TRUCK LOADOUT DISCHARGER

This spec was used on a project at the Fountain Valley, CA WWTP that will bid July 2012.

TRUCK LOADOUT DISCHARGER

PART 1 - GENERAL

1.1      SUMMARY

A.   Section Includes:

1.   Truck loadout discharge assembly.

B.   Scope

1.   The discharge assembly, consisting of a lower hopper section, screw conveyors,, and gates, will be installed on the existing loadout hopper following demolition of the existing system.

2.   The system work must be performed in the proper sequence as detailed in Section 01140, Work Restrictions. Temporary loadout facility will be in operation while this system is installed.

C.  Related Sections include but are not necessarily limited to:

1.   Division 01, Additional General Requirements

2.   Section 01140, Work Restrictions

3.   Section 05505, Metal Fabrications

4.   Section 09800, Protective Coating

5.   Section 11005, Equipment: Basic Requirements

6.   Section 11121, Screw Conveyors

7.   Section 16220, Electric Motors

8.   Section 16418, Variable Frequency Drives Below 100 HP

9.   Section 17300, Control Strategies

10. Section 17405, Process Instrumentation and Control

D. Coordination:

1.   Coordinate  delivery,  installation,  and   startup  of   hopper  extension  screw    

1.2 discharge system, and gates.

QUALITY ASSURANCE   

A.   Referenced Standards:  

1.   American Iron and Steel Institute (AISI):

a.   Steel Products Manual

2.   ASTM International (ASTM):

a.   A36, Standard Specification for Carbon Structural Steel

3.   American Welding Society (AWS):

a.   A5.1 Standard Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding

b.   D1.1 Structural Welding Code Steel

B.   Qualifications:

1.   Supplied by a single manufacturer or supplier.

2.   Manufacturer shall have a minimum of three similar size and configuration units in operation.

C.  Warranty

1.   The truck loadout discharger 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.

1.3      SUBMITTALS

A.   Shop Drawings:

1.   See requirements in Section 11005, Equipment: Basic Requirements.

2.   Manufacturer's literature, illustrations, specifications, detailed drawings, data and descriptive literature on all valves and appurtenances.

3.   Complete motor data, as required in Section 16220, Electric Motors.

4.   A letter from the discharger manufacturer confirming compatibility between the drive motor and VFD being provided.

5.   Control panel layout and construction Drawings showing the location of operator interface devices and other auxiliary components, as required in Sections 16442, Control Panels, and 17405, Process Instrumentation Control.

6.   Panel elementary control diagrams and interconnect wiring diagrams including power wiring.

7.   Functional description of internal and external instrumentation and control.

8.   Deviations from Drawings and Specifications.

9.   Engineering data including dimensions, materials, size and weight.

10. Structural design calculations sealed by Professional Civil or Structure Engineer registered in the State of California.

11. Fabrication, assembly, installation and wiring diagrams.

1.4      PROJECT CONDITIONS 

A.   Location:

1.   Dewatered municipal biosolids storage and loadout facility.

2.   Interior location.

PART 2 - PRODUCTS

2.1      ACCEPTABLE MANUFACTURERS

A.   Subject to compliance with the Contract Documents, the following manufacturers are acceptable:

1.   Spirac.

2.   Schwing Bioset.

3.   Biosec Enviro.

4.   RDP Technologies.

5.   Or Equal.

2.2      MATERIALS

A.   Steel Plate: Stainless steel, ASTM A276, Type 304

B.   Steel Shapes: Stainless steel, ASTM A276, Type 304

C.  Structural Members: Stainless steel, ASTM A276, Type 304

D.  Screw Flights: Stainless steel, ASTM A276, Type 304

E.   Screw Torque Tubes: Stainless steel, ASTM A276, Type 304

F.   Hardware: Stainless steel, ASTM A320, Type 316

G.  Gates, Slide Gate Blade: Stainless steel, ASTM A276, Type 304

H.  Slide Gate Frame: Stainless steel, ASTM A276, Type 304

2.3      EQUIPMENT

A.   Performance and Configuration Requirements:

1.   Material Description:

a.   Maximum Sludge Density: 65 lb/cu. ft. (1040 kg/m3). 

b.   Minimum Sludge Density: 60 lb/cu. ft. (960 kg/m3.).

c.   Maximum Sludge Moisture: 75 percent.

d.   Minimum Sludge Moisture: 65 percent.    

e.   Abrasive.    

f.    Corrosive.    

g.   Contains oil, grease, and polymer.    

h.   Maximum Lump Size 1 inch.

B.   Truck  Loadout screw conveyors:

1.   Quantity: Four.

2.   Size: 24-inch diameter.

3.   Type: Shafted with ribbon flights.

C.  Conveyor Gates (15JGAT885; 15JGAT886; 15JGAT887; 15JGAT888):

1.   Size 48 inches x 48 inches nominal.

2.   Pneumatic actuators. 

D.  Capacity:

1.   Discharge Rate: Load out 20 cubic yards in 15 minutes maximum with all gates open and all conveyors in operation, regardless of level in hopper.

2.4      COMPONENTS 

A.   General:

1.   Design for both continuous and for intermittent operation at a capacity not less than that specified.

2.   Static and dynamic loading of the mechanical and structural components shall be calculated using the maximum density of the dewatered sludge. Structural calculations shall assume bins are 100 percent full of maximum density sludge. All bin structural design calculations shall be sealed by a registered Professional Civil or Structure Engineer in the state of California.

3.   The compatibility of the equipment with the feed equipment and all other related equipment shall be the responsibility of the CONTRACTOR.

4.   The entire system (bins, dischargers, conveyors, gates, etc.) will be supported from the existing silo to which it is attached. No supports or bracing will be permitted from the floor or from the adjacent platform.

B.   Loadout Hopper:

1.   The bin will be constructed of A36 and A572 carbon steel plate of minimum 1/4 inch thickness and will be reinforced as required.

2.   Maximum deflection to the hopper shall be limited to less than 1/200 of the span. Reinforcing members such as angles, beams, stiffeners, and gussets shall be externally mounted to provide a smooth interior surface.

3.   Each bin shall be provided with appropriate structural supports to adequately support the bin and any other loads imposed upon it from other equipment.

C.  Extraction Screw Conveyors:

1.   General:

a.   Extraction  screw  conveyor(s)  will  in  general  consist  of  conveyor  with continuous flighting, shafts and couplings, high strength shaft bolting, trough ends, seals, bearings, electric motors, speed reducers, supports and grease fittings.

b.   Provide means to remove and replace the extraction conveyor within the location and structure it is housed.

2.   Screws:

a.   The extraction screw conveyor(s) shall be furnished complete with supports suitable for mounting in the bottom of the bin.

b.   The extraction screw conveyor assembly shall be an integral unit with the bin with discharge locations through the gates as shown on the Plans.

3.   Drive:

a.   The extraction screw conveyor assembly will incorporate a drive assembly to power the screws separately.

b.   The drive assemblies will consist of a 10 HP (minimum), 480 Volt, 3 phase, TEFC motor with an AGMA Class I  helical gear  screw conveyor drive with adapter flange mounting and end thrust capacity to achieve specified speed.

c.   The motor shall be inverter duty rated for 6 to 90 Hz with sufficient power to start and continuously operate when under full bin load.

4.   Flighting:

a.   Designed to achieve uniform discharge through the gates. 

b.   Minimum of 1/4 inch thick.

c.   Torque tube shall be of sufficient size to limit deflection to 0.2 inch maximum. Pipe ends shall have a sleeve coupling with shear bolt to stub shaft to mount the drive.

5.   Shafting: End shafts will be fabricated from C 1045 steel, minimum.

6.   Trough End Bearings:  Each screw will include regreasable roller bearing at non- drive end. The bearing will be capable of handling all impending radial loading.

7.   Stuffing Box:

a.   Shaft seals will be provided at the trough ends and shall be of the packing gland type with a minimum 4 rows packing.

b.   A lantern ring with grease purge connection shall be provided for additional sealing.

8.   Troughs:

a.   Troughs shall be integral to the silo and shall transport sludge to outlets.

b.   Minimum thickness of 1/4 inch complete with external stiffeners as required.

9.   Discharge Gates:

a.   Discharge gates (two for each conveyor section) under the bin shall be provided to seal the bin when not in use.

b.   Gate Blade Maximum Deflection: 1/8 inch over actual width. 

c.   Fabricated from single piece of 304 stainless steel.

d.   Support blade on heavy duty rollers with minimum diameter of 2-1/4 inches;

maximum 6-inch centers.

e.   Gate opening shall be 48 inches x 48 inches nominal.

f.    Designed to operate as an integral part of the system and shall be supplied by the manufacturer.

g.   In closed position, the gate blade shall seal against an elastomer seal. Seal leakage shall not exceed 0.05 GPM per linear foot of perimeter.

10. Pneumatic cylinder gate actuator:

a.   Provide two 6-inch diameter (minimum) heavy duty cylinders per gate. 

b.   Side mounted.

c.   Double acting.

d.   Hard chrome-plated rod with double seal configuration. 

e.   Sized for actuation at 80 psig.

f.    Provide solenoid type directional control valve, four-way, double coil, three- position  with  cylinder  ports  blocked  in  center  position.  NEMA  4  rated  and mounted to gate frame.

g.   A gate control panel shall be provided with an Open-Close-Remote selector switches and other devices as shown on the Drawings.

11. Guarding:   OSHA style guarding will be provided by the manufacturer at all rotating components.

2.5      SPARE PARTS

A.   Extra Materials:

1.   Furnish OCSD the following extra parts:

a.   Two extraction screw conveyors 

b.   One extraction screw drive

c.   One set of rope packings for each Conveyor seal.

2.   Initial supply of necessary lubricants as recommended by the manufacturer.

PART 3 - EXECUTION

3.1      PREPARATION

A.   Field verify dimensions of existing hopper prior to fabrication.

B.   For protective coating of all components and required surface preparation refer to section 09800, Protective Coating.

3.2      INSTALLATION

A.   See Section 11005, Equipment: Basic Requirements.

B.   See sequencing requirements in Section 01140, Work Restrictions. 

C.  Vertically and horizontally align, level and plumb units into position.

3.3   MAINTENANCE OF INSTALLED EQUIPMENT, GATES AND VALVES

A.   Maintain the operability and functionality of all installed equipment, gates and valves between the time of installation and the commissioning period.  See Specification section 01660 for requirements.

3.4   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 01820, Training of OCSD Personnel, for requirements.

3. Commissioning:     See  Specification section  01810, Commissioning, for requirements.   Number of  hours  shall  be  as  required to  meet all  testing and commissioning requirements, but shall not be less than 16 hours.

Sludge Collection: Screw Conveyors

SLUDGE COLLECTION:  SCREW CONVEYORS

PART 1 - GENERAL

1.1      SUMMARY

A.   Section Includes:

1.   Screw conveyors and appurtenances.

a.   Classifying (shafted) screw conveyors.
b.   Cross and collection (shaftless) screw conveyors.
c.   Conveyor chutes and slide gates.
d.   Structural supports.

B.   Related Work Specified Elsewhere

1.   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.

2.   Division 01, Additional General Requirements

3.   Section 05505, Metal Fabrications

4.   Section 09800, Protective Coating

5.   Section 11005, Equipment: Basic Requirements

6.   Section 11250, Sludge Cake Pumping System

7.   Section 15101, Valve Operators

8.   Section 16220, Electric Motor

9.   Section 17300, Control Strategies

10. Section 17405, Process Instrumentation and Control

1.2      QUALITY ASSURANCE

A.   Reference Specifications, Codes, and Standards:

1.   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.



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

a.   American Bearing Manufacturers Association (ABMA):
b.   American Gear Manufacturers Association (AGMA):
c.   American Iron and Steel Institute (AISI)
d.   ASTM International (ASTM)
e.   American Welding Society Publication (AWS)
f.    Institute of Electrical and Electronics Engineers (IEEE)
g.   National Electrical Manufacturers Association Standards
h.   Occupational Safety and Health Act

B.   Miscellaneous:

1.   All equipment specified in this section to be supplied by one manufacturer.

1.3      CONTRACTOR QUALIFICATIONS

A.   Provide evidence of at least fifteen (15) years demonstrable experience in the design and manufacture of shafted and shaftless conveyor systems. The Supplier shall have at least ten (10) full-scale shafted and shaftless conveyor systems operating successfully for at least five (5) years that were designed and furnished under the supplier’s own name. References shall be similar in size and length as indicated in this section. Equipment bought and re-sold; or supplied under a license or marketing agreement shall not be considered for meeting the experience clause.

1.4   WARRANTY

A.   The screw conveyors 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.   Liner:

a.   For a wear indicator (two color) liner, excessive wear shall be indicated by appearance of the bottom indicator layer (second color) along more than 30 percent of the conveyor length during the first three year period after beneficial occupancy of the Work.  If these wear indications occur, the conveyor supplier shall provide new formed and banded liner to replace all the liner in the conveyor that has excessive wear.
b.   If a one color liner is used the excessive wear shall be indicated if the thickness of the liner, at three points over a 30 percent long section of the conveyor, is 1/4 inch thick or less at the thinnest point of the liner, during the first three year period after Beneficial Occupancy of the Work.  Since one color liners prohibit a simple visual inspection confirmation for the liner thickness status at the spiral-liner contact point, the conveyor manufacturer shall supply a  field technician to the jobsite on the annual acceptance date for three consecutive years to remove a minimum 30 percent of all liners and demonstrate to OCSD that at a minimum 1/4 inch of liner is remaining.  If excessive liner wear is found, the conveyor supplier shall provide new formed and banded liner to replace all the liner in the conveyor that has excessive wear.

2.   Screw:  Excessive wear on the screw shall be indicated by loss of more than 20 percent of the height of the main outer screw section over 30 percent of the total length of the screw. If excessive screw wear is found during the first three year period after Beneficial Occupancy of the Work, the conveyor supplier shall provide new screw to replace the screw in the conveyor that has excessive wear.

1.5      SUBMITTALS

A.   Shop Drawings:

1.   See Section 11005, Equipment: Basic Requirements.

2.   Fabrication and/or layout drawings.
a.   Detailed drawings showing supports, drives, connection details, materials of construction, etc.
b.   Structural calculations signed by a professional Civil or Structural Engineer registered in the State of Virginia for all structural support members.

3.   Product technical data:
a.   Cut sheets for electric motors and ancillary items manufactured by others.
b.   Conveyor torque requirement calculations.
c.   Torque calculations for the gear reducer and reducer motor.
d.   Horsepower calculations for the drive motor(s).
e.  Utilize spiral strength calculations for spring (spiral) compression and elongation showing the supplied spiral meets or exceeds spring effect intent of 9.1.2 herein (for conveyors 40 feet or longer).
f.    The CONTRACTOR is responsible for coordination of all mechanical and electrical equipment, and structural interconnecting or otherwise interfacing with the  conveyor  and  any  site  measurements required  for  a  detailed  conveyor submittal.
g.   Acknowledgement that products submitted meet requirements of standards referenced.
h.   Manufacturer's installation instructions.

PART 2 - PRODUCTS

2.1      ACCEPTABLE MANUFACTURERS

A.   Subject to compliance with the Contract Documents, the following manufacturers are acceptable:

1.   Screw conveyors:
a.   Custom Conveyor Corporation.
b.   Jim Myers & Sons (JMS).
c.   Spirac.
d.   Or Equal.

2.2      MATERIALS

A.   Material Standards:

1.   Flighting:
a.   Shafted Conveyors: AISI 304 stainless steel.
b.   Shaftless conveyors:

1)   Cold-formed high-strength alloy steel, minimum hardness 225 Brinell. Steel composition shall be: .31 percent C, 1.44 percent Cr, .64 percent Mo, 64 percent V, 4 percent Mn.

2)   Tensile Strength, Minimum: 110,000 pounds per inch.

3)   Yield Strength, Minimum: 80,000 pounds per inch.

2.   Pipe Shaft: AISI 304 stainless steel.

3.   Troughs: AISI 304 stainless steel.

4.   Covers: AISI 304 stainless steel.

5.   Chutes and Inlets: AISI 304 stainless steel.

6.   Wear liner:
a.   UHMW polyethylene.
b.   Shore Hardness D: 65.
c.   Dynamic Coefficient of Friction: 0.11.

7.   Slide gates:
a.   Frame: AISI 304 stainless steel. b.   Liner: UHMW PE.

8.   Structural Supports: AISI 304 stainless steel.
a.   Grease extension tubes and grease rack: AISI 304 stainless steel.

9.   Hardware & Fasteners: AISI 316 stainless steel.

10. Fabrication:   All welds to be continuous unless otherwise specified.   Facing surfaces of field-welded components shall be beveled and match marked.

11. Edge Grinding:   Sharp corners of all cut and sheared edges shall be made smooth.

12. Surface Preparation

a.   All iron and mild steel surfaces to be painted shall be dry abrasive blasted in accordance with SSPC-SP6, and in accordance with Section 09800, Protective Coating.   Surfaces shall be painted or hot dip galvanized within 24 hours to prevent rusting and surface discoloration.

b.   Stainless steel shall be cleaned with mild abrasive wheels and/or nonferrous blast media to remove heavy scale and welding carbon and/or passivated with stainless steel cleaner then rinsed.

c.   Painting:  After surface preparation, ferrous metal surfaces, if any, except for the spiral flighting shall receive a minimum of one (1) coat of epoxy primer. Provide a total minimum dry film thickness of 3 mils prior to shipment to jobsite. Primer  shall  be  compatible  with  the  paint  system  specified  in  Specification section 09800, Protective Coating.  Finish coats shall be applied at the jobsite by the CONTRACTOR.

d.   The spiral shall be furnished with one coat of shop primer only.

e.   Electric motors, gear reducers, and other purchased sub-components shall be furnished with the manufacturer’s standard finish.

f.    Stainless steel surfaces do not require painting.

2.3      DESIGN REQUIREMENTS

A.   Application:
1.   Provide the Following Conveyors:  Refer to construction drawings for equipment location.

B.   Physical Properties of Material to Convey:
1.   Centrifuge Dewatered Cake, 25 – 35 percent total solids.

C.  Design Criteria:
Type:  Shafted or Shaftless  
Performance  
Material Density (lb/cf): 65  
Capacity (cfh): 1827  
Trough Fill Rate: 30 percent  
System Design  
Approx. Length, feet: Refer to Construction Drawings  
Degrees Incline: 15 
Feed Inlet From: Cross Conveyor  
Discharge Outlet: Cake Pumps  
No. of Discharges: 2  
Shaft Min OD, inches: 4  
Spiral OD, Min, inches: 24  
Spiral Min Thickness, inches: 3/8 (2) 3 inch x1 inch outer  
Min. Spiral Pitch, inches: 24  
Max Liner Length, feet: 4  
Min Liner Thickness,inches: 1/2  
Trough Width: Refer to Construction Drawings  
Min chute thickness, inch: 3/16  
Min lid length, inch: 60  
Min Lid Thickness, inches:   1/8  
Location of Drive: Pull
Type of Drive: Constant Speed reversible  
Maximum HP: 50  
Motor Enclosure: TEFC  
Max Speed (RPM):  20

2.4      COMPONENTS
A.   Troughs:

1.   Trough:
a.   Provide U-type troughs, 3/16 inch minimum thickness.
b.   Use only channel type trough with built-in parallel steel channels.
c.   End seals, shrouds, inlet, discharge, etc., to be constructed from 3/16 inch
(minimum) thick steel.
d.   All openings shall be reinforced with steel angle.
e.   Coordinate opening sizes and connection details with all affected equipment.
f.    Drains: Drain connection with 150-pound flange per conveyor of sizes and at
locations shown on construction drawings.
g.   Provide  spray  wash  system  for  classifying  conveyors  as  indicated  on construction drawings including but not limited to valves, actuators and nozzles.
h.   Provide  flanged  flush  water  connections  as  indicated  on  construction drawings.

B.   Liners (Shaftless Conveyors):

1.   Wear Liner (UHMW):
a.   The wear liner for each conveyor shall be fabricated of Durawear’s Xythelon
3/8 inch thick ultra high molecular weight polyethylene.  The wear liner shall be
furnished in maximum four foot sections to provide ease of replacement.  The liner shall be held in place with clips; no fasteners will be allowed.

C.  Flighting:

1.   Shafted conveyors:
a.   Welding: Continuous, all sides, to pipe shaft.
b.   Pitch between flights to vary no more than 2 percent of the flight outside diameter.
c.   Classifying type screw with paddles at drain zone, ribbon flights at inlet zone, solid face flights to solids discharge point

2.   Shaftless Conveyors:

a.   Formed from one continuous flat bar.   The spiral flights shall be designed with the stability to prevent distortion and jumping in the trough. The torsional rating of the auger flighting shall be reached at 30 percent of the Fy value in the extreme fiber of the flight material. The spiral shall be rolled in such a way as to limit "neckdown" of the outside edge of the cold rolled spiral to 10 percent of the thickness of the inside edge of the spiral. The spiral edges shall be smooth in the as-rolled condition and not show cracks or grinding marks when tested with a dye-penetrant.
b.   Full penetration welds at all splice connections.  Spiral connections shall be welded according to AISC B-U3-GF and be six full-pass full-penetration welds. Flights shall be welded in a jig or the trough to assure true alignment. The OD of the joined spirals shall be completely concentric with no misalignment.   Weld jointed spirals shall be straight and not show any misalignment or thump when rotated.
c.   Concentric to within plus or minus 2 millimeter.
d.   Torsional rating to exceed 150 percent of drive torque rating.  The torsional rating of the auger flighting shall be reached at 30 percent of the Fy value in the extreme fiber of the flight material.   Supplier shall demonstrate that, at 250 percent of the motor nameplate horsepower, the drive unit cannot product more torque than the torsional rating of the flighting, and that the “spring effect” of the spiral shall not exceed +1/32 inch per foot of length at maximum load conditions.
e.   Design with adequate stability to prevent distortion and jumping in the trough
f.    Connect to drive through flanged connection plate welded to spiral.   The spiral flighting shall be connected to the drive shaft by welding the spirals to the 3/4 inch (20 millimeter) minimum circular Drive/Coupling torque transmission plates welded to the spiral as follows:

1)   The drive-coupling plate and drive shaft shall first be machined with 45 degree 1/4 inch matching bevels for welding. The drive-coupling plate shall be bevel machined on both sides for welding. The Drive Coupling plate attached to  the  drive shaft will  use a  six  (6)  pass full penetration weld cleaning after each pass.

2)   The shaft and coupling plate must be maintained at a 90 degree angle. Place the coupling plate and shaft into a sturdy jig made for this purpose and tack weld. Proceed with the first pass.  The drive coupling plate shaft shall then be put into a  lathe and the plate side opposite the shaft shall be machined to ensure a 90 degree connection.
a)   Weld both sides of the shaft with six (6) passes to the coupling plate.
b)   Weld the second spiral coupling torque transmission plate to the spiral. The spiral end shall have a 45 degree clean ground edge at the coupling plate.    Place  the  spiral  and  coupling into  a  sturdy jig  that maintains the spiral level, and the coupling plate at the correct height for welding to the spiral.
c)   Grind smooth on both matching sides and properly reinforced and welded with a curved gusset plate at 180 degrees.  The centerline of the spiral shall be perpendicular to the torque plate within plus or minus
0.015 inch.   A separate 3/4-inch (20 millimeter) minimum torque transmission plate shall be bored with a countersunk and chamfered hole equal to the 1/4 inch less than the shaft diameter and the drive shaft
shall be lathe-turned, keyed and undercut concentrically to a tight fit then
welded to the plate with a six pass full penetration weld technique.  The shaft shall be perpendicular to the torque plate within plus or minus 0.015 inch.  The torque plates shall be connected with three (3) 3/4-inch No. 8 bolts and no space shall show between the connected plates. Spirals welded directly to a shaft or connected in any other way will not be accepted.

D.  Slide Gates:
1.   Maximum vertical dimension of 4 inches excluding the electric motor operator.
2.   In the full, open position 1.5 x spiral pitch is exposed to the opening in the direction of transport.
3.   Opening at least the full width of the conveyor trough.
4.   Steel and UHMW PE 3/16 inch minimum thickness.
5.   The UHMW PE shall have a machined groove to accept the gate blade and give a positive seal.

6.   Actuators:
a.   Electric  actuators  meeting  the  requirements  of  Section  15101,  Valve
Operators.
b.   The  conveyor  manufacturer  shall  provide  electric  motor  operated  gate operator by Rotork model IQ 10, Limitorque model MX 05, Or Equal.
c.   The actuator shall be NEMA 4 rated, have internal adjustable limit switches, and a manual override hand wheel.
d.    The actuator shall be supported underneath the conveyor trough by supports designed and supplied by the conveyor manufacturer.

E.   Trough Cover:
1.   Classifying  Conveyors:  Provide  hinged  access/inspection  cover  over  drain section with toggle clamps and wire mesh safety guard.
2.   Provide  fresh  air  supply  and  foul  air  withdrawal  connections  as  shown  on construction drawings.

F.   Chutes:
1.   Provide chutes constructed from 3/16 inch (minimum) thick steel plate reinforced with steel angles.
2.   Attach chutes to conveyors with bolted and gasketed flanges.

G.  Drive:    Complete  with  motor  mount,  trough  plate,  speed  reducer,  drive  shaft assembly.

H.  Electric Motors:
1.   Motors shall be in accordance with Section 16220, Electric Motors.
2.   1750 rpm.
3.   480 V, 3 PH, 60 Hz.
4.   TEFC.
5.   Torque overload cutout.

I.    Speed Reducer:
1.   Output: As scheduled.
2.   Hollow shaft mounted type gear motor rated a minimum AGMA Class II, single, double reduction or triple reduction
3.   NORD Gear Corporation Unicase, Atlas Gear Company, Or Equal.
4.   Shaft mounted drive with shrink disc hollow shaft design.
5.   Shaft of sufficient diameter to transmit the required torque and welded with a six pass welding process to a coupling plate to effectively transmit torque from the drive shaft to the flight.
6.   A gland packing ring consisting of two Teflon coated packing rings shall seal the drive shaft at its penetration through the end plate.
7.   Connection  of  the  spiral  to  the  drive  system  shall  be  through  a  flanged connection plate that  is  welded to  the  spiral  forming a  smooth and  continuous transformation from the flange plate to the spiral.
8.   The drive shaft shall have a mating flange and shall be bolted to the spiral connection plate.
9.   A  grease  lubricated  labyrinth  seal  shall  be  shaft  mounted  internally  in  the conveyor between the back plate and spiral coupling connection.

J.   Lubrication:
1.   Furnish stainless steel grease extension tube to each bearing.
2.   Centralize the  location of  grease fittings  and  mount  on  rack  constructed of stainless steel.
3.   Locate racks in easily accessible locations.

K.   Structural Supports:
1.  Provide structural supports as required to install conveyors as shown on construction drawings.
2.   Include  beams,  angles,  etc.,  as  required  and  anchoring  devices  to  attach conveyors to structure.

L.   Accessories:

1.   Emergency Stop Switch: Provide each conveyor with and emergency safety stop switch NEMA 4X, with orange vinyl coated galvanized aircraft cable along both sides and mounting hardware. The quantity of emergency stop switches shall be as shown on the P&IDs and Electrical control schematics.
2.   Motion Sensor:
a.   Provide each conveyor with  zero  speed (motion) switch  installed at  the opposite end of the motor.
b.   NEMA 4X, 120V.
c.   Shaftless: Control Concepts or equal.
d.   Shafted: Milltronics MFA-4 with MSP-12 probe, Or Equal from Turck Inc.
3.   Conveyor Door Switch:  Provide a NEMA 4 direct acting limit switch with normally open contacts rated at 10 Amps, 120 Vac for each access door on the shaftless conveyors. The limit switch shall be a series 802T type by Allen Bradley, Series 9000 by Square D, Or Equal.

M.  Comply with Section 11005, Equipment: Basic Requirements.

PART 3 - EXECUTION

3.1      INSTALLATION

A.   General: Install screw conveyors to locations and lengths shown on Drawings.

B.   Install per manufacturer's written instructions and Section 11005, Equipment:  Basic
Requirements.

3.2      MAINTENANCE OF INSTALLED EQUIPMENT, GATES AND VALVES

A.   Maintain the operability and functionality of all installed equipment, gates and valves between the time of installation and the commissioning period.  See Specification section
01660, Shipping, Storage and Handling Requirements, for requirements.

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 four separate site visits as follows:

1.   Inspection of equipment installation – two trips (8 hours minimum, each)

2.   Training of OCSD personnel.  See Specification section 01820, Training of OCSD Personnel, for requirements.

3.   Commissioning:       See   Specification   section   01810,   Commissioning,   for requirements.   Number of  hours shall be  as  required to  meet all testing and commissioning requirements, but shall not be less than 16 hours.

Shaftless Screw Conveyor

PART 1 GENERAL

1.01       SCOPE OF WORK

A. Furnish all labor, materials, equipment, and incidentals required to install and test, complete and ready for operation, one shaftless screw conveyor as shown on the Drawings and as specified herein.

B. The units shall be furnished by the centrifuge manufacturer and installed with all necessary accessory equipment and auxiliaries, whether specifically mentioned in these Specifications or not, as required for an installation incorporating the highest standards for the type of service including field testing and instructing the regular operating personnel in the care, operation and maintenance of all equipment.

C. Electric motors shall be furnished as part of the scope of work of this section; and shall be in accordance with this Section.

1.02       RELATED WORK

A.   Concrete work is included in Division 3.

B.    Painting, except as specified herein, is included in Division 9.

C.    Electrical, except as specified herein, is included in Division 16.

D.   Instrumentation, except as specified herein, is included in Division 13.

E.    Mechanical piping and appurtenances, valves, pipe hangers and supports are included in
Division 15.

1.03      SUBMITTALS

A. Submit, In accordance with this Section, six copies of all materials required to establish compliance with these Specifications and shall include the following:

1. Certified shop and erection drawings showing details, sizes, grades, and materials of construction; dimensions; and any anchor bolt locations.

2.    Descriptive literature, bulletins, and catalogs of the equipment.

3. The total weight of the equipment including the weight of the single largest item or component, both when empty and when loaded with the maximum specified load of wet debris.

4.    Complete bill of materials for all equipment components.

5. List of the manufacturer's recommended spare parts. Include gaskets, packing, etc. on the list.

6.    Documentation of the AGMA rating of the drive assembly.

7.    Details of the torque overload device.

8.    Complete description of surface preparation and shop prime painting.

9.    Complete data on motor in accordance with this Section.

10.  Manufacturer's Warranty as specified in this Section.

11.  Factory test results as specified in PART 3.

B. In the event that it is impossible to conform with certain details of the Specifications, describe completely all non-conforming aspects.

C.    Operation and Maintenance Data

1. Furnish sets of operating and maintenance instructions as specified in this Section. Prepare them specifically for this installation, and include all required cuts, drawings, equipment lists, spare parts, descriptions, and other information as required to instruct operating and maintenance personnel unfamiliar with this equipment. Include copies of all approved shop drawings in the Operation and Maintenance Manuals.

D.   Submit the manufacturers' certification of proper installation and operation as required in PART
3.

E.    Additional Submittal Requirements

1.    Shop drawings of all fabricated items, structural supports, and associated items.

2. The conveyor support systems shall be designed by the manufacturer for all applicable loads (dead, live, dynamic, etc.), for normal and seismic conditions. Design loadings shall be transmitted to the concrete foundation. Design calculations for all of the items covered by these Shop Drawings shall be submitted to the Engineer and signed/sealed by a registered professional engineer in the State of Wyoming and shall show design stresses in all structural members and connections. Fabrication of the conveyor systems and supports shall not commence until shop drawings have been approved.

3.    Size, length and spacing of anchor bolts or attachments to the concrete foundations.

4. Detail installation and layout drawings, specifications and catalog cut sheets of all items of equipment showing all dimensions, parts, construction details, and materials.

5.    Wiring Diagrams.

1.04       REFERENCE STANDARDS

A.   American National Standards Institute (ANSI)

B.    American Institute of Steel Construction (AISC)

C.    American Society of Testing and Materials (ASTM)

D.   American Gear Manufacturers Association (AGMA)

E.    Conveyor Equipment Manufacturers Association (CEMA)

F.    National Electrical Manufacturers Association (NEMA)

G.   Occupational Safety and Health Administration (OSHA)

H.   American Welding Society (AWS D.1.1-90)

I.     American Bearing Manufacturer's Association (ABMA)

J.     National Electric Code (NEC)

K.   Society for Protective Coatings (SSPC)

1.05      QUALITY ASSURANCE

A. The equipment covered by these Specifications shall be the product of a single reputable and qualified manufacturer who is of proven ability.

B. These Specifications call attention to certain features, but do not purport to cover all details entering into the construction of the equipment.

C. Should equipment which differs from these Specifications be offered and determined by the Engineer to be the equal of that specified, such equipment shall be acceptable only on the basis that any revision in the design and construction of the structure, piping, appurtenant equipment, electrical work, or any other portion of the work required to accommodate such a substitution be made at no additional cost to the Owner and be as approved by the Engineer.

D. The equipment shall be as manufactured by JDV Equipment; Spirac; Jim Myers & Sons, or equal. These named manufacturers' standard products may or may not conform to these Specifications, and in case of conflict between these Specifications and a manufacturer's standard products, these Specifications shall have precedence.

E. The manufacturer shall furnish an engineer experienced in the erection, alignment, and operation of the equipment furnished under this Section for a minimum of one trip for a minimum total time at the site of not less than one day, which includes certifying its readiness for operation. Each day shall include a full eight-hour working day on the project site; travel time shall be additional to these requirements.

F. A factory representative who has complete knowledge of the proper operation and maintenance of the equipment furnished shall be provided for one day as defined above, and in addition to the days required above, to instruct representatives of the Owner and Engineer on proper operation and maintenance of the equipment. An additional trip is not necessarily required, if the training can be satisfactorily scheduled as an extension of the installation and inspection trips, as provided hereunder and provided that the final operational test is successful, and provided that the Operation & Maintenance Manuals instructions have been furnished and approved.

1.06       DESCRIPTION OF SYSTEM

A. Screw Conveyor shall be design to convey the dewatered sludge from the centrifuge to the truck load-out hopper without sustaining structural or mechanical damage.

B. All items furnished shall be amply designed and constructed for the maximum stresses occurring during fabrication, installation and both continuous and intermittent operation.

1.07      MAINTENANCE

A.   Furnish all special tools required for normal operation and maintenance of the equipment.

B.    Provide spare parts for each screw conveyor.
1.    2 bearing assemblies.

1.08        MANUFACTURER’S WARRANTY

A. The DESIGN/BUILDER shall obtain from the manufacturer its warranty that the screw conveyor will be free from defects in design, materials, and workmanship for a period of one year following Substantial Completion. Said warranty, containing no exclusions or limitations, shall be in a form acceptable to and for the benefit of the Owner, and shall be submitted by the DESIGN/BUILDER as a condition of Final Payment.

PART 2 PRODUCTS

2.01 MATERIALS AND EQUIPMENT
A. General
1. The shaftless screw conveyor system specified herein shall be furnished by one manufacturer with a minimum of five years experience in the manufacture of shaftless screw waste treatment conveying systems installed in municipal wastewater treatment facilities.  The shaftless screw conveyors shall be supplied directly by a manufacturer with not less than fifty separate operating installations of shaftless conveyors of its own manufacture, that are similar size and capacity as the systems specified herein.

2. All parts furnished shall be amply designed and constructed for the maximum stresses occurring during fabrication, erection and continuous operation. All materials for the conveyors and cleaning systems 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.    All parts of duplicate equipment shall be interchangeable without modification. Manufacturer's design shall accommodate all the requirements of these specifications.

4. All supports for conveyors shall be provided for the conveyor support framing. The DESIGN/BUILDER shall be responsible for coordinating the placement all supports necessary to tie the equipment together and shall have the undivided responsibility for the system's structural integrity.

5. Exposed welds shall be ground smooth to form a neat uniform fillet without weakening the base metal.

6. Molded shaped members shall be formed with clean, sharp rises without dents, scratches, cracks or other defects.

7. Shop Welding: Screw conveyor manufacturer's shop welding procedures, welders and welding operators shall be qualified and certified in accordance with the requirement of AWS D1.1 "Welding In Building Construction". Shop drawings shall clearly show complete information regarding location, type, size and length of all welds in accordance with AWS A2.0 "Standard Welding Symbols". Special conditions shall be fully explained by notes and details.

B. All structural supports shall be provided for the conveyors' support. The manufacturer 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. Detailed drawings and calculations, signed by a professional engineer licensed in the State of Wyoming, shall be submitted to the Engineer for review and comment prior to fabrication.

C. Except where specifically allowed by the Engineer, all hardware including washers, clips, clamps and fasteners of any type shall be constructed of Type 304L stainless steel. All anchor bolts shall be Type 316 stainless steel and have a minimum of 3/8-in diameter.

D.   Design Requirements

1. The screw conveyor shall be a shaftless design that is capable of conveying 20-30% solids dewatered sludge, weighing 60-65 PFC, at a rate of approximately 200 cubic feet per hour. Under no circumstances shall the dewatered sludge be discharged from the conveyors except through designated outlets. The configuration of the unit shall be push type.
Adequate seals shall be provided on the drive end to prevent material from entering the gear box.

2. The conveyor shall be designed and manufactured to handle intermittent loading of dewatered sludge from the centrifuge to the truck load-out hopper 24 hours per day, 7 days per week. The torque capacity of the drive unit shall be sufficient to start the conveyor with
100 percent trough loading.

3. Operating Parameters including length, incline, pitch, flight diameter, inlets, outlets, gates, and drive requirements shall be as shown on the schedule below.


Screw Conveyor Location: Dewatering Building  
Classification: Unclassified  

Screw Length (ft): 36 (to be verified based on selected centrifuge)  

Pitch (degrees): 5 (to be verified based on selected centrifuge)  

Inlets: Connected to Centrifuge Discharge (Coordinate sizing with centrifuge manufacturer)  

Outlets: Discharge outlet (size based on shaft diameter), 4‐inch dia drain  

Gates: None  

Drive Requirements: Per Manufacturer calculations

E.    Materials

1. Trough, Chutes: 304L Stainless Steel  

2. Covers:        14 Ga Min 304L Stainless Steel  

3. Drive & End Plates:  1/2-in Min 304L Stainless Steel drive, 3/8-in non-drive  

4. Spiral Flighting: Minimum 254 mm diameter, 80,000 lb. yield, with spiral insert, Micro-Alloy min. 250 Brinell Hardness  

5. Wear Liner: Plastimeric, (UHMW), 1/2-in thick min.  

6. Hardware:     Type 304L Stainless Steel  

7. Cover Fasteners:     Type 304L Stainless Steel bolts

8.    Drive Shaft:      AISI 1045 steel

F.    Spiral Flighting

1. Spiral flighting for the shaftless screw conveyors shall be designed to convey material without a center shaft. The minimum overall spiral weight and surface pressure shall be as specified herein. The conveyor will include an inner flight to increase axial strength and capacity of the conveyor. The minimum spiral weight shall be specified herein.

2. Spiral flights shall be cold-formed high strength chrome alloy steel with a minimum hardness of 250 Brinell and the bar thickness shall not vary by more than 20 percent from the outer edge to the inner edge. The spiral flights shall be designed with the stability to prevent distortion and jumping in the trough. The torsional rating of the auger flighting such that, at 150 percent of the motor nameplate horsepower, the drive unit cannot produce more torque max. than the torsional rating of the flighting, and that the "spring effect" of the spiral shall not exceed plus 0.7 mm per 100 mm of length at maximum load conditions.

3. The spiral flighting shall be formed in sections from one continuous flat bar and shall be concentric to within 2mm plus/minus. Sectional flighting formed from plate shall not be permitted.

4. Spiral flighting shall have full penetration welds at all splice connections. The flights shall be aligned to assure true alignment when assembled in the field and shall be made in accordance with the supplier's requirements. The spiral flights shall be coupled to the end shaft by a flanged, bolted connection.

5. A gland packing ring consisting of two Teflon coated packing rings shall seal the drive shaft at its penetration through the end plate, along with a greased labyrinth sealing system.

6. The connection of the spiral to the drive system shall be through a flanged connection plate that is welded to the spiral forming a smooth and continuous transformation from the flange plate to the spiral. The drive shaft shall have a mating flange and shall be bolted to the spiral connection plate.  Additionally, a grease lubricated labyrinth seal shall be shaft mounted internally in the conveyor between the back plate and spiral coupling connection.

G.   Trough and Liner

1. Troughs shall be similar to the dimensional standards of CEMA 300 and enclosure classification IIE. Each conveyor trough shall be U-shaped, fabricated from a minimum 1/8-in Type 304L stainless steel plate.  Stiffeners shall be placed across the top of the trough and fastened to both sides of the trough to maintain trough shape and act as a face seal for the covers; apply a continuous gasket, totaling one half inch width, to the entire top face of the trough top flange and stiffeners. The gasket shall be Buna-N rubber, 1/8-in thick with a Durometer hardness of 40.

2. Each trough shall be equipped with filling and/or discharge openings as required by the contract drawings. The filling opening shall be flanged and suitable for interconnection to the centrifuge. Any interconnecting devices such as chutes and hoppers shall be fabricated from the same grade of material as the troughs and to a gauge to suit the applications requirements.

3. A discharge port shall be provided at the discharge end of the conveyor for sludge discharge to load out.

4. The lowest point of the conveyor trough at the centrifuge end shall include a 4" minimum diameter drain connection. The outlet shall be piped to a drain as shown on the drawings, along with adequate cleaning facilities.

5. The portion of each trough that is not covered by the filling chute shall be covered by a stainless steel cover with gasketing per 2.01.E. Covers shall be held in place with stainless steel screw clamps or bolts on 24” maximum centers. The covers shall be manufactured in maximum five foot length section to allow for access to the conveyors. The covers shall have a 1 inch turndown edge on the two long sides. To prevent unsafe access to the conveyors, quick opening covers will not be allowed.

6. The trough shall include a replaceable wear liner fabricated of ultra high molecular weight polyethylene (UHMWP) per 2.01.E. The liner shall be impregnated with a lubricant material to reduce liner wear and extend operational life. The wear liner shall be furnished in maximum four foot sections to provide ease of replacement. The liner shall be held in place with permanently welded clips positioned at each liner end, mid point and spanning liner joint; no fasteners which penetrate the trough will be allowed. The liner shall be provided with a visual indication of excess wear.

7. Trough ends thickness shall be per 2.01.E and include top flange and support foot. The drive-end trough end shall include provisions for drive support and shaft seal packing replacement and adjusting.

H.   Conveyor Supports

1. Each conveyor shall be furnished complete with supports suitable for mounting as shown on the contract drawings and as required by the supplier's design. The supports shall be shop fabricated. Supports shall be fabricated from Stainless Steel grade 304L. Supports shall be assembled and test fitted to the conveyor prior to its delivery to the jobsite and then disassembled ready for shipment. Supports and conveyor segments shall be match marked and shipped to the jobsite for assembly by the general DESIGN/BUILDER or others. At a minimum, each conveyor shall be provided with supports at the inlet and discharge end, with intermediate supports as required.

2. 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.

3. 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 (of angles about Z- Z axis). 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.

I.     Drive Units

1.    Motors shall be supplied as noted herein.

2. Each spiral conveyor shall be driven by a constant-speed integral gear reducer/motor drive unit mounted to an adapter flange mounted to the end plate of the conveyor (centrifuge end per the Drawings). The adapter flange shall allow the leakage of any material from the conveyor trough to atmosphere rather than into the gear reducer/ motor drive unit. Direct coupling of the gear reducer/motor drive unit to the end flange of the conveyor will not be acceptable.

3. The drive unit shall be rigidly supported so there is no visible "wobble" movement under any operating condition. In the event of a prolonged power failure or emergency system shutdown the drive system shall be designed, at a minimum, to start the conveyor from a dead stop with the trough filled throughout its entire cross sectional area and length with partially dried and hardened dewatered material.

4. Each motor shall be 460 Volt, 3 Phase, 60 Hz, TEFC, severe duty motor with 1.15 SF and class F insulation. Motor and appurtenances shall have Design B speed/torque characteristics suitable to start with the conveyor fully loaded without using the service factor..

5. The motor shall be provided with internal thermal switches to monitor the temperature of each phase winding. These thermal switches shall be supplemental to external motor overload protection and shall be connected to the control circuit.

6. Gear Reducers. All gears shall be AGMA Class II, single or double reduction, helical gear units with high capacity roller bearings. Bearings shall be designed for the thrust loads from the fully loaded startup condition and shall have a ABMA B10 life of 30,000 hours.
The reducer will be the standard air cooled unit with no auxiliary cooling. The gear reducer shall be sized with a torque service factor of 2.0 times the absorbed power or 1.5 times the motor nameplate, at the driven shaft speed, whichever is greater.

7. Motion Failure Alarm Unit. Each conveyor drive unit shall be equipped with a motion failure alarm unit with stainless steel mounting hardware. 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.

J.     Cable Operated Safety Switch System (Emergency Pull Cord)

1. An emergency pull cord and switch shall be located on one side of each conveyor as indicated on the Drawings.

a. Switches shall be activated by pulling on the tag lines, which shall run the full length of the conveyor.

b. Switches shall have manual reset flag arm and a positive safety lock to prevent accidental reset of the switch.

c. Switches shall be housed in a Feraloy Iron Alloy Enclosure with stainless steel plunger and corro-free epoxy powder coat finish with gaskets.

d.    Switch shall be rated for 120 VAC electrical service.

e.    Switches shall be Crouse-Hinds AFUX Series or equal.

2.    The actuating force on cable shall be field-adjustable.

3. The pull cord shall be 3/32-in 7 x 7 galvanized aircraft cable with orange colored protective vinyl or mylar coating (3/16-in OD).

a. Pull cord support eyebolts shall be Type 316 stainless steel and shall be provided at a maximum spacing of ten-foot centers.

b. Pull cord shall be arranged so that it extends out from the frame providing easy operation.

K.   Safety
1.    All necessary safety equipment and guards to meet OSHA requirements shall be provided.

L.    Instrumentation and Controls
1.    Provide H-O-A local switch for normal operations.
2.    Start / Stop signal shall originate from the Centrifuge Control Panel
3. Alarm conditions shall be transmitted to the Centrifuge Control Panel for integration into the SCADA System.
4.    Fail Conditions shall be transmitted to the Centrifuge Control Panel for integration into the SCADA System.

2.02      ANCHOR BOLTS

A. The manufacturer shall design the anchor system and provide and all anchor bolts required for the installation of the equipment shall be furnished by the equipment manufacturer. Anchor bolts shall be Type 316 stainless steel.

2.03      SHOP PAINTING

A.   All exposed steel surfaces shall be prepared and shop primed in accordance with Section 09901.

PART 3 EXECUTION
3.01       INSTALLATION

A. Installation and initial lubrication shall be in strict accordance with the manufacturer's instructions and recommendations in the locations shown on the Drawings. Installation shall include furnishing the required oil and grease for initial operation. Anchor bolts shall be set in the concrete in accordance with the manufacturer's recommendations and setting drawings.

B. The DESIGN/BUILDER shall be responsible for the coordination of this equipment with the requirements of the belt conveyor to obtain a complete, integrated, and satisfactory operating installation.

3.02       FIELD PAINTING

A.   Field painting is included in Section XXXX.

3.03      FIELD TESTING

A. The manufacturer's engineer shall inspect the final installation and supervise a test run of the equipment.

B. Working under the direction of the manufacturer's engineer, and in the presence of the Engineer, the DESIGN/BUILDER shall perform dry field tests on the screw conveyor as follows:

1. First, the screw conveyor shall have a dry test run to demonstrate the correct alignment, smooth operation, proper and equal spacing of screen bars, freedom from vibration, excessive noise and overheating of the parts and bearings.

2. Secondly, an overload torque test shall be conducted to test the torque overload device to operate and stop the screw conveyor at a loading condition equal to 150 percent of the actual working load of the drive or as required to protect the drive unit, whichever is less. The necessary adjustments and settings to the overload device shall be made at this time to ensure that the screw conveyor will stop, switch off the drive motor, and sound an alarm when a predetermined overload condition occurs in the screw.

C. Once solids are available, the screw conveyor shall be operated for a period of not less than 8 hours. The units shall operate without binding, clogging, excessive noise or vibration, overheating and to demonstrate proper solids collection and discharge.

D. In the event of improper installation or improper operation, all defects shall be corrected, at no additional cost to the Owner, until the equipment operates to the satisfaction of the Engineer.

E. Submit a certificate from the manufacturer stating that the installation is in complete accordance with the manufacturer's requirements, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication, and care of the equipment.