SECTION 11650A DETAIL BIOSOLIDS THERMAL DRYING SYSTEM WELDED STEEL TANKS WITH SLIDING FRAME

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

SECTION 11650A

DETAIL BIOSOLIDS THERMAL DRYING SYSTEM WELDED STEEL TANKS WITH SLIDING FRAME


PART 1 GENERAL

1.1 SECTION INCLUDES:

A. Wet Cake Storage Silos:
1. Truck Receiving Silo: T-11-17.
2. Feed Storage Silo: T-11-20.

B. Hydraulic Power Unit:
1. Hydraulic Power Unit No. 1: M-11-17.
2. Hydraulic Power Unit No. 2: M-11-20.

C. Components and appurtenances of each tank including but not limited to:
1. Silo
2. Hydraulic Power Unit and Sliding Frame
3. Hydraulically actuated Bi-fold Loading Door with control station (Truck Receiving Silo only)
4. High and Low level switches
5. Radar level measurement sensor

D. Local Control Panels:
1. Truck Receiving Silo Local Control Panel: 60-LCP-11-17
2. Feed Storage Silo Local Control Panel: 60-LCP-11-20

1.2 SYSTEM DESCRIPTION

A. See General Specification Section 11650, Solids Thermal Drying System – General.

B. The Work covered under this Section will provide sludge storage bin for temporary storage of dewatered sludge. The Push Floor Truck Receiving Bin described shall be from a single Supplier/Manufacturer, complete with all necessary components and ancillary items, including a local control panel.

C. The Contract Drawings and this Section provide a brief description of the minimum requirements and features of the equipment to be furnished. It is the Manufacturer's responsibility to furnish and install the equipment complete in all details, performance and reliability meeting the requirements and intent of the schematic and conceptual drawings and these specifications.

1.3 REFERENCES

A. American Society for Testing and Materials (ASTM):

B. American Welding Society (AWS):

C. Underwriters Laboratory (UL)

D. Standards of the Conveyor Equipment Manufacturer’s Association (CEMA).

E. National Electric Code.

F. Standards of the National Electrical Manufacturer’s Association (NEMA).

G. Institute of Electrical and Electronic Engineers.

H. American National Standards Institute. (ANSI)

I. American Gear Manufacturer’s Association. (AGMA)

J. American Institute of Steel Construction.(AISC)

1.4 DESIGN REQUIREMENTS

A. See General Specification Section 11650, Solids Thermal Drying System – General.

B. General:
1. Truck Receiving Silo (T-11-17):
a. Quantity: One (1).
b. Approximate inside wall Size:
1) Length: 20 feet
2) Width: 10 feet
3) Height: 14.5 feet plus supports, inlet and outlet flanges.
4) Inlet Bar Screen: openings centered on 12” (300mm)
5) Outlet elevation clearance (bottom of floor elevation to ground level): 3.25 feet
c. Volume: 2,900 cubic feet (less angle of repose).
d. Bin Extraction direct to suction of two progressive cavity pumps.
2. Feed Storage Silo (T-11-20):
a. Quantity: One (1).
b. Approximate inside wall Size:
1) Diameter: 13.5 feet
2) Height: 24.25 feet plus supports, inlet and outlet flanges.
3) Outlet elevation clearance (bottom of floor elevation to ground level): 3.25 feet
c. Volume: 3,240 cubic feet (less angle of repose).
d. Bin Extraction direct to suction of two progressive cavity pumps.

C. Design Parameters:
1. Design Data:
a. Maximum Sludge Weight, 65 lb/cu. ft. (1040 kg/m3 ).
b. Minimum Sludge Weight, 60 lb/cu. ft. (960 kg/m3.).
c. Maximum Sludge Solids, 25 percent.
d. Minimum Sludge Solids, 15 percent.
e. Abrasive.
f. Corrosive.

g. Contains oil, grease and polymer.
h. Maximum Lump Size 1”.
2. The Push Floor Storage Silos shall be designed to have maximum deflection of 1/200 when fully loaded, and 1% story drift per ASCE 7-10.
3. The Push Floor Storage Silos and associated equipment must be capable of start- up and continuous operation when fully loaded with dewatered sludge cake with a range of characteristics.

1.5 SUBMITTALS

A. See General Specification Section 11650, Solids Thermal Drying System - General:
1. Complete assembly and installation drawings.
2. Descriptive information on material and equipment furnished.
3. Manufacturer's qualifications.
4. Manufacturer’s design calculations.
5. Submit structural calculations stamped by Professional Engineer registered in the State of Illinois for support system.
6. Provide total dead and live loads from tank at each support.

B. Submit certificates of proper installation and operator training under the provisions of DIVISION 1.

C. Submit field test documentation under the provisions of DIVISION 1.

1.6 OPERATION AND MAINTENANCE DATA

A. See General Specification Section 11650, Solids Thermal Drying System - General.

1.7 DELIVERY, STORAGE AND HANDLING

A. See General Specification Section 11650, Solids Thermal Drying System - General.

1.8 QUALITY ASSURANCE

A. See General Specification Section 11650, Solids Thermal Drying System - General.

1.9 EQUIPMENT SUPPLIER'S QUALIFICATIONS:

A. See General Specification Section 11650, Solids Thermal Drying System - General.

1.10 PAYMENT SCHEDULE

A. See General Specification Section 11650, Solids Thermal Drying System – General.


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. See General Specification Section 11650, Solids Thermal Drying System – General.

B. All tanks shall all be the end product of manufacturer specializing in the design, fabrication welded steel tanks with sliding frame. The manufacturer shall be responsible for the complete system including all items covered herein.

2.3 METAL FABRICATION

A. See General Specification Section 11650, Solids Thermal Drying System – General.

2.4 EQUIPMENT

A. Acceptable Manufacturers:
1. Schwing Bioset Inc., Somerset, WI.
2. Or Equal.

B. Wet Cake Silo:
1. One (1) wet cake storage silo shall be supplied to receive and one (1) to store dewatered biosolids for feeding to the drying system.
2. The receiving Bin shall consist of a rectangular bin, sliding frame mechanism, support structure and hydraulic power package. The silo shall consist of a cylindrical bin, sliding frame mechanism, support structure and hydraulic power package.
3. Bins:
a. Fabricate hopper of minimum 1/4 inch thick structural and plate carbon steel, ASTM A36.
b. Fabricate roof of minimum 1/4 inch diamond steel plate.
c. Fabricate floor (flat within 3/32 inch) of minimum 1/2 inch thick ASTM A36 steel plate.
d. Provide a top access hatch of 30 inch diameter, and hinged side access hatch of 36 inch diameter. Both to be gasketed and bolted.
e. Provide openings and attachment flanges for sliding frame hydraulic cylinder stuffing boxes, dryer feed pumps, drain pipe, odor control connection and inlet conveyor connection.
4. Sliding Frame Mechanism: Design to discharge sludge at a constant rate into the dryer feed transfer pumps.
a. Mechanism to include::
1) One sliding floor assembly
2) Two floor guides of A36 carbon steel.

3) One double acting hydraulic cylinder.
4) One nickel-chrome extension shaft.
5) One stuffing box and catch tray.
b. Hydraulic cylinder to be complete with proximity switches wired to a NEMA 4X junction box for directional flow to either the rod or piston side of the cylinder.
5. Support Structure:
a. Fabricate of A36 structural steel, self-supporting and able to accept a load of cake equal to the maximum volume of the cylindrical bin with static, dynamic and seismic loads applicable
b. Design to permit free and uniform expansion or contraction of the cylindrical bin and to permit installation and easy access to the dryer feed transfer pumps.
c. Include support for the hydraulic cylinder, including cylinder trunnions and safety cover.
6. The silo shall be covered and include flanged connections for the feed conveyor, vent connection, instrument connections and top access door. A ladder with safety cage as required shall be provided from grade to the top of the silo.
7. Hydraulic power package
a. Provide one hydraulic power package consisting of a hydraulic oil pump, 10 HP, TEFC motor, local electrical enclosure, skid mounted with oil reservoir.
b. Include local pressure indicator, filter, cleanout cover and initial fill of oil.
c. Provide random lengths of carbon steel hydraulic tubing for connection to sliding frame cylinder.

C. Bi-Fold Doors:
1. General Design:
a. Provide Truck Receiving Bin with a Bi-fold Retracting Door to allow trucks to discharge into the bin. Bi-Fold Doors shall be either square or rectangular shape and shall be designed with attachment to bin or concrete as shown on drawings.
b. Design the Bi-Fold Doors to withstand the local snow loads and as specified in this section.
c. Bi-Fold Doors shall be open and close in specified times and retract to more than 60% of opening.
2. Frame:
a. Door opening size shall be as shown on the drawings (16ft x 10ft) with bar grate spaced at 12 inches.
b. Construct door sections of minimum 11 gauge carbon steel with reinforced edges and stiffeners spaced at less than 4 feet.
c. Include proximity sensors for end of travel detection.
d. Door hinges shall be equipped with bearings rated for 4000 lb radius load and 2000 lb thrust load. Thrust bearings shall be ball type. Radial bearings shall be roller needle type.
e. Install door with an incline greater than 10 degrees from horizontal to shed water.
f. Equip the door with rollers for door to roll at installed incline.

g. Paint door surfaces with epoxy paint system with total dry film thickness greater than 6 mils.
3. Operator:
a. Actuating Mechanism: Hydraulic operator shall be provided by the door manufacturer.
b. A single hydraulic cylinder rated for 3000 PSI oil pressure shall be supplied to open and close the door under fully loaded conditions while supplied with minimum 1600 PSI oil supplied by the hydraulic power unit. The cylinder shall be controlled by a 24vdc solenoid operated, spring centered, three position valve to control the travel of the door. Hydraulic cylinder shall be equipped with an adjustable counterbalance valve to control closing speed.
c. The door shall be equipped with a pair of proximity sensors to monitor end of travel of the Bi-Fold Door.
d. Door shall be hydraulically actuated and open to more than 60% of opening.
e. Actuator shall open the door in less than 30 seconds. Close speed shall also be less than 30 seconds.
f. Door actuator shall be powered by the Push Floor Hydraulic unit and controlled by the Push Floor Control Panel. A remote open/close local push button station complete with indicator lights and E-stop shall be located near the door where shown on drawings. See electrical drawings for push button and indicator colors.
4. Materials:
a. Frame: Carbon Steel, painted.

2.5 ACCESSORIES

A. Not Used.

2.6 FINISHING

A. Shop and Field Painting:
1. Conform to Section 09900.
2. System No. 2 on all inside bin surfaces (in contact with sludge cake).
3. System No. 5 on exposed metal surfaces located inside of structures and enclosures.
4. System No. 6 on exposed metal surfaces located outside of enclosed structures and exposed to weather.
5. Verify compatibility of shop prime and field paint.

2.7 ELECTRICAL

A. See General Specification Section 11650, Solids Thermal Drying System – General.

2.8 INSTRUMENTATION AND CONTROL

A. Furnish controls and control panels compatible with the wet cake storage silo systems herein. Control panels and controls shall be furnished in accordance with Division 13

and Division 16, Contract Drawings 09-I-15 and 09-I-16, and shall conform to the requirements herein.

B. Provide local-mounted control stations, switches and instrumentation for each Silo:
1. Enclosure/Switch: NEMA 7X/rated for Class 1 Division 1 environment.
2. Switches:
a. Bi-Fold Truck Loading Door Open/Close Hand Control Switch. (Truck Receiving Silo only)
b. Bi-Fold Truck Loading Door Open Position Switch. (Truck Receiving Silo only)
c. Bi-Fold Truck Loading Door Closed Position Switch. (Truck Receiving Silo only)
d. Sliding Fram Extend Proximity Switch
e. Sliding Fram Retract Proximity Switch
f. Silo Low Level Switch
g. Silo High Level Switch
h. Level Element and Level Transmitter

C. Silo Control Panels 60- LCP-11-17 and 60-LCP-11-20 minimum requirements:
1. Enclosure: NEMA 4X stainless steel.
a. Provide Hoffman enclosure, or equal.
b. Surface mount switches and lights on exterior of panel door.
c. Built in accordance with specification section 13325.
d. Components in accordance with specification section 13326. Alternately panel lights and switches can be replaced (except Emergency Stop Mushroom Pushbutton) with a Allen-Bradley, PanelView Plus, 6 inch or larger color touch screen. All indicators, buttons, switches described below shall be implemented via touch screen.
2. Power supply: 480 volt, 3 phase, 60 Hz.
3. Provide single panel disconnect with panel protection.
4. Provide NEMA rated motor starter in panel with overload auxiliary “Fail” contact for operation of Hydraulic Power Unit.
5. Provide transformer for all panel components and controls.
6. Provide a motor current monitoring device for operation of Hydraulic Power Unit.
7. Provide a Allen Bradley MicroLogix 1400 series PLC controller with Ethernet port for interface to plants central SCADA system. Provide programming for control of entire system locally from front of control panel or remotely from plants central SCADA control system.
8. Indicator Lights:
a. “High Oil Pressure”- red.
b. “Low Oil Level”- red.
c. “High Oil Temperature”- red.
d. “Motor Overload”- red.
e. “Frame Jammed”- red.
f. "Power On” – white.
g. “Motor Running” - green.
h. “Motor Off” - green.
i. “Frame Running” - green.
j. “Tank High Level” – red.

k. “Tank Low Level” – red.
9. Control Pushbuttons:
a. Reset
b. Motor Start
c. Motor Stop
d. Emergency Stop
10. Control Two Position Selector Switches:
a. Extend/Retract
b. Auto/Manual
11. Input signals:
a. Local Truck Loading Open/Close Selector Switch. (Truck Receiving Silo only)
b. Bi-Fold Truck Loading Door Open Position Switch. (Truck Receiving Silo only)
c. Bi-Fold Truck Loading Door Closed Position Switch. (Truck Receiving Silo only)
d. Motor high temp switch.
e. Sliding Fram Extend Proximity Switch
f. Sliding Fram Retract Proximity Switch
g. Silo Low Level Switch
h. Silo High Level Switch
i. Level Element and Level Transmitter
12. Outputs:
a. Motor Power
b. Truck Loading control signal (Truck Receiving Silo only)
c. Sliding Frame control signal
13. Displayed analogsignals:
a. Tank Level

D. Functional Description:
1. The controls shall provide complete control of the Storage Silo loading and dryer feed to associated Dryer Feed Pumps as shown on project P&IDs.
2. The E-Stop Switch shall be wired directly to the control circuits for the associated Motor Starter Coil.
3. The PLC shall monitor all field mounted components, display values on local panel and provide data access registers for access by the plant SCADA system via the Biosolids Dryer Control Panel as follows:
a. Local Truck Loading Open/Close Selector Switch Status. (Truck Receiving Silo Only).
b. Bi-Fold Truck Loading Door Open Status. (Truck Receiving Silo only)
c. Bi-Fold Truck Loading Door Closed Status. (Truck Receiving Silo only)
d. Motor high temp alarm status.
e. Motor Current analog value.
f. Sliding Fram Extended
g. Sliding Fram Retracted
h. Silo Low Level
i. Silo High Level
j. Silo Level analog value.
4. When control panel is in the Manual Mode, Sliding Frame shall be operated from the Local Control Panel. When control panel is in the Automatic Mode, Sliding

Fram shall be operated from the plant SCADA system via the Biosolids Dryer Control Panel.
5. When Silo Low Level signal is present, associated Cake Transfer Pumps or Dryer Feed Pumps shall be stopped by the plant SCADA system via the Biosolids Dryer Control Panel.
6. Manual resetting of the system shall not be required in the event of a power outage.
7. Panel shall be provided with all factory standard equipment and personnel safety features and interlocks.


PART 3 EXECUTION

3.1 INSTALLATION

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

B. Any coating damage will be repaired per manufacturer's recommendations.

3.2 FIELD TESTING

A. Water Leakage Test:
1. Fill silos with water to the normal liquid level line. All valves and gates to the silos.
2. Examine all exposed portions of the structure and mark all visible leaks or damp spots.
3. Drain the silo and make necessary repairs. The Contractor's method of repair shall be subject to the requirements of these Specifications and submitted for review by the Engineer.
4. Once the repairs have been completed the silos shall be retested until all leaks are repaired.

3.3 MANUFACTURER'S SERVICES

A. See General Specification Section 11650, Solids Thermal Drying System - General.

B. Minimum Service Requirements:
1. Installation: As required for proper installation.
2. Start-up and field testing: One (1) eight (8) hour day (not necessarily consecutive) on site.
3. Operator training: One half day on site.

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

END OF SECTION