SECTION 11650C DETAIL BIOSOLIDS THERMAL DRYING SYSTEM BIOSOLIDS THERMAL DRYER

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

SECTION 11650C

DETAIL BIOSOLIDS THERMAL DRYING SYSTEM BIOSOLIDS THERMAL DRYER


PART 1 GENERAL

1.1 SECTION INCLUDES:

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

B. Local Control Panels:
1. None.

1.2 SYSTEM DESCRIPTION

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

1.3 REFERENCES

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

1.4 DESIGN REQUIREMENTS

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

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. Electrical motor data.
4. Drive details, including calculations and procedures used for selection of drive components, service factor of gear reducer based on absorbed horsepower and installed motor horsepower.
5. Manufacturer’s literature, illustrations, specifications, and engineering data including total weight of each unit, structural loads at supports, connection details, and performance data.
6. Drawings shall show dimensions, overall arrangement of equipment and materials of construction.
7. Dryer sensors, instruments and safety switches.

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.

2.3 METAL FABRICATION

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

2.4 INDIRECTLY HEATED THERMAL DRYER

A. Manufacturers:
1. Komline-Sanderson, Peapack, NJ.
2. Andritz Separation Inc., Arlington, TX.

3. Or equal.

B. General:
1. One (1) indirectly heated biosolids dryer shall be provided to meet the process conditions specified in the Design Requirments. The dryer shall consist of a vessel mounted on a common base with a heated jacket. The vessel is to contain a dual shaft agitator arrangement comprised of hollow agitator shafts with multiple hollow paddles. The agitator shafts and paddles are hollow thus allowing their use as heat transfer surfaces in conjunction with the heat transfer surface of the jacketed trough.
2. The indirectly heated dryer shall be designed in accordance to the design requirements as specified in the Design Requirements using thermal fluid as the heating medium.

C. Trough and Cover:
1. Trough, trough jacket and vaulted bolted cover shall be 304 stainless steel for all process wetted parts. The interior surface of the trough bottom shall be protected with abrasion resistant, hardened materials in the last 67% of the trough length.
2. The trough shall be fitted with a jacket to provide heating for drying of the dewatered cake. The trough jacket shall be designed and stamped in accordance with ASME Code Section VIII, Division I, with design temperature and pressure of 550°F at 125 psig.
3. The trough and cover on the process side shall be designed for a pressure of 2.5 psig. The cover shall include explosion panels to vent dryer gasses above 1.45 psig. Explosion panels shall be designed in accordance with NFPA 68 guidelines and shall be ducted to outside the building.
4. Vaulted cover shall provide sufficient space to allow for the removal of vapors generated during the drying process, with vapor velocities not to exceed 2 feet per second to minimize dust entrainment. The dryer shall include the following appurtenances:
a. Two (2) flanged inlets in cover at the drive end for biosolids feed.
b. One (1) flanged inlet for fines return from Off Spec Return Conveyor.
c. Two (2) manways and one (1) view port along one side of cover.
d. One (1) flange for vapor removal in the cover at a location where the majority of steam vapors form.
e. Two (2) product discharge modes: one side discharge flange with adjustable weir, and one bottom discharge with slide gate(s).
f. Four (4) flanged connections near trough bottom for thermocouples that penetrate through the jacket and trough.
g. Three (3) sparge water connections in cover with individual spray nozzles in the event of upset or emergency conditions.
h. The trough shall be a closed system to minimize air leakage through feed inlet, product discharge, etc. The trough end heads shall be designed to permit vertical removal of agitator shafts.
i. Deflagration protection for the dryer and personnel shall be provided by relief panels with ducting to outside the building. The sizing of the panels and duct will be in accordance with NFPA 68 and ASTM-E 1226- 10.

5. All heated exterior surfaces of the dryer shall be insulated, except at ends, to minimize heat loss and to protect operating personnel. A 4 inch minimum thickness of closed cell glass insulation shall be provided and shall be banded to the trough and covered with 0.024 inch thick Type 304 stainless steel sheathing. The dryer cover shall be insulated with 1½ inch thick fiberglass insulation with a fabric cover.

D. Agitator Assemblies:
1. Two intermeshing agitator assemblies shall be provided for the dryer. The agitator assemblies shall be comprised of hollow agitator shafts with multiple, independent, hollow, wedge shaped paddles.
2. The agitators shall be manufactured with process contact surfaces of 304/304L stainless steel except for the shaft adjacent to the last five (5) paddles which shall have hard surfacing weld applied directly onto the carbon steel shaft.
3. The assemblies shall be designed and positioned to promote local mixing and agitation of the process mass. Biosolids shall be transported down the length of the trough by displacement due to the continuous addition of biosolids feed.
4. The agitator assemblies shall be designed, manufactured, inspected, tested, and stamped in accordance with ASME Code for Unfired Pressure Vessels, Section VIII, Division I, for 550°F at 125 psig. There will be no exceptions to this code stamp requirement.
5. Each agitator assembly shall consist of a number of discontinuous wedge-shaped paddles. These paddles shall be mounted on a central hollow pipe which serves as the primary structural member of the agitator shaft.
6. Paddles shall be hollow to permit flow of the heating medium throughout.
7. All paddles shall have chromium carbide hard facing alloy weld applied on crowns. The paddles on the last 67 % of the agitator shall also have chromium carbide hard facing alloy weld applied on its sides to within 1 inch of the radius of the shaft. There will be no exceptions to this requirement.
8. Each agitator shaft shall be supported at its trunnion ends by self-aligning double row spherical roller bearings, minimum B-10 life of 100,000 hours, and mounted in split case pillow blocks. Housings shall be of cast iron construction with grease fitting for lubrication using high temperature grease.
9. The non-drive end trunnion ends shall be arranged to allow for circulation of thermal fluid into and out of each agitator through a rotary joint. Shaft trunnions shall be provided with replaceable wear sleeves in the area where stuffing boxes are located.

E. Dryer Drive:
1. Primary reduction:
a. Belt drive with OSHA approved guard and adjustable motor mount.
2. Secondary Reduction:
a. Directly couple the reducer to the drive agitator.
b. Drive to transmit rotation and torque to the driven agitator through a set of spur gears rotating in an oil bath gear case.
c. Gear box shall mechanically synchronize the agitator assemblies.

F. Motor:

1. Furnish motor compatible with the driven equipment herein. Motors shall be furnished as specified in Section 11338, and shall conform to the detailed requirements herein:
a. Motor nameplate horsepower: 250 hp.
b. Type drive: Constant speed
c. Provide inverter duty motor.
d. Nominal (synchronous) motor rpm: 1800.
e. Motor mounting: Horizontal.
f. Enclosure: TEFC.
g. Power: 460 volt, 3 phase, 60 Hz.
h. The motor shall have NEMA B starting torque and low starting current. The motor shall not be overloaded beyond the nameplate rating under any normal conditions encountered.
i. Motor to be provided with Klixon bimetal opening contact type overload temperature sensor in each phase winding. Sensors shall open when motor temperature exceeds manufacture recommended operation temperature and shall automatically reset when motor temperature reaches safe operating temperature. Sensors to be connected in series, with each sensor located in the hottest spot of the phase windings.
j. Motor shall be suitable for a Class II Division II Group G hazardous area.

G. Mounting Base
1. A single mounting base shall be provided for the dryer constructed of carbon steel. The base shall include support for the jacketed trough, pedestals for the agitator pillow blocks, and a base for the drive assembly components.

2.5 ACCESSORIES

A. Not Used.

2.6 FINISHING

A. Shop and Field Painting:
1. Carbon Steel (Base and Supports): Blast clean per Spec. SSPC-SP-10. Apply one coat of Tnemec Series 104HS epoxy to a dry film thickness of 4 mils followed by one coat of Tnemec Series 1075 urethane to a dry film thickness of 3 mils. Color is Bare Beige.
2. Trough: None.
3. Trough Jacket: None.
4. Guards: Blast clean per Spec. SSPC-SP-10. Apply one coat of Tnemec Series 104HS epoxy to a dry film thickness of 4 mils. Color is Lemon Yellow.
5. Machined Surfaces Coat with a suitable rust preventative.
6. Other exposed non-stainless steel metal surfaces located inside of structures and enclosures shall conform to Section 09900, System No. 5. Verify compatibility of shop prime and field paint.
7. Other exposed non-stainless steel metal surfaces located outside of structures and enclosures shall conform to Section 09900, System No. 6. 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 CONTROLS

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


PART 3 EXECUTION

3.1 INSTALLATION

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

3.2 EQUIPMENT START UP AND COMMISIONING

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

3.3 PERFORMANCE TESTING

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

3.4 ACCEPTANCE

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

3.5 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:  Ten (10) eight (8) hour day (not necessarily consecutive) on site.
3. Operator training: One(1) eight (8) hour day (not necessarily consecutive) on site.

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


END OF SECTION