SECTION 11650G DETAIL BIOSOLIDS THERMAL DRYING SYSTEM TUBULAR DRAG CONVEYORS

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


SECTION 11650G

DETAIL BIOSOLIDS THERMAL DRYING SYSTEM TUBULAR DRAG CONVEYORS


PART 1 GENERAL

1.1 SECTION INCLUDES:

A. Tubular Drag Conveyors:
1. Product Conveyor No. 1: M-12-1.

B. Major components included, but not limited to:
1. Drag conveyor.
2. Drive system.
3. Supports.
4. Electrical Controls.
5. Safety Accessories.

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, shown 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.

B. Tubular Drag Conveyor
1. Number of units: 1
2. Designation: Drag Conveyor 1
3. Operating schedule: Continuous duty
4. Design handling capacity: 50 cu ft/hr
5. Material density: 60 lb/ cu ft
6. Percent solids: 15 percent - 20 percent solids by dry weight
7. Minimum drive horsepower: 5.0 hp
8. Inlet temperature of material: 100° F

1.5 SUBMITTALS

A. Shop Drawings: Submit data under provisions of DIVISION 1, including the following:
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. Control diagrams and panel layout.
9. Conveyor sensors, instruments and safety switches.

B. Furnish operation and maintenance manuals under the provisions of DIVISION 1.

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

D. 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 EQUIPMENT

A. Acceptable Manufacturers:
1. Hapman, Kalamazoo, MI.
2. Flexicon Corporation, Bethlehem, PA.
3. Spiroflow Systems, Inc., Monroe, NC.
4. Chain-vey, Modern Process Equipment Corporation, Chicago, IL.
5. 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. Dried biosolids shall be delivered to the System from the dryer system via a cooling screw conveyor provided by others. The conveyor will drop the dried biosolids into a chute leading to the dryer product discharge conveyor provided under this Section. The chute shall also be provided under this section.
5. 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.
6. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation.

C. Materials Of Construction:
1. Unless otherwise specified or permitted, the materials used in the fabrication of the equipment under this section shall conform to the following:
a. Housing: Standard schedule 40 mild steel.
b. Chutes: Standard mild steel minimum 3/16-inch.
c. For Conveyor Supports: Galvanized, ASTM A153 and A385, 18-8 Stainless Steel or zinc-plated ASTM B633, SC4.
2. Hardware:
a. All fasteners shall be hot dip galvanized or stainless steel. Zinc plated fasteners shall not be used.
b. All stainless steel bolts shall be assembled using an anti-seize compound.
c. All structural bolts shall be A-325, hot-dip galvanized.

D. Drag Conveyor:
1. The dryer product transfer conveyor shall be a tubular drag chain conveyor by type.
2. Shall receive dried biosolids from a flanged connection on the cooling screw conveyor provided by others. The cooling screw conveyor will discharge via chute to the dryer product transfer conveyor; the chute shall be provided with the dryer product transfer conveyor. The dryer product transfer conveyor shall discharge into the top of the silo as shown on drawings.
3. The dryer product transfer conveyor shall be fully enclosed with no leakage from anywhere besides the loading and discharge ports.
4. The dryer product transfer conveyor shall be designed and sized to meet the performance requirement section described in this specification.
5. The dryer product transfer conveyor shall be self-cleaning to prevent biosolids accumulation on any part of the conveyance system.
6. The dryer product transfer conveyor shall be constructed of appropriate material considering the abrasive and corrosive nature of dried biosolids.
7. The internals shall be of a nonsparking design for the handling of combustible particulate and dust.

E. Chain:
1. Drop forged carbon steel rivetless chain.
2. Two-piece replaceable UHMW-PE flights, spaced as manufacturer recommends based on loading.

F. Housing:
1. Harden all bends to 600 BHN.

2. Drive box with inlet and outlet tube.
3. Provide two (2) inspection openings for chain installation and inspection.

G. Chutes:
1. Provide chutes to connect between discharge flange on the cooling screw conveyor rotary valve of the dryer system to the System.
2. Provide connections between all system equipment handling dried biosolids.

H. Drive System
1. Drive assembly shall consist of an integral gearmotor. 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 Class II speed reducer as manufactured by Eurodrive.
2. The gear reducer and drive shall be designed to provide an applied torque adequate to start a full loaded conveyor.
3. Drive shall have an AGMA service factor of 1.4 and shall operate on 460V/3 phase/60 Hz power.
4. A hardened tooth drive sprocket for the conveying chain is keyed and set- screwed to the drive shaft.
5. A jackscrew takeup mechanism shall be provided to take up slack in the chain.
6. An unbalanced load type chain vibrator and mild steel hammer assembly shall be mounted at conveyor discharge to minimize carry back.

I. 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: See design requirements.
b. Type drive: Constant speed.
c. Nominal (synchronous) motor rpm: 1800.
d. Motor mounting: C-faced to gear reducer.
e. Enclosure: TEFC.
f. Power: 460 volt, 3 phase, 60 Hz.
g. Minimum Service Factor: 1.15.
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 sensor in each winding.
j. Motor shall be suitable for operation in a Class II Division II Group G hazardous area.

J. 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 10 feet-0 inches on center.
3. Provide baseplates at each ground support leg for anchor bolting
4. Height/length of support will be as indicated 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.

2.5 FINISHING

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

2.6 INSTRUMENTATION AND CONTROLS

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. Control panels shall be NEMA 4X, stainless steel.

C. 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/7 enclosure. A 0 to 60 second time delay relay shall be provided for startup of the conveyor.  Motion Failure unit shall have DPDT switches for interface to Motor Control Center (MCC). Deliver the time delay relay to the Motor Control Center (MCC) supplier for installation. Conveyer supplier shall coordinate electrical requirements with MCC supplier. Provide technical data for time delay relay to Motor Control Center supplier prior to MCC design submittal.

D. Emergency Shutdown: Provide two E-Stop switches for conveyors as shown on P&ID 09-I-21. Provide NEMA 4X/7 prewired connection box for interface to Motor Control

Center (MCC). Conveyer supplier shall coordinate electrical requirements with MCC supplier.

E. 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: 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