SECTION 11650J DETAIL SOLIDS THERMAL DRYING SYSTEM THERMAL FLUID HEATING SYSTEM

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


SECTION 11650J

DETAIL SOLIDS THERMAL DRYING SYSTEM THERMAL FLUID HEATING SYSTEM


PART 1 GENERAL

1.1 SECTION INCLUDES:

A. Thermal Fluid Heating System:
1. Thermal Fluid Heat Exchanger: M-11-11.
2. Thermal Fluid Pump: P-11-12.
3. Thermal Fluid Heater: M-11-13.
4. Expansion Tank: T-11-14. 5. FV-11-11-1.
6. PCV-11-14.
7. PRV-11-14-1.
8. PRV-11-14-2.

B. Local Control Panels:
1. 60-LCP-11-3 Heater Control Panel.

C. Major Components included, but not limited to:
1. Controls and boiler trim.
2. Thermal fluid connections.
3. Fuel burning system and connection.
4. Chimney connection.
5. Electrical controls.
6. Gages and thermometers.

1.2 SYSTEM DESCRIPTION

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

1.3 REFERENCES

A. AGA - Directory of Certified Appliances and Accessories.

B. ANSI/AGA Z223.1 National Fuel Gas Code.

C. ANSI/ASME SEC1 - Boilers and Pressure Vessels Code - Rules for Construction of Power Boilers.

D. ANSI/ASME SEC8D - Boilers and Pressure Vessels Code - Rules for Construction of Pressure Vessels.

E. ANSI/NFPA 70 - National Electrical Code.

F. HI (Hydronic Institute) - Testing and Rating Standard for Cast Iron and Steel Heating Boilers.

1.4 DESIGN REQUIREMENTS

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

B. General:
1. Type of Boiler: Coiled Tube.
2. Fluid Capacity: 180 gal
3. Construction Codes ASME, Hartford, National Board
4. Boiler Shell Insulation Mineral Wool Insulation

C. Performance:
1. Minimum efficiency: Minimum 80 percent from 30 to 100 percent of full load firing rate.
2. Provide heater capable of producing hot thermal fluid with gross input of 14,100 MBh when firing on natural gas.

D. Design Criteria:
1. The thermal fluid heater operating temperature shall not exceed the flash point of the thermal fluid per NFPA 30.
2. The heater will have a minimum output capacity of 12,000 MBh to handle the process requirements of the dryer system.

E. Regulatory Requirements:
1. Conform to ASME SEC 1for construction of boilers.
2. Conform to applicable ANSI/NFPA code for internal wiring of factory wired equipment.

1.5 SUBMITTALS

A. See General Specification Section 11650, Solids Thermal Drying System - General:
1. Product Data and equipment cutsheets, including product description, model number, capacities, design conditions, operating characteristics, performance data, dimensions, clearances, weights, service sizes, etc.
2. Equipment drawings including:
a. End Assembly Drawings, for all equipment. Drawings should include overall dimensions, locations and sizes of all connections.
b. Mechanical Arrangement Drawings. Drawings should include dimensions, locations and sizes of skid interconnections along with a detailed bill of material.
c. Room Layout. Drawings shall include all sub-assemblies and all interconnecting piping. Drawings must include overall dimensions, size and location of utility connections, required clearances for operation and maintenance.
d. Schematic flow diagram of gas valve trains.
e. Electrical schematics for all control panels. Provide the ladder-type wiring diagrams showing all components, all interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field wiring.

3. Submit calculations for Seismic design including required anchoring.

B. Provide authorized boiler inspection and ASME Data Report prior to shipment; submit copy of inspection report to Engineer.

C. Provide a certified factory fire-test using natural gas, submit a copy of the data sheets results to the Engineer prior to shipment.

D. Submit manufacturer's installation instructions under provisions of Division 1.

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

F. 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. General:
1. Mount the thermal fluid heater and controls and thermal fluid pump on a common base with all components piped and wired. Components will include the circulating pump, forced draft blower, temperature control instruments, pressure gages, temperature gages, pushbuttons, control transformer, safety valve(s), thermocouples or thermo wells, and other components required for a complete thermal fluid heater.
2. All thermal fluid connections on the thermal fluid cooler shall be 300 lb. flanges.

B. Thermal Fluid Heater:
1. Manufacturers:
a. Vapor Power International, Franklin, IL.
b. Or equal.
2. Heater:
a. The heater shall be of a forced circulation design.
b. Design and stamp according to the specifications of the ASME Section 1
- Pressure Vessel Code for 225 psig at 750°F.
c. Hydro-test at 340 psig.
d. Heater inlet and outlet connections: ANSI 300 pound flanged and fitted with thermowells to monitor the heater inlet and outlet temperatures.
e. Each individual coil outlet into the common supply heater should contain a thermowell and thermometer for monitoring of the individual coil temperature.
f. Design the heating coils to have sufficient fluid velocities to ensure maximum permissible film temperature of the fluid is not exceeded
g. Externally insulate the shell with a minimum of two inches of mineral wool insulation, to prevent heat loss radiation, accidental injuries and overheating of the working environment.
h. Heater pressure relief valve: Valve sized for ASME Section 1 liquid with 300 pound inlet flange and 150 pound outlet flange.
3. Burner:
a. Fully modulating, forced draft burner with 10:1 turndown ratio on natural gas.
b. The burner, fan, motor and fuel train shall comply with applicable nationally recognized testing laboratories (N.F.P.A., Industrial Risk Insurers, Factory Mutual and U.L. regulations).

c. The flame safety system shall be an ultraviolet sensitive flame detector and burner sight glass, directly viewable from the floor level without the use of mirrors or other devices.
d. The flame safeguard shall be a Honeywell RM7800, or approved equal, providing automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics, and troubleshooting with an alpha- numeric characterized read-out that displays the recent combustion faults.
e. The control panel shall contain a minimum of the following independently labeled fault lights:
1) High Thermal Fluid Temperature
2) High Flue Gas Temperature
3) Low Thermal Fluid Level in Expansion Tank
4) Low Thermal Fluid Flow
5) Burner or Flame Failure
f. The control panel shall include a Honeywell Modbus module remote Start/Stop, Remote/Local switch and remote cycling contacts to allow for remote temperature set point and control.
g. A differential pressure switch (or transmitter) with indication, shall continuously monitor flow based on differential pressure at the thermal fluid heater outlet and shall shut off the burner if the flow drops below 90% of the design value.
h. The thermal fluid system shall also contain the following control devices:
1) High Thermal Fluid Temperature Switch.
2) Low Combustion Air Switch
3) Temperature Sensors (for Thermal Fluid Supply & Return)
4) One Pressure Relief Valve (ASME Section 1)
5) One Low Fluid Level Switch (in Expansion Tank) (LSL-11-14).
6) Flame Safeguard Control

C. Thermal Fluid Pump: P-11-12.
1. Manufacturers:
a. SIHI.
b. Dean.
c. Or equal.
2. Pump:
a. Provide air-cooled centrifugal pump designed for organic thermal fluids.
b. Design pump suitable for pumping thermal fluid with temperatures up to 650°F.
c. Pump volute, back plate suction piece:
1) Construction: Close-grained cast iron ASTM A48 CL30.
2) Suction and discharge flanges: ANSI, 300 pound bolt circles.
d. Impeller:
1) Construction: Close-grained cast iron ASTM A48 CL30 or bronze ASTM B585.
e. Seal:
1) Type: Single mechanical.
2) Designed for thermal fluid use to 650°F.
f. Bearing housing:

1) Construction: Cast iron ASTM A48 CL30.
g. Shaft:
1) Construction: Ground and polished carbon steel C1045.
h. Shaft bearings:
1) Pump side bearing-type: Ball or roller type, AFBMA Standard.
2) Motor side bearing: Ball or roller type bearings, AFBMA Standard.
3) Lubrication: Grease.
4) Bearing life: B-10 life of 50,000 hours AFBMA 9.
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: 75 hp.
2) Type drive: Constant speed
3) Provide inverter duty motor.
4) Nominal (synchronous) motor rpm: 3600.
5) Motor mounting: Horizontal.
6) Enclosure: TEFC.
7) Power: 460 volt, 3 phase, 60 Hz.
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 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.
4. Mechanical Drive:
a. Direct: Neoprene or EPDM sleeved flexible couplings, Dodge, Woods, Rexnord or equal with OSHA approved guard.
5. Pump Base:
a. Construction: Minimum 3/8-inch thick fabricated steel.
b. Provide common pump and motor mounting.
c. Factory mount complete pumping unit including motor, coupling, coupling guard and motor.

D. Expansion Tank (T-11-14):
1. Manufacturers:
a. Vapor Power International, Franklin, IL.
b. Or equal.
2. Expansion Tank:
a. Provide system with a horizontal, saddle mounted expansion tank.
b. Design to hold up to 150% of system thermal fluid expansion volume tank complete with the necessary connections and over-flow.
c. Design and fabricate to 50 psig @ 450°F design and include the following features:

1) A Low Fluid Level Switch mounted in the bottom of the Expansion Tank,
2) A Sight glass/level Indicator,
3) A Nitrogen Manifold to provide a blanket of nitrogen in the expansion tank.
4) PCV-11-14:
a) Provide a pressure control valve to control the nitrogen addition to the expansion tank with thermal fluid contraction.
5) PRV-11-14-1:
a) Provide a pressure relief valve to relieve nitrogen from the expansion tank with thermal fluid expansion.
d. PRV-11-14-2:
1) Provide a relief valve to protect the vessel from overpressure.

E. Thermal-fluid:
1. Provide Paratherm HE, Multitherm IG-1, or equal thermal-fluid for complete system fill including thermal fluid heat exchanger, biosolids dryer, thermal heater, expansion tank and all thermal-fluid piping volume, plus 10 percent excess.

F. Thermal Fluid Heat Exchanger (M-11-11):
1. Manufacturers:
a. Gould
b. Atlas
c. Or equal.
2. Thermal Fluid Cooler:
a. Design, manufacture, inspect, test and stamp in accordance with the latest revision of the ASME Code for Unfired Pressure Vessels, Section VIII, Division 1, for a maximum working pressure of 125 psig at a design temperature of 550° F.
b. All thermal fluid connections on the thermal fluid cooler shall be 300 lb. flanges.
c. The Equipment Supplier shall provide a thermal fluid cooler to expedite the cooling of the dryer. The thermal fluid cooler shall be piped in parallel with the dryer and be isolated with automatic valves with positioning switches. The fluid cooler shell shall be fabricated from carbon steel; the tubes shall be fabricated from stainless steel.
d. FV-11-11-1:
1) Provide a flow control valve to divert thermal fluid to the thermal fluid cooler during shutdown.
2) Provide a pneumatically actuated valve.
3) Designed for a working pressure of 125 psig at 550° F.
4) Provide with open and closed position switches.

2.5 ACCESSORIES

A. None.

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. Heater Control Panels 60-LCP-11-3 shall be built with the following minimum requirements:
1. Control Panel shall be built in accordance to Specification Section 13325 "Control Panel Enclosure Construction".
2. Components within the Control Panel shall be furnished in accordance to Specification Section 13326 "Control Panel Mounted Instruments and Devices".
3. Control Panel shall be furnished with an Allen Bradley Compact Logix Series PLC in accordance with Specification Section 13322 "PLC System".
4. Control Panel shall include plant SCADA network interface via panel mounted Ethernet Switch. This same switch shall be utilized to interface with all local control panels associated with the drying process, as well as desktop PC.
5. All Control Panel and Desktop PC programming shall be provided as part of the Biosolids Dryer system. PLC shall be fully programmed to reflect the specifics of the indirect thermal dryer system.


PART 3 EXECUTION

3.1 INSTALLATION

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

B. Provide connection of gas service in accordance with ANSI/AGA Z223.1.

C. Pipe relief valves to thermal oil overflow tank.

D. Mount thermometer in boiler breeching within 12 inches of flue nozzle.

E. All thermometers shall be well mounted.

3.2 FIELD QUALITY CONTROL

A. Division 1 - Quality Requirements and Division 1- Execution Requirements: Field inspecting, testing, adjusting, and balancing.

B. Perform combustion test including boiler firing rate, over fire draft, gas flow rate, heat input, burner manifold gas pressure, percent carbon monoxide, percent oxygen, percent excess air, flue gas temperature at outlet, ambient temperature, net stack temperature,

percent stack loss, percent combustion efficiency, and heat output. Perform test at minimum, mid-range and high fire.

C. Arrange with local authorities having jurisdiction for inspection of boiler, piping, and for certificate of operation.

3.3 ADJUSTING

A. Division 1 - Execution Requirements: Requirements for starting and adjusting.

3.4 CLEANING

A. Division 1 - Execution Requirements: Requirements for cleaning.

B. Flush and clean boilers upon completion of installation, in accordance with manufacturer's start-up instructions.

3.5 MANUFACTURER'S FIELD 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 functional testing: One day on site.
3. Operator training: One day on site.
4. Post start-up training: One day onsite.

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


END OF SECTION