SECTION 11650F
DETAIL BIOSOLIDS THERMAL DRYING SYSTEM DRY PRODUCT HANDLING EQUIPMENT
PART 1 GENERAL
1.1 SECTION INCLUDES:
A. 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.
B. Local Control Panels:
1. None.
1.2 SYSTEM DESCRIPTION
A. See General Specification Section 11650, Solids Thermal Drying System - General:
B. The Contractor shall furnish, install, and place in satisfactory operation dry product tubular drag conveyor complete with all supports, spare parts, accessories and appurtenances as specified herein, show on the Drawings, and as required for a complete and operable system
C. All necessary safety equipment and guards to meet OSHA requirements shall be provided
D. The Contractor shall be responsible for coordinating the placement of all supports necessary to tie the equipment together and shall have the undivided responsibility for the system’s structural integrity
1.3 REFERENCES
A. See General Specification Section 11650, Solids Thermal Drying System - General:
B. The following is a list of standards which may be referenced in this section:
1. American Society for Testing and Materials (ASTM)
2. National Electrical Manufacturers Association (NEMA)
3. American Gear Manufacturers Association (AGMA)
4. American Welding Society (AWS)
5. Conveyor Equipment Manufacturers Association (CEMA)
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. Provide total dead and live loads from conveyors at each support.
5. 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.
6. Manufacturer’s literature, illustrations, specifications, and engineering data including total weight of each unit, structural loads at supports, connection details, and performance data.
7. Drawings shall show dimensions, overall arrangement of equipment and materials of construction.
8. Conveyor 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 DRY PRODUCT HANDLING EQUIPMENT:
A. Manufacturers:
1. Marin-Conveyor Division, Ft Worth, TX.
2. Or equal.
B. General:
1. All equipment shall be the end product of one conveyor system supplier. The supplier shall be responsible for the complete system including all items covered herein.
2. All parts furnished shall be amply designed and constructed for the maximum stresses occurring during fabrication, transportation, erection and continuous operation. All materials for the conveyors shall be new and shall be of the very best quality, entirely suitable for the service to which the units are to be subjected and shall conform to all applicable sections of these specifications.
3. The conveyor equipment shall be factory pre-assembled, factory pre-wired, and factory tested to the greatest extent practical.
4. All parts and components shall be factory-assembled in sections convenient for field handling and installation but requiring the minimum amount of work for field assembly. No cutting or welding should be required on either field assembly or erection.
5. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation.
6. Drive System
a. Drive assembly shall consist of an integral gearmotor or motor with C- face adapter and shaft mounted reducer. Gear housing shall be cast iron,
furnishing complete protection under all conditions of service. Gears shall be manufactured and rated for continuous duty in accordance with AGMA Standards, of heat treated alloy steel. Provide splash type gear lubrication. Gear reducer shall be AGMA Class II speed reducer.
b. The gear reducer and drive shall be designed to provide an applied torque adequate to start a full loaded conveyor.
c. Drive shall have an AGMA service factor of 1.4 and shall operate on 460V/3 phase/60 Hz power.
C. Conveyor Supports:
1. Provide supports suitable for mounting as shown on the drawings and as required by supplier’s design. The supports shall be capable of supporting the equipment weight when fully loaded. The supports shall be fabricated from standard shapes and plates. Supports shall be match marked and shipped to the job site for installation in the field.
2. At a minimum, each conveyor shall be provided with supports at the inlet and discharge end, with intermediate supports at maximum 10 feet-0 inches on center.
3. Provide baseplates at each ground support leg for anchor bolting.
4. Height/length of support as required for floor support and the arrangement shown on Drawings
5. The supports shall be designed to avoid interference with other equipment or equipment supports.
6. All structural supporting members shall be designed such that the ratio of the unbraced length to least radius of gyration (slenderness ratio) shall not exceed 120 for any compression member and shall not exceed 240 for any tension member. In addition, all structural members and connections shall be designed so that the unit stresses will not exceed the American Institute of Steel Construction allowable stresses by more than 1/3 when subject to loading of twice the maximum design operating torque of the spiral conveyor drive motors.
7. All shop welding shall conform to the latest standards of the American Welding Society (AWS). The supports shall be designed to avoid interference with other equipment or equipment supports.
D. Dryer Discharge Conveyor (M-11-2):
1. Design to receive the dried product exiting the Paddle Dryer (M-11-1) through the Rotary Valve (M-11-7) and convey it to the Cooling Conveyer (M-11-3).
2. Size per the process requirements of the Drying System per the Design Requirements.
3. Nominal screw diameter: 12”
4. Nominal length: 19 ft.
5. Construct the wetted parts of the conveyor, including the top cover, screw and trough out of 304 stainless steel.
6. Form the trough of the conveyor into a flared “U” shape.
7. Provide conveyor with a formed flange to connect to the dryer’s discharge connection.
8. Provide the conveyor with bolted and gasketed top covers to provide a dust tight seal.
9. Each section of the conveyor top cover shall be no longer than 4 feet in length for handling and maintenance purposes.
10. Provide conveyor supports to grade constructed out of 304 stainless steel construction, minimum ¼” thickness.
11. Motor:
a. 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:
1) Motor nameplate horsepower: 3HP.
2) Type drive: Constant speed.
3) Nominal (synchronous) motor rpm: 1800.
4) Motor mounting: C-faced to gear reducer.
5) Enclosure: TEFC.
6) Power: 460 volt, 3 phase, 60 Hz.
7) Minimum Service Factor: 1.15.
8) 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.
9) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
10) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
E. Cooling Conveyor (M-11-3):
1. Design to cool and convey the dried product exiting the Dryer Discharge Conveyor (M-11-2) and convey it to the Product Screener (M-11-4).
2. Size per the process requirements of the Drying System per the Design Requirements.
3. Nominal screw diameter: 12”
4. Nominal length: 21 ft.
5. Construct the wetted parts of the conveyor, including the top cover, screw and trough out of 304 stainless steel.
6. Form the trough of the conveyor into a “U” shape.
7. Provide the conveyor with bolted and gasketed top covers to provide a dust tight seal.
8. Each section of the conveyor top cover shall be no longer than 4 feet in length for handling and maintenance purposes.
9. Provide conveyor supports to grade constructed out of 304 stainless steel construction, minimum ¼” thickness.
10. Cooling Water:
a. Use circulating non-potable water as the indirect cooling media in the conveyor water jacket.
b. There shall be no contamination of the cooling water. The cooling water shall enter and exit the flanged connections on the cooler.
11. Provide a product temperature gauge to monitor the outlet temperature of the product.
12. Motor:
a. 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:
1) Motor nameplate horsepower: 5 hp.
2) Type drive: Variable speed.
3) Provide inverter duty motor.
4) Nominal (synchronous) motor rpm: 1800.
5) Motor mounting: C-faced to gear reducer.
6) Enclosure: TEFC.
7) Power: 460 volt, 3 phase, 60 Hz.
8) Minimum Service Factor: 1.15.
9) 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.
10) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
11) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
F. Produce Screener (M-11-4):
1. Manufacturers:
a. Kason.
b. Or equal.
2. Supply a vibrating screener to classify the dried solids.
3. Size per the process requirements of the Drying System per the Design Requirements.
4. The vibrating screener shall be 48 inch diameter and shall have two decks with the first deck classifying all particles larger than 10 mm using a 3/8” screen and discharging them to the off -spec return conveyor described below.
5. The second deck shall classify all particles less than 1.0 mm (fines) using an 18- mesh market grade screen. These particles shall also be returned to the dryer by the Off-Spec Return Conveyor (M-11-6).
6. Product having particle sizes between 1.0 mm and 10 mm will be discharged directly into Cooling Conveyor (M-11-5).
7. Product contact parts of the vibrating screener shall be fabricated from Type 304 stainless steel with all necessary clamp rings, gaskets, dust cover assembly, and hardware mounted on vibration isolation springs in turn mounted to a fixed epoxy coated carbon steel base.
8. Connections:
a. Inlet Connection: 13-inch diameter connection located in the cover of the vibrating screener.
b. Vent Connection: 2-inch diameter connection located in the cover of the vibrating screen.
c. Outlet Connections:
1) Provide with separate 8-inch diameter connections for acceptable product discharge, recycled product and tramp material.
2) Provide trap material discharge with diverter valve to permit removal of tramp material.
d. Provide flexible connections for the screener inlet, vent and discharge connections.
e. Provide a 6-inch diameter inspection port with removable plastic lid in the cover of the screener.
9. Provide the screener with anti-blinding device under the lower screen deck to aid in the removal of fibrous and near sized material.
10. Equip the vibrating screen with grounding lugs.
11. A safety switch with NEMA 7 enclosure (ZS-11-4) shall be provided on the maintenance access door on the base of the vibrating screener. The switch shall be interlocked to shut down the screener when the door is opened.
12. Motor:
a. 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:
1) Motor nameplate horsepower: 2½.
2) Type drive: Constant speed.
3) Nominal (synchronous) motor rpm: 1800.
4) Motor mounting: C-faced to gear reducer.
5) Enclosure: TEFC.
6) Power: 460 volt, 3 phase, 60 Hz.
7) Minimum Service Factor: 1.15.
8) 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.
9) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
G. Cooling Conveyor (M-11-5):
1. Design to cool and convey the dried product exiting the Product Screener (M-11-
4) and convey it to the Product Conveyor No. 1 (M-12-1).
2. Size per the process requirements of the Drying System per the Design Requirements.
3. Nominal screw diameter: 12”
4. Nominal length: 20 ft.
5. Construct the wetted parts of the conveyor, including the top cover, screw and trough out of 304 stainless steel.
6. Form the trough of the conveyor into a “U” shape.
7. Provide the conveyor with bolted and gasketed top covers to provide a dust tight seal.
8. Each section of the conveyor top cover shall be no longer than 4 feet in length for handling and maintenance purposes.
9. Provide conveyor supports to grade constructed out of 304 stainless steel construction, minimum ¼” thickness.
10. Cooling Water:
a. Use circulating non-potable water as the indirect cooling media in the conveyor water jacket.
b. There shall be no contamination of the cooling water. The cooling water shall enter and exit the flanged connections on the cooler.
11. Provide a product temperature gauge to monitor the outlet temperature of the product.
12. Motor:
a. 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:
1) Motor nameplate horsepower: 5 hp.
2) Type drive: Variable speed.
3) Provide inverter duty motor.
4) Nominal (synchronous) motor rpm: 1800.
5) Motor mounting: C-faced to gear reducer.
6) Enclosure: TEFC.
7) Power: 460 volt, 3 phase, 60 Hz.
8) Minimum Service Factor: 1.15.
9) 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.
10) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
11) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
H. Off-Spec Return Conveyor (M-11-6):
1. Design to receive the recycled product exiting the Product Screener (M-11-4) through Rotary Valve (M-11-23) and convey it to the feed end of the Paddle Dryer (M-11-1).
2. Size per the process requirements of the Drying System per the Design Requirements.
3. Nominal screw diameter: 6”
4. Nominal length: 30 ft.
5. Construct the conveyor trough of non-split flanged tubular sections.
6. Construct the wetted parts of the conveyor including the screw and trough out of 304 stainless steel.
7. Conveyor shall have an inlet connection to accept recycled product from the product screener and an outlet connection for discharge of recycled material to connection on the feed end of the dryer.
8. Provide conveyor supports to grade constructed out of 304 stainless steel construction, minimum ¼” thickness.
9. Motor:
a. 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:
1) Motor nameplate horsepower: 3HP.
2) Type drive: Constant speed.
3) Nominal (synchronous) motor rpm: 1800.
4) Motor mounting: C-faced to gear reducer.
5) Enclosure: TEFC.
6) Power: 460 volt, 3 phase, 60 Hz.
7) Minimum Service Factor: 1.15.
8) 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.
9) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
10) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
I. Rotary Valve (M-11-7):
1. Manufacturers:
a. Prater-Sterling.
b. Or equal.
2. Provide a rotary valve at the discharge of the dryer to isolate the dryer from the product handling system per NFPA 69 requirementsConstruct the rotary valve out of carbon steel construction.
3. Motor:
a. 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:
1) Motor nameplate horsepower: 2 hp.
2) Type drive: Variable speed.
3) Provide inverter duty motor.
4) Nominal (synchronous) motor rpm: 1800.
5) Motor mounting: Horizontal.
6) Enclosure: TEFC.
7) Power: 460 volt, 3 phase, 60 Hz.
8) Minimum Service Factor: 1.15.
9) 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.
10) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
11) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
J. Rotary Valve (M-11-23):
1. Manufacturers:
a. Prater-Sterling.
b. Or equal.
2. Provide a rotary valve at the discharge of the off-spec return conveyor to isolate the dryer from the product handling system.
3. Construct the rotary valve out of carbon steel construction.
4. Motor:
a. 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:
1) Motor nameplate horsepower: ½ hp.
2) Type drive: Variable speed.
3) Provide inverter duty motor.
4) Nominal (synchronous) motor rpm: 1800.
5) Motor mounting: Horizontal.
6) Enclosure: TEFC.
7) Power: 460 volt, 3 phase, 60 Hz.
8) Minimum Service Factor: 1.15.
9) 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.
10) Motor to be provided with Klixon bimetal opening contact type overload sensor in each winding.
11) Motor shall be suitable for operation in a Class II Division II Group G hazardous area.
2.5 ACCESSORIES
A. Chutes:
1. Provide connections between all system equipment handling dried biosolids.
2. Provide chutes with flexible connectors between inlet and outlet of sequential equipment.
3. Design to prevent dust from escaping from the equipment.
2.6 FINISHING
A. Shop and Field Painting:
1. 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.
2. 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.
B. Motion Failure Alarm Unit: Each conveyor drive unit shall be equipped with a motion failure alarm unit. The location and mounting details shall be as recommended by the conveyor manufacturer. Motion sensors shall be the non-contacting type using a probe with a pre-amplifier and main electronic assembly. The main electronic unit shall operate on 120 volt, single phase, 60 Hz power supply, and shall be housed in a NEMA 4X enclosure. A 0 to 60 second time delay shall be provided for startup of the conveyor. Motion Failure unit shall have DPDT switches for interface to Motor Control Center (MCC). Conveyer supplier shall coordinate electrical requirements with MCC supplier.
C. Emergency Shutdown: Each conveyor shall be furnished with an emergency trip cord and safety switch. The cord shall run the full length of each conveyor. The trip switch
shall immediately stop all conveyors when the switch is actuated. Provide DPDT switches for remote trip and trip location indication. Provide NEMA 4X prewired connection box for interface to Motor Control Center (MCC). Conveyer supplier shall coordinate electrical requirements with MCC supplier.
D. Electronic Motor Power Monitor/Trip:
1. Each conveyor motor starter shall incorporate an electronic motor power monitor/trip. The "Electronic" Detector shall connect directly to the motor cable and first measure the motor input power and then compensate for the internal losses in the motor. This will ensure that power readings under supply voltage variation conditions are automatically compensated for and that the detector will always sense the output shaft power from the electric motor. Unit shall have DPDT contact outputs.
2. The compensation setting shall be adjustable to suit any induction motor regardless of size.
3. The normal load level for the conveyor motor is to be set by an alarm level control. If the set load level is exceeded, the internal relay will change state. The output relay contact will be used for alarm and shut-down of the conveyor and for the control of other conveyors or equipment in the process.
4. The speed of trip on sensing an overload condition shall be adjustable between the ranges 0.1 and 3.0 seconds.
5. Deliver the unit to the Motor Control Center supplier for installation. Provide technical data to Motor Control Center (MCC) supplier so unit sizing and wiring requirements can be accommodated prior to MCC design submittal. Conveyer supplier shall coordinate electrical requirements with MCC supplier.
PART 3 EXECUTION
3.1 INSTALLATION
A. Install in accordance with the Drawings, shop drawings, and manufacturer's instruction.
B. Lubricate as required. Lubricate parts and components such as gear boxes and bearings prior to shipment.
C. Position conveyor directly under center of gravity of the cooling conveyor discharge.
3.2 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: Two (2) 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
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