SECTION 11650I DETAIL BIOSOLIDS THERMAL DRYING SYSTEM COMPRESSED AIR/NITROGEN SYSTEM

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


SECTION 11650I

DETAIL BIOSOLIDS THERMAL DRYING SYSTEM COMPRESSED AIR/NITROGEN SYSTEM


PART 1 GENERAL

1.1 SECTION INCLUDES

A. 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.

B. Local Control Panels:
1. Air Compressor Control Panel: 60-LCP-12-1.
2. Air Compressor Control Panel: 60-LCP-12-2.
3. Air Dryer Control Panel: 60-LCP-12-3.

C. Major components of each system include but not limited to:
1. Air compressor(s).
2. Electric drive(s).
3. Air receivers.
4. Air cooling, filtering and drying equipment.
5. Accessories.
6. Electrical controls.

1.2 SYSTEM DESCRIPTION

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

B. Provide complete system to deliver dry compressed air for supply to Nitrogen Generator described below and supply air for dryer system pneumatically controlled valves and actuators.

1.3 REFERENCES

A. ASME Boiler and Pressure Vessel Code Section V111, Division 1.

1.4 DESIGN REQUIREMENTS

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

B. Designed to support the air and nitrogen requirements of the Biosolids Thermal Drying System.

C. Compressors:
1. Number: 2.

2. Capacity: 59 cfm at 160 psi.

D. Wet and Dry Tanks:
1. Number: 2:
2. Size: 240 gallons.
3. Rating: 200 psi.

1.5 SUBMITTALS

A. Shop Drawings: Submit under provisions of Division 1, including the following:
1. Complete assembly and installation drawings.
2. Descriptive information on material and equipment furnished.
3. Electrical data.

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. Kaeser Compressors, Fredricksburg, VA.
2. Sullair, Michigan City, IN.
3. Or equal.

B. Compressors:
1. Air compressor shall be a single-stage, oil-flooded, air-cooled rotary screw compressor completely pre-piped and with pre-wired control panel. Compressor shall be Kaeser Compressors, Inc., model SK-15 or equal.
2. Compressor shall be manufactured under strict ISO 9001:2008 quality control standards.
3. Compressor shall be tested as a completely assembled, piped and wired unit.
4. Capacity shall be 59 cfm free air delivery at a discharge pressure of 150 psig. Compressor shall be capable of continuous full-flow operation 24 hr./day at rated capacity and pressure.
5. Motor voltage shall be 480V, 3 phase, 60 Hz. Control system voltage shall be 115 V, 1 phase, 60 Hz.
6. Standard compressor package shall be suitable for use in a 40ºF to 115ºF ambient temperature range.
7. Airend:
a. Rotors - Airend rotors shall have a Sigma profile. Rotors shall be precision-machined from cast iron. Airend drive shaft to be tapered for easy removal of airend pulley. All cast parts shall be 100% inspected for compliance with design tolerances in accordance with ISO 9001:2008 quality procedures.
b. Casing - Airend casing shall be cast iron construction.
c. Bearings - Airend rotors shall be supported on both ends by cylindrical roller bearings to carry radial loads. Angular contact ball bearings shall be installed on the discharge end of each rotor to carry thrust loads with minimal friction.
8. Drive Motor:
a. Motor horsepower: 15 hp.
b. Motor shall have TEFC enclosure.
c. Motor winding shall be 100% copper (aluminum not acceptable) and designed for full voltage starting.
d. Motor service factor shall be a minimum of 1.15.
e. Motor speed shall be 3600 rpm.
f. Motor insulation shall be Class “F” (Class “B” not acceptable).

g. Motor must meet or exceed Energy Independence and Security Act (EISA 2007) standards for motor efficiency. Motor efficiency shall be 91
% or higher.
9. Starters
a. Starter(s) shall be magnetic, wye-delta, reduced voltage starter(s), to ensure low starting current and reduce thrust-bearing loads.
b. Starter(s) shall be integrally mounted and wired in the compressor package, and located in control enclosure.
10. Drive
a. Drive shall be multi-ribbed single belt drive for reliability and ease of maintenance.
b. Drive shall include automatic belt tensioning device with visual adjustment indicator to maintain proper tension on the belt, prolong belt life, and maintain efficient power transfer from the motor to the airend.
c. Belt shall be 100% oil-resistant.
11. Control Cabinet
a. Control cabinet shall have NEMA 12 protection.
b. Electrical components shall be UL listed and/or CSA approved and labeled as required.
c. Electrical schematic diagram shall be included in the service manual for ease of reference.
d. Cabinet backplate shall be galvanized for improved grounding.
12. Compressor Instrument Panel:
a. Instrument panel shall consist of a Sigma Control 2™ system, or equal. Control system shall be designed for ambient temperatures ranging from
–4°F to +140°F.
b. The controller shall have embedded controller technology and sophisticated operating system. The unit shall include a stabilized 24V DC power supply and remote start/stop programmable timers. A buffer battery with a lifetime of ten years shall be included for protection of system memory and internal clock.
c. The unit shall be EMI (electromagnetic interference) protected to ensure proper functioning of the controller in industrial conditions. The unit shall include additional digital and analog inputs and outputs for monitoring of standard and optional sensors.
d. Standard communications include: RFID for user access and security, Ethernet for remote monitoring with included Web Server, and an SD card reader slot to enable long term data logging and saving of system parameters.
e. A user interface shall be integral to the unit, and shall include ergonomic controls with LED indication of important functions, and a background illuminated, plain text and graphical display capable of displaying information in many languages.
f. The controller shall monitor critical compressor and control functions and shut the compressor down in the event of motor overload, high airend temperature, incorrect rotation, or loss of drive.
13. Enclosure:
a. Compressor shall have steel frame assembly and be completely enclosed, including bottom. All models shall include hinged doors and/or

removable access panels for easy access to the compressor for maintenance. All models shall incorporate safety interlock switch on front access panel for protection of operators and maintenance personnel.
b. Enclosure shall be heavily sound insulated, and compressor shall have a maximum full load noise level of 67 dB(A) at 3 feet in accordance with ISO 2151 using ISO 9614-2 methods. All sound dampening material shall be oil repelling and cleanable.
c. Airend and motor shall be mounted on a steel frame isolated from compressor frame with rubber vibration isolators.
d. Compressor frame shall be isolated from the floor by rubber vibration pads. No special foundation shall be required.
e. All access panels/doors shall have slotted key locks or handles. Door key shall be provided.
f. Ambient cooling air shall enter enclosure after passing through a filter mat.
g. Compressor shall be fitted with an air inlet filter rated at 4 microns.
h. Cabinet panels shall have a “powder coat” type paint finish, which shall be durable and scratch-resistant.
i. All access panels/doors shall be gasketed to minimize dust or dirt entering the compressor enclosure.
14. Internal Piping
a. All major air and oil pipes shall be made of steel and feature flexible Aeroquip connections with o-ring seals to reduce the likelihood of cracks and leaks.
15. Lubrication/Cooling System
a. Compressor shall have differential pressure fluid circulation system. Compressors requiring a pump and/or stop valve are not acceptable.
b. Compressor shall be factory-filled with semi-synthetic or optional full synthetic lubricant.
c. Fluid filter shall be spin-on type capable of removing particles down to 10 microns or less.
d. Compressor fluid cooler shall have thermostatic control valve to maintain optimum operating temperature.
e. Compressor shall have an ASME separator tank/sump with integral fluid separator element and minimum 217 psig rated working pressure. Separation system shall include three stages - mechanical separation and two-stage coalescing filter. Compressor package shall have a maximum fluid carryover of 1 - 3 ppm. Separator shall also include sump pressure gauge, fill plug, fluid level sight glass, and quick disconnects for measuring air pressure differential across filter element. ASME coded safety relief valve shall be installed on fluid separator tank. Separator shall also be equipped with quick disconnect and fluid drain hose for pressurized fluid changes.
f. Fluid coolers and aftercoolers shall be easily accessible for ease of maintenance. Air-cooled aftercooler and fluid cooler shall be integrally mounted to the compressor enclosure. Aftercooler approach temperature shall be less than 10.8ºF.
g. Fluid cooler shall include drain plugs to ensure complete fluid removal without costly flushing.

h. Cabinet shall have three-zone cooling air flow to provide cool ambient air to coolers, motor, and cabinet enclosure.
16. Compressor Control
a. Compressor shall have automatic dual control as standard. Compressor shall automatically load after starting if system demands it. Compressor shall have time delay to shut down the compressor after running unloaded for a pre-determined period of time to avoid excessive motor starting.
b. Compressor shall cut in at 140 psig and cut out at 150 psig.
17. Testing and Inspection
a. Parts must be inspected as part of strict ISO 9001:2008 quality control program.
b. Each compressor shall be run and tested for leaks, pressure, temperature, rotation, and full load amp draw.

C. Heatless (pressure-swing) Regenerative Compressed Air Dryers
1. General Description:
a. Vendor shall supply one packaged, fully assembled, piped, an·d wired pressure-swing (heatless) type regenerative desiccant dryer. Dryer shall be complete with: two pressure vessels (towers) each containing a desiccant bed fully charged with activated alumina; controller and control valves to direct inlet and purge air flows from tower to tower; a means of regulating purge air usage and a pressure relief valve. All components shall be mounted on a structural steel frame with ·floor stand and lifting lugs. Dryer shall be ready to start up after utility. connections are made.
2. Operation:
a. Dryer shall operate automatically and continuously and produce the specified outlet pressure dew point.
b. Inlet conditions: 138 SCFM at 150 PSIG and 100°F (saturated).
c. Outlet pressure dew point shall be: -40°F, at above conditions when dryer is operating on a 10 minute cycle.
d. Pressure drop across dryer shall be: 3 PSID.
e. Maximum working pressure of the dryer shall be: 150 PSIG
3. Components:
a. Desiccant Tower Design:
b. Dryer shall be complete with two (2) drying towers (pressure vessels) containing the desiccant beds. Towers shall be designed so that air velocity through the desiccant bed is not greater than sixty (60) feet per minute @ 100 psig in order to prevent desiccant fluidization and subsequent deterioration. Compressed air shall have minimum contact (residence) time in the tower of 4.8 seconds so that 1 00% saturated air at the dryer inlet is dried to the specified dew point at the dryer outlet. Beds shall be sized with sufficient desiccant so that the effects of desiccant aging (normally a loss of 30% before reaching a steady state) are negated.
c. Dryer capacities are based on 1 00°F saturated inlet air at 100 psig.
d. To satisfy these conditions, each tower shall contain at least 0.6 pounds of activated alumina desiccant for each scfm of flow at standard rated

inlet conditions (1 00 psig, 100 oF saturated). Bed design shall be such that moisture and temperature fronts do not break through the bed before tower switchover occurs. The average purge rate shall not exceed 14.4 % at standard rated flow conditions.
4. Desiccant Tower Construction:
a. Each tower shall be furnished with separate drain and fill ports so that desiccant can be replaced without disconnecting piping. A pressure gauge shall be provided for each tower.
b. Removable, cleanable, stainless steel air diffusers shall be mounted on inlet and outlet of each tower to prevent air channeling.
c. Diffusers shall be accessible for cleaning.
d. Pressure vessels large enough to require ASME code compliance shall be built and stamped in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.
5. Controller:
a. A controller shall be furnished to sequence operation of inlet and purge/repressurization valves so that one tower is drying the inlet compressed air stream, while the other tower is depressurized, regenerated, and repressurized.
b. A solid-state controller shall be provided and be protected by a replaceable fuse. Controller shall include a cycle time selector so that cycle time can be field adjusted for 4, 10, 16 or 24 minute cycles. This allows the user to select an outlet pressure dew point, based on cycle time, of -100°F, -40°F, -4°F or +38°F respectively (at 100°F inlet air temperature).
c. The controller shall be supplied with power on, tower drying, tower regenerating, pressure switch status, service reminder and alarm lights.
d. The controller shall also include a manually adjustable purge economizer. Adjustments shall be in increments of 10% from 100% to 30% of dryer capacity. The purge economizer shall allow the reduction of purge valve open time when the dryer is operated at less than maximum flow capacity. A diagnostic test mode shall allow manual stepping through the control sequence.
e. Controller shall be mounted in a NEMA 4X electrical box and be provided with an on/off switch mounted on the box.
6. Air Control Valves (inlet switching and purge/repressurization):
a. Inlet and outlet air valves shall be non-lubricated, shuttle valves having corrosion resistant shuttle.
b. Purge/repressurization valves shall be normally closed, pilot operated, "Y" angle, poppet type.
c. Pilot air, used for purge/repressurization valve actuation, shall be dried and filtered through a twenty-micron filter. Pilot air shall be used to both open and close valves.
d. Valves controlling pilot air shall be non-lubricated solenoid operated type with hermetically sealed coils. (150 psig maximum working pressure models).
7. Normally Closed PIR Valves:
a. When dryer is de-energized the purge/repressurization valves will close.
8. Piping:

a. All piping shall be threaded, grooved or flanged for ease of component replacement.
9. Purge Air Regulation:
a. Purge air shall be regulated by an adjustable valve and pressure reducing orifice. Purge flow indication is via the purge pressure gauge installed downstream of the purge pressure-regulating valve and upstream of the purge orifice. Indication of correct purge flow rate is via pressure reading on the purge pressure gauge.
10. Purge Exhaust Mufflers:
a. Purge air shall be exhausted through mufflers to reduce noise level. Each tower shall have its
b. own muffler. Dryers shall be shipped with an extra set of muffler inserts.
Mufflers shall be
c. equipped with pressure relief device to prevent excessive backpressure.
11. Repressurization:
a. After purging and prior to tower switchover, the tower being purged shall be slowly repressurized to line pressure to prevent bed movement and desiccant abrasion.
b. Standard and Purge Saving Controller repressurization times shall be 60 seconds for 10 minute cycle.
c. Time allotted for repressurization shall permit full re-pressurization of the off-line tower plus a short idle time before tower changeover occurs.
12. Flow Direction:
a. Flow direction during drying cycle shall be upward in order to concentrate any liquid water present in the inlet air at bottom of tower, preventing desiccant contamination. This also allows for the discharge of moisture and other contaminants through the exhaust muffler during depressurization.
b. Purge flow shall be downward in order to maintain driest desiccant on top of tower and prevent bed movement during tower depressurization.
13. Power Supply:
a. KAD and KAD-PS Series: 120/1/60 VAC
14. Standards Conformity:
a. Standard dryers shall be certified by the Certification and Testing Division of the Canadian Standards Association to comply with UL No. 1995 and CAN/CSA-22.2 No. 236-05 and CAN/CSA-22.2 No. 14-05.

D. Nitrogen Generator:
1. Provide a nitrogen generator to supply nitrogen for purging the product storage silos and to provide an insulating pad for the thermal fluid heater system expansion tank. Nitrogen generator shall receive dry, oil free air supply from air compressors.
2. Nitrogen generator shall be membrane type complete with pre-filters, post filter, nitrogen flow control valve, nitrogen outlet pressure regulator, nitrogen flow meter, and controls. Provide an integral oxygen analyzer to monitor nitrogen purity. Nitrogen generator shall be housed in a pre-piped and pre-wired floorstanding module.
3. Nitrogen generator shall have a nitrogen output capacity of 600 cubic feet per hour at a minimum nitrogen purity of 93%

4. Nitrogen generator shall be Parker Balston Model HFX0-9 or approved equal.

2.5 ACCESSORIES

A. Each compressor system shall be provided with the necessary regulator valves to maintain the desired pressure for the installed equipment. Regulators shall be designed for              a maximum inlet pressure of 125 psi and a maximum temperature of 200 degrees F. Regulators shall be single seated, pilot operated with valve plug, bronze body and trim, and threaded connections. The regulator valve shall include a pressure gauge and shall be provided with an adjustment screw for adjusting the pressure differential from 0 to 125 psig.

B. Wet & Dry Tank:
1. 240 Gallon Vertical Tank Rated for 200 PSI MWP
2. ASME Data Plate
3. Integral base
4. NPT Fittings as required to meet system connections
5. Painted Exterior
6. Relief Valve 1/2", 200 PSI, 358 CFM
7. Liquid Filled Gauge, Back Mount, 4", 200 PSI

C. Wet Tank Condensate Drain:
1. Eco-Drain31 Electronic Demand Type Automatic Condensate Drain, 115V

D. Condensate Filter:
1. KCF50 Oil/Water Condensate Filter

E. A pressure gauge calibrated to 150 psi and equipped with a gauge cock and pulsation dampener shall be furnished for installation adjacent to pressure switches.

2.6 FINISHING

A. Factory finish with manufacturer’s standard finishes.

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. Control Panel and Components (60-LCP-12-1, 60-LCP-12-2):
1. Furnish controls and control panel compatible with the air compressor system herein. Control panels and controls shall be furnished in accordance with Division 13 and Division 16, and shall conform to the requirement herein.
2. Electrical controls shall include: magnetic starter, solenoid valves for unloading (Normally/Fail closed), low voltage transformer and control circuitry, primary pressure switch main panel circuit breaker disconnect.
3. Control Panel:

a. Enclosure: NEMA 4X stainless steel.
b. Provide Hoffman enclosure, or equal; sized for the application, with full subpanel.
c. Provide stainless steel enclosure drip shield.
4. Power supply: 460 volt, 3 phase, 60 Hz.
5. Provide single panel disconnect with panel protection.
6. Starter: Internal to control panel circuit breaker type combination motor starter.
a. Starter circuit power is 120vac.
b. Provide CPT.
c. Provide auxiliary N.O. and N.C. contacts.
d. Provide overload alarm relay contact.
7. Switches:
a. Front of panel HOA compressor M-12-14.
b. Front of panel HOA Compressor M-12-15.
8. SPDT dry contacts for each Compressor:
a. Common alarm (FAIL).
b. Motor (RUN).
c. Compressor (REMOTE).
9. Provide power input for remote start of each compressor as follows:
a. Dry Contact Start Input.
10. Functional Description(Alternate A):
a. Provide capacity modulation range from 100 to 40 percent.
b. Inlet valve is controlled by the pilot valve and pressure regulator holding constant pressure.
c. Below 40 percent air demand, machine will unload by means of pressure setting in microprocessor and blowdown valve, reducing receiver pressure and minimizing no load power consumption.
d. Dual control feature stops machine after preset time in unload mode.
e. Machine remains in standby mode until system pressure falls to load setting.
11. Functional Description (Alternate B):
a. Machine will unload by means of pressure setting in microprocessor and blowdown valve, reducing receiver pressure and minimizing no load power consumption.
b. Dual control feature stops machine after preset time in unload mode.
c. Machine remains in standby mode until system pressure falls to load setting.


PART 3 EXECUTION

3.1 INSTALLATION

A. In accordance with Drawings, shop drawings, and manufacturer's instructions.

3.2 MANUFACTURER'S SERVICES

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

B. Minimum service requirements per unit:

1. Installation: As required for proper installation.
2. Startup and field testing: One full day on site.
3. Operator Training: One full day on-site.

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


END OF SECTION