixing cup temperature of the thermal fluid shall not exceed the fluid’s flash point. The EQUIPMENT SUPPLIER shall provide thermal fluid data sheets showing compliance. Dryers operating at fluid temperatures exceeding the fluid’s flash point shall not be acceptable due to the increased risk of inadvertent combustion.

B. Performance Requirements
1. The indirect drying system shall process dewatered waste activated sludge from an extended air activated sludge process with fine screening (1/4-inch spacing)

and grit removal and without primary clarification to produce a Class A product in accordance with 40 CFR PART 503 requirements.
2. The indirectly heated thermal biosolids drying system shall be designed for the following operating conditions:
a. Dryer Production Rate, wet (lbs/hr): 11,600.
b. Design Feed Solids, dry solids: 15% (Range 14 to 18%).
c. Biosolids: Waste Activated Sludge (extended aeration).
d. Number of Drying Systems: One.
e. Evaporation Rate, lb/hr: 9,700.
f. Design Product Solids, dry solids: 92%.
g. Maximum Product Temperature exiting the product cooler: 120°F.
h. Heat Transfer Medium: Thermal oil.
i. Area Classification: Per NFPA 820 Latest Edition.
3. The evaporation rate shall be the guaranteed rate. The dryer system will be designed to operate continuously, 24 hours per day, five days per week.
4. Natural gas will be used as the fuel source for the drying system. The energy demand for the drying system shall not exceed 1,450 BTU per pound of water evaporated. Energy demand shall be verified during performance testing.
5. Utility Requirements
a. Electrical: 3 Phase, 60 Hz, 480 Volt Power is required.
b. Gas: 16,500 CFH of Natural Gas is required at the Thermal Fluid Heater based on 85% heater efficiency. Natural Gas is assumed to have an LHV of 1,000 BTU/cft.
c. Plant Water: 380 gallons per minute at 40 psig with a maximum water temperature of 75°F. The water is filtered plant effluent with a normal suspended solids content of less than 10 mg/l.

C. Performance Guarantee:
1. The EQUIPMENT SUPPLIER shall guarantee performance of the complete system.
2. The EQUIPMENT SUPPLIER shall submit a performance bond relative to the process design conditions listed above. The bond provided shall be for guarantee of the drying system evaporation rate as specified herein and for the successful operation of the drying system equipment in accordance with its intended purpose without excessive failures.
3. In the event that the equipment is not meeting the guaranteed performance standards, the EQUIPMENT SUPPIER shall alter the equipment to meet the guaranteed performance standards. All costs associated with modifications shall be borne by the manufacturer. Upon modifying the equipment, the performance tests shall be repeated. All costs associated with the retesting, including Engineer’s and Contractor’s costs, shall be borne by the EQUIPMENT SUPPLIER.

D. Design Criteria
1. Governing Code International Building Code 2012 edition.
2. Seismic Loading per Drawing 01-S-2 Building 60-Structural Data.

1.5 SUBMITTALS

A. Shop Drawings: Submit under provisions of Division 1, including the following:

1. Divide and submit the Shop Drawings up per detailed specification sections.
2. Product Data and equipment cutsheets, including product description, model number, capacities, design conditions, operating characteristics, performance data, dimensions, clearances, weights, service sizes, etc.
3. Electrical schematics for all control panels. Provide the ladder-type wiring diagrams showing all components, all interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field wiring.
4. Provide instrumentation list.
5. Provide complete detailed Manufacturer’s P&ID’s showing field instrumentation, motor control, local control and IO.
6. Provide Manufacturer process flow diagram (English Units) from cake feed through cooled product, including cooling water, leakage air, dryer off-gas, exhaust to aeration basin, and thermal fluid.

B. See Detail Biosolids Thermal Drying System Specifications at the end of this section.

1.6 OPERATION AND MAINTENANCE DATA

A. Submit operation and maintenance data under provisions of Division 1.

B. Divide and submit the operation and maintenance manuals up per detailed specification sections.

C. Include manufacturer's descriptive literature, operating instructions, cleaning procedures, replacement parts list, and maintenance and repair data.

1.7 DELIVERY, STORAGE AND HANDLING

A. Deliver, store, and handle the equipment under the provisions of DIVISION 1.

1.8 QUALITY ASSURANCE

A. The EQUIPMENT SUPPLIER shall be ISO 9001 Certified.

B. The complete biosolids drying system shall be supplied by the EQUIPMENT SUPPLIER of the indirectly heated dryer. The EQUIPMENT SUPPLIER shall be responsible for the interfacing of all supplied equipment.

C. The completed work shall include all necessary permanent devices, such as machinery guards and similar items required by OSHA and other federal health and safety regulations.

D. Welding shall comply with AWS standards and shall be accomplished using the metal- arc or gas-shielded arc method described in the American Welding Society’s Welding Handbook. As supplemented by other AWS standards Qualification of welders, all welding shall comply with AWS and ASME standards. The pressure parts of the dryer will be manufactured and stamped in accordance with ASME Section VIII.

E. The biosolids indirectly heated thermal dryer system’s EQUIPMENT SUPPIER shall demonstrate that they have experience with NFPA standards and that the drying system

provided is in conformance with these standards per OSHA Directive CPL03-00-008. These include:
1. NFPA 30 – Flammable and Combustible Liquid.
2. NFPA 68 – Standard on Explosion Protection by Deflagration Venting.
3. NFPA 69 – Standard on Explosion Prevention Systems.
4. NFPA 654 – Standard for Prevention of Fire Dust and Explosions from Manufacturing, Processing, and Handling Combustible Solids.
5. NFPA 820 – Standard for Fire Protection in Wastewater Treatment and Collection Facilities

1.9 EQUIPMENT SUPPLIER'S QUALIFICATIONS:

A. The biosolids dryer specified under this Section shall be furnished by an EQUIPMENT SUPPLIER with a minimum of ten (10) years of experience in the business of engineering, designing, and manufacturing indirectly heated biosolids dryers for drying dewatered municipal biosolids cake.

B. Confidence derived from direct experience over a sustained period of operation under actual WWTP conditions is critical. Accordingly, the EQUIPMENT SUPPLIER shall have at least three (3) municipal dryer systems installed and in operation, each successfully operating for a minimum of five (5) years and consistently generating Class A biosolids using a dual shafted paddle dryer of a similar size and type as herein specified.

1.10 PAYMENT SCHEDULE

A. Issuance of all engineering submittals - 10%

B. Release for fabrication following approved shop drawings - up to 15% with submission of purchase orders to the Owner.

C. Equipment delivery to the site - up to 60% with partial lien waivers.

D. Commissioning - 10% after successful completion of 30 consecutive days of system operation by the Owner.

E. Substantial Completion - 5% at project substantial completion


PART 2 PRODUCTS

2.1 ACCEPTABLE EQUIPMENT SUPPLIERS

A. Komline-Sanderson, Peapack, NJ.
1. The contract documents are based on this equipment.

B. Andritz Separation Inc., Arlington, TX.
1. Bidders proposing to offer Andritz Separation as the Equipment Supplier shall incorporate in the price all additional costs for and be responsible for layout, piping, plumbing, mechanical, HVAC, structural, instrumentation and control,

electrical, and all other changes to the Work required to incorporate the proposed equipment into the Work.

C. Or Equal.

2.2 GENERAL

A. All equipment shall be the end product of one Dryer Equipment Supplier. The supplier shall be responsible for the complete system including all items covered herein.

2.3 METAL FABRICATION

A. Fabricated metal parts described herein shall conform to Section 05500.

B. All welds shall be continuous unless otherwise specified. Facing surfaces of bolted joints shall be shop primed. Facing surfaces of field welded components shall be beveled and match marked.

C. Edge Grinding. Sharp corners of all cut and sheared edges shall be made smooth.

D. Anchor bolts, fasteners, nuts, and washers: 316 stainless steel.

2.4 EQUIPMENT

A. See Detailed Biosolids Thermal Drying System Specifications at the end of this section.

2.5 ACCESSORIES

A. See Detailed Biosolids Thermal Drying System Specifications at the end of this section.

2.6 FINISHING

A. See Detailed Biosolids Thermal Drying System Specifications at the end of this section.

2.7 ELECTRICAL

A. Electrical Equipment. All electrical equipment shall conform to applicable standard of the National Electrical Manufactures Association (NEMA) and the National Electrical Code (NEC). Both power and control equipment shall be insulated for not less than 600 volts even though operating voltages may be lower.

B. All electrical equipment shall meet and shall be provided in accordance to Division 16 specification requirements.

C. All field mounted control panels shall be NEMA 4X stainless steel and NEMA 7 as required to meet hazardous location requirements per NEC and NFPA 520.

2.8 INSTRUMENTATION AND CONTROL

A. Control panels shall be furnished in accordance with the Division 13 specifications and the P&ID Contract Drawings 09-I-15, 09-I-16, 09-I-17, 09-I-18, 09-I-19, 09-I-20, 09-I- 21, 09-I-22 and 09-I-23 and shall conform to the requirements herein.

B. Biolsolids Dryer Control Panels 60-LCP-11-1 shall consolidate all instrumentation and control functions for the drying process including the following:
1. Control of the Truck Receiving Silo T-11-17 and associated hydraulic power unit M-11-17 via Ethernet connection to control panel 60-LCP-11-17.
2. Control of the Cake Transfer Pumps P-11-18 and P-11-19 via wired control connections to Adjustable Speed Controllers 60-ASC-11-18 and 60-ASC-11-19 located within the Drying Buildings Motor Control Center (MCC).
3. Control of the Feed Storage Silo T-11-20 and associated hydraulic power unit M- 11-20 via Ethernet connection to control panel 60-LCP-11-20.
4. Control of the Dryer Feed Pumps P-11-21 and P-11-22 via wired control connections to Adjustable Speed Controllers 60-ASC-11-21 and 60-ASC-11-22 located within the Drying Buildings Motor Control Center (MCC).
5. Control of Paddle Dryer M-11-1 and via wired connection to associated Reduced Voltage Motor Starter or Across the Line Motor Starter located in Drying Buildings Motor Control Center (MCC).
6. Control of the Paddle Dryers discharge Rotary Valve M-11-7 via wired control connections to Adjustable Speed Controllers 60-ASC-11-7 located within the Drying Buildings Motor Control Center (MCC).
7. Control of the Dryer Discharge Conveyor M-11-2 via wired control connections to Adjustable Speed Controllers 60-ASC-11-2 located within the Drying Buildings Motor Control Center (MCC).
8. Control of the Cooling Conveyor M-11-3 via wired control connections to Adjustable Speed Controllers 60-ASC-11-3 located within the Drying Buildings Motor Control Center (MCC).
9. Control of the Product Screener M-11-4 via wired control connections to Motor Starter located within the Drying Buildings Motor Control Center (MCC).
10. Control of the Cooling Conveyor M-11-5 via wired control connections to Adjustable Speed Controllers 60-ASC-11-5 located within the Drying Buildings Motor Control Center (MCC).
11. Control of the Off-Spec Return Conveyor M-11-6 via wired control connections to Motor Starter located within the Drying Buildings Motor Control Center (MCC).
12. Control of the Off-Spec Rotary Valve M-11-23 via wired control connections to Adjustable Speed Controllers 60-ASC-11-23 located within the Drying Buildings Motor Control Center (MCC).
13. Control of Off-Gas Duct M-11-8 and Spray Tower Condenser M-11-9 via wired control of Spray Valves FV-11-16 and FV-11-9-2.
14. Control of the Dryer Off Gas Compressor P-11-10 and Water Separator T-11-10 via wired control connections to Adjustable Speed Controllers 60-ASC-11-10 located within the Drying Buildings Motor Control Center (MCC) and W3 Control Valve FV-11-10.
15. Control of the Thermal Fluid Heat Exchange M-11-11 via hardwired connection to control panel 60-LCP-11-1.

16. Control of the Thermal Fluid Pump P-11-12 via Ethernet connection to control panel 60-LCP-11-3.
17. Control of the Thermal Fluid Heater M-11-13 via Ethernet connection to control panel 60-LCP-11-3.
18. Control of the Product Conveyor No.1 M-12-1 via wired control connections to motor starter located within the Drying Buildings Motor Control Center (MCC).
19. Control of the Product Silo Distribution Conveyor M-12-4 via wired control connections to motor starter located within the Drying Buildings Motor Control Center (MCC) and Product Chute Valves FV-12-4-1, FV-12-4-2 and FV-12-4-3.
20. Control of the Product Silo Distribution Conveyor M-12-4 Product Chute Valves FV-12-4-1, FV-12-4-2 and FV-12-4-3 via hardwired connection to 60-LCP-11-1.
21. Control of the Product Silo No.1 M-12-5, Product Silo Load Out Spout No.1 M- 12-6 and Product Silo Vibrating Discharge No. 1 M-12-7 via Ethernet connections to Silo Control Panel 60-LCP-12-5.
22. Control of the Product Silo No.2 M-12-8, Product Silo Load Out Spout No.2 M- 12-9 and Product Silo Vibrating Discharge No.2 M-12-10 via Ethernet connections to Silo Control Panel 60-LCP-12-5.
23. Control of the Product Silo No.3 M-12-11, Product Silo Load Out Spout No.3 M- 12-12 and Product Silo Vibrating Discharge No.3 M-12-13 via Ethernet connections to Silo Control Panel 60-LCP-12-5.
24. Control of Air Compressor M-12-14 and Air Compressor M-12-15, via hardwired connections to Air Compressor Control Panel 60-LCP-12-1 and 60- LCP-12-2.
25. Control of Air Dryer M-12-15 via hardwired connections to Conveyer Air Dryer Control Panel 60-LCP-12-3.
26. Control of Nitrogen Generator M-12-18 via hardwired connections to 60-LCP- 11-1.
27. Control of Dust/Fines Collection Tank T-12-19 via hardwired connections to Dust Collection Tank Control Panel 60-LCP-12-4 and 60-LCP-11-1.
28. Control of the Dust Collection Tank Rotary Valve P-12-19 via wired control connections to motor starter located within the Drying Buildings Motor Control Center (MCC).
29. Control of the Dust Collection Tank Exhaust Fan M-12-19 via wired control connections to motor starter located within the Drying Buildings Motor Control Center (MCC).

C. Biolsolids Dryer Control Panels 60- LCP-11-1 shall be built with the following minimum requirements:
1. Control Panel shall be built in accordance to Specification Section 13325 "Control Panel Enclosure Construction".
2. Components within the Control Panel shall be furnished in accordance to Specification Section 13326 "Control Panel Mounted Instruments and Devices".
3. Control Panel shall be furnished with an Allen Bradley Compact Logix Series PLC in accordance with Specification Section 13322 "PLC System".
4. Control Panel shall be furnished with an Allen Bradley front of panel mounted Touchscreen Compact Operator Interface system in accordance with Specification Section 13323 "HMI System".

5. Control Panel shall include plant SCADA network interface via panel mounted Ethernet Switch. This same switch shall be utilized to interface with all local control panels associated with the drying process, as well as desktop PC.
6. All Control Panel and Desktop PC programming shall be provided as part of the Biosolids Dryer system. PLC and Desktop PC shall be fully programmed to reflect the specifics of the indirect thermal dryer system.
7. The panel shall consolidate all instrumentation and control functions for the drying process.
8. The control system shall be capable of controlling the process rate, or varying the process rate or temperature of the indirect thermal dryer system
9. The feed rate signal set points to initiate control of the system shall be adjustable from the control panel.
10. The PLC shall include non-volatile and battery backup memory capable of retaining stored data relative to all on-board conditions including alarms, bio- solids indirect thermal drying system and elapsed operating hours.
11. A desktop PC shall be provided to interface with the PLC. The PC shall display the following minimum functions:
a. Feed Pump Speed
b. Dryer Drive Motor Amps
c. Dryer Bed Temperatures
d. Thermal Fluid Supply and Return Temperatures

D. Other local control panels See Detailed Biosolids Thermal Drying System Specifications at the end of this section.

E. The EQUIPMENT SUPPLIER shall provide on-line bio-solids indirect thermal dryer system monitors, which shall continuously automatically track the throughput and temperature in the dryer.
1. On-line monitor shall incorporate a display screen for visual trend analysis up to 24-hour basis on the dryer operational parameters.
2. The EQUIPMENT SUPPLIER shall provide alarms to indicate a condition in which the indirect thermal dryer system performance may be jeopardized, as follows
a. High and low bed discharge temperature from dryer.
b. High dryer vapor temperature
c. High condenser water level.
d. High product cooler discharge temperature.
e. All motor overloads.
f. High/low level on dryer feed hopper and dry storage silo.
g. Zero speeds on all conveyors.
h. High condenser outlet temperatures
i. High dryer amps.
j. Low air pressure.

F. System Field Instrumentation and Control Devices.
1. All Instrumentations and Control field instruments and control components shown on Contract Drawings 09-I-15, 09-I-16, 09-I-17, 09-I-18, 09-I-19, 09-I-20, 09-I-21, 09-I-22 and 09-I-23 shall be furnished by the EQUIPMENT SUPPLIER

and shall conform to the requirements herein and to the requirements of Division 13000.


PART 3 EXECUTION

3.1 INSTALLATION

A. Install in accordance with the Drawings, shop drawings, and manufacturer's instruction.

B. A qualified erection technician shall guide the CONTRACTOR with the proper assembly and installation of the equipment and coordinate with the CONTRACTOR as to the schedule for the services. EQUIPMENT SUPPLIER shall furnish a part time field engineer to periodically inspect the installation of equipment.

C. All equipment furnished by EQUIPMENT SUPPLIER shall be placed into successful operation according to the written instructions of the EQUIPMENT SUPPLIER. All required adjustments, tests, operation checks, and other startup activities shall be provided by EQUIPMENT SUPPLIER.

3.2 EQUIPMENT START UP AND COMMISIONING

A. Competent and experienced personnel shall be furnished to supervise the system start-up and provide operator instruction for the items included in the scope of supply. These services shall include thirty (30) days on site split between two (2) or more site trips.

B. Mechanical Testing: The drying systems shall be given field mechanical tests to assure compliance with specifications. If the test indicates adjustments are necessary to ensure conformance, such adjustments shall be made by the CONTRACTOR. Mechanical testing shall demonstrate that the equipment has been properly installed, with no defects, and is free of overheating, excessive vibration, overloading and excessive noise. Testing shall also confirm correct operation with control stations and interlocks. No biosolids shall be processed for these tests.

C. Electrical and Grounding Tests: Grounding resistance tests shall be conducted on all equipment, vessels, piping and ductwork in the drying system. Grounding will be the responsibility of the CONTRACTOR.

D. Control System Test: The complete control system as specified herein shall be tested to confirm that the system operates correctly in accordance with the specified requirements. Field instruments shall be tested prior to testing the control system as a whole.

E. Integrated Drying System Test: Upon successful completion of the above tests and services, an integrated drying system test shall be performed to demonstrate that the system as a whole is complete. The test shall handle and process dewatered cake in accordance with Section 1.4B above. The integrated drying system test shall be two (2) twelve (12) hour runs to be completed within 72 hours. The EQUIPMENT SUPPLIER shall submit test data that shows the operation parameters for the test and typical record keeping required to properly monitor the drying system.

F. Training: The EQUIPMENT SUPPLIER shall provide training in the proper operation and maintenance of the equipment. Manufacturer’s representatives who will provide training shall be factory trained, articulate, and knowledgeable in the installation, operation, and maintenance (including the information in the operations and maintenance manuals) of the drying system. Two (2) days will be included for training of plant operating personnel.

3.3 PERFORMANCE TESTING

A. Test Procedures for Solids Throughput and Evaporation Capacity:
1. During mechanical tests, the dryer feed pump will have been calibrated to determine the feed rate as a function of the pump speed. The wet feed rate to the dryer and the solids feed rate will be determined by this data.
2. Performance testing shall be conducted over a 24 hour period. Dewatered biosolids samples shall be taken once every six (6) hours to determine average cake percent solids feed to the dryer. The OWNER shall provide a consistent solids content in the dewatered cake.
3. Average final product percent solids shall be determined from samples taken at the discharge of the second product cooler and will be determined by the standard loss of weight method. The EQUIPMENT SUPPLIER shall provide a drying system mass balance demonstrating performance compliance for solids and evaporation capacity.

B. Test Procedure for Product Quality: Samples shall be taken at the second product cooler every six (6) hours during the test. For solids content, each sample shall be analyzed and the average of all test samples used to determine whether requirements have been met. For confirmation that the requirements of a Class A product are met, the appropriate parameters as defined by 503 EPA regulations shall be monitored. No individual sample shall fall outside of the requirements of the 503 EPA regulations. Product solids content shall be analyzed based on the current edition of Standard Methods for Examination of Water and Wastewater.

C. Test Procedure for Specific Heat Energy. Total fuel readings shall be taken at the start, each hour, and the end of the test. This data will be plotted to determine drying systems fuel usage over time and combined with the evaporation rate demonstrated by the mass balance developed as part of the solids and evaporation capacity analysis to generate the specific heat energy. The specific heat energy will be reported in units of BTU per pound of evaporated water. Natural gas shall be used as the fuel source. The lower heating value (LVH) as certified by the natural gas supplier shall be used in the computations of specific heat energy. A dedicated natural gas meter or a natural gas meter isolated from other  Plant users for the duration of the test, calibrated by the OWNER, shall be used during this test.

D. The Performance Test: The Performance Test shall be completed within the first sixty
(60) days after the integrated system test. If the drying system meets the guaranteed performance and design requirements, the drying system shall be deemed to have passed the Performance Test. If the drying system does not meet the guaranteed performance and design requirements as determined by performance tests, then the EQUIPMENT SUPPLIER shall modify the drying system as required and retest.

E. Performance Test Report: Within 30 days after completion of the Performance Tests, the Performance Test report shall be submitted by the EQUIPMENT SUPPLIER, in accordance with the Submittals Section, with the following information:
1. A general description of the testing, including the date and time of the Performance Test for the dryer.
2. A description of all samples’ collection and measurement techniques.
3. Raw data collection sheets including operating data and original copies of all laboratory results.
4. Descriptions of operations problems, unusual conditions, equipment failures or malfunctions, and other factors adversely affecting performance of the biosolids drying system if applicable.
5. Analysis of the test data

F. Performance test results in comparison with the Guaranteed Performance and Design Requirements.

3.4 ACCEPTANCE

A. Within 30 days of submittal of Performance Test report, the OWNER shall notify the EQUIPMENT SUPPLIER of acceptance or non-acceptance of the drying system.

B. The drying system shall comply with the requirements as set forth in the Design Requirements of this section. If the system fails the Performance Test, the EQUIPMENT SUPPLIER shall make whatever adjustments are determined to be necessary and re-run the test.

3.5 MANUFACTURER'S SERVICES

A. Provide manufacturer's services under provisions of DIVISION 1.

B. Minimum Service Requirements:
1. Installation: As required for proper installation.
2. Start-up and field testing: Fourteen (14) eight (8) hour day (not necessarily consecutive) on site.
3. Operator training: Two (2) eight (8) hour days (not necessarily consecutive) on site.
4. Post start-up training: Two (2) eight (8) hour days.

C. Service to Repair Defective Work: Provide during one-year warranty period under the provisions of General Conditions.


END OF SECTION