GRINDERS

These grinders are used upstream of progressive cavity pumps. It names JWC Environmental and Franklin Miller.

GRINDERS

PART 1 - GENERAL

1.1      THE REQUIREMENT

A.   The CONTRACTOR shall furnish and install in-line grinders, together with all cutters, drives, motors, valves, mounts, supports, control, accessories, and appurtenances necessary to  make  the  equipment  complete  and  operable,  in  accordance  with  the Contract Documents.

1.2      RELATED WORK SPECIFIED ELSEWHERE

A.   The requirements of the following Sections and divisions apply to the Work of this Section.  Other Sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work.

1.   Additional General Requirements

2.   Operation and Maintenance Manuals

3.   Commissioning

4.   Training of OCSD Personnel

5.   Miscellaneous Metalwork

6.   Protective Coating

7.   Equipment Basic Requirement

8.   Progressive Cavity Pumps

9.   Electric Motors

10. Control Panels

11. Control Strategies

12. Process Instrumentation and Controls

1.3      REFERENCE SPECIFICATIONS, CODES AND STANDARDS

A.   All Work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these Specifications.

B.   Comply  with  the  applicable  editions  of  the  following  codes,  regulations  and standards.

1.   American Bearing Manufacturers Association (ABMA):
2.   American Iron and Steel Institute (AISI)
3.   ASTM International (ASTM)
4.   American Welding Society Publication (AWS)
5.   Institute of Electrical and Electronics Engineers (IEEE)
6.   National Electrical Manufacturers Association Standards
7.   Occupational Safety and Health Act
8.   Electrical Manufacturers Association

C.  Comply  with  the  applicable reference  Specifications as  directed  in  the  General Requirements and Additional General Requirements.

1.4      CONTRACTOR SUBMITTALS

A.   See  Section  11005,  Equipment:    Basic  Requirements, for  requirements  for  the mechanics and  administration of  the  submittal process  Submittals shall  include the following:

1.   Shop drawings, including cut sheets, material specifications, assembly diagrams, and materials list.

2.   Grinder head loss curves.

3.   Brochures and catalogue cuts.

4.   Recommended  complete  master  wiring  diagrams  and  elementary  control diagrams, including required coordination with other electrical control devices and power supply.  Standard pre-printed sheets simply marked to indicate applicability to this Contract will not be acceptable.

5.   Coordination letter from the grinder manufacturer stating that all Work has been coordinated with the supplier of low voltage motor controls supplied under Section 16480, Low Voltage Motor Control.

6.   Manufacturer’s list of recommended spare parts.

7.   Manufacturer’s recommended field test procedures.

8.   Operation and Maintenance Manuals.

1.5      QUALITY ASSURANCE

A.   General:

1.   Comply with the requirements specified herein and  the  applicable reference Specifications of the General Requirements and Additional General Requirements.

2.   Comply with the applicable Sections of Division 11, Equipment.

B.   Manufacturer’s Qualifications:

1. Manufacturer shall have a minimum of five years experience producing substantially similar equipment and shall be able to show evidence of at least five installations in satisfactory operation for at least five years.

1.6      WARRANTY

A.   The grinders and all components specified in this Section shall be warranted by the manufacturer for a minimum three (3) year period after beneficial occupancy of the Work pursuant to “Use Prior to Final Completion” of the General Conditions, against defects in workmanship and materials.

1.7      TOOLS

A.   The  CONTRACTOR  shall  supply  one  set  of  any  special  tools  necessary  for adjustment or maintenance; one set of gaskets and one set of cutters.

PART 2 - PRODUCTS

2.1      MANUFACTURER

A.   Manufacturers: JWC Environmental, Inc.; Franklin Miller; Or Equal.

2.2      GENERAL

A.   General:   The grinders shall be capable of grinding continuously sludge types as identified in Table 1 of this Section.  The grinders shall be automatically operated to run in conjunction with the corresponding feed pumps.   The design conditions and other pertinent requirements for the equipment are listed in Table 1 attached to this Section.

B.   Construction:

1.  Each sludge grinder shall be of the in-line configuration with flanged-end connections of the size shown in Table 1.  The flanges shall be 150 pound drilled to conform to ASME B16.1 standard.  A cleanout shall be provided on the inlet side of the body.   The grinder body shall be constructed of ASTM A48 gray iron top end housing, with ASTM A36 steel bottom covers, and ASTM A536-84 ductile iron side rails.   The grinder shall have two counter-rotating shafts with mechanical seals, spacers, and intermeshing cutters.  Grinder drive and driven shafts shall hexagonal, measuring 2-1/2 inches across the flats, and be made of AISI 4140 heat treated hexagon steel  with  a  minimum  tensile strength rating of  not  less  than  149,000 pounds per inch, and hardened to 38-42 Rockwell C.  One shaft shall not exceed a speed of 40 rpm and the other shaft shall not exceed a speed of 80 rpm. The spacers shall be constructed of AISI 8620 alloy steel, surface ground to a thickness of 0.446 inches and hardened to 34-38 Rockwell C.  The cutters shall be constructed of AISI
8620 alloy steel, surface ground to a thickness of 0.438 inches and hardened to 60-65 Rockwell C. Cutters shall have 11 cam shaped teeth, with a tooth height not greater than 11/16 inch above the root diameter of the cutter; the OD of the cam cutter shall be 7.50 inches. . Seals shall be mechanical face-type that operate on a reverse pressure principal with a design pressure rating of 90 psig. The dynamic and rotating seal faces shall be tungsten carbide wit 6 percent nickel binder.  The radial and axial loads shall be borne by sealed, oversized, deep-groove ball bearings.  The sludge grinders shall be capable of running dry and shall not require an external water source.

2.   The gear reducer shall be manufactured by Sumitomo Machinery Corporation of America and designed for continuous heavy-duty shock loads per AGMA 420.07, and shall be internal planetary mechanism with trochoidal curved tooth profile.  It shall be vertically mounted with a 43:1 single reduction, and shall be grease lubricated.  A flexible coupling shall isolate the gear and motor from the rest of the unit.

3.   All motors shall be heavy-duty, constant-speed type with a maximum speed of 1800 rpm, acceptable for a wet and corrosive Class I, Division 2, Group D hazardous location and shall conform to the requirements shown in Table 1.  Motors shall be furnished by the grinder manufacturer and shall be coordinated to the requirements of the grinders.  Motors shall conform to the requirements of Section 16220, Electric Motors.

2.3      LUBRICATION

A.   The CONTRACTOR shall supply the initial lubrication and all necessary sealing fluids.

2.4      PROTECTIVE COATING

A.   All  equipment  and  piping  shall  be  coated  in  accordance  with  Section  09800, Protective Coating.

PART 3 - EXECUTION

3.1      GENERAL

A.   Grinders shall be installed in accordance with the manufacturer's written instructions and Shop Drawings; provided that nothing contained in said instructions or Shop Drawings  shall  authorize  the  CONTRACTOR to  vary  from  the  requirements of  the Contract Documents.

3.2      MAINTENANCE OF INSTALLED EQUIPMENT

A.   Maintain the operability and functionality of all installed equipment between the time of  installation  and  the  commissioning  period.  

3.3      MANUFACTURER’S FIELD SERVICES

A.   Furnish the services of authorized technical representatives of the Manufacturer to assist/inspect the installed equipment and to certify that the equipment has been properly installed and is ready to operate, train OCSD personnel, conduct pre-operational mechanical checkout of the equipment, place equipment into operation, optimize the performances of the equipment and perform the field performance testing.

B.   At a minimum, conduct three separate site visits as follows:

1.   Inspection of equipment installation (8 hours minimum)

2.   Training of  OCSD  Personnel:    See  Specification section XXXXX

3. Commissioning:    See Specification section XXXXXX for requirements.   Number of hours shall be as required to meet all testing and commissioning requirements, but shall not be less than 8 hours.

3.4      FIELD TESTING

A.   Upon completion of the installation, each piece of equipment shall be tested for satisfactory operation without excessive noise, vibration, and overheating.  All equipment shall be adjusted and checked for alignment, clearances, supports, and adherence to safety standards. All the commissioning and testing procedures shall be followed as specified in Section 01810, Commissioning.


B.   The following spare parts shall be furnished, one set for each type of grinder supplied:

1.   Gasket kit

2.   Full cutter and spacer assembly


SEE FOLLOWING TABLE 1

TABLE 1
SPECIFIC CONDITIONS AND REQUIREMENTS GRINDERS

A.    Design Conditions


Tag #: 15LGDR080

System: Thickening Centrifuge Feed Pump

Location: Centrifuge Building Basement

Feed Liquid: WAS/Primary Sludge/Trickling Filter Sludge

Quantity: 2

Minimum Inlet Diameter (in.): 12

Maximum Flow (gpm):  1600

Solids Concentration (% TS): 0.5-5

Maximum Headloss (psig) :  3.0

Minimum Speed (rpm): 1,725

Maximum Motor Size (hp): 10

Power:   480V, 3PH, 60 Hz, Class I, Division 2